ENERGY EFFICIENCY IN

PUMPS AND PUMPING

SYSTEM

Afrin Fathima
Anagha R
Annamol Sunny
Ashif A R
Pump types
• Pumps come in variety of sizes for a wide range of
applications.
• They classified according to operating principle as,

Centrifugal Pump
(most economical)
Dynamic Pumps
Pumps

Special effects
Pump

Rotary Pump
Displacement
Pumps Reciprocating
Pump

• Positive displacement pumps are more efficient then

centrifugal pumps.
• Centrifugal pumps account majority of electricity worldwide.
 Centrifugal pumps
• Very simple design.
• Two main parts are the impeller
and the diffuser.
• Impeller is the moving part,
attached to a shaft and driven by
a motor.
• Water enters the centre of
impeller and exits the impeller
with the help of centrifugal force.
• As water leaves low pressure
created, causing more water to
flow.
• ATM pressure and centrifugal
force cause this to happen.
• Pressure will develops depends on the impeller diameter,
no:of impellers, size of impeller eye and shaft speed.
• Capacity is determined by the exit width of the impeller.
• The head and capacity are the main factors, which affects the
horsepower size of the impeller.
• The more quantity water to be pumped, more energy is
required.
• Since the pump is a dynamic device, it is convenient to
consider the pressure in terms of head, ie meters of liquid
column.
• The pump generates same head of liquid whatever the
density of liquid being pumped.
• The standard convention for
centrifugal pump is to draw the
pump performance curves showing
flow on horizontal axis and head
on vertical axis.
• Given the significant amount of
electricity attributed to pumping
systems, even small improvements
in pumping efficiency could yield
very significant savings of
electricity.
• The pump is the most inefficient
component in pumping systems.
 System characteristics
• A pressure is needed to make the liquid flow at the
required rate and this must overcome head ‘losses’ in
the system.
• Losses are two types, static and friction head.
• Static head is the difference in height of supply and
destination. shown in figure below.
• Where flow velocity in the pipe assumed to be very
small.
• Static head is independent of flow.
• Friction head(dynamic head) is friction loss, on the moving
liquid in pipes, valves and equipment in the systems.
• Friction tables are universally available for various pipes and
valves.
• In case of fittings friction is stated as an equivalent length of
pipe of the same size.
• Most systems have combination of static and
friction head. And the system curves for two cases
are given below.

• Static head reduced by specific installation.

• Friction loss must be eliminated to reducing
pumping cost
• But, after eliminating unnecessary pipe fittings
Pump curves
• The performance of pump can be expressed
graphically as head against flow rate.
• The centrifugal pump has a curve where the head
falls graphically with increasing flow. This is called
the pump characteristic curve(head – flow curve).
Pump operating point
• When a pump is installed in a system the effect
can be illustrated graphically by superimposing
head flow and system curves.
• The operating point will always be where the two
curves intersect.
 FACTORS AFFECTING PUMP
PERFORMANCE
• Matching pump and system head-flow
characteristics
• Centrifugal pumps are characterized by relationship
between flow rate (Q), they produce and the pressure
(H)at which the flow is delivered.
• Pump efficiency varies with flow and pressure.
• The choice of pump for a given application depends upon
how the pump head flow characteristics matches the
requirements of the system d/s of the pump.
 FACTORS AFFECTING PUMP PERFORMANCE

• Effect of over sizing the pump

• A pump is selected based on how well the pump curve
and system head flow curves match.
• The system curves change with physical configuration of
the system (like; height or elevation, diameter and length
of piping ,no. and type of fittings and pressure drops
across various equipments).
• The pump operating point is identified as the point,
where the system curve crosses the pump curve when
they are super imposed on each other.
• Energy loss in throttling
• Efficient pumping system operation
• The first step to achieve energy efficiency in pumping
sysytem is to target end-use.
 FACTORS AFFECTING PUMP PERFORMANCE

• A water balance would establish usage pattern and

highlight areas where water consumption can be reduced
or optimized.
• Good water conservation measures, alone may eliminate
the need for some pumps.
• Once, flow requirements are optimized, then the
pumping system can be analysed for energy
conservation opportunities.
• Common symptoms that indicate opportunities for
energy efficiency in pumps are as follows;
 SYMPTOMS THAT INDICATE POTENTIAL OPPURTUNITY FOR ENERGY
SAVINGS
Symptoms Likely reason Best solutions
Throttle valve controlled Oversized pump Trim impeller, smaller
systems impeller, variable speed
drive, two speed drive ,
lower rpm

