FluidEquipment_Mr. Eli Okeljas - Aquatechtrade
FluidEquipment_Mr. Eli Okeljas - Aquatechtrade
FluidEquipment_Mr. Eli Okeljas - Aquatechtrade
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Advances in Mega-scale High Pressure<br />
Feed Pumps and Energy Recovery<br />
Devices Promise Further Reduction in<br />
the Cost of Permeate.<br />
Authors: <strong>Eli</strong> Oklejas (presenter)<br />
Subodh Paranjpe<br />
AquaTech India 2011<br />
Mumbai, India.<br />
Copyright © 2011 Fluid Equipment Development Company page 1
FEDCO Characteristics<br />
(Fluid Equipment Development Company)<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Main market is RO Desalination<br />
• 2,500+ SWRO pumps and ERDs installed<br />
worldwide in the past 6 years.<br />
Complete Responsibility<br />
Specialty Markets<br />
• FEDCO designs and builds all products under the FEDCO name<br />
• FEDCO provides the complete HP pump and ERD package<br />
• Single source warranty responsibility<br />
• Single source procurement<br />
• FEDCO does all manufacturing at its USA facility (no out-sourcing).<br />
• Very high pressure membrane<br />
separation processes (100+ bar).<br />
Copyright © 2011 Fluid Equipment Development Company page 2
Certificates and Intellectual Property<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
ISO 9001 (Quality Management)<br />
• Expect certification by April 2011<br />
ISO 14001 (Environmental)<br />
• Expect certification by April 2011<br />
CE Stamp<br />
• Available on HPBs and most FEDCO pumps<br />
Intellectual Property<br />
• Numerous issued patents on pump, ERD and system designs<br />
• High number of patent applications<br />
• Numerous patent applications in preparation<br />
• Numerous registered software packages, product names, etc.<br />
Copyright © 2011 Fluid Equipment Development Company page 3
Qualifications<br />
Partial User List of<br />
Advanced Pumps and ERDs<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
General Electric<br />
Veolia<br />
Doosan<br />
IDE<br />
Biwater<br />
AES Arabia<br />
ITT<br />
Harn RO<br />
Inima<br />
Befesa<br />
Ion Exchange<br />
Seven Seas<br />
Various Militaries<br />
Case Marine<br />
Metito<br />
Al Fatah<br />
Exxon<br />
Shell<br />
Asian Tech<br />
Ace Water<br />
SC Water<br />
Severn Trent<br />
Doosan Hydro<br />
Highland<br />
Consolidated<br />
Crane<br />
Wabag<br />
SWCC<br />
Utico<br />
Wetico<br />
Seimens<br />
SAWACO<br />
Tahil<br />
Tam<br />
Tedaguq<br />
Cadagua<br />
WTD<br />
TEMAK<br />
Copyright © 2011 Fluid Equipment Development Company page 4
Global Market Experience<br />
Qualifications<br />
Background<br />
FEDCO<br />
headquarters<br />
FEDCO<br />
MENA Office<br />
Marine/offshore<br />
Mega-scale<br />
Products<br />
US/Canada<br />
Mexico/Central<br />
America<br />
Mediterranean<br />
N. Africa<br />
Middle East<br />
Korea<br />
China<br />
India<br />
Japan<br />
Pacific Islands<br />
Life Cycle<br />
Costs<br />
Maldives<br />
Singapore<br />
South<br />
America<br />
Australia<br />
S. Africa<br />
FEDCO Sales Centers – India, KSA, China, Korea<br />
FEDCO Sales and Service Centers – USA, Israel,<br />
Spain, Mexico, India<br />
Copyright © 2011 Fluid Equipment Development Company page 5
New Product Design Process<br />
Qualifications<br />
All designs start for<br />
3-dimensional solid<br />
models<br />
Computational Fluid<br />
Dynamics (CFD) to<br />
maximize efficiency<br />
Finite Element<br />
Analysis (FEA) to<br />
confirm stress safety<br />
factors<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Casting Solidification<br />
Analysis to maximize<br />
casting quality<br />
Casting patterns<br />
machined from solid<br />
model for best<br />
accuracy<br />
Finished part is fully<br />
engineered in every detail<br />
Integrated process developed over 5 years<br />
Copyright © 2011 Fluid Equipment Development Company page 6
Software Packages Developed In-house<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
SELECTOR – Automatic selection of optimized<br />
pump and ERD configurations,<br />
