1 Effectiveness vs Life Cycle Cost

Pump Alternatives Evaluation Using Effectiveness and Life Cycle

Cost Analysis







Teacher: Ing. Fernando Lpez

2/12/2013
NAME ID
Gabriel E. Tejada A. 2010-2206
Liudmila Diaz 2008-0915
Victor Peralta 2009-1579
Maintenance Engineering

2 Effectiveness vs Life Cycle Cost
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 Analysis
Pumps Evaluation
Old 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 Relations
Conclusions
References




3 Effectiveness vs Life Cycle Cost
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 the
limit. 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.


4 Effectiveness vs Life Cycle Cost
Theoretical Background

Diaphragm Pumps
A diaphragm pump (also known as a Membrane pump, Air Operated Double
Diaphragm Pump (AODD) or Pneumatic Diaphragm Pump) is a positive displacement
pump that uses a combination of the reciprocating action
of rubber, thermoplastic or teflon diaphragm and suitable valves either side of the
diaphragm (check valve, butterfly valves, flap valves, or any other form of shut-off
valves) to pump a fluid.

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 in air 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 of
the 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.

5 Effectiveness vs Life Cycle Cost
Those employing one or more unsealed diaphragms with the fluid to be pumped
on 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 diaphragm
moving 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 an internal combustion engine.

Characteristics
Have good suction lift characteristics, some are low pressure pumps with low
flow rates; others are capable of higher flow rates, dependent on the effective
working diameter of the diaphragm and its stroke length. They can
handle sludge and slurries with a relatively high amount of grit and solid
content.
Suitable for discharge pressure up to 1,200 bar
Have good dry running characteristics.
Can be used to make artificial hearts.
Are used to make air pumps for the filters on small fish 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 cause water hammer (This can be minimized by
using a pulsation dampener)



6 Effectiveness vs Life Cycle Cost
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 are
being 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 with
the 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 maintainability is the probability of maintaining the equipment under operation. It
is often expressed as shown.

The capability is the ability that has the equipment to perform.








7 Effectiveness vs Life Cycle Cost
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 the
LCC 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 Costs equation.

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.

8 Effectiveness vs Life Cycle Cost
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 site
supervision 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.


9 Effectiveness vs Life Cycle Cost
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 fully
automated 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

10 Effectiveness vs Life Cycle Cost
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

11 Effectiveness vs Life Cycle Cost
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.






12 Effectiveness vs Life Cycle Cost
Pump Alternatives Evaluation Using Effectiveness and Life Cycle
Cost Analysis

Pumps Evaluation
The 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.



13 Effectiveness vs Life Cycle Cost
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.


14 Effectiveness vs Life Cycle Cost


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%.













15 Effectiveness vs Life Cycle Cost
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 Hrs
6) Calculate the availability of each device 98.15% %
7) Calculate the rate of device failure 0.0016
Failure/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.











16 Effectiveness vs Life Cycle Cost
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.


17 Effectiveness vs Life Cycle Cost

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.






18 Effectiveness vs Life Cycle Cost
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 A
Mains Requirements: voltage 24 V DC
Pumping speed 7 LPM
Sound Pressure Level 45 dB
Weight 0.397 kg
Ambient Temperature 10-40 C
New 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.








19 Effectiveness vs Life Cycle Cost
Effectiveness calculations
Now we present one table with data that help us at evaluate the situation with the
GAST 15D 1150 Series Diaphragm Pump.


New Pump 1 up time and down time
Source: Own source.


20 Effectiveness vs Life Cycle Cost


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 98.57%, reliability 63.91%, maintainability 55.65% and capability 73.43%,
finally calculate effectiveness equals 25.74%.














21 Effectiveness vs Life Cycle Cost
Questions and Answers assigned about New Pump 1

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 about New Pump 1
Source: Own source.











22 Effectiveness vs Life Cycle Cost
Life Cycle cost Analysis New Pump 1
In previous pages we define what it is at life cycle cost, then now we will apply this
knowledge for calculate the LCC of 15D 1150 Series.


23 Effectiveness vs Life Cycle Cost

Life Cycle Cost elements for New PUMP 1.


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






24 Effectiveness vs Life Cycle Cost
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 A
Mains Requirements: voltage 24 V DC
Pumping speed 6 LPM
Sound Pressure Level 45 dB
Weight 0.397 kg
Ambient 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.










25 Effectiveness vs Life Cycle Cost
Effectiveness calculations
Now we present one table with data that help us at evaluate the situation with the
Parker BTC Series Diaphragm pump.


New Pump 2 up time and down time
Source: Own source.


26 Effectiveness vs Life Cycle Cost


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 98.25%, reliability 59.38%, maintainability 59.39% and capability 63.07%,
finally calculate effectiveness equals 21.85%.














27 Effectiveness vs Life Cycle Cost
Questions and Answers assigned about New pump 2

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 about New Pump 2
Source: Own source.












28 Effectiveness vs Life Cycle Cost
Life Cycle cost Analysis New Pump 2
In previous pages we define what it is at life cycle cost, then now we will apply this
knowledge for calculate the LCC of Parker BTC series.


29 Effectiveness vs Life Cycle Cost

Life Cycle Cost elements for New PUMP 2.


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






30 Effectiveness vs Life Cycle Cost
Effectiveness and LCC Relations
Now we have all the data to calculi the graphics, to determinate with of this pump
were going to choose. 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.


31 Effectiveness vs Life Cycle Cost
Now we have a pattern that we have to calculate E and C to determinate which of
these pumps are better.
E= 35
C= 38
According 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.


32 Effectiveness vs Life Cycle Cost
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.



33 Effectiveness vs Life Cycle Cost
References

Hydraulic Institute (2001). Pump Life Cycle Costs: A Guide to LCC Analysis for
Pumping Systems.
Paul, P. (1997). Availability, Reliability, Maintainability, and Capability. Hilton
Hotel. Beaumont, Texas.
Paul, P. (1996). Lyfe Cycle Cost Tutorial. Marriott Houston Westside Houston,
Texas.
www.DirectIndustries.com
www.Gast.com
www.Pfeiffer.com