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[null,"ENERGY EFFICIENCY TOOLS FOR PUMPING SYSTEM"]
[null,"VER_03/160424"]
[null,"INTRODUCTION: This workbook consists of multiple tools that conduct Assessment of Pumping System, calculate Energy Performance of Pumps, and calculate Energy Saving Potentials in the System."]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white.\n2. Results of calculations will be displayed in orange cells.\n3. Examples of data and calculation are shown in each tool."]
[null,"SOURCES:"]
[null,"1. Grundfos Ecademy\n2. Bureau of Energy Efficiency India\n3. www.energy.gov"]
[null,"WHO WE ARE:"]
[null,"ESPIRE is a partnership project between the Training and Development Centers of the Bavarian Employers‘ Association (bfz) gGmbH and business associations in Lahore and Karachi in Pakistan. \n\nThe objective of ESPIRE project is to support industries in Pakistan to work economically more efficiently and ecologically more sustainable and start making energy conservation and cleaner production part of their work routine. \n\nMain project partners are; Pakistan Association of Automotive Parts and Accessories Manufacturers (PAAPAM), Pakistan Hosiery Manufacturers Association (PHMA), Pakistan Readymade Garments Manufacturers and Exporters Association (PRGMEA), Small and Medium Enterprises Development Authority (SMEDA), Towel Manufacturers Association of Pakistan (TMA).\n\nThe Project is funded by the German Federal Ministry for Economic Cooperation and Development (BMZ) via Sequa gGmbH."]
[null,"DISCLAIMER:"]
[null,"The information, calculations and conclusions in this tool are based on the projects executed by the experts and consultant under Project ESPIRE by bfz gGmbH – International Division. Some sources (as mentioned above) were also consulted to validate the contents. The efficiency improvement measures proposed in this tool are tested and tried in many companies in Pakistan. However, implementation of these measures in any particular case should be based on real time data analysis by qualified engineers after judging financial viability. Bfz gGmbH – International Division and it's Project Partners in Pakistan accepts no liability whatsoever to any person, company or entity for any injury, loss or damage that may arise in connection with any misuse or reliance on the information.\n\nThe tool is provided as a freeware. Users may make copies and distribute the tool without making any changes."]
[null,"CONTACT:"]
[null,"Users may contact following for any clarification, suggestion and/or improvement in this tool;"]
[null,"Muhammad Salman Butt\nProject Manager\nProject ESPIRE\nbfz gGmbH International Division\n0092 300 4322343",null,"Sajid Mahmood Lakhan\nManaging Director\nGreen Energy Associates, Karachi\n0092 321 2117115\nsajid@gea.com.pk"]

{"sheet":"1| Checklist Pumping System","index":1,"n_rows":49,"n_cols":4,"rows_kept":49,"cut":false,"hidden":false,"merged":[[42,1,42,3],[1,1,1,3],[37,1,37,3],[38,2,38,3],[39,2,39,3],[40,2,40,3]]}
[]
[null,"CHECKLIST FOR PUMP & PUMPING SYSTEM"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","DESIGN / PURCHASE","RATING"]
[null,"-","Select pump size appropriate to the load for optimum efficiency. Avoid purchasing of oversized or undersized pumps.","»"]
[null,"-","Select the pump type appropriate to the requirement i.e. axial, centrifugal etc. with right impeller size.","»"]
[null,"-","Ensure that the selected pump is compatible with variable-speed drives.","»"]
[null,"-","Ensure basic instrumentation of pumps [e.g. pressure gauges, flow meters, energy meters, etc.]","»"]
[null,"-","Reduce system resistance by pressure drop assessment and selection of right pipe size and material.","»"]
[null,"- -","Optimise the plant design and pipe layout to minimize pumping need and pressure losses. Maximize the pipe diameter.","»"]
[null,"- -","Develop purchasing specifications of all pumps, including criterion to judge energy performance.","»"]
[null,"- -","Setup multiple sized pumping system for varying flows.","»"]
[null,null,"USE","RATING"]
[null,"-","Conduct water balance analysis to identify wastages and ensure that the system is balanced in order to minimize flows and reduce pump power requirements.","»"]
