A Comparative Study of Life Cycle Cost Analysis of Pumps

2010 ◽  
Author(s):  
Laxman Yadu Waghmode ◽  
Anil Dattatraya Sahasrabudhe
Keyword(s):  
Life Cycle ◽  
Product Design ◽  
Failure Rate ◽  
Life Cycle Cost ◽  
Global Market ◽  
Design Stage ◽  
Time Interval ◽  
Repair Cost ◽  
Maintenance And Repair ◽  
Initial Cost

For a product to be commercially successful and increasingly competitive in this global market place, it is imperative that engineers must understand and design for each phase in the life cycle of a product. The life cycle cost (LCC) of any piece of equipment, such as a pump represents the total cost to procure, install, operate, maintain and dispose of that equipment. For sustainment dominated products or systems, the lifetime energy and/or maintenance costs dominate the life cycle cost as compared to its initial cost. The initial cost is only a fraction of the life cycle cost. Therefore, a due consideration to the life cycle cost issues at product design stage is quite essential. The LCC analysis is recommended only at the product design phase, as up to 80% of product LCC is committed at this phase. A better understanding of the cost components that make up the life cycle cost is expected to provide the product designers an opportunity to considerably reduce product LCC. In this paper, a methodology for LCC analysis based on reliability and maintainability principles has been applied to three different pumps and the results of analysis have been compared. For analysis purpose, two pumps have been selected from the literature and the data available therein is utilized. The third pump is selected from a well known pump manufacturer from India and the required data is obtained directly from the manufacturer. To model the maintenance and repair cost the concept of expected number of failures in a given time interval has been applied. The maintenance and repair cost is estimated for two different maintenance and repair strategies, the renewal/replacement upon failure strategy and minimal repair upon failure strategy and under the conditions of constant failure rate (exponential distribution) in first case and increasing failure rate (Weibull distribution) in the second case. The results obtained have been presented and compared at the end. The methodology presented in this paper is expected to help the pump designers to estimate and compare the life cycle cost of their different design alternatives.

On the Expected Number of Failures and Maintenance Cost Prediction of Repairable Systems From Life Cycle Cost Modeling Perspective

2010 ◽  
Author(s):  
Laxman Yadu Waghmode ◽  
Anil Dattatraya Sahasrabudhe
Keyword(s):  
Life Cycle ◽  
Life Cycle Cost ◽  
Life Time ◽  
Maintenance Cost ◽  
Repairable System ◽  
Repair Cost ◽  
Repairable Systems ◽  
Expected Number ◽  
Maintenance And Repair ◽  
Repair Costs

The objective of this paper is to provide some useful insights on how cost driving events are related to the characteristics of failure distributions and the product lifetime (design life) in case of repairable systems. Repairable systems are those that can be restored to their fully operational capabilities by any method, other than the replacement of the entire system. In case of repairable systems, the components can be repaired or adjusted rather than replaced, whenever a breakdown occurs and thus such systems experience multiple failures over their life span. For majority of repairable systems, the life time maintenance and repair costs dominate the life cycle cost. To predict the maintenance and repair cost, failure data, maintenance data and repair time data is needed which is not readily available at the system design stage. When a repairable system is put into service, how many times it will fail over its life span depends on its reliability. Similarly, how fast the system is restored to its working condition when it fails (maintainability), also affect the costs incurred. Thus, the expected number of failures, time lost in restoring the system after each failure and cost per failure are important from life time maintenance cost prediction viewpoint. The expected number of failures depends upon the time to failure distribution of the system components and the after repair state of the system. In this paper, a modeling methodology is suggested for prediction of life time maintenance and repair cost of repairable systems based on expected number of failures. The repairable system lifetime is modeled using a two parameter Weibull distribution. The expected number of failures are estimated for renewal process (as-good-as-new after repair state) and minimal repair process (as-bad-as-old after repair state). The expected maintenance and repair costs are also evaluated for six different failure distributions. The technique has been illustrated through a specific application, namely an industrial pump and the results are presented.

Evaluating the effectiveness of InDeaTe tool in supporting design for sustainability

2020 ◽  
Vol 34 (1) ◽  
pp. 45-54
Author(s):  
Shakuntala Acharya ◽  
Kiran Ghadge ◽  
B. S. C. Ranjan ◽  
Suman Devadula ◽  
Amaresh Chakrabarti
Keyword(s):  
Life Cycle ◽  
Design Process ◽  
Global Market ◽  
Design Methods ◽  
Life Cycle Thinking ◽  
Design Stage ◽  
Cycle Phase ◽  
Design Database ◽  
Design For Sustainability ◽  
Selection Of

