BS EN ISO 14414-2015
Content
BS EN ISO 14414:2015
BSI Standards Publication
Pump system energy
assessment
BS EN ISO 14414:2015
BRITISH STANDARD
National foreword
This British Standard is the UK implementation of EN ISO
14414:2015.
The UK participation in its preparation was entrusted to Technical
Committee MCE/6, Pumps and pump testing.
A list of organizations represented on this committee can be
obtained on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
© The British Standards Institution 2015. Published by BSI Standards
Limited 2015
ISBN 978 0 580 71451 1
ICS 23.080
Compliance with a British Standard cannot confer immunity from
legal obligations.
This British Standard was published under the authority of the
Standards Policy and Strategy Committee on 30 April 2015.
Amendments issued since publication
Date
Text affected
EN ISO 14414
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
April 2015
ICS 23.080
English Version
Pump system energy assessment (ISO/ASME 14414:2015)
Evaluation énergétique des systèmes de pompage
(ISO/ASME 14414:2015)
Energetische Bewertung von Pumpensystemen
(ISO/ASME 14414:2015)
This European Standard was approved by CEN on 10 January 2015.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same
status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United
Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2015 CEN
All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.
Ref. No. EN ISO 14414:2015 E
BS EN ISO 14414:2015
EN ISO 14414:2015 (E)
Foreword
This document (EN ISO 14414:2015) has been prepared by Technical Committee ISO/TC 115 "Pumps" in
collaboration with by Technical Committee CEN/TC 197 “Pumps” the secretariat of which is held by AFNOR.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by October 2015, and conflicting national standards shall be withdrawn at
the latest by October 2015.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
Endorsement notice
The text of ISO/ASME 14414:2015 has been approved by CEN as EN ISO 14414:2015 without any
modification.
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Contents
Page
Foreword...........................................................................................................................................................................................................................................v
Introduction................................................................................................................................................................................................................................. vi
1 Scope.................................................................................................................................................................................................................................. 7
2
3
4
5
6
Normative references....................................................................................................................................................................................... 7
Terms and definitions...................................................................................................................................................................................... 8
Identification of the assessment team, authority and functions......................................................................... 8
4.1
Identification of assessment team functions................................................................................................................. 8
4.2
Assessment team structure, leadership and competency.................................................................................. 9
4.3
Facility management support..................................................................................................................................................... 9
4.4
Communications..................................................................................................................................................................................... 9
4.5
Access to facilities, personnel and information........................................................................................................... 9
4.6
Assessment objectives, scope and boundaries.......................................................................................................... 10
4.7
Action plan................................................................................................................................................................................................ 10
4.7.1 General................................................................................................................................................................................... 10
4.7.2 Assessment scheduling............................................................................................................................................ 11
4.8
Initial Data Collection and Evaluation.............................................................................................................................. 11
4.8.1 General................................................................................................................................................................................... 11
4.8.2 Initial facility specialist interviews................................................................................................................ 11
4.8.3 Energy project history.............................................................................................................................................. 11
4.8.4 Energy cost......................................................................................................................................................................... 11
4.8.5 Initial system data........................................................................................................................................................ 12
4.9
Objective check..................................................................................................................................................................................... 12
Conducting the Assessment....................................................................................................................................................................12
5.1
Assessment Levels............................................................................................................................................................................. 12
5.1.1 General................................................................................................................................................................................... 12
5.1.2 Level 1 assessments.................................................................................................................................................... 13
5.1.3 Level 2 assessments.................................................................................................................................................... 14
5.1.4 Level 3 Assessments................................................................................................................................................... 14
5.2
Walk Through......................................................................................................................................................................................... 15
5.3
Understanding system functional requirements..................................................................................................... 16
5.4
Determining system boundaries and system energy demand.................................................................... 16
5.5
Information needed to assess the efficiency of a pumping system......................................................... 16
5.5.1 General................................................................................................................................................................................... 16
5.5.2 Electrical motor/drive information............................................................................................................... 16
5.5.3 Pump information......................................................................................................................................................... 17
5.5.4 Liquid properties information........................................................................................................................... 18
5.5.5 Detailed system data.................................................................................................................................................. 18
5.5.6 Measured data.................................................................................................................................................................. 19
5.6
Data collection....................................................................................................................................................................................... 19
5.6.1 System information..................................................................................................................................................... 19
5.6.2 Measurement of pump and motor operating data........................................................................... 20
5.6.3 Pressure................................................................................................................................................................................. 20
5.6.4 Flow........................................................................................................................................................................................... 20
5.6.5 Input power........................................................................................................................................................................ 20
5.7
Cross validation.................................................................................................................................................................................... 21
5.8
Wrap-up meeting and presentation of initial findings and recommendations............................. 21
Reporting and documentation.............................................................................................................................................................21
6.1
Final assessment report................................................................................................................................................................ 21
6.2
Data for third party review........................................................................................................................................................ 21
6.3
Review of final report by assessment team members........................................................................................ 22
Annex A (normative) Report Contents.............................................................................................................................................................23
© ISO/ASME 2015 – All rights reserved
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Annex B (informative) Recommendations on efficient system operation and energy
reduction - Examples.....................................................................................................................................................................................27
Annex C (informative) Expertise, experience and competencies.........................................................................................45
Annex D (informative) Recommended guidelines for analysis software.....................................................................48
Annex E (informative) Example of prescreening worksheet.....................................................................................................50
Annex F (informative) Specific Energy.............................................................................................................................................................51
Annex G (informative) Pumping system parasitic power.............................................................................................................55
Annex H (informative) Example of pumping system efficiency indicator...................................................................58
Bibliography.............................................................................................................................................................................................................................. 61
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ISO/ASME 14414:2015(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2. www.iso.org/directives
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any
patent rights identified during the development of the document will be in the Introduction and/or on
the ISO list of patent declarations received. www.iso.org/patents
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the meaning of ISO specific terms and expressions related to conformity
assessment, as well as information about ISO’s adherence to the WTO principles in the Technical Barriers
to Trade (TBT), see the following URL: Foreword - Supplementary information
ISO/ASME 14414 was prepared by ISO/TC 115, Pumps, in collaboration with ASME EA Standards
Committee — Industrial System Energy Assessment.
ASME is the registered trademark of The American Society of Mechanical Engineers.
This standard was developed under procedures accredited as meeting the criteria for American National
Standards. The Standards Committee that approved the standard was balanced to assure that individuals
from competent and concerned interests have had an opportunity to participate. The proposed code or
standard was made available for public review and comment that provides an opportunity for additional
public input from industry, academia, regulatory agencies, and the public-at-large.
ASME does not “approve”, “rate”, or “endorse” any item, construction, proprietary device, or activity.
ASME does not take any position with respect to the validity of any patent rights asserted in connection
with any items mentioned in this document, and does not undertake to insure anyone utilizing a standard
against liability for infringement of any applicable letters patent, nor assumes any such liability. Users
of a standard are expressly advised that determination of the validity of any such patent rights, and the
risk of infringement of such rights, is entirely their own responsibility.
Participation by federal agency representative(s) or person(s) affiliated with industry is not to be
interpreted as government or industry endorsement of this standard.
ASME accepts responsibility for only those interpretations of designated documents issued in accordance
with the established ASME procedures and policies, which precludes the issuance of interpretations by
individuals. ASME will not issue written interpretations of this edition of this standard.
ISO/ASME 14414 was approved as an American National Standard by the American National Standards
Institute on 2015-02-06.
© ISO/ASME 2015 – All rights reserved
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Introduction
Pumping systems account for a significant portion of a facility’s energy consumption in many industries.
In the majority of pumping systems the energy added to the working liquid by the pump is much greater
than is required by the process. The excess energy added to the system (e.g. due to throttled control
valve) increases heat, noise and vibration but also can bring the system’s maintenance costs. The
addition of excessive energy to the system often results in over-sizing piping system components such
as pumps, process components, and control valves, resulting in an increase in capital costs.
This International Standard provides a method to assess pump systems, to identify and quantify pump
system energy consumption reduction opportunities and reliability improvement opportunities. It gives
a common definition for what constitutes an assessment for both users and providers of assessment
services. Its objective is to provide clarity for these types of services which have been variously described
as energy assessments, energy audits, energy surveys and energy studies.
In all cases, systems (energy-using logical groups of equipment organized to perform a specific
function) are analysed through various techniques such as measurement, resulting in identification,
documentation and prioritization of energy performance improvement opportunities.
When contracting for assessment services, facility personnel may use this International Standard to define
and communicate their desired scope of assessment activity to third party contractors or consultants.
This International Standard is expected to contribute to decreased energy consumption and consequently
to decreased carbon footprint.
This International Standard includes the required assessment report content in Annex A. It gives
examples of efficient system operation and energy reduction opportunities in Annex B, information on
competencies and experiences welcomed to perform audit in Annex C, guidelines for analysis software
in Annex D, a typical example of pre-screening worksheet in Annex E, information on specific energy
in Annex F, information on the concept of parasitic power in Annex G and examples of pumping system
efficiency indicator in Annex H.
This International Standard is developed within the framework of ISO 50001, ISO 50002 and ISO 50003.
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© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
INTERNATIONAL STANDARD
Pump system energy assessment
1 Scope
This International Standard sets the requirements for conducting and reporting the results of a pumping
system energy assessment (hereafter referenced as “assessment”) that considers the entire pumping
system, from energy inputs to the work performed as the result of these inputs.
The objective of a pumping system energy assessment is to determine the current energy consumption
of an existing system and identify ways to improve system efficiency.
These requirements consist of
— organizing and conducting an assessment,
— analysing the data from the assessment, and
— reporting and documenting assessment findings.
This International Standard is designed to be applied, to open and closed loop pumping systems typically
used at industrial, institutional, commercial, and municipal facilities, when requested.
This International Standard is focused on assessing electrically-driven pumping systems, which are
dominant in most facilities, but is applicable with other types of drivers, such as steam turbines and
engines, and drives such as belt.
The International Standard does not
a) specify how to design a pumping system,
b) give detailed qualifications and expertise required of the person using the International Standard
although provides a list of body of knowledge in Annex C,
c) address the training or certification of persons,
d) specify how to implement the recommendations developed during the assessment, but does include
requirements for an action plan,
e) specify how to measure and validate the energy savings that result from implementing assessment
recommendations,
f) specify how to make measurements and how to calibrate test equipment used during the assessment,
g) specify how to estimate the implementation cost or conduct financial analysis for recommendations
developed during the assessment,
h) specify specific steps required for safe operation of equipment during the assessment. The facility
personnel in charge of normal operation of the equipment are responsible for ensuring that it is
operated safely during the data collection phase of the assessment,
i) address issues of intellectual property, security, confidentiality, and safety.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
© ISO/ASME 2015 – All rights reserved
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ISO 17769-1, Liquid pumps and installation — General terms, definitions, quantities, letter symbols and
units — Part 1: Liquid pumps
ISO 17769-2, Liquid pumps and installation — General terms, definitions, quantities, letter symbols and
units — Part 2: Pumping system
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 17769-1 and ISO 17769-2, and
the following apply.
3.1
system energy demand
minimum amount of energy which a pumping system in a specified process requires
3.2
components
individual items of equipment within a system
EXAMPLE
Pump, motor, drive, valve, heat exchanger.
3.3
hydraulic power
water horsepower
power imparted to the liquid by the pump
3.4
electrical power input
power required to support the pumping system operation
3.5
specific energy
energy consumed to move a certain volume of liquid through the system
3.6
parasitic power
power imparted to the shaft of a pump and not used to move the fluid through the system
4 Identification of the assessment team, authority and functions
4.1 Identification of assessment team functions
The assessment team composed of knowledgeable personnel shall have members that are assigned
responsibility and authority to carry out the following functions:
— resource allocation, in order to:
— allocate funding and resources necessary to plan and execute the assessment,
— exercise final decision making authority on resources,
— oversee the eventual participation of non-facility personnel including contracts, scheduling,
confidentiality agreements, and statement of work.
— coordination, logistics and communications, in order to:
— obtain necessary support from facility personnel and other individuals and organizations
during the assessment,
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— participate in organizing the assessment team and coordinate access to relevant personnel,
systems, and equipment,
— organize, schedule activities and manage the assessment.
4.2 Assessment team structure, leadership and competency
The assessment team should comprise of personnel from cross functional backgrounds. It shall include:
— an assessor who has the pump system analysis competencies as described in Annex C;
— the host organization representative who has overall responsibility and ownership for the assessment;
— experts on the processes and the function of the system;
— experts on the maintenance practises of the pumping system;
— experts who can provide the team with cost data.
The assessment team may be from the host organization or enhanced by using outsourced specialists
particularly considering the competence of the assessor
The host organization shall appoint the assessment team leader. This person may be a host facility
employee or an external assessor. In small organisations, the team leader may be the competent assessor.
4.3 Facility management support
Facility management shall understand and support the purpose of the assessment.
Facility management shall allow assessment team members from the facility to participate in the
assessment to the extent necessary.
The assessment team shall gain written support of facility management prior to conducting the
assessment, as follows:
— commit the necessary funding, personnel, and resources to support the assessment;
— communicate to facility personnel the assessment’s importance to the organization.
4.4 Communications
Lines of communication required for the assessment shall be established.
The assessment team shall provide clear guidance to facilitate communications among members of the
assessment team so all necessary information and data can be communicated in a timely manner. This
shall include administrative data, logistics information, as well as operational and maintenance data.
4.5 Access to facilities, personnel and information
The assessment team shall have access to:
— facility areas and pump systems required to conduct the assessment,
— facility personnel (engineering, operations, maintenance, …), their equipment vendors, contractors
and others, to collect information pertinent and useful to the assessment activities and analysis of
data used for preparation of the report,
— other information sources such as drawings, manuals, data sheet, maintenance records, test reports,
historical utility bill information, computer monitoring and control data, electrical equipment
panels, and calibration records.
© ISO/ASME 2015 – All rights reserved
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All data initially identified as essential to the assessment shall be obtained in discussions with
knowledgeable facility staff.
4.6 Assessment objectives, scope and boundaries
The overall objectives and scope of the assessment including portion(s) of the facility and boundaries
of the system(s) that are to be assessed shall be discussed and agreed upon at an early stage by the
assessment team.
The assessment team shall develop a list of site specific objectives for each pumping system, such as
performance improvement targets.
4.7 Action plan
4.7.1 General
An action plan for the assessment shall be developed and agreed upon by the assessment team and
system owners in order to facilitate the assessment and to make it clear to all assessment team members
how the assessment shall be conducted.
The plan shall be flexible and should accommodate various outcomes depending on findings during the
assessment, among others:
a) establish information objectives, in particular:
— determine system boundaries (see 5.4);
— review information that has been collected before the start of the assessment;
— identify how much is known about the systems and what information has to be obtained;
— start with a level 1 assessment (see 5.1.2);
b) identify informational objectives for the assessment (see 5.1):
— determine how extensive the assessment is;
— identify the systems that are included in the assessment;
— identify what information is available and what is necessary to collect;
— identify information that is available on paper records (such as logs) or in the facility computer
systems and what system parameters are necessary to measure;
— identify who is going to be involved and responsible for the collection of necessary data;
c) establish measurement requirements (see 5.6) in particular:
— identify whether a snapshot of the conditions is sufficient (level 2 according to Table 1) or if it is
necessary to collect information during an extended period of time (level 3 according to Table 2);
— identify if permanently installed measurement equipment is available and trustworthy;
d) identify additional informational objectives and in particular true process demands (see 5.4);
e) identify the methods required to meet assessment informational objectives:
— identify how the data are going to be analysed, taking into account the recommendations
from Annex B;
— identify tools/software programs that are going to be used;
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f) identify content of the report and responsibilities.
4.7.2
Assessment scheduling
The dates of the assessment, and dates and times of key meetings shall be designated in advance of
beginning the assessment.
The assessment meetings shall include:
— kick-off meeting. It shall occur just prior to the commencement of the assessment. The purpose of
this meeting is to review information to be collected in the initial data collection and evaluation
(see 4.8) and establish the work schedule. At this meeting, the assessment team should discuss the
safety protocols, tools, methods, measurement, metering and diagnostic equipment required;
— daily schedule(s) for the on-site assessment;
— periodic reporting to facility managers in the form of debriefings should occur as agreed-upon by
the assessment team;
— wrap-up meeting at the conclusion of the onsite activities. It is designed to outline the assessment
investigations and initial recommendations (see 5.8).
The assessment team shall determine corrective courses of action for irregularities that may or do occur
during an assessment (e.g. the failure of a computerized records system).
4.8 Initial Data Collection and Evaluation
4.8.1 General
Before the start of the assessment, the initial data collection shall be made. To expedite the process,
precollection data are optional.
NOTE
4.8.2
This information is used in all assessment phases.
Initial facility specialist interviews
The assessment team shall collect information on operating practices and any specific operating
considerations that affect energy use for the equipment through contact with personnel and specialists.
The assessment team shall also have access to facilities personnel who understand connected systems
that will be influenced by changes made to the pumping system.
4.8.3
Energy project history
The assessment team shall collect and review information on energy saving projects, assessments,
audits, baselines, or benchmarking already conducted for the pumping systems being assessed.
4.8.4
Energy cost
The assessment team shall collect cost data including electricity cost per kWh, or other similar terms,
considering all charges such as demand charges, peak rates, time-of-the-day rate and any other costs up
to the point of use. Where necessary, appropriate costs should be assigned to onsite generated electricity.
These costs should be used in subsequent analyses. If electricity is generated on site the avoided cost or
potential sales cost of the energy should be used.
The assessment team shall agree on the period during which the costs are considered valid.
The assessment team should also consider issues such as demand charges and trends to identify
situations not made obvious by the use of average values.
© ISO/ASME 2015 – All rights reserved
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From this information, the assessment team shall determine an average annual energy cost per kWh
over the previous 12 months.
If a facility has established a marginal cost for energy, it may be used in the energy cost saving calculation
4.8.5
Initial system data
The assessment team shall:
— define the functional needs of the system(s);
— identify high energy consumption equipment;
— identify control method(s);
— identify throttle control systems;
— identify high, low or negative static head systems;
— identify inefficient devices (obvious signs of disrepair or incorrect operation);
— identify lower mean time before failure (MTBF) pump systems, which generally indicate poor
efficiency operation (see Annexes F and H);
— identify small power input systems that have significant influence on facility reliability and
efficiency. All of them shall be considered, not because of their energy consumption but for the
consequence on the efficiency of the whole facility.
4.9 Objective check
Prior to conducting the assessment, the assessment team shall ensure that the action plan meets the
stated assessment objectives.
The action plan of assessment and the objectives shall be reviewed for relevance, cost-effectiveness, and
capacity to produce the desired results.
5 Conducting the Assessment
5.1 Assessment Levels
5.1.1 General
Depending on the needs of the host organization, one or more of the levels of assessment given in Table 1
shall be selected.
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Table 1 — Assessment Level Overview
Activities
Pre-screening opportunities
Walk through
Identify systems with potential saving opportunities
Evaluate systems with potential saving opportunities
Measurement of operating data for a typical single
operating point
Measurement/data logging of systems with variable operating conditions
Level 1
assessment
Level 2
assessment
Level 3
assessment
Required
Required
Required
Required
Required
Required
Optional
Optional
Optional
Not Applicable
Required
Required
Required
Not Applicable
Required
Required
Required
Required
NOTE 1 A level 1 assessment is a qualitative review with possible quantitative elements intended to determine the potential
for significant energy savings based on further assessments and to identify specific systems that merit a greater level of
attention.
NOTE 2 A level 2 assessment is a quantitative review intended to determine energy consumption and potential savings
based on measurement of a single steady-state operating condition requiring a single set of measurements.
NOTE 3 A level 3 assessment is a quantitative review that takes varying system demands into account by monitoring
the system over a time span long enough to capture the various operating conditions which require their own set of
measurements.
Depending on the level of assessment, data shall be collected in accordance with Table 2.
5.1.2
Level 1 assessments
Level 1 assessment shall include gathering of system information for pumping systems considered for
evaluation within the scope of the assessment.
Level 1 assessment shall start with the pre-screening.
During the pre-screening, the control methods for the different systems shall be noted. It shall be
determined which systems are best suited for a closer evaluation. It should also be noted if changes to
the pump system will affect other systems, thereby introducing constraints on potential optimization
strategies for the pump system.
As much information as practical should be collected during the level 1 assessment.
The availability at the facility of some types of data (see 5.5) should also be reported during the level 1
assessment even if it is not collected.
A pre-screening worksheet shall be used to assist in this pre-screening exercise. A typical example of
worksheet to aid in the data collection process is given in Annex E.
In general, the steps taken during the pre-screening shall include the following:
a) sort by driver size, annual operating hours, and estimated energy cost;
b) focus on centrifugal pumps operating at fixed speed;
c) focus on pumping systems that throttle and recirculate for flow control;
d) look for energy-waste symptoms such as large difference in supply and demand, commonly achieved
through valve throttling and by-pass flows (see 5.5.5);
e) identify inefficient pumping systems via maintenance and operational staff interviews and review
of maintenance records;
f) select for assessment those systems that appear most likely to exhibit savings potential.
© ISO/ASME 2015 – All rights reserved
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From this information the assessment team shall make estimates regarding the potential for energy savings
in each system and shall select the pumping systems that meet the criteria for level 2 or level 3 assessments.
5.1.3
Level 2 assessments
Level 2 assessments shall be performed when it is clear that the observed operating conditions are
representative for the operation of the systems and the changes in operating condition are small or
non-existent.
Level 2 assessments shall be performed using data taken from the facility information systems, in paper
or electronic format, or by using portable measuring devices. The measurements shall cover a limited
amount of time, thus giving a snapshot of the operating conditions at the time of measurement.
5.1.4
Level 3 Assessments
Level 3 assessments shall be made on pumps systems where conditions vary substantially over time.
For such systems, the assessment team shall record the system performance data over the time period
or capture data at the extreme duty points. This activity shall be associated with more extensive use of
in situ monitoring to ensure that the operating conditions can be accurately determined at the various
duty points (i.e. design point, normal, rated, maximum and minimum flow rates). The monitoring shall
be made by connecting transducers to data logging equipment and recording the sensor output, or in
some facilities, where historical information is stored, the relevant information should be downloaded
from the facility information system.