Bypass line (partially or Oversized pump Trim impeller, smaller

completely ) open impeller, variable speed
drive, two speed drive ,
lower rpm
Multiple parallel pump Pump use not monitored or Install controls
system with the same no. Of controlled
pumps always operating
Constant pump operation in Wrong system design On-off controls
a batch environment
High maintenance cost Pump operated far away Match pump capacity with
from best efficiency point system requirement
(BEP)
 FACTORS AFFECTING PUMP PERFORMANCE

• Effect of speed variation

• The equations relating rotodynamic pump
performance parameters of flow,head and power
absorbed to speed are known as Affinity laws;
• Q↔N
• H ↔ N2
• P ↔ N3
• Where, Q=flow rate
• H=Head
• P=Power absorbed
• N=Rotating speed
• Efficiency is essentially independent of speed.
 FACTORS AFFECTING PUMP PERFORMANCE
• Doubling the speed of the centrifugal pump will increase
the power consumption by 8 times.
• conversely a small reduction in speed will result in drastic
reduction in power consumption.
• This forms the basis for energy conservation in centrifugal
pumps with varying flow requirements.
• Effect of impeller diameter change
• Q↔D
• H ↔ D2
• P ↔ D3
• Efficiency varies when the diameter is changed within a
particular casing.
• Diamter changes are generally limited to reducing the
diameter to about 75% of the maximum i.e. a head
reduction of 50%;beyond this the efficiency and NPSH(net
positive suction head available) are badly affected.
 FACTORS AFFECTING PUMP PERFORMANCE

• Pump suction performance(NPSH)

