Issue Focus: Energy-Efficient Solutions for Industrial Competitiveness
Energy Matters was a quarterly newsletter for DOE's Advanced Manufacturing Program (AMO). It provided in-depth technical articles to help industry professionals save energy, reduce costs, and increase productivity. These archived issues may contain broken links or information that is no longer accessible. Some of the following documents are available as Adobe Acrobat PDFs.
This issue highlights DOE's Industrial Technologies Program's long history of successful partnerships, and looks ahead to new ventures that will meet U.S. industrial energy-efficiency challenges. Also included: a new animation to show the workings of the Super Boiler; a Save Energy Now case study on steam system optimization at a fertilizer plant; the new Ask an Energy Expert column; and introduction to two ITP Software tools now available in metric version.
In This Issue
- Energy Efficiency in the Spotlight
- Super Boiler: A Super Hero of Steam Generation
- Save Energy Now Assessment Helps Energy Savings Grow for Fertilizer Company
- Ask an Energy Expert: Assessing Compressed Air Systems
- DOE Industrial Software Tools Go Metric
Energy Efficiency in the Spotlight
What's in the New Energy Legislation?
- Corporate average fuel economy
- Renewable fuels standard
- Energy efficiency equipment standards
- Repeal of oil and gas tax incentives.
The Omnibus Appropriations Act of 2008 provides $1.72 billion for DOE's energy efficiency and renewable energy programs to help the nation meet its goals. See Division C, Title III section of this report (PDF 384 KB) for more information.
As 2008 begins, energy issues continue to be at the forefront of the nation's consciousness. Rising and volatile fuel prices, global warming concerns, and dependence on foreign oil all accelerate the drive toward energy-efficient, clean technologies and practices.
How is DOE's Industrial Technologies Program (ITP) meeting these challenges? What's in store for the future?
The emphasis on efficiency as an energy resource puts ITP in the spotlight, as it fortifies its current programs and gears up for new ways to reduce U.S. industrial energy use.
New legislation signed into law in December 2007, boosts federal support of energy-efficiency programs, expanding the commitment of the Energy Policy Act of 2005 (EPAct) (PDF 3.1 MB). Download Adobe Reader. EPAct calls for 25% reduction in energy use by 2017, a goal ITP targets through its many program elements.
Since 1979, ITP has been committed to improving U.S. industrial energy efficiency and productivity, reducing carbon emissions, and enhancing national energy security. Through activities such as Save Energy Now, BestPractices tools and resources, partnerships with states and trade associations, data center efficiency efforts, and a comprehensive R&D portfolio, ITP offers real solutions for industry.
The common thread running through ITP's long history of industrial energy efficiency is collaboration. Creating working alliances with private companies, trade organizations, states, utilities, and universities has been the key to the program's success.
Continuing Collaborations to Meet Industrial Efficiency Needs
ITP leads federal efforts to improve industrial energy efficiency, environmental performance, and competitiveness through a solid foundation of partnerships such as the following.
Teaming Up with Industry to Save Energy Now
A key ITP partnering activity is its Save Energy Now campaign, which continues to help U.S. companies find energy-saving opportunities in their facilities. Since 2005, more than 450 of the nation's most energy-intensive industrial plants have participated in this effort, resulting in total implemented energy savings of approximately $95 million to date. Through this campaign, ITP provides resources to help companies like Alcoa, Boise Cascade, J.R. Simplot, and many others identify energy and cost-saving opportunities in their facilities.
An essential component of Save Energy Now is its 3-day plant energy assessments. In these assessments, companies team up with a DOE Energy Expert or Industrial Assessment Center to gauge a plant's energy use, and find ways to optimize systems. This highly successful project has evolved into a major activity, as ITP increased the number of assessments performed each year and expanded the types of systems targeted. Results show that large plants can cut their total energy use by an average of 8%, or more than $2.5 million per year.
