U.S.

DepartmentofEnergy
EnergySavingsAssessment(ESA)
OverviewofthePumpingSystem
AssessmentTool(PSAT)
Date: December15,2008
By:DonCasada
DiagnosticSolutions,LLC
[email protected]
865-938-0965

Motor-drivenequipmentisadominant
electricityconsumer
Industrialmotorsystems:
- arethesingle largest electrical end use
categoryintheAmericaneconomy
- accountfor25%ofallU.S.electricalsales

Pumpsarethelargestindustrialuserof
motor-drivenelectricalenergy
Fluidhandlingequipment,
includingpumps,fans,and
compressors,accountfor
over60%ofindustrialmotor-
drivenenergy.
Pumps
24.8%
Fans
13.7%
CompressedAir
15.8%
R
e
f
r
i
g
%

12.2%

4
.3
%

e
r
a
t
i
o
n

6
.
7
M
aterialhandling
Materialprocessing
22.5%
O
th
e
r









BestPracticesencouragesathree-tiered
prescreeningandassessmentapproach
Initialprescreeningbasedonsize,run
time,andpumptype
Secondaryprescreeningtonarrowthe
focustosystemswheresignificantenergy
reductionopportunitiesaremorelikely
Opportunityassessmentand
quantificationofpotentialsavings

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Thebulkofmotor-drivenenergyisused
byarelativelysmallpartofthepopulation
P
e
r
c
e
n
t

o
f

e
n
e
r
g
y
/
p
o
p
u
l
a
t
i
o
n

100
90
80
70
60
50
40
30
20
10
0
E
n
e
r
g
y

10%ofpopulation
uses80%ofenergy
i
o
n

u
l
a
t
P
o
p
Cumulativemotorhorsepowerrange

Primaryprescreening
Allplant Bigloads Bigcentrifugal
motorsystems thatrunalot loadsthatrunalot
Policiesand
practices
Filter1
Seldomused,
smallloads
Filter2
Non-centrifugal,
ASDloads
Moderate
priority

Pumpenergybasicsarefundamentalto
secondaryprescreening
Q

H

T

sg
E =
5308

pump motor

drive
E energy,kilowatt-hours
Q flowrate,gpm
H head,ft
T time,hours
sg specificgravity,dimensionless
5308 Unitsconversionconstant
pumpefficiency,fraction
pump
motorefficiency,fraction
motor
driveefficiency,fraction
drive

Fivebasiccausesoflessthanoptimal
pumpingsystemoperation
Installedcomponents areinherentlyinefficientat
thenormaloperatingconditions
Theinstalledcomponents havedegradedin
service
Moreflowisbeingprovidedthanthesystem
requires
Moreheadisbeingprovidedthanthesystem
requires
Theequipmentisbeingrunwhennotrequiredby
thesystem

Secondaryprescreening
Allplant Bigloads Bigcentrifugal
motorsystems thatrunalot loadsthatrunalot
Policiesand
practices
Filter1
Seldomused,
smallloads
Filter2
Symptomor
experienced-based
segregation
Non-centrifugal,
ASDloads
Moderate
priority
Highest
Priority










Somesymptomsofinterest
Throttlevalve-controlledsystems
Bypass(recirculation)linenormallyopen
Multipleparallelpumpsystemwithsamenumber
ofpumpsalwaysoperating
Constantpumpoperationinabatchenvironment
orfrequentcyclebatchoperationinacontinuous
process
Cavitationnoise(atpumporelsewhereinthe
system)
Highsystemmaintenance
Systemsthathaveundergonechangeinfunction

PumpingSystemAssessmentTool(PSAT)
Anopportunityquantificationtool
Reliesonfieldmeasured(orestimated)fluidand
electricalperformancedata
Usesachievablepumpefficiencyalgorithmsfrom
theHydraulicInstitute
Motorperformance(efficiency,current,power
factor)curvesdevelopedfromaveragemotordata
availableinMotorMaster+(supplementedby
manufacturerdataforlargersize,slowerspeed
motors)

Amatteroffocus
PSATisbasedoncomponentperformance
Itcanbeusedtoevaluatecomponent-level
performance
Butitcanalsobeusedtoevaluatesystem-
levelconditions

Anexamplesystem
P2
V2
0psig
V1
F1
DeliveredtoTank2
L1
Measureddata
F1=6050gpm
L1=12ftaboveground
Motornameplate:350HP,1185rpm,83amps,2300V
Suctionlineis20-inSchedule10SS
P2=75.5psig(5ftaboveground)
Dischargeis16-inSchedule10SS
Fluid=paperstockat120degF
Motorcurrent=80.5amps

Headcalculation
PSATincludesapumpheadcalculatortosupportuser-measured
pressure,flowdata.
Tanktopipe
entranceloss
Checkvalve,
SRelbow
Component-basedanalysis
Results
Inputs

