Pumping System Performance Draft Presentation 02 May 2012 Darren Hewerdine – Veolia Water Central, in collaboration with Tata Consultancy Services : Engineering Division Pump Centre Conference and Exhibition 2012 PUMPS & SYSTEMS 2nd May 2012 International Centre, Telford.
Why are we here today? High Level Drivers. Concept, Inspiration. Solution and processes. Success? For our customers
High Level Drivers: To be a high performing sustainable water business. Future energy cost is a risk. Minimising carbon is important. Reducing energy usage and operational costs are key drivers.
Concept, Inspiration : Understanding the performance of systems. Many companies have extensive pump performance test information. System efficiency information is scarce. Late 2009 we implemented a new standard for calculating ‘live’ efficiencies and energy cost information, in the site PLC. • Implementation would be piecemeal, through AMP 5. • But the information would be ‘live’ on telemetry. We met TCS Engineering, late 2010. We brainstormed how we can work together. We soon determined that the information we wanted is readily available on our oracle database. Submetering & performance monitoring is a key topic of the Water UK Energy Group for the last year. A sub group formed late 2011.
Solutions and Processes : Data. Wire to Water Efficiency % (15min and Daily). Specific Energy kWh/Ml (15min and Daily). Specific Pumping Costs £/Ml (15min and Daily). Pumping System Cost £ (15 min and Daily). Pumping System Energy kWh (15 min and Daily). Integrated Flow Ml (15 min and Daily) Pumping System kWh v’s Ml (Optimiser configuration) Network System mhead v’s l/s (System Characteristic) Manufacturer’s Pump Curve mhead, % eff, power v’s l/s. Pump Speed, Hz, %, rpm, relating site performance to reference speed. APH and component lifts June Return figure, plus granularity.
Proving Benefits, supports the business case. Proving benefits is an important driver. Many existing methods were available, but may require ; • extrapolation from limited test data. • Reliance upon engineering calculations. • Use of ‘average’ tariffs. Integrated daily Flow, Cost and Energy information is agreed by stakeholders as first hand evidence of savings.
Proving Benefits: Submetering and Tariffs. New kW submeters installation programme. Accuracy of tariffs critical for credibility. Must include marginal costs; DUOS & CRC.
Proving Benefits: Tariffs are complex. Tariffs require assigning to sites. Tariff data updated twice per year onto telemetry system as weekly diurnal profiles.
Information leads to Actions. Alarms on variance; for who? Action timeframe? Alarms on variance: For ACTION / investigation by the energy team. Wire to Water Efficiency, Red, Amber, Green (Target), set for each pumpset for approximate payback on intervention. Alarms on Variance from kWh v’s Ml curves (pump performance + network system curve).
Data presentation! Reports; All data in graphical, table and downloadable format. Prioritised list of pumpsets for action; opex penalty for performance below target efficiency. Report export to PDF, Excel,
Pump Performance! Manufacturer’s Pump Curves digitised. Relating site performance to reference speed.
Average Pumping Head! Manufacturer’s Pump Curve digitised. Pump Speed, Hz, %, rpm, relating site performance to reference speed. APH and component lifts m, plus June Return and site APH.
A few details and challenges leading to Success. User log on and privileges. Shared database resource. Data backup. GMT / BST configuration. Telemetry outstation replacement programme. Update of APH calculation. Pressure gauge calibration. New pressure gauge installation. Fully configurable for new sites and pumps. Software support. SAT tests and SIR’s. Internal resources.
Success. System implementation went smoothly, satisfying the needs of the business, with a co-operative relationship throughout. Once the outline scope was agreed, the finer details were discussed and agreed during development. Onsite Engineering and IT expert / liaison. IT and engineering support overseas. Nearly there; Final commissioning and alarm configuration. Using TCS Engineering to resource initial check and investigation. Business as usual.
Why were we here today? High Level Drivers. Concept, Inspiration. Solution and processes. Success to date. Nearly business as usual… For our customers
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