ENERGY CONSERVATION

IN

PUMPS
 PUMP TYPES

• Dynamic – Centrifugal and special

effect pumps.
• Displacement pumps – Rotary or
Reciprocating pumps.
 PUMPS
• Principle - Any liquid can be handled by any of
the pump designs.

• Centrifugal pump is generally the most economical

followed by rotary and reciprocating pumps.
 PUMPS

• Although, positive displacement

pumps are generally more
efficient than centrifugal pumps,
the benefit of higher efficiency
tends to be offset by increased
maintenance costs
CENTRIFUGAL PUMPS
 PUMPS

• A centrifugal pump is not positive

acting; it will not pump the same
volume always.

• Greater the depth of the water,

the lesser is the flow from the
pump.
 PUMPS

• when it pumps against increasing

pressure, the less it will pump.

• For these reasons it is important

to select a centrifugal pump that
is designed to do a particular job.
 PUMPS

• The pump generates the same head of

liquid whatever the density of the
liquid being pumped.
 PUMPS

• The actual contours of the hydraulic

passages of the impeller and the
casing are extremely important, in
order to attain the highest efficiency
possible.
PUMP PERFORMANCE
CURVE
 PUMPS

• The head and capacity are the main

factors, which affect the horsepower size
of the motor to be used.
 PUMPS

• Head - impeller diameter, number of

impellers, - size of impeller eye & shaft
speed.
• Capacity - exit width of the impeller.
 PUMPS

• Total developed head

H= The difference of discharge and
suction pressure
• The pump head represents the net work
done on unit weights of a liquid in
passing from inlet of the pump to the
discharge of the pump.
 PUMPS
There are three heads in common use in
pumps namely
(i) Static head
(ii) Velocity head
(iii) Friction head
 PUMPS
• The frictional head in a system of
pipes, valves and fittings varies as a
function (roughly as the square) of the
capacity flow through the system.
• System resistance: The sum of
frictional head in resistance & total
static head.
HYDRAULIC POWER, PUMP SHAFT POWER
AND ELECTRICAL INPUT POWER
Hydraulic power Ph
= Q(m3/s) xTotal head, hd - hs (m) x  (kg/m3) x g (m2/s) 1000
Where hd - discharge head,
hs – suction head,  - density of the fluid,
g – acceleration due to gravity
Pump shaft power Ps = Hydraulic power, Ph pump
efficiency, Pump
Electrical input power = Pump shaft power P
Motor efficiency MOTOR
STATIC HEAD
DYNAMIC (FRICTION) HEAD
SYSTEM WITH HIGH STATIC
HEAD
SYSTEM WITH LOW STATIC
HEAD
PUMP CURVE
PUMP OPERATING POINT
 TYPICAL PUMP
CHARACTERISTIC CURVES
 SELECTING A PUMP

System Curve
Head
Meters

Flow (m3/hr)
 SELECTING A PUMP
Pump Curve at
Const. Speed

82%
Operating Point
System Curve
Head
Meters

500 m3/hr

Flow (m3/hr)
 SELECTING A PUMP
Pump Curve at
Const. Speed

82%
50 Operating Point
Head,
m System Curve

300 500

Flow (m3/hr)
 SELECTING A PUMP

Pump Curve at
Const. Speed Pump Efficiency
77%
Partially
70
closed valve 82%
50 Full open valve
Head,
m System Curves

300 500

Flow (m3 /hr)

 SELECTING A PUMP
Pump Curve at
Const. Speed Pump Efficiency 77%

70 m Partially B 82%
closed valve
A
50 m
Full open valve
42 m
System Curves C
Head
Meters
Static Operating Points
Head
300 m3 /hr 500 m3 /hr
3
Flow (m /hr)
EFFICIENCY CURVES
28.6 kW

14.8 kW
IF WE SELECT E, THEN THE
PUMP EFFICIENCY IS 60%
• Hydraulic Power = Q (m3/s) x Total head, hd - hs (m) x  (kg/m3) x g (m2/s)
1000

= (68/3600) x 47 x 1000 x 9.81

1000
= 8.7 kW
 
• Shaft Power - 8.7 / 0.60 = 14.5 Kw
• Motor Power - 14.8 / 0.9 = 16.1Kw
(considering a motor efficiency of 90%)
IF WE SELECT A, THEN THE
PUMP EFFICIENCY IS 50%
• Hydraulic Power = Q (m3/s) x Total head, hd - hs (m) x  (kg/m3) x g (m2/s)
1000

(68/3600) x 76 x 1000 x 9.81

1000
= 14 kW
 
Shaft Power - 14 / 0.50 = 28 Kw
Motor Power - 28 / 0.9 = 31 Kw (considering a
motor efficiency of 90%)
USING OVERSIZED PUMP !
As shown in the drawing, we should be using impeller "E" to
do this, but we have an oversized pump so we are using the
larger impeller "A" with the pump discharge valve throttled
back to 68 cubic meters per hour, giving us an actual head of
76 meters.