Table 2 — Required and optional data for assessment level 1, 2 and 3
Level 1
assessment
Level 2
assessment
Level 3
assessment
Required
Required
Required
Required
Required
Required
Operating parameters (including flow and pressure)
Optional
Required
Required
Cavitation at pump or in system
Optional
Required
Required
System information
Description of the facility
Pumping system inventory (provided prior to assessment
start) for systems that meet pre-screening criteria
- List of pumps
- Pump description (including pumped media)
- Pump type
- Pump application
- Physical location of pump
- Installed motor data (rated nameplate power, voltage, full
load amperage, and frequency)
- Annual operational hours (or % operation)
- Control method e.g. control valve, variable speed drive
(VSD), bypass
Pump curve(s)
Design point
Maintenance level (low, medium, high)
Equipment information (service type, time in service, shared
duty, voltage)
Typical flow rates and variations thereof
Duration diagrams
Histograms
14
Optional
Optional
Optional
Optional
Optional
Optional
Optional
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
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Table 2 (continued)
Level 1
assessment
Level 2
assessment
Level 3
assessment
Maintenance costs
Optional
Required
Required
Rating of any other drive system (e.g. steam turbine drive)
Optional
Required
Required
System information
Process and instrument diagrams (PID)/Digital control system (DCS) screen-shots
5.2 Walk Through
Optional
Required
Required
A walk through is required for level 2 and 3 assessments and may be required for some pumping systems
undergoing a level 1 assessment.
The walk through shall entail examination throughout ensuring that the information provided to the
assessment team reflects the configuration of the existing systems.
For the pumping systems undergoing level 2 and 3 assessments, after the walk through is completed, the
information listed in 5.5 shall be collected using the methodologies specified in 5.6.
All components of the system shall be considered and pertinent information such as valve locations,
locations of available pressure taps, flow meters, valve positions etc. should be noted.
During the walk through, information about the control methods for the different systems such as valve
settings should be noted.
The assessment team shall also identify any existing conditions that are often associated with inefficient
pumping system operation.
These conditions may be identified through the following potential indicators:
a) pumping systems where significant throttling takes place1)
b) pumping systems with recirculation of flow used as a control scheme;
c) pumping systems with large flow or pressure variations;
d) systems with multiple pumps where the number of operated pumps is not adjusted in response to
changing conditions;
e) systems serving multiple end uses where a minor user sets the pressure requirements1);
f) cavitating equipment1);
g) high vibration and/or noisy pumps, motors or piping1);
h) equipment with high maintenance requirements (low MTBF) 1),
i) systems for which the functional requirements have changed with time, but the pumps have not;
j) worn, eroded, corroded, distorted or broken impellers/diffusers/vanes or wear rings and casings
(if available, this information can be provided by facility staff);
k) clogged pipelines or pumps (usually requires historical data to be discovered);
l) systems which have a low pumping system efficiency indicator (for information, see Annex H);
m) seized valves or leaking recirculation valves;
n) sealing systems, especially high temperature, requiring cooling (see B.4.3);
1)
Possible indication of excessive parasitic power level (see Annex H).
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o) lack of proper inlet screening, where appropriate.
5.3 Understanding system functional requirements
The assessment team shall determine what are the normal operating conditions as well as operation
under extreme and abnormal conditions, knowing the limits within which the system is designed to
operate and how the operating conditions are distributed overtime.
If accurate records are not available and the facility personnel may be unable to supply the needed
information, the assessment team shall monitor the system over some period of time in order to establish
the demands on the system.
5.4 Determining system boundaries and system energy demand
The assessment team shall determine the system boundaries and system energy demand of each
pumping system undergoing a level 2 or 3 assessment.
A pumping system assessment shall consider the overall efficiency of the existing system.
NOTE
If the subsystems are part of a larger facility system, the system boundary is complex and the boundary
is determined prior to any measurements and calculations
5.5 Information needed to assess the efficiency of a pumping system
5.5.1 General
After the decision is taken on which pumping systems require further investigation, the following
information from 5.5.2 to 5.5.6 shall be gathered.
The assessment team shall determine the data collection needs for each system being evaluated.
The assessment team shall maintain quality assurance in the design and execution of a measurement
plan as a consistent, repeatable, and reproducible process.
The measurement plan shall adhere to principles of safety, transparency, and reliability.
The measurement plan shall include the measurements required to develop an annual energy
consumption baseline for the pumping system. This is typically done by taking instantaneous flow,
pressure and electrical measurements and determining operating hours at varying system conditions.
Cross-checking should be done to ensure the data are correct.
5.5.2
Electrical motor/drive information
Initial motor/drive information to be collected from the nameplate (if available) or manufacturer’s data
sheets shall include:
a) line frequency;
b) motor size (rated power);
c) motor rated speed;
d) motor rated voltage;
e) motor full load amps (FLA) - the current to the motor when operating at rated power;
f) motor power rating information;
g) nominal efficiency or efficiency class (if provided);
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h) motor type and characteristics;
i) type of drive (e.g. variable frequency drive, belt, gear, direct);
j) motor history (e.g. original, rewound, replaced).
5.5.3
Pump information
5.5.3.1 Rotodynamic pumps
This information should be obtained from the pump nameplate (if available) and any records that may
be kept on file for the pump.
If the information from the nameplate and records differ, this should be noted and addressed later in the
assessment of the system. Pump information required (when available) shall include:
a) type of pump and model;
b) manufacturer name;
c) serial number;
d) customer tag number;
e) number of stages;
f) type of drive;
g) nominal speed – (r/min);
h) design point (flowrate and head);
i) impeller diameter (installed and maximum);
j) pump performance curves, if available, including rated total head, flow, power, efficiency and net
positive suction required (NPSHR),
k) maintenance records;
l) pump cavitation or recirculation problems;
m) sealing system data.
5.5.3.2 Positive displacement (PD) Pumps
This information should be obtained from the pump nameplate (if available) and any records that may
be kept on file for the pump.
If the information from the nameplate and records differ, this should be noted and addressed later in the
assessment of the system. Pump information required (when available) shall include:
a) type of pump and model;
b) manufacturer name;
c) serial number;
d) customer tag number;
e) pump description/model number;
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f) rated data:
— speed (r/min);
— pressure;
— temperature;
— power;
g) system data (operating conditions);
h) relief valve setting;
i) pump performance curves;
j) maintenance records;
k) pump cavitation, recirculation line, or other operational problems;
l) sealing system.
5.5.4
Liquid properties information
Required liquid information shall include:
a) name of the liquid;
b) dynamic viscosity;
c) temperature;
d) density;
e) presence of solids and their characterization;
f) vapour pressure at running pressure and temperature conditions;
g) free gas percentage, when applicable;
h) hazards,
i) inflammability.
5.5.5
Detailed system data
Required systems data information shall include:
a) system layout,
b) unusual operating conditions;
c) PID diagrams,
d) pump control method:
— variable speed drive (VSD);
— throttled (valve percentage open if available);
— by-pass/recirculation;
— on/off;
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— not controlled (pumps just run).
For rotodynamic pumps, the following additional information shall be collected:
— static head and if possible system curve;
— net positive suction head available (NPSHA);
— load profile. Through discussion with operating personnel, note approximate annual, seasonal,
weekly, and daily operating hours at various flows.
For PD pumps, the following additional information shall be collected:
— discharge pressure;
— suction pressure;
— relief valve set pressure;
— net positive inlet pressure available (NPIPA).
Additional information should be collected on NPSHA for rotodynamic pumps and NPIPA for PD
pumps, when needed.
5.5.6
Measured data
5.5.6.1 Electrical data
Required electrical data shall include:
— power;
— actual motor voltage and current to calculate power.
5.5.6.2 Operating system data
Sufficient operating data should be collected during the assessment to determine where energy is
expanded in the system. This should include:
— flowrate in each flow circuit of the system;
— as stated;
— pump shaft (r/min), when appropriate;
— control valve set points and valve positions
— supply and destination tank levels and pressures
— installed equipment in operation.
5.6 Data collection
5.6.1
System information
When possible, the assessment team shall identify the system curve of the pumping system. For most
systems, the system curve may be calculated from two different operating points on the curve: the
static head at zero flow and one operating point.
NOTE
The system curve is essential for the understanding of the complete pumping system and the
consequences resulting from changes to any part of the system. In some rare cases it is impossible to determine a
system curve; however, the pump operating point can still be determined.
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Demand variations as a function of time shall be established so that the appropriate measurements can
be made.
5.6.2
Measurement of pump and motor operating data
The primary required data to be measured shall be head, flow, power, and operating time.
If the operating conditions of the pumping system are constant or only vary minimally in time, a snapshot
of the operating conditions may be enough to assess the system.
If the system demand varies over time, the assessment team shall determine if the system needs to be
monitored over time and what time period is reasonable to get a representation of all operating conditions.
Operating data may also be used if readily available in the facility process control or database of
historical operating conditions.
Uncertainty on measurements and uncertainty on final results should be estimated during the evaluation
of the assessment.
5.6.3 Pressure
Pressure measurements should be made using calibrated instruments with the ideal measurement
location being approximate 2 diameters of straight pipe, from inlet/outlet flanges if available.
To measure pump efficiency, pressure measurements should be made close to the pump on both the
suction and the discharge side.
When measuring pump performance it is recommended that head losses between the suction and
discharge head measurement points and the pump be estimated.
For accurate calculation of the pump total head, the velocity and the instrument elevation shall be taken
into account.
5.6.4 Flow
The system flow rate shall be determined to establish pump and system efficiencies. Flow rates shall be
measured using properly sized instruments, whether it be for an individual pump or total system flow.
Measurements shall be made with calibrated flow meters that are properly installed into the system
and known to be accurate across the range of measured conditions. The flow meter should be installed
according to the manufacturer’s recommendations. When it is necessary to use portable flow meters,
verification of the measurements should be performed by re-installing the flow meter in an alternate
location or using multiple measurement techniques. If large variations are found, then the measurements
shall be considered unreliable.
If the flow rate is determined from the pressure drop across a component with known characteristics
or by using data from the pump manufacturer’s performance curve, the data should be cross-correlated
with both pressure and power measurements or by using multiple measurement techniques if there is
doubt about the accuracy of the measurements.
5.6.5
Input power
Whenever possible, the input power should be measured directly using a power meter, which should give
the most accurate results. When it is not possible to measure power directly, an acceptable alternative
shall be to measure voltage and current delivered to the motor. Then using the estimated power factor,
the motor input power shall be calculated. If a power drive system is used, the input power shall be
measured before the variable frequency drive.
Electrical measurements shall be performed only by a qualified person.
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5.7 Cross validation
When the needed parameter is not directly measurable, it may be estimated through measures of other
parameters, such as:
— pump head combined with pump head curve to estimate flow rate;
— electric power combined with motor performance curve (or estimates) to estimate shaft power, and
then use the shaft power and pump shaft power curve to estimate flow rate;
— measured valve position and flow rate combined with the valve characteristic curve to estimate
differential pressure;,
— measured drawdown and fill times, along with well or sump dimensional data to estimate pump
flow rate.
Such estimation methods may be used for preliminary quantification of potential energy savings
opportunities and to help determine whether the magnitude of savings is sufficient to warrant further
investigation.
NOTE
It is beyond the scope of this International Standard to detail the various cross-validation techniques,
but they are vital tools in the assessment and solution development process.
5.8 Wrap-up meeting and presentation of initial findings and recommendations
The presentation of findings and preliminary recommendations shall be conducted as final step in
conducting the assessment. This wrap-up meeting should be attended by the entire assessment team.
During this meeting, outstanding questions and issues from the assessment team should be addressed. The
tentative results of the assessment shall be formally presented and should include but not be limited to:
— review of the assessment process used;
— efficiency of the system(s) and components assessed;
— tentative recommended improvements, with preliminary energy and cost savings, if available;
— discussion of any further analysis recommended, and;
— any general comments and observations.
The results presented shall be qualified as preliminary, subject to further analysis and refinement. Target
dates for the delivery of a draft and final versions of the written report shall be set by mutual agreement.
For more information, see Annex B.
6 Reporting and documentation
6.1 Final assessment report
At the conclusion of the onsite assessment and any required follow-up data analysis, the assessment
results shall be reported in a final written report, as described in Annex A.
6.2 Data for third party review
The report or other documentation delivered with the report shall include sufficient raw data from the
assessment so that the analyses performed in 5.6 can be confirmed by a third party. This documentation
shall be structured so it can be easily accessed by verifiers and other persons not involved in its development.
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6.3 Review of final report by assessment team members
Before the assessment report is finalized, members of the assessment team shall review the assessment
report for accuracy and completeness and provide comments. Upon review of the draft report and
requests for modifications, the assessment team shall provide a consensus acceptance, and then prepare
and issue the report in final form.
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Annex A
(normative)
Report Contents
A.1 Executive Summary
This section shall condense and summarize the report in brief. The executive summary shall provide
an overview of:
a) facility background, products made and energy objectives;
b) objectives and scope of the assessment;
c) system(s) assessed and measurement boundaries used;
d) annual energy usage;
e) performance opportunities identified with associated energy and cost savings;
f) estimated energy and cost savings ;
g) list of recommendations to accomplish the estimated energy and cost savings identified.
A.2 Introduction and facility information
Brief description and background, team and scope of the assessment shall be included in this section.
A.3 Assessment objectives and scope
This report section shall contain a brief statement of the assessment’s objectives. The report shall
identify the boundaries of the specific system(s) on which the assessment was performed and why the
boundaries were selected. This report section shall include a description of the general approach and
methodology used to conduct the assessment.
A.4 Description of system(s) studied in assessment and significant system issues
The report shall include a detailed description of the specific system(s) on which the assessment was
performed. Depending on the system assessed, the discussion of system operation can be extensive and
should be supported by graphs, tables and system schematics. Supporting documentation should also be
included to clarify the operation of the system components and their interrelationships.
Any significant system issues shall be described, including an operational review of system. Any
existing best practices found (methods and procedures found to be most effective at energy reduction)
shall be documented.
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A.5 Assessment data collection and measurements
The methods used to identify and interview key facility personnel, obtain data, and conduct
measurements shall be identified, including an overview of the measurement plan. Relevant data for
level 2 and 3 assessments shall include:
— definition of system requirements and a determination of how system operation changes during the
year (drawings, system process data);
— pump total head (TH), flow and system estimated curve;
— electrical energy consumption data;
— determination of pump operating hours and flow intervals;
— pump performance information, when available;
— measurement or estimation of system losses.
This section should also include a discussion of data accuracy and the need for verification before the
recommended projects are approved.
A.6 Data analysis
The report shall include the outcome of the measurements and data analysis in accordance with site
specific assessment objectives, assessment plan of action and statement of work. Any significant
analytical methods, measurements, observations, and results from data analysis from completed action
items shall be documented.
A.7 Annual energy consumption baseline
If sufficient data exist, the assessment report shall contain the baseline of total annual energy consumption
for the pumping system. The analytical method used to develop the annual energy consumption baseline
(see 5.5.1) shall be described. Facility functional and production process observations and information
shall be reported.
The report shall clearly describe the assessment baseline as a basis for both routine and non-routine
adjustments. Adjustments are calculated from identifiable physical facts with respect to changes in the
physical facility and production process. The report shall provide sufficient information on the facility
functional baseline during the assessment to provide a basis for adjustments.
NOTE 1 Routine adjustments are those energy-governing factors that are expected to change such as
production volume variations. Baseline relationships of production dependent and time dependent system energy
consumption are clearly stated.
NOTE 2 Non-routine adjustments are related to factors that are not usually expected to change during the
short-term. Factors such as facility size, the design, type and number of production lines involving pumping
systems are examples of non-routine adjustments.
A.8 Performance improvement opportunities identification and prioritization
The analysis shall quantify estimates of energy reduction and energy cost savings from recommended
performance improvement opportunities. Additional calculations may address other energy and nonenergy benefits. The report shall identify the methods of calculation and software models used with
assumptions clearly stated.
Performance improvement opportunities can include those from maintenance improvements;
operational improvements; equipment upgrades and replacement; revising control strategies; process
improvements and change-over; and other actions that reduce energy consumption.
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Details on performance improvement opportunities to be documented and reported shall include a
sufficiently detailed description of the actions required for project implementation. To aid in the selection
of projects for implementation, the assessment team should categorize the opportunities identified to
be of high, medium or low priority based on factors such as
— energy and cost savings;
— likelihood of achieving projected savings;
— likelihood of long project life with sustained savings;
— impact to on-going operations;
— changes or modifications necessary for the existing equipment;
— time and cost for implementation;
— complexity of implementation steps;
— potential parallel benefits (e.g. improved profitability, improved reliability and maintenance costs,
improved operations, lower environmental impact).
In the analysis section of the report, the pumping system energy consumption baseline shall be
established and energy savings opportunities developed.
For all assessment levels, the analysis for energy consumption baseline development and proposed
recommendations should be performed in sufficient detail to allow facility staff to understand all parts of
the analysis. If software is used, the data entered into the software shall be clearly defined. The supporting
analysis data may include spreadsheets, diagrams, software output screen captures, and calculations.
The steps, assumptions and calculations of the analysis should be presented in a logical detailed format
that can be understood by other engineering professionals for third party verification if required.
This part of the assessment may also address other energy and non-energy benefits such as improving
resource utilization, reducing per unit production cost, reducing life cycle costs, and improving
environmental performance. These benefits can be mutually agreed upon with facility management.
NOTE
The amount of detail included in the energy efficiency recommendations vary considerably for each
assessment level.
Recommendations are typically classified as operation and maintenance recommendations (OMs) or as
energy conservation measures (ECMs). The recommendations reviewed in this report section shall be
prioritized in order based on facility staff acceptance and cost effectiveness. Each subsequent measure
should include the interactive savings effect of the previously recommended measure. Consideration
must also be given to projects that may be easily implemented versus improvements that may not be
easily pursued until facility production lines are out of service.
The presentation of each measure should be limited to a brief description of the proposed improvement
and a summary of the benefits. If needed, it is also appropriate to recommend a higher level assessment
before the measure is pursued.
General observations of non-pumping system related energy saving opportunities should also be discussed.
A.9 Recommendations for implementation activities
Details on performance improvement opportunities shall include the next steps needed to move from the
identified performance improvement opportunities to implementation of the listed measures. Methods
for refining data analysis as needed, and for obtaining reliable implementation cost estimates should be
addressed. Methods for optimizing and maintaining system performance following implementation of
adopted measures should be identified.
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Implementation cost estimates for the performance improvement opportunities, if developed as an
optional activity, are intended to be screening or feasibility estimates and could also include preparing
metrics such as return on investment and payback period.
The assessment report should note that further engineering analysis be performed prior to implementing
the recommendations contained in the assessment report.
A.10 Appendices
Information that is lengthy and not required for the presentation of the report should be included
in appendices to ensure clarity of the body of the report. Detailed supporting data, such as energy
consumption calculations, cost savings calculations, and economic analysis, should be referenced and
included in the report appendices.
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Annex B
(informative)
Recommendations on efficient system operation and energy
reduction - Examples
B.1 General recommendations for efficient system operation
The operating characteristics of pumps should match the characteristics of load and piping resistance,
so as to keep the pumps running in accordance with the manufacturer’s specifications.
For any large power system with long operation time, measurement of pressure, flow rate, and power
should be made at relevant points in the system regularly to test the efficiency of operation in order to
ensure that the system is operated efficiently.
Preferably the pump should operate at the best efficiency point (BEP) and in any case not outside the
allowable operating range (AOR) defined by the pump manufacturer (see Figure B.1).
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Key
Y1
Y2
Y3
Y4
X
1
2
3
4
a
b
head, expressed in meters
efficiency, expressed in percentage
power, expressed in kilowatts
NPSH3, expressed in meters
Flow rate, expressed in cubic meters per hour
head
power
efficency
NPSH3
Preferred operating region.
Allowable operating region.
NOTE
High pump efficiency does not guarantee high system efficiency, especially if the pump is oversized vs.
the system demand.
Figure B.1 — Example of curves and allowable operating range
The example curve in Figure B.2 shows how fast the mean time between failures (MTBF) falls off when
the pump operating point moves away from BEP.
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Key
A
B
C
D
E
F
G
H
high temperature rise
low flow cavitation
low flow bearing and seal life
reduced impeller life
suction recirculation
discharge recirculation
low bearing and seal life
cavitation
Curve 1
Curve 2
Curve 3
X
Y
pump curve H(Q)
pump efficiency curve
reliability curve/MTBF
flow in percent of flow at BEP
head in percent of head at BEP
Figure B.2 — Example of pump reliability curve
Manufacturers normally indicate a preferable operating region around BEP and sometimes also an
allowable operating region. How these regions are defined differ between manufacturers. Care should
be exercised to operate as close to BEP as possible. A deviation of −20 % or +10 % from the flow at BEP
could mean that the mean time between failures (MTBF) is cut in half! For pumps with variable flow,
the selection of the best efficiency point in relation to the operating range needs careful consideration.
B.2 System management to ensure economic operation
B.2.1 General
Three-phase asynchronous motors used for driving pumps should be sized to operate at or close to
maximum efficiency for all operating conditions (normally 50 % to 100 % load and 35 % to 100 % load
for high efficiency motors according to IEC 60034 series). For other types of drive, the operating range
should be in accordance with manufacturer recommendations.
Rules for operation management, maintenance and repair should be established.
Operation performance logs and technical archives should be kept and maintained.
Personnel responsible for management and operation should be adequately trained for their positions.
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B.2.2 System management recommendations
Efficient system components should be used and operated in such a way that high system efficiency
is maintained.
For systems operating a long time under part load or having large demand changes, proper measures
should be taken in order to maintain high operating efficiency for all conditions, when it is technologically
and financially practicable.
Process requirements should be evaluated to determine that the system is running efficiently, within
applicable quality, health and safety requirements. If the system is not running within the established
boundaries, a plan for correction should be made and implemented.
