IPPTA ZONAL SEMINAR 6 th & 7 th of Aug’2015 Hotel Courtyard Marriott, Ahmedabad RAJESH MAGAR. V CRI Pumps Pvt. Ltd., Coimbatore.

IPPTA ZONAL SEMINAR 6th & 7th of Aug’2015

Hotel Courtyard Marriott, Ahmedabad

RAJESH MAGAR . VCRI Pumps Pvt. Ltd., Coimbatore

“LIFE CYCLE COST - OF CENTRIFUGAL PUMPS

IN PAPER & PULP INDUSTRIES

FOR MAXIMISING PROFITS”.

TITLE :

The Life Cycle Cost (LCC), of any piece of Equipment is the total “lifetime” cost…

which starts from Purchase, Install, Operate, Maintain

and Dispose of that Equipment.

Definition :

Centrifugal pumps are the most common Pump type and predominantly used in the Pulp and Paper Industries.

Applications :- Paper stock and Fibrous Pulp - Fan Pump - White, Black & Green Liquors- Process & Fibrous Effluents- Dewatering & De-inking Liquors- Air Entrained Liquors- Corrosive and Non-Corrosive Liquors- All corrosive and Non corrosive Effluents- Liquors with Suspended solids

INTRODUCTION :

Engineering : Are often overly conservative when specifying and selecting pumps & generally advice a redundant equipment i.e. Stand-by pump to avoid costly failures.

Purchase Dept : Buys lower grade equipment to get favorable purchase price variances.

Project engineering: Builds plant with a 6 month view of successfully running the plant only during start-ups, rather than long term view of low cost operation.

Process Engineering: Operates equipment using a philosophy that the equipment is capable of operating at 150% of rated condition.

Maintenance: Defers required corrective/preventive actions to reduce budgets & thus long term cost increase because of neglect for short term management gains.

Conventional Approach of Purchasing Equipment :

Pumps are the Heart of any Process Industry & generally Industrial Pumping systems often have a lifespan of 15 to 20 years. This means that a poor decision can haunt a user for many years.

Pumps need to be installed, maintained, and sometimes repaired. They also require electricity (or other driving means) to run. All too often, the final decision is dictated by one of the more insignificant costs of the total LCC, namely, the “Purchase Price”.

Beyond the purchase price:

Generally, in today’s work culture, people only consider the procurement cost neglecting other important costs. Here the procurement cost of an equipment is like a tip of iceberg which does not show the underlying hidden cost. The consideration of only the tip of iceberg is hazardous as the difficulties and hazards generally are hidden in the inside as depicted below :

Purchase cost - Tip of the iceberg

As most organizations only consider the Initial purchase and installation cost of the equipment.

It is in the fundamental interest of the Plant designer to evaluate the Life Cycle Cost, of different equipments before installation of new plant or expansion.

In today’s competitive market, organizations must continuously seek cost saving methods, which will improve their profitability.

LCC also helps in developing awareness about environmental impact of their business and conserving energy , to reduce emission, preserve natural resources and reduce carbon foot print.

Why should an Organization care about LCC…?

According to the Hydraulic Institute life-cycle-costing for pumps is calculated as following : LCC = Cip + Ce + Cm + Co + Cs + Cenv + Cin wherein,

Cip = Initial purchase price (pump, system, pipe, auxillary services) Ce = Energy costs (predicted cost for system operation, including pump driver, controls, and any auxillary services) Cm = Maintenance and repair costs (routine and predicted repairs) Co = Operation costs (labor cost of normal system supervision) Cs = Downtime costs (loss of production) Cenv = Environmental costs & disposal costs (contamination from pumped liquid and auxiliary equipment) Cin = Installation and commissioning cost (including training).Note :Each of these values vary widely in significance from application to application, in Process Industries such as Paper & Pulp, Petrochemical (or) Pharmaceutical.

