Training Session on Energy Equipment

Pumps & Pumping Systems

Presentation from the Energy Efficiency Guide for Industry in Asia www.energyefficiencyasia.org

Electrical Equipment/ Pumps

UNEP 2006

Training Agenda Pumps

Introduction Type of pumps Assessment of pumps Energy efficiency opportunities

Electrical Equipment/ Pumps

UNEP 2006

Introduction -hat are Pumping Systems

Electrical Equipment/ Pumps
!"# of wor$d%s e$ectrica$ energy demand !&'&"# of energy usage in some industries (sed for
)omestic* commercia$* industria$ and agricu$tura$ ser+ices ,unicipa$ water and wastewater ser+ices

UNEP 2006

Introduction -hat are Pumping Systems

./0ecti+e of pumping system Transfer $iquid from source to destination 1ircu$ate $iquid around a system
(US DOE, 2001)

Electrical Equipment/ Pumps

UNEP 2006

Introduction -hat are Pumping Systems

,ain pump components
Pumps Prime mo+ers e$ectric motors* diese$ engines* air system Piping to carry f$uid 2a$+es to contro$ f$ow in system .ther fittings* contro$* instrumentation

Electrical Equipment/ Pumps

End'use equipment
3eat e4changers* tan5s* hydrau$ic machines

UNEP 2006

Introduction Pumping System 1haracteristics

Electrical Equipment/ Pumps
3ead
6esistance of the system Two types static and friction
estinati!n Stati c "ea

Static head
)ifference in height /etween source and destination Independent of f$ow
Static "ea

s!urce

#l!$ UNEP 2006

Introduction Pumping System 1haracteristics

Static head consists of
Static suction head 7hS8 $ifting $iquid re$ati+e to pump center $ine Static discharge head 7h)8 +ertica$ distance /etween center$ine and $iquid surface in destination tan5

Electrical Equipment/ Pumps

Static head at certain pressure

3ead 7in feet8 9 Pressure 7psi8 : !.;< Specific gra+ity

UNEP 2006

Introduction Pumping System 1haracteristics

=riction head
6esistance to f$ow in pipe and fittings )epends on si>e* pipes* pipe fittings* f$ow rate* nature of $iquid Proportiona$ to square of f$ow rate 1$osed $oop system on$y has friction head 7no static head8
#ricti!n "ea

Electrical Equipment/ Pumps

#l!$ UNEP 2006

Introduction Pumping System 1haracteristics

In most cases Tota$ head 9 Static head ? friction head
S%stem cur&e S%stem cur&e

Electrical Equipment/ Pumps

S%stem "ea
Static "ea

#ricti!n "ea

S%stem "ea

#ricti!n "ea Static "ea

#l!$

#l!$

UNEP 2006

Introduction Pumping System 1haracteristics

Pump performance cur+e 6e$ationship /etween head and f$ow
=$ow increase System resistance increases 3ead increases =$ow decreases to >ero
#l!$ 'ea

Electrical Equipment/ Pumps

@ero f$ow rate

pump /urnout

Per(!rmance cur&e (!r centri(u)al pump

ris5 of

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UNEP 2006

Introduction Pumping System 1haracteristics

Pump operating point
)uty point rate of f$ow at certain head Pump operating point intersection of pump cur+e and system cur+e
'ea
Static "ea Pump per(!rmance cur&e Pump !peratin) p!int

Electrical Equipment/ Pumps

S%stem cur&e

#l!$

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UNEP 2006

Introduction Pumping System 1haracteristics

Electrical Equipment/ Pumps
Pump suction performance 7APS38
1a+itation or +apori>ation /u//$es inside pump If +apor /u//$es co$$apse Erosion of +ane surfaces Increased noise and +i/ration 1ho5ing of impe$$er passages Aet Positi+e Suction 3ead APS3 A+ai$a/$e how much pump suction e4ceeds $iquid +apor pressure APS3 6equired pump suction needed to a+oid 12 UNEP 2006 ca+itation

Training Agenda Pumps

Introduction Type of pumps Assessment of pumps Energy efficiency opportunities

Electrical Equipment/ Pumps

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UNEP 2006

Type of Pumps Pump 1$assification

1$assified /y operating princip$e
Pumps

Electrical Equipment/ Pumps

Dynamic

(t)ers *e+g+
"mpulse, -uoyancy.

