When considering that an estimated 85% of pumps are not optimized to their overall systems, it makes sense that the lack of focus on efficiency can cost end users both money and reliability. That’s why assessing and improving the performance of entire pumping systems is essential to achieve operational excellence and reduce environmental impact.
In the past several years, there has been a sharp increase in the number of end users actively seeking to optimize their pumps and reduce their energy usage. This trend is driven by a desire to reduce operating costs and maintain an edge in competitive markets. In many cases, energy reductions are also part of a more extensive sustainability strategy that is championed by corporate management and is related to
publicly announced reductions in greenhouse gas emissions.
Hydro approaches energy efficiency differently with a more holistic approach, Hydro Energy Edge. They have a unique experience as a brand-agnostic company focused on enhancing end users’ existing installed equipment. This experience has provided expert insight into how equipment performance can be improved by implementing technological upgrades and understanding how equipment operates as part of the greater system.
With energy optimization, it’s important to understand both what goes into it (how do we get there?) and what comes out of it (benefits beyond just energy savings).
Hydro Energy Edge is less of a strictly defined product and more of a personalized roadmap of how an organization can approach energy optimization and gauge what actions will bring them the most value for their investment.
Hydro’s Energy Edge program takes advantage of in-house engineering, field testing, remanufacturing, performance testing, condition monitoring, and parts capabilities to provide an end-to-end solution to improve energy usage and reliability. The process starts with getting the necessary design and operation data to perform a comprehensive analysis of current performance and identify opportunities for improvement.
Depending on the findings, solutions can range from system operations recommendations to hydraulic modifications to a newly-designed drop-in replacement. When choosing the latter, end users are provided with a pump outfitted with custom hydraulics instead of an off-the-shelf replacement; this not only optimizes performance, but minimizes cost, lead time, and risk by ensuring that the solution is exactly suited to its system and fits into the existing equipment footprint.
A Case Study in Energy Savings
A large petroleum exploration and production company has a vision that has proven to be exceptionally effective in achieving substantial energy savings and operational improvements. They recognized that there is a great opportunity to minimize the cost and maximize oil production by ensuring equipment is exactly matched to the demand.
Beyond the impressive financial savings of approximately $1 million USD annually, the principal achievement lies in the substantial reduction of carbon dioxide emissions—approximately 3,540 tons per year. This equates to the CO2 absorption capacity of about 168,571 trees or the removal of approximately 770 cars from the streets. This reduction in power consumption of their rotating equipment and associated emissions reduction strongly supports their corporate strategy of creating value and driving sustainability.
This achievement was powered by a proactive approach to environmental stewardship and equipment ownership. Hydro and the end user worked together to consider current operating regimes, interaction of the pump and its system, and future operating requirements. Hydro then re-rated the equipment with new hydraulic performance using impellers designed through CFD to match the system and operational requirements. At the end of the project, not only was the equipment more energy- and cost-efficient, but it was also more reliable.
The environmental impact of successful energy optimization projects underscores the crucial importance of implementing advanced engineering solutions that not only reduce equipment total lifecycle costs but also significantly contribute to environmental conservation.
For more information about Hydro’s Energy Edge, please read this article.
