strategies to optimizing pump efficiency and lcc … forum on energy: immediate solutions, emerging...

2006 Forum on Energy:Immediate Solutions, Emerging Technologies

May 15-17Appleton, WI

Strategies to Optimizing Pump Efficiency and LCC Performance

Presented by: Joe Ruggiero

Title: Strategic Account ManagerCompany: ITT IBG Goulds Pumps

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Pumping Systems Are Energy Intensive

9%Primary Metals

19%Food Processing

26%Chemicals

31%Forest Products

59%Petroleum

Pump Energy (% of Total Motor

Energy Use)

Industry Type

A 150 hp pump uses about $40,000 in electricity annuallyA 150 hp pump uses about $40,000 in electricity annually

MECS 1994, Bureau of Economic Analysis 1997Census of Manufacturers, 1993

Finnish Technical Research Center Report: "Expert Systems for Diagnosis of the Condition and Performance of Centrifugal Pumps"

Evaluation of 1690 pumps at 20 process plants:• Average pumping efficiency is below 40%

• Over 10% of pumps run below 10% efficiency

• Major factors affecting pump efficiency: • throttled valves• pump over-sizing

• Seal leakage causes highest downtime and cost

Excessive Valve Throttling is Expensive

• Higher energy consumption • Lower process reliability • Poor process control

– increased variability– manual operation

Control engineers need to incorporate the pumping Control engineers need to incorporate the pumping system as part of the automation architecturesystem as part of the automation architecture

Some Fundamentals

Fixed vs. Variable Speed Pumping

Hydraulic System

Q

H

System Curve”- Static Head-- Friction Head

= operating point

H = HeadQ = Flow

Q

H

Pump Curve:- Motor Speed-- Impeller Diam.

Basic Pump Curves

The operating point is at the intersection of the pump and system curves.

Q

H

•Valve throttling results in excess power consumption

•Excess energy noted in blue area.

•Bypass lines consume excess power consumption.

•Excess energy noted in blue area.

Thrust Brg. Horz.Overall Vibration Vs. Flow

Fixed Speed with Control Valve vs Variable Speed

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 500 1000 1500 2000 2500

Flow (GPM)

Vibr

atio

n (IP

S) Test 11 VariableSpeed Test 17.5" DiaTest 1 1785 Rpm17.5" Dia

Stock Pump

BEP = 1500 GPM

•Fixed Speed•Variable Speed

BEP

Reliability Issues Relative to BEP

Pump Performance CurveVariable Speed: Maximizes HQ Flexibility

0

10

20

30

40

50

60

0 250 500 750 1000 1250Capacity, GPM

Tota

l Hea

d Ft

C

A

83% N90% N

70% N60% N

100% N

N = Speed

•Variable speed control meets the exact flow and head requirements

•No excess energy is consumed!

Effect of pump speed changes on a system

with low static head.

0

10

20

30

40

50

60

70

80

0 200 400 600 800 1000 1200

F lo w R ate m 3 /h

Tota

l Hea

d m

0

50

100

150

200

250

300

350

400

Pow

er k

W

7 1 %

8 3 %

8 6 %

8 3 %

1 4 8 0 rp m

1 3 5 0 rp m

1 1 8 4 r p m

1 4 8 0 rp m

1 3 5 0 rp m

1 1 8 4 rp m

S y s te mCu rv e

Is o - e f f ic ie n c yL in e s

O p e ra tin g p o in ts

Effect of pump speed changes on a system

with high static head.

0

10

20

30

40

50

60

70

80

0 200 400 600 800 1000 1200Flow Rate m3/h

Tota

l Hea

d m

0

50

100

150

200

250

300

350

400

Pow

er k

W

71%

83%86%

83%

1480rpm

1350rpm

1184rpm

1480rpm

1350rpm

1184rpm

SystemCurve

Iso-eff iciencyLines

Operating points

Affinity Laws in ActionEnergy savings are possible because of affinity laws.

Speed reduction provides significant energy savings at partial load.

The reduction of the speed provides:

Flow reduction according to the linear function

Head reduction according to asquare function

Power reduction according to a cubic function!

