Flow Solutions

Energy-Efficient Flow
Solutions By Design

Positive Displacement Sliding Vane

Pump Technology Delivers Superior
Energy-Saving Advantages in
Process Applications

Process | Energy | Military & Marine

When Efficiency is Measured in Kilowatts . . . It’s Time to Put Some
Energy Into Learning About Positive Displacement Sliding Vane Pumps

Introduction n Increase operational reliability and process

integrity by emphasizing the use of energy-efficient
Today, high energy prices impose an unprecedented technologies that support enhanced mechanical
profit-robbing threat to every manufacturing operation, efficiency
large or small, worldwide. Left unmanaged, energy
expenditures can quietly, and quickly, erode a company’s n Reduce vulnerability to energy price volatility
financial performance, productivity and ultimately its
competitiveness. Since pumps account for nearly 27% of total electricity
use in the industrial sector, as manufacturers work
With this threat in mind, manufacturing operations to align their energy-efficiency initiatives with their
around the globe are implementing energy management business goals, pump system improvements will play an
processes and procedures that seek to: increasingly important role in this effort. Because there
is no “one-pump-fits-all” solution, particular attention
n Drive productivity improvements that increase to proper pump selection will become increasingly
financial performance important in the effort to select the right pump not
only to deliver productivity gains, but to also control
n Control energy expenses by reducing power energy consumption.
consumption without compromising output
performance or, preferably, while simultaneously With this in mind, by virtue of its inherent energy and
improving production levels mechanically-efficient design, positive displacement
sliding vane pump technology is uniquely suited to offer
manufacturers immediate, high-value advantages and
Table of Contents solutions in fulfilling their energy-saving initiatives.
Mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
This booklet is part of Blackmer’s Smart Energy
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Flow Solutions initiative. It is not intended to be a
Reduce Energy Costs & Improve System Performance . . 3 comprehensive pump selection guide. The purpose of
Measuring & Managing Energy Consumption . . . . . . . . . . 5 this booklet is to educate readers on positive displacement
Calculating Potential Energy Savings . . . . . . . . . . . . . . . . . 7 sliding vane pumps; how they work and why. By virtue
Reducing Energy Waste Through Proper Pump of their design, they offer best-in-class energy-efficiency,
Selection & Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 productivity improvement, and total life cycle cost
advantages over other pump technologies. For more
Barriers to Proper Pump Selection & Pump
information on Blackmer Smart Energy Flow Solutions,
System Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
visit www.BlackmerSmartEnergy.com
Using Life Cycle Costs for Proper Pump Selection . . . . . 9
Proper Pump Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Proper Pump Selection for Energy Efficiency . . . . . . . . . . 15
Energy Costs Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Sliding Vane Pumps vs. Gear Pumps . . . . . . . . . . . . . . . . . . 16
Advanced Sliding Vane Pump Technology
Provides Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Motors & Variable Speed Drives . . . . . . . . . . . . . . . . . . . . . 19 NOTE: Much of the following information is presented
in U.S. Standard units of measure, due, primarily, to the
source materials utilized. However, the data is globally
applicable.

2
 Blackmer Smart Energy™ Flow Solutions Mission
Enable pump users to a gain a competitive business advantage through the deployment of energy-saving positive
displacement sliding vane pump technology.

Blackmer will accomplish this mission by providing end-users, engineering consultants, OEMs and distributors with
education, tools and knowledge on the energy-saving value and performance-enhancing advantages of positive
displacement sliding vane pumps.

Overview and overall energy-efficiency are measured and affected

by the pumps and overall system configuration is vital to
In today’s competitive marketplace, all companies, developing successful energy-efficient pumping systems.
regardless of their business, are concerned about the In addition, knowing the fundamental differences,
bottom line. Around the world, energy costs continue to advantages and disadvantages between the various pump
rise as demand increases for greater profitability through technologies, relative to performance and energy-saving
cost control. In other words, the reduction of energy design characteristics, is also necessary in order to select
consumption is a key component in controlling costs. the pump capable of producing optimum results.
Higher energy costs impact the bottom line of every
company, particularly processing operations where, Reduce Energy Costs And Improve System
according to the Hydraulic Institute, pumps represent Performance
27% of the electricity used by industrial systems.
Any company that uses industrial pump systems can
Pumping systems are a major energy consumer and are realize both energy and non-energy benefits by applying
mission critical to every plant’s operation. A wealth of energy-saving improvements to their operations. Relative
energy-saving advice is available from a wide variety of to pumping systems, energy-saving improvement
sources, such as the United States Department of Energy’s opportunities fall into two categories: 1) existing
Industrial Technologies Program (ITP) and the Hydraulic systems (which far exceed new systems), and 2) new
Institute’s Pump Systems Matter initiative, among others. systems. For new systems, begin by selecting the best
Central to their energy-saving advice is the need for pump technology, properly sized for the application.
companies to take a systems approach in order For retrofit applications, identifying, re-engineering and
to significantly improve their energy-efficiency. correcting improperly sized or poorly designed pumping
This approach will enable operations to improve systems can result in a company achieving multiple goals
reliability, performance and efficiency of their overall simultaneously:
pumping systems, which in turn will result in not only
greater energy savings but also higher productivity, n Reduced energy consumption
performance and profitability.
n Reduced operations, production and maintenance costs
This means utilizing the best pumping technology
(centrifugal or positive displacement), properly sized n Improved productivity
with the appropriate piping design, control valve
configurations and motors to ensure the highest n Improved product quality
efficiency for particular applications.
n Improved capacity utilization
Although the operating principles of positive
displacement and centrifugal pumps differ widely, in n Improved system reliability
many cases both types can be used to serve the same
applications. In areas where centrifugals cannot be used, n Improved worker safety
and, more importantly, in the “overlap” applications
where centrifugals and PD pumps may both be used, Northwest Energy Efficiency Alliance states that: “A dollar
positive displacement pumps can likely offer substantial saved on energy, maintenance or production is equivalent
opportunities to improve processes, uptime, to $17 in sales income (assuming a 6% gross margin).” 1­­­
and energy savings.
Energy is the single largest cost of ownership of an
There is a specific “best-use” for all pump technologies. industrial pump system, representing between 50-90%
Understanding how pump efficiency, system efficiency of total life cycle costs, depending on the technology.
1
SOURCE: Northwest Energy Efficiency Alliance / Industrial Efficiency Alliance – How Continuous Energy Improvements Reduce Costs and Improve System Performance

3
With so many opportunities for companies to with >10 employees (50,000 plants) have adopted basic
immediately improve bottom line performance through energy management principles.2 According to statistics
energy-efficient pump system improvement, it is easy to published by the Hydraulic Institute, energy-saving pump
understand why today 25% of the 200,000 U.S. plants system opportunities abound for all pump size ranges.

