KIRLOSKAR BROTHERS LTD. - ASHRAE · PDF fileThis is a proprietary document of Kirloskar...

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis – Systematic Approach

KIRLOSKAR BROTHERS LTD.

A PRESENTATION BY



Life Cycle Costs In Pumps and Pumping Systems

(Based On Guidelines of Hydraulic institute )



STUDY CARRIED OUT BY



Life Cycle Cost (LCC)

The LCC of any piece of equipment is the whole

“Lifetime” cost required to Purchase, Install,

Operate, Maintain and Dispose off that equipment.



CAPITAL COSTS

Pumps

Civil Works

M&E

ENERGY COSTS

Efficiency

Process Optimisation

MAINTAINENCE COSTS

MTBF

Replacement Parts

Down time

DISPOSAL COSTS

WHOLE LIFE COST



•Initial cost

•Fuel economy

• Safety

• Durability

• Utility

• Maintenance

• Insurance

• Performance

• Resell value

• Price

Buying Decision

Considerations

Personal Level

Cost of Acquisition

Cost of Usage

Cost of Disposal

Cost

of

Ownership`



Life Cycle Cost (LCC)

Typical LCC for Medium Sized Industrial

Pumping System. Capital Cost

Energy Cost

Maintenance Cost

Other costs likeOperating, down

time, etc

@ 82%

@ 10%

@ 5%

@3%



Purchase price

Operating cost

Maintenance cost

Pumping systems account for nearly 25% of worlds electrical demand (in developed

countries) and range up to 50% in certain industrial plant operation.

The developed world has become acutely aware of the effect of energy wastage.

Introduction of levies on CO2 emissions now directly taxes the inefficient users of energy.



Why LCC ?

Why should organizations care about life cycle cost?

Many organizations only consider the Initial purchase and installation cost

of the equipment.

In today’s competitive market organizations must continuously seek cost saving which

will improve their profitability.

Along with economic reasons , LCC helps in developing awareness about environmental

impact of their business and conserving energy as one way to reduce emission,

preserve natural resources and reduce carbon foot print. This will also help in reducing

emission of Green House gases.



Causes of Hydraulic Deterioration

• Fluid erosion of internal clearances

• Mechanical wear resultant of shaft deflection

• Oxidation increasing surface roughness

• Excessive internal re-circulation

• Cavitation/Vane Pass



Hydraulic Deterioration

Head/Flow

Efficiency

Deteriorated

Deteriorated

Efficiency Loss

=

More Power per

hour

Flow Reduces = More Hours run

Original BEP



Facts about pump power consumption The table below shows rise in pumping cost due to drop in

efficiency for 20 kW pump-set during the period of operation.

Sr.

No.

No of Years Efficiency (* ) Pumping Cost

Per Day Per Annum

1 1st Year 80.0 % 2160 788400

2 2nd Year 79.2 % 2187 798380

3 3rd Year 78.4 % 2215 808615

4 4th Year 77.6 % 2244 819117

5 5th Year 76.8 % 2274 829895

6 6th Year 76.0 % 2304 840960

7 7th Year 75.3 % 2335 852324

8 8th Year 74.5 % 2367 864000

9 9th Year 73.8 % 2400 876000

10 10th Year 73.0 % 2434 888338

Normally pump efficiency drops at 1% per annum for

drinking water application due to erosion and corrosion.



10 Year Additional Energy Cost Due To Efficiency

Degradation

(Rs.6 per kW/Hr)

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

9000000

50kW

150k

W

250k

W

350k

W

Absorbed Power KW

Co

st

(IN

R)

Degradation Cost

Additional Energy Cost

Rs. 4.5 million

Average 1% pa For

Conventional Pump

LLC Average

0.25% pa



= 125 MW pa

Saved Generation

5% Saving on 100 KW = 44 MW pa =

Rs. 0.38 million

Pump rarely

BEP



3-Dimensional Streamline Plot of the pump

Turbo Design

ORIGINAL PUMP

EFF. – 83%

MODIFIED PUMP

EFF – 89.5%



Efficiency Improvement by Material Coatings

DIFFERENCE IN DROPLET CONTACT ANGLE

Water droplet Water droplet

Coating

SUBSTRATE

Hydrophobic

Material

Polymer

(Easter Resin)

Semi- Hydrophobic

Material

Polypropylene

Attractive

Material – Cast Iron



Glass flake technology - Tortuous path

Tortuous path for corrosive ion

Layers of glass flakes

Coating

SUBSTRATE



Cross section of LLC Series Horizontal Split Casing Pump

C:/Documents and Settings/11117/Desktop/NTPC_Presentation_17.12.12/HSC_CSD.ppsx



Mechanical Seal ReplacementHorizontal Split Case Pumps

REMOVE GUARD

REMOVE SPACER

REMOVE BEARING

RETAINING NUT

REMOVE BEARINGS AND

REMOVE MECHANICAL SEAL

REASEMBLE FOR USE

REMOVE PUMP COUPLING

REMOVE BEARING HOUSING



Installation



STANDARD FEATURES OF LLC PUMPS

The pumps are provided with removable and renewable Labyrinth profile casing

ring. Materials and hardness of the Impeller and casing ring is standardized to

ensure that they are not susceptible to galling and premature wear.