•Hence, additional power drawn by A over E is 31 –16.1 = 14.9 kW.

•Extra energy used - 8760 hrs/yr x 14.9 = 1,30,524 kw.
= Rs. 5,22,096/annum
In this example, the extra cost of the electricity is more than the cost
of purchasing a new pump.
 FLOW VS SPEED
If the speed of the impeller is increased from N 1
to N2 rpm, the flow rate will increase from Q 1 to
Q2 as per the given formula:
           
 FLOW VS SPEED

The affinity law for a centrifugal pump with the

impeller diameter held constant and the speed
changed:
Flow:
Q1 / Q2 = N1 / N2
Example:   100 / Q2 = 1750/3500 Q2 = 200 m3/hr
 
 HEAD VS SPEED

The head developed(H) will be proportional to the

square of the quantity discharged, so that
 HEAD VS SPEED
HEAD VS SPEED

Head:

H1/H2 = (N12) / (N22)

Example:    100 /H2 = 1750 2 / 3500
H2 = 400 m
 POWER VS SPEED

The power consumed(W) will be the product of H

and Q, and, therefore
 EFFECT OF SPEED
VARIATION
Power(kW):

kW1 / kW2 = (N13) / (N23)

Example:   5/kW2 = 17503 / 35003

kW2 = 40
EFFECT OF SPEED
VARIATION
THE AFFINITY LAW FOR A CENTRIFUGAL
PUMP WITH THE SPEED HELD CONSTANT
AND THE IMPELLER DIAMETER CHANGED
Flow:
Q1 / Q2 = D1 / D2
Example: 100 / Q2 = 8/6
Q2 = 75 m3/hr
Head:
H1/H2 = (D1) x (D1) / (D2) x (D2)
Example: 100 /H2 = 8 x 8 / 6 x 6
H2 = 56.25 m
Horsepower(BHP):
kW1 / kW2 = (D1) x (D1) x (D1) / (D2) x (D2) x (D2)
Example: 5/kW2 = 8 x 8 x 8 / 6 x 6 x 6
kW2 = 2.1 kW
 REDUCING IMPELLER DIAMETER

• Changing the impeller diameter gives a

proportional change in peripheral
velocity
 REDUCING IMPELLER DIAMETER

• Diameter changes are generally limited

to reducing the diameter to about 75%
of the maximum, i.e. a head reduction
to about 50%
• Beyond this, efficiency and NPSH are
badly affected
 REDUCING IMPELLER DIAMETER

• However speed change can be used

over a wider range without seriously
reducing efficiency
• For example reducing the speed by
50% typically results in a reduction of
efficiency by 1 or 2 percentage points.
 REDUCING IMPELLER DIAMETER

• It should be noted that if the change in

diameter is more than about 5%, the
accuracy of the squared and cubic
relationships can fall off and for precise
calculations, the pump manufacturer’s
performance curves should be referred
to
IMPELLER DIAMETER REDUCTION ON
CENTRIFUGAL PUMP PERFORMANCE
 PUMP SUCTION
PERFORMANCE (NPSH)
• Net Positive Suction Head Available – (NPSHA)
• NPSH Required – (NPSHR)
• Cavitation
• NPSHR increases as the flow through the pump
increases
• as flow increases in the suction pipework, friction
losses also increase, giving a lower NPSHA at the
pump suction, both of which give a greater chance
that cavitation will occur
 PUMP CONTROL BY
VARYING SPEED:PURE
FRICTION HEAD
• Reducing speed in the
friction loss system
moves the intersection
point on the system
curve along a line of
constant efficiency
• The affinity laws are
obeyed
 PUMP CONTROL BY
VARYING SPEED:STATIC +
FRICTION HEAD
• Operating point for the pump
moves relative to the lines of
constant pump efficiency when
the speed is changed
• The reduction in flow is no
longer proportional to speed
• A small turn down in speed
could give a big reduction in
flow rate and pump efficiency
• At the lowest speed illustrated,
(1184 rpm), the pump does not
generate sufficient head to
pump any liquid into the system
PUMPS IN PARALLEL
SWITCHED TO MEET
DEMAND
PUMPS IN PARALLEL
WITH SYSTEM CURVE
 PUMPING SYSTEMS

• Ensure adequate NPSH at site of installation.

 PUMPING SYSTEMS

• Ensure availability of basic instruments at

pumps like pressure gauges, flow meters.
 PUMPING SYSTEMS

• Operate pumps near best efficiency point.