Energy Savings – Efficiency Opportunities by Pump Size

6000

5000

4000
GWhr / Year

3000

2000

1000

0
1-5 6-20 21-50 51-100 101-200 201-500 501-1000 1000+
HP HP HP HP HP HP HP HP
Source: Pump Systems Matter – U.S. Industrial Motor Systems Market Opportunities Assessment, U.S. Department of Energy

A report published by the U.S. Department of Energy3

Range Of Savings -
revealed energy-saving opportunities by making changes Efficiency Measures
% Of System Energy
to pump systems. These suggestions included:
1) Reduce Overall System 5 – 20%
1) Reduce pump speed Requirements
2) Match Pump Size To Load 10 – 30%
2) Match pump size to the load

3) Reduce overall system requirements 3) Reduce Or Control Pump Speed 5 – 50%

4) Component Purchase 1 – 3%

5) Operations & Maintenance 1 – 5%

2
SOURCE: Pump Systems Matter
3
An Assessment of the U.S. Industrial Motor System 1998

4
Measuring & Managing Energy According to the U.S. Department of Energy, the U.S.
has more than 2.4 million pumps that will consume
Consumption 142 billion kWh annually in industrial manufacturing
processes. At 5 to 10 cents per kWh, this adds up to
The most common unit of measurement on an electric
a rather substantial amount of money. It is easy to
meter is the kilowatt-hour.
understand how improving the energy efficiency of
even one pump could produce substantial financial
n A kilowatt-hour (kWh) is a unit of energy equivalent
savings for any operation. For illustrative purposes,
to one kilowatt (1 kW) of power expended for one
the table below summarizes the electrical costs of a
hour of time.
continuously operated centrifugal pump driven by
a 100 HP motor. It is easy to see what a 10% reduction
in energy consumption would mean:

Pumping Energy Costs for Pump Driven by 100-HP Motor (assumes 90% motor efficiency)
Energy Costs for Various Electricity Costs
Operating Time
2 cents per kWh 4 cents per kWh 6 cents per kWh 8 cents per kWh 10 cents per kWh

1 hour $1.60 $3.30 $4.90 $6.60 $8.20

24 hours $39 $79 $119 $159 $198

1 month $1,208 $2,416 $3,625 $4,833 $6,042

1 year $14,500 $29,000 $43,600 $58,000 $72,600

Source: U.S. Department of Energy – Energy Efficiency and Renewable Energy; Pump Systems Matter Energy Tip Bulletin #4

Pumps are wasting energy when they fail to convert the
electric power they consume into the fluid motion that
they were designed to provide.
There are several critical equations with which you will
want to be familiar when considering selection of • For electric motors, efficiency ranges are generally
a new pump or when analyzing a pump system 85% to 92%.
for energy-efficiency.
1) Pump Efficiency – the rate at which a pump imparts
energy (output energy) to the pumpage divided by
the rate at which the pump requires energy (input
energy). The efficiency of a pump is related to its
hydraulic, mechanical and volumetric losses.
Imparted Energy
Efficiency =
Inputted Energy
EXAMPLE: If 1.25 HP must be applied to the input
shaft when the pump is doing the work equivalent
to 1 HP, the pump efficiency will be 80% (1 divided
by 1.25)
2) Wire-to-Water Efficiency – takes into consideration
the efficiency of the electric motor driver and the
efficiency of the pump. Overall efficiency is a product
of both a pump’s and the power unit’s efficiency.
• Pumps operating at efficiencies between 60-70%
can be improved.
• Pumps operating at efficiencies less than 50% need
major repairs, system changes or replacement.
3) Specific Energy – the actual power required to pump
a given volume of fluid (kWh/Q)
Energy Used
Specific Energy =
Pumped Volume
4) Power – a measure of the rate at which work is done or
energy is converted

Energy Converted
Power =
Time Taken

5
 5) Pump Output (Hydraulic or Water Horsepower ­– The most common prime mover for a pump is a fixed
WHP) is the liquid horsepower delivered by the pump. speed, alternating current (ac) electric motor. Motors
are measured in horsepower delivered. Since pumps
POSITIVE DISPLACEMENT
serve such a wide range of needs, pump sizes range from
Flow Rate (GPM) x fractions of a horsepower to several thousand horsepower,
Hydraulic depending on the application. As the horsepower
Horsepower = Pressure (PSI)
increases so too does the energy cost to operate
(Water HP) 1714 the pump.

The combined efficiency of the motor and pump

CENTRIFUGAL
determines the wire-to-water efficiency of the system.
Flow Rate (GPM) x Achieving high wire-to-water efficiency is desired, and
Hydraulic
choosing pumps and motors with high wire-to-water
Horsepower = Head (FT) x Specific Gravity
efficiency is needed to ensure long-term efficiency – but
(Water HP) 3960 managing energy efficiency of a pumping system is more
complicated than just choosing high efficiency pumps
and motors. There are a variety of sources within a
6) Pump Input (Brake Horsepower – BHP) is the actual pumping system that can waste energy including control
horsepower delivered to the pump shaft. valves and throttling, pipe size and configuration and
pump wear, to name a few.

