Scribd
Upload
77 views

Pumping 6

This document provides tips for improving the efficiency of pumping systems. It suggests surveying pumps to identify those operating at flows more than 30% from their best efficiency point or in systems with imbalances over 20%. Opportunities for improving efficiency include replacing oversized or misapplied pumps, improving impeller sizing, and adding variable speed drives. Conducting periodic reviews can help identify low-cost efficiency improvements for pumping systems.

Uploaded by

Foulen Fouleni
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
77 views

Pumping 6

This document provides tips for improving the efficiency of pumping systems. It suggests surveying pumps to identify those operating at flows more than 30% from their best efficiency point or in systems with imbalances over 20%. Opportunities for improving efficiency include replacing oversized or misapplied pumps, improving impeller sizing, and adding variable speed drives. Conducting periodic reviews can help identify low-cost efficiency improvements for pumping systems.

Uploaded by

Foulen Fouleni
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 2

Energy Tips Pumping Systems

Pumping Systems Tip Sheet #6 October 2005

Industrial Technologies Program

Suggested Actions
Survey your facilitys pumps. Identify flow rates that vary 30% or more from the BEP and systems imbalances greater than 20%. Identify misapplied, oversized, or throttled pumps and those with bypass lines. Assess opportunities to improve system efficiency. Consult with suppliers on the cost of trimming or replacing impellers and replacing pumps. Determine the cost-effectiveness of each improvement.

Match Pumps to System Requirements


An industrial facility can reduce the energy costs associated with its pumping systems, and save both energy and money, in many ways. They include reducing the pumping system flow rate, lowering the operating pressure, operating the system for a shorter period of time each day, and, perhaps most important, improving the systems overall efficiency. Often, a pumping system runs inefficiently because its requirements differ from the original design conditions. The original design might have been too conservative, or oversized pumps might have been installed to accommodate future increases in plant capacity. The result is an imbalance that causes the system to be inefficient and thus more expensive to operate.

Correct Imbalanced Pumping Systems


If the imbalance between the systems requirements and the actual (measured) discharge head and flow rate exceeds 20%, conduct a detailed review of your plants pumping system. Calculate the imbalance as follows: Imbalance (%) = [(Qmeas x Hmeas)/(Qreq x Hreq) 1] x 100% , where Qmeas Hmeas Qreq Hreq = = = = measured flow rate, in gallons per minute (gpm) measured discharge head, in feet required flow rate, in gpm required discharge head, in feet.

Resources
DOE and Hydraulic Institute, Improving Pumping System Performance: A Sourcebook for Industry. Hydraulic Institute HI is a nonprofit industry association for pump and pump system manufacturers; it provides product standards and a forum for the exchange of industry information for management decisionmaking. In addition to the ANSI/HI pump standards, HI has a variety of energy-related resources for pump users and specifiers, including training, guidebooks, and more. For more information, visit www.pumps. org, www.pumplearning.org, and www.pumpsystemsmatter.org. U.S. Department of EnergyDOEs Pumping System Assessment Tool (PSAT) can help you assess pumping system efficiency and estimate energy and cost savings. PSAT uses pump performance data from Hydraulic Institute standards and motor performance data from the MotorMaster+ database. Visit the BestPractices Web site at www.eere.energy.gov/bestpractices for more information on PSAT and for upcoming training in improving pumping system performance and in becoming a qualified pumping system specialist.

A pump may be incorrectly sized for current needs if it operates under throttled conditions, has a high bypass flow rate, or has a flow rate that varies more than 30% from its best efficiency point (BEP) flow rate. Such pumps can be prioritized for further analysis, according to the degree of imbalance or mismatch between actual and required conditions. Energy-efficient solutions include using multiple pumps, adding smaller auxiliary (pony) pumps, trimming impellers, or adding a variable-speed drive. In some cases, it may be practical to replace an electric motor with a slower, synchronous-speed motore.g., using a motor that runs at 1,200 revolutions per minute (rpm) rather than one that runs at 1,800 rpm. Conduct quick reviews like this periodically. Especially for multipump systems, this can be a convenient way to identify opportunities to optimize a system at little or no cost.

