LIFECYCLE COST CALCULATOR
Centrifugal Compressor Shaft Sealing Solutions
John Crane’s Lifecycle Cost Calculator provides comprehensive, application-specific decision support in the drive to improve economics and reduce methane emissions in the natural gas industry.
Aura Data Sheet
Aura Video Introduction
This tool provides insight on:
• reducing your total cost of ownership
• managing environmental responsibility
• achieving regulation compliance
The Lifecyle Cost Calculator compares the economic outcomes of wet seal to gas seal retrofit against the next best alternatives.
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cost reduction
This scenario examines a single compressor operation in natural gas processing, where the process gas is owned by the equipment operator.
This scenario is indicative of a multiple compressor operation in natural gas transmission, assuming the compressor operator owns the gas in the pipeline.
IMPROVED RELIABILITY
This scenario illustrates a multiple compressor operation in gas transmission when the equipment operator does not own the gas flowing through the compressor.
REGULATION TO REDUCE METHANE EMISSIONS
This scenario focuses on natural gas processing when the plant doesn’t own the natural gas flowing through an unspared compressor.
Increased ThroughPut
Aura Overview
US Compressor Installed Base
John Crane has examined four typical scenarios to illustrate the different outcomes across the natural gas value stream.
John Crane’s Aura Gas Seal Technology reduces total cost of ownership through reduced emissions and downtime. The Lifecycle Cost Calculator enables accurate cost and payback calculation for detailed retrofit justification.
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project example at a glance
Industry Segment:
Natural gas processing
Site:
Single compressor operation, process gas owned by equipment operator
Equipment Utilization:
355 days a year
End Product:
Natural gas (85% methane)
LIFECYCLE COST calculator BY THE NUMBERS
When the lifecycle cost is calculated over 15 years, the results for this installation show the following projected costs and savings:
Complete Economic Analysis
improved reliability
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Customer Goals
Our Solution: Turnkey Upgrade Service
Downtime from oil seal maintenance and replacements is hurting production. While oil seal methane-venting represents an economic opportunity, the company is looking to improve the efficiency of operations with a short-term payback. Additionally, the company has publicized a commitment to the environment and recognized that action is required to eliminate methane emissions and prepare the way for compliance with potential environmental regulation.
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Technical Solution
This service includes the removal/disposal of the oil seal and system, and the installation and commissioning of narrow section gas seal, separation seals, and gas seal system. Before commencing, we’ll audit equipment and perform a baseline emissions measurement. This is a custom gas seal solution where rotor dynamics optimization and compressor modification are required. Other optional services are provided based on need, including:
customer goals
Total Estimated Lifecycle Cost (SM)
Time (Years)
Oil Seal Routed to Atmosphere Oil Seal Routed to Flare Oil Seal Routed to Capture/Use Gas Seal
Lifecycle Cost Versus Time
Segment 1: No spare. Operator owns the gas
Gas Processing
Lost Energy from Seal Friction Energy Required to Operate Seal Oil System Lost Energy due to Leakage Cost of Product Loss due to Leakage Lost Energy to Overcome Pipe Friction Due To Oil Contamination Replacement of Consumed Seal Oil Maintenance and Downtime Costs Cost of Process and Purge Gas Used During Compressor Blowdown Cost of Gas Seal Separation Gas Consumption Carbon Tax Carbon Credit Other Costs/Credits Total Operating Costs
Annual Operating Costs
$/year $/year $/year $/year $/year $/year $/year $/year $/year $/year $/year $/year $/year
