Saving Energy through Innovation

Characteristics of Pumping SystemsCentrifugal pumps have the following benefits when operating at its Best Efficiency Point (BEP)

The main symptoms of pumping systems under non-optimal conditions are:

Opportunities Improving Pumping SystemsPumping systems are generally oversized; valves strangled or operate away from its Best Efficiency Point (BEP) and non-ideal suction conditions. Our approach is to do a complete analysis of your pumping system in order to save money.

• Smooth operation• Increased bearing life• Increased mechanical seals lifespan

• Reduced risk of cavitation• Minimum vibration• Noise Reduction.

• Existence of restricted valve• Existence of bypass flow• oversized pumps• Pumps operating away of its BEP• Changes in the conditions of the

initial pumping system• Large number of items• Noise presence due to cavitation• Pumping systems with different

pump models.

Caudal

Speed Variation

Caudal

Start / Stop

Caudal

EnergyWasted

Energy Required

Choke Valve

Caudal

Bypass

Cavitation

Pump Curve

Slight Shelf Life of Bearings Mechanical Seals

Best Practice-10% to +5% of BEP

Commercial Practice-30% to +15%

Best Practice-20% to +10%

Best Efficiency Point (BEP)

Lower Shelf Life of Bearings and Mechanical Seals

Decrease Impeller Life

Recirculation Download

Suction Recirculation

Curve Reliability

Temperature Increase

Mean Time Between Failures (TPEF)

Low Flow Cavitation

% Flow

% H

eigh

t

% R

elia

bili

ty

Avoid

Reconsider

© Barringer & Associates, Inc. 2004

Optimum

Services and SolutionsNeptuno Energy™ offers a complete solution for energy saving projects for new pumping systems as well as for existing facilities:

Evaluation of Pumping SystemsOur Pumping System Assessment is based on the Energy Assessment for Pumping Systems ASME EA-2 standard, allowing to understand the requirements of each system, their function and operation through the revision of the ultimate goal (and use) the system pumping, and then with a review of each component and the consideration of interactions between them, to assess opportunities for optimization. This process can be summarized in five simple steps:

By using proven techniques for assessment of his pumping system, Neptuno Energy™ offers a complete solution for energy savings. Efficiency improvements as minimum as 1% can lead to significant results in terms of cost savings and reduced CO2 emissions.

World-Class SupportAs the first and only member in Chile and Latin America Hydraulic Institute and sponsor of the initiative to improve efficiency in pumping systems, Pump Systems Matter™, Neptuno Energy™ has all the tools, knowledge and prestige to assist their customers improve their pumping systems, saving energy and reducing the life cycle cost.

• consultancy• Operational recommendations• Energy Pumping System Assessment (ASME EA-2)• Tests of Centrifugal Pumps (ISO 9906)• Repowering Pumping Systems• Custom Engineered Pumps

• Improved Design and Components• Material Up-grade• Computer Fluid Dynamics (CFD)• Finite Element Analysis (FEA)• Reverse Engineering.

1 2 3 4 5Data analysisand efficiency calculatingcurrent.

Data collection and identification of opportunities for improvement.

With hierarchical detailed recommendations report.

Working with the client to implement recommended changes to the system.

Support and measure-ment of energy consumption and CO2 emission reduction.

EvaluationInstallation

Analysis System Pumping

Reporting and Acclaim Implementation Support

Energy cost: 0.1 (US$/kW)Power: 800 (kW)

Hours per year: 8750 (h)Annual Savings: US$ 7.500

Annual Savings by 1% Improvement in Efficiency

Power (kW)

200 400 600 800 12001000

2000

4000

6000

8000

10000

14000

12000

1400 1600

Energy cost: 0.43 (kg CO2/kW)Power: 800 (kW)

Hours per year: 8750 (h)annual Savings: US$ 30.000

Annual CO2 savings by 1% Improvement in Efficiency

Power (kW)

200 400 600 800 12001000

10000

20000

30000

40000

50000

1400 1600

Signature Projects

RE

LIA

BIL

ITY

RE

PO

WE

RIN

GE

FF

ICIE

NC

Y

REPOWERING RECLAIM WATER PUMPING SYSTEM OF TRANQUE EL MAURO

Client: Compañía Minera Los Pelambres (Antofagasta Minerals)

REDESIGN OF BOWL ASSEMBLY FOR VERTICAL TURBINE PUMPS

Client: Minera Escondida Ltda (BHP Billiton)

objectives:• Increase pumping capacity of 800 reclaimed water

(l/s) to 1,100 (l/s)• Reduce energy consumption• Standardize pumping stations• Reuse 1500 (hp) motors

solutions:• Change pumps to ones with more capacity and

better efficiency• Custom engineered design through CFD and FEA• Custom fabrication

objectives:• Avoid high levels of chlorides affect the

operation• Increase equipment life• Reuse existing motors • Pump replacement should not affect

continuity of operation.

solutions:• Material upgrade for impellers and casing to

Duplex 2205• Change wear ring materials to new

generation of polymer• Reutilization of 1300 (hp) motors. Results:

• Increased life of the pumps• Zero impact with the addition of new corrosive waters.

