SyncroFlo Municipal University and Hydraulic Institute, Pump Systems Optimization

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1 SyncroFlo Municipal University and Hydraulic Institute, Pump Systems Optimization COURSE SYLLABUS September 16 th 18 th, /16/13 Day One Hydraulic Institute Workshop (8:30am) PUMP SYSTEMS OPTIMIZATION: ENERGY EFFICIENCY AND BOTTOM LINE SAVINGS One day workshop presented by Hydraulic Institute and Pump System Matter INSTRUCTOR William C. Livoti 1. Introduction 15 Minutes 1.1. Agenda 1.2. Learning Objectives 2. Why Efficient Pumping Systems are important 45 Minutes 2.1. Review Opportunities Save Energy Now Assessments results What users say their Systems Cost and potential Savings from systems optimization 2.2. The business case for pumping system optimization 2.3. Magnitude of the opportunity both with energy and other savings within a plant 2.4. Computing energy costs of pumping systems 2.5. Exercise- Estimate & calculate the annual energy cost of your biggest pump 3. System Optimization and Improvement opportunities 40 Minutes 3.1. System optimization and best efficiency point 3.2. Changes to BEP effect efficiency, reliability, maintenance etc 3.3. Systems improvement opportunities and symptoms 3.4. Case studies of facilities that improved the operations 3.5. Why improvement opportunities exist 4. Basic Pump System Interaction 70 Minutes 4.1. Pump & system curves 4.2. Exercise Reading curves and calculating values 5. Screening Pumping Systems 40 Minutes 5.1. Basic data gathering using the Pump System Basic Assessment Guide & Pre-screening Form 5.2. Exercise Rank system for good candidates 6. Analysis Tools for Pumping Systems 60 Minutes 6.1. Available tools and analysis methods 6.2. Case study example using modeling tool 6.3. Exercise What s wrong with this pumping system? 7. Improving the Performance of Pumping Systems 45 Minutes 7.1. Performance improvement solutions 7.2. Variable speed pumping 7.3. Exercise How can this pumping system be improved?

2 8. Life-Cycle Cost analysis 45 Minutes 8.1. LCC, simple payback, IRR and NPV 8.2. Life cycle cost study 8.3. Exercise Life-cycle cost analysis 9. Developing an Action Plan Learning Objectives As a result of this workshop, the participants will better understand: The benefits of improving the performance of pumping systems System optimization and basic pump system interaction How to screen pumping systems for good system improvement candidates How to identify and implement basic performance improvement opportunities How to plan and propose an action plan to management 9/17/13 Day Two SyncroFlo Municipal Training (8:30am) Mechanical Section: 1. Introduction 15 Minutes 1.1. Instructor John P. Kahren/SFI SyncroFlo history Dedication to quality Third party certifications 2. Types of systems 30 Minutes 2.1. Instructor John tucker/sfi Tank to tank Tank to grid Grid to tank Grid to grid 3. Pump Suction 30 Minutes 3.1. Instructor John Tucker/SFI NPSH vs. NPSHa vs. NPSHr Cavitation and its prevention Suction lifting Inlet submergence Suction sources Protection against debris Piping requirements Individual requirements Manifolds Suction valving requirements 4. Pump types 60 Minutes 4.1. Instructor John Tucker/SFI End suction Close coupled Flex coupled Split case Horizontal Vertical In-line

3 Close coupled Split coupled Vertical Multistage Vertical turbines Canned Submersible Wet pit sump Regenerative turbine Factory testing 5. Motor types 50 Minutes 5.1. Instructor Keith Kloiber/WEG Enclosures ODP TEFC XP Horizontal types T Frame Close coupled C Face D Face Vertical types WP TEFC XP Motors for VFD application Submersible types Well pumps Sump pumps Accessories Winding T-stats Space heaters Steady bushing Bearing insulation Others 6. Isolation & Check Valves 45 Minutes 6.1. Instructor Ed Gardner/Valmatic Isolation valves Butterfly valves Gate Valves Plug valves Check valves Silent Tilt disc Swing check Others 7. Control Valves 45 Minutes 7.1. Instructor Lorne Davis/Claval Pressure reducing valves Pump control valves Flow control valves

4 Pressure relief valves Surge anticipator valves By-pass valves 8. Piping 30 Minutes 8.1. Instructor John Santi/SFI steel Fusion bonded steel Stainless steel Copper PVC HDPE Ductile Iron Cement lined ductile iron 9. Bladder Tanks 45 Minutes 9.1. Instructor Guy Kirk/Wessel s Correct application Comparison to hydro-pneumatic ASME VS. non-asme 10. Structural Skids 30 Minutes Instructor Todd Weir/SFI Function Types Open Deck plated Insulated With buildings 11. Coatings 45 Minutes Instructor Dean Ridge/PPG Standard coating system Intermediate coating system High performance coating system Galvanizing 12. Buildings 60 Minutes Instructor/Metal buildings Rodney Wright/Parkline Instructor/Fiberglass buildings John Miller/ShelterWork Metal buildings Fiberglas buildings Other types

5 9/28/13 Day Three SyncroFlo Municipal Training (8:30am) Electrical Section: 1. Line Side Controls 45 Minutes 1.1. Instructor Richard Morse/SFI Service entrance disconnects Enclosure ratings TVSS Main disconnects Phase monitors Motor disconnects Full voltage starters Soft starters 2. Variable Speed Drives 60 Minutes 2.1. Instructor David Hicks/AIC VFD Enclosure ratings VFD line side ratings Load side connections IEEE 519 & VFD by-passes Motor requirements 3. Logic Controls 45 Minutes 3.1. Instructor Steve Bradley/SFI SCADA ready SFI Municipal PLC & OIT SFI Commercial PLC & OIT SFI programming capabilities Relay Logic 4. Supporting Components 45 Minutes 4.1. Instructor Richard Morse/SFI Breakers Surge suppressors Relays Ethernet switches Strictly Ethernet Ethernet & fiber optic ) RTU interface panels Conduit EMT Rigid Seal-tite PVC XP

6 5. Instrumentation 45 Minutes 5.1. Instructor TBA Pressure transmitters & switches Gauge pressure transmitters Differential pressure transmitters Pressure switches Differential pressure switches Level transmitters and switches Submersible transmitters Acoustic transmitters Radar transmitters Submersible float switches Thru the wall level switches Flow transmitters & switches Signal conditioners Pressure gauges

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