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Pump Characteristics
P. S. Mahar 1 and R. P. Singh 2
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Abstract: The total cost of a pumped water supply system includes the capital costs of the pipeline and pumping units, the replacement costs
of various components included, and the energy costs related to the system’s operation. The capital cost of pipeline and energy cost
are nonlinear functions of the pipe diameter. In addition, the pump characteristics, the replacement costs of components, and the escalating
energy costs are of a nonlinear nature. In this paper, a nonlinear optimization model is developed to design a pumping main for required
discharge, static head, pump characteristics, and economic parameters. The optimization model minimizes the total annual cost of the
pumping main and pump, satisfying the pump characteristic curve equations. The applicability of the developed model is demonstrated
with the help of a design example. The optimization model determines the optimal diameter of pumping main with pump efficiency
for a required discharge or optimal discharge range with pump efficiency for an available diameter. The optimization model shows the
effect of escalating costs of components and energy on the size of pumping main. Further, the model can also be used to determine the
optimal operating conditions for a new pumping system or to evaluate an existing pumping system. DOI: 10.1061/(ASCE)PS.1949-1204
.0000157. © 2013 American Society of Civil Engineers.
Author keywords: Optimization model; Pumping main; Capital cost; Energy cost; Pump characteristic curves.
Introduction in Mays and Tung (1992), Lansey (2000), and Bhave (2003).
Lansey and Awumah (1994) minimized energy consumption costs
Water supply systems consist of different components such as res- to determine optimal pump operation schedules for water distribu-
ervoirs/tanks, pumps, pipeline, valves, and fittings. To meet the de- tion systems using dynamic programming. Ormsbee and Lansey
mand of increasing population, the design of a new water supply (1994) reviewed and discussed the optimal control methodologies
system or improvements to an existing one are important problems for water supply pumping systems considering the type of system,
for the designers. The general design problem of a water supply the type of hydraulic model used, the type of demand model used,
system involves minimizing the overall cost of the system subject the type of optimization method used, and the nature of resulting
to meeting the pressure and flow requirements. Conventionally, the optimal control policy.
water supply systems have been designed by trial-and-error meth- In water supply systems, pumping mains transport water over
ods on the basis of engineering judgment. More efficient and ac- long distances to meet the required flow and pressure. As a water
curate optimization methods have been applied to design of water supply system may be subjected to different loading conditions
supply systems during the last four decades, covering various as- (Mays 2004), the pump has to operate at different discharge, head,
pects such as cost of pipe networks, energy costs, pumping oper- and efficiency points. The discharge, head, and efficiency of a
ations, and pumping mains. Many researchers minimized the cost pump are represented by its characteristic curves having a nonlinear
of pipe networks using linear programming (Alperovits and Shamir nature. The pump characteristic curves and the system head curve
1977; Fujiwara et al. 1987), nonlinear programming (Shamir 1974; can be used to select the size of a pumping main and proper oper-
Lansey and Mays 1989; Varma et al. 1997), and dynamic program- ating range of the pump to result in the minimum energy cost with
ming (Liang 1971; Yang et al. 1975). Application of advanced tech- maximum possible efficiency. This will help in minimizing the
niques of optimization like genetic algorithms (Tolson et al. 2004; overall cost of the water supply system. The cost minimization
Prasad and Park 2004; Tu et al. 2005; Kadu et al. 2008; Krapivka of a pumping main has drawn little attention of researchers.
and Ostfeld 2009), ant colony optimization (Zecchin et al. 2007), Swamee (1996, 2001) developed methodology for optimal design
and differential evolution (Vasan and Simonovic 2010) have been of pumping mains using geometric programming. However, the
used to optimize the cost of pipe networks. A detailed description nonlinear pump characteristics were not included in the geometric
of optimal design of pipelines for water supply systems is available programming approach. In addition, the optimization models have
ignored the inclusion of escalation in the capital cost of the com-
1
Professor and Head, Civil Engineering Dept., College of Technology, ponents to be replaced and the energy cost that affects the design of
GBPUA&T Pantnagar, 263 145, Distt. Udham Singh Nagar (Uttarakhand), pipelines (Jensen 1981). The capital cost of discrete pipe sizes, the
India (corresponding author). E-mail: pooransmahar@yahoo.co.in operating characteristics of pumps, and the energy cost to overcome
2
Professor, Irrigation and Drainage Engineering Dept., College of the pipe friction are nonlinear in nature. Therefore, it will be more
Technology, GBPUA&T Pantnagar, 263 145, Distt. Udham Singh Nagar appropriate to use a nonlinear programming model to select optimal
(Uttarakhand), India. E-mail: rajprasin1@rediffmail.com
pipe size on the basis of replacement cost of the pump and its op-
Note. This manuscript was submitted on May 4, 2012; approved on
August 7, 2013; published online on September 2, 2013. Discussion erating characteristics for the required flow rate and pressure head.
