1、 ASME EA-2G2010Guidance for ASME EA-2, Energy Assessment for Pumping Systems(ANSI Designation: ASME TR EA-2G2010)AN ASME TECHNICAL REPORTINTENTIONALLY LEFT BLANKASME EA-2G2010Guidance for ASME EA-2, Energy Assessment for Pumping Systems(ANSI Designation: ASME TR EA-2G2010)Three Park Avenue New York,
2、 NY 10016 USAA TECHNICAL REPORT PREPARED BY ASME AND REGISTERED WITH ANSIDate of Issuance: September 24, 2010This Guide will be revised when the Society approves the issuance of a new edition. There will be no addenda or written interpretations of the requirements of this Guide issued to this editio
3、n.ASME is the registered trademark of The American Society of Mechanical Engineers.ASME does not approve, rate, or endorse any item, construction, proprietary device, or activity.ASME does not take any position with respect to the validity of any patent rights asserted in connection with any items m
4、entioned in this document, and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable letters patent, nor assumes any such liability. Users of a code or standard are expressly advised that determination of the validity of any such patent rights,
5、 and the risk of infringement of such rights, is entirely their own responsibility.Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code or standard.ASME accepts responsibility for only thos
6、e interpretations of this document issued in accordance with the established ASME procedures and policies, which precludes the issuance of interpretations by individuals.No part of this document may be reproduced in any form,in an electronic retrieval system or otherwise,without the prior written pe
7、rmission of the publisher.The American Society of Mechanical EngineersThree Park Avenue, New York, NY 10016-5990Copyright 2010 byTHE AMERICAN SOCIETY OF MECHANICAL ENGINEERSAll rights reservedPrinted in U.S.A.iiiCONTENTSForeword ivCommittee Roster vCorrespondence With the EA Committee . vi1 Scope 12
8、 Introduction to Pumping Systems . 13 Overview of the Standard: How to Use ASME EA-2 . 64 Guide to Organizing the Assessment 75 Guide to Conducting the Assessment . 106 Guide to Analysis of Data From the Assessment . 167 Guide to Reporting and Documentation 20Figures1 Example Pumping System . 22 Exa
9、mple of Hourly Flow Demand in a Building 133 Example of Annual Variation of Flow Rate Demand . 134 Example of Daily Variations of Flow Rate Demand . 145 Typical Annualized Duration Curve 146 Flow Rate Duration Diagram . 157 Flow Rate Duration Diagram Using Two Pumps One Large and One Small . 158 Sim
10、plified Flow Diagram for Examples 1 and 2 . 179 Provided Versus Required Flow 1810 Required Energy Use and the Different Types of Excess Energy Use . 1911 Example of Process Diagram . 2112 Example Flow Balance 2313 Annual Flow Profile Example 2414 Simple Pumping System Schematic 24Tables1 Energy Uni
11、t Cost Summary . 92 Assessment Level Overview 103 Example Flow Duration Summary Table . 134 Existing Versus Optimal Analysis Results (Example 1) . 175 Power Waste-Based Analysis Results (Example 2) . 206 Example Project Summary Table Format for a Level 2 or 3 Assessment . 217 Equipment Nameplate Dat
12、a 228 Measurement Methods . 239 Flow Data From Distributed Control System 2410 Flow Interval Data . 2511 Electrical Measurements . 2512 Pump Operating Hours 2613 Baseline Data 2614 Pump Efficiency Calculations 2715 Project Savings and Cost Summary 27Nonmandatory AppendicesA References . 29B Expanded
13、 Glossary . 30ivFOREWORDThis guidance document provides technical background and application details in support of the understanding and application of ASME EA-2, Energy Assessment for Pumping Systems. This guidance document provides background and supporting information to assist in applying the st
14、andard. The guidance document covers such topics as rationale for the technical requirements of the assessment standard, technical guidance, application notes, alternative approaches, tips, techniques, rules of thumb, and example results from fulfilling the requirements of the assessment standard. T
15、his guidance document was developed to be used as an application guide on how to utilize ASME EA-2.ASME EA-2 provides a standardized framework for conducting an assessment of pumping systems. A pumping system is defined as one or more pumps and those interacting or interrelating elements that togeth
