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Global Training and Support Guide

Global Training and Support Guide.

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Global Training and Support Guide

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  1. Global Training and Support Guide

  2. For more than a century, Blackmer has been at the forefront of flow technology problem solving. From the first positive displacement rotary vane pump to its patented cavitation/noise suppression innovation, Blackmer has led the way in solutions for the safe, reliable and energy-efficient transfer of high-value and hazardous liquids and gases in mobile and process applications worldwide. CentrifugalPumps Peristaltic (Hose) Pumps Positive Displacement, Sliding Vane Pumps ReciprocatingGas Compressors 2

  3. Introduction • High energy prices impose a competitive andprofit-robbing threat to every manufacturing operation, large or small, worldwide • Left unmanaged, energy expenditures can quietlyand quickly erode a company’s financial performance, productivity, and competitive position 3

  4. Smart “Energy Management” is the Key to: • Driving productivity improvements that increase financial performance • Controlling energy expenses by reducing power consumption without compromising output performance • Increasing operational reliability by emphasizing the use of energy-efficient technologies that support enhanced mechanical efficiency • Reducing vulnerability to energy price volatility 4

  5. Blackmer started its Smart Energy™ Flow Solutions initiative to help educate companies on how theycan reduce energy consumption through theuse of positive displacement sliding vanepump technologies. Blackmer Smart Energy™ Flow Solutions Mission Enable pump users to a gain a competitive business advantage throughthe deployment of energy-saving positive displacement sliding vanepump technology. Blackmer will accomplish this mission by providing end-users, engineering consultants, OEMs, and distributors with education, tools, and knowledge onthe energy-saving value and performance-enhancing advantages of positive displacement sliding vane pumps. 5

  6. A Global Opportunity Worldwide industrial energy consumption is expected to increase by 42%, or an average of 1.3% per year, from 2007 to 2035. 95% of the growth occurs in developing nations. Global energy consumption rose in 2010 at the fastest pace since 1973, as rapidly growing developing nations led a strong rebound from the Great Recession. China has now surpassed the United States as the world’s biggest consumer of energy, accounting for 20.3% of global demand compared with 19% for the U.S. 6

  7. Key Points to Ponder • Pumps represent 27% of the electricity used in industrial applications* • Energy is the single largest cost-of-ownership component of an industrial pump system – representing between 50-90% of total life cycle costs, dependingon the technology • A reduction of energy consumption is a key component to controlling costs • Using the right pump technology, properly sized for a specific application, is an important step towards reducing pump energy consumption Industrial EnergyConsumption *Source: Hydraulic Institute 7

  8. Pumps – A Vital Part of an Energy-Efficient System • There is a specific “best use” for every pump technology • Understanding how pump efficiency, system efficiency and overall energy efficiency are measured and affected by the pumps and overall system configuration is vital to developing a successful energy-efficient pumping system • Knowing the fundamental advantages and disadvantages between pump technologies is necessary to selectingthe right pump for optimum performance andenergy-saving results 8

  9. Choosing The Right Pump Technology Can Help a Company Achieve Simultaneous Goals: Reduce energy consumption Improve worker safety Reduce operations, production and maintenance costs Improve capacity utilization Improve productivity Improve system reliability Improve product quality 9

  10. Published Reports confirm many opportunities for companies to immediately improve bottom line performance through energy-efficient pump system improvements Source: Pump Systems Matter – U.S. Industrial Motor Systems Market Opportunities Assessment,U.S. Department of Energy 12

  11. A dollar saved on energy, maintenance or production is equivalent to $17 in sales income (assuming a 6% gross margin)* * SOURCE: Northwest Energy Efficiency Alliance / Industrial Efficiency Alliance – How Continuous Energy Improvements Reduce Costs and Improve System Performance 11

  12. Managing Global Energy Consumption Global net electricity demand is projected to grow by 1.4% per year between 2007 and 2035, with the strongest growth in developing countries. The chemical industry made up 22% of the total world industrial energy consumption in 2007. Energy represents 60% of this industry’s operating costs. 12

  13. Managing Global Energy Consumption Improving the energy efficiency of even one pump in a manufacturing process could produce substantial financial savings for any operation. The table to the right summarizes the electrical costs of a continuously operated centrifugal pump (driven by a 100 HP motor) at 10 cents per kWh. Even a 10% reduction in energy consumption adds up to considerable savings. 13

