pump system basic asses guide for web

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Pump SystemBasic Assessment Guide

S T E P 1

Preliminary

Milestones

S T E P 2

Assessment

Meeting

On-site

S T E P 3

On-Site

Inspection

S T E P 4

Gathering

Data

S T E P 5

Data Analysis

S T E P 6

Reporting





Pump System – Basic Assessment Guide

Contents

Purpose 3

Background 3

Pump System Assessment 3

• Step 1 – Preliminary milestones 4

Initiation 4

Pre-assessment preparation (by site staff) 4

• Step 2 – Assessment Meeting On-site 4

• Step 3 – On-site Inspection 5

• Step 4 – Gathering Data 5

• Step 5 – Data analysis 6

• Step 6 – Reporting 6

Attachment 1 – Pump System Pre-screening Form 7

Attachment 2 – Level 1 Assessment Agenda (example) 8

References 8

Pump Systems Matter 6 Campus Drive, First Floor North

Parsippany, NJ 07054-4406

Phone: 973.267.9700, x222

E-mail: [email protected]

Website: www.PumpSystemsMatter.org

Pump System Basic Assessment Guide, Copyright ©2007, All Rights Reserved





Step 1 – Preliminary Steps

Before an assessment starts, certain agreements between

plant personnel and the assessor have to be in place. To

ensure a timely and efcient assessment, site staff should

collect a variety of data in advance and provide it to the

assessor before any on-site work.

Initiation

Before the investigation begins, facility managers must

negotiate an agreement with the assessor on key issues,

including:

Personnel to be involved•

Lead staff at the site•

Scope of work•

Time frame•

Pre-assessment preparation•

Training, if necessary•

Pre-assessment preparation (by site staff)

Plant personnel should complete certain pre-assessment work

before the on-site meeting, particularly data collection.

Essential Priority Data is listed below. Secondary data will

eventually be required, but is not necessary before the

assessment (scope of pre-assessment data should be

determined during initiation discussions). Pre-assessment work

should also indicate whether certain information (listed below)

is available at the site, even if it is not collected.

The Pump System Pre-screening Form (Attachment 1) lists

information needed about each pump system in the plant. This

form is available in Microsoft Excel spreadsheet format and is

available on the www.PumpSystemsMatter.org website under

the “Tools” category.

Pre-assessment data:

Description of the facility•Data on all plant systems that are of interest, (e.g. >50•

horsepower (HP))

Priority Data (provided prior to arrival)•

List of pumps•

Pump description (including: process area, pumped•

media, pump type, etc.)

Installed motor HP•

Yearly operational hours (or percent operation)•

Control method (control valve, variable speed drive•

(VSD), by-pass)

Secondary Data:•

Operating parameters (power/current, ow, pressure)•

Cavitation at pump or in system•

Maintenance level (low, medium, high)•

Equipment Information (service type, time in service,•

shared duty, voltage)

Available information (Y/N)•

Typical ow rates and variations•

Duration diagrams•

Maintenance costs•

Process & Instrument Diagrams (PID)/Digital Control•System (DCS) screen-shots

Safety, health, and environmental training must be completed

before in-plant activities begin.

Step 2 – Assessment Meeting On-site

The rst assessment meeting reviews the work to be done.

Attachment 2 gives an example of an agenda for the meeting.

The facility manager or lead person from the plant will normally

describe their processes, systems, expectations, etc. The

meeting will review the list of pumps and pumping systems

prepared in Step 1 and select a few for closer study.

Priorities for detailed investigation include:

Pump systems with high energy use (Large motors that run•

continuously or frequently)

Systems with higher than average maintenance costs•

Systems with known problems such as cavitation noise or •

excess vibration

Systems that have undergone change of duty•

Systems that are controlled by throttling valves•

Systems that use by-pass or recirculation regulation•

Systems where several pumps are normally run in parallel•

Systems which involve a batch type process, and in which•

one or more pumps operate continuously

Systems with frequent on/off cycling of a pump in a•

continuous process

Systems with no ow, pressure, or power indication•

Based on the information from the meeting, an assessment

action plan will be developed, which consists of:

Prioritizing opportunities•

Selecting systems for which to collect additional data•

Developing data collection strategy, considering:•




– Basic Assessment Guide

Ability of plant staff to collect the data•

Sensors installed for ow meters, pressure taps,•

power, etc.

Data available in the plant’s computer system•

True process demand•

Step 3 – On-site Inspection

Following the initial meeting, the assessor and the site lead will

carry out a visual inspection of the plant in general with focus

on systems identied as priorities. This inspection should take

place when systems are operational and operators and other personnel are available to explain operations and the demands

on the systems.

Site personnel should have operational data and process and

control diagrams (PID/DCS) available for reference. With the

permission of the site lead, the assessor will take photos to

assist in later analysis.

Figure 1: Walking down the systems. It is not always easy

to gure out what you are looking at. An updated PID will help

clarify details and provide reference for future analysis.