Last year, DOE recognized about 170 plants as Energy Champions and Energy Savers. These companies implemented recommendations from Save Energy Now energy assessments that have resulted in a cumulative savings of 13.8 trillion Btu—worth more than $73 million.
Partnering to Meet Challenges of Energy-Hungry Data Centers
The rapid growth of energy-intensive data centers, which account for about 1.5% of all U.S. retail electricity sales, has triggered efforts to improve the energy efficiency in this sector. Improved data center efficiency could save 20 billion kWh per year by 2015, and potentially defer the need to build an additional 2,300 MW of new generating capacity. Using the Save Energy Now assessment model, ITP is working to meet data efficiency challenges through activities such as energy assessments, software tool development, training for data center energy managers, and partnerships.
In 2007, DOE signed an agreement with The Green Grid, a consortium of information technology companies and associations, to work together to help data center facilities implement energy management programs and adopt clean energy technologies. The Green Grid focuses on improving energy efficiency in data centers through research, standards development, published studies, and continuing education.
Joining Forces to Develop Cutting-Edge Innovations
ITP's R&D of energy-efficient technologies is another important collaboration. These partnerships have produced more than 600 energy-saving technologies, 220 of which have entered the marketplace. These technologies pack a powerful punch by delivering better performance for both specific industries and cross-cutting manufacturing processes while saving energy. Read ITP's new report, Energy Technology Solutions: Public-Private Partnerships Transforming Industry (PDF 3.7 MB) for details on technologies commercially available and those expected to enter the marketplace in the near future. Download Adobe Reader. Through its diverse R&D portfolio and technical assistance to U.S. industry, ITP has helped save nearly 5 quadrillion Btu of energy, equivalent to 86 million metric tons of carbon emissions.
Watch the ITP Solicitations Web site for an announcement in late February or early March 2008 of a new funding opportunity. This solicitation will seek proposals for R&D of transformational technologies for energy-intensive industrial processes. The areas of interest include: iron and steelmaking; alternative chemical processes; forest products; energy-intensive processes; industrial reactions and separation; sustainable manufacturing; and waste heat minimization and recovery. Through solicitations, ITP offers cost-shared awards for R&D of technologies that will reduce energy and environmental impacts, and enhance the economic competitiveness of U.S. industries.
Working at the Local Level to Boost National Efficiency
In 2007, ITP ramped up its efforts to tackle industrial energy efficiency at the state level, where the greatest impact can be achieved. Nineteen states were chosen to receive Save Energy Now energy assessments through a state solicitation, new partnerships were formed, and resources were made available to assist state activities.
DOE and the State of Wisconsin signed the first agreement to address industrial energy use throughout the state. This is an important step in leveraging and supporting each state's own capabilities. More information.
In response to a solicitation issued by DOE, ITP selected 19 states to receive a total of 96 industrial plant assessments at local facilities. The awarded projects totaled $950,000, and they represent 5.8 trillion Btu in potential natural gas savings. They could also reduce carbon dioxide emissions of 390,000 metric tons per year. Read about the awards.
Also, ITP formed a partnership with the National Association of State Energy Officials to develop state outreach programs to provide assistance and information to industrial partners through state energy offices. In another effort, DOE is providing training resources to Purdue University's Technical Assistance Program for a new worker training and energy efficiency certification program (see the Fall 2007 issue of Energy Matters for details).
Visit ITP's new State Activities Web site to find out what's happening in your state, including energy statistics, economic indicators, events and training, R&D, and which companies have completed a Save Energy Now energy assessment.
Industrial Assessment Centers Work Together with Manufacturers
The 26 university-based Industrial Assessment Centers (IAC) can be a win-win for everyone involved. They improve industrial efficiency by providing no-cost plant assessments for small- and medium-sized manufacturers, and the hands-on training they provide helps to develop tomorrow's energy engineers. Since the program's inception in 1976, IACs have saved U.S. companies $700 million in energy costs. Recently, North Carolina State University's IAC received an award of appreciation for plant assessments conducted on industrial facilities in the Danville, Virginia, area.