P = Power

Variable Speed Control

Opportunities and Benefits

U.S. Motor Systems Market Opportunity Assessment

“Motor systems equipped with VSD’s account for only 4% of motor energy usage, compared to the potential for application on 18 - 25% of the total energy used…”

Source: DOE-Office of Industrial Technology

Conventional

Motor

DCS

Star

ter

New Approach

Motor

DCS

VSD

Traditional Pumping System(Fixed speed pump, control valve, transmitter)

Variable Speed DrivePumping System

Pumping System Elements

FI

Control loops are tightly associated with pumping systemsControl loops are tightly associated with pumping systems

FI

“Adapts to process changes”

“Impacted by process changes”

Pressure Control

Shower Bank

Pressure Control

TDH

- F

EET

Flow Control

Flow Control

Optimizing Pump Performance

A Systems Approach

Ultimategoal

FluidsystemPumpCoupling

The Systems Approach

Motor

Adjustablespeed drive

Motor breaker/starter

Transformer

Electric utilityfeeder • Focusing on individual components often

overlooks potential design and operating cost-savings.

• Future component failures are frequently caused by initial system design.

• Use a LCC approach in designing systems and evaluating equipment options.

Focus here

Prescreening Methodology

Primaryscreening

Back burner stuff:1) Size and timeAND

2) Load typeSmall Loads:- Low Run Hours,- Non-centrifugal loads

Secondaryscreening

First: Can it be turned off?

Properly Matched Pump:- System Need = Supply

Analysis-based

Symptom-based

Source: DOE - OIT

Pump Symptoms that Indicate Potential Opportunity

hThrottled valve-controlled systems

hBypass (recirculation) line normally open

hMultiple parallel pump system with same number of pumps always operating

hConstant pump operation in a batch process or frequent cycle operation in a continuous process

hPresence of cavitation noise (at pump or elsewhere in the system)

Energy Savings Methods

1- 2%Replace pump with more efficient model

1- 3%Replace motor with more efficient model

10 - 20%Equalize flow over product cycle using surge vessels

10 - 30%Install parallel system for highly variable loads

5 - 40%Reduce speed for fixed load

10 - 60%Replace throttling valves with speed controls

SavingAction

Source: DOE - Office of Industrial Technology

Throttled Valve with

Bypass (recirculation line) normally open

PM Saveall Supply Pump

Paper Machine Saveall Supply

108001080010800106001060010600OUTAGE10400GPM

202020202020OUTAGE20Static Head in Ft

87%87%87%87%87%87%OUTAGE87%Other Control Valve (HV433A)

40%41%35%35%41%37%OUTAGE31%Tank level control valve position (LV 159)

6060606058580UTAGE60Motor Load in amps

888888OUTAGE8Suction Pressure in Ft

767676797979OUTAGE81Pump Discharge Pressure in Ft

320034103200315330352975OUTAGE3130Speed ft/min

504660515150OUTAGE51Grade Basic Weight lb

Installed Motor 350HP

10,33110,33110.33110,33110,3311033110,33110,331Design 10,331 GPM@ 99.1' TDH

30-Sep29-Sep28-Sep27-Sep24-Sep23-Sep22-Sep21-Sep#72-40910-20

35PM Save-all Supply Pump

Eliminate By-pass line & Valves, Cavitation and High Maintenance

Greenfield Project Benefits

Fisher

• Potential to downsize pumps, motors and pipes (smaller footprint)• Eliminate valves, starters, pneumatic lines, and related wiring• Reduce medium voltage power requirements in MCC

Fisher

Pump Optimization Benefits Summary

• Reduce Energy and Maintenance Cost• Improve Pump and Process Reliability• Increase Process Uptime and Throughput• Improve Process Control & Quality

– less variability– higher % of loops in automatic

• Reduce Fugitive Emissions

High Reliability Impact VFD Applications

• Mill Water Supply – Pressure control

• Seal Water Supply– Pressure control– Reduce process downtime

• Stock Blending– Consistency control– Improve product quality

• WW Dilution– Consistency control

• Machine Chest– Basis Weight MD control– Improve PM performance

• Broke Chest– Reduce Energy & Maintenance

• Repulper Chest– Reduce Energy & Maintenance

“There are many high impactapplications that improve bottom line performance”

Strategies to Optimizing Pump Efficiency and LCC Performance

Thank You!