Global Training and

Support Guide

Smart Energy

Energy-Efficient Flow Solutions

For more than a century, Blackmer has been at the forefront of flow technology problem solving. From the first
positive displacement rotary vane pump to its patented cavitation/noise suppression innovation, Blackmer has
led the way in solutions for the safe, reliable and energy-efficient transfer of high-value and hazardous liquids
and gases in mobile and process applications worldwide.

Centrifugal
Pumps
Positive
Displacement,
Sliding Vane
Pumps

Reciprocating
Gas Compressors

Peristaltic
(Hose) Pumps

Smart Energy

Energy-Efficient Flow Solutions

Introduction
High energy prices impose a competitive and
profit-robbing threat to every manufacturing operation,
large or small, worldwide
Left unmanaged, energy expenditures can quietly
and quickly erode a companys financial performance,
productivity, and competitive position

Smart Energy

Energy-Efficient Flow Solutions

Smart Energy Management is the Key to:

Driving productivity improvements that increase
financial performance
Controlling energy expenses by reducing power
consumption without compromising output
performance
Increasing operational reliability by emphasizing
the use of energy-efficient technologies that support
enhanced mechanical efficiency
Reducing vulnerability to energy price volatility

Smart Energy

Energy-Efficient Flow Solutions

Blackmer started its Smart Energy Flow Solutions

initiative to help educate companies on how they
can reduce energy consumption through the
use of positive displacement sliding vane
pump technologies.

Blackmer Smart Energy Flow Solutions Mission

Enable pump users to a gain a competitive business advantage through
the deployment of energy-saving positive displacement sliding vane
pump technology.
Blackmer will accomplish this mission by providing end-users, engineering
consultants, OEMs, and distributors with education, tools, and knowledge on
the energy-saving value and performance-enhancing advantages of positive
displacement sliding vane pumps.

Smart Energy

Energy-Efficient Flow Solutions

A Global Opportunity
Worldwide industrial energy consumption is expected to increase
by 42%, or an average of 1.3% per year, from 2007 to 2035.
95% of the growth occurs in
developing nations.
Global energy consumption rose in
2010 at the fastest pace since 1973,
as rapidly growing developing nations
led a strong rebound from the Great
Recession.
China has now surpassed the United
States as the worlds biggest
consumer of energy, accounting for
20.3% of global demand compared
with 19% for the U.S.

Smart Energy

Energy-Efficient Flow Solutions

Key Points to Ponder

Pumps represent 27% of the electricity used in industrial applications*

Energy is the single largest cost-of-ownership component of an industrial pump
system representing between 50-90% of total life cycle costs, depending
on the technology
A reduction of energy consumption is a key component to controlling costs
Using the right pump technology, properly sized for a specific
application, is an important step towards reducing pump
energy consumption

Industrial Energy
Consumption

*Source: Hydraulic Institute

Smart Energy

Energy-Efficient Flow Solutions

Pumps A Vital Part of an Energy-Efficient System

There is a specific best use for every pump technology
Understanding how pump efficiency, system
efficiency and overall energy efficiency are measured
and affected by the pumps and overall system
configuration is vital to developing a successful
energy-efficient pumping system
Knowing the fundamental advantages and disadvantages
between pump technologies is necessary to selecting
the right pump for optimum performance and
energy-saving results

Smart Energy

Energy-Efficient Flow Solutions

Choosing The Right Pump Technology Can Help a

Company Achieve Simultaneous Goals:
Reduce energy
consumption

Improve worker
safety

Reduce operations,
production and
maintenance costs

Improve capacity
utilization

Improve
productivity

Improve system
reliability

Improve product
quality

Smart Energy

Energy-Efficient Flow Solutions

Published Reports confirm many opportunities for companies

to immediately improve bottom line performance through
energy-efficient pump system improvements

Source: Pump Systems Matter U.S. Industrial Motor Systems Market Opportunities Assessment,
U.S. Department of Energy

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Smart Energy

Energy-Efficient Flow Solutions

A dollar saved on energy, maintenance or production is

equivalent to $17 in sales income (assuming a 6% gross margin)*

* SOURCE: Northwest Energy Efficiency Alliance / Industrial Efficiency Alliance How Continuous Energy
Improvements Reduce Costs and Improve System Performance

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Smart Energy

Energy-Efficient Flow Solutions

Managing Global Energy Consumption

Global net electricity demand is projected to grow by 1.4%
per year between 2007 and 2035, with the strongest growth
in developing countries.
The chemical industry made up 22% of the total world industrial energy
consumption in 2007. Energy represents 60% of this industrys operating costs.

