Industrial electrical motors account for two-thirds of the US industrial electricity usage. Pumping systems account for an estimated 25 percent of this electrical motor consumption, while pumping systems in use in US chemical facilities consume over 37,000 GWh/year, based on US Department of Energy (DOE) data. A study funded by DOE estimates potential energy savings within the chemical industry alone of approximately 20 percent, representing an energy savings of over 7,500 GWh/year, through industrial pumping systems optimization using existing, proven techniques and technologies. This energy savings potential represents significant cost savings potential for industrial facilities. Additionally, it has been shown that energy efficiency improvements to industrial systems usually provide improved reliability, improved productivity, and reduced environmental costs.

Industries worldwide depend upon pumping systems for their daily operation. These systems account for nearly 20 percent of the world's industrial electrical energy demand and range from 25-50 percent of the energy usage in certain industrial plant operations. Purchase decisions for a pump and its related system components are typically based upon a low bid, rather than the cost to operate the system over its lifetime. Additionally, plant facilities personnel are typically focussed on maintaining existing pumping system reliability rather than optimizing the systems for best energy efficiency. To ensure the lowest energy and maintenance costs, equipment life, and other benefits, the system components must be carefully matched to each other, and remain so throughout their working lives. Life Cycle Cost (LCC) analysis is a tool that can help companies minimize costs and maximize energy efficiency for many types of systems, including pumping systems. Increasing industry awareness of the total cost of pumping system ownership through life cycle cost analysis is a goal of the US Department of Energy (DOE). This paper will discuss what DOE and its industry partners are doing to create this awareness. A guide book, Pump Life Cycle Costs: A Guide to LCC Analysis for Pumping Systems, developed by the Hydraulic Institute (HI) and Europump (two pump manufacturer trade associations) with DOE involvement, will be overviewed. This guide book is the result of the diligent efforts of many members of both associations, and has been reviewed by a group of industrial end-users. The HI/Europump Guide provides detailed guidance on the design and maintenance of pumping systems to minimize the cost of ownership, as well as LCC analysis. DOE, Hydraulic Institute, and other organizations' efforts to promote LCC analysis, such as pump manufacturers adopting LCC analysis as a marketing strategy, will be highlighted and a relevant case study provided.

In 1996, the US Department of Energy s Office of Industrial Technologies (OIT) Motor Challenge program began a unique collaboration with industry called the Allied Partner program. Partnerships were sought with equipment suppliers and manufacturers, utilities, consultants, and state agencies that had extensive existing relationships with industrial customers. Partners were neither paid nor charged a fee for participation. The assumption was that these relationships could serve as the foundation for conveying a motor system efficiency message to many more industrial facilities than could be reached through a typical government-to-end-user program model. A substantial effort was made to engage industrial suppliers in delivering program information as part of their customer interactions. A recent independent evaluation of the Motor Challenge program attributes $16.9 million or nearly 67 percent of the total annual program energy savings to the efforts of Allied Partners in the first three years of operation.In 1997, the Compressed Air Challenge(R) (CAC) was developed as an outgrowth of the partnership concept. In this model, OIT is one of 15 sponsors who collaborated to create a national program of compressed air system training. The CAC has gone a step further by setting up a development and deployment model based on shared interests and shared costs among public, private, and not-for-profit organizations that serve industrial customers. Since the first CAC training session in 1999, approximately 3800 people have been trained by CAC qualified instructors--both end users and suppliers. More impressively, the entire compressed air market has begun to shift from a component-based to a system-based approach, largely as the result of collaboration. The typical leverage for OIT participation in a CAC training session is 10:1.During the past year, OIT has reorganized to integrate all of its near-term industrial offerings such as the Motor, Compressed Air, and Steam Challenges under a single program, BestPractices. As part of this reorganization, the Allied Partner program has been reshaped to extend the impact of all BestPractices program activities. This new model, which is still evolving, is based on the best of the former Motor Challenge, but is more ambitious concerning the level of collaborative activities negotiated with Allied Partners. For example, partnerships with 7 member companies of the Hydraulic Institute (HI) involve preparing their staff to become qualified to use and train customers to use OIT s Pumping System Assessment Tool (PSAT). These pumping industry experts will provide a public benefit by greatly increasing customer access to PSAT training and awareness of the systems approach. Participating HI member companies are anticipating a business benefit by providing a valuable service to key customers that is associated with USDOE.

Since 1996, the US Department of Energy's Office of Industrial Technologies (USDOE) has been involved in a unique voluntary collaboration with industry called the Allied Partner program. Initially developed under the Motor Challenge program, the partnership concept continues as a central element of USDOE's BestPractices, which in 2001 integrated all of USDOE's near-term industrial program offerings including those in motors, compressed air, pump, fan, process heating and steam systems. Partnerships are sought with end use industrial companies as well as equipment suppliers and manufacturers, utilities, consultants, and state agencies that have extensive existing relationships with industrial customers. Partners are neither paid nor charged a fee for participation. Since the inception of Allied Partners, the assumption has been that these relationships could serve as the foundation for conveying a system energy-efficiency message to many more industrial facilities than could be reached through a typical government-to-end-user program model. An independent evaluation of the Motor Challenge program, reported at the last EEMODS conference, attributed US $16.9 million or nearly 67 percent of the total annual program energy savings to the efforts of Allied Partners in the first three years of operation. A recent evaluation of the Compressed Air Challenger, which grew out of the former Motor Challenger program, attribute additional energy savings from compressed air training alone at US $12.1 million per year. Since the reorganization under BestPractices, the Allied Partner program has been reshaped to extend the impact of all BestPractices program activities. This new model is more ambitious than the former Motor Challenge program concerning the level of collaborative activities negotiated with Allied Partners. This paper describes in detail two new types of program initiatives involving Allied Partners: Qualified Specialist Training and Energy Events. The Qualified Specialist activity was conceived as a way of engaging the supply side of industry, consultants, and utilities to greatly increase use of decision making software developed by USDOE to assist industrial facilities in assessing the energy efficiency of their energy-using systems. To date, USDOE has launched Qualified Specialist training with member companies of the Hydraulic Institute (HI) and with distributors and consultants associated with the Compressed Air Challenge. These activities train and qualify industry professionals to use and to train customers to use USDOE's Pumping System Assessment Tool (PSAT) and AIRMaster + software programs, respectively. The industry experts provide a public benefit by greatly increasing customer access to the software and assessment techniques. Participating Specialists anticipate a business benefit by providing a valuable service to key customers that is associated with USDOE. The Energy Event concept was developed in 2001 in cooperation with the California Energy Commission in response to the state's energy crisis and has been extended to other geographic areas during 2002. The three California events, named "Energy Solutions for California Industry," relied on Allied Partners to provide system-based solutions to industrial companies as both speakers and exhibitors. These one-day events developed a model for a serious solutions-oriented format that avoids the typical trade show atmosphere through strict exhibitor guidelines, careful screening of speaker topics, and reliance on case studies to illustrate cost- and energy-saving opportunities from applying a systems approach. Future plans to use this activity model are discussed as well as lessons learned from the California series.