benchmark your water/wastewater facilities to...
TRANSCRIPT
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Benchmark Your Water/Wastewater Facilities to Achieve Energy Savings
Noah L. Mundt, P.E, CEM
December 3, 2013
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Increasing EE in Water/Wastewater Pump
Systems
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Welcome & Introduction
• APS Pump & Blower Program. – Overview.
– Why pumps & blowers for energy efficiency?
– Average energy metrics for water/wastewater
• Relation to Governor’s Energy Office. – Water Energy Partnership in Arizona (WEPA).
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Meeting Agenda
• Pump Basics. • Pumps & Systems. • Pump Optimization Techniques. • WW System & Energy Components. • WW System Benchmarking & Evaluation. • EE Measures in WW Systems. • EE Programs & Incentives.
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Why Pumps for Energy Efficiency?
5
7% 10%
40%
25%
10% 3% 5% Installation
Pump
Energy
Maintenance
Operating
Downtime
Environmental
Optimizing Pumps Systems, Hydraulics Institute & Pump Systems Matter
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Why Pumps for Energy Efficiency?
6
Optimizing Pumps Systems, Hydraulics Institute & Pump Systems Matter
7% 10%
40%
25%
10% 3% 5%
About 40% of the pump lifecycle cost is spent for energy
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Pumps in Water & Wastewater
7
• Water Distribution Pumps – Booster Station : 700 – 1,200 kWh/MG – Well Pumps: 1,000 – 1,800 kWh/MG
• Waste Water Treatment Plants – System :
1,000 – 3,500 kWh/MG
Pumps in Water & Wastewater
facilities account for (1/7) of AZ state energy consumption.
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Common Pump Types
• Well Pumps
• Booster Pumps
Deep Well Turbine
Submersible
Centrifugal
Turbine
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Deep Well Turbine Pumps
• Most common in well pumping applications where water is to be pumped out of several hundred feet of depth.
• Driving mechanism is located over the surface and a column shaft connects the motor to the pump.
• Pumps often have several stages.
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Submersible Well Pumps
• Commonly used in situations where water tables fluctuate considerably over the season and noise is a factor.
• Often used in conjunction with booster pumps so as to provide a positive suction head.
• Motor and pumping components located beneath the ground surface.
• Requires less maintenance.
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Centrifugal Booster Pumps
• Commonly used as booster pumps in water/wastewater systems.
• Rotational energy of the impeller converted to pressure energy of water.
• Can be used for vertical as well as horizontal water pumping.
• High Efficiency over range of operating conditions.
• Also used in applications such as chilled water, power plants and industrial pumping.
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Turbine Booster Pumps
• Commonly used in booster stations with multiple pumps.
• Priming not needed.
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Pump System Components
13
Prime Mover
Piping/Control Valves for flow
Column Shaft/Tube
Pump Bowl Assembly
Pump Impeller
Electric Motor
Diesel/Gas Engines
Air System
Radial Flow
Axial Flow
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Flow Control in Pumps
Four (4) most common types of flow control in pumping systems are:
• On/Off controls with a switch / timer.
• Manual Throttling Valve flow control.
• Discharge Flow Control Valve.
• Variable Frequency Drives.
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Principle of VFD
=
pf*120ω
Change in frequency leads to change in the synchronous speed of motor shaft
As per the Pump Affinity Laws:
=
designdesigndesign dd
NN
QQ 111 *
3
1
3
11 *
=
designdesigndesign dd
NN
PP
Pump Affinity Laws.
