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This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
KIRLOSKAR BROTHERS LTD.
A PRESENTATION BY
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
Life Cycle Costs In Pumps and Pumping Systems
(Based On Guidelines of Hydraulic institute )
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
STUDY CARRIED OUT BY
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 whole
“Lifetime” cost required to Purchase, Install,
Operate, Maintain and Dispose off that equipment.
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
CAPITAL COSTS
Pumps
Civil Works
M&E
ENERGY COSTS
Efficiency
Process Optimisation
MAINTAINENCE COSTS
MTBF
Replacement Parts
Down time
DISPOSAL COSTS
WHOLE LIFE COST
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
•Initial cost
•Fuel economy
• Safety
• Durability
• Utility
• Maintenance
• Insurance
• Performance
• Resell value
• Price
Buying Decision
Considerations
Personal Level
Cost of Acquisition
Cost of Usage
Cost of Disposal
Cost
of
Ownership`
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
Life Cycle Cost (LCC)
Typical LCC for Medium Sized Industrial
Pumping System. Capital Cost
Energy Cost
Maintenance Cost
Other costs likeOperating, down
time, etc
@ 82%
@ 10%
@ 5%
@3%
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Life Cycle Cost Analysis – Systematic Approach
Purchase price
Operating cost
Maintenance cost
Pumping systems account for nearly 25% of worlds electrical demand (in developed
countries) and range up to 50% in certain industrial plant operation.
The developed world has become acutely aware of the effect of energy wastage.
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
Why LCC ?
Why should organizations care about life cycle cost?
Many organizations only consider the Initial purchase and installation cost
of the equipment.
In today’s 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.
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Life Cycle Cost Analysis – Systematic Approach
Causes of Hydraulic Deterioration
• Fluid erosion of internal clearances
• Mechanical wear resultant of shaft deflection
• Oxidation increasing surface roughness
• Excessive internal re-circulation
• Cavitation/Vane Pass
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Life Cycle Cost Analysis – Systematic Approach
Hydraulic Deterioration
Head/Flow
Efficiency
Deteriorated
Deteriorated
Efficiency Loss
=
More Power per
hour
Flow Reduces = More Hours run
Original BEP
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Life Cycle Cost Analysis – Systematic Approach
Facts about pump power consumption The table below shows rise in pumping cost due to drop in
efficiency for 20 kW pump-set during the period of operation.
Sr.
No.
No of Years Efficiency (* ) Pumping Cost
Per Day Per Annum
1 1st Year 80.0 % 2160 788400
2 2nd Year 79.2 % 2187 798380
3 3rd Year 78.4 % 2215 808615
4 4th Year 77.6 % 2244 819117
5 5th Year 76.8 % 2274 829895
6 6th Year 76.0 % 2304 840960
7 7th Year 75.3 % 2335 852324
8 8th Year 74.5 % 2367 864000
9 9th Year 73.8 % 2400 876000
10 10th Year 73.0 % 2434 888338
Normally pump efficiency drops at 1% per annum for
drinking water application due to erosion and corrosion.
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
10 Year Additional Energy Cost Due To Efficiency
Degradation
(Rs.6 per kW/Hr)
0
1000000
2000000
3000000
4000000
5000000
6000000
7000000
8000000
9000000
50kW
150k
W
250k
W
350k
W
Absorbed Power KW
Co
st
(IN
R)
Degradation Cost
Additional Energy Cost
Rs. 4.5 million
Average 1% pa For
Conventional Pump
LLC Average
0.25% pa
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
= 125 MW pa
Saved Generation
5% Saving on 100 KW = 44 MW pa =
Rs. 0.38 million
Pump rarely
BEP
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Life Cycle Cost Analysis – Systematic Approach
3-Dimensional Streamline Plot of the pump
Turbo Design
ORIGINAL PUMP
EFF. – 83%
MODIFIED PUMP
EFF – 89.5%
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Life Cycle Cost Analysis – Systematic Approach
Efficiency Improvement by Material Coatings
DIFFERENCE IN DROPLET CONTACT ANGLE
Water droplet Water droplet
Coating
SUBSTRATE
Hydrophobic
Material
Polymer
(Easter Resin)
Semi- Hydrophobic
Material
Polypropylene
Attractive
Material – Cast Iron
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Life Cycle Cost Analysis – Systematic Approach
Glass flake technology - Tortuous path
Tortuous path for corrosive ion
Layers of glass flakes
Coating
SUBSTRATE
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
Cross section of LLC Series Horizontal Split Casing Pump
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
Mechanical Seal ReplacementHorizontal Split Case Pumps
REMOVE GUARD
REMOVE SPACER
REMOVE BEARING
RETAINING NUT
REMOVE BEARINGS AND
REMOVE MECHANICAL SEAL
REASEMBLE FOR USE
REMOVE PUMP COUPLING
REMOVE BEARING HOUSING
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
Installation
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
STANDARD FEATURES OF LLC PUMPS
The pumps are provided with removable and renewable Labyrinth profile casing
ring. Materials and hardness of the Impeller and casing ring is standardized to
ensure that they are not susceptible to galling and premature wear.
