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LIFE CYCLE COST Optimizing Pump Systems Dr. Gunnar Hovstadius Dir. Technology ITT FT PowerPoint PPT Presentation


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LIFE CYCLE COST Optimizing Pump Systems Dr. Gunnar Hovstadius Dir. Technology ITT FT. PRICE FUEL ECONOMY SAFETY DURABILITY. UTILITY MAINTENANCE INSURANCE PERFORMANCE RESELL VALUE. All of us use LCC. Energy & Maintenance costs LCC.

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LIFE CYCLE COST Optimizing Pump Systems Dr. Gunnar Hovstadius Dir. Technology ITT FT

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Life cycle cost optimizing pump systems dr gunnar hovstadius dir technology itt ft

LIFE CYCLE COST

Optimizing Pump Systems

Dr. Gunnar Hovstadius

Dir. Technology ITT FT


All of us use lcc

PRICE

FUEL ECONOMY

SAFETY

DURABILITY

UTILITY

MAINTENANCE

INSURANCE

PERFORMANCE

RESELL VALUE

All of us use LCC


Energy maintenance costs lcc

Energy & Maintenance costs LCC

  • 70% of energy production in industrialised countries drive electric motors

  • 70% of electric motors drive pumps, compressors and fans

  • Pumped systems account for 20% of the world’s electric energy demands

  • Energy and maintenance costs during the life of a pump system are usually more than10 times its purchase price


Pump lcc the product of and a spirit of global cooperation

PumpLCC, the product of … and a spirit of global cooperation

  • 1994 - U.S. DOE invited HI to participate in the Motor Challenge Program

  • 1995 - Flygt develops Sewage Lift station “DOE Energy Showcase” in CT

  • 1996 - Europump forms the Enersave committee

  • 1998 - HI and Europump form a joint committee to develop LCC guidelines

  • 2000 - Europump-HI “Pump Life CycleCosts-Global Best Practices” Guideline


Hydraulic institute europump

Hydraulic Institute - Europump

Life Cycle Cost (LCC) is the total lifetime

cost to purchase, install, maintain, and

dispose of that equipment. Costs:

  • Initial purchase

  • installation and commissioning

  • energy

  • operating

  • maintenance

  • downtime, loss of production

  • environmental cost

  • decommissioning


Cost components

Cost Components

  • Life Cycle Cost is the total lifetime cost to purchase, install, operate, maintain and dispose of that equipment.

    • HI/EP Oct. 2000

  • The purchase price is

    typically less than 15% of

    the total ownership cost.

  • Environmental

    7%


    Content

    CONTENT

    Chapter

    Executive Summary

    Introduction

    1Life Cycle Cost

    2Pumping System Design

    3Analyzing Existing Pumping Systems

    4Examples of LCC Analysis

    5Effective Procurement using LCC

    6Recommendations

    7References

    8Glossary

    9Appendix A - E


    Appendixes

    APPENDIXES

    ASystem Curves

    BPumping Output and System Control

    CPump Efficiencies

    DCase History - Cost Savings

    EElectrical Drivers and Transmissions


    Manual calculation chart

    MANUAL CALCULATION CHART

    System description:

    Input:

    n - Life in years:

    i - Interest rate, %:

    p - Inflation rate %:

    - Initial investment cost:

    1

    - Installation and commissioning cost:

    2

    - Energy price (present) per kWh:

    - Weighted average power in kW:

    - Average Operating hours/year:

    Energy cost/year (calculated) = Energy price x

    3

    Weighted average power x Average Operating

    hours/

    yr

    - Operating cost/year:

    4

    - Average Maintenance cost (routine

    5

    maintenance/year):

    - Down time cost/year:

    6

    -Other yearly costs :

    7

    Sum of yearly costs

    -

    : (3+4+5+6+7)

    8


    Manual calculation cont

    MANUAL CALCULATION ....cont.


    Systems not pumps

    SYSTEMS, notpumps

    • LCC starts with the SYSTEM.

    • Replacing a 75% efficient pump with a 80% efficient pump will save almost 7% electricity cost

    • BUT … if pump systems are incorrectly sized, efficient pumps will operate at inefficient points

    • 75% of all engineered pump systems are estimated to be oversized.


