Reducing energy consumption by energy management
and energy audits in the pumping stations
Mohamed Kaddari, Mahmoud El Mouden, Abdelowahed Hajjaji
Laboratory of Engineering Sciences for Energy (LabSIPE)
University Research Center (CUR) in Renewable Energies &
Intelligent Systems for Energy "EnR&SIE"
National School of Applied Sciences, Chouaib Doukkali University
El Jadida, Morocco
moh.kaddari@gmail.com
Abstract— The implementation of energy savings strategies
has become a necessity and improving the performance of
industrial facilities is no longer a prestige, it has now become
mandatory for all industrial companies. This paper includes a
critical analysis and energy management problems in a typical
pumping station, which usually causes excessive energy
consumption. Based on the results of energy auditing and energy
performance of the most energy-consuming equipment an
approach has been developed, which achieves optimal
combination to answer such a water demand, while taking into
account having optimal flow, minimum consumption and with
maximum efficiency. The results showed that this pumping
station consumed a monthly average electrical energy of 15
422MWh and having a potential to save 1 313MWh of energy, a
8.30% electrical energy saving potential. The benefits of
implementing the energy efficiency measures related to electricity
and water are substantial both in terms of energy savings and in
terms of cost savings.
Keywords—Energy audit; Energy management; Energy
savings; Energy efficiency; Pumping station
I. INTRODUCTION
The Moroccan energy context is characterized by a quasi-
total dependence. Indeed, Morocco is an energy importing
country with a height of 95% of its annual consumption and its
energy bill is growing increasing, given the increasing demand
for energy that accompanies the great projects of the
Kingdom. Concerned by this problem, several companies seek
to align themselves with the directives promulgating the law
No. 47-09 on energy efficiency. The Law No. 47-09 aims to
increase energy efficiency in the use of energy sources, avoid
waste, reduce the burden of energy costs on the national
economy and contribute to sustainable development [1]. Its
implementation is mainly based on the principles of energy
efficiency requirements, energy impact studies, mandatory
energy audit and technical control. It also aims to integrate
energy efficiency techniques into all sectorial development
programs, encouraging industrial companies to generalize
energy audits. Global energy consumption is increasing and
continued gas emissions at or higher than current rates would
engender more warming [2]. Saving energy means conserving
precious resources and of course securing significant financial
savings that will be used to control costs and survive the
vagaries of competition [3-4].
The international standard ISO 50001 was published in
June 15, 2011 [5]. This standard on energy management
systems (EMS) aims to improve the energy performance of
XXX-X-XXXX-XXXX-X/XX/$XX.00 ©20XX IEEE
Abdellah Semlali
Laboratory of Condensed Matter Physics (LPMC)
University Research Center (CUR) in Renewable Energies &
Intelligent Systems for Energy "EnR&SIE"
Faculty of Sciences, Chouaib Doukkali University
El Jadida, Morocco
any organization. It could have an impact on 60% of the
global energy demand according to the International Energy
Agency. ISO 50001 will provide for organizations several
management strategies to increase energy efficiency, reduce
costs and improve energy performance [6]. Effective
management of electric energy regulation has been introduced
in several countries to promote energy efficiency. As a result,
they are forcing large commercial and industrial electrical
consumers to manage their equipment in order to develop and
implement EEMs to reduce energy losses, energy costs and
ensure the efficient use of electrical energy [7-8].
This paper is structured around four main axes detailed
according to the following parts:
 The first part presents the general context of the work
and defines the adopted methodology.
 The second part is devoted to the analysis of
statistical data of a typical site, the energy diagnosis,
the identification of the anomalies and the evaluation
of the management mode.
 The third part will focus on assessing the energy
performance of the most energy-consuming
equipment.
 The fourth part will consist of the preparation of
improvement and management prepositions.
II. METHODOLOGY
The energy audit is a diagnostic that aims to highlight the
strengths and weaknesses of an industry in terms of energy
performance [9-10-11]. The objective is to identify energy
deposits and limit or even eliminate the waste of energy and
reduce their energy bills [12]. After a detailed inventory, a set
of solutions for energy, economic and environmental
improvements is proposed. This audit is mainly based on three
parts: The energy audit of the existing state (preliminary
audit), evaluation of energy performance (in-depth audit) and
development of improvement actions.
A. Diagnosis of the Existing State (preliminary audit)
The first part aims to develop an overall assessment of
energy consumption, for this purpose an analysis of energy
bills, is necessary in order to quantify the energy consumed by
the site and to define the threshold of current consumption in
the form of energy ratios. These ratios will form the basis of
percentage of target energy saving. The data recovered from
the industrial site at this first stage are: Water
treatement
 Electricity consumption of the last three years. 2% Pumping
Station
 Production quantities for the last three years. Power plant 28%
25%
 Layout and plan of the industrial site.
 Catalogues and data sheets of all industrial
equipment. Water
ditribution
Production 7%
An analysis of the data by regression and by correlation of Units
the consumption with the production makes it possible to 10%
estimate the deposits of possible energy savings to be realized
thanks to the establishment of an energy management Airconditioni
program. ng &
Compressor
28%
B. Assessment of Energy Performance (in-depth audit)
This step involves developing an approach for calculating
and choosing performance indicators and establishing the
energy balance at each site installation. In order to target the Fig.1. Power consumption of the pumping station
most energy items, we rely on the archive of electric meters, to
make a distribution of the total energy consumption in percent. A. Distribution of Electricity Consumption in the Pumping