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Smart Energy

Energy-Efficient Flow Solutions

Managing Global Energy Consumption

Improving the energy efficiency of even one pump in a
manufacturing process could produce substantial financial
savings for any operation.
The table to the right
summarizes the electrical
costs of a continuously
operated centrifugal pump
(driven by a 100 HP motor)
at 10 cents per kWh.
Even a 10% reduction
in energy consumption
adds up to considerable
savings.

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Smart Energy

Energy-Efficient Flow Solutions

Geographic Opportunities

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Smart Energy

Energy-Efficient Flow Solutions

Geographic Opportunities
Americas
United States
2.4 million pumps consuming 142 billion kWh annually
Projected 25% reduction in industrial production energy use by 2017

Canada
Projected 0.6% industrial energy consumption growth rate in next 20 years

Mexico
1.9% annual industrial energy consumption growth rate

South America
Brazil 2.1% annual industrial energy consumption growth rate

Other Central & South American Countries

20% projected growth rate between 2007-2035

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Smart Energy

Energy-Efficient Flow Solutions

Geographic Opportunities
EMEA
Europe
Energy legislation mandating Smart Meters to gauge electric usage

Russia
Least energy-efficient economy in the world
0.2% annual projected industrial energy growth

Middle East
2.2% annual industrial energy consumption growth rate
Chemical sector is the largest consumer of energy
Numerous petrochemical projects underway in Saudi Arabia, Qatar, Kuwait,
UAE, and Iran

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Smart Energy

China

Energy-Efficient Flow Solutions

Geographic Opportunities
Asia

Industrial sector accounts for

75% of total energy consumption
High demand for industrial pumps
due to infrastructure development
Government mandates dramatic
energy reduction in the coming
decade

India
Growth expected from light
manufacturing and services
Opportunities are abundant as
government mandates industries
to develop efficiencies in energy
consumption

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Between 2003 and 2006, this market witnessed rapid growth driven by the huge
demand from industries such as water and wastewater treatment, power
generation, oil and gas, and chemicals and petrochemicals.

Smart Energy

Energy-Efficient Flow Solutions

How To Measure Energy Efficiency in Pumps

Pumps waste energy when they fail to convert the electric power they consume
into the fluid motion they were designed to provide
Critical measurement equations used to select a new pump or when analyzing a
pump system for energy efficiency:
Efficiency =

Imparted Energy
Inputted Energy

Specific Energy =

Energy Used
Pumped Volume

Power =

Energy Converted
Time Taken

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Smart Energy

Energy-Efficient Flow Solutions

How To Measure Energy Efficiency in Pumps

Horsepower
(alternating =
current)

19

kW x Efficiency
746

Smart Energy

Energy-Efficient Flow Solutions

Measuring & Managing Energy Consumption

When pumps operate at optimum levels they use less energy and increase
reliability, saving both energy and maintenance costs
The maintenance and productivity benefits of improving a pump systems
performance are generally one to two times the value of the energy savings

Calculating Potential Energy Savings

Savings = kW (in input electric energy) x Annual Operating Hours x

(1 Actual System Efficiency)

Optimal System Efficiency

EXAMPLE:
1) Operating Efficiency (300 HP pump = 55% Efficiency)
2) Optimal Operating Efficiency (300 HP = 78% Efficiency)
3) Pump draws 235 kW x 6,000 hours of service per year
Savings = 235 kW x 6,000 Hrs/Yr x