[null,"-","Ensure that the pumping demand  is reduced and system has a low required flow rate.","»"]
[null,"-","Ensure that the operating pressure of the pumping system is kept low.","»"]
[null,"-","Avoid using bypass lines and throttle valves. Instead minimise pressure losses through valves and fittings.","»"]
[null,"-","Optimise number of stages in multi-stage pump in case of head margins.","»"]
[null,"-","Increase fluid temperature differential to reduce pumping rates in case of heat exchangers.","»"]
[null,"- -","Adapt to wide load variation with variable speed drives or sequenced control of multiple pumping units.","»"]
[null,"- -","In the case of over designed pump, provide variable speed drive, or downsize / replace the impeller or replace it with the correct sized pump for efficient operation.","»"]
[null,"- - -","Use booster pumps for small loads that require higher pressures or higher heads.","»"]
[null,null,"SAFETY & MAINTENANCE","RATING"]
[null,"-","Regularly monitor pumping efficiency and energy performance of pumping system.","»"]
[null,"-","Monitor vibration of pumps periodically, identify pumps with increased vibration and take immediate corrective and preventive action.","»"]
[null,"-","Monitor differential head and temperature rise across the pump (also known as thermodynamic monitoring). ","»"]
[null,"-","Perform distribution system inspection for scaling or contaminant build-up. ","»"]
[null,"-","Check and maintain pump efficiency after repair or maintenance. ","»"]
[null,"-","Monitor leaks in pumps regularly and immediately fix identified leaks.","»"]
[null,"-","Conduct bearing inspection for increased noise and repair / replace based on conditions.","»"]
[null,"-","Ensure bearing lubrication replacement, once annually or semi-annually based on prevailing conditions or as per manufacturer's guidelines.","»"]
[null,"-","Put pressure or flow sensors in the location that will help ensure process requirements are met without excess pumping energy.","»"]
[null,"-","Replace worn impellers, especially in caustic or semi-solid applications. ","»"]
[null,"-","Inspect pumps for wear in seals, rings, impellers and bearings and take immediate corrective and preventive measures.","»"]
[null,"-","Develop and implement a predictive and preventive maintenance programme.","»"]
[null,"-","Develop guidelines for proactive repair/replace decisions based on operating and maintenance cost and energy performance.","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

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[]
[null,"PUMPING EFFICIENCY CALCULATION"]
[null,"ISSUE:  Pumps are normally most ignored facility in a company. Companies normally rely on expertise of pump suppliers while making any decision in this area. \n\nWHAT WE DO HERE: Calculate Pumping Efficiency."]
[null,null,"Example",null,"Actual Motor Power"]
[null,null,20,null,null,"[kW]",">","Actual power (kW) consumed by motor of pump"]
[null,null,null,null,"Motor Efficiency"]
[null,null,0.92500000000000004,null,null,"[%]",">","Check Motor Efficiency from Manufacturer's datasheet",null,null,null,{"$f":"E23","v":0},"m"]
[null,null,null,null,"Pump Shaft Power"]
[null,null,{"$f":"C5*C7","v":18.5},null,{"$f":"E5*E7","v":0},"[kW]",">","= Actual Motor Power x Motor Efficiency",null,null,null,null,null,{"$f":"E25","v":0},{"$f":"F25","v":"[bar]"}]
[null,null,null,null,"Electricity Unit Price"]
[null,null,18,null,null,"[Rs/kWh]",">","Electricity average unit price",null,{"$f":"L7+L15","v":0},"m"]
[null,null,null,null,"Annual Operating Hours"]
[null,null,4500,null,null,"[h/yr]",">",null,null,null,null,null,null,null,{"$f":"E29","v":0},{"$f":"F29","v":"[m3/h]"}]
[null,null,null,null,"Fluid Density"]
[null,null,1000,null,null,"[kg/m3]",">","Water = 1000 kg/m3, Medium Strength Waste Water =~ 1030 kg/m3",null,null,null,{"$f":"E21","v":0},"m"]
[null,null,null,null,"Depth of suction vessel surface"]
[null,null,20,null,null,"[m of head]",">","Check in Drawings: Vertical distance from surface of source reservior / bore hole / suction vessel to ground surface [+ve if below surface, -ve if above surface, \"0\" for submersed pump]"]