Brake Flow Rate (GPM) x A pump’s efficiency can degrade as much as 10-25%
before it is replaced.4 Efficiencies of 50-60% or lower
Horsepower = Head (FT) x Specific Gravity are common. However, because these inefficiencies are
(BHP) 3960 x Pump Efficiency not readily apparent, opportunities for energy savings
by repair or replacement of components are often
overlooked.
NOTE:The constant 3960 is obtained by dividing the
number of foot-pounds for one horsepower (33,000) by the When pumps are improperly sized (over or under sized),
weight of one gallon of water (8.33 pounds). when long-term operating costs are not considered, or
when a lack of expertise results in the use of pumps being
OR improperly matched to applications, energy is wasted.
And, as a result, for every kilowatt of power “input” to
the pump, less is being transferred to the fluid.
Brake Horsepower = Water HP (WHP)
Not only is the company paying more for additional
(BHP) Pump Efficiency energy input, but wear on the pump is also accelerated
reducing component life. Maintenance costs are increased
as are unexpected and premature failures, resulting in
7) Fluid Energy = Fluid Power x Operating Time additional productivity losses.

8) Horsepower – is defined as the power required to
raise a weight of 33,000 lbs. a vertical distance of 1
foot in 1 minute. The rate of work performed by a
pump (in horsepower) is proportional to the weight
of the liquid it delivers per minute, multiplied by
the total equivalent vertical distance in feet through
which is moved.
Pumps are selected based on the maximum demand
of the system. However, the maximum demand may
only actually be required a small percentage of the total
run time. Therefore, the greater the separation between
pump capacity and real-time demand, the greater the
inefficiency and energy waste of the system.

Horsepower kW x Efficiency
=
(alternating current) 746

4
U.S. Department of Energy Pump Systems Matter Tip Sheet #4

6
Calculating Potential Energy Savings n A power reduction of 135 horsepower (100 kW)
in a process running 24/7 reduces energy cost
When pumps operate at optimum levels they use less $40,000 per year (based on an energy price of
energy and increase reliability, saving both energy and $0.05/kWh).
maintenance costs.
n The maintenance and productivity benefits of
improving a pump system’s performance are
generally one to two times the value of the
energy savings.

Calculating Potential Energy Savings

(1 – Actual System Efficiency)

Savings = kW (in input electric energy) x Annual Operating Hours x
Optimal System Efficiency
EXAMPLE:

1) Operating Efficiency (300 HP pump = 55% Efficiency)

2) Optimal Operating Efficiency (300 HP = 78% Efficiency)

3) Pump draws 235 kW x 6,000 hours of service per year

(1 – 0.55)
Savings = 235 kW x 6,000 Hrs/Yr x = 415,769 kWh per year @ 0.05 per kWh = $20,788 Savings
0.78

Reducing Energy Waste Through Proper n Ensure proper motor alignment (poor alignment of
motor and load increases motor power consumption)
Pump Selection & Application
n­­ Reducing pumping system flow rates (lower flow
The best way to deal with poorly performing pumping
equates to lower energy losses)
systems is to specify them correctly in the first place.
The best systems meet the real-time requirements of the
n Lowering operating pressures
process while using the least amount of energy. Industrial
facilities can reduce energy consumption, increase the life
n Operating the system for a shorter period of time
of components and reduce maintenance budgets by:
during each day
n Selecting the pump technology best suited for the
n Maintaining pumps and all system components
application
in virtually new condition to avoid efficiency loss
(wear is a significant cause of decreased pump efficiency;
n Properly sizing pumps, control valves and piping
corrosion in pipes increases friction)
systems to real-time requirements (avoid excessive
margin of error capacity and/or total pressure or head)

n Improve inlet/outlet conditions to reduce restrictions,

turbulence and frictional losses

7
Planning for a satisfactory, economical and energy-saving
pump installation involves two basic items:
1) Selecting the proper type, size and speed of pumping
equipment
2) Making a careful study of the suction and discharge
conditions, including details of the piping layout
The proper selection of the pumping equipment must
also consider all of the application conditions:
1) HOW MUCH FLOW?
Approximate DELIVERY required in
gallons per minute
2) HOW MUCH PUSH?
Differential PRESSURE required in
pounds per square inch (PSI)
3) WHAT LIQUID?
Type of LIQUID to be handled
4) HOW HEAVY?
Specific GRAVITY of the liquid
5) HOW THICK?
Maximum VISCOSITY of the liquid in
Seconds Saybolt Universal (SSU)
6) HOW HOT?
Pumping TEMPERATURE of the liquid in
degrees of Fahrenheit
7) HOW MUCH PULL?
SUCTION conditions when pumping in
inches of mercury for vacuum, or psi for
pressure
8) HOW LONG?
Type of SERVICE, i.e. intermittent duty,
semi-continuous duty, or continuous
duty
8
Barriers To Proper Pump Selection & Pump
System Optimization
Many pumps users do not know how to properly select
and apply pumps to a system, so pump system operating
costs are inadvertently increased as a result. Using pump
selection software programs can help to optimize
pump selection.
While manufacturers, such as Blackmer, can help
influence pump specification and proper selection for a
particular application, they are generally not involved
in the engineering of the overall system. In an effort to
reduce costs, end-users have trimmed engineering staffs,
slowly losing their in-house pump expertise. Greater
responsibility is being placed on manufacturers to assist
with the efforts to increase equipment reliability and
operational efficiencies. Industry leading manufacturers,
such as Blackmer, are providing applications and
engineering expertise, pre- and post-sales support, such
as pump specification and selection programs, technical
training and counseling, start-up assistance, maintenance
and troubleshooting advice and technological
innovations for the purpose of helping end-users to
optimize their pumping systems.
blackOPS® – Blackmer Optimum Pump Solutions
allows users to select pump data and pump curves so
they can select the proper positive displacement or
centrifugal pumps for their application.
End-users are beginning to rely more heavily on outside
contractors to provide engineering, procurement and
construction (EPC) for projects. This practice removes the
pump user from the decision-making process beyond the
basic requirements developed by the pump user.
EPCs are typically first-cost driven and have little or no
incentive to optimize a pump system for reduced life
cycle costs (LCC). In fact, since the primary motivation is
to first reduce costs, risks and time to project completion,
energy-efficiency is often not a consideration, which
ultimately has a negative impact on long-term operating
performance and profitability.
Reducing first costs – improves EPC competitive
positions but frequently results in pump systems which
are not energy efficient.
Minimizing time to project completion – eliminate the
time necessary to analyze alternative equipment options.
The trade-off is first-cost vs. LCC.
Reducing risks – is generally accomplished by adding
safety margins to each step of the design/construction
process. This results in oversized equipment, contributing
to mismatched pumps and system components that
operate with increased maintenance and energy
consumption. Excessive safety factors also reduce system
reliability. Industry sources claim that a 10-15% safety
margin is routinely applied to pumps and motors to
accommodate anticipated capacity increases, and that
overall 70% of pumps are not properly sized resulting
in wasted energy, reduced reliability and higher than
necessary maintenance costs.

