Pump and Fan system

Presented By
J.Nagesh Kumar
Sr.Dy.Director
National Productivity Council
AIP,Ambattur,Chennai-98
npcaip@vsnl.com

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Centrifugal Pumps

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Energy Balance for a Typical Pumping

System
100%
ELECTRICITY
MOTOR

12% LOSS

COUPLING

2% LOSS

PUMPS
VALVES
PIPES

24% LOSS
9% LOSS
11% LOSS

WORK DONE ON WATER

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Operating Point Defined

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Unsafe Safety Allowance

System heads should be estimated as accurately
as possible
Do not add a margin for safety to the system
head
In trying to match the over specified head, a
larger pump will be recommended by the
supplier
The larger pump will operate at a higher capacity
point (as required by the actual system head)
This can overload the pump motor and require
greater throttling

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Efficiency Curves
28.6 kW

14.8 kW

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Operation with Throttling

B

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Typical pump characteristic

curves

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The affinity law for a centrifugal pump

Flow:

Head:

Q1 / Q2 = N1 / N2

H1/H2 = (N12) / (N22)

Example:

Example:

100 / Q2 = 1750/3500

100 /H2 = 1750 2/ 3500 2

Q2 = 200 m3/hr

H2 = 400 m

Kilowatts (kW):
kW1 / kW2 = (N13) / (N23)
Example:
5/kW2 = 17503 / 35003
kW2 = 40
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Flow Control
Strategies
Bypass valve

Zero savings

Throttle output

Increased system pressure drop

Move system curve and reduces efficiency
Effect less in flat H-Q curve

Trim impeller
Buy a new pump
Variable speed drive

Most efficient
Power varies as cube of speed
Different flow rates without affecting efficiency

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Why Oversized Pump ?

Safety margins were added to the original calculations. Several
people are involved in the pump buying decision and each of them is
afraid of recommending a pump that proves to be to small for the job.
It was anticipated that a larger pump would be needed in the future,
so it was purchased now to save buying the larger pump later on.
It was the only pump the dealer had in stock and you needed one
badly. He might have offered you a "special deal" to take the larger
size.
You took the pump out of your spare parts inventory. Capital
equipment money is scarce so the larger pump appeared to be your
only choice.
You purchased the same size pump as the one that came out of the
application and that one was over sized also.

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Energy conservation
measures
Conduct water balance minimise water consumption
Avoid idle cooling water circulation in DG sets,
compressors, refrigeration systems
In multiple pump operations, judiciously mix the
operation of pumps and avoid throttling
Have booster pump for few areas of higher head
Replace old pumps by energy efficient pumps
In the case of over designed pump, provide variable
speed drive, trim / replace impeller or replace with
correct sized pump
Remove few stages in multi-stage pump with over
designed head

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Energy Savings
Opportunities
Give efficiency of the pump due consideration

while selecting a pump.

Select pumps to match head flow requirements.
Select a motor to match the load with high
efficiency.
Optimize the piping design.
Monitor all important system parameters like:
motor kW, pump head, flow temperature.
Use pumps in series and parallel so that
mismatch in system design or variations in
operating conditions can be handled properly.

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Energy Savings
Opportunities (Contd.)
Use variable speed drives for variations of
flow due to process requirement.
If the head flow is higher than needed by 5
to 15%, (i) The existing impeller should be
trimmed to a smaller diameter, (ii) or a new
impeller with a smaller diameter is to be
put.
In multistage pumps, add or remove stages
to the existing pump, allowing an increase /
decrease in delivered head of flow, if
required.

