Total system efficiency
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Transcript of Total system efficiency
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TOTAL SYSTEM EFFICIENCY
Brian GongolDJ Gongol & Associates, Inc.
March 22, 2016
Nebraska Rural Water Association ConferenceKearney, Nebraska
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Efficiency: Who really cares?
Not the person who drives thisto the grocery store
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Of course we SHOULD care, right?
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Resources are finite
Only the state capitol gets a gold dome
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Water systems are big users of energy
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Utilities have a special responsibility
You provide essential services, usually undera monopoly or near-monopoly condition
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Rate dollars are after-tax dollars
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Money saved is a leveraged bonus
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Substitution effect
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We can say it's all for the environment
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But it's really about public health
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Money wasted displaces other public goods
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The problem is, we really DON'T care
"How can you say that?"
Well, it's simple...
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Revealed preferences
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What's your household public works budget?
(...if you even bother to have one)
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How does it compare to your travel budget?
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Why we don't really care
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Low electrical rates
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Cheap borrowing
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Low regard for worker time
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Public disregard for the state of public works
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The day of reckoning cometh
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Why we will be forced to care
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Rising energy costs
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Carbon emission regs and electricity costs
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European electricity costs vs. our costs
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Anticipated shortages of fresh water
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Rising treatment costs pressuring budgets
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Declining or flat populations
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Aging infrastructure
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Higher future interest rates
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Shrinking water workforce
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Compounding costs of deferred maintenance
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Costs of catastrophic failure
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The conventional definition of "efficiency"
Pump hydraulic efficiency
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The second order definition is still too narrow
Maybe include motor efficiencyor throw in a VFD so it looks good?
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Measure efficiency by total system impact
Think of yourself as atrustee of public assets.
You serve the public best bydelivering the services they expect
with a minimum of waste.
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Not everything that counts can be measured
The love of a child,puppy kisses,
the smell of flowersafter a rain
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But counting is a good place to start
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What we might measure to gauge efficiency
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Energy consumption
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Losses (especially unmetered losses)
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Labor costs (including opportunity costs)
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Total cost of ownership (TCO)
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Everything can be converted to dollars
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Even hidden savings deserve a dollar value
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Boards don't want to know your specialty
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Dollars are common currency to every industry
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Total system efficiency includes:
Hydraulic efficiency
Energy efficiency
Maintenance efficiency
Longevity/durability
Adaptability to future conditions
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Part 1: Pump hydraulic efficiency
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Clearances
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Pump specific speed
A dimensionless value that indicatesthe relative efficiency of a pump impeller design
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Vane adjustments (numbers, angles)
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Smooth coatings
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Straight pipe entering the suction
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Suction diffusers (straightening flow)
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Part 2: Motor/engine efficiency
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110/220/460 volt differences
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VFDs
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Soft starters
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Two-speed motors
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Across-the-line starters
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High-efficiency/premium-efficiency
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VFD misapplication: Static head prevails
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Fill towers at full speed
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Hydrostatic tanks
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VFD misapplication: Missing the (BE) point
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Transmission losses
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Part 3: Valves
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Surge control
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Save on pipe damage
If waves on a beach can erode boulders into sand,what are surge waves doing inside your pipes?
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Air control
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Maximize pipe diameter
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Throttling
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Emergency cut-in valves for an emergency
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Part 4: Pipework
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Bends
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Pipe smoothness
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Corrosion and losses
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Friction losses aren't just theoretical
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Part 5: Labor and TCO efficiency
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Preventive/predictive maintenance
Fix-on-failure wouldn't work for an airline,so why do utilities use it so much?
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Preventive maintenance and knowledge
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Labor training and continuous improvement
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Quantify downtime
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Part 6: Longevity/durability
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Major repair work is disruptive and costly
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Realistically assess how long things will last
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Is the system robust or fragile?
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Can it survive periods of neglect?
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Part 7: Auditing your system
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Total water supplied (own plus imports)
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Authorized consumption (billed/unbilled)
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Losses (apparent and real)
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Apparent losses
Unauthorized consumption Metering error Data errors
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Real losses
Distribution losses Tank leakage and overflow Service connection leakage
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Benchmarks and baselines
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To recap
We ignore efficiency We won't forever Pump efficiency matters It's not the only thing by far Total cost of ownership matters most TCO includes hydraulics, motors/engines, maintenance,
longevity, and adaptability to future conditions
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Questions?
Thank you for coming!
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Thank you for your attention!
Contact us anytime with questions
Brian Gongol DJ Gongol & Associates 515-223-4144 [email protected]
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References:
US electric prices: http://www.eia.gov/electricity/data/browser/#/topic/7?
agg=0,1&geo=vvvvvvvvvvvvo&endsec=vg&linechart=ELEC.PRICE.US-ALL.M~~~ELEC.PRICE.WNC-ALL.M&columnchart=ELEC.PRICE.US-ALL.M&map=ELEC.PRICE.US-ALL.M&freq=M&start=200101&end=201402&ctype=linechart<ype=pin&rtype=s&maptype=0&rse=0&pin=
Germany, EU electric prices: http://epp.eurostat.ec.europa.eu/statistics_explained/index.php/Electricity_and_natural_gas_price_statistics
Fed funds rate: http://research.stlouisfed.org/fred2/series/FEDFUNDS
Motor efficiency standards: https://www.eia.gov/todayinenergy/detail.cfm?id=18151
Suction vane drawing and sample pump curve courtesy Patterson Pump Co. Valve photographs courtesy GA Industries Some material in Part 7 adapted from the AWWA water loss auditing tool:
http://www.awwa.org/resources-tools/water-knowledge/water-loss-control.aspx
Special thanks to Shane Kinsey (City of Johnston, Iowa) and Rose Ann DiGiovanni (Patterson Pump Co.) for observations that extended the scope of this presentation
All other photos are original work by and copyright reserved to Brian Gongol