7,432 26,242 527 255,776 27,192 77,990 822,000 42 0 0 0 0 1,217,201
7,432 26,242 527 17,604 27,192 77,990 822,000 42 0 0 0 0 979,029
218 0 400 15,637 0 0 31,500 6 11,773 0 0 0 59,534
One-time Costs
Initial Purchase Cost (Investment) Installation Cost Decommissioning and Disposal Cost Total Retrofit Costs Payback
$ $ $ $ months
65,000 75,000 0 140,000 None
15,000 80,000 0 95,000 5
365,000 210,000 10,000 585,000 6
Present Value Calculations
Initial Purchase and Installation Cost Decommissioning and Disposal Cost Present Value of Annual Operating Costs
$ $ $
0 0 16,876,540
140,000 0 16,876,540
95,000 0 13,574,280
575,000 10,000 825,441
Power Consumption Calculations
Seal Friction Energy Lost Energy Required to Operate Seal Oil System Energy Lost to Compress Gas That is Leaked Energy Lost to Overcome Pipe Friction Due To Oil Contamination Energy Lost to Compress Gas That is Vented During Compressor Blowdown Total Power Consumption
MWh/year MWh/year MWh/year MWh/year MWh/year MWh/year
564 262 40 2065 0.6 2932
17 0 30 0 0.1 47
Carbon Footprint
CO2 Equivalent Emissions from Seal Friction Lost Energy CO2 Equivalent Emissions to Operate Seal Oil System CO2 Equivalent Emissions Resulting From Energy Required to Compress Gas That is Leaked CO2 Equivalent Emissions Resulting From Compressed Gas That is Leaked CO2 Equivalent Emissions Resulting From Pipe Friction Due To Oil Contamination Energy Lost to Compress Gas That is Vented During Compressor Blowdown Total CO2 Equivalent Emissions
Metric tons/year Metric tons/year Metric tons/year Metric tons/year Metric tons/year Metric tons/year Metric tons/year
102.1 145.3 7.2 59,466.2 373.8 3.4 60,098.0
102.1 145.3 7.2 5,205.0 373.8 0.4 5,834.0
102.1 145.3 7.2 4,092.8 373.8 3.4 4,275.0
3.1 0.0 5.4 3,65.3 0.0 0.5 3,644.0
Abatement Costs
Simple Abatement Cost Lifecycle Abatement Cost
$/ton CO2e/year $/ton CO2e/year
0.00 0.00
2.58 20.91
1.72 16.46
10.36 1.67
Total Estimated Lifecycle Cost
$
16,876,544
17,016,544
13,669,279
1,410,441
Scenario 1
Scenario 2
Scenario 3
Scenario 4
Oil Seal Vented to Atmosphere
Oil Seal Vented to Flare
Oil Seal with Enhanced Leakage Recovery
Gas Seal
35 30 25 20 15 10 5 0
0 5 10 15 20 25
Application Detail
Assumes 1 compressor running approximately 100% utilization with the equipment operator owning the natural gas flowing through the compressor Centrifugal compressor with 2 seals running on a 5.52 shaft at 9,440 rpm and 470 psi Assumes methane content of 85% with a natural gas value of $2.86 per thousand cubic ft Assumes oil seal mean time between repair of 12 months Lost production due to oil seal maintenance estimated to be 200 hours per year
The Lifecycle Cost Calculator
VS
$20M
Mitigation Option A 15 year total lifecycle cost of implementing and operating a flare device with existing oil seal technology
$13M
Mitigation Option B 15 year total lifecycle cost of implementing an emission capture-and-reuse device with existing oil seal technology
$2M
Mitigation Option C 15 year total lifecycle cost of upgrading and operating the gas seal in place of the oil seal technology
• • • • •
Coupling change Replacement filters Dry gas seal management
• • •
Aura data sheet
Aura OVERVIEW
Uncontrolled Methane Emissions Video
aura video Introduction
Gas Seal Retrofit Webinar
FULL CASE STUDY
Using the Aura 120NS to replace old oil seal technology, John Crane offers unique retrofitting solutions to increase system efficiency while avoiding costly equipment modifications.
REGULAtion Designed To Reduce Methane emissions
Cost reduction
Operation of multiple compressors was highlighting the opportunity to save millions of dollars by upgrading shaft seals from oil seal to gas seal technology. These savings would be achieved by eliminating process gas losses and reducing downtime and maintenance costs. By following through on their publicized commitment to the environment and meeting potential emission regulations, the company learned how they could achieve a less than one-year payback by investing in compressor sealing retrofits.
