# Presentation: 913978

## Energy-saving opportunities inPumping Systems:

- Where they are and how to recognize them

- MAM-001aR1

## Big Picture Perspectives: Industrial Motor Systems

- Industrial motor systems:
- -	are the *single largest electrical end use* category in the American economy
- -	account for 25% of U.S. electrical sales

**Notes:**
These values come from the United States Industrial Motor Systems Market Opportunities Assessment, 1998 (DOE), as does much of the other energy consumption pattern information in this presentation.  The Assessment report is available on the web at:

www.oit.doe.gov/bestpractices/explore_library/pdfs/mtrmkt.pdf

## Motor loads dominate industrial electrical energy consumption

**Process**
**Heating**

**Electrolytics**

**Motor-Driven**
**Equipment **

**Lighting**
**& Other**

## Over 60% of industrial motor-system energy consumption involves fluid handling

**Pumps**
**24.8%**

**Fans**
**13.7%**

**Compressed Air**
**15.8%**

**Refrigeration**
**6.7%**

**Material handling**
**12.2%**

**Material processing**
**22.5%**

**Other**
**4.3%**

- Just over 1/3 of the
- motor population
- accounts for almost
- 2/3 of the energy

- A large portion are
- centrifugal devices

**Notes:**
Pumps, fans, compressed air, and refrigeration devices account for 36.8% of the industrial motor population, but 61.0% of the industrial motor energy consumption.

A large portion of the motor-driven devices in these systems are centrifugal designs.  Centrifugal equipment efficiency is sensitive to the operating point of the system.  This is particularly important for pumps and fans.

Of course, this distribution varies from plant to plant, or even from facility to facility within a given plant.  The Market Opportunities Assessment document provides some indications of likely distribution of loads by industry type.

## A small fraction of the motor population is responsible for most of the energy consumption

- 0

- 10

- 20

- 30

- 40

- 50

- 60

- 70

- 80

- 90

- 100

- _>_ 1000

- > 500

- > 200

- > 100

- > 50

- > 20

- > 5

- > 1

- Cumulative motor horsepower range

- Percent of energy/population

- Population

- 10% population
- uses 80% energy

- Note the descending order (left to right)

**Notes:**
It is immediately apparent from this graph where (at least from a national perspective) the focus of motor-system energy savings should be. 

Let's assume that the average potential reduction in energy in smaller systems (comprising 90% of the population) was 20%.  And let's also assume that the bigger systems (comprising 10% of the population) only have half that percentage opportunity - 10%. 

If we fully implemented those savings nationwide, changing 10% of the population would give us an 8% reduction in national motor-system energy consumption, while changing 90% of the population would give us half that savings - 4%.

By the way, the assumption that the percentage opportunity for the big stuff is less than the smaller equipment is not necessarily a valid assumption, so the disparity in opportunity is likely even more dramatic.

What if your facility doesn't have any 500+ hp motors?  The same concept still applies - focus on the relatively big stuff that runs a lot.  

## 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%)

## Life cycle cost - example automobileFull size vehicle, $28,000 price tag, 24 mpg

**Purchase:**

**51%**

**Maintenance, **

**Insurance**

**31%**

**Energy**

**16%**

**Miscellaneous**

**2%**

**Notes:**
Assumptions:
Drive the car 12,500 miles/year for 10 years
Initial year fuel price = $1.50/gallon
Initial year maintenance & insurance = $2,000
Initial year miscellaneous expenses =$100

Discount rate = 8%
Energy inflation rate = 10%
Other cost inflation rates = 4%

Total life cycle ownership cost in current day  dollars = $54,000 and the cost per mile driven is 43 cents.

## Life cycle cost - 250-hp pump and motor$28,000 initial cost, 95% motor efficiency

- First year energy cost = $69,000

- Life cycle cost - 250-hp pump and motor$28,000 initial cost, 95% motor efficiency

- First year energy cost = $69,000

**Purchase**

**3%**

**Maintenance, **

**downtime**

**21%**

**Energy**

**74%**

**Miscellaneous **

**operations**

**2%**

**Notes:**
Assumptions:
Operate the pump for 7,000 hours/year for 10 years
Initial year electricity price = 5 cents/kwhr
Initial year maintenance & insurance = $20,000
Initial year miscellaneous expenses =$2,000

Discount rate = 8%
Energy inflation rate = 5%
Other cost inflation rates = 4%

Total life cycle ownership cost in current day  dollars = $810,000

Note that the fuel price is very conservatively low, and the inflation rate assumed for electricity is only half that assumed for gasoline.

## Higher first cost pump and motor ($56K),low service time (2,000 hrs/year)

- First year energy cost = $19,600

- First year energy cost = $19,600

- Higher first cost pump and motor ($56K),low service time (2,000 hrs/year)

**Purchase**

**20%**

**Maintenance**

**15%**

**Energy**

**59%**

**Miscellaneous **

**operations**

**6%**

**Notes:**
Assumptions:
Operate the pump for 2,000 hours/year for 10 years
Initial year electricity price = 5 cents/kwhr
Initial year maintenance & insurance = $5,000
Initial year miscellaneous expenses =$2,000

Discount rate = 8%
Energy inflation rate = 5%
Other cost inflation rates = 4%

Total life cycle ownership cost in current day  dollars = $285,000

Note that the fuel price is very conservatively low, and the inflation rate assumed for electricity is only half that assumed for gasoline.

