1. Custom Hydraulic Solutions “Pump Optimization”

2. 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!

3. Total Cost of Ownership Source: Texas A&M Turbomachinery Lab – Life Cycle Extension Course

4. Pump Optimization What is Pump Optimization? – Reduce the total cost of ownership Increase Mean Time Between Repairs (MTBR) Reduce maintenance cost Reduce power consumption

5. Pump Curve Sensitivity for Pump Reliability

6. Where does the pump operate? Allowable Operating Region Preferred Operating Region BEP VIBRATION HEAD Basic limit Maximum allowable @ flow limits 80%110%

7. Case Study – Pump Optimization (2) Coal Fired 900MW Supercritical boilers equipped with GE Turbines Unit 1 – 1970 Unit 2 – 1971

8. (2) Marley hyperbolic cooling towers Case Study – Pump Optimization

9. (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

10. MTBR of 2 years Typical Repair $62,000 Primary failure mode was cavitation. Pump Evaluation NPSHr – 22ft NPSHa – 22ft Case Study – Pump Optimization

11. 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

12. 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

13. CHS – NPSHr Reduction Original Impeller DesignSA – CHS Design CFD shows cavitation in original design CFD shows cavitation reduction in CHS vane design

14. CHS – NPSHr Reduction

15. 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

16. 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?

17. Customer Hydraulic Solutions Pump Optimization Richard Martinez VP of Operations richardm@standardalloys.com Booth 216