FOREST PRODUCTS

May 2002

BestPractices
Project Case Study

OFFICE OF INDUSTRIAL TECHNOLOGIES ENERGY EFFICIENCY AND RENEWABLE ENERGY, U.S. DEPARTMENT OF ENERGY

B ENEFITS

Saves 700,000 kilowatt-hours (kWh) annually Reduces maintenance costs by $10,000 per year Improves equipment life Increases efficiency

Pump System Optimization Saves Energy and Improves Productivity at Daishowa America Paper Mill
Summary
In 2000, Daishowa America implemented an improvement project on the effluent pumping system at its paper mill in Port Angeles, Washington. Because of chronic maintenance issues and rising energy costs, personnel at the Port Angeles mill decided to review the pumping system for optimization opportunities. The review led mill personnel to implement a system-level project that decreased the pumping systems energy consumption. The project involved the installation of mechanical Adjustable Speed Drives (ASDs) on two pumps in the mills pumping system. The project allowed the system to operate more effectively, and resulted in annual energy savings of $32,000 and 700,000 kilowatt-hours (kWh). The project also eliminated many problems that led to excessive maintenance costs and resulted in annual maintenance savings of $10,000. Because the project received partial funding from the Northwest Energy Efficiency Alliance (NEEA), the total mill project cost was $60,000. With a total annual savings of $42,000, the simple payback was slightly more than 15 months.

A PPLICATIONS
Effluent pump systems are widespread in the paper industry and can consume a significant portion of the electricity used in paper mills. In cases where multiple pumps are used, a proper control strategy can improve efficiency and save energy by optimally matching the available pumping capacity to the system requirements.

DAISHOWA AMERICAS PORT ANGELES PAPER MILL

Company/Plant Background
Daishowa America is the U.S. subsidiary of Daishowa Paper Manufacturing Company, Ltd., of Japan. The Port Angeles Mill in Port Angeles, Washington, is an integrated pulp and paper mill. The mill uses wood and recycled pulp to produce approximately 160,000 tons of directory papers annually. The company primarily sells the paper to publishers of telephone directories throughout the United States. The effluent pumping system at the Port Angeles mill is vital to the mills production process because it treats the wastewater created by the paper manufacturing process. The system has three 100-hp (horsepower) centrifugal pumps. Prior to the project, two of the pumps operated in parallel to pump all of the raw effluent from the main pump station sump to a clarifier. The third pump was used as a backup or during extreme process upsets. The mills treatment process requires a minimum flow rate of 4,800 gallons per minute (gpm) to be reliable.

Project Overview
At the suggestion of NEEA, staff at the Port Angeles mill agreed to a review of the effluent pumping system to determine whether the systems control scheme could be improved. Although the minimum flow rate required by the treatment process was 4,800 gpm, the review showed that when both pumps operated at full load, their combined capacity was 7,000 gpm. The excess 2,200 gpm was being recirculated back to the sump. The size of the pumps and the systems control scheme caused the excess pumping. The primary system control was a level control in which a throttling valve and a bypass valve worked in tandem to maintain a minimum level in the sump. As the level in the sump rose, the throttling valve opened and the bypass valve closed. Conversely, as the level in the sump fell, the discharge valve closed and the bypass valve opened. Controlling the pumps this way required starting them at full load from a dead start. This created flow surges and pipe hammer that led to stress in the systems piping. In addition, starting the pumps from a dead start caused a long duration of locked rotor currents, which overheated the pump motors. The reviewers found that cavitation and excessive vibration were present in the piping because the pumps operated at full capacity. Although the pumps were moving 2,200 gpm in excess of the process requirements, the total volume moved was still too small given the pump operating speed. This disparity led to further process-piping fatigue and shortened equipment life. Reviewers also discovered that one of the parallel pumps drew significantly more power than the other. As a result, plant personnel took the pumps apart to inspect the impellers and discovered that the impellers were severely worn, which caused the pumps to operate less efficiently.

