Energy saving potential in reservoir pumping

Pumping systems account for up to 22 % of the energy consumed by electrical motors in European industry. Many studies have shown that there is also a lot of potential for energy savings in these systems with the improvement of devices, flow control or surrounding sys-tem. The best method for more energy efficient pumping has to be found for each system separately. This thesis studies how energy saving potential in reservoir pumping system is affected by surrounding variables, such as the static head variation and friction factor. The objective is to create generally applicable graphs to quickly compare methods for reducing pumping system’s energy costs. The gained results are several graphs showcasing how the chosen variables affect energy saving potential of the pumping system in one specific case. To judge if these graphs are generally applicable, more testing with different pumps and environments are required.

Motor Types Comparison Determining Efficiency in Pumping Systems

Pumping, fan and compressor systems consume most of the motor electricity power in both the industrial and services sectors. A variable speed drive brings relevant improvements in a fluid system leading to energy saving that further on can be translated into Mtons reduction of CO 2 emissions. Standards and regulations are being adopted for fluid handling systems to limit the less efficiency pumps out of the European market on the coming years and a greater potential in energy savings is dictated by the Energy Efficiency Index (EEI) requirements for the whole pumping system and integrated pumps. Electric motors also have an International Efficiency (IE) classification in order to introduce higher efficiency motors into the market. In this thesis, the applicability of mid-size common electric motor types to industrial pumping system took place comparing the motor efficiency characteristics with each other and by analyzing the effect of motor dimensioning on the pumping system and its impact in the energy consumption.

Investment recovery period in electric motor of higher efficiency in pumping for irrigation

Neste trabalho, ajustou-se um modelo matemático para quantificar o efeito do rendimento do motor elétrico sobre os custos de um sistema de bombeamento para irrigação na estrutura tarifária de energia elétrica convencional e horo-sazonal verde, bem como calcular o tempo de recuperação do capital investido no equipamento de maior rendimento. em seguida, o mesmo foi aplicado a um sistema de irrigação tipo pivô central em duas opções de rendimento do motor elétrico: 92,6% (linha padrão) e 94,3% (linha alto rendimento), sendo que o custo de aquisição do primeiro correspondeu a 70% do segundo. A potência do motor elétrico era de 100 cv. Os resultados mostraram que o modelo permitiu avaliar se um motor de alto rendimento era viável economicamente em relação ao motor-padrão em cada estrutura tarifária. Nas duas estruturas tarifárias, o motor de alto rendimento não foi viável. Na tarifa horo-sazonal verde, somente seria viável se seu rendimento fosse 4,46% superior ao do motor-padrão. Na tarifa convencional, somente seria viável se o ganho de rendimento superasse 2,71%.

IMPROVING FLOW DISTRIBUTION IN SMALL-SCALE WATER-SUPPLY SYSTEMS THROUGH THE USE OF FLOW-REDUCING DISCS AND METHODS FOR ANALYZING THE EFFECTIVENESS OF SOLAR POWERED PUMPING FOR A DRINKING WATER SUPPLY IN RURAL PANAMA

As continued global funding and coordination are allocated toward the improvement of access to safe sources of drinking water, alternative solutions may be necessary to expand implementation to remote communities. This report evaluates two technologies used in a small water distribution system in a mountainous region of Panama; solar powered pumping and flow-reducing discs. The two parts of the system function independently, but were both chosen for their ability to mitigate unique issues in the community. The design program NeatWork and flow-reducing discs were evaluated because they are tools taught to Peace Corps Volunteers in Panama. Even when ample water is available, mountainous terrains affect the pressure available throughout a water distribution system. Since the static head in the system only varies with the height of water in the tank, frictional losses from pipes and fittings must be exploited to balance out the inequalities caused by the uneven terrain. Reducing the maximum allowable flow to connections through the installation of flow-reducing discs can help to retain enough residual pressure in the main distribution lines to provide reliable service to all connections. NeatWork was calibrated to measured flow rates by changing the orifice coefficient (θ), resulting in a value of 0.68, which is 10-15% higher than typical values for manufactured flow-reducing discs. NeatWork was used to model various system configurations to determine if a single-sized flow-reducing disc could provide equitable flow rates throughout an entire system. There is a strong correlation between the optimum single-sized flow- reducing disc and the average elevation change throughout a water distribution system; the larger the elevation change across the system, the smaller the recommended uniform orifice size. Renewable energy can jump the infrastructure gap and provide basic services at a fraction of the cost and time required to install transmission lines. Methods for the assessment of solar powered pumping systems as a means for rural water supply are presented and assessed. It was determined that manufacturer provided product specifications can be used to appropriately design a solar pumping system, but care must be taken to ensure that sufficient water can be provided to the system despite variations in solar intensity.

