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Optimizing Pumping Systems Article Featured in Pumps & Systems Magazine

With pumping systems accouting for about 20% of the world's energy usage, a great potential for cost and energy savings exists within such systems. Unfortunately, pumping system design engineers work in an environment where budget and schedule constraints limit their ability to optimize their systems using traditional methods. "Optimizing Pumping Systems To Minimize First Or Life-Cycle Cost", featured in the October 2002 issue of Pumps & Systems magazine, describes the new technology of IntelliFlow® embodied in AFT Mercury that now allows the systems engineer to truly optimize the sizing of their systems' piping and components resulting in huge savings potentials. Jointly authored by Trey Walters of AFT and Judy Hodgson of Dupont, the article also presents several real world examples where life cycle cost savings of up to 70% were achieved. The Pumps & Systems article was derived from "Optimizing Pumping Systems to Minimize First or Life-Cycle Cost", presented to the 19th International Pump Users Symposium. You can find the full text of this original paper by clicking here.

Applied Flow Technology Article Featured in Chemical Processing

Cutting Cost in Pump and Pipe Sizing, by Trey Walters, P.E., Chemical Processing, June 2002

Trey Walters
President and Director of Software Development
Applied Flow Technology Corporation

ABSTRACT
Numerical optimization methods offer a powerful new technology for pump users when combined with pumping system analysis software. Whether the design goal is to reduce First Costs or Life Cycle Costs, this technology promises to significantly reduce pumping system costs and energy usage.

Optimization methods work by automatically selecting pipe and pump sizes to minimize cost. Design engineers define the constraints for the system, such as flowrate, NPSH margin, or fluid velocity. The optimization software then finds the combination of pipe and pump sizes to minimize the cost while satisfying the constraints.

A new design concept is introduced called the Optimal Pumping System Operating Point (OPSOP). In simple terms, the OPSOP uses cost data to identify the optimum tradeoff in pipe, pump and (optionally) energy costs for a system that may have one or more duty points. Using this information, a new and improved method of pump sizing is described.

A cost comparison of a system designed using traditional methods and as optimized for initial cost and life cycle cost is shown.

 

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Optimizing Pumping Systems to Minimize First or Life Cycle Cost

Judy Hodgson, JE Hodgson Consulting, USA; Trey Walters, P.E., Applied Flow Technology Corporation, USA

ABSTRACT
Numerical optimization methods offer a powerful new technology for pump users when combined with pumping system analysis software. Whether the design goal is to reduce First Costs or Life Cycle Costs, this technology promises to significantly reduce pumping system costs and energy usage.

Optimization methods work by automatically selecting pipe and pump sizes to minimize cost. Design engineers define the constraints for the system, such as flowrate, NPSH margin, or fluid velocity. The optimization software then finds the combination of pipe and pump sizes to minimize the cost while satisfying the constraints.

A new design concept is introduced called the Optimal Pumping System Operating Point (OPSOP). In simple terms, the OPSOP uses cost data to identify the optimum tradeoff in pipe, pump and (optionally) energy costs for a system that may have one or more duty points. Using this information, a new and improved method of pump sizing is described.

To establish benchmark comparisons for typical petrochemical pumping systems, these optimization methods were applied to four previously designed DuPont systems. With a modest amount of effort, First Cost reductions were as much as 17 percent, and Life Cycle Cost reductions were as much as 72 percent (based on 10 years), with savings of over US $100,000 in several cases.

 

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AFT & Dupont Present Pumping Systems Optimization Paper at 19th International Pump Users Symposium

Applied Flow Technology and Dupont Engineering presented the jointly developed paper "Optimizing Pumping Systems To Minimize First or Life Cycle Cost", describing the groundbreaking technology of IntelliFlow as implemented in AFT Mercury along with case histories on Dupont pumping systems. For years plant owners/operators have realized the importance of optimizing system design for life cycle cost (LCC) to minimize total plant cost. Probably no where is this more important than in pumping systems who's operating costs are typically several times their initial cost. Though the importance has been understood, this area has been largely ignored due to a lack of design tools. With the introduction of AFT Mercury incorporating IntelliFlowTM, the technology now exists to optimize piping systems of all types for life cycle cost as well as first cost. The subject paper, jointly developed by AFT's President & Director of Software Development, Trey Walters, and one of Dupont Engineering's leading pump applications experts, Judy Hodgson, describes this important new technology and several case histories of its application to Dupont pumping systems.

 

 

 

 

Applied Flow Technology and Dupont present technical paper on pump application optimization

Trey Walters of Applied Flow Technology and Judy Hodgson of Dupont Engineering in Wilmington, DE jointly presented a technical paper paper describing methods to optimize pump applications in piping systems at the 19th International Pump Users Symposium in Houston, TX. Ms. Hodgson and Mr. Walters will describe the methodology, based on the ground breaking technology of AFT Mercury, and the significant cost reduction potential available as illustrated by case histories. click here to read the article.