Station
This distribution makes it possible to identify the most
energy-consuming equipment, which will then be the subject The motor-pumps have 80% of the power consumption
of the in-depth study for the development of improvement used by the station, as shown in Figure 2. Therefore, we are
actions. interested in our study only by the motor-pumps.
C. Development of Improvement Actions
The objective is to develop energy saving actions
Fans
according to three criteria: 7%
Lighting
 Technique. Other 1%
3%
 Economic.
 Ecological. Compressor
9%
This means that the evaluation must take into account
several factors, and the decision-making process is of crucial
importance in this context.
III. DIAGNOSIS OF THE EXISTING SITUATION
Motor-pump
This audit is conducted in the typical water pumping 80%
stations during 2017, which comprises 15 pump units of
different characteristics.
This part aims to analyse the inventory and the energy
consumption of the pumping station, in order to draw Fig.2. Distribution power consumption in the pumping station
conclusions about the consumption of energy compared to the
production, then to follow and to interpret the specific Generally, pumping systems are responsible for about 18%
consumptions and the parameters of the energy bill. of energy consumption in industrial motor driven systems [13-
Our system consumes 28% of the platform's electrical 14].
energy, i.e. 185 056 MWh per year. It is clear that the station B. Management Mode and Anomalies
in question is energy-intensive, so any improvement will have The management of the seawater pumping system is done
a positive effect on the annual energy bill. by relying on the demand of consumers and users by starting
Figure 1 below represents the contribution of this station in or stopping a motor pump. After an inspection of the state of
the total plant consumption. the station, we were able to note some failures such as:
 Start and Stop of motor-pumps sometimes
unjustified, that reduces the lifetime of critical
equipment.
  The discharged flow is sometimes larger than the U: the measured voltage (V).
flow demanded by the customer, which causes an
I: the measured current (A).
overflow at the spillway.
cosφ: power factor.
 Blackout of the station.
The electromechanical efficiency corresponds to the
 The flow of the discharged water is measured at the
efficiency of the motor pump assembly is:
regrouping pipe, which does not allow controlling the
performances of each motor-pump. 𝑃ℎ
ɳ𝑒𝑚 = (3)
𝑃𝑒
IV. PERFORMANCE EVALUATION
Hydraulic power is calculated using equation (4):
A. Meseared Parameters
The measurement of the quantities necessary for the audit 𝐻𝑀𝑇 × 𝑄 × 𝜌 × 𝑔
𝑃ℎ = (4)
must be made with precision so that the results of analysis 1000
resulting from it are useable. In this sense, it is important to Where:
define exactly the technical parameters necessary so that the
measurement companion is neither undersized, implying in Q: flow (m3 /s).
fact errors in the analysis, nor oversized, implying ρ: density of seawater (Kg /m3).
unnecessary expenditures in terms of material resources
human and temporal. The parameters to be measured are g: the acceleration of gravity (m /s2).
classified into two types: hydraulic measurements and Pdischarge: Discharge pressure (Pa).
electrical measurements.
Psuction: Suction pressure (Pa).
B. Hydraulic Measurements
The hydraulic parameters are measured using calibrated HMT: The manometric head of the pump is obtained by:
measuring equipment. The system shall not suffer any 𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 − 𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛
disturbance during the measurement. These measures will be 𝐻𝑀𝑇 = (5)
𝜌×𝑔
carried out directly in the discharge lines. The following
measurements are necessary to obtain the hydraulic data and E. Specific Consumption
parameters: Specific consumption represents the relationship between
 Pump discharge flow. the energy used by the seawater pumping system and the total
volume of water produced and delivered to the customer. The
 Suction and discharge pressure. specific consumption is calculated as follows:
C. Electrical Measurements 𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 (𝐾𝑊ℎ)
𝐶𝑠 = (6)
Electrical measurements are collected by electrical 𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑤𝑎𝑡𝑒𝑟 (𝑚3 )
technicians, under normal operating conditions and not at the
The specific consumption of the pumping station varies
time of starting the pumps. The parameters to be measured
between 0.132 and 0.161 KWh/m3 with an average of 0.153
are:
KWh /m3. As it shown in Figure 3 below.
 Voltage
 Current
 Power factor
D. Efficiency of the Motor Pump Units
The efficiency of the pumps (ɳp) is calculated with the
hydraulic power (Ph) divided by the absorbed mechanical
power (Pm):
𝑃ℎ
ɳ𝑝 = × 100 (1)
𝑃𝑚
Because of the difficulty of measuring the mechanical
power separately and then determine the efficiency of the
pump, it is recommended to evaluate the electromechanical
efficiency of motor-pump.
The electric power is calculated by the equation (2):
𝑃𝑒 = √3 × 𝑈 × 𝐼 × 𝑐𝑜𝑠𝜑 (2)
Where: Fig.3. Evolution of specific consumption
 V. ESTABLISHEMENT OF A MANAGEMENT SYSTEM FOR THE SEA
WATER PUMPING STATION
We conclude that the pumping station has the largest
consumption point in our system of study, it also known
management failures: the overflow at the spillway and the
brutally start-stop of motor-pump which is not justified. For
these reasons, we propose and validate a pumping station
management system to ensure the customer's continuous
supply of seawater, while optimizing pumped flow and energy
consumption. In order to make our problem solvent we have
considered the following hypotheses:
 Preservation of material flow (no leaks in pipes).
 The sea level is average.
TABLE I: CALCULATION OF THE ELECTROMECHANICAL EFFICIENCY OF MOTOR -PUMP
 Reliability of data obtained from daily records.
 Price of KWh is 0.7 DH.
A. Formulation of the Problem
To solve our problem, we use the "Microsoft Excel"
software. The latest version of Excel 2013 will be used. We
try to determine the optimal operation of the pumping station
in order to reduce the cost of energy bills. While ensuring that
water demand is satisfied continuously and respecting the
storage conditions.
Table I shows the calculation results of the
electromechanical performance, it should be noted that the
measures have been done for a one month, and we have taken
an average value.

