Pump Alternative’s Evaluation Using Effectiveness and Life Cycle Cost Analysis.pdf

8/12/2019 Pump Alternatives Evaluation Using Effectiveness and Life Cycle Cost Analysis.pdf

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1 Effectiveness vs Life Cycle Cost

Pump Alternatives Evaluation Using Effectiveness and Life CycleCost Analysis

Teacher: Ing. Fernando Lpez

2/12/2013

NAME ID

Gabriel E. Tejada A. 2010-2206Liudmila Diaz 2008-0915

Victor Peralta 2009-1579

Maintenance Engineering
http://www.google.com.do/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=keJuZk2pccnC5M&tbnid=yoKdJ7Jt13YzvM:&ved=0CAUQjRw&url=http://onbloggingwell.com/blog-maintenance-checklist-part-1/&ei=buucUuHrLcXpkAfY7YFI&bvm=bv.57155469,d.eW0&psig=AFQjCNHUiJUsal_P-fH0HPpoTYgip4umYA&ust=1386101954239233


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List of Contents

Introduction

Theoretical Background

Diaphragm Pumps Characteristics

Effectiveness Availability Reliability Maintainability Capability

Life Cycle Cost (LCC) Elements of LCC Cic- Initial investment cost Cin- Installation and commissioning cost Ce- Energy cost Co- Operation Cost Cm- Maintenance and repair cost Cs- Downtime and loss of production cost Cenv- Environmental cost Cd- Decommissioning cost

Pump Alternatives Evaluation Using Effectiveness and Life Cycle Cost AnalysisPumps EvaluationOld Pump: Pffeifer MVP 006 Effectiveness calculations Questions and Answers assigned about Old Pump Life Cycle cost Analysis Old Pump

New Pump 1: GAST 15D 1150 Series Effectiveness calculations Questions and Answers assigned about New pump 1 Life Cycle cost Analysis New Pump 1

New Pump 2: PARKER BTC Series Effectiveness calculations Questions and Answers assigned about New pump 2 Life Cycle cost Analysis New Pump 2

Effectiveness and LCC RelationsConclusionsReferences


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Introduction

One of the most important procedures of a company that uses machines, equipment,electric and mechanic devices, is the maintenance. For that reason Engineers use the

maintenance to increase the productivity and reduce production costs. Also the

engineers use methods to determinate which equipment are the most efficient to

achieve the best results.

In this investigation we are going to talk about three diaphragm pumps, one of them is

already in use but is presenting some failures and his operating time is getting to thelimit. For that reason we are going to replace it with a new one. We have two choices

with similar characteristics and performance, but different brands.

We are going to use Life Cycle Cost calculations and effectiveness methods to find

which pump would be the preferable option to make the work.


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Theoretical Background

Diaphragm Pumps

A diaphragm pump (also known as a Membrane pump, Air Operated Double

Diaphragm Pump (AODD) or Pneumatic Diaphragm Pump) is apositive displacement

pump that uses a combination of the reciprocating action

of rubber,thermoplastic orteflondiaphragm and suitable valves either side of the

diaphragm (check valve, butterfly valves, flap valves, or any other form of shut-off

valves) to pump afluid.

Diaphragm Pump Schematics

There are three main types of diaphragm pumps:

Those in which the diaphragm is sealed with one side in the fluid to be pumped,and the other inair or hydraulic fluid. The diaphragm is flexed, causing the

volume of the pump chamber to increase and decrease. A pair of non-return

check valves prevents reverse flow of the fluid.

Those employing volumetric positive displacement where the prime mover ofthe diaphragm is electro-mechanical, working through a crank or geared motor

drive, or purely mechanical, such as with a lever or handle. This method flexes

the diaphragm through simple mechanical action, and one side of the

diaphragm is open to air.
http://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Rubberhttp://en.wikipedia.org/wiki/Thermoplastichttp://en.wikipedia.org/wiki/Polytetrafluoroethylenehttp://en.wikipedia.org/wiki/Diaphragm_(mechanics)http://en.wikipedia.org/wiki/Check_valvehttp://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Airhttp://en.wikipedia.org/wiki/Hydraulic_fluidhttp://en.wikipedia.org/wiki/Hydraulic_fluidhttp://en.wikipedia.org/wiki/Airhttp://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Check_valvehttp://en.wikipedia.org/wiki/Diaphragm_(mechanics)http://en.wikipedia.org/wiki/Polytetrafluoroethylenehttp://en.wikipedia.org/wiki/Thermoplastichttp://en.wikipedia.org/wiki/Rubberhttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pump


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Those employing one or more unsealed diaphragms with the fluid to be pumpedon both sides. The diaphragm(s) again are flexed, causing the volume to

change.

