Performing an Audit

and
Assessing Data
 Perform an Audit
Types of Energy Audits
• Desktop
• Use only nameplate data (horsepower or Kw)
• May use only our Inventory Table
• How are we operating our processes?
• Pitfall to this is it uses assumed efficiency & load
• Energy Survey and Analysis
• Use voltmeters, ammeters or, preferably, a Power meter, and
flow measurement
• How are we operating our processes?
• Computer Modeling
• Usually requires a consultant or more technical expertise
• How are we operating our processes?
 Table of Equipment
Motor List - Area of Plant Equipment
 Rated hp.
 Number of units
 Hours/day that each runs
 Age
 Efficiency
 Power factor
 Daily/monthly cost for group
 All of the above can be obtained using nameplate data
 Or can actually measure using volt, amps, or a Power meter.

Process Type Equipment Hp Efficiency FLA Avg Amps Duty Cycle/yr kWh Use $/kWh Elec Cost % of Total kWh
Influent Pumping Pump 1 100
Influent Pumping Pump 2 100
Secondary Bloour 1 100 90% 45 35 8760 564750 $ 0.08 $ 47,061.61 16%
Secondary Bloour 2 100 90% 45 35 8760 564750 $ 0.08 $ 47,061.61 16%
$ -
Anoxic Mixing Mixer 1 25 $ 0.08 0%
$ -
Anoxic Mixing Mixer 2 25 $ 0.08 0%
$ -
Anoxic Mixing Mixer 3 25 $ 0.08 0%
$ -
Anoxic Mixing Mixer 4 25 $ 0.08 0%
Total 1129499 $ 94,123.21 31%

Suggest that we do this for all motors. Why?

 The ENERGY AUDIT
Identify priorities:

• Look for Low Hanging Fruit

• Get biggest bang for our buck
• Operating Procedures
• Older equipment
• Outdated technology
• Simple vs. complex

Operator incentives will generally find ways to save. Must understand billing structure
Motor Nameplate
 Desktop- Evaluation
Equipment Evaluation Calculation:
Use Nameplate Data
 RelianceElectric, 75 hp.,
 230/460 volt, amps 175/87.6,

 1780 rpm, 94.1 % efficiency

 Power Factor 84.9%
 Run time 6.25 hours per day

1.73 X Volts X Amps X Power Factor ÷ 1000 = Kilowatt (Kw)

1.73 X 460 volts X 87.6 Amps X 0.849 Power Factor ÷ 1000 = 60.2 Kw Demand

Annual Kw = 60.2 (Kw) X 6.25 hr/day X 365 days/year = 137,331 Kw hr/year

 Energy Survey & Analysis
Equipment Evaluation Calculation
Use Field Gathered Data
 Reliance Electric,
 75 hp. - 230/460 volt, amps 175/87.6

 1780 rpm, 94.1 % efficiency

 Measured Data: Volts : L1/L2 477, L2/L3 472, L1/L3 482 = avg. 477

 amps 86.9, 87.0, 86.2 = average 86.7

 Amperage imbalance 0.57 %

 Power Factor 0.849

 Run time 6.25 hours per day

1.73 X Volts X Amps X Power Factor ÷ 1000 = Kilowatt (Kw)

1.73 X 477 volts X 86.7 Amps X 0.849 Power Factor ÷ 1000 = 60.7 Kw Demand

Annual Kw = 60.7 (Kw) X 6.25 hr/day X 365 days/year = 138,472 Kw hr/year

 Monitor and Measure Results
Track performance
Set up a method to continuously gather the data
Pay attention to other changes made that may affect the
data
Develop a plan to maintain the new equipment or
processes
Remember that this is not a one-time event. It should be
ongoing continuous improvement
 Correcting Power Factor
Installing capacitors (large investment)
Minimizing the operation of idling or lightly-loaded
motors
Avoid operation of equipment above the rated
voltage
Replace standard motors with high efficiency as
the old one wear out or fails
 Example Cost Calculation
Data
25 hp pump
Operates an average of 18 hours/day
Load factor = 65%
Motor efficiency = 90%
Power cost = $0.08/kwh
Monthly cost = 25 hp x 0.746 kwh/hp x 1.0/0.90 x
$0.08/kwh x 0.65 x 18 hours/day x 30 days/month =
$582.00
What is the approximate Demand for this motor?
 Calculating The Cost

Assumptions
Not all motors run at full load
Will assume Power costs are ~ $0.08/kwh
Motor efficiency = 90%
Load factor on pump = 65%