[null,null,null,null,"Height of Pump"]
[null,null,1,null,null,"[m of head]",">","Check in Drawings: Vertical distance from ground surface to centerline of pump [+ve if pump is above surface, -ve if below surface, \"0\" for submersed pump]"]
[null,null,null,null,"Static Suction Head"]
[null,null,{"$f":"C17+C19","v":21},null,{"$f":"E17+E19","v":0},"[m of head]",">","= Height of Pump + Depth of Vessel Surface "]
[null,null,null,null,"Static Discharge Head"]
[null,null,28,null,null,"[m of head]",">","Check in drawings: Vertical Distance from centerline of pump to surface of delivery vessel / reservoir",null,null,null,null,null,null,null," "]
[null,null,null,null,"Pump Discharge Head (pressure)"]
[null,null,3,null,null,"[bar]",">","Pump Discharge Pressure from Pressure Gauge measurement at discharge flange"]
[null,null,null,null,"Length of Discharge Pipe"]
[null,null,5,null,null,"[km]",">","Running length of the discharge pipe"]
[null,null,null,null,"Pump Discharge Flow Rate"]
[null,null,110,null,null,"[m3/h]",">","Measure from flow meter or estimate"]
[null,null,null,null,"Inlet Pipe Diameter"]
[null,null,0.25,null,null,"[m]",">"]
[null,null,null,null,"Outlet Pipe Diameter"]
[null,null,0.15,null,null,"[m]",">"]
[null,null,null,null,"Total Head"]
[null,null,{"$f":"C$21+'4| Conversions'!C$9+'4| Conversions'!C$25","v":51.723634177677248},null,{"$f":"E$21+'4| Conversions'!E$9+'4| Conversions'!E$25","v":{"$error":"#DIV/0!"}},"[m of head]",">","= Static Suction Head + Total Discharge Head + Velocity Head Differential [Velocity Head Differential is calculated automatically]"]
[null,null,null,null,"Pump Hydraulic Power Output"]
[null,null,{"$f":"C35*'4| Conversions'!C14*C15*9.81/3600000","v":15.504159344758756},null,{"$f":"E35*'4| Conversions'!E14*E15*9.81/3600000","v":{"$error":"#DIV/0!"}},"[kW]",">","= Flow rate x Density x Total Head x g ÷ 3600000"]
[null,null,null,null,"Pump Hydraulic Efficiency"]
[null,null,{"$f":"C37/C9","v":0.83806266728425705},null,{"$f":"E37/E9","v":{"$error":"#DIV/0!"}},"[%]",">","= Pump Hydraulic Output ÷ Pump Shaft Power"]
[null,null,null,null,"System Friction Losses (discharge side)"]
[null,null,{"$f":"'4| Conversions'!C9-C23","v":2.5909999999999975},null,{"$f":"'4| Conversions'!E9-E23","v":0},"[m of head]",">","= Pump discharge head - Static Discharge Head"]
[null,null,null,null,"Friction Loss per km of Discharge Pipe"]
[null,null,{"$f":"C41/C27","v":0.51819999999999955},null,{"$f":"E41/E27","v":{"$error":"#DIV/0!"}},"[m of head per km]",">","= System Friction Loss ÷ Length of Discharge Pipe"]
[null,null,null,null,"Piping Efficiency"]
[null,null,{"$f":"1-(('4| Conversions'!C9-C23)/'4| Conversions'!C9)","v":0.91530188617567265},null,{"$f":"1-(('4| Conversions'!E9-E23)/'4| Conversions'!E9)","v":{"$error":"#DIV/0!"}},"[%]",">","= 1 - (System Friction Loss ÷ Pump Discharge Head) "]
[null,null,null,null,"Overall Efficiency"]
[null,null,{"$f":"C45*C39*C7","v":0.70954931459129345},null,{"$f":"E45*E39*E7","v":{"$error":"#DIV/0!"}},"[%]",">","= Motor Efficiency x Pump Efficiency x Piping Efficiency"]
[]
[]
[null,"OVERALL EFFICIENCY CLASSIFICATION:"]
[null,null,"EFFICIENCY","OPTIMIZATION GUIDLINES"]
[null,null,0.8,"System is runnning well. Continuously monitor energy performance"]
[null,null,0.7,"Install Motor Control System to Further optimize system efficiency"]
[null,null,0.6,"Install pipes having lesser friction losses, Improve Housekeeping"]
[null,null,0.5,"Install energy efficient motor, investigate option for using smaller pump"]
[null,null,0.4,"Carry out detailed assessment of pumping system"]
[null,null,0.3,"Consult Experts; Redesign pumping system"]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white \n"]
[null,"ADDITIONAL TIPS"]
[null,"1. Compare calculated efficiencies with worldcalss benchmark"]

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[]
[null,"PUMP ENERGY PERFORMANCE CALCULATION"]
[null,"ISSUE: Pumps are big energy consumers but often ignored while monitoring energy perfromance. \n\nWHAT WE DO HERE: Develop Energy Performance Indicators, Calculate Electricity Consumption Breakdown."]
