Download - FEDCO HPB Pressure Booster and
Copyright©2010FluidEquipmentDevelopmentCompany‐ page1
Comparisonof
FEDCOHPBPressureBoosterand
ERIPressureExchanger
Preparedby
FluidEquipmentDevelopmentCompanyMarch2009
FluidEquipmentDevelopmentCompany,FEDCO,HPB,MSS,SSD,HP‐HEMI,LP‐HEMI,LPH,PPD,LPS,LPB,ROTOR‐FLO,aretrademarksofFluidEquipmentDevelopmentCompany,LLCEnergyRecovery,Inc.,ERI,PX,PressureExchangerandPXPressureExchangeraretrademarksofEnergyRecovery,Inc.Copyright©FluidEquipmentDevelopmentCompany
Copyright©2010FluidEquipmentDevelopmentCompany‐ page2
TableofContents
WhattoLookforinanEnergyRecoveryDevice
MethodologyofComparison
EquipmentEvaluated
HPBPrinciplesofOperation,Construction,Installation,OperationandOverhaul
HP‐HEMI
FeedPressureControl
PXPrinciplesofOperation,RotorBlowThrough,RotorFailure,MultipleUnitReliability
PXAuxiliaryEquipmentandMulti‐TrainOperation
OperatingRange
Safety‐EquipmentandPersonnel
PXEffectonHPPumpPerformance
EconomicsAnalysis,SpecificEnergyConsumption,LifeCycleCostandCapitalCosts
Toughness–AbilitytoDealwithUnexpectedConditions
WarrantyLengthandExceptions
SummaryofComparison
FEDCOTrainingandContactInformation
3
4
5
6
11
12
13
19
21
22
23
24
26
27
29
30
Copyright©2010FluidEquipmentDevelopmentCompany‐ page3
WhattoLookforinaEnergyRecoveryDevice(ERD)
LifeCycleCost–minimizesthecostpermeateoverthelifeoftheplant;
LowCapitalCost–equallyimportanttoLifeCycleCost,theequipmentmustbeaffordabletoencouragecustomerstousedesalinationasasolutiontowaterscarcityandsystembuilderstowinproposalswithcompetitivebids;
Reliability–provideyearsofcontinuousservicewithzeromaintenance;
Safety–inherentlysafeforpersonnelandequipment;
Easeofoperationandmaintenance–Forasystemtoworkforyears,itmustbeeasytooperateandmaintainedregardlessoftheleveloftrainingorexperience;
LongTermSupport–supplierfinancialstrengthandindependence.
Copyright©2010FluidEquipmentDevelopmentCompany‐ page4
MethodologyofComparison
TheFEDCOHPBturbochargermanufacturedbyFluidEquipmentDevelopmentCompany(FEDCO)iscomparedwiththePressureExchanger(PX)manufacturedbyEnergyRecovery,Inc.(ERI).
Alldatausedinthiscomparisonwereobtainedfromthefollowingsources:1. PublisheddatafromFluidEquipmentDevelopmentCompany(FEDCO);2. PublisheddatafromEnergyRecovery,Inc.(ERI)• Primarily“Installation,Operation&MaintenanceManuals”for“65SeriesPressureExchanger™”(ERI
Docnumber80019‐01‐02)referredtoas“PXManual”inthisdocument3. Reasonableengineeringestimates
Allcalculationsanddataarefullytransparent.DetailsareavailablefromFEDCOuponrequest.
Ifthereareanyerrorsinthedataoranalysis,pleasecontactusimmediatelyandwewillcorrectaccordingly.
Anynewinformationregardingthedatainthispresentationwillbegreatlyappreciated.