Oversized Pumps Undersized Pumps

Often paired with oversized control valves and piping. Oversized Create cavitation which causes vibration, premature wear that
control valves consume wasted energy with excessive pressure leads to energy-wasting slip, seal problems and possibly loose bolts,
drops which shortens valve life misalignment and pipe leakage
Want to deliver a higher GPM than the system requires in centrifugal Cause motor over-amps resulting in increased electric consumption
systems, the head is raised to unneeded pressures:
EXCESS HEAD x FLOW = ENERGY WASTE
Create excessive pressure, velocity, noise, vibration, heat and energy Create unstable hydraulics that cause excessive pump vibration, wear
waste and failure
Cause re-circulation in centrifugal pumps
Rarely a problem in PD pumps because the slower the pump runs the
better
Undersized Piping Leads to:
Restricted flow Requires larger pumps that waste energy
Large pressure losses
Big pipes cost more than smaller diameter pipes Contractors can save initial costs by bidding smaller pipes that
consume more energy
Bad suction at inlet Potential pump repairs, downtime and lost production
Too small on discharge side PD pump will push the fluid though but at higher pressures and energy
costs

Using LCC (Life Cycle Costs) for Proper LCC - Relative Comparison
Centrifugal vs. Positive Displacements (PD) Pumps
Pump Selection
1.0
Improper pump selection can cost money in
downtime, lost production, maintenance costs and
energy consumption. When purchasing pumps, it is
recommended that pump users pay close attention to 0.8
total cost of ownership or life cycle costs (LCC) analysis
Total Life Cycle Cost (LCC)

to compare operations, maintenance and energy

consumption costs between pump technologies that could
be used for the same application. An analysis of LCC, as 0.6

a management tool, can dramatically reduce waste and

maximize efficiency. The NET cost savings based on LCC
will often justify a higher initial price for a more energy- 0.4
efficient pump. Life-cycle costing helps identify the lowest
total cost of ownership:

n Initial equipment cost 0.2

n Installation & Commissions

n Energy costs
0.0
n Maintenance & Repairs Centrifugals PD Pumps
n Downtime costs n Initial Pump Cost n Installation, maintenance, operating,
n Decommissioning costs n Energy Cost environmental & downtime costs

9
 Pump Technology Matrix

SELF-PRIMING

Volute NON-SELF-PRIMING Open

Single Impeller
Radial DIFFUSER
Suction Single
Flow REGENERATIVE TURBINE Stage SEMI-OPEN IMPELLER
VERTICAL TURBINE DOUBLE SUCTION CLOSED IMPELLER
Centrifugal MIXED FLOW MULTI-STAGE

Kinetic AXIAL FLOW SINGLE-STAGE OPEN IMPELLER

(Dynamic) SEMI-OPEN IMPELLER
OTHER JET (EDUCTOR/EJECTOR MULTI-STAGE
SPECIAL ACTION

Pumps
PISTON SINGLE-ACTING SIMPLEX
PLUNGER DOUBLE-ACTING DUPLEX
RECIPROCATING
TRIPLEX
MULTIPLEX
Positive
DIAPHRAGM
Displacement
BELLOWS FLUID OPERATED (Air/Hydraulic)

MECHANICALLY OPERATED

Blade
Vane ROLLER

AXIAL
Single Rotor PISTON
RADIAL
FLEXIBLE IMPELLER
TUBE & ROLLER
Rotary PERISTALTIC
LINER
SINGLE SCREW SPUR
TIMED
PROGRESSIVE CAVITY HELICAL
UNTIMED
LIQUID RING HERRINGBONE
EXTERNAL
MULTIPLE ROTOR GEAR CRESCENT
INTERNAL
LOBE SINGLE/MULTIPLE NO CRESCENT
CIRCUMFERENTIAL PISTON SINGLE/MULTIPLE
MULTIPLE SCREW SINGLE/MULTIPLE TIMED
OTHER UNTIMED
SPECIAL ACTION

Source: Schematic courtesy of Chemical Processing Magazine

Proper Pump Selection
Although the operating principles of positive
displacement and centrifugal pumps differ widely,
both types of pumps can be used to serve many of
the same applications. In these instances, certain
positive displacement pumps may offer substantial
opportunities to improve processes and productivity as
well as maintenance and energy cost savings. Positive
displacement pumps generally require less NPSHA than
centrifugal pumps, and they offer more flexibility relative
to dealing with varying changes in pressure and flow
requirements of continuous-type processes.
Also, positive displacement pumps maintain higher
efficiencies throughout the viscosity range. Therefore, in
the overlap where both types of pumps can operate, a
positive displacement pump’s high mechanical efficiency
can offer improved energy efficiency.
The delta in wire-to-water efficiencies of positive
displacement pumps as compared to centrifugal pumps
decreases as flow rates increase. That is, the larger the
standard centrifugal pump the greater efficiency it has
at its best efficiency point (BEP). Therefore, the potential
efficiency advantage afforded by positive displacement
pumps should be reviewed in high flow applications.
However, since centrifugal pumps operate dependent of
the system curve they rarely operate at their BEP, even
if they are sized/selected appropriately. This is due to
the routine practice of building in a safety margin for
anticipated capacity increases. Changes in the system
curve, due to factors such as suction/discharge height
variations, blockage, etc. will also shift the centrifugal
pumps’ operating point. Positive displacement
pumps, specifically sliding vane pumps, do not have
this limitation as their output is, to a large extent,
independent of the system curve. Further, as with positive
displacement gear and lobe pumps, centrifugal pumps’
internal clearances increase over time resulting in a
decrease in efficiency. Positive displacement sliding vane
pumps utilize self-adjusting vanes that eliminate clearance
increase problems to maintain near original hydraulic
efficiency over time. This feature offers substantial energy
savings benefits.

