Pump System Optimization
Pump System Optimization
Agenda
• Why Pumps
• Overview of Systems Approach
• Industrial Pump System Optimization
• Maintenance and Reliability
• Case Studies
– Deep well pump for potable water, Hawaii
– SINOPEC Yangtze Petrochemical Company in Jiangsu Province, China
– Chevron refinery, Richmond CA
– Visteon automotive Glass plant, TN
Industrial Plant
Energy Usage
Pumping
Systems
25%-50%
P&P Motor Energy Savings Potential (US DOE)
• The energy savings opportunities from systems are far greater than
from individual components
Defining
the System
Input
P F1
P
MCC
Maintenance Costs
Flow
60 l/s
Energy wasted
in pump and
motor
Flow
30 l/s
Useful energy System curve with valve fully open
Throttling: Duty Point Moves to Left on the Pump Curve
Wasted Energy in
Motor, Pump and Head Pressure drop in the valve
S3 makes the friction losses
Valve
larger and the system
S1
curve steeper. The system
curve gets steeper and
steeper as the valve
closes. 2 valve-positions
shown
Flow
15 l/s
Useful energy Needed System curve with valve fully open
flow
Flow
Useful energy the same as before. Valve
losses are eliminated
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• Avoid over-sizing
• Balance supply to demand
• Avoid throttling valves
• Where appropriate use VFDs
• Use high quality equipment
• Integrate pumps in the process control system
You are not managing what you do
not measure
&
If you do not manage you cannot
save!
25
26
Four case studies
System Curve
560
480
Static
400 Head
100% speed
320 92% speed
83% speed
240
80
160
80
0 40 80 120 160 200 240 280 320 360 400 440
Flow (m3/hr)
At a flow rate of 238 m3/hr, the pump would need to operate 3657 hours
annually to satisfy flow requirements. This corresponds to 1623 874
kWh/year or 211,103 USD in annual energy costs, saving approximately
57 000 USD.
Payback: instantaneous
SINOPEC Yangtze Petrochemical Company in Jiangsu
Province, China
• The project included installation of 34 VSDs on existing
pump systems which were generally oversized with rates
of flow controlled by throttling valves (see Jiangsu
Energy Conservation Center 2005).
• After the project was completed, the specific energy
consumption of the pumps was reduced from 8.016 kWh
to 5.766 kWh per ton of crude oil. 6.26 million tons of
crude oil was refined in 2003.
• The plant thus achieved electricity savings of 14.08
million kWh/a (with 11 270 tons of CO2 emissions
reduction), amounting to 6.62 million Yuan RMB (approx.
660 000 USD).
• The payback period of the project was 0.48 years.
Result of test
¾ The pump is delivering 2.7 times more fluid power than
needed
Gunnar Hovstadius
[email protected]
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Industrial Energy Efficiency
in the Philippines.
Energy Management in
Industry
Today’s meeting:
Initiate the development of an industrial energy
efficiency program for the Philippines responding to:
2
Energy Concerns of Industry - Purpose of the Project
4
Energy Management Results
1 Btu/lb of product
6
Components of an EM Standard
8
ANSI MSE 2000:2008
www.ansi.org
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For more information, see McKane, A. et al, 2007 Setting the Standard for Industrial Energy Efficiency,
http://industrial-energy.lbl.gov/node/399
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Why System Energy Efficiency Matters
11
Systems Optimization
12
Why are industrial energy systems important?
13
14
Capacity Building for systems optimization
15
16
Systems improvements in China
17
18
Project Participation
19
Project Participation
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This week and the next 6 months
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22
Thank you for your
attention..
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JOB DESCRIPTION 11-5X
Project No: GF/PHI/09/001
Background
Energy Intensive industries will be the target sector of the project, specifically, (a) Cement; (b) Sugar; (c)
Electronic; (d) Steel; (e) Chemical; (f) Food (to be selected); (g) automotive; (h) ceramic.
Companies will be invited by the Philippine Department of Energy (PDOE) to participate in this project. They will
be selected based on their active participation with the governments’ energy efficiency and conservation program.
Many industrial establishments complies with the PDOE reportorial requirements under Department’s Memorandum
Circular 93-03-05 which requires them to submit Quarterly Energy Consumption report and an Annual Energy
Conservation Program. The priority industrial establishments to be selected will be those who are already recipient
of the local Energy Efficiency Award (the Don Emilio Abello Energy Award) given annually by the PDOE. All of
these awardees are compliant with the Department’s Circular.
As elsewhere, in the Philippines markets and policy makers typically focus on individual system components, such
as motors, pumps or boilers, with an efficiency improvement potential of 2-5% instead of optimizing the entire
systems. Large savings can often be achieved by analyzing and then optimizing the complete motor and steam
systems. System energy efficiency requires attention to the whole production scheme and offers substantial energy
saving opportunities. The estimated potential for improvement in systems is 20 to 25% for motor systems and 10 to
15% for steam systems. It is the overall efficiency of the system that is the key - most systems lose on average
approximately 55% of their input energy before reaching the process or end-use work.
