Energy
Conservation in
PUMPING SYSTEMS
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Flow Control is Needed
Example: Water consumption at home
Midnight Morning Afternoon
A glass of water Shower Watering the garden
0,1 litre per second 1 litre per second 10 litres per second
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Reducing Pumping Energy Usage
1 On-off control.
2 Throttle the discharge valve.
3 By-pass the process to control flow. Energy reduction?
4 Variable speed drive for the pump.
5 Trim the pump impeller.
6 Coat the pump interiors with smooth material.
7 Reduce the process demand.
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Flow Control Methods
Throttling by a valve
By-passing by a valve
On-off control of the pump
Variable speed control of the pump
Parallel running of Pumps
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Reading the Curves
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Throttling Increases Resistance in the System
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By-Passing
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On-Off Control
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Variable Speed Control
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Pump Efficiencies at Different Speeds
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Static Head vs Pump Efficiency in Variable Speed Control
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Consider Variable Speed Control when...
The pump is a part of the control
system. The pump output varies.
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Relative Power Consumption
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Energy Consumption of a Pump
is the Power multiplied by the Time
P
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Duty Cycle Curve
1 2 1
Median Flow Q m
Q Q Q
6 max 3 50 6 min
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Energy Use Calculation: Median Flow Method
(= Energy Consumption in Variable Speed Control)
Qmax = 300 l/s
Q50 = 210 l/s
Qmin = 81 l/s
𝟑𝟎𝟎 𝟐 ∗ 𝟐𝟏𝟎 𝟖𝟏
Q𝒎 = + + l/s = 204 l/s
𝟔 𝟑 𝟔
and the equivalent power is 42 kW.
The total energy is
W = 42 kW*5000 h = 210 MWh
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Reading the Power Consumed by a Pump
Duty point of a pump:
Nominal
x Throttle control
x Variable speed control
Power consumption of
the pump in variable speed
control
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Segmented Duty Cycle
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Comparison based on Energy Consumption
Time Flow Throttle Variable Speed
Control Control
1480 rpm
% h % l/s kW MWh rpm kW MWh
40 2000 90 270 75 150 1400 64 128
30 1500 62 186 71 107 1180 35 53
30 1500 32 96 65 98 920 24 36
Compared to throttle control variable speed control
saves energy
355 - 217 MWh = 138 MWh
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Variable Speed Control Saves Energy
Cost saving =
saved energy*energy price
137 MWh * Rs.3700/MWh = Rs. 5.07 lakhs/year
For Variable Speed AC Drives
the Payback Period would be
less than Two Years
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Impeller Diameter Trimming
• Flow exceeds required flowrate
• Head developed exceeds required head.
• Other methods are not suitable or expensive.
When
𝑸𝟐 𝑫𝟐
• = .
𝑸𝟏 𝑫𝟏
𝑯𝟐 𝑫𝟐𝟐
New 2 • =
How much 𝑯𝟏 𝑫𝟏𝟐
New 2
• Irreversible low-cost method to reduce energy
usage.
• Keeping a margin for higher head and flow will
reduce savings.
Result •
𝑷𝟐
𝑷𝟏
=
𝑫𝟐𝟑
𝑫𝟑𝟏
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1.When mechanical torque is applied to the rotor, it accelerates and advances by a
mechanical angle causing
2.Stator currents to flow and create a field rotating at synchronous speed.
3.The (rotating) stator poles so created strongly attract the poles on the rotor and
create an opposing torque on the rotor.
4.When the electro-mechanical torque equals the mechanical torque, the
acceleration of the rotor ceases.
5.The mechanical angle will stabilise at a new angle , given by 𝛿 = 𝛼𝑝/2, where
is the torque angle (or power angle).
6.When the phase angle between EO and E increases, EX increases, causing I to
increase resulting in greater active power being delivered by the generator.
21
Impeller Trimming Process
Document the changes.
Over-file and/ or under-file impeller vanes to
preserve vane angle 2 and increase Q.
Test and verify head and flow between trimmings.
Trim in stages.
Obtain correction factor.
Use affinity laws to determine required
diameter
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Etabloc 100-315 with 293mm Impeller
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Etabloc 100-315 with 293mm Impeller
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Impeller Diameter Correction - Stepanoff
• Calculate required diameter
using affinity laws.
• Use this chart to obtain
corrected diameter ratio.
• Determine the corrected
diameter.
• Trim in stages.
• Test flow and head after each
reduction.
• Over-file and or under-file
trimmed impeller.
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Impeller Diameter Correction - Rütschi
• Calculate the specific speed of the
pump using the equation
𝑛 𝑄
𝑛 =
𝐻
• Calculate D’ the required diameter
using affinity laws.
• Read off the value of k from the chart
to obtain D = D – D’.
• Trim in stages.
• Test flow and head after each
reduction.
• Over-file and or under-file trimmed
impeller.
• The shaded area is the range of
scatter of test points.
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Impeller Over-filing and Under-filing
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Influence of Surface Roughness on Pump Efficiency
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Coat the Pump Interior with Smooth Lining Material
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Improving Efficiency by Coating
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1. 180 m3/ h pump.
30
