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WO2006039743A1 - Estimation des couts de propriete de systemes de pompage de fluides - Google Patents

Estimation des couts de propriete de systemes de pompage de fluides Download PDF

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Publication number
WO2006039743A1
WO2006039743A1 PCT/AU2005/001557 AU2005001557W WO2006039743A1 WO 2006039743 A1 WO2006039743 A1 WO 2006039743A1 AU 2005001557 W AU2005001557 W AU 2005001557W WO 2006039743 A1 WO2006039743 A1 WO 2006039743A1
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WO
WIPO (PCT)
Prior art keywords
rotating machine
speed
wear
efficiency
cost
Prior art date
Application number
PCT/AU2005/001557
Other languages
English (en)
Inventor
Heath Seuren
Original Assignee
Heath Seuren
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2004905894A external-priority patent/AU2004905894A0/en
Application filed by Heath Seuren filed Critical Heath Seuren
Priority to AU2005294108A priority Critical patent/AU2005294108A1/en
Publication of WO2006039743A1 publication Critical patent/WO2006039743A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00—Testing machines, pumps, or pumping installations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0088—Testing machines

Definitions

  • the present invention relates to a method and a processor program product for estimating the total cost of ownership of a fluid pumping system.
  • a method of estimating costs associated with a fluid pumping system including the steps of: obtaining one or more duty points for the fluid pumping system; specifying one or more variable-speed or fixed-speed rotating machines capable of meeting each duty point; for each variable-speed rotating machine at best efficiency, obtaining an operating speed at each duty point; for each fixed-speed rotating machine at best efficiency, obtaining an operating time at eacfy duty point; for each variable-speed rotating machine, calculating increased operating speeds at each duty point due to wear-induced efficiency losses relative to the operating speed at best efficiency; for each fixed-speed rotating machine, calculating increased operating times at each duty point due to wear-induced efficiency losses relative to the operating time at best efficiency; for each rotating machine at each duty point, calculating wear-induced energy costs corresponding to wear-induced efficiency losses based at least in part on the increased operating speeds or the increased operating times.
  • the method may include the further step of calculating a lifecycle cost for each rotating machine based at least in part on the corresponding wear-induced energy costs.
  • the step of calculating a lifecycle cost for each rotating machine may further be based at least in part on repair costs to restore the rotating machine to best efficiency.
  • the method may include the further step of determining a lifecycle cost for each rotating machine having the lowest sum of wear-induced energy costs and repair costs.
  • the two or more rotating machines may be specified to operate in series or parallel and sequentially or synchronously.
  • the fluid pumping system may be a liquid pumping system or a gas pumping system. If the fluid pumping system is a liquid pumping system, the one or more rotating machines may be one or more centrifugal pumps. If the fluid pumping system is a gas pumping system, the one or more rotating machines may be one or more centrifugal compressors or fans.
  • the present invention also provides a method of estimating costs associated with a fluid pumping system, the method including the steps of: obtaining a lifetime over which costs associated with the system are to be estimated; obtaining at least one duty point required of the system; obtaining an annual operating time required at the required duty point; obtaining an electricity rate; specifying at least one variable speed rotating machine capable of meeting the required duty point; obtaining original performance curve data for the specified rotating machine operating at a nominal speed; obtaining a repair cost to restore the efficiency of the rotating machine to the best efficiency point; obtaining a wear time for the rotating machine operating at the nominal speed to lose a predetermined efficiency relative to the best efficiency point; calculating a new speed required for the rotating machine to operate at the required duty point based at least in part on the original performance curve data at the nominal speed and affinity laws; simulating wear in the rotating machine by iteratively calculating worn speeds required for the rotating machine to operate at the required duty point based at least in part on the new speed and efficiency losses relative to the best efficiency point of the rotating machine; for each it
  • the method preferably includes specifying a plurality of rotating machines and, for each specified rotating machine, performing the iterative wear simulation calculations and displaying the lowest sum of the lifetime energy cost and the maintenance cost.