2
1
2
11 *
=
designdesigndesign dd
NN
HH
15
Decreasing flow will
reduce energy usage by the
cube
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Pump Affinity Laws
0
0.2
0.4
0.6
0.8
1
1.2
0 0.2 0.4 0.6 0.8 1 1.2
Flo
w,
Hea
d &
Po
wer
Rat
io
Speed Ratio
Flow Ratio
Head Ratio
Power Ratio
For a given impeller diameter:
Speed decreased by 20%, power reduced by
49%
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0
0.2
0.4
0.6
0.8
1
1.2
0 0.2 0.4 0.6 0.8 1 1.2
Flo
w,
Hea
d &
Po
wer
Rat
io
Speed Ratio
Ideal
Actual
100HP VFD Operation
17 EE of VSD Systems
VFD Operational Regime is between
40% - 95%
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0
0.2
0.4
0.6
0.8
1
1.2
0 0.2 0.4 0.6 0.8 1 1.2
Flo
w,
Hea
d &
Po
wer
Rat
io
Speed Ratio
Ideal
Actual
10HP VFD Operation
18 EE of VSD Systems
VFD Operational Regime is between
60% - 95%
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VFD Energy Savings
19 EE of VSD Systems
0
0.2
0.4
0.6
0.8
1
1.2
0 0.2 0.4 0.6 0.8 1 1.2
Flo
w,
Hea
d &
Po
wer
Rat
io
Speed Ratio
Constant Speed
Ideal
Actual
Energy Savings
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Pump OPE Determination
=
IHPsgHQ
OPE *3960**η
where:
ηOPE – Operational Plant Efficiency
Q – Baseline flow rate (GPM) from pump test.
H – Total Head – hs + hd
sg – Specific Gravity – 1.0 for water
IHP – Input Horse Power – Input kW/0.746
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Meeting Agenda
• Pump Basics. • Pumps & Systems. • Pump Optimization Techniques. • WW System & Energy Components. • WW System Benchmarking & Evaluation. • EE Measures in WW Systems. • EE Programs & Incentives.
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Pump Curves
Performance Curves, Turbine Well Pump, Goulds
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System Curves
• A fluid flow system can be characterized with a system curve.
• The system curve establishes the relation between the head and flow in the system.
( )QfH =
CBQAQH ++= 2
where: headofcomponentfrictiondynamicA )(α
headofcomponentdrawdownB αheadofcomponentstaticC α
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Single Pump System Curve
0
100
200
300
400
500
600
700
800
900
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm)
System Curve
350 HP Turbine Well Pump
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Duty/Operational Point
0
100
200
300
400
500
600
700
800
900
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed System Curve
Operating Point
350 HP Turbine Well Pump
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Types of System
• Open Loop Systems aka Static Head Dominated Systems.
o Primary effect of these systems is to overcome the static head.
o Examples include pump systems in deep well applications, boiler feed water systems, water/fire protection systems in high rise buildings
• Closed Loop Systems aka Friction Dominated Systems.
o These systems have water circulating in a closed loop with the help of a pump
o Examples include HVAC CHW, HW, CW pumps, hydronic heating systems, etc.
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Static Head Dominated Systems
0
100
200
300
400
500
600
700
800
900
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed System Curve
27
Static (Hs)
Friction (Hf)
Hs >>Hf
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Friction Dominated Systems
28
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed System Curve
Friction (Hf)
Hf >>Hs
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Varying Discharge Flow Rate
• Changing the System Curve. o Static Head Elevation changes.
o Discharge Flow Control Valve Adjustment.
o Manual Throttling Valve Adjustment.
• Changing the Pump Curve. o Impeller Size Adjustment.
o Variable Frequency Drive Installation.
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Effect of Elevation Changes
0
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200
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400
500
600
700
800
900
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed System Curve
30
Decreasing the static head results in more flow from the pump due to the
system curve being shifted right
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Effect of Flow Control Valve
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm)
Pump Curve System Curve
Desired Flow (flow with CV)
Normal Operating Point (flow w/o CV)
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Effect of Flow Control Valve
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm)
Pump Curve System Curve
32
Head loss across CV.
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Effect of Manual Throttling Valves
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0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed System Curve
Manually throttling the inlet valve increases the resistance in the system
and shifts the curve to the left
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Impeller Size Adjustment
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed Operating Condition
Decreasing impeller size shifts pump curve down.
Large Impeller
Small Impeller
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Effect of VFD
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed Operating Condition
Decreased VFD set point
60 Hz
55 Hz
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0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed Operating Condition System Curve
Effect of VFD
Pump Operating Point with VFD
Normal Operating Point
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Effect of VFD/Impeller Size Adj.
0
100
200
300
400
500
600
700
800
900
1000
0 200 400 600 800 1000 1200
Hea
d in
Fee
t
Flow (gpm) Constant Speed Operating Condition System Curve
Allows the pump to operate on the system curve.
