Training Session on Energy

Equipment

Pumps & Pumping

Electrical Equipment/

Systems
Pumps

Presentation from the

“Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org

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© UNEP 2006
 Training Agenda: Pumps

Introduction
Electrical Equipment/

Type of pumps
Pumps

Assessment of pumps
Energy efficiency opportunities

2
© UNEP 2006
 Introduction

What are Pumping Systems

Electrical Equipment/

• 20% of world’s electrical energy

demand
Pumps

• 25-50% of energy usage in some

industries
• Used for
• Domestic, commercial, industrial and
agricultural services
• Municipal water and wastewater services
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© UNEP 2006
 Introduction

What are Pumping Systems

Electrical Equipment/

Objective of pumping system

Pumps

• Transfer liquid
from source to
destination
• Circulate liquid
around a system
(US DOE, 2001)
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© UNEP 2006
 Introduction

What are Pumping Systems

Electrical Equipment/

• Main pump components

• Pumps
Pumps

• Prime movers: electric motors, diesel engines,

air system
• Piping to carry fluid
• Valves to control flow in system
• Other fittings, control, instrumentation
• End-use equipment
• Heat exchangers, tanks, hydraulic machines 5
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 Introduction

Pumping System Characteristics

Electrical Equipment/

• Head
destination
• Resistance of the system Stati
c
• Two types: static and friction
Pumps

head

source
• Static head
• Difference in height between
source and destination Static
head
• Independent of flow

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Flow© UNEP 2006
 Introduction

Pumping System Characteristics

Electrical Equipment/

• Static head consists of

• Static suction head (hS): lifting liquid relative to
Pumps

pump center line

• Static discharge head (hD) vertical distance
between centerline and liquid surface in
destination tank
• Static head at certain pressure
Head (in feet) = Pressure (psi) X 2.31
Specific gravity
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© UNEP 2006
 Introduction

Pumping System Characteristics

Electrical Equipment/

• Friction head
• Resistance to flow in pipe and fittings
Pumps

• Depends on size, pipes, pipe fittings, flow

rate, nature of liquid
• Proportional to square of flow rate
• Closed loop system
only has friction head Friction
head
(no static head)

Flow 8
© UNEP 2006
 Introduction

Pumping System Characteristics

Electrical Equipment/

In most cases:
Total head = Static head + friction head
Pumps

System
System
curve
Friction curve
head
System System
head head Friction
Static head head

Static head

Flow Flow
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© UNEP 2006
 Introduction

Pumping System Characteristics

Electrical Equipment/

Pump performance curve

• Relationship between
Pumps

head and flow Head

• Flow increase
• System resistance increases
• Head increases Flow

• Flow decreases to zero Performance curve for

centrifugal pump
• Zero flow rate: risk of
pump burnout
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© UNEP 2006
 Introduction

Pumping System Characteristics

Electrical Equipment/

Pump operating point

Pumps

• Duty point: rate Pump performance

curve
of flow at certain
Pump
head operating
• Pump operating Head System point
curve
point:
intersection of Static
head
pump curve and
system curve
Flow
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© UNEP 2006
 Introduction

Pumping System Characteristics

Electrical Equipment/

Pump suction performance (NPSH)

• Cavitation or vaporization: bubbles inside pump
Pumps

• If vapor bubbles collapse

• Erosion of vane surfaces
• Increased noise and vibration
• Choking of impeller passages
• Net Positive Suction Head
• NPSH Available: how much pump suction
exceeds liquid vapor pressure
• NPSH Required: pump suction needed to avoid 12
cavitation © UNEP 2006
 Training Agenda: Pumps

Introduction
Electrical Equipment/

Type of pumps
Pumps

Assessment of pumps
Energy efficiency opportunities

13
© UNEP 2006
 Type of Pumps

Pump Classification
Electrical Equipment/

Classified by operating principle

Pumps

Pumps

Others (e.g. Positive

Dynamic Impulse, Buoyancy) Displacement

Centrifugal Special effect Rotary Reciprocating

Internal External Slide

Lobe
gear gear vane 14
© UNEP 2006
 Type of Pumps

Positive Displacement Pumps

Electrical Equipment/

• For each pump revolution

• Fixed amount of liquid taken from one end
Pumps

• Positively discharged at other end

• If pipe blocked
• Pressure rises
• Can damage pump

• Used for pumping fluids other than

water 15
© UNEP 2006
 Type of Pumps

Positive Displacement Pumps

Electrical Equipment/

• Reciprocating pump
• Displacement by reciprocation of piston
Pumps

plunger
• Used only for viscous fluids and oil wells

• Rotary pump
• Displacement by rotary action of gear, cam
or vanes
• Several sub-types
• Used for special services in industry 16
© UNEP 2006
 Type of Pumps