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Air conditioning System

Resinoid plant
46 TR x 2nos in operation

Recirculated
cooled
air

Resinoid Moulding

Hot Well

Cold Well

Recirculated
cooled and
washed
air

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Avoid Cold well Pumps

Resinoid plant
46 TR x 2nos in operation

Recirculated
cooled
air
Hot Well

Resinoid Moulding
Recirculated
cooled and
washed
air

Annual Savings Rs.3

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New line

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Open circuit pumping system (Existing)

5 kw x 2 no

Calibrator
Piercing press
Elongator
Push Bench
Reeler

Pressure
Sand Filter

Stretch reducing mill

Mandrel bar cooling

195 m3/hr
50 m
41 kw

175 m3/hr
20 m
18 kw

Settling Tank
Scale
pit

350 m3/hr
25 m
45 kw

Cold Well

Hot Well

Settling Tank

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Open circuit pumping system (Proposed)

5 kw x 2 no

Calibrator
Piercing press
Elongator
Push Bench
Reeler

Pressure
Sand Filter

Stretch reducing mill

Mandrel bar cooling

195 m3/hr
50 m
41 kw

175 m3/hr
20 m
18 kw

Settling Tank
Scale
pit

350 m3/hr
25 m
45 kw

Cold Well

Hot Well

Settling Tank

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Closed circuit pumping system

Fans :30 kw x 3 no

Rotary hearth furnace

Walking beam furnace
Roll down furnace
Spiral fin welding

Switch off during

6-9 AM & PM

Nitrogen generator
Normalising furnace
Tempering Furnace
Air compressors

60 m3/hr
50 m
110 kw

Hydraulic systems
Cold Well

Return
water
sump

600 m3/hr
20 m
48 kw

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Existing cooling water system for tube

plant
10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
2
1

Warming mill

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

Feeding mill

K4

0.23 m3/hr
Extruder

Extruder
die cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

0.4 m3/hr

Extruder
conveyor cooling

3 m3/hr

9.4 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

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Modified cooling water system for tube

plant
10 HP
Actual - 6 kW

100 TR

Final
compounding
mill

8 m3/hr

2.5 m3/hr
Warming mill
1

HP - 20
Actual - 11 kW
H - 29 m
Q - 23 m3/hr

HP - 7.5
Actual - 4 kW
H - 22 m
Q - 16m3/hr

K4

Feeding mill

HP - 3
Actual 1.4 kW
H - 22 m
Q - 17m3/hr

0.23 m3/hr
Extruder

Extruder
die cooling
Extruder
conveyor cooling

Return water sump

HP - 10
Actual - 6 kW
H - 29 m
Q - 17m3/hr

HP - 20
Actual - 12 kW
H - 39 m
Q - 23 m3/hr

HP - 20
Actual - 16.2 kW
H - 56 m
Q - 15 m3/hr

0.4 m3/hr

3 m3/hr

9.4 m3/hr

Modified pumping system

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Dump Chest to Belcore

(Existing Practice)

HD Cleaner
Belcore
Dump
Chest

Belcore
Feed Chest
10 m
120 m3/hr
Kw

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10 m
120 m3/hr
Kw

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Connect HD cleaner pump outlet to

Belcore feed pump
HD Cleaner
Belcore
Dump
Chest
10 m
120 m3/hr
Kw

10 m
120 m3/hr
Kw

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Centrifugal fans

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Difference between fans, blowers

and compressors
As per ASME the specific pressure, i.e, the ratio of the discharge
pressure over the suction pressure is used for defining the fans,
blowers and compressors as highlighted below :

Equipment
Fans
Blowers
Compressors

Specific Ratio

Pressure rise (mmWg)

Up to 1.11

1136

1.11 to 1.20

1136 2066

more than 1.20

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Energy audit of fan

Collect fan and motor specifications with
ducting network
Measure motor power input
Measure fan and motor speed
Measure static pressure at various points in
the duct
Measure total and static pressure and
compute flow
Estimate the system efficiency and check
fan operating point
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Fan and Blower

Controls
The volume of air moved by fans and blowers is adjusted in four
basic ways:
Changing the rotational speed is the most efficient. If the volume
requirement is constant, it can be achieved by selecting
appropriate pulley sizes. If the volume varies with the process,
adjustable-speed drives can be used.
Changing the blade angle is a method used with some vane-axial
fans.
Restricting the airflow is accomplished with dampers or valves
which close off the airflow at the inlet or outlet. Inlet vanes, which
swirl the air entering the centrifugal fan or blower, are more
efficient than dampers or butterfly valves.
Venting the high-pressure air, or recirculating it to the inlet, is
often used with positive-displacement blowers. It is sometimes
used with fan systems, but is the least efficient method as there is
no reduction in the air being moved.

