SPP Energy”s pump system assessments off to a flying start

Phil Black - PII Editor 12/07/2011

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The SPP Energy Division has already chalked up a number of success stories since its recent launch. The team has completed pump system assessments for four major water utilities with Framework Prequalification in progress for a further two utilities. Major work has also been undertaken for Imerys Minerals, Oikos Oil, Mars Confectionary and GSK Smith Kline – the following Case Studies give an idea of the potential savings.

Through the use of proven systems and techniques, SPP Energy offers a complete energy saving solution for pumping systems that can be applied equally to new projects and existing installations – ultimately producing a detailed report making recommendations for corrective action and clearly showing cost savings, kW/hr savings, payback time and CO2 reduction.

Case Study 1: Imerys Minerals
Imerys Minerals Limited installed four high pressure SPP Split Case BS08E Centrifugal pumps during 2001. The nominal speed of these units is 1490 rpm with fixed speed drives and 355 kw Electric Motors.

These pumps have been working on a rotational basis between 25% and 75% utilisation but with two pumps on demand at all times.

Imerys Minerals are very proactive in their energy saving programs but required more information on the performance and efficiency of these units. SPP Pumps were called on to conduct a full condition monitoring program involving the following tests:

Thermodynamic “wire to water” efficiency testing.
Ultrasonic flow measurement with conventional pressure gauges and power analyser
Vibration analysis
Bearing temperature monitoring

SPP have already identified considerable financial savings and corresponding CO2 reduction, and further options are being explored that could potentially generate even greater annual savings.

Case Study 2: GSK
GSK are enjoying a major expansion of their Coleford facility but this has placed an additional burden on the main effluent pumping station. Situated adjacent to SPP’s South West Service Centre the company was ideally placed to offer local technical support. Initially SPP were asked to extend the existing service contract to include an assessment of the pumps current performance and condition to aid development plans.

Since there was little background or historical information regarding flows and volumes of discharge, initial investigations were focused on the pump operating duty point and the efficiency of the machines. Once the individual pump duties were established the In Flow could be established from simple monitoring techniques incorporating sump volume measurements and timing fill / discharge cycles.

From these initial investigations it was established that one pump was “Dead Heading” and running continuously without contributing to the discharge rate and accelerating pump wear in the process. Investigations are ongoing but based on the savings from one pump operating at closed valve overall annual savings could be considerable.

The financial gains from establishing an efficient and reliable pump system which will ensure that there are no environmental overruns could also be far greater, as the Environment Agency imposes heavy penalties for such breaches. GSK’s proactive response has ensured that this risk has been all but eliminated.

Training and accreditation
Training is an essential element – SPP Energy has a team of Technicians fully accredited to the US Department of Energy”s PSAT qualification for Pump Systems Assessment, working to globally recognised standards set by the American Department of Energy. The team also operates within guidelines set by EU Government legislation, BPMA, the Carbon Trust, and major insurance assessors and is currently helping to develop an accreditation programme that will help to establish ISO, BS and EN Standards.

For further information on SPP Pumps new Energy Division please contact Claire Comber, Marketing Manager, on 0118 932 5289 or visit www.spppumps.com/energy