When the volume of a chamber of either type of pump is increased (the diaphragmmoving up), the pressure decreases, and fluid is drawn into the chamber. When the

chamber pressure later increases from decreased volume (the diaphragm moving

down), the fluid previously drawn in is forced out. Finally, the diaphragm moving up

once again draws fluid into the chamber, completing the cycle. This action is similar to

that of the cylinder in aninternal combustion engine.

Characteristics

Have good suction lift characteristics, some are low pressure pumps with lowflow rates; others are capable of higher flow rates, dependent on the effective

working diameter of the diaphragm and its stroke length. They can

handlesludge andslurries with a relatively high amount of grit and solid

content.

Suitable for discharge pressure up to 1,200bar Have good dry running characteristics. Can be used to make artificial hearts. Are used to make air pumps for thefilters on smallfish tanks. Can be up to 97% efficient. Have good self-priming capabilities. Can handle highly viscous liquids. A viscosity correction chart can be used as a

tool to help prevent under-sizing AOD pumps.

Are available for industrial, chemical and hygienic applications Cause a pulsating flow that may causewater hammer (This can be minimized by

using a pulsation dampener)
http://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Sludgehttp://en.wikipedia.org/wiki/Slurryhttp://en.wikipedia.org/wiki/Bar_(unit)http://en.wikipedia.org/wiki/Filter_(aquarium)#Undergravel_filtershttp://en.wikipedia.org/wiki/Fish_tankshttp://en.wikipedia.org/wiki/Water_hammerhttp://en.wikipedia.org/wiki/Water_hammerhttp://en.wikipedia.org/wiki/Fish_tankshttp://en.wikipedia.org/wiki/Filter_(aquarium)#Undergravel_filtershttp://en.wikipedia.org/wiki/Bar_(unit)http://en.wikipedia.org/wiki/Slurryhttp://en.wikipedia.org/wiki/Sludgehttp://en.wikipedia.org/wiki/Internal_combustion_engine


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Effectiveness

This indicator measures the amount of work generated from PMs measured as the

number of defects found per PM performed. It is invaluable in determining whether

the frequency of a routine is correct or needs to be revised. If few or no defects arebeing found, the PM is either not being done or the frequency of inspection needs to

be lengthened.

We calculate the effectiveness of both machines in order to determinate which one is

more effective.

The effectiveness equation is the product of those four components.

The availability is percentage of time that the equipment will be working. Deals withthe duration of up-time for operations and is a measure of how often the system is

alive and well. It is often expressed as (up-time)/(up-time + downtime).

The reliability is the probability in which the equipment will be working its requiring

function under stated conditions for a period of time. It is often expressed as shown.

The maintainabilityis the probability of maintaining the equipment under operation. It

is often expressed as shown.

The capabilityis the ability that has the equipment to perform.


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Life Cycle Cost (LCC)

The life cycle cost (LCC) of any piece of equipment is the total lifetime cost to

purchase, install, operate, maintain, and dispose of that equipment. Determining LCC

involves following a methodology to identify and quantify all of the components of theLCC equation. When used as a comparison tool between possible design or overhaul

alternatives, the LCC process will show the most cost-effective solution within the

limits of the available data.

The components of a life cycle cost analysis typically include initial costs, installation

and commissioning costs, energy costs, operation costs, maintenance and repair costs,

down time costs, environmental costs, and decommissioning and disposal costs.

Elements of Life Cycle Cost

In the next figure we can see the equation of LCC with all the elements that we need to

calculate it.

Elements of Life Cycle Costsequation.