10
Selecting the proper pump begins by knowing: Differential pressure is critical to energy-savings and
pump life. Smaller pipe size and large pipe runs may
1) Total head or pressure against which it must operate reduce initial cost, but they can cause higher differential
pressure for pumps. This results in higher energy
2) Desired flow rate consumption and higher operating costs.

3) Suction lift Once system conditions and liquid properties are known,
the next step is to determine whether a centrifugal of PD
4) Fluid characteristics (Temperature, corrosiveness, etc.) pump is the better choice.

The piping system and pump interact to determine the

operating point of pumps: flow rate and pressure.

Basic Comparison – Centrifugal Pumps Vs. Positive Displacement Pumps

Centrifugal Positive Displacement

Mechanics Imparts velocity to the liquid resulting in a pressure at the Captures confined amounts of liquid and transfers it from
outlet (pressure is created and flow results). the suction to the discharge port (flow is created and
pressure results).

Performance Flow varies with changing pressure. Flow is constant with changing pressure.

Viscosity Efficiency decreases with increasing viscosity due to Efficiency increases with increasing viscosity.
frictional losses inside the pump (typically not used on
viscosities above 850 cSt).

Efficiency Efficiency peaks at best-efficiency-point. At higher or Efficiency increases with increasing pressure.
lower pressures, efficiency decreases.

Inlet Conditions Liquid must be in the pump to create a pressure Negative pressure is created at the inlet port. A dry pump will
differential. A dry pump will not prime on its own. prime on its own.

Source: Chemical Engineering – Facts At Your Fingertips; Department Editor: Kate Torzewski

Flow versus Pressure Efficiency versus Viscosity

250 100

200 80
EFFICIENCY %

Positive Positive
HEAD FEET

150 60

100 40
Centrifugal Centrifugal
50 20

0 0
0 50 100 150 0 250 500 750 1000
CAPACITY (gal/min) VISCOSITY (cSt)

Efficiency versus Pressure Flow versus Viscosity

80 110
Positive
Positive 100
70 90
EFFICIENCY %

FLOWRATE %

80
60
70
Centrifugal Centrifugal
60
50
50

40 40
55 80 105 0 100 200 300 400 500
FEET OF HEAD VISCOSITY (cSt)

11
 Comparing Centrifugal Pumps To Positive Displacement Pumps

If The System Calls For: The Best Pump To Use Is:

Pressurized network of piping with a constant pressure requiring constant flow rate Centrifugal

Constant flow at various pressures Positive Displacement

Constant flow at various viscosities Positive Displacement

Constant flow at high viscosities (particularly above 850 cSt) Positive Displacement

Line stripping Positive Displacement

Dry running – short duration Positive Displacement

Priming Positive Displacement

Shear sensitive Positive Displacement

Entrained gases Positive Displacement

High flow / low head Centrifugal

Low flow / high head Positive Displacement

Summary
Consider Positive Displacement Pumps over 4) System requires high-pressure, low-flow
Centrifugals when:
5) Line stripping is required (some PD technologies)
1) Working fluid is highly viscous (over 850 cSt)
6) Suction lift or self-priming is required
2) Flow rate must be predictable over a wide
7) Working fluid is shear-sensitive
flow range (flow must be metered or
precisely controlled) 8) Energy-savings/efficiency is a primary concern

3) Flow rate must remain constant under varying

system pressures

“Though engineers may be first inclined to install centrifugal pumps, many applications dictate the need for PD pumps.
Because of their mechanical design and ability to create flow from pressure input, PD pumps provide a high efficiency under
most conditions, thus reducing energy use and operation costs.”

Chemical Engineering – Facts at Your Fingertips (Department Editor: Kate Torzewski)

12
 Centrifugal Pump Highlights

n Roto-dynamic principle: accelerates fluid and n Good for applications requiring high flow/low
converts this kinetic energy into pressure head in which viscosity is not prohibitively high

• Centrifugal pumps are subject to the Affinity Laws: n If part of a process changes often or
continuously, some method of altering the
- Flow is directly proportional to changes in pump characteristics is necessary. Common
speed practices include:

- Pressure increases by the square of changes • Throttling valves

in speed
- Obstruct flow – increase head pressure
- Horsepower increases by the cube of changes (increases energy consumption)
in speed
- Producing 70% flow requires up to 90% of the
• Higher flow rates create higher flow velocities energy used at full speed
which leads to friction loss and higher energy
consumption • On/Off Control

• Pressure is expensive. Pressure through a pipe is
proportional to the square of the fluid velocity;
given the same size pipe, a flow rate that is
2x higher endures 4x more friction loss. This
means that it costs more to pump a higher than
necessary flow rate.
• Horsepower is expensive – BHP increases greatly
as speed increases
- Used in cases where step-less control is not
necessary (keeping pressure in the tank
between preset limits)
- Pump is either running or stopped
- Average energy consumption is the same as
average run time (70% energy consumption
for 70% average flow)

n Make up 75% of the industrial process • Variable speed drives (VSD)

pump industry
- Changes pump speed and flow generated
n Complex to select the right pump resulting in (consumes less energy than throttling)
the tendency to over-size the pump
- The greater the static head, the lower the
• Increases the cost of operating and maintaining possible energy savings between a VSD
and Throttling
• Creates operating problems such as excessive flow
noise, inefficient operation and pipe vibration n The larger the centrifugal pump, generally,
the greater its efficiency at its BEP
• Creates performance degrading and pump
damaging cavitation and recirculation