[null,null,"Example",null,"Annual Electricity Consumption"]
[null,null,{"$f":"'2| Pump Efficiency'!C13*'2| Pump Efficiency'!C5","v":90000},null,{"$f":"'2| Pump Efficiency'!E13*'2| Pump Efficiency'!E5","v":0},"[kWh/yr]",">","= Actual Motor Power x Annual Operating Hours"]
[null,null,null,null,"Annual Electricity Cost"]
[null,null,{"$f":"C5*'2| Pump Efficiency'!C11","v":1620000},null,{"$f":"E5*'2| Pump Efficiency'!E11","v":0},"[Rs/yr]",">","= Annual Electricity Consumption x Electricity Unit Price"]
[null,null,null,null,"Volume of Fluid Displaced"]
[null,null,{"$f":"'2| Pump Efficiency'!C13*'4| Conversions'!C14","v":495000},null,{"$f":"'2| Pump Efficiency'!E13*'4| Conversions'!E14","v":0},"[m3/yr]",">","= Pump Discharge Flow rate x Annual Operating Hours"]
[null,null,null,null,"Energy Performance Indicators (EnPIs)"]
[null,null,null,null,"Specific Energy Consumption "]
[null,null,{"$f":"C5/C9","v":0.18181818181818182},null,{"$f":"E5/E9","v":{"$error":"#DIV/0!"}},"[kWh/m3]",">","= Annual Electricity Consumption ÷ Volume of Fluid Displaced"]
[null,null,null,null,"Specific Energy Consumption per meter of Head"]
[null,null,{"$f":"C12*1000/('2| Pump Efficiency'!C21+'2| Pump Efficiency'!C23)","v":3.7105751391465676},null,{"$f":"E12*1000/('2| Pump Efficiency'!E21+'2| Pump Efficiency'!E23)","v":{"$error":"#DIV/0!"}},"[kWh/1000 m3/m]",">","= kWh/m3 x 1000 ÷ (Static Suction Head + Static Discharge Head)"]
[null,null,null,null,"Specific Energy Cost"]
[null,null,{"$f":"C7/C9","v":3.2727272727272729},null,{"$f":"E7/E9","v":{"$error":"#DIV/0!"}},"[Rs/m3]",">","= Annual Electricity Cost ÷ Volume of Fluid Displaced"]
[null,null,null,null,"Specific Energy Cost per meter of Head"]
[null,null,{"$f":"C16*1000/('2| Pump Efficiency'!C21+'2| Pump Efficiency'!C23)","v":66.790352504638221},null,{"$f":"E16*1000/('2| Pump Efficiency'!E21+'2| Pump Efficiency'!E23)","v":{"$error":"#DIV/0!"}},"[Rs/1000 m3/m]",">","= Rs/m3 x 1000 ÷ (Static Suction Head + Static Discharge Head)"]
[]
[]
[null,null,null,null,"System Losses"]
[null,null,null,null,"Motor Efficiency Loss"]
[null,null,{"$f":"C7*(1-'2| Pump Efficiency'!C7)","v":121499.99999999993},null,{"$f":"E7*(1-'2| Pump Efficiency'!E7)","v":0},"[Rs/yr]",">","Loss due to inefficiency of motor"]
[null,null,null,null,"Pump Efficiency Loss"]
[null,null,{"$f":"C7*(1-'2| Pump Efficiency'!C39)","v":262338.4789995036},null,{"$f":"E7*(1-'2| Pump Efficiency'!E39)","v":{"$error":"#DIV/0!"}},"[Rs/yr]",">","Loss due to inefficiency of pump"]
[null,null,null,null,"Piping Efficiency Loss"]
[null,null,{"$f":"C7*(1-'2| Pump Efficiency'!C45)","v":137210.9443954103},null,{"$f":"E7*(1-'2| Pump Efficiency'!E45)","v":{"$error":"#DIV/0!"}},"[Rs/yr]",">","Loss due to inefficiency of piping"]
[null,null,null,null,"Total Loss"]
[null,null,{"$f":"SUM(C23:C27)","v":521049.42339491384},null,{"$f":"SUM(E23:E27)","v":{"$error":"#DIV/0!"}},"[Rs/yr]",">","= Sum all losses"]
[null,null,null,null,"Useful Work Done"]
[null,null,{"$f":"C7-C29","v":1098950.5766050862},null,{"$f":"E7-E29","v":{"$error":"#DIV/0!"}},"[Rs/yr]",">","= Annual Electricity Cost - Total Loss"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. This sheet does not require any data entry.\n"]

