1. Economic Benefits Achieved
Through Fluid System Optimization
An Open Discussion

2. Cost of operation savings through System Optimization
What if?
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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
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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
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5. Cost of operation savings through System Optimization
Delivering to the end user?
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6. Cost of operation savings through System Optimization
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7. Cost of operation savings through System Optimization
And for the rest of us….
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8. Positive Displacement Screw Pumps
The worlds shortest pump training session..
Really the worlds shortest…
Honest!!
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9. Imo 3 Screw Pump
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10. Double Ended Pump
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11. Geared Twin Screw Pump
INLET OUTLET
TIMING GEARS
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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…
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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
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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.
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15. Cost of operation savings through System
Optimization
Fuel flow to turbine combustors
Controlled Flow Rate
Dependant Upon the
Control
Flow Divider
Power Output Loads
Bypass
Bypass flow return to source Valve
Pump Output Full Flow and Pressure
Fuel inlet
Inlet
Filtration
250HP, 3585 RPM
Premium Efficiency
Imo AK12DHZ-275E
IEEE-841 Motor
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16. Cost of operation savings through System Optimization
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17. Cost of operation savings through System Optimization
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18. Cost of operation savings through System Optimization
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19. Cost of operation savings through System Optimization
Output at 100% load, 1500 psi
Distillate B100
Pump RPM 3585 3585
Viscosity 1.8 cSt 10 cSt
Delivered Flow (GPM) 203 214
BHP Required 234 234
Typical flow to turbine for 100% 180 180
load
By Pass Flow 22 34
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20. Cost of operation savings through System Optimization
Output at 70% load, 1000 psi
Distillate BioDiesel
Pump RPM 3585 Full Motor Speed
Delivered Flow (GPM) 211 216
BHP Required 162 162
Typical Flow to turbine for 70% Load 135 135
By Pass Flow 76 81
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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”!
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22. Cost of operation savings through System Optimization
Fuel flow to turbine combustors
Controlled Flow Rate
Dependant Upon the
Control
Flow Divider
Power Output Loads
Bypass
Bypass flow returned to source Valve
Pump Output Full Flow and Pressure
Colfax
“Smart System”
Inlet Controls
Fuel inlet Filtration
250HP, 3585 RPM
Imo AK12DHZ-275E
Premium Efficiency
IEEE-841 Motor
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23. Cost of operation savings through System Optimization
Pump Output at Controlled operational speeds
Distillate BioDiesel
Pump RPM 2600 Controlled Motor Speed
Delivered Flow 144 148
BHP Required 113 113
Typical Flow to turbine for 70% 135 135
Load
By Pass Flow 9 GPM 13 GPM
By Pass Flow Differential 67 GPM-86% 68 GPM-81%
Horsepower Saved 49 49
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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
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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:
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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…
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27. Another example
A large New England Steam Turbine Plant which operates primarily on residual fuel.
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28. Savings
$ / MW-hr 0.065 0.15 0.20 0.25
Savings Per Year $60,191.04 $138,902.40 $185,203.20 $231,504.00
Savings Over 5 years $300,955.20 $694,512.00 $926,016.00 $1,157,520.00
Savings over 25
$1,504,776.00 $3,472,560.00 $4,630,080.00 $5,787,600.00
years
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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.
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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…
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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”
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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:
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33. Cost of operation savings through System Optimization
•The cost of Energy saved is $1,800,209.00 over 5 years
Energy Costs for 5 Years "per Pump" @ 10 cents US per kW/hr:
Crude oil at 300 cP $1,166,490.36 Crude oil at 300 cP $578,343.96
TCO for crude oil at 300 cP $6,156,199.74 TCO for crude oil at 300 cP $4,355,990.55
TCO Breakdown for Centrif Pumps at 300 cP TCO Breakdown for PD Pumps at 300 cP
13% 19%
11%
61% 20%
76%
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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
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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.
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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.
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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:
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38. Colfax Buffalo
372A5012 Main and Auxiliary Lube Oil Pump 9FA 50Hz CT
BHP Kw $ / hr $ / Yr $ / 25 Yr BHP Kw $ / hr $ / Yr $ / 25 Yr
108 80.57 $9.77 $85,575.30 $2,139,382.53 113 84.30 $10.54 $92,306.31 $2,307,657.75
63% 60
1050 GPM
303 ft
Maintenance Major Maintenance Event Major Maintenance Event
Inspect / Replace Main Bearing 6 bearing service events and 1 Major service
Service interval 5.7 years Service interval 1year
Cost per interval $5,000.00 Cost per interval $13,000.00
Cost Over 25 years $15,000.00 Cost Over 25 years $325,000.00
Cost of at least one failure $20,000.00
TCO Colfax $2,159,382.53 TCO Buffalo $2,652,657.75
incl. Energie costs incl. Energie costs
excl. Purchase price excl. Purchase price
Differential $493,275.22
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39. Cost of operation savings through System Optimization
The Common Thread?
An economic analysis along with
component or system design…
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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”…
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41. Cost of operation savings through System Optimization
The world’s largest Positive
Displacement Pump
Manufacturer.
The 6th largest pump / fluid
system manufacturer…
Global…15 manufacturing
locations
Strategically located Service and
Applications engineering
personnel…
Our reach is Global, your
contacts are local…
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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…
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43. Cost of operation savings through System Optimization
Our Brands
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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…
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45. Cost of operation savings through System Optimization
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46. Cost of operation savings through System Optimization
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47. Cost of operation savings through System Optimization
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48. Cost of operation savings through System Optimization
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49. Cost of operation savings through System Optimization
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50. Cost of operation savings through System Optimization
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51. Cost of operation savings through System Optimization
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52. Cost of operation savings through System Optimization
Thank You!!!!
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