Energy Efficiency in Pump

Specification
Before setting out to i m p r o v e e n e r g y efficiency it is a good idea to r e m i n d yourself
a b o u t one of N e w t o n ' s laws - namely, t h a t e n e r g y can n e i t h e r be created nor destroyed.
Mechanical energy, electrical energy, heat energy, light energy, sound energy, w h a t e v e r
t y p e you care to choose all e n e r g y has to go s o m e w h e r e and, u l t i m a t e l y , it has to add
up. W h e n it comes to pumps and pipes it is w o r t h bearing this in mind. Trevor Benjamin
disusses the criteria and offers a guide f o r the unwary.

o continue the Newtonian

Kirloskar brothers limited
performancecurve of pump RKB 40/12 L (singlestags)
This curve relates to liquid of SP. GR. = 1.0 & viscosity as water
No. HD11316AA)2
suc. 50 mm DEL 40 mm
n = 2900 (nominal) rpm
T analogy, power that goes
into a central heating
circulating pump will largely be
recovered as useful heat in
This curve is applicable for standard material & clear liquid the system. Even friction losses
For stages 6 & above refer graph no. HD11320AA00 in the line will not necessarily be
30% 40% 50% 55% Max. no. of stages H N = 5/5 wasted. All that is happening
t3~ 59 % Min. no. of stages H N = 2/2 is that a different way has been
25 found of translating the electrical
energy being brought into the
building into space heating, instead
20
of putting it through a boiler.
I10~ \ ">#" Power going into a building's air
=~ 15 conditioning unit, on the other
hand, would be almost totally
i..~ Min. safe flow wasted and actually end up adding
lO
to the heating problem. In this
instance, the problem is more
I I
with the application of the pump
!.5
(i.e. air conditioning) than with
its specification.

i
L0
J
J
J
1.5 J
J A n o t h e r important aspect to re-
member in this debate is that moving
.0
).8 I I I I I I energy around is not a good thing for
efficiency, unless it's being recycled.
6C For example, there is very little merit
embarking on an energy conser-
5C vation scheme - say, turning out the

5 4C lights - if that scheme necessitates

turning the central heating up to
g 3C 7.5~ compensate.
2C 5.0~
Z
Specifications
2.5~
g Pump specifications affect the energy
0 s
I
1'0 l's 20
I
Is 3'0 o a:
Dischrge Q - m3/hr
efficiency of any system, be it resi-
Recommended I dential, industrial or utilitarian.
delivery pipe size m m 65 I 80 I 100
Recommended
suct,ionpipe size mm 65 I 80 I 100
For example, a 20 kW rated pump
set, situated in our heating scenario
BEP Figure 1: Typical mid-range centrifugal pump curves. mentioned above, could be fitted

W O R L D PUMPS April 2001 0262 1762/01/$ - see front matter © 2001 Elsevier Science Ltd. All rights reserved
CHEMISTS SEE FLUOROPOLYMERS.
ENGINEERS SEE INNOVATIVE SOLUTIONS.

