Pump Life Cycle Cost 3 Maintenance Cost Reduction
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WORKSHOP CARTAGENA, JULY 2007 Pump Life Cycle Cost
Maintenance cost reductions and down time cost reductions by upgrading Bad Acting pumps. (Engineering capabilities Technical Services By: Daniel Irigo
Pump Division
LYFE CYCLE COST (LCC) Pump LCC reduction. Energy optimalization Operation cost reductions Maintenance cost reductions. Elimination down time cost Reduced inventory cost Reduced environmental costs.
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
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies There are several maintenance strategies used by our end-users. Run to failure Preventive Maintenance Predictive and pro-active Maintenance Risk based Maintenance management.
Selection of the best Maintenance Strategy is very dependent on the process of the customer!
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Run to failure This is a very simple Maintenance Strategy, where Equipment is taken out of service after it shows a failure. This can range from a leaking mechanical seal up to a Catastrophic failure. Typical used in seasonal processes Example:
- Sugar Mill - Runs only 3
4 months per year
Process has to be operational 30% of the year, the rest of the year is used to repair and overhaul all equipment
Nothing is measured during the production period, and there is redundancy when critical pumps run to failure.
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Run to failure This was the very first Maintenance Strategy, where Customer is only reactive to pump problems and failures. It is still used in continuous processes like for example Refineries. (For example: AGIP Refineries in Italy like the PRIOLO Refinery).
Generates many pumps to fail, giving a low MTBR. Due to the many unexpected pump repairs, and very short time available for repair, the repair quality is most of the times compromised resulting in quick fix and just suitable to operate.
AGIP prioli, population of 650 pumps generates around 15 pump repairs in the shop per month or a 180 200 pumps in the shop per year, next to many interventions in the field! It continuously reduces the overall state and quality of the installed pump population.
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Run to failure
If you use a Run to Failure strategy it either requires a high level of inventory in warehouse, or a quick delivery of spare parts to cover the unexpected failures (repairs).
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Preventive Maintenance In this maintenance strategy, equipment and pumps are opened for inspections and possible repairs on a regular basis. The process is stopped for these general inspections (Shut-downs, refineries etc. scheduled plant outage, power-plants)
The period for these preventive inspections is typically lower than the average Mean Time Between Repairs (MTBR) of equipment. Typical used for processes with a high economic risk factor to loose production or processes generating a high safety risk if pumps fail unscheduled.
Example:
- Nuclear Power Plant - Safety pumps, running only for test, a few hours per month.
Preventive maintenance every refueling cycle 14
17 months
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Preventive Maintenance Preventive maintenance can also be applied during the operation of the customer process, if pumps are installed with a 100% spare unit (Redundancy). For many years preventive maintenance was used in O&G, Power, Chemical and other industries. While in Western Europe it is not generally used anymore, except for Power Plants (Nuclear) and the Chemical industry, it is still used by almost all Our customers in Africa, Middle East and FSU.
It generates a higher maintenance cost than needed, certainly when equipment is inspected and found to be in good condition.
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Preventive Maintenance Example: Esso/EXXON European refineries use almost all predictive / risk based maintenance Management except Esso Fawley and Esso Ingolstadt refinery. Esso Fawley still opens around 180 pumps per year preventively! This consumes
35 / 40% of their maintenance budget
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Predictive Maintenance This maintenance strategy uses condition monitoring techniques to predict the machine condition. Pumps are basically only overhauled repaired when a Bad machine condition is predicted.
Condition monitoring
LYFE CYCLE COST (LCC)
Pump Division
Conditioning Monitoring Process Plant, Chemical Plant, Refinery
Weekly Weeklyor orMonthly Monthly data datataking. taking.
Hand-hold vibro-meter
mm/sec
RMS
Pump P001 Alarm Level - - - - - - - - - - - - - - - * * * * * * * * * * *
Time
Pump Division
LYFE CYCLE COST (LCC) Conditioning Monitoring
Vibration operational spectrum (FFT)
LYFE CYCLE COST (LCC) Conditioning Monitoring
Permanent installed system
Pump Division
LYFE CYCLE COST (LCC)
Pump Division
Conditioning Monitoring From Measured Vibration Data we can produce. Filtered vibrations, bode plot FFT (spectrum) with speed variation
Coupled to truth table
LYFE CYCLE COST (LCC) Conditioning Monitoring Truth table by vibration specialist (Troubleshooting chart)
Pump Division
LYFE CYCLE COST (LCC) Conditioning Monitoring Truth table by vibration specialist (Troubleshooting chart)
Pump Division
LYFE CYCLE COST (LCC) Conditioning Monitoring Result of database search
Pump Division
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Predictive
pro-active Maintenance
Is now a days most frequently used maintenance strategy Method in Western Europe. It reduces the amount of pump repairs, and hence reduces the maintenance cost, as only machines with bad conditions are repaired. It requires an experienced rotating equipment engineer To judge the machine conditions.
