Improving the Energy Efficiency of Pump Systems by ctg14933


									                                                       U.S. Department of Energy • Office of Energy Efficiency and Renewable Energy

Improving the Energy Efficiency
of Pump Systems
Pumping System Assessment                     electrical energy savings. Although
Tool (PSAT) Saves Energy                      PSAT does not tell how to improve
PSAT software uses data that are              systems, it does prioritize attractive
typically available or easily obtained in     opportunities and supports broader or
                                              narrower searches for improving              Use PSAT to perform the
the field (e.g., pump head, flow rate,
and motor power) to estimate potential        efficiency.                                  following key functions:
energy and dollar savings in industrial       PSAT assesses current pump system            • Establish system efficiency.
pump systems. The software is                 operating efficiency by comparing field      • Quantify potential energy savings.
available without charge from the U.S.        measurements of the power delivered          • Examine the economic and
Department of Energy for evaluating           to the motor with the fluid work (flow        energy impacts of different
industrial pump systems.                      and head) required by the application. It
                                                                                            operating scenarios.
Pump Prescreening                             estimates a system’s achievable efficiency
                                              based on pump efficiencies (from             • Provide data for trending
Use the PSAT prescreening filter to           Hydraulic Institute standards) and            system performance.
identify areas that are likely to offer the   performance characteristics of pumps         • Clarify impacts of operational
greatest savings. Look for symptoms           and motors (based on the                      changes on demand charges.
associated with inefficient energy            MotorMaster+ database). Subsequent
consumption:                                                                               • Identify degraded or poorly
                                              comparison of the actual and achiev-
                                              able efficiencies distinguishes systems       performing pumps.
• Throttle-valve control for the system
                                              with lower levels of opportunity from
• Cavitation noise or damage
                                              those that warrant additional engineer-
  in the system
                                              ing analysis.
• Continuous pump operation to
  support a batch process
                                              “PSAT has proven to be a
• Constant number of parallel                 versatile, straightforward tool for
  pumps supporting a process with             quickly assessing the optimization
  changing demands                            potential in an existing pumping
                                              system. Many engineers in our
• Bypass or recirculation line                organization have taken the DOE-             Download free tools from the
  normally open                               produced training to become
                                                                                           U.S. Department of Energy to
• High system maintenance                     Qualified PSAT Specialists, and
                                              we have been successful using                improve the energy efficiency
• Systems that have undergone                 the tool to demonstrate savings              of pump systems. Visit
  change in function                          opportunities to our customers.”
                                                         Gunnar Hovstadius, Ph.D.
Quantifying Potential Savings
                                                            Director of Technology
PSAT identifies energy savings opportuni-                      ITT Fluid Technology
ties in pumping systems and quantifies                    Qualified PSAT Specialist
those opportunities in both dollars and

         Bringing you a prosperous future where energy is clean, abundant, reliable, and affordable
PSAT Gets Results                          energy. The bypass flow control set-up
Large savings may come from one            was replaced with a properly sized
large application or process, but may      pump and energy-efficient motor
also develop from multiple small           that would be operated only when
applications that, when combined,          productive.
keep total consumption low enough to                               Energy      Average
                                                Industry           Savings    $ Savings
avoid increased utility charges based on   (No. of Assessments)    (Million    (Annual)
threshold demand.                                                 Btu/year)
                                           Aluminum (2)           1,882,500     $74,400
At a gold mine, the PSAT prescreening
                                           Chemicals (1)          1,601,200    $106,000
filter identified three pumping systems
                                           Forest Products (7) 4,717,400       $186,500
for further analysis. Over $170,000
                                           Mining (7)             9,419,100    $410,700
per year (2,398,200 kWh) in potential
savings were identified.                   Petroleum (2)          1,150,000     $46,000
                                           Steel (2)              5,787,500    $231,500   A Strong Energy Portfolio
Prescreening at a paper mill identified
one system that presented a significant                                                   for a Strong America
energy savings opportunity. The            “PSAT identified a significant
                                                                                          Energy efficiency and clean,
identified potential savings of more       energy savings opportunity in one
                                                                                          renewable energy will mean a
than $64,000 per year (2,252 MWh)          of our large water circulation
                                           systems. We were impressed                     stronger economy, a cleaner
were traced to inefficient operating                                                      environment, and greater energy
                                           with DOE’s willingness to help
practices rather than pump degrada-        and with their assessment                      independence for America.
tion.                                      capabilities.”                                 Working with a wide array of
                                                                                          state, community, industry, and
Smaller facilities are not exempt from                          Jeff Hackworth,
                                                               Energy Manager,            university partners, the U.S.
energy savings. An aluminum rolling
                                                       Rohm and Haas Texas Inc.           Department of Energy’s Office of
mill applied PSAT to four related                                                         Energy Efficiency and Renewable
                                                         2003 Texas Technology
systems and identified over $38,000                                                       Energy invests in a diverse
per year (1,015,000 kWh) in potential                                                     portfolio of energy technologies.
                                           “For many industrial facilities, the
A pumping system assessment for an         energy consumed in pumping
                                           fluids comprises a large fraction              Office of Industrial Technologies
Alcoa plant in Pennsylvania identified
                                           of total energy consumption…                   Energy Efficiency
savings in three systems. After
                                                                                          and Renewable Energy
prescreening, a PSAT analysis of the       PSAT provides a relatively simple
                                                                                          U.S. Department of Energy
three systems identified $110,000 per      indication of effectiveness by
                                                                                          Washington, D.C. 20585
                                           estimating the work done by the
year in potential savings.
                                           pumping system and compares
A USX steel mill employed PSAT to          that to the estimated energy
examine its hood spray application that    input into the system.”
used bypass flow control. The mill                              Robert Asdal,
discovered an opportunity to save                           Executive Director
$41,700 per year and use 13% less                      The Hydraulic Institute
                                           Hydraulic Institute Press Release,
                                                                August 2000               June 2003

          For more information, visit or call 1-800-DOE-3732

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