ORDER ENTRY – Automatic generation of<br />
custom BOMs, custom outline drawings, custom<br />
machining dimensions, CNC program<br />
generation, etc.<br />
RO HYDRAULIC MODELS – close simulation of<br />
HP pumps, ERDs and membranes useful to<br />
prediction component efficiencies and overall<br />
Specific Energy Consumption (SEC) over typical<br />
variable operating conditions of RO trains.<br />
HYDRAULIC DESIGNERS – Several<br />
packages that generate detailed hydraulic<br />
designs for pumps and turbines that are finetuned<br />
against exhaustive CFD analysis and<br />
test stand data.<br />
Copyright © 2011 Fluid Equipment Development Company page 7
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Computational Fluid Dynamics (CFD)<br />
at a World Class Level<br />
CFD can refine the hydraulic design of turbine nozzle, volute and impeller vane<br />
geometry as well as pump impeller and diffuser geometry.<br />
Years of CFD analysis and hundreds of tests are required<br />
to achieve predictions of test stand performance to within<br />
1% of efficiency and pressure differential for complex fluid<br />
machines such as turbochargers.<br />
Proper use of CFD is essential for optimizing HPB<br />
performance over a broad range of flows and pressures.<br />
Life Cycle<br />
Costs<br />
FEDCO HPB-1400 - first<br />
turbocharger to exceed<br />
80% transfer efficiency.<br />
Copyright © 2011 Fluid Equipment Development Company page 8
State of the Art Manufacturing<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
• Modern networked CNC machines<br />
• New facilities<br />
• World class manufacturing team<br />
Copyright © 2011 Fluid Equipment Development Company page 9
Product Testing<br />
Qualifications<br />
• Accurate testing is key to consistent performance<br />
• Test system certified by independent 3 rd party<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Large product test<br />
area<br />
Hydrostatic Testing<br />
Each unit is hydrostatic pressure tested to verify integrity of all pressure<br />
containment components. Hydraulic Institute standards apply.<br />
Copyright © 2011 Fluid Equipment Development Company page 10
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
FEDCO Product Families<br />
Standard SWRO System Packages – MSS and MSD pumps<br />
and HPB ERDs<br />
• 100 to 2500 m 3 /day permeate<br />
• delivery in 4-10 weeks<br />
Mega SWRO System Packages – SSD pumps and HPB ERDs<br />
• Unit sizes for 15,000 m 3 /day permeate per train and larger<br />
• Delivery in as little as 6 weeks, typically 16-24 weeks<br />
Low Pressure BWRO Packages – LPS, LPH, LPD and BPB<br />
pumps and ERDs<br />
• Flows to 700 m3/hr<br />
• Delivery in 4-8 weeks<br />
Upgrade packages - HPX<br />
• Flows to 2,000 m3/hr<br />
• Replace isobaric chambers<br />
Copyright © 2011 Fluid Equipment Development Company page 11
Equipment Configuration<br />
Qualifications<br />
The HPB produces up to 50% of the membrane pressure requirement, thereby,<br />
reducing the energy input and size of the HP feed pump and motor and motor<br />
starter.<br />
Background<br />
P=66 bar<br />
Membrane<br />
Q=645 m3/h<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
P=2 bar<br />
Q=1500 m3/h<br />
Feed<br />
Feed Pump<br />
P=36 bar<br />
P<br />
T<br />
HPB energy<br />
recovery<br />
P=1.0 bar<br />
Permeate<br />
P=65 bar<br />
Q=855 m3/h<br />
• Works just like an automotive turbocharger<br />
• Automatically boosts feed pressure<br />
• Fully powered by brine pressure<br />
• Absolutely no other equipment required<br />
• No parasitic losses<br />
• No brine/feed mixing<br />
Copyright © 2011 Fluid Equipment Development Company page 12
Hydraulic Pressure Booster (HPB)<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
BRINE<br />
Turbine section<br />
Pump section<br />
FEED<br />
Copyright © 2011 Fluid Equipment Development Company page 13
HPB General Features<br />
Qualifications<br />
Background<br />
Water-lubricated<br />
bearings<br />
Can discharge<br />
brine against any<br />
back pressure<br />
O-ring mounting for<br />