Project Implementation
Mill personnel decided to implement a system-level project based on the review. The project centered on installing mechanical ASDs, replacing the worn impellers on both pumps, and upgrading the pump instrumentation. The ASDs would replace the throttle and bypass valve operation and would match the systems output to the mills requirements. Several factors made the selected mechanical ASDs more suitable for the mills environment and needs than electronic Variable Speed Drives (VSD). One factor that made this ASD model attractive was its easy installation. The ASD installation simply required moving the pumps back on their bases

and installing spacers between the motors and the pumps. No inverter-duty motors, extensive rewiring, or reconfiguration of the pump stations were necessary. Second, ruggedness and a lack of sensitive electronic parts made these mechanical ASDs less prone to maintenance problems in an environment such as the mills effluent treatment process. Because the mills system is a mediumvoltage application, these ASDs were less costly than comparable VSDs. Finally, these ASDs are mechanical, so there are no direct connections between the motors and pumps; this substantially reduces vibration and allows softstart capability.

AN EFFLUENT PUMP WITH

THE

MECHANICAL ASD

Project Results
The implementation of the project has improved the operation of the effluent pumping system and resulted in significant energy savings for the Port Angeles mill. With the newly configured pumping system, the mill no longer depends on bypass and throttling valves to control the pumping system. The ASDs can vary the pump speed to match the pump output capacity with the mills required process flow rate. The new configuration allows the mill to baseload only one of the pumps while operating the other one at partial load. By not operating both pumps at full capacity, cavitation and vibration have been drastically reduced. Because they are uncoupled from the pump motors, the ASDs allow the pumps to start gradually, which eliminates water surges and pipe hammer. This, in turn, lessens stress on the systems piping and internal components, reduces maintenance needs, and prolongs equipment life. The systems flow rate has declined by 31 percent, or 2,200 gpm from 7,000 gpm, and rarely exceeds 4,800 gpm. Power demand has declined from 142 kW to 62 kW. The reduction in the systems flow rate and power demand are due to the installation of the ASDs, the rebuilt pumps, and the operation of one pump at partial load versus two pumps at full load. The mill saves $32,000 and 700,000 kWh in annual energy costs, and $10,000 per year in maintenance costs. Because of a cost sharing

arrangement in which NEEA funded a portion of the mills project cost, the mills total cost for the project was $60,000. The simple payback was slightly more than 15 months.

Lessons Learned
The proper control scheme is critical for the efficient operation of a pumping system. Relying on bypass and throttling valves to control a pumping system can lead to energy waste and excessive maintenance requirements. At the Port Angeles mill, the use of bypass and throttling valves led the mill to operate its pumps at a greater capacity than necessary, and in ways that created unnecessary stress on the process piping and internal system components. Operating the pumps in this manner caused the system to waste energy because it moved 2,200 gpm in excess of the process requirements. The improvement project on the Port Angeles Mills effluent pumping system reduced the systems flow rate by 31 percent and allowed one pump to operate at variable load. These changes reduced energy consumption. In addition, the project eliminated sources of stress on the systems process piping and on the pumps internal components, resulting in lower maintenance costs and increased equipment life. The Mechanical ASD The ASD installed by Daishowa America is a non-electronic, mechanical device that is usually placed between a motor and the load the motor is driving, whether it is a pump, fan, or blower. The drive consists of two independent components that have no physical contact with each other. One component, a rotor assembly containing permanent magnets, is mounted on the load shaft. The second component, a copper conductor assembly, is connected to the motor shaft. Relative motion between the magnets and the copper creates a magnetic field that transmits torque through the air gap between the components. The width of the air gap can be changed, which allows the amount of torque transmitted between the motor and load to be continuously adjusted. This allows precise speed control, including soft starts and stops. Because of the lack of a direct mechanical connection between the motor and load, the ASD also eliminates wear-and-tear caused by vibration. This ASD is wellsuited for medium-voltage applications in harsh environments, and for drives in which efficiency is linear with speed, such as fluid drives.

BestPractices is part of the Office of Industrial Technologies (OITs) Industries of the Future strategy, which helps the countrys most energy-intensive industries improve their competitiveness. BestPractices brings together emerging technologies and best energy management practices to help companies begin improving energy efficiency, environmental performance, and productivity right now. BestPractices emphasizes plant systems, where significant efficiency improvements and savings can be achieved. Industry gains easy access to near-term and long-term solutions for improving the performance of motor, steam, compressed air, and process heating systems. In addition, the Industrial Assessment Centers provide comprehensive industrial energy evaluations to small- and medium-size manufacturers.

