Pump System Optimization Checklist

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1 i n d u s t r i a l e ff i c i e n c y Pump System Optimization Checklist The pump optimization checklist can help you determine if a pump system is a good candidate for performance optimization. Good optimization projects can generate enough savings in the first year or two to cover all project implementation and engineering costs, including having an expert analyze your system. Often the energy costs are small in comparison to other benefits your company can realize, including boosting productivity and reducing maintenance. The causes of poorly performing pump systems aren t always obvious. Noise and vibration, which may indicate efficiency problems, are often accepted as normal. But these signs may indicate performance problems that are costing your company thousands, even tens of thousands, of dollars a year in operating and maintenance costs. Complete this checklist to help you determine if your system is a good candidate for energy savings. Causes of Inefficient Pump Systems Poor system control using an oversized pump or motor and using valves to throttle down or bypass the flow. Inefficient components inefficient pumps, motors, and speed reducers, or poorly designed piping. Maintenance problems dirty filters and heating coils. worn seals, cavitated impellers or equipment that is not set up properly. Poor inlet and outlet conditions restricted, uneven or turbulent flow near the pump. Benefits of Efficiency Corrective action in poor system control, inefficient components, maintenance problems and poor inlet and outlet conditions will boost your system s performance resulting in lower operating costs. An efficient system offers other benefits too. Save money on capacity upgrades Extend equipment life Reduce safety hazards Decrease noise and vibration Optimized fan systems can boost productivity, decrease maintenance and cost 20-50% less to operate

2 Assessment Process requirements dictate system performance. Production information indicates how systems are being used. Please refer to the insert sheet for special notes for each question on this page. Process Information 1. In the near term (0-2 years), are there plans to increase, decrease or cease production? Increase Decrease Cease Don t know Stay same 2. Are process retrofits being considered or planned? Yes No System Information 1. System 2. Description 3. Horsepower 4. Hours of operation 5. Are there any maintenance problems that affect production or product quality? Control Vibration Noise Failure Capacity Other (describe) 6. Is the amount of flow required by the process fixed or variable? Fixed flow at approximately % of machine capacity Variable flow (describe variation) 7. Is the pressure required by the process fixed or variable? Fixed Variable 8. Is there any know wasted flow? Bypass Spillage Leaks Estimated % 9. When was this system installed? 10. Have the process requirements changed since the system was installed? Yes No If yes, describe 11. Is the system belt drive or direct drive? Belt drive Direct drive 12. Is there an adjustable speed drive installed on the machine? Yes No Pump Information 1. Is the system flow regulated with a throttling valve? Yes No 2. If there is a throttling valve, how is it adjusted? Automatically adjusted Manually adjusted Fixed position

3 Key Points Process Information 1. If production rates vary in the future, this must be taken into account in the performance optimization analysis. Production lines that feed strong stable markets may be able to tolerate higher cost or longer payback optimization projects, since they are more likely to be around for a while. 2. Processes or mechanical systems about to be retrofit can be excellent optimization opportunities because the incremental cost of efficient equipment compared to standard efficiency equipment is so low that paybacks are in the one- to two-year range. System Information 1. Write in the name of your system. 2. Write a brief description of this system s function within process. 3. High horsepower fan, pump or blower systems that operate long hours are most likely to have large energy savings that can justify hiring an expert. Examine large systems with known problems or inefficiencies first. These are likely to be the best optimization candidates. Systems more than 100 hp that operate inefficiently 4,000 hrs/yr are likely to have savings of more than $ 1 0, / y r, which can pay for an expert feasibility study to find low cost optimization techniques to yield an overall payback of under two years. 4. See key point #3. 5. Operating problems can indicate wasted energy. Systems that are not operating properly are likely to be energy inefficient. Problems that affect production can indicate a good optimization opportunity. 6. If the flow requirements are fixed at less than 80 percent of the system s capacity, you may have an excellent opportunity for optimization which may have a one- to two-year payback. If flow requirements vary over time, you may have a good multi-speed or variable speed optimization opportunity. In systems under 75 hp, a variable speed drive may be a cost effective opportunity. In larger systems, it usually pays to conduct further investigations since other options can sometimes capture the savings with a much smaller investment. In this case, it s probably worth hiring an expert or attending performance optimization training in order to find out more about your opportunity. 7. An adjustable speed drive (asd) may not be appropriate if the process requires a fixed pressure. Depending on the situation, other optimization techniques may be more cost effective. Large constant pressure systems should be examined carefully by an expert before making a large investment such as purchasing an asd. 8. Wasted flow can indicate a good optimization candidate. 9. Older systems may have been sized for previous process requirements. 10. Process requirements changing since installation can indicate a good optimization candidate. 11. Because belt-driven systems are easy and inexpensive to adjust, they can be excellent optimization candidates. 12. If there is an asd driving the machine, there are unlikely to be any additional optimization opportunities that the asd is not already capturing. Optimization opportunities will exist only if the machine is not operating correctly or if the asd has been misapplied. Pump Information 1. Systems regulated with a throttling valve may be excellent optimization candidates. 2. Manually adjusted or fixed position throttling valves and bypass or spill valves are usually indicators of constant volume systems, which often are excellent performance optimization opportunities.

4 Pump Information Tables Manufacturer Model Serial Number Type Design Data Normal operating data (if available) speed flow pressure power speed flow pressure power rpm gpm ft. head bhp rpm gpm ft. head bhp Motor Information Design Data Measured (if available) full load full load volts power efficiency speed amps volts rpm amps bhp rpm / / / / Sketch of Installation If it appears there is a possibility of a good optimization opportunity, draw a sketch of the installation or a line diagram of the flow.

5 Sound Like a Good Opportunity? Large systems that operate long hours against a mostly closed throttling valve are great optimization opportunities. If your system is bigger than 100 hp and operates 4,000 hours per year or more, your savings could easily cover the cost of having an expert help you measure the exact needs of the process. Having an expert involved helps insure you receive a cost-effective solution for big or critical systems the first time. For smaller systems, sometimes solving an operational problem is more valuable than the energy savings. You may be able to capture the savings by analyzing the system yourself if you ve attended the Performance Optimization training course. If you believe you have a good optimization opportunity after completing this checklist and would like help assessing your opportunity, fax the questionnaire, sketch of the system and the equipment information table to your optimization service provider listed below. If you need assistance with locating an optimization expert, or need additional training and information, The Energy Center of Wisconsin at Industrial@ecw.org. 595 Science Drive Madison, WI Phone (608) Fax: (608) ecw@ecw.org Web: ECW.All rights reserved