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Multiple Pumps
• Pumps in Parallel.
• Pumps in Series.
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Output Flow from System
Output Flow from System
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Pumps in Parallel
39
Flow (GPM)
Hea
d (f
t.)
Pump#1 Pump#1,2 Pump#1,2,3
As more pumps come on, flow output increases for the same TDH delivered
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Pumps in Parallel
40
Flow (GPM)
Hea
d (f
t.)
Steep System Curve
Fractional Increase in flow output from pumps due to
a steep system curve
The increased flow delivered from the pumps in parallel depends on the
system curve.
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Pumps in Parallel
41
Flow (GPM)
Hea
d (f
t.) System Curve
1 2
3
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System Curve Development
42
Flow (GPM)
Hea
d (f
t.) System Curve-2
Shape of the system curve is a function of static and friction
heads in the system.
System Curve-1
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System of Pumps – Case Study – Booster Pump Station
• Baseline Condition – (5) Booster pumps operating in parallel at constant speed, throttling flow control.
• Proposed Condition – (3) Booster pumps with VFDs.
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Baseline Pump Station System
0
50
100
150
200
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300
0 2000 4000 6000 8000 10000 12000 14000
Sys
tem
Hea
d (
in f
eet)
System Flow (in GPM)
System Static Head
Booster pump # 1 operational
Booster pump # 1 & 2 operational
Booster pump # 1,2 & 3 operational
Booster pump # 1,2,3 & 4 operational
Booster pump # 1,2,3,4 & 5 operational
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Baseline Pump Station System
0
50
100
150
200
250
300
0 2000 4000 6000 8000 10000 12000 14000
Sys
tem
Hea
d (
in f
eet)
System Flow (in GPM)
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System Operating Regime.
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Proposed Pump Station
0
50
100
150
200
250
300
350
400
450
500
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Hea
d (
ft)
Gallons per Minute (GPM)
Proposed Pump Curve
System Curves
46
Sequencing strategy for the pump
operation can be obtained from these
results.
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Pumps in Series
47
Flow (GPM)
Hea
d (f
t.)
Pump#1
Pump#1,2
Pump#1,2,3
As more pumps come on, system TDH increases for the same flow output.
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Pumps in Series
48
Flow (GPM)
Hea
d (f
t.)
Steep System Curve
Large increase in head with little increase in
flow output
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Pumps in Series
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Flow (GPM)
Hea
d (f
t.)
Relatively small increase in head with increase in flow due
to shallow system curve.
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Pump Optimization EE Measures
Wide variety of EE measures to optimize pump operation and its energy use. These include –
– Pump Efficiency (OPE) Improvement • Bowl Replacements
• Impeller Replacements
– Column Tube/Shaft/Piping Replacements (reduce friction losses) – Right Sizing Pumps – Pump schedule changes (EE/DR) – Pump Sequencing. – System Improvements (match with design conditions). – Prescriptive EE Measures–
• Variable Speed Drives.
• High Efficiency motors.
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Pump Optimization Considerations
Pump Optimization
Pump Size
Annual Operational
Hours
Existing Efficiency
Energy Prices
Utility Incentives
System Constraints
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Time for a Small Break!!
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Meeting Agenda
• Pump Basics. • Pumps & Systems. • Pump Optimization Techniques. • WW System & Energy Components. • WW System Benchmarking & Evaluation. • EE Measures in WW Systems. • EE Programs & Incentives.
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Typical Wastewater Processing
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Major Energy Consuming Equipment
Primary Treatment
• Pumps • Gravity Driven Flow/Solid Seperation
Secondary Treatment
• Pumps • Blowers/Aerators • Process Equipment (Solids)
Tertiary Treatment
• Pumps • Lighting
Pumps & Blowers
account for 80% - 90% of the total plant
energy!
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Pumps in WW Treatment Plants
56
Pump Systems
- Influent Pump(s) - Booster Pump(s)
Pump Types: - Centrifugal. - Submersible.
Typical Discharge Pressure Levels = 15-30 psig.
- Booster Pump(s)
Pump Types: - Centrifugal. - Turbine.