 PUMPING SYSTEMS

• Modify pumping system and pumps losses to

minimize throttling.
 PUMPING SYSTEMS

• Adapt to wide load variation with variable

speed drives or sequenced control of
multiple units.
 PUMPING SYSTEMS
• Stop running multiple pumps - add an
auto-start for an on-line spare or add a
booster pump in the problem area.
 PUMPING SYSTEMS
• Use booster pumps for small loads
requiring higher pressures.
 PUMPING SYSTEMS
• Increase fluid temperature differentials to
reduce pumping rates in case of heat
exchangers.
 PUMPING SYSTEMS
• Repair seals and packing to minimize
water loss by dripping.
 PUMPING SYSTEMS
• Balance the system to minimize flows and
reduce pump power requirements.
 PUMPING SYSTEMS

• Avoid pumping head with a free-fall return

(gravity); Use siphon effect to advantage
 PUMPING SYSTEMS

• Conduct water balance to minimise water

consumption
 PUMPING SYSTEMS

• Avoid cooling water re-circulation in DG sets,

air compressors, refrigeration systems, cooling
towers feed water pumps, condenser pumps
and process pumps.
 PUMPING SYSTEMS
• In multiple pump operations,
carefully combine the operation
of pumps to avoid throttling
 PUMPING SYSTEMS

Provide booster pump for few

areas of higher head
 PUMPING SYSTEMS
• Replace old pumps by energy
efficient pumps
 PUMPING SYSTEMS
• In the case of over designed pump,
provide variable speed drive, or
downsize / replace impeller or
replace with correct sized pump for
efficient operation.
 PUMPING SYSTEMS
• Optimise number of stages in multi-
stage pump in case of head margins
 PUMPING SYSTEMS

• Reduce system resistance by pressure

drop assessment and pipe size
optimisation
 PUMPING SYSTEMS

• VFDs may offer operating cost

reductions by allowing higher pump
operating efficiency, but the principal
savings derive from the reduction in
frictional or bypass flow losses
 PUMPING SYSTEMS
• Using a system perspective to identify
areas in which fluid energy is
dissipated in non-useful work often
reveals opportunities for operating
cost reductions.
 PUMPING SYSTEMS
• For example, in many systems,
increasing flow through bypass lines
does not noticeably impact the
backpressure on a pump.
 PUMPING SYSTEMS
• Consequently, in these applications pump
efficiency does not necessarily decline
during periods of low flow demand.
 PUMPING SYSTEMS
• By analyzing the entire system, however,
the energy lost in pushing fluid through
bypass lines and across throttle valves can
be identified.
 PUMPING SYSTEMS

• Another system benefit of VFDs is a soft

start capability. During startup, most
motors experience in-rush currents that
are 5 - 6 times higher than normal
operating currents.
 PUMPING SYSTEMS

• This high current fades when the motor

spins up to normal speed. VFDs allow the
motor to be started with a lower startup
current (usually only about 1.5 times the
normal operating current).
 PUMPING SYSTEMS
• EXAMPLE OF PUMP EFFICIENCY CALCULATION
• A chemical plant operates a cooling water pump for process
cooling and refrigeration applications. During the
performance testing the following operating parameters
were measured;
• Measured Data
• Pump flow, Q 0.40 m3/ s
• Power absorbed, P 325 kW
• Suction head (Tower basin level), h1 +1 M
• Delivery head, h2 55 M
• Height of cooling tower 5 M
• Motor efficiency 88 %
 PUMPING SYSTEMS
• EXAMPLE OF PUMP EFFICIENCY CALCULATION
• Type of drive Direct coupled
• Density of water 996 kg/ m3
• Pump efficiency
• Flow delivered by the pump 0.40 m3/s
• Total head, h2 -(+h1) 54 M
• Hydraulic power 0.40 x 54 x 996 x 9.81/1000 = 211
kW
• Actual power consumption 325 kW
• Overall system efficiency (211 x 100) / 325 = 65 %
• Pump efficiency 65/0.88 = 74 %
 PUMPING SYSTEMS
SYSTEM CURVE

• Location of equipments
• The Refrigeration plant is located at +0.00
level and the Process plant condensers are
located at +15 M level.
• One cooler having a design pressure drop of
1.9 kg/cm2 is located at the 0.00 level
(ground level). Other relevant data can be
inferred from the earlier section.
PUMPING SYSTEMS
SYSTEM CURVE
 PUMPING SYSTEMS
• The step-by-step approach for determining system
resistance curve is given below.
• Step-1 Divide system resistance into Static and dynamic
head
• Find static head;
• Static head (Condenser floor height) ; 15M
• Find dynamic head;
• Dynamic Head = Total Head – Static Head
• Dynamic head = (54-15) = 39 M
 PUMPING SYSTEMS
• STEP-2 Check the maximum
resistance circuit
• Resistance in the different circuits is as
under
PUMPING SYSTEMS
 PUMPING SYSTEMS
• STEP 3 ; Draw system resistance curve
• Choose the condenser loop as it offers maximum
resistance and is also having a static head
component
• Static head: 15 M
• Dynamic head at full load; 39 M
• Compute system resistance at different flow rates
PUMPING SYSTEMS
 PUMPING SYSTEMS

• STEP 4 - Plot the system resistance against flow in

the pump efficiency curves provided by the vendor
and compare actual operating duty point and see
whether it operates at maximum efficiency.
• In the example provided it is found that the pump
system efficiency is lower by 4 % due to change in
operating conditions.
PUMPING SYSTEMS
SYSTEM RESISTANCE CURVE