PUMPS BSEE
original manufacturers’ recommendations and parts.
Reliability/security
Efficient, well maintained pumps are more likely to be reliable and unlikely to fail prematurely causing loss of production or services.
Valves
Valves are considered to waste energy within a pumping system, however if installed they should be checked for correct operation.
Pumps not in use
Stand by pump units or pumps with no demand should be switched off to save energy.
Is the pump working most of the time close to its best efficiency point?
Rotodynamic pumps operating away from BEP not only waste energy, but also reduce the life expectancy of the pump.
System alterations
When upgrading, changing or expanding a pumping system the demand may have changed and existing pumps may not be the most efficient solution.
Purchasing the correct pump set When purchasing a pump set, price should not be the deciding factor. If a pump is sized correctly the return on investment is shorter, likewise if a pump is oversized and is wasting energy going forward you will have this additional cost for the anticipated life of the pump set.
Has energy check been done on the existing system?
Under UK ESOS regulation all non SME organisations are mandated to carry out energy audits. Pumping Systems can offer substantial energy savings.
When specifying a new pump, ask for a high efficiency motor to be fitted. If you are replacing or rewinding a motor then evaluate
Questions that engineers, PMs and buyers should ask
QHas an alternative configuration been considered?
AIn some cases moving from an existing pump layout to an alternative can offer energy saving possibilities.
ABy looking for early signs of pump wear which can include increased noise, vibration or power consumption, major energy and maintenance savings can be achieved.
QIs the Pump Performance Monitored?
QHas ease of maintenance been allowed for?
AWhen designing or replacing pumps, ease of future maintenance requirements should be considered.
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www.bsee.co.uk
the cost of fitting a High Efficiency motor remembering to factor in the running savings which will pay back any increase in cost. Invest in carrying out an energy audit. Review your utility bills and understand the energy you are using.
Carry out an audit if: uYour energy bills are high uYou have continuously operating pumps uYou have many pumps in the system uYou have processes with varying flows uYou have throttled pumps uYou have pumps which are on bypass uYou have noisy valves or pipework uYou have critical systems which have been subject to breakdowns
uOften you can take simple action like just turning a pump off
The purpose of an energy audit is to reduce operating costs by reducing energy consumption and the government has estimated that most companies can reduce their energy consumption by 10% to 20%. Energy audits carried out by BPMA members have shown that savings from 30 to 50% are not unusual. When deciding whether or not to carry out an energy audit a good starting point is to assume that you will save at least 10% of your current energy consumption. By reviewing utility bills you can get an indication of the savings to be made and investment that you should be prepared to put into the auditing process.
In most industrial sites about two-thirds of the energy is consumed by electric motors. In its lifetime the cost of energy consumed by an electric motor may be 100 times its purchase cost. So the reduction of losses in the motor itself is very important and modern electric motor design can reduce the energy loss in the motor by up to 30%. Many pumps and motors are operated at full power constantly, irrespective of process needs, and in some sites this offers the potential of large cost reductions.
Given the amount of energy consumed by pumps through their normal operation, and the potential for energy efficiency gains within pump systems, the BPMA have developed a Certified Pump System Auditor Scheme (CPSA).
Through the CPSA, pump engineers are being trained to correctly assess the efficiency of pump systems, and to provide appropriate recommendations in order to improve the efficiency of those systems. The CPSA accreditation is achieved by successfully completing a four-day residential course, followed by the satisfactory completion of a pump system audit. Only then is ‘Certified Pump System Auditor’ status achieved. Within the full ESOS Guidance document, the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by "Lead Assessors" approved by the Environment Agency. Accordingly it is hoped that CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company-wide energy audits.
http://www.bpma-cpsa.co.uk BUILDING SERVICES & ENVIRONMENTAL ENGINEER APRIL 2016 35
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