Copyright©2010FluidEquipmentDevelopmentCompany‐ page5
EquipmentEvaluated
ERIPX‐220Nominalratings:• Feedflow=50m3/hr(220gpm)
(PXunitsrequiresubstantialadditionalequipmenttoachievefunctionalitywhichwillbeincludedintheevaluation)
FEDCOHydraulicPressureBooster(HPB)Nominalratings:• Feedflow=10to2800m3/hr(44–12,300gpm)
FEDCOHP‐HEMINominalratings:• Feedflow=300to2800m3/hr
Copyright©2010FluidEquipmentDevelopmentCompany‐ page6
HPB‐PrincipleofOperation
FEDCOHydraulicPressureBooster(HPB)
TheHPBproducesupto50%ofthemembranepressurerequirement,thereby,reducingtheenergyinputandsizeoftheHPfeedpump,motorandmotorstarter/VFD.Typicalinstallationandoperationareindicatedbelow.
P=2barQ=120m3/h
P=66bar
P=38barP=64barQ=78m3/h
P=0.5bar(maybeatvirtuallyanydesiredvalue)
Feed
Permeate
Q=42m3/h
MSSFeedPump(oranyothertypeof
HPpump)
HPBenergyrecoverydevice
• Worksjustlikeanautomotiveturbocharger• Automaticallyboostsfeedpressure• Fullypoweredbybrinepressure• Absolutelynootherequipmentrequired
P T
P&IDSymbolforTurbochargers
Brine(turbine)
Feed(pump)
KeyConcepts
Copyright©2010FluidEquipmentDevelopmentCompany‐ page7
HPB–InternalConstruction
Turbinenozzle
Turbineimpeller
Rotorshaft
Pumpimpeller
Brinecontrolvalve
FEED
BRINE
Bearing
Membrane
• Onemovingpart• Noshaftseal–zeroleakagetoatmosphere• Waterlubricatedbearings• Integralbrinecontrolvalve• All‐duplexorSuperDuplexConstruction• Quietandsmoothoperation• MostcompactsizeofallERDs
Features
Copyright©2010FluidEquipmentDevelopmentCompany‐ page8
HPB‐Installation
• nohighpressureboosterpumps• nospecialinstrumentation• noisolationvalves• brinedisposalatanypressure
Integralbrinecontrolvalve
Lowpressurebrinetodisposal
Highpressurebrinefrommembrane
Highpressurefeedtomembrane
Feet
Victaulic™pipejoints
Mediumpressurefeedfromfeedpump
HPB‐40
HPB‐1000
TheHPBcanbeinstalledinanyorientation‐sideways,vertical,etc.Connectthe4pipesandtheinstallationiscomplete.
Features
Copyright©2010FluidEquipmentDevelopmentCompany‐ page9
HPBOperation
Toincreasebrinepressure:
Todecreasebrinepressure:• Openthevalve
• Closethevalve
• Easytrainingofoperatingstaffs,replacementstaffintuitivelylearnsoperation• OperatorerrorcannotdamagetheHPBorfeedpump• Simplicitydemandedbymilitaryusers,off‐shoreoperators,hotelsandresorts• Reducescomplexityinlargesystemstherebyreducingsystemcontrolcosts.
manualorautomaticvalveactuator
Features
• Startthelowpressurefeedpump,ventairfromsystem• Starthighpressurefeedpump• Walkaway–systemisrunning
Operation
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HPB–Overhaul
OverhaulRequirements• 15‐60minutes• Noskilledlabor• Nospecialtools• Nomeasurements• Sameprocedureforevery
HPBmodel
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HydraulicEnergyManagementIntegration(HEMI)
TheHP‐HEMIisanHPBwithamotorattachedtothelowpressure(brineoutlet)endoftherotor.Themotorhelpsadjusttherotorspeedtoprovidethedesiredfeedpressure.TheHEMImotoristypically10‐15%ofsizeofHPfeedpumpmotorandusesastandard(lowvoltage)VFD.TheHEMI:• Regulatesfeedflowandpressurefordesiredmembraneperformance;• EliminatesneedforVFDorcontrolvalveontheHPfeedpump;• Regulatesbrineflowandpressureasrequiredfordesiredmembraneperformance;• CanprovidetotalfeedandbrineregulationviaPLCcontrol(providedbyFEDCO).
