Smart Energy Presentation

8/18/2019 Smart Energy Presentation

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Global Training and

Support Guide


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Smart Energy Energy-Efficient Flow Solutions

For more than a century, Blackmer has been at the forefront of flow technology problem solving. From the firstpositive displacement rotary vane pump to its patented cavitation/noise suppression innovation, Blackmer hasled the way in solutions for the safe, reliable and energy-efficient transfer of high-value and hazardous liquidsand gases in mobile and process applications worldwide.

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PositiveDisplacement,Sliding Vane

Pumps

CentrifugalPumps

Reciprocatingas Compressors

Peristaltic!"ose# Pumps


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$ntroduction

igh energy prices impose a competitive andprofit-robbing threat to every manufacturing operation,large or small, worldwide

!eft unmanaged, energy e"penditures can quietly

and quickly erode a company#s financial performance,productivity, and competitive position

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Smart &Energy 'anagement( is t)e *ey to+

Driving productivity improvements that increasefinancial performance

Controlling energy epenses by reducing powerconsumption without compromising output

performance $ncreasing operational relia.ility by emphasizing

the use of energy-efficient technologies that supportenhanced mechanical efficiency

Reducing vulnera.ility to energy price volatility


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Blackmer started its Smart Energy ™ Flow Solutions

initiative to help educate companies on how they

can reduce energy consumption through the

use of positive displacement sliding vane

pump technologies.

0lac1mer Smart Energy$ Flow Solutions 'ission

%nable pump users to a gain a competitive business advantage throughthe deployment of energy-saving positive displacement sliding vanepump technology.

Blackmer will accomplish this mission by providing end-users, engineeringconsultants, &%'s, and distributors with education, tools, and knowledge on

the energy-saving value and performance-enhancing advantages of positivedisplacement sliding vane pumps.


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lo.al 3pportunity

Worldwide industrial energy consumption is expected to increase

by 42%, or an average of 1!% per year, from 2""# to 2"!$

$% of t&e growt& occurs indeveloping nations

(lobal energy consumption rose in)*+* at the fastest pace since +,as rapidly growing developing nationsled a strong rebound from the (reatecession.

0hina has now surpassed the 1nited2tates as the world#s biggestconsumer of energy, accounting for)*.3 of global demand comparedwith +3 for the 1.2.

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5

*ey Points to Ponder

4umps represent )3 of the electricity used in industrial applications5

%nergy is the single largest cost-of-ownership component of an industrial pumpsystem 6 representing between 7*-*3 of total life cycle costs, dependingon the technology

8 reduction of energy consumption is a key component to controlling costs

– 6sing t)e rig)t pump tec)nology, properly si7ed for a specificapplication, is an important step towards reducing pump

energy consumption

'Source: Hydraulic Institute

$ndustrial EnergyConsumption


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Pumps 9 Vital Part of an Energy-Efficient System

9here is a specific :best use; for every pump technology

– 1nderstanding how pump efficiency, systemefficiency and overall energy efficiency are measuredand affected by the pumps and overall systemconfiguration is vital to developing a successful

energy-efficient pumping system


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C)oosing ;)e Rig)t Pump ;ec)nology Can "elp aCompany c)ieve Simultaneous oals+

educe energyconsumption

educe operations,

production andmaintenance costs

=mproveproductivity

=mprove productquality

=mprove workersafety

=mprove capacity

utilization

=mprove systemreliability


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(ublis&ed )eports confirm many opportunities for companiesto immediately improve bottom line performance t&roug&

energy*efficient pump system improvements


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+ dollar saved on energy, maintenance or production iseuivalent to -1# in sales income .assuming a /% gross margin0'

' S)35 (orthwest Energy Efficiency %lliance ) Industrial Ef ficiency %lliance " How *ontinuous EnergyImprovements +educe *osts and Improve System erformance


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'anaging lo.al Energy Consumption

Global net electricity demand is pro6ected to grow by 14% per year between 2""# and 2"!$, wit& t&e strongest growt&in developing countries

;)e c)emical industry made up 22= of t)e total world industrial energyconsumption in 2>>5? Energy represents 4>= of t)is industry@s operating costs?


