This is a proprietary document of Kirloskar Brothers Limited Life Cycle Cost Analysis – Systematic...

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis – Systematic Approach

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Life Cycle Costs In Pumps and Pumping Systems(Based On Guidelines of Hydraulic institute Standard)



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Life Cycle Cost (LCC)

The LCC of any piece of equipment is the total “Lifetime” cost required toPurchase, Install, Operate, Maintain , and Dispose of that equipment.



Purchase price

Operating cost

Maintenance cost

Pumping system account for nearly 20% of worlds electrical demand and range from 20- 50% of pump energy usage in certain industrial plant operation. For majority of the facilities, lifetime energy and maintenance cost

will dominate the LCC



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Why LCC

Why should organizations care about life cycle cost?

Many organizations only consider the Initial purchase and installation cost of the equipment.

It is in the fundamental interest of the plant designer and manager to evaluate the LCC of Different solutions before installation of new plant or major over haul.

This Evaluation will help in identifying financially attractive alternative / solution.

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.

The developed world has become acutely aware of the effect of it’s energy waste and the introduction of levies on CO2 emissions now directly taxes the inefficient users of energy.



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Cross section of LLC Series Vertical Turbine Pump

LLC Series – Horizontal Split Casing Pumps



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FEATURE/ADVANTAGE CUSTOMER BENEFIT

Shaft Couplings Keyed muff type couplings fitted as standard. Easily removable, unlike lower cost screwed couplings ensuring increased component life.Reduced maintenance costs.

Universal Seal Chamber

Customer specified mechanical seals or traditional soft packed gland arrangements.

Site standards and customer specified options accommodated. Facilitates compliance with customer frame contracts for mechanical seals etc.

Spacer Coupling Spacer Coupling as standard. Facilitates removal of cartridge type mechanical seals without disturbing thrust bearing assembly or driver and negates the need for expensive split mechanical seals.Substantial reduction in maintenance costs.

Thrust Bearing Assembly

Heavy duty thrust bearing assembly. Anti-friction or Michell type thrust bearings dependant on load. Minimum L10 life in excess of 50,000 hours under all design load conditions.

Headpiece Large heavily engineered fabricated headpieces, ensure minimal vibration and long bearing life.

Longevity of design combined with increased bearing life ensures lowest cost of ownership.

Coatings Drinking water approved coatings. Facilitates use on potable water applications.

LLC VERTICAL TURBINE FEATURES & BENEFITS (Contd…)LLC Series – Horizontal Split Casing Pumps



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Cross section of LLC Series Horizontal Split Casing Pump




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LLC HSC FEATURES & BENEFITS

Casing FEATURE/ADVANTAGE CUSTOMER BENEFIT

Axially split casing with nozzles in the bottom half casing

Rotating element can be removed in-situ, without need to disturb either the pipework or driver avoiding the need for subsequent re-alignment

Enhanced bearing life.Less downtime.Reduced maintenance costs.

Double volute casings, where radial loads dictate.

Reduces radial load and subsequent shaft deflection. Only incorporated where necessary, as double volute design tends to have an efficiency penalty. SPP (Our) policy on smaller frames is to enhance the L3/D4 ratio, by incorporating more generous size pump shafts. Enhancement in L/D ratio helps in limiting shaft deflection lesser than wear ring clearance.

Enhanced bearing life.Some competitors offer double volute across the range. This is not energy efficient. SPP’s (Our) smaller frames will be more efficient reducing energy costs.

Coating An efficiency enhancing drinking water approved coating is standard for water applications. This is optional for general service pumps.

Reduced energy consumption/cost.




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Impeller Precision casting in austenitic stainless steel as standard. Axially hydraulic balance of double suction design improves efficiency and enhances bearing life.Rotating assemblies are dynamically balanced minimizing vibration.

Increased component lifeIncreased cavitation resistance.Superior hydraulic performance.Increased bearing and component life.All above result in reduced maintenance costs.

Impeller Fixing

Positively locked and keyed to pump shaft.The new Weir Uniglide E does not incorporate a key driven impeller, hence it will be difficult to remove and may not offer the conservative thinking engineer the comfort required.

Easily removable and positively driven.Pump handing can be changed insitu. Not so easy with a shrink fit impeller.Security of operationLower maintenance costs.