• Consumes more energy than necessary for the duty

n Variable flow/pressure relationship

• The amount of fluid a centrifugal pump moves

depends on the differential pressure

• As pump differential pressure increases the flow

rate decreases

• Low flow in centrifugal pumps consume

more energy

• Excess pressure is expensive

13
 Positive Displacement Pumps Highlights
■ Positive displacement pumps pressurize fluid
utilizing a collapsing volume action
• Have a fixed displacement volume
• Flow rates are directly proportional to their speed
• The pressures they generate are determined by
the system’s resistance to flow
■ Make up approximately 15% of industrial
process pump industry
■ Effective at generating high pressure in
low-flow applications
■ Simple to operate and maintain
■ Handle a wide viscosity range (Low and High
viscosity fluids)
• Advantage over centrifugal pump when pumpage
is highly viscous (by directly pressurizing fluids,
PD pumps use less energy)
• Sliding vane technology is exceptional on thin
and low-lubricity fluids (LPG, Refrigerants,
Solvents, Fuel Oils, Gasoline, Liquid
Carbon Dioxide)
• Sliding vane technology is exceptional on
non-lubricating liquids (thick and thin)
• Sliding vane technology is better in shear-
sensitive applications than many other PD
designs and centrifugal pump technologies
■ Typically more efficient than centrifugal
pumps... in some cases significantly
more efficient
14
■ Lower overall cost of ownership than centrifugal
pumps (based on LCC)
• Possibly higher initial (purchase) cost
• Typically lower energy costs – many times
significantly lower
■ Rotary PD designs minimize pulsation as
compared to reciprocating technologies
• Sliding vane and gear technologies exhibit little
to no pulsation
■ Dry Run, self-priming and superior suction
lift capabilities
• Can operate with entrained gases in the pumpage
• Pumps or suction piping can be placed above the
fluid level to simplify layout
■ Well suited for metered-flow applications
■ Sealless options available – (eliminate leaks
when handling high-value chemicals, hazardous
or corrosive liquids to yield substantial cost
savings and safety)
• Magnetically coupled/drive pumps
• Eccentric disc pumps
• Peristaltic hose pumps
• Air diaphragm pumps
■ Designed for high efficiency that results in
high reliability and energy savings
• High volumetric efficiency
- Self-adjusting vanes on sliding vane pumps
eliminate the energy-robbing slip caused
by wear; maintain near original efficiency
throughout the pump’s operating life
• High mechanical efficiency
Proper Pump Selection For Energy Efficiency:
Positive Displacement Pumps Are Not Created Equal
Positive displacement pumps are not created equal. lost production, maintenance costs and energy consumption.
There are significant differences between PD pump types. Following is an overview of several types of leading positive
Improper pump selection can cost money in downtime, displacement pumps:

PD Pump Features Viscosity Range Flow Rates

Sliding n Exceptional for thin liquids due to direct contact of vanes to casing and minimal Very thin (LPG, 1 to > 2,000
Vane internal clearances Refrigerants, GPM
n Excellent on thick liquids at slow speeds Solvents, Fuel
n Exceptional efficiency at low flow rates Oils, Gasoline,
n Excellent suction lift and line stripping capabilities Liquid Carbon
n Self-adjusting vanes eliminate energy-robbing slip and capacity loss to provide Dioxide,
substantial energy savings Ammonia, etc.) to
n High mechanical efficiency = energy savings High viscosities
n Differential pressure to 200 psi up to 50,000 cSt
n Speed to 3,600 RPM
n Hydrodynamic journal bearing models significantly reduce friction, excessive heat
build-up and energy loss
n Motor speed models are specifically designed for continuous duty operation for low and
medium viscosity applications
n Low energy consumption

Internal n Differential pressure to 200 psi (higher pressures are attainable) High viscosities 0.5 - 1,500
Gear n Speed to 3,600 RPM up to 1,000,000 cSt GPM
n Metal-to-metal gear results in wear and slip, resulting in efficiency degradation and
higher energy consumption over time

External n Do not perform well under critical suction conditions, especially with volatile liquids High Viscosity up Drops per
Gear n Good for high pressure applications such as hydraulics to 1,000,000 cSt minute to
n Differential pressure to 3,000 psi + 1,500 GPM
n Speed to 3,600 RPM
n Metal-to-metal gear design subject to efficiency degradation
n Must be rebuilt or replaced
n No clearance adjustments for wear which results in slip, efficiency degradation and
higher energy consumption

Lobe n Used frequently for food-type products due to sanitary nature and ease of cleaning Low Viscosity 5 - 3,000
n Vertical drain port reduces efficiency by 15-20% with diminished GPM
n Sanitary Models: Differential pressure to 200 psi performance up
n Non-Sanitary Models: Differential pressure to 400 psi to 1,000,000 cSt

Air n No bearings or rotating shaft Medium viscosity 1 - 500

Diaphragm n Can handle a wide range of shear-sensitive, abrasive and non-abrasive liquids as well to 26,000 cSt GPM
(AODD) as solids
n High pressure operation can cause excessive wear around valve seats as the check
valve closes
n Variable speed flow operation
n Requires air compression system. Electricity is used to run compressors.
n Energy accounts for 70% of compressed air life cycle cost – air is not free.
High energy costs.

