Pump Efficiency Testing By Thermodynamic Method

milind.junagade@securemeters.com Secure Meters Ltd.

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Pump & System Curves

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Operation away from B.E.P.

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Typical In-Service Test Result

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Conventional Technique

Pgr = Input (kW)

P = Shaft (kW) = Pgrhm

PH = Output = gQH = Pgrhmhp

...

hp = gQH Pgrhm

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The Thermodynamic Technique 1

hp Efficiency = Work Done

Effort

or

Work Out Work In

Work In = Work Out + Losses

hp = hp =

Wo Wo + Losses 1 1+ Losses / Wo

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The Thermodynamic Technique 2

Losses

= Cp.d.Q.dT

Work Out = g.d.Q.H Losses Wo Cp.dT = g.H

1 Efficiency= 1 + Cp.dT hp g.H

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Thermodynamic Flowmeter 1

hp =
. .

gQH P hm gr

P h mh gr p Q= gH

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Thermodynamic Flowmeter 2
P hm gr
gH . hp

Q =

Q =

P hm gr
gH P hm gr

1 1 + Cp.dT g.H

Q =

gH + Cp.dT

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Flow Measurement

EFFICIENCY(%) POWER(kW) HEAD(m) FLOW(l/s)

Yatesmeter Conventional

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Thermodynamic Uncertainty vs. Head

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Thermodynamic vs. Conventional Measurement

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Validation
The thermodynamic technique has undergone rigorous testing by the following:
UK
Water Research Centre National Engineering Laboratories Central Electricity Generating Board Exeter University

Germany Pump Manufacturers:

Damstadt University Flowserve Weir KSB Sulzer Ebara SPP

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Case - Sulzer
Pump MF: Sulzer Type: HPcp 200-335/8s Duty Flow: 610 m3/hr Duty Head: 1867 m Speed: 3465 rpm

Motor MF: ASEA Power: 8000 kW Speed: 3550 rpm

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Case - Dryscale
Pump MF: Dryscale Type: 72/72 Centrifugal Horizontal, Single Stage Duty Flow: 98,625 gpm Duty Head: 65ft. Speed: 295 rpm Motor MF: Type: Power: Speed: Voltage: Current: Phases: Frame: Contract: Year: Brush Induction 2420 HP 991 rpm 11,000 V 116A 3 @ 50Hz, Star PQ 50, 112 6 01/51194 1969

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Case - Weirs
Pump MF: Weirs Type: SDC 250/250 Split-Case Horizontal Motor MF: Type: Power: Speed: Voltage: Current: PF: Weight: Year MF: Stromberg HLUT 315 BK2 315 kW 1482 rpm 415 V 536 A 0.85 1700 kg 1987

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Case - Korean Government Test Rig

Flowrate l/s Yatesmeter SBC

297 297 167 169 224 225 257 257

Notes:
SBC Test Rig is a new $1m facility The magnetic flowmeter is in an ideal position
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Case Korean Government Test Rig

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Case -Melbourne Water.

Melbourne Water is one of the largest Users of Energy in Victoria ( Over $ 14 million) Cost Saving target up to $ 218,000 by Pump Efficiency and Pumping Station operation improvement Number of Pumps to be tested 23 nos.to startwith

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Melbourne Water Hired AEMS .

Test and Report performance of Each pump Undertake a calibration check on the flow meter on each pump Undertake an analysis of the performance of each station using the data available from the existing SCADA system and produce an optimised pumping schedule for each station

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Melbourne Water.
Determine pump condition and opportunities for energy reduction by pump refurbishment Produce a comprehensive report that includes plant condition, efficiency, mode of plant operation and opportunities for energy reduction through revised operating schedule Train Melbourne Water staff in system testing, analysis and system optimisation

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The Yatesmeter

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Portable Yatesmeter:

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Fixed Yatesmeter:

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System Diagram

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Horizontal Pumps

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Vertical Can Pumps

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Vertical Wet-Pit Pumps

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Submersible Wet Pit

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Contaminated Pumps

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Specifications
Accuracy Tapping Fluid Temperature Differential Temperature kW Range Head Range ISO 5198 1/2" BSP/NPT 0 -300C 0.5 mK 0.75kW-72MW 3m 4000m

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Pump Testing Standards

Standard
ISO 5198 Precision Class ISO 9906 Grade 1 ISO 9906 Grade 2 ISO 9906 Grade 2 Annex A

Accuracy
2.5 % 3.0 % 5.0 % 7.0 % Yates Meter (1%) Manufacturer Test by request Standard Manufacturer Test Mass Production Pumps > 10 KW

