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Transcript of Psat Webcast
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U.S.DepartmentofEnergy EnergySavingsAssessment(ESA)
Overview of the Pumping SystemAssessment Tool (PSAT)
Date: December 15, 2008By: Don Casada
Diagnostic Solutions, [email protected]
865-938-0965
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Motor-driven equipment is a dominant
electricity consumer
Industrialmotorsystems:
- arethesingle largest electrical end usecategoryintheAmericaneconomy
- accountfor25%ofallU.S.electricalsales
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Pumps are the largest industrial user of
motor-driven electrical energy
Fluidhandlingequipment,includingpumps,fans,andcompressors,accountforover60%ofindustrialmotor-drivenenergy.
Pumps24.8%
Fans13.7%
Compressed Air15.8%Refrig
%
12.2%
4.3%
eration
6.7
Materialhandling
Material processing22.5%
Other
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BestPractices encourages a three-tiered
prescreening and assessment approach Initialprescreeningbasedonsize,run
time,andpumptype
Secondaryprescreeningtonarrowthefocustosystemswheresignificantenergy
reductionopportunitiesaremorelikely Opportunityassessmentand
quantificationofpotentialsavings
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>10
00
>50
0
>20
0
>10
0
>50
>20
>5
>1
The bulk of motor-driven energy is used
by a relatively small part of the population
Pe
rcentofenergy/popula
tion
100
90807060
50403020
100
Ene
rgy
10%ofpopulationuses80%ofenergy
ion
ulat
Pop
Cumulativemotorhorsepowerrange
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Primary prescreening
Allplant Bigloads Bigcentrifugalmotorsystems thatrunalot loadsthatrunalot
Policies andpractices
Filter1
Seldomused,smallloads
Filter2
Non-centrifugal,ASDloads
Moderatepriority
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Pump energy basics are fundamental to
secondary prescreening
Q H T sgE =
5308 pump motor drive
E energy,kilowatt-hoursQ flowrate,gpm
H head,ft T time,hours sg specificgravity,dimensionless
5308 Unitsconversionconstant pumpefficiency,fractionpump motorefficiency,fractionmotor
driveefficiency,fractiondrive
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Five basic causes of less than optimal
pumping system operation
Installedcomponents areinherentlyinefficientat
thenormaloperatingconditions Theinstalledcomponents havedegradedin
service
Moreflowisbeingprovidedthanthesystemrequires
Moreheadisbeingprovidedthanthesystemrequires
Theequipmentisbeingrunwhennotrequiredby
thesystem
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Secondary prescreening
Allplant Bigloads Bigcentrifugalmotorsystems thatrunalot loadsthatrunalot
Policies andpractices
Filter1
Seldomused,smallloads
Filter2 Symptom orexperienced-based
segregationNon-centrifugal,
ASDloads
Moderatepriority
HighestPriority
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Some symptoms of interest
Throttlevalve-controlledsystems
Bypass(recirculation)linenormallyopen
Multipleparallelpumpsystemwithsamenumberofpumpsalwaysoperating
Constantpumpoperationinabatchenvironment
orfrequentcyclebatchoperationinacontinuousprocess
Cavitationnoise(atpumporelsewhereinthe
system)
Highsystemmaintenance
Systemsthathaveundergonechangeinfunction
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Pumping System Assessment Tool (PSAT)
Anopportunityquantificationtool
Reliesonfieldmeasured(orestimated)fluidandelectricalperformancedata
Usesachievablepumpefficiencyalgorithmsfrom
theHydraulicInstitute Motorperformance(efficiency,current,powerfactor)curvesdevelopedfromaveragemotordata
availableinMotorMaster+(supplementedbymanufacturerdataforlargersize,slowerspeedmotors)
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A matter of focus
PSATisbasedoncomponentperformance
Itcanbeusedtoevaluatecomponent-levelperformance
Butitcanalsobeusedtoevaluatesystem-levelconditions
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An example system
P2
V20psig
V1
F1
DeliveredtoTank2
L1
MeasureddataF1=6050gpmL1=12ftabovegroundMotornameplate:350HP,1185rpm,83amps,2300V
Suctionlineis20-inSchedule10SS P2=75.5psig(5ftaboveground)Dischargeis16-inSchedule10SS Fluid=paperstockat120degF
Motorcurrent=80.5amps
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Head calculationPSATincludesapumpheadcalculatortosupportuser-measured
pressure,flowdata.
