Thusitha Sugathapala

Department of Mechanical Engineering

University of Moratuwa
26
th
JANUARY 2011
Lecture Series on Energy Efficienct Building Codes
Organized by
Lanka Association of Building Services Engineers
Energy Conservation in Fluid Machinery
(Pumps and Fans)
OVERVIEW
INTRODUCTION
ELECTRIC MOTORS
Selection & Sizing of Motors
Motor Control
Preventive & Predictive Maintenance
Pumps
Basics
Performance Characteristics
FLUID FLOW SYSTEMS
System Performance
Energy Conservation in Fluid Flow Systems
INTRODUCTION
Fluid machinery, including pumps, and drive systems
consume considerable amount of energy
Electric motor and drive systems typically account for
over 50% of electricity used in building systems
A large proportion of which is used to drive fluid machinery such
as pumps, fans and chillers.
In industries, the drive systems may consume up to 90%
of the factory demand for electricity
Pumps are used in many applications:
water supply and distribution in domestic & commercial sectors
and for industrial processes
pumping of variety of liquids, and slurry
waste/sewage pumping etc.
In total, about 200 GWh per year of electricity is used for
powering pumps,
equivalent to about 3% of Sri Lanka's entire electricity use.
In addition, fans and blowers are used in commercial
and industrial sectors
- equivalent to about 2% of Sri Lanka's entire electricity use.
Fluid Machinery offer substantial and varied
opportunities for:
energy efficiency gains
energy cost savings, and
improving environmental conditions within the facility.
INTRODUCTION
Energy Conservation Opportunities
Motor Sizing - Motors can be correctly sized to match the load
they are expected to drive.
Motor Selection - High efficiency motors, with improved
efficiency ratings can be substituted for
standard construction motors.
Motor Controls- When the driven equipment have to meet a
variable demand, controls can be used to
reduce capacity and improve efficiency.
Maintenance - Proper care of motors can prolong their service
life and avoid the electrical and mechanical
problems, which contribute to lower energy
efficiency.
ELECTRIC MOTORS

0.75 HP

7.5 HP
75 HP
Efficiency of a motor depends on
the design
the voltage level and voltage balance of the power supply
the load at which it operates
its kWrating, and
its synchronous speed
0
10
20
30
40
50
60
70
80
90
100
0 25 50 75 100 125 150
% of Rated Load
E
f
f
i
c
i
e
n
c
y

(
%
)
ELECTRIC MOTORS
Load Factor:
Load factor is one of the key parameter which determines the
running efficiency of an electric motor.
ELECTRIC MOTORS
Motor Speed:
For the same kW rating, motors with higher speeds generally have
a higher efficiency at rated load than motors with lower speeds.
ELECTRIC MOTORS
ELECTRIC MOTORS
High Efficient Motors (HEMs)
HEMs are designed to minimize the inherent losses of motors
PUMPS
A machine in which energy is transmitted to a liquid is
known as a pump
Pumps are usually driven by electric motors
Classification
Rotor-dynamic pumps
Positive displacement pumps
Rotor-dynamic Pumps:
Most commonly used pumps
Consist of rotating impeller
Centrifugal pumps (Axial, Mixed, Radial flow)
Positive Displacement Pumps:
Operate due to change of volume occupied by the fluid within
the machine
Vane, Gear, Piston, Diaphragm, Screw, Lobe
Positive Displacement Pumps:
PUMPS
Rotor-dynamic Pumps:
FANS AND BLOWERS
Devices that cause flow of a gas by creating a pressure
difference are known as fans or blowers
These machines are usually driven by electric motors
Classification based on pressure levels
Blowers generate relatively higher pressure than fans
Engineering practice distinguishes fans and blowers for
low pressure and compressors for high pressure.
The gaseous fluid transported by a fan is most often air
and/or toxic fumes, whereas blowers may transport a
mixture of particulate and air
Specific ratio: The ratio of the discharge pressure over the suction pressure
Classification based on to the direction of flow through
the rotor:
Axial Fans: Have high volume capability for large duct size
ventilation applications
Centrifugal Fans: Have high pressure capability for applications
such as boilers, bag-houses, and conveyors.
FANS AND BLOWERS
Axial Flow Fan Centrifugal Fan
PERFORMANCE CHARACTERISTICS
OF Fluid Machinery
Basics
Main operational parameters:
Head H
Flow rate Q
Efficiency q = P
out
/ P
in
Other parameters:
Speed N
Impeller / Rotor Diameter D
Power Input P
in
Hydraulic Power Output P
out
= HgQ = ApQ
Net Positive Suction Head (NPSH)
Centrifugal Machines:
Efficiency
Curve
Head
Best Efficiency
Point (BEP)
Flow Rate - Q
H
Lower Speed
Higher Speed
q