• If the incoming liquid is at a pressure with insufficient
margin above its vapour pressure , then vapour cavities or
bubbles appear along the impeller vanes behind the inlet
edges. This phenomenon is known as Cavitation.
• Its undesirable effects are;
1. The collapsing cavitation bubbles can erode the vane
surface especially when pumping water based liquids.
2. Noise and vibration are increased , with possible
shortened seal and bearing life.
3. The cavity areas will initially partially choke the impeller
passages and reduce the pump performance . In extreme
cases , total loss of pump developed head occurs.
 1. Flow control valve
• With this control method, the pump runs continuously and
a valve in the pump discharge line is opened or closed to
adjust the flow to the required value.
• With the valve fully open, the pump operates at "Flow 1".
When the valve is partially closed it introduces an
additional friction loss in the system, which is proportional
to flow squared.
• The new system curve cuts
the pump curve at “Flow 2",
which is the new operating
point.
• The head difference between
the two curves is the pressure
drop across the valve.
• It is usual practice with valve control to have the valve
10% shut even at maximum flow.
• Energy is therefore wasted overcoming the resistance
through the valve at all flow conditions.
• There is some reduction in pump power absorbed at
the lower flow rate, but the flow multiplied by the
head drop across the valve, is wasted energy.
• It should also be noted that, while the pump will
accommodate changes in its operating point as far as
it is able within its performance range, it can be forced
to operate high on the curve, where its efficiency is
low,and its reliability is affected.
• Maintenance cost of control valves can be high,
particularly on corrosive and solids-containing liquids.
2. Parallel pumps for varying demand
• Multiple pumps : some turned off during low
demand
• Used when static head is >50% of total head
• System curves does not change
• Flow rate lower than sum of individual flow rates
 3. By-pass control
• With this control approach, the pump runs
continuously at the maximum process demand duty,
with a permanent by pass line attached to the outlet.
• When a lower flow is required the surplus liquid is
bypassed and returned to the supply source.
• An alterative configuration may have a tank supplying
a varying process demand which is kept full by a fixed
duty pump running at the peak flow rate.
• Most of the time the tank over flows and recycles back
to the pump suction.
 4. Start/stop control of pumps
• Flow is controlled by switching pumps on or off
• Stop the pump when not needed
• Example :
– 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)
 5. Impeller Trimming
• Process of machining the diameter of an impeller to
reduce the energy added to system fluid
• Consideration
– 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
 6. Variable Speed Drives (VSDs)
• In contrast, pump speed adjustments provide the most
efficient means of controlling pump flow.
• By reducing pump speed, less energy is imparted to the fluid
and less energy needs to be throttled
• or bypassed.
• There are two primary methods of reducing pump speed:
multiple-speed pump motors and variable speed drives
(VSDs).
• Although both directly control pump output, multiple-speed
motors and VSDs serve entirely separate applications.
• Multiple-speed motors contain a different set of windings for
each motor speed; consequently, they are more expensive
and less efficient than single speed motors.
• Multiple speed motors also lack subtle speed changing
capabilities within discrete speeds.
• VSDs control pump speeds using several different types of
mechanical and electrical systems.
• Mechanical VSDs include hydraulic clutches, fluid
couplings, and adjustable belts and pulleys.
• Electrical VSDs include eddy current clutches,
woundrotor motor controllers, and variable frequency
drives (VFDs).
• VFDs adjust the electrical frequency of the power
supplied to a motor to change the motor's rotational
speed.
• VFDs are by far the most popular type of VSD.
Energy Conservation Opportunities
Selecting the Right Pump / Pumping system
• Oversized pump
– Requires flow control (throttle valve or by- pass line)
– Pump efficiency is reduced
• Solutions if pump already purchased
– VSDs or two-speed drives
– Lower RPM
– Smaller or trimmed impeller
• In case of over designed pump, provide variable speed
drive or downsize/resize impeller or replace with correct
sized pump for efficient operation
• Ensure adequate NPSH at site of installation
• Ensure availability of basic instruments at pumps like
pressure gauges, flow meters
• Operate pumps near best efficiency point
• Modify pumping systems and pump losses to minimize
throttling
• Adapt to wide load variation with variable speed drives
or sequenced control of multiple units
• Stop running multiple pumps- add an auto-start for an
on-line spare or add booster pump in the problem areas
• Use booster pumps for small loads requiring high
pressures
• Increase fluid temperature differentials to reduce
pumping rates in case of heat exchangers
• Repair seals and packing to minimize water loss by
dripping
• Balance the system to minimize flows and reduce pump
power requirements
• Avoid pumping head with a free-fall return (gravity); Use
siphon effect to advantage
• Conduct water balance to minimize water consumption
• Avoid cooling water recirculation in DG sets, air
compressors, refrigeration systems, cooling tower feed
water pumps, condenser pumps and process pumps
• Replace old pumps by energy efficient pumps
• In case of over designed pump, provide variable speed
drive or downsize/resize impeller or replace with correct
sized pump for efficient operation
• Optimise number of stages in case of multi-stage pump
in case of head margins
• Reduce system resistance by pressure drop assessment
and pipe size optimisation
• Old Labelling (Revision 2- 2009)
• Example : Vikram Pumps
AQUASUB ENGINEERING Coimbatore (Tamil Nadu)
• Manufacturers of BEE Star Labelled Appliances
(Agricultural Pump Set)
Energy Conservation Measures in Pump sets
• Adapting the latest technologies in the design and
development of pump sets to enhance the efficiency at
par with international standards
• Maintaining the consistency in the manufacturing by
implementing stringent quality strategies
• Latest foundry practices are implemented to produce
smooth hydraulic profiles of impellers and
diffusers/bowls/volutes to reduce the frictional losses to
achieve higher efficiency level
• Advanced machineries are used for manufacturing the
various parts of the pump sets for attaining sustainable
and consistent efficiency levels
• Usage of high quality in-house processed electrical
laminations contributes less wattage losses and energy
efficient pump sets
• Better and optimum raw material usage to operate
efficiently at wider voltage bands
 C.R.I. PUMPS PRIVATE LIMITED, Coimbatore

Key Energy Saving Projects

• •Maharashtra AgDSM pilot project at Sholapur through
MSEDCL
• •Installation of energy efficient pump sets through AP Agro
scheme
• •Installation of energy efficient pumps for new connections
through Tamilnadu Govt. Scheme
• •Successful execution of Tamilnadu AgDSM scheme (Phase
1)
• •Western railway project for supplying of energy efficient
pumps
• •Supplying of energy efficient pumps for Chhattisgarh Gram
Panchayat Scheme
Havells – Self priming Monoblock pump
Cost/Energy
Savings
Kirloskar Pump – Cost Savings
Oswal Pumps- Datasheet
THANK YOU