Shaft Corrosion resistant rigid stainless steel shaft as standard. Low L3/D4 ratio ensures minimum deflection and long bearing life. Maintains optimum efficiency longer, as no contact between impeller and wear rings.

Increased bearing and shaft life. Reduced maintenance and energy costs.

LLC HSC FEATURES & BENEFITS (Contd…)




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Bearings API type double row thrust bearing assembly.Thrust Bearing assembly situated at drive end, ensuring any thermal growth on high temperature service is not transmitted to coupling and driver.

L10 life in excess of 50,000 hours, under all design load conditions.Security of operation for the more conservative thinking engineer.

Wear Rings Hard metallic serrated casing wear rings. Impeller wear rings are optional and can be fitted during overhaul.

Long life and reduced energy consumption. Lowest whole life cost option. Minimises initial capital cost and can be fitted during overhaul if impeller wear is evident.

Seal Chamber

Universal seal chamber.Weir Uniglide E does not accommodate soft packed gland and is fitted with a Weir Mech. Seal.Maintains regulated pressure in at seal faces ensuring no dry running and facilitates high temperature operation.

Accepts most commercially available single or double cartridge mechanical seals or traditional gland packing.Operation up to 120oC with standard seal arrangement. Low capital and maintenance costs.





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Mechanical Seals

Customer specified mechanical seals.Site standards and customer specified options accommodated. Facilitates suction lift with single cartridge seal options.

Facilitates frame contracts for consumable parts seals, bearings etc.Operation with negative suction pressures/suction lifts without expensive barrier fluid systems. Ease of maintenance and operation, reducing running and maintenance costs.

Throttle Bush

Throttle Bush reduces energy consumption and facilitates suction lift with single mechanical seals.

Low energy costs, also facilitates a wider range of application, reducing capital and maintenance costs.

Bearing Housings

Externally removable bearing housing. Ease of maintenance. Bearings and seals can be removed without removing top half casing.Bosses are provided as standard for condition monitoring transducers.

Lower maintenance costs. Minimal downtime.Improved reliability with reducing downtime and associated costs.





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Coating options Efficiency enhancing drinking water approved coating applied as standard on potable water applications, optional for industrial use.

Reduces energy costs.

Base plates Channel section base plate incorporating motor jacking screws as standard ensure vibration free operation and easy alignment on site.

Reduces expensive down time and maintenance costs.

Spacer Coupling as standard.

A spacer coupling facilitating removal of the drive end bearing and seal in-situ, without need to remove and re-align the drive motor.

Reduces expensive down time and maintenance costs.





Hydraulic Deterioration

Head/Flow

Efficiency

Deteriorated

Deteriorated

Efficiency Loss Efficiency Loss = = More Power More Power per hourper hour

Efficiency Loss Efficiency Loss = = More Power More Power per hourper hour

Flow Reduces = More Hours runFlow Reduces = More Hours runFlow Reduces = More Hours runFlow Reduces = More Hours runOriginal BEPOriginal BEP



10 Year Additional Energy Cost Due To Efficiency Degradation (Rs.6 per kW/Hr)

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

9000000

Absorbed Power KW

Co

st (

INR

)

Degradation CostDegradation Cost

Additional Energy Cost

Rs. 5.6 million)

Average 1% pa

LLC Average 0.25% pa



= 125,000 kW paSaved Generation

5% Saving on 100 KW = 44,000 kW pa = Rs. 0.38 million

Pump rarely BEP



In ten years you would lose

$657 thousand

CO2 Emissions Saving / Year per 1% Efficiency

0.43 kg CO2/kWh

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

0kW 50kW 100kW 150kW 200kW 250kW 300kW 350kW

Absorbed Power

Carb

on E

miss

ions (

kg C

O2

)

20000 miles 1.8 Family Saloon

Round the world flight



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ConclusionLife Cycle Cost is a highly practical tool for the users which can

be very effectively used to evaluate and compare any equipment, particularly for complex pumping systems to make

purchase decision from the available alternatives and safeguard own interests. KBL has used this concept effectively in the

products and introduced this in the market.



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THANK YOU

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This is a proprietary document of Kirloskar Brothers Limited Life Cycle Cost Analysis – Systematic...

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