Pump Life Cycle Cost 4 Inventory Cost Reduction

WORKSHOP CARTAGENA - JULY 2007 Pump Life Cycle Cost

Inventory cost reductions by using standarization and intelligent stock. By: Daniel Irigo

Managing _ Supply _ Intelligent Spare Parts Stock Analysisinstalled installedPumps Pumps Analysis

Timingofofsupply supply-Timing Pumpsnot notcritical critical Pumps

Timingofofsupply supply Timing Pumpscriticals criticals Pumps emergency ++44emergency

Impellers Shafts Wear Rings Bushings Gaskets Impellers Shafts Wear Rings Bushings Gaskets

Pump Division

TypePumps PumpsInstalled Installed Type Quantityper perPump PumpType Type Quantity IdentificationCritical CriticalPumps Pumps Identification ObsoletePumps Pumpsstill stillrunning running Obsolete DefinitionStandard StandardMaterials Materials Definition Interchangeabilitylevel level Interchangeability weeks 66weeks week 11week week 11week week 11week week 11week week 11week 36Hours Hours 36 36Hours Hours 36 36Hours Hours Workshop Repsol YPF Refineria La Plata / Pump Life Cycle Cost 4 36 October 2006 / 2 36Hours Hours 36

Pump Division

Customer refinery layout REFINERY FLOW DIAGRAM

CRUDE UNIT

LPG AND GAS

STABILIZER SECTION

STRAIGHT RUN GASOLINE

VAPOR RECOVERY

REFINERY FUEL

GAS

LPG

CRUDE UNIT

CRUDE

ATMCS TWA SECTION

HYDRO TREATING

NAPHTHA

REFORMATE HYDRO TREATING

MIDDLE DISTILLATES

HVY ATMOS GAS OIL

CRUDE UNIT

REFORMING

CATALYTIC CRACKING

GASOLINE

VAC GAS OIL

FRACTIONATOR BOTTOMS

VACUUM SECTION

SOLVENT EXTRACTION LUBE BASE STOCKS

HYDRO GASOLINE-NAPHTHA-MIDDLE DISTILLATES CRACKING

LUBE OIL SOLVENT DEWAKING

WAXES

PROPANE DEASPHALTER

T H R E A T I N G

REGULAR

GASOLINE

PREMIUM

GASOLINE

SOLVENTS

B L E N D I N G

AVIATION FUELS

DIESELS

HEATINGS OILS

LUBE OILS

GREASES

ASPHALTS

GASOLINE - NAPHTHA - MIDDLE DISTILLATES FUEL OIL

VISBREAKER

ASPHALT

INDUSTRIAL

FUELS

REFINERY

GASOLINE - NAPHTHA - MIDDLE DISTILLATES DELAYED COKER

RETURN

FUEL OIL

Topping TYPICAL TOPPING UNIT GAS INCONDENSABILI

115 °C

INIEZIONE DI AMMONIACA ED INIBITORE DI CORROSIONE

RIFLUSSO DI TESTA

BENZINA LEGGERA

STRIPPER

VAPORE

FORNO

NAFTA

380 °C

200 °C

P U M P A R O U N D

RECUPERI DI CALORE

STRIPPER

VAPORE

KEROSENE

STRIPPER

VAPORE

GASOLIO

GREZZO RESIDUO PRIMARIO

RETURN

Pump Division

Pump Division

Pumps installed in the Refinery SERIAL NUMBER 15842 27215 28565 12387201 12387202 123887204 12387203 28924 12112201 12112202 16375 19120 16751 16752 16772 12387301 12387302 1204686-01 1204680-02 D48295 29459 D29458 16781 38258 39092

PROCESS

IT EM G905 G056 G1013 G133D G133E G209E G209D G1049 G3204A G3204B G345 G21 G142 G144 G144S G303D G303E G503B G503C G928S G1158C G1158R G406 G039 G051

Q.T Y 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

T YPE CNE CNFJ HN HNN HNN HNN HNN CNEX HAS HAS HN HN HN HN HN HNN HNN HNN HNN HNN HXB HXB CNE CNFEJ CNFEJ

PUMP SIZ E 1X52 1X104 1X91 1X91 1X91 1X91 1X91 1 1/ 2X82 1 1/ 2X134 1 1/ 2X134 1 1/ 2 X71 1 1/ 2X91 1 1/ 2X112 1 1/ 2X112 1 1/ 2X112 1 1/ 2X71 1 1/ 2X71 1 1/ 2X122 1 1/ 2X122 1 1/ 2X122 1 1/ 2X113 1 1/ 2X113 2X72 2X104 2X104