Motor-
Pump 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Number

Voltage (V) 10200 10100 10100 10100 10100 10100 10100 10100 10100 10100 10100 10100 10100 10100 10100

Current (A) 278 163 319 323 164 278 232 143 296 278 175 240 279 160 333

Power
0.78 0.79 0.8 0.79 0.82 0.78 0.82 0.83 0.75 0.76 0.79 0.84 0.77 0.81 0.79
factor
Aspiration
pressure 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000
(Pa)
Suppression
pressure 740000 740000 740000 740000 740000 745000 740000 740000 745000 740000 740000 743000 741000 743000 720000
(Pa)

Flow (m3/h) 16000 8900 18900 18500 8900 16000 13500 8000 14000 14500 8100 13500 16200 9100 19800

Density
1030 1030 1030 1030 1030 1030 1030 1030 1030 1030 1030 1030 1030 1030 1030
(Kg/m3)

Gravity
9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8
(m/s2)
Mano
metric high 71.33 71.33 71.33 71.33 71.33 71.82 71.33 71.33 71.82 71.33 71.33 71.63 71.43 71.63 69.35
(m)
Hydraulic
Power 3200.00 1780.00 3780.00 3700.00 1780.00 3222.22 2700.00 1600.00 2819.45 2900.00 1620.00 2711.25 3244.50 1827.58 3850.00
(KW)
Electric
Power 3830.78 2252.60 4464.26 4463.74 2352.49 3793.23 3327.91 2076.27 3883.49 3695.96 2418.43 3526.63 3758.06 2267.12 4601.94
(KW)
Electro
Mechanic
83.53 79.02 84.67 82.89 75.66 84.95 81.13 77.06 72.60 78.46 66.99 76.88 86.33 80.61 83.66
efficiency
(%)