15
Energy Costs Comparison – Vane/Lobe/Gear
Of the leading positive displacement technologies,
sliding vane pumps are generally the most energy
efficient. Significant design advancements have given
sliding vane technology a decisive advantage over lobe
and gear pumps, specifically with regards to optimized
performance, low-shear capability, lowest life cycle cost
and best energy efficiency. This is due in part to the
self-adjusting vane design-feature that eliminates energy-
Energy Costs – Mechanical Efficiency Comparison, PD Pumps: Vane / Lobe / Gear
Sliding Vane Pumps Vs. Gear Pumps
Comparison of Sliding Vane Pumps Vs. Internal Gear Pumps
Sliding Vane Pumps
n Superior mechanical performance
n Provides greater energy savings
n 24% More efficient than gear pumps
n Sliding vane pumps have a number of non-metallic vanes that
slide into and out of slots in the pump rotor.
n When the pump driver turns the rotor, centrifugal force, rods and/
or pressurized fluid causes the vanes to move outward in their
slots and bear against the inner bore of the pump casing, forming
pumping chambers
n This fluid is passed around the pump casing to the discharge port
n Each revolution displaces a constant volume of fluid
n Variances in pressure have minimal effect
n The sliding vanes automatically adjust to maintain near perfect
clearances throughout operating life
n Energy-wasting turbulence and slippage are minimized and high
volumetric efficiency and low energy consumption are maintained
16
robbing slip and promotes high volumetric efficiency
even after substantial time in service. Both gear and
lobe pumps are subject to wear that increases internal
clearances within the pump housing that result in slip
and efficiency degradation. Following is a Mechanical
Efficiency Comparison between three leading positive
displacement technologies. From the lowest to the highest
viscosity, sliding vane technology provides the highest
level of mechanical efficiency which equates to the lowest
overall energy consumption.
50-100 GPM; 50-100 PSI;
4-1,620 cSt viscosity;
same model on all viscosities
Internal Gear Pumps
n Less mechanically efficient
n Consume more energy than vane pumps
n Internal gear pumps utilize an outer gear called a rotor that is
used to drive an inner gear called the idler
n The gears create a void as they come out of mesh - the volumes
are reduced and liquid is forced out the discharge port
n Each revolution displaces a constant volume of fluid
n Variances in pressure has minimal effect
n The metallic gears wear over time resulting in wider clearances;
this increases energy-robbing slippage and significantly
decreases volumetric efficiency
n In order to compensate for performance degradation, pump speed
is increased which requires greater energy consumption
By eliminating the need to increase the pump speed
Sliding Vane Pump vs. Internal Gear Pump
over time, sliding vane pumps save additional energy
Mechanical Efficiency Comparison at 160 cSt and 100 PSI
when compared to gear pumps. Sliding vane pumps are
inherent energy savers by virtue of their design. This
technology not only reduces energy costs but helps
to create an overall more efficient pumping system,
providing solutions for seals, suction, product shear, and
volumetric efficiency problems to offering unique benefits
such as leak-free assurance, line stripping, metering, and

ME
non-pulsating flow – all while saving energy.

Sliding Vane Pump vs. Internal Gear Pump Sliding Vane Pump vs. Internal Gear Pump
Mechanical Efficiency Comparison at 1 cSt and 75 PSI Mechanical Efficiency Comparison at 5,250 cSt and 100 PSI
ME

ME

Annual Energy Cost Savings: Sliding Vane vs. Internal Gear Pumps
Liquid WHP Efficiency KW Annual Power Annual Savings with
Pump GPM PSI BHP
Viscosity (Water) Pump Motor (1) Input Cost (2) Sliding Vane Pumps
Pump Sized for Stated Flow
Thin Sliding Vane 20.1 68% 88% 17.0 $3,828
310 75 13.6 $552
1 cSt Internal Gear 23.0 59% 88% 19.5 $4,380
Viscous Sliding Vane 12.2 65% 88% 10.3 $2,323
180 75 7.9 $1,485
5,250 cSt Internal Gear 20.0 39% 88% 17.0 $3,809
Pump Sized for Wear Factor Allowance
Thin Sliding Vane 20.1 68% 88% 17.0 $3,828
310 75 13.6 $1,333
1 cSt Internal Gear 27.1 50% 88% 23.0 $5,161
Viscous Sliding Vane 12.2 65% 88% 10.3 $2,323
180 75 7.9 $1,771
5,250 cSt Internal Gear 21.5 37% 88% 18.2 $4,094
1) Typical
2) Assumes 8 hours/day, 6 days/week, 52 weeks/year Duty Cycle and $0.09 KWh. Power Cost may be directly ratioed for other electric rates or duty cycles

17
Advanced Sliding Vane Pump Technology 125 psi
Provides Energy Savings 1
Non-Hydrodynamic Hydrodynamic

Minimum Film Thicknes Ratio

0.9 Internal
Gear Pump 1
L/D = 1.5 L/D =
0.8
For even greater flexibility, efficiency and productivity, 0.7
560 ssu

advanced vane pump designs include motor speed 0.6

0.5

technology, unique “designed-in” features such as a 0.4

0.3
40 ssu
PV30
hydrodynamic journal bearing and one mechanical seal. 0.2
0.1
These innovative features serve to further improve the 0
0.000 0.001 0.010 0.100 1.000 10.000
fundamental pumping process and improve energy Bearing Characteristic Number (S)

efficiency. Additionally, motor speed vane pumps do not

require a gear reducer, so they offer upfront equipment, 1 cSt @ 125 psi
installation and energy cost savings. Non-Hydrodynamic Hydrodynamic
1

