Energy Efficiency Considerations

in Pumps and Pump Stations

Jeff Foray, P.E. (JeffForay@KennedyJenks.com)

WSU Extension Energy Program

14 March 2014
How Do You Save Energy?

► Don’t design it wrong

► Operate smart

► Fix stuff

Thanks for your time, any questions e-mail me at

JeffForay@KennedyJenks.com
Energy in a Pumping System
Pumps and Other Fluid Movers

► Centrifugal pumps are

the most common
 End suction
 Split case
 Turbines
 Submersibles
► Positive displacement
pumps
► Other devices
 Fans
 Compressors
Some Basic Stuff

► Flow: 1 mgd = 694 gpm

► Head: 1 psi = 2.31 feet
► Head Loss: liquid friction,
velocity2
► Power: 1 hp = .75 kW
► Money ($.07/kwhr)
 1 mgd at 100 feet (22 hp) for a
year is about $10,000
 2 mgd in same pipe is about
$18,000 a year
 1 hp for a year about $500
What is Efficiency?

► Good divided by
the total
► Energy Losses in
Pumps:
 Mechanical
(friction in
bearings, etc.)
 Volumetric
(recirculation)
 Hydraulic (liquid
friction)
Calculating Pump Horsepower

Q = flow in gpm
Qxh h = head (pressure) in
hp = feet (1 psi = 2.31 feet of
eff X 3,960 head)
eff = efficiency

• Water horsepower: ignore efficiency

• Brake horsepower: pump efficiency only (size the
motor)
• Wire-to-water horsepower: pump x motor
efficiency (size the electrical service)
Typical Pump Efficiencies

► Pump only (brake, no motor)

 Non-clog centrifugal, 25 hp: 65%
 Submersible wastewater, 34 hp: 75%
 Vertical turbine, water, 30 hp: 81%
 End Suction, water, 30 hp: 75%
► Bigger is better: add about 5 points at
200 hp
► Slower is better: add a couple points
below 1200 rpm
 Pump Curve: Superbasics

Operating Point
Pump curve
Head
(feet or psi) System curve Dynamic
Losses

Static
Pressure

Flow
Pump Curve: Less Basic

► Nerdy but crucial

► Best Efficiency
Point (BEP)
► Typically drops
off about 20%
from BEP
► How pump is
applied
determines how
efficient it will be
Minimum/Maximum/Normal
Pump and System Curves
System Curve
Normal

High Static
Head

Low Static
Head
Dynamic Losses May Vary
System Curve
Normal
High Dynamic
Head

Low Dynamic
Head
Operation at Low End of Pump Curve
System Curve
Normal
High Dynamic
Head

Low Dynamic
Head
Operation at High End of Pump
Curve
System Curve
Normal
High Dynamic
Head

Low Dynamic
Head
Variable Speed Pumping
► Variable Speed
Drives (VFD’s)
 Vary motor
speed from
about 50% to
100%
 Drive is about
98% efficient
 2 to 4 times cost
of starter
► Why? Moving water
slower reduces
friction
Why VFD’s? Throttling Stinks

1,125 gpm 2,250 gpm

250 throttling valve
1,800 RPM curve
70 hp
90 hp
200
1,200 RPM curve
Head
VFD: System
(feet) 150
36 hp
curve
100
System curve:
50 throttled

0
0 500 1,000 1,500 2,000 2,500

Flow (gpm)
Pump Selection – Seems Easy

70
Looks great for peak
20 40 design conditions
60 50 60
74
Head (feet)

82
50 80 System curve
81
82
40 74
60
30
585 rpm
0
0 500 1000 1500 2000 2500 3000 3500
Flow (gpm)
Not So Fast…..
Pumps are often unstable and inefficient
70 at average/ minimum conditions

20 40
50 60 Efficiency is just 40%
60
at 500 gpm
74
82
Head (feet)

50 System curve
80
81
40 82
74
60
30
585 rpm
460 rpm 500 rpm
0
0 500 1000 1500 2000 2500 3000 3500
Flow (gpm)
Follow Standards

► Hydraulic Institute
 Pump Intake
Design (9.8)
 Allowable
Operating Region
(9.6.3)
► Read “Pumping
Station Design”
(Sanks)
Electric Motors

► Most applications: NEMA

standard
 Enclosure type: TEFC, open drip-
proof, weather protected
 1992 Energy Act
► Submersibles use special
motors
► Inverter Duty: improved
cooling, insulation
Electric Motor Efficiency

100
► Standard % full load 90
efficiency efficiency
80
motors: 90% 70 75 - 100
60 Hp
► Premium 30 - 60
50
efficiency: 10% Hp
40 15 -25
more expensive, 30 Hp
5% more 20
efficient 10
0
► Efficiency is 0 20 40 60 80 100 120
constant to
about 50% load % full load
Improving Pump Efficiency

► Don’t Design it Wrong

 Invest in a good predesign
 Decide how it will operate before messing around with
layouts and equipment selection
 Pick pumps to operate efficiently operate at conditions
where the pump will actually operate most of the time
 Consider variable speed drives or smaller pumps to
improve efficiency at low flows
Improving Pumping Efficiency

► Operate Smart
 Pump as slowly as possible
 Utilize storage to level out pumping rate
 Eliminate throttling
► Fix Stuff
 Test pumps regularly (inc electrical measurements)
 Visual inspection of interior
 Modify or replace impeller to match conditions
 Replace old motors (pre Energy Act, 1992 to 1997)
Example: Big Water Pump Station

Figure 3 - Projected Average Day Power Usage, 2011 Projected Average Day Flow

1800 30

1600
25
Average Power (kW)

Average Flow (mgd)

1400

1200 20

1000
15
800

600 10

400
5
200

0 -
January February March April May June July August September October November December

Average PowerMonth
Consumption
Current Condition Pumps - 877 kW
After PS 1 Upgrade - 780 kW

After PS 1 Upgrade Current Condition Pumps Projected Average Daily Flow

Energy Before and After Upgrade

Current Condition Pumps

After PS 1 Upgrade
39 kW
16 kW
76 kW
91 kW

614 kW 611 kW
190 kW

123 kW

Average Hydraulic Power Loss

Average Hydraulic Power Loss Average Hyd Power
Average Hyd Power Average Motor Loss
Average Motor Loss AFD Loss
Savings Compared to Current Pumps