20

(1 - 0.55)
0.78

= 415,769 kWh per year @ 0.05 per kWh = $20,788 Savings

Smart Energy

Energy-Efficient Flow Solutions

Reducing Energy Waste Begins with

Proper Pump Selection for the Application
Select the pump technology best
suited for the application
Properly size pumps, control valves
and piping for real-time requirements
(avoid excessive margin of error
capacity and/or total pressure
or head)
Reduce restrictions, turbulence
and frictional losses

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Smart Energy

Energy-Efficient Flow Solutions

Reducing Energy Waste Begins with

Proper Pump Selection for the Application
Ensure proper motor alignment (poor alignment of motor
and load increases motor power consumption)
Reduce flow rates = lower energy losses
Lower operating pressures
Maintain pumps and system components to avoid
efficiency loss (wear is a significant cause of decreased
pump efficiency; corrosion in pipes increases friction)

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Smart Energy

Energy-Efficient Flow Solutions

Consider Application When Choosing

Pumping Equipment

23

1. HOW MUCH FLOW?

Approximate DELIVERY
required in gallons/litres
per minute

5. HOW THICK?
Maximum VISCOSITY
of the liquid in Seconds
Saybolt Universal (SSU)

2. HOW MUCH PUSH?

Differential PRESSURE
required in pounds per
square inch (PSI) or Bar

6. HOW HOT?
Pumping TEMPERATURE
of the liquid in degrees
of Fahrenheit or Centigrade

3. WHAT LIQUID?
Type of LIQUID to
be handled

7. HOW MUCH PULL?

SUCTION conditions when
pumping in vacuum, or PSI/Bar
for pressure

4. HOW HEAVY?
Specific GRAVITY
of the liquid

8. HOW LONG?
Type of SERVICE, e.g., intermittent
duty, semi-continuous duty, or
continuous duty

Smart Energy

Energy-Efficient Flow Solutions

Many pump users do not know how to properly

select and apply pumps to a system, so pump
system operating costs are inadvertently
increased as a result.

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Using pump selection software

programs can help operators
optimize pump selection

Leading pump manufacturers

also provide applications and
engineering expertise, pump
specification and selection
programs, technical training
and support

allows users to select pump data and pump curves so

they can select the proper positive displacement or
centrifugal pumps for their application.

Smart Energy

Energy-Efficient Flow Solutions

Proper Pump Selection

Although the operating principles of positive displacement and
centrifugal pumps differ widely, both types of pumps can be used
to serve many of the same applications

Source: Schematic courtesy of

Chemical Processing Magazine

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Smart Energy

Energy-Efficient Flow Solutions

Its time to put some energy into learning about the energy-saving
advantages of positive displacement sliding vane pumps
There is no one-pump-fits-all
solution
The right pump delivers
productivity gains and helps
control energy consumption
Positive displacement sliding vane
pumps, by virtue of their inherent
energy and mechanically-efficient
designs, are uniquely suited to
offer manufacturers immediate
advantages in performance
and energy savings

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Smart Energy

Energy-Efficient Flow Solutions

Using LCC (Life Cycle Costs) for Proper Pump Selection

27

An analysis of Life Cycle Costs

(LCC) can dramatically reduce
waste and maximize efficiency
The NET cost savings based on
LCC will often justify a higher
initial price for a more energyefficient pump
Life-cycle costing helps identify
the lowest total cost of ownership
by considering:
Initial equipment cost
Installation and Commissions
Energy costs
Maintenance and Repairs
Downtime costs
Decommissioning costs

Total Life Cycle Cost (LCC)

LCC Relative Comparison

Centrifugal vs. Positive Displacement (PD) Pumps

Centrifugals
Initial Pump Cost
Energy Cost

PD Pumps
Installation, maintenance,
operating, environmental
and downtime costs

Smart Energy

Energy-Efficient Flow Solutions

Basic Comparison Centrifugal Pumps Vs. Positive Displacement Pumps

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Centrifugal

Positive Displacement

Mechanics

Imparts velocity to the liquid resulting in

a pressure at the outlet (pressure is
created and flow results)

Captures confined amounts of liquid and

transfers it from the suction to the
discharge port (flow is created and
pressure results)

Performance

Flow varies with changing pressure

Flow is constant with changing pressure

Viscosity

Efficiency decreases with increasing

viscosity due to frictional losses inside
the pump (typically not used on
viscosities above 850 cSt)

Efficiency increases with increasing

viscosity

Efficiency

Efficiency peaks at best-efficiencypoint. At higher or lower pressures,

efficiency decreases.