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7mproving t&e energy efficiency of even one pump in amanufacturing process could produce substantial financialsavings for any operation

'anaging lo.al Energy Consumption

9he table to the rightsummarizes the electrical

costs of a continuouslyoperated centrifugal pump>driven by a +** 4 motor?at +* cents per k@h?Even a = reductionin energy consumptionadds up to considera.le

savings?


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eograp)ic 3pportunities


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nited States ).A million pumps consuming +A) billion k@h annually 4roected )73 reduction in industrial production energy use by )*+

3anada 4roected *.C3 industrial energy consumption growth rate in ne"t )* years

8exico +.3 annual industrial energy consumption growth rate

Sout& +merica Brazil 6 ).+3 annual industrial energy consumption growth rate

t&er 3entral 9 Sout& +merican 3ountries )*3 proected growth rate between )**-)*7

eograp)ic 3pportunitiesmericas


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urope %nergy legislation mandating :2mart 'eters; to gauge electric usage

)ussia !east energy-efficient economy in the world

*.)3 annual proected industrial energy growth

8iddle ast ).)3 annual industrial energy consumption growth rate

0hemical sector is the largest consumer of energy

Dumerous petrochemical proects underway in 2audi 8rabia, Eatar,


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3&ina =ndustrial sector accounts for

73 of total energy consumption

igh demand for industrial pumpsdue to infrastructure development

(overnment mandates dramaticenergy reduction in the coming

decade

eograp)ic 3pportunitiessia

Between ,-- and ,--/& this market witnessed rapid growth driven 0y the huge

demand from industries such as water and wastewater treatment& power

generation& oil and gas& and chemicals and petrochemicals.


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"ow ;o 'easure Energy Efficiency in Pumps


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"ow ;o 'easure Energy Efficiency in Pumps


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'easuring 'anaging Energy Consumption

Calculating Potential Energy Savings

Savings A 2%/ 1B 4,>>> "rsr A ?>/ per 1B) A G2>,588 Savings!< - >?//#

>?58

EH'PIE+

> "P pump A //= Efficiency#

2# 3ptimal 3perating Efficiency !%>> "P A 58= Efficiency#

%# Pump draws 2%/ 1B 4,>>> )ours of service per year

2>

@hen pumps operate at optimum levels they use less energy and increasereliability, saving both energy and maintenance costs

9he maintenance and productivity benefits of improving a pump system#sperformance are generally one to two times the value of the energy savings

Savings A 1B !in input electric energy# nnual 3perating "ours !< J ctual System Efficiency#

3ptimal System Efficiency

S t E E Effi i t Fl S l ti


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Reducing Energy Baste 0egins wit)Proper Pump Selection for t)e pplication

2<

2elect the pump technology bestsuited for the application

4roperly size pumps, control valvesand piping for real-time requirements

>avoid e"cessive margin of errorcapacity and/or total pressureor head?

educe restrictions, turbulence

and frictional losses

Smart Energ Energ Efficient Flo Sol tions


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Reducing Energy Baste 0egins wit)Proper Pump Selection for t)e pplication

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%nsure proper motor alignment >poor alignment of motorand load increases motor power consumption?

educe flow rates G lower energy losses

!ower operating pressures

'aintain pumps and system components to avoidefficiency loss >wear is a significant cause of decreasedpump efficiencyH corrosion in pipes increases friction?

Smart Energy Energy Efficient Flow Solutions


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Consider pplication B)en C)oosing

Pumping EKuipment


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1sing pump selection softwareprograms can help operatorsoptimize pump selection

!eading pump manufacturersalso provide applications andengineering e"pertise, pumpspecification and selection

programs, technical trainingand support

allows users to select pump data and pump curves sothey can select the proper positive displacement or

centrifugal pumps for their application.

'any pump users do not 1now )ow to properlyselect and apply pumps to a system, so pump

system operating costs are inadvertentlyincreased as a result?