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies So far we have seen the 3 major maintenance strategies used on rotating machines / pumps. Although these 3 methods will give different Mean Time Between Overhaul and Repair (MTBO MTBR) they all can be supplemented by a bad-actor program to Eliminate bad-actors in the existing pump population.
Run to Failure
Preventive Maintenance
Predictive maintenance
Lowest MTBO MTBR Higher MTBR
LYFE CYCLE COST (LCC) Maintenance Strategies Bad Actors Typical 5 to 15 pumps on a large installed population of 500 2000 pumps will show largest amount of repairs & failures consuming 30 40 % of the maintenance budget. This are the Bad Actors and frequent failure/repair are caused by:
Wrong pump design for the application Design weaknesses in the pump Mis-use of the pump (operators) Pump-system problems BEP flow/head conditions Etc.
Pump Division
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies You can always produce with your customer the plant Bad Actor list.
By upgrades/retrofitting of these Bad Actors, the plant pump MTBR will strongly improve, and maintenance cost will be reduced.
This will create a pump population which is more predictable for failures
Customer introduce now Risk based maintenance management
This brings the highest savings in maintenance cost!!!
LYFE CYCLE COST (LCC) RISK ASSESSMENT RISK DEFINED BY CONSEQUENCES AND PROBABILITIES CONSEQUENCES - SAFETY - ENVIRONMENT - PRODUCT LOSSES
PROBABILITIES - TIME FRAME TO BE USED - HISTORICAL / STATISTIC DATA - SOMETIMES COMBINATION OF EVENTS NEEDED - MITIGATING
CONSEQUENCES USUALLY MANAGEMENT RESPONSIBILITY
PROBABILITIES USUALLY A TECHNICAL RESPONSIBILITY
Pump Division
LYFE CYCLE COST (LCC) RISK BASED MAINTENANCE (1)
CONSEQUENCES
USED FOR WORK SELECTION AND RISK ASSESSMENT
WORK TO BE DONE
WORK MAY BE DONE LATER
PROBABILITY
Pump Division
LYFE CYCLE COST (LCC) RISK BASED MAINTENANCE (2)
CONSEQUENCES
USED FOR WORK SELECTION AND RISK ASSESSMENT
WORK TO BE DONE
WORK MAY BE POSTPONED
NO WORK TO BE DONE
PROBABILITY
Pump Division
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies
Risk based maintenance management
Can only be applied on a Healthy population
Where bad actors are eliminated as this reduces
The probability in this method.
Repair work can be postponed or cancelled to drive cost down Some customer are using this method, like for example EXXON Europe. EXXON Refinery, preventive maintenance (Fawley) pump annual maintenance cost per year 2800 Euro MTBR 24 months
EXXON Refinery, predictive maintenance, followed by Risk based maintenance management (Rotterdam)
End 1980 s large investment to reduce bad actors.
1990 2000 predictive maintenance pump annual cost per year 1200/1300 Euro MTBR 85 months
2000 2005 predictive, risk based maintenance pump annual cost per year 850 Euro MTBR 85 months.
Pump Division
LYFE CYCLE COST (LCC) Upgrading Bad Acting pumps Reduced
maintenance costs Repair costs Reduce inventory levels due to better reliability availability Eliminate down time costs.
LYFE CYCLE COST (LCC)
Pump Division
Upgrading Bad Acting pumps 1. Dedicated engineering team in Flowserve (Technical Services) to solve Bad Actors. 2. Dedicated LCC database asset management software for pumps and mechanical seals.
3. Dedicated programs for reduced inventory cost, generic Bad Acting pumps, energy reduction etc.
LYFE CYCLE COST (LCC)
Pump Division
Basic Technology Groups
Materials Welding
Vibro Elastics
New Materials
Noise
Repair welding
Vibrations
PTA Welding
Pulsations
HVOF overlay
Etc.