In 2007, IACs and the Manufacturing Extension Partnership joined forces to offer an expanded reach of services to small- and medium-sized plants, which will include plant assessments, technical tools and information, and training opportunities.
Reaching Out Through New U.S. and International Partnerships
In 2007, ITP broadened its range of opportunities to meet energy-efficiency challenges through two new U.S. partnerships and an international outreach effort.
ITP worked with industry, government, and nonprofit organizations to kick off the Superior Energy Performance (SEP) partnership, which aims to improve the energy intensity of U.S. manufacturing 25% by 2017 through voluntary initiatives. Ongoing activities include establishing American National Standards Institute (ANSI) criterion for energy management and systems assessments; and developing ANSI-accredited plant certification and practitioner programs. SEP launched the Energy Quick Start Web site, which includes a comprehensive listing of energy efficiency and conservation resources that are available from public and nonprofit sources.
Another new partnership was launched in June 2007, as DOE and the National Association of Manufacturers (NAM), joined forces to meet U.S. manufacturers' energy efficiency challenges through a new Memorandum of Understanding (MOU). NAM is the nation's largest industry trade member organization, advocating on behalf of manufacturers through legislation and regulatory activities, and providing resources for members. The MOU signifies an important outreach effort to merge DOE's portfolio of technologies and energy-saving resources with NAM's connection to 14,000 member companies.
DOE also signed a MOU in mid-September 2007 with China's National Development Reform Committee (NDRC) to increase cooperation and energy efficiency in the country's industrial sector, which accounts for 70% of China's total energy demand. Under the MOU, a DOE team of industrial energy efficiency experts and an NDRC counterpart team will conduct on-site audits of plant production processes and energy systems at up to 12 facilities in China. DOE will provide tools to conduct the plant audits and train factory personnel on plant audit techniques. DOE will also conduct a comparison study of the Chinese enterprises and U.S. manufacturing plants to identify differences in best practices.
BestPractices Pools Resources for Plant Managers
A cornerstone of nearly all ITP activities is its toolbox of practical, hands-on resources for plant personnel. ITP's BestPractices program develops and disseminates information on technical resources, partnership opportunities, and energy management tools for plant managers, corporate executives, technical staff, and the general public. You can access this comprehensive portfolio of helpful software tools, systems-specific and Qualified Specialist training, technical publications, and other resources on ITP's BestPractices Web site, free of charge.
Future Looks Bright with New Initiatives
What's ahead in 2008? ITP is expanding its reach to U.S. industry through these new initiatives currently underway.
Utility Outreach Offers Benefits to Industry Partners
Among the new activities is a partnership with utility companies. Utility companies play a unique role in energy management because of their close relationship with industrial customers. ITP is excited about this new opportunity to work with U.S. utility companies to make industrial facilities more energy efficient, as well as help determine how utilities themselves can become more efficient. A utility action plan is scheduled to be completed in Spring 2008.
Evaluating the Viability of Combined Heat and Power
The passage of the recent Omnibus 2008 Appropriations Act (see sidebar) enables ITP to accelerate its Combined Heat and Power (CHP) activities in 2008. ITP is currently evaluating a range of options, including deployment efforts, with a particular focus on bio-based and opportunity fuels. ITP's continued support of CHP activities includes working with the eight Regional Application Centers and participating in selected demonstrations. The demonstrations will provide third party validation of the performance and benefits of the CHP system.
Exploring the Use of Alternative Fuels in Manufacturing Processes
In 2008, ITP's Fuel and Feedstock Flexibility initiative will begin activities to integrate opportunity fuels into manufacturing processes. Rising and volatile natural gas prices mean higher costs for industry and greater uncertainty about future energy costs. This presents an opportunity to explore the use of alternative fuels in manufacturing processes. This deployment-focused initiative will link industrial users with advanced fuel research taking place throughout DOE, and increase knowledge of fuel and flexibility opportunities within U.S. industry. ITP will explore these options with industry and develop data to assist industry with better understanding the opportunities.