easy bearing<br />
Change-out<br />
Top discharge for easy piping<br />
Multi-vane diffuser<br />
for High efficiency<br />
and radial force<br />
balance<br />
Mega-scale<br />
Products<br />
One (1) piece rotor<br />
machined from bar<br />
stock for high<br />
strength<br />
Custom machined<br />
impeller and diffuser<br />
geometry for maximum<br />
pressure boost<br />
Life Cycle<br />
Costs<br />
Low noise and<br />
negligible vibration<br />
Integral brine control valve<br />
allows adjustment of brine<br />
flow and pressure<br />
Single end cap design<br />
Bearing lubricated by feed (leakage<br />
to brine = 0.1% of flow)<br />
Victaulic pipe<br />
joints for easy<br />
installation<br />
Passivated castings to<br />
minimize surface rust<br />
Copyright © 2011 Fluid Equipment Development Company page 14
How the HPB Controls Brine Pressure<br />
Qualifications<br />
Background<br />
HPB Auxiliary brine nozzle controls brine<br />
flow and pressure<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Copyright © 2011 Fluid Equipment Development Company page 15
HPB Installation<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
High pressure<br />
brine from<br />
membrane<br />
Low pressure<br />
brine to disposal<br />
High pressure<br />
feed to membrane<br />
From feed<br />
pump<br />
Life Cycle<br />
Costs<br />
The HPB can be installed in any orientation<br />
- sideways, vertical, etc.<br />
Connect the 4 pipes and your installation is complete<br />
• inherently safe design<br />
• no external tubes and valves<br />
• no electrical equipment, HP pumps, etc.<br />
• vastly simpler installation<br />
Copyright © 2011 Fluid Equipment Development Company page 16
HPB Operation<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
To decrease<br />
brine flow:<br />
• Close the valve<br />
To increase<br />
brine flow:<br />
• Open the valve<br />
1. No training of operating staff<br />
2. Operator error can not damage the HPB or feed pump<br />
3. Simplicity demanded by military users, off-shore operators,<br />
hotels and resorts<br />
4. Reduces complexity in large systems thereby reducing control<br />
system costs.<br />
Copyright © 2011 Fluid Equipment Development Company page 17
HPB Overhaul<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
15 to 60 minutes to overhaul HPB<br />
• No special tools, No measurements<br />
• No skills required<br />
• Can be overhauled by plant maintenance<br />
personnel.<br />
Life Cycle<br />
Costs<br />
Copyright © 2011 Fluid Equipment Development Company page 18
Mega SWRO System Packages<br />
Qualifications<br />
HP Feed Pumps, Energy Recovery and System Control<br />
Background<br />
Mega-scale<br />
Products<br />
HPB and HP-HEMI<br />
• feed flows to 3,200 m3/hr<br />
• delivery in 16-26 weeks<br />
Life Cycle<br />
Costs<br />
SSD high pressure feed pumps<br />
• flow rates to 1,400 m3/hr<br />
• efficiency to 90+%<br />
• power recovery<br />
*patent pending<br />
Copyright © 2011 Fluid Equipment Development Company page 19
Feed pressure (bar)<br />
Mega SWRO System Packages<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
SSD Series HP Pump<br />
SSD-500<br />
SSD-700<br />
SSD-1000<br />
SSD-1400<br />
Hydraulic Pressure Booster (HPB)<br />
HPB-500<br />
HPB-700<br />
HPB-1000<br />
HPB-1400<br />
HPB-2000<br />
HPB-2800<br />
Life Cycle<br />
Costs<br />
100<br />
80<br />
60<br />
40<br />
SSD Range<br />
HPB Range<br />
20<br />
500 1000 1500 2000 2500 3000<br />
Feed capacity (m3/hr)<br />
Copyright © 2011 Fluid Equipment Development Company page 20
HPBs for Mega SWRO Projects<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Design Criteria – Feed booster and interstage booster<br />
Flows - 400 to 3,200 m3/hr<br />
Pressures – Up to 83 bar<br />
Delivery – 12 - 24 weeks<br />
Life Cycle<br />
Costs<br />
Options – Flange connections, Aux valve actuator<br />
Materials – Duplex 2205, Super Duplex 2507<br />
Hydraulic Design – Computational fluid dynamics (CFD) to customdesign<br />
entire hydraulic flow path for each project.<br />
