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2006 Forum on Energy:Immediate Solutions, Emerging Technologies
May 15-17Appleton, WI
Strategies to Optimizing Pump Efficiency and LCC Performance
Presented by: Joe Ruggiero
Title: Strategic Account ManagerCompany: ITT IBG Goulds Pumps
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Pumping Systems Are Energy Intensive
9%Primary Metals
19%Food Processing
26%Chemicals
31%Forest Products
59%Petroleum
Pump Energy (% of Total Motor
Energy Use)
Industry Type
A 150 hp pump uses about $40,000 in electricity annuallyA 150 hp pump uses about $40,000 in electricity annually
MECS 1994, Bureau of Economic Analysis 1997Census of Manufacturers, 1993
Finnish Technical Research Center Report: "Expert Systems for Diagnosis of the Condition and Performance of Centrifugal Pumps"
Evaluation of 1690 pumps at 20 process plants:• Average pumping efficiency is below 40%
• Over 10% of pumps run below 10% efficiency
• Major factors affecting pump efficiency: • throttled valves• pump over-sizing
• Seal leakage causes highest downtime and cost
Excessive Valve Throttling is Expensive
• Higher energy consumption • Lower process reliability • Poor process control
– increased variability– manual operation
Control engineers need to incorporate the pumping Control engineers need to incorporate the pumping system as part of the automation architecturesystem as part of the automation architecture
Some Fundamentals
Fixed vs. Variable Speed Pumping
Hydraulic System
Q
H
System Curve”- Static Head-- Friction Head
= operating point
H = HeadQ = Flow
Q
H
Pump Curve:- Motor Speed-- Impeller Diam.
Basic Pump Curves
The operating point is at the intersection of the pump and system curves.
Q
H
•Valve throttling results in excess power consumption
•Excess energy noted in blue area.
•Bypass lines consume excess power consumption.
•Excess energy noted in blue area.
Thrust Brg. Horz.Overall Vibration Vs. Flow
Fixed Speed with Control Valve vs Variable Speed
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 500 1000 1500 2000 2500
Flow (GPM)
Vibr
atio
n (IP
S) Test 11 VariableSpeed Test 17.5" DiaTest 1 1785 Rpm17.5" Dia
Stock Pump
BEP = 1500 GPM
•Fixed Speed•Variable Speed
BEP
Reliability Issues Relative to BEP
Pump Performance CurveVariable Speed: Maximizes HQ Flexibility
0
10
20
30
40
50
60
0 250 500 750 1000 1250Capacity, GPM
Tota
l Hea
d Ft
C
A
83% N90% N
70% N60% N
100% N
N = Speed
•Variable speed control meets the exact flow and head requirements
•No excess energy is consumed!
Effect of pump speed changes on a system
with low static head.
0
10
20
30
40
50
60
70
80
0 200 400 600 800 1000 1200
F lo w R ate m 3 /h
Tota
l Hea
d m
0
50
100
150
200
250
300
350
400
Pow
er k
W
7 1 %
8 3 %
8 6 %
8 3 %
1 4 8 0 rp m
1 3 5 0 rp m
1 1 8 4 r p m
1 4 8 0 rp m
1 3 5 0 rp m
1 1 8 4 rp m
S y s te mCu rv e
Is o - e f f ic ie n c yL in e s
O p e ra tin g p o in ts
Effect of pump speed changes on a system
with high static head.
0
10
20
30
40
50
60
70
80
0 200 400 600 800 1000 1200Flow Rate m3/h
Tota
l Hea
d m
0
50
100
150
200
250
300
350
400
Pow
er k
W
71%
83%86%
83%
1480rpm
1350rpm
1184rpm
1480rpm
1350rpm
1184rpm
SystemCurve
Iso-eff iciencyLines
Operating points
Affinity Laws in ActionEnergy savings are possible because of affinity laws.
Speed reduction provides significant energy savings at partial load.
The reduction of the speed provides:
Flow reduction according to the linear function
Head reduction according to asquare function
Power reduction according to a cubic function!