YEAR 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

RUN YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES

BILL OF MAT . CRIT ICAL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Pump Division

TOTAL Q.TY

U

Customer Pump Population and Technical Data 18

ITEM SWS2MP01A

Q.TA' 1

MFR WORTH

PUMP 2HNN122

SERIAL NUMBER 1223120/01

SWS2MP01B

1

WORTH

2HNN122

1223120/02

SWS2MP02A

1

WORTH

1HNN91

1223121/02

SWS2MP02B

1

WORTH

1HNN91

1223121/01

SWS2MP03A

1

WORTH

1HNN111

D48838

SWS2MP03B

1

WORTH

1HNN111

D48839

SWS1MP22A

1

KSB

ETA50-20

3101198368-2

SWS1MP22B

1

KSB

ETA50-20

3101198368-1

SWSMP101A

1

TURO

6-65HP/2

IT3799

SWSMP101B

1

TURO

6-65HP/2

IT3800

SWSMP107A SWSMP107B SWSMP108A SWSMP108B SWSMP109A

1 1 1 1 1

WORTH WORTH N. PIGNONE N. PIGNONE HALBERG

3HNN91 3HNN91 T1½X11TC T1½X11TC B100A

40235 40236 P12032 P12031 603429

SWSMP109B

1

HALBERG

B100A

603430

SWSMP110C

1

WORTH

1½HNN91

D49156

SWSMP110D

1

WORTH

1½HNN91

D49157

SERVICE S2-D2 S2-C1 S2-D2 S2-C1 S2-D2 SLOP S2-D2 SLOP S2-D1 S2-C1 S2-D1 S2-C1 D112 SLOP D112 SLOP S20D40 C101BIS S20D40 C101BIS V108 V108 SLOP SLOP C101BIS API C101BIS API V110 C101BIS V110

FLUID H2O ACIDA

Q m3/h -

temp. C° 40

H mt. -

SEAL MFR FLEX

SEAL RRAL 0450 A5FY

H2O ACIDA

-

40

-

FLEX

RRAL 0450 A5FY

IDROCARB.

-

40

-

FLEX

RRAL 0400 A5FY

IDROCARB.

-

40

-

FLEX

RRAL 0400 A5FY

H2O ACIDA

-

85

-

FLEX

RRAL 0400 A5DYY061

H2O ACIDA

-

85

-

FLEX

RRAL 0400 A5DYY061

IDROCARB.

-

30

-

FLEX

R2400 ORSPC40

IDROCARB.

-

30

-

FLEX

R2400 ORSPC40

H2O ACIDA

-

30

-

SEALOL

670AQ CSGF 000.025

H2O ACIDA

-

30

-

CRANE

2½9BT.QR1C1

H2O DEMIN. H2O DEMIN. IDROCARB. IDROCARB. H2O ACIDA

63 63 -

195 195 70 70 125

40 40 -

CRANE CRANE FLEX FLEX SEALOL

2"909BP QAR 1K1 2"909BP QAR 1K1 RRAL 0400Y002 RRAL 0400Y002 680AQCSGF000 025

H2O ACIDA

-

125

-

SEALOL

680AQ CSGF 000.025

H2O ACIDA

-

85

-

FLEX

RRAL 0400A5DYY071

H2O ACIDA

-

85

-

FLEX

RRAL 0400A5DYY071

Pump Division

Customer Pump Population and Technical Data SEAL SIZE RRAL 0450 A5FY

COUPLING

TYPE 1 -

DESE

GEAR

TYPE 2

R.T.

