DATA COLLECTION AND PUMP ENERGY SAVING OPPORTUNITIES. Presented By: Rick Rumsey, P.E.

Transcription

1 DATA COLLECTION AND PUMP ENERGY SAVING OPPORTUNITIES Presented By: Rick Rumsey, P.E.

2 Data Collection Customer Information Pump Motor Information Pump Information Irrigation System Information Historic Energy Usage

3 Data Collection Sheet

4 Data Collection Sheet

5 Data Collection Sheet

6 Data Collection Sheet

7 Pump Nameplate

8 Motor Nameplate

9 Motor Nameplate

10 Data Collection Sheet

11 Data Collection Sheet

12 Data Collection Sheet

13 Data Collection Sheet

14 Data Collection Sheet

15 Energy Saving Opportunities Improve the Pump Efficiency Improve the Pump Efficiency Worn pumps Wrong pump for the job Lower System Pressures Trim the pump impeller Install a variable frequency drive (VFD) Lower Pumping Flow Rate Replace worn equipment Fix leaks Check system flow against required flow

16 Pump Tests Measurements Flow Rate (ultrasonic flow meter, permanently installed flow meter, based on distribution system) Pressure (pressure gauge at the pump) Lift (well sounder, well log, tape measure) Power Use (utility meter, portable power meter) Pump Efficiency Calculation Efficiency = Pump Output/Pump Input Water Horsepower = Flow * TDH/3,960

17 VFD s Are they the Right Choice?

18 A VFD Example Existing System 40 hp centrifugal pump and pivot on sloping ground. The elevation change is 130 ft. Proposed System Install new VFD to adjust pressure as pivot changes in elevation. Flow remains constant.

19 Vertical Turbine Pump Curve End-Suction Centrifugal Pump Curve Match the operation of a centrifugal pump Match the operation of a centrifugal pump with that of a short-coupled vertical turbine pump to compare energy savings with a variable speed drive.

20 Proposed VFD Application Existing System Existing System 40 hp centrifugal pump serves a half pivot. The pump test measured 564 gpm at 87 psi. The measured power was 31.9 kw for an overall efficiency of 68.5% and a pump efficiency of 76%. Proposed System Install a VFD with pressure control transducer at the end of the pivot to adjust pump pressure as elevation changes.

21 Projected Savings with Centrifugal Pump (Constant Flow Conditions) Energy Saving Measure: Install a VFD on the centrifugal pump. Projected in the original report (September 2011) Energy Savings (kwh) 9,102 Cost Savings ($/year) $241 Total Project Cost $3,500 Utility Incentive $1,639 Simple Payback After Incentive 7.7 years

22 Projected Savings with a Turbine Pump (Constant Flow Conditions) Energy Saving Measure: Install a VFD on the turbine pump. Projected Energy Savings (kwh) 11,227 Cost Savings ($/year) $298 Total Project Cost $3,500 Utility Incentive $2,240 Simple Payback After Incentive 4.2 years

23 Projected Savings with Centrifugal Pump (Assume Constant Head Conditions and Flow is Reduced in Half 50% of the Time) Energy Saving Measure: Install a VFD on the centrifugal pump. Projected Energy Savings (kwh) 1,428 Cost Savings ($/year) $38 Total Project Cost $3,500 Utility Incentive $0 Simple Payback After Incentive 92 years

24 Projected Savings with Turbine Pump (Assume Constant Head Conditions and Flow is Reduced in Half 50% of the Time) Energy Saving Measure: Install a VFD on the turbine pump. Projected Energy Savings (kwh) 6,084 Cost Savings ($/year) $161 Total Project Cost $3,500 Utility Incentive $2,240 Simple Payback After Incentive 7.8 years

25 Completed Project Existing System Existing System 15 hp centrifugal pump connected to a gravity pressure pipeline boosting the pressure to a center pivot Pump providing 50 psi at the pump and 76 psi at the pivot Measured pump efficiency of 75% Proposed System New 7.5 hp pump designed to supply 25 psi at the pump and about 50 psi at the pivot. Estimated new pump efficiency of 77% Installed System New 7.5 hp pump supplying design flow at 31 psi and efficiency of 81% (note: gravity pipeline pressure was higher)