P ROJECT PARTNERS
Daishowa America Port Angeles, WA MagnaDrive Seattle, WA Northwest Energy Efficiency Alliance Seattle, WA

F OR A DDITIONAL I NFORMATION , P LEASE C ONTACT:

OIT Clearinghouse Phone: (800) 862-2086 Fax: (360) 586-8303 clearinghouse@ee.doe.gov Visit our home page at www.oit.doe.gov

INDUSTRY OF THE FUTUREFOREST PRODUCTS AND AGENDA 2020

In November 1994, DOEs Secretary of Energy and the Chairman of the American Forest and Paper Association signed a compact, establishing a research partnership involving the forest products industry and DOE. A key feature of this partnership was a strategic technology plan-Agenda 2020: A Technology Vision and Research Agenda for Americas Forest, Wood, and Paper Industry. Agenda 2020 includes goals for the research partnership and a plan to address the industrys needs in six critical areas: Energy performance Recycling Environmental performance Sensors and controls Capital effectiveness Sustainable forestry OIT Forest Products Industry Team Leader: Valri Robinson (202) 586-0937.

Please send any comments, questions, or suggestions to webmaster.oit@ee.doe.gov Office of Industrial Technologies Energy Efficiency and Renewable Energy U.S. Department of Energy Washington, DC 20585-0121

DOE/GO-102002-1558 May 2002

MOTOR CHALLENGE
Project Fact Sheet

A Business Case Study

T OWN OF T RUMBULL P UMP O PTIMIZATION P ROJECT Y IELDS $60,000 N ET P RESENT V ALUE

T OTAL V ALUE A DDED
Net Present Value : $60,000 Internal Rate of Return: 52% Payback: 1.9 years
The Town of Trumbull was looking for a way to increase the operating performance of one of its 10 sewage pumping stations. Built in 1971, the station consisted of twin sewage handling pumps (40-hp direct drive, wound rotor motor) vertically mounted below ground, handling 340,000 gallons of raw sewage per day. The system used one pump to handle the entire peak flow under normal operation, and used the second pump in only extreme conditions. Each pump rarely operated more than five minutes at a time. The system experienced frequent breakdowns, occasional flooding, and sewage spills.

BENEFITS
Reduced energy consumption by almost 44% Reduced cleaning and maintenance Extended equipments expected life Increased system capacity 25% Decreased noise

Decision
With the help of ITT Flygt Corporation (new-pump manufacturer), engineers investigated total system performance and decided to add a smaller, 10-hp pump with direct online motor starters and a level control system with float switches. The new pump handles the same volume as the original pumps during non-peak periods, but runs for longer periods of time. The old pumps handle infrequent peak flows. The 2 compressors for the bubbler level control system and the 2 circulating pumps for the old motor control system were also eliminated, and lighting efficiencies were implemented.

E XISTING 40- HP PUMP M OTOR

OFFICE OF INDUSTRIAL TECHNOLOGIES ENERGY EFFICIENCY AND RENEWABLE ENERGY

U.S. DEPARTMENT OF ENERGY

Rationale
This decision produced the following results:
u

u u u

Reduced energy consumption by almost 44% due to: lower outflow rate reduced losses in the piping system lighting system upgrades elimination of the bubbler level control and cooling water pumps Reduced cleaning and maintenance requirements (supplies and labor) and associated downtime eliminated the need to replace 2 mechanical seals per year new, submersible pump is much easier to swap out if repair/replacement is needed Extended equipments expected life due to longer operating times and reduced power input Increased system capacity 25%, potentially deferring need for additional pump stations Decreased noise from new pump, improving relations with local residents

Motor Challenge, administered by the Office of Industrial Technologies, is a voluntary partnership program with U.S. industry to promote the use of energyefficient electric motor systems. Thousands of industrial partners have joined Motor Challenge and are improving their, and in turn, the Nation s competitiveness and efficiency. Motor Challenge assists the OIT Industries of the Future by identifying near-term gains in energy efficiency these industries can achieve by adopting existing technologies.