Step 4 – Gathering Data

Basic pump system assessment includes gathering readily

available data about the system. Data that is not easily

obtained at the assessment stage will be collected during a

higher level of study.

Basic pump and motor data includes information from the

equipment nameplates and the pump curve.

Site personnel should provide operational data such as ow

rate, delivered pressure and power for the pumps that have

been identied as priorities for study. The data may be available

from the DCS or Plant Information (PI) system or may have to

be measured at the site.

Plant operators may be able to download the needed

information from their computer systems. For example,

computer logs could be a good source of information about the

historic and present ow rates. (A system with a consistent ow

rate is simpler to optimize than one with large variations in ow

rate).

Valve losses can be estimated from the ow rate and valve data

such as loss coefcient and percent open. If such data is not

available, energy losses at the valve can be calculated from the

pressure drop measured across the valve and ow rate.

The basic pump system assessment may show that additional

data gathering is needed, during a subsequent, more detailed

investigation.

Figure 2: Information from the motor and pump nameplates

can be collected during the inspection.

Figure 3a: Motor nameplate.





Figure 3b: Pump nameplate. The pump RPM is typicallya nominal speed. Actual speed will be closer to the RPM

shown in Figure 3a. Other performance data will be affected

accordingly.

Nameplate information regarding pump and motor should

be collected as part of a pump system assessment. The

nameplate information does not always accurately represent

the operating conditions since it provides nominal values.

For example, new high or premium efciency motors run with

less slip (faster) than older standard efciency motors, The

pump performance curve depends on what speed the pump is

running at, which means that the pump might deliver more ow

and draw more power than the nameplate indicates.

Since pumps do not normally run at nominal speeds, actual

speed measurements will be needed if a system is selected

for in-depth study at a later stage. A tachometer or strobe light

may be used to determine the actual running speed of the

pump & motor.

Step 5 – Data Analysis

Data analysis involves comparing the observed energy use to

an optimum where the pump supplies the true system demand

as efciently as possible. True system demand is not what

the pump delivers, but what is needed in terms of ow and

head. For example, if there is a control valve in the system, the

needed pressure is the pressure downstream of the controlvalve, not upstream of the valve.

System demand might change with time, so it is important to

establish the boundaries of ow and pressure. Systems with

little or no variability are usually relatively simple to deal with;

however, systems with large variability typically need a more

complicated assessment with operating data recorded for some

time in order to obtain information about the variations.

After determining the true system demand, the analyst

compares it to what the pump is delivering.

Often, the analyst will be able to give a rough estimate of

potential savings following the analysis.

Step 6 – Reporting After completing the analysis, the assessor will write a report

detailing the ndings, usually in collaboration with the site staff

involved in the assessment. The report lists and describes the

systems that were investigated in as much detail as possible,

including factors such as:

Normal operating conditions, (head and ow) and variations•

thereof

Throttling conditions and values•

Estimated saving opportunities•

This information can be summarized in a format such as the

Pumping System Pre-screening Form.The report identies priority systems for further work and

the measurements needed. Where possible, it describes the

savings opportunities and their potential size.




– Basic Assessment Guide

P u m p S y s t e m P r e

- s c r e e n i n g F o r m

( A M i c r o s o f t E x c e l v e r s i o n i s a v a i l a b l e o n t h e w w w . P u m p S y s t e m s M a t t e r . o r g w e b s i t e u n d e r “ T o

o l s ” )

Attachment 1

O p e r a t i n g h o u r s o r % o f

t i m e e q u i p m e n t

o p e r a t e s

P o w e r o r C u r r e n t

F l o w r e q u i r e m e n t s h a v e

c h a n g e d o r a r e

e x p e c t e d t o c h a n g e

D e s i g n f l o w r a t e

O p e r a t i o n a l f l o w r a t e

D e s i g n h e a d

O p e r a t i o n a l h e a d

S t a t i c h e a d

U p s t r e a m p r e s s u r e

D o w n s t r e a m p r e s s u r e

( a f t e r c o n t r o l v a l v e , o r

b y p a s s l i n e , e t c )

C a v i t a t i o n a t p u m p o r

i n s y s t e m ?

S y s t e m m a i n t e n a n c e

l e v e l ( H i / M e d / L o )

T y p i c a l f l o w r a t e s a n d

v a r i a t i o n t h e r e o f

D u r a t i o n d i a g r a m s

M a i n t e n a n c e C o s t s

P I D / D C S s c r e e n - s h o t s

8 0

C u r r e

n t

N o

8 5 , 2 3 4 g p

m

9 0 , 0 0 0

3 2 '

3 0 ' 6

' s u b m e r s i o n

1 2 p s i

7 p s i

n o

M e d

8 0 , 0 0 0 t o

9 0 , 0 0 0 g p m

n a

T y p i c a l m o t o r r e p a i r

2 0 K , t y p i c a l p u m p

r

i r

s e e a t t a c h e d

4 0

C u r r e

n t

N o

1 , 8 0 0 g p m

1 , 8 0 0 g p

m

2 4 0 '