Typical Discharge Pressure Levels = 10-20 psig.
- Booster Pump(s)
Pump Types: - Centrifugal. - Turbine.
Typical Discharge Pressure Levels = 0-20 psig.
Primary Pumps Secondary Pumps Tertiary Pumps
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Blowers/Aerators
• Blowers/aerators are aeration devices that are used for introducing air into the treatment ponds/basins
• The ingested air helps in growing bacteria that could assist in the biological digestion of the raw sewage .
• Responsible for 50-70% of total plant energy consumption
www.spencerturbine.com www.hellotrade.com 57
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Blowers in WW Treatment Plants
58
Blowers
Positive Displacement Blowers - Uses reciprocating/rotary mechanism - Typical Blower Eff. = 45% - 65% - Flow Range = 5-50,000 scfm - Pr. Range = 1-14 psig - Min flow = 50% of design
MS Centrifugal Blowers - Uses centrifugal mechanism - Typical Blower Eff. – 50% - 70% - Flow Range = 500-30,000 scfm - Pr. Range = 4-14 psig - Min flow = 60% of design
MS Centrifugal Blowers with VFDs - Uses centrifugal mechanism with variable frequency drives - Typical Blower Eff. – 60% - 70% - Flow Range = 500-30,000 scfm - Pr. Range = 4-24 psig - Min flow = 50% of design
SS Centrifugal Blowers - Uses centrifugal mechanism - Contains only 1 stage - Typical Blower Eff. – 70% - 80% - Flow Range = 500-30,000 scfm - Pr. Range = 4-24 psig - Min flow = 45% of design
HS Turbo Blowers - Uses turbo blowers with integrated variable frequency drive mechanisms - Typical Blower Eff. – 70% - 80% - Flow Range = 400-10,000 scfm - Pr. Range = 4-35 psig - Min flow = 50% of design
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Aerator Types
Wastewater Engineering Treatment and Reuse – Metcalf and Eddy
Aerator
Horizontal Axis
Surface Submerged
Vertical Axis
Surface Submerged
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Aerator Types
Aeration System Transfer Rate lb Oxygen/hp.h
Standard Field
Surface low-speed 2.5-3.5 1.2-2.4 Surface low-speed with draft tube 2.0-4.6 1.2-2.1 Surface high-speed 1.8-2.3 1.2-2.0 Submerged turbine with draft tube 2.0-3.3 1.2-1.8 Submerged turbine 1.8-3.5 1.2-1.8 Submerged turbine with sparger 2.0-3.3 1.2-1.8 Horizontal rotor 1.5-3.6 0.8-1.8
Wastewater Engineering Treatment and Reuse – Metcalf and Eddy 60
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Air Diffusers
• Diffusers are used for diffusing the air from the blower into the aeration basins.
• The type of diffuser determines the transfer efficiency of the air injected into the basins.
• Diffuser performance thus plays an important role in the aeration efficiency of WW plant
Air Diffuser Types 61
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Diffuser Types
Wastewater Engineering Treatment and Reuse – Metcalf and Eddy 62
Porous
• Disk • Dome • Membrane • Panel
• State of art, current trend and offer higher oxygen transfer efficiencies
Non-Porous
• Orifice • Slotted Tube • Static Tube
• These aeration devices offer low oxygen transfer efficiencies
Others
• Jet Aerators • Aspiring
Aerators • U-tube
Aerators
• These aeration devices offer low – medium oxygen transfer efficiencies
Aeration Diffusers
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Porous Diffusers
63
Porous Diffusers
Disc Typical SOTE is 25%-35%
Dome Typical SOTE is 27%-37%
Membrane Typical SOTE is 26%-33%
Panel Typical SOTE is 38%-43%
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Meeting Agenda
• Pump Basics. • Pumps & Systems. • Pump Optimization Techniques. • WW System & Energy Components. • WW System Benchmarking & Evaluation. • EE Measures in WW Systems. • EE Programs & Incentives.
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WW System Benchmarking
• ENERGY STAR benchmarking. Web link – http://www.energystar.gov • Other Benchmarking Metrics.