These modifications can be easily replicated at other sites (new sites or retrofit). A new pump site under construction in Trumbull is using the submersible pump technology and saving an additional $10,000 - $12,000 by eliminating the need to dig a second hole.
12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Value Added: 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Equipment Cost, fully installed: $12,000 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Annual Savings: 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Energy savings $2,600 31,900 kWh/yr 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Maintenance Savings: 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Supplies $1,800 2 seals/yr * $900 each 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Labor $1,800 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 Total $6,200 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789 12345678901234567890123456789012123456789012345678901234567890121234567890123456789

PROJECT PARTNERS
Town of Trumbull Trumbull, CT ITT Flygt Corporation Trumbull, CT

FOR ADDITIONAL INFORMATION, PLEASE CONTACT:

The OIT Information Clearinghouse Phone: (800) 862-2086 Fax: (360) 586-8303 http://www.motor.doe.gov

Incremental Cashflow Analysis

($Thousands) (years) 0 SAVINGS Energy Supplies Labor 1 2.6 1.8 1.8 2 2.6 1.8 1.8 6.2 3 2.6 1.8 1.8 6.2 4 2.6 1.8 1.8 6.2 Time (years 0 - 12) 5 6 7 8 2.6 1.8 1.8 6.2 2.6 1.8 1.8 6.2 2.6 1.8 1.8 6.2 2.6 1.8 1.8 6.2 9 2.6 1.8 1.8 6.2 10 2.6 1.8 1.8 6.2 11 2.6 1.8 1.8 6.2 12 2.6 1.8 1.8 6.2

Visit our home page at www.oit.doe.gov Please send any comments, questions, or suggestions to webmaster.oit@ee.doe.gov

COST 12.0 Incremental (12.0) 6.2 savings (years cont) 13 SAVINGS Energy 2.6 Supplies 1.8 Labor 1.8 Incremental 6.2 Savings 14 2.6 1.8 1.8 6.2

15 2.6 1.8 1.8 6.2

16 2.6 1.8 1.8 6.2

17 2.6 1.8 1.8 6.2 $601 52%

Time (years 13 - 25) 18 19 20 21 2.6 1.8 1.8 6.2 2.6 1.8 1.8 6.2 2.6 1.8 1.8 6.2 2.6 1.8 1.8 6.2

22 23 2.6 2.6 1.8 1.8 1.8 1.8 6.2 6.2

24 2.6 1.8 1.8 6.2

25 2.6 1.8 1.8 6.2

Office of Industrial Technologies Energy Efficiency and Renewable Energy U.S. Department of Energy Washington, D.C. 20585

NET PRESENT VALUE INTERNAL RATE OF RETURN

1

February 1999

Cashflows are discounted at 7%.

CASE STUDY
Summary

Showcase Demonstration

OPTIMIZING PUMP SYSTEMS AT A COAL SLURRY PREPARATION PLANT

Project Profile Peabody Holding Company, the largest U.S. coal producer, Industry: Coal Mining has completed a project to improve the performance of a coal slurry pumping system at its Randolph Coal Preparation plant. Process: Coal Slurry Separation Changes to the coal washing process resulted in cyclone pump System: Cyclone Pump systems that were larger than necessary to meet system requirements. Finding ways to increase the efficiency of these Technology: Resized Pump, oversized pump systems was the objective of this Motor Energy-Efficient Motor Challenge Showcase Demonstration Project. This case study describes the performance optimization conducted by the Showcase Demonstration team on one of the six classifying cyclone pumps. Using a systematic approach, three energy-saving opportunities were identified involving the motor, belt drive, and pump components of the pumping system. The modifications saved 87,184 kWh of electricity, equivalent to $5,231 in annual energy cost savings, and overall energy consumption of the pumping system decreased by approximately 15 percent. Total costs to implement the project amounted to $15,693 yielding a simple payback of 3.3 years. When performed on each of the remaining five pumps, the performance optimization will result in an estimated 523,000 kWh in energy savings and $31,000 in annual energy cost savings. Company Background Peabody Holding Company, Inc. generates more than $2 billion in annual revenues by providing policy management and strategic planning to the Peabody Group, comprised of 50 coal mining, marketing, and related corporations in the United States and Australia. Together, these corporations operate 29 mines and own or operate roughly 12 billion tons of steam and metallurgical coal reserves throughout the world. Peabody initiated this Motor Challenge Showcase Demonstration project in order to improve their motor systems and because of their heightened awareness of energy efficiency and environmental concerns. Project Overview The Randolph Coal preparation plant processes and cleans bituminous coal supplied by Peabodys Marissa Underground Mine, located in west-central Illinois near Baldwin, Illinois. The coal is removed by continuous miners using the Room and Pillar method, a coal extraction technique