26 Completed Project Success Story Energy Saving Measure: Replace the 15 hp pump Projected in the original report (September 2012) As built final inspection results (November 2012) Energy Savings (kwh) 11,956 12,019 Cost Savings ($/year) $562 $565 Total Project Cost $4,882 $3,164 Salmon River Electric Incentive $2,989 $2,215 Simple Payback After Incentive 3.4 years 1.7 years

27 Project Photo

28 Completed Project Success Story Existing System Existing System 300 hp vertical turbine pump. Pump test measured 2,924 gpm at 113 psi. The measured power was 236 kw for an overall efficiency of 62.6% and a pump efficiency of 68.4%. Proposed System Replace with a new pump Installed System 300 hp vertical turbine pump. Pump test measured 3,470 gpm at 116 psi. The measured power was 234 kw for an overall efficiency of 77.4% and a pump efficiency of 84.6%.

29 Project Photo

30 Completed Project Success Story Energy Saving Measure: Replace a 300 hp short-coupled turbine pump Projected in the original report (September 2011) As built final inspection results (July 2012) Energy Savings (kwh) 27,589 67,514 Cost Savings ($/year) $731 $1,762 Total Project Cost $8,422 $8,422 Utility Incentive $4,211 $4,211 Simple Payback After Incentive 5.8 years 2.3 years

31 Completed Project Success Story Existing System Existing System 30 hp short-coupled vertical turbine pump serving two wheel lines. Pump test measured 467 gpm at 53.6 psi. The measured power was 23.9 kw for an overall efficiency of 46.4% and a pump efficiency of 52.5%. Proposed System Upgrade pump and add two wheel lines Installed System Upgraded 30 hp short-coupled vertical turbine pump and replaced wheel lines with a new half pivot. Pump test measured 456 gpm at 43.4 psi. The measured power was 15.3 kw for an overall efficiency of 57.5% and a pump efficiency of 65.3%.

32 Project Photos 2011 with Wheel Lines 2012 with Pivot

33 Completed Project Success Story Energy Saving Measure: Upgrade 30 hp short-coupled turbine pump and replace 2 wheel lines with a pivot on 80 ac. Projected in the original report (September 2011) As built final inspection results (July 2012) Energy Savings (kwh) 10,707 17,120 Cost Savings ($/year) $283 $446 Total Project Cost $ wheel line cost $ pivot cost Utility Incentive $1927 $2,046 Simple Payback After Incentive

34 Custom Project Example VFD 2 gpm each Hand lines on grass pasture 253 acres total 250 Hp deep well turbine pump System operates with only one pivot running about 66% of the time Pump is designed for two pivots operating together

35 Custom Project Example VFD Energy Efficiency Measure Install a variable frequency drive to the pumping plant allowing the system to operate at reduced pressures when pumping at reduced flow rates with only one pivot running Pressure was previously controlled by throttling the flow with a valve

36 Custom Project Example VFD Energy and Cost Savings The system was operated with and without the VFD operating and energy use was measured The total calculated energy savings by installing the VFD is about 84,300 kwh per year Per year $$ savings at $0.0405/kWh is about $3,414/year

37 Custom Project Example VFD Project Cost Analysis Energy Total Incentive Payback Savings Project ($0.12/kWh before Energy Efficiency Measures (kwh/yr) Cost + $50/kW) incentive 1 Install a VFD to the pumping plant 84, $3,414 $ 37,710 $10, EEM # Average Demand Savings (kw/mo.) Electric Cost Savings ($/yr) Payback after incentive Project Total 84,296 0 $ 3,414 $ 37,710 $10, Percentage of cost paid by Incentive 27% Installed Cost after Incentive $27,594 Incentive $10,116

38 VFD Energy Savings Factors % of time the system operates at reduced flow Flow or pressure variation of the system Pump curve/operating characteristics Energy cost of water Pressure reducing potential

39 Questions??? Contact Information: Rick Rumsey Rumsey Engineering (208)