Inputsections1-3
Basicdesign,operatingprofileandcostinputs


Inputsection4
Accurateperformancedataisessential
fluid
electrical



Alternateformsofelectricaldatainput
Eithermotorcurrentorpowercanbe
usedtoestimatethemotorshaftload




Results:optimizationrating
Theoptimizationratingisakintoanexamgradeofhowwelltheexisting
operationcompareswithoptimal.
237.1
x100=88.6
267.5





Results:cost,savingspotential
Annualenergycostsfor
theexistingandoptimal
casesaretabulated,and
thepotentialcostsavings
islisted

Asystem-levelperspective
Recircflow
V2
0psig
V1
Requiredflowrate:2800gpmsenttoTank2
F2
F1
F1=6050gpm
F2=2800gpm
P2
L1
DeliveredtoTank2
71.3ftfrictionloss
acrosscontrolvalve
Requiredhead= Pumphead: 175.3ft
- valveloss 71.3ft
104.0ft




Asystem-levelperspective
PSATanalysisusingtherequiredfluiddata
Optimalequipmentsizedtomeettherequired
conditionscouldsaveover$68,000/year.

PSATdoesnotidentifysolutions;
someoptions
Trimmedimpeller
Reducedspeedmotor
Adjustablespeeddrive
Differentpump
Otherfactors,suchasloadvariability,extentofsystem
headthatisstatic,andpumpdetails(curve,impellersize,
etc.)wouldbeneededtoevaluatealternativesolutions


Helppop-upscreensproviderun-timeassistance
TheContextHelpwindowdisplaysinformationaboutthecontrolorindicatorunderneaththemousepointer



TheBackgroundinformationbuttonprovides
accesstoassessmentguidanceandcurvesused
byPSATtoperformitscalculations




User'smanualandothersupportfeaturesare
included
UsersofPSAT2004canconvertsaved
logandsummaryfilestothe2008
version(aone-timeoperation)
Ademoofthetooluse

Examplesystem
Suctionlinesize:14-inchsch.40CS(13.1"ID)
Discharge(exceptreducersatvalveV1):12-inchsch.40CS(11.9"ID)
Fluid:waterat70

F
ValveV1is8-inchv-portball
Costofelectricityis5cents/kWh
Motoris460-Volt,250-hp,1780rpm,nameplateefficiency=95.8%
Allpressuregaugesat5ftaboveground
Pumpissinglestageendsuction
Bothtanksareopentoatmosphere
HX
P
1
P
2
10ft
100ft
P
3
F
V1
5ft
Table1.Measuredoperatingdata
Condition Q,gpm P1,psig P2,psig P3,psig MotorkW %oftimeatCondition
A 2000 90 52 50 135 50%
B 3160 75 66 61 150 40%

We'lldoPSATcalculations
forConditionA
Calculatepumphead
Annualenergycost
Potentialsavings
Developasystemcurvewithartificial
controlvalvelosseseliminated
Takealookatsomeofthebackground
informationanddata

Otheroptionsfortheside-by-side
comparison
Samepump,differentoperatingconditions
Samepump,differenttimes- suchasin
periodicperformancetesting/trending
Parallelpumps
Oldpump/newpump
etc.,etc.


AvalvelossestimatingtoolaccompaniesPSAT
Basedonstandardvalveequations(ISA75.01)


Softwaredownload(free)
andtraininglinks
www1.eere.energy.gov/industry/bestpractices/software.html
TherearetwoPSATworkshops
End-user Specialist


PSATspecialistsarelistedon
theDOEwebsite
http://apps1.eere.energy.gov/industry/bestpractices/qualified_specialists/tool.cfm?software_id=2#find

FindAdditionalTraining
VisittheDOEBestPracticesTraining
Website:
www1.eere.energy.gov/industry/
bestpractices/training.html
SeetheTrainingCalendarforevents
inyourarea:
www1.eere.energy.gov/industry/
bestpractices/events_calendar.asp
BecomeaQualifiedSpecialist:
apps1.eere.energy.gov/industry/
bestpractices/qualified_specialists/

SeetheIndustrialEnergySavers
WebSite
20waystosaveenergynow
Toolsandtrainingyoucanusetoidentifysavings
opportunities
Industryexpertiseavailable
Assessmentsforyourplant
DevelopanActionPlan
Learnhowothershavesaved
AccesstheNationalIndustrial
AssessmentCenter(IAC)Database
www.energysavers.gov/industrymanagers.html

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researchlibrarians,energyspecialists,and
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Voice: 877-337-3463
E-mail: [email protected]
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informationandresources:
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Data


Acknowledgments
U.S.DepartmentofEnergys
IndustrialTechnologiesProgram