Pumps and pumping systems.pptx

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1

Training Session on Energy

Equipment

Pumps & Pumping

Systems

Presentation from the

“Energy Efficiency Guide for Industry in Asia”

www.energyefficiencyasia.org

© UNEP 2006

Electrical

Equip

ment/

Pum

ps



2

© UNEP 2006

Training Agenda Pumps

Introduction

Type of pumps

Assessment of pumps

Energy efficiency opportunities

Electrical

Equip

ment/

Pum

ps



3

© UNEP 2006

Introduction

• !"# of wor$d%s e$ectrica$ energy

demand• !'"# of energy usage in some

industries

•(sed for • )omestic* commercia$* industria$ and

agricu$tura$ ser+ices

• ,unicipa$ water and wastewater ser+ices

-hat are Pumping SystemsElectrical

Equip

ment/

Pum

ps



4

© UNEP 2006

Introduction

/0ecti+e of pumping system


Equip

ment/

Pum

ps

(US DOE, 2001)

• Transfer $iquid

from source to

destination

• 1ircu$ate $iquid

around a system



5

© UNEP 2006

Introduction

• ,ain pump components•

Pumps• Prime mo+ers e$ectric motors* diese$ engines*

air system

• Piping to carry f$uid

•2a$+es to contro$ f$ow in system

• ther fittings* contro$* instrumentation

• End'use equipment• 3eat e4changers* tan5s* hydrau$ic machines


Equip

ment/

Pum

ps



6

© UNEP 2006

Introduction

• 3ead• 6esistance of the system

• Two types static and friction

• Static head•

)ifference in height /etweensource and destination

• Independent of f$ow

Pumping System 1haracteristicsElectrical

Equip

ment/

Pum

ps

destinatin

surce

Stati

c!ead

Static

!ead

"l#



7

© UNEP 2006

Introduction

• Static head consists of •

Static suction head 7hS8 $ifting $iquid re$ati+e topump center $ine

• Static discharge head 7h)8 +ertica$ distance

/etween center$ine and $iquid surface in

destination tan5

• Static head at certain pressure


Equip

ment/

Pum

ps

3ead 7in feet8 9 Pressure 7psi8 : !.;<

Specific gra+ity



8

© UNEP 2006

Introduction

• =riction head•

6esistance to f$ow in pipe and fittings• )epends on si>e* pipes* pipe fittings* f$ow

rate* nature of $iquid

• Proportiona$ to square of f$ow rate

•1$osed $oop systemon$y has friction head

7no static head8


Equip

ment/

Pum

ps

"rictin

!ead

"l#



9

© UNEP 2006

Introduction

In most cases

Tota$ head 9 Static head ? friction head


Equip

ment/

Pum

ps

S$stem!ead

"l#

Static !ead

"rictin

!ead

S$stem

cur%e

S$stem!ead

"l#

Static !ead

"rictin

!ead

S$stem

cur%e



10

© UNEP 2006

Introduction

Pump performance cur+e

• 6e$ationship /etween

head and f$ow• =$ow increase

• System resistance increases

•3ead increases

• =$ow decreases to >ero

• @ero f$ow rate ris5 of

pump /urnout


Equip

ment/

Pum

ps

&ead

"l#

Per'rmance cur%e 'r

centri'ual pump



11

© UNEP 2006

Introduction

Pump operating point


Equip

ment/

Pum

ps

• )uty point rate of

f$ow at certain

head

• Pump operating

point

intersection of

pump cur+e and

system cur+e"l#

&ead

Static

!ead

Pump per'rmance

cur%e

S$stem

cur%e

Pump

peratin

pint



12

© UNEP 2006

Introduction

Pump suction performance 7PS38

• 1a+itation or +apori>ation /u//$es inside pump

• If +apor /u//$es co$$apse

• Erosion of +ane surfaces

• Increased noise and +i/ration

• 1ho5ing of impe$$er passages

• et Positi+e Suction 3ead

• PS3 A+ai$a/$e how much pump suction

e4ceeds $iquid +apor pressure

• PS3 6equired pump suction needed to a+oid

ca+itation


Equip

ment/

Pum

ps



13

© UNEP 2006


Introduction

Type of pumps

Assessment of pumps


Electrical

Equip

ment/

Pum

ps



15

© UNEP 2006

Type of Pumps

Positi+e )isp$acement PumpsElectrical

Equip

ment/

Pum

ps

• =or each pump re+o$ution

• =i4ed amount of $iquid ta5en from one end• Positi+e$y discharged at other end

• If pipe /$oc5ed• Pressure rises

• 1an damage pump

• (sed for pumping f$uids other than

water



17

© UNEP 2006

Type of Pumps

)ynamic pumpsElectrical

Equip

ment/

Pum

ps

• ,ode of operation

• 6otating impe$$er con+erts 5inetic energy intopressure or +e$ocity to pump the f$uid