HP‐HEMI‐1000HP‐HEMImodelscoverflowrangesfrom300to2000+m3/hr
Brineauxnozzleactuator
100hpHEMImotor
PLCcontrollerwithGUIinterface
Copyright©2010FluidEquipmentDevelopmentCompany‐ page12
FeedPressureControl
TheHP‐HEMIcanproducetheexactamountoffeedboostneededtomeetmembranerequirements.TheHPpumprunsatconstantspeedandwithoutathrottlevalvetoregulatefeedpressure.TheHEMImodulatesfeedandbrinepressureexactlyasneededtoachievedesiredmembranepressurefromaconstantpressurefeedsupply.
ThePXsystem,incomparison,hasabsolutelynoabilitytoregulatefeedpressure.Therefore,costlyandenergywastingfeedthrottlevalvesorVariableFrequencyDrivesontheHPpumparerequired.ThatisonereasonwhytheHEMIcandeliveralowerenergyconsumptionthanthePXsysteminrealisticfieldoperation.
Thechart(below)presentsatypicalannualpressurevariation.TheHEMIsmoothlyadjustsitsoperationtodelivertherequiredmembranepressurewithoutanythrottling.NotethattheHPpumpoperatesatfixedpressurethuseliminatingtheneedforafeedcontrolvalveorvariablefrequencydrive.
FeedpressuretoHPpump
80
60
40
20
Pressure(b
ar)
Jan Feb Mrch Aprl May June July Aug Sept Oct Nov Dec
DischargepressurefromHPpump
DischargepressurefromHEMI(membranepressure)
HPPumpDP(constant)
HEMIDP(variable)
HEMIPerformancewithVariableMembranePressure
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PXPrincipleofOperation
Qf=feedflowQb=brineflowQp=permeateflow
1–“P&IDDIAGRAM–TypicalInstallation”,PXManual
HighinletpressureboosterpumpwithVFD.BoostspressureandusedtocontrolPXrotorrotation.
Membrane
FM1
FM2
HPflowmeter
HPfeedpump
Isolationvalve(3)
Controlvalve.Providesbackpressuretopreventcavitationandcontrolfill/purgerateofrotorpassages.
Asimplifiedsystemdiagram[1]–specialflushingpiping,safetyinterlocks,PXsampleports,etc.omittedforclarity.Indicatedflowsareapproximate.
Residualpressurereliefvalve
Qp
Qb
Qp
Qb
QfQf
PXunits(1to20+)
Copyright©2010FluidEquipmentDevelopmentCompany‐ page14
PX‐PrincipleofOperation
Agivenrotorchannelisalternatelyfilledwithlowpressurefeedandthenpurgedwithhighpressurebrinewiththefillpurgecyclecontrolledbytherateofrotorrotation,brinedischargecontrolvalveandHPboostpump.
Rotorrotationratemustbecloselymatchedtothefill/purgerate.However,therotorspeedandfill/purgecyclerateoperateindependentlytherebyrequiringadjustmentoftheHPboosterpumpandbrinecontrolvalvetomaintainacceptableoperation.
Changesinfeedwaterconditionsorpretreatmentpressuremayrequireongoingadjustmentstomaintainthephaserelationshipbetweenrotorrotationandfill/purgecycletimes.
Rotorbearing
Endseal
CYCLESTART
LPbrineDischarge–flowratecontrolledbybrinecontrolvalve,pretreatmentpressureandbrinedisposalpressure
HPbrinefill
LPfeedfill
HPfeeddischarge–flowratecontrolledbyHPboosterpump
CYCLEEND
Rotor
Rotorchannel
LPfeedfillport
HPfeeddischargeport
LPbrinedischargeport
HPbrinefillport
SealareaRotorbearing
Copyright©2010FluidEquipmentDevelopmentCompany‐ page15
PX–RotorBlowThrough
Unbalanceoperationmeansthattherotorspeediswrongforchannelfillratesresultinginthebrine/feedinterfacemovingoutsidetherotorchannelresultingin“blowthrough[1]”.Brineblowthroughcanreachveryhighlevelstherebypossibleforcingasystemshutdown.Attheveryleast,feedpressurewillriseandpermeatequalitywilldeteriorateduetoexcessivefeedTDS.