## Pump and motor component efficiencies:Seventy+ years of progress

- 		Pump			Motor
- _Year__	__efficiency (%)__	__efficiency(%)_
- 1928			80				87.5
- 1955			85				90.5
- 2002			88				95.4

- Achievable efficiency estimates for commercially available 75-hp pump and motor

**Notes:**
Estimates for 1750 rpm, double suction centrifugal pump rated at 2500 gpm, 80 feet head, powered by 75 hp open drip-proof motor

Sources of older data:
The Vertical Pump by Johnston (Johnston Pumps  1954)
Pump Engineering Data (Economy Pumps  1954)
Sources of current data:
MotorMaster database
Pump manufacturer (several)

## What can you deduce about thesurroundings from this picture?

## Are you in a lush forest?

## Or the Badlands?

## With pumping systems, motor and pump performance is just part of the bigger picture

## The Pareto Principle or "the vital few and trivial many"

- J. M. Juran, who first used the term "Pareto Principle" also coined a more descriptive phrase:

**Input**

**20%**

**80%**

**Output**

**20%**

**80%**

- (Relatively few are responsible for relatively much)

*"The VITAL FEW and the trivial many"*

**Notes:**
The "Pareto Principle" was coined by J.M. Juran, an American industrial engineer and a renowned expert in the field of quality control.  He coined the term in the context of how a relatively small group of sources were responsible for a large fraction of quality problems, and noted that this was similar in concept to the general distribution of wealth identified by Vilfredo Pareto, an Italian economist and engineer (most of the wealth is possessed by a small part of the population).

The fact is that the "vital few and trivial many" (a Juran phrase) applies in many arenas of life, from personal to corporate to national to global.  While the exact numbers may differ from 80/20, the general principle has wide application.

It is important to note that both positive and negative connotations apply.  For example, 25% of the people in a group may be responsible for 75% of the production, while 15% of the group are cause 90% of the problems. 

In a machinery context, 10% of the pumps might represent 60% of the energy saving opportunity, while 20% of the pumps demand 85% of the maintenance attention.

## Prescreening to narrow the field of focus - i.e., to select the VITAL FEW for further review 

- All plant
- motor systems

- Policies and
- practices bin

**Notes:**
Policies and practices that might be applied would generally apply to components.  

For example, a facility might establish a standard policy of repairing all motors 50 hp and larger, but purchasing new motors in the smaller sizes.  

Another example might be that lined bowls will be selected on all vertical turbine pumps for increased efficiency.

Generally speaking, the individual efficiency and energy savings differentials associated with policies and practices are small, compared to those available from system optimization.  But because the implementation is on the broad population, significant savings can still result.

## Look for:
Throttle valve-controlled systems
Bypass (recirculation) line normally open
Multiple parallel pump system with same number of pumps always operating
Constant pump operation in a batch environment or frequent cycle batch operation in a continuous process
Cavitation noise (at pump or elsewhere in the system)
High system maintenance
Systems that have undergone change in function

- Throttle valve-controlled systems
- Bypass (recirculation) line normally open
- Multiple parallel pump system with same number of pumps always operating
- Constant pump operation in a batch environment or frequent cycle batch operation in a continuous process
- Cavitation noise (at pump or elsewhere in the system)
- High system maintenance
- Systems that have undergone change in function

- Example symptoms in pumping systems that indicate potential opportunity

## Many life cycle elements influence reliability, cost, and productivity of motor-driven systems

- Design
- Procurement
- Construction/Installation
- Testing/Troubleshooting
- Operation
- Maintenance
- Insurance
- Regulations
- Decommissioning
- Down time
- etc....

- .

**Notes:**
Ultimately, asset management is one dimensional, and that dimension is cost.  There are costs of design, purchase, construction, installation, testing, operation, maintenance, regulation, insurance, decommissioning, and others.  

All of these elements, to a greater or lesser extent, are interdependent.  

An example: operational and maintenance costs can be reduced by a robust design accompanied by solid installation.  Alternatively, the negative effects of a less robust design can be somewhat ameliorated by well-trained, knowledgeable operators and maintenance personnel.

Another example: a procurement policy that is based on lowest purchase cost will almost always have a negative impact on operating and maintenance (and other)costs.

But it is difficult to quantify all the elements of cost in a universal sense.  Particularly difficult to quantify are those cost elements associated with downtime, and in some cases, decommissioning.

## Most of these elements are interdependent

- Affect
- Maintenance

- Example: other factors do or may affect maintenance

## Just like any stable control system, optimal asset management requires feedback

- Maintenance
- does, should
- or may affect

- Unfortunately, feedback is often weak or non-existent

- Down time

## Life cycle elements are an integrated system, much like the physical systems themselves

- The elements can be treated as components
- For example, procurement can be on lowest first cost basis, without regard to the effect on maintenance or operations
- The elements can be treated as a system
- For example, procurement considers all the elements of cost and is based on lowest total life cycle cost

## Ideally, all the life cycle elements could be analyzed with a single common denominator

- Design
- Procurement
- Construction/Installation
- Testing/Troubleshooting
- Operation
- Maintenance
- Insurance
- Regulations
- Decommissioning
- Down time
- etc....

- Cost

## When considering options, some elements can often be disregarded - even at the system level

- Insurance
- Regulations
- Decommissioning

## Alternatives & supplements to life cycle cost analysis

- Probabilistic analysis of reliability & risk (commercial software is available)
- Engineering judgment
- Weighted/graded evaluation
- Sole-source contracting (initial selection would involve overall cost/reliability considerations)
- Outsourcing - shed some of the decision-making responsibility

**Notes:**
Example: Simple weighted-graded analysis

## Contingency planning - making the change when a failure occurs

- The alternatives evaluation picture changes dramatically when failures occur
- Changes that couldn't be justified when the system was functional may very well be after failure
- The alternative may actually be less costly than simple repair/replace of the existing component