Screening Pumping Systems for Energy Savings Opportunities
In most industrial settings, energy consumed by pumping systems is responsible for a major part of the overall electricity bill. In some cases, the energy is used quite efficiently; in others, it is not. Facility operators may be very familiar with pumpin
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Diagnostic Solutions, LLC
Abstract In most industrial settings, energy consumed by pumping systems is responsible for a major part of the overall electricity bill. In some cases, the energy is used quite efficiently; in others, it is not. Facility operators may be very familiar with pumping system equipment controllability, reliability, and availability, but only marginally aware of system efficiency. The cost of energy consumed by pumps usually dominates the pump life cycle cost. But many end users, already stretched to support day-to-day facility operations, lack the time and resources to perform a methodical engineering study of, in some cases, hundreds of pumps within their facilities to understand the energy costs and the potential opportunity for reduction. Under the auspices of the Department of Energy's (DOE) Best Practices Program, prescreening guidance documents and a computer program called PSAT (Pumping System Assessment Tool) have been developed to help end users, consultants, and equipment distributors recognize, both qualitatively and quantitatively, pumping system efficiency improvement opportunities. This paper describes the general methodologies employed and shows case study examples of the prescreening and software application.
Background Industrial electrical motors account for two-thirds of the US industrial electricity. Pumping systems account for an estimated 25% of this electrical motor consumption. A recent study funded by the US Department of Energy estimates potential energy savings of approximately 20%, representing over 20,000 GWh/year, through industrial pumping systems optimization using existing, proven techniques and technologies (Ref 1). This energy savings potential represents significant cost savings potential for industrial facilities. For example,
F. Parasiliti et al. (eds.), Energy Efficiency in Motor Driven Systems © Springer-Verlag Berlin Heidelberg 2003
540 an average paper mill can save up to $200,000/year through pumping systems optimization alone, based on the DOE study. Additionally, it has been shown that energy efficiency improvements to industrial systems usually provide improved reliability, improved productivity, and reduced environmental costs. Many end-users are consumed by the day-to-day activities required to support facility operations, and lack the time and resources to perform a methodical engineering study of what can be hundreds of pumps at their facility. The following discussions will provide a background on pumping systems efficiency and introduce some tools available to help end-users quickly recognize opportunities to profit from their pumping systems. System Optimization Generally speaking, the best strategy for pumping systems optimization is to begin at the end of the line and work backwards through the pump, motor, and back to the transformer. The elements and the order of review contemplated is: 1. 2. 3. 4. 5. 6. 7. 8.
Ultimate goal or purpose Piping system Pump Gear or coupling Motor Adjustable speed drive (if applicable) Motor starter Tra
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