UPGRADE OF FRESH WATER PUMPING SYSTEM AT UJINA

Client: Compañía Minera Doña Inés de Collahuasi (Xstrata/Angloamerican/Mitsui)

objectives:• Take advantage of available power• Increase pump efficiency• Reduce electricity consumption

solutions:• Redesign first suction stage through CFD

and FEA• Material Upgrade• Fabrication of new Bowl Assembly

Results:• increased Capacity by 14%• Increased efficiency by 4%• Total power consumption of 1000 (hp) motor.

Results:• Increased capacity by 31%• Reduced energy consumption by 34%• Annual energy savings of $ 1M per year• Standardization of equipment with Neptuno Pumps® VTP

850X™• Reutilization of six (6) motors 1500 (hp).

powered by

powered by

Energy for the Future

90% of a pump´s Life Cycle Cost represents energy consumption and maintenance, relegating to the background initial purchase cost to a second plane.

Implementing the recommendations of Neptuno Energy™ you can achieve reductions in energy consumption of up to 30% and the following benefits

Maximizing Energy Efficiency through Innovation

• Reduce maintenance costs• increase productivity• Reduce production costs• Improve utilization of installed

capacity• Improve reliability• Improve process safety.

Source: Ministry of Energy, Government of Chile. www.minergia.clSource: Brook Hunt weighted averages. Except Chile, calculated with Brook Hunt and Codelco

Source: Hydraulic Institute, Europump & Office of Industrial Technologies Energy Efficiency and Renewable Energy, U.S. Department of Energy.

Centrifugal pumps are one of the most used machines in the world and one of the largest consumers of energy in industrial and commercial applications, reaching up to 25% of global energy demand by electric motors.

Neptuno Energy™ takes advantage of its extensive experience in design and manufacture of industrial centrifugal pumps for some of the largest projects in the world, to maximize the energy efficiency of pumping systems, both in operation and in design stage, in order to provide greater economic benefit from your operation or project.

The Neptuno Energy™ initiative is part of the National Strategy for Energy of the Ministry of Energy of Chile and its Action Plan for Energy Efficiency 2012-2020 (PAEE20), which seeks to reduce by 12% the energy demand projected for the year 2020, encouraging the adoption of energy efficiency measures through the promotion and implementation of energy management systems and incorporating efficient technologies and project assistance from industry and mining.

Solutions Focused on Life Cycle Cost

Read The National Energy Strategy 2012 - 2030 Ministry of Energy of the Government of Chile.

PeruMexicoChileBrazilArgentina World

0,13

0,11

0,09

0,07

0,05

0,032000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Cost of Electricity in Copper Mining(US$/kWh)

150.000

200.000

250.000

300.000

350.000

2000 2002 2004 2006 2008 2010 2012 2014 2016 2018 2020

PAEE20 BAU

12%

Energy Consumption Projection to 2020 PAEE20 (Tcal)

90%Operation andMaintenance

Neptuno Energy™, Neptuno Pumps®, VTPSelector™, Neptuno Barge Pump System™, Innovation that flows.™ and any and all Neptuno Fluid Technology Ltd. brand, product, service and feature names, logos and slogans are trademarks or registered trademarks or trademarks of Neptuno Fluid Technology Ltd. All other brand, product, service and feature names or trademarks are the property of their respective owners. This brochure is for general presentation only. All performances and/or applications shown are only for general information and may not be applied for every case. For actual pump performance and information please contact us. This brochure does not provide any warranty or guarantee of any kind. Directions for use and safety will be given separately with any purchase. We are constantly improving the performance of our equipment and therefore reserve the right to make alterations to the information without previous notice. This publication is the property of Neptuno Fluid Technology Ltd. Reproduction of all or any portion of this material is prohibited by law.

Copyright © Neptuno Fluid Technology Ltd. All Rights Reserved.

Commitment to EnvironmentNeptuno® 3R - Reuse, Reduce and Recycle: We are a production company that reuses and recycles metal raw materials and industrial wastes to produce new products with high added value engineering, contributing to maximum utilization of resources and keeping our environment clean. To learn more about our program visit: www.neptunoeng.com/en/recycle.html

CHILE & WORLDWIDE Headquarters

Avda. Circunvalación 64B - P. O. Box 358 - Iquique, Chile

Tel: (+56) (57) 2424685 - Fax: (+56) (57) 2425504

e-mail: info@neptunoenergy.com

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