Dynamic pumps
Electrical Equipment/

• Mode of operation
• Rotating impeller converts kinetic energy
Pumps

into pressure or velocity to pump the fluid

• Two types
• Centrifugal pumps: pumping water in
industry – 75% of pumps installed
• Special effect pumps: specialized conditions

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 Type of Pumps

Centrifugal Pumps
Electrical Equipment/

How do they work?

• Liquid forced into
Pumps

impeller
• Vanes pass kinetic
energy to liquid: liquid
rotates and leaves
impeller
• Volute casing converts
kinetic energy into
pressure energy
(Sahdev M) 18
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 Type of Pumps

Centrifugal Pumps
Electrical Equipment/

Rotating and stationary components

Pumps

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(Sahdev)
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 Type of Pumps

Centrifugal Pumps
Electrical Equipment/

Impeller Sahdev)

• Main rotating part that provides centrifugal

acceleration to the fluid
Pumps

• Number of impellers = number of pump stages

• Impeller classification: direction of flow, suction type
and shape/mechanical construction

Shaft
• Transfers torque from motor to impeller during pump
start up and operation
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© UNEP 2006
 Type of Pumps

Centrifugal Pumps
Electrical Equipment/

Casings
• Functions Volute Casing (Sahdev)
• Enclose impeller as “pressure vessel”
Pumps

• Support and bearing for shaft and impeller

• Volute case
• Impellers inside casings
• Balances hydraulic pressure on pump shaft

• Circular casing
• Vanes surrounds impeller
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• Used for multi-stage pumps © UNEP 2006
 Training Agenda: Pumps

Introduction
Electrical Equipment/

Type of pumps
Pumps

Assessment of pumps
Energy efficiency opportunities

22
© UNEP 2006
 Assessment of pumps

How to Calculate Pump Performance

Electrical Equipment/

• Pump shaft power (Ps) is actual horsepower

delivered to the pump shaft
Pump shaft power (Ps):
Pumps

Ps = Hydraulic power Hp / pump efficiency ηPump

Pump Efficiency (ηPump):
ηPump = Hydraulic Power / Pump Shaft Power

• Pump output/Hydraulic/Water horsepower (Hp) is

the liquid horsepower delivered by the pump
Hydraulic power (Hp):
Hp = Q (m3/s) x Total head, hd - hs (m) x ρ (kg/m3) x g (m/s2) / 1000

hd - discharge head hs – suction head, 23

ρ - density of the fluid g – acceleration due to gravity
© UNEP 2006
 Assessment of pumps

Difficulties in Pump Assessment

Electrical Equipment/

• Absence of pump specification data

to assess pump performance
Pumps

• Difficulties in flow measurement and

flows are often estimated
• Improper calibration of pressure
gauges & measuring instruments
• Calibration not always carried out
• Correction factors used 24
© UNEP 2006
 Training Agenda: Pumps

Introduction
Electrical Equipment/

Type of pumps
Pumps

Assessment of pumps
Energy efficiency opportunities

25
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 Energy Efficiency Opportunities

1. Selecting the right pump

Electrical Equipment/

2. Controlling the flow rate by speed

variation
Pumps

3. Pumps in parallel to meet varying

demand
4. Eliminating flow control valve
5. Eliminating by-pass control
6. Start/stop control of pump
7. Impeller trimming 26
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 Energy Efficiency Opportunities

1. Selecting the Right Pump

Electrical Equipment/

Pump performance curve for centrifugal

pump
Pumps

BEE India,
2004
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© UNEP 2006
 Energy Efficiency Opportunities

1. Selecting the Right Pump

Electrical Equipment/

• Oversized pump
• Requires flow control (throttle valve or by-
pass line)
Pumps

• Provides additional head

• System curve shifts to left
• Pump efficiency is reduced

• Solutions if pump already purchased

• VSDs or two-speed drives
• Lower RPM
• Smaller or trimmed impeller 28
© UNEP 2006
 Energy Efficiency Opportunities

2. Controlling Flow: speed

variation
Electrical Equipment/

Explaining the effect of speed

• Affinity laws: relation speed N and
Pumps

• Flow rate Q  N
• Head H  N2
• Power P  N3

• Small speed reduction (e.g. ½) = large

power reduction (e.g. 1/8)
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© UNEP 2006
 Energy Efficiency Opportunities

2. Controlling Flow: speed

variation
Electrical Equipment/

Variable Speed Drives (VSD)

• Speed adjustment over continuous
range
Pumps

• Power consumption also reduced!

