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Colfax Americas Lunch And Learn Presentation Economics Of System Optimization

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An overview of positive displacement pumps for the power generation market.

An overview of positive displacement pumps for the power generation market.

Published in: Education

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  • 1. Economic Benefits Achieved Through Fluid System Optimization An Open Discussion
  • 2. Cost of operation savings through System Optimization
    • What if?
  • 3. Cost of operation savings through System Optimization
    • What Matters?
      • It’s not...Just the pump,
      • Nor the individual components
    • It is…
      • A properly designed integral system,
      • And the operation of the same
  • 4. Cost of operation savings through System Optimization
    • That results in an “Optimized System”…
      • Which Provides for:
      • Efficient Operation
      • Reduced Maintenance
      • Enhanced Reliability
      • Increased Uptime and Availability
  • 5. Cost of operation savings through System Optimization
    • Delivering to the end user?
  • 6. Cost of operation savings through System Optimization
  • 7. Cost of operation savings through System Optimization
    • And for the rest of us….
  • 8. Positive Displacement Screw Pumps
    • The worlds shortest pump training session..
    • Really the worlds shortest…
    • Honest!!
  • 9. Imo 3 Screw Pump
  • 10. Double Ended Pump
  • 11. Geared Twin Screw Pump
  • 12. Cost of operation savings through System Optimization
    • Ok, Who are these Colfax Guys anyway??
    • Well, were not just Imo Pumps any More….
    • That is assured!
    • Global scope
    • 10 Separate business units
    • 15 Manufacturing locations
    • 30+ Strategic Partners
    • We’ll talk a bit more later on…
  • 13. Cost of operation savings through System Optimization
    • Application #1
    • Energy savings by means of “optimizing” the system to allow for proper operation.
    • The issue: An operational system that has optimal pump and system efficiency at 100% turbine load. However the system efficiency is compromised at normal operating levels of 70% load.
    • Project main Fuel Injection pumps feeding a 110Mw Simple Cycle Peaker
  • 14. Cost of operation savings through System Optimization
    • The Project;
    • HECO (Hawaiian Electric Co.) at the Campbell Industrial Park generating station on the island of Oahu.
    • The prime mover at this 110-MW simple cycle power plant is a U.S. manufactured combustion turbine.
    • The plant is designed to operate with B100 BioDiesel renewable fuel as its primary fuel supply, a unique feature in today’s marketplace.
    • Clean distillate fuel will also be used for system flush prior to shutdown and will be contained in the system during extended shutdown periods.
  • 15. Cost of operation savings through System Optimization Bypass flow return to source Fuel inlet Imo AK12DHZ-275E Flow Divider Fuel flow to turbine combustors Pump Output Full Flow and Pressure Control Bypass Valve Controlled Flow Rate Dependant Upon the Power Output Loads Inlet Filtration 250HP, 3585 RPM Premium Efficiency IEEE-841 Motor
  • 16. Cost of operation savings through System Optimization
  • 17. Cost of operation savings through System Optimization
  • 18. Cost of operation savings through System Optimization
  • 19. Cost of operation savings through System Optimization 34 22 By Pass Flow Typical flow to turbine for 100% load BHP Required Delivered Flow (GPM) Viscosity Pump RPM Output at 100% load, 1500 psi 180 234 203 1.8 cSt 3585 Distillate 180 234 214 10 cSt 3585 B100
  • 20. Cost of operation savings through System Optimization 81 76 By Pass Flow 135 135 Typical Flow to turbine for 70% Load 162 162 BHP Required 216 211 Delivered Flow (GPM) Full Motor Speed 3585 Pump RPM BioDiesel Distillate Output at 70% load, 1000 psi
  • 21. Cost of operation savings through System Optimization
    • This type of operation is prevalent in nearly all combustion turbine installations built by US based manufactures.
    • Well, we now do know that this type of system can easily be “Optimized” by the addition of some Colfax “Smart System Controls”!
  • 22. Cost of operation savings through System Optimization Bypass flow returned to source Fuel inlet 250HP, 3585 RPM Premium Efficiency IEEE-841 Motor Imo AK12DHZ-275E Flow Divider Fuel flow to turbine combustors Pump Output Full Flow and Pressure Control Bypass Valve Controlled Flow Rate Dependant Upon the Power Output Loads Colfax “ Smart System” Controls Inlet Filtration
  • 23. Cost of operation savings through System Optimization 49 49 Horsepower Saved 68 GPM-81% 67 GPM-86% By Pass Flow Differential 13 GPM 9 GPM By Pass Flow 135 135 Typical Flow to turbine for 70% Load 113 113 BHP Required 148 144 Delivered Flow Controlled Motor Speed 2600 Pump RPM BioDiesel Distillate Pump Output at Controlled operational speeds
  • 24. Cost of operation savings through System Optimization
    • Hawaiian electric rates are $.299 / Kw/Hr
    • Horsepower saved 49
    • Equivalent kilowatts 35
    • What are the savings?
    • 1 hour = $10.99
    • 1 day = $263.72
    • 1 year = $96,257.00
    • 5 year = $481,285.00
  • 25. Cost of operation savings through System Optimization
    • Consider that:
    • Without considering inflation and fuel costs in the future the energy saved in the operation of this fairly small combustion turbine will be nearly $2,500,000.00 over the 25 year life expectancy of the plant!