Developing Next-Generation Manufacturing Technologies
In partnership with the Interagency Working Group on Manufacturing R&D, ITP will work to develop integrated and intelligent manufacturing processes to dramatically reduce the energy intensity of the U.S. manufacturing sector. The first step will be a technology roadmap workshop to facilitate collaboration, review priorities, and shape strategies for R&D. Initial research will focus on technologies such as integrated process predictive tools, and wireless real-time sensors systems that are synergistic and adaptable. This initiative will also explore techniques needed for nanomanufacturing to enable the mass production and application of nanoscale materials, structures, devices, and systems to transform industrial processes.
Through all of these partnerships, ongoing and new, ITP has fostered energy-efficient technologies and practices to improve the productivity of manufacturing processes, reduce energy use and costs, and cut harmful emissions. This means increased productivity and profits for companies like yours, and a cleaner environment for everyone.
Super Boiler: A Super Hero of Steam Generation
Steam boilers play a major role in manufacturing, heating, and electricity generation, yet industrial steam generation technology has not undergone any major design breakthroughs in the last 100 years. In fact, about 80% of U.S. boilers are more than 25 years old. This presents an opportunity for a revolutionary technology called the Super Boiler, which is demonstrating improved efficiency, reduced emissions, and lower fuel costs for industry.
In U.S. industry, steam boilers account for about 37% of energy use, mostly in the food, paper, chemicals, refining, and primary metals industries. It costs industry about $18 billion annually just to feed these boilers. New steam generation technologies are currently in development that will substantially increase energy efficiency and reduce environmental impacts for U.S. industry.
An Energy-Efficient and Cost-Effective Solution
Enter the Super Boiler, which combines ultra-high efficiency, low emissions, state-of-the-art controls, and a smaller boiler footprint into a super hero package of steam generation technology. DOE and its partners recently celebrated the success of the initial year-long field test of the Super Boiler at Specification Rubber Products in Alabaster, Alabama, and additional demonstration projects are in the works. DOE predicts that this technology could save industry more than 185 trillion Btu of natural gas by 2020, and about $10 billion in annual energy costs—goals that meet immediate needs for efficient steam technology solutions and contribute to DOE's strategic, long-term Super Boiler 2020 program.
From Development to Demonstration to Commercial Market
DOE's Industrial Technologies Program (ITP) partnered with Gas Technology Institute (GTI) and Cleaver-Brooks, Inc. to develop the Super Boiler, a first-generation package boiler that increases efficiency, reduces emissions, and requires less floor space than conventional boilers. The two-stage firetube design includes a transport membrane condenser (TMC) and compact humidifying air heater (HAH) to extract sensible and latent heat from the flue gas for increased energy efficiency; compact convective zones with intensive heat transfer; state-of-the-art controls; and a staged/intercooled combustion system for ultra-low emissions (see "How Does It Work?").
"The development of this technology is being driven primarily by rising energy prices, combined with increasingly stringent emissions regulations," explained GTI's Rick Knight, Technology Development Manager, Power Generation. "Today, industry, manufacturers, and the government are teaming with GTI to develop cleaner, more efficient ways to use fossil fuels."
In the initial field demonstration, a single-stage 300-hp boiler was installed at Specification Rubber Products, a rubber gasket manufacturer, where it has operated successfully for more than 8,000 hours. The boiler demonstrated a fuel-to-steam efficiency of 93%-94% and reduced NOx levels to less than 9 parts per million. It also cut annual natural gas use by 13%, and reduced makeup water consumption by more than 6%. Beginning in January 2008, the second field test will use a two-stage unit and be conducted at Clement Pappas & Company, a fruit juice manufacturer in Ontario, California. In addition, a TMC retrofit project on a conventional boiler is being scheduled at Third Dimension Inc., a cabinet packaging facility in West Jordan, Utah. View the Super Boiler Overview video.