Minimum Film Thicknes Ratio

0.9
1
L/D = 1.5 L/D =
0.8

Hydrodynamic Journal Bearing 0.7

0.6
0.5
0.4
The Hydrodynamic Journal Bearing is a performance- 0.3
PV30
enhancing design feature that significantly improves 0.2
0.1
Internal
Gear Pump

overall pump efficiency, reliability and extends bearing 0

0.000 0.001 0.010 0.100 1.000 10.000

life. With this design, the pump shaft rides on a fluid Bearing Characteristic Number (S)

boundary during load conditions to eliminate shaft-to-

bearing contact, friction and wear. 1 cSt @ 60 psi
Non-Hydrodynamic Hydrodynamic
1
Since there is no metal-to-metal contact or wear in this
Minimum Film Thicknes Ratio
0.9
1
L/D = 1.5 L/D =
0.8
hydrodynamic condition, bearing life can be indefinite. 0.7
0.6
Motor speed vane pumps are engineered to achieve 0.5

hydrodynamic mode (full film operation – the point 0.4

0.3
PV30
offering the lowest bearing friction and the least wear) 0.2
0.1
Internal
Gear Pump

faster than any other pump in its class to preserve 0

0.000 0.001 0.010 0.100 1.000 10.000

bearing life. These pumps also maintain optimum Bearing Characteristic Number (S)

bearing characteristics even under a wide range of

operating conditions.
Reduced shaft-to-bearing contact minimizes friction,
lowers power loss, and improves reliability and bearing
life, resulting in higher mechanical efficiency and smart
energy cost savings.
ProVane® Motor Speed Sliding Vane Pump
With Hydrodynamic Journal Bearing Advantage
Cavitation Suppression Liner
Cavitation is a physical barrier to efficiency that can severely
impact a pump’s performance as the liquid changes to a
vapor inside the pump chamber. This effect decreases flow
through the pump and can cause substantial damage to the
pump as the vapor bubbles collapse back to the liquid state.
Cracking and popping noises indicate cavitation, which can
lead to expensive repairs if left uncorrected.
According to the Department of
Energy Industrial Technologies
Program’s Sourcebook for Industry,
the effects of cavitation include
increased maintenance costs,
slip, capacity loss as well as poor
system performance. Centrifugal
pumps are susceptible to these factors as well as “internal
recirculation,” a performance-degrading-effect that occurs at
low flow rates, which can damage the impeller and rotor.

Unique to vane technology, a Cavitation Suppression Liner

minimizes the pump’s wear effects associated with cavitation.
This patented solution helps to reduce the potential for slip
and capacity loss, ensuring the highest level of efficiency and
energy savings.

18
Relief Valve High Efficiency Motors

Blackmer® relief valves are designed to protect your pump The efficiency of a motor is the ratio of mechanical power
in a high pressure build-up situation. Ideal for variable output to electrical power input.
flow and pressure conditions, the relief valve offers:

Output Power
n Superior ability over other PD pumps to hold pressure Efficiency = x 100%
under variable flow/pressure conditions Input Power
n Maintains motor horsepower requirement to help
=
control energy consumption Input Power - Losses
x 100%
Input Power
n Highly engineered to
provide better control
over set points and High efficiency motors can help to minimize losses
operating conditions within a motor. Operations where the motor is running
at less than 60% of its rated load should be reviewed
n Lowers heat generation and replaced.

In general, correctly sizing the motor to the load offers

the greatest improvement opportunity. A high-efficiency
motor (partly loaded) may use more energy than a
smaller, less efficient motor in the same application.
Gear Pump Vane Pump
60 Typical Motor Efficiency at
Typical Motor Efficiency at Different Loads
different loads
50
100
40 75kW
90
7.5kW
Flow

30
80
0.75kW
20 70
Efficiency %

10 60

50
0
20 40 60 80 100 120 140 160 40

Differential Pressure 30
20
10

Motors & Variable Speed Drives 0

0 25 50 75 100 125 150 175
% Rated Load
Most pumps are driven by electric motors. According to
the Hydraulics Institute, up to 90% of prime movers in
process applications are driven by motors. Fixed speed
alternating current (AC) motors are the most common
Variable Speed Drives
type of motors. Variable frequency controls for AC
VSDs regulate the speed of the motor, reducing fluid flow.
motors allow for speed ranges between 25% and 110%
However, energy can be wasted when using VSDs. It is
of synchronous speed.
best to avoid:

High efficiency motors may not be required for sliding

1. Creation of excess pressure
vane pumps – and can actually decrease productivity and
cost more if misapplied. In high-run-time applications,
2. More flow through system than is necessary
improved motor efficiencies can reduce operating costs.
However, it is often more effective to take a systems
3. High frictional losses created from high average flows
approach that uses proper pumps, measurements and
sizing, coupled with effective maintenance practices to
4. Multiple pipes or ducts carrying fluid that is not
avoid unnecessary energy consumption.
being used

19
Every Blackmer Product Comes With A Value-Added Extra:
Applications Engineering/Technical Support/Customer Care
When it comes to flow solutions, uptime, output, reliability and profitability are critical to every operation’s mission. To this
end, Blackmer knows that reliable, proven flow technologies are critically important, but we also know that this represents
only one part of the overall equation. The other, equally important part involves having trained, knowledgeable and
customer-focused staff, which is why we make substantial investments in our people. It is through their collaborative effort
with customers that the greatest achievements are realized.

n Applications Engineers – experts in peace-of-mind assurance,

making sure your equipment is always right for the job

n Market & Product Specialists – unparalleled technical knowledge,

on-site product training, troubleshooting, installation and
product-selection consultation, and total life cycle attention

n Regional Sales Management – proven technicians with an

“above and beyond” commitment to every customer’s mission

n Customer Care Specialists – action-oriented specialists

committed to making sure every order receives immediate at-
tention, is accurately processed and followed up, and to help-
ing keep your process flowing smoothly

When you put it all together, for mission critical flow solutions,
it’s easy to see why leading companies around the world have
one common demand … Better Get Blackmer.

Total Life Cycle Support

From the moment of initial contact and equipment selection through Regional Sales
every point of the product and application life cycle, Blackmer Manager
specializes in helping customers get the maximum value from their Customer Care
Market & Product
flow technology assets by providing total life cycle support.
Specialist

Manufacturing

Application Design
Engineer Engineering

www.blackmer.com
Brochure ATK-0200-003 03/10
Copyright © 2010, Blackmer ­­­­­­Process | Energy | Military & Marine

World Headquarters
1809 Century Avenue SW, Grand Rapids, MI 49503-1530 USA
T 616.241.1611 F 616.241.3752

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