Projecto de saneamento do sub-sistema da Ericeira: interceptor, emissários e sistemas elevatórios: fase III: emissário da Quinta das Pedras, Fonte Boa dos Nabos, interceptor do Outeirinho e desactivação da estação elevatória EE10

Relatório de Estágio para obtenção do grau de Mestre em Engenharia na Área de Especialização em Edificações

Sistema de Torre de Refrigeração

Mestrado em Engenharia Química - Ramo Optimização Energética na Indústria Química

Teollisuuden ja yhdyskuntien energiatehokkuusselvitykset, auditoinnit 2008–2010

Nykypäivänä energiansäästötavoitteet ovat haasteena yhä useammalle energiankuluttajalle. Tavoitteisiin päästäkseen yritykset ja kunnalliset energiankuluttajat kaipaavat usein apua kannattavien energiansäätökeinojen löytämiseksi. Erilaiset energiakatselmukset vastaavat tähän tarpeeseen ja ovat esimerkki tuloksellisesta energiansäästöstä. Lappeenrannan teknillinen yliopisto on tutkinut energiatehokkuutta pitkään erilaisissa projekteissa teollisuuden kanssa yhteistyössä. Osa LUT:n energiatehokkuustutkimusta ovat energia-auditoinnit yrityksille ja kunnille, joita LUT Energian projektin puitteissa alettiin kehittää vuoden 2008 syksyllä. Energia-auditointien fokuksena on pyritty pitämään pumppausprosessien energiatehokkuuden optimointia, sillä aihetta on tutkittu yliopistolla laajasti. Pumppausprosesseissa on todettu olevan merkittävä energiansäästöpotentiaali: pumppauksen kuluttamasta energiasta voi olla mahdollista säästää jopa 50 % erilaisilla laite- ja säästötaparatkaisuilla. Pumppausprosessien energia-auditointeja on tehty teollisuuden pumppauskohteisiin kuin myös kunnallisiin vesi-huoltolaitoksiin. Lisäksi energia-auditointien puitteissa on tutkittu energiansäästömahdollisuuksia rakennuksissa. Energiansäästökohteita etsitään sekä lämpö- että sähköenergian osalta. Energia-auditoinneissa pumppausten osalta energiansäästöpotentiaalia on todettu olevan etenkin suuren kokoluokan pumpuissa, joilla on pitkä vuosittainen käyttöaika. Myös pumppujen säätötavalla on suuri merkitys energiankulutukseen. Rakennusten osalta on pyritty selvittämään, kuinka energiankulutus jakautuu eri kulutusryhmien kesken. Säästökohteita on löydetty muun muassa rakennusten tiiviydestä, ilmanvaihdosta kuin valaistuksestakin. Monia auditointien asiakkaita on kiinnostanut etenkin led-teknologian hyödyntäminen yleisvalaistuksessa sekä muut keinot säästää valaistuksen energiankulutuksessa. Pyrkimyksenä on kehittää energia-auditointeja projektin aikana saavutettujen kokemusten avulla sekä myös liiketaloudellisessa mielessä opinnäytetutkielmien avulla. Menestyksekäs palveluliiketoiminta edellyttää määriteltyjä toimintatapoja, riittävän tarkkaa palvelujen rajausta ja koko energia-auditointiprosessin kehittämistä aina asiakassuhteen luomisesta sen jatko-hoitoon saakka.

Pumppauksen energiansäästökartoitus teollisuuslaitoksessa

Tässä diplomityössä on suoritettu pumppauksen energiansäästökartoitus Nordkalkin Lappeenrannan teollisuuslaitoksessa. Tavoitteena on kuvata teollisuuslaitoksen nykyistä pumppauksen tarvetta sekä etsiä energiansäästökohteita. Työn valmistelussa on käytetty apuna energiankulutustiedoista koostettuja energiataseita sekä yrityksen valmistelemia pumppulistoja. Energiansäästökohteita haettaessa tässä tarkastelutyössä huomio on kohdistettu pumppujen säätötapoihin ja mahdollisuuksiin vähentää virtaamaa tai pumppujärjestelmän kokonaisnostokorkeutta. Pumppujärjestelmän toiminnan määrittämisessä on käytetty hyväksi tilavuusvirran ja sähkötehon mittauksia sekä teoreettista tarkastelua kokonaisnostokorkeuden ja pumpun toimintapisteen selvittämiseksi. Kaikkien tarkasteltavien pumppujen osalta on hyödynnetty laitevalmistajien tarjoamia tietoja. Pumppujen vuotuisen toiminnan arviointi on suoritettu tuotantotietojen sekä käyttöhenkilökunnan haastatteluilla kerätyn tiedon perusteella. Työn lopussa on esitetty tarkastelukohteiksi valittujen pumppujärjestelmien energiatehokkuuden parantamiseksi suositeltavia toimenpiteitä. Suositeltavien toimenpiteiden sisältäessä investointeja on niille laskettu nykyarvot sekä takaisinmaksuajat. Energiansäästökohteiksi valittujen pumppujärjestelmien yhteenlaskettu vuosittainen energiansäästö on 352 MWh/a (24640 €/a) investointikustannusten (hankintakustannukset) ollessa 12000 €.