For this purpose, we have classified the pumps according
to their nominal flow, 3 pumps of 18000 m3/h, 7 pumps of
15000 m3/h, 4 pumps of 9000 m3/h and one pump of 7500
m3/h, the number of possible combinations is equal to:
𝑁 = ∑4𝑛𝑖=1 2𝑛𝑖 +1 = 23+1 + 27+1 + 24+1 + 21+1 = 308
Where: (n1 = 3, n 2 = 7, n3 = 4 and n4 = 1) denoting the
number of pumps for the same rate flow.
We then proceed to calculate the flow, power and
efficiency of the different combinations. In order to simplify
(7) the calculation, we reduce the combinations number by
eliminating any combination not having a flow in this interval:
[65000 - 110000] m3/h, which represents the plant
consumption of seawater in its normal operation. We have 113
combinations left.
After generating the combinations according to the pumps
flow, we go on to the second step, which consists in extracting
sub-combinations by introducing the characteristics of each
motor-pump units. Each combination contains a number of
sub-combinations calculated using cardinality by equation (8):
4 1, those that have the minimum power absorbed.
n
NSub−combntion = ∏ Cmii
i=1
Where:
m: number of operating pumps.
n: number of pumps with same flow.
n1 =3
n2 =7
{ (9)
n3 =4
n4 =1
We will illustrate equation (8) by the example below. Let
us calculate the number of sub-combinations drawn from the
combination where the pumps are operating: 3 pumps of
18,000 m3 /h, 2 pumps of 15,000 m3/h, a pump of 9,000 m3/h
and a pump of 7,500 m3/h. The number of sub-combination is:
4
n consumption of the station in 15 days, and consumption that
NSub−combntion = ∏ Cmii = C33 × C27 × C14 × C11 = 84 (10)
i=1
Therefore, 84 possible combinations result from the
combination of the previous example.
Finally, after scanning all the combinations, we found
17314 combinations, of which we calculated the flow, the
power and the corresponding efficiency. Verification of
combinations is done using the "Remove duplicate rows in
Excel" function. We now have a database of all possible
combinations with their flow, power consumption and
efficiency.
B. Calculation of Seawater Demand
The demand for seawater varies according to the number
of production lines or workshops in operation of each unity.
For this, it is sufficient to create an Excel table containing the
different production lines and their operating status in order to
calculate the total demand, as shown in Table II.
TABLE II. CALCULATION OF SEAWATER DEMAND
State of the plant
Users Number of operating Demand (m3/h)
line
Power plant 5 17895
Production lines 7 76040
Total demand (m3/h) 93935
To find the optimal combination of each demand it is
necessary to make conditions on the flow, the power
consumption and the efficiency, in order to choose the
combination able to pump the exact required flow and having
a minimum power with a maximum efficiency.
Condition 1 "optimum flow": This is the first condition in our
calculation page; it is to identify combinations with a flow rate
higher than the demand with a minimum of overflow.
Condition 2 "minimum power absorbed": The purpose of this
second condition is to choose between the combinations of test
(8)
Condition 3 "maximum efficiency": The third condition
consists in choosing the combination having a maximum of
efficiency between the combinations, which passed the
condition 1, and the condition 2.
The tests are done using the "IF" function which checks
whether the condition is respected and returns a value if the
result of a condition already specified is true, and another
value if it is false.
VI. RESULTS AND DISCUSSIONS
The display of the optimal combination, its characteristics,
flow and absorbed power is done using the Excel function
"VLOOKUP" to search for a value in the column in question
and return it to a specified cell.
To quantify the gain resulting from the use of this
management system, we compared the actual energy
would have consumed during the same period (from May-25
to June-8 2017).
Figure 4 shows the evolution of the demand, the pumped
flow and the flow to be pumped after improvement during this
period. We note that the pumped flow is much higher than the
demand, which explains the overflow of the spillway. The
evolution of the flow after improvement follows perfectly the
demand, in other words, it is the optimum flow.
Fig.4. Evolution of demand, pumped flow and flow after improvement.
Figure 5 shows the evolution of the real absorbed power
and the improved power using our management mode during
the same period. We see clearly that the real power is much
higher than the improved power; moreover, we observe some
spikes at the evolution of the real power, explained by the
unjustified start-stop pumps.

Fig.5. Variation in real and improved power consumption.
Finally, we calculate the expected gain by the difference
between the energy actually consumed and the energy that
should be consumed using our proposed management mode
during a trial period. The results of the expected gain are
shown in Table III.
TABLE III. EXCEPTED G AIN
15 days 1 year
Old consumption MWh 7 911.13 189 867.20
New consumption MWh 7 254.40 174 105.79
Gain by MWh 656.72 15 761.41
Gain by DHs 459 707.77 11 032 986.48
Gain by % 8.3% 8.3%
The annual gain is calculated on the assumption that this
month represents the normal running of the plant and can be
considered as a sample. So, this project has made us an annual
gain of about 11MDH.
VII. CONCLUSION
In this paper, we have studied the implementation of a
management system of seawater pumping stations. An
approach to choose the ideal combination in order to answer
such a demand of water is developed, while taking into
consideration to have optimum flow, low power consumption
and with maximum efficiency. A preliminary audit allowed us
to identify the major problems of the pumping station. Then an
in-depth audit was done to evaluate the efficiency of the
systems as well as the management of consumption. Finally,
we closed our case study by showing that the improvement
solutions and the proposed energy optimization method, allow
us to achieve an annual gain estimated at 11MDH, another
advantage is that this type of project does not require any
investment and increases the lifetime of the critical equipment
of the production.
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