The LCC process is a way to predict the most cost-effective solution; it does not

guarantee a particular result, but allows the plant designer or manager to make a

reasonable comparison between alternate solutions within the limits of the available

data.


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Cic - Initial Investment Costs

The initial costs will also usually include the following items:

Engineering (e.g. design and drawings, regulatory issues). The bid process. Purchase order administration. Testing and inspection. Inventory of spare parts. Training. Auxiliary equipment for cooling and sealing water.

Cin - Installation and Commissioning (Start-up) Costs

Installation and commissioning costs include the following:

Foundationsdesign, preparation, concrete and reinforcing, etc. Setting and grouting of equipment on foundation. Connection of process piping. Connection of electrical wiring and instrumentation. Connection of auxiliary systems and other utilities. Provisions for flushing or water runs. Performance evaluation at start-up.

Installation can be accomplished by an equipment supplier, contractor, or by user

personnel. This decision depends on several factors, including the skills, tools, and

equipment required to complete the installation; contractual procurement

requirements; work rules governing the installation site; and the availability of

competent installation personnel. Plant or contractor personnel should coordinate sitesupervision with the supplier. Care should be taken to follow installation instructions

carefully. A complete installation includes transfer of equipment operation and

maintenance requirements via training of personnel responsible for system operation.


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Commissioning requires close attention to the equipment manufacturers instruction

for initial start-up and operation. A checklist should be used to ensure that equipment

and the system are operating within specified parameters. A final sign off typically

occurs after successful operation is demonstrated.

Ce - Energy Costs

Energy consumption is often one of the larger cost elements and may dominate the

LCC, especially if pumps run more than 2000 hours per year. Energy consumption is

calculated by gathering data on the pattern of the system output. If output is steady,

or essentially so, the calculation is simple. If output varies over time, then a time-based

usage pattern needs to be established.

Co - Operation Costs

Operation costs are labor costs related to the operation of a pumping system. These

vary widely depending on the complexity and duty of the system. For example, a

hazardous duty pump may require daily checks for hazardous emissions, operational

reliability, and performance within accepted parameters. On the other hand, a fullyautomated non-hazardous system may require very limited supervision. Regular

observation of how a pumping system is functioning can alert operators to potential

losses in system performance. Performance indicators include changes in vibration,

shock pulse signature, temperature, noise, power consumption, flow rates, and

pressure.

Cm - Maintenance and Repair Costs

Obtaining optimum working life from a pump requires regular and efficient servicing.

The manufacturer will advise the user about the frequency and the extent of this

routine maintenance. Its cost depends on the time and frequency of service and the


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cost of materials. The design can influence these costs through the materials of

construction, components chosen, and the ease of access to the parts to be serviced.

Cs - Downtime and Loss of Production Costs

The cost of unexpected downtime and lost production is a very significant item in the

total LCC and can rival the energy costs and replacement parts costs in its impact.

Despite the design or target life of a pump and its components, there will be occasions

when an unexpected failure occurs. In those cases where the cost of lost production is

unacceptably high, a spare pump may be installed in parallel to reduce the risk. If a

spare pump is used, the initial cost will be greater but the cost of unscheduled

maintenance will include only the cost of the repair.

Cenv - Environmental Costs, Including Disposal of Parts and Contamination

from Pumped Liquid

The cost of contaminant disposal during the lifetime of the pumping system varies

significantly depending on the nature of the pumped product. Certain choices can

significantly reduce the amount of contamination, but usually at an increased

investment cost. Examples of environmental contamination can include: cooling water

and packing box leakage disposal; hazardous pumped product flare-off; used lubricant

disposal; and contaminated used parts, such as seals. Costs for environmental

inspection should also be included.

Cd - Decommissioning/Disposal Costs

In the vast majority of cases, the cost of disposing of a pumping system will vary little

with different designs. This is certainly true for non-hazardous liquids and, in most

cases, for hazardous liquids also. Toxic, radioactive, or other hazardous liquids will have

legally imposed protection requirements, which will be largely the same for all system


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designs. A difference may occur when one system has the disposal arrangements as

part of its operating arrangements (for example, a hygienic pump designed for

cleaning in place) while another does not (for example, a hygienic pump designed for

removal before cleaning). Similar arguments can be applied to the costs of restoring

the local environment. When disposal is very expensive, the LCC becomes much more

sensitive to the useful life of the equipment.

