Optimizing the efficiency and reliability of fluid system operations: An ongoing process

At most industrial facilities, motor loads associated with pumps and fans are the dominant electric energy users. As plant loads and consequent system functions change, the optimal operating conditions for these components change. In response, modifications to system operations are often made with only one consideration in mind - keeping the system on line. At the Y-12 plant in Oak Ridge, a fluid system energy efficiency improvement methodology is being developed to facilitate the systematic review and modification of system design and operations to increase operational efficiency. Since the bulk of the changes are associated with reducing the numbers and/or loads of motor-driven pumps or fans, there are direct benefits in reduced electrical generation and consequent waste heat production and air emissions. This paper will discuss the types of inefficiencies that tend to evolve as system functional requirements change and equipment ages, describe some of the fundamental parameters that are useful in identifying these inefficiencies, provide examples of design and operating changes being made, and detail the resultant savings in energy.