q
.
Q g H P
P
out
in
= =
PERFORMANCE CHARACTERISTICS
OF Fluid Machinery
Centrifugal Machines:
PERFORMANCE CHARACTERISTICS
OF Fluid Machinery
Axial Flow
Radial Flow
Mixed Flow
Centrifugal Machines:
Efficient Region
of Operation
PERFORMANCE CHARACTERISTICS
OF Fluid Machinery
Affinity (or Similarity) Laws:
If Machine 1 and Machine 2 are from the same geometric
family and are operating at homogeneous points
.
5
1
2
3
1
2
1
2
1
2
2
1
2
2
1
2
1
2
3
1
2
1
2
1
2
|
|
.
|

\
|
|
|
.
|

\
|
=
|
|
.
|

\
|
|
|
.
|

\
|
=
|
|
.
|

\
|
=
D
D
N
N
P
P
D
D
N
N
H
H
D
D
N
N
Q
Q

PERFORMANCE CHARACTERISTICS
OF Fluid Machinery
Dimensionless Parameters
PERFORMANCE CHARACTERISTICS
OF PUMPS

. t Coefficien Power
t Coefficien Flow
t Coefficien Head
5 3
3
2 2
D N
P
C
ND
Q
C
D N
gH
C
P
Q
H

=
=
=

. efficiency Pump = = q

P
gQH
C
C C
P
Q H

4 / 1
2
1
1
2
1
1
|
|
.
|

\
|
~

D
D
q
q
Effects of size on efficiency
Dimensionless Parameters: Specific Speed
Most pump applications involve a known head and discharge for
the particular system, and a speed range dictated by electric
motor speeds or cavitation requirements.
The designer then select the best size and type for the pump.
To help this selection, one needs a dimensionless parameter
involving speed, discharge and head but not size.
This is realized by introducing the parameter Specific Speed
PERFORMANCE CHARACTERISTICS
OF Fluid Machinery

( )
4 / 3
2 / 1
4 / 3
2 / 1
4 / 3
2 / 1
form Common
Units) (SI form ess Dimensionl
H
NQ
N
gH
Q
C
C
s
H
Q
s
=
= =
e
e
e
s
< 1 Radial-flow
1 < e
s
< 4 Mixed-flow
e
s
> 4 Axial-flow
Dimensionless Parameters: Specific Speed
PERFORMANCE CHARACTERISTICS
OF Fluid Machinery
FLUID FLOW SYSTEMS
Energy in flowing fluids:
Energy per unit weight of a flowing fluid is given by
. Z
2g
V
g
p
H
2
+ + =
Total energy
per unit weight
Pressure
energy
per unit weight
Kinetic energy
per unit weight
Potential
energy
per unit weight
Fluid machinery generate both pressure energy and kinetic energy
FLUID FLOW SYSTEMS
System Components:
Consists of
- Fluid Machinery (Pumps, Fans, Blowers, Compressors)
- Prime Mover (Electric Motor, IC Engine)
- Pipes, Ducts
- Fittings (Valves, Dampers, Grilles, Diffusers, Elbows,
Bends, Tee Junctions, Filters, Acoustic Silencers)
- End use equipments (Such as Tanks, Heat Exchangers, and
Hydraulic Equipments)
Could be open-loop or close-loop
FLUID FLOW SYSTEMS
System Components:
System Performance:
Depends on performances of all components
Energy Balance
- Energy Supply : Pump / Fan / Overhead Tank
- Energy Losses : Pipes; Ducts; Fittings
- Energy Gain : Static head (suction; delivery)
- Correct Balance of Energy Supply, Losses and Energy
Gain: Operating Point
Pipes / Ducts:
Function
- Efficient transmission of flow
Sizing
- Limits on velocities, noise intensities and space availability
- Energy (Frictional) Losses: Wall Friction & Fitting
FLUID FLOW SYSTEMS
Energy Losses:
Wall Friction Losses
V
Flow
A
A
B
B
V
( ) velocity Flow
Diameter - Length; - Factor; Friction Moody -
Loss Pressure
=
|
.
|

\
|
|
.
|

\
|
=
4
2
/ D Q/ V
D L f
D
2
D fr
V
2
1
D
L
f p
FLUID FLOW SYSTEMS
Energy Losses:
Wall Friction Losses: Moody Chart
FLUID FLOW SYSTEMS
Energy Losses:
Component Losses
FLUID FLOW SYSTEMS
Energy Losses:
Component Losses
t Coefficien Loss Fitting - ;
2
1
2
K V K p
l
|
.
|

