Lecture 2

Fluid transport loads (Pumps)

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 Fluid Transport Loads (Pumps)
• Types of pumps
• Centrifugal pumps
• Affinity laws
• Flow control methods
• Identifying good opportunities
• Cases
 The Motor System

Improving the energy performance of the motor system by

reviewing the actual load requirements
 Why pump systems?
• Transporting a fluid (and sometimes even
solids using a fluid medium) – very common in
industry
• Pumps represent 22% of all industrial motor
loads
• Usually good opportunity for motor energy
performance optimisation

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Where are pumps used?

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Pumps

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Typical Pump Motor System

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 Centrifugal Pumps
• Focus on this group of pumps
• Why?
– Very common
– Good candidate for energy optimisation in terms of
affinity laws

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How does a centrifugal pump work?

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 How does this benefit the motor?
• Traditionally pump systems have been installed
with the flow controlled in the mechanical part of
the system, using a valve or a bypass
• With new drive and motor technology, it is now
possible to control flow more efficiently by
controlling motor directly

• Energy benefit: best for centrifugal pumps (via

affinity laws)

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Affinity Laws for Centrifugal Loads

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Typical Pump Control Methods

Relative power consumption

on an average flow rate of
70% with different control
methods.

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 Case Study

Pump Optimisation

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 Problem Statement
• An 85 kW pump is rated at 270l/s at 2 bar.
• The pump supplies cooling water to a process and
the flow is controlled by means of a throttle valve.

• You are asked to determine and quantify the

opportunity for energy saving.
– Energy cost is EGP 0.5/kWh
– Motor efficiency is 90%

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 Approach
• Determine demand, and then match it to
supply
260 l/s for 3 months
160 l/s for 9 months

85kW

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 Findings
Actual process requires:
• 260 l/s for 3 months per year
• 160 l/s for 9 months per year

Motor electrical input power was measured at

90kW when delivering 260 l/s, and 85 kW when
delivering 160 l/s

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 Possible Solutions
1. Install VSD on existing pump.
2. Install second smaller pump to handle low
flow period. (A 55kW motor (eff=90%), rated
at 160 l/s at 2 bar is available in the
Maintenance Stores).

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 Existing Energy Consumption
• Existing energy consumption:
– 85kW x (3/4) x 8760h = 558,450 kWh
– 90kW x (1/4) x 8760h = 197,100 kWh

• Existing energy cost:

– 755,550kWh x EGP 0.5 = EGP 377,775

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 Installing VSD
• Remove throttle and use VSD for flow control
• Assume VSD internal losses of 5%

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 VSD Savings
• Power consumption:
– 85kW x (1/0.9) x (260/270)^3 x 1.05 = 88.5 kW
– 85kW x (1/0.9) x (160/270)^3 x 1.05 = 20.6 kW

• Energy Consumption:
– 88.5kW x (1/4) x 8760 = 193,815 kWh
– 20.6kW x (3/4) x 8760 = 135,342 kWh

• Saving = 755,550 – 329,157 = 426,393 kWh

= EGP 213,196 per year
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 Feasibility of VSD Solution
• Pump pressure is proportional to the square of
the change in flow. Check if the pressure will
be sufficient at 160 l/s flow.
• At low speeds, motors will have reduced fan
cooling. Check if the cooling is adequate during
low flow conditions.
• Capital cost of VSD, including commissioning

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Installing a smaller pump
260 l/s for 3 months
160 l/s 160 l/s for 9 months

55 kW
270 l/s

85 kW

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 Installing smaller pump
• Energy consumption:
– 55kW x (1/0.9) x (3/4) x 8760h = 401,500 kWh
– 90kW x (1/4) x 8760h = 197,100 kWh

• Saving = 755,550 - 598,600 = 156,950 kWh

= EGP 78,475 per year

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 Case Study

Oil Lubrication System

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 Problem Statement
• A process requires oil lubrication.
• This is supplied by 2 x 15kW centrifugal pumps
in a closed loop system.

• You are asked to determine and quantify the

opportunity for energy saving.
– Energy cost is EGP 0.5/kWh
– Motor efficiency is 85%
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 Oil Lubrication System

CLOSED

15 kW

OPEN Process

15 kW

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 Findings
• Only one pump is operated at a time with a
manual weekly changeover between pumps.
• The other pump is on standby and provides
redundancy to improve system reliability.
• The pump is operated at full load with the
valve position 100% open.

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 Application of VSD
• Good opportunity for the application of a VSD:
– Centrifugal pumps, thus affinity laws apply wth good
possible savings
– Closed loop system, head (pressure) does not need to
be considered for VSD

• By installing a VSD on each pump (or a large VSD

to control both pumps), we can slow down both
pumps to produce 50% flow each
• Using affinity laws, each motor will only consume
1/8th of its full load power
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 VSD Savings
• Existing power consumption:
– 15kW x (1/0.85) = 17.6 kW

• VSD power consumption

– 15kW x (1/0.85) x (½)^3 = 2.2 kW
– Power for 2 pumps = 4.4 kW

• Energy saving
– (17.6 – 4.4)kW x 8760h = 115,632 kWh per year

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 Exercise
• A company draws cooling water from a nearby
canal.
• It is pumped using one of two 315kW motors.
(One motor standby) and delivers a steady flow of
2100m3/h.
• Upon investigation it was found that:
– The process only requires 700m3/h, with a peak flow of
1000 m3/h during extreme weather
– Excess water is pumped back to the intake sump via a
bypass line
– Motors are direct on line start
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 Open
2100 m3/h 700 m3/h

315 kW

Closed

Process
315 kW

Intake

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 Oil Lubrication System

• Discuss the possible solutions for energy

optimisation of this motor system.

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