{Hp X (0 .746)/motor efficiency (.90)} x monthly hours x

$/kwhr x load factor (0.65) = Monthly costs
Field Survey and Analysis

Better Than a Desktop Survey

but requires more skills & reliable
instruments
 WARNING
You need a qualified electrician to use the following
equipment.
You will be going into live panels to take these
measurements.
You will need very specific PPE depending on our
activities.
DO NOT ATTEMPT TO DO THIS IF we HAVE NOT
HAD THE REQUIRED SAFETY TRAINING
 Equipment Needed
Power meter (or ammeter and volt meter)
Tachometer (to measure pump speed)
Calibrated flow meter
Magnetic flow meters rarely need calibration, unless exposed to solids
Calibrated pressure gages
Always best to use a new calibrated pressure gage
Gages that have been installed for some time can be reading
incorrectly, especially if subjected to solids
Usually a waste of money to install gages on all pumps
Best to install fittings and bring a good gage to take measurements
when needed
 Measuring Power
It is best to measure with a Power meter (if we have
a qualified electrician to set it up). This involves going
into the electrical panel.

The Power meter will give us

Exact kw, kwh, and Power factor
A correlation with actual flowrate, etc., if a
flowmeter is available
 System Measurements
For 460 volt systems measure all three legs of the Power feed.
The voltage to the motor should be within 10% of the
nameplate. Example nameplate 460v : Range 414v – 506v

The voltage deviation in any one leg should be < 1% from

the average. Example 1 % of 460v = 4.6v

The amperage Imbalance should be < 5% from the average

If it does not meet the above criteria, take steps to

troubleshoot the system
 Data to Collect
Pump Speed (rpm)
Flowrate (gpm or cfm)
Pressure in and out (psig)
Volts and amps on all legs of power in
Power used (kw)
Power factor
VFD % of full scale
 Measuring Flowrate
Best if you have an installed flow meter, that is
calibrated
Magnetic flow meters require little calibration, unless
in a sludge line and subject to buildup
Venturi meters require calibration
Can install a temporary flow meter (strap-on)
If possible, pump in or out of a tank and measure
levels
 Measure Pressure
You may have a pressure gage installed on the pump
discharge. It probably does not read correctly

Best to install a calibrated gage (certified) on both suction

and discharge side of the pump

TDH is the discharge pressure minus the suction pressure

Impeller Size: 10”
Total Head: 45 ft
Capacity: 200 gpm
Eff.: 58% bhp: 3.9

Impeller Size: 10”

Total Head: 40 ft
Capacity: 400 gpm
Eff.: 73% bhp: 5.5
 Pump Curves
Provided by the manufacturer when delivered

Always good practice to verify the curve during

commissioning (make it a requirement of the
specification)

Good practice to check each pump’s performance on

a schedule
 Pump Curves
Plots flow vs. TDH

Also shows Best Efficiency Point (BEP) – minimum

stress on the pump system, max efficiency

Shows brake horsepower (bhp) vs. flow

If a VFD, will show several curves

If a tested pump is on the curve and operating at the

BEP, we have done our job well.
How to determine actual pump efficiency

Ep= 3.14 X Head ft. X Flow MG

Power kWh X Eff. Motor
Parameter How to Determine
Head in Feet Pressure Gages
Calculated from Water elevations
Flow Quantity Flow Meter
Well volume calculation & drawdown
Power Consumption Watt Meter
Clamp on Amp Meter & Volt Meter
Motor Efficiency Manufacturer Specifications
Calculate theoretical pump efficiency
A raw sewage pump operating at a head of 30 feet draws down a 25 ft. by 25
ft. wet well by 3 ft. with the inlet valve closed in 3 minutes. During this period
the current draw on the 50 hp. 460 volt motor was measured to be 63 amps.
What is the efficiency of the pump?

Flow Quantity MG = 25 ft. X 25 ft. X 3 ft. X 7.48 gal/ft3 = .o14 MG

1,000,000

Power Consumption KwHr =

1.73 X 460V X 63 Amps X .81 PF X 3 minutes / 60 min/hr. = 2 kwhr
1000

Ep= 3.14 X 30 Head ft. X .014 Flow MG

2.0 Power kWh X 0.90 Eff. Motor
Calculate theoretical pump efficiency
A raw sewage pump operating at a head of 30 feet draws down a 25 ft. by
25 ft. wet well by 3 ft. with the inlet valve closed in 3 minutes. During this
period the current draw on the 50 hp. 460 volt motor was measured to be
63 amps. What is the efficiency of the pump?

Flow Quantity MG = 25 ft. X 25 ft. X 3 ft. X 7.48 gal/ft3 = .o14 MG

1,000,000

Power Consumption KwHr =

1.73 X 460V X 63 Amps X .81 PF X 3 minutes / 60 min/hr. = 2 kwhr
1000

Ep = 3.14 X 30 Head ft. X .014 Flow MG = 0.73

2.0 Power kWh X 0.90 Eff. Motor
Wire-To-Water Efficiency

A 100% efficient pump/motor combination would require one

kWHr of electricity to raise .318 MG of water one foot.
Ep = 3.14 X Head ft. X Flow MG = Power X Ep X Em = .318
Power kWh X Eff. Motor 3.14 X Head

So to determine the theoretical gallons/kWHr for any

other head, simply divide 318,000 by the head.