Monitoring of centrifugal pump operation by a frequency converter

Centrifugal pumps are widely used in industrial and municipal applications, and they are an important end-use application of electric energy. However, in many cases centrifugal pumps operate with a significantly lower energy efficiency than they actually could, which typically has an increasing effect on the pump energy consumption and the resulting energy costs. Typical reasons for this are the incorrect dimensioning of the pumping system components and inefficiency of the applied pump control method. Besides the increase in energy costs, an inefficient operation may increase the risk of a pump failure and thereby the maintenance costs. In the worst case, a pump failure may lead to a process shutdown accruing additional costs. Nowadays, centrifugal pumps are often controlled by adjusting their rotational speed, which affects the resulting flow rate and output pressure of the pumped fluid. Typically, the speed control is realised with a frequency converter that allows the control of the rotational speed of an induction motor. Since a frequency converter can estimate the motor rotational speed and shaft torque without external measurement sensors on the motor shaft, it also allows the development and use of sensorless methods for the estimation of the pump operation. Still today, the monitoring of pump operation is based on additional measurements and visual check-ups, which may not be applicable to determine the energy efficiency of the pump operation. This doctoral thesis concentrates on the methods that allow the use of a frequency converter as a monitoring and analysis device for a centrifugal pump. Firstly, the determination of energy-efficiency- and reliability-based limits for the recommendable operating region of a variable-speed-driven centrifugal pump is discussed with a case study for the laboratory pumping system. Then, three model-based estimation methods for the pump operating location are studied, and their accuracy is determined by laboratory tests. In addition, a novel method to detect the occurrence of cavitation or flow recirculation in a centrifugal pump by a frequency converter is introduced. Its sensitivity compared with known cavitation detection methods is evaluated, and its applicability is verified by laboratory measurements for three different pumps and by using two different frequency converters. The main focus of this thesis is on the radial flow end-suction centrifugal pumps, but the studied methods can also be feasible with mixed and axial flow centrifugal pumps, if allowed by their characteristics.

Savings Calculator for Centrifugal Pumps

Centrifugal pumps are one of the major energy consuming end-devices in developed coun-tries both in industrial and services sectors. According to recent studies, even 30 % of the energy used in pumping systems could be saved by more careful choosing of devices and system design. One of the most efficient and affordable ways to decrease the energy con-sumption of the pumping system is to substitute traditionally used flow control methods, like valve control, with modern variable speed drive (VSD) control. In this thesis, Microsoft Excel based program, Savings Calculator for Centrifugal Pumps (SCCP), is designed. SCCP calculates the achievable energy and financial savings when throttle control is substituted by VSD control in the pumping system. Compared to the sim-ilar existing programs, the goal is to make SCCP calculations more accurate and require less input information. Also some useful additional features are added to the designed program to make it more user friendly. The reliability of the calculations of designed program seem to vary depending on case. The results are corresponding accurately to the laboratory measurements, but there occurs high deviations in some cases, when the results are compared to the pump information specified by manufacturer. On the basis of verification in this thesis, SCCP seems to be at least as accurate as similar existing programs and it can be used as help in investment decision whether to have VSD or not.

Comparison of Model-Based Flow Rate Estimation Methods in Frequency-Converter-Driven Pumps and Fans

Fluid handling systems such as pump and fan systems are found to have a significant potential for energy efficiency improvements. To deliver the energy saving potential, there is a need for easily implementable methods to monitor the system output. This is because information is needed to identify inefficient operation of the fluid handling system and to control the output of the pumping system according to process needs. Model-based pump or fan monitoring methods implemented in variable speed drives have proven to be able to give information on the system output without additional metering; however, the current model-based methods may not be usable or sufficiently accurate in the whole operation range of the fluid handling device. To apply model-based system monitoring in a wider selection of systems and to improve the accuracy of the monitoring, this paper proposes a new method for pump and fan output monitoring with variable-speed drives. The method uses a combination of already known operating point estimation methods. Laboratory measurements are used to verify the benefits and applicability of the improved estimation method, and the new method is compared with five previously introduced model-based estimation methods. According to the laboratory measurements, the new estimation method is the most accurate and reliable of the model-based estimation methods.

