When two critical motors—rated at 18.5 kW (25 hp) and 90 kW (120 hp)—burned out, the maintenance team faced a common decision: rewind or replace. While rewinding is often less expensive upfront, it can result in reduced efficiency. This case study presents a comparative cost analysis, revealing that motor replacement offers greater long-term value, with a break-even point reached within two years.
After pump efficiency fell from 90.5 to 85.5 percent, a water distribution pump was refurbished. The refurbishment resulted in the pump being able to provide a higher head with a better efficiency at the same flow rate. Because the pump output could be matched to the system requirements by the installed variable frequency drive, the refurbishment reduced the power absorbed and achieved a payback period of under two years.
Analysis of the pump was showed the pressure generated was considerably higher than required. Reducing the impeller size was explored which reduced the power demand by 25 percent. Fitting an alternative motor to the pump allowed more energy consumption reductions.
The heating system in an office building required renovation. The options considered were replacing the 3 existing pumps with ones that were the same power and eventually replacing the thermostatic valves, as well as redesigning the system to have four sub-systems with optimized dimensions using equal friction loss per pump. The latter option allowed for smaller pumps to be used which cut down on the life-cycle cost.
A pump used in an open system for pumping water from circulation tank into two wire tanks was worn down and had decreased efficiency. Analysis was done to compare the cost benefit of installing two modifications to the existing system. With an increased demand required only during startup, the conclusion was installing a new smaller pump parallel to the old pump to provide the base load duty. The old pump would only be used during the start up period.
A 30-year-old circulator needs to be replaced in a one-family house. An analysis on the system was done, which concluded that the electronic circulator could be downsized due to the existing hydraulic resistance in the system.
Overview: Replacements are being considered for a cooling water system that currently consists of four volute casing pumps. A cost analysis is done comparing the baseline versus variable pitch propeller pumps and mixed flow pumps with variable inlet guide vanes. Mixed flow pumps have the fastest payback in this application with a payback time of 0.4 years.
To successfully achieve PSC Level 1 certification, it is suggested to follow a structured learning path. This article provides a step-by-step guide to help you prepare effectively.
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