Energy-saving opportunities in Pumping Systems:

1
Energy-saving opportunities inPumping Systems

• Where they are and how to recognize them

MAM-001aR1
2
Big Picture Perspectives Industrial Motor Systems
Industrial motor systems - are the single
largest electrical end use category in the
American economy - account for 25 of U.S.
electrical sales
3
Motor loads dominate industrial electrical energy
consumption
Process Heating
Lighting Other
Electrolytics
Motor-Driven Equipment
4
Over 60 of industrial motor-system energy
consumption involves fluid handling
Just over 1/3 of the motor population accounts
for almost 2/3 of the energy
Other 4.3
Pumps 24.8
Material processing 22.5
Material handling 12.2
Fans 13.7
Refrigeration 6.7
Compressed Air 15.8
A large portion are centrifugal devices
5
A small fraction of the motor population is
responsible for most of the energy consumption
100
90
80
70
60
10 population uses 80 energy
50
Percent of energy/population
40
30
Population
20
10
0
gt 5
gt 1
gt 50
gt 20
gt 500
gt 200
gt 100
gt 1000
Cumulative motor horsepower range
Note the descending order (left to right)
6
Comparing life cycle costs automobile and
pump/motor combination
Common assumptions Discount rate 8 Non-energy
inflation rate 4 Lifetime 10 years
Item Automobile Pump motor Initial energy cost
rate 1.50/gal 5 cents/kWhr Energy inflation
rate 10/yr 5/yr Operating
extent 12,500 miles/yr 7000 hr/yr (80)
7
Life cycle cost - example automobileFull size
vehicle, 28,000 price tag, 24 mpg
Miscellaneous
2
Energy
16
Purchase
51
Maintenance,
Insurance
31
8
Life cycle cost - 250-hp pump and motor28,000
initial cost, 95 motor efficiency
Miscellaneous
Purchase
operations
3
2
Maintenance,
downtime
21
First year energy cost 69,000
First year energy cost 69,000
First year energy cost 69,000
Energy
74
9
Higher first cost pump and motor (56K),low
service time (2,000 hrs/year)
Miscellaneous
operations
6
Purchase
20
Maintenance
15
Energy
First year energy cost 19,600
First year energy cost 19,600
First year energy cost 19,600
59
10
Pump and motor component efficienciesSeventy
years of progress
Pump Motor Year efficiency () efficiency() 1
928 80 87.5 1955 85 90.5 2002 88 95
.4
Achievable efficiency estimates for commercially
available 75-hp pump and motor
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What can you deduce about thesurroundings from
this picture?
12
Are you in a lush forest?
13
Or the Badlands?
14
With pumping systems, motor and pump performance
is just part of the bigger picture
15
The Pareto Principle or "the vital few and
trivial many"
J. M. Juran, who first used the term "Pareto
Principle" also coined a more descriptive phrase
"The VITAL FEW and the trivial many"
(Relatively few are responsible for relatively
much)
Input
Output
20
80
20
80
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Prescreening to narrow the field of focus - i.e.,
to select the VITAL FEW for further review
All plant motor systems
Policies and practices bin
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Example symptoms in pumping systems that indicate
potential opportunity

• Look for
• Throttle valve-controlled systems
• Bypass (recirculation) line normally open
• Multiple parallel pump system with same number of
  pumps always operating
• Constant pump operation in a batch environment or
  frequent cycle batch operation in a continuous
  process
• Cavitation noise (at pump or elsewhere in the
  system)
• High system maintenance
• Systems that have undergone change in function

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Many life cycle elements influence reliability,
cost, and productivity of motor-driven systems

• Design
• Procurement
• Construction/Installation
• Testing/Troubleshooting
• Operation
• Maintenance
• Insurance
• Regulations
• Decommissioning
• Down time
• etc.

.
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Most of these elements are interdependent
Example other factors do or may affect
maintenance
Affect Maintenance
20
Just like any stable control system, optimal
asset management requires feedback
Maintenance does, should or may affect
Down time
Unfortunately, feedback is often weak or
non-existent
21
Life cycle elements are an integrated system,
much like the physical systems themselves

• The elements can be treated as components
• For example, procurement can be on lowest first
  cost basis, without regard to the effect on
  maintenance or operations
• The elements can be treated as a system
• For example, procurement considers all the
  elements of cost and is based on lowest total
  life cycle cost

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Ideally, all the life cycle elements could be
analyzed with a single common denominator

• Design
• Procurement
• Construction/Installation
• Testing/Troubleshooting
• Operation
• Maintenance
• Insurance
• Regulations
• Decommissioning
• Down time
• etc.

Cost
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When considering options, some elements can often
be disregarded - even at the system level

• Insurance
• Regulations
• Decommissioning

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Alternatives supplements to life cycle cost
analysis

• Probabilistic analysis of reliability risk
  (commercial software is available)
• Engineering judgment
• Weighted/graded evaluation
• Sole-source contracting (initial selection would
  involve overall cost/reliability considerations)
• Outsourcing - shed some of the decision-making
  responsibility

25
Contingency planning - making the change when a
failure occurs

• The alternatives evaluation picture changes
  dramatically when failures occur
• Changes that couldn't be justified when the
  system was functional may very well be after
  failure
• The alternative may actually be less costly than
  simple repair/replace of the existing component