At all of these sites, continued improvements to the technology will move it to commercial marketing of high-efficiency, low-emissions industrial firetube boilers. At present, both the one- and two-stage boiler designs are being considered.
"There is no reason to compromise when tackling energy efficiency, emissions, saving water, saving floor space, and improving operability of industrial boilers," said Knight. "We can do them all."
How Does It Work?
View an animation of the Super Boiler technology (two-stage version).
Save Energy Now Assessment Helps Energy Savings Grow for Fertilizer Company
Improving production and steam system efficiency is a top priority for Terra Nitrogen Company, L.P., a major U.S. producer of nitrogen fertilizer products. Although Terra Nitrogen already had an active energy savings program in place, a DOE Save Energy Now energy assessment was performed to identify additional energy savings opportunities. DOE Energy Expert Veerasamy Venkatesan of VGAEC, Inc., worked with plant personnel to analyze the plant's energy-consuming steam system.
Nitrogen fertilizer manufacturing captures naturally occurring nitrogen from the atmosphere and combines it with hydrogen from natural gas under heat and pressure to form anhydrous ammonia. Ammonia is then applied directly to crops as a nitrogen fertilizer and used as a building block to make other nitrogen fertilizer products, such as urea ammonium nitrate solution.
Each year, Terra Nitrogen's manufacturing facility in Verdigris, Oklahoma, produces 2.2 million tons of urea ammonium nitrate solution and 1.1 million tons of ammonia. The plant requires significant amounts of natural gas to produce hydrogen and fuel its steam systems, which provide critical support to the ammonia production processes. As a result, natural gas costs account for most of Terra Nitrogen's total expenses—approximately $7 per MMBtu.
Steam Software Tools Reveal Energy-Saving Potential
"One of the most beneficial aspects of the assessment was that the DOE Energy Expert validated several existing projects so they could be justified and approved by management," said Dallas Robinson, Plant Manager for Terra Nitrogen.
For example, before the energy assessment, Terra Nitrogen had installed a loop dehydrator in its ammonia plant #1. While plant management understood the potential for significant natural gas savings from this project, the analysis performed using DOE's Steam System Assessment Tool (SSAT) confirmed the scale of potential energy savings resulting from not only installing a loop dehydrator, but also retrofitting a back-pressure turbine with a condensing turbine in ammonia plant #2.
In fact, analyzing the steam system proved to be so beneficial that it has become an area of focus for Terra Nitrogen's maintenance plan. "The SSAT pointed out the importance and cost savings of good steam trap maintenance," remarked Robinson. "We took the next step by bringing in a steam trap manufacturer to train our mechanics and third party insulating contractors on proper installation, assessment, and replacement techniques."
From Implementation to Energy Savings
Terra Nitrogen approved and successfully implemented five of the eight improvement projects revealed during the Save Energy Now assessment to save approximately $3.5 million and 497,000 MMBtu in natural gas annually, with a simple payback of 11 months.
"The Save Energy Now assessment process is valuable because it highlights and validates existing programs and uncovers potential blind spots (processes, equipment, and cost evaluations) in energy losses and costs," stated Robinson. "The resulting energy savings were real and on target, and the savings were significant."
Ask an Energy Expert: Assessing Compressed Air Systems
A new year brings ideas for new ventures. In this first issue of 2008, Energy Matters is kicking off its Ask an Energy Expert column. This new regular feature will address issues that involve energy efficiency of compressed air, fans, process heating, pumping, and steam systems. The column will answer frequently asked questions that arise during Save Energy Now energy assessments, and will be authored by DOE's Energy Experts, who are skilled at helping industrial facilities identify ways to improve system efficiency.
In this issue, Tom Taranto, a Compressed Air Energy Expert, offers Energy Matters readers the answers to some common questions he has encountered during energy assessments on compressed air systems.
What benchmarks can I use to check my compressed air system efficiency?