16、er accomplish the desired work of moving a fluid. A pumping system thus generally includes pump(s), driver(s), drives, distribution pip-ing, valves, sealing systems, controls, instrumentation, and end-use equipment such as heat exchangers. Assessments performed using the requirements set by ASME EA-
17、2 involve collecting and analyzing system design, operation, energy use, and performance data and identifying energy performance improvement opportunities for system optimization. These assessments may also include additional information, such as recommendations for improving resource utiliza-tion,
18、reducing per-unit production costs, reducing life cycle costs, and improving environmental performance of the assessed system(s). ASME EA-2 provides a common definition for what constitutes an assessment for both users and providers of assess-ment services. The objective is to provide clarity for th
19、ese types of services that have been variously described as energy assessments, energy audits, energy surveys, and energy studies. In all cases, systems (energy-using logical groups of equipment organized to perform a specific function) are analyzed through various techniques such as measurement, re
20、sulting in the identification, documentation, and prioritization of energy performance improvement opportunities. This Guide is part of a portfolio of documents and other efforts designed to improve the energy efficiency of facili-ties. Initially, assessment standards and guidance documents are bein
21、g developed for compressed air, process heating, pumping, and steam systems. Other related existing and planned efforts to improve the efficiency of facilities include(a) ASME Assessment Standards, which set the requirements for conducting and reporting the results of a com-pressed air, process heat
22、ing, pumping, and steam assessments(b) a certification program for each ASME assessment standard that recognizes certified practitioners as individu-als who have demonstrated, via a professional qualifying exam, that they have the necessary knowledge and skills to apply the assessment standard prope
23、rly(c) an energy management standard, A Management System for Energy, ANSI/MSE 2000:2008, which is a stand-ardized approach to managing energy supply, demand, reliability, purchase, storage, use, and disposal and is used to control and reduce an organizations energy costs and energy-related environm
24、ental impactNOTE: ANSI/MSE 2000:2008 will eventually be superseded by ISO 50001, now under development.(d) an ANSI measurement and verification protocol that includes methodologies for verifying the results of energy efficiency projects(e) a program, Superior Energy Performance, that will offer an A
25、NSI-accredited certification for energy efficiency through application of ANSI/MSE 2000:2008 and documentation of a specified improvement in energy performance using the ANSI measurement and verification protocolThe complementary documents described above, when used together, will assist organizatio
26、ns seeking to establish and implement company-wide or site-wide energy plans.Publication of this Technical Report that has been registered with ANSI has been approved by ASME. This document is registered as a Technical Report according to the Procedures for the Registration of Technical Reports with
27、 ANSI. This document is not an American National Standard, and the material contained herein is not normative in nature. Comments on the content of this document should be sent to the Managing Director, Technical, Codes and Standards, ASME.vEA INDUSTRIAL SYSTEM ENERGY ASSESSMENT STANDARDS COMMITTEE(
28、The following is the roster of the Committee at the time of approval of this Guide.)STANDARDS COMMITTEE OFFICERSF. P. Fendt, ChairP. E. Sheaffer, Vice ChairR. L. Crane, SecretarySTANDARDS COMMITTEE PERSONNELJ. A. Almaguer, The Dow Chemical Co.R. D. Bessette, Council of Industrial Boiler OwnersR. L.
29、Crane, The American Society of Mechanical EngineersG. T. Cunningham, Tennessee Tech UniversityT. J. Dunn, Weyerhaeuser Co.F. P. Fendt, The Dow Chemical Co.A. R. Ganji, San Francisco State UniversityJ. C. Ghislain, Ford Motor Co.T. A. Gunderzik, XCEL EnergyS. J. Korellis, Contributing Member, Electri
30、c Power Research InstituteA. T. McKane, Lawrence Berkeley National LaboratoryW. A. Meffert, Georgia Institute of TechnologyJ. L. Nicol, Science Applications International Corp.J. D. Rees, North Carolina State UniversityP. E. Scheihing, U.S. Department of EnergyP. E. Sheaffer, Resource Dynamics Corp.