{"sheet":"Dropdown","index":4,"n_rows":5,"n_cols":3,"rows_kept":5,"cut":false,"hidden":true,"merged":[]}
[]
[null,"Discharge Rate","Pressure"]
[null,"[m3/h]","[m of head]"]
[null,"[g/h]","[bar]"]
[null,null,"[psi]"]

{"sheet":"4| Conversions","index":5,"n_rows":25,"n_cols":8,"rows_kept":25,"cut":false,"hidden":false,"merged":[[2,4,2,7],[9,4,9,7],[14,4,14,7]]}
[]
[null,"Conversions for Calculations"]
[null,null,null,null,"Discharge Head"]
[null,null,"Example",null,"bar to [m of head]"]
[null,null,{"$f":"IF('2| Pump Efficiency'!F25=\"[bar]\", '2| Pump Efficiency'!C25*10.197, \"-\")","v":30.590999999999998},null,{"$f":"IF('2| Pump Efficiency'!F25=\"[bar]\", '2| Pump Efficiency'!E25*10.197, \"-\")","v":0},"[m of head]",null,"1 bar = 10.197 m of head"]
[null,null,null,null,"psi to [m of head]"]
[null,null,{"$f":"IF('2| Pump Efficiency'!F25=\"[psi]\", '2| Pump Efficiency'!C25*0.703249614902049, \"-\")","v":"-"},null,{"$f":"IF('2| Pump Efficiency'!F25=\"[psi]\", '2| Pump Efficiency'!E25*0.703249614902049, \"-\")","v":"-"},"[m of head]",null,"1 psi = 0.703 m of head"]
[null,null,null,null,"Final Value"]
[null,null,{"$f":"IF(C5=\"-\",IF(C7=\"-\",'2| Pump Efficiency'!C25,C7),C5)","v":30.590999999999998},null,{"$f":"IF(E5=\"-\",IF(E7=\"-\",'2| Pump Efficiency'!E25,E7),E5)","v":0},"[m of head]",null,"Value for calculations"]
[null,null,null,null,"Flow Rate"]
[null,null,null,null,"g/h to m3/h"]
[null,null,{"$f":"IF('2| Pump Efficiency'!F29=\"[g/h]\", '2| Pump Efficiency'!C29*0.004546092, \"-\")","v":"-"},null,{"$f":"IF('2| Pump Efficiency'!F29=\"[g/h]\", '2| Pump Efficiency'!E29*0.004546092, \"-\")","v":"-"},"[m3/h]",null,"1 g/h = 0.004546092 m3/h"]
[null,null,null,null,"Final Value"]
[null,null,{"$f":"IF(C12=\"-\",'2| Pump Efficiency'!C29,C12)","v":110},null,{"$f":"IF(E12=\"-\",'2| Pump Efficiency'!E29,E12)","v":0},"[m3/h]",null,"Value for calculations"]
[null,null,null,null,"Velocity Head Calculation"]
[null,null,null,null,"Inlet Velocity (Vi)"]
[null,null,{"$f":"$C$14/((PI()*('2| Pump Efficiency'!C31/2)^2)*3600)","v":0.62247266631496845},null,{"$f":"$E$14/((PI()*('2| Pump Efficiency'!E31/2)^2)*3600)","v":{"$error":"#DIV/0!"}},"[m/s]",null,"= Discharge flow rate ÷ Inlet pipe area"]
[null,null,null,null,"Outlet Velocity (Vo)"]
[null,null,{"$f":"$C$14/((PI()*('2| Pump Efficiency'!C33/2)^2)*3600)","v":1.7290907397638011},null,{"$f":"$E$14/((PI()*('2| Pump Efficiency'!E33/2)^2)*3600)","v":{"$error":"#DIV/0!"}},"[m/s]",null,"= Discharge flow rate ÷ outlet pipe area"]
[null,null,null,null,"Inlet Velocity head (H-Vi)"]
[null,null,{"$f":"((C17^2)/(2*9.81))","v":1.9748838955620081E-2},null,{"$f":"((E17^2)/(2*9.81))","v":{"$error":"#DIV/0!"}},"[m of head]",null,"= Vi² ÷ 2g"]
[null,null,null,null,"Outlet Velocity head (H-Vo)"]
[null,null,{"$f":"((C19^2)/(2*9.81))","v":0.15238301663287099},null,{"$f":"((E19^2)/(2*9.81))","v":{"$error":"#DIV/0!"}},"[m of head]",null,"= Vo² ÷ 2g"]
[null,null,null,null,"Velocity Head Difference"]
[null,null,{"$f":"C23-C21","v":0.13263417767725091},null,{"$f":"E23-E21","v":{"$error":"#DIV/0!"}},"[m of head]",null,"= H-Vi - H-Vo"]