ENERGY CONSERVATION IN PUMPS

Presented By

M.V.Pande Dy.Director NPTI, Nagpur

INTRODUCTION
Pumps provide the motive force to move liquids against the resistance of a piping system and against changes in elevation. Pumping systems account for nearly 20% of the worlds electrical energy demand. Furthermore, they range between 25-50% of the energy usage in certain industrial plant operations A centrifugal pump is one of the simplest pieces of equipment in any process plant.

WATER PUMPS IN POWER STATION

BOILER FEED WATER PUMP

Boiler feed pump is the major power consumer among all power consuming equipment in the power plant. BFP may constitute about 25% of the total auxiliary power consumption. BFP Main Parameters for 210 MW unit
Motor Speed Disch. head Capacity Power kW mWC TPH RPM 200 KHI 1834.6 430 4000 4320 FK 6D 30 Model

5050

2104

398

3500

BFP LAYOUT

BFP LAYOUT

Centrifugal Pumps
The purpose of a centrifugal pump is to first convert energy of a prime mover, such as a electric motor or turbine, into velocity or kinetic energy, Then this is converted further into pressure energy of a fluid that is being pumped.

Pumping System Characteristics

HEAD LOSS To transfer a liquid from a source to a required destination, or to circulate liquid around a system, pressure is needed to make the liquid flow at the required rate. This must overcome the head losses in the system. Losses are of two types, static and friction head. STATIC HEAD Static head is simply the difference in height of the supply and destination reservoirs and is independent of flow. Static Head

Static Head vs. Flow

Dynamic (Friction) Head

Friction head is the head required to overcome the resistance to flow in the pipe and fittings. It is dependent upon the size, condition and type of pipe, number and type of pipe fittings, flow rate, and nature of the liquid. The friction losses are proportional to the square of the flow rate. A closed loop circulating system without a surface open to atmospheric pressure, would exhibit only friction losses and would have a system friction head loss vs. flow curve.

Friction Head vs. Flow

System With High Static Head

System With Low Static Head

Pump Curve
The performance of a pump can be expressed graphically as head against flow rate. The centrifugal pump has a curve where the head falls gradually with increasing flow.

Pump Operating Point

The operating point of the pump is determined by the intersection of the system curve and the pump curve A pump application might need to cover several duty points, of which the largest flow and/or head will determine the rated duty for the pump. For a centrifugal pump, an increasing system resistance will reduce the flow, but the maximum head is limited

Pump Suction Performance (NPSH)

Cavitation may occur when the local static pressure in a fluid reach a level below the vapor pressure of the liquid at the actual temperature. This may happen when the fluid accelerates in a control valve or around a pump impeller. The vaporization itself does not cause the damage. Instead the damage happens when the vapor almost immediately collapses after evaporation as velocity is decreased and pressure increased. There are three undesirable effects of cavitation: 1. The collapsing cavitation bubbles can erode the vane surface, especially when pumping water-based liquids. 2. Noise and vibration are increased, with possible shortened seal and bearing life. 3. The cavity areas will initially partially choke the impeller passages and reduce the pump performance. In extreme cases, total loss of pump developed head occurs.

The value, by which the pressure in the pump suction exceeds the liquid vapour pressure, is expressed as a head of liquid and referred to as net positive suction head available, NPSHA.

Pump Performance Curve

Hydraulic Power, Pump Shaft Power and Electrical Input Power

Pump output/Hydraulic power is the liquid horsepower delivered by the pump

Hydraulic power Ph = Q (m3/s) x Total 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 input (Ps) is the actual power delivered to the pump shaft Pump shaft power Ps = Hydraulic power, Ph pump efficiency, Pump Electrical input power = Pump shaft power P Motor

Typical Pump Characteristic Curves

This figure illustrates a typical vendor-supplied head-flow curve for a centrifugal pump. Pump head-flow curves are typically given for clear water. The choice of pump for a given application depends largely on how the pump head-flow characteristics match the requirement of the system downstream of the pump.

Affinity Laws
For a centrifugal pump, there is a relationship between the impeller peripheral velocity and the generated head. Peripheral velocity is directly related to shaft rotational speed, for a fixed impeller diameter. Subsequently varying the rotational speed has a direct effect on the performance of the pump. All the parameters like head, efficiency, power etc. will change if the speed is varied. Therefore, it is important to have an appreciation of how these parameters vary in order to safely control a pump at different speeds. The equations that relate roto-dynamic pump performance parameters of flow, head and power absorbed, to speed are known as the affinity laws. They say that flow rate is proportional to the rotating speed; head is proportional to the square of the rotating speed; and that power is proportional to the cube of the rotating speed. It is relevant to note that flow control by speed regulation is always more efficient than by a control valve.