Diffusion alloying (TMT) Surface treatement
Hydraulic Design Overall Efficiency Cavitation Recirculation Etc.
Mechanical Design General Design
Runout
Bearings
NPSHa
Seals
Transients
Seal systems Warm-up Internal alignments Etc.
Erosion Corrosion
Application Knowledge
Flowserve, basic technology groups covering all areas for Workshop Re LCC reductions of centrifugal pumps
Foundations Driver Technology Etc.
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Material selection based on product and application.
PTA welding for hard facing of close running clearances.
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Wear area s
Overlay welding Laser hardening wear rings HVOF spraying Diffusion Alloying
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Diffusion Alloying
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
Cavitations resistant materials (X-Cavalloy). Gasket areas, overlay welding. Corrosion engineering expertise. Etc.
MDPR Mean depth of penetration a standard measure of resistance to cavitation damage
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Vibrations Rotor-dynamic analysis Lateral critical speed Unbalance response Eigen value / stability Torsional analysis (transient)
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Vibrations Structural dynamic analysis Foundation analysis Unbalance response analysis Structural resonances FEM
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Vibrations Field measurements Spectrograms Signature analysis Modal analysis Running mode analysis Etc.
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Noise Noise intensity measurements
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Pulsations Finite element acoustic analysis (acoustic resonance) Field measurements Spectrograms Signature analysis Etc.
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Hydraulic Design Expertise Efficiency improvements Computational Fluid Dynamic analysis / Potential flow analysis. New guidelines for minimum continuous flow. New cavitations criteria (40,000 hours). Suctions eye re-circulation. Discharge re-circulation. Rotating stalls. System analysis for NPSHa
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Test Capabilities Full load Q-H and NPSH testing up to 20 MWatt available from high voltage net.
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Test Capabilities Suction eye recirculation testing (pitot tube). Flow visualization testing. Cavitations testing by paint removal. Model testing of vertical cooling water pumps in-take designs. Field performance testing with accuracy equal to or close to test bed testing Applying torque metering and data logging technology
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
CFD analysis example
Original impeller
New impeller
Application Knowledge
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Flow visualization testing
Purpose build full scale model for flow visualization testing
Permanent set up for full scale or scaled model test
Mechanical Design Knowledge
Application Knowledge
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Field performance testing
Torque meter
Flow meter
Data logger
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Mechanical Design Engineering Bearing design. Shaft sealing designs. Balance drum/disc evaluations. Axial thrust. Radial forces, sag boring. Thermal shocks, axial locking inner assemblies. Warming-up flows, analysis. Transient thermal analysis.
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Turn-Key Project Engineering Piping / supports. Foundation / civil. Instrumentation / Logics. Auxiliary systems.
Application Knowledge
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Pump Division
Mechanical Design Knowledge
Application Knowledge
Flowserve has delivered over 3000 100% boiler-feed pumps for 300, 450, 600, 900 MWatt conventional power plants, and feed-water pumps in Nuclear Power plants from 400 to 1100 MWatt. Application knowledge is available for: Over 52 MWatt BFP Nuclear power plants Hydro-test over 650 bar Conventional power blocks High speed, 100% pump 300 MWatt Supercritical power blocks 8x10x14 HDB 4 stg 8500 rpm Co-generation power blocks 10 Mwatt 12.5 Mwatt, 6000 rpm invertors fed E-motors direct driving BFP s Etc.
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Application Knowledge Min. flow systems Deaerator design Bleed-off lines (ITO) Attemperation stages Transient plant conditions 50% pump run-out evaluation Driver related items: Slow-roll turbine Fluid couplings Variable speed E-motors Etc.
Foundation design Low-tuned Table design
Transient operating conditions Warming up systems Shaft sealing Throttle bushing T-controlled Throttle bushing P controlled Mechanical seals
Boiler filling Intermittent operation Condenser foundation deformation
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Application Knowledge Brite Euram foundation springs
Mechanical Design Knowledge
Application Knowledge
Pump Division
Life Cycle Costs (LCC)
Maintenance cost reductions and down time cost reductions by upgrading Bad Acting pumps. (Engineering capabilities Technical Services By: Daniel Irigo
Pump Division
LYFE CYCLE COST (LCC) Pump LCC reduction. Energy optimalization Operation cost reductions Maintenance cost reductions. Elimination down time cost Reduced inventory cost Reduced environmental costs.