B.2.3 System updating and improvement
For any system that fails to meet the established efficiency requirements after an assessment, the system
operation should be examined and a report should be produced to document the current operation,
including: test method and data analysis, efficiency improvement measures, and responsibilities.
This report should be kept in an accessible location.
When pump systems have been installed or undergo updates, an assessment should be conducted to
establish base operating conditions.
B.2.4 Pump system piping
Increasing the internal pipe diameter is usually the most effective way to decrease the pipe friction
losses and the resulting energy consumption. For example, 10 % diameter increase leads to a decrease
of approximately 40 % in losses for the turbulent flow region. In general, flow velocities should be kept
as low as practically possible in regard to the liquid material suspended being pumped.
The number of pipe bends should be minimized and the radius of curvature of turns should be as large
as economically feasible in order to minimize friction losses. A minimum of 1,4 times longer than the
pipe diameter is recommended for such turns.
Rapid diameter changes should be avoided. Diffusers should be used when possible.
When selecting components, considerations should be made to minimize the friction losses across the
equipment. The equipment should be suitable for the liquid being pumped.
The elevation and pressure on the surface of liquid in a tank affects the systems static head. Wherever
possible, static head should be minimized.
B.3 Common causes and remedies for excessive energy consumption for
rotodynamic pump
B.3.1 General
It is important that a thorough understanding of system requirements be established before the
application of any analysis technique. This includes distinguishing between system design specifications
and actual process requirements before evaluating energy savings opportunities.
It should be understood that once physical or operational changes are made, the system curve may likely
change, resulting in different system requirements and the need for another iteration of system analysis.
Each time the system is modified there is the potential to redefine optimal operation for that system.
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B.3.2 Reduce system head losses
Examples of opportunities to reduce the system head are shown below. This list is not comprehensive.
Rather, it shows some of the most common opportunities identified by experience:
a) remove/reduce unnecessary throttling and/or recirculation flows;
b) clean or perform maintenance on fouled components such as heat exchangers;
c) isolate flow paths to non-essential equipment or equipment that is not operating;
d) maintain proper fill and venting of elevated sections of pipe;
e) reduce/remove sediment and scale build-up in pipelines, heat exchangers, and process components;
f) do not employ an air gap between pipe discharge and receiving tank when isolation is not necessary;
m) adjust flow rate to meet process demands without exceeding them;
k) maintain the design pumping temperature when pumping viscous products;
i) separate secondary systems that demand very low flow rates with a head much higher than required
by the main system.
B.3.3 Reduction of system flowrate
Examples of opportunities to reduce the system flow rate are shown below. This list is not comprehensive.
Rather, it shows some of the most common opportunities identified by experience:
j) maintain the optimum differential temperatures in heat exchanger applications, preferably
considering exchanger design efficiency;
l) isolate unnecessary flow paths, unnecessary pump recirculation and leaking valves, check valves,
minimum flow valves;
l) reduce the flowrate in the batch processes that are basically fill and drain, as long as it does not
create an unacceptable change to the production schedule;
m) turn off pumps when flow is not needed.
B.3.4 Ensuring that components operate close to best efficiency
The operating efficiencies of the various components that comprise the pumping system can vary
substantially depending on where they operate on their respective curves. As a rule, motors should
operate where their efficiency curve is flat. Rotodynamic pumps should preferably be operated close to
BEP (see Figure B.2). Operation away from BEP quickly reduces pump efficiency and reliability.
It should also be noted that different types of electric motors and other drivers can differ substantially
in efficiency.
NOTE
Excess system energy consumption can occur when installed equipment is operated away from the
best efficiency point. There are many possible reasons but most of them are related to changes from projected
specification, change in system requirements; all of them will lead to less energy efficient systems. Some of the
more common factors, are listed below:
— during the initial design stage of a system and before the system has been in operation, there are many
uncertainties. Selection of equipment tends to be conservative and this in addition to service factors and
design margins will often result in oversized systems,
— systems designed for excessive requirements;
— when the actual system requirement is considerably different than the pump capability, the system efficiency
will inherently suffer (and, it might be noted, so will reliability);
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— changes in system conditions, either due to changes in requirements or aging of the system itself or due to
changes of specific component and equipment;
— lack of understanding that energy consumption might accounts for largest cost when it comes to make
decision in new investments and therefore installing equipment with higher life cycle cost than possible.
B.3.5 Change pumping system run time
Opportunities based on changing system run time are often used where the system requirement is
dominated by friction head. Such uses include, but are not limited to:
— pumps/lift stations,
— systems with electric rates that change based on time of use or have a demand component,
— systems that run when the process is not operating. Often a recirculation loop is employed rather
than turning a pump off when flow is not needed,
— systems with multiple parallel pumps that are running more pumps than necessary to fulfil the
process demands.
A good practice to enhance pumping efficiency is to monitor specific energy (see Annex F).
In most instances pumping capacity is larger than needed. This is especially true in applications
involving storage, for example filling up tanks in industrial applications, pumping down wet wells or
filling up reservoirs in municipal applications. The pumps are started and stopped by the liquid level in
the wet well or the tank/reservoir. Lower flow rates will mean an increased run time but on the other
hand lower flow rates will result in savings due to the reduced friction losses.
In installations with high demand changes lowering flow rates could mean lower power demand and
hence cost savings can be achieved. (This does not always mean that energy savings are achieved).
In many applications pumps may run longer than necessary. Examples of such applications are multiple
pumps running in parallel and producing more flow than necessary. This is not uncommon in applications
involving cooling towers and chillers. The operators are not switching pumps off when they could be
turned off, but let them run even if they are not needed. This situation can be recognized by measuring
the temperature difference over the cooling tower/ heat exchanger. If the temperature difference is
lower than optimal, the flow rate is too high. In such a situation, one or more pumps could be turned off
or the capacity might be lowered by changing the speed of the pump(s).
B.4 Examples of basic energy reduction opportunity calculations for
rotodynamic pumps
B.4.1 Calculation of existing and post assessment energy consumption
B.4.1.1 General
The objective is to minimize the energy consumption of the existing system. This is accomplished by
evaluating the operation of the existing system, identify possible reductions in system head, flow rate,
and run time, and running the system components closer to their optimum conditions.
32
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
The hydraulic power imparted to the liquid by the pump is as shown in Formula (B.1)
Pw =
where
QH ρ
QH ρ
(SI units) or Pw =
(US units)
367000
331232
Pw
is the hydraulic power supplied by the pump expressed in kilowatts (kW);
H
is the total head, at flow rate Q, expressed in meters or feet);
Q
ρ
(B.1)
is the flow rate expressed in cubic meters per hour (m3/h) or gallon per minute (gpm);
is the liquid density expressed in kilogram per cubic meter (kg/m3) or pound per cubic foot
(lb/ft3).
The electrical power Pe required to support the pumping system operation is shown in Formula (B.2)
Pe =
where
ηP
ηM
ηD
Pw
η Pη Mη D
(B.2)
is the pump efficiency;
is the motor efficiency;
is the drive efficiency (if no drive installed set ηD to 1).
To optimize pump systems, the following operations are performed:
— minimization of the flowrate;
— minimization of the pump head;
— optimization run time;
— maximization of the component efficiency.
Improvements can be accomplished using existing equipment. Additional savings can sometimes be
achieved through equipment replacement.
B.4.2 Example
The following example demonstrates the calculations to determine:
— initial power consumption;
— power consumption after making improvements in operation;
— power consumption after replacing components.
Figure B.3 illustrates a transfer liquid system from Tank A to Tank B. A recirculation line maintains
constant pump discharge pressure. A level control valve maintains constant level in Tank B: 4,5 bar (65
psi) upstream of the pressure reducing valve. The pump is direct motor-driven.
The following data are recorded:
— liquid: water temperature 20 °C (68 °F) and density 998,3 kg/m3 (62,32 lb/ft3)
— plant electric cost: $ 0,10/kWh
— measured flowrate: 450 m3/h (2 000 gpm)
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— measured process flowrates: 340 m3/h (1 500 gpm) to tank B, 110 m3/h (500 gpm) recirculation
by-pass
— measured pump total head: 46 m (150 ft)
— Pe:78 kW
— motor efficiency: 94 %
— 6 132 h (70 %) annual operation
Key
1
2
P
L
tank A
tank B
pressure control
level control
Figure B.3 — Example of simplified flow diagram
This example consists of the following steps:
a) to determine annual power consumption and annual operating cost.
Figure B.4 illustrates the curve of the pump.
34
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Key
1
2
3
X
head, expressed in meters
NPSH3, expressed in meters
power, expressed in kilowatts
flow rate, expressed in cubic meters per hour
Figure B.4 — Example of pump operating curve (as found flow rate of 450 m3/h)
The power consumption, calculated using Formula (B.2), is 82,9 kW.
The pumped system runs 6 132 h/y (0,7 × 8 760 h/y).
The annual operating cost, AOC, is calculated as follows:
h
$
$
AOC = 82, 9 kW ×6 132 ×0, 10
= 50 830
kWh
y
y
b) to determine present system demand
(B.3)
The result of data provided shows that:
— present system demand is 340 m3/h;
— bypass flow of 110 m3/h can be eliminated to save energy.
c) to determine current annual power consumption and annual operating cost without component
replacement
Eliminating the bypass flow results in:
— flowrate: 340 m3/h;
— head: 48,7 m;
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— efficiency of 62 %.
The power consumption, calculated using Formula (B.2) is 77,3 kW. The annual operating cost is $47 400.
Pump Modifications
Further savings can be achieved by acting on the following additional data collected after the first analysis:
— control valve differential pressure can be reduced from 1,75 bar down to 1 bar;
— impeller trimming from 327 mm to 282 mm reduces the head to 41,3 m at 340 m3/h with an
efficiency of 65 %.
The resulting power consumption Pe, calculated using Formula (B.2), is 63,5 kW. The annual operating
cost is $ 38 930.
d) to determine annual power consumption and annual operating cost of the system considering
component replacement
Installing variable speed drive to existing pump results in:
— 1,580 r/min for 340 m3/h;
— head: 37,9 m;
— pump efficiency of 66 %.
The resulting power consumption Pe, calculated using Formula (B-2) is 59,5 kW.
The annual operating cost is $36 490.
Purchase new pump for current demand:
— flowrate: 340 m3/h;
— head: 41,9 m;
— pump efficiency of 84 %;
— motor efficiency of 94 %.
The resulting power consumption Pe, calculated using Formula (B.2) is 49 1 kW. The annual operating
cost is $ 30 110.
Table B.1 gives the summary of the calculated energy reduction.
Table B.1 — Summary of the results
Conditiona
As found
Eliminate by-pass
Trim impeller
Add variable frequency
drive b
New pump
a
Flow
m3/h
Head
m
Pump efficiency
Power consumption
Operating cost
340
48,7
%
62
kW/h
$
65
63,5
38 940
84
49,1
30 110
450
340
340
340
46,5
73
37,9
66
41,3
41,9
82,9
77,3
59,5
50 830
47 400
36 490
All examples use the following system conditions: 20°C water, motor efficiency 94 %, power cost $0,10/kWh, 6,132
h/year operation
b
36
The efficiency of the variable frequency drive is 95 %, as specified by the manufacturer.
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
B.4.3 Secondary systems: sealing systems
Sealing systems can be another cause of excessive energy consumption. The excess energy related to
the use of inappropriate seals or seal support systems, may consume large amounts of energy and other
utilities. Further inspection by a specialist is recommended, see Example.
Further inspection by a specialist is recommended, see Example.
During operation the sealing assembly (mechanical seal and seal support system) contributes to the
total energy consumption of the pump-sealing assembly mainly due to the friction and viscous shear
of the fluid in the seal chamber (also known as frictional losses), and the energy consumption of the
seal support system which is implemented in order to maintain an acceptable environment in the seal
chamber. In certain applications the energy consumption level of the support system can be equal to or
even greater than that of the pump drive.
Table B.2 provides an example of qualitative assessment of the energy impact of different commonly
used seal piping plans (see API 682).
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.2 — Example of energy impact based on API 682 seal piping plans
Basic seal
arrangement
API
Plan
01
Internal recirculation from
discharge to seal
02
Dead end, no recirculation
11
External recirculation from
discharge to seal
13
14
Single mechanical seals and the
inboard seal of
dual unpressurized seals
Description
External recirculation from
seal to suction
External recirculation from
discharge to seal to suction
21
External recirculation from
discharge through a cooler to
seal
23
Internal recirculation from
seal to cooler and back to seal
31
External recirculation from
discharge through cyclone
separator to the seal
32
Flush fluid is injected to the
seal from external source
41
Recirculation from discharge
through cyclone separator and
cooler to the seal
62
External atmospheric quench
Efficiency losses
Thermala
0
Electricalb
2
Comments
Waterc
0
0
1
0
0
2
0
0
2
0
0
2
0
3
2
1
2
1
1
0
2
0
3
1
3
3
1
2
1
Thermal energy losses
may occur and water
may be consumed if
the seal chamber is
designed with cooling
or heating jacket.
1
1
May consume a high
amount of thermal
energy when cooling
the process medium is
required
Is the most effective
when cooling of the
process medium is
required.
May consume the highest amount of thermal
energy to replace the
process fluid heat
lost by injecting the
cooler external fluid.
If plan 32 used in cold
application, the then no
thermal impact
May consume a high
amount of thermal
energy when cooling
the process medium is
required
If seam is used as a
quench fluid, the thermal loss may be significant if not controlled
a
Thermal losses refer to cooling of the flush or barrier fluid, lost and recovery process heat and energy required to
separate diluents.
b
Electrical losses refer to additional electrical power absorbed by the seal face (value of 1) and flow loss of the pump due
to recirculation (value of 1).
c
Water losses refer to the water consumption to operate the piping plan. Air cooling may be used to avoid cooling water
usage.
0
no impact on efficiency
2
moderate impact on efficiency
1
3
38
minor impact on efficiency
major impact on efficiency
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.2 (continued)
Basic seal
arrangement
Dual pressurized
mechanical seals
Dual unpressurized mechanical
seals
API
Plan
53
54
Description
Pressurized external barrier
fluid reservoir supplies clean
fluid to the seal
External barrier fluid system
supplies clean fluid to the seal
at pressure higher than seal
chamber pressure
74
Externally supplied barrier
gas to seal at pressure higher
than seal chamber pressure
52
Unpressurized external buffer
fluid reservoir supplies clean
fluid to the seal
72/
75/
76
Externally supplied gas buffer
for arrangement 2 seals.
Buffer gas pressure is lower
than the process side pressure
of the seal
Efficiency losses
Comments
Thermala
Electricalb
Waterc
1
1
1
2
2
2
0
0
0
1
0
1
0
1
0
May consume a low
thermal energy when
the temperature of
the process medium is
higher than the temperature of the barrier
fluid
Electrical energy
consumed in the processing of the nitrogen
barrier gas is considered negligible
May consume a low
thermal energy when
the temperature of
the process medium is
higher than the temperature of the barrier
fluid
Electrical energy
consumed in the processing of the nitrogen
barrier gas is considered negligible
a
Thermal losses refer to cooling of the flush or barrier fluid, lost and recovery process heat and energy required to
separate diluents.
b
Electrical losses refer to additional electrical power absorbed by the seal face (value of 1) and flow loss of the pump due
to recirculation (value of 1).
c
Water losses refer to the water consumption to operate the piping plan. Air cooling may be used to avoid cooling water
usage.
0
no impact on efficiency
2
moderate impact on efficiency
1
3
minor impact on efficiency
major impact on efficiency
For some pump system applications, the selection of the seal support system is a major contributor to
the overall pump system energy consumption:
EXAMPLE
Water based abrasive slurry. This application involves a single stage end-suction, overhung, foot
mounted slurry pump (OH1) which is pumping a water based black liquor slurry in a paper mill at 75 ° C (170 °F).
The pump shaft speed is 3600 r/min, the pump shaft diameter is 50 mm (2.00 in.), the seal chamber pressure is
345 kPag (50 psig), and the pump driver would consume 37 kW (50 hp). One common method of sealing the shaft
is either packing with a lantern ring, or a single mechanical seal using Plan 32, both with a 1,9 lpm (0,5 gpm) clean
water flush at 10 °C (50 °F) is applied. The net energy consumption of these sealing systems is 84 kW (113 hp)
primarily due to the need to heat and evaporate the water diluent in a downstream process that was introduced
through the flush. An alternative sealing system for this slurry application would be the use of a dual pressurized
seal with an API piping plan 54 to circulate a clean barrier fluid through the cavity between the inboard and
outboard seals. This seal and system approach reduces the sealing system energy consumption to 3,9 kW (5.2
hp) which results in an energy savings of 80,1 kW (117,8 hp). Even if a switch to a dual pressurized seal were not
practical, a reduction in flush flow rate through the use of a close clearance bushing or a different placement of
the lantern ring for the packing arrangement can easily cut the required flow rate down to 0,4 lpm (0,1 gpm) with
a reduction of energy consumption of 67 KW (90 hp).
© ISO/ASME 2015 – All rights reserved
39
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
B.5 Explanation of basic energy reduction opportunity calculations for positive
displacement pumps
B.5.1 General
Positive displacement (PD) pumps have very different characteristics than rotodynamic pumps and in
many applications low energy consumption has been a primary driver of their initial selection. Due to
the differences in PD pump characteristics, the recommended control logic is different from that used
with rotodynamic pumps.
Closely matching the positive displacement pump performance, the process requirement approaches
the optimal energy consumption.
When evaluating systems, the following is valid for PD pumps:
— PD pumps at constant speed are constant flow devices;
— flow varies with viscosity and pressure changes due to “slip” which is fluid internally returned from
high pressure to low pressure region of the pump (suction). Slip flow is minor and can be ignored in
system energy evaluations;
— flow variation with pressure change is much less than for rotodynamic pumps;
— rules for positive displacement pumps are:
— flow rate varies directly with speed,
— power requirement varies directly with speed,
— pressure differential is determined by the system hydraulics,
— both flow and power increase with a viscosity increase,
— PD pumps generate pressure to meet system requirements, dead heading and discharge throttling
should not be practiced. Safety requires a pressure relief device in downstream of the pump but this
should not be an energy issue unless the unit is improperly sized and is recirculating through the
relief valve.
— PD pumps are not head producing devices and are rated and calculated directly based on pressure
differential and not head.
Head to pressure relation is calculated using Formula (B.4):
P = H ρ g × 10−5 (SI) or P =
where
P
H
ρ
g
40
Hρ g
(US)
2, 31
(B.4)
is the pressure expressed in bar (bar) or pound per square inch (psi)
is the head expressed in meters (m) or feet (ft)
is the density expressed in kilogram per cubic meter (kg/m3) or pound per cubic foot (lb/
ft3)
is equal to 9,81 m/s2 or 32,2 ft/s2
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
The hydraulic power imparted to the liquid by the pump is calculated using Formula (B.5):
Pw =
where
Q∆p
36
Pw
Δp
Q
(SI) or Pw =
Q∆p
(US)
1714
(B.5)
is the hydraulic power supplied by the pump expressed in kilowatts (kW) or horsepower (hp);
is the difference of pressure expressed in bar (bar) or pound per square inch (psi);
is the flow expressed in cubic meters per hour (m3/h) or gallon per minute (gpm);
The electrical power required to support the pumping system operation is calculated using Formula (B.6):
Pe =
where
Pw + PI
η Mη D
(B.6)
Pe
is the electrical power input expressed in kilowatts (kW) or horsepower (hp);
ηM
is the motor efficiency when supplying the power required by the pump at flow rate Q;
PI
ηD
is the internal power losses which are mechanical and viscous, expressed in kilowatts (kw)
or horsepower (hp);
is the drive (belt, adjustable speed, gear, etc.) efficiency;
Pump internal power losses are those from mechanical friction, internal recirculation and the viscous
losses from the drag effect on parts in the liquid flow path. An estimation of these values can be obtained
from the pump manufacturers.
Driver size is based on maximum viscosity and pressure differential.
PD pumping systems are deemed to be operating at the optimal performance level when the system
functional requirements are met with:
— minimum demand flow rate,
— minimum demand differential pressure,
— minimum run time,
— maximum component efficiencies.
The optimal hydraulic power added to the system is the value calculated with the above conditions
inserted into Formula B.12 and the optimal electrical power is calculated (Formula B.13) using the
optimal hydraulic power and the best available pump, motor and drive efficiencies.
As prescribed in this International Standard, the assessment should establish a baseline of total annual
energy consumption for the pumping system(s) assessed.
B.5.2 Example
B.5.2.1 Existing conditions (see Table B.3):
A system transfers liquid from tank A to tank B (see Figure B.5).
All flow goes to tank B.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Tank B is always full and excess flow returns to tank A.
B.5.2.2 Improved conditions (see Table B.3):
A recirculation line is installed to maintain the constant flowrate and to supply demand flow.
Energy is saved since less liquid is forced through the feed line to tank B, thus lowering friction losses
No discharge throttling can be used. The pump is directly driven by a motor (without gear, belt, or
variable speed drive).
B.5.2.3 Main features of operating conditions are:
— the system liquid has a specific gravity of 0,85 and the facility average electric cost rate is $ 0,05/kWh,
— the liquid is turbine lube oil with viscosity of 90 cSt (420 SSU) at 40°C (104 °F),
— measured pump flow rate: 450 m3/h (2000 gpm),
— optimal flow rate: 340 m3/hour (1 500 gpm) going to tank B. 110 m3/h (484 gpm) is over-flowing or
pumped through the by-pass line directly back to tank A
— measured pump outlet pressure: 4 bar (60psi),
— optimal pump outlet pressure at the reduced flow (optimal flowrate) to tank B (total pump flow
being the same): 2,7 bar (40 psi),
— measured electric power: 73,4 kW
The system operates at the above conditions 70 % of the time.
NOTE
This example, while similar to the rotodynamic example, uses a liquid that is considerably more
viscous, so results cannot be compared and are useful only to illustrate the concepts presented.
Key
1
2
L
tank A
tank B
level control
Figure B.5 — Simplified Flow Diagram for Table B.3
Table B.3 gives the results of first analysis.