9,120 26,242 1,616 702,091 27,192 77,990 22,000 42 0 0 0 0 866,293
9,120 26,242 1,616 49,706 27,192 77,990 22,000 42 0 0 0 0 213,908
267 0 1,267 43,492 0 0 13,500 6 15,387 0 0 0 73,919
425,000 210,000 10,000 645,000 10
0 0 12,011,190
140,000 0 12,011,190
95,000 0 2,965,843
635,000 10,000 1,024,890
693 262 123 2065 0.6 3144
20 0 96 0 0.1 116
125.4 145.3 22.3 163,231.1 373.8 3.4 163,901.0
125.4 145.3 22.3 14,287.3 373.8 0.4 14,954.0
125.4 145.3 22.3 11,556.2 373.8 3.4 12,226.0
3.6 0.0 17.4 10,111.7 0.0 0.5 10,133.0
0.94 5.44
0.63 1.35
4.19 0.72
12,011,191
12,151,191
3,060,843
1,669,890
Segment 2: Spare. Operator owns the gas
Gas Transmission
16 14 12 10 8 6 4 2 0
$9M
$2.75M
$1.5M
Assumes 2 compressors running approximately 50% utilization with the equipment operator owning the natural gas flowing through the pipeline Centrifugal compressor with 2 seals running on a 7.0 shaft at 8,000 rpm and 1,200 psi Assumes methane content of 95% with a natural gas value of $2.86 per thousand cubic ft Assumes oil seal mean time between repair of 12 months Lost production due to oil seal maintenance estimated to be 200 hours per year
Natural gas transmission
177 days a year
Natural gas (90% methane)
Multiple compressor operation, process gas owned by equipment operator
project at a glance
This company sought alignment with their publicized commitment to the environment and meeting potential emission regulations, specifically in their desire to address oil-seal related downtime and maintenance expenses. After comparing three viable options, John Crane’s Lifecycle Cost Calculator showed that this gas transmission company could immediately reduce emissions and save money by upgrading the shaft seals from contacting oil seal to non-contacting gas seal technology.
Increased throughput
Improved reliability
9,120 26,242 1,616 0 27,192 77,990 22,000 28 0 0 0 0 164,188
267 0 1,267 0 0 0 13,500 4 15,387 0 0 0 30,425
15,000 80,000 0 95,000 None
425,000 210,000 10,000 645,000 58
0 0 2,276,474
140,000 0 2,276,474
95,000 0 2,276,474
635,000 10,000 421,844
0.94 1.08
0.63 1.04
4.19 0.46
2,276,474
2,416,474
2,371,474
1,066,844
Segment 3: Spare. Operator does not own the gas
$2.4M
$2.3M
$1M
Assumes 2 compressors running approximately 50% utilization with the equipment operator not owning the natural gas flowing through the pipeline Centrifugal compressor with 2 seals running on a 7.0 shaft at 8,000 rpm and 1,200 psi Assumes methane content of 95% with a natural gas value of $2.86 per thousand cubic ft Assumes oil seal mean time between repair of 12 months Lost production due to oil seal maintenance estimated to be 200 hours per year
REGULATION Designed To Reduce Methane EMISSIONS
John Crane helps companies follow through on their commitments to a clean environment and/or regulatory compliance.
Natural gas (95% methane)
Multiple compressor operation, process gas not owned by equipment operator
Unspared, mission-critical equipment, such as compressors, require the highest levels of reliability in order to minimize service interruption. By upgrading the shaft seal from oil seals to the time-tested technology of gas seals, the company saw the opportunity to reduce downtime and maintenance costs by dramatically increasing MTBR. Less than one-year payback was required to meet corporate guidelines in this scenario. As an additional benefit in this scenario, the company would be on track for full compliance with potential environmental regulations.
$12.6M
$12.5M
Legislation Designed To Reduce Methane emissions
REGULATion Designed To Reduce Methane emissions
7,432 26,242 527 0 27,192 77,990 822,000 28 0 0 0 0 961,411
218 0 400 0 0 0 31,500 4 11,773 0 0 0 43,895
365,000 210,00 10,000 585,000 8
0 0 13,330,000
140,000 0 13,330,000
95,000 0 13,330,000
575,000 10,000 608,606
102.1 145.3 7.2 4,092.8 373.8 3.4 4,725.0
3.1 0.0 5.4 3,635.3 0.0 0.5 3,644.0
2.58 16.55
1.72 16.16
10.36 1.41
13,330,002
13,470,002
13,425,002
1,193,606
Segment 4: No spare. Operator does not own the gas
25 20 15 10 5 0
Assumes 1 compressors running approximately 100% utilization with the equipment operator not owning the natural gas flowing through the compressor Centrifugal Compressor with 2 seals running on a 5.52 shaft at 9,440 rpm and 470 psi Assumes methane content of 85% with a natural gas value of $2.86 per thousand cubic ft Assumes oil seal mean time between repair of 12 months Lost production due to oil seal maintenance estimated to be 200 hours per year
increased throughPut
Using the Aura 120NS to replace old oil seal technology, John Crane offers unique retrofitting solutions to improve compressor reliability while minimizing upgrade investment costs.
Operation and process gas not owned by equipment operator
Application:
Single compressor