• Two types
• Mechanical: hydraulic clutches, fluid couplings,
adjustable belts and pulleys
• Electrical: eddy current clutches, wound-rotor
motor controllers, Variable Frequency Drives
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(VFDs)
© UNEP 2006
 Energy Efficiency Opportunities

2. Controlling Flow: speed

variation
Electrical Equipment/

Benefits of VSDs
• Energy savings (not just reduced flow!)
Pumps

• Improved process control

• Improved system reliability
• Reduced capital and maintenance
costs
• Soft starter capability
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© UNEP 2006
 Energy Efficiency Opportunities

3. Parallel Pumps for Varying Demand

Electrical Equipment/

• Multiple pumps: some turned off during low

demand
Pumps

• Used when static head is >50% of total head

• System curve
does not change
• Flow rate lower
than sum of
individual
flow rates
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(BPMA)
© UNEP 2006
 Energy Efficiency Opportunities

4. Eliminating Flow Control Valve

Electrical Equipment/

• Closing/opening discharge valve (“throttling”)

to reduce flow
Pumps

• Head increases:
does not reduce
power use
• Vibration and
corrosion: high
maintenance
costs and reduced
pump lifetime
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(BPMA)
© UNEP 2006
 Energy Efficiency Opportunities

5. Eliminating By-pass Control

Electrical Equipment/

• Pump discharge divided into two

flows
Pumps

• One pipeline delivers fluid to destination

• Second pipeline returns fluid to the source

• Energy wastage because part of fluid

pumped around for no reason

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© UNEP 2006
 Energy Efficiency Opportunities

6. Start / Stop Control of Pump

Electrical Equipment/

• Stop the pump when not needed

• Example:
Pumps

• Filling of storage tank

• Controllers in tank to start/stop

• Suitable if not done too frequently

• Method to lower the maximum
demand (pumping at non-peak hours)
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© UNEP 2006
 Energy Efficiency Opportunities

7. Impeller Trimming
Electrical Equipment/

• Changing diameter: change in

velocity
Pumps

• Considerations
• Cannot be used with varying flows
• No trimming >25% of impeller size
• Impeller trimming same on all sides
• Changing impeller is better option but more
expensive and not always possible 36
© UNEP 2006
 Energy Efficiency Opportunities

7. Impeller Trimming
Electrical Equipment/

Impeller trimming and centrifugal pump performance

Pumps

(BEE India,
2004)
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© UNEP 2006
 Energy Efficiency Opportunities

Comparing Energy Efficiency

Electrical Equipment/

Options
Parameter Change Trim impeller VFD
Pumps

control valve
Impeller 430 mm 375 mm 430 mm
diameter
Pump head 71.7 m 42 m 34.5 m
Pump efficiency 75.1% 72.1% 77%
Rate of flow 80 m3/hr 80 m3/hr 80 m3/hr
Power 23.1 kW 14 kW 11.6 kW
consumed
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© UNEP 2006
 Training Session on Energy
Equipment


Electrical Equipment/

Pumps & Pumping

Systems
Pumps

THANK YOU
FOR YOUR ATTENTION

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© UNEP 2006
 Disclaimer and References

• This PowerPoint training session was prepared as part of

the project “Greenhouse Gas Emission Reduction from
Electrical Equipment/

Industry in Asia and the Pacific” (GERIAP). While

reasonable efforts have been made to ensure that the
contents of this publication are factually correct and
Pumps

properly referenced, UNEP does not accept responsibility

for the accuracy or completeness of the contents, and shall
not be liable for any loss or damage that may be occasioned
directly or indirectly through the use of, or reliance on, the
contents of this publication. © UNEP, 2006.
• The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is
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available on www.energyefficiencyasia.org
© UNEP 2006