Positive Displacement

Centrifugal

pecial effect

!otary

!eciprocating

"nternal gear

#$ternal gear

%o&e

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li'e vane
UNEP 2006

Type of Pumps Positi+e )isp$acement Pumps

=or each pump re+o$ution
=i4ed amount of $iquid ta5en from one end Positi+e$y discharged at other end

Electrical Equipment/ Pumps

If pipe /$oc5ed
Pressure rises 1an damage pump

(sed for pumping f$uids other than water

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UNEP 2006

Type of Pumps Positi+e )isp$acement Pumps

6eciprocating pump
)isp$acement /y reciprocation of piston p$unger (sed on$y for +iscous f$uids and oi$ we$$s

Electrical Equipment/ Pumps

6otary pump
)isp$acement /y rotary action of gear* cam or +anes Se+era$ su/'types (sed for specia$ ser+ices in industry

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UNEP 2006

Type of Pumps )ynamic pumps

,ode of operation
6otating impe$$er con+erts 5inetic energy into pressure or +e$ocity to pump the f$uid

Electrical Equipment/ Pumps

Two types
1entrifuga$ pumps pumping water in industry B C&# of pumps insta$$ed Specia$ effect pumps specia$i>ed conditions

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UNEP 2006

Type of Pumps 1entrifuga$ Pumps

Electrical Equipment/ Pumps
3ow do they wor5D
Eiquid forced into impe$$er 2anes pass 5inetic energy to $iquid $iquid rotates and $ea+es impe$$er 2o$ute casing con+erts 5inetic energy into pressure energy

(Sa" e& *)

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UNEP 2006

Type of Pumps 1entrifuga$ Pumps

6otating and stationary components

Electrical Equipment/ Pumps

(Sa" e&)

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UNEP 2006

Type of Pumps 1entrifuga$ Pumps

Electrical Equipment/ Pumps
Impe$$er
,ain rotating part that pro+ides centrifuga$ acce$eration to the f$uid Aum/er of impe$$ers 9 num/er of pump stages Impe$$er c$assification direction of f$ow* suction type and shapeFmechanica$ construction
Sa" e&)

Shaft
Transfers torque from motor to impe$$er during pump start up and operation

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UNEP 2006

Type of Pumps 1entrifuga$ Pumps

Electrical Equipment/ Pumps
1asings =unctions
+!lute ,asin) (Sa" e&)

Enc$ose impe$$er as pressure +esse$ Support and /earing for shaft and impe$$er

2o$ute case
Impe$$ers inside casings Ga$ances hydrau$ic pressure on pump shaft

1ircu$ar casing
2anes surrounds impe$$er (sed for mu$ti'stage pumps

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UNEP 2006

Training Agenda Pumps

Introduction Type of pumps Assessment of pumps Energy efficiency opportunities

Electrical Equipment/ Pumps

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UNEP 2006

Assessment of pumps 3ow to 1a$cu$ate Pump Performance

Pump shaft power 7Ps8 is actua$ horsepower de$i+ered to the pump shaft
Pump shaft power (Ps): Ps - '% raulic p!$er 'p / pump e((icienc% 5Pump Pump Efficiency (Pump): 5Pump - '% raulic P!$er / Pump S"a(t P!$er

Electrical Equipment/ Pumps

Pump outputF3ydrau$icF-ater horsepower 73p8 is the $iquid horsepower de$i+ered /y the pump
Hydraulic power (Hp): 'p - . (m//s) 0 1!tal "ea , " 2 "s (m) 0 3 (4)/m/) 0 ) (m/s2) / 1000
" 2 isc"ar)e "ea 3 2 ensit% !( t"e (lui "s 6 sucti!n "ea , ) 6 accelerati!n ue t! )ra&it%

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UNEP 2006

Assessment of pumps )ifficu$ties in Pump Assessment

A/sence of pump specification data to assess pump performance )ifficu$ties in f$ow measurement and f$ows are often estimated Improper ca$i/ration of pressure gauges & measuring instruments
1a$i/ration not a$ways carried out 1orrection factors used

Electrical Equipment/ Pumps

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UNEP 2006

Training Agenda Pumps

Introduction Type of pumps Assessment of pumps Energy efficiency opportunities

Electrical Equipment/ Pumps

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UNEP 2006

Energy Efficiency .pportunities

<. Se$ecting the right pump !. 1ontro$$ing the f$ow rate /y speed +ariation ;. Pumps in para$$e$ to meet +arying demand H. E$iminating f$ow contro$ +a$+e &. E$iminating /y'pass contro$ I. StartFstop contro$ of pump C. Impe$$er trimming
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UNEP 2006

Electrical Equipment/ Pumps

Energy Efficiency .pportunities <. Se$ecting the 6ight Pump

Electrical Equipment/ Pumps
Pump performance cur+e for centrifuga$ pump

7EE 8n ia, 2009

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UNEP 2006

Energy Efficiency .pportunities <. Se$ecting the 6ight Pump

.+ersi>ed pump
6equires f$ow contro$ 7thrott$e +a$+e or /y' pass $ine8 Pro+ides additiona$ head System cur+e shifts to $eft Pump efficiency is reduced

Electrical Equipment/ Pumps

So$utions if pump a$ready purchased

2S)s or two'speed dri+es Eower 6P, Sma$$er or trimmed impe$$er

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UNEP 2006

Energy Efficiency .pportunities !. 1ontro$$ing =$ow speed +ariation E4p$aining the effect of speed
Affinity $aws re$ation speed A and
=$ow rate J A 3ead 3 A! Power P A;