  • the plurality of rotating machines may be specified to operate in series or parallel.
  • the rotating machines in parallel or series may operate sequentially or synchronously.
  • the method preferably includes the further step of calculating lifetime greenhouse gas emissions for each specified rotating machine based at least on the corresponding lowest sum of the lifetime energy cost.
  • the calculated greenhouse gas emissions may be displayed for each specified rotating machine.
  • the method preferably includes obtaining a plurality of duty points required of the system and performing the iterative wear simulation calculations for each duty point.
  • the fluid pumping system is preferably a liquid pumping system, such as a water pumping system, and the rotating machine is preferably a centrifugal pump.
  • the fluid pumping system may be a gas pumping system, such as a heating, ventilation or air conditioning system, and the rotating machine may be a centrifugal compressor or fan.
  • the present invention also provides a processor program product disposed on a processor- readable medium, the processor program product having processor instructions for causing at least one processor to execute the above methods.
  • Figure 1 are head-capacity and efficiency performance curves for a first example of a typical centrifugal pump, "Pump A", at fixed speed;
  • Figure 2 are power and Net Positive Suction Head required (NPSHR) performance curve& for Pump A at fixed speed;
  • NPSHR Net Positive Suction Head required
  • Figure 3 are head-capacity and efficiency curves for Pump A at a new speed to meet a required duty point on a system head-capacity curve;
  • Figure 4 are head-capacity and efficiency curves for Pump A with no wear and 30% wear
  • Figure 5 is a graph of wear induced speed increases versus efficiency losses for Pump A
  • Figure 6 is a graph of wear induced shaft power increases versus efficiency losses for Pump A
  • Figure 7 is a graph of wear induced input power increases versus efficiency losses for Pump A
  • Figure 8 is a graph of Pump A power costs over 15 years versus efficiency losses
  • Figure 9 is a graph of Pump A increases in run times at 100% speed versus efficiency losses
  • Figure 10 is a graph of Pump A maintenance costs versus efficiency losses
  • Figure 11 is a graph of Pump A maintenance and power costs over 15 years versus efficiency losses
  • Figure 12 is a higher resolution graph of Pump A maintenance and power costs over 15 years versus efficiency losses
  • Figure 13 is a table of wear induced power and maintenance cost data for Pump A
  • Figure 14 are head-capacity and efficiency performance curves for an alternative second example of a typical centrifugal pump, "Pump B", at fixed speed;
  • Figure 15 is a table of wear induced power and maintenance cost data for Pump B;
  • Figure 16 are head-capacity and efficiency performance curves for an alternative third example of a typical centrifugal pump, "Pump C", at fixed speed;
  • Figure 17 is a table of wear induced power and maintenance cost data for Pump C
  • Figure 18 is a graph of the most economical total power, maintenance and capital costs for Pumps A, B and C;
  • Figure 19 is a graph of Greenhouse gas emissions for Pumps A, B and C; and Figures 20A-F is a sample report generated by a software embodiment of the present invention.
  • the present invention provides a method for estimating, over a lifetime of 15 years, the ownership costs associated with a typical adjustable speed centrifugal pump, "Pump A”, equipped with an AC Variable Frequency Drive (VFD) operating in a typical liquid pumping system, such as a water pumping system.
  • a typical adjustable speed centrifugal pump "Pump A”
  • VFD AC Variable Frequency Drive
  • the design flow rate of the liquid pumping system is specified as 264 litres/second for 3000 hours per year. First, the following data relating to Pump A is obtained.
  • Electricity rate $0.12 per kilowatt hour.
  • VFD efficiencies Input frequency 50Hz efficiency: 98%; Minimum efficiency at nominated 30Hz: 95%.
  • performance curves for Pump A are obtained from the pump manufacturer. Pump manufacturers perform pump tests to determine the operating characteristics of the pumps they manufacture. The pump performance characteristic curves are developed with the pump operating a fixed speed. If the speed of the pump is changed, the curves must be modified in accordance with the Affinity Laws. These laws are expressed in the following equations.
  • Figure 2 illustrates the head-capacity curve for Pump A at the new speed, combined with the system curve.
  • the duty point of Pump A and the system in which it is used is the intersection of the pump and system curves.
  • FIG 4 illustrates the wear induced performance degradation of Pump A as its efficiency decreases away from its BEP.
  • the performance of Pump A degrades due to wearing of the hydraulic components, the only way to maintain the required flow rate is to increase the pump speed via the VFD.
  • the head-capacity curves will be modified in accordance with the Affinity Laws.
