WORKSHOP

CARTAGENA - JULY 2007

Pump Life Cycle Cost
Inventory cost reductions by using
standarization and intelligent stock.

By: Daniel Irigo

 Managing _ Supply _ Intelligent
Pump Division

Spare Parts Stock

TypePumps
Type PumpsInstalled
Installed
Quantityper
Quantity perPump
PumpType Type
Analysisinstalled
installedPumps
Pumps IdentificationCritical
Identification CriticalPumps Pumps
Analysis
ObsoletePumps
Obsolete Pumpsstill stillrunning
running
DefinitionStandard
Definition StandardMaterialsMaterials
Interchangeabilitylevel
Interchangeability level
Impellers 66weeks
weeks

Timingofofsupply
supply--
Shafts 11week
week
Timing
Pumpsnotnotcritical
critical
Wear Rings 11week
week
Pumps
Bushings 11week
week
Gaskets 11week
week
Impellers 11week
week
Timingofofsupply
Timing supply Shafts 36Hours
36 Hours
Pumpscriticals
Pumps criticals 36Hours
Hours
Wear Rings 36
++44emergency
emergency
36Hours
Hours
Bushings 36
Workshop Repsol YPF Refineria La Plata / Pump Life Cycle Cost 4

Gaskets 36Hours
36 Hours October 2006 / 2
 Pump Division

Customer refinery layout

REFINERY FLOW DIAGRAM

CRUDE UNIT LPG AND GAS VAPOR REFINERY FUEL

RECOVERY
STABILIZER STRAIGHT RUN GASOLINE GAS
SECTION
LPG
CRUDE UNIT T
NAPHTHA HYDRO REFORMATE
REFORMING H
TREATING REGULAR
ATMCS R
HYDRO E GASOLINE
TWA MIDDLE DISTILLATES
CRUDE TREATING A
SECTION
T PREMIUM
HVY ATMOS GAS OIL CATALYTIC GASOLINE I
CRACKING N GASOLINE
CRUDE UNIT VAC GAS OIL G
FRACTIONATOR BOTTOMS SOLVENTS
B AVIATION FUELS
L
SOLVENT
E
VACUUM EXTRACTION DIESELS
N
SECTION HYDRO GASOLINE-NAPHTHA-MIDDLE DISTILLATES D HEATINGS OILS
LUBE BASE STOCKS CRACKING I
LUBE OIL N LUBE OILS
G
SOLVENT
DEWAKING WAXES GREASES

PROPANE
ASPHALTS
DEASPHALTER
GASOLINE - NAPHTHA - MIDDLE DISTILLATES
INDUSTRIAL
VISBREAKER FUEL OIL

FUELS
ASPHALT
REFINERY
GASOLINE - NAPHTHA - MIDDLE DISTILLATES
DELAYED FUEL OIL
COKER

RETURN
 Pump Division

Topping
TYPICAL TOPPING UNIT

115 °C GAS INCONDENSABILI

INIEZIONE DI AMMONIACA ED

INIBITORE DI CORROSIONE

RIFLUSSO DI TESTA

BENZINA LEGGERA

STRIPPER
VAPORE

FORNO
NAFTA
380 °C

P
U
M
P
STRIPPER VAPORE
-
A
R
O KEROSENE
U
200 °C N
D

RECUPERI DI STRIPPER
VAPORE
CALORE

GASOLIO

GREZZO
RESIDUO PRIMARIO

RETURN
 Pump Division

Pumps installed in the Refinery

SERIAL NUMBER PROCESS IT EM Q.T Y T YPE PUMP SIZ E YEAR RUN BILL OF MAT . CRIT ICAL
15842 G905 1 CNE 1X52 0 YES 0
27215 G056 1 CNFJ 1X104 0 YES 0
28565 G1013 1 HN 1X91 0 YES 0
12387201 G133D 1 HNN 1X91 0 YES 0
12387202 G133E 1 HNN 1X91 0 YES 0
123887204 G209E 1 HNN 1X91 0 YES 0
12387203 G209D 1 HNN 1X91 0 YES 0
28924 G1049 1 CNEX 1 1/ 2X82 0 YES 0
12112201 G3204A 1 HAS 1 1/ 2X134 0 YES 0
12112202 G3204B 1 HAS 1 1/ 2X134 0 YES 0
16375 G345 1 HN 1 1/ 2 X71 0 YES 0
19120 G21 1 HN 1 1/ 2X91 0 YES 0
16751 G142 1 HN 1 1/ 2X112 0 YES 0
16752 G144 1 HN 1 1/ 2X112 0 YES 0
16772 G144S 1 HN 1 1/ 2X112 0 YES 0
12387301 G303D 1 HNN 1 1/ 2X71 0 YES 0
12387302 G303E 1 HNN 1 1/ 2X71 0 YES 0
1204686-01 G503B 1 HNN 1 1/ 2X122 0 YES 0
1204680-02 G503C 1 HNN 1 1/ 2X122 0 YES 0
D48295 G928S 1 HNN 1 1/ 2X122 0 YES 0
29459 G1158C 1 HXB 1 1/ 2X113 0 YES 0
D29458 G1158R 1 HXB 1 1/ 2X113 0 YES 0
16781 G406 1 CNE 2X72 0 YES 0
38258 G039 1 CNFEJ 2X104 0 YES 0
39092 G051 1 CNFEJ 2X104 0 YES 0
 Pump Division