Efficiency increases with increasing

pressure

Inlet Conditions

Liquid must be in the pump to create a

pressure differential. A dry pump will not
prime on its own

Negative pressure is created at the inlet

port. A dry pump will prime on its own

Smart Energy

Energy-Efficient Flow Solutions

Comparing Centrifugal Pumps to

Positive Displacement Pumps

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If the system calls for:

The best pump to use

is:

Pressurized network of piping with a constant pressure

requiring constant flow rate

Centrifugal

Constant flow at various pressures

Positive Displacement

Constant flow at various viscosities

Positive Displacement

Constant flow at high viscosities (Particularly above 850 cSt)

Positive Displacement

Line stripping

Positive Displacement

Dry running short duration

Positive Displacement

Priming

Positive Displacement

Shear sensitive

Positive Displacement

Entrained gases

Positive Displacement

High flow/low head

Centrifugal

Low flow/high head

Positive Displacement

Smart Energy

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Energy-Efficient Flow Solutions

Smart Energy

Energy-Efficient Flow Solutions

Consider Positive Displacement Pumps

over Centrifugal Pumps when:
1. Working fluid is highly viscous (over 850 cSt)
2. Flow rate must be predictable over a wide
flow range (flow must be metered or
precisely controlled)
3. Flow rate must remain constant under varying
system pressures
4. System requires high-pressure, low-flow
5. Line stripping is required (some PD technologies)
6. Suction lift or self-priming is required
7. Working fluid is shear-sensitive
8. Energy-savings/efficiency is a primary concern

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Smart Energy

Energy-Efficient Flow Solutions

Positive Displacement Pumps Are Not Created Equal

PD pumps make up approximately 15% of industrial pump population

There are significant differences between PD pump types

PD Pump

Features

Sliding
Vane

Internal
Gear

Differential pressure to 200 psi (higher pressures are

attainable)
Speed to 3,600 RPM
Metal-to-metal gear wears and slips over time, resulting
in efficiency degradation and higher energy consumption

Exceptional for thin liquids

Excellent on thick liquids at slow speeds
Exceptional efficiency at low flow rates
Excellent suction lift and line stripping capabilities
Self-adjusting vanes provide substantial energy savings
High mechanical efficiency = energy savings
Differential pressure to 200 psi
Speed to 3,600 RPM
Low energy consumption

Viscosity Range

Flow Rates

Very thin (LPG,

Refrigerants,
Solvents, Fuel
Oils, Gasoline,
Liquid Carbon
Dioxide,
Ammonia,
etc.) to high
viscosities up to
50,000 cSt

3.79 to >7,580 L/min

(1 to > 2,000 GPM)

High viscosities up to
1,000,000 cSt

1.8 - 5,685 L/min

(0.5 - 1,500 GPM)

Improper pump selection can cost money in downtime,

lost production, maintenance costs and energy consumption.

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Smart Energy

Energy-Efficient Flow Solutions

PD Pump

Features

Viscosity Range

Flow Rates

External Gear

Do not perform well under critical suction conditions, especially

with volatile liquids
Good for high pressure applications such as hydraulics
Differential pressure to 3,000 psi+
Speed to 3,600 RPM
Metal-to-metal gear design subject to efficiency degradation
Must be rebuilt or replaced
No clearance adjustments for wear which results in slip,
efficiency degradation and higher energy consumption

High viscosities up to
1,000,000 cSt

Drops per minute to

5,685 L/min
(Drops per minute to
1,500 GPM)