  • Figure 5 illustrates the increase in speed required to restore the performance of Pump A to the required duty point when wear occurs. In each case, a speed increase is accompanied by an increase in the required shaft power of Pump A.
  • Figure 6 illustrates the increases in the shaft power of Pump A for wear induced efficiency losses.
  • Figure 7 illustrates that as the load on the motor increases and the speed of the VFD increases, so too does the input power.
  • the increases in speed necessary to operate Pump A at the required duty when wear occurs must be taken into account when estimating maintenance intervals. This can be done by recalculating the run times of Pump A at 100% frequency. For example, if Pump A has a nominated service time of 8000 hours to loose 10% of efficiency at the BEP, then if Pump A runs at 25Hz to achieve the required duty, the real run hours for maintenance purposes is only 4000 hours, so Pump A would only have lost 5% off its efficiency after the run clock displays 8000 hours. The real run hours increases as Pump A starts to wear because there is an increase in the speed to achieve the required duty, as illustrated in Figure 9.
  • Pump A has a nominated time of 8000 hours to lose 10% efficiency, so if this time is halved to 4000 hours Pump A would only have worn enough to lose 5% efficiency. So a 10% loss matches the maintenance interval specified by the manufacturer, a 9% loss equals the maintenance interval multiplied by 0.9, an 11% loss would therefore equal the maintenance interval multiplied by 1.1 and so on. Based on the nominated time to lose 10% efficiency, a pro-rata service interval for each 1% wear-induced efficiency loss may be calculated for Pump A to be 800 hours (ie 8000 hours multiplied by 0.1).
  • This calculated service interval for 1% efficiency losses may be used to calculate the maintenance costs for each redefined performance curve with simulated wear as follows: (((run times at 100% results for 0% loss + run times at 100% results for 1% loss) x the term of assessment) / the calculated service interval in hours) x the maintenance cost obtained above.
  • the calculated maintenance costs for Pump A at 0-30% wear induced performance losses relative to BEP are illustrated in Figure 10.
  • the next step is to determine the most economical balance between these two costs.
  • the most economical point is the efficiency loss iteration that has the lowest sum of the power costs and the maintenance costs for the required duty point over the 15 year lifetime. This information can be used to schedule maintenance of Pump A and indicates the best method of running Pump A with the most economical balance between power cost and maintenance cost.
  • Figure 11 illustrates the combined power and maintenance costs for Pump A at 0-30% wear induced performance losses relative to BEP.
  • the combined power and maintenance costs for Pump A are illustrated with greater resolution at 5-30% losses in Figure 12.
  • the lowest point on the curve corresponds to a 14% loss in efficiency and this point represents the most economical balance of maintenance and power consumption for Pump A.
  • the most economic time to schedule maintenance to restore Pump A to its BEP is when it completes 11200 operating hours at 100% speed. This figure may be converted to the corresponding actual or real run hours displayed on the pump's run meter to assist maintenance scheduling.
  • Pump B requires more frequent maintenance at intervals of 4000 hours, but at a lower maintenance cost of $2,000.
  • the capital cost of Pump B is $3,000.
  • Pump C is a highly efficient pump that has the longest maintenance interval at 12,000 hours, however it also has the highest maintenance cost at $3,500.
  • the capital cost of Pump C is $9,000.
  • Figure 18 illustrates the most economical total power, maintenance and capital costs for Pumps A, B and C. It can be seen that Pump C is the most cost efficient investment with a total cost over the 15 year lifetime of $108,374. Compared to Pump C, Pump B will cost an additional $31,166 in power costs over the 15 year lifetime.
  • Greenhouse gas emissions associated with the quantity used in tonnes of carbon dioxide equivalent (t CO2-e) may be calculated with the following equation.
  • Q is the electricity used expressed in kWh
  • EF is an Emission Factor in kg CO 2 -e/kWh that depends on location within an electricity network and represents CO 2 , CH 4 and N 2 O emissions from power stations.
  • an EF of 1.392 in kg CO 2 -e/kWh is used based on the Emission Factor for Victoria, Australia published at http ://www. greenhouse. Rov.au/workbook/pubs/workbook.pdf.
  • the above greenhouse gas emission equation may be modified for use with the present method as follows.
  • Emissions (t CO 2 -e) "Power cost with wear, this is the average yearly cost multiplied by the term of investment" / Power Cost x 1.392 / 1000
  • Figure 19 illustrates the estimated Greenhouse gas emissions for Pumps A, B and C based on the power data calculated using the above methodology.