42
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.3 — Actual existing (oversized) vs. proposed improved system flow results
Condition
Existing system
Improved
system
Potential savings
Flowrate
m3/h (gpm)
450 (2 000)
Outlet
pressure
bar (psi)
Pump
power
input
kW
Motor
efficiency
2,7 (40)
55,7
94
450 (2000)
whereof
340 m3/h to
tank B
─
4,0 (58)
1,3 (19)
Ratio of optimal power/measured power
%
73,4
94
─
─
Electrical
power
input
kW
Annual
energy
MWh
Annual
energy
cost
$1,000
59
363,3
18,2
0,76
─
─
78
─
478,9
─
23,9
5,7
Pump operating at same speed and flow but delivered flow to tank B is reduced to 340 m3/h (1500 gpm), due to the
NOTE
by-passing. The pressure is reduced from 4 bar (58 psi) to 2,7 bar (40 psi) due to the lower pressure drop in the recirculation
valve controlled loop
B.5.2.4 Optimised conditions (see Table B.4):
Add variable frequency drive to control flow to meet demand.
Close by-pass line.
Transitioning to a VSD allows the tank B level controller to set the speed of the tank A pump to match the
process demand and to save the energy consumed by the recirculation control loop as well as minimising
the system losses between the tanks (see Figure B.6).
Key
1
2
L
VSD
tank A
tank B
level control
variable frequency drive
Figure B.6 — Simplified flow diagram for Table B.4
Table B.4 gives the results of second analysis:
© ISO/ASME 2015 – All rights reserved
43
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.4 — Optimal system flow results vs. flow matched to system without recirculation control
Flowrate
Condition
Improved
system:
2,7 bar
(40 psi)
Optimised
system
reduced
speed/flow/
pressure: 2,7
bar (40 psi)
Potential
savings:
existing vs
improved
Potential
savings:
optimal vs
existing
m3/h (gpm)
450 (2000)
whereof 340
(1500) to
tank B
340 (1500)
Operating
speed
r/min
Pump
power
input
kW
Motor
Variable Electric
efficiency frequency power
%
drive
kW
efficiency
Annual
energy
cost
$1000
1200
55,7
94
_
59
363,3
18,2
925
39,4
92
96
44,6
273,5
13,7
Savings
relative
existing:
5,7
_
_
-
-
16,3
22 %
34
46 %
_
_
_
115,6
-
-
-
205,4
Beyond these special considerations the methods used in B.4 can be considered.
44
Annual
energy
MWh
Savings
relative
existing:
10,2
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex C
(informative)
Expertise, experience and competencies
C.1 Systems
This section identifies the areas of expertise/experience relevant to be mastered by the assessor(s) in
respect of the system and the liquid pumped.
— Pump system energy basics:
— Assessors should be familiar with pumping systems which can include a wide variety of facility
and equipment including process units, tanks and pressure vessels. The type and number of
pumps and drives installed will also vary according to the system being assessed.
— Assessors should be familiar with pumps, drives, control valves, process components and be able
to determine the factors for each system component that contribute to the energy consumption
of the system.
— System performance characteristics:
— Assessors should be familiar with how the physical properties of the process liquid effect the
pumped system including, density, viscosity and vapour pressure and how these physical
properties affect the operation of the various components found in a pumping system.
— Assessors should be familiar with all the different elements of head, such as total head, static
head and friction head, and be able to determine each of them for any given system. They
should also be able to generate and understand a system curve and be able to understand the
operational envelope over time (duration diagram).
— Assessors should be proficient in determining the friction head losses for all components of the
system being assessed using the various methodologies for determining friction head loss.
— Assessor should be capable of establishing the system demand and profile.
— Assessors should be capable of optimising velocity within the system considering energy
consumption, liquid dynamics and system demand.
— Assessors should be capable of determining the system characteristics for parallel and series
pumping configurations
C.2 Pumps
This section identifies the areas of expertise /experience relevant to be mastered by the assessor/s with
regards to the aspects of the pump characteristics and liquid influences relative to the hydraulics of the
pump and the effects on the system.
— Liquid energy basics
— Assessors should be capable of determining the various components of energy, including
pressure, geodetic head, flowrate and velocity head, and how they relate to Bernoulli’s principle.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— Assessors should have the ability to determine the variance of the liquid properties e.g. density,
viscosity temperature etc.
— Pump characteristics:
— Assessors should understand pump performance characteristics and their interaction with
the system. Such characteristics include, head, flow, power, efficiency, NPSHA/R, pump affinity
laws and their mathematical relationships.
— System characteristics and impact on pump behaviour:
— Assessors should be capable of determining such changes that may be required to optimize the
type of pump and selection for the system in question.
— Assessors should understand the performance characteristics of parallel and series pumping
applications and their interaction with the respective systems, at nominal speed or variable speed.
— Data gathering
— Assessors should be capable of undertaking (after identifying the system boundaries) a review
of the pumping systems prior to the physical measurement to establish the priority and the
measurement requirements
— Assessors should be capable of undertaking accurate and repeatable direct or indirect
measurements of the pump parameters, driver (electric or otherwise) and system operational
characteristics.
C.3 Motors and drives
This subclause defines the areas of expertise and knowledge relevant to be mastered on motor
characteristics, power factor corrections, variable speed drives (mechanical and electrical) and their
effects on rotodynamic pumps. Assessors should have an understanding of:
— motor performance characteristics including various options for starting including soft starter,
star/delta, auto-transformer and via a variable speed drive. The assessor should also be familiar
with the torque/speed relationship imposed on the motor by the pump during start up and how to
ensure that this is optimised for correct motor selection.
— transmissions such as gear box, belt drives, liquid or magnetic couplings.
— the different types of variable speed drives and their performance and efficiency characteristics.
— the factors involved in matching the pump, system and drive. A knowledge of high and low static
head systems and their impact on the speed at which the pump is driven is essential.
C.4 Analysis and reporting
This subclause defines the expertise relevant to be mastered on the analysis of the measured field
data to form the basis of a logical and coherent report, with the objective of identifying energy saving
opportunities within the pumping system, as described in Annex A.
— Assessors should be experienced in analysing the gathered field data and be capable of understanding
the interaction between the various components within a system including the pump(s), process
components and control components. These include the performance and system characteristic
curves, and also have expertise in the assessment of time based variations and their impact on the
system characteristic.
— Assessors should be able to define the performance and system characteristic curves, and the
influence of demand variations on systems.
46
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— Assessors should have experience and knowledge of the various components found in a system in
order to determine their impact on the system efficiency.
— Assessors should be able to analyse the energy implications of system control philosophy.
© ISO/ASME 2015 – All rights reserved
47
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex D
(informative)
Recommended guidelines for analysis software
The main objective of the system assessment methodology is to identify the actual system demand,
compare it with the current process data and identify where energy savings can be made.
The software should have generic pump and motor algorithms within its database to compare the
specific data to best available data.
The methodology to analyse a system should be documented identifying the source of data and the
formulas and methods used to arrive at the conclusions.
The methodology employed regardless of means (hand calculations, spread sheet, or computer software)
should factor the following:
a) The analysis software should be transparent in identifying the source of data within the
embedded algorithms:
— Process data:
— Liquid properties: liquid name, temperature, density (specific gravity), viscosity,
calculated NPSHA/R
— Static head: liquid level in source and destination, pressure on liquid surface source and
destination
— Process element(s): manufacturer, identification, designed differential pressure, operational
differential pressure, flowrate.
— Nameplate data:
— Pump: manufacturer’s description (type, size, number of stages), pump curve, rotational
speed, fixed or variable speed.
— Motor: manufacturer, NEMA/IEC frame size, power, number of phases, frequency, speed,
voltage, full load apps, power factor, NEMA/ISO nominal efficiency or efficiency class,
guaranteed efficiency.
— VSD: manufacturer, efficiency.
— Control valve element: manufacturer, valve model, size, characterization, pressure rating,
direction of flow, control valve data supplied by manufacturer.
— Operating data:
— Pump: suction pressure, discharge pressure, flow rate, nominal speed (r/min), and efficiency
from pump curve.
— Motor: power consumption, line voltage, line current, power factor and efficiency under
operating load.
— VSD: efficiency at load conditions.
— Control valve element: valve position, differential pressure.
b) Determination the actual energy consumption of the various elements based on current operating
system conditions
48
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
c) Determination the optimum system operating conditions along with the corresponding energy
consumption.
d) Cross validation the results to determine the energy into the system and energy consumed by the
system is equal.
e) Identification of potential energy savings determined from the collated data and quantified by using
unit costs of energy.
© ISO/ASME 2015 – All rights reserved
49
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex E
(informative)
Example of prescreening worksheet
Table E.1 gives a typical example of typical prescreening worksheet.
Table E.1 — Typical example of prescreening worksheet
50
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex F
(informative)
Specific Energy
F.1 General
A pump system is built to move a certain volume of liquid from one point to another (in circulating
systems these points are the same). A useful measure for calculating the cost of pumping is the specific
energy consumption, Es, which is defined as the energy consumed to move a certain volume through the
system and has the advantage of being a direct measurement of the cost of pumping once you know the
cost of energy.
Specific energy is also a useful measure for comparing different system solutions.
In a constant flow system, the specific energy Es is calculated by using the formula (F1).
ES =
Where
Pe ⋅ t Pe
=
(F.1)
V
Q
t
Pe
is the time;
is the input power to driver.
In a system with varying flowrates, Es is a function of flowrate (Q), therefore this dependence is
differently evaluated.
Es is calculated from pump, motor and drive data for different loads and speeds provided by the
manufacturers.
When E S = f (Q ) has been calculated, this information is combined with the system load data to obtain
the operating cost. System designs can be compared based on number of pumps as well as different
methods of regulation.
F.2 Specific energy in different type of pump systems
The head needed from the pump can be separated into static head, Hs, and dynamic friction loss head,
Hf. Substituting Hs + Hf. for the total head and adding a drive efficiency for speed controlled systems
generates the following equation for input power:
Pe =
Q ⋅(HS + H f )⋅ ρ ⋅ g
(F.2)
ηdrive ⋅ηmotor ⋅ηpump
In a system without static head or closed loop systems, Hs is equal to zero.
The specific energy is here dependent on the frictional head loss which, in turn, is determined by the losses
in the pipe system (including throttling valves), and by the combined drive - motor - pump efficiency.
The combined drive - motor - pump efficiency is evaluated for each duty point. It is noted that the pump
efficiency remains approximately the same in a system of this type when the speed is changed, whereas
the drive-motor efficiency can drop considerably as the load is reduced.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
If, the system curve is changed by changing the setting of a valve, this changes the duty point of the
pump and, hence, its efficiency.
In a system with static head, the specific energy is derived as follows.
ES =
where
(HS + H f ) ⋅ ρ ⋅ g
HS ⋅ ρ ⋅ g
Pin
=
=
Q ηdrive ⋅ηmotor ⋅ηpump
fHS ⋅ηdrive ⋅ηmotor ⋅ηpump
f HS =
(F.3)
HS
(F.4)
HS + H f
The hydraulic system factor, fHS, indicates the relative amount of static head in the system.
Es has a minimum value: H S ⋅ ρ ⋅ g which occurs if all efficiencies are equal to 100 % and there are no
friction losses. If there is no variable drive in the system, then ... The factors in the denominator are all
functions of the flowrate and vary with the duty point. If a variable speed drive is used the duty point
moves along the system curve.
The efficiency of a high efficiency motor is fairly constant down to about 30 % load. However, the drop
in combined motor-drive efficiency can be substantial if the motor load drops below 75 % of full speed.
The denominator: can also be seen as the overall efficiency.
The hydraulic system factor fHS approaches 1 when the friction losses approach 0.
The specific energy increases significantly as the duty point moves towards shut off head in systems
with static head due to reduced pump, motor and drive efficiencies.
In systems with high static head, specific energy increases at a relatively moderate decrease in pump
speed. In such systems, the area of usefulness of a variable speed drive can be improved by making sure
that the system curve and full speed pump curve intersected to the right of the pumps best efficiency point.
To calculate the cost of pumping, the specific energy is calculated along the system curve, or for a
number of flow rates. Combining this information with the information in the system load profile the
cost of pumping can be determined.
Figure F.1 shows the specific energy as a function of pump speed for three different system curves
depending on systems with and without static head when a variable speed drive is used.
The saving potential is very large at low static heads and the reverse in high static head situations. When
the speed is low enough to cause the pump to operate at, or close to, shut-off head, the specific energy
goes towards infinity.
52
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
a) Specific energy as a function of pump speed
Key
A
B
C
D
PS
b) corresponding system curves
no static head, friction only
moderate static head
high static head
on-off regulated system (for reference)
Pump speed
Figure F.1 — Specific energy as a function of pump speed for different system curves
When the pump is throttled, the duty point moves to the left on the pump curve, see Figure F.2.
The vertical lines, in Figure F.2, represent the valve throttling loss.
The specific energy is calculated for each operating point by dividing the input power to the motor by
the flowrate. Es increases rapidly as the flow is reduced – see dashed curve in Figure F.3.
Key
1
pressure drop as a result of valve throttling
Figure F.2 — Example of flowrate with a throttled valve
In a throttled system, the specific energy follows a curve similar to the dashed curve in Figure F.3.
The specific energy for a speed regulated pump system can be higher than that for an on-off regulated
system with static head, but is lower and saves energy compared to a throttled system.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Key
1
2
3
NOTE
54
throttled system
speed regulated system with some static head
on-off regulation
Variable speed drives save on energy.
Figure F.3 — Comparison of regulation by throttling
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex G
(informative)
Pumping system parasitic power
G.1 General
Parasitic power may be used as an indicator to identify inefficient (and unreliable) pumping systems, and
support pump and control method selection, in order to ensure high efficiency, reliability and equipment
life expectancy along the entire operating range.
G.2 Parasitic power equations
Pw =
where
ρ ⋅ Q ⋅ g ⋅( H s + H f )
(SI) or
3, 6 × 106
Pw =
d ⋅ Q ⋅( H s + H f )
(US)
3960
Pw
is the hydraulic power expressed in kW or hp;
ρ
is the density expressed in kilograms per cubic meter (kg/m3) or pound per cubic foot
(lbm/ft3);
d
Q
is the specific gravity (dimensionless);
g
is the flowrate expressed in cubic meter per hour (m3/h) or gallon per minute (gpm);
Hs
is the static head expressed in meter (m) or foot (ft);
Hf
(G.1)
is a constant equal to 9,81m/s2 or 32,2 (ft/s2);
is the friction head expressed in meter (m) or foot (ft);
The total power absorbed in the shaft of the pump Pa, expressed in kilowatt (kW), is calculated using
formula (G.2)
Pa =
Pw
ηp
(G.2)
Pw = η p ⋅ Pa
Parasitic power definitions:
Pp = (1 −ηp )⋅ Pa
Where
(G.3)
ηp
is the pump efficiency;
Pa
is the total power absorbed in the shaft of the pump in kW;
Pp
is the parasitic power in kW or hp;
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Another way to express (G3) is:
Pa = Pw + Pp
(G.4)
G.3 Conclusions
G.3.1 From formula (G.4): the lower the required shaft power (Pa) to achieve a certain condition
(hydraulic power - Pw), the lower the parasitic power resulting in higher pump system life expectancy
and reduced energy consumption.
G.3.2 From Formula (G.1): for a given condition, the higher the pump efficiency, the lower the parasitic
power resulting in higher pump system life expectancy and reduced energy consumption.
G.3.3 The lower the friction head (Hf) in the system, to be overcome by the pump to achieve a given
condition (hydraulic power - Pw), the lower the parasitic power resulting in higher pump system life
expectancy and reduced energy consumption.
NOTE
Pa = Pw / ηp = Q·( H s + H f )·ρ·g / ηp That means that the control valve position plays an important
role on destructive power.
Conclusions G.3.1 to G.3.3 are three guidelines to be considered when evaluating pumping system
efficiency and reliability.
G.4 Relationship between parasitic power and vibration level
Figure G.1 shows several vibration levels measured in a kerosene exportation pump, under different
parasitic power levels, calculated for each condition according to Formula (G.1).
Key
1
2
parasitic power
vibration level
Figure G.1 — Example of parasitic power and vibration level curve using variable speed control
in a low static head system
56
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
The vibration increases with parasitic power. At low parasitic power levels, vibration increases slowly.
Above a certain threshold, vibration level assumes an asymptotic growth. This asymptotic growth may
happen either at very low flowrates (recirculation) or at very high flowrates (cavitation).
G.5 Correlation between parasitic power level in a pumping system and MTBF
It is considered a good practice to operate the pump in range of 80 % to 110 % of the best efficiency
flow, in order to achieve high efficiency and high MTBF. Usually, the largest parasitic power occurs at the
higher limit of this range (110 % of the best efficiency flow). Pump and control system should be selected
in a way to ensure permanent pump operation below this threshold.
In most cases this is an easy task when using variable speed control. In cases where VSD application is
not recommended, pump selection with the rated point at the right side of the BEP, as far as viable, is a
good way to reduce the parasitic power at low flows.
NOTE
Parasitic power has the ability to predict the severity of pump system operation (closely related to energy
efficiency), along the entire operating range, even before the equipment and control method have been selected.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex H
(informative)
Example of pumping system efficiency indicator
H.1 General
The pumping system efficiency indicator (PSEI) is approximate and used to give a ‘first-pass’ indication
of the pumping system efficiency.
The PSEI example described in H.2 is applicable to water. Similar indicators can be developed for other liquids.
The PSEI is a number between 0 and 100, indicating how much of the energy supplied to a pumping
system is necessary.
For example, if the PSEI is calculated to be 36, then for every 100 units of energy supplied, only 36 units
are required. The remaining 64 units are unnecessary.
PSEI can be used for:
— open and closed pumping systems;
— any pump type (centrifugal or positive displacement);
— any number of installed pumps.
PSEI can be calculated from either of the following two sets of data:
— instantaneous data. This gives an energy efficiency indicator at the time of measurement.
— longer-term data. This gives an indication covering all pumping conditions over a period of time.
H.2 PSEI calculation
H.2.1 Table H.1 gives the symbols and units used to calculate PSEI
58
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table H.1 — Units of variables and symbols used
Item
Symbol
SI Units
US Units
Yn
l/s
Static head (vertical height difference between
source and destination)
Q
-
-
HS
Specific length
L
m
L1
m
-
Pumping system efficiency indicator (PSEI)
Flowrate from source to destination
Distance transferred (shortest horizontal distance from source to destination)
Equipment losses
Input power to station (electrical power used by
the pumping system at the time of measurement)
Volume delivered from source to destination in
the defined time period
Input Energy to Station
H.2.2 Transfer Duties, (a) Instantaneous Data
ΔH
m
and
ft
ft
-
ft
Pe
kW
kW
Ee
kWh
kWh
V
m3
The Pumping system efficiency indicator Y1 is calculated using Formula (H.1)
Y1 = K 1 ⋅
gpm
Q ⋅( HS + L / L1 +∆H )
Pe
L1 = 43.3⋅ | Q |0.61 (SI) or L1 = 8.15⋅ | Q |0.61 (US)
Where K1 is equal to 1,25 (SI) or 0,24 (US).
g
(H.1)
(H.2)
H.2.3 Transfer duties, (b) longer term data
The Pumping system efficiency indicator Y0 is calculated using Formula (H.3)
V ⋅( H + L / L +∆H )
S
1
E
e
Where K0 is equal to 0,35 (SI) or 3,7 (US).
Y =K ⋅
0
0
(H.3)
H.2.4 Closed loop duties. For closed loop applications, select the appropriate formula from (H.1) to (H.3).
The value to be used for L is the minimum distance around the pumped loop from pump outlet to pump inlet.
H.3 Interpretation of results
If the Indicator is low, this identifies a potential problem within the pumping system such as one or more
of the following and further investigation is advised:
— bad match of pump with system demand;
— pump operating well away from best efficiency point;
— high velocities in pipelines;
— poor control;
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— excessive wear in pump;
— obstructions in pipe work/valves/fittings.
60
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Bibliography
[1]
ISO 50001, Energy management systems — Requirements with guidance for use
[3]
ISO 50003, Energy management systems - Requirements for bodies providing audit and certification
of energy management systems
[2]
[4]
[5]
[6]
[7]
[8]
[9]
ISO 50002, Energy audits — Requirements with guidance for use
API 682, Pumps-shaft sealing systems for centrifugal and rotary Pumps, Third Edition
ANSI/ASHRAE/IES Standard 90.1:2013 - Energy Standard for Buildings Except Low-Rise
Residential Buildings
ASME EA-2-2009 Energy assessment for pumping systems
ASME EA-2G-2010, Guidance for ASME EA-2, Energy Assessment for Pumping Systems
BLOCH. H. P. - Improving Machinery Reliability. Gulf Publishing Company, Texas, 1998
CASADA. D. - Energy and Reliability Considerations for Adjustable Speed Driven Pumps – 1999 IETC
Proceedings – ESL - IE-99/05-09 - Houston, Texas Oak Ridge National Laboratory
[10] Europump and Hydraulic Institute. Variable Speed Pumping – A guide to successful
applications. Elsevier Ltd, 2004
[11] Europump and Hydraulic Institute. Optimizing Pumping Systems – A guide for improved
energy, efficiency and profitability. Pump Systems Matter, 2008
[12] MARTINS and LIMA -. How to improve reliability in centrifugal pump systems through the
automatic tune-up of pumps within their best operational condition, 2008 – 24th International
Pump Users Symposium
[13]
MARTINS and LIMA –. Improving reliability in a high static head system through VFD application,
2010 – 26th International Pump Users Symposium
[15]
STADLER. Hugo, 1998, Energy Savings by means of Electrical Drives, Loher Gmbh, Germany
[14]
MATTOS. E. E. - FALCO, R. - Bombas Industriais. McKlausen Editora, 1998
© ISO/ASME 2015 – All rights reserved
61
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BSI Standards Publication
Pump system energy
assessment
BS EN ISO 14414:2015
BRITISH STANDARD
National foreword
This British Standard is the UK implementation of EN ISO
14414:2015.