Lubricationflow(feedleakingintothebrinestream(1‐2%whenunitsarenew)
Brine/feedinterface–theinterfacelocationoscillatesfromoneendofthechanneltotheotherendseveralhundredtimesperminute.Atnormaloperation,4‐5%ofbrinemixeswithfeedandentersthemembrane
Rotorrotationisdrivenbyimpingementofflowonendofrotor
“UNBALANCED”OPERATION–RotorBlowThrough
LPfeedenteringLPbrine“Blowthrough”
HPbrineenteringHPfeed“Blowthrough”
“BALANCED”OPERATION
BlowThrough
[1]‐page15,PXManual
Copyright©2010FluidEquipmentDevelopmentCompany‐ page16
StuckPXRotorFailure
Therearetwotypesofrotorfailure.Onefailureinvolvesdestructionoftherotorand/orbearingsurfaces.Thisdiscussionwillfocusonastalledorstuckrotor.
AstuckrotorcreatesabrineflowintoHPfeedstreamapproximatelyequaltonormalunitrating.Forexample,astalledPX‐220mayinjectfrom45to55m3/hrofbrineintothefeedstream[1].Thisisthemostextremeformof“blowthrough”.
Factorsthatcanstalltherotorinclude:• bio‐fouling[2]• debrisinthefeedorbrinestreams[3]• precipitatessuchasvarioussalts[4]• Severalanti‐scalantsandvariouswatertreatmentchemical[5]• damagedrotor,bearingorendplatescausedby:
• airbubbles[6]• operationoutsidethespecifiedflowrange[7]• pressurespikesdamagingtherotorand/orbearingsurfaces[8]• cavitation[9]
Brinepassestomembrane
Feedpassestobrinedrain
Potentialstickingarea
• Systemisshutdown;• PXarrayisolatedanddrained;• Failedunitphysicallyremovedtoworkarea;• Disassembled,cleanedandre‐assembled(49+steps).Pleaserefertopage10tocomparewiththeinternalinspectionoftheHPB.
Un‐stickingthePXrotor• TorqueexertedbyfeedorbrineimpingingonthePXrotorislow;• ThePXbearingsurfacesareverylarge(i.e.Theentirerotor);• Thecombinationoflowtorque,largebearingsurfacesandsmallclearancescreatesensitivitytobio‐foulingandotherfoulants.Incontrast,theHPBhashightorqueandsmallbearingsurfacesmakingrotorstickingvirtuallyimpossible.
WhythePXrotorsticksandtheHPBdoesnot
1‐privatecommunicationswithPXusers2‐page13,PXManual3‐page27,PXManual
4–Privatecommunications5‐page12,PXManual6‐page8,PXManual
7‐page11,PXmanual8‐page8,PXManual9‐page11,PXManual
Copyright©2010FluidEquipmentDevelopmentCompany‐ page17
PotentialPXRotorDestruction
Cavitation
“Failuretodoso[maintainingflowlimits]canresultindamageordestructiontothePXunitand/orotherequipment.”[1]
Operatingbeyondflowlimits
”…[sufficientbackpressurerequiredto]preventdestructivecavitation”[2]
AirBubbles“LargebubblescandamagethePXdevice”[3]
Pressurespikes
“Pressure/flowspikesrequireparticularconsiderationinsystemswithmultipleSWROtrainsastrainsgoon‐andoff‐line.Anautomaticflowcontrolsystemistypicallynotresponsiveenoughtoprovideconstantflowduringsuddenpressurechanges.Emergencyshutdownsequencesshouldincludeshuttingdowntheseawatersupplypump(s)toavoidoverflow.”[4]
ThePXrotorisdescribedasbeingverytoughbasedonitsceramicconstruction.However,thefactorsthatcandestroytherotorcanoccurinvirtuallyanyseawaterROsystem.