Electrical Equipment/ Pumps

Sma$$ speed reduction 7e.g. K8 9 $arge power reduction 7e.g. <FL8

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UNEP 2006

Energy Efficiency .pportunities !. 1ontro$$ing =$ow speed +ariation 2aria/$e Speed )ri+es 72S)8
Speed ad0ustment o+er continuous range Power consumption a$so reducedM Two types
,echanica$ hydrau$ic c$utches* f$uid coup$ings* ad0usta/$e /e$ts and pu$$eys E$ectrica$ eddy current c$utches* wound'rotor motor contro$$ers* 2aria/$e =requency )ri+es 30 72=)s8

Electrical Equipment/ Pumps

UNEP 2006

Energy Efficiency .pportunities !. 1ontro$$ing =$ow speed +ariation Genefits of 2S)s

Energy sa+ings (not just reduced flow!) Impro+ed process contro$ Impro+ed system re$ia/i$ity 6educed capita$ and maintenance costs Soft starter capa/i$ity
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Electrical Equipment/ Pumps

UNEP 2006

Energy Efficiency .pportunities ;. Para$$e$ Pumps for 2arying )emand

Electrical Equipment/ Pumps

,u$tip$e pumps some turned off during $ow demand (sed when static head is N&"# of tota$ head System cur+e does not change =$ow rate $ower than sum of indi+idua$ f$ow rates
(7P*:)

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UNEP 2006

Energy Efficiency .pportunities H. E$iminating =$ow 1ontro$ 2a$+e

1$osingFopening discharge +a$+e 7thrott$ing8 to reduce f$ow 3ead increases does not reduce power use 2i/ration and corrosion high maintenance costs and reduced pump $ifetime
(7P*:)

Electrical Equipment/ Pumps

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UNEP 2006

Energy Efficiency .pportunities &. E$iminating Gy'pass 1ontro$

Pump discharge di+ided into two f$ows
.ne pipe$ine de$i+ers f$uid to destination Second pipe$ine returns f$uid to the source

Electrical Equipment/ Pumps

Energy wastage /ecause part of f$uid pumped around for no reason

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UNEP 2006

Energy Efficiency .pportunities I. Start F Stop 1ontro$ of Pump

Stop the pump when not needed E4amp$e
=i$$ing of storage tan5 1ontro$$ers in tan5 to startFstop

Electrical Equipment/ Pumps

Suita/$e if not done too frequent$y ,ethod to $ower the ma4imum demand 7pumping at non'pea5 hours8
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UNEP 2006

Energy Efficiency .pportunities C. Impe$$er Trimming

1hanging diameter change in +e$ocity 1onsiderations
1annot /e used with +arying f$ows Ao trimming N!&# of impe$$er si>e Impe$$er trimming same on a$$ sides 1hanging impe$$er is /etter option /ut more e4pensi+e and not a$ways possi/$e

Electrical Equipment/ Pumps

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UNEP 2006

Energy Efficiency .pportunities C. Impe$$er Trimming

Impe$$er trimming and centrifuga$ pump performance

Electrical Equipment/ Pumps

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(7EE 8n ia, 2009) UNEP 2006

Energy Efficiency .pportunities 1omparing Energy Efficiency .ptions

Parameter Impe$$er diameter Pump head Pump efficiency 6ate of f$ow Power consumed 1hange contro$ +a$+e 9/0 mm ;1=; m ;<=1> ?0 m//"r 2/=1 4@ Trim impe$$er /;< mm 92 m ;2=1> ?0 m//"r 19 4@ 2=) 9/0 mm /9=< m ;;> ?0 m//"r 11=6 4@

Electrical Equipment/ Pumps

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UNEP 2006

Training Session on Energy Equipment

Pumps & Pumping Systems

T3AAO P.( =.6 P.(6 ATTEATI.A

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UNEP 2006

Electrical Equipment/ Pumps

)isc$aimer and 6eferences

/ This PowerPoint training session was prepared as part of the project Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific (GERIAP) !hi"e reasona#"e efforts ha$e #een made to ensure that the contents of this pu#"ication are factua""y correct and proper"y referenced% &'EP does not accept responsi#i"ity for the accuracy or comp"eteness of the contents% and sha"" not #e "ia#"e for any "oss or damage that may #e occasioned direct"y or indirect"y through the use of% or re"iance on% the contents of this pu#"ication ( &'EP% )**+ / The GERIAP project was funded #y the ,wedish Internationa" -e$e"opment .ooperation Agency (,ida) / /u"" references are inc"uded in the te0t#oo1 chapter that is a$ai"a#"e on www energyefficiencyasia org 40

Electrical Equipment/ Pumps

UNEP 2006