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Improving efficiency in a water distribution system

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Improving efficiency isn't just a matter of picking a pump with a high hydraulic efficiency number and plugging in a VFD. Much more goes into real efficiency in all its forms.

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Improving efficiency in a water distribution system

  1. 1. EFFICIENT PUMP SYSTEMS Brian Gongol DJ Gongol & Associates, Inc. September 15, 2015 Iowa AWWA Fall Short Course DMACC / Ankeny, Iowa
  2. 2. Efficiency: Who really cares? Not the person who drives this to the grocery store
  3. 3. Of course we SHOULD care
  4. 4. Resources are finite Only the state capitol gets a gold dome
  5. 5. Water systems are big users of energy
  6. 6. Rate dollars are after-tax dollars
  7. 7. Money saved is a leveraged bonus
  8. 8. Substitution effect
  9. 9. We can say it's all for the environment
  10. 10. But it's really about public health
  11. 11. Money wasted displaces other public goods
  12. 12. The problem is, we really DON'T care "How can you say that?" Well, it's simple...
  13. 13. Revealed preferences
  14. 14. What's your household public works budget? (...if you even bother to have one)
  15. 15. How does it compare to your travel budget?
  16. 16. Why we don't really care
  17. 17. Low electrical rates
  18. 18. Cheap borrowing
  19. 19. Low regard for worker time
  20. 20. Public disregard for the state of public works
  21. 21. The day of reckoning cometh
  22. 22. Why we will be forced to care
  23. 23. Rising energy costs
  24. 24. Carbon emission regs and electricity costs
  25. 25. European electricity costs vs. our costs
  26. 26. Anticipated shortages of fresh water
  27. 27. Rising treatment costs pressuring budgets
  28. 28. Declining or flat populations
  29. 29. Aging infrastructure
  30. 30. Higher future interest rates
  31. 31. Shrinking water workforce
  32. 32. Compounding costs of deferred maintenance
  33. 33. Costs of catastrophic failure
  34. 34. Not everything that counts can be measured The love of a child, puppy kisses, the smell of flowers after a rain
  35. 35. But counting is a good place to start
  36. 36. What we might measure to gauge efficiency
  37. 37. Energy consumption
  38. 38. Losses (especially unmetered losses)
  39. 39. Labor costs (including opportunity costs)
  40. 40. Total cost of ownership (TCO)
  41. 41. Everything can be converted to dollars
  42. 42. Even hidden savings deserve a dollar value
  43. 43. Dollars are common currency to every industry
  44. 44. Boards don't want to know your specialty
  45. 45. Part 1: Pump efficiency
  46. 46. Clearances
  47. 47. Pump specific speed A dimensionless value that indicates the relative efficiency of a pump impeller design
  48. 48. Vane adjustments (numbers, angles)
  49. 49. Smooth coatings
  50. 50. Straight pipe entering the suction
  51. 51. Suction diffusers (straightening flow)
  52. 52. Part 2: Motor efficiency
  53. 53. 110/220/460 volt differences
  54. 54. VFDs
  55. 55. Soft starters
  56. 56. Two-speed motors
  57. 57. Across-the-line starters
  58. 58. High-efficiency/premium-efficiency
  59. 59. VFD misapplication: Static head prevails
  60. 60. Fill towers at full speed
  61. 61. Hydrostatic tanks
  62. 62. VFD misapplication: Missing the (BE) point
  63. 63. Transmission losses
  64. 64. Part 3: Valves
  65. 65. Surge control
  66. 66. Save on pipe damage
  67. 67. Air control
  68. 68. Maximize pipe diameter
  69. 69. Throttling
  70. 70. Emergency cut-in valves for an emergency
  71. 71. Part 4: Pipework
  72. 72. Bends
  73. 73. Pipe smoothness
  74. 74. Corrosion and losses
  75. 75. Part 5: Labor and (TCO) efficiency
  76. 76. Preventive/predictive maintenance (direct benefits)
  77. 77. Preventive maintenance and knowledge
  78. 78. Labor training and continuous improvement
  79. 79. Quantify downtime
  80. 80. Part 7: Auditing your system
  81. 81. Total water supplied (own plus imports)
  82. 82. Authorized consumption (billed and unbilled)
  83. 83. Losses (apparent and real)
  84. 84. Apparent losses  Unauthorized consumption  Metering error  Data errors
  85. 85. Real losses  Distribution losses  Tank leakage and overflow  Service connection leakage
  86. 86. To recap  We ignore efficiency  We won't forever  Pump efficiency matters  It's not the only thing by far  Total cost of ownership matters most
  87. 87. Questions?  Thank you for coming!
  88. 88. Thank you for your attention!  Contact us anytime with questions  Brian Gongol  DJ Gongol & Associates  515-223-4144  info@djgongol.com
  89. 89. References:  US electric prices:  http://www.eia.gov/electricity/data/browser/#/topic/7? agg=0,1&geo=vvvvvvvvvvvvo&endsec=vg&linechart=ELEC.PRICE.US-ALL.M~~~ELEC.PRICE.WNC- ALL.M&columnchart=ELEC.PRICE.US-ALL.M&map=ELEC.PRICE.US- ALL.M&freq=M&start=200101&end=201402&ctype=linechart&ltype=pin&rtype=s&maptype=0&rse =0&pin=  Germany, EU electric prices:  http://epp.eurostat.ec.europa.eu/statistics_explained/index.php/Electricity_and_natural_gas_price _statistics  Fed funds rate:  http://research.stlouisfed.org/fred2/series/FEDFUNDS  Suction vane drawing and sample pump curve courtesy Patterson Pump Co.  Valve photographs courtesy GA Industries  Some material in Part 7 adapted from the AWWA water loss auditing tool:  http://www.awwa.org/resources-tools/water-knowledge/water-loss-control.aspx  Special thanks to Shane Kinsey (City of Johnston, Iowa) and Rose Ann DiGiovanni (Patterson Pump Co.) for observations that extended the scope of this presentation  All other photos are original work by and copyright reserved to Brian Gongol

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