period open until February 2, 2014; separate discussions must be submitted This paper presents the application of a nonlinear programming
for individual papers. This paper is part of the Journal of Pipeline Systems model for optimal design of a pumping main by considering
Engineering and Practice, © ASCE, ISSN 1949-1190/04013010(6)/ pump characteristics. The model considers capital investment
$25.00. and replacement costs of the components and energy cost with
H ¼ a0 þ a1 Q þ a2 Q 2 ð6Þ
treatment plants, and cost of water losses are also included in the
total cost of the water supply system (Kanakoudis and Tolikas where H = pump head (m); Q = pump discharge (L=s); and a0 , a1 ,
2003). The maintenance and repair costs are generally considered and a2 = constants. Similarly the efficiency-capacity curve for the
as a percentage of the capital cost of the system or omitted from the pump can be represented as
cost analysis, as their effect will be common for selecting compo-
nents from different alternatives. Kanakoudis and Tolikas (2001) η ¼ b0 þ b1 Q þ b2 Q2 ð7Þ
calculated optimum replacement time for pipes of a water network
using present value method of analysis. Kanakoudis (2004) intro- where η = efficiency of the pump, (percent); and b0 , b1 , b2 = con-
duced a methodology for preventive maintenance schedule/policy stants. The efficiency of the pump is calculated as
of water supply networks. Kanakoudis and Tolikas (2004) devel-
100QH
oped a methodology that analyzes the possible preventive mainte- η¼ ð8Þ
nance actions in a water supply system. These studies used 75BHP
technicoeconomic analysis that takes into account all kinds of costs
where BHP = brake horsepower. The capital cost of the pump can
for repair and replacement of trouble causing parts of a network.
be represented as (Bhave 2003)
Bhave (2003) has described and applied present worth method,
annual cost method, benefit cost ratio method, and rate of return 73.5QHCu
method for economic analysis of a water supply system. The Cp ¼ ð9Þ
75η
methodology presented in this study uses the annual cost method
(James and Lee 1971) of life-cycle cost analysis. where Cp = capital cost of the pump (Rs); and Cu = cost of pump-
ing unit (Rs=kW). Because the life of the pump is less than that of
the pipeline, the replacement cost of the pump with escalating rate
Pipeline Cost during the project life can be calculated (Jensen 1981) as
where C = Hazen-Williams coefficient for pipe material. The value A design example is presented to show the applicability of the
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of Ea can be calculated as (Jensen 1981) developed nonlinear optimization model. The following subsec-
tions describe the design example, its optimal solution, and related
ð1 þ eÞn − ð1 þ iÞn i discussion.
Ea ¼ ð17Þ
ð1 þ eÞ − ð1 þ iÞ ð1 þ iÞn − 1
where e = decimal equivalent annual rate of energy cost increase Design Example
(here, e is not equal to i). Eqs. (14)–(17) can be combined to relate In a water supply system, a centrifugal pump has to supply water
the annual energy cost with diameter as through a pumping main having a length of 1,000 m. The optimal
QH s diameter of the pumping main and the optimal operating conditions
Ec ¼ K 3 ð18Þ of the pump were designed using the following data:
η
• Design period = 30 years;
where K 3 = constant that can be calculated as • Daily pumping hours = 16;
• Static head = 5 m;
73.5 × t × Ce × Ea • Expected pump life = 15 years;
K3 ¼ ð19Þ
75 • Cost of pumping unit = Rs 6,000=kW;
• Cost of energy = Rs 2.5=kW · h;
Total Cost • Interest rate = 7%;
• Escalation rate for fixed and energy costs = 5%;
The total annual cost of the pumping main with pump can be
• Hazen-Williams coefficient = 115; and
represented as
• Minor loss = 10% of the friction head loss.
T c ¼ F 1 þ F 2 þ Ec ð20Þ The available diameters of CI pipes and their unit cost for the
pumping main are given in Table 1 as applicable in Uttarakhand
where T c = total annual cost of the pumping main including pump. Drinking Water Resources Development & Construction Nigam,
Dehradun (Uttarakhand), India for 2003. Table 2 includes the data
related to the pump characteristics (Punmia et al. 2010).
Optimization Model
As the diameter of the pumping main increases, the capital cost Solution
increases and the energy cost to overcome the frictional head loss
The given data were used to calculate the annual costs and
decreases. The diameter that will result in the minimum cost can be
other parameters required for use in the formulated nonlinear
easily obtained if the pump has to run at peak efficiency (Bhave
2003). Because head, efficiency, and discharge of a pump are in-
terrelated, any change in the demand or static head of the supply Table 1. Unit Capital Cost of Available C I Pipe Sizes
system may significantly affect the efficiency of the pump, and Pipe diameter (mm) Cost per unit length (Rs=m)
hence the energy consumption. Further, in actual practice the pump
may not run at fixed efficiency for the required discharge because 150 655.00
of varying demands. Therefore, it is important to determine the 200 960.00
250 1,290.00
range of efficiency for optimal operation of the pump to result
300 1,660.00
in the minimum total cost of the system for the required discharge 350 2,095.00
and pressure head. 400 2,550.00
The cost functions of the pumping main with pump are nonlin- 450 3,080.00
ear [Eqs. (4), (12), and (18)]. The relationship between the head,
efficiency, and discharge of the pump and system head requirement
are also nonlinear in nature [Eqs. (6), (7), and (15)]. Therefore, a Table 2. Pump Characteristics Data
nonlinear optimization model is required to obtain the diameter of
the pumping main and optimal operating conditions of the pump Discharge (L=s) Head (m) Efficiency (%)
to result in the minimum value of the total cost of the system. 0 20 0
The objective of the optimization model is to obtain the optimal 8 18.6 48
diameter of the pumping main and operating conditions of the 16 16.7 69
pump, which can be achieved by minimizing the total annual cost 24 14 75
of the system given by Eq. (20) with constraints related to pump 32 10.9 70
characteristics and system head requirements. The objective func- 40 7.4 60
48 3.6 47
tion can be written as
Notation
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