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
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies There are several maintenance strategies used by our end-users. Run to failure Preventive Maintenance Predictive and pro-active Maintenance Risk based Maintenance management.
Selection of the best Maintenance Strategy is very dependent on the process of the customer!
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Run to failure This is a very simple Maintenance Strategy, where Equipment is taken out of service after it shows a failure. This can range from a leaking mechanical seal up to a Catastrophic failure. Typical used in seasonal processes Example:
- Sugar Mill - Runs only 3
4 months per year
Process has to be operational 30% of the year, the rest of the year is used to repair and overhaul all equipment
Nothing is measured during the production period, and there is redundancy when critical pumps run to failure.
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Run to failure This was the very first Maintenance Strategy, where Customer is only reactive to pump problems and failures. It is still used in continuous processes like for example Refineries. (For example: AGIP Refineries in Italy like the PRIOLO Refinery).
Generates many pumps to fail, giving a low MTBR. Due to the many unexpected pump repairs, and very short time available for repair, the repair quality is most of the times compromised resulting in quick fix and just suitable to operate.
AGIP prioli, population of 650 pumps generates around 15 pump repairs in the shop per month or a 180 200 pumps in the shop per year, next to many interventions in the field! It continuously reduces the overall state and quality of the installed pump population.
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Run to failure
If you use a Run to Failure strategy it either requires a high level of inventory in warehouse, or a quick delivery of spare parts to cover the unexpected failures (repairs).
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Preventive Maintenance In this maintenance strategy, equipment and pumps are opened for inspections and possible repairs on a regular basis. The process is stopped for these general inspections (Shut-downs, refineries etc. scheduled plant outage, power-plants)
The period for these preventive inspections is typically lower than the average Mean Time Between Repairs (MTBR) of equipment. Typical used for processes with a high economic risk factor to loose production or processes generating a high safety risk if pumps fail unscheduled.
Example:
- Nuclear Power Plant - Safety pumps, running only for test, a few hours per month.
Preventive maintenance every refueling cycle 14
17 months
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies Preventive Maintenance Preventive maintenance can also be applied during the operation of the customer process, if pumps are installed with a 100% spare unit (Redundancy). For many years preventive maintenance was used in O&G, Power, Chemical and other industries. While in Western Europe it is not generally used anymore, except for Power Plants (Nuclear) and the Chemical industry, it is still used by almost all Our customers in Africa, Middle East and FSU.
It generates a higher maintenance cost than needed, certainly when equipment is inspected and found to be in good condition.
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Preventive Maintenance Example: Esso/EXXON European refineries use almost all predictive / risk based maintenance Management except Esso Fawley and Esso Ingolstadt refinery. Esso Fawley still opens around 180 pumps per year preventively! This consumes
35 / 40% of their maintenance budget
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Predictive Maintenance This maintenance strategy uses condition monitoring techniques to predict the machine condition. Pumps are basically only overhauled repaired when a Bad machine condition is predicted.
Condition monitoring
LYFE CYCLE COST (LCC)
Pump Division
Conditioning Monitoring Process Plant, Chemical Plant, Refinery
Weekly Weeklyor orMonthly Monthly data datataking. taking.
Hand-hold vibro-meter
mm/sec
RMS
Pump P001 Alarm Level - - - - - - - - - - - - - - - * * * * * * * * * * *
Time
Pump Division
LYFE CYCLE COST (LCC) Conditioning Monitoring
Vibration operational spectrum (FFT)
LYFE CYCLE COST (LCC) Conditioning Monitoring
Permanent installed system
Pump Division
LYFE CYCLE COST (LCC)
Pump Division
Conditioning Monitoring From Measured Vibration Data we can produce. Filtered vibrations, bode plot FFT (spectrum) with speed variation
Coupled to truth table
LYFE CYCLE COST (LCC) Conditioning Monitoring Truth table by vibration specialist (Troubleshooting chart)
Pump Division
LYFE CYCLE COST (LCC) Conditioning Monitoring Truth table by vibration specialist (Troubleshooting chart)
Pump Division
LYFE CYCLE COST (LCC) Conditioning Monitoring Result of database search
Pump Division
Pump Division
LYFE CYCLE COST (LCC) Maintenance Strategies Predictive
pro-active Maintenance
Is now a days most frequently used maintenance strategy Method in Western Europe. It reduces the amount of pump repairs, and hence reduces the maintenance cost, as only machines with bad conditions are repaired. It requires an experienced rotating equipment engineer To judge the machine conditions.
