Purchase Justification For Laser Shaft Alignment: Power Saving Calculation

Purchase justification for laser shaft alignment
Power saving calculation

Boxes filled
Figure 1 The effect on power consumption of misalignment
The graphs above are reprinted from a report of the investigation into the effects of misalignment
on power consumption that was carried out at the ICI Rocksavage Site, Runcorn from 4th July–
16th August 1994.
The pump was installed to circulate water through a closed loop of piping with the motor running
at 3000 rpm. The motor rating was 7.5 KW. Pure horizontal offsets and angular misalignment
were introduced into the machine set, and the current drawn by the motor was recorded.
Data in yellow boxes can be modified to suit plant details and costs
Number of
Alignment Data KW Rating Units
Measured misalignment 0.30 mm 15 KW 0
Power loss 0.34% 35 KW 0
Cost of power per KWh 0.04 75 KW 10

Pu
Operating hours per day 24 125 KW 0
nual cost of power loss
Operating days per year 320 300 KW 0
Number of pumps per
Total additional cost of power consumed across plant 594.00 Total cost of power los
Total cost of extra pow
Total cost of extra pow
Page 1 of 16
Seal replacement cost (for cartridge seals at average costs from seal manufacturers)
Figure 2 Mechanical seal time to failure due to shaft misalignment
In this graph, the lower threshold values are taken from the Durametallic Intec Training Handbook.
Failure is defined when the seal starts to leak. In practise, the seals are not replaced immediately
but continued to be used for some time. Based on data from AES Seals, the upper threshold values
show seal life based on typical industry practice. For the purposes of this purchase justification, the
more conservative upper curve is used.
Alignment Data KW Rating cost of seals
Measured misalignment 0.30 mm 15 KW 180.00 (based on figure 2)
Failure interval in months 28.55 35 KW 210.00 Pu
75 KW 244.00
125 KW 325.00
300 KW 430.00 Seal cost
Total additional cost of seals consumed across plant per year 732.93
this is the additional cost of seals over the expected annual cost when m'cs aligned to 0.05mm
Annual cost of seals
Page 2 of 16
Number of pumps per
Total cost of sea
Total cost of seals cons
Bearing replacement cost for motor only (based on average costs from bearing distributers) Total cost of seals cons
this is the additional cost of bearings over the expected annual cost when machines are aligned to 0.05mm
Alignment data KW Rating Brg Cost

(each brg)
Measured misalignment 0.30 mm 15 KW 21.00
Replacement interval in months 28.55 35 KW 22.00
75 KW 60.00 Pu
125 KW 72.00
300 KW 230.00
aring cost
Total additional cost of bearings consumed across plant per year 432.46
Pump repair cost (based on average repair times from manufacturers)

Annual cost of bearings
Man Hours
KW Rating repair time Number of pumps per
Cost per hour 32.00 15 KW 12 Total cost of bearing
Repair interval in months 28.55 35 KW 14 Total cost of bearings c
50 KW 22 Total cost of bearings c
125 KW 28
250 KW 39
Total additional cost of pump repairs across plant 2114.70
Page 3 of 16
Summary
Annual savings on plant when alignment is better than 0.05 mm compared Pu