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What to Look for in the

Field
Overall system efficiency will be determined by the type of fan or
blower, its interaction with the air distribution system, and the method of
control.
Determine whether the right type of fan or blower is used for an
application. Is your fan or blower is providing the best efficiency and
performance in a given application.
The efficiency of a system depends on the number and type of bends
and restrictions. Sharp bends, especially, increase the resistance the fan
or blower must overcome. Bends and restrictions near the inlet or outlet
seriously degrade capacity and efficiency.
With a properly selected fan or blower and well-designed air distribution
system, the method of control is the main thing determining energy
efficiency. In systems requiring constant air volume, the speed of a beltdriven fan or blower should be adjusted by proper selection of pulley
sizes, and equipment should operate only when needed. In systems
requiring variable airflow, an adjustable-speed control is most efficient.

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Energy conservation in fans

Match fan capacity to demand

downsizing, pulley change, VSD..

Avoid unnecessary demand

excess air reduction

idling

Reduce pressure drops

Remove redundant ducts

Modify ducting with minimum bends

Drive system

Provide direct drive where possible

Replace V-belt by flat belt

Replace with energy efficient fans

Regular preventive maintenance

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Checklist for energy savings in

Fans and Blowers
Use smooth, well-rounded air inlet cones for fan
air intakes.
Avoid poor flow distribution at the fan inlet.
Minimize fan inlet and outlet obstructions.
Clean screens, filters, and fan blades regularly.
Use airfoil-shaped fan blades.
Minimize fan speed.
Use low-slip or no-slip belts.
Check belt tension regularly.
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Checklist for energy savings in

Fans and Blowers (contd.)
Use variable speed drives for large variable fan
loads.
Use energy-efficient motors for continuous or nearcontinuous operation
Eliminate ductwork leaks.
Turn fans off when they are not needed.
Blowers
Use smooth, well-rounded air inlet ducts or cones
for air intakes.
Minimize blower inlet and outlet obstructions.
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Checklist for energy savings in

Fans
and
Blowers
(contd.)
Clean screens and filters regularly.
Minimize blower speed.
Use low-slip or no-slip belts.
Check belt tension regularly.
Eliminate variable pitch pulleys.
Use variable speed drives for large variable blower loads.
Use energy-efficient motors for continuous or nearcontinuous operation.
Eliminate ductwork leaks.
Turn blowers off when they are not needed.

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Flow control

Recirculation
Damper

100

Power

VFC

75
50

VFD

25

Ideal

25

50

Flow

75

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100

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Impact of speed reduction

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Use of VSD: Boiler ID fan case

study

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Use of VSD: Boiler ID fan case

study
(contd.)

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Twin Benefits due to fan speed

control

Thermax Boiler

Economiser

6 TPH
10.75 Kg/cm2
Coconut shell
fired
Primary Air
Fan

Dust
Collector
Secondary Air
Fan
Damper

Hopper
Coconut shell
crusher

14 % O2
9 % O2

Induced Draft
Fan

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Energy saving in Boiler ID fan by

speed reduction through pulley
change
8
1470 RPM

6
1470 RPM

10

26 kW

1181 RPM

10

14 kW

882RPM

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Regulate with dampers in each

equipment
30 HP dust collector in Resinoid plant

Variable
Speed Drive

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22 lathe

22 edger

Dry disc
Blow booth

Existing:
No dampers
Suction remains
even when M/c
not operating

Pneumatically
actuated dampers

Conical Edger

22 lathe

22 edger

Dry disc
Blow booth

Conical Edger

16 kW (all dampers open)

14.4 (3 dampers closed)

Proposed:
Provide dampers
Suction only in M/cs
operating
Operate fan with
variable speed drive

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