SyncroFlo Municipal University and Hydraulic Institute, Pump Systems Optimization COURSE SYLLABUS September 16 th 18 th, 2013 9/16/13 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 2.1.1. Save Energy Now Assessments results 2.1.2. 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?
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 1.1.1. SyncroFlo history 1.1.2. Dedication to quality 1.1.3. Third party certifications 2. Types of systems 30 Minutes 2.1. Instructor John tucker/sfi 2.1.1. Tank to tank 2.1.2. Tank to grid 2.1.3. Grid to tank 2.1.4. Grid to grid 3. Pump Suction 30 Minutes 3.1. Instructor John Tucker/SFI 3.1.1. NPSH vs. NPSHa vs. NPSHr 3.1.2. Cavitation and its prevention 3.1.3. Suction lifting 3.1.4. Inlet submergence 3.1.5. Suction sources 3.1.6. Protection against debris 3.1.7. Piping requirements 3.1.7.1. Individual requirements 3.1.7.2. Manifolds 3.1.8. Suction valving requirements 4. Pump types 60 Minutes 4.1. Instructor John Tucker/SFI 4.1.1. End suction 4.1.2. Close coupled 4.1.3. Flex coupled 4.1.4. Split case 4.1.5. Horizontal 4.1.6. Vertical 4.1.7. In-line
4.1.8. Close coupled 4.1.9. Split coupled 4.1.10. Vertical Multistage 4.1.11. Vertical turbines 4.1.12. Canned 4.1.13. Submersible 4.1.14. Wet pit sump 4.1.15. Regenerative turbine 4.1.16. Factory testing 5. Motor types 50 Minutes 5.1. Instructor Keith Kloiber/WEG 5.1.1. Enclosures 5.1.1.1. ODP 5.1.1.2. TEFC 5.1.1.3. XP 5.1.2. Horizontal types 5.1.2.1. T Frame 5.1.2.2. Close coupled 5.1.2.3. C Face 5.1.2.4. D Face 5.1.3. Vertical types 5.1.3.1. WP-1 5.1.3.2. TEFC 5.1.3.3. XP 5.1.4. Motors for VFD application 5.1.5. Submersible types 5.1.6. Well pumps 5.1.7. Sump pumps 5.1.8. Accessories 5.1.8.1. Winding T-stats 5.1.8.2. Space heaters 5.1.8.3. Steady bushing 5.1.8.4. Bearing insulation 5.1.9. Others 6. Isolation & Check Valves 45 Minutes 6.1. Instructor Ed Gardner/Valmatic 6.1.1. Isolation valves 6.1.1.1. Butterfly valves 6.1.1.2. Gate Valves 6.1.1.3. Plug valves 6.1.2. Check valves 6.1.3. Silent 6.1.4. Tilt disc 6.1.5. Swing check 6.1.6. Others 7. Control Valves 45 Minutes 7.1. Instructor Lorne Davis/Claval 7.1.1. Pressure reducing valves 7.1.2. Pump control valves 7.1.3. Flow control valves
7.1.4. Pressure relief valves 7.1.5. Surge anticipator valves 7.1.6. By-pass valves 8. Piping 30 Minutes 8.1. Instructor John Santi/SFI 8.1.1. steel 8.1.2. Fusion bonded steel 8.1.3. Stainless steel 8.1.4. Copper 8.1.5. PVC 8.1.6. HDPE 8.1.7. Ductile Iron 8.1.8. Cement lined ductile iron 9. Bladder Tanks 45 Minutes 9.1. Instructor Guy Kirk/Wessel s 9.1.1. Correct application 9.1.2. Comparison to hydro-pneumatic 9.1.3. ASME VS. non-asme 10. Structural Skids 30 Minutes 10.1. Instructor Todd Weir/SFI 10.1.1. Function 10.1.2. Types 10.1.2.1. Open 10.1.2.2. Deck plated 10.1.2.3. Insulated 10.1.2.4. With buildings 11. Coatings 45 Minutes 11.1. Instructor Dean Ridge/PPG 11.1.1. Standard coating system 11.1.2. Intermediate coating system 11.1.3. High performance coating system 11.1.4. Galvanizing 12. Buildings 60 Minutes 12.1. Instructor/Metal buildings Rodney Wright/Parkline 12.2. Instructor/Fiberglass buildings John Miller/ShelterWork 12.2.1. Metal buildings 12.2.2. Fiberglas buildings 12.2.3. Other types
9/28/13 Day Three SyncroFlo Municipal Training (8:30am) Electrical Section: 1. Line Side Controls 45 Minutes 1.1. Instructor Richard Morse/SFI 1.1.1. Service entrance disconnects 1.1.1.1. Enclosure ratings 1.1.1.2. TVSS 1.1.1.3. Main disconnects 1.1.1.4. Phase monitors 1.1.1.5. Motor disconnects 1.1.1.6. Full voltage starters 1.1.1.7. Soft starters 2. Variable Speed Drives 60 Minutes 2.1. Instructor David Hicks/AIC 2.1.1. VFD Enclosure ratings 2.1.2. VFD line side ratings 2.1.3. Load side connections 2.1.4. IEEE 519 & 1992 2.1.5. VFD by-passes 2.1.6. Motor requirements 3. Logic Controls 45 Minutes 3.1. Instructor Steve Bradley/SFI 3.1.1. SCADA ready 3.1.2. SFI Municipal PLC & OIT 3.1.3. SFI Commercial PLC & OIT 3.1.4. SFI programming capabilities 3.1.5. Relay Logic 4. Supporting Components 45 Minutes 4.1. Instructor Richard Morse/SFI 4.1.1. Breakers 4.1.2. Surge suppressors 4.1.3. Relays 4.1.4. Ethernet switches 4.1.4.1. Strictly Ethernet 4.1.4.2. Ethernet & fiber optic 4.1.5. 5) RTU interface panels 4.1.6. Conduit 4.1.6.1. EMT 4.1.6.2. Rigid 4.1.6.3. Seal-tite 4.1.6.4. PVC 4.1.6.5. XP
5. Instrumentation 45 Minutes 5.1. Instructor TBA 5.1.1. Pressure transmitters & switches 5.1.1.1. Gauge pressure transmitters 5.1.1.2. Differential pressure transmitters 5.1.1.3. Pressure switches 5.1.1.4. Differential pressure switches 5.1.2. Level transmitters and switches 5.1.2.1. Submersible transmitters 5.1.2.2. Acoustic transmitters 5.1.2.3. Radar transmitters 5.1.2.4. Submersible float switches 5.1.2.5. Thru the wall level switches 5.1.3. Flow transmitters & switches 5.1.4. Signal conditioners 5.1.5. Pressure gauges