Purchase justification for laser alignment

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Power saving Seal replacement cost Bearing replacement cost Pump repair cost

Power saving calculation

Alignment Data KW Rating Number of Units
Measured misalignment
Power loss
Cost of power per KW
Operating hours per day
Operating days per year
Total additional cost of power consumed across plant:1.571,31 €

Figure 1 The effect on power consumption of misalignment

The graphs are reprinted from a report of the investigation into the effects of misalignment on power consumption that was carried out at the ICI Rocksavage Sire, 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.

Seal replacement cost (for cartridge seals at average costs from seal manufacturers)

Alignment Data KW Rating Cost of seals
Measured misalignment
Failure interval in months
Total additional cost of seals consumed across plant per year:1.571,31 €

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.

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

This is the additional cost of bearings over the expected annual cost when machines are aligned to 0.05mm.

Alignment Data KW Rating Bearing Cost (each bearing)
Measured misalignment
Replacement interval in months
Total additional cost of seals consumed across plant per year:1.571,31 €

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

Alignment Data KW Rating Man Hours repair time
Cost per hour
Replacement interval in months
Total additional cost of pump repairs across plant:1,069.59 €

Summary

Annual savings on plant when alignment is better than 0,05 compared to typical measured alignment of 9,00 mm.

Saving on power costs 4.210.005,85 €
Saving on replacement seals 3.791,89 €
Saving on replacement bearings 1.432,76 €
Saving on pump repairs 10.427,69 €
Total additional cost over one year ** 4.225.658,18 €
Total additional running cost of 5 year period ** 21.128.290,92 €
** these cost are additional to the expected annual running cost of the asset when aligned to 0.05 mm:306,51 €
Power saving Seal replacement cost Bearing replacement cost Pump repair cost

Power saving calculation

Recommended offset tolerance
Power loss
Cost of power per KW
Operating hours per day
Operating days per year
Pump rating (KW)
Cost of power loss per pump per year
Number of pumps per unit rating
Total cost of power loss per year
Total cost of extra power consumed across plant when offset = 0.05 mm:3.892,73 €

Seal replacement cost (for cartridge seals at average costs from seal manufacturers)

Measured misalignment
Failure interval in months
Seal cost 15KW
Seal cost 35KW
Seal cost 75KW
Seal cost 125KW
Seal cost 300KW
Annual cost of seals per pump
Number of pumps per unit rating
Total cost of seals per year
Total cost of seals consumed across plant when offset = 0.05 mm:446,54 €

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

Measured misalignment
Replacement interval in months
Bearing cost 15KW
Bearing cost 35KW
Bearing cost 75KW
Bearing cost 125KW
Bearing cost 300KW
Annual cost of seals per pump
Number of pumps per unit rating
Total cost of seals per year
Total cost of seals consumed across plant when offset = 0.05 mm:10,80 €

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

Cost per hour
Repair interval in months
Pump rating
Number of pumps per unit rating
Total cost of pump repairs per year
Total pump repair costs across plant when offset = 0.05 mm:158,40 €

Summary

Total yearly cost of repair and power waste when aligned to +/- 0.05 MM OFFSET: 5.650,98 €