pump

efficiency
testing
and
monitoring

Almost 70% of the world’s electricity is consumed by the industry horses, commonly known as motors. Out of
this, 70% is used to drive roto-dynamic machines, which are primarily pumps, blower, fans and compressors.
These machines operate with varying degrees of efficiency (20 and 90%).
- Juned Ansari

G
reater the inefficiency of the consumption of these machines and common is the “conventional
machine, greater is the their systems in a plant. method”. This measures the input
energy wasted. It therefore To fulfil this need, two methods energy and output from the system.
becomes important to test, evaluate have been commonly used in the The second one, a more practical
and monitor the energy industry. The first and the most approach, is the thermodynamic

86May 2010Electrical India

Pump Efficiency Testing and monitoring.indd 86 4/29/2010 5:03:30 PM

 Pump Performance

method (an assessment of the losses). This machine and thus uncertainty of
article talks about performance measurement is very low. This makes the
monitoring of pumps using the method ideal and suitable even for
thermodynamic method. smaller machines. The method is based
Also importantly, the same method on the first law of thermodynamics and
can also be applied effectively for requires differential pressure and
monitoring of blowers, compressors and temperature measurement across the
hydro turbines with ease. machine to evaluate the efficiency.
When this is combined with power
Introduction measurement, flow can be calculated
Centrifugal pumps are found accurately. The basic equations are
operating with varying degrees of shown below:
efficiency and performance shortfalls. 1 Pi xh m xh p
Over the complete life cycle of the hp = Q=
txgxH
d1 + p n
pump, energy consumption is the
C xDT
biggest contributor (amounting to
gxH
90-95%) to the total “Life Cycle Cost” of Where,

P
the machine, . Even if a pump is Cp= Specific heat of the fluid (KJ/Kg-K)
Pump operating at 70% efficiency, 30% of the ΔT= Differential temperature across the
performance energy fed to it is wasted in the form of pump in mK (milli Kelvin)
heat, noise and vibration. For a 100 kW H= Pump head in meters (m)
testing and machine, 30 kW is simply unavailable for Pi= Input power to the motor in kW
monitoring any useful work. Over the life cycle of ηp= Pump efficiency (%)
the pump, many times, the value of the Q= Pump flow rate in m3/s
shows asset loss is more than the cost of the machine This method has been used extensively
condition itself. on more than 12,000 pumps across the
Obviously, only a certain part of the world and the results were overwhelming.
and also
wasted energy (as no machine can be Following studies will establish this fact.
helps in 100% efficient), can be saved by testing
averting , monitoring and corrective actions on Study 1
the pumps at regular intervals. Pump We have been engaged in permanent
catastrophic performance testing and monitoring monitoring of all of the pumps within a
failures. shows asset condition and also helps in number of pumping stations for a UK
averting catastrophic failures. A number water company. The initial monitoring
of pumps when monitored revealed that the combined average
simultaneously (Multi Pump Monitoring), operating efficiency of the station was low
will give an insight to the way a station (67%) and a better “operating” schedule as
is being operated and reveals any presented. The new operating regime, if
operating deficiencies. This is critical, followed, would improve the operating
especially in the process industry, where efficiency to 82%. Such operating schedule
along with reducing energy consumption alterations do not need any capital
and implementing energy efficiency, the expenditure and are immediately accepted
Operations teams are equally concerned by the management. The charts below
about minimising downtime and the depict the case and are self explanatory.
direct impact on the total plant specific The system has been operational for the
energy consumption. last 5 years, with an annual operating cost
reduction of 26%.
Thermodynamic Method
Unlike the conventional method Study 2
which involves flow measurement for This study on a pump, carried out in an
efficiency evaluation, thermodynamic Indian chemical industry It has shown how
method measures the inefficiency of the errors at the design stage can lead to trouble

Electrical IndiaMay 201087

Pump Efficiency Testing and monitoring.indd 87 4/29/2010 5:03:34 PM

 Pump Performance

Fig. 1: Pre and Post Implementation Charts

when plant begins operation. A Pre-Replacement Post-Replacement Relative % age

wrongly sized pump, with lower than Performance Performance Change
required flow through the system was
Flow Rate (I/s): 74.6 151.2 102.7
selected and this affected production.
A thorough investigation and pump Pump Head (m): 27.8 34.0 22.3
testing revealed that there was mis-
match between pump and the system. Power to Motor (kW); 60.6 98.6 62.7
To achieve the desired performance, a
Pump Efficiency (%): 43.9 67.4 53.9
recommendation for installing a
bigger impeller in the existing pump Pumping Cost (kWh/MI) 225.4 181.2 -19.6
was made. By implementing the
recommendation, the plant reduced Saving for same flow (Rs.) - 458,571 -
the specific power consumption of the
pump. The pump has Efficiency improvement is directly
been running efficiently related with energy and carbon
for last 9 months footprint reduction. Testing is
without any problems. recommended for pumps, blowers
and compressors for efficient running.
Conclusion We do not want to be blamed by
A thorough pump the future generations for not
and system testing and allowing them the use of these
analysis can reveal the scarce resources? Let us conserve
operating deficiencies energy, water and environment. 
and asset condition.
Thermodynamic
method for pump Juned Ansari is a gold medalist
testing delivers mechanical engineer and a
qualified energy auditor
accuracy better than
working as Energy Efficiency
±1% which is also Analyst in Secure Meters
verified by the Fluid Juned Ansari
Limited.The company's
Control Research website can be accessed at
Fig. 2 www.securetogether.com.
Institute (FCRI), India.

88May 2010Electrical India

Pump Efficiency Testing and monitoring.indd 88 4/29/2010 5:03:38 PM