The UK participation in its preparation was entrusted to Technical
Committee MCE/6, Pumps and pump testing.
A list of organizations represented on this committee can be
obtained on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
© The British Standards Institution 2015. Published by BSI Standards
Limited 2015
ISBN 978 0 580 71451 1
ICS 23.080
Compliance with a British Standard cannot confer immunity from
legal obligations.
This British Standard was published under the authority of the
Standards Policy and Strategy Committee on 30 April 2015.
Amendments issued since publication
Date
Text affected
EN ISO 14414
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
April 2015
ICS 23.080
English Version
Pump system energy assessment (ISO/ASME 14414:2015)
Evaluation énergétique des systèmes de pompage
(ISO/ASME 14414:2015)
Energetische Bewertung von Pumpensystemen
(ISO/ASME 14414:2015)
This European Standard was approved by CEN on 10 January 2015.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same
status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United
Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2015 CEN
All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.
Ref. No. EN ISO 14414:2015 E
BS EN ISO 14414:2015
EN ISO 14414:2015 (E)
Foreword
This document (EN ISO 14414:2015) has been prepared by Technical Committee ISO/TC 115 "Pumps" in
collaboration with by Technical Committee CEN/TC 197 “Pumps” the secretariat of which is held by AFNOR.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by October 2015, and conflicting national standards shall be withdrawn at
the latest by October 2015.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
Endorsement notice
The text of ISO/ASME 14414:2015 has been approved by CEN as EN ISO 14414:2015 without any
modification.
3
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Contents
Page
Foreword...........................................................................................................................................................................................................................................v
Introduction................................................................................................................................................................................................................................. vi
1 Scope.................................................................................................................................................................................................................................. 7
2
3
4
5
6
Normative references....................................................................................................................................................................................... 7
Terms and definitions...................................................................................................................................................................................... 8
Identification of the assessment team, authority and functions......................................................................... 8
4.1
Identification of assessment team functions................................................................................................................. 8
4.2
Assessment team structure, leadership and competency.................................................................................. 9
4.3
Facility management support..................................................................................................................................................... 9
4.4
Communications..................................................................................................................................................................................... 9
4.5
Access to facilities, personnel and information........................................................................................................... 9
4.6
Assessment objectives, scope and boundaries.......................................................................................................... 10
4.7
Action plan................................................................................................................................................................................................ 10
4.7.1 General................................................................................................................................................................................... 10
4.7.2 Assessment scheduling............................................................................................................................................ 11
4.8
Initial Data Collection and Evaluation.............................................................................................................................. 11
4.8.1 General................................................................................................................................................................................... 11
4.8.2 Initial facility specialist interviews................................................................................................................ 11
4.8.3 Energy project history.............................................................................................................................................. 11
4.8.4 Energy cost......................................................................................................................................................................... 11
4.8.5 Initial system data........................................................................................................................................................ 12
4.9
Objective check..................................................................................................................................................................................... 12
Conducting the Assessment....................................................................................................................................................................12
5.1
Assessment Levels............................................................................................................................................................................. 12
5.1.1 General................................................................................................................................................................................... 12
5.1.2 Level 1 assessments.................................................................................................................................................... 13
5.1.3 Level 2 assessments.................................................................................................................................................... 14
5.1.4 Level 3 Assessments................................................................................................................................................... 14
5.2
Walk Through......................................................................................................................................................................................... 15
5.3
Understanding system functional requirements..................................................................................................... 16
5.4
Determining system boundaries and system energy demand.................................................................... 16
5.5
Information needed to assess the efficiency of a pumping system......................................................... 16
5.5.1 General................................................................................................................................................................................... 16
5.5.2 Electrical motor/drive information............................................................................................................... 16
5.5.3 Pump information......................................................................................................................................................... 17
5.5.4 Liquid properties information........................................................................................................................... 18
5.5.5 Detailed system data.................................................................................................................................................. 18
5.5.6 Measured data.................................................................................................................................................................. 19
5.6
Data collection....................................................................................................................................................................................... 19
5.6.1 System information..................................................................................................................................................... 19
5.6.2 Measurement of pump and motor operating data........................................................................... 20
5.6.3 Pressure................................................................................................................................................................................. 20
5.6.4 Flow........................................................................................................................................................................................... 20
5.6.5 Input power........................................................................................................................................................................ 20
5.7
Cross validation.................................................................................................................................................................................... 21
5.8
Wrap-up meeting and presentation of initial findings and recommendations............................. 21
Reporting and documentation.............................................................................................................................................................21
6.1
Final assessment report................................................................................................................................................................ 21
6.2
Data for third party review........................................................................................................................................................ 21
6.3
Review of final report by assessment team members........................................................................................ 22
Annex A (normative) Report Contents.............................................................................................................................................................23
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex B (informative) Recommendations on efficient system operation and energy
reduction - Examples.....................................................................................................................................................................................27
Annex C (informative) Expertise, experience and competencies.........................................................................................45
Annex D (informative) Recommended guidelines for analysis software.....................................................................48
Annex E (informative) Example of prescreening worksheet.....................................................................................................50
Annex F (informative) Specific Energy.............................................................................................................................................................51
Annex G (informative) Pumping system parasitic power.............................................................................................................55
Annex H (informative) Example of pumping system efficiency indicator...................................................................58
Bibliography.............................................................................................................................................................................................................................. 61
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© ISO/ASME 2015 – All rights reserved
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Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2. www.iso.org/directives
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any
patent rights identified during the development of the document will be in the Introduction and/or on
the ISO list of patent declarations received. www.iso.org/patents
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the meaning of ISO specific terms and expressions related to conformity
assessment, as well as information about ISO’s adherence to the WTO principles in the Technical Barriers
to Trade (TBT), see the following URL: Foreword - Supplementary information
ISO/ASME 14414 was prepared by ISO/TC 115, Pumps, in collaboration with ASME EA Standards
Committee — Industrial System Energy Assessment.
ASME is the registered trademark of The American Society of Mechanical Engineers.
This standard was developed under procedures accredited as meeting the criteria for American National
Standards. The Standards Committee that approved the standard was balanced to assure that individuals
from competent and concerned interests have had an opportunity to participate. The proposed code or
standard was made available for public review and comment that provides an opportunity for additional
public input from industry, academia, regulatory agencies, and the public-at-large.
ASME does not “approve”, “rate”, or “endorse” any item, construction, proprietary device, or activity.
ASME does not take any position with respect to the validity of any patent rights asserted in connection
with any items mentioned in this document, and does not undertake to insure anyone utilizing a standard
against liability for infringement of any applicable letters patent, nor assumes any such liability. Users
of a standard are expressly advised that determination of the validity of any such patent rights, and the
risk of infringement of such rights, is entirely their own responsibility.
Participation by federal agency representative(s) or person(s) affiliated with industry is not to be
interpreted as government or industry endorsement of this standard.
ASME accepts responsibility for only those interpretations of designated documents issued in accordance
with the established ASME procedures and policies, which precludes the issuance of interpretations by
individuals. ASME will not issue written interpretations of this edition of this standard.
ISO/ASME 14414 was approved as an American National Standard by the American National Standards
Institute on 2015-02-06.
© ISO/ASME 2015 – All rights reserved
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Introduction
Pumping systems account for a significant portion of a facility’s energy consumption in many industries.
In the majority of pumping systems the energy added to the working liquid by the pump is much greater
than is required by the process. The excess energy added to the system (e.g. due to throttled control
valve) increases heat, noise and vibration but also can bring the system’s maintenance costs. The
addition of excessive energy to the system often results in over-sizing piping system components such
as pumps, process components, and control valves, resulting in an increase in capital costs.
This International Standard provides a method to assess pump systems, to identify and quantify pump
system energy consumption reduction opportunities and reliability improvement opportunities. It gives
a common definition for what constitutes an assessment for both users and providers of assessment
services. Its objective is to provide clarity for these types of services which have been variously described
as energy assessments, energy audits, energy surveys and energy studies.
In all cases, systems (energy-using logical groups of equipment organized to perform a specific
function) are analysed through various techniques such as measurement, resulting in identification,
documentation and prioritization of energy performance improvement opportunities.
When contracting for assessment services, facility personnel may use this International Standard to define
and communicate their desired scope of assessment activity to third party contractors or consultants.
This International Standard is expected to contribute to decreased energy consumption and consequently
to decreased carbon footprint.
This International Standard includes the required assessment report content in Annex A. It gives
examples of efficient system operation and energy reduction opportunities in Annex B, information on
competencies and experiences welcomed to perform audit in Annex C, guidelines for analysis software
in Annex D, a typical example of pre-screening worksheet in Annex E, information on specific energy
in Annex F, information on the concept of parasitic power in Annex G and examples of pumping system
efficiency indicator in Annex H.
This International Standard is developed within the framework of ISO 50001, ISO 50002 and ISO 50003.
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© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
INTERNATIONAL STANDARD
Pump system energy assessment
1 Scope
This International Standard sets the requirements for conducting and reporting the results of a pumping
system energy assessment (hereafter referenced as “assessment”) that considers the entire pumping
system, from energy inputs to the work performed as the result of these inputs.
The objective of a pumping system energy assessment is to determine the current energy consumption
of an existing system and identify ways to improve system efficiency.
These requirements consist of
— organizing and conducting an assessment,
— analysing the data from the assessment, and
— reporting and documenting assessment findings.
This International Standard is designed to be applied, to open and closed loop pumping systems typically
used at industrial, institutional, commercial, and municipal facilities, when requested.
This International Standard is focused on assessing electrically-driven pumping systems, which are
dominant in most facilities, but is applicable with other types of drivers, such as steam turbines and
engines, and drives such as belt.
The International Standard does not
a) specify how to design a pumping system,
b) give detailed qualifications and expertise required of the person using the International Standard
although provides a list of body of knowledge in Annex C,
c) address the training or certification of persons,
d) specify how to implement the recommendations developed during the assessment, but does include
requirements for an action plan,
e) specify how to measure and validate the energy savings that result from implementing assessment
recommendations,
f) specify how to make measurements and how to calibrate test equipment used during the assessment,
g) specify how to estimate the implementation cost or conduct financial analysis for recommendations
developed during the assessment,
h) specify specific steps required for safe operation of equipment during the assessment. The facility
personnel in charge of normal operation of the equipment are responsible for ensuring that it is
operated safely during the data collection phase of the assessment,
i) address issues of intellectual property, security, confidentiality, and safety.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
© ISO/ASME 2015 – All rights reserved
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ISO 17769-1, Liquid pumps and installation — General terms, definitions, quantities, letter symbols and
units — Part 1: Liquid pumps
ISO 17769-2, Liquid pumps and installation — General terms, definitions, quantities, letter symbols and
units — Part 2: Pumping system
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 17769-1 and ISO 17769-2, and
the following apply.
3.1
system energy demand
minimum amount of energy which a pumping system in a specified process requires
3.2
components
individual items of equipment within a system
EXAMPLE
Pump, motor, drive, valve, heat exchanger.
3.3
hydraulic power
water horsepower
power imparted to the liquid by the pump
3.4
electrical power input
power required to support the pumping system operation
3.5
specific energy
energy consumed to move a certain volume of liquid through the system
3.6
parasitic power
power imparted to the shaft of a pump and not used to move the fluid through the system
4 Identification of the assessment team, authority and functions
4.1 Identification of assessment team functions
The assessment team composed of knowledgeable personnel shall have members that are assigned
responsibility and authority to carry out the following functions:
— resource allocation, in order to:
— allocate funding and resources necessary to plan and execute the assessment,
— exercise final decision making authority on resources,
— oversee the eventual participation of non-facility personnel including contracts, scheduling,
confidentiality agreements, and statement of work.
— coordination, logistics and communications, in order to:
— obtain necessary support from facility personnel and other individuals and organizations
during the assessment,
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— participate in organizing the assessment team and coordinate access to relevant personnel,
systems, and equipment,
— organize, schedule activities and manage the assessment.
4.2 Assessment team structure, leadership and competency
The assessment team should comprise of personnel from cross functional backgrounds. It shall include:
— an assessor who has the pump system analysis competencies as described in Annex C;
— the host organization representative who has overall responsibility and ownership for the assessment;
— experts on the processes and the function of the system;
— experts on the maintenance practises of the pumping system;
— experts who can provide the team with cost data.
The assessment team may be from the host organization or enhanced by using outsourced specialists
particularly considering the competence of the assessor
The host organization shall appoint the assessment team leader. This person may be a host facility
employee or an external assessor. In small organisations, the team leader may be the competent assessor.
4.3 Facility management support
Facility management shall understand and support the purpose of the assessment.
Facility management shall allow assessment team members from the facility to participate in the
assessment to the extent necessary.
The assessment team shall gain written support of facility management prior to conducting the
assessment, as follows:
— commit the necessary funding, personnel, and resources to support the assessment;
— communicate to facility personnel the assessment’s importance to the organization.
4.4 Communications
Lines of communication required for the assessment shall be established.
The assessment team shall provide clear guidance to facilitate communications among members of the
assessment team so all necessary information and data can be communicated in a timely manner. This
shall include administrative data, logistics information, as well as operational and maintenance data.
4.5 Access to facilities, personnel and information
The assessment team shall have access to:
— facility areas and pump systems required to conduct the assessment,
— facility personnel (engineering, operations, maintenance, …), their equipment vendors, contractors
and others, to collect information pertinent and useful to the assessment activities and analysis of
data used for preparation of the report,
— other information sources such as drawings, manuals, data sheet, maintenance records, test reports,
historical utility bill information, computer monitoring and control data, electrical equipment
panels, and calibration records.
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All data initially identified as essential to the assessment shall be obtained in discussions with
knowledgeable facility staff.
4.6 Assessment objectives, scope and boundaries
The overall objectives and scope of the assessment including portion(s) of the facility and boundaries
of the system(s) that are to be assessed shall be discussed and agreed upon at an early stage by the
assessment team.
The assessment team shall develop a list of site specific objectives for each pumping system, such as
performance improvement targets.
4.7 Action plan
4.7.1 General
An action plan for the assessment shall be developed and agreed upon by the assessment team and
system owners in order to facilitate the assessment and to make it clear to all assessment team members
how the assessment shall be conducted.
The plan shall be flexible and should accommodate various outcomes depending on findings during the
assessment, among others:
a) establish information objectives, in particular:
— determine system boundaries (see 5.4);
— review information that has been collected before the start of the assessment;
— identify how much is known about the systems and what information has to be obtained;
— start with a level 1 assessment (see 5.1.2);
b) identify informational objectives for the assessment (see 5.1):
— determine how extensive the assessment is;
— identify the systems that are included in the assessment;
— identify what information is available and what is necessary to collect;
— identify information that is available on paper records (such as logs) or in the facility computer
systems and what system parameters are necessary to measure;
— identify who is going to be involved and responsible for the collection of necessary data;
c) establish measurement requirements (see 5.6) in particular:
— identify whether a snapshot of the conditions is sufficient (level 2 according to Table 1) or if it is
necessary to collect information during an extended period of time (level 3 according to Table 2);
— identify if permanently installed measurement equipment is available and trustworthy;
d) identify additional informational objectives and in particular true process demands (see 5.4);
e) identify the methods required to meet assessment informational objectives:
— identify how the data are going to be analysed, taking into account the recommendations
from Annex B;
— identify tools/software programs that are going to be used;
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f) identify content of the report and responsibilities.
4.7.2
Assessment scheduling
The dates of the assessment, and dates and times of key meetings shall be designated in advance of
beginning the assessment.
The assessment meetings shall include:
— kick-off meeting. It shall occur just prior to the commencement of the assessment. The purpose of
this meeting is to review information to be collected in the initial data collection and evaluation
(see 4.8) and establish the work schedule. At this meeting, the assessment team should discuss the
safety protocols, tools, methods, measurement, metering and diagnostic equipment required;
— daily schedule(s) for the on-site assessment;
— periodic reporting to facility managers in the form of debriefings should occur as agreed-upon by
the assessment team;
— wrap-up meeting at the conclusion of the onsite activities. It is designed to outline the assessment
investigations and initial recommendations (see 5.8).
The assessment team shall determine corrective courses of action for irregularities that may or do occur
during an assessment (e.g. the failure of a computerized records system).
4.8 Initial Data Collection and Evaluation
4.8.1 General
Before the start of the assessment, the initial data collection shall be made. To expedite the process,
precollection data are optional.
NOTE
4.8.2
This information is used in all assessment phases.
Initial facility specialist interviews
The assessment team shall collect information on operating practices and any specific operating
considerations that affect energy use for the equipment through contact with personnel and specialists.
The assessment team shall also have access to facilities personnel who understand connected systems
that will be influenced by changes made to the pumping system.
4.8.3
Energy project history
The assessment team shall collect and review information on energy saving projects, assessments,
audits, baselines, or benchmarking already conducted for the pumping systems being assessed.
4.8.4
Energy cost
The assessment team shall collect cost data including electricity cost per kWh, or other similar terms,
considering all charges such as demand charges, peak rates, time-of-the-day rate and any other costs up
to the point of use. Where necessary, appropriate costs should be assigned to onsite generated electricity.
These costs should be used in subsequent analyses. If electricity is generated on site the avoided cost or
potential sales cost of the energy should be used.
The assessment team shall agree on the period during which the costs are considered valid.
The assessment team should also consider issues such as demand charges and trends to identify
situations not made obvious by the use of average values.
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From this information, the assessment team shall determine an average annual energy cost per kWh
over the previous 12 months.
If a facility has established a marginal cost for energy, it may be used in the energy cost saving calculation
4.8.5
Initial system data
The assessment team shall:
— define the functional needs of the system(s);
— identify high energy consumption equipment;
— identify control method(s);
— identify throttle control systems;
— identify high, low or negative static head systems;
— identify inefficient devices (obvious signs of disrepair or incorrect operation);
— identify lower mean time before failure (MTBF) pump systems, which generally indicate poor
efficiency operation (see Annexes F and H);
— identify small power input systems that have significant influence on facility reliability and
efficiency. All of them shall be considered, not because of their energy consumption but for the
consequence on the efficiency of the whole facility.
4.9 Objective check
Prior to conducting the assessment, the assessment team shall ensure that the action plan meets the
stated assessment objectives.
The action plan of assessment and the objectives shall be reviewed for relevance, cost-effectiveness, and
capacity to produce the desired results.
5 Conducting the Assessment
5.1 Assessment Levels
5.1.1 General
Depending on the needs of the host organization, one or more of the levels of assessment given in Table 1
shall be selected.
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Table 1 — Assessment Level Overview
Activities
Pre-screening opportunities
Walk through
Identify systems with potential saving opportunities
Evaluate systems with potential saving opportunities
Measurement of operating data for a typical single
operating point
Measurement/data logging of systems with variable operating conditions
Level 1
assessment
Level 2
assessment
Level 3
assessment
Required
Required
Required
Required
Required
Required
Optional
Optional
Optional
Not Applicable
Required
Required
Required
Not Applicable
Required
Required
Required
Required
NOTE 1 A level 1 assessment is a qualitative review with possible quantitative elements intended to determine the potential
for significant energy savings based on further assessments and to identify specific systems that merit a greater level of
attention.
NOTE 2 A level 2 assessment is a quantitative review intended to determine energy consumption and potential savings
based on measurement of a single steady-state operating condition requiring a single set of measurements.
NOTE 3 A level 3 assessment is a quantitative review that takes varying system demands into account by monitoring
the system over a time span long enough to capture the various operating conditions which require their own set of
measurements.
Depending on the level of assessment, data shall be collected in accordance with Table 2.
5.1.2
Level 1 assessments
Level 1 assessment shall include gathering of system information for pumping systems considered for
evaluation within the scope of the assessment.
Level 1 assessment shall start with the pre-screening.
During the pre-screening, the control methods for the different systems shall be noted. It shall be
determined which systems are best suited for a closer evaluation. It should also be noted if changes to
the pump system will affect other systems, thereby introducing constraints on potential optimization
strategies for the pump system.
As much information as practical should be collected during the level 1 assessment.
The availability at the facility of some types of data (see 5.5) should also be reported during the level 1
assessment even if it is not collected.
A pre-screening worksheet shall be used to assist in this pre-screening exercise. A typical example of
worksheet to aid in the data collection process is given in Annex E.
In general, the steps taken during the pre-screening shall include the following:
a) sort by driver size, annual operating hours, and estimated energy cost;
b) focus on centrifugal pumps operating at fixed speed;
c) focus on pumping systems that throttle and recirculate for flow control;
d) look for energy-waste symptoms such as large difference in supply and demand, commonly achieved
through valve throttling and by-pass flows (see 5.5.5);
e) identify inefficient pumping systems via maintenance and operational staff interviews and review
of maintenance records;
f) select for assessment those systems that appear most likely to exhibit savings potential.
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From this information the assessment team shall make estimates regarding the potential for energy savings
in each system and shall select the pumping systems that meet the criteria for level 2 or level 3 assessments.
5.1.3
Level 2 assessments
Level 2 assessments shall be performed when it is clear that the observed operating conditions are
representative for the operation of the systems and the changes in operating condition are small or
non-existent.
Level 2 assessments shall be performed using data taken from the facility information systems, in paper
or electronic format, or by using portable measuring devices. The measurements shall cover a limited
amount of time, thus giving a snapshot of the operating conditions at the time of measurement.
5.1.4
Level 3 Assessments
Level 3 assessments shall be made on pumps systems where conditions vary substantially over time.
For such systems, the assessment team shall record the system performance data over the time period
or capture data at the extreme duty points. This activity shall be associated with more extensive use of
in situ monitoring to ensure that the operating conditions can be accurately determined at the various
duty points (i.e. design point, normal, rated, maximum and minimum flow rates). The monitoring shall
be made by connecting transducers to data logging equipment and recording the sensor output, or in
some facilities, where historical information is stored, the relevant information should be downloaded
from the facility information system.