Randolph Coal Preparation Plant

2
involving rotary drums that shear coal, shale, and fire clay from the coal seam. After removing large non-coal fragments, water is added to the raw coal to produce a 12 percent coal slurry to separate the remaining shale, fire clay, and other particles from the coal. Six 200 hp classifying cyclone pumps transport the coal slurry from a common sump to the two classifying cyclones which separate the slurry into two types. The slurry containing smaller mesh particles is discarded while the slurry containing larger mesh particles is dewatered and discharged as clean coal. The Randolph preparation plant was selected for process optimization due to numerous changes to the coal washing process. The six pumps used to transport slurry to the cyclones exceeded system process requirements, which can lead to inefficient operation. Alternatives to increase the energy efficiency of the pumping system were identified and evaluated. This project focuses on one (Number 5) of the six cyclone classifying pumps which is representative of all six pumps. Only one pump was selected so that multiple system optimization techniques could be explored without excessive costs. Project Team In addition to the host company, the Showcase Demonstration project team involved several Motor Challenge partners including U.S. Electric Motors, GIW Industries, Inc. and the local electric utility. U.S. Electric Motors and GIW Industries, Inc. supplied the equipment and performed system modifications throughout the projects implementation period. Electric metering of the pumping system for the base case and alternative scenarios was provided by the local electric utility. Other mechanical engineering services and hardware provided to the host company were performed by The Benham Group. Project Implementation - The Systems Approach
DISTRIBUTOR
CLASSIFYING CYCLONES

SIC: 1211 Products: Clean coal Location: Marissa, Illinois Employees: 66 Showcase Team Leader: Ronald Cross Company Philosophy: Peabody is committed to implementing an energy efficiency plan that is cost-effective and supports voluntary actions to reduce greenhouse gases.

PANAMETRICS PT-868 ULTRASONIC FLOWMETER

CLASSIFYING SUMP

20 ft.

21 ft. 6 in.

DISCHARGE PRESSURE TRANSDUCER

Project engineers realized the current system was oversized, not operating at its best efficiency point, and had not received proper maintenance over the years. To determine potential improvement opportunities, the engineers applied the systems approach. The systems approach is a way to increase the efficiency of an electric motor system by shifting the focus away from the individual elements and functions to total system performance. By utilizing the systems approach, Peabody Holding was able to determine an overall strategy for optimizing the No. 5 cyclone pump.The strategy involved all three main elements of the pumping system: the pump casing and impeller, the motor, and the V-belt drive. The Old System Under normal conditions, the pump runs at constant volume and operates approximately 16 hours a day for 250 days a year. The original pump system utilized a 10" x 10" casing equipped with a 32" diameter impeller designed to pump an estimated 4,650 gallons per minute (gpm) at a head of 114 feet. The pump was driven by a 200 hp, 1,750 rpm standard efficiency motor through a conventional V-belt

SUCTION PRESSURE TRANSDUCER

CLASSIFYING CYCLONE PUMP

Classifying Cyclone Pump

60 ft.