ThecostofrepairingaPXunitwithworn‐outordestroyedrotorisapparentlyquiteclosetothecostofanentirelynewunit[5].Incontrast,ifanHPBrotorneedsreplacement(forexampleduetomassiveingestionofdebris),thecostofanewrotorandbearingsetisabout40%ofthenewunitcost.Moreover,therotorcanoftenberefurbishedtoan“asnew”conditionbyFEDCOforafractionofthecostofanoverhaulkit.
1‐page11,PXmanual2‐page11,PXManual3‐page8,PXManual
4‐page8,PXmanual5‐PrivatecommunicationswithPXusers
Copyright©2010FluidEquipmentDevelopmentCompany‐ page18
MultiplePXUnitsandSystemReliability
TheabovestatementmeansthatasinglefailedPXunitinanarrayof1‐4unitscanforcesystemshutdown.Here’swhy:• afailedunitallowsbrineflowintothefeedequaltoor
exceedingtheratedcapacity;• forexample,aPX‐220mayallow50m3/hrofbrine
contaminationofthefeedstream[1];• Highlevelsofbrinecontaminationgreatlydegradessystem
performancetothepointofpreventingsystemoperation;• Thereforepotentialforsystemfailureisincreasedby400%
comparedtoasingleunitofsimilarreliabilityinaPXsystemwithfour(4)units.
“…withaconservativedesign,aplantwithmultiplePX'sindesignsoffiveormorecantypicallyoperateindefinitelywithoneormorePX'sremovedfromservice…”‐fromERIpublishedstatements
Failureofanyunitmayrequiresystem
shutdown.
1 2 3 4 5 6 7 8 9 10
1.0
0.8
0.6
0.4
0.2
MTB
F
NumberofPXunits/train
MeanTimeBetweenFailures(MTBF)istheaveragetimebetweenfailuresofagivenitem.TwooperatingunitswiththesameMTBFwillexperienceafailureinoneoftheunitsat50%ofthesingleunitMTBF[2].Extendingthisconcepttoasystemthatallows1failureper5operatingunitsresultsintheadjacentchart.HeretheMTBFappliestoROsystemfailurerelativetotheMTBFofasinglePXdevice.
Thus,multiplePXunitscreateashortersystemMTBF.
1‐privatecommunicationswithvariousPXusers2‐“ReliabilityandMTBFOverview”byScottSpeaks,VicorReliabilityEngineering
SinglePXunitMTBF(referencevalue)
MTBFofsystemequippedwithmultiplePXunitsrelativetosingleunitMTBF
Copyright©2010FluidEquipmentDevelopmentCompany‐ page19
PXAuxiliaryEquipment
A–Residualpressureremainsonthefeedsideofthesystemaftershutdown.Thisvalverelievespressuretoreducepotentialforaccidentsduringsystemmaintenance
B–Aflowmeterratedformembranepressureisneededtohelpachieve“flowbalance”ofthePXunits
C–ThispumpregulatesPXfeedrateandmustbeadjustedincombinationwithvalveFtoachieve“flowbalance”.Mustberatedformembranepressureoperation.
D–EachPXunitgeneratessoundlevelsupto92dB.Anarrayof10unitsmayemitatotaldBof102dBmakingacousticalenclosureshighlydesirableifnotmandatory.
E–Toreducepipestrain,aspoolpieceisrequiredforeachPXconnectionwith2Victaulic™jointsperspoolpiece.APXarrayof20unitsrequire80spoolpiecesand160Victaulic™joints.
F–Regulatesbrineflowtohelpachieve“flowbalance”
G–Neededtohelpachieve“flowbalance”
H–Isolatesunitsfromcleaningchemicals
I–Usedtodetectexcessivebrinemixingindicatingafailedunit
J–Four(4)manifolds
Notshown:• specialflushingpipesandvalves• safetyinterlocks• cleaningbypasslines• specialpressurecontrolvalvesandemergencyshutdownformulti‐trainoperation.