Table 2 — Required and optional data for assessment level 1, 2 and 3
Level 1
assessment
Level 2
assessment
Level 3
assessment
Required
Required
Required
Required
Required
Required
Operating parameters (including flow and pressure)
Optional
Required
Required
Cavitation at pump or in system
Optional
Required
Required
System information
Description of the facility
Pumping system inventory (provided prior to assessment
start) for systems that meet pre-screening criteria
- List of pumps
- Pump description (including pumped media)
- Pump type
- Pump application
- Physical location of pump
- Installed motor data (rated nameplate power, voltage, full
load amperage, and frequency)
- Annual operational hours (or % operation)
- Control method e.g. control valve, variable speed drive
(VSD), bypass
Pump curve(s)
Design point
Maintenance level (low, medium, high)
Equipment information (service type, time in service, shared
duty, voltage)
Typical flow rates and variations thereof
Duration diagrams
Histograms
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Optional
Optional
Optional
Optional
Optional
Optional
Optional
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
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Table 2 (continued)
Level 1
assessment
Level 2
assessment
Level 3
assessment
Maintenance costs
Optional
Required
Required
Rating of any other drive system (e.g. steam turbine drive)
Optional
Required
Required
System information
Process and instrument diagrams (PID)/Digital control system (DCS) screen-shots
5.2 Walk Through
Optional
Required
Required
A walk through is required for level 2 and 3 assessments and may be required for some pumping systems
undergoing a level 1 assessment.
The walk through shall entail examination throughout ensuring that the information provided to the
assessment team reflects the configuration of the existing systems.
For the pumping systems undergoing level 2 and 3 assessments, after the walk through is completed, the
information listed in 5.5 shall be collected using the methodologies specified in 5.6.
All components of the system shall be considered and pertinent information such as valve locations,
locations of available pressure taps, flow meters, valve positions etc. should be noted.
During the walk through, information about the control methods for the different systems such as valve
settings should be noted.
The assessment team shall also identify any existing conditions that are often associated with inefficient
pumping system operation.
These conditions may be identified through the following potential indicators:
a) pumping systems where significant throttling takes place1)
b) pumping systems with recirculation of flow used as a control scheme;
c) pumping systems with large flow or pressure variations;
d) systems with multiple pumps where the number of operated pumps is not adjusted in response to
changing conditions;
e) systems serving multiple end uses where a minor user sets the pressure requirements1);
f) cavitating equipment1);
g) high vibration and/or noisy pumps, motors or piping1);
h) equipment with high maintenance requirements (low MTBF) 1),
i) systems for which the functional requirements have changed with time, but the pumps have not;
j) worn, eroded, corroded, distorted or broken impellers/diffusers/vanes or wear rings and casings
(if available, this information can be provided by facility staff);
k) clogged pipelines or pumps (usually requires historical data to be discovered);
l) systems which have a low pumping system efficiency indicator (for information, see Annex H);
m) seized valves or leaking recirculation valves;
n) sealing systems, especially high temperature, requiring cooling (see B.4.3);
1)
Possible indication of excessive parasitic power level (see Annex H).
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o) lack of proper inlet screening, where appropriate.
5.3 Understanding system functional requirements
The assessment team shall determine what are the normal operating conditions as well as operation
under extreme and abnormal conditions, knowing the limits within which the system is designed to
operate and how the operating conditions are distributed overtime.
If accurate records are not available and the facility personnel may be unable to supply the needed
information, the assessment team shall monitor the system over some period of time in order to establish
the demands on the system.
5.4 Determining system boundaries and system energy demand
The assessment team shall determine the system boundaries and system energy demand of each
pumping system undergoing a level 2 or 3 assessment.
A pumping system assessment shall consider the overall efficiency of the existing system.
NOTE
If the subsystems are part of a larger facility system, the system boundary is complex and the boundary
is determined prior to any measurements and calculations
5.5 Information needed to assess the efficiency of a pumping system
5.5.1 General
After the decision is taken on which pumping systems require further investigation, the following
information from 5.5.2 to 5.5.6 shall be gathered.
The assessment team shall determine the data collection needs for each system being evaluated.
The assessment team shall maintain quality assurance in the design and execution of a measurement
plan as a consistent, repeatable, and reproducible process.
The measurement plan shall adhere to principles of safety, transparency, and reliability.
The measurement plan shall include the measurements required to develop an annual energy
consumption baseline for the pumping system. This is typically done by taking instantaneous flow,
pressure and electrical measurements and determining operating hours at varying system conditions.
Cross-checking should be done to ensure the data are correct.
5.5.2
Electrical motor/drive information
Initial motor/drive information to be collected from the nameplate (if available) or manufacturer’s data
sheets shall include:
a) line frequency;
b) motor size (rated power);
c) motor rated speed;
d) motor rated voltage;
e) motor full load amps (FLA) - the current to the motor when operating at rated power;
f) motor power rating information;
g) nominal efficiency or efficiency class (if provided);
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h) motor type and characteristics;
i) type of drive (e.g. variable frequency drive, belt, gear, direct);
j) motor history (e.g. original, rewound, replaced).
5.5.3
Pump information
5.5.3.1 Rotodynamic pumps
This information should be obtained from the pump nameplate (if available) and any records that may
be kept on file for the pump.
If the information from the nameplate and records differ, this should be noted and addressed later in the
assessment of the system. Pump information required (when available) shall include:
a) type of pump and model;
b) manufacturer name;
c) serial number;
d) customer tag number;
e) number of stages;
f) type of drive;
g) nominal speed – (r/min);
h) design point (flowrate and head);
i) impeller diameter (installed and maximum);
j) pump performance curves, if available, including rated total head, flow, power, efficiency and net
positive suction required (NPSHR),
k) maintenance records;
l) pump cavitation or recirculation problems;
m) sealing system data.
5.5.3.2 Positive displacement (PD) Pumps
This information should be obtained from the pump nameplate (if available) and any records that may
be kept on file for the pump.
If the information from the nameplate and records differ, this should be noted and addressed later in the
assessment of the system. Pump information required (when available) shall include:
a) type of pump and model;
b) manufacturer name;
c) serial number;
d) customer tag number;
e) pump description/model number;
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f) rated data:
— speed (r/min);
— pressure;
— temperature;
— power;
g) system data (operating conditions);
h) relief valve setting;
i) pump performance curves;
j) maintenance records;
k) pump cavitation, recirculation line, or other operational problems;
l) sealing system.
5.5.4
Liquid properties information
Required liquid information shall include:
a) name of the liquid;
b) dynamic viscosity;
c) temperature;
d) density;
e) presence of solids and their characterization;
f) vapour pressure at running pressure and temperature conditions;
g) free gas percentage, when applicable;
h) hazards,
i) inflammability.
5.5.5
Detailed system data
Required systems data information shall include:
a) system layout,
b) unusual operating conditions;
c) PID diagrams,
d) pump control method:
— variable speed drive (VSD);
— throttled (valve percentage open if available);
— by-pass/recirculation;
— on/off;
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— pumps in series or in parallel, or split duty;
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— not controlled (pumps just run).
For rotodynamic pumps, the following additional information shall be collected:
— static head and if possible system curve;
— net positive suction head available (NPSHA);
— load profile. Through discussion with operating personnel, note approximate annual, seasonal,
weekly, and daily operating hours at various flows.
For PD pumps, the following additional information shall be collected:
— discharge pressure;
— suction pressure;
— relief valve set pressure;
— net positive inlet pressure available (NPIPA).
Additional information should be collected on NPSHA for rotodynamic pumps and NPIPA for PD
pumps, when needed.
5.5.6
Measured data
5.5.6.1 Electrical data
Required electrical data shall include:
— power;
— actual motor voltage and current to calculate power.
5.5.6.2 Operating system data
Sufficient operating data should be collected during the assessment to determine where energy is
expanded in the system. This should include:
— flowrate in each flow circuit of the system;
— as stated;
— pump shaft (r/min), when appropriate;
— control valve set points and valve positions
— supply and destination tank levels and pressures
— installed equipment in operation.
5.6 Data collection
5.6.1
System information
When possible, the assessment team shall identify the system curve of the pumping system. For most
systems, the system curve may be calculated from two different operating points on the curve: the
static head at zero flow and one operating point.
NOTE
The system curve is essential for the understanding of the complete pumping system and the
consequences resulting from changes to any part of the system. In some rare cases it is impossible to determine a
system curve; however, the pump operating point can still be determined.
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Demand variations as a function of time shall be established so that the appropriate measurements can
be made.
5.6.2
Measurement of pump and motor operating data
The primary required data to be measured shall be head, flow, power, and operating time.
If the operating conditions of the pumping system are constant or only vary minimally in time, a snapshot
of the operating conditions may be enough to assess the system.
If the system demand varies over time, the assessment team shall determine if the system needs to be
monitored over time and what time period is reasonable to get a representation of all operating conditions.
Operating data may also be used if readily available in the facility process control or database of
historical operating conditions.
Uncertainty on measurements and uncertainty on final results should be estimated during the evaluation
of the assessment.
5.6.3 Pressure
Pressure measurements should be made using calibrated instruments with the ideal measurement
location being approximate 2 diameters of straight pipe, from inlet/outlet flanges if available.
To measure pump efficiency, pressure measurements should be made close to the pump on both the
suction and the discharge side.
When measuring pump performance it is recommended that head losses between the suction and
discharge head measurement points and the pump be estimated.
For accurate calculation of the pump total head, the velocity and the instrument elevation shall be taken
into account.
5.6.4 Flow
The system flow rate shall be determined to establish pump and system efficiencies. Flow rates shall be
measured using properly sized instruments, whether it be for an individual pump or total system flow.
Measurements shall be made with calibrated flow meters that are properly installed into the system
and known to be accurate across the range of measured conditions. The flow meter should be installed
according to the manufacturer’s recommendations. When it is necessary to use portable flow meters,
verification of the measurements should be performed by re-installing the flow meter in an alternate
location or using multiple measurement techniques. If large variations are found, then the measurements
shall be considered unreliable.
If the flow rate is determined from the pressure drop across a component with known characteristics
or by using data from the pump manufacturer’s performance curve, the data should be cross-correlated
with both pressure and power measurements or by using multiple measurement techniques if there is
doubt about the accuracy of the measurements.
5.6.5
Input power
Whenever possible, the input power should be measured directly using a power meter, which should give
the most accurate results. When it is not possible to measure power directly, an acceptable alternative
shall be to measure voltage and current delivered to the motor. Then using the estimated power factor,
the motor input power shall be calculated. If a power drive system is used, the input power shall be
measured before the variable frequency drive.
Electrical measurements shall be performed only by a qualified person.
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ISO/ASME 14414:2015(E)
5.7 Cross validation
When the needed parameter is not directly measurable, it may be estimated through measures of other
parameters, such as:
— pump head combined with pump head curve to estimate flow rate;
— electric power combined with motor performance curve (or estimates) to estimate shaft power, and
then use the shaft power and pump shaft power curve to estimate flow rate;
— measured valve position and flow rate combined with the valve characteristic curve to estimate
differential pressure;,
— measured drawdown and fill times, along with well or sump dimensional data to estimate pump
flow rate.
Such estimation methods may be used for preliminary quantification of potential energy savings
opportunities and to help determine whether the magnitude of savings is sufficient to warrant further
investigation.
NOTE
It is beyond the scope of this International Standard to detail the various cross-validation techniques,
but they are vital tools in the assessment and solution development process.
5.8 Wrap-up meeting and presentation of initial findings and recommendations
The presentation of findings and preliminary recommendations shall be conducted as final step in
conducting the assessment. This wrap-up meeting should be attended by the entire assessment team.
During this meeting, outstanding questions and issues from the assessment team should be addressed. The
tentative results of the assessment shall be formally presented and should include but not be limited to:
— review of the assessment process used;
— efficiency of the system(s) and components assessed;
— tentative recommended improvements, with preliminary energy and cost savings, if available;
— discussion of any further analysis recommended, and;
— any general comments and observations.
The results presented shall be qualified as preliminary, subject to further analysis and refinement. Target
dates for the delivery of a draft and final versions of the written report shall be set by mutual agreement.
For more information, see Annex B.
6 Reporting and documentation
6.1 Final assessment report
At the conclusion of the onsite assessment and any required follow-up data analysis, the assessment
results shall be reported in a final written report, as described in Annex A.
6.2 Data for third party review
The report or other documentation delivered with the report shall include sufficient raw data from the
assessment so that the analyses performed in 5.6 can be confirmed by a third party. This documentation
shall be structured so it can be easily accessed by verifiers and other persons not involved in its development.
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ISO/ASME 14414:2015(E)
6.3 Review of final report by assessment team members
Before the assessment report is finalized, members of the assessment team shall review the assessment
report for accuracy and completeness and provide comments. Upon review of the draft report and
requests for modifications, the assessment team shall provide a consensus acceptance, and then prepare
and issue the report in final form.
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex A
(normative)
Report Contents
A.1 Executive Summary
This section shall condense and summarize the report in brief. The executive summary shall provide
an overview of:
a) facility background, products made and energy objectives;
b) objectives and scope of the assessment;
c) system(s) assessed and measurement boundaries used;
d) annual energy usage;
e) performance opportunities identified with associated energy and cost savings;
f) estimated energy and cost savings ;
g) list of recommendations to accomplish the estimated energy and cost savings identified.
A.2 Introduction and facility information
Brief description and background, team and scope of the assessment shall be included in this section.
A.3 Assessment objectives and scope
This report section shall contain a brief statement of the assessment’s objectives. The report shall
identify the boundaries of the specific system(s) on which the assessment was performed and why the
boundaries were selected. This report section shall include a description of the general approach and
methodology used to conduct the assessment.
A.4 Description of system(s) studied in assessment and significant system issues
The report shall include a detailed description of the specific system(s) on which the assessment was
performed. Depending on the system assessed, the discussion of system operation can be extensive and
should be supported by graphs, tables and system schematics. Supporting documentation should also be
included to clarify the operation of the system components and their interrelationships.
Any significant system issues shall be described, including an operational review of system. Any
existing best practices found (methods and procedures found to be most effective at energy reduction)
shall be documented.
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ISO/ASME 14414:2015(E)
A.5 Assessment data collection and measurements
The methods used to identify and interview key facility personnel, obtain data, and conduct
measurements shall be identified, including an overview of the measurement plan. Relevant data for
level 2 and 3 assessments shall include:
— definition of system requirements and a determination of how system operation changes during the
year (drawings, system process data);
— pump total head (TH), flow and system estimated curve;
— electrical energy consumption data;
— determination of pump operating hours and flow intervals;
— pump performance information, when available;
— measurement or estimation of system losses.
This section should also include a discussion of data accuracy and the need for verification before the
recommended projects are approved.
A.6 Data analysis
The report shall include the outcome of the measurements and data analysis in accordance with site
specific assessment objectives, assessment plan of action and statement of work. Any significant
analytical methods, measurements, observations, and results from data analysis from completed action
items shall be documented.
A.7 Annual energy consumption baseline
If sufficient data exist, the assessment report shall contain the baseline of total annual energy consumption
for the pumping system. The analytical method used to develop the annual energy consumption baseline
(see 5.5.1) shall be described. Facility functional and production process observations and information
shall be reported.
The report shall clearly describe the assessment baseline as a basis for both routine and non-routine
adjustments. Adjustments are calculated from identifiable physical facts with respect to changes in the
physical facility and production process. The report shall provide sufficient information on the facility
functional baseline during the assessment to provide a basis for adjustments.
NOTE 1 Routine adjustments are those energy-governing factors that are expected to change such as
production volume variations. Baseline relationships of production dependent and time dependent system energy
consumption are clearly stated.
NOTE 2 Non-routine adjustments are related to factors that are not usually expected to change during the
short-term. Factors such as facility size, the design, type and number of production lines involving pumping
systems are examples of non-routine adjustments.
A.8 Performance improvement opportunities identification and prioritization
The analysis shall quantify estimates of energy reduction and energy cost savings from recommended
performance improvement opportunities. Additional calculations may address other energy and nonenergy benefits. The report shall identify the methods of calculation and software models used with
assumptions clearly stated.
Performance improvement opportunities can include those from maintenance improvements;
operational improvements; equipment upgrades and replacement; revising control strategies; process
improvements and change-over; and other actions that reduce energy consumption.
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ISO/ASME 14414:2015(E)
Details on performance improvement opportunities to be documented and reported shall include a
sufficiently detailed description of the actions required for project implementation. To aid in the selection
of projects for implementation, the assessment team should categorize the opportunities identified to
be of high, medium or low priority based on factors such as
— energy and cost savings;
— likelihood of achieving projected savings;
— likelihood of long project life with sustained savings;
— impact to on-going operations;
— changes or modifications necessary for the existing equipment;
— time and cost for implementation;
— complexity of implementation steps;
— potential parallel benefits (e.g. improved profitability, improved reliability and maintenance costs,
improved operations, lower environmental impact).
In the analysis section of the report, the pumping system energy consumption baseline shall be
established and energy savings opportunities developed.
For all assessment levels, the analysis for energy consumption baseline development and proposed
recommendations should be performed in sufficient detail to allow facility staff to understand all parts of
the analysis. If software is used, the data entered into the software shall be clearly defined. The supporting
analysis data may include spreadsheets, diagrams, software output screen captures, and calculations.
The steps, assumptions and calculations of the analysis should be presented in a logical detailed format
that can be understood by other engineering professionals for third party verification if required.
This part of the assessment may also address other energy and non-energy benefits such as improving
resource utilization, reducing per unit production cost, reducing life cycle costs, and improving
environmental performance. These benefits can be mutually agreed upon with facility management.
NOTE
The amount of detail included in the energy efficiency recommendations vary considerably for each
assessment level.
Recommendations are typically classified as operation and maintenance recommendations (OMs) or as
energy conservation measures (ECMs). The recommendations reviewed in this report section shall be
prioritized in order based on facility staff acceptance and cost effectiveness. Each subsequent measure
should include the interactive savings effect of the previously recommended measure. Consideration
must also be given to projects that may be easily implemented versus improvements that may not be
easily pursued until facility production lines are out of service.
The presentation of each measure should be limited to a brief description of the proposed improvement
and a summary of the benefits. If needed, it is also appropriate to recommend a higher level assessment
before the measure is pursued.
General observations of non-pumping system related energy saving opportunities should also be discussed.
A.9 Recommendations for implementation activities
Details on performance improvement opportunities shall include the next steps needed to move from the
identified performance improvement opportunities to implementation of the listed measures. Methods
for refining data analysis as needed, and for obtaining reliable implementation cost estimates should be
addressed. Methods for optimizing and maintaining system performance following implementation of
adopted measures should be identified.
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Implementation cost estimates for the performance improvement opportunities, if developed as an
optional activity, are intended to be screening or feasibility estimates and could also include preparing
metrics such as return on investment and payback period.
The assessment report should note that further engineering analysis be performed prior to implementing
the recommendations contained in the assessment report.
A.10 Appendices
Information that is lengthy and not required for the presentation of the report should be included
in appendices to ensure clarity of the body of the report. Detailed supporting data, such as energy
consumption calculations, cost savings calculations, and economic analysis, should be referenced and
included in the report appendices.
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BS EN ISO 14414:2015
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Annex B
(informative)
Recommendations on efficient system operation and energy
reduction - Examples
B.1 General recommendations for efficient system operation
The operating characteristics of pumps should match the characteristics of load and piping resistance,
so as to keep the pumps running in accordance with the manufacturer’s specifications.
For any large power system with long operation time, measurement of pressure, flow rate, and power
should be made at relevant points in the system regularly to test the efficiency of operation in order to
ensure that the system is operated efficiently.
Preferably the pump should operate at the best efficiency point (BEP) and in any case not outside the
allowable operating range (AOR) defined by the pump manufacturer (see Figure B.1).
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Key
Y1
Y2
Y3
Y4
X
1
2
3
4
a
b
head, expressed in meters
efficiency, expressed in percentage
power, expressed in kilowatts
NPSH3, expressed in meters
Flow rate, expressed in cubic meters per hour
head
power
efficency
NPSH3
Preferred operating region.
Allowable operating region.
NOTE
High pump efficiency does not guarantee high system efficiency, especially if the pump is oversized vs.
the system demand.
Figure B.1 — Example of curves and allowable operating range
The example curve in Figure B.2 shows how fast the mean time between failures (MTBF) falls off when
the pump operating point moves away from BEP.
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Key
A
B
C
D
E
F
G
H
high temperature rise
low flow cavitation
low flow bearing and seal life
reduced impeller life
suction recirculation
discharge recirculation
low bearing and seal life
cavitation
Curve 1
Curve 2
Curve 3
X
Y
pump curve H(Q)
pump efficiency curve
reliability curve/MTBF
flow in percent of flow at BEP
head in percent of head at BEP
Figure B.2 — Example of pump reliability curve
Manufacturers normally indicate a preferable operating region around BEP and sometimes also an
allowable operating region. How these regions are defined differ between manufacturers. Care should
be exercised to operate as close to BEP as possible. A deviation of −20 % or +10 % from the flow at BEP
could mean that the mean time between failures (MTBF) is cut in half! For pumps with variable flow,
the selection of the best efficiency point in relation to the operating range needs careful consideration.
B.2 System management to ensure economic operation
B.2.1 General
Three-phase asynchronous motors used for driving pumps should be sized to operate at or close to
maximum efficiency for all operating conditions (normally 50 % to 100 % load and 35 % to 100 % load
for high efficiency motors according to IEC 60034 series). For other types of drive, the operating range
should be in accordance with manufacturer recommendations.
Rules for operation management, maintenance and repair should be established.
Operation performance logs and technical archives should be kept and maintained.
Personnel responsible for management and operation should be adequately trained for their positions.
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B.2.2 System management recommendations
Efficient system components should be used and operated in such a way that high system efficiency
is maintained.
For systems operating a long time under part load or having large demand changes, proper measures
should be taken in order to maintain high operating efficiency for all conditions, when it is technologically
and financially practicable.
Process requirements should be evaluated to determine that the system is running efficiently, within
applicable quality, health and safety requirements. If the system is not running within the established
boundaries, a plan for correction should be made and implemented.