• Two types• 1entrifuga$ pumps pumping water in

industry B C# of pumps insta$$ed

• Specia$ effect pumps specia$i>ed conditions



18

© UNEP 2006

Type of Pumps

1entrifuga$ PumpsElectrical

Equip

ment/

Pum

ps

3ow do they wor5D

(Sa!de% )

•iquid forced intoimpe$$er

• 2anes pass 5inetic

energy to $iquid $iquid

rotates and $ea+es

impe$$er

• 2o$ute casing con+erts

5inetic energy into

pressure energy



19

© UNEP 2006

Type of Pumps


Equip

ment/

Pum

ps

6otating and stationary components

(Sa!de%)



20

© UNEP 2006

Type of Pumps


Equip

ment/

Pum

ps

Impe$$er Sa!de%)

• ,ain rotating part that pro+ides centrifuga$

acce$eration to the f$uid

• um/er of impe$$ers 9 num/er of pump stages

• Impe$$er c$assification direction of f$ow* suction type

and shapeFmechanica$ construction

Shaft

• Transfers torque from motor to impe$$er during pump

start up and operation



21

© UNEP 2006

Type of Pumps


Equip

ment/

Pum

ps

1asings

*lute +asin (Sa!de%)• =unctions

• Enc$ose impe$$er as “pressure +esse$”• Support and /earing for shaft and impe$$er

• 2o$ute case• Impe$$ers inside casings

• a$ances hydrau$ic pressure on pump shaft

• 1ircu$ar casing• 2anes surrounds impe$$er

• (sed for mu$ti'stage pumps



22

© UNEP 2006


Introduction

Type of pumps

Assessment of pumps


Electrical

Equip

ment/

Pum

ps



23

Assessment of pumps

• Pump shaft power 7Ps8 is actua$ horsepower

de$i+ered to the pump shaft

• Pump outputF3ydrau$icF-ater horsepower 73p8 is

the $iquid horsepower de$i+ered /y the pump

3ow to 1a$cu$ate Pump PerformanceElectrical

Equipme

nt/

Pum

ps

Hydraulic power (Hp):

&p - (m./s) tal !ead, !d !s (m) (3/m.) (m/s2) / 1000

Pump shaft power (Ps):

Ps &$draulic p#er &p / pump e''icienc$ 4Pump

Pump Efficiency (ηPump):

4Pump &$draulic P#er / Pump S!a't P#er

© UNEP 2006!d disc!are !ead !s 5 suctin !ead, densit$ ' t!e 'luid 5 acceleratin due t ra%it$



24

© UNEP 2006

Assessment of pumps

• A/sence of pump specification data

to assess pump performance• )ifficu$ties in f$ow measurement and

f$ows are often estimated

•Improper ca$i/ration of pressuregauges & measuring instruments

• 1a$i/ration not a$ways carried out

• 1orrection factors used

)ifficu$ties in Pump AssessmentElectrical

Equipme

nt/

Pum

ps



25

© UNEP 2006


Introduction

Type of pumps

Assessment of pumps


Electrical

Equipme

nt/

Pum

ps



26

© UNEP 2006

Energy Efficiency pportunities

<. Se$ecting the right pump

!. 1ontro$$ing the f$ow rate /y speed

+ariation

;. Pumps in para$$e$ to meet +arying

demand

H. E$iminating f$ow contro$ +a$+e

. E$iminating /y'pass contro$

. StartFstop contro$ of pump

C. Impe$$er trimming

Electrical

Equipme

nt/

Pum

ps



27

© UNEP 2006


<. Se$ecting the 6ight PumpElectrical

Equipme

nt/

Pum

ps

Pump performance cur+e for centrifuga$

pump

EE 7ndia,

2008



28

© UNEP 2006


<. Se$ecting the 6ight PumpElectrical

Equipme

nt/

Pum

ps

• +ersi>ed pump• 6equires f$ow contro$ 7thrott$e +a$+e or /y'

pass $ine8• Pro+ides additiona$ head

• System cur+e shifts to $eft

• Pump efficiency is reduced

• So$utions if pump a$ready purchased• 2S)s or two'speed dri+es

• ower 6P,

• Sma$$er or trimmed impe$$er



29

© UNEP 2006


!. 1ontro$$ing =$ow speed

+ariationElectr

ical

Equipme

nt/

Pum

ps

E4p$aining the effect of speed

•Affinity $aws re$ation speed and• =$ow rate J

• 3ead 3 !