Modelagem e simulação de um sistema de bombeio mecânico em poços direcionais utilizando parâmetros concentrados

This work aims presenting the development of a model and computer simulation of a sucker rod pumping system. This system take into account the well geometry, the flow through the tubing, the dynamic behavior of the rod string and the use of a induction motor model. The rod string were modeled using concentrated parameters, allowing the use of ordinary differential equations systems to simulate it s behavior

Detecção e classificação de modos de operação do bombeio mecânico via cartas dinamométricas

The precision and the fast identification of abnormalities of bottom hole are essential to prevent damage and increase production in the oil industry. This work presents a study about a new automatic approach to the detection and the classification of operation mode in the Sucker-rod Pumping through dynamometric cards of bottom hole. The main idea is the recognition of the well production status through the image processing of the bottom s hole dynamometric card (Boundary Descriptors) and statistics and similarity mathematics tools, like Fourier Descriptor, Principal Components Analysis (PCA) and Euclidean Distance. In order to validate the proposal, the Sucker-Rod Pumping system real data are used

Simulação computacional da interação fluido-estrutura em bombas de cavidades progressivas

The pumping through progressing cavities system has been more and more employed in the petroleum industry. This occurs because of its capacity of elevation of highly viscous oils or fluids with great concentration of sand or other solid particles. A Progressing Cavity Pump (PCP) consists, basically, of a rotor - a metallic device similar to an eccentric screw, and a stator - a steel tube internally covered by a double helix, which may be rigid or deformable/elastomeric. In general, it is submitted to a combination of well pressure with the pressure generated by the pumping process itself. In elastomeric PCPs, this combined effort compresses the stator and generates, or enlarges, the clearance existing between the rotor and the stator, thus reducing the closing effect between their cavities. Such opening of the sealing region produces what is known as fluid slip or slippage, reducing the efficiency of the PCP pumping system. Therefore, this research aims to develop a transient three-dimensional computational model that, based on single-lobe PCP kinematics, is able to simulate the fluid-structure interaction that occurs in the interior of metallic and elastomeric PCPs. The main goal is to evaluate the dynamic characteristics of PCP s efficiency based on detailed and instantaneous information of velocity, pressure and deformation fields in their interior. To reach these goals (development and use of the model), it was also necessary the development of a methodology for generation of dynamic, mobile and deformable, computational meshes representing fluid and structural regions of a PCP. This additional intermediary step has been characterized as the biggest challenge for the elaboration and running of the computational model due to the complex kinematic and critical geometry of this type of pump (different helix angles between rotor and stator as well as large length scale aspect ratios). The processes of dynamic generation of meshes and of simultaneous evaluation of the deformations suffered by the elastomer are fulfilled through subroutines written in Fortan 90 language that dynamically interact with the CFX/ANSYS fluid dynamic software. Since a structural elastic linear model is employed to evaluate elastomer deformations, it is not necessary to use any CAE package for structural analysis. However, an initial proposal for dynamic simulation using hyperelastic models through ANSYS software is also presented in this research. Validation of the results produced with the present methodology (mesh generation, flow simulation in metallic PCPs and simulation of fluid-structure interaction in elastomeric PCPs) is obtained through comparison with experimental results reported by the literature. It is expected that the development and application of such a computational model may provide better details of the dynamics of the flow within metallic and elastomeric PCPs, so that better control systems may be implemented in the artificial elevation area by PCP

Sistema de destilação solar com pré-aquecimento em concentrador cilindro parabólico

Due to the increasing need to promote the use of resources that support the environment and the clean industry, the science has developed in the area of natural resource use as well as enhanced use of the renewable energy sources. Considering also the great need for clean water and wide availability of salt or brackish water, added to the great solar energy potential in northeastern of the Brazil, it was developed a solar distiller whose main difference is its system of pre-solar heating also. From experimental adjustments, the system was developed by the use of a cylindrical solar concentrator coupled to a conventional distiller. The system is designed such that attempt to facilitate the process termination trap to ensure constant movement of the fluid mass and thus enable higher temperatures to the system and thus fetch a higher amount of distillate collected. In a stage of the experiment were used a forced circulation to try to further increase the amount of energy exchange system. To develop the study were set up four settings for comparison in which one was only distiller simple as basic parameter, the second proposed configuration were with the coupling of the concentration triggered manually every 30 minutes to monitor the sun, the third configuration occurred with automatic triggering of a timer, and the fourth configuration was also used a pumping system that tried to improve the circulation of the fluid. With the comparative analysis of the results showed a gain in the amount of distillate system, especially in the forced model