Tanktopipeentranceloss Checkvalve,
SRelbow
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Component-based analysis
ResultsInputs
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Input sections 1-3
Basicdesign,operatingprofileandcostinputs
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Alternate forms of electrical data input
Eithermotorcurrentorpowercanbe usedtoestimatethemotorshaftload
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Results: optimization rating
Theoptimizationratingisakintoanexamgradeofhowwelltheexistingoperationcompareswithoptimal.
237.1x100=88.6
267.5
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Results: cost, savings potential
Annualenergycostsfortheexistingandoptimal
casesaretabulated,andthepotentialcostsavingsislisted
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A system-level perspective
Recircflow
V20psig
V1
Requiredflowrate:2800gpmsenttoTank2
F2
F1 F1=6050gpm
F2=2800gpm
P2
L1
DeliveredtoTank2
71.3ftfrictionloss acrosscontrolvalve
Requiredhead= Pumphead: 175.3ft
- valveloss 71.3ft
104.0ft
A s stem le el perspecti e
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A system-level perspectivePSATanalysisusingtherequiredfluiddata
Optimalequipmentsizedtomeettherequiredconditionscouldsaveover$68,000/year.
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PSAT does not identify solutions;
some options
Trimmedimpeller Reducedspeedmotor
Adjustablespeeddrive
Differentpump
Otherfactors,suchasloadvariability,extentofsystem
headthatisstatic,andpumpdetails(curve,impellersize,etc.)wouldbeneededtoevaluatealternativesolutions
Help pop up screens provide run time assistance
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Help pop-up screens provide run-time assistance
TheContextHelpwindowdisplaysinformationaboutthecontrolorindicatorunderneaththemousepointer
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User's manual and other support features areincluded
UsersofPSAT2004canconvertsavedlogandsummaryfilestothe2008
version(aone-timeoperation)
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A demo of the tool use
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We'll do PSAT calculations
for Condition A
Calculatepumphead
Annualenergycost Potentialsavings
Developasystemcurvewithartificialcontrolvalvelosseseliminated
Takealookatsomeofthebackgroundinformationanddata
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A valve loss estimating tool accompanies PSAT
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A valve loss estimating tool accompanies PSAT
Basedonstandardvalveequations(ISA75.01)
Software download (free)
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Software download (free)and training links
www1.eere.energy.gov/industry/bestpractices/software.html
There are two PSAT workshops
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There are two PSAT workshops
End-user Specialist
PSAT specialists are listed on
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PSAT specialists are listed onthe DOE web site
http://apps1.eere.energy.gov/industry/bestpractices/qualified_specialists/tool.cfm?software_id=2#find
Find Additional Training
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Find Additional Training
VisittheDOEBestPracticesTrainingWebsite:www1.eere.energy.gov/industry/
bestpractices/training.html
SeetheTrainingCalendarforevents
inyourarea:www1.eere.energy.gov/industry/bestpractices/events_calendar.asp
BecomeaQualifiedSpecialist:apps1.eere.energy.gov/industry/bestpractices/qualified_specialists/
See the Industrial Energy Savers
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See the Industrial Energy SaversWeb Site
20waystosaveenergynow
Toolsandtrainingyoucanusetoidentifysavings
opportunities
Industryexpertiseavailable
Assessmentsforyourplant
DevelopanActionPlan
Learnhowothershavesaved
AccesstheNationalIndustrialAssessmentCenter(IAC)Database
www.energysavers.gov/industrymanagers.html
EERE I f ti C t
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EERE Information Center
On-callteamofprofessionalengineers,scientists,researchlibrarians,energyspecialists,and
communicationsinformationstaff.
Voice: 877-337-3463
E-mail: [email protected]: www1.eere.energy.gov/informationcenter
Web Site and Resources
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Web Site and Resources
VisittheseDOEWebsitesforthelatest informationandresources:
IndustrialTechnologiesProgram(ITP)Website:
www1.eere.energy.gov/industry/FactSheets
NewslettersBestPracticesWebsite:TipSheets
www1.eere.energy.gov/industry/bestpracticesBrochures
SaveEnergyNowWebsite: ReportsSoftwarewww1.eere.energy.gov/industry/saveenergynow
Tools
Data
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Acknowledgments
U.S.DepartmentofEnergys
IndustrialTechnologiesProgram