Psat Webcast

8/11/2019 Psat Webcast

1/39

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


2/39

Motor-driven equipment is a dominant

electricity consumer

Industrialmotorsystems:

- arethesingle largest electrical end usecategoryintheAmericaneconomy

- accountfor25%ofallU.S.electricalsales


3/39

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


4/39

BestPractices encourages a three-tiered

prescreening and assessment approach Initialprescreeningbasedonsize,run

time,andpumptype

Secondaryprescreeningtonarrowthefocustosystemswheresignificantenergy

reductionopportunitiesaremorelikely Opportunityassessmentand

quantificationofpotentialsavings


5/39

>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


6/39

Primary prescreening

Allplant Bigloads Bigcentrifugalmotorsystems thatrunalot loadsthatrunalot

Policies andpractices

Filter1

Seldomused,smallloads

Filter2

Non-centrifugal,ASDloads

Moderatepriority


7/39

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


8/39

Five basic causes of less than optimal

pumping system operation

Installedcomponents areinherentlyinefficientat

thenormaloperatingconditions Theinstalledcomponents havedegradedin

service

Moreflowisbeingprovidedthanthesystemrequires

Moreheadisbeingprovidedthanthesystemrequires

Theequipmentisbeingrunwhennotrequiredby

thesystem


9/39

Secondary prescreening

Allplant Bigloads Bigcentrifugalmotorsystems thatrunalot loadsthatrunalot

Policies andpractices

Filter1

Seldomused,smallloads

Filter2 Symptom orexperienced-based

segregationNon-centrifugal,

ASDloads

Moderatepriority

HighestPriority


10/39

Some symptoms of interest

Throttlevalve-controlledsystems

Bypass(recirculation)linenormallyopen

Multipleparallelpumpsystemwithsamenumberofpumpsalwaysoperating

Constantpumpoperationinabatchenvironment

orfrequentcyclebatchoperationinacontinuousprocess

Cavitationnoise(atpumporelsewhereinthe

system)

Highsystemmaintenance

Systemsthathaveundergonechangeinfunction


11/39

Pumping System Assessment Tool (PSAT)

Anopportunityquantificationtool

Reliesonfieldmeasured(orestimated)fluidandelectricalperformancedata

Usesachievablepumpefficiencyalgorithmsfrom

theHydraulicInstitute Motorperformance(efficiency,current,powerfactor)curvesdevelopedfromaveragemotordata

availableinMotorMaster+(supplementedbymanufacturerdataforlargersize,slowerspeedmotors)


12/39

A matter of focus

PSATisbasedoncomponentperformance

Itcanbeusedtoevaluatecomponent-levelperformance

Butitcanalsobeusedtoevaluatesystem-levelconditions


13/39

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


14/39

Head calculationPSATincludesapumpheadcalculatortosupportuser-measured

pressure,flowdata.

Tanktopipeentranceloss Checkvalve,

SRelbow


15/39

Component-based analysis

ResultsInputs


16/39

Input sections 1-3

Basicdesign,operatingprofileandcostinputs


17/39


18/39

Alternate forms of electrical data input

Eithermotorcurrentorpowercanbe usedtoestimatethemotorshaftload


19/39

Results: optimization rating

Theoptimizationratingisakintoanexamgradeofhowwelltheexistingoperationcompareswithoptimal.

237.1x100=88.6

267.5


20/39

Results: cost, savings potential

Annualenergycostsfortheexistingandoptimal

casesaretabulated,andthepotentialcostsavingsislisted


21/39

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


22/39

A system-level perspectivePSATanalysisusingtherequiredfluiddata

Optimalequipmentsizedtomeettherequiredconditionscouldsaveover$68,000/year.


23/39

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


24/39

Help pop-up screens provide run-time assistance

TheContextHelpwindowdisplaysinformationaboutthecontrolorindicatorunderneaththemousepointer


25/39


26/39

User's manual and other support features areincluded

UsersofPSAT2004canconvertsavedlogandsummaryfilestothe2008

version(aone-timeoperation)


27/39

A demo of the tool use


28/39


29/39

We'll do PSAT calculations

for Condition A

Calculatepumphead

Annualenergycost Potentialsavings

Developasystemcurvewithartificialcontrolvalvelosseseliminated

Takealookatsomeofthebackgroundinformationanddata


30/39

A valve loss estimating tool accompanies PSAT


31/39

A valve loss estimating tool accompanies PSAT

Basedonstandardvalveequations(ISA75.01)

Software download (free)


32/39

Software download (free)and training links

www1.eere.energy.gov/industry/bestpractices/software.html

There are two PSAT workshops


33/39

There are two PSAT workshops

End-user Specialist

PSAT specialists are listed on


34/39

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


35/39

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


36/39

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


37/39

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


38/39

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


39/39

Acknowledgments

U.S.DepartmentofEnergys

IndustrialTechnologiesProgram

Documents

Psat Webcast