    • And this operational scheme will work on:
  • 26. Cost of operation savings through System Optimization
    • Boiler Fuel Injection Pumps in Steam Turbines.
    • Fuel Transfer and Forwarding.
    • Boiler Feed and Condensate Pumps.
    • Any system that has a variable system flow or pressure demand is a candidate for this type of upgrade…
  • 27. Another example
    • A large New England Steam Turbine Plant which operates primarily on residual fuel.
  • 28. Savings $5,787,600.00 $4,630,080.00 $3,472,560.00 $1,504,776.00 Savings over 25 years $1,157,520.00 $926,016.00 $694,512.00 $300,955.20 Savings Over 5 years $231,504.00 $185,203.20 $138,902.40 $60,191.04 Savings Per Year 0.25 0.20 0.15 0.065 $ / MW-hr
  • 29. Cost of operation savings through System Optimization
    • Application #2
      • Savings gained by considering other options in equipment selection in lieu of the “Usual Type” of equipment previously utilized.
      • Then when using TCO comparisons in the design stage the overall economic benefits will be clearly evident
    • Project:
      • Pipe line, Fuel Transfer, and Unloading systems
    • Solution:
      • The use of Positive Displacement pumps in lieu of the “Obvious Choice” Centrifugal machines.
  • 30. Cost of operation savings through System Optimization
    • Let’s look at a pipeline application where the operational conditions would normally call out for a multi-stage centrifugal pump….
    • This application is for a 4380GPM pipeline delivering a light crude oil…
  • 31.
    • In the Oil and Gas Industry there still remains a preference for the use of centrifugal pumps (even when horribly misapplied) because….
    • ”We can always fix them in our shops”
  • 32. Cost of operation savings through System Optimization
    • How about a pump that doesn’t break down?
    • Or, “Yes you can do an on-site repair quick and cheap”
    • But do you know how much it really costs to operate the equipment?
    • Despite the initial capital equipment costs and 5 years of parts and maintenance charges being nearly equal….
    • The total “Savings Gained” are:
  • 33. Cost of operation savings through System Optimization
    • The cost of Energy saved is $1,800,209.00 over 5 years
  • 34. Cost of operation savings through System Optimization
    • Application #3
      • Savings by means of utilizing “Optimally Designed” equipment.
    • Project:
      • Main Lube and Seal Oil Pump for GE Frame 7-FA/FB Gas Turbines
    • Solution:
      • The application of pump sets that were specifically designed for this type of “Mission Critical” service
  • 35. Cost of operation savings through System Optimization
    • The Problems
    • Excessive Maintenance Costs.
    • Short Maintenance Intervals
    • Many Field Failures
    • Unresponsive Supplier
    • OEM Turbine Manufacturer does not consider the operators cost of operation.
  • 36. Cost of operation savings through System Optimization
    • The Solution:
    • To Incorporate a pump that had been from the onset, specifically designed, for “Mission Critical Application” service.
    • Providing:
    • Robust design
    • Very High Reliability
    • Low maintenance requirements
    • Extended service intervals to coincide with planned outages.
  • 37. Cost of operation savings through System Optimization
    • On average the cost of maintenance of the original design pumps is from $15,000.00 to $17,000.00 per year per turbine…
    • A Combined Cycle installation of 2 two Combustion Turbines and one Steam Turbine can cost around $40-$45 K per year
    • The Savings gained by doing it right are:
  • 38.  
  • 39. Cost of operation savings through System Optimization
    • The Common Thread?
    • An economic analysis along with component or system design…
  • 40. Cost of operation savings through System Optimization
    • So who is Colfax?
    • We are:
    • A world leader in the development, engineering, manufacturing, distribution, service and support of pumping and fluid-handling systems…
    • A synergistic group of individual pump, systems, instrumentation manufactures, and “Strategic Partners”…
  • 41. Cost of operation savings through System Optimization
    • The world’s largest Positive Displacement Pump Manufacturer.
    • The 6 th largest pump / fluid system manufacturer…
    • Global…15 manufacturing locations
    • Strategically located Service and Applications engineering personnel…
    • Our reach is Global, your contacts are local…
  • 42. Cost of operation savings through System Optimization
    • 9 individual pump manufacturing business units
    • Specialized Instrumentation and Controls group
    • We have access to nearly every pump technology!
    • Skid and System design and construction expertise In US and international specifications…
  • 43. Cost of operation savings through System Optimization
    • Our Brands
  • 44. Cost of operation savings through System Optimization
    • Your pump and fluid systems design and equipment selection expertise has grown exponentially…..
    • No charge for opinions…
    • Here’s some interesting pictures…
  • 45. Cost of operation savings through System Optimization
  • 46. Cost of operation savings through System Optimization
  • 47. Cost of operation savings through System Optimization
  • 48. Cost of operation savings through System Optimization
  • 49. Cost of operation savings through System Optimization
  • 50. Cost of operation savings through System Optimization
  • 51. Cost of operation savings through System Optimization
  • 52. Cost of operation savings through System Optimization
    • Thank You!!!!