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Life Cycle Cost Analysis Systematic Approach

Life Cycle Costs In Pumps and Pumping Systems


(Based On Guidelines of Hydraulic institute Standard)

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach


Life Cycle Cost (LCC)

The LCC of any piece of equipment is the total Lifetime cost required to Purchase, Install, Operate, Maintain , and Dispose of that equipment.

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach


Pumping system account for nearly 20% of worlds electrical demand and range from
20- 50% of pump energy usage in certain industrial plant operation. For majority of the facilities, lifetime energy and maintenance cost will dominate the LCC

Purchase price

Operating cost Maintenance cost

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach


Why LCC Why should organizations care about life cycle cost? Many organizations only consider the Initial purchase and installation cost of the equipment. It is in the fundamental interest of the plant designer and manager to evaluate the LCC of Different solutions before installation of new plant or major over haul. This Evaluation will help in identifying financially attractive alternative / solution. In todays competitive market organizations must continuously seek cost saving which will improve their profitability.

Along with economic reasons , LCC helps in developing awareness about environmental impact of their business and conserving energy as one way to reduce emission, preserve natural resources and reduce carbon foot print. This will also help in reducing emission of Green House gases.
The developed world has become acutely aware of the effect of its energy waste and the introduction of levies on CO2 emissions now directly taxes the inefficient users of energy.
This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps

Cross section of LLC Series Vertical Turbine Pump


This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps
LLC VERTICAL TURBINE FEATURES & BENEFITS (Contd)
FEATURE/ADVANTAGE Shaft Couplings Keyed muff type couplings fitted as standard. CUSTOMER BENEFIT Easily removable, unlike lower cost screwed couplings ensuring increased component life. Reduced maintenance costs. Site standards and customer specified options accommodated. Facilitates compliance with customer frame contracts for mechanical seals etc. Facilitates removal of cartridge type mechanical seals without disturbing thrust bearing assembly or driver and negates the need for expensive split mechanical seals. Substantial reduction in maintenance costs. Anti-friction or Michell type thrust bearings dependant on load. Minimum L10 life in excess of 50,000 hours under all design load conditions. Longevity of design combined with increased bearing life ensures lowest cost of ownership. Facilitates use on potable water applications.

Universal Seal Chamber

Customer specified mechanical seals or traditional soft packed gland arrangements.

Spacer Coupling

Spacer Coupling as standard.

Thrust Bearing Assembly Headpiece Coatings

Heavy duty thrust bearing assembly.

Large heavily engineered fabricated headpieces, ensure minimal vibration and long bearing life. Drinking water approved coatings.

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps

Cross section of LLC Series Horizontal Split Casing Pump


This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps
LLC HSC FEATURES & BENEFITS
Casing
Axially split casing with nozzles in the bottom half casing

FEATURE/ADVANTAGE
Rotating element can be removed insitu, without need to disturb either the pipework or driver avoiding the need for subsequent re-alignment

CUSTOMER BENEFIT
Enhanced bearing life. Less downtime. Reduced maintenance costs.

Double volute casings, where radial loads dictate.

Reduces radial load and subsequent shaft deflection. Only incorporated where necessary, as double volute design tends to have an efficiency penalty. SPP (Our) policy on smaller frames is to enhance the L3/D4 ratio, by incorporating more generous size pump shafts. Enhancement in L/D ratio helps in limiting shaft deflection lesser than wear ring clearance.
An efficiency enhancing drinking water approved coating is standard for water applications. This is optional for general service pumps.

Enhanced bearing life. Some competitors offer double volute across the range. This is not energy efficient. SPPs (Our) smaller frames will be more efficient reducing energy costs.

Coating

Reduced energy consumption/cost.

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps
LLC HSC FEATURES & BENEFITS (Contd)

FEATURE/ADVANTAGE Impeller Precision casting in austenitic stainless steel as standard. Axially hydraulic balance of double suction design improves efficiency and enhances bearing life. Rotating assemblies are dynamically balanced minimizing vibration. Positively locked and keyed to pump shaft. The new Weir Uniglide E does not incorporate a key driven impeller, hence it will be difficult to remove and may not offer the conservative thinking engineer the comfort required.

CUSTOMER BENEFIT Increased component life Increased cavitation resistance. Superior hydraulic performance. Increased bearing and component life. All above result in reduced maintenance costs. Easily removable and positively driven. Pump handing can be changed insitu. Not so easy with a shrink fit impeller. Security of operation Lower maintenance costs.

Impeller Fixing

Shaft

Corrosion resistant rigid stainless steel shaft as standard. Low L3/D4 ratio ensures minimum deflection and long bearing life. Maintains optimum efficiency longer, as no contact between impeller and wear rings.