It is noticed that the Initial capital costs represent only a small fraction of the total LCC for process equipment. “Energy Cost” and “Maintenance costs” typically remain the highest Single source of cost over a pump’s life.

Pie-Chart depicting the Total LCC :

I ) Energy Costs (Ce) :The energy savings potential for pumping systems within the Pulp and paper industry is estimated at over 6,000 GWh/year, yet capital expenditures for pumping-related energy efficiency improvement projects are very minimal. Energy consumption - is often one of the larger cost elements and dominates the LCC, especially if pumps run more than 5000 hours, per year. The Power input for a Pump is given by the following equation : P = Q x H x s.g. [kW]

367 x hp where P = power, Q = rate of flow (m3/hr), H = head (m) or (ft), hp = pump efficiency and s.g. = specific gravity of liquidReducing Energy Costs can be achieved by the following 3 methods :a) Replace Old Inefficient Pumps by New Efficient Pumpsb) Energy Savings through Pump Controlc) Proper Pump selection & System Changes

Application : Unbleached Pulp Existing Pump Proposed CRI Pump

Duty Parameters :

Flow 440 m3/hr 440 m3/hr

Head 14 Mtrs 14 Mtrs SG of liquid 1.03 1.03 Model APP-C-31-150 ECC - 8 x 6 x17

Efficiency % 62 % 70%

BKW 27.8 ( Approx.) 24.7

Motor Rating 37 KW 30 KW

Speed 1450 RPM 1450 RPM MOC CI / SS 316 CI / SS 316

1 (a) Replace Old Inefficient Pumps by New Efficient Pumps :Pump specifiers and purchasers are often overly conservative when specifying and selecting pumps. Often pumps are specified for planned future production increases, resulting in some Inefficiencies.

Note : The difference in Bkw - 3.1 Kw. It is estimated that the savings per annum will be approximately Rs. 1,35,780/- by replacing the Old Pump with New Energy Efficient Pump . Considering commercial energy price at Rs. 5/- kwhr , the ROI will be approximately 9 months !!

Operating Conditions :

Centrifugal Back Pull-out with Open Impeller .

Head : to 95 mts

Capacity : to 3200 m3/hr

RPM - 1000 & 1500

Working Pr. – 10 Bar

Temperature - 232 deg C

MOC Offered – SS 316, 304, CI & any other alloys of Steel

1 ) Paper & Pulp Pumps (CRI Make - ECP) Suitable for Pulp Consistency upto 8%

Manufactured strictly to ANSI B 73.1 , with Semi-Open Impeller

Operating Conditions :Head : Upto 120 mts

Capacity: to 1000 m3/hr

RPM - 750 to 3600

Working Pr. - 10 to 16bar

Temperature - -20 to + 200 deg C

MOC Offered – SS 316, 304, CD4MCu, Hastealloy, Alloy 20, & any other alloys of Steel.

2 ) PROCESS Pumps (CRI Make -ECC) Suitable for Pulp Consistency upto 4%

3 ) SLURRY Pumps (CRI Make - ECH) Suitable for

For Applns. such as Green liquor, white liquor, and lime mud abrasive liquids (all products of the chemical pulping process).

Operating Conditions :Head : to 90 mts

Capacity: Upto 3200 m3/hr

RPM - 750 to 1450

Working Pr. – 10 bar

Temperature - 200 deg C

MOC Offered – Hichrome, Nihard & Rubberlined

Pump Type : End suction Centrifugal Pump Back Pull-out Pump with Closed Impeller.

I (b) Energy Savings through Pump Control :

(i) Use of Variable Speed Drives (VFD) to control pump flow rate or maintain pressure. Black liquor pumps are often candidates for variable speed drives because the black liquor viscosity can vary significantly with relatively minor variation in temperature, thus altering the Pressure requirements and Pump Performance.