• Power P ;

• Sma$$ speed reduction 7e.g. K8 9 $arge

power reduction 7e.g. <FL8



30

© UNEP 2006


Electr

ical

Equipme

nt/

Pum

ps

2aria/$e Speed )ri+es 72S)8

• Speed ad0ustment o+er continuous

range

• Power consumption a$so reducedM

• Two types

• ,echanica$ hydrau$ic c$utches* f$uid coup$ings*

ad0usta/$e /e$ts and pu$$eys

• E$ectrica$ eddy current c$utches* wound'rotor

motor contro$$ers* 2aria/$e =requency )ri+es

72=)s8


+ariation



31

© UNEP 2006


Electr

ical

Equipme

nt/

Pum

ps

enefits of 2S)s

•Energy sa+ings (not just reduced flow!)

• Impro+ed process contro$

• Impro+ed system re$ia/i$ity

• 6educed capita$ and maintenancecosts

• Soft starter capa/i$ity


+ariation



32

© UNEP 2006


;. Para$$e$ Pumps for 2arying )emandElectr

ical

Equipme

nt/

Pum

ps

• ,u$tip$e pumps some turned off during $ow

demand

• (sed when static head is N"# of tota$ head

• System cur+e

does not change

•

=$ow rate $ower than sum of

indi+idua$

f$ow rates

(P9)



33

© UNEP 2006


H. E$iminating =$ow 1ontro$ 2a$+eElectr

ical

Equipme

nt/

Pum

ps

• 1$osingFopening discharge +a$+e 7“thrott$ing”8

to reduce f$ow

• 3ead increases

does not reduce

power use

•2i/ration andcorrosion high

maintenance

costs and reduced

pump $ifetime

(P9)



34

© UNEP 2006


. E$iminating y'pass 1ontro$Electr

ical

Equipme

nt/

Pum

ps

• Pump discharge di+ided into two

f$ows• ne pipe$ine de$i+ers f$uid to destination

• Second pipe$ine returns f$uid to the source

•Energy wastage /ecause part of f$uidpumped around for no reason



35

© UNEP 2006


. Start F Stop 1ontro$ of PumpElectr

ical

Equipme

nt/

Pum

ps

• Stop the pump when not needed

• E4amp$e

• =i$$ing of storage tan5

• 1ontro$$ers in tan5 to startFstop

• Suita/$e if not done too frequent$y

• ,ethod to $ower the ma4imum

demand 7pumping at non'pea5 hours8



36

© UNEP 2006


C. Impe$$er TrimmingElectr

ical

Equipme

nt/

Pum

ps

• 1hanging diameter change in

+e$ocity• 1onsiderations

• 1annot /e used with +arying f$ows

•o trimming N!# of impe$$er si>e

• Impe$$er trimming same on a$$ sides

• 1hanging impe$$er is /etter option /ut more

e4pensi+e and not a$ways possi/$e



37

© UNEP 2006


C. Impe$$er TrimmingElectr

ical

Equipme

nt/

Pum

ps

Impe$$er trimming and centrifuga$ pump performance

(EE 7ndia,

2008)



38

© UNEP 2006


1omparing Energy Efficiency

ptions

Electr

ical

Equipme

nt/

Pum

ps

Parameter 1hangecontro$ +a$+e

Trim impe$$er 2=)

Impe$$erdiameter

8.0 mm .:; mm 8.0 mm

Pump head :1<: m 82 m .8<; m

Pump efficiency :;<1= :2<1= ::=

6ate of f$ow >0 m./!r >0 m./!r >0 m./!r

Powerconsumed

2.<1 3? 18 3? 11<6 3?



39

Training Session on Energy

Equipment

Pumps & Pumping

Systems

T3AO (

=6 (6 ATTETI

© UNEP 2006

Electr

ical

Equipme

nt/

Pum

ps



40

)isc$aimer and 6eferences

Electr

ical

Equipme

nt/

Pum

ps

• This PowerPoint training session was prepared as part of

the project “Greenhouse Gas Emission Reduction from

Industry in Asia and the Pacific” (GERIAP) !hi"e

reasona#"e efforts ha$e #een made to ensure that the

contents of this pu#"ication are factua""y correct and

proper"y referenced% &'EP does not accept responsi#i"ity for

the accuracy or comp"eteness of the contents% and sha"" not

#e "ia#"e for any "oss or damage that may #e occasioned

direct"y or indirect"y through the use of% or re"iance on% the

contents of this pu#"ication &'EP% **+• The GERIAP project was funded #y the ,wedish

Internationa" -e$e"opment .ooperation Agency (,ida)

• /u"" references are inc"uded in the te0t#oo1 chapter that is

i" #" ffi i i

Pumps and pumping systems.pptx

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