tl.~'ll tJOII
o: ~':s/~ : . : . , ~ .:;~':,:: >, :: ,,:: DEFY THE ORDINARY,

FL U O R O E L A S I O M E R S PERFLUOROE[ ASIOMERS F[UOROTHERMOPLASTIC$

PT~E CUSTOM P]FE C()MPOUNDS SPECIALTY ADDITIVES
 with a motor that has an efficiency their maximum rated output. If you The pump too has a Best Efficiency
of 90%. That means to get 20 kW select your motor 'with plenty in Point (BEP). A typical curve is
at the shaft the electrical input hand' you will thereafter pay for it in shown here (see BEP figures 1 and 2).
will be 22.2kW. If the pump wasted energy. With a fixed speed pump there is
efficiency is 60% then, assuming it only one set of conditions that
is running at full motor load, 8.8kW The power factor will also deteriorate matches this point. Either side of
is being put into the water. The with reduced load, but this will only this requires more power for the
temperature rise can be measured. affect your pocket, as you will be same flow. Ideally the pump is
It is low because a pump of that paying for Watts that you are not selected for the BEE but of course the
power will be passing huge actually consuming. The energy as engineer who specified the head,
quantities of water, but it is still such is not being wasted. The power only calculated this. He probably had
8.8 kW, enough to heat a house factor is the difference between the a ' little in hand'.
comfortably. actual wattage and the wattage read
by the voltmeter and ammeter. A n The pump manufacturer quoted for
The motor at 90% is an efficient A.C. motor is an inductive device the duty specified, but was cautious
machine but the grid that supplies it and so Ohm's law does not apply and not to select a unit that was just
loses 30%. Power stations should be you cannot just measure Volts and on duty. The engineer who designed
in the centre of towns. Combined Amps, they are slightly out of the unit drew curves that allowed
heat and power schemes, using the synchronisation. Power factor the factory to reliably meet the duty
waste heat from the cooling towers to changes less with load, than does the without rejects. Altogether the
provide free heating, are tempting overall efficiency. pump will be bigger than required
but, as yet, are not universally
adopted. The 30% loss from the grid
warms up the air in the countryside.
The 10% loss from the motor warms Friction loss in smooth bore pipe
up its surroundings, which may or Losses in m/100 or ft./100 ft.
may not be beneficial. The 40% loss
from the pump is circulated through I.G.P.M. 2" 3" 4" 6" 8" 10" 12" m3/h
the pipework. 50 10 1.4 0.3 10
75 20 3 0.7 15
Both machines - pump and motor - 100 35 5 1 0.1 20
150 12 2.5 0.35 30
translate some of the electrical
200 18 4.5 0.6 50
energy into a small amount of sound 300 40 10 1.2 0.4 75
energy but this in turn becomes 400 18 2.2 0.7 100
further heat energy and can be 500 28 3.5 1.1 0.35 125
ignored in this respect. 600 38 4.5 1.5 0.5 150
700 6.5 2 0.7 175
800 8 2.7 0.8 200
Running Time 900 10 3.4 1 0.4 225
1000 13 4 1.4 0.5 250
Time is money and any part of a 1200 18 6 2 0.8 300
system that is continuously running, 1400 26 8 3 1 350
spends it - fast. At one end of the 1600 32 11 4 1.5 400
1800 36 14 4.5 2 450
scale there are pumps such as those in
2000 38 17 5 2.5 500
a motor car, the fuel pump for 2500 25 9 4 650
instance, which may only run for 4 3000 38 12 5 750
hours per week. It doesn't have a lot 4000 21 8 1000
of time to waste money. The washer 5000 32 13 1250
pump runs for only a few minutes a m3/h x 4 = g.p.m, approx.
year. A water supply pump or a
refrigeration plant may run for a full The above tables refer to new pipes. Moderate Mitre elbow or toe 5
corrosion may increase the resistance by 25%, Round elbow 3
168 hours a week, consuming 40 severe corrosion by 50% to 100%. To compute Slow bend 2
times more power. the resistance of bends and other fittings, an Square edged entrance 3
'equivalent length' for each fitting should be Gate valve fully open 2
added to the actual length of straight pipe. The Globe valve fully open 10
Best Efficiency equivalent length in feet can be estimated with
sufficient accuracy by multiplying the factors in
Non-return valve (flap type)
Foot-valve and strainer (clean)
3
5
Point (BEP) the following table by the pipe diameter in inches,

In the 20kW example previously For instance a 5" Gate valve is equivalent to 12ft. of extra pipe.
mentioned, the motor was rated at
90%. To achieve this, normal three
phase motors need to be working near BEP Figure 2: Friction loss in smooth bore pipe.