  • the difference between using Pump B and C is 361 tonnes of emission (tCO 2 -e) over the 15 year lifecycle. It will be appreciated that the comparison of Greenhouse gas emissions may be commercially relevant when comparing pump emissions, as this represents tangible financial and greenhouse gas emission savings.
  • embodiments of the method of the present invention can be used to make better decisions on when maintenance should be provided. This may allow reductions in maintenance intervals, and hence less disruptions to the pumping service being provided by the pump system. Further, embodiments may also indicate that it may be cheaper to purchase a pump with a higher up-front capital cost if this solution has a longer lifecycle.
  • the method of the present invention is preferably implemented as computer software that can be run on an individual computer or on networked computers.
  • the software may include conventional functionality of exemplary pump selection software such as generating system curves, overlaying system curves and pump performance curves, calculating net positive suction head available (NPSHa), searching and listing all pumps from a range that can meet the specified duty point, and performing calculations for multiple pumps operated in series or parallel, either sequentially or synchronously.
  • exemplary pump selection software such as generating system curves, overlaying system curves and pump performance curves, calculating net positive suction head available (NPSHa), searching and listing all pumps from a range that can meet the specified duty point, and performing calculations for multiple pumps operated in series or parallel, either sequentially or synchronously.
  • the software may automatically screen or filter candidate pumps to ensure that the NPSHr by the pump is less than the NPSHa, and automatically determine if a calculated new speed needed to meet a required duty point overspeeds or exceeds the pump manufacturer's specified or rated operating speed range. This will safeguard against a pump being used outside of acceptable operating limits on the basis of information generated by the software.
  • the embodiments described above are intended only to serve as examples, and that many other embodiments are possible within the spirit and the scope of the present invention. For example, the above embodiment required a single duty point for the purpose of simplifying the description only. It will be appreciated that the method of the present invention may be implemented for fluid pumping systems having multiple duty points.
  • variable speed pumps evaluates variable speed pumps as a non-limiting example only.
  • the method of the present invention may be applied to fixed speed pumps where the operating speed remains constant, but run time increases as wear induced performance degradation increases.
  • the method may be adapted to fixed-speed (or direct online) pump operation by iteratively calculating the wear induced increases in run time and their corresponding increases in power consumption and cost.
  • a fixed-speed pump runs at one constant speed and variation in flow and head is a direct result of wear which causes a reduction in flow and head and therefore increases the pump's run time to transfer the nominated amount of flow.
  • An example application of the method of the present invention to a fixed-speed pump is provided below.
  • centrifugal pump in a liquid pumping system. It will be appreciated that method of the present invention may be implemented for centrifugal compressors or fans used in gas pumping systems, such as heating, ventilation or air conditioning systems.
  • Figures 20A-F is a sample report generated by a software embodiment of the invention for an example water pump station.
  • the sample report includes summaries of system data and pump data provided by a user.
  • the sample report also includes in Figure 2OC a summary of configuration options and calculated costs associated with the example pump station.
  • the summary in Figure 2OC indicates that the most efficient configuration is the direct online (or fixed-speed) option with a full lifecycle cost of $324,888 based on a service interval of 4000 hours.
  • the second most efficient configuration occurs in the Synchronous NPSHA configuration with a lifecycle cost of $376,631 based on a service interval of 7200 hours.
  • Figures 2OD and 2OE are summaries for the direct online option for different duty requirements at different efficiency losses.
  • Figure 2OF is a cost summary for the direct online option.
  • the direct online option summarised in Figures 20D-F illustrates the application of the method of the present invention to a fixed-speed pump.
  • the embodiment software of the present invention calculates wear-induced increases in run times for the direct online pump option to meet the specified duty requirements.
  • Figure 2OF summarises the increased run times for the direct online option for 0-30% efficiency losses due to wear, together with the corresponding increases in power costs.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Control Of Non-Positive-Displacement Pumps (AREA)