Now we present with this graphics the way to determinate witch equipment is

preferable than the other.

Relation between LCC and Effectiveness.


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Pump Alternatives Evaluation Using Effectiveness and Life Cycle

Cost Analysis

Pumps EvaluationThe objective of this project is to select a Diaphragm pump, considering the best

balance between effectiveness and cost depending on their life cycle consists of the

different variables such as costs: initial, installation, operation, maintenance,

environment, downtime and disposal costs.

Old Pump: Pffeifer MVP 006

MVP 006-4, Diaphragm pump, 24 VDC

Source: Recovered from a PDF Document sent to us from www.pfeiffer-vacuum.com

Table 1.Old Machine Specifications.


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Effectiveness calculations

Now we present one table with data that help us at evaluate the situation with the

Pfeiffer MVP 006 Diaphragm Pump

Old Pump up time and down time

Source:Own source.


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Effectiveness of Old Machine.

Source:Own source.

In this table we can see the item for calculate the effectiveness, those are availability in

this case equals 98.15%, reliability 61.19%, maintainability 67.52% and capability 66.94%,

finally calculate effectiveness equals 27.14%.


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Questions and Answers assigned about Old Machine

Here show the table with questions suggested by our assessor, they are a mode of

resume the things more important of this PUMP for later can do a good calculate and

excellent comparison with other machine.

Questions Old Pump Units

1) What is the total number of hours that was operating the

device?7,330.00 Hrs

2) What is the total failures for the period observed? 12.00 Failures

3) Calculate the MTBF for the period observed 610.83 Hrs

4) Calculate the MTTR for the period observed 11.50 Hrs

5) Calculate the total hours for the period observed 8,760.00 Hrs6) Calculate the availability of each device 98.15% %

7) Calculate the rate of device failure 0.0016Failure/hr

s

8) Calculate the reliability of each device 61.19% %

9) Calculate the rate of repair of the device 0.0870 Rep/hrs

10) Calculate the maintainability of each device 67.52% %

11) Calculate the capability of each device 66.94% %

12) Calculate the effectiveness of each device 27.15% %

13) Calculate LCC 16,798.88 USD

Questions about Old Machine.

Source:Own source.


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Life Cycle cost Analysis Old Pump

In previous pages we define what it is at life cycle cost, then now we will apply this

knowledge for calculate the LCC of MVP 006-4, Diaphragm pump, 24 V DC.


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Life Cycle Cost elements for Old PUMP.

As we can see all the cost for calculate LCC, within them initial cost (Cic) for our case is

equals USD 156.99 , the installation cost (Cin) in this context equals USD 106.75, then

continuous with the cost is energy cost (Ce) equals USD 119,77. operation cost (Co)

equals USD 86.34, Maintenance and repair cost (Cm) equals USD 6,967.50, down time

costs (Cs) equals USD 9,019.29 and finally decommissioning/disposal cost (Cd) equals

47.10, the LCC is the sum all costs equals USD 16,798.88.


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New Pump 1: GAST 15D 1150 Series

Now we are going to talk about the specifications, RAMC calculation and LCC

calculations to have all the data of the diaphragm pump Parker BTC Series.

GAST 15D 1150 Series

Technical Data GAST 15D Series

Exhaust Pressure max. 20 PSI (1379 mbar)Rate current absorption 0.6 AMains Requirements: voltage 24 V DCPumping speed 7 LPMSound Pressure Level 45 dBWeight 0.397 kg

Ambient Temperature 10-40 CNew Pump 1: Specifications.

The pumping speed doesnt match with the old pump but we are going to use a

throttle valve to regulate the pumping flow of the pump to obtain 6 LPM, but it match

with other specs.


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GAST 15D 1150 Series Diaphragm Pump.

New Pump 1 up time and down time

Source:Own source.


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Source:Own source.