In order to avoid waste of water through continuous Gland leakage in soft packed
pumps, the casing stuffing box /seal chamber is designed to facilitate externally
removable shaft mounted, non split, self aligning cartridge type Mechanical seal of
any reputed make.
Pump is supplied with Spacer type flexible coupling.
Ease of access to the parts to be serviced is ensured i.e. Mechanical Seal &
Bearings, without removing the upper half casing, recourse to disturb either pipe
work or prime mover.
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Life Cycle Cost Analysis – Systematic Approach
In order to avoid bare metal casing from getting oxidized and to reduce the relative
surface roughness of the pump casing, Corrocoat Coating of thickness 1 mm DFT
with properties of good erosion & corrosion protection including protection
against cathodic action is applied on casing internal surface coming in contact
with water.
The coating applied is suitable for potable water application and certified by
Authorized National Lab.
The pump is supported by two drive end bearings and one non drive end bearing
of anti-friction type, located on each side of the pump. The bearings are grease
lubricated, ball or roller bearing type. The bearing on the pump is designed to
withstand the unbalanced radial & axial hydraulic thrust. Bearings are designed for
L101ife of minimum 50000 hours of operation in the operating range.
The supplied pump offers low operation cost by way of sustained efficiency with
no degradation for first two years and there after by approx. 0.25% (i.e.
degradation in efficiency by approx. ¼ as compared to conventional pump) every
year up to economical life i.e.10 years.
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
28
Cross section of LLC Series Vertical Turbine Pump
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Life Cycle Cost Analysis – Systematic Approach
ADVANTAGES OF LOWEST LIFECYCLE COST
SERIES PUMP
Sr. No. Component Feature Benefit Advantage
1 Impellers Precision casting in austenitic
stainless steel as standard.
Increased corrosion resistance &
thereby increased component life.
Increased Sustainability.
Reduced maintenance
costs.
2 Bottom
Bearing
Impeller in between the bearings
with bottom Bearing in the bell
mouth
Higher Rigidity Increased Sustainability
3 Wear Rings
Hard Metallic serrated wear rings
of zinc free bronze. (Applicable
for closed impellers)
Long life and reduced energy
consumption
Energy Saving & Increased
Sustainability
4 Impeller
Guide Piece
Precision Casting in austenitic
stainless steel as standard.
(Applicalbe for open/semiopen
impellers)
Increased component life.
Increased corrosion resistance.
Increased Sustainability.
Reduced maintenance
costs.
5 Bearing Span Span less than 2m Enhanced bearing life. Faciliatates
variable speed operation Increased Sustainability
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
ADVANTAGES OF LOWEST LIFECYCLE COST
SERIES PUMP
Sr. No. Component Feature Benefit Advantage
6 Bearing Span Span less than 2m Enhanced bearing life. Faciliatates
variable speed operation Increased Sustainability
7 Intermediate
Bearings
Composite bearing suitable for dry
start running. (Fabric-impregnated
with resin)
High wearing resistence. User
friendly for operation. Avoids cost
for pre-lubricaiton. Presents
deformaiton due heating
Increased Sustainability
8 Shafts Stainless steel as standard
ASTMA276-410 (H&T)
Enhanced corrosion resistance and
component life. Higher shaft dia. Increased Sustainability
9 Coatings Corrocoat - Hydrophobic Coatings Offers protection against erosion,
corrosion and galvanic action.
Protects base matieral and
enhances its life.
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
ADVANTAGES OF LOWEST LIFECYCLE COST
SERIES PUMP Sr. No. Component Feature Benefit Advantage
10 Shafts
Sleeves
Hard Stainless steel shaft sleeves
fitted below bearings as standard
Enhanced corrosion resistance
and component life. Increased Sustainability
11 Bearing Span Full ring Bearing Spider Improved surface contact Higher
Rigidity Increased Sustainability
12
Stuffingbox /
Mech seal
Holder
Additional Bearing in Stuffingbox /
Mech seal Holder Higher Rigidity Increased Sustainability
13 Shaft
Couplings
Keyed muff type couplings fitted
as standard.
Easily removable, avoiding seizure
or jamming on shaft after few
years of operation, ensuring
increased component life.
Reduced maintenance
costs.
14
Thrust
Bearing
Assembly
Heavy duty thrust bearing
assembly.
Anti-friction or mitchell type thrust
bearings dependant on load.
Minimum L10 life in excess of
50,000 hours under all design load
conditions.
Increased Sustainability.
Reduced maintenance
costs.
15 Headpiece Large Fabricated headpieces. Minimum vibration and long
bearing life.
Increased Sustainability.
Reduced maintenance
costs.
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach LIFE CYCLE COST ANALYSIS – SYSTEMATIC
APPROACH
A PRESENTATION BY
FULL RING BEARING
SPIDER
LLC PUMPS
BEARING SPIDER
CONVENTIONAL
PUMPS
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach LIFE CYCLE COST ANALYSIS – SYSTEMATIC
APPROACH
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach
This is a proprietary document of Kirloskar Brothers Limited
Life Cycle Cost Analysis – Systematic Approach