Year Automation Conference 2015 Increase pressure for costs reduction - How much? Marcos Assialdi HBR / TGEx.

Apresentação em tema: "Year Automation Conference 2015 Increase pressure for costs reduction - How much? Marcos Assialdi HBR / TGEx."— Transcrição da apresentação:

1 year Automation Conference 2015 Increase pressure for costs reduction - How much? Marcos Assialdi HBR / TGEx

2 year Increase pressure for costs reduction - How much? Introduction  As it is known by all the engineering involved with hydraulic speed governors, increased work pressure implies the reduction of acquisition costs as well as manufacturing costs.  The present lecture intend to quantify this cost reduction and establish the conditions under which this prerogative is valid, aiming to get more and more competitive solutions. 2

3 year Increase pressure for costs reduction - How much? Contents  1Theoretic concepts.  2Increase of pressure implies in reduction of manufacturing costs.  3Case: PCH São Lourenço. Budget versus manufacturing costs.  4 Conclusion. 3

4 year 1 Theoretic concepts 4

5 year Servo actuator 1Francis Turbine - Section 5 Wicket Gate Mechanism

6 year 6 ____ Compressed Air ____ Pressurized Oil ____ Control Line ____ Drain Line Air Compressor Air Receiver Air/Oil Tank Hydraulic Power Unit Servo Actuator with Linear Position Transducer Proportional Valve Digital Speed governor Speed Signal Feedback Nitrogen/Oil Accumulator 1 Hydraulic Governor Overview

7 year 1Work Capacity Calculation 7

8 year 1Hydraulic Governor Calculation 8

9 year 9 Wc = Fsm x Stroke = Ph x Ap x Stroke = Ph x Vol Wc = Work Capacity (Nm) Fsm = Servomotor force (N) Stroke = Servomotor stroke (m) Ph = Hydraulic Pressure (Pa) Ap = Piston area (m2) Vol = Servomotor Volume (m3) 1Work Capacity - Definition

10 year 10 Wc (fixed) = Ph ( ↑ ) x Vol ( ↓ ) 2Increase of pressure implies in reduction of manufacturing costs Relation between pressure and volume Wc = Work Capacity (Nm) Ph = Hydraulic Pressure (Pa) Vol = Servomotor Volume (m3)

11 year 11 Vol ( ↓ ) = $ ( ↓ ) 2Relation between volume and cost

12 year 12 3PCH São Lourenço – Mato Grosso – Brazil Sample Case Study

13 year 13 Solution Final cost = 402.210 EUR 2 Digital Governor panels 2 HPUs: 60 bar (Runner) + 140 bar (Distributor) Problem Estimated cost in the proposal = 353.945 EUR Real cost attending the proposal = 965.305 EUR 2 Digital Governor panels 2 Hydraulic Power Units: 60 bar (Runner + Distributor) 2 Pressure tank (Air + Oil) 1 Air Compressor 3PCH São Lourenço – Mato Grosso – Brazil Sample Case Study

14 year 14 3PCH São Lourenço – Mato Grosso – Brazil Sample Case Study

15 year 15 3PCH São Lourenço – Mato Grosso – Brazil Sample Case Study – Hydraulic Diagram

16 year 16 Analyzing these values we notes a total cost reduction of about 58% of the high pressure system relative to low pressure system. The acceptance of the criteria demonstrated here from hydroelectric customers, with cost advantages, manufacture and logistics of maintenance, makes attractive solution not only for new projects, but also for modernization of existing plants. 4Conclusion

17 year Increase pressure for costs reduction - How much? Questions ? 17