  14. Geographic Opportunities 14

  15. Geographic Opportunities Americas • United States • 2.4 million pumps consuming 142 billion kWh annually • Projected 25% reduction in industrial production energy use by 2017 • Canada • Projected 0.6% industrial energy consumption growth rate in next 20 years • Mexico • 1.9% annual industrial energy consumption growth rate • South America • Brazil – 2.1% annual industrial energy consumption growth rate • Other Central & South American Countries • 20% projected growth rate between 2007-2035 15

  16. Geographic Opportunities EMEA • Europe • Energy legislation mandating “Smart Meters” to gauge electric usage • Russia • Least energy-efficient economy in the world • 0.2% annual projected industrial energy growth • Middle East • 2.2% annual industrial energy consumption growth rate • Chemical sector is the largest consumer of energy • Numerous petrochemical projects underway in Saudi Arabia, Qatar, Kuwait, UAE, and Iran 16

  17. Geographic Opportunities Asia • China • Industrial sector accounts for 75% of total energy consumption • High demand for industrial pumps due to infrastructure development • Government mandates dramatic energy reduction in the coming decade • India • Growth expected from light manufacturing and services • Opportunities are abundant as government mandates industries to develop efficiencies in energy consumption Between 2003 and 2006, this market witnessed rapid growth driven by the huge demand from industries such as water and wastewater treatment, power generation, oil and gas, and chemicals and petrochemicals. 17

  18. How To Measure Energy Efficiency in Pumps • Pumps waste energy when they fail to convert the electric power they consume into the fluid motion they were designed to provide • Critical measurement equations used to select a new pump or when analyzing a pump system for energy efficiency: Imparted Energy Efficiency = Inputted Energy Energy Used Specific Energy = Pumped Volume Energy Converted Power = Time Taken 18

  19. How To Measure Energy Efficiency in Pumps kW x Efficiency Horsepower (alternating = current) 746 19

  20. (1 - 0.55) 0.78 Savings = 235 kW x 6,000 Hrs/Yr x = 415,769 kWh per year @ 0.05 per kWh = $20,788 Savings Measuring & Managing Energy Consumption • When pumps operate at optimum levels they use less energy and increase reliability, saving both energy and maintenance costs • The maintenance and productivity benefits of improving a pump system’s performance are generally one to two times the value of the energy savings Calculating Potential Energy Savings (1 − Actual System Efficiency) Savings = kW (in input electric energy) x Annual Operating Hours x Optimal System Efficiency EXAMPLE: 1) Operating Efficiency (300 HP pump = 55% Efficiency) 2) Optimal Operating Efficiency (300 HP = 78% Efficiency) 3) Pump draws 235 kW x 6,000 hours of service per year 20

  21. Reducing Energy Waste Begins with Proper Pump Selection for the Application • Select the pump technology best suited for the application • Properly size pumps, control valves and piping for real-time requirements (avoid excessive margin of error capacity and/or total pressureor head) • Reduce restrictions, turbulenceand frictional losses 21

  22. Reducing Energy Waste Begins withProper Pump Selection for the Application • Ensure proper motor alignment (poor alignment of motor and load increases motor power consumption) • Reduce flow rates = lower energy losses • Lower operating pressures • Maintain pumps and system components to avoid efficiency loss (wear is a significant cause of decreased pump efficiency; corrosion in pipes increases friction) 22

  23. Consider Application When Choosing Pumping Equipment • HOW THICK? • Maximum VISCOSITY of the liquid in Seconds Saybolt Universal (SSU) • HOW MUCH FLOW? • Approximate DELIVERY required in gallons/litresper minute • HOW MUCH PUSH? • Differential PRESSURE required in pounds per square inch (PSI) or Bar • HOW HOT? • Pumping TEMPERATURE of the liquid in degrees of Fahrenheit or Centigrade • HOW MUCH PULL? • SUCTION conditions when pumping in vacuum, or PSI/Bar for pressure • WHAT LIQUID? • Type of LIQUID to be handled • HOW HEAVY? • Specific GRAVITY of the liquid • HOW LONG? • Type of SERVICE, e.g., intermittent duty, semi-continuous duty, or continuous duty 23