Customer Pump Population and

TOTAL Q.TY 18
Technical Data
U ITEM Q.TA' MFR PUMP SERIAL NUMBER SERVICE FLUID Q m3/h temp. C° H mt. SEAL MFR SEAL
SWS2MP01A 1 WORTH 2HNN122 1223120/01 S2-D2 H2O ACIDA - 40 - FLEX RRAL 0450 A5FY
S2-C1
SWS2MP01B 1 WORTH 2HNN122 1223120/02 S2-D2 H2O ACIDA - 40 - FLEX RRAL 0450 A5FY
S2-C1
SWS2MP02A 1 WORTH 1HNN91 1223121/02 S2-D2 IDROCARB. - 40 - FLEX RRAL 0400 A5FY
SLOP
SWS2MP02B 1 WORTH 1HNN91 1223121/01 S2-D2 IDROCARB. - 40 - FLEX RRAL 0400 A5FY
SLOP
SWS2MP03A 1 WORTH 1HNN111 D48838 S2-D1 H2O ACIDA - 85 - FLEX RRAL 0400 A5DYY061
S2-C1
SWS2MP03B 1 WORTH 1HNN111 D48839 S2-D1 H2O ACIDA - 85 - FLEX RRAL 0400 A5DYY061
S2-C1
SWS1MP22A 1 KSB ETA50-20 3101198368-2 D112 IDROCARB. - 30 - FLEX R2400 ORSPC40
SLOP
SWS1MP22B 1 KSB ETA50-20 3101198368-1 D112 IDROCARB. - 30 - FLEX R2400 ORSPC40
SLOP
SWSMP101A 1 TURO 6-65HP/2 IT3799 S20D40 H2O ACIDA - 30 - SEALOL 670AQ CSGF 000.025
C101BIS
SWSMP101B 1 TURO 6-65HP/2 IT3800 S20D40 H2O ACIDA - 30 - CRANE 2½9BT.QR1C1
C101BIS
SWSMP107A 1 WORTH 3HNN91 40235 V108 H2O DEMIN. 63 195 40 CRANE 2"909BP QAR 1K1
SWSMP107B 1 WORTH 3HNN91 40236 V108 H2O DEMIN. 63 195 40 CRANE 2"909BP QAR 1K1
SWSMP108A 1 N. PIGNONE T1½X11TC P12032 SLOP IDROCARB. - 70 - FLEX RRAL 0400Y002
SWSMP108B 1 N. PIGNONE T1½X11TC P12031 SLOP IDROCARB. - 70 - FLEX RRAL 0400Y002
SWSMP109A 1 HALBERG B100A 603429 C101BIS H2O ACIDA - 125 - SEALOL 680AQCSGF000 025
API
SWSMP109B 1 HALBERG B100A 603430 C101BIS H2O ACIDA - 125 - SEALOL 680AQ CSGF 000.025
API
SWSMP110C 1 WORTH 1½HNN91 D49156 V110 H2O ACIDA - 85 - FLEX RRAL 0400A5DYY071
C101BIS
SWSMP110D 1 WORTH 1½HNN91 D49157 V110 H2O ACIDA - 85 - FLEX RRAL 0400A5DYY071
 Pump Division

Customer Pump Population and

SEAL SIZE
Technical Data
COUPLING TYPE 1 DESE GEAR TYPE 2 R.T. MOTOR TYPE M SERIAL N POWER RPM VOLT
RRAL 0450 A5FY - MARELLI 180M/2 1223120/01 18.5 2910 380

