Q&A - Fluids Handling

Process Engineering asked Florent Violain, LCC development manager at Sterling Fluid Systems (UK) Ltd to identify technologies offering the biggest potential savings for plant owners and operators in the UK:

Which fluids handling technology, do you think offers the biggest potential for reducing operating costs in the UK process industries right now, and why?

A. Applying a system approach to a) Audit energy consumption and b) examine the failures of existing pumping systems offers the biggest potential when it comes to reducing operating costs within the UK process industries.

Pumping systems account for nearly 20% of the world’s electrical energy demand and are responsible for 25 - 50% of energy usage in certain industrial plant operations. The cost of running a pump is generally perceived as fixed, however 20 - 80% of energy could be saved using a system approach.

Therefore, costs should be considered as variable. Auditing the installed base in Great Britain could potentially save more than 10TWh of electricity per year, avoiding the emission of approximately 5.5 million tonnes of CO2.

Installing an efficient pump and motor will only provide small energy savings. In order to achieve overall efficiency, the complete pumping system must be taken into account.

What’s a good starting point for adopting this approach?

A. Energy efficiency is the primary focus when assessing an installed base, not only because energy fees are by far the largest part of a pump’s life cycle cost (40 - 90%), but also because it drives a system’s reliability.

System inefficiencies waste useful energy by converting it into heat and vibration, which badly affects components. The further away a pump operates from its best efficiency point, the lower the mean time between failure. Therefore, it can be concluded that saving energy has the potential to reduce maintenance and down time costs.

The assessment provides quantified savings potential and practical guidance, highlighting effective solutions and the possible ROI. Processes that have experienced modifications throughout their history can now be streamlined with a short ROI time, ultimately leading to a more flexible system with a higher level of resilience.

Pumping systems are critical assets in many processes. Enhancing them reduces plant down time and operating costs, while improving flexibility as well as productivity.

What are the main barriers to the adoption of this technology among UK plant owner/operators?

A. The main barrier among UK plant owners and operators is a certain lack of awareness. Pumping is generally seen as a well understood and well managed technology.
People do not realise how huge the savings are that could be achieved when looking at pumping systems. The focus is usually concerned with replacing hardware and technology, not on assessing methodologies and improving existing systems.

What support is available to facilitate uptake of this technology and leverage its full capabilities?

A. Achieving full capabilities depends on the quality of the assessment. Therefore, the skills of the assessing team and the methodology used is instrumental. Acknowledged qualifications and accreditations encourage pump users to gain confidence in such a service.

However, there are not many recognised bodies that certify auditors for pumping systems - this is still a growing area. Nevertheless, the work carried out by the US Department of Energy and the British Pump Manufacturer Association with the CPSA - Certified Pump System Auditor - is pointing in the right direction.