FM1
FM2
HPfeedpump
Isolationvalve(3)(H)
Controlvalve(F)
HighinletpressureboosterpumpwithVFD(C)
HPflowmeter(B)
Acousticalenclosure(D)
Sampletap(4)(I)
LPflowmeter(G)
Residualpressurereliefvalve(A)
Spoolpiece(E)
Manifold(J)
Copyright©2010FluidEquipmentDevelopmentCompany‐ page20
PXMulti‐TrainOperation
Membrane
Membrane
Membrane
A
B
C
AroutinepumptripontheHPpumporLPfeedpumpsupplywillcauseamomentarychangeinfeedsupplypressure.TheconsequencescanresultinseveredamagetothePXERD[1].
Forexample,atripofPumpB(diagramatright)cancausePXunitsintrainsAandCtosufferdestructionfromamomentarypressure/flowspike.
Specialfastactingcontrolvalves,emergencyshutdownsandotherspecialmeansareneededtoreducethepotentialfordestructionofthePXunits[2].
Or,thePXtrainscanbesuppliedbyaseparatepretreatedwatersupplysystemwithseparatefeedpumpsandsupplypiping[3].Substantialaddedcostsandcomplexitiesareincurred.
PXequipmentpackage
HPpump
LPpump
Pressurepulsation
HPBandHEMIunitsareimmunefromeffectsofflowsurgesandpressurespikes
Potentialrotordamage
Potentialrotordamage
1–page8,PXManual2–page8,PXManual3–page8,PXManual
Copyright©2010FluidEquipmentDevelopmentCompany‐ page21
OperatingRange
PXflowlimits
TypicalmembraneresponsetochangesinfeedTDS
HPBoperatingenvelop
ForPX,theLPbrinepressuremustbeatleast1barlessthanLPfeedpressuretoallowpurgigofbrinefromthePXrotorchannels.
Thislinkagebetweenfeedpretreatmentpressureandbrinedischargepressurecomplicatestheneedtodischargebrineathigherpressures.
HPBhasnorestrictionofLPbrinepressurerelativetofeedpressure.
• HPBhydrauliccharacteristicsmatchmembraneperformance.
• HPBisnotsubjecttoseveredamageordestructionifflowreacheshydrauliclimits.
PXpressurerequirements
Copyright©2010FluidEquipmentDevelopmentCompany‐ page22
Safety
ThePXhasavarietyofstringentoperatingrequirementsthat,ifnotcloselyadhered,canresultinseriousequipmentdamageandpossibleinjurytopersonnel.Examplesinclude:1. VerystrictflowlimitsotherwisePXunitsmaybedestroyed[1];2. Retainingringcanfailwith“catastrophic”resultsifexposedtomoisture[2];3. Highpressureremaininsystemaftershutdownexposingmaintenancepersonneltorisk[3];
ThePXrequiresadditionalequipmentwhichinvolve:1. BoosterpumpandVFDwithassociatedelectricalcomponents,wiring,conduits,etceachwiththeirownhazards
andsafetyrequirements;2. Additionallockout–tagoutsafetyprocedures;3. Highlytrainedmaintenancepersonnelrequiredformotor,VFD,PLCcontrolsandinterlocks,highaccuracyflow
meterssamplingoffeedandbrineateachPXunit,etc.;4. HundredsofadditionalVictaulic™highpressurepipejointsinlargePXarrays;5. StoppageofPXrotorduringsystemoperationisequivalenttoasuddenblockageofthebrineflow.Feed
pressuremayriseabruptly.Ifsafetyequipmentfailstorespond,seriousdamagecanoccurthroughthesystem;6. Noiselevelsthatcangreatlyexceed90dB.90dBisconsideredharmfultounprotectedoperatingstaff[4].
1–p.8,PXManual2–p.11,PXManual
3–p.9,PXManual4–OccupationalSafetyandHealthAdministration(OSHA)–Regulation1910.5(a)
Copyright©2010FluidEquipmentDevelopmentCompany‐ page23
PXEffectonHPPumpEfficiencyEfficiency(%
)
10
101 100 1000 10000
20
30
40
50
60
70
80
90
100
Flow(m3/h)
Illustratedintheadjacentfigure,efficienciesofwell‐designcentrifugalHPpumpsincreasefromabout57%tonearly90%overflowrangestypicalofROsystems.