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies So far we have seen the 3 major maintenance strategies used on rotating machines / pumps. Although these 3 methods will give different Mean Time Between Overhaul and Repair (MTBO MTBR) they all can be supplemented by a bad-actor program to Eliminate bad-actors in the existing pump population.
Run to Failure
Preventive Maintenance
Predictive maintenance
Lowest MTBO MTBR Higher MTBR
LYFE CYCLE COST (LCC) Maintenance Strategies Bad Actors Typical 5 to 15 pumps on a large installed population of 500 2000 pumps will show largest amount of repairs & failures consuming 30 40 % of the maintenance budget. This are the Bad Actors and frequent failure/repair are caused by:
Wrong pump design for the application Design weaknesses in the pump Mis-use of the pump (operators) Pump-system problems BEP flow/head conditions Etc.
Pump Division
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies You can always produce with your customer the plant Bad Actor list.
By upgrades/retrofitting of these Bad Actors, the plant pump MTBR will strongly improve, and maintenance cost will be reduced.
This will create a pump population which is more predictable for failures
Customer introduce now Risk based maintenance management
This brings the highest savings in maintenance cost!!!
LYFE CYCLE COST (LCC) RISK ASSESSMENT RISK DEFINED BY CONSEQUENCES AND PROBABILITIES CONSEQUENCES - SAFETY - ENVIRONMENT - PRODUCT LOSSES
PROBABILITIES - TIME FRAME TO BE USED - HISTORICAL / STATISTIC DATA - SOMETIMES COMBINATION OF EVENTS NEEDED - MITIGATING
CONSEQUENCES USUALLY MANAGEMENT RESPONSIBILITY
PROBABILITIES USUALLY A TECHNICAL RESPONSIBILITY
Pump Division
LYFE CYCLE COST (LCC) RISK BASED MAINTENANCE (1)
CONSEQUENCES
USED FOR WORK SELECTION AND RISK ASSESSMENT
WORK TO BE DONE
WORK MAY BE DONE LATER
PROBABILITY
Pump Division
LYFE CYCLE COST (LCC) RISK BASED MAINTENANCE (2)
CONSEQUENCES
USED FOR WORK SELECTION AND RISK ASSESSMENT
WORK TO BE DONE
WORK MAY BE POSTPONED
NO WORK TO BE DONE
PROBABILITY
Pump Division
LYFE CYCLE COST (LCC)
Pump Division
Maintenance Strategies
Risk based maintenance management
Can only be applied on a Healthy population
Where bad actors are eliminated as this reduces
The probability in this method.
Repair work can be postponed or cancelled to drive cost down Some customer are using this method, like for example EXXON Europe. EXXON Refinery, preventive maintenance (Fawley) pump annual maintenance cost per year 2800 Euro MTBR 24 months
EXXON Refinery, predictive maintenance, followed by Risk based maintenance management (Rotterdam)
End 1980 s large investment to reduce bad actors.
1990 2000 predictive maintenance pump annual cost per year 1200/1300 Euro MTBR 85 months
2000 2005 predictive, risk based maintenance pump annual cost per year 850 Euro MTBR 85 months.
Pump Division
LYFE CYCLE COST (LCC) Upgrading Bad Acting pumps Reduced
maintenance costs Repair costs Reduce inventory levels due to better reliability availability Eliminate down time costs.
LYFE CYCLE COST (LCC)
Pump Division
Upgrading Bad Acting pumps 1. Dedicated engineering team in Flowserve (Technical Services) to solve Bad Actors. 2. Dedicated LCC database asset management software for pumps and mechanical seals.
3. Dedicated programs for reduced inventory cost, generic Bad Acting pumps, energy reduction etc.
LYFE CYCLE COST (LCC)
Pump Division
Basic Technology Groups
Materials Welding
Vibro Elastics
New Materials
Noise
Repair welding
Vibrations
PTA Welding
Pulsations
HVOF overlay
Etc.