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Proper Pump Selection

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8lthough the operating principles of positive displacement andcentrifugal pumps differ widely, both types of pumps can be used

to serve many of the same applications

Source5 Schematic courtesy of *hemical rocessing !aga1ine



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9here is no :one-pump-fits-all;solution

9he right pump deliversproductivity gains and helpscontrol energy consumption

4ositive displacement sliding vanepumps, by virtue of their inherentenergy and mechanically-efficientdesigns, are uniquely suited tooffer manufacturers immediateadvantages in performanceand energy savings

7t:s time to put some energy into learning about t&e energy*saving

advantages of positive displacement sliding vane pumps



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8n analysis of !ife 0ycle 0osts>!00? can dramatically reducewaste and ma"imize efficiency

9he D%9 cost savings based on!00 will often ustify a higherinitial price for a more energy-efficient pump

!ife-cycle costing helps identifythe lowest total cost of ownershipby considering

– =nitial equipment cost

– =nstallation and 0ommissions

– %nergy costs

– 'aintenance and epairs

– Iowntime costs

– Iecommissioning costs

ICC 9 Relative ComparisonCentrifugal vs? Positive Displacement !PD# Pumps

6sing ICC !Iife Cycle Costs# for Proper Pump Selection

Centrifugals PD Pumps

; o t a l I i f e C y c l e

C o s t ! I C C #

=nitial 4ump 0ost

%nergy 0ost

=nstallation, maintenance,operating, environmentaland downtime costs



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0asic Comparison 9 Centrifugal Pumps Vs? Positive Displacement Pumps

Centrifugal Positive Displacement

'ec)anics=mparts velocity to the liquid resulting ina pressure at the outlet >pressure iscreated and flow results?

0aptures confined amounts of liquid andtransfers it from the suction to thedischarge port >flow is created andpressure results?

Performance Flow varies with changing pressure Flow is constant with changing pressure

Viscosity

%fficiency decreases with increasing

viscosity due to frictional losses insidethe pump >typically not used onviscosities above L7* c2t?

%fficiency increases with increasingviscosity

Efficiency%fficiency peaks at best-efficiency-point. 8t higher or lower pressures,efficiency decreases.

%fficiency increases with increasingpressure

$nlet Conditions!iquid must be in the pump to create apressure differential. 8 dry pump will notprime on its own

Degative pressure is created at the inletport. 8 dry pump will prime on its own

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Comparing Centrifugal Pumps toPositive Displacement Pumps

$f t)e system calls for+ ;)e .est pump to useis+

Pressuri7ed networ1 of piping wit) a constant pressurereKuiring constant flow rate

Centrifugal

Constant flow at various pressures Positive Displacement

Constant flow at various viscosities Positive Displacement

Constant flow at )ig) viscosities !Particularly a.ove 8/> cSt# Positive Displacement

Iine stripping Positive Displacement

Dry running 9 s)ort duration Positive Displacement

Priming Positive Displacement

S)ear sensitive Positive Displacement

Entrained gases Positive Displacement

"ig) flowlow )ead Centrifugal

Iow flow)ig) )ead Positive Displacement

2:



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%>



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Consider Positive Displacement Pumpsover Centrifugal Pumps w)en+

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Positive Displacement Pumps re Not Created EKual

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PD Pump Features Viscosity Range Flow Rates

SlidingVane

%"ceptional for thin liquids %"cellent on thick liquids at slow speeds %"ceptional efficiency at low flow rates %"cellent suction lift and line stripping capabilities 2elf-adusting vanes provide substantial energy savings igh mechanical efficiency G energy savings Iifferential pressure to )** psi 2peed to ,C** 4' !ow energy consumption

Jery thin >!4(,efrigerants,2olvents, Fuel&ils, (asoline,!iquid 0arbonIio"ide,

8mmonia,etc.? to highviscosities up to7*,*** c2t

. to M,7L* !/min>+ to M ),*** (4'?

$nternalear

Iifferential pressure to )** psi >higher pressures areattainable?

2peed to ,C** 4' 'etal-to-metal gear wears and slips over time, resulting

in efficiency degradation and higher energy consumption

igh viscosities up to+,***,*** c2t

+.L - 7,CL7 !/min>*.7 - +,7** (4'?