ThePXreducesHPpumpflowtothatofthepermeateflowthusreducingpumpefficiencyrelativetoapumphandlingtheentirefeedflow.
Forexample,assumeanSWROsystemproduces450m3/hrat45%recovery.WiththePX,theHPpumphandles450m3/hrbutwithanHPBorHEMIthefeedpumphandles1,000m3/hr.TheexpectedHPpumpefficienciesare80.7%and84.2%respectively–over4%reductioninHPpumpefficiencyforthePX.
Thus,thePXreducesfeedpumpefficiencyforagiventraincapacity.
TypicalHPPumpEfficiencyversusFlowRate
WithHPBorHEMI
WithPX
Copyright©2010FluidEquipmentDevelopmentCompany‐ page24
EconomicAnalysisSEC(kw‐hr/m
3 )
1.00
5.00
6.00
7.00
8.00
2.00
3.00
4.00
10 100 1000 10000
NoERD
HPB
PX
HEMI
Qfeed(m3/hr)
SpecificEnergyConsumption
Recovery=45%Psuc=2barPm=60‐70barPr=58‐68barPex=1barFeedthrottlepressurecontrolHPPefficiencyfromchartonpage21
Period=15yearsPower=$0.09kw‐hrInterest=7%Inflation=3%Fieldrate=950USD/day(maintenance)Cost=1.50USD(lostrevenueduringdowntime)AllpumpefficienciesarecalculatedwithoutregardtotypeofERD.
Overhaul:PX‐5yearsHPB&HEMI‐6years
MajorAssumptions
Conclusions• HPBSECwithin3‐12%ofPX• HEMIbeatsthePXSECinallcases• HPBandHEMImatchesorbeatsthePXinLifeCycleCost
TheHPBandHEMIprovidealowerLCCandlowercostpermeate
0
LifeCycleCost(USD
)(millions)
500 1000 2000
NoERD
PX
HPB
HEMI
Qfeed(m3/hr)1500 2500
5
10
15
20
25
30
35
LifeCycleCost
Copyright©2010FluidEquipmentDevelopmentCompany‐ page25
BidCompetitiveness
0
CapExandInstall(USD
)(millions)
500 1000 2000
NoERD
PX
HPB
HEMI
Qfeed(m3/hr)1500 2500
0.2
0.6
0.8
1.0
1.4
1.6
1.8 CapitalandInstallationCosts
1.2
0.4
Thischartillustratesthecapitalandinstallationcostsforthefollowingequipment:• ERD• highpressurepump• controlvalve,• contactor• associateddesignandprocurementcosts.
TheHPBandtheHEMIpackageshavemuchlowertotalcostthanwiththePXpackageresultinginasubstantialreductionofthetotalSWROsystem.
WiththeHPBandHEMI,theOEMcanofferlowerbidpriceswithgreatermargins.
Copyright©2010FluidEquipmentDevelopmentCompany‐ page26
Toughness‐AbilitytoHandletheUnexpected
70C/60C
20micron
Nopotentialdamage
Norestrictions
Nopotentialdamage
NopotentialforERDdamagefromoperatingerror
Zero
TurnoffHPpump,LPpump
TurnofHPpump,LPpump
Nodamagetounit
Nodamage
Noproblems
Temperature(Storage/operating)
Particlesize
Bio‐fouling
Anti‐scalantsandwatertreatmentchemicals
Pressurespikes
Mis‐operation
Brineintrusionintofeed
Startup
Shutdown
Membranecleaning
Flowvariation
Airbubblesinfeedorbrine
HPB PX45C/45C[1]
5micron[2]
Cancauseunitfailure–warrantyrequiresextensiveprecautions[3]
Totalprohibitiononseveraltypes,verystrictusagerequirementsonothers.Nowatertreatmentchemicalsofanykind[4].
