Energy & Life Cycle Cost Savings

in Pumping Systems
AWWA-DSS Conference
September 19, 2006

Robert Lax
ITT Goulds Residential & Commercial Water

Karen Sanchez
ITT Bell & Gossett Residential & Commercial Water

Vestal Tutterow
Alliance to Save Energy
Page 1
Presentation Overview

Why Care About Pumps?

The Water Cycle
The Systems Approach
Life Cycle Costing
Reducing Energy Costs
Reducing Maintenance Costs
Variable Speed Control

Page 2
Why Care About Pumping Systems?

• All water facilities and distribution systems rely

on pumping systems for their daily operation.
• Pumping system operation can be expensive.
• These systems often have significant
opportunities for performance improvement.

Page 3
 Pumping Systems are Often Energy
Intensive

• Water and wastewater facilities consume over 50

billion kWh/year in the U.S.
• = > $4 billion/year
• Over 45% of consumption is by pumping systems

50
45
Facility electricity use

40
35
30
25
20
15
10
5
0
Pumps Filtration Other
Page 4
 Energy Costs 11% Of Water Utilities’
Operating Budgets

35%

30%
BUDGET

25%

20%

15%
Average
10%
11%
5%

0%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
UTILITY
Source: AWWARF study of 19 facilities
Page 5
Opportunities in Pumping Systems

Efficiency Measures Range of Savings

(% of system energy)
Reduce Overall System 5-20%
Requirements
Match Pump Size to Load 10-30%

Reduce or Control Pump 5-50%

Speed
Component Purchase 1-3%

Operation & Maintenance 1-5%

Measures highlighted in yellow are “system”-related opportunities

Source: US Industrial Motor Systems Market Opportunities Assessment

US Dept. of Energy, 1998
Page 6
Why Improvement Opportunities Exist

• Lack of a systems approach during the

design process

• Overly conservative or improper pump

selection, resulting in poor performance

• Improper installation or operation

• Poor maintenance

• System requirements change over time

Page 7
 Recent Study at Leading Chemical
Company
• The company evaluated internal practices and those
at two of its major engineering contractors on recent
projects
– The goal was to identify frequency of correctly sized pumps
as part of a Six Sigma project

Frequency of Correctly Sized Pumps

at Leading Chemical Company

Correct
10%

Incorrect
90%
Page 8
 Methods Used to Determine Pump
Operating Point During Specification

• Use “Same As Last Time”

• Hand Calculation
• Spreadsheet
• Hydraulic Computer Modeling

Page 9
 Pump vs. System Standards
Pump Standards System Standards
• Pump design is subject to • With few exceptions, there are
numerous standards no standards to guide system
design
– HI, API, ANSI, ISO.
• Engineering contractors and
• Pump hydraulic data is subject to owner/operators are allowed to
numerous standards choose (or ignore) how to
calculate system hydraulics
– Developed head, Efficiency,
NPSHr – Specified pump operating
point not subject to
Pump Curve
standards

Actual Operating
Head

Point (without control)

System Curve

Volumetric Flow Rate

Page 10
 A Common Scenario

Flow control using throttle or bypass valves

Bypass valve

Chillers
Cooling
Tower

Throttle valve
=
Bypass valve
Pump

Equivalent to driving down the road with

your brakes on
Page 11
Water Treatment Cycle

Page 12
Typical Filtration Process

Page 13
Municipal Distribution Systems

Page 14
 The Systems Approach

Electric utility • Component optimization involves

feeder segregating components and
analyzing in isolation
Transformer
• System optimization involves
Motor breaker/ looking at how the whole group
starter functions together and how
changing one can help another
Adjustable
speed drive
(electrical)
Fluid Ultimate
Motor Coupling Pump
system goal

Page 15
Importance of a “Systems Approach”

• Focusing solely on individual components

overlooks potential cost-savings
• Component failures are often caused by
system problems
• Supports a life cycle cost approach in
designing systems and evaluating repair and
maintenance options.

Page 16
Which Systems Merit the Most
Attention?
Some likely candidates:
• Large systems
• Systems with high operating hours
• Problem systems
• Production-critical systems

Keep in mind the 80/20 rule:

• About 80% of the potential savings will
come from about 20% of the systems

Page 17
 Life Cycle Costs

LCC can be a tool to convince management

to pursue energy savings projects

• LCC considers
– purchase costs – maintenance costs
– installation & – down time costs
commissioning costs – decommissioning
– energy costs costs
– other operating costs – environmental costs

Page 18
Life Cycle Costs

Page 19
 Comparing life cycle costs: automobile
and pump/motor combination

Common assumptions
Discount rate = 8%
Non-energy inflation rate = 4%
Lifetime = 10 years

Item Automobile Pump & motor

Initial energy cost rate $1.50/gal 5 cents/kWhr
Energy inflation rate 10%/yr 5%/yr
Operating extent 12,500 miles/yr 7000 hr/yr (80%)

Page 20
 Life Cycle Costing

Life cycle cost example -- automobile

Full size vehicle, $28,000 price tag, 24 mpg

Miscellaneous
Energy 2%
16%

Purchase:
51%

Maintenance,
Insurance
31%

Page 21
 Life Cycle Costing

Life cycle cost - 250-hp pump and motor

$28,000 initial cost, 95% motor efficiency
Miscellaneous Purchase
operations 3%
2% Maintenance,
downtime
21%

