1. Economic Benefits AchievedThrough 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?

• Its 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

Well 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 todays 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 inletImo 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 inlet250HP, 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 SystemControls 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$2,500,000.00over 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.

• Thenwhen 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

Lets look at a pipeline application where the operational conditionswould 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 doesnt 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 worlds largest Positive Displacement Pump Manufacturer.

The 6 thlargest pump / fluid system manufacturer

Global15 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 andfluid systems design and equipment selection expertise has grown exponentially..

No charge for opinions

Heres 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!!!!