Pumping systems offer a tremendous opportunity for improvements in Operation and Maintenance (O&M) costs.

Obviously, new designs have a clean slate, so to speak, and the insightful designer is offered a broad spectrum of design alternatives and associated benefits (or not) for the end user/operations staff.  In such situations, the key parameter or benchmark should always keep “life-cycle-costs” in its solutions or recommendations.

Field conditions can create difficulty in obtaining valid system data

Existing pumping stations, likewise, hold a wide reservoir of potential for improvements – ranging from motor upgrades to control system replacements.  An important element of any upgrade will be the field survey of existing systems.  Such a survey should have a well developed plan or strategy from the onset.  An integral part of the plan would include measurement of key operating parameters.  Listing these and preparing a tabulation for use in later design phases will be important in its variety and its specificity.  Here are suggested measurements for pumping systems – just as a starter:

1. Motor amps and watts under various load and no-load conditions
2. If variable speed drives, take multiple measurements at corresponding points with pump discharge pressure, flow, and watts/amps recorded at specific flows/heads.
3. Note location of the pressure gauges and flow measurement devices ( a photo would be the optimum for this).
4. Measure static pressure with the pump off…be sure you have the gauge located where it can read static pressure (ahead of any check valve).
5. Take measurements 1, 2, and 3 with pumps “off”, pumps on  and multiple pumps on (in multiple pump stations).
6. Note motor model and serial numbers; likewise for pumps and controls.
7. Borrow a portable watt meter and record flow (you may also need a portable flow meter), watts and speed for at least a few days in sequence.
8. Request digital watt meter data for the pumping station from the electric power company serving your community or utility.  This data can reveal unusual conditions which might be triggering higher peak demand charges.
9. Obtain 12 months of electric utility bills for the pumping station and examine these for demand charges and other rate premium charges.

In his famous books, Steven Covey states it best:

“Begin with the end in mind.  Particularly in a field study in field conditions, a good set of tools and a firm set of data requirements can be the difference between exceptional and “just average” for pumping station systems upgrades.”

Don’t leave home without it!

Don