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With regard to financing or loans for energy efficiency investments, the Development Bank of the Philippines
(DBP) has a (Php. 3.84 Billion) loan portfolio for Energy Efficiency Related Projects under its Environment
Development Program. The DBP is utilizing the borrowed funds from the Japan Bank for International Cooperation
(JBIC) for its Environment Development Program. The lending program provides concessional terms to borrowing
companies. Interest rate is 9.5- 10%, lower than commercial lending rates of 13-15%. Payment periods are up to 15
years with grace periods of 2-3 years, more favorable than usual 5- 10 years repayment periods of industrial loans.
The next funding facility from the JBIC is expected before the end of 2008 amounting to Php 10 Billion.
Energy Management Standards constitute a viable policy tool and market-based mechanism for effecting sustainable
energy efficiency in industry. They offer an expert and best practices - based framework for organizations and
enterprises to develop energy efficiency goals, plan interventions, prioritize efficiency measures and investments,
monitor and document results and ensure continuity and constant improvement of energy performance. Standards
will be instrumental in shifting the market for energy-consuming equipment from component-based solutions to
sustainable energy management - including the purchase and provision of products and services that result in the
optimization of industrial energy systems.
In February 2008, the Technical Management Board of ISO approved the establishment of a new project committee
(PC 242) appointed to develop the new ISO Management System Standard for Energy (ISO 50001). UNIDO is
actively engaged with the provision of technical inputs to PC 242. The Secretariat of PC 242 has been assigned to
the partnership of the American National Standards Institute (ANSI) and the Brazilian Association for
Standardization (ABNT). ISO PC 242 currently includes 20 member countries and 5 observer countries. The
working draft of the new standard is planned to be ready by March 2009. Publication is expected by the end of 2010.
As of October 2007, the Philippines ISO registration reached to almost 1,500 for ISO 9001 certifications and 500 for
ISO 14001certifications. Prior experience with similar industrial management standards (quality and environment)
is already available in the country.
Though both system optimization approach and energy management standards are applicable to every sector, the
project will primarily target energy intensive industries. The sectors will be selected after in close consultations with
the Department of Energy. The stakeholders will be involved from the project design phase and their commitment
will be sought. Some of the industries/plants will be identified during the PPG phase and the rest of selection will
be completed during the implementation stage. Within the scope of the PPG as part of activities targeted to define
the existing baseline for energy management and efficiency, UNIDO plans to execute national surveys in industry.
UNIDO will make use and build on its survey on energy management in industry piloted in Singapore in July 2008.
The planned survey will start raising the level of awareness of industry about energy efficiency and energy
management standards.
The project is intended to improve energy efficiency by implementing the components on policy, capacity building
and demonstration projects. The project will build capacity of stakeholders including industrial enterprises,
equipment suppliers, distributors, engineering/energy service companies and government planners to develop
services focused on capturing system level efficiencies. Estimated potential for improvement in systems efficiency is
20 to 25% for motor systems and 10 to 15% for steam systems. With introduction of ISO energy management
standards, energy efficieny will be integrated into management systems of industrial enterprises to accelerate
adoption of energy efficient best practices on continuous basis that will result into improved reliabity of the
operations and productivity of enterprises. In addition, the competitive position of companies will be enhanced
through their eventual incorporation of energy efficient-operation into the ISO certification process. The project will
also contribute substantially to meeting Indonesia’s goals for reduction in energy intensity, energy elasticity and
greenhouse gas emissions. The project will have the following five components:
Component 1: National program to implement ISO energy management standard and recognition programs
The main outcome from this component is compliance to a policy instrument that encourages industrial enterprises
to adopt ISO energy management standards to deliver sustainable improvements in industrial energy efficiency and
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improve competitiveness. The energy management standards will provide enterprises with a management structure
and process for continuously improving operational energy efficiency resulting a change in corporate culture
through integration of energy efficiency in the management systems.
The outputs from the project include:
x Industrial facilities understand importance of energy management standard and undertake energy
management planning
x Structure in place for reporting energy intensity improvements for any plant implementing the standard
x National awareness campaign on the benefits of energy management
x National recognition program established for industrial facilities that comply with the energy
management standards
x Use of preferred suppliers encouraged through targeted incentives
Component 2: Technical assistance to build capacity through tools and training on Energy Management, including
industrial systems optimization, to enable industries comply with ISO standards
This capacity building component will lead to create a cadre of energy efficiency professionals both within
industrial facilities as well as consultants and suppliers to initiate a process to transform local markets to effectively
manage energy and optimize industrial systems. The outputs from the project include:
x Web-based guidance tools on industrial systems developed
x Energy management and system optimization experts offer awareness training to industry representatives
x Plant engineers trained on the use of system optimization library
x Suppliers of energy efficient products and services trained on the system optimization
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This component deals with the management of four components mentioned above.
With the implementation of the above components, it is expected that by the end of project, there will be a critical
mass of demonstration system optimization projects and operational projects resulting from adoption of energy
management standards; and a cadre of energy efficiency professionals both within industrial facilities as well as
consultants and suppliers. The baseline scenario and results from demonstration projects will be disseminated
through the workshops/seminars for further adoption of energy management standards and application of system
optimization approach by industrial enterprises. The combination of a policy instrument on energy management
standards and capacity building of industrial energy efficiency professionals, is likely to ensure that more of
industrial energy efficiency projects will be developed and replicated even after completion of the GEF project.