Flowserve Corporation · NYSE:FLS
Flowserve — Flowserve Energy Summit 2005
21 slides from Flowserve's conference presentation, Oct 17, 2005
Slide 1: Energy Reduction Through Fluid Flow Analysis & Optimization
Energy Reduction Through Fluid Flow Analysis & Optimization Flowserve Energy Summit October 17th, 2005 Dallas, Texas Trey Walters, P.E. President and Chief Technology Officer
Slide 2: The Pump Footprint on National Energy Generation
The Pump Footprint on National Energy Generation According to US Department of Energy reports, pumps consume almost 20% of the electrical energy in the United States In some industrial facilities pumps consume up to 50% of the electrical energy 2 Flowserve Energy Summit, October 17, 2005
Slide 3: Pumps Are Components in Systems
Pumps Are Components in Systems All pumps function as part of a piping system Energy efficiency improvements focused solely on pumps is misguided Efficiency improvements must focus on the pump system 3 Flowserve Energy Summit, October 17, 2005
Slide 4: Recent Study at Leading Chemical Company
Recent Study at Leading Chemical Company The company evaluated internal practices and those at two of its major engineering contractors on recent projects The goal was to identify frequency of correctly sized pumps as part of a six-sigma project Frequency of Correctly Sized Pumps at Leading Chem
Slide 5: Methods Used in Industry to Select Pumps
Methods Used in Industry to Select Pumps Use “Same As Last Time” Hand Calculation Spreadsheet Pump System Computer Modeling 5 Flowserve Energy Summit, October 17, 2005
Slide 6: What is Pump System Computer Modeling?
What is Pump System Computer Modeling? Pump system computer modeling is the application of well-accepted principles of fluid mechanics to the calculation of flow through pump and piping systems Mathematical models are used to simulate the fluid flow 6 Flowserve Energy Summit, October 17, 2005
Slide 7: How Can Pump System Computer Modeling Help?
How Can Pump System Computer Modeling Help? For new system designs, pump system modeling helps engineers properly size their pumps and thereby reduce energy usage Pumps can be matched to systems Ensure pumps operate near their best efficiency point For existing systems, pump system modeling
Slide 8: Acceptance of Pump System Computer Modeling
Acceptance of Pump System Computer Modeling With 20% of our electrical energy used by pumps, one would think that pump system computer modeling would be widely accepted in industry – but it is not While CAD companies have a combined revenue in the billions of dollars, there are only a handful of
Slide 9: Opportunities in Existing Systems
Opportunities in Existing Systems There are many more existing systems than new systems built each year Because of their sheer numbers, the potential for energy reduction in existing systems is enormous However, in most cases engineers cannot change the piping to effect energy reduction This
Slide 10: Opportunities in New Systems
Opportunities in New Systems In new systems, the piping can be treated as a design variable and changed – usually for no additional cost The opportunities on new systems exceed those on existing systems by at least a factor of ten When the piping can be changed and optimized, the number of var
Slide 11: What is Pump System Optimization?
What is Pump System Optimization? On existing system engineers can “optimize” the system using techniques such as: Variable speed drives Better matching pump and system Pump replacement Impeller trim Operational changes On new systems, automated optimization search tools are now availa
Slide 12: Optimizing New Systems
Optimizing New Systems Conventional Pump System Modeling Tool Graphical Interface Input Output Yes No Converged Hydraulic Solver on Optimum? Optimization Engine 12 Flowserve Energy Summit, October 17, 2005
Slide 13: Optimization Example
Optimization Example Find systems with minimum initial cost and life cycle cost Note there are over 40 quadrillion design possibilities for this system 13 Flowserve Energy Summit, October 17, 2005
Slide 14: Finding the Pump "Sweet Spot"
Finding the Pump "Sweet Spot" Optimization can identify the pump “Sweet Spot” This is the pump operating point which, when combined with the optimized piping system, yields the absolute lowest cost Power (hp) 125 150 175 200 225 This is the 10 year 5.0 Optimal System Cost (Millions of Dollars) l
Slide 15: Industry Experience With Pump System Optimization
Industry Experience With Pump System Optimization Application on four systems at a leading chemical company showed: Initial cost reduction averaged 10% and up to 17% Life Cycle Cost reduction over 5 years averaged 50% and up to 70% Results presented at 2002 International Pump Users Symposium
Slide 16: PSIM: Pump System Improvement Modeling Tool
PSIM: Pump System Improvement Modeling Tool Purpose: A freely available, simplified educational tool for pump system hydraulic modeling to allow users to better understand the complexities of pump system behavior and calculate energy consumption of pumps 16 Flowserve Energy Summit, October 17, 2
Slide 17: PSIM Interface
PSIM Interface PSIM is based on a leading commercially available tool and is therefore itself of commercial quality PSIM offers a highly graphical, drag-and-drop interface to simplify usage 17 Flowserve Energy Summit, October 17, 2005
Slide 18: PSIM Capabilities
PSIM Capabilities PSIM can simulate a wide range of pump and system behavior and calculate hydraulic performance and energy usage 18 Flowserve Energy Summit, October 17, 2005
Slide 19: PSIM Output
PSIM Output PSIM can generate pump vs. system curves, an invaluable tool for understanding pump systems 19 Flowserve Energy Summit, October 17, 2005
Slide 20: PSIM's Role Within Pump Systems Matter
PSIM’s Role Within Pump Systems Matter PSIM is the first tool adopted by Pump Systems Matter for sponsorship PSIM will be used by instructors and students in Pump Systems Matter training curricula PSIM will increase industry awareness of the value of pump system modeling tools 20 Flowserve Ene
Slide 21: What Should Be Done?
What Should Be Done? Owner/Operators must be made to understand the energy impact of pumping systems They need to seriously consider life cycle cost principles when awarding contracts Pump systems engineers need to be educated on the energy impact of improperly sized pumps Industry needs to