3
drive. After performing system analyses, the team determined that the original system exceeded process requirements. Overall wireto-water system efficiency was rated at less than 59 percent. Average volume flow was estimated at an average of 3,612 gpm at a head of 107 feet, less than the pumps most efficient operating point. Overall energy consumption was estimated at 513,766 kWh of electricity per year. Alternatives Considered Several alternatives were considered to optimize the pump system. One option involved slowing down the pump to reduce speed and lower energy consumption levels; however, Coal Slurry Pumping System initial calculations showed little energy savings from performing this task. Engineers also considered staging the six pumps, but this proved impractical. Another area explored was replacing the V-belt drive with a newer toothed-belt drive, rated at efficiency levels of 98 percent. After several tests, it was determined that the toothed-belt drive did not significantly increase the efficiency of the pump system. In addition, toothed-belt drives are less tolerant of contamination and are significantly more noisy than V-belt drives. The optimal solution proved to be a combination of system modifications which include replacing the pumps motor with a more efficient motor, downsizing the pump, and re-tensioning the V-belt. The New System The modified system uses a smaller pump with an 8" x 10" casing and a 32" diameter impeller with an output that more accurately matches system flow requirements. The original motor was replaced with a new premium efficiency 200 hp, 1800 rpm motor rated at 96.5 percent efficiency. At the time of replacement, the team also determined that the motor slide base should be replaced as a result of extreme corrosion. Maintenance of the V-belt drive, to prevent corrosion and set the proper tension, was also performed. Results Prior to system modifications, the pumping system operated at an average 58.7 percent wire-to-water efficiency. After the motor and slide base were replaced, efficiency levels increased to 60.4 percent. By re-tensioning the V-belt drive, efficiency increased by an additional 2.5 percentage points to 62.9 percent. The most significant efficiency increase occurred after the pump was downsized to match volume flow requirements. Efficiency increased another 10.7 percent to an average wire-to-water efficiency of 73.6 percent. Overall energy efficiency as a result of the motor replacement, V-belt drive tensioning, and pump modifications increased by 14.9 percentage points from 58.7 percent to 73.6 percent efficiency. Why Oversized Pumps Decrease Performance Many design engineers purposely oversize pumps, taking into account factors such as safety margins, potential corrosion build up, and the possibility of increased flow requirements in the future. This often leads to throttling the system with a control valve because the pump delivers more flow than the system requires. The result is a pump that is not running at its Best Efficiency Point (BEP). Possible consequences of this include noise and vibration, excessive bearing loads, cavitation, and excessive power consumption. Pumps that are being throttled and are operating far off their BEP should be considered for retrofit. Possible changes that should be considered are retrofitting with a smaller pump, using an impeller with a smaller diameter, or slowing the operating speed of the pump. In many cases, these changes will not only save energy, but also increase the reliability of the system.

4
The reduction in annual energy consumption is estimated to be 87,184 kWh of electricity, equivalent to approximately $5,231 in cost savings. With a cost of $15,693, the project yielded a simple payback of 3.3 years. In addition, the project resulted in lower maintenance costs for replacement parts since the new pump is smaller. Lessons Learned Performance Improvement Summary
Annual Energy and Cost Savings Net Cost to Implement Project Annual Energy Cost Savings Simply Payback (years) Demand Savings (kW) $15,693 $5,231 3.3 21.8

Aside from the energy savings achieved by modifying the system, Energy Savings (kWh) 87,184 several lessons were learned during the project implementation process. The experiences gained may provide practical Total Annual Emissions Reductions information for other projects targeting energy efficiency CO2 182,633 lbs improvements. The lessons learned include: (1) To ensure that pump systems are performing at optimal levels, the volume flow Carbon Equivalent 49,900 lbs rate should be calculated to determine the appropriate sized 5,115 lbs SO2 pump, rather than automatically replacing old pump casings with new pump casings of the same size when they wear out. By not NOx 1,090 lbs only replacing the pump casing but by changing the size of the PM 42.4 lbs pump casing to more accurately match the required flow rate, operating costs can be reduced significantly; (2) High performance CO 21 lbs belt drives can increase energy efficiency and reduce costs; Non-Methane Hydrocarbons 2.5 lbs however, routine maintenance of the V-belt drive rather than replacement of the drive with high performance belt drives may yield higher savings. Also, high performance belt drives are noisy relative to V-belt drives; and (3) After a pump casing and impeller are replaced with smaller ones, the system requires less motor power than was needed prior to system modifications. A smaller motor may be sufficient to operate the system, and can reduce project costs. About Motor Challenge
The Motor Challenge is a joint effort by the U.S. Department of Energy (DOE), industry, motor systems equipment manufacturers and distributors, and other key stakeholders to put information about energy-efficient electric motor system technology in the hands of people who can use it. Showcase Demonstration Projects target electric motor-driven system efficiency and productivity oppor tunities in specific industrial applications. They show that efficiency potential can be realized in a cost-effective manner and encourage replication at other facilities. DOE provided technical assistance and independent performance validation (IPV) of energy savings. A DOEsponsored IPV team reviewed the test plan and provided assistance, as requested by the host site, on testing procedures, instrumentation techniques, and data acquisition. The DOE team developed a detailed IPV Report thoroughly documenting the project. The Report is available by calling the number listed below. DOE did not witness the actual test data, and the conclusions in this case study are based solely on data provided by the host site and their partners. For more information on becoming involved in the Motor Challenge or sponsoring a Showcase Demonstration, call the Motor Challenge Information Clearinghouse at (800) 862-2086.