    Pumps and system sizing energy to burn

    PUMPS and SYSTEM SIZINGEnergy to Burn

    • SYSTEM HEAD CALCULATIONS ARE CONSERVATIVE - SAFETY FACTORS

    • SINGLE PUMP, CONSTANT SPEED SYSTEMS SIZED FOR MAX DUTY

      • STATUTORY RULES IN MUNICIPAL

        WASTEWATER PUMPING

      • 40 DEG+ , THREE DAYS OF THE YEAR

    • SYSTEM COMPONENTS ARE OVER-

      SIZED - SAFETY FACTORS


    Pumps expensive water heaters

    Pumps: expensive water heaters

    • Pumps, over-sized for REAL system demands, lead to

      • frequent on / off cycling

      • closing of throttling valves

    • RESULT:

      • adding friction head to the system,

      • increasing Pump kW (electric power required)


    Energy

    ENERGY

    • Efficient pumps & efficient systems =>

      Specific Energy ( Wh/l pumped fluid )

      Calculate specific energy for the system and compare different solutions and different components


    Maintenance

    Maintenance

    • Throttled / oversized pumps run outside BEP

      • operate less efficiently,

      • generate radial loads & wear faster

        ….whereas

    • Accurately sized pumps and systems

      • reduce maintenance costs

      • increase seal, bearing, shaft life

      • increase MTBF

      • decrease labor maintenance

      • reduce production loss

      • reduce our warranty goodwill costs


    Lcc comparison example

    LCCComparison - Example

    10 Year Pump Life: : 80% eff60% eff

    800 gpm @ 90 ftBHP16.95 kw22.60 kw

    • Pump / Motor Price $ 2,500 2,500

      ( with 30 hp motor)

    • Installation 500 500

    • Energy Costs* 33,900 45,200

      $ 0.05/ KwHr x 4000 hrs/yr x 10 yrs

    • Maintenance

      Parts (seals, bearings, shaft, impeller) - 4,000 8,000

      Labor 5 hrs/10hrs 2,000 4,000

    • Downtime - BI insurance pro-rate 1,200 1,200

    • Environmental ($ 150 x 2/yr and 3/yr) 3,000 4,500

    • Decommission650 650

      TOTAL LCC Comparison$ 47,550 $66,550

      Operating Savings $ 19,000


    Life cycle cost customer economic value

    LIFE CYCLE COSTCustomer Economic value

    • Reducing costs increases competitiveness

      • US Dept. Of Energy estimates 75-122 B KwH per year can be saved by “optimizing” motor driven pump systems

      • Savings would be between $ 4-6 B per year

    • Increase public services without raising public taxes and fees

      • Responding to the demands of private operators of public services to find system savings


    Life cycle cost environmental value

    LIFE CYCLE COSTEnvironmental Value

    Global commitment to environmental solutions -

    • Rio: Reduce ozone threatening emissions

    • Kyoto - commitment to reduce energy

    • 1 KwHr of electricity produces 600 grams of CO2. Saving 75-122B KwH will reduce 45 to 75 Billion Kg in CO2


    Putting lcc to work

    PUTTING LCC TO WORK

    • Think systems, not components.

    • Education of

      System owners, designers, specifiers, purchasers and producers

    • Concentrate on system performance, rather than component performance

    • Develop system specifications


    Life cycle cost

    LIFE CYCLE COST

    • ITT Industries EMBRACES LCC AS A TOOL FOR SELECTING AN OPTIMAL SOLUTION TO CREATE ECONOMIC AND ENVIRONMENTAL VALUE OVERTHE LIFE OF A SYSTEM


    New lcc focused products systems from itt industries

    New LCC Focused products/systems from ITT Industries

    • PumpSmart - advanced electronics and algorithms monitor system demands and varies the speed of the unit or shuts it down to protect the pump

    • Hydrovar Contol System - converts the pump from a constant speed to a variable speed unit

    • N-Pump - revolutionary impeller reduces the energy consumption by 30-50%

    • Sanitaire - a fine bubble aeration system that cuts energy costs by up to 50%


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