Flow vs Speed
If the speed of the impeller is increased from N1 to N2 rpm, the flow rate will increase from Q1 to Q2 as per the given formula:

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 = 1480/740
Q2 = 50 m3/hr

Head Vs speed
The head developed(H) will be proportional to the square of the quantity discharged, so that

Head:
H1/H2 = (N12) / (N22) Example: 100 /H2 = (14802) / (7402)
H2 = 25 m

Power Vs Speed
The power consumed(W) will be the product of H and Q, and, therefore

Power(kW):
kW1 / kW2 = (N13) / (N23) Example: 50/kW2 = (14803) / (7403)
As can be seen from the affinity laws, reducing the speed by half of the centrifugal pump, will reduce the power consumption by 8 times. This forms the basis for energy conservation in centrifugal pumps with varying flow requirements.

kW2 = 6.25

Energy Efficiency Opportunities

ENERGY CONSERVATION OPPORTUNITIES

Avoiding over sizing of pump
Pump Curve at Const. Speed 70 m 50 m 42 m Head Meters Static Head 300 500 System Curves Pump Efficiency 77%
Oversize Pump

B Partially closed valve

82%

A
Full open valve

Required Pump

Operating Points

Flow (m3/hr)

1.Avoiding Over sizing of Pump- contd. Efficiency Curves

28.6 kW

14.8 kW

If we select impeller 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 = 16.1 kW (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%)

1.Avoiding Over sizing of Pump- contd.

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.

2.Using variable speed drives (VSD) for variable flow

Most existing systems that require flow control make use of bypass lines, throttling valves, or pump speed adjustments. As mentioned earlier, the most efficient of these is pump speed control. When a pumps speed is reduced, less energy is imparted to the fluid and less energy needs to be throttled or bypassed. There are two primary methods of reducing pump speed : Multiple speed pump method & variable speed drive. We are looking closer at the variable speed drive, also called VSD. VSDs allow pump speed adjustments over a continuous range and avoid the need to jump from speed to speed as with multiple-speed pumps. The major advantages of VSD application in addition to energy saving are: First, improved process control. By matching pump output flow or pressure directly to the process requirements, small variations can be corrected more rapidly by a VSD than by other control forms, which improves process performance. Secondly, improved system reliability: Any reduction in speed achieved by using a VSD has major benefits in reducing pump wear, particularly in bearings and seals. Furthermore, by using reliability indices, the additional time periods between maintenance or breakdowns can be accurately computed. Third, reduction of capital and maintenance costs: Offset the capital cost of a VSD by eliminating control valves, by-pass lines, and conventional starters. Fourth, soft starter capability: VFDs allow the motor the motor to have a lower startup current.

Effect of speed variation

Pump flow 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 flow 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

3.Reducing impeller diameter

Changing the impeller diameter gives a proportional change in peripheral velocity 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 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. 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 manufacturers performance curves should be referred to

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 Power (KW): 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

Impeller Diameter Reduction on Centrifugal Pump Performance

4. Impeller Trimming
For this option, the following should be considered: This option cannot be used where varying flow patterns exist. The impeller should not be trimmed more than 25% of the original impeller size, otherwise it leads to vibration due to cavitation and therefore decrease the pump efficiency. The balance of the pump has to been maintained, i.e. the impeller trimming should be the same on all sides. Changing the impeller itself is a better option than trimming the impeller, but is also more expensive and sometimes the smaller impeller is too small.

5. Use of Pumps in parallel to meet varying demand

Particularly for systems where static head is a high proportion of the total, another energy efficient method of flow control is to install two or more pumps to operate in parallel. Variation of flow rate is achieved by switching on and off additional pumps to meet demand. The combined pump curve is obtained by adding the flow rates at a specific head

Energy Conservation Opportunities in Pumping Systems- Summary

Understand system characteristics Avoid over sizing of pumps Consider impeller trimming and other easy-to implement alternatives Consider variable speed drives wherever possible Operate pumps near best efficiency point. Modify pumping system/pumps losses to minimize throttling. Stop running multiple pumps - add an auto-start for an on-line spare or add a booster pump in the problem area. Conduct water balance to minimise water consumption Replace old pumps by energy efficient pumps

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