Increased bearing and shaft life. Reduced maintenance and energy costs.

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps
LLC HSC FEATURES & BENEFITS (Contd)
FEATURE/ADVANTAGE Bearings API type double row thrust bearing assembly. Thrust Bearing assembly situated at drive end, ensuring any thermal growth on high temperature service is not transmitted to coupling and driver. Hard metallic serrated casing wear rings. Impeller wear rings are optional and can be fitted during overhaul. Universal seal chamber. Weir Uniglide E does not accommodate soft packed gland and is fitted with a Weir Mech. Seal. Maintains regulated pressure in at seal faces ensuring no dry running and facilitates high temperature operation. CUSTOMER BENEFIT L10 life in excess of 50,000 hours, under all design load conditions. Security of operation for the more conservative thinking engineer.

Wear Rings

Long life and reduced energy consumption. Lowest whole life cost option. Minimises initial capital cost and can be fitted during overhaul if impeller wear is evident. Accepts most commercially available single or double cartridge mechanical seals or traditional gland packing. Operation up to 120oC with standard seal arrangement. Low capital and maintenance costs.

Seal Chamber

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Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps
LLC HSC FEATURES & BENEFITS (Contd)
FEATURE/ADVANTAGE Mechanical Seals Customer specified mechanical seals. Site standards and customer specified options accommodated. Facilitates suction lift with single cartridge seal options. Throttle Bush reduces energy consumption and facilitates suction lift with single mechanical seals. Externally removable bearing housing. Ease of maintenance. Bearings and seals can be removed without removing top half casing. Bosses are provided as standard for condition monitoring transducers. CUSTOMER BENEFIT Facilitates frame contracts for consumable parts seals, bearings etc. Operation with negative suction pressures/suction lifts without expensive barrier fluid systems. Ease of maintenance and operation, reducing running and maintenance costs. Low energy costs, also facilitates a wider range of application, reducing capital and maintenance costs. Lower maintenance costs. Minimal downtime. Improved reliability with reducing downtime and associated costs.

Throttle Bush Bearing Housings

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Life Cycle Cost Analysis Systematic Approach LLC Series Horizontal Split Casing Pumps
LLC HSC FEATURES & BENEFITS (Contd)
FEATURE/ADVANTAGE Coating options Efficiency enhancing drinking water approved coating applied as standard on potable water applications, optional for industrial use. Channel section base plate incorporating motor jacking screws as standard ensure vibration free operation and easy alignment on site. A spacer coupling facilitating removal of the drive end bearing and seal in-situ, without need to remove and re-align the drive motor. CUSTOMER BENEFIT Reduces energy costs.

Base plates

Reduces expensive down time and maintenance costs.

Spacer Coupling as standard.

Reduces expensive down time and maintenance costs.

This is a proprietary document of Kirloskar Brothers Limited

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Life Cycle Cost Analysis Systematic Approach Hydraulic Deterioration


Original BEP Flow Reduces = More Hours run

Head/Flow

Deteriorated

Efficiency

Efficiency Loss = More Power per hour

Deteriorated

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Life Cycle Cost Analysis Systematic Approach Degradation Cost


10 Year Additional Energy Cost Due To Efficiency Degradation (Rs.6 per kW/Hr)
9000000 8000000 7000000 6000000
Average 1% pa

Cost (INR)

5000000 4000000 3000000 2000000 1000000 0


50 kW 15 0k W 25 0k W
LLC Average 0.25% pa Additional Energy Cost Rs. 5.6 million)

Absorbed Power KW

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35 0k W

Life Cycle Cost Analysis Systematic Approach

5% Saving on 100 KW = 44,000 kW pa = Rs. 0.38 million = 125,000 kW pa Saved Generation

Pump rarely BEP

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach

CO2 Emissions Saving / Year per 1% Efficiency 0.43 kg CO2/kWh


14,000 12,000
Carbon Emissions (kg CO2)

In ten years you would lose


$657 thousand

10,000 8,000 6,000 4,000

20000 miles 1.8 Family Saloon

Round the world flight

2,000 0 0kW

50kW

100kW

150kW

200kW

250kW

300kW

350kW

Absorbed Power

This is a proprietary document of Kirloskar Brothers Limited

Life Cycle Cost Analysis Systematic Approach

Conclusion Life Cycle Cost is a highly practical tool for the users which can be very effectively used to evaluate and compare any equipment, particularly for complex pumping systems to make purchase decision from the available alternatives and safeguard own interests. KBL has used this concept effectively in the products and introduced this in the market.

This is a proprietary document of Kirloskar Brothers Limited

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Life Cycle Cost Analysis Systematic Approach

THANK YOU
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This is a proprietary document of Kirloskar Brothers Limited

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