RRAL 0450 A5FY - MARELLI 180M/2 1223120/02 18.5 2910 380

RRAL 0400 A5FY - MARELLI D1C112M/2 1223121/02 4 2905 380

RRAL 0400 A5FY - MARELLI D1C112M/2 1223121/01 4 2905 380

RRAL 0400 A5DYY061 - MARELLI D1C132SB/2 D48838 7.5 2890 380

RRAL 0400 A5DYY061 - MARELLI D1C132SB/2 D48839 7.5 2890 380

R2400 ORSPC40 - MARELLI 132SB/2 3101198368-2 7.5 2905 380

R2400 ORSPC40 - SCHORCH KR751/2M132M 3101198368-1 7.5 2900 380

670AQ CSGF 000.025 - ANSALDO 225M/2 IT3799 45 2960 380

2½9BT.QR1C1 - ANSALDO 225M/2 IT3800 45 2960 380

2"909BP QAR 1K1 - ANSALDO 160MR/2 40235 11 2930 380

2"909BP QAR 1K1 - ANSALDO 160MR/2 40236 11 2930 380
RRAL 0400Y002 - ANSALDO 160M/2 P12032 15 2920 380
RRAL 0400Y002 - ANSALDO 160M/2 P12031 15 2920 380
680AQCSGF000 025 - ANSALDO 160L/2 603429 18.5 2920 380

680AQ CSGF 000.025 - ANSALDO 160L/2 603430 18.5 2920 380

RRAL 0400A5DYY071 - MARELLI C132S/2 D49156 7.5 2905 380

RRAL 0400A5DYY071 - MARELLI C132S/2 D49157 7.5 2905 380

 Pump Division

Identification critical pumps

Critical pumps are:
1. Critical to maintain refinery output
2. Critical because of Bad Acting .
3. Critical as no redundancy is available
4. Critical for health, safety and
environmental issues.

Store critical pumps in refinery database

 Generation Engineering Data Pump Division

Normally a refinery has pumps of many different

brand names and different sizes and types
An indepth review of the customer pump population is required to
collect from each pump, turned, parts information and gasket
information.
(Turned parts are typical shaft wearrings and bushings.)
Flowserve (17 pump herritages) Drawing and BOM
readily available
Non Flowserve pumps Retrieve data and reverse
engineering for drawings

Store in refinery database

 Pump Division

Generation Engineering Data

An indepth review of the customer pump
population is required to collect from each
active pump all casted parts data
(Impellers, difusers etc.)
Flowserve (17 pump herritages) Data is available
Non Flowserve Retrieve data

Store in refinery database

 Standarization Pump Division

Turned parts
Reduce many different kind of materials used, sometimes
we see over 40 different materials used (ASTM, DIN, etc)
Select 3 materials suitable to do all services and standarize.

Store in refinery database

Select raw material dimensions for the 3 selected materials
to suit the production of all turned parts
Casted parts
Hydraulic engineer to review a standarization to eliminate
almost similar hydraulics. Also review hydraulic optimalization

Define critical pump casted part inventory level.

 FLOWSERVE INTELLIGENT STOCK RECOMMENDATION
Pump Division
a PUMP TYPE (INSTALLED PUMPS) HNN -HNNT- HN -HNI-HPX 237
HDS 18
LN 27
HED 14
UXH 6
UZD 3
Flowserve CNFE-CNFJ
MR
12
5

Intelligent HL
GAUK
WUC
2
1
1
HAS 26
Stock 8BHU
VARIE
1
40
TOTAL Q.TY 393
b PARTS TO HAVE IN STOCK IMPELLER FLOWSERVE
SHAFT FLOWSERVE
CASING RING FLOWSERVE
IMPELLER RING FLOWSERVE
BUSHING FLOWSERVE
SHAFT SLEEVE FLOWSERVE
DIAPHRAM FLOWSERVE
GASKETS FLOWSERVE

VALUE OF PROPOSED STOCK

a PUMPS NOT CRITICAL Euro
6 WEEKS IMPELLERS AVAILABLE T.B.A.
1 WEEK SHAFTS AVAILABLE T.B.A.
1 WEEK WEAR PARTS/ BUSHINGS AVAILABLE T.B.A.
1 WEEK SHAFT SLEEVES AVAILABLE T.B.A.
1 WEEK GASKETS AVAILABLE T.B.A.
b CRITICAL PUMPS + 4 EMERGENCY
1 WEEK IMPELLERS 68 330 K.Euro
36 HOURS SHAFTS 48 70 K.Euro
36 HOURS WEAR PARTS/ BUSHINGS 520 160 K.Euro
36 HOURS GASKETS 144 4 K.Euro