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Our Services
We offer innovative thermodynamic technology with proven reliability for unmatched performance in your pumping applications. Our pump performance monitoring equipment provides a comprehensive hydraulic profile of your pumps and systems. Equipment can be supplied for both temporary and permanent installation. Pump Testing Our service combines the advantages of Yatesmeter technology, which allows us to bring the equivalent of a test rig to your pump. A comprehensive report is produced which recommends the most cost effective course of action to ensure the optimum performance of all pump systems. Multi-pump monitoring With the use of our multi-pump monitoring techniques we can provide equipment to monitor whole pumping stations. The logged data can provide an insight into the way the pumping plant is operated and allow us to schedule the most cost effective running combination. System Analysis An analysis is made of how individual pumps work in relation to their systems. Recommendations are then made as to how pumping may be optimized to increase energy efficiency and reduce cost.

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Our Services
Training We provides a comprehensive training package on Energy related topics in pumping as well as instruction on the use of their pump performance monitoring equipment. Flowmeter Audits Flowmeter Audits gauge the accuracy and reliability of primary and secondary flowmeter instrumentation, to visible standards. Precise flow measurement enhances leakage detection and allows for accurate calculation of performance indices. Energy Analysis We offer an in-depth analysis of energy consumption within your company to identify inefficiencies and recommend strategies for energy savings. Management of Refurbishment After identifying the need to refurbish your pump leave us to organize your refurbishment. We provide a comprehensive service, which includes tendering, visual inspection and spares recommendation.

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Pump Efficiency Measurement

Checking in-circuit performance System curve generation for the pumping station Assess best operation point Flow meter calibration

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Multi-Pump Monitoring
Minimise energy use as system conditions change Wide range of reports for each of the pumps Optimum pumping schedule for the station Reduction in station energy consumption and cost by 15 20 %

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CASE STUDY:
South West Water - Littlehempston WTW

Yatesmeters achieve savings of 11.4%

Pumping Plant: 1*450kW FS 1*290kW FS 3*275kW VS 1*400kW VS 300,000 69% 77% 33,000 2.7 years

Annual Running Costs: Station Efficiency (BEFORE): Station Efficiency (AFTER): Annual Energy Savings: Payback Period:

Before Implementation of Pumping Schedule

Overall Pumping Efficiency
90

After Implementation of Pumping Schedule

Overall Pumping Efficiency
90

For further Information contact:

Advanced Energy Monitoring Systems Ltd. The Energy Centre Finnimore Industrial Estate Ottery St. Mary Devon EX11 1NR Telephon e: Fax: Email: Website: +44 (0) 1404 812294 +44 (0) 1404 812603 info@yatesmeter.co. uk www.yatesmeter.co. uk

80

80

70 Combined Pump Efficiency (%) Combined Pump Efficiency (%)

70

60

60

50

50

40

40

30

30

20

20

10

Average Efficiency = 069%

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 Volume Flow Rate (Ml/d) Station Data Savings Threshold

10

0 0.0

Average Efficiency = 77%

5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 Volume Flow Rate (Ml/d) Station Data Schedule Savings Threshold

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CASE STUDY:
South West Water Restormel WTW

Yatesmeters achieve savings of 18.2%

Pumping Plant: Station Capacity: 1*225kW FS 2*250kW VS 1*190kW FS 160Ml/d @ 33.5m 130,000 66.9% 81.8% 23,400 45,000 1.9 years

Annual Running Costs: Station Efficiency (BEFORE): Station Efficiency (AFTER): Annual Energy Savings: Implementation: Payback Period:

Before Implementation of Pumping Schedule

After Implementation of Pumping Schedule

For further Information contact:

Advanced Energy Monitoring Systems Ltd. The Energy Centre Finnimore Industrial Estate Ottery St. Mary Devon EX11 1NR Telephon e: Fax: Email: Website: +44 (0) 1404 812294 +44 (0) 1404 812603 info@yatesmeter.co. uk www.yatesmeter.co. uk

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Pump Deterioration Over Time

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Refurbishment

Advice on the suitability of refurbishers facilities Inspection of pump Recommendations on work required and spares Re-testing of pump to validate post-refurbishment performance

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Typical % age of actions taken on pump units tested

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Typical Pump Refurbishment Expenditure

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Secure Meters Test Rig

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Secure Meters Test Rig

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?
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Thanks !
Contact Details: milind.junagade@securemeters.com +91-9930360842

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