PD pumps ma1e up approimately


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%%

PD Pump Features Viscosity Range Flow Rates

Eternal ear Io not perform well under critical suction conditions, especiallywith volatile liquids

(ood for high pressure applications such as hydraulics Iifferential pressure to ,*** psiN 2peed to ,C** 4' 'etal-to-metal gear design subect to efficiency degradation 'ust be rebuilt or replaced Do clearance adustments for wear which results in slip,

efficiency degradation and higher energy consumption

igh viscosities up to+,***,*** c2t

Irops per minute to7,CL7 !/min>Irops per minute to+,7** (4'?

Io.e 1sed frequently for food-type products due to sanitary natureand ease of cleaning

Jertical drain port reduces efficiency by +7-)*3 2anitary models Iifferential pressure to )** psi Don-sanitary models Iifferential pressure to A** psi

!ow viscosity withdiminished performanceup to +,***,*** c2t

+ - ++,* !/min>7 - ,*** (4'?

ir Diap)ragm!3DD#

Do bearings or rotating shaft 0an handle a wide range of shear-sensitive, abrasive and

non-abrasive liquids as well as solids igh pressure operation can cause e"cessive wear around

valve seats as the check valve closes Jariable speed flow operation equires air compression system. %lectricity is used to run

compressors. %nergy accounts for *3 of compressed air life cycle cost - air

is not free. igh energy costs.

'edium viscosity to)C,*** c2t

. - +,L7 !/min>+ - 7** (4'?

$mproper pump selection can cost money in downtime,lost production, maintenance costs and energy consumption?



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Sliding Vane Pumps vs? $nternal ear PumpsSliding Vane and Eccentric Disc Pumps vs? ear and Io.e Pumps

Sliding Vane Pumps $nternal ear Pumps

2uperior mechanical performance

4rovides greater energy savings

)A3 more efficient than gear pumps

2liding vanes automatically adust to maintainnear perfect clearances throughout operating life

%nergy-wasting turbulence and slippage areminimized and high volumetric efficiency and low

energy consumption are maintained

!ess mechanically efficient

0onsume more energy than slidingvane pumps

9he metallic gears wear over time resultingin wider clearances. 9his increases energy-robbing slippage and significantly decreasesvolumetric efficiency

=n order to compensate for performancedegradation, pump speed is increased whichrequires greater energy consumption

%



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Energy Cost ComparisonJane/!obe/(ear

0

10

20

30

40

50

60

70

80

90

4 160 530 1620

Vane

Lobe

Gear

Viscosity !cSt#

' e c ) a n i c a l E f f i c i e n c y

%/

From the lowest to the highest viscosity& sliding vane technology provides the highest level of mechanical efficiency which e2uates

into the lowest energy consumption.

-> P'#O%?/ - 4?:> 0ar !/>-> PS$#O

- cSt viscosityOsame model on all viscosities



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Sliding Vane Pumps vs? $nternal ear Pumps

%4

Sliding vane pump tec)nology

not only reduces energy costs.ut )elps to create an overallmore efficient pumping system,providing solutions for seals,suction, product s)ear, andvolumetric efficiency pro.lems?



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Sliding Vane Pumps vs? $nternal ear Pumps

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Summary !eft unmanaged, energy costs can quietly erode profits

4umps account for )3 of total electrical use in theindustrial sector

4ump system improvements 6 such as using the proper pump forthe application 6 can help to reduce energy consumption

4ositive displacement sliding vane pumps are inherently energy-

efficient and offer advantages over centrifugal pumps and other4I pumps in specific applications

:8 dollar saved on energy, maintenance or production isequivalent to O+ in sales income >assuming a C3 gross margin?.; " (orthwest Energy Efficiency %lliance

%nergy-saving advice is available from– Blackmer 2mart %nergy$ =nitiative >www.Blackmer2mart%nergy.com?

– 1.2. Iepartment of %nergy >=ndustrial 9echnology 4rogram?

– ydraulic =nstitute >4ump 2ystems 'atter?

– Dorthwest %nergy %fficiency 8lliance



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%:

0lac1mer Smart Energy

Solutions@e are proud to provide customerswith products that enable them toreduce energy consumption and

preserve natural resources. Blackmer cares deeply aboutpioneering new technologies andprocesses that allow our partners topromote sustainability for our world.

0lac1mer@s Commitment to Sustaina.ility



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