Abstract

ANDRADE CEDENO, Rogger José. Energy Management of a Pump Station using Statistical Process Control. A Case Study: Aqueduct “La Esperanza” – Pacific Refinery. Rev Politéc. (Quito) [online]. 2018, vol.40, n.2, pp.7-18. ISSN 2477-8990.

Energy efficiency is essential for the sustainable development of countries, and has a major impact on both profitability and sustainability of an industry's production. Pump systems are widely used in the industry, and are designed to operate at an optimum duty point; deviation from which will result in an energy waste. Statistical Process Control (SPC) is a quality management tool used for process monitoring and control, that allows the identification of especial causes that produce variation so that they can be removed, achieving continuous improvement. With the application of CEP in the case study, it is detected that the low reliability of the electrical supply causes most plant stops. In addition, it is detected that in continuous operation, the efficiency drops to values lower than 70%, even though the engineering specification of the project establishes a value of 73%. The improvement actions implemented prevent efficiency dropping to less than 72%. With the improved process it is determined that the plant has a sigma level between 3 and 4. Finally, for the economic analysis several scenarios are made depending on the water requirements. It is determined that because of the use of variable speed drives savings are achieved between 57 and 69% (between 1.05 and 2.11 MMUSD), and that because of the use of CEP additional savings are achieved between 2,4 and 5,3% (73 and 127 MUSD).

Keywords : energy efficiency; pump systems; process control systems; variable speed drives; statistical process control; control charts; quality management.

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