Pump Life Cycle Cost 2 Data Of Pumps
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WORKSHOP CARTAGENA, JULY 2007 Pump Life Cycle Cost
Pump Life Cycle Cost data of pumps in O&G upstream, pipelines and down stream refining over 40 years By: Daniel Irigo
Pump Division
LIFE CYCLE COST (LCC) While it would be very time consuming to analyze the LCC of each pump in a refinery in order to generate total LCC for all the pumps, it is possible to use general total refinery cost data to derive at the same total LCC for all refinery pumps. Assume:
= Refinery with 500 pumps = 100,000 BPD refining = Deep conversion, refinery margin is 6,25 $ per barrel = Refinery operates 50 weeks and has 2 week scheduled shut-down each year. = Cost of energy 30$ per Mwhr. = Availability, 99%, due to pump reliability
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMPS
Initial cost plus installation and commissioning cost C + C ic
in
The current cost in Europe and North America to purchase 500 new refinery pumps is 25 million $. The engineering and installation cost including all piping, foundations, civil work, electrical systems, auxiliary systems and commissioning is between 30 45 million $. This gives a total CAPEX of 70 million $.
CAPEX = C ic + C in = 70 million $
LIFE CYCLE COST (LCC)
Pump Division
REFINERY PUMPS Energy cost
Ce
.
With an average drive power of 50kw per pump for all these 500 pumps and 50 weeks operation per year the total energy cost at 30 $ per MwHR is 252 million $ over 40 years. C e = 252 million $.
Operating cost
Co
.
In refineries, most of the operational labor cost on pumps is filter cleaning. Around 5% of the 500 installed pumps will have suction filters which require frequent cleaning. Certainly when refinery processes form coke particles, filter cleaning could be necessary on a weekly basis with a cost of 50,000 $ per year per filter including disposal cost of debris and this results in a total cost over 40 years just for filter cleaning of 50 million $. C o = 50 million $.
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMPS Maintenance cost Cm. 500 pumps with average 2000 $ per pump per year maintenance cost. Inventory, spare parts Parts consumption per year Parts value inventory Inventory cost (warehouse, WACC, etc.) =
650,000 $ 1,500,000 $ 20%
Rotating equipment engineer, maintenance staff and workshop, cost allocations for all 500 pumps 500,000 $ per year. Cm
98 million $
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMP Down time cost Cs
99% availability Annual production losses 0,01 X 50 X 7 X 100,000 X 6,25 = 2,187,500 $
Cs = 87,5 million $
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMP Refinery 500 pumps, total LCC CAPEX 40 YEARS OPEX C ic + C in = 70 Million $ C e = 252 Million $
C o = 50 Million $ C m = 98 Million $ C s = 87,5 Million $ 70 Million $ LCC =
487,5 Million $ 557,5 Million $
Pump Division
LYFE CYCLE COST (LCC) REFINERY PUMP
Maintenance cost 17.5%
Operational cost 9% Down time cost 16%
Operational cost 9%
Down time cost 16%
CAPEX 12.5% CAPEX 12.5%
Energy cost 45%
Maintenance cost 17.5%
Energy cost 45%
LCC for one refinery with 500 pumps
LYFE CYCLE COST (LCC) CENTRIFUGAL PUMP CAPEX OPEX Application Cin Cinst Ce Cop Cor Upstream O&G 10% 30% 15% 38% Pipeline 8.5% 88% 0.5% 3% Downstream O&G 12.5% 45% 9% 17.5% (Average data)
Pump Division
Cdt 7% 0% 16%
Cin
=
Initial cost
Cinst
=
Installation cost
Ce
=
Energy cost
Cop
=
Operational cost
Cor
=
Maintenance and repair cost
Cdt
=
Down time cost (Loss of production)
Pump Division
LYFE CYCLE COST (LCC) CENTRIFUGAL PUMPS
Important elements OPEX LCC cost 1) Pipelines energy 2) Upstream O&G energy + maintenance/repair 3) Down stream O&G energy + downtime cost + maintenance / repair
Pump Division
LYFE CYCLE COST (LCC)
Pump LCC reduction. Energy optimalization Operation cost reductions Maintenance cost reductions.
Pump Division
LYFE CYCLE COST (LCC) Structured method to audit a refinery for pump LCC Bad actor listing Review maintenance method history Review of 40 pumps with highest drive power Review pump operation issues Inventory and sourcing review for parts.