In this table we can see the item for calculate the effectiveness, those are availability in

this case equals 98.57%, reliability 63.91%, maintainability 55.65% and capability 73.43%,



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Questions and Answers assigned about New Pump 1




Questions about New Pump 1

Source:

Own source.


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Life Cycle cost Analysis New Pump 1


knowledge for calculate the LCC of 15D 1150 Series.


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Life Cycle Cost elements for New PUMP 1.


equals USD 782.28, the installation cost (Cin) in this context equals USD 178.51, then

continuous with the cost is energy cost (Ce) equals USD 110, Operation cost (Co) equals

USD 144.38, Maintenance and repair cost (Cm) equals USD 5,399.4, down time costs

(Cs) equals USD 8603.4, and finally decommissioning/disposal cost (Cd) equals 78.75,

the LCC is the sum all costs equals USD 15296.72.


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New Pump 2: PARKER BTC Series

Now we are going to talk about the specifications, RAMC calculation and LCC

calculations to have all the data of the diaphragm pump Parker BTC Series.

PARKER BTC Series

Technical Data Gast 15D

Exhaust Pressure max. 20 PSI (1378 mbar)Rate current absorption 0.9 AMains Requirements: voltage 24 V DCPumping speed 6 LPM

Sound Pressure Level 45 dBWeight 0.397 kgAmbient Temperature 5-70 C

New Pump 2: Specifications.

In this table we present all the characteristics of this pump and we can see that all of

these match with the specs of the old pump.


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Parker BTC Series Diaphragm pump.

New Pump 2 up time and down time

Source:Own source.


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Source:Own source.

In this table we can see the item for calculate the effectiveness, those are availability inthis case equals 98.25%, reliability 59.38%, maintainability 59.39% and capability 63.07%,



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Questions and Answers assigned about New pump 2




Questions about New Pump 2

Source:Own source.


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Life Cycle cost Analysis New Pump 2


knowledge for calculate the LCC of Parker BTC series.


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Life Cycle Cost elements for New PUMP 2.


equals USD 1043, the installation cost (Cin) in this context equals USD 238, then

continuous with the cost is energy cost (Ce) equals USD 141.86, Operation cost (Co)

equals USD 297.50, Maintenance and repair cost (Cm) equals USD 6,421.00, down time

costs (Cs) equals USD 9,710.85, and finally decommissioning/disposal cost (Cd) equals

105.00, the LCC is the sum all costs equals USD 17,957.06.


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Effectiveness and LCC Relations

Now we have all the data to calculi the graphics, to determinate with of this pump

were going tochoose. In this order the next data present relations of effectiveness

and life cycle cost of those pump.

Effectiveness and LCC Relations

As we can see the MVP 006 is more effective than the others pumps, but it has an

average of the LCC of the others pumps. We are going to compare the MVP 006 with

GAST 15D 1150 Series and PARKER BTC Series to determinate with of this is the better

choice.


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Now we have a pattern that we have to calculate E and C to determinate which of

these pumps are better.

E= 35

C= 38According with the results E is less than C we chose as a better pump the GAST 15D

1150 Series.

Now we are going to relate the old pump and the other new pump.

In this particular pattern, we see that Pfeiffer MVP 006 has more effectiveness and

lowest LCC than PARKER BTC Series. In this order the choice is Pfeiffer MVP 006.


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Conclusions

We evaluate the LCC and effectiveness of three diaphragm pumps of different brands

but with the same technical specifications.

We can conclude with this:

MVP 006-4, Diaphragm pump, 24 VDC

GAST 15D 1150 Series

PARKER BTC Series

The GAST 15D 1150 Series Diaphragm Pump is the better choice.


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References

Hydraulic Institute (2001). Pump Life Cycle Costs: A Guide to LCC Analysis forPumping Systems.

Paul, P. (1997). Availability, Reliability, Maintainability, and Capability. HiltonHotel. Beaumont, Texas.

Paul, P. (1996). Lyfe Cycle Cost Tutorial. Marriott Houston Westside Houston,Texas.

www.DirectIndustries.com www.Gast.com www.Pfeiffer.com

Documents

Pump Alternative’s Evaluation Using Effectiveness and Life Cycle Cost Analysis.pdf