Auditing Water System Pumps for Efficient Operation. Tyler Clary, P.E. City of Vancouver
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1 Auditing Water System Pumps for Efficient Operation Tyler Clary, P.E. City of Vancouver
2 City of Vancouver System Fourth largest water utility in Washington State Service area of 65-square square-miles serving about 210,000 people Average 10 Billion Gallons Annually 40 groundwater wells 49 Booster Pumps Power Bill $1,000,000/yr
3 Energy Audit Objectives Assess all system pumps for efficiency Assess system for inefficiencies Identify cost effective energy saving projects Make modifications for the low hanging fruit projects Include energy savings projects in the capital budget
4 Evaluating Pump/Motor Efficiency Wire to Water Efficiency Calculated Current vs. Measured Current
5 Flow Meter Calibrate first One meter per pump is best Master station meter Ultrasonic meters
6 Pressure Gauges Make sure they are accurate Needed to determine total head Best to have multiple gauges
7 Level Meters (Well Pumps Continuous Meters Manual Meters
8
9 Amp Meter Hand Held Permanently Mounted
10 Power Data Logger
11
12 Pump Curve Flow rate and Total Dynamic Head (TDH used with pump curve to determine pump efficiency
13 Motor Efficiency Data Motor Manufacturers provide spec sheets showing efficiency at certain loads Load Characteristics of a 200 HP motor, 460 V, 60 Hz % of Rated Load S.F. Efficiency Speed (rpm Line Amperes
14
15 Well Example
16
17 ( BHP (0.746 (80(0.746 ( Flow( TDH (500gpm(216 psi Power BrakeHorse Power( BHP 65 kw 80hp ( MotorEfficiency ( PumpEfficiency (0.92 (1714 (0.78(1714 Calculated Current ( Flow( TDH (500gpm(216 psi BrakeHorsePower( BHP 80hp ( PumpEfficiency(1714 (0.78(1714 ( BHP(0.746 (80hp(0.746 MotorInputPower 65kW ( MotorEfficiency (0.92 ( Power(1000 (65kW (1000 CalculatedCurrent 83Amps ( Voltage(1.732( PowerFactor (475V (1.732(0.95 Calculated Current 83 Amps Measured Current 96 Amps Efficiencies NOT Correct
18 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714 What If Currents Don t t Match? Use judgment to determine if motor or pump is operating inefficiently If motor is new, then probably a pump problem Modify efficiency until measured current matches calculated current ( Flow( TDH (500gpm(216 psi BrakeHorsePower( BHP hp ( PumpEfficiency(1714 ( (1714 ( BHP(0.746 (93hp(0.746 MotorInputPower kW ( MotorEfficiency ( ( Power(1000 (75kW (1000 CalculatedCurrent 96Amps ( Voltage(1.732( PowerFactor (475V (1.732(0.95
19
20 Bad Pumps Can Be Placed Into Two Categories No longer behaving as designed Behaving as designed, but are used inappropriately
21 Well Example
22 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714 Control Valves
23 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714
24 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714
25 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714 Control Valve Cost Example 1: ( Flow( ValveHeadloss( ElectCost( Use% (500gpm(40 ft($0.04 / kwh(0.50 $ / yr $557 / ( PumpEfficiency( MotorEfficiency (0.78(0.92 yr Example 2: ( Flow( ValveHeadloss( ElectCost( Use% (2500gpm(65 ft($0.04 / kwh(0.50 $ / yr $4800 / ( PumpEfficiency( MotorEfficiency (0.70(0.96 yr
26 Contact Electrical Utility Request past bills Compare bills to calculated values Determine what billing schedule you are on Use rates to evaluate your energy cost Do they have peak time rates that can be avoided Demand charges
27 Demand Charges Pay utility to size system large enough for generation, transmission and distribution Calculate cost based on max 30 minute average kw usage for month 95% of monthly bill ($2,500
28 Operations Cost Table Height High Cost/MG WS 8 HH $51.50 WS 14 HH $54.10 WS 9 HH $56.00 WS 15 HH $60.50 WS 7-1 HH $71.13 WS 7-2 HH $96.51 WS 1 St John's HH $98.89 WS 1 WS 5 HH $ WS 1 49th HH $ WS 4 WS 5 HH $ WS 1 WS 5 Ells HH $ WS 4 Ells HH $ Ells WS 5 HH $ Ellsworth HH $131.20
29 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714 What City of Vancouver Done Installed VFD at booster station Found open valves Budgeted smaller pump installation at one booster Budgeted for VFD installation at large booster station Replace four old motors with high efficiency Installed soft starts to decrease demand Reduced pump starts to decrease demand charges Replace oversized pumps when rebuild required
30 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714 Savings VFD install saved $9,000/yr Reduced pump starts saved $18,000/yr High efficiency motor installs $4,600/yr for 4 High efficiency motor installs $4,600/yr for 4 motors Future pump replacements $9,000/yr Future VFD install save $12,500/yr
31 ( Flow ( TDH (500 gpm (216 psi BrakeHorse Power ( BHP 80 hp ( PumpEfficiency (1714 (0.78(1714 Tyler Clary City of Vancouver ( tyler.clary@ci.vancouver.wa.us
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