to typical measured alignment of 0.3 mm.
Man hour
Saving on power costs 594.00
Annual repair costs
Saving on replacement seals 732.93
Number of pumps per
Saving on replacement bearings 432.46
otal cost of pump repair
Saving on pump repairs 2114.70
Total pump repair costs
Total additional cost over one year ** 3874.09
Total pump repair costs
Total additional running cost of 5 year period ** 19370.45
** these cost are additional to the expected annual running cost 1395.96
of the asset when aligned to 0.05 mm
Page 4 of 16
Boxes filled yellow can be modified
(based on figure 1)
Pump rating
nual cost of power loss per pump GBP15.61 GBP36.42 GBP78.04 ###
Number of pumps per unit rating
Total cost of power loss per year GBP0.00 GBP0.00 ### GBP0.00
Total cost of extra power consumed across plant with measured offset
Total cost of extra power consumed across plant when offset = 0.05 mm
Page 5 of 16
(based on figure 2)
Pump rating
30 mm shaft diameter
###
###
Annual cost of seals per pump GBP75.67 GBP88.28 ### ###
Page 6 of 16
Number of pumps per unit rating 0 0 10 0
Total cost of seals per year GBP0.00 GBP0.00 ### GBP0.00
Total cost of seals consumed across plant with measured offset
Total cost of seals consumed across plant when offset = 0.05 mm
Pump rating
Annual cost of bearings per pump GBP17.66 GBP18.50 GBP50.45 GBP60.54
Total cost of bearings per year GBP0.00 GBP0.00 ### GBP0.00
Total cost of bearings consumed across plant with measured offset
Total cost of bearings consumed across plant when offset = 0.05 mm
Page 7 of 16
Pump rating
Man hours to repair
Annual repair costs per pump ### ### ### ###
otal cost of pump repairs per year GBP0.00 GBP0.00 ### GBP0.00
Total pump repair costs across plant with measured offset
Total pump repair costs across plant when offset = 0.05 mm
Page 8 of 16
###
GBP0.00
GBP780.36
GBP186.36
Page 9 of 16
###
Page 10 of 16
0
GBP0.00
GBP1,025.73
GBP292.80
###
GBP0.00
GBP504.46
GBP72.00
Page 11 of 16
###
GBP0.00
GBP2,959.50
GBP844.80
Page 12 of 16
Best case example
Power saving calculation
Recommended offset tolerance 0.05 mm
Power loss 0.08%
Cost of power per KWh GBP0.040
Operating hours per day 24.00
Operating days per year 320.00
Pump rating (KW) 15 KW 35 KW 75 KW 125 KW 300 KW
t of power loss per pump per year GBP3.73 GBP8.70 GBP18.64 GBP31.06 GBP74.55
Number of pumps per unit rating 0 0 10 0 0
Total cost of power loss per year GBP0.00 GBP0.00 ### GBP0.00 GBP0.00
Total cost of extra power consumed across plant when offset = 0.05 mm GBP186.36
Seal replacement cost (for cartridge seals at average costs from seal manufacturers)
Measured misalignment 0.05 mm
Failure interval in months 100.00
15 KW ###
35 KW 210.00 210
Seal cost 75 KW 244.00 ###
125 KW 325.00 ###
300 KW 430.00 ###
Annual cost of seals per pump GBP21.60 GBP25.20 GBP29.28 GBP39.00 GBP51.60
Total cost of seals per year GBP0.00 GBP0.00 ### GBP0.00 GBP0.00
Total cost of seals consumed across plant when offset = 0.05 mm GBP292.80
Bearing replacement cost (based on average costs from bearing distributers)
Measured misalignment 0.05 mm
Page 1 of 16
Replacement interval in months 100.00
15 KW GBP21.00
35 KW 22.00 GBP22.00
earing cost 75 KW 60.00 GBP60.00
125 KW 72.00 GBP72.00
300 KW 230.00 ###
Annual cost of bearings per pump GBP2.52 GBP2.64 GBP7.20 GBP8.64 GBP27.60
Total cost of bearings per year GBP0.00 GBP0.00 GBP72.00 GBP0.00 GBP0.00
Total cost of bearings consumed across plant when offset = 0.05 mm GBP72.00
Pump repair cost (based on average repair times from manufacturers)
Cost per hour GBP32.00
Repair interval in months 100.00
Pump rating 15 KW 35 KW 50 KW 125 KW 250 KW
Man hours to repair 12.00 14.00 22.00 28.00 39.00
Annual repair costs per pump GBP46.08 GBP53.76 GBP84.48 ### ###
Total cost of pump repairs per year GBP0.00 GBP0.00 ### GBP0.00 GBP0.00
Total pump repair costs across plant when offset = 0.05 mm GBP844.80
total yearly cost of repair and power waste when aligned to +/- 0.05 MM OFFSET 1395.96
Page 2 of 16
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Purchase Justification For Laser Shaft Alignment: Power Saving Calculation

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Purchase Justification For Laser Shaft Alignment: Power Saving Calculation

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Purchase justification for laser shaft alignment

Power saving calculation

Figure 1 The effect on power consumption of misalignment

Measured misalignment 0.30 mm 15 KW 0

Power loss 0.34% 35 KW 0

Cost of power per KWh 0.04 75 KW 10

Total cost of extra pow

Total cost of extra pow

Figure 2 Mechanical seal time to failure due to shaft misalignment

Alignment Data KW Rating cost of seals

Measured misalignment 0.30 mm 15 KW 180.00 (based on figure 2)

Failure interval in months 28.55 35 KW 210.00 Pu

300 KW 430.00 Seal cost

Total cost of sea

Total cost of seals cons

Alignment data KW Rating Brg Cost

Measured misalignment 0.30 mm 15 KW 21.00

Replacement interval in months 28.55 35 KW 22.00

Pump repair cost (based on average repair times from manufacturers)

Cost per hour 32.00 15 KW 12 Total cost of bearing

Repair interval in months 28.55 35 KW 14 Total cost of bearings c

50 KW 22 Total cost of bearings c

Total additional cost of pump repairs across plant 2114.70

Annual savings on plant when alignment is better than 0.05 mm compared Pu

Number of pumps per unit rating

Annual cost of seals per pump GBP75.67 GBP88.28 ### ###

Total cost of seals per year GBP0.00 GBP0.00 ### GBP0.00

Total cost of seals consumed across plant with measured offset

Total cost of seals consumed across plant when offset = 0.05 mm

Annual cost of bearings per pump GBP17.66 GBP18.50 GBP50.45 GBP60.54

Number of pumps per unit rating 0 0 10 0

Total cost of bearings per year GBP0.00 GBP0.00 ### GBP0.00

Total cost of bearings consumed across plant with measured offset

Total cost of bearings consumed across plant when offset = 0.05 mm

Man hours to repair

Annual repair costs per pump ### ### ### ###

Number of pumps per unit rating 0 0 10 0

Total pump repair costs across plant with measured offset

Total pump repair costs across plant when offset = 0.05 mm

Power saving calculation

Recommended offset tolerance 0.05 mm

Power loss 0.08%

Cost of power per KWh GBP0.040

Operating hours per day 24.00

Operating days per year 320.00

Pump rating (KW) 15 KW 35 KW 75 KW 125 KW 300 KW

Number of pumps per unit rating 0 0 10 0 0

Measured misalignment 0.05 mm

Failure interval in months 100.00

Seal cost 75 KW 244.00 ###

125 KW 325.00 ###

300 KW 430.00 ###

Number of pumps per unit rating 0 0 10 0 0

Bearing replacement cost (based on average costs from bearing distributers)

Measured misalignment 0.05 mm

earing cost 75 KW 60.00 GBP60.00

125 KW 72.00 GBP72.00

300 KW 230.00 ###

Number of pumps per unit rating 0 0 10 0 0

Pump repair cost (based on average repair times from manufacturers)

Cost per hour GBP32.00

Repair interval in months 100.00