First year energy

Energy
74% cost = $69,000
Page 22
 Life Cycle Costing

Higher first cost pump and motor ($56K),

low service time (2,000 hrs/year)
Miscellaneous
operations
6% Purchase
20%

Maintenance
15%

Energy
59%
First year energy
cost = $19,600
Page 23
 Outlook for Life Cycle Costing

• Pump manufacturers are considering LCC to be

the single largest driver in the US pump market
over the next 10 years
• End user emphasis will move from pump
features and lowest price to lifetime
performance and manufacturer service &
support
• New ISO standard on LCC for the petroleum
and natural gas industries

Page 24
 LCC Summary

• LCC goes hand-in-hand with the systems approach

• LCC can be a tool to convince management to
pursue energy savings projects
• LCC analysis is structured to aid corporate
decision-making, using sound economic
techniques and terminology
• Hydraulic Institute and EUROPUMP joint guidebook
– www.pumps.org

Page 25
 Straying from the BEP is expensive
System Curve
(as Specified)
Pump Curve

Specified
Operating Point
Head

System Curve
Uncertainty

Volumetric Flow Rate

Page 26
 Flow Control in Pumping Systems

Two options to achieve flow control in pumping systems

are:

– change the system curve (usually done by valve

throttling);

– change the pump curve by reducing the pump- impeller

peripheral speed (can be accomplished by impeller
trimming, downsizing the pump/motor speed, or by
using an AFD).

Page 27
 Throttling: the Duty Point Moves
to the Left on the Pump Curve

Pressure drop in the valve

Wasted makes the friction losses
Energy larger and the system
Head
curve steeper. The system
curve gets steeper and
steeper as the valve
closes. 2 valve-positions
shown

Flow
300 gpm
Useful energy Needed System curve with valve fully open
flow

Page 28
 How an AFD saves energy

Friction only
System curve with valve fully open
NO Wasted
Energy
Head

With a smaller pump or a

reduced speed pump, the
same rate of flow can be
delivered without the large
losses in the valve

Flow

Useful energy the same as before.

Valve losses are eliminated

Page 29
 Shaft Power: Throttling vs. AFD

100

80

60 Shaft power with

Shaft power,

fixed speed motor

40

Shaft power with

20 adjustable
frequency drive
0
0 500 1000 1500 2000 2500 3000
Flowrate,

Page 30
 AFD Application for Flow Control

• AFDs can be effective in:

– Frictional head-dominated systems
– Systems where continuous flow is needed and
where flow/head requirements change with time
– Soft start and soft shutdown requirements on
equipment.
– Load starting limitations with power utility.
– Complete system control and integration.

Page 31
 AFD Application for Flow Control

• AFD’s may not be the best choice for:

– Systems with constant flow requirements (e.g. Flow
does not vary throughout the day)

– Systems operated in batch mode

– Static-head dominated systems (but careful pump

selection can significantly improve the range of effectiveness
of AFD applications in these systems)

– Poor regulated power or Open Delta power systems.

Page 32
 Capital Cost Savings

• For new systems, AFD cost may

be offset by elimination of
− Control Valves
− Bypass lines
− Conventional starters

Page 33
 Update O&M Practices
• Establish basic system maintenance checklists
and schedules.
• Predictive maintenance techniques improve
reliability via early detection of equipment
problems.
– Valve overhauls
– Heat exchanger cleaning
– Mechanical joint repair
• For pump & motor bearings, consider –
– Vibration analysis
– Oil analysis

Page 34
 Selling Projects to Management

• Present energy savings and operating

benefits in a way that responds to corporate
priorities.
• Operating priorities at most plants include:
– High productivity
– High utilization rates--maintaining high reliability (downtime
is often prohibitively expensive)
– Lower operating costs

• Describe projects in the financial language of

management, such as LCC
Page 35
 Additional Resources
• Pump Systems Matter™ (PSM) places a primary focus on pump
systems education and outreach and addresses energy savings and
total cost of pump ownership. This program is the first industry-led
market transformation initiative in the United States.
– www.pumpsystemsmatter.org
– A Guide to Life Cycle Cost Analysis for Pumping Systems, 2000
– Pump System Improvement Modeling Tool (PSIM)
– Case Studies
– Training (under development)

• Vision: PSM initiative assists North American pump users gain a

more competitive business advantage through strategic, broad-
based energy management and pump system performance
optimization
• Mission: To provide end-users, engineering consultants and pump
suppliers with tools and collaborative opportunities to integrate
pump system performance optimization and efficient energy
management practices into normal business operations

Page 36
 Additional Resources

• U.S. Department of Energy BestPractices:

– www.eere.energy.gov/industry/bestpractices
– Improving Pumping System Performance, A
Sourcebook for Industry, 2nd edition, 2006.
– Pump System Assessment Tool (PSAT)
– Case Studies, Tip Sheets
– Training
– Information Clearinghouse: (877) 337-3463

Page 37
Questions???

Page 38