Diffusion alloying (TMT) Surface treatement
Hydraulic Design Overall Efficiency Cavitation Recirculation Etc.
Mechanical Design General Design
Runout
Bearings
NPSHa
Seals
Transients
Seal systems Warm-up Internal alignments Etc.
Erosion Corrosion
Application Knowledge
Flowserve, basic technology groups covering all areas for Workshop Re LCC reductions of centrifugal pumps
Foundations Driver Technology Etc.
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Material selection based on product and application.
PTA welding for hard facing of close running clearances.
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Wear area s
Overlay welding Laser hardening wear rings HVOF spraying Diffusion Alloying
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Diffusion Alloying
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
Cavitations resistant materials (X-Cavalloy). Gasket areas, overlay welding. Corrosion engineering expertise. Etc.
MDPR Mean depth of penetration a standard measure of resistance to cavitation damage
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Vibrations Rotor-dynamic analysis Lateral critical speed Unbalance response Eigen value / stability Torsional analysis (transient)
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Vibrations Structural dynamic analysis Foundation analysis Unbalance response analysis Structural resonances FEM
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Vibrations Field measurements Spectrograms Signature analysis Modal analysis Running mode analysis Etc.
Hydraulic Design
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Noise Noise intensity measurements
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC) Materials Welding
Vibro Elastics
Hydraulic Design
Pulsations Finite element acoustic analysis (acoustic resonance) Field measurements Spectrograms Signature analysis Etc.
Mechanical Design Knowledge
Pump Division
Application Knowledge
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Hydraulic Design Expertise Efficiency improvements Computational Fluid Dynamic analysis / Potential flow analysis. New guidelines for minimum continuous flow. New cavitations criteria (40,000 hours). Suctions eye re-circulation. Discharge re-circulation. Rotating stalls. System analysis for NPSHa
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Test Capabilities Full load Q-H and NPSH testing up to 20 MWatt available from high voltage net.
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Test Capabilities Suction eye recirculation testing (pitot tube). Flow visualization testing. Cavitations testing by paint removal. Model testing of vertical cooling water pumps in-take designs. Field performance testing with accuracy equal to or close to test bed testing Applying torque metering and data logging technology
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
CFD analysis example
Original impeller
New impeller
Application Knowledge
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Flow visualization testing
Purpose build full scale model for flow visualization testing
Permanent set up for full scale or scaled model test
Mechanical Design Knowledge
Application Knowledge
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Field performance testing
Torque meter
Flow meter
Data logger
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Mechanical Design Engineering Bearing design. Shaft sealing designs. Balance drum/disc evaluations. Axial thrust. Radial forces, sag boring. Thermal shocks, axial locking inner assemblies. Warming-up flows, analysis. Transient thermal analysis.
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Turn-Key Project Engineering Piping / supports. Foundation / civil. Instrumentation / Logics. Auxiliary systems.
Application Knowledge
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Pump Division
Mechanical Design Knowledge
Application Knowledge
Flowserve has delivered over 3000 100% boiler-feed pumps for 300, 450, 600, 900 MWatt conventional power plants, and feed-water pumps in Nuclear Power plants from 400 to 1100 MWatt. Application knowledge is available for: Over 52 MWatt BFP Nuclear power plants Hydro-test over 650 bar Conventional power blocks High speed, 100% pump 300 MWatt Supercritical power blocks 8x10x14 HDB 4 stg 8500 rpm Co-generation power blocks 10 Mwatt 12.5 Mwatt, 6000 rpm invertors fed E-motors direct driving BFP s Etc.
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Mechanical Design Knowledge
Application Knowledge
Application Knowledge Min. flow systems Deaerator design Bleed-off lines (ITO) Attemperation stages Transient plant conditions 50% pump run-out evaluation Driver related items: Slow-roll turbine Fluid couplings Variable speed E-motors Etc.
Foundation design Low-tuned Table design
Transient operating conditions Warming up systems Shaft sealing Throttle bushing T-controlled Throttle bushing P controlled Mechanical seals
Boiler filling Intermittent operation Condenser foundation deformation
LYFE CYCLE COST (LCC)
Pump Division
Capabilities Materials Welding
Vibro Elastics
Hydraulic Design
Application Knowledge Brite Euram foundation springs
Mechanical Design Knowledge
Application Knowledge
Pump Division
Life Cycle Costs (LCC)
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