\
|
= A
(a) Flow through a Pipe Bend
B
B
Eddy Zone
Eddy Zone
A
A
A
A
B
B
(b) Flow through a Pipe Orifice
Eddy Zones
FLUID FLOW SYSTEMS
Energy Losses:
Component Losses: K Factors
Total System Head
FLUID FLOW SYSTEMS
1.0 Pipe Exit 0.04 Coupling/Union
0.5 Pipe Entrance (sharp) 1.8 Standard T (side outlet)
5.5 Gate Valve (1/2 Open) 1.5 180 Bend
0.2 Gate Valve (Open) 0.3 90 Smooth Bend
40 Globe Valve (1/2 Open) 0.45 45 Standard Elbow
10 Globe Valve (Open) 0.9 90 Standard Elbow
K Type of Fitting K Type of Fitting
1.0 Pipe Exit 0.04 Coupling/Union
0.5 Pipe Entrance (sharp) 1.8 Standard T (side outlet)
5.5 Gate Valve (1/2 Open) 1.5 180 Bend
0.2 Gate Valve (Open) 0.3 90 Smooth Bend
40 Globe Valve (1/2 Open) 0.45 45 Standard Elbow
10 Globe Valve (Open) 0.9 90 Standard Elbow
K Type of Fitting K Type of Fitting
( ) .
2
2
0 0
2
2
1 2
Q K H
gA
Q
K
D
L
f Z Z H
sys
+ =
|
.
|

\
|
+ + =

System Operating Point:
FLUID FLOW SYSTEMS
Pump Head
BEP
Flow Rate - Q
H
Efficiency
Curve
System Head
System
Operating
Point
Required
Operating
Point
Selection of Fluid Machine:
FLUID FLOW SYSTEMS
Life Cycle Cost:
Energy cost contribute to the largest part of the lifecycle cost
Energy cost
83%
Maint enance
3%
Invest ment
14%
Energy cost
91%
Maint enance
1%
Invest ment
8%
10 kW Pump
130 kW Pump
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Numerous opportunities for energy saving
Modern designs with higher efficiencies
Best design practices (need System Approach)
- Avoid over-sizing
- Appropriate flow-control
- Multiple machines than single larger one
- Appropriate Maintenance practices
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Over-Sizing:
In many applications, fluid machines are oversized for
the load they are serving, due to a number of factors.
Designers add safety factors as insurance against failure.
Designers want the ability to increase the output of driven
equipment at some time in the future.
The existing load is less than the initial design load due to
energy management activities and changes in building use.
Larger motors can override load fluctuations without
dropping out.
Voltage imbalances in three phase power supplies can cause
increases in motor losses, and so a larger machine is
required to meet the duty.
However, these practices often lead to excessive loss in energy,
resulting high operating cost.
Further, larger machines cost more to buy, install and maintain.
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Flow Control:
Fluid machinery are required to perform over a range of flows
and pressures called, The Duty Cycle.
How the machine is controlled to achieve the required range, can
have a significant energy cost.
The type of control should be selected on the basis of cost, the
precision of control required and the frequency and magnitude
of system flow changes.
Method of Flow Control
Flow control valve / Damper Control: High Energy Loss
By-Pass Valve: No gain
Blade Pitch Control
Guide Vane Control
Impeller Trimming
Multiple Machines with On-off Control
Variable Speed Drive (VSD): Most Efficient
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Throttling and By-Passing for Oversized Machines:
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Impeller Trimming for Oversized Machines:
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Flow Control With VSD:
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Flow Control With VSD:
- Comparison with throttled damper
0
5
10
15
20
25
30
35
40
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45
Flow Rate (m3/s)
H
e
a
d

(
m
)
Throttled Damper
N= 3000 rpm
N= 1500 rpm
Damper fully open
A
B
C
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Pumps in Combinations:
- Pumps in Parallel: For high flow rate applications
0
10
20
30
40
50
60
70
0 0.2 0.4 0.6 0.8
Flow Rate Q
H
e
a
d


H
High Flow
Rate
Demand
Low Flow
Rate
Demand
Two Pumps
Single
Pump
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Pumps in Combinations:
0
10
20
30
40
50
60
70
0 0.1 0.2 0.3 0.4 0.5
Flow Rate Q
H
e
a
d


H
High Head
Load
Low Head
Load
Two
Pumps
Single
Pump
- Pumps in Series: For high head applications
ENERGY CONSERVATION IN FLUID
FLOW SYSTEMS
Pump Cavitation:
Results in noise, vibration, surface damage and reduction of
performance
Net Positive Suction Head Requirement:
Discharge pipe
Suction pipe
Location of minimum
pressure in the pump
2
1
.
1
S
v
h z
g
p p
NPSH A

ENERGY CONSERVATION IN FLUID

FLOW SYSTEMS
CASE STUDY