  24. Many pump users do not know how to properly select and apply pumps to a system, so pump system operating costs are inadvertently increased as a result. • Using pump selection software programs can help operators optimize pump selection • Leading pump manufacturers also provide applications and engineering expertise, pump specification and selection programs, technical training and support allows users to select pump data and pump curves so they can select the proper positive displacement or centrifugal pumps for their application. 24

  25. Proper Pump Selection • Although the operating principles of positive displacement and centrifugal pumps differ widely, both types of pumps can be used to serve many of the same applications Source: Schematic courtesy ofChemical Processing Magazine 25

  26. ProperPump Selection It’s time to put some energy into learning about the energy-saving advantages of positive displacement sliding vane pumps • There is no “one-pump-fits-all” solution • The right pump delivers productivity gains and helps control energy consumption • Positive displacement sliding vane pumps, by virtue of their inherent energy and mechanically-efficient designs, are uniquely suited to offer manufacturers immediate advantages in performanceand energy savings 26

  27. Using LCC (Life Cycle Costs) for Proper Pump Selection LCC – Relative ComparisonCentrifugal vs. Positive Displacement (PD) Pumps • An analysis of Life Cycle Costs (LCC) can dramatically reduce waste and maximize efficiency • The NET cost savings based on LCC will often justify a higher initial price for a more energy-efficient pump • Life-cycle costing helps identify the lowest total cost of ownership by considering: • Initial equipment cost • Installation and Commissions • Energy costs • Maintenance and Repairs • Downtime costs • Decommissioning costs Total Life Cycle Cost (LCC) Centrifugals PD Pumps Initial Pump Cost Installation, maintenance, operating, environmental and downtime costs Energy Cost 27

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  29. Comparing Centrifugal Pumps to Positive Displacement Pumps 29

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  31. Consider Positive Displacement Pumps over Centrifugal Pumps when: • Working fluid is highly viscous (over 850 cSt) • Flow rate must be predictable over a wideflow range (flow must be metered orprecisely controlled) • Flow rate must remain constant under varying system pressures • System requires high-pressure, low-flow • Line stripping is required (some PD technologies) • Suction lift or self-priming is required • Working fluid is shear-sensitive • Energy-savings/efficiency is a primary concern 31

  32. Positive Displacement Pumps Are Not Created Equal • PD pumps make up approximately 15% of industrial pump population • There are significant differences between PD pump types Improper pump selection can cost money in downtime, lost production, maintenance costs and energy consumption. 32

  33. Improper pump selection can cost money in downtime, lost production, maintenance costs and energy consumption. 33

  34. Sliding Vane Pumps vs. Internal Gear Pumps 34

  35. Energy Cost ComparisonVane/Lobe/Gear From the lowest to the highest viscosity, sliding vane technology provides the highest level of mechanical efficiency which equatesinto the lowest energy consumption. Mechanical Efficiency 189 - 379 L/min (50-100 GPM); 3.45 - 6.90 Bar (50-100 PSI);4-1,620 cSt viscosity;same model on all viscosities Viscosity (cSt) 35

  36. Sliding Vane Pumps vs. Internal Gear Pumps Sliding vane pump technology not only reduces energy costs but helps to create an overall more efficient pumping system, providing solutions for seals, suction, product shear, and volumetric efficiency problems. 36

  37. Sliding Vane Pumps vs. Internal Gear Pumps 37

  38. Summary • Left unmanaged, energy costs can quietly erode profits • Pumps account for 27% of total electrical use in theindustrial sector • Pump system improvements – such as using the proper pump for the application – can help to reduce energy consumption • Positive displacement sliding vane pumps are inherently energy-efficient and offer advantages over centrifugal pumps and other PD pumps in specific applications • “A dollar saved on energy, maintenance or production is equivalent to $17 in sales income (assuming a 6% gross margin).”– Northwest Energy Efficiency Alliance • Energy-saving advice is available from: • Blackmer Smart Energy™ Initiative (www.BlackmerSmartEnergy.com) • U.S. Department of Energy (Industrial Technology Program) • Hydraulic Institute (Pump Systems Matter) • Northwest Energy Efficiency Alliance

  39. Blackmer’s Commitment to Sustainability Blackmer Smart Energy® Solutions We are proud to provide customers with products that enable them to reduce energy consumption and preserve natural resources. Blackmer cares deeply about pioneering new technologies and processes that allow our partners to promote sustainability for our world. 39

  40. A Valuable Resource www.blackmersmartenergy.com

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