February 1997
Printed with a renewable source ink on paper containing at least 50% wastepaper, including 20% postconsumer waste

Contact: Motor Challenge Information Clearinghouse (800) 862-2086 www.motor.doe.gov

ORNL/MC-CS3

BestPractices

GLASS
March 2003

Project Case Study

OFFICE OF INDUSTRIAL TECHNOLOGIES ENERGY EFFICIENCY AND RENEWABLE ENERGY, U.S. DEPARTMENT OF ENERGY

B ENEFITS

Saves $280,000 annually Reduces annual energy consumption by 3.2 million kWh Reduces water consumption Improves system performance Reduces purchases of water treatment chemicals Yields a simple payback of 15 months

Millwater Pumping System Optimization Improves Efficiency and Saves Energy at an Automotive Glass Plant
Summary
In 2001, Visteon Corporations automotive glass plant in Nashville, Tennessee, renovated its millwater pumping system. Over time, technological advances had improved the plants manufacturing efficiency, which lowered demand for process cooling water. However, because of its size and configuration, the pumping system was providing more water than necessary. The renovation project involved retrofitting the systems large, aging pumps with smaller units fitted with Variable Speed Drives (VSDs) to more effectively match the systems output to the plants demand. The completed project greatly improved the systems efficiency and reduced the plants water use, saving substantial amounts of energy and water treatment chemicals. In addition, the project improved plant safety by eliminating an electrical hazard on the pump barge. The projects total cost was $350,000 and the total annual savings were $280,000, yielding a simple payback of 15 months.

A PPLICATIONS
Mill or river water pumping systems provide process-cooling water for industrial plants and can consume significant quantities of energy. Optimizing aging and inefficient mill or river water pumping systems can reduce energy consumption, water use, and chemical treatment of river water.

Plant Background
Visteon is an automotive parts manufacturer that was spun off from Ford Motor Corporation in 2000. With 81,000 employees and more than 130 technical,

The Barge Pumping System at Visteons Nashville Plant

manufacturing, sales, and service facilities in 23 countries, Visteon produces a wide range of automotive components for manufacturers all over the world. The companys three main business segments are Dynamics and Energy Conversion; Comfort, Communication and Safety; and Automotive Glass. The Visteon Nashville glass plant opened in 1956 and has since undergone 10 expansions that have doubled its floor space and production output. It is the worlds largest complete automotive glass production plant with more than 2 million square feet of work and storage space. The plant produces windshields, backlights, and door glass. The millwater pumping system is important because it provides water for the process cooling applications. Prior to project completion, the plant was served by three 350-horsepower (hp) centrifugal pumps mounted on a barge in the Cumberland River. Two of the pumps were constantly operated in parallel to pump water from the river to a clarifier where the water was chemically treated. The third pump was kept for back up use.

Project Overview
Working with Tencarva Machinery Company, plant personnel reviewed the pumping system in relation to the plants process cooling water needs. The review team began by assessing of the plants water demand, which allowed Tencarva to determine the optimal size and type of pumping system. The existing pumps were installed in 1968 when the plants load was approximately 5,200 gallons per minute (gpm). Since then, increases in manufacturing efficiency and reduced need for cooling water by the compressed air system had significantly reduced the plants load. The assessment indicated that under normal operating conditions, the plant could operate effectively with 3,125 gpm. Although plant personnel knew that the flow rate of 5,200 gpm was excessive before the review, the rate could not be adjusted because of the pump system design. The pumps had an on/off control system and because one pumps output was insufficient, two pumps were required to operate at full load. Running both pumps this way consumed excess energy. Furthermore, the excess water was passed through the clarifier before being returned to the river, which consumed more water treatment chemicals than necessary. The review also revealed that the pumping systems controls were antiquated and did not have remote monitoring capability. Therefore, two powerhouse operators had to go to the barge twice a day to perform the required system checks manually. In addition, the pumps controls and electrical substation, located on the barge, created an electrocution hazard when the deck of the barge flooded. The barges deck gets flooded periodically when storms allow debris to get wedged in the wheels that allow the barge to rise and fall with the river level. The debris prevents the barge from rising,

Project Implementation
The plant personnel decided to retrofit the millwater pumping system based on Tencarvas system review and recommendations. The project centered on replacing the existing 350-hp pumps with two 250-hp pumps, each fitted with a VSD. The proposed system design called for one pump to operate continuously while the second one would be brought online in a trim capacity to maintain the appropriate clarifier tank levels. The project was implemented without interrupting the plants water supply, so production was unaffected. Existing bypass piping was utilized to isolate each pump as it was being replaced. In addition, the clarifier tank was filled with enough water to buffer the system while the new pumps were activated.