AbstractIn today's aggressive global market, innovation is key for success and design solutions require not only to achieve competitive edge, but also to address the growing environmental, social, and economic needs of the community at large. Consideration of these three pillars of sustainability makes a design inclusive, and life cycle thinking is found to be a promising approach across the literature. However, most supports for design address certain facets or aid singular tasks, and the use of design methods and tools, which have the potential to significantly improve the design process, is low due to inappropriate use and selection of these methods. InDeaTe (Innovation Design database and Template) is a holistic, knowledge-driven, computer-based tool for design of sustainable systems, such as products, manufacturing systems andservice systems and has been developed to address and integrate the aspects of sustainability on a singular design platform. It comprises of the generic design process Template that imbibes life cycle thinking into the process by incorporating consideration of every life cycle phase in each design stage, where design activities are performed iteratively. It further supports the design process by aiding the use and selection of appropriate design methods and tools in concurrence with the primary motivation of improving sustainability of the system with the aid of the InDeaTe Design Database. This paper discusses the ontological underpinnings behind the conceptualization of the InDeaTe methodology and the development of the supporting tool. The paper further reports empirical findings from six different case studies conducted for evaluating the effectiveness of InDeaTe tool in supporting design for sustainability (DfS). The results show that InDeaTe tool has potential in supporting DfS.

Research on Electric Power Equipment Preventive Maintenance Cycle on the Basis of Economic Life Cycle Costing

2012 ◽  
Vol 605-607 ◽  
pp. 296-299
Author(s):  
Yan Li ◽  
Yu Mei Hu ◽  
Yun Feng Luo ◽  
Chang Chen Liu
Keyword(s):  
Life Cycle ◽  
Electric Power ◽  
Failure Rate ◽  
Preventive Maintenance ◽  
Life Cycle Cost ◽  
Specific Effect ◽  
Economic Life ◽  
Variance Ratio ◽  
Power Equipment ◽  
Economic Life Cycle

The maintenance strategy is a tradeoff between cost and reliability. In this paper we consider the maintenance plan from the view of economic life cycle cost and reliability. We discuss the maintenance interval optimization on the premise that the preventive maintenance mitigates failure rate level and intensifies failure variance ratio meanwhile. The specific effect of this kind of preventive maintenance on failure rate and its variance ratio is explored, and then we construct a life cycle cost model of electric power equipment and propose the annuity of life cycle cost minimization as a method for seeking an optimal maintenance interval solution.

A Life Cycle Cost Analysis Approach for Selection of a Typical Heavy Usage Multistage Centrifugal Pump

2006 ◽  
Author(s):  
Laxman Y. Waghmode ◽  
Ravindra S. Birajdar ◽  
Shridhar G. Joshi
Keyword(s):  
Life Cycle ◽  
Cost Analysis ◽  
Centrifugal Pump ◽  
Life Cycle Cost ◽  
Lifetime Cost ◽  
Maintenance Cost ◽  
Life Cycle Costs ◽  
Life Cycle Cost Analysis ◽  
Initial Cost ◽  
Multistage Centrifugal Pump

It is well known that the pumps are the largest consumers of industrial motor energy and account for more than 25% of electricity consumption. The life cycle cost of a pump is the total lifetime cost associated with procurement, installation, operation, maintenance and its disposal. For majority of heavy usage pumps, the lifetime energy and/or maintenance cost will dominate the life cycle costs. Hence a greater understanding of all the cost components making up the total life cycle costs should provide an opportunity to achieve a substantial savings in energy and maintenance costs. This will further enable optimizing pumping system efficiency and improving pump and system reliability. Therefore in this context, the life cycle cost analysis of heavy usage pumps is quite important. This paper focuses on an application of a methodology of determining the life cycle cost of a typical heavy usage multistage centrifugal pump. In this case, all the cost components associated with the pump-set have been determined and classified under different categories. The data with regard to initial investment costs, operation costs, maintenance and repair costs and disposal costs for the pump considered for this case study was collected from the concerned pump manufacturer along with the unit cost of each component, quantity used and their weights. By applying the principles of reliability and maintainability engineering and using the data obtained from the design, manufacturing and maintenance departments, the component-wise values of MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair) were estimated. The results of the life cycle cost analysis of the specimen pump were compared with the life cycle costs of similar pumps reported in the literature. From this comparison of results, it can be concluded that, the initial cost of the pump is the only a fraction of the total life cycle cost. The operating cost of the pump dominates the life cycle costs especially in case of heavy usage pumps. The maintenance cost varies approximately from 0.6 to 2.5 times the initial cost of the pump. The life cycle cost of the pump varies approximately from 12 to 33 times the initial cost of the pump. The operation and maintenance cost is almost 92 to 97 per cent of the life cycle cost. The detailed analysis carried out in this paper is expected to provide guidelines to the pump manufactures/practicing engineers in selecting a heavy usage multistage centrifugal pump based on the total lifetime cost rather than only on initial price.