Abstract

L’invention concerne un procédé d’estimation des coûts associés à un système de pompage de fluides, le procédé comprenant les étapes consistant à : obtenir un ou plusieurs points de fonctionnement pour le système de pompage de fluides ; préciser une ou plusieurs machines rotatives à vitesse variable ou à vitesse fixe capables d’atteindre chaque point de fonctionnement ; pour chaque machine à vitesse variable au rendement optimal, obtenir une vitesse de fonctionnement à chaque point de fonctionnement ; pour chaque machine rotative à vitesse fixe au rendement optimal, obtenir une durée de fonctionnement à chaque point de fonctionnement ; pour chaque machine rotative à vitesse variable, calculer, à chaque point de fonctionnement, des vitesses de fonctionnement croissantes dues aux pertes de rendement par usure par rapport à la vitesse de fonctionnement au rendement optimal ; pour chaque machine rotative à vitesse fixe, calculer, à chaque point de fonctionnement, des durées de fonctionnement croissantes dues aux pertes de rendement par usure par rapport à la durée de fonctionnement au rendement optimal ; pour chaque machine rotative à chaque point de fonctionnement, calculer les coûts en énergie dus à l’usure correspondant aux pertes de rendement par usure en fonction, en partie au moins, des vitesses de fonctionnement croissantes ou des durées de fonctionnement croissantes.
PCT/AU2005/001557 2004-10-12 2005-10-10 Estimation des couts de propriete de systemes de pompage de fluides WO2006039743A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2005294108A AU2005294108A1 (en) 2004-10-12 2005-10-10 Estimating ownership costs of fluid pumping systems

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2004905894A AU2004905894A0 (en) 2004-10-12 Estimating ownership costs of fluid pumping systems
AU2004905894 2004-10-12

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WO2006039743A1 true WO2006039743A1 (fr) 2006-04-20

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104520585A (zh) * 2012-02-02 2015-04-15 Ghd私人有限公司 泵效确定系统和确定泵效的相关方法
EP2440784A4 (fr) * 2009-06-12 2017-11-22 Cidra Corporate Services, Inc. Procédé et appareil pour prédire des besoins de maintenance d'une pompe sur la base au moins en partie d'une analyse de performance de pompe
EP4325390A4 (fr) * 2021-05-27 2025-02-19 Siemens Ag Procédé de quantification d'état de produit et de prédiction de durée de vie restante, et appareil et système

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
"A Guide to LCC Analysis for Pumping Systems", PUMP LIFE CYCLE COSTS, January 2001 (2001-01-01), Retrieved from the Internet <URL:http://www.eere.energy.gov/industry/bestpractices/pdfs/pumplcc_1001.pdf> *
"Energy Savings in Industrial Water Pumping Systems", DEPARTMENT OF ENVIRONMENT, TRANSPORT AND THE REGIONS, GOOD PRACTICE GUIDE, vol. 249, September 1998 (1998-09-01), Retrieved from the Internet <URL:http://www.watfordcontrol.co.th/CaseStudy/EnergySaving/GPG24.PDF> *
HODGSON J. ET AL: "Optimizing Pumping Systems to Minimize First or Life-Cycle Cost", PROC. 19TH INTERNATIONAL PUMP USERS SYMPOSIUM, February 2002 (2002-02-01), Retrieved from the Internet <URL:http://www.aft.com/news/pdf/Optimizing_Pumping_Systems.pdf> *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2440784A4 (fr) * 2009-06-12 2017-11-22 Cidra Corporate Services, Inc. Procédé et appareil pour prédire des besoins de maintenance d'une pompe sur la base au moins en partie d'une analyse de performance de pompe
CN104520585A (zh) * 2012-02-02 2015-04-15 Ghd私人有限公司 泵效确定系统和确定泵效的相关方法
EP4325390A4 (fr) * 2021-05-27 2025-02-19 Siemens Ag Procédé de quantification d'état de produit et de prédiction de durée de vie restante, et appareil et système

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