MOTOR MARELLI

TYPE M 180M/2

SERIAL N 1223120/01

POWER 18.5

RPM 2910

VOLT 380

RRAL 0450 A5FY

-

MARELLI

180M/2

1223120/02

18.5

2910

380

RRAL 0400 A5FY

-

MARELLI

D1C112M/2

1223121/02

4

2905

380

RRAL 0400 A5FY

-

MARELLI

D1C112M/2

1223121/01

4

2905

380

RRAL 0400 A5DYY061

-

MARELLI

D1C132SB/2

D48838

7.5

2890

380

RRAL 0400 A5DYY061

-

MARELLI

D1C132SB/2

D48839

7.5

2890

380

R2400 ORSPC40

-

MARELLI

132SB/2

3101198368-2

7.5

2905

380

R2400 ORSPC40

-

SCHORCH

KR751/2M132M

3101198368-1

7.5

2900

380

670AQ CSGF 000.025

-

ANSALDO

225M/2

IT3799

45

2960

380

2½9BT.QR1C1

-

ANSALDO

225M/2

IT3800

45

2960

380

2"909BP QAR 1K1 2"909BP QAR 1K1 RRAL 0400Y002 RRAL 0400Y002 680AQCSGF000 025

-

ANSALDO ANSALDO ANSALDO ANSALDO ANSALDO

160MR/2 160MR/2 160M/2 160M/2 160L/2

40235 40236 P12032 P12031 603429

11 11 15 15 18.5

2930 2930 2920 2920 2920

380 380 380 380 380

680AQ CSGF 000.025

-

ANSALDO

160L/2

603430

18.5

2920

380

RRAL 0400A5DYY071

-

MARELLI

C132S/2

D49156

7.5

2905

380

RRAL 0400A5DYY071

-

MARELLI

C132S/2

D49157

7.5

2905

380

Pump Division

Identification critical pumps Critical pumps are: 1. Critical to maintain refinery output 2. Critical because of Bad Acting . 3. Critical as no redundancy is available 4. Critical for health, safety and environmental issues.

Store critical pumps in refinery database

Generation Engineering Data

Pump Division

Normally a refinery has pumps of many different brand names and different sizes and types An indepth review of the customer pump population is required to collect from each pump, turned, parts information and gasket information. (Turned parts are typical shaft wearrings and bushings.) Flowserve (17 pump herritages)

Drawing and BOM readily available

Non Flowserve pumps

Retrieve data and reverse engineering for drawings

Store in refinery database

Pump Division

Generation Engineering Data An indepth review of the customer pump population is required to collect from each active pump all casted parts data (Impellers, difusers etc.) Flowserve (17 pump herritages)

Data is available

Non Flowserve

Retrieve data

Store in refinery database

Standarization

Pump Division

Turned parts Reduce many different kind of materials used, sometimes we see over 40 different materials used (ASTM, DIN, etc) Select 3 materials suitable to do all services and standarize.

Store in refinery database Select raw material dimensions for the 3 selected materials to suit the production of all turned parts

Casted parts Hydraulic engineer to review a standarization to eliminate almost similar hydraulics. Also review hydraulic optimalization Define critical pump casted part inventory level.

FLOWSERVE INTELLIGENT STOCK RECOMMENDATION Pump Division a

PUMP TYPE (INSTALLED PUMPS)

HNN -HNNT- HN -HNI-HPX HDS LN HED UXH UZD CNFE-CNFJ MR HL GAUK WUC HAS 8BHU VARIE

b

PARTS TO HAVE IN STOCK

IMPELLER SHAFT CASING RING IMPELLER RING BUSHING SHAFT SLEEVE DIAPHRAM GASKETS

Flowserve Intelligent Stock

a

b

VALUE OF PROPOSED STOCK PUMPS NOT CRITICAL 6 WEEKS IMPELLERS 1 WEEK SHAFTS 1 WEEK WEAR PARTS/ BUSHINGS 1 WEEK SHAFT SLEEVES 1 WEEK GASKETS CRITICAL PUMPS + 4 EMERGENCY 1 WEEK IMPELLERS 36 HOURS SHAFTS 36 HOURS WEAR PARTS/ BUSHINGS 36 HOURS GASKETS

237 18 27 14 6 3 12 5 2 1 1 26 1 40 TOTAL Q.TY FLOWSERVE FLOWSERVE FLOWSERVE FLOWSERVE FLOWSERVE FLOWSERVE FLOWSERVE FLOWSERVE

393

AVAILABLE AVAILABLE AVAILABLE AVAILABLE AVAILABLE

Euro T.B.A. T.B.A. T.B.A. T.B.A. T.B.A.