B.2.3 System updating and improvement
For any system that fails to meet the established efficiency requirements after an assessment, the system
operation should be examined and a report should be produced to document the current operation,
including: test method and data analysis, efficiency improvement measures, and responsibilities.
This report should be kept in an accessible location.
When pump systems have been installed or undergo updates, an assessment should be conducted to
establish base operating conditions.
B.2.4 Pump system piping
Increasing the internal pipe diameter is usually the most effective way to decrease the pipe friction
losses and the resulting energy consumption. For example, 10 % diameter increase leads to a decrease
of approximately 40 % in losses for the turbulent flow region. In general, flow velocities should be kept
as low as practically possible in regard to the liquid material suspended being pumped.
The number of pipe bends should be minimized and the radius of curvature of turns should be as large
as economically feasible in order to minimize friction losses. A minimum of 1,4 times longer than the
pipe diameter is recommended for such turns.
Rapid diameter changes should be avoided. Diffusers should be used when possible.
When selecting components, considerations should be made to minimize the friction losses across the
equipment. The equipment should be suitable for the liquid being pumped.
The elevation and pressure on the surface of liquid in a tank affects the systems static head. Wherever
possible, static head should be minimized.
B.3 Common causes and remedies for excessive energy consumption for
rotodynamic pump
B.3.1 General
It is important that a thorough understanding of system requirements be established before the
application of any analysis technique. This includes distinguishing between system design specifications
and actual process requirements before evaluating energy savings opportunities.
It should be understood that once physical or operational changes are made, the system curve may likely
change, resulting in different system requirements and the need for another iteration of system analysis.
Each time the system is modified there is the potential to redefine optimal operation for that system.
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B.3.2 Reduce system head losses
Examples of opportunities to reduce the system head are shown below. This list is not comprehensive.
Rather, it shows some of the most common opportunities identified by experience:
a) remove/reduce unnecessary throttling and/or recirculation flows;
b) clean or perform maintenance on fouled components such as heat exchangers;
c) isolate flow paths to non-essential equipment or equipment that is not operating;
d) maintain proper fill and venting of elevated sections of pipe;
e) reduce/remove sediment and scale build-up in pipelines, heat exchangers, and process components;
f) do not employ an air gap between pipe discharge and receiving tank when isolation is not necessary;
m) adjust flow rate to meet process demands without exceeding them;
k) maintain the design pumping temperature when pumping viscous products;
i) separate secondary systems that demand very low flow rates with a head much higher than required
by the main system.
B.3.3 Reduction of system flowrate
Examples of opportunities to reduce the system flow rate are shown below. This list is not comprehensive.
Rather, it shows some of the most common opportunities identified by experience:
j) maintain the optimum differential temperatures in heat exchanger applications, preferably
considering exchanger design efficiency;
l) isolate unnecessary flow paths, unnecessary pump recirculation and leaking valves, check valves,
minimum flow valves;
l) reduce the flowrate in the batch processes that are basically fill and drain, as long as it does not
create an unacceptable change to the production schedule;
m) turn off pumps when flow is not needed.
B.3.4 Ensuring that components operate close to best efficiency
The operating efficiencies of the various components that comprise the pumping system can vary
substantially depending on where they operate on their respective curves. As a rule, motors should
operate where their efficiency curve is flat. Rotodynamic pumps should preferably be operated close to
BEP (see Figure B.2). Operation away from BEP quickly reduces pump efficiency and reliability.
It should also be noted that different types of electric motors and other drivers can differ substantially
in efficiency.
NOTE
Excess system energy consumption can occur when installed equipment is operated away from the
best efficiency point. There are many possible reasons but most of them are related to changes from projected
specification, change in system requirements; all of them will lead to less energy efficient systems. Some of the
more common factors, are listed below:
— during the initial design stage of a system and before the system has been in operation, there are many
uncertainties. Selection of equipment tends to be conservative and this in addition to service factors and
design margins will often result in oversized systems,
— systems designed for excessive requirements;
— when the actual system requirement is considerably different than the pump capability, the system efficiency
will inherently suffer (and, it might be noted, so will reliability);
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— changes in system conditions, either due to changes in requirements or aging of the system itself or due to
changes of specific component and equipment;
— lack of understanding that energy consumption might accounts for largest cost when it comes to make
decision in new investments and therefore installing equipment with higher life cycle cost than possible.
B.3.5 Change pumping system run time
Opportunities based on changing system run time are often used where the system requirement is
dominated by friction head. Such uses include, but are not limited to:
— pumps/lift stations,
— systems with electric rates that change based on time of use or have a demand component,
— systems that run when the process is not operating. Often a recirculation loop is employed rather
than turning a pump off when flow is not needed,
— systems with multiple parallel pumps that are running more pumps than necessary to fulfil the
process demands.
A good practice to enhance pumping efficiency is to monitor specific energy (see Annex F).
In most instances pumping capacity is larger than needed. This is especially true in applications
involving storage, for example filling up tanks in industrial applications, pumping down wet wells or
filling up reservoirs in municipal applications. The pumps are started and stopped by the liquid level in
the wet well or the tank/reservoir. Lower flow rates will mean an increased run time but on the other
hand lower flow rates will result in savings due to the reduced friction losses.
In installations with high demand changes lowering flow rates could mean lower power demand and
hence cost savings can be achieved. (This does not always mean that energy savings are achieved).
In many applications pumps may run longer than necessary. Examples of such applications are multiple
pumps running in parallel and producing more flow than necessary. This is not uncommon in applications
involving cooling towers and chillers. The operators are not switching pumps off when they could be
turned off, but let them run even if they are not needed. This situation can be recognized by measuring
the temperature difference over the cooling tower/ heat exchanger. If the temperature difference is
lower than optimal, the flow rate is too high. In such a situation, one or more pumps could be turned off
or the capacity might be lowered by changing the speed of the pump(s).
B.4 Examples of basic energy reduction opportunity calculations for
rotodynamic pumps
B.4.1 Calculation of existing and post assessment energy consumption
B.4.1.1 General
The objective is to minimize the energy consumption of the existing system. This is accomplished by
evaluating the operation of the existing system, identify possible reductions in system head, flow rate,
and run time, and running the system components closer to their optimum conditions.
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ISO/ASME 14414:2015(E)
The hydraulic power imparted to the liquid by the pump is as shown in Formula (B.1)
Pw =
where
QH ρ
QH ρ
(SI units) or Pw =
(US units)
367000
331232
Pw
is the hydraulic power supplied by the pump expressed in kilowatts (kW);
H
is the total head, at flow rate Q, expressed in meters or feet);
Q
ρ
(B.1)
is the flow rate expressed in cubic meters per hour (m3/h) or gallon per minute (gpm);
is the liquid density expressed in kilogram per cubic meter (kg/m3) or pound per cubic foot
(lb/ft3).
The electrical power Pe required to support the pumping system operation is shown in Formula (B.2)
Pe =
where
ηP
ηM
ηD
Pw
η Pη Mη D
(B.2)
is the pump efficiency;
is the motor efficiency;
is the drive efficiency (if no drive installed set ηD to 1).
To optimize pump systems, the following operations are performed:
— minimization of the flowrate;
— minimization of the pump head;
— optimization run time;
— maximization of the component efficiency.
Improvements can be accomplished using existing equipment. Additional savings can sometimes be
achieved through equipment replacement.
B.4.2 Example
The following example demonstrates the calculations to determine:
— initial power consumption;
— power consumption after making improvements in operation;
— power consumption after replacing components.
Figure B.3 illustrates a transfer liquid system from Tank A to Tank B. A recirculation line maintains
constant pump discharge pressure. A level control valve maintains constant level in Tank B: 4,5 bar (65
psi) upstream of the pressure reducing valve. The pump is direct motor-driven.
The following data are recorded:
— liquid: water temperature 20 °C (68 °F) and density 998,3 kg/m3 (62,32 lb/ft3)
— plant electric cost: $ 0,10/kWh
— measured flowrate: 450 m3/h (2 000 gpm)
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BS EN ISO 14414:2015
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— measured process flowrates: 340 m3/h (1 500 gpm) to tank B, 110 m3/h (500 gpm) recirculation
by-pass
— measured pump total head: 46 m (150 ft)
— Pe:78 kW
— motor efficiency: 94 %
— 6 132 h (70 %) annual operation
Key
1
2
P
L
tank A
tank B
pressure control
level control
Figure B.3 — Example of simplified flow diagram
This example consists of the following steps:
a) to determine annual power consumption and annual operating cost.
Figure B.4 illustrates the curve of the pump.
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ISO/ASME 14414:2015(E)
Key
1
2
3
X
head, expressed in meters
NPSH3, expressed in meters
power, expressed in kilowatts
flow rate, expressed in cubic meters per hour
Figure B.4 — Example of pump operating curve (as found flow rate of 450 m3/h)
The power consumption, calculated using Formula (B.2), is 82,9 kW.
The pumped system runs 6 132 h/y (0,7 × 8 760 h/y).
The annual operating cost, AOC, is calculated as follows:
h
$
$
AOC = 82, 9 kW ×6 132 ×0, 10
= 50 830
kWh
y
y
b) to determine present system demand
(B.3)
The result of data provided shows that:
— present system demand is 340 m3/h;
— bypass flow of 110 m3/h can be eliminated to save energy.
c) to determine current annual power consumption and annual operating cost without component
replacement
Eliminating the bypass flow results in:
— flowrate: 340 m3/h;
— head: 48,7 m;
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
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— efficiency of 62 %.
The power consumption, calculated using Formula (B.2) is 77,3 kW. The annual operating cost is $47 400.
Pump Modifications
Further savings can be achieved by acting on the following additional data collected after the first analysis:
— control valve differential pressure can be reduced from 1,75 bar down to 1 bar;
— impeller trimming from 327 mm to 282 mm reduces the head to 41,3 m at 340 m3/h with an
efficiency of 65 %.
The resulting power consumption Pe, calculated using Formula (B.2), is 63,5 kW. The annual operating
cost is $ 38 930.
d) to determine annual power consumption and annual operating cost of the system considering
component replacement
Installing variable speed drive to existing pump results in:
— 1,580 r/min for 340 m3/h;
— head: 37,9 m;
— pump efficiency of 66 %.
The resulting power consumption Pe, calculated using Formula (B-2) is 59,5 kW.
The annual operating cost is $36 490.
Purchase new pump for current demand:
— flowrate: 340 m3/h;
— head: 41,9 m;
— pump efficiency of 84 %;
— motor efficiency of 94 %.
The resulting power consumption Pe, calculated using Formula (B.2) is 49 1 kW. The annual operating
cost is $ 30 110.
Table B.1 gives the summary of the calculated energy reduction.
Table B.1 — Summary of the results
Conditiona
As found
Eliminate by-pass
Trim impeller
Add variable frequency
drive b
New pump
a
Flow
m3/h
Head
m
Pump efficiency
Power consumption
Operating cost
340
48,7
%
62
kW/h
$
65
63,5
38 940
84
49,1
30 110
450
340
340
340
46,5
73
37,9
66
41,3
41,9
82,9
77,3
59,5
50 830
47 400
36 490
All examples use the following system conditions: 20°C water, motor efficiency 94 %, power cost $0,10/kWh, 6,132
h/year operation
b
36
The efficiency of the variable frequency drive is 95 %, as specified by the manufacturer.
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
B.4.3 Secondary systems: sealing systems
Sealing systems can be another cause of excessive energy consumption. The excess energy related to
the use of inappropriate seals or seal support systems, may consume large amounts of energy and other
utilities. Further inspection by a specialist is recommended, see Example.
Further inspection by a specialist is recommended, see Example.
During operation the sealing assembly (mechanical seal and seal support system) contributes to the
total energy consumption of the pump-sealing assembly mainly due to the friction and viscous shear
of the fluid in the seal chamber (also known as frictional losses), and the energy consumption of the
seal support system which is implemented in order to maintain an acceptable environment in the seal
chamber. In certain applications the energy consumption level of the support system can be equal to or
even greater than that of the pump drive.
Table B.2 provides an example of qualitative assessment of the energy impact of different commonly
used seal piping plans (see API 682).
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.2 — Example of energy impact based on API 682 seal piping plans
Basic seal
arrangement
API
Plan
01
Internal recirculation from
discharge to seal
02
Dead end, no recirculation
11
External recirculation from
discharge to seal
13
14
Single mechanical seals and the
inboard seal of
dual unpressurized seals
Description
External recirculation from
seal to suction
External recirculation from
discharge to seal to suction
21
External recirculation from
discharge through a cooler to
seal
23
Internal recirculation from
seal to cooler and back to seal
31
External recirculation from
discharge through cyclone
separator to the seal
32
Flush fluid is injected to the
seal from external source
41
Recirculation from discharge
through cyclone separator and
cooler to the seal
62
External atmospheric quench
Efficiency losses
Thermala
0
Electricalb
2
Comments
Waterc
0
0
1
0
0
2
0
0
2
0
0
2
0
3
2
1
2
1
1
0
2
0
3
1
3
3
1
2
1
Thermal energy losses
may occur and water
may be consumed if
the seal chamber is
designed with cooling
or heating jacket.
1
1
May consume a high
amount of thermal
energy when cooling
the process medium is
required
Is the most effective
when cooling of the
process medium is
required.
May consume the highest amount of thermal
energy to replace the
process fluid heat
lost by injecting the
cooler external fluid.
If plan 32 used in cold
application, the then no
thermal impact
May consume a high
amount of thermal
energy when cooling
the process medium is
required
If seam is used as a
quench fluid, the thermal loss may be significant if not controlled
a
Thermal losses refer to cooling of the flush or barrier fluid, lost and recovery process heat and energy required to
separate diluents.
b
Electrical losses refer to additional electrical power absorbed by the seal face (value of 1) and flow loss of the pump due
to recirculation (value of 1).
c
Water losses refer to the water consumption to operate the piping plan. Air cooling may be used to avoid cooling water
usage.
0
no impact on efficiency
2
moderate impact on efficiency
1
3
38
minor impact on efficiency
major impact on efficiency
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.2 (continued)
Basic seal
arrangement
Dual pressurized
mechanical seals
Dual unpressurized mechanical
seals
API
Plan
53
54
Description
Pressurized external barrier
fluid reservoir supplies clean
fluid to the seal
External barrier fluid system
supplies clean fluid to the seal
at pressure higher than seal
chamber pressure
74
Externally supplied barrier
gas to seal at pressure higher
than seal chamber pressure
52
Unpressurized external buffer
fluid reservoir supplies clean
fluid to the seal
72/
75/
76
Externally supplied gas buffer
for arrangement 2 seals.
Buffer gas pressure is lower
than the process side pressure
of the seal
Efficiency losses
Comments
Thermala
Electricalb
Waterc
1
1
1
2
2
2
0
0
0
1
0
1
0
1
0
May consume a low
thermal energy when
the temperature of
the process medium is
higher than the temperature of the barrier
fluid
Electrical energy
consumed in the processing of the nitrogen
barrier gas is considered negligible
May consume a low
thermal energy when
the temperature of
the process medium is
higher than the temperature of the barrier
fluid
Electrical energy
consumed in the processing of the nitrogen
barrier gas is considered negligible
a
Thermal losses refer to cooling of the flush or barrier fluid, lost and recovery process heat and energy required to
separate diluents.
b
Electrical losses refer to additional electrical power absorbed by the seal face (value of 1) and flow loss of the pump due
to recirculation (value of 1).
c
Water losses refer to the water consumption to operate the piping plan. Air cooling may be used to avoid cooling water
usage.
0
no impact on efficiency
2
moderate impact on efficiency
1
3
minor impact on efficiency
major impact on efficiency
For some pump system applications, the selection of the seal support system is a major contributor to
the overall pump system energy consumption:
EXAMPLE
Water based abrasive slurry. This application involves a single stage end-suction, overhung, foot
mounted slurry pump (OH1) which is pumping a water based black liquor slurry in a paper mill at 75 ° C (170 °F).
The pump shaft speed is 3600 r/min, the pump shaft diameter is 50 mm (2.00 in.), the seal chamber pressure is
345 kPag (50 psig), and the pump driver would consume 37 kW (50 hp). One common method of sealing the shaft
is either packing with a lantern ring, or a single mechanical seal using Plan 32, both with a 1,9 lpm (0,5 gpm) clean
water flush at 10 °C (50 °F) is applied. The net energy consumption of these sealing systems is 84 kW (113 hp)
primarily due to the need to heat and evaporate the water diluent in a downstream process that was introduced
through the flush. An alternative sealing system for this slurry application would be the use of a dual pressurized
seal with an API piping plan 54 to circulate a clean barrier fluid through the cavity between the inboard and
outboard seals. This seal and system approach reduces the sealing system energy consumption to 3,9 kW (5.2
hp) which results in an energy savings of 80,1 kW (117,8 hp). Even if a switch to a dual pressurized seal were not
practical, a reduction in flush flow rate through the use of a close clearance bushing or a different placement of
the lantern ring for the packing arrangement can easily cut the required flow rate down to 0,4 lpm (0,1 gpm) with
a reduction of energy consumption of 67 KW (90 hp).
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
B.5 Explanation of basic energy reduction opportunity calculations for positive
displacement pumps
B.5.1 General
Positive displacement (PD) pumps have very different characteristics than rotodynamic pumps and in
many applications low energy consumption has been a primary driver of their initial selection. Due to
the differences in PD pump characteristics, the recommended control logic is different from that used
with rotodynamic pumps.
Closely matching the positive displacement pump performance, the process requirement approaches
the optimal energy consumption.
When evaluating systems, the following is valid for PD pumps:
— PD pumps at constant speed are constant flow devices;
— flow varies with viscosity and pressure changes due to “slip” which is fluid internally returned from
high pressure to low pressure region of the pump (suction). Slip flow is minor and can be ignored in
system energy evaluations;
— flow variation with pressure change is much less than for rotodynamic pumps;
— rules for positive displacement pumps are:
— flow rate varies directly with speed,
— power requirement varies directly with speed,
— pressure differential is determined by the system hydraulics,
— both flow and power increase with a viscosity increase,
— PD pumps generate pressure to meet system requirements, dead heading and discharge throttling
should not be practiced. Safety requires a pressure relief device in downstream of the pump but this
should not be an energy issue unless the unit is improperly sized and is recirculating through the
relief valve.
— PD pumps are not head producing devices and are rated and calculated directly based on pressure
differential and not head.
Head to pressure relation is calculated using Formula (B.4):
P = H ρ g × 10−5 (SI) or P =
where
P
H
ρ
g
40
Hρ g
(US)
2, 31
(B.4)
is the pressure expressed in bar (bar) or pound per square inch (psi)
is the head expressed in meters (m) or feet (ft)
is the density expressed in kilogram per cubic meter (kg/m3) or pound per cubic foot (lb/
ft3)
is equal to 9,81 m/s2 or 32,2 ft/s2
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
The hydraulic power imparted to the liquid by the pump is calculated using Formula (B.5):
Pw =
where
Q∆p
36
Pw
Δp
Q
(SI) or Pw =
Q∆p
(US)
1714
(B.5)
is the hydraulic power supplied by the pump expressed in kilowatts (kW) or horsepower (hp);
is the difference of pressure expressed in bar (bar) or pound per square inch (psi);
is the flow expressed in cubic meters per hour (m3/h) or gallon per minute (gpm);
The electrical power required to support the pumping system operation is calculated using Formula (B.6):
Pe =
where
Pw + PI
η Mη D
(B.6)
Pe
is the electrical power input expressed in kilowatts (kW) or horsepower (hp);
ηM
is the motor efficiency when supplying the power required by the pump at flow rate Q;
PI
ηD
is the internal power losses which are mechanical and viscous, expressed in kilowatts (kw)
or horsepower (hp);
is the drive (belt, adjustable speed, gear, etc.) efficiency;
Pump internal power losses are those from mechanical friction, internal recirculation and the viscous
losses from the drag effect on parts in the liquid flow path. An estimation of these values can be obtained
from the pump manufacturers.
Driver size is based on maximum viscosity and pressure differential.
PD pumping systems are deemed to be operating at the optimal performance level when the system
functional requirements are met with:
— minimum demand flow rate,
— minimum demand differential pressure,
— minimum run time,
— maximum component efficiencies.
The optimal hydraulic power added to the system is the value calculated with the above conditions
inserted into Formula B.12 and the optimal electrical power is calculated (Formula B.13) using the
optimal hydraulic power and the best available pump, motor and drive efficiencies.
As prescribed in this International Standard, the assessment should establish a baseline of total annual
energy consumption for the pumping system(s) assessed.
B.5.2 Example
B.5.2.1 Existing conditions (see Table B.3):
A system transfers liquid from tank A to tank B (see Figure B.5).
All flow goes to tank B.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Tank B is always full and excess flow returns to tank A.
B.5.2.2 Improved conditions (see Table B.3):
A recirculation line is installed to maintain the constant flowrate and to supply demand flow.
Energy is saved since less liquid is forced through the feed line to tank B, thus lowering friction losses
No discharge throttling can be used. The pump is directly driven by a motor (without gear, belt, or
variable speed drive).
B.5.2.3 Main features of operating conditions are:
— the system liquid has a specific gravity of 0,85 and the facility average electric cost rate is $ 0,05/kWh,
— the liquid is turbine lube oil with viscosity of 90 cSt (420 SSU) at 40°C (104 °F),
— measured pump flow rate: 450 m3/h (2000 gpm),
— optimal flow rate: 340 m3/hour (1 500 gpm) going to tank B. 110 m3/h (484 gpm) is over-flowing or
pumped through the by-pass line directly back to tank A
— measured pump outlet pressure: 4 bar (60psi),
— optimal pump outlet pressure at the reduced flow (optimal flowrate) to tank B (total pump flow
being the same): 2,7 bar (40 psi),
— measured electric power: 73,4 kW
The system operates at the above conditions 70 % of the time.
NOTE
This example, while similar to the rotodynamic example, uses a liquid that is considerably more
viscous, so results cannot be compared and are useful only to illustrate the concepts presented.
Key
1
2
L
tank A
tank B
level control
Figure B.5 — Simplified Flow Diagram for Table B.3
Table B.3 gives the results of first analysis.