scholarly journals Test sequencing problem arising at the design stage for reducing life cycle cost

2013 ◽  
Vol 26 (4) ◽  
pp. 1000-1007 ◽  
Author(s):  
Shigang Zhang ◽  
Zheng Hu ◽  
Xisen Wen
Keyword(s):  
Life Cycle ◽  
Life Cycle Cost ◽  
Design Stage ◽  
Sequencing Problem

A Method of Evaluating Life Cycle Costs of Industrial Gas Turbines

1989 ◽  
Vol 111 (4) ◽  
pp. 637-641
Author(s):  
R. B. Spector
Keyword(s):  
Life Cycle ◽  
Gas Turbines ◽  
Life Cycle Analysis ◽  
Life Cycle Cost ◽  
Life Cycle Costs ◽  
Initial Cost ◽  
Relative Value ◽  
Industrial Gas Turbines ◽  
Combined Cycles ◽  
New Criterion

When aeroderivative gas turbines were first introduced into industrial service, the prime criterion for assessing the “relative value” of equipment was derived by dividing the initial (or capital) cost of the equipment by the number of kilowatts produced. The use of “dollars per kilowatt” as an assessment parameter emanated from the utility sector and is still valid providing that the turbomachinery units under consideration possess similar performance features with regard to thermal efficiency. Second-generation gas turbines being produced today possess thermal efficiencies approximately 45 percent greater than those previously available. Thus, a new criterion is required to provide the purchaser with a better “value” perspective to differentiate the various types of turbomachinery under consideration. This paper presents a technique for combining the initial cost of equipment with the costs of fuel consumed, applied labor, and parts to arrive at an assessment parameter capable of comparing the relative merits of varying types of turbomachinery. For simplicity, this paper limits the life cycle cost derivation and discussion to turbogenerator units; however, the principles of this type of life cycle analysis can also be applied to gas turbines in mechanical drive applications and/or combined cycles.

scholarly journals Analysis of different impact rates on the forecasts cost of building project using sensitivity analysis techniques

2021 ◽  
Vol 4 (1) ◽  
pp. 040-051
Author(s):  
Godwin Adie Akeke ◽  
Melody Sunday Osok
Keyword(s):  
Sensitivity Analysis ◽  
Life Cycle ◽  
Discount Rate ◽  
Life Cycle Cost ◽  
Net Present Value ◽  
Discount Rates ◽  
Discounted Cost ◽  
Analysis Techniques ◽  
Initial Cost ◽  
Building Project

Over the years, Life Cycle Costing (LCC) has been recognized and used as an important technique for evaluating, forecasting and discounting the future costs of building to the present day value, from conception, design to completion, operation, maintenance, down to decommissioning. This work presents a study of Analysis on different discount rate of the forecasts cost of building project using sensitivity analysis techniques, the case study being Calabar International Conference Center (CICC) building project. Life cycle cost analysis was conducted and forecast for 51 years using Net present value (NPV) with the following discount rates 4%, 5%, 6%, 8%, 10%, 12% and 13% respectively. Results showed that the lower the discount rates, the higher the cost value and via vasa. The building had a positive value >0 indicating a significant benefit at the end of the study period. The percentage contribution of the discount rate on the initial cost, salvage value and the life cycle cost indicates that at 4% the initial cost accounted for 85% of the discounted cost, life cycle cost 13% and salvage value 2%. The salvage value recorded 0% at 12% and 13% discount rate The higher the discount rates the higher the discounted initial cost and the lower the life cycle cost.

scholarly journals Design Implications and Opportunities of Considering Fatigue Strength, Manufacturing Variations and Predictive LCC in Welds

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1527
Author(s):  
Mathilda Karlsson Hagnell ◽  
Mansoor Khurshid ◽  
Malin Åkermo ◽  
Zuheir Barsoum
Keyword(s):  
Life Cycle ◽  
Fatigue Strength ◽  
Life Cycle Cost ◽  
Design Stage ◽  
Direct Result ◽  
Welded Structures ◽  
Early Design Stage ◽  
Repair Costs ◽  
Welded Structure ◽  
Cost Reductions

Fatigue strength dictates life and cost of welded structures and is often a direct result of initial manufacturing variations and defects. This paper addresses this coupling through proposing and applying the methodology of predictive life-cycle costing (PLCC) to evaluate a welded structure exhibiting manufacturing-induced variations in penetration depth. It is found that if a full-width crack is a fact, a 50% thicker design can result in life-cycle cost reductions of 60% due to reduced repair costs. The paper demonstrates the importance of incorporating manufacturing variations in an early design stage to ensure an overall minimized life-cycle cost.

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