68 48 520 144

330 K.Euro 70 K.Euro 160 K.Euro 4 K.Euro

total amount

564 K.Euro

Turned Parts Supply

Pump Division

36- HOURS

Casted Parts Supply

Pump Division

IMPELLERS

DIAPHRAMS

CASING

1- WEEK

Pump Division

lCUSTOMER

DATA

lPRODUCTION lTYPE

OF PROCESS

lTYPE

OF SERVICE

lOPERATING lDRIVER

CONDITIONS

DATA

lMECHANICAL

SEAL DATA

lITEM lPUMP lSERIAL lBILL

NUMBER

OF MATERIAL

lCOMPONENT lARTICLE lCONSTRUCTION

DRAWING

lMATERIAL lRAW

CLIENTE AGIP REGIONE SICILIA LOCALITA' PRIOLO SETTORE RAFFINERIA CAPACITA' 15 MILIONI DI TONNELLATE ANNO UNITA' TOPPING ITEM P101A Q.TA' 1 MACCHINA POMPA SERVIZIO FONDO COLONNA CONDIZIONI FUNZIONAMENTO Q / H / NPSHA/TEMP/ MOTRICE MOT.EL. GIUNTO FLESSIBILE COSTRUTTORE TIPO MATRICOLA LISTA PEZZI ARTICOLO DESCRIZIONE Q.TA' TOTALE CODICE ASTM CS DISEGNO GREZZO UNITA' MISURA DISEGNO FORMULA DIMENSIONE PESO DIM.Max DIM MIN CODICE MATERIALE FORMA

WORTHINGTON 2HNN112 19003 1002000000 4023102960 ALBERO 14 A434_4140 BM45235 8011220800 MM 678 CM04399100 D 080^2*Pi/4 3,92 80 0 8235 TONDO

4022305950 BUSSOLA 10 B584_C938 BM45235 8317011330 MM 15 AM05118400 D-d 70^2-35^2 2,25 70 35 8701 CANNELLA

MATERIAL CODE RETURN

Intelligent stocking

Pump Division

Advantages Reduced inventory levels and inventory capital value is reduced due to raw material stocking instead of complete finished machining value. When pump is taken out of service for overhaul, parts arrive for the critical pumps when pump is open and inspected. This reduces the time of being out of service, sometimes by 50% For emergency repairs, still genuine parts according original design data are used, and heat treated, which is most of times not done when turned parts have to be made locally under emergency. One phone call starts the entire supply chain for parts delivery (automatic)

Pump Division

Standardization Flowserve has developed special standardization programs, which also bring refinery pumps to latest API 610 edition and allow API 682 mech. Seal implementation.

Example: RV-X- program for single stage overhung process pumps

Pump Division

What is RV-X- ? It is Flowserve API-610 10th edition power frame upgrade back pull out assembly.

It is a complete pump less - Pump case - Case ring - Impeller

- Impeller ring - Impeller locknut - Seal - Coupling guard

Pump Division

RV-X- Features & Benefits Eliminates disturbance to existing Suction and discharge piping.

Increase Reliability.

- Heavy duty construction (available in 3 sizes only)

- Metal to metal casing fit with fully confined gasket cavity. - Controlled compression gasket ensures proper sealing and alignment. - Air gap at the drip pocket - Insulate bearing housing in high temperature applications.

Increase Seal Life - Low L3 / D4 - Large Radial and Thrust Bearings.

Pump Division

RV-X- Features & Benefits Continued Eliminate need for cooling water jacket at the bearing housings. -Standard outboard fan. - Provision for cooling fan. - Provision for oil mist lubrication (optional).

Reduce Inventory - Parts & Seals. - Three std. Size seal chambers (API # 4, 6 & 8) - Three frame size for 95% of overhang process pumps

Quick delivery. - Parts and materials of construction are standardized. S6 (Carbon Steel) C6 (Chrome Steel) A8 (Stainless Steel)

RV-X- Frame Selection (3) Standard Assembly Frame sizes : - A Frame : 8.5 through 10.0 impellers - B Frame : 10.5 through 17.0 impellers - C Frame : 18.0 through 21.0 impellers

Pump Division

(3) Standard seal chambers per Table 6 : - A Frame : seal chamber size #4 - 49.5 mm - B Frame : seal chamber size #6 - 69.5 mm - C Frame : seal chamber size #8 - 86.0 mm

RV-X- Frame A API Seal Chamber Size # 4

Pump Division

RV-X- : Lower L3/D4 Shaft Stiffness Index L

Pump Division

D Stiffer Shaft Means: Less loading on mechanical seal. Less chances of rubbing wearing rings. Results in: Inc rease MTBR and higher reliabilit y.

Pump Division

Life Cycle Costs (LCC)