Example
This example shows the energy savings that can be obtained by not using an oversized pump. Assume that a process requires 1,500 tons of refrigeration during the three summer months, but only 425 tons for the remaining nine months. The process uses two chilled water pumps operating at 3,500 gpm and requiring 200 brake horsepower (bhp) each. Both are used in summer, but two-thirds of the flow rate is bypassed during the remaining months.

One 3,500-gpm pump is therefore replaced with a new 1,250-gpm pump designed to have the same discharge head as the original unit. Although the new pump requires only 50 bhp, it meets the plants chilled water requirements most of the year (in all but the summer months). The older pump now operates only in the summer. Assuming continuous operation with an efficiency ( m) of 93% for both motors, we can calculate the energy savings from operating the smaller pump as follows: Savings = (200 hp 50 hp)/ m x 0.746 kW/hp x (9 months/12 months) x 8,760 hours/year = 790,520 kWh/year

BestPractices is part of the Industrial Technologies Program Industries of the Future strategy, which helps the countrys most energy-intensive industries improve their competitiveness. BestPractices brings together emerging technologies and best energy-management practices to help companies begin improving energy efficiency, environmental performance, and productivity right now. BestPractices emphasizes plant systems, where significant efficiency improvements and savings can be achieved. Industry gains easy access to near-term and long-term solutions for improving the performance of motor, steam, compressed air, and process heating systems. In addition, the Industrial Assessment Centers provide comprehensive industrial energy evaluations to small- and medium-size manufacturers.

At an average energy cost of 5 cents per kWh, annual savings would be about $39,525.

References
Variable Speed Pumping: A Guide to Successful Applications, Hydraulic Institute and Europump (www.pumps.org), 2004. Conduct an In-Plant Pump Survey, DOE Pumping Systems Tip Sheet, 2005. Trim or Replace Impellers on Oversized Pumps, DOE Pumping Systems Tip Sheet, 2005. Optimize Parallel Pumping Systems, DOE Pumping Systems Tip Sheet, 2005. Adjustable Speed Pumping Applications, DOE Pumping Systems Tip Sheet, 2005.

FOR ADDITIONAL INFORMATION, PLEASE CONTACT: EERE Information Center 1-877-EERE-INF (1-877-337-3463) www.eere.energy.gov Industrial Technologies Program Energy Efficiency and Renewable Energy U.S. Department of Energy Washington, DC 20585-0121 www.eere.energy.gov/industry

About DOEs Industrial Technologies Program


The Industrial Technologies Program, through partnerships with industry, government, and non-governmental organizations, develops and delivers advanced energy efficiency, renewable energy, and pollution prevention technologies for industrial applications. The Industrial Technologies Program is part of the U.S. Department of Energys Office of Energy Efficiency and Renewable Energy. The Industrial Technologies Program encourages industry-wide efforts to boost resource productivity through a strategy called Industries of the Future (IOF). IOF focuses on the following eight energy and resource intensive industries: Forest Products Metal Casting Petroleum Aluminum Glass Mining Steel Chemicals The Industrial Technologies Program and its BestPractices activities offer a wide variety of resources to industrial partners that cover motor, steam, compressed air, and process heating systems. For example, BestPractices software can help you decide whether to replace or rewind motors (MotorMaster+), assess the efficiency of pumping systems (PSAT), compressed air systems (AirMaster+), steam systems (Steam Scoping Tool), or determine optimal insulation thickness for pipes and pressure vessels (3E Plus). Training is available to help you or your staff learn how to use these software programs and learn more about industrial systems. Workshops are held around the country on topics such as Capturing the Value of Steam Efficiency, Fundamentals and Advanced Management of Compressed Air Systems, and Motor System Management. Available technical publications range from case studies and tip sheets to sourcebooks and market assessments. The Energy Matters newsletter, for example, provides timely articles and information on comprehensive energy systems for industry. You can access these resources and more by visiting the BestPractices Web site at www.eere.energy.gov/ industry/bestpractices or by contacting the EERE Information Center at 877-337-3463 or via email at www.eere.energy.gov/informationcenter/.

A S TRONG E NERGY P ORTFOLIO FOR A S TRONG A MERICA


Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energys Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies. DOE/GO-102005-2160 October 2005 Pumping Systems Tip Sheet #6

You might also like