– Typical Range is 1,000 – 3,500 kWh/MGD
– These metrics are a function of treatment processes. Typical ranges for
• Primary = 1,000 – 1,200 kWh/MGD
• Secondary = 1,200 – 1,800 kWh/MGD
• Tertiary = 2,000 – 3,500 kWh/MGD
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WW System Evaluation
66
Small Plants = ≤ 2.0 MGD Medium Plants = 2.0 – 20.0 MGD
Large Plants = > 20.0 MGD
EPA Publication
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Meeting Agenda
• Pump Basics. • Pumps & Systems. • Pump Optimization Techniques. • WW System & Energy Components. • WW System Benchmarking & Evaluation. • EE Measures in WW Systems. • EE Programs & Incentives.
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Conventional EE Measures
68
Pumping Systems
• Pump Eff. Improvements
• Right Sizing Pumps • Pump Schedule
Changes • Pump Sequencing • System
Improvements • VSDs • HE Motors
Mechanical Aeration Systems
• Conventional Retrofits
• Adjustable Weirs to change submergence
• Aerator type retrofits
• Aerator Cycling • Multi-Impeller
Aerators • DO Control
Blower Aeration Systems
• Right Sizing Blowers
• Dedicated Blowers for Channel Aeration
• Diffuser Configuration
• Intermittent Aeration
• DO Control • Single stage
centrifugal blowers with IGV and VDV
• Fine Bubble Diffusers
Solids Processing Systems
• UV Disinfection • Membrane
Bioreactors • Biological Nutrient
Removal (Aeration cycling)
• Hyperbolic Mixers
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Innovative & Emerging EEMs
69
Pumping Systems
• Power Factor Correction
• VFD Sequencing • Optimized Rotor &
Stator Design • Low Friction
Bearings • Dynamic Rotor
Balancing • Ultra Premium
Efficient Motors
Mechanical Aeration Systems
• Automated DO Control
• Respirometry • Off-Gas Analysis • SymBio process • BIOS
Blower Aeration Systems
• Automated DO Control
• High Speed Gearless (Turbo) Blowers
• Ultra fine porous membrane diffuser panels
• Diffuser Foul Prevention
Solids Processing Systems
• Anaerobic Digestion
• Pulsed Large Bubble Mixing
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Meeting Agenda
• Pump Basics. • Pumps & Systems. • Pump Optimization Techniques. • WW System & Energy Components. • WW System Benchmarking & Evaluation. • EE Measures in WW Systems. • EE Programs & Incentives.
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APS Solutions for Business
71
• Pump Test Program
• Tests for the Overall Plant Efficiency of individual pumps & blowers
• APS covers half the cost of testing
• Technical Assistance
• Cash incentives to help cover the cost of studies, could possibly include pump system studies or WWTP audits.
• Prescriptive Incentive Application
• High-efficiency motor replacement
• Installation of VFD (some restrictions apply)
• Custom Incentive Application
• All other energy efficiency measures not covered by the prescriptive application
• $0.09/first year kWh saved up to 75% of incremental cost
• Must pass a TRC test so submit a pre-application
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APS Solutions for Business
72
• Additional equipment rebates offered in our program include:
• Lighting
• Cooling
• Refrigeration
• Whole Building
• Will look at any proven energy savings under our custom program
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Program Requirements
73
• APS customer on qualifying rate
• Qualifying rates include E-32, E221, all commercial retail rates
• > 40% load factor ~ 3,000+ operating hours per year, per pump
• >15 hp
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Individual Pump Testing
74
• 50% off Testing for APS customers for Qualifying Pumps and Blowers
• Tests determine Overall Plant Efficiency (OPE) – standard measurement of pump efficiency
• Measures head, flow and energy demand • Result shows the hydraulic energy out as a percentage of
electric energy input
• Regular testing allows owners to • Track the performance of their pumps, • Identify problems before they become critical • Plan for repairs • Identify candidates for improvement
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Next Steps
• Submit a request form • Gather information on pumping and blower system
• Photographs of piping system are helpful
• Existence of test ports
• Pumps approved for testing • Test Contractor contacts to schedule tests • Test performed • Review Results • Get quote for repairs • Submit a pre-application for incentives
• Notification required prior to repair work being performed
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Q & A
76