Pump Health | Case Study | FLEXIM Ultrasonic Flow Meters | Aquip

The Aquip team analysed the efficiency of 5 major pump stations within the Queensland irrigation networks.

Our Pump Health Assessment service aims to provide a clear picture of your system’s performance – ultimately saving money, reducing machinery downtime and minimising negative environmental impacts.

Specifications

Project	Pump Health
Project Overview	Aquip was engaged to complete a comprehensive assessment and analyse the efficiency of 5 major pump stations within the Queensland irrigation networks. These networks deliver crucial water supply to support agricultural development throughout the region. Field testing information was gathered using a variety of sources and instruments depending on availability across the different pump locations. Where flow meters were installed and accessible from SCADA, we used this information, similarly for amperage and kW data. Where no flow meter was available we used the F601 Ultrasonic portable with suitable transducers as this allows measurement from 50mm to 6.5m in diameter. To measure vibration a Prüftechnik VibXpert II was utilised. A Pruftechnik Rotalign Ultra iS was used to conduct alignment across the stations. To measure pump pressures, transducers were installed with onsite dials interpreted to give amperage, voltage and kW readings. On low voltage sites, a Power Quality Meter can be used to measure voltage, amperage, kW, kVA and power factor.
Project Challenges	Our client was facing increased electricity bills due to tariff changes. It was anticipated costs would increase by approximately 20%. Our team where engaged to conduct a survey of existing pump stations in an attempt to maximise energy savings. Our assessment identified several pumps displaying poor hydraulic efficiencies. Previous pump repair criteria were focused on mechanical elements only including bearing and seal problems.
Project Results	Based on the above information collected, the motor power and the pump efficiency was calculated and a comprehensive report was supplied to the client outlining recommendations. By using our Pump Health Assessment that incorporates both mechanical pump health and hydraulic performance testing, pump repairs can generate significant savings of up to $100,000 per pump annually (when pumps have in excess of 1 MW drivers). The aim of our recommendations was to provide our client with a self-funding upgrade proposal to deliver costs savings within a specified time period.

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