Introduce a LCC data-base
Pump Division
Life Cycle Costs (LCC)
Pump Life Cycle Cost data of pumps in O&G upstream, pipelines and down stream refining over 40 years By: Daniel Irigo
Pump Division
LIFE CYCLE COST (LCC) While it would be very time consuming to analyze the LCC of each pump in a refinery in order to generate total LCC for all the pumps, it is possible to use general total refinery cost data to derive at the same total LCC for all refinery pumps. Assume:
= Refinery with 500 pumps = 100,000 BPD refining = Deep conversion, refinery margin is 6,25 $ per barrel = Refinery operates 50 weeks and has 2 week scheduled shut-down each year. = Cost of energy 30$ per Mwhr. = Availability, 99%, due to pump reliability
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMPS
Initial cost plus installation and commissioning cost C + C ic
in
The current cost in Europe and North America to purchase 500 new refinery pumps is 25 million $. The engineering and installation cost including all piping, foundations, civil work, electrical systems, auxiliary systems and commissioning is between 30 45 million $. This gives a total CAPEX of 70 million $.
CAPEX = C ic + C in = 70 million $
LIFE CYCLE COST (LCC)
Pump Division
REFINERY PUMPS Energy cost
Ce
.
With an average drive power of 50kw per pump for all these 500 pumps and 50 weeks operation per year the total energy cost at 30 $ per MwHR is 252 million $ over 40 years. C e = 252 million $.
Operating cost
Co
.
In refineries, most of the operational labor cost on pumps is filter cleaning. Around 5% of the 500 installed pumps will have suction filters which require frequent cleaning. Certainly when refinery processes form coke particles, filter cleaning could be necessary on a weekly basis with a cost of 50,000 $ per year per filter including disposal cost of debris and this results in a total cost over 40 years just for filter cleaning of 50 million $. C o = 50 million $.
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMPS Maintenance cost Cm. 500 pumps with average 2000 $ per pump per year maintenance cost. Inventory, spare parts Parts consumption per year Parts value inventory Inventory cost (warehouse, WACC, etc.) =
650,000 $ 1,500,000 $ 20%
Rotating equipment engineer, maintenance staff and workshop, cost allocations for all 500 pumps 500,000 $ per year. Cm
98 million $
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMP Down time cost Cs
99% availability Annual production losses 0,01 X 50 X 7 X 100,000 X 6,25 = 2,187,500 $
Cs = 87,5 million $
Pump Division
LIFE CYCLE COST (LCC) REFINERY PUMP Refinery 500 pumps, total LCC CAPEX 40 YEARS OPEX C ic + C in = 70 Million $ C e = 252 Million $
C o = 50 Million $ C m = 98 Million $ C s = 87,5 Million $ 70 Million $ LCC =
487,5 Million $ 557,5 Million $
Pump Division
LYFE CYCLE COST (LCC) REFINERY PUMP
Maintenance cost 17.5%
Operational cost 9% Down time cost 16%
Operational cost 9%
Down time cost 16%
CAPEX 12.5% CAPEX 12.5%
Energy cost 45%
Maintenance cost 17.5%
Energy cost 45%
LCC for one refinery with 500 pumps
LYFE CYCLE COST (LCC) CENTRIFUGAL PUMP CAPEX OPEX Application Cin Cinst Ce Cop Cor Upstream O&G 10% 30% 15% 38% Pipeline 8.5% 88% 0.5% 3% Downstream O&G 12.5% 45% 9% 17.5% (Average data)
Pump Division
Cdt 7% 0% 16%
Cin
=
Initial cost
Cinst
=
Installation cost
Ce
=
Energy cost
Cop
=
Operational cost
Cor
=
Maintenance and repair cost
Cdt
=
Down time cost (Loss of production)
Pump Division
LYFE CYCLE COST (LCC) CENTRIFUGAL PUMPS
Important elements OPEX LCC cost 1) Pipelines energy 2) Upstream O&G energy + maintenance/repair 3) Down stream O&G energy + downtime cost + maintenance / repair
Pump Division
LYFE CYCLE COST (LCC)
Pump LCC reduction. Energy optimalization Operation cost reductions Maintenance cost reductions.
Pump Division
LYFE CYCLE COST (LCC) Structured method to audit a refinery for pump LCC Bad actor listing Review maintenance method history Review of 40 pumps with highest drive power Review pump operation issues Inventory and sourcing review for parts.
Introduce a LCC data-base
Pump Division
Life Cycle Costs (LCC)
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