2 0 0 '

2 0 '

8 0 p s i

6 0 p s i

n o

M e d

1 , 8 0 0 t o

1 , 0 0 0 g p m

U n i t s

o p e r a t e

a s

n e e d e d

M o t o r r e p a i r $ 2 , 0 0 0

P u m p r e p a i r $ 1 0 , 0 0 0

s e e a t t a c h e d

A d d i t i o n a l I n f o r m a t i o n

( i s a c q u i r a b l e ? )

O t h e r

s y m p t o m s

O p e r a t i n g P a r a m e t e r s

( p r o v i d

e i f r e a d i l y a v a i l a b l e , o t h e r w i s e i n d i c a t e w i t h c h e c k

i f i t i s a c q u i r a b l e )

A = H i g h P r i o r i t y G r e y f i e l d s i n d i c a t e p r i o r i t y d a t a e n t r i e s

B = M e d P r i o r i t y

N o A c t i o n

P r i o r i t y

S y s t e m

n a m e / d e s c r i p t i o n

P u m p T y p e [ M C , P D ,

V a c u u m , C e n t r i f u g a l ]

C e r t i f i e d P u m p

P e r f o r m a n c e C u r v e

P u m p I D / p r o c e s s a r e a

M o t o r n a m e p l a t e d a t a

S e r v i c e

( e . g . u t i l i t y , p r o c e s s ,

e t c . )

T i m e i n s e r v i c e ( y e a r s )

I n d i c a t e s h a r e d d u t y

p u m p s y s t e m s / i n

s e r v i c e s p a r e s

V o l t a g e

A d j u s t a b l e s p e e d d r i v e

T h r o t t l e d

( % o p e n i f a v a i l a b l e )

B y p a s s / R e - c i r c

O n / o f f

M o r e t h a n o n e

p u m p / s p l i t d u t y

N o t c o n t r o l l e d ( p u m p s

j u s t r u n )

A = H i g h P r i o r i t y

C i r c u l a t i n g W a t e r S y s t e m

C e n t r i f u g a l

Y e s

U n i t s A , B , C

A l l i s C h a l m e r s

,

9 0 0 h p , 4 4 0 r p m ,

l 1

C i r c W a t e r

5 y e a r s

( 3 ) 1 / 3 c a p a c i t y

p u m p s o p e r a t e i n

r l l l r

4 0 0 0

n o

X

X

c o n t r o l l e d

d u r i n g s t a r t - u p

B = M e d P r i o r i t y

G e n e r a l S e r v i c e W a t e r

C e n t r i f u g a l

Y e s

A , B , C , D

R e l i a n c e , 3 5 0 h

p ,

1 7 5 0 r p m , 4 6 0

v o l t , 4 1 4 F L A ,

G e n e r a l S e r v i c e

W a t e r

4 y e a r s

P u m p s b r o u g h t

o n l i n e a s n e e d e d

4 6 0

n o

X

X

X

X

C o n t r o l s c h e m e s

( c h e c k a l l t h a t a p p l y )

E q u i p m e n t I n f o r m a t i o n




Attachment 2

Assessment Agenda (example)

Presentation of participants Site lead person

Objectives of the meeting Site lead person

Explanation of assessment procedures Assessment specialist

Description of the facility and systems Site lead person

Presentation of the pre-assessment work Site lead person

Discussion and prioritization of systems All

Plant walk through Plant to decide

Closer look at chosen systems Engineers, operators, assessors, site lead

Data gathering Plant personnel and assessor

Report Assessor

Presentation of results Site lead and assessor

PSM Sponsor, BC Hydro, led the creation of this guide

References

Pumping System Assessment Levels Guide, authored by :1.

U.S. Department of Energy PSAT instructors and specialists: Don Casada, Chris Milan, Daryl Cox, and Tom Angle

The Department of Energy’s Pump System Assessment Tool (PSAT) Workshop2.

PSM Sponsors and others involved in the draft review:4.

Dave Brockway (Intelliquip, LLC)•

Todd Brown (Moyno, Inc.)•

Tony Egan (Armstrong Limited)•

Randy Ferman (Flowserve)•

Roy Horner (Sulzer, Inc.)•

Ray Hardee (Engineering Software, Inc.)•

John Manna (ITT Industrial & BioPharm Group)•

John Sajovic (GE Consumer & Industrial)•

George Spargo (Xcel Energy )•

Vestal Tutterow (Alliance to Save Energy)•

Trey Walters (Applied Flow Technology)•

Lead: Gunner Hovstadius (contracted by BC Hydro)3.

Assisted by PSM sponsors who collaborated on the content:

Nicholas Dalziel (BC Hydro)•

William C. Livoti (Baldor – Dodge – Reliance)•

Mike Pemberton (ITT Industrial & BioPharm Group)•

Greg Towsley (Grundfos)•

Dave Wathier (Iwaki America Inc.)•



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