One-Day

Introductory
Pump System
OptimisationTraining

Facilitated by:

1
Welcome

2
 Training Approach

• Interactive Exercises
• Regular Reviews
• Opportunities for Q&A
• Scheduled Breaks

Please Silence Your Cell Phone

If you must take the call, please exit the room

3
 Course Outline
• The benefits of Pump System Optimisation
• Pump System LCC & Energy Cost Calculations
• The System Approach to Pump Systems & Process Demands
• Pump & Valve Types & Uses
• Pump System Fluid Relationships
o Fundamental Hydraulics
o Total Head
o System Curves
• Pump Performance Characteristics
• Pump System Energy Use

4
 Training Workbook
The information on the slides in this presentation
is also in your workbook
Your training workbook contains:

• Reference materials
• Worksheets and checklists
• Job aids
• Course evaluation
MAKE NOTES !!
5
 Pumping systems account for 22% of the
world’s electric motor energy demand

Fans
16% Other
Air Equipment
Compressors 35%
18%

Cooling
Compressors Conveyors Pumps
7% 2% 22%

Data Courtesy of European Commission

6
LCC – Life Cycle Costs – What to
Consider
• Purchase costs
• Installation & Commissioning costs
• Energy costs
• Other operating costs
• Maintenance costs
• Down time costs
• Decommissioning costs
• Environmental costs

7
 Comparing life cycle costs
Motor Car vs Pump & Motor combination
Common assumptions;
• Discount rