5 Steps to Successful Pump Systems

Optimization
Evaluating the entire system for possible improvement will help
facilities lower energy use and improve reliability.
by Mark Sullivan

Wastewater treatment facilities, chemical and power-generation

plants, electric and gas companies, municipalities, and commercial
buildings all have a common prime movercentrifugal pumps.
Collectively, these pumping systems represent an enormous amount
of electrical energy usage. Pump systems, on average, represent the
highest energy usage of any type of rotating equipment employed in
industrial and commercial facilities. For example, pumping systems
account for 20 to 30 percent of electrical energy consumption in
wastewater plants and up to 46 percent in municipal water systems.
By comparison, chemical and allied product plants typically use
enough electrical power in pump systems to run a small city.

Pump system designs are normally in the range of 65 to 85 percent

at their best efficiency point (BEP). Because of oversizing and
sometimes undersizing, pump systems typically operate well below
their BEP. The excess energy usage is transmuted into vibration,
heat and noise, all of which increase maintenance and energy costs.

When not optimized for best efficiency, pump systems drain

maintenance budgets by decreasing the mean time between repairs.
Pump systems represent one of the best ways to reduce overall plant
operating costs.

The Underlying Cause of Pump Inefficiency

Figure 1. Life-cycle cost of a standard 75-hp pumping system over 20
years of operation (Graphics courtesy of Hydraulic Institute)
Figure 2. The impact on pump reliability when operating outside of its
acceptable range. Note that most of the issues occur when the pump
is operating to the left of design, which is where pumps typically
operate due to oversizing.

One reason so many pumping systems run significantly below their

BEP is that organizations focus on purchase price rather than the
total life-cycle cost (LCC) of the system. Figure 1 depicts the LCC of
a standard 75-horsepower (hp) pumping system over 20 years of
operation. While the initial purchase price and installation cost
represent 17 percent of the LCC, 55 percent of costs are related to
operations, and the 28 percent balance is maintenance costs. In
severely oversized systems, the first cost of the pump can drop to 10
percent or less. Rather than base a purchasing decision on price
alone, plant designers should evaluate a systems total LCC and
make decisions that will minimize energy and maintenance costs.

Another important factor affecting pump efficiency is the lack of

system standards that guide the design of efficient pumping systems.
As a result, engineering, procurement and construction (EPC) firms
continue to use the same design approachesif-it-aint-broke-dont-
fix-it syndrome. These routine configurations typically consist of a
fixed-speed control valve system. This design approach has been
mostly unchallenged. The design engineer often cites time and
budget as the reasons other designs, such as not using a variable-
speed drive or parallel multi-pump system in lieu of an oversized
control valve system, are not considered.

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If the design process uses more due diligence, engineering firms can
easily overcome perceived barriers to achieve the lowest practical
LCC. Furthermore, without a design standard, end users will lack the
needed information to effectively challenge designers and prove that
a system is poorly or incorrectly conceived. Even today, industry
continues to design and install oversized pumping systems because
of the lack of a standard. There is no good reason not to use pump
and pipe design tools and techniques that optimize the selection of
best pump, pipe and control valve combinations to achieve the lowest
LCC.

Effects of Pump Inefficiency

For maximum efficiency, pumps should operate at or near their
mechanical BEP. Optimally, pumps should not run at flow more than
10 to 15 percent outside of the BEP. When operating at excess
capacity or greater than BEP, pumps may surge and vibrate, creating
potential bearing and shaft seal problems while requiring excessive
power. Cavitation may also occur, causing damage to pump
components.

When pumps operate at reduced capacity, or lower than BEP, fixed-

vane angles may cause eddy currents within the impeller, inside the
casing and between the wear rings. The radial thrust on the rotor will
increase, causing higher shaft stresses, increased shaft deflection,
and potential bearing and mechanical seal problems. Radial vibration
and axial shaft movement will also increase. Figure 2 shows the
effects of operating away from the BEP on the pump.

The Need for Pump Systems Optimization

Systems optimization is the process of evaluating pumping systems
to identify opportunities for improvements that will reduce energy
consumption and improve reliability. Improving a single component
installing a more efficient motor, for examplewill do little to improve
overall system efficiency. Engineers who wish to implement systems
optimization must evaluate how all pump components work together
and determine how to make certain system changes to improve net
efficiency.