Lobe

Used frequently for food-type products due to sanitary nature

and ease of cleaning
Vertical drain port reduces efficiency by 15-20%
Sanitary models: Differential pressure to 200 psi
Non-sanitary models: Differential pressure to 400 psi

Low viscosity with

diminished performance
up to 1,000,000 cSt

19 - 11,370 L/min
(5 - 3,000 GPM)

Air Diaphragm
(AODD)

No bearings or rotating shaft

Can handle a wide range of shear-sensitive, abrasive and
non-abrasive liquids as well as solids
High pressure operation can cause excessive wear around
valve seats as the check valve closes
Variable speed flow operation
Requires air compression system. Electricity is used to run
compressors.
Energy accounts for 70% of compressed air life cycle cost - air
is not free.
High energy costs.

Medium viscosity to
26,000 cSt

3.79 - 1,895 L/min

(1 - 500 GPM)

Improper pump selection can cost money in downtime,

lost production, maintenance costs and energy consumption.

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Smart Energy

Energy-Efficient Flow Solutions

Sliding Vane Pumps vs. Internal Gear Pumps

Sliding Vane and Eccentric Disc Pumps vs. Gear and Lobe Pumps
Sliding Vane Pumps

Superior mechanical performance

Less mechanically efficient

Provides greater energy savings

Consume more energy than sliding

vane pumps

24% more efficient than gear pumps

Sliding vanes automatically adjust to maintain
near perfect clearances throughout operating life
Energy-wasting turbulence and slippage are
minimized and high volumetric efficiency and low
energy consumption are maintained

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Internal Gear Pumps

The metallic gears wear over time resulting

in wider clearances. This increases energyrobbing slippage and significantly decreases
volumetric efficiency
In order to compensate for performance
degradation, pump speed is increased which
requires greater energy consumption

Smart Energy

Energy-Efficient Flow Solutions

Energy Cost Comparison

Vane/Lobe/Gear

Mechanical Efficiency

From the lowest to the highest viscosity, sliding vane technology

provides the highest level of mechanical efficiency which equates
into the lowest energy consumption.
90
80
70
60
50
40
30
20
10
0

Vane
Lobe
Gear

160

530

Viscosity (cSt)

35

1620

189 - 379 L/min (50-100 GPM);

3.45 - 6.90 Bar (50-100 PSI);
4-1,620 cSt viscosity;
same model on all viscosities

Smart Energy

Energy-Efficient Flow Solutions

Sliding Vane Pumps vs. Internal Gear Pumps

Sliding vane pump technology
not only reduces energy costs
but helps to create an overall
more efficient pumping system,
providing solutions for seals,
suction, product shear, and
volumetric efficiency problems.

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Smart Energy

Energy-Efficient Flow Solutions

Sliding Vane Pumps vs. Internal Gear Pumps

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Smart Energy

Energy-Efficient Flow Solutions

Summary
Left unmanaged, energy costs can quietly erode profits
Pumps account for 27% of total electrical use in the
industrial sector
Pump system improvements such as using the proper pump for
the application can help to reduce energy consumption
Positive displacement sliding vane pumps are inherently energyefficient and offer advantages over centrifugal pumps and other
PD pumps in specific applications
A dollar saved on energy, maintenance or production is
equivalent to $17 in sales income (assuming a 6% gross margin).
Northwest Energy Efficiency Alliance

Energy-saving advice is available from:

Blackmer Smart Energy Initiative (www.BlackmerSmartEnergy.com)

U.S. Department of Energy (Industrial Technology Program)

Hydraulic Institute (Pump Systems Matter)

Northwest Energy Efficiency Alliance

Smart Energy

Energy-Efficient Flow Solutions

Blackmers Commitment to Sustainability

Blackmer Smart Energy
Solutions
We are proud to provide customers
with products that enable them to
reduce energy consumption and
preserve natural resources.
Blackmer cares deeply about
pioneering new technologies and
processes that allow our partners to
promote sustainability for our world.

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Smart Energy

Energy-Efficient Flow Solutions

A Valuable Resource

www.blackmersmartenergy.com