One of the Two New 250-HP VSD-Controlled Barge Pumps

In addition to being smaller, the new pumps possess remote monitoring capability, which eliminates the need for powerhouse operators to check the system manually. Finally, the pump controls and the electrical substation that serves the barge were relocated on land to eliminate the electrocution hazard.

Results
The Nashville plants pumping system project has yielded important energy savings and has improved the systems performance. Before project completion, the plant operated two of its three 350-hp centrifugal pumps at full load, which moved 5,200 gpm. The VSDs are now able to vary the pumps output capacity to accurately match the plants load and provide better tank level control of the clarifier. With the new system in place, the systems flow rate averages 3,125 gpm, a 40% reduction. Because the plant is able to meet its load by operating one pump at a time, plant personnel alternate each pump to share the load equally, thus preventing excess wear of either pump. The reduced flow rate has saved 3.2 million kilowatt-hours (kWh) and $98,000 per year.

In addition to energy savings, the project has allowed the plant to reduce its purchases of water treatment chemicals, saving $116,000 annually. The plant also saves $66,000 per year by checking the pumping system remotely. This new functionality precludes the need for the powerhouse operators from going onto the barge to manually check the pumps. The total project savings are thus $280,000 per year and, with a total project cost of $350,000, the simple payback is just 15 months. Also, plant safety was improved by the eliminating the electrical hazard posed by the controls being located on the pump barge. Finally, the more efficient utilization and reduced use of Cumberland River water is important because policies under review by the Tennessee Valley Authority (TVA) indicate that additional surcharges may be forthcoming for the use of TVA-controlled inland water.

BestPractices is part of the Office of Industrial Technologies Industries of the Future strategy, which helps the countrys most energy-intensive industries improve their competitiveness. BestPractices brings together emerging technologies and best energy-management practices to help companies begin improving energy efficiency, environmental performance, and productivity right now. BestPractices emphasizes plant systems, where significant efficiency improvements and savings can be achieved. Industry gains easy access to near-term and long-term solutions for improving the performance of motor, steam, compressed air, and process heating systems. In addition, the Industrial Assessment Centers provide comprehensive industrial energy evaluations to small- and medium-size manufacturers.

Lessons Learned
Aging and improperly configured industrial pumping systems can waste energy and incur high maintenance or operating costs. As industrial plants evolve over time and manufacturing processes become more efficient, demand requirements will also shift. Recognizing and adjusting the output capacities of industrial motor systems in response to changing demand patterns saves energy and improves productivity. In the case of the Nashville Glass Plant, replacing aging, fixedoutput pumps with smaller units fitted with VSDs created an optimally sized pumping system that can effectively vary output in response to demand. Such reconfiguring leads to important savings in energy, maintenance, and water treatment chemicals.

P ROJECT PARTNERS
Visteon Corporation Nashville, TN Tencarva Machinery Company Nashville, TN

F OR A DDITIONAL I NFORMATION , P LEASE C ONTACT:

OIT Clearinghouse Phone: 800-862-2086 Fax: 360-586-8303 clearinghouse@ee.doe.gov Visit our home page at www.oit.doe.gov Please send any comments, questions, or suggestions to webmaster.oit@ee.doe.gov Office of Industrial Technologies Energy Efficiency and Renewable Energy U.S. Department of Energy Washington, DC 20585-0121

Industry of the FutureGlass

In April 1996, several organizations representing the glass industry signed a compact with the Department of Energy (DOE) in an effort to encourage technological innovations that will reduce energy consumption, pollution, and production costs in the industry. The glass industry published a report entitled Glass: A Clear Vision for a Bright Future, which articulated the industry's vision of its future. This compact set the foundation for collaborative efforts between the industry and the Federal government. Signed by both key industry players and Department of Energy officials, it was a formal commitment to align DOE's limited resources to meet the challenges identified in the vision. OIT Glass Industry Team Leader: Elliot Levine 202-586-1476.

DOE/GO-102003-1658 March 2003