Compressed air systems and the industries they serve are very diverse. As a result, statistical data necessary to establish industry benchmarks are not available. There are however, two important measures of compressed air system efficiency; the total air demand of the system, and the compressed air supply efficiency (CASE).
Air demand can be measured in million standard cubic feet (MMscf) consumed over some period of time, for example, daily, such as MMscf/day. According to Compressed Air Challenge® Fundamentals of Compressed Air Systems training, 50% or more of the compressed air supplied to a typical air system is wasted. It is important to eliminate waste, including leakage, artificial demand, and inappropriate use of compressed air.
One measure of compressed air supply efficiency is the CASE Index, determined by metering energy (kWh) entering, and measuring compressed airflow (in standard cubic feet per minute, or scfm) leaving the compressed air plant. CASE Index is measured as standard cubic feet (scf) per unit of energy (kWh). It has a potential range from 0 to 325; higher indices represent better efficiencies.
Another measure of supply efficiency is specific power (kW/100 cubic feet per minute, or cfm), as listed on Compressed Air and Gas Institute (CAGI) standard performance reporting data sheets for air compressors and dryers. See these data sheets in Appendix C of Improving Compressed Air System Efficiency: A Sourcebook for Industry (PDF 1.1 MB). Download Adobe Reader. Equipment efficiency, operating in test lab conditions, is reported as "Specific Package Input Power" and may range from 16 to 24 kW/100 cfm (lower specific power represents better efficiency).
The actual plant air system energy efficiency is affected by many factors, including part-load efficiency, control strategy, and the system's supply/demand balance. Increased system efficiency will result in your plant air system's performance more closely approaching the specific package input power of your equipment.
- Compressed Air Tip Sheet #3: Minimize Compressed Air Leaks (PDF 265 KB) Download Adobe Reader.
- Compressed Air Tip Sheet #4: Analyzing Your Compressed Air System (PDF 243 KB)
- Compressed Air Tip Sheet #7: Compressed Air Systems Control Strategies (PDF 243 KB)
I have heard about "inappropriate use of compressed air." What makes air use inappropriate?
Compressed air power is essential to the operation of most industrial manufacturing and process facilities. However, compressed air as an energy source is extremely inefficient. For many compressed air uses, there are alternatives in equipment or methods that use a more efficient energy source. If the alternative can accomplish the manufacturing task, it may be inappropriate to use compressed air. On the other hand, careful consideration of other factors such as reliability and maintenance may determine that while it is less efficient, compressed air use is still the best choice.
More than 85% of the electrical energy input to an air compressor is lost to waste heat. That leaves less than 15% of the electrical energy consumed to be converted to pneumatic compressed air energy. For the typical plant air system operating at 100 pounds per square inch gauge (psig), 7.5 horsepower (hp) is consumed by the air compressor to deliver 1 hp of work to the manufacturing process.
One example of inappropriate use that is frequently found is a blowing application that uses compressed air to cool, clean, or dry surfaces. Application of low-pressure blowers or fans can often accomplish the blowing task with significant energy savings. High pressure compressed air is often used for sparging, or agitating a tank of liquid by blowing bubbles through the liquid. Again, low-pressure blowers can be a more efficient energy source. Tank unloading involves pressurizing a tank truck or rail car with air to force the liquid out of the tank. For many liquid tanks it is recommended that the air pressure be regulated to 18 psig maximum with a safety relief valve set at 20 psig to protect the tank. If air padding is the preferred method to unload the tank, positive displacement-type blowers can provide the necessary airflow and pressure. The use of an electrically driven pump should also be considered.
- Compressed Air Tip Sheet #2: Eliminate Inappropriate Uses of Compressed Air (PDF 262 KB) Download Adobe Reader.
- Compressed Air Tip Sheet #11: Alternative Strategies for Low-Pressure End Uses (PDF 247 KB)
Questions/comments about this column? Contact Tom Taranto at: TomTar@aol.com.