Copyright © 2011 Fluid Equipment Development Company page 21
SSD High Pressure Pumps<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
High Pressure Feed Pumps for Mega-SWRO<br />
Ultra-high Efficiency Low Capital Cost<br />
Design Criteria – Specifically for SWRO Service<br />
Flows - 400 to 1,400 m3/hr<br />
Efficiency - 84 to 90+%<br />
Delivery - 12-20 weeks (subject to motor availability)<br />
Single stage – End suction design<br />
Direct drive – Standard 2-pole motors (no VFD or gear box)<br />
Hydraulic Design - Best efficiency point is always the duty point<br />
achieved by using computational fluid dynamics (CFD) to<br />
custom-design the hydraulic flow path.<br />
Copyright © 2011 Fluid Equipment Development Company page 22
SSD Features<br />
Qualifications<br />
High Pressure Feed Pumps for Mega-SWRO<br />
Background<br />
Mega-scale<br />
Products<br />
Multi-vane<br />
diffuser ring<br />
Disc<br />
coupling<br />
2-pole motor (50<br />
or 60 Hz)<br />
Life Cycle<br />
Costs<br />
Duplex or<br />
Super Duplex<br />
MOC<br />
Mechanical seal<br />
(operates at low<br />
pressure)<br />
Common<br />
base<br />
Coupling<br />
guard<br />
SSD - Brine-to-electricity<br />
Turbine generator - includes<br />
controls, contactors<br />
Copyright © 2011 Fluid Equipment Development Company page 23
SSD Design<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Designed Specifically for RO<br />
Service<br />
• DP range up to 44 bar<br />
• Only available in duplex SS<br />
and Super Duplex SS<br />
• Every aspect of design and<br />
manufacture aimed at<br />
maximum possible efficiency<br />
• Water lubricated bearings<br />
• Seal operates at inlet pressure<br />
• Very compact footprint<br />
Shaft<br />
Diffuser ring<br />
Impeller<br />
Shaft<br />
bearing<br />
Seal chamber<br />
drain line<br />
Copyright © 2011 Fluid Equipment Development Company page 24
Recent Major Projects<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
SSD-500 and<br />
HPB-500 for<br />
Turks & Caicos<br />
480m 3 /hr duty<br />
point (feed)<br />
Life Cycle<br />
Costs<br />
SPECIFIC ENERGY CONSUMPTION = 2.6 kWh/m 3<br />
- Feed = 41,000 ppm, Permeate TDS = 255 ppm Recovery = 45%<br />
- 5,000 m 3 /day permeate production, Power cost = $0.33/kWh<br />
- Lowest reported SEC in the Caribbean on trains of this size<br />
Copyright © 2011 Fluid Equipment Development Company page 25
Recent Major Projects<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Major Power Plant in India<br />
• HPB-700 provided on emergency<br />
basis to replace failing units<br />
supplied by a competitor<br />
• Fully-customized HPB-700<br />
shipped in six (6) weeks after<br />
purchase order<br />
• Constructed with a Super Duplex<br />
SS 2507 rotor and diffuser<br />
• Displayed up to 15% higher<br />
efficiency than competitor’s unit<br />
• Noise level reduced by 10 dB<br />
• Exceeded all requirements<br />
Copyright © 2011 Fluid Equipment Development Company page 26
Qualifications<br />
Background<br />
Recent Major Projects<br />
Jeddah Airport Expansion - Five (5) HPB-1000 units<br />
• Commissioned March 2009<br />
• Customer required fast delivery, high reliability and low capital cost.<br />
• Customer reports complete satisfaction with performance and ease of<br />
operation.<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
HPB-1000 in Jeddah, Saudi Arabia<br />
SWRO train – HPB at lower right corner<br />
Copyright © 2011 Fluid Equipment Development Company page 27
Recent Major Projects<br />
Qualifications<br />
Background<br />
Jeddah III SWRO – Sixteen (16) HPB-1400 units<br />
• Unit feed flow in excess of 1,600 m3/hr<br />
• Super Duplex 2507 Construction<br />
• Brine control actuator<br />
• Highest net efficiency ever achieved by a turbine based RO ERD device<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Copyright © 2011 Fluid Equipment Development Company page 28
What is the HEMI?<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Hydraulic Energy Management Integration<br />
• Provides total control of feed flow and brine flow<br />
