In the world, more than 180 million pumps, which consume more than 10800 billion kWh annually, are used in industrial manufacturing processes. Even one pump can consume substantial energy. Pumps contributes for more than 20% of total energy consumption in most of industries.
Surveying Your Pumping Systems
Pumps larger than a minimum size and with significant operating hours should be surveyed to determine a baseline for your current pumping energy consumption and costs, identify inefficient pumps, determine efficiency measures, and estimate the potential for energy savings. . The survey team should gather pump and drive motor nameplate information and document operating schedules to develop load profiles, then obtain head/capacity curves (if available) from the pump manufacturers to document the pumping system design and operating points. The team should also note the system flow rate and pressure requirements, pump style, operating speed, number of stages, and specific gravity of the fluid being pumped. If possible, the team should also measure and note the flow rate and the suction and discharge pressures and note conditions that are associated with inefficient pump operation, including indicators such as:
• Pumps with high maintenance requirements
• Oversized pumps that operate in a throttled condition
• Cavitating or badly worn pumps
• Misapplied pumps
• Pumping systems with large flow rate or pressure variations
• Pumping systems with bypass flow
• Throttled control valves to provide fixed or variable flow rates
• Noisy pumps or valves
• Clogged pipelines or pumps
• Wear on pump impellers and casings that increase clearances between fixed and
moving parts
• Excessive wear on wear rings and bearings
• Improper packing adjustment that causes
• Multiple pump systems where excess capacity is bypassed or excess pressure is provided
• Changes from initial design conditions. Distribution system cross-connections, parallel
main lines, or changes in pipe diameter or material may change the original system curve.
• Low-flow rate, high-pressure end use applications. An entire pumping system may be operated
at high pressure to meet the requirements of a single end use. A booster or dedicated pump may allow system operating pressure to be reduced.
Pumping System Efficiency Measures
Measures to improve pumping plant efficiency includes,
• Shut down unnecessary pumps. Re-optimize pumping systems when a plant’s water use requirements change. Use pressure switches to control the number of pumps in service when flow rate requirements vary.
• Restore internal clearances.
• Replace standard efficiency pump drive motors with NEMA Premium™ motors.
• Replace or modify oversized pumps. Install new properly sized pumps. Trim or change the
pump impellers to match the output with system requirements when the pumping head exceeds system requirements. Consult with the vendor to determine the minimum impeller diameter for a pump casing.
• Meet variable flow rate requirements with an adjustable speed drive or multiple pump arrangement instead of throttling or bypassing excess flow.
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