P = Power
Variable Speed Control
Opportunities and Benefits
U.S. Motor Systems Market Opportunity Assessment
“Motor systems equipped with VSD’s account for only 4% of motor energy usage, compared to the potential for application on 18 - 25% of the total energy used…”
Source: DOE-Office of Industrial Technology
Conventional
Motor
DCS
Star
ter
New Approach
Motor
DCS
VSD
Traditional Pumping System(Fixed speed pump, control valve, transmitter)
Variable Speed DrivePumping System
Pumping System Elements
FI
Control loops are tightly associated with pumping systemsControl loops are tightly associated with pumping systems
FI
“Adapts to process changes”
“Impacted by process changes”
Pressure Control
Shower Bank
Pressure Control
TDH
- F
EET
Flow Control
Flow Control
Optimizing Pump Performance
A Systems Approach
Ultimategoal
FluidsystemPumpCoupling
The Systems Approach
Motor
Adjustablespeed drive
Motor breaker/starter
Transformer
Electric utilityfeeder • Focusing on individual components often
overlooks potential design and operating cost-savings.
• Future component failures are frequently caused by initial system design.
• Use a LCC approach in designing systems and evaluating equipment options.
Focus here
Prescreening Methodology
Primaryscreening
Back burner stuff:1) Size and timeAND
2) Load typeSmall Loads:- Low Run Hours,- Non-centrifugal loads
Secondaryscreening
First: Can it be turned off?
Properly Matched Pump:- System Need = Supply
Analysis-based
Symptom-based
Source: DOE - OIT
Pump Symptoms that Indicate Potential Opportunity
hThrottled valve-controlled systems
hBypass (recirculation) line normally open
hMultiple parallel pump system with same number of pumps always operating
hConstant pump operation in a batch process or frequent cycle operation in a continuous process
hPresence of cavitation noise (at pump or elsewhere in the system)
Energy Savings Methods
1- 2%Replace pump with more efficient model
1- 3%Replace motor with more efficient model
10 - 20%Equalize flow over product cycle using surge vessels
10 - 30%Install parallel system for highly variable loads
5 - 40%Reduce speed for fixed load
10 - 60%Replace throttling valves with speed controls
SavingAction
Source: DOE - Office of Industrial Technology
Throttled Valve with
Bypass (recirculation line) normally open
PM Saveall Supply Pump
Paper Machine Saveall Supply
108001080010800106001060010600OUTAGE10400GPM
202020202020OUTAGE20Static Head in Ft
87%87%87%87%87%87%OUTAGE87%Other Control Valve (HV433A)
40%41%35%35%41%37%OUTAGE31%Tank level control valve position (LV 159)
6060606058580UTAGE60Motor Load in amps
888888OUTAGE8Suction Pressure in Ft
767676797979OUTAGE81Pump Discharge Pressure in Ft
320034103200315330352975OUTAGE3130Speed ft/min
504660515150OUTAGE51Grade Basic Weight lb
Installed Motor 350HP
10,33110,33110.33110,33110,3311033110,33110,331Design 10,331 GPM@ 99.1' TDH
30-Sep29-Sep28-Sep27-Sep24-Sep23-Sep22-Sep21-Sep#72-40910-20
35PM Save-all Supply Pump
Eliminate By-pass line & Valves, Cavitation and High Maintenance
Greenfield Project Benefits
Fisher
• Potential to downsize pumps, motors and pipes (smaller footprint)• Eliminate valves, starters, pneumatic lines, and related wiring• Reduce medium voltage power requirements in MCC
Fisher
Pump Optimization Benefits Summary
• Reduce Energy and Maintenance Cost• Improve Pump and Process Reliability• Increase Process Uptime and Throughput• Improve Process Control & Quality
– less variability– higher % of loops in automatic
• Reduce Fugitive Emissions
High Reliability Impact VFD Applications
• Mill Water Supply – Pressure control
• Seal Water Supply– Pressure control– Reduce process downtime
• Stock Blending– Consistency control– Improve product quality
• WW Dilution– Consistency control
• Machine Chest– Basis Weight MD control– Improve PM performance
• Broke Chest– Reduce Energy & Maintenance
• Repulper Chest– Reduce Energy & Maintenance
“There are many high impactapplications that improve bottom line performance”
Strategies to Optimizing Pump Efficiency and LCC Performance
Thank You!