Extensivesystemmodifications,fastactingvalves,emergencyshutdownsprescribed[5[.
ComplexoperatingrequirementincreasespotentialforoperatorerrorresultinginpossibledestructionofERDandothersystemcomponents
“Normal”leakageis5+%ofbrineflowandcanbemuchhigherifflowsare“unbalanced”[6[
Followmulti‐pageprocedures,verifysafetyinterlocksareinplace,perform“flowbalance”toprevent“blowthrough”[7].
Followingshutdownsequence,systemremainsdangerouslypressurizedforaperiodoftime[8].
PXunitsmustbephysicallyremovedfromsystemorisolationvalesemployed[9].
Rotorcanbedestroyedbyslightvariationsinflowratebeyondspecifiedlimits[10].
Voidswarranty,candestroytheunit[11]
Factor
1–p.4,PXManual2–p.11,PXManual3–p.13,PXManual
4–p.11,PXManual5–p.8,PXManual6–p.2“ERITechnicalBulletin:IsobaricDeviceBrine/SeawaterMixingEffect”
7–p.15,PXManual8–p.9,PXManual9–p.14,PXManual
10–p.7,PXManual11–p.8,PXManual
Copyright©2010FluidEquipmentDevelopmentCompany‐ page27
WarrantyLength
WiththeHPB,thereisoneandonlyonewarranty.
WiththePX,manysuppliersofcriticalequipmentareinvolvedeachwiththeirownwarranty,length,termsandexceptions.Warrantymanagementandadministrationcanbecomemajordifficulties.
FEDCO‐Three(3)yearsfromshipment
PLC,sensors,actuators?
PX‐Two(2)yearsfromshipment[1]
HPboosterpump–18months?
HP&LPflowmeters?
Control,isolation&samplevalves?
MotorandVFD?
MultiplewarrantiesfrommultipliersuppliersforthePXsystem
1–p.29,PXManual
Copyright©2010FluidEquipmentDevelopmentCompany‐ page28
WarrantyExceptions
Everydisclaimerandexceptioninawarrantymayrepresentmultiplefailuresinthefieldforwhichthesupplierhandnoanswerandnosolution.
Aqualitywarrantyhasaminimumofexceptions,warningsanddisclaimers.ThePXwarrantyreflectsavarietyofoperatingissuesforwhichERIhasaddressedthroughwarrantyexceptions–i.e.thePXdesignrestrictionsarenowtheresponsibilityofthecustomer.
Incomparison,theFEDCOwarranty:• keepdebrisfromtheunit• maintainbrinedisposalpressure• avoidexcessivepipestrain.
Copyright©2010FluidEquipmentDevelopmentCompany‐ page29
SummaryofComparison
LifeCycleCost–provideslowestcostofpermeate
Capitalcost–lowestengineering,procurementandpurchasecost
Brinefeedmixing–nocontaminationoffeedwithbrine
Reliability–fewestcomponents,simplestconstruction
Easeofoperation–requiresleastamountoftraining,lesspotentialforoperatorerror
Noise–whichERDisinherentlyquieter
Safety–LeastamountofHPequipment,piping,joints,noelectricalcomponents
Maintenance–noauxiliaries,easierandlowercostoverhauls
OperatingRange–broadestoperatingrange,immunetomis‐operation
Toughness–abilitytohandletheunexpected
ReliabilityandWarranty–longestandmostgenerouswarranty
FEDCOHPB
ERIPXSystem
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FEDCOTraining
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WiththemostcomprehensiveproducelinesfromanyROequipmentsupplier,FEDCOoffersthemostcomprehensivetrainingonallaspectsof:
• HPBandHP‐HEMI• MSSfeedpumps• SSDfeedpumps• LP(lowpressure)ERDsandpumps• ROsystemcontrolformaximumenergyefficiency
Classsizesrangefrom2to10.ContactFEDCOtodayfordetails.
ComprehensivetrainingonSelection,InstallationCommissioningandMaintenanceofallFEDCOProducts