- - 2 8 i WORLD P U M P S April 2001 www.worldpumps.com

 |
The U N I V E R S A L II PD
From extended run, ClP configurations to
high-pressure applications- up to 500 psig
The UNIVERSAL II PD pump introduced new fatigue-life
and sanitary technologies.
Today, targeted engineering and extensive field testing
have enhanced the capabilities of the Universal II.
• Rated operating pressure up to 500 psig.
High-pressure models are replacing maintenance-
intensive plunger pumps in certain applications.
• Larger diameter shafts in seal area for greater
strength and stiffness. Heavy-duty bearing frame
(stainless steel option) and double-tapered roller
bearings assure precise rotor location and longer
seal life.
• Field-proven ClP configurations available, including
free-draining body and vertical porting (as
shown above).
• Single-wing rotor and rectangular flange options.
EHEDG
APPROVED © 2 0 0 0 W a u k e s h a Cherry-Burrell
RES No.418- USE THE ENQUIRYSERVICE @www.worldpumps.com
i~i~'i!~ ii~ ~
• Exclusive, non-galling Waukesha "88" alloy
rotors standard.
• Universal 3-way mounted gear case standard.
Dimensions of all models interchangeable with
other Universal Series pump models.
Before you generate your next specs, ask your
Waukesha Cherry-Burrell distributor about
UNIVERSAL II. Or, call 262-728-1900.
Visit our website at www.gowcb.com.
For helpful sanitary CAD design piping solutions
using WCB PARTS, visit www.ssesoftware.com
~ W'~Imlm
Clmrry-Burmll
® A UnitedDominionCompany
Your imagination.
Our ingenuity.
CERTIFIED
and will be running to the right hand side of the curve,
with poorer results.
Variable Speed
Variable speed from an engine can be used where
appropriate to get closer to the BEP and the fuel can be
monitored, but electrically driven pumps require detailed
post installation tests and trimming of the impeller
diameter, which is rarely practical.
Electric variable speed drives, particularly inverter
drives, can be used to trim the speed to match the duty,
but they have their own efficiency problem and waste
some of the input power. Mechanical devices, including
belt drives, have inherent losses. The benefit is mainly
achieved in variable demand systems where a pump would
be grossly over-rated to meet one duty but requires a
modest duty for much of the time. Computer control can
be a sophisticated tool to achieve efficiency over a
variable system.
Multi-pump systems can be used to meet variable demand,
without variable speed. Typically water supply pressure
systems use this approach. A multi-pump system is
shown in the photograph (see picture 1). The set is rated
at 1,000 m3/h and 200 bars for test purposes. That
would be 6,000 kW. But the 200 bars is only required at
2 m3/h and the main flow at 1 bar. By selecting a piston
pump for the pressure duty and a mixed flow pump for
the flow the power becomes 20 kW. A n intermediate
pump provides the middle flow and pressure, still within
20 kW.
Positive Displacement v
Centrifugal
In all our discussions there is the spectre of capital cost.
Undoubtedly, the piston pump and other Positive
Displacement (PD) pumps, give you more output for
your money. They are low on running costs but high on
capital costs. That's why they do not appeal to most
accountants.
A piston pump can be 90% efficient, that is it consumes a
third less power than its equivalent centrifugal. Also it
remains that way at varying loads. But it is big and
expensive, and that requires more resources to produce it
and house it in the first place.
PD pumps essentially used for viscous materials have good
characteristics and often variable speed drives or
adjustable outputs. Pipework improvements are generally
the best way forward.
Open v Closed Impellers
Specifying open impellers to handle solids inevitably
takes more power. The alternative is to have impellers
Picture 1: Multi-pump outfits can reduce the power requirement
for variable duties.
that partially block, and waste power that way. The fully
open or recessed impeller will pass big solids but will take
a lot of driving. In between there are many configurations
to suit different conditions. Regular backflushing on
shutdown helps keep impellers clear without lowering the
efficiency too far.
Head Calculations
You would not buy a suit without a measure of your inside
leg, but so many specifications call for heads based on
some casually produced figure.
The careful buyer may choose a supplier because the price
is 10% lower, but if the engineer has over calculated the
head the unit is twice as dear as need be.
Twice the head is twice the power, 50% of which is going
to be wasted. The buyer will actually be paying more. The
user will be paying more in running costs.
The maintenance man will be more fully employed
because the pump is outside its BEE The BEP is
the cruising speed of the machine. The loss of
efficiency either side of the BEP represents turbulence.
Turbulence causes wear. This energy is going into
destroying the components it touches and stretching
its effects out to non-contact parts such as bearings, seals
and couplings.
Net Positive Suction Head
Required (NPSHR)
The suction can be restricted enough to cause minor
cavitation at the impeller or other part of the inlet. This
appears as pock marks on the underside of the vane tips,
like Gruyere cheese.
The cavitation bubbles take up the space reserved for the
liquid and the most obvious result is loss of head - the
overall specific gravity has changed. Hot liquids, even at
flooded conditions, cause most cases but even a well known
submersible pump has the potential to under-perform due
to its poor NPSHR. This is true even when the pump is
cold and fully submerged.
 Concentrated chemicals at elevated
temperatures prove to be an insurmountable
challenge for most pumps. Their seals just can't
survive such demanding conditions for long.
But like an X Games athlete, AIMSIMAG is
up to even the most extreme challenges.

A N S I M A G magnetic-drive pumps are designed

with no seals, fewer parts and tougher materials
to take on extremely corrosive combinations--

for example. With no seals to succumb to your

extreme environment, an A N S I M A G helps
you avoid downtime, keeping productivity up
month after month, year after year.

Find out more about how A N S I M A G goes to

extremes to deliver peak performance. Because
continuing to push the limits of an ordinary
pump could put you in a precarious position.

Up and Running"

i"-~--__ ~ ~
Simple by Design"
~ -- -
Sundyne
C 0 R P O R A T I 0 N ~IIW~'
ANSIMAG, Incorporated, Bloomingdale, Illinois USA • Fax 847-290-0481 • Representatives and Sales Offices Worldwide • www.ansimag.com/wp
• ANSIMAG o HMD/KONTRO * MASO/SINE • SCMP " SUNDYNECOMPRESSORS " SUNDYNE • SUNFLO "

