Pump Life Cycle Cost 3 Maintenance Cost Reduction

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

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!
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.
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

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).
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
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

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

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
Conditioning Monitoring
Process Plant, Chemical Plant, Refinery
Weekly
WeeklyororMonthly
Monthly
data
datataking.
taking.
Hand-hold vibro-meter
Pump P001
mm/sec Alarm Level - - - - - - - - - - - - - - - *
RMS * * * * * *
* * * *
Time
Pump Division

Vibration operational
spectrum (FFT)
Permanent
installed
system
From Measured
Vibration Data we can
produce.
FFT (spectrum) Filtered vibrations, bode plot
with speed variation
Coupled to truth table

Truth table by vibration

specialist
(Troubleshooting chart)
Truth table by vibration

specialist
(Troubleshooting chart)
Result of database search
Pump Division

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.
Pump Division
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
Lowest MTBO
Preventive Maintenance MTBR
Predictive maintenance Higher MTBR
Pump Division
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.
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!!!

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

RISK BASED MAINTENANCE (1)

USED FOR WORK SELECTION AND RISK ASSESSMENT
CONSEQUENCES
WORK TO BE DONE
WORK MAY BE DONE LATER
PROBABILITY
RISK BASED MAINTENANCE (2)

USED FOR WORK SELECTION AND RISK ASSESSMENT
CONSEQUENCES
WORK TO BE DONE
WORK MAY BE
POSTPONED
NO WORK TO BE DONE
PROBABILITY
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

Upgrading Bad Acting pumps
Reduced maintenance costs

Repair costs
Reduce inventory levels due to better
reliability availability
Eliminate down time costs.
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.
Basic Technology Groups
Materials Vibro Hydraulic Mechanical Application

Welding Elastics Design Design Knowledge
New Materials Noise Overall General Design Runout

Efficiency
Repair welding Vibrations Bearings NPSHa
Cavitation
PTA Welding Pulsations Seals Transients
Recirculation
HVOF overlay Etc. Seal systems
Etc. Foundations
Diffusion Warm-up
alloying (TMT) Driver
Internal Technology
Surface alignments
treatement Etc.
Etc.
Erosion
Corrosion
Flowserve, basic technology
groups covering all areas for
Workshop Re
LCC reductions of centrifugal
pumps

Knowledge
Material selection based on

product and application.
PTA welding for hard facing

of close running clearances.

Knowledge
Wear area s
Overlay welding
Laser hardening
wear rings
HVOF spraying
Diffusion Alloying

Knowledge
Diffusion Alloying

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

Knowledge
Vibrations
Rotor-dynamic analysis
Lateral critical speed
Unbalance response
Eigen value / stability
Torsional analysis
(transient)

Knowledge
Vibrations
Structural dynamic analysis
Foundation analysis
Unbalance response
analysis
Structural resonances FEM

Knowledge
Vibrations
Field measurements
Spectrograms
Signature analysis
Modal analysis
Running mode
analysis
Etc.

Knowledge
Noise
Noise intensity measurements

Knowledge
Pulsations
Finite element acoustic analysis
(acoustic resonance)
Field measurements
Spectrograms
Signature analysis
Etc.
Capabilities
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
Capabilities
Knowledge
Test Capabilities
Full load Q-H and NPSH testing up to 20 MWatt available
from high voltage net.
Capabilities
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
Capabilities
Knowledge
CFD analysis example
Original impeller New impeller

Capabilities
Knowledge
Flow visualization testing
Purpose build full scale Permanent set up for full scale

model for flow or scaled model test
visualization testing
Capabilities
Knowledge
Field performance testing
Torque meter Flow meter Data logger

Capabilities
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.
Capabilities
Knowledge
Turn-Key Project Engineering

Piping / supports.
Foundation / civil.
Instrumentation / Logics.
Auxiliary systems.
Capabilities Pump Division

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:
Nuclear power plants Over 52 MWatt BFP
Conventional power blocks Hydro-test over 650 bar
Supercritical power blocks High speed, 100% pump 300 MWatt
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.
Capabilities
Knowledge
Application Knowledge
Min. flow systems Foundation design
Low-tuned
Deaerator design
Table design
Bleed-off lines (ITO)
Transient operating conditions
Attemperation stages
Warming up systems
Transient plant conditions
Shaft sealing
50% pump run-out evaluation
Throttle bushing T-controlled
Driver related items:
Throttle bushing P controlled
Slow-roll turbine
Mechanical seals
Fluid couplings
Boiler filling
Variable speed E-motors
Intermittent operation
Etc.
Condenser foundation deformation
Capabilities
Knowledge
Application Knowledge
Brite Euram foundation
springs
Pump Division
Life Cycle Costs (LCC)

Pump Life Cycle Cost 3 Maintenance Cost Reduction

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pump Life Cycle Cost 3 Maintenance Cost Reduction

Uploaded by

Copyright:

Available Formats

WORKSHOP

CARTAGENA, JULY 2007

LYFE CYCLE COST (LCC)

Pump LCC reduction.

LYFE CYCLE COST (LCC)

Introduce a LCC data-base

Selection of the best Maintenance Strategy is very

Process has to be operational 30% of the year, the rest of the

Generates many pumps to fail, giving a low MTBR.

LYFE CYCLE COST (LCC)

If you use a Run to Failure strategy it either

Example: - Nuclear Power Plant

For many years preventive maintenance was used in

It generates a higher maintenance cost than needed, certainly when

LYFE CYCLE COST (LCC)

Example: Esso/EXXON European refineries use almost all predictive / risk

LYFE CYCLE COST (LCC)

This maintenance strategy uses condition monitoring

LYFE CYCLE COST (LCC)

Coupled to truth table

Truth table by vibration

Truth table by vibration

LYFE CYCLE COST (LCC)

Is now a days most frequently used maintenance strategy

It reduces the amount of pump repairs, and hence reduces

It requires an experienced rotating equipment engineer

Although these 3 methods will give different Mean Time

Typical 5 to 15 pumps on a large installed population of

Wrong pump design for the application

By upgrades/retrofitting of these Bad Actors, the plant pump

This will create a pump population which is more

Customer introduce now Risk based maintenance management

This brings the highest savings in maintenance cost!!!

CONSEQUENCES USUALLY MANAGEMENT RESPONSIBILITY

PROBABILITIES USUALLY A TECHNICAL RESPONSIBILITY

RISK BASED MAINTENANCE (1)

WORK MAY BE DONE LATER

RISK BASED MAINTENANCE (2)

LYFE CYCLE COST (LCC)

Reduced maintenance costs

LYFE CYCLE COST (LCC)

Basic Technology Groups

Materials Vibro Hydraulic Mechanical Application

New Materials Noise Overall General Design Runout

Materials Vibro Hydraulic Mechanical Application

Material selection based on

PTA welding for hard facing

Materials Vibro Hydraulic Mechanical Application

Materials Vibro Hydraulic Mechanical Application

Materials Vibro Hydraulic Mechanical Application

Cavitations resistant materials

Materials Vibro Hydraulic Mechanical Application

Materials Vibro Hydraulic Mechanical Application

Materials Vibro Hydraulic Mechanical Application

Materials Vibro Hydraulic Mechanical Application

Materials Vibro Hydraulic Mechanical Application

Hydraulic Design Expertise

CFD analysis example

Original impeller New impeller

Flow visualization testing

Purpose build full scale Permanent set up for full scale

Field performance testing

Torque meter Flow meter Data logger