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.
Cutting Cost in Pump and Pipe Sizing, by Trey Walters, P.E., Chemical Processing, June 2002
President and Director of Software Development
Applied Flow Technology Corporation
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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