Pump Health – Case Study

Project Summary

Aquip Systems was engaged to complete a comprehensive assessment and analysis of 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.

Project Scope

Pump Station Efficiency Assessment, Queensland

Project Details

• Field testing across 5 pump stations in regional Queensland
• 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
• By incorporating hydraulic performance assessments, pump repairs can generate significant savings of up to $100,000 per pump annually (when pumps have in excess of 1 MW drivers)
• Aquip was engaged to conduct this survey encompassing almost 20 pumps equating to significant potential costs savings

Project Overview

• 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 Flexim 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.
• 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

Benefits

• 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