"Green Pumps" Program: Refurbishing Pumps to Improve Energy Efficiency
Industrial Pump Servicing: Refurbishing for Improved Efficiency vs. Repair and Maintenance Only
A program for refurbishing old, large pumps to increase efficiency.
Synopsis:
The Green Pumps program provides services to owners of large, typically industrial, pumps. Refurbishing a pump would typically include replacing wear rings, bearings and shaft sleeves, and inspecting and replacing the impeller if necessary. Pump casings may be sent out for sandblasting and to apply a slick, NSF-approved, brushable-type, ceramic-filled epoxy coating on the inside of the volute (interior casing) of the pump to reduce friction losses in the system and increase pump efficiency.
It is important to choose appropriate applications for pump refurbishment and the applying of coatings as the pump is one component of a pumping system. In many constant-speed pump applications, reducing friction losses by coating the volute will increase the efficiency of the pump but can actually increase total energy use. An Electrical Apparatus Service Association (EASA) report (see below under Additional Information) discusses conditions under which coatings make sense from an energy efficiency standpoint. Pumps that operate at full-flow and cycle as needed will produce energy savings. Those with high heads and low flows will not benefit from a coating upgrade, nor would oversized pumps that use a modulating discharge valve to achieve a specific flow. In the latter instance, the discharge valve would close to compensate for any friction reduction provided by the coating, with the valve recreating the friction that the coating eliminated. Circulating water pumps would run at increased flow and pressure and with increased energy consumption. If the increased flow and pressure provide no additional benefits, operating costs would increase, not decrease. Reduced-friction coatings are beneficial in systems with adjustable speed drives.
Energy Savings: 7%
Energy Savings Rating: Approved Measure
What's this?
| Level | Status | Description |
| 1 | Concept not validated | Claims of energy savings may not be credible due to lack of documentation or validation by unbiased experts. |
| 2 | Concept validated: | An unbiased expert has validated efficiency concepts through technical review and calculations based on engineering principles. |
| 3 | Limited assessment | An unbiased expert has measured technology characteristics and factors of energy use through one or more tests in typical applications with a clear baseline. |
| 4 | Extensive assessment | Additional testing in relevant applications and environments has increased knowledge of performance across a broad range of products, applications, and system conditions. |
| 5 | Comprehensive analysis | Results of lab and field tests have been used to develop methods for reliable prediction of performance across the range of intended applications. |
| 6 | Approved measure | Protocols for technology application are established and approved. |
Simple Payback is one tool used to estimate the cost-effectiveness of a proposed investment, such as the investment in an energy efficient technology. Simple payback indicates how many years it will take for the initial investment to "pay itself back." The basic formula for calculating a simple payback is:
Simple Payback = Incremental First Cost / Annual Savings
The Incremental Cost is determined by subtracting the Baseline First Cost from the Measure First Cost.
For New Construction, the Baseline First Cost is the cost to purchase the standard practice technology. The Measure First Cost is the cost of the alternative, more energy efficienct technology. Installation costs are not included, as it is assumed that installation costs are approximately the same for the Baseline and the Emerging Technology.
For Retrofit scenarios, the Baseline First Cost is $0, since the baseline scenario is to leave the existing equipment in place. The Emerging Technology First Cost is the Measure First Cost plus Installation Cost (the cost of the replacement technology, plus the labor cost to install it). Retrofit scenarios generally have a higher First Cost and longer Simple Paybacks than New Construction scenarios.
Simple Paybacks are called "simple" because they do not include details such as the time value of money or inflation, and often do not include operations and maintenance (O&M) costs or end-of-life disposal costs. However, they can still provide a powerful tool for a quick assessment of a proposed measure. These paybacks are rough estimates based upon best available data, and should be treated with caution. For major financial decisions, it is suggested that a full Lifecycle Cost Analysis be performed which includes the unique details of your situation.
The energy savings estimates are based upon an electric rate of $.09/kWh, and are calculated by comparing the range of estimated energy savings to the baseline energy use. For most technologies, this results in "Typical," "Fast" and "Slow" payback estimates, corresponding with the "Typical," "High" and "Low" estimates of energy savings, respectively.