In order to avoid waste of water through continuous Gland leakage in soft packed

pumps, the casing stuffing box /seal chamber is designed to facilitate externally

removable shaft mounted, non split, self aligning cartridge type Mechanical seal of

any reputed make.

Pump is supplied with Spacer type flexible coupling.

Ease of access to the parts to be serviced is ensured i.e. Mechanical Seal &

Bearings, without removing the upper half casing, recourse to disturb either pipe

work or prime mover.



In order to avoid bare metal casing from getting oxidized and to reduce the relative

surface roughness of the pump casing, Corrocoat Coating of thickness 1 mm DFT

with properties of good erosion & corrosion protection including protection

against cathodic action is applied on casing internal surface coming in contact

with water.

The coating applied is suitable for potable water application and certified by

Authorized National Lab.

The pump is supported by two drive end bearings and one non drive end bearing

of anti-friction type, located on each side of the pump. The bearings are grease

lubricated, ball or roller bearing type. The bearing on the pump is designed to

withstand the unbalanced radial & axial hydraulic thrust. Bearings are designed for

L101ife of minimum 50000 hours of operation in the operating range.

The supplied pump offers low operation cost by way of sustained efficiency with

no degradation for first two years and there after by approx. 0.25% (i.e.

degradation in efficiency by approx. ¼ as compared to conventional pump) every

year up to economical life i.e.10 years.



28

Cross section of LLC Series Vertical Turbine Pump



ADVANTAGES OF LOWEST LIFECYCLE COST

SERIES PUMP

Sr. No. Component Feature Benefit Advantage

1 Impellers Precision casting in austenitic

stainless steel as standard.

Increased corrosion resistance &

thereby increased component life.

Increased Sustainability.

Reduced maintenance

costs.

2 Bottom

Bearing

Impeller in between the bearings

with bottom Bearing in the bell

mouth

Higher Rigidity Increased Sustainability

3 Wear Rings

Hard Metallic serrated wear rings

of zinc free bronze. (Applicable

for closed impellers)

Long life and reduced energy

consumption

Energy Saving & Increased

Sustainability

4 Impeller

Guide Piece

Precision Casting in austenitic

stainless steel as standard.

(Applicalbe for open/semiopen

impellers)

Increased component life.

Increased corrosion resistance.


Reduced maintenance

costs.

5 Bearing Span Span less than 2m Enhanced bearing life. Faciliatates

variable speed operation Increased Sustainability




SERIES PUMP

Sr. No. Component Feature Benefit Advantage

6 Bearing Span Span less than 2m Enhanced bearing life. Faciliatates

variable speed operation Increased Sustainability

7 Intermediate

Bearings

Composite bearing suitable for dry

start running. (Fabric-impregnated

with resin)

High wearing resistence. User

friendly for operation. Avoids cost

for pre-lubricaiton. Presents

deformaiton due heating

Increased Sustainability

8 Shafts Stainless steel as standard

ASTMA276-410 (H&T)

Enhanced corrosion resistance and

component life. Higher shaft dia. Increased Sustainability

9 Coatings Corrocoat - Hydrophobic Coatings Offers protection against erosion,

corrosion and galvanic action.

Protects base matieral and

enhances its life.




SERIES PUMP Sr. No. Component Feature Benefit Advantage

10 Shafts

Sleeves

Hard Stainless steel shaft sleeves

fitted below bearings as standard

Enhanced corrosion resistance

and component life. Increased Sustainability

11 Bearing Span Full ring Bearing Spider Improved surface contact Higher

Rigidity Increased Sustainability

12

Stuffingbox /

Mech seal

Holder

Additional Bearing in Stuffingbox /

Mech seal Holder Higher Rigidity Increased Sustainability

13 Shaft

Couplings

Keyed muff type couplings fitted

as standard.

Easily removable, avoiding seizure

or jamming on shaft after few

years of operation, ensuring

increased component life.

Reduced maintenance

costs.

14

Thrust

Bearing

Assembly

Heavy duty thrust bearing

assembly.

Anti-friction or mitchell type thrust

bearings dependant on load.

Minimum L10 life in excess of

50,000 hours under all design load

conditions.


Reduced maintenance

costs.

15 Headpiece Large Fabricated headpieces. Minimum vibration and long

bearing life.


Reduced maintenance

costs.


Life Cycle Cost Analysis – Systematic Approach LIFE CYCLE COST ANALYSIS – SYSTEMATIC

APPROACH

A PRESENTATION BY

FULL RING BEARING

SPIDER

LLC PUMPS

BEARING SPIDER

CONVENTIONAL

PUMPS


Life Cycle Cost Analysis – Systematic Approach LIFE CYCLE COST ANALYSIS – SYSTEMATIC

APPROACH

KIRLOSKAR BROTHERS LTD. - ASHRAE · PDF fileThis is a proprietary document of Kirloskar...

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