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 As the pump is passing some vacuum
bubbles instead of heavy liquid it will
take less power, in proportion, so
power is not wasted. The Amps
will fall and so will the Watts. A
Pump Guard will protect against this
effect.
Pipework
It is dramatic what a series of 90 °
bends can do to flow. It sometimes
appears academic to choose a slow
bend instead of an elbow, but it
is going to be there for the life
of the installation, consuming Watts,
quietly and unobtrusively. You
won't even know what it is costing
you.
The most unsuitable bends are to
be found in the plastics catalogues.
Very compact 90 degree bends can
be snugly solvent-welded together.
A very neat installation can be
made with a series of bends and
the temptation to use many of them
is irresistible. The results on the
head and flow losses, however,
mean bigger pumps and motors.
-- . .- -I'--. i - :
design, manufacturing and after sales
- _ =-- __ _--_-- _- _ :
tailor-made systems for liquid,
mixing or powder dosing functions
--. ._ __-- _ .. _- :
oil, gas, chemical, water treatment
ROY
Dosing and mixing of liquids
RES No.420 - USE THE ENQUIRY SERVICE @
-~ WORLD PUMPS April 2001
Pump tees can present a similar smaller than desirable in order to
problem. flush solids.
One good case for 'a little bit in N o z z l e s a n d Jets
hand' is that of pipe sizing. It is
obvious that a bigger pipe will pass
more. Once installed, it is too late
to change to a bigger size. Pipe sizes
are designed so that each increment
in nominal size passes twice the
flow. The cross sectional area
doubles. The reduction in head is
enormous. At least 75% of losses
can be saved by going up one pipe
size. Other than for very short
lengths of pipe efficiency is in the
pipe size.
The cost of installing pipe is
high compared to the cost of the
material itself, so keep your pipes
large. With the lower velocities
in larger pipes, the effects of Good jets and generous p i p e w o r k have
real impact and waste less power.
bends and fittings is less. Your
calculations for head will be
more accurate and the attendant Spray systems in particular use
benefits (outlined in the paragraph multi-jets to wash parts. Getting the
entitled, 'Head Calculations'), will combination to work well is often
be relevant. Just occasionally the trial and error. Using holes drilled in
pipe diameter will have to be the spray bar is common, but wrong.
Modular
dosing
systems
PRIMEROYAL
the new robust and sturdy
dosing pump, 30 0001/h, 700 bar
10, Grande Rue - 27360 Pont-Saint-Pierre - France
Tel : +33 (0)2 32 68 30 12 • Fax : +33 (0)2 32 68 30 91
www.dosapro.com
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The jet is a hydrodynamic device
that converts pressure in to velocity.
The rough hole destroys half of
the energy.
Fully tested and developed jets are
readily available and can increase the
scouring of the jet, with no increase
in pressure and power.
Drivers
High efficiency electric motors are
available from some manufacturers
and these are an excellent way of
reducing costs on long running
systems or plant operations. The
small extra cost that is necessary to
get the higher efficiency can be
rapidly repaid.
Where appropriate, diesel engines
are very efficient as they cut
out the middle-man, and the
national grid, and apply the power
direct at the pump shaft. The
waste heat may also be recovered
in some cases. Diesel engines are,
however, high maintenance items.
Petrol and gas engines are only
generally applied to small equip- it is a 'velocity squared' law, and
ment. any really stiff breeze blows them
over unless they are very heavily
Compressed air has many uses, constructed.
particularly as a power source for
diaphragm pumps. Generating com- Getting it Right
pressed air and powering motors with
it is, however, low on the efficiency
scale. Getting the head right is the first
step to efficiency. Good pipework
Direct water power is rarely used is a real energy saver, although to
to drive pumps but the 'hydraulic the untrained observer it is doing
ram' is an effective way of using low nothing. Selecting the Best Efficiency
quality water energy from streams - Point (BEP) in the curve comes
energy that would otherwise go to easily after that. Follow these steps
waste. and energy efficiency, with all
its attendant benefits, could be
Wind power was once very popular yours. •
for water supply and examples
are still to be found occasionally
in South Africa and other parts of
the world. The piston pump, TREVOR BENJAMIN
down the well, is efficient and Clearline Assistance UK Ltd,
delivers to varying heads at variable High View,
drive speeds, without loss of Ponteland,
Northumberland,
efficiency. The energy can be stored NE20 9ET,
in reservoirs and drawn off through England.
large pipes on demand. Like all Tel: +44 (0)1661 822 480
Fax: +44 (0)1661 822 480
wind powered equipment they E-mail:
need a stiff breeze to deliver power, trevor@ high-view24.de mon.co.uk

BeenThere.PumpedThat.
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w r o t e t h e b o o k o n it, to g u i d e y o u t h r o u g h d i f f e r e n t i a l h e a d s a n d h e t e r o g e n e o u s flows. ("Slurry T r a n s p o r t
U s i n g C e n t r i f u g a l P u m p s " is a v a i l a b l e t h r o u g h y o u r l o c a l b o o k s t o r e . )
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