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Why are energy usage and savings important parts of the cost of pump ownership?
Enhanced Operating Efficiency = Energy and Maintenance Savings!!
Pumps and Energy Consumption Facts:
According to the Hydraulic Institute:
- 5% of industrial energy goes to pumps
- Pumping systems account for nearly 20% of the world's electrical energy demand and range from 20% to 25% of the energy usage in certain industrial plant operations.
- Energy consumption is 90% of the total cost of owning a pump
- Maintenance and repair is a significant component of pumping system lifecycle costs, and an effective maintenance program can minimize these costs
[In making a choice of pumping systems to purchase,] many organizations only consider the initial purchase and installation cost of a pumping system. . . . As national and global markets continue to become more competitive, organizations must continually seek cost savings that will improve the profitability of their operations. Plant equipment operations are receiving particular attention as a source of cost savings, especially minimizing energy consumption and plant downtime. . . .
Some studies have shown that 30% to 50% of the energy consumed by pump systems could be saved through equipment or control system changes.
In addition to the economic reasons [for considering lifecycle costs], many organizations are becoming increasingly aware of the environmental impact of their businesses, and are considering energy efficiency one way to reduce emissions and preserve natural resources.
For a majority of facilities, the lifetime energy and/or maintenance costs [of pump equipment] will dominate the lifecycle costs, . . . especially if pumps run more than 2,000 hours per year. . . Depending upon the process, downtime costs can be [even] more significant than the energy or maintenance elements of the equation. Careful consideration should therefore be given to productivity losses due to downtime.
How does the TWT Deposit Control System help address the energy waste that occurs in a typical pump operation?
Just some examples:
- Scale deposits cause pump packing and seals to deteriorate. When packings deteriorate, air is allowed into the pump, causing uneven pressure on the impeller and harmonic bumping. This will essentially cause the pump to eventually rip itself apart, all the while running more and more inefficiently and causing increased energy consumption, right up to the time it ceases to function. Further, the oxidation caused by deteriorated packings will lead to corrosion in the pump as well, again degrading performance along the way. At one high usage commercial location, pump packings that had required replacement at least three times per year did not require any replacement for more than two years following the installation of a TWT Deposit Control System.
- The pumps used to pump the slurry into the water stream in wastewater treatment plants are subject to scale buildup to the extent that two pumps are usually needed - one to pump, while the other is being cleaned. A TWT Deposit Control System placed on the suction side of the pumps prevents scale deposition on these pumps. The savings on labor for just a few weeks pays for the deposit control system.
- In the petro-chemical industry, TWT deposit control prevents packing and volute failure due to abrasion and occlusion
- In the maritime industry, transfer lines to pumps choke with deposits from the precipitation of impurities in crude oil or other cargo. The TWT Deposit Control System holds these impurities in suspension so that they do not collect on the pumps, valves, and heads, inhibiting heat transfer and pump efficiency
- In commercial aquariums, to balance the pH, the facility will use calcium carbonate to raise the pH to the desired 7.0 to 7.5. The calcium carbonate is sacrificial. The calcium carbonate is fed into the tanks, and that in turn causes problems downstream with pumps and aerators. The TWT Deposit Control System controls scale formation from this calcium carbonate, protecting the pumps.
- Pump energy costs rise as the pumps and lines become
clogged. Triangular Wave Deposit Control Systems keep not only the
pumps, but the lines clean as well, keeping energy costs and
consumption down.
This situation is common in many, many industries; just a few among
them are:
- Petroleum
- Chemical
- Life Science
- Agri-science
- Meat Processing
- Pulp and Paper
- Water Utilities
- Wastewater
- Textiles
- many, many others
These examples represent but a very few of the ways that TWT Deposit Control Systems treat plumbing infrastructure and industrial processing equipment, of which pumps play just one part. They enhance operating efficiency, are environmentally responsible, and generate tangible cost savings, usually paying for themselves in a short time. Please contact your TWT authorized representative, distributor, or dealer to start benefiting immediately.