(ii) Use of Power monitors to track motor power usage and/or shut them down if power deviates. The potential Pumping and Motor system energy efficiency savings - is equal to 5% of the operating margins within the pulp and paper industry (DOE* 1998).

(iii) Use of PLC or similar logic controls to monitor - Flows, Pressures, Power Consumption, Temperature, etc., These are a bit complex and costly, but allow just a few operators to monitor multiple pumps and systems.

* US Department of Energy's Office, of Industrial Technologies

I (c) Proper Pump selection & System Changes :

Generally, the pump selection has to always be close to and on the left hand side of the Best Efficiency Point (BEP). The BEP is the point at which the pump operates most cost-effectively in terms of both Energy efficiency and Maintenance considerations. Thus, operation near the BEP minimizes wear to seals, bearings and other parts.

I (c) Proper Pump selection & System Changes (Cont’d) :Narrow pipes running through a maze of twists and turns as shown below- increases the System Head required and in turn, the Pump power. Whereas, Larger pipe sizes create less friction for a given flow rate than smaller pipe sizes. The reduced friction loss reduces the pressure requirements, but the larger pipe size incurs an extra initial equipment cost. Add to that any changes in viscosity, product buildup, or corrosion on the pipe walls, and the power requirement can climb further.

II) Maintenance Costs (Cm) :

Obtaining optimum working life from a pump requires regular and efficient servicing. Inadequate maintenance lowers pump system efficiency, causes pumps to wear out more quickly and increases costs. Better maintenance will reduce these problems and the most important – to save energy. Following are the maintenance Checks :

Replacement of worn impellers, especially in caustic applications.

Trimming of Pump impellers

Bearing lubrication replacement, once annually or semi-annually.

Inspection and replacement of Gland packing seals

Inspection and replacement of mechanical seals

Pump/motor alignment check.

Pump Impeller Trimming : Oversized and throttled pumps that produce excess pressure are excellent candidates for impeller replacement or “trimming,” to save energy and reduce costs.

Trimming reduces the impeller’s tip speed, which in turn reduces the amount of energy imparted to the pumped fluid; as a result, the pump’s flow rate and pressure both decrease.

Correcting pump oversizing in Paper Industries can save upto 15% to 25% of electricity consumption for pumping systems.

Open /Stock Impeller Semi –Open Closed

Angular contact paired bearingSingle row ball bearing

Existing pump LLC / CRI Pump

Improved Bearing Life (> 50000 hrs) by Using Angular Contact Bearings at DE & NDE

Inspection and Replacement of Mechanical Seals :

Mechanical seal failures accounts for up to 70% of pump failures in many applications, thus increasing the downtime costs.

However the most important factor contributing to adequate seal life is without doubt the use of appropriate STUFFING BOX design.

Modern pump stuffing box designs for use in fibre plants are generally based upon the “Taper or big bore concept”.

Energy Savings Tips for Paper Pulp Industries : One straight forward way to increase the efficiency of a pump system by 2-5% points is to install a higher efficiency motor.

Another energy-efficient retrofit opportunity, especially for paper stock pumps, is to replace the pump "stock" impellers with "process" impellers..

Slowing a pump's speed will reduce the system pressure and flow, and therefore the brake horsepower is reduced and the pump efficiency curve will shift to the left. For example, a 20% reduction in pump speed will reduce the flow rate by 20%, but the power consumption will decrease by almost 50%.

Run LCC calculations for all new pump installations. Existing pumps should be examined as well.An experienced Pump Representative / Solutions Providers from CRI Pumps - can assist with this and help you perform a Pump Survey (or) a Power Audit, to help identify problems and suggest potential solutions.

CONCLUSION :Significant opportunities exist to improve the - Energy Efficiency and reduce the Life Cycle Costs of Pumping Systems in the pulp and paper industry by using existing technologies and proven Practices.

Savings can be optimized by taking a systems approach, which considers the entire process system and the individual Equipment, rather than the Purchase cost alone……!!!

THANK YOU……