42
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.3 — Actual existing (oversized) vs. proposed improved system flow results
Condition
Existing system
Improved
system
Potential savings
Flowrate
m3/h (gpm)
450 (2 000)
Outlet
pressure
bar (psi)
Pump
power
input
kW
Motor
efficiency
2,7 (40)
55,7
94
450 (2000)
whereof
340 m3/h to
tank B
─
4,0 (58)
1,3 (19)
Ratio of optimal power/measured power
%
73,4
94
─
─
Electrical
power
input
kW
Annual
energy
MWh
Annual
energy
cost
$1,000
59
363,3
18,2
0,76
─
─
78
─
478,9
─
23,9
5,7
Pump operating at same speed and flow but delivered flow to tank B is reduced to 340 m3/h (1500 gpm), due to the
NOTE
by-passing. The pressure is reduced from 4 bar (58 psi) to 2,7 bar (40 psi) due to the lower pressure drop in the recirculation
valve controlled loop
B.5.2.4 Optimised conditions (see Table B.4):
Add variable frequency drive to control flow to meet demand.
Close by-pass line.
Transitioning to a VSD allows the tank B level controller to set the speed of the tank A pump to match the
process demand and to save the energy consumed by the recirculation control loop as well as minimising
the system losses between the tanks (see Figure B.6).
Key
1
2
L
VSD
tank A
tank B
level control
variable frequency drive
Figure B.6 — Simplified flow diagram for Table B.4
Table B.4 gives the results of second analysis:
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table B.4 — Optimal system flow results vs. flow matched to system without recirculation control
Flowrate
Condition
Improved
system:
2,7 bar
(40 psi)
Optimised
system
reduced
speed/flow/
pressure: 2,7
bar (40 psi)
Potential
savings:
existing vs
improved
Potential
savings:
optimal vs
existing
m3/h (gpm)
450 (2000)
whereof 340
(1500) to
tank B
340 (1500)
Operating
speed
r/min
Pump
power
input
kW
Motor
Variable Electric
efficiency frequency power
%
drive
kW
efficiency
Annual
energy
cost
$1000
1200
55,7
94
_
59
363,3
18,2
925
39,4
92
96
44,6
273,5
13,7
Savings
relative
existing:
5,7
_
_
-
-
16,3
22 %
34
46 %
_
_
_
115,6
-
-
-
205,4
Beyond these special considerations the methods used in B.4 can be considered.
44
Annual
energy
MWh
Savings
relative
existing:
10,2
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex C
(informative)
Expertise, experience and competencies
C.1 Systems
This section identifies the areas of expertise/experience relevant to be mastered by the assessor(s) in
respect of the system and the liquid pumped.
— Pump system energy basics:
— Assessors should be familiar with pumping systems which can include a wide variety of facility
and equipment including process units, tanks and pressure vessels. The type and number of
pumps and drives installed will also vary according to the system being assessed.
— Assessors should be familiar with pumps, drives, control valves, process components and be able
to determine the factors for each system component that contribute to the energy consumption
of the system.
— System performance characteristics:
— Assessors should be familiar with how the physical properties of the process liquid effect the
pumped system including, density, viscosity and vapour pressure and how these physical
properties affect the operation of the various components found in a pumping system.
— Assessors should be familiar with all the different elements of head, such as total head, static
head and friction head, and be able to determine each of them for any given system. They
should also be able to generate and understand a system curve and be able to understand the
operational envelope over time (duration diagram).
— Assessors should be proficient in determining the friction head losses for all components of the
system being assessed using the various methodologies for determining friction head loss.
— Assessor should be capable of establishing the system demand and profile.
— Assessors should be capable of optimising velocity within the system considering energy
consumption, liquid dynamics and system demand.
— Assessors should be capable of determining the system characteristics for parallel and series
pumping configurations
C.2 Pumps
This section identifies the areas of expertise /experience relevant to be mastered by the assessor/s with
regards to the aspects of the pump characteristics and liquid influences relative to the hydraulics of the
pump and the effects on the system.
— Liquid energy basics
— Assessors should be capable of determining the various components of energy, including
pressure, geodetic head, flowrate and velocity head, and how they relate to Bernoulli’s principle.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— Assessors should have the ability to determine the variance of the liquid properties e.g. density,
viscosity temperature etc.
— Pump characteristics:
— Assessors should understand pump performance characteristics and their interaction with
the system. Such characteristics include, head, flow, power, efficiency, NPSHA/R, pump affinity
laws and their mathematical relationships.
— System characteristics and impact on pump behaviour:
— Assessors should be capable of determining such changes that may be required to optimize the
type of pump and selection for the system in question.
— Assessors should understand the performance characteristics of parallel and series pumping
applications and their interaction with the respective systems, at nominal speed or variable speed.
— Data gathering
— Assessors should be capable of undertaking (after identifying the system boundaries) a review
of the pumping systems prior to the physical measurement to establish the priority and the
measurement requirements
— Assessors should be capable of undertaking accurate and repeatable direct or indirect
measurements of the pump parameters, driver (electric or otherwise) and system operational
characteristics.
C.3 Motors and drives
This subclause defines the areas of expertise and knowledge relevant to be mastered on motor
characteristics, power factor corrections, variable speed drives (mechanical and electrical) and their
effects on rotodynamic pumps. Assessors should have an understanding of:
— motor performance characteristics including various options for starting including soft starter,
star/delta, auto-transformer and via a variable speed drive. The assessor should also be familiar
with the torque/speed relationship imposed on the motor by the pump during start up and how to
ensure that this is optimised for correct motor selection.
— transmissions such as gear box, belt drives, liquid or magnetic couplings.
— the different types of variable speed drives and their performance and efficiency characteristics.
— the factors involved in matching the pump, system and drive. A knowledge of high and low static
head systems and their impact on the speed at which the pump is driven is essential.
C.4 Analysis and reporting
This subclause defines the expertise relevant to be mastered on the analysis of the measured field
data to form the basis of a logical and coherent report, with the objective of identifying energy saving
opportunities within the pumping system, as described in Annex A.
— Assessors should be experienced in analysing the gathered field data and be capable of understanding
the interaction between the various components within a system including the pump(s), process
components and control components. These include the performance and system characteristic
curves, and also have expertise in the assessment of time based variations and their impact on the
system characteristic.
— Assessors should be able to define the performance and system characteristic curves, and the
influence of demand variations on systems.
46
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— Assessors should have experience and knowledge of the various components found in a system in
order to determine their impact on the system efficiency.
— Assessors should be able to analyse the energy implications of system control philosophy.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex D
(informative)
Recommended guidelines for analysis software
The main objective of the system assessment methodology is to identify the actual system demand,
compare it with the current process data and identify where energy savings can be made.
The software should have generic pump and motor algorithms within its database to compare the
specific data to best available data.
The methodology to analyse a system should be documented identifying the source of data and the
formulas and methods used to arrive at the conclusions.
The methodology employed regardless of means (hand calculations, spread sheet, or computer software)
should factor the following:
a) The analysis software should be transparent in identifying the source of data within the
embedded algorithms:
— Process data:
— Liquid properties: liquid name, temperature, density (specific gravity), viscosity,
calculated NPSHA/R
— Static head: liquid level in source and destination, pressure on liquid surface source and
destination
— Process element(s): manufacturer, identification, designed differential pressure, operational
differential pressure, flowrate.
— Nameplate data:
— Pump: manufacturer’s description (type, size, number of stages), pump curve, rotational
speed, fixed or variable speed.
— Motor: manufacturer, NEMA/IEC frame size, power, number of phases, frequency, speed,
voltage, full load apps, power factor, NEMA/ISO nominal efficiency or efficiency class,
guaranteed efficiency.
— VSD: manufacturer, efficiency.
— Control valve element: manufacturer, valve model, size, characterization, pressure rating,
direction of flow, control valve data supplied by manufacturer.
— Operating data:
— Pump: suction pressure, discharge pressure, flow rate, nominal speed (r/min), and efficiency
from pump curve.
— Motor: power consumption, line voltage, line current, power factor and efficiency under
operating load.
— VSD: efficiency at load conditions.
— Control valve element: valve position, differential pressure.
b) Determination the actual energy consumption of the various elements based on current operating
system conditions
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© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
c) Determination the optimum system operating conditions along with the corresponding energy
consumption.
d) Cross validation the results to determine the energy into the system and energy consumed by the
system is equal.
e) Identification of potential energy savings determined from the collated data and quantified by using
unit costs of energy.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex E
(informative)
Example of prescreening worksheet
Table E.1 gives a typical example of typical prescreening worksheet.
Table E.1 — Typical example of prescreening worksheet
50
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex F
(informative)
Specific Energy
F.1 General
A pump system is built to move a certain volume of liquid from one point to another (in circulating
systems these points are the same). A useful measure for calculating the cost of pumping is the specific
energy consumption, Es, which is defined as the energy consumed to move a certain volume through the
system and has the advantage of being a direct measurement of the cost of pumping once you know the
cost of energy.
Specific energy is also a useful measure for comparing different system solutions.
In a constant flow system, the specific energy Es is calculated by using the formula (F1).
ES =
Where
Pe ⋅ t Pe
=
(F.1)
V
Q
t
Pe
is the time;
is the input power to driver.
In a system with varying flowrates, Es is a function of flowrate (Q), therefore this dependence is
differently evaluated.
Es is calculated from pump, motor and drive data for different loads and speeds provided by the
manufacturers.
When E S = f (Q ) has been calculated, this information is combined with the system load data to obtain
the operating cost. System designs can be compared based on number of pumps as well as different
methods of regulation.
F.2 Specific energy in different type of pump systems
The head needed from the pump can be separated into static head, Hs, and dynamic friction loss head,
Hf. Substituting Hs + Hf. for the total head and adding a drive efficiency for speed controlled systems
generates the following equation for input power:
Pe =
Q ⋅(HS + H f )⋅ ρ ⋅ g
(F.2)
ηdrive ⋅ηmotor ⋅ηpump
In a system without static head or closed loop systems, Hs is equal to zero.
The specific energy is here dependent on the frictional head loss which, in turn, is determined by the losses
in the pipe system (including throttling valves), and by the combined drive - motor - pump efficiency.
The combined drive - motor - pump efficiency is evaluated for each duty point. It is noted that the pump
efficiency remains approximately the same in a system of this type when the speed is changed, whereas
the drive-motor efficiency can drop considerably as the load is reduced.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
If, the system curve is changed by changing the setting of a valve, this changes the duty point of the
pump and, hence, its efficiency.
In a system with static head, the specific energy is derived as follows.
ES =
where
(HS + H f ) ⋅ ρ ⋅ g
HS ⋅ ρ ⋅ g
Pin
=
=
Q ηdrive ⋅ηmotor ⋅ηpump
fHS ⋅ηdrive ⋅ηmotor ⋅ηpump
f HS =
(F.3)
HS
(F.4)
HS + H f
The hydraulic system factor, fHS, indicates the relative amount of static head in the system.
Es has a minimum value: H S ⋅ ρ ⋅ g which occurs if all efficiencies are equal to 100 % and there are no
friction losses. If there is no variable drive in the system, then ... The factors in the denominator are all
functions of the flowrate and vary with the duty point. If a variable speed drive is used the duty point
moves along the system curve.
The efficiency of a high efficiency motor is fairly constant down to about 30 % load. However, the drop
in combined motor-drive efficiency can be substantial if the motor load drops below 75 % of full speed.
The denominator: can also be seen as the overall efficiency.
The hydraulic system factor fHS approaches 1 when the friction losses approach 0.
The specific energy increases significantly as the duty point moves towards shut off head in systems
with static head due to reduced pump, motor and drive efficiencies.
In systems with high static head, specific energy increases at a relatively moderate decrease in pump
speed. In such systems, the area of usefulness of a variable speed drive can be improved by making sure
that the system curve and full speed pump curve intersected to the right of the pumps best efficiency point.
To calculate the cost of pumping, the specific energy is calculated along the system curve, or for a
number of flow rates. Combining this information with the information in the system load profile the
cost of pumping can be determined.
Figure F.1 shows the specific energy as a function of pump speed for three different system curves
depending on systems with and without static head when a variable speed drive is used.
The saving potential is very large at low static heads and the reverse in high static head situations. When
the speed is low enough to cause the pump to operate at, or close to, shut-off head, the specific energy
goes towards infinity.
52
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
a) Specific energy as a function of pump speed
Key
A
B
C
D
PS
b) corresponding system curves
no static head, friction only
moderate static head
high static head
on-off regulated system (for reference)
Pump speed
Figure F.1 — Specific energy as a function of pump speed for different system curves
When the pump is throttled, the duty point moves to the left on the pump curve, see Figure F.2.
The vertical lines, in Figure F.2, represent the valve throttling loss.
The specific energy is calculated for each operating point by dividing the input power to the motor by
the flowrate. Es increases rapidly as the flow is reduced – see dashed curve in Figure F.3.
Key
1
pressure drop as a result of valve throttling
Figure F.2 — Example of flowrate with a throttled valve
In a throttled system, the specific energy follows a curve similar to the dashed curve in Figure F.3.
The specific energy for a speed regulated pump system can be higher than that for an on-off regulated
system with static head, but is lower and saves energy compared to a throttled system.
© ISO/ASME 2015 – All rights reserved
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BS EN ISO 14414:2015
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Key
1
2
3
NOTE
54
throttled system
speed regulated system with some static head
on-off regulation
Variable speed drives save on energy.
Figure F.3 — Comparison of regulation by throttling
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex G
(informative)
Pumping system parasitic power
G.1 General
Parasitic power may be used as an indicator to identify inefficient (and unreliable) pumping systems, and
support pump and control method selection, in order to ensure high efficiency, reliability and equipment
life expectancy along the entire operating range.
G.2 Parasitic power equations
Pw =
where
ρ ⋅ Q ⋅ g ⋅( H s + H f )
(SI) or
3, 6 × 106
Pw =
d ⋅ Q ⋅( H s + H f )
(US)
3960
Pw
is the hydraulic power expressed in kW or hp;
ρ
is the density expressed in kilograms per cubic meter (kg/m3) or pound per cubic foot
(lbm/ft3);
d
Q
is the specific gravity (dimensionless);
g
is the flowrate expressed in cubic meter per hour (m3/h) or gallon per minute (gpm);
Hs
is the static head expressed in meter (m) or foot (ft);
Hf
(G.1)
is a constant equal to 9,81m/s2 or 32,2 (ft/s2);
is the friction head expressed in meter (m) or foot (ft);
The total power absorbed in the shaft of the pump Pa, expressed in kilowatt (kW), is calculated using
formula (G.2)
Pa =
Pw
ηp
(G.2)
Pw = η p ⋅ Pa
Parasitic power definitions:
Pp = (1 −ηp )⋅ Pa
Where
(G.3)
ηp
is the pump efficiency;
Pa
is the total power absorbed in the shaft of the pump in kW;
Pp
is the parasitic power in kW or hp;
© ISO/ASME 2015 – All rights reserved
55
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Another way to express (G3) is:
Pa = Pw + Pp
(G.4)
G.3 Conclusions
G.3.1 From formula (G.4): the lower the required shaft power (Pa) to achieve a certain condition
(hydraulic power - Pw), the lower the parasitic power resulting in higher pump system life expectancy
and reduced energy consumption.
G.3.2 From Formula (G.1): for a given condition, the higher the pump efficiency, the lower the parasitic
power resulting in higher pump system life expectancy and reduced energy consumption.
G.3.3 The lower the friction head (Hf) in the system, to be overcome by the pump to achieve a given
condition (hydraulic power - Pw), the lower the parasitic power resulting in higher pump system life
expectancy and reduced energy consumption.
NOTE
Pa = Pw / ηp = Q·( H s + H f )·ρ·g / ηp That means that the control valve position plays an important
role on destructive power.
Conclusions G.3.1 to G.3.3 are three guidelines to be considered when evaluating pumping system
efficiency and reliability.
G.4 Relationship between parasitic power and vibration level
Figure G.1 shows several vibration levels measured in a kerosene exportation pump, under different
parasitic power levels, calculated for each condition according to Formula (G.1).
Key
1
2
parasitic power
vibration level
Figure G.1 — Example of parasitic power and vibration level curve using variable speed control
in a low static head system
56
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
The vibration increases with parasitic power. At low parasitic power levels, vibration increases slowly.
Above a certain threshold, vibration level assumes an asymptotic growth. This asymptotic growth may
happen either at very low flowrates (recirculation) or at very high flowrates (cavitation).
G.5 Correlation between parasitic power level in a pumping system and MTBF
It is considered a good practice to operate the pump in range of 80 % to 110 % of the best efficiency
flow, in order to achieve high efficiency and high MTBF. Usually, the largest parasitic power occurs at the
higher limit of this range (110 % of the best efficiency flow). Pump and control system should be selected
in a way to ensure permanent pump operation below this threshold.
In most cases this is an easy task when using variable speed control. In cases where VSD application is
not recommended, pump selection with the rated point at the right side of the BEP, as far as viable, is a
good way to reduce the parasitic power at low flows.
NOTE
Parasitic power has the ability to predict the severity of pump system operation (closely related to energy
efficiency), along the entire operating range, even before the equipment and control method have been selected.
© ISO/ASME 2015 – All rights reserved
57
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Annex H
(informative)
Example of pumping system efficiency indicator
H.1 General
The pumping system efficiency indicator (PSEI) is approximate and used to give a ‘first-pass’ indication
of the pumping system efficiency.
The PSEI example described in H.2 is applicable to water. Similar indicators can be developed for other liquids.
The PSEI is a number between 0 and 100, indicating how much of the energy supplied to a pumping
system is necessary.
For example, if the PSEI is calculated to be 36, then for every 100 units of energy supplied, only 36 units
are required. The remaining 64 units are unnecessary.
PSEI can be used for:
— open and closed pumping systems;
— any pump type (centrifugal or positive displacement);
— any number of installed pumps.
PSEI can be calculated from either of the following two sets of data:
— instantaneous data. This gives an energy efficiency indicator at the time of measurement.
— longer-term data. This gives an indication covering all pumping conditions over a period of time.
H.2 PSEI calculation
H.2.1 Table H.1 gives the symbols and units used to calculate PSEI
58
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Table H.1 — Units of variables and symbols used
Item
Symbol
SI Units
US Units
Yn
l/s
Static head (vertical height difference between
source and destination)
Q
-
-
HS
Specific length
L
m
L1
m
-
Pumping system efficiency indicator (PSEI)
Flowrate from source to destination
Distance transferred (shortest horizontal distance from source to destination)
Equipment losses
Input power to station (electrical power used by
the pumping system at the time of measurement)
Volume delivered from source to destination in
the defined time period
Input Energy to Station
H.2.2 Transfer Duties, (a) Instantaneous Data
ΔH
m
and
ft
ft
-
ft
Pe
kW
kW
Ee
kWh
kWh
V
m3
The Pumping system efficiency indicator Y1 is calculated using Formula (H.1)
Y1 = K 1 ⋅
gpm
Q ⋅( HS + L / L1 +∆H )
Pe
L1 = 43.3⋅ | Q |0.61 (SI) or L1 = 8.15⋅ | Q |0.61 (US)
Where K1 is equal to 1,25 (SI) or 0,24 (US).
g
(H.1)
(H.2)
H.2.3 Transfer duties, (b) longer term data
The Pumping system efficiency indicator Y0 is calculated using Formula (H.3)
V ⋅( H + L / L +∆H )
S
1
E
e
Where K0 is equal to 0,35 (SI) or 3,7 (US).
Y =K ⋅
0
0
(H.3)
H.2.4 Closed loop duties. For closed loop applications, select the appropriate formula from (H.1) to (H.3).
The value to be used for L is the minimum distance around the pumped loop from pump outlet to pump inlet.
H.3 Interpretation of results
If the Indicator is low, this identifies a potential problem within the pumping system such as one or more
of the following and further investigation is advised:
— bad match of pump with system demand;
— pump operating well away from best efficiency point;
— high velocities in pipelines;
— poor control;
© ISO/ASME 2015 – All rights reserved
59
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
— excessive wear in pump;
— obstructions in pipe work/valves/fittings.
60
© ISO/ASME 2015 – All rights reserved
BS EN ISO 14414:2015
ISO/ASME 14414:2015(E)
Bibliography
[1]
ISO 50001, Energy management systems — Requirements with guidance for use
[3]
ISO 50003, Energy management systems - Requirements for bodies providing audit and certification
of energy management systems
[2]
[4]
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[6]
[7]
[8]
[9]
ISO 50002, Energy audits — Requirements with guidance for use
API 682, Pumps-shaft sealing systems for centrifugal and rotary Pumps, Third Edition
ANSI/ASHRAE/IES Standard 90.1:2013 - Energy Standard for Buildings Except Low-Rise
Residential Buildings
ASME EA-2-2009 Energy assessment for pumping systems
ASME EA-2G-2010, Guidance for ASME EA-2, Energy Assessment for Pumping Systems
BLOCH. H. P. - Improving Machinery Reliability. Gulf Publishing Company, Texas, 1998
CASADA. D. - Energy and Reliability Considerations for Adjustable Speed Driven Pumps – 1999 IETC
Proceedings – ESL - IE-99/05-09 - Houston, Texas Oak Ridge National Laboratory
[10] Europump and Hydraulic Institute. Variable Speed Pumping – A guide to successful
applications. Elsevier Ltd, 2004
[11] Europump and Hydraulic Institute. Optimizing Pumping Systems – A guide for improved
energy, efficiency and profitability. Pump Systems Matter, 2008
[12] MARTINS and LIMA -. How to improve reliability in centrifugal pump systems through the
automatic tune-up of pumps within their best operational condition, 2008 – 24th International
Pump Users Symposium
[13]
MARTINS and LIMA –. Improving reliability in a high static head system through VFD application,
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[15]
STADLER. Hugo, 1998, Energy Savings by means of Electrical Drives, Loher Gmbh, Germany
[14]
MATTOS. E. E. - FALCO, R. - Bombas Industriais. McKlausen Editora, 1998
© ISO/ASME 2015 – All rights reserved
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