total amount 564 K.Euro

 Pump Division

Turned Parts Supply

36- HOURS
 Pump Division

Casted Parts Supply

IMPELLERS
DIAPHRAMS
CASING

1- WEEK
 Pump Division
CLIENTE AGIP
lCUSTOMER DATA REGIONE SICILIA
LOCALITA' PRIOLO
SETTORE RAFFINERIA
lPRODUCTION
CAPACITA' 15 MILIONI DI TONNELLATE ANNO
UNITA' TOPPING
lTYPE OF PROCESS ITEM P101A
Q.TA' 1
lTYPE OF SERVICE MACCHINA POMPA
SERVIZIO FONDO COLONNA
lOPERATING CONDITIONS CONDIZIONI FUNZIONAMENTO
Q / H / NPSHA/TEMP/
MOTRICE MOT.EL.
GIUNTO FLESSIBILE
lDRIVER DATA
COSTRUTTORE WORTHINGTON
lMECHANICAL SEAL DATA TIPO 2HNN112
MATRICOLA 19003
lITEM LISTA PEZZI 1002000000
ARTICOLO 4023102960 4022305950
lPUMP DESCRIZIONE ALBERO BUSSOLA
Q.TA' TOTALE 14 10
CODICE ASTM A434_4140 B584_C938
lSERIAL NUMBER CS DISEGNO BM45235 BM45235
GREZZO 8011220800 8317011330
lBILL OF MATERIAL UNITA' MM MM
MISURA 678 15
lCOMPONENT DISEGNO CM04399100 AM05118400
FORMULA D D-d
lARTICLE DIMENSIONE 080^2*Pi/4 70^2-35^2
PESO 3,92 2,25
DIM.Max 80 70
lCONSTRUCTION DRAWING DIM MIN 0 35
CODICE MATERIALE 8235 8701
lMATERIAL FORMA TONDO CANNELLA

lRAW MATERIAL CODE

RETURN
 Intelligent stocking Pump Division

Advantages
Reduced inventory levels and inventory capital value is
reduced due to raw material stocking instead of complete
finished machining value.
When pump is taken out of service for overhaul, parts arrive
for the critical pumps when pump is open and inspected.
This reduces the time of being out of service, sometimes by
50%
For emergency repairs, still genuine parts according original
design data are used, and heat treated, which is most of
times not done when turned parts have to be made locally
under emergency.
One phone call starts the entire supply chain for parts
delivery (automatic)
 Pump Division

Standardization

Flowserve has developed special

standardization programs, which also bring
refinery pumps to latest API 610 edition and
allow API 682 mech. Seal implementation.

Example: RV-X- program for single stage overhung

process pumps
 Pump Division

What is RV-X- ?
It is Flowserve API-610 10th
edition power frame upgrade
back pull out assembly.

It is a complete pump less

- Pump case
- Case ring
- Impeller

- Impeller ring
- Impeller locknut
- Seal
- Coupling guard
 Pump Division

RV-X- Features & Benefits

Eliminates disturbance to existing Suction and discharge piping.

Increase Reliability.

- Heavy duty construction (available in 3 sizes only)

- Metal to metal casing fit with fully confined gasket cavity.

- Controlled compression gasket ensures proper sealing and alignment.
- Air gap at the drip pocket
- Insulate bearing housing in high temperature applications.

Increase Seal Life

- Low L3 / D4
- Large Radial and Thrust Bearings.
 Pump Division

RV-X- Features & Benefits

Continued
Eliminate need for cooling water jacket at the bearing housings.
-Standard outboard fan.
- Provision for cooling fan.
- Provision for oil mist lubrication (optional).

Reduce Inventory - Parts & Seals.

- Three std. Size seal chambers (API # 4, 6 & 8)

- Three frame size for 95% of overhang process pumps

Quick delivery.
- Parts and materials of construction are standardized.
S6 (Carbon Steel)
C6 (Chrome Steel)
A8 (Stainless Steel)
 RV-X- Frame Selection
Pump Division

(3) Standard Assembly Frame sizes :
- A Frame : 8.5 through 10.0
impellers
- B Frame : 10.5 through 17.0
impellers
- C Frame : 18.0 through 21.0
impellers
(3) Standard seal chambers per Table 6 :
- A Frame : seal chamber size #4 - 49.5
mm
- B Frame : seal chamber size #6 - 69.5
mm
- C Frame : seal chamber size #8 - 86.0
mm
 RV-X- Frame A Pump Division

API Seal Chamber Size # 4

RV-X- : Lower L3/D4 Shaft Pump Division

Stiffness Index
L

Stiffer Shaft Means:

Less loading on mechanical seal.
Less chances of rubbing wearing rings.
Results in:
Inc rease MTBR and higher reliabilit y.
 Pump Division

Life Cycle Costs (LCC)