Then actual efficiency of a particular pump/motor

combination equals:
Actual Gallons / kWHr
Theoretical Gallons / kWHr
Calculation of Wire-To-Water Efficiency

A pump raises 10 million gallons of wastewater an average of 30

feet during a month, and consumes 1340 kWHr in the process.
What is the approximate pump/motor efficiency?

 Theoretical Pumped at 30 ft of head

318,000 = 10,607 gals / kWHr
30

 Actual Pumped = 10,000,000 = 7463 gals/ kWHr

1340 kWHr

 Pump/motor combination equals:

Actual Gallons / kWHr = 7463 gals/ kWHr = 70%
Theoretical Gals / kWHr 10,607 gals/ kWHr
 Causes of Pump Inefficiency
Wrong type of application
Oversized
Poor system design
Cavitation – can lead to pump failure
Wear ring clearance excessive
Internal recirculation
Poor flow control maybe pumping more than process needs
Bearings worn
Mechanical seal leakage – or improper packing adjustment
 Possible Fixes to Pump Problems
If a pump is oversized (common)
Replace the impeller with a smaller one
Trim the impeller
Use a Variable Frequency Drive
Install a smaller pump for lower flow periods
Energy Conservation Measures For Motors

 Motor Rewind / Overhaul

 Match Motor to Load

 Improving power factor with capacitors

 Replacement with energy efficient motors

 You need to include cost of installation in your analysis.

 Energy Conservation Measures For Motors
Motor Rewind / Overhaul

Usually remains the best option:

• Especially when it’s a special order motor (non-stock).

• Its already a premium efficiency motor

• Its needed ASAP

• Should evaluate this option before failure occurs

• Will the overhaul reduce or improve efficiency – Talk to your motor shop

 97% of a motors Lifetime real cost is Energy Consumption. Less than 1% is purchase cost
 Energy Conservation Measures For Motors
Motor Rewind / Overhaul

Let’s Look at an example:

You have a 10 hp. Return Sludge Motor that has failed. The efficiency of the
motor is 88.5% and rewind will cost $700. A new premium efficiency motor 91.7%
will cost $1100. The return sludge pump operates 24 hours / day.

Rewound Motor Energy Consumption Premium Motor Energy Consumption

10 hp X 0.746 Kw/hp = 8.4 kW 10 hp X 0.746 Kw/hp = 8.1 kW

0.885 eff 0.917 eff

Annual energy cost = $7,358 Annual energy cost = $7,096

8.4 kW X 24 hrs./day X 365 day/yr. X .10 / kWh 8.1 kW X 24 hrs./day X 365 day/yr. X .10 / kWh

New Premium vs Rewind $1,100 - $700 = $400

Annual Energy savings $7,358 - $7,096 = $262 / year
Payback Period $400 / $262 = 1.5 years
Note: There will also be a savings related to the lower demand charge

 You need to include cost of installation in your analysis.

 Energy Conservation Measures For Motors
Match Motor to Load

Usually not a good option:

• Unless motor is loaded at less then 50% or OVERLOADED

• Motors are generally most efficient at about 75 - 80% load.

• Power Factor is a consideration when under loaded.

• Designers sometimes oversize motors thinking about future upgrade

• Smaller motors (< 10 hp) are more affected by underload

• Load is difficult to determine. Suggest use amperage draw to estimate

 Energy Conservation Measures For Motors
Match Motor to Load

Usually a good option when:

• Motors are significantly oversized and under loaded.

• Motors are moderately oversized and under loaded. Replace

when Fail

• Motors that are properly sized but standard efficiency. Do

analysis

• Target the replacement motor load at 75%

Energy Conservation Measures For Motors
Match Motor to Load
Let’s Look at an example:
You have a 10 hp. Motor. The motor is operating at ½ load and is 88.5% efficient. A
new premium efficiency 7.5 hp. motor is 91.7% efficient and will cost $900. The motor
operates 24 hours / day.

10 hp Motor 5 hp. load 7.5 hp Motor 5 hp load

5 hp X 0.746 Kw/hp = 4.2 kW 5 hp X 0.746 Kw/hp = 4.0 kW

0.885 eff 0.917 eff

Annual energy cost = $3,679 Annual energy cost = $3,504

4.2 kW X 24 hrs./day X 365 day/yr. X .10 / kWh 4.0 kW X 24 hrs./day X 365 day/yr. X .10 / kWh

New 7.5 hp Premium = $900

Annual Energy savings $3,679 - $3,504 = $175 / year
Payback Period $900 / $175 per year = 5 years
Note: There will also be a savings related to the lower demand charge

 You need to include cost of installation in your analysis.