• Provides high efficiency energy recovery<br />
HEMI VFD<br />
(
{Pressure (barg)<br />
Qualifications<br />
Background<br />
HPP Pressure and Membrane Requirement<br />
- With HEMI Control<br />
• HPP sized based on lowest pressure condition<br />
• Feed pressure established by HEMI feed boost<br />
• HPP runs at constant speed and pressure<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
70<br />
60<br />
50<br />
40<br />
30<br />
HEMI<br />
pressure<br />
boost<br />
50 barg<br />
Membrane<br />
Pressure<br />
Requirement<br />
20<br />
10<br />
30 barg<br />
2 barg<br />
HP Pump<br />
Pressure<br />
HPP inlet<br />
pressure<br />
Winter Summer Winter<br />
Copyright © 2011 Fluid Equipment Development Company page 30
How the HEMI Works<br />
Qualifications<br />
Main motor (1,400 kW) (no VFD)<br />
Background<br />
2 barg<br />
Pump section<br />
30 barg 50-70 barg<br />
FM1<br />
Mega-scale<br />
Products<br />
HP pump<br />
Actuator<br />
Life Cycle<br />
Costs<br />
HPB<br />
FM2<br />
Turbine section<br />
Auxiliary motor<br />
(0-300 kW output)<br />
Motor Drive<br />
VFD (380/50/3 power)<br />
Copyright © 2011 Fluid Equipment Development Company page 31
HEMI Control Philosophy<br />
Qualifications<br />
FM1<br />
Background<br />
FM2<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
PLC<br />
Brine Nozzle<br />
Actuator<br />
HEMI VFD<br />
Permeate too HIGH Reduce VFD Hz (reduce feed boost)<br />
Permeate too LOW Increase VFD Hz (increase feed boost)<br />
Brine too HIGH Close brine nozzle (reduce brine flow)<br />
Brine too LOW Open brine nozzle (increase brine flow)<br />
Table 1 – PLC control philosophy<br />
Copyright © 2011 Fluid Equipment Development Company page 32
HEMI PLC<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Copyright © 2011 Fluid Equipment Development Company page 33
Life Cycle Cost Analysis (LCC)<br />
Qualifications<br />
Background<br />
A systematic procedure defined by Europump and US Hydraulic Institute to<br />
evaluate life-time costs of pumping equipment based on all cost factors<br />
The LCC “weighs” these factors to determine the “optimal investment” for<br />
an ERD or pump. The LCC tells you how much money you have “at the end<br />
of the day.”<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
cost of energy<br />
initial costs<br />
training cost<br />
installation costs<br />
maintenance<br />
net cost of capital<br />
downtime<br />
decommissioning<br />
Copyright © 2011 Fluid Equipment Development Company page 34
Life Cycle Costs – Costs vs Time<br />
Qualifications<br />
Background<br />
Cost<br />
($)<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Design/engin<br />
eering/biddin<br />
g<br />
HP pump and ERD<br />
Initial Cost (capital)<br />
Installation/<br />
training<br />
Downtime<br />
Energy<br />
Sch. Maint.<br />
Decommission<br />
Inflation<br />
Vital for<br />
successful<br />
low bid by<br />
OEM<br />
Vital for system owner<br />
to achieve low cost of<br />
permeate<br />
Time (years)<br />
Copyright © 2011 Fluid Equipment Development Company page 35
Summary of LCC Factors<br />
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Life Cycle<br />
Costs<br />
Design<br />
Procurement<br />
Cost of capital<br />
Commissioning<br />
Training<br />
Maintenance<br />
Downtime<br />
Energy<br />
Negligible to minimal – no special equipment<br />
Single source & single warranty responsibility<br />
Usually lowest of all ERD and HPP packages<br />
Typically < one (1) day per train<br />
Negligible, new staff quickly trained<br />
Minimal<br />
Minimal – simply design and fast overhaul<br />
With HEMI, lowest SEC of all ERDs<br />
Table 2 – LLC characteristics of HPB, HEMI and SSD<br />
CONCLUSION – SSD + HPB or HEMI has lowest LCC of<br />
currently available HPP and ERD packages<br />
Copyright © 2011 Fluid Equipment Development Company page 36
Qualifications<br />
Background<br />
Mega-scale<br />
Products<br />
Thank You for Your Attention<br />
Life Cycle<br />
Costs<br />
Questions?<br />
Copyright © 2011 Fluid Equipment Development Company page 37
Change language