31、V. C. Tutterow, Project Performance Corp. L. Whitehead, Tennessee Valley AuthorityA. L. Wright, Oak Ridge National LaboratoryR. G. Wroblewski, Productive Energy Solutions, LLCV. C. Tutterow, Chair, Project Performance Corp.S. A. Bolles, Vice Chair, Process Energy Services, LLCD. F. Cox, Vice Chair,
32、Oak Ridge National LaboratoryG. O. Hovstadius, Vice Chair, G. Hovstadius Consulting, LLCP. E. Sheaffer, Secretary, Resource Dynamics Corp.W. V. Adams, Flowserve Corp.T. L. Angle, Weir Specialty PumpsD. A. Casada, Diagnostic Solutions, LLCA. R. Fraser, Eugene Water selecting the correct valve for an
33、application depends on a number of factors, such as ease of maintenance, reli-ability, leakage tendencies, cost, and the frequency with which the valve will be open and shut. Valves can be used to isolate equipment or regulate flow. Isolation valves are designed to seal off a part of a system for op
34、erating purposes or maintenance. Flow-regulating valves either restrict flow through a system branch (throttle valve) or allow flow around it (bypass valve). A throttle valve controls flow by increasing or decreasing the flow resistance across it. In contrast, a bypass valve allows flow to go around
35、 a system compo-nent by increasing or decreasing the flow resistance in a bypass line. A check valve allows fluid to move in only one direction, thus protecting equipment from being pressurized from the wrong direction and helping to keep fluids flowing in the right direction. Check valves are used
36、at the discharge of many pumps to prevent flow reversal when the pump is stopped.2.2.5 Seals and Sealing Systems. The point at which the shaft penetrates the pump casing, known as the stuffing box, provides a leak path that must be sealed. This area is normally sealed using packing or mechan-ical se
37、als. For systems in which fluid leakage is not a significant concern, packing is usually used because it is much less expensive and requires less sophisticated maintenance skills. Mechanical seals provide supe-rior sealing, but they are typically more expensive and harder to repair or replace. Most
38、pumps sold today are provided with mechanical seals.Auxiliary systems are sometimes necessary to control the environment in which the seal operates. Seals in gen-eral are energy efficient devices, but the systems used to control their operating environment may be worth investigating to identify ener
39、gy saving opportunities in some applications. ASME B73.1 and API 682 stand-ards cover typical sealing system arrangements found in industry. Energy consumption of sealing systems can vary widely depending on the type.2.2.5.1 Packing. There are two basic types of pack-ing problems: overtightening and
40、 improper installation. Packing typically requires some leakage in order to remain lubricated and cooled. If packing rings are over tightened, friction between the packing and shaft will generate excessive heat, which can destroy the packing and possibly damage the shaft.Since packing comes in direc
41、t contact with the pump shaft, it wears over time, increasing the leakage rate. Consequently, the packing gland must be periodically tightened to squeeze the packing against the shaft and keep leakage to an acceptable level. Improper packing ASME EA-2G20104installation leads to uneven compression of
42、 the packing rings (overtightening of one, insufficient tightening of others) or an overly loose fit between the packing and shaft. This often results in excessive leakage, which in turn can cause housekeeping problems (such as wet floors), high ambient moisture levels, and, if the fluid is toxic, c
43、ontamination problems. If the fluid is expensive, leakage also has a direct economic cost.2.2.5.2 Mechanical Seals. Mechanical seals are typically used in applications that call for superior sealing. The effectiveness of mechanical seals is highly dependent on correct installation and a continuously
44、 clean operating environment. Mechanical seals have two primary failure mechanisms: degradation of the face material and loss of spring or bellows tension, which allows the faces to separate more easily. Degradation of the seal face is usually caused by debris that wedges into a seal face and causes
45、 damage. To minimize the risk of this type of damage, mechanical seals are often serv-iced by special flushing lines that have filters to catch debris. Seal faces are held together by a force that is usu-ally provided by springs or bellows. However, compres-sive properties are often lost because of
46、fatigue, fouling, and/or corrosive environments, which degrade spring and bellows materials. To minimize fatigue loads on mechanical seals, the seal must be precisely aligned so that spring movement is minimal during each shaft rev-olution. For more information on mechanical seals, see reference 6 i
47、n Nonmandatory Appendix A.2.2.6 end-use equipment. The essential purpose of a pumping system may be to provide cooling, to sup-ply or drain a tank or reservoir, or to provide hydraulic power to a machine. Therefore, the nature of the end-use equipment is a key design consideration in determining how
48、 the piping and valves should be configured. There are many different types of end-use equipment, and the fluid pressurization needs and pressure drops across this equipment vary widely. For heat exchangers, flow is the critical performance characteristic; for hydraulic machinery, pressure is the ke
49、y system need. Pumps and pumping system components must be sized and config-ured according to the needs of the end-use processes.2.3 Principles2.3.1 design Practices. Fluid systems are usually developed to support the needs of other systems. For example, in cooling system applications, the heat trans-fer requirements determine how many heat exchangers are needed, how large each heat exchanger should be, and how much flow is required. Pump capabilities are then calculated based on the system layout and equip-ment characteristics. In other applications, such as muni