Tom Taranto is an independent compressed air system professional with more than 30 years of experience providing services to industrial clients, utilities, and energy agencies. He is the owner of Data Power Services, LLC. In addition, he is a DOE Compressed Air Energy Expert, senior instructor for Qualified AIRMaster+ Specialists, and instructor for Compressed Air Challenge® Fundamentals and Advanced courses. Tom holds a Bachelors degree in Mechanical Engineering from Clarkson University.
Please submit your own questions about industrial systems management for consideration in future issues to the Energy Matters Editor.
DOE Industrial Software Tools Go Metric
The U.S. Department of Energy's Industrial Technologies Program (ITP) has just released new versions of two industrial energy system assessment tools that enable data measurements in both English and metric units. AirMaster+ Version 1.2.0 and the Pumping System Assessment Tool (PSAT) 2008 are part of ITP's popular suite of software tools that help industrial users evaluate the efficiency of their current compressed air and pumping systems, and identify opportunities for potential improvements. The new metric options give users greater flexibility in assessing a wider range of equipment.
In more ways than before, AirMaster+ Version 1.2.0, for compressed system analysis, and PSAT 2008, for pumping system analysis, can help industrial users target opportunities to boost efficiency and the bottom line in their manufacturing plants.
AIRMaster+ Makes It Easy to Identify Compressed Air System Improvements
AIRMaster+ provides a systematic approach for assessing the supply-side performance of compressed air systems. Using plant-specific data, this tool helps you evaluate operational costs for various equipment configurations and system profiles. It also calculates potential cost savings and simple payback periods.
With its new features, you can input either English or metric data on pressure selections and airflows, and shift between units for comparison. Then, save these unit selections in your company files and access them in future analyses. To help you figure implementation costs and cost savings into the decision-making equation, AirMaster+ Version 1.2.0 also includes a currency selection feature. In addition, this enhanced tool is equipped with regional and language setting capabilities to customize each analysis even further.
AIRMaster+ Version 1.2.0 offers a world of possibilities for improving compressed air system performance. Learn more and download AirMaster+ Version 1.2.0 today to find the right savings scenario for your compressed air systems.
PSAT Helps You Prime the Pumping Savings
ITP's time-tested PSAT software is your resource to estimate and prioritize potential energy and dollar savings in industrial pumping systems using data that is typically available or easily obtained in the field, such as pump head, flow rate, and motor power. PSAT's prescreening filter shows areas that are likely to offer the greatest savings and helps you target symptoms of inefficiency.
PSAT is still a straightforward and proven tool for quickly assessing the optimization potential in existing pumping systems. However, the new version, PSAT 2008, and its accompanying valve tool, expands the versatility with options for entering, converting, and obtaining key data in either English or metric units.
More New Features for PSAT 2008
As always, PSAT 2008 uses achievable pump performance data from Hydraulic Institute standards and motor performance data from ITP's MotorMaster+ database to calculate potential savings. In addition, this updated version includes several new features that enhance its capabilities. For example, you can specify the optimal pump efficiency and existing motor efficiency ratings.
PSAT 2008 also lets you save and retrieve log files, default values, and system curves, making it easier to share analyses with other users. If you are currently using PSAT 2004, the new tool contains a utility to update log and summary files to PSAT 2008.
Download PSAT 2008 today, and start saving energy and money in your industrial pumping systems
ITP's Tools Target Energy Savings Opportunities
AIRMaster+ Version 1.2.0 and PSAT 2008 join MotorMaster+ International as part of the ITP's collection of software tools with metric capabilities to help you evaluate a broad range of energy systems. Use ITP's complete collection of BestPractices software tools, as part of a strategy for energy efficiency and cost savings in your plant. All of these tools are available to you free of charge. To increase your knowledge and get the most from the tools, attend a related BestPractices training session, or contact a Qualified Specialist, an industry professional who has advanced training and experience in using the tools.
For more information on any of these BestPractices resources, contact the EERE Information Center, or call 1-877-EERE-INF (1-877-337-3463).
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