Greater pump system efficiency achieved through systems

optimization will improve reliability and lower operating costs by
reducing wear and tear. This will decrease downtime and costs
associated with lost production, maintenance and repairs, while
extending equipment life. Costs associated with downtime routinely
exceed energy and reliability costs combined.

Approaches to Systems Optimization

As with any engineering project, the pump systems optimization
process begins with organizing an assessment team. The individuals
chosen should be knowledgeable in one or more critical areas. The
team will also work cross-functionally with the team leader and other
members to meet the studys overarching goals. The following steps
are vital to a successful pump systems optimization program.

1. Prescreening
Initially, pumps are prescreened to identify those with the greatest
savings potential. Pumping systems should be screened for any of
the following symptoms:

highly throttled flow-control valves

existence of bypass line (recirculation) flow regulation

batch-type processes involving one or more pumps running

continuously

frequent on/off pump cycling

cavitation noise either at the pump or in the system

parallel pump system with the same number of pumps always

working

a pump system that has undergone a change in function

without modification
 a pump system with no means of measuring flow, pressure or
power

Pumping systems with one or more symptoms are typically ideal for
further assessment. Large, high-maintenance systems that are
mission-critical to the process or facility operation are often a top
priority.

2. Assessment
Next, pump systems selected for assessment must be thoroughly
evaluated. Depending on the requirements of the plant or facility, the
selection of the correct pump system assessment level is important
to meet the projects goals.

Level 1 pump system assessment is a qualitative review that

determines potential energy savings and reliability
improvements to identify pumps worthy of further attention.

Level 2 is a quantitative review that determines energy

consumption and reliability improvements based on
measurement made during steady-state operating conditions
using a single set of measurements.

Level 3 is a quantitative review measuring system demands by

tracking and monitoring the system over longer time periods to
obtain various operating conditions.

3. Data Collection
The next step in the systems optimization process involves data
collection. Data are collected on energy costs and the pump systems
using appropriate data-acquisition systems. For example, collected
data can be used to compare the measured rates of flow and head to
the required rates.

An analysis may reveal an imbalance between measured and

required conditions, which is evidence of an inefficient system.
Comparing existing operating conditions to design conditions can
also show an improperly sized pump.

An original pump performance curve can be useful for constructing a

curve for the operating points of the existing system.
Comparing a single test point to the original curve can help determine
if the first step to systems optimization will be the overhaul of a worn
pump or if the system must be further investigated. The curve will
also help determine if the rotodynamic pump is operating at its BEP.
Those operating outside the BEP range will be inefficient and
consume more energy.

Other components of the existing system also must be assessed,

including valves, bypass lines, piping configurations and suction
piping that may provide optimization opportunities.

4. Life-Cycle Costing
Because the odds of receiving approval for optimization projects are
significantly higher when the potential projects can be proven to
improve plant profitability and reduce operating costs, an LCC
analysis can justify system optimization by indicating a lower total
cost of ownership. In an LCC analysis, the following elements are
reviewed:

initial purchase

installation and commissioning

electrical or other energy costs

operation costs

maintenance and repair costs

downtime costs

environmental costs

decommissioning/disposal costs

LCC analysis requires an evaluation of alternative systems.

Because lifetime energy and maintenance costs dominate life-
cycle costs, end users must know the current cost of energy to
estimate the annual price escalation for energy and
maintenance costs.

5. Benefits Documentation
 Advantages of pump systems optimization not readily
quantified through an LCC analysis include:

o increased productivity

o reduced production costs

o improved product quality

o improved capacity utilization

o improved reliability

o improved worker safety

These benefits should be presented to management as a focus

on the bottom line. Relating pump system improvements to
cost efficiency will help sell the project to management.

Training Opportunities
The Hydraulic Institute recently introduced a Pump Systems
Assessment (PSA) Certificate Program that provides instruction on
how to gauge the knowledge and capabilities of individuals required
to conduct pump systems assessments and implement process
changes at facilities.

As the pool of nationally certified PSA professionals grows, industry

will become increasingly confident in the implementation of pump
systems optimization initiatives. Over time, this educational effort will
help increase the average pump system efficiency above todays
average of 40 percent. Also, energy consumption in pump systems
will begin to decrease as recommended mechanical and control
modifications are implemented.

About the Author

Mark Sullivan, director of marketing and educationat the Hydraulic
Institute/Pump Systems Matter Educational Foundation, leads all
strategic planning and development, marketing and technical training
initiatives at the institution.