custom hydraulic solutions “pump optimization”. custom hydraulic solution what is a custom...
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Custom Hydraulic Solutions
“Pump Optimization”
Custom Hydraulic Solution
• What is a Custom Hydraulic Solution (CHS)?– Adjust the hydraulic performance of a pump while
changing the fewest components possible thereby protecting the capital investment.
– Match the standard operating point to the best efficiency point (BEP).
– Don’t expect different results from the same action!
Total Cost of Ownership
7%
15%
8%
43%
23%
4%
Pump Installation EnvironmentEnergyRepairDowntime
Investment 30%Maintenance 27%
Energy 43%
Source: Texas A&M Turbomachinery Lab – Life Cycle Extension Course
Pump Optimization
• What is Pump Optimization?– Reduce the total cost of
ownership• Increase Mean Time Between
Repairs (MTBR)• Reduce maintenance cost• Reduce power consumption
Pump Curve Sensitivity for Pump Reliability
Where does the pump operate?
AllowableOperating
Region
Preferred Operating
Region
BEP
VIBR
ATIO
NH
EAD
Basic limit
Maximumallowable
@ flow limits
80% 110%
Case Study – Pump Optimization•(2) Coal Fired 900MW Supercritical boilers equipped with GE Turbines•Unit 1 – 1970•Unit 2 – 1971
•(2) Marley hyperbolic cooling towers
Case Study – Pump Optimization
•(3) BB1 pumps per unit•BEP Condition
•88,000 GPM•100 ft TDH•444 RPM•NPSHr 22 ft•2500 HP available
Case Study – Pump Optimization
•MTBR of 2 years•Typical Repair $62,000•Primary failure mode was cavitation.•Pump Evaluation
•NPSHr – 22ft•NPSHa – 22ft
Case Study – Pump Optimization
Solution Method
• Traditional Reliability Improvements– Apply coatings– Upgrade metallurgy
• CHS – Pump Optimization– Reduce/eliminate
cavitation– Extend MTBR– Increase capacity– Reduce power
consumption– Upgrade metallurgy– Minimize the capitol
investment
Custom Hydraulic Solution
• Computation Fluid Dynamics (CFD)– The eye is too small– The inlet vanes are too heavily loaded– The number of vanes are too low– The rake of vane produces a non-uniform flow
field
CHS – NPSHr Reduction
Original Impeller Design SA – CHS DesignCFD shows cavitation in original design
CFD shows cavitation reduction in CHS vane design
CHS – NPSHr Reduction
0
3
6
9
12
15
18
21
24
27
30
50
60
70
80
90
100
110
120
130
140
150
0 20000 40000 60000 80000 100000 120000 140000
NP
SH
R
TD
H
USGPM
PERFORMANCE COMPARISON
OEM TDH SA TDH OEM NPSHR SA NPSHR
CHS – Pump Optimization
Original Impeller BEP Condition
• 88,000 GPM• TDH – 100 ft• NPSHr – 22 ft• η – 88.9% *• BHP – 2500
SA-CHS Impeller BEP Condition
• 94,000 GPM• TDH – 100 ft• NPSHr – 17 ft• η – 94.9% *• BHP – 2500
* As measured with field performance test equipment
CHS – Pump Optimization
• Results– Eliminated a 30 year old cavitation problem– Extended the MTBR to 6 years– Increase the capacity 6,000 GPM per pump– Upgraded the metallurgy– Maintenance Cost Savings over 6 years $721,000– Energy Cost Savings over 6 years $1,634,508
Questions?
Customer Hydraulic Solutions
• Pump Optimization
Thank you for your attention
Richard MartinezVP of Operations
[email protected] Booth 216