Energy efficiency is becoming increasingly crucial in the industrial sector as environmental concerns grow and the desire to minimize costs grows inexorably. Pumping systems account for approximately 20% of the world’s electrical energy demand, and a study conducted by the United States Department of Energy indicated that pumping systems account for 16 percent of the power expenditures associated with a typical industrial plant. This example demonstrates how critical it is to increase your pumping systems…
This article discusses five ways to reduce the amount of energy used by your pumping equipment
- Make sure that the pump is not oversized.
The tendency for engineers to be conservative when specifying pumps is that they will often provide a margin of safety in terms of the duty of the supplied pump compared to the commitment required for the application in question. The literature shows that water pumps such as centrifugal pumps, which account for approximately 80% of all installed pumps, are often oversized by 20-30 percent. Because increased flow and pressure performance necessitates more power from the motor, an oversized pump might result in excessive energy consumption.
- Trimming the impeller
Trimming the impeller of an oversized pump is a relatively cost-effective method of lowering the pressure and flow produced by the pump. While shaving the impeller to achieve the required duty is significantly more energy-efficient than using a throttling valve to achieve the same result, as the impeller is shaved, the clearances between it and the casing become more prominent, it is less efficient than a full-sized impeller in the process. As a result, variable speed drives are frequently the preferred choice among manufacturers for the energy economy.
- Drives with variable frequency output
Variable frequency drives, as their name implies, adjust the rotational speed of the motor to achieve the actual head and flow demand of the application rather than the maximum amount of charge and flow the pump can produce. VFDs are often used to restrict needless energy consumption in two scenarios: the first is to slow the motor down on a pump that has been larger at the specification stage, and the second is to limit unnecessary energy consumption in an engine that has been oversized at the specification stage.
- Pumping systems that operate in parallel
Using several pumps as an alternative to variable frequency drives (VFDs) for a system with varying duty needs is an energy-efficient approach. A single pump may spend most of its working life running far away from its Best Efficiency Point when the requirements of “worst-case” conditions are much higher than standard operating conditions. It is possible that the construction of a second, smaller pump that is designed to satisfy the average system demand could relieve pressure on the larger pump, which would otherwise be forced to operate at or below its maximum capacity.
- Minimize the pressure loss in the pipework
Another method of conserving energy is to optimize the system pipework to prevent frictional pressure drops. This reduces the amount of power required by the water pumps to compensate for these losses. Pipe diameter, length, internal surface arrangement, and components installed within the pipework all impact system pressure drop. As a result, these factors should be considered when evaluating energy efficiency improvements.
First and foremost, in order to construct a system in an energy-efficient manner, it is vital to ensure that the efficiency rates of the pump and other components are as high as feasible. Aside from that, each pump must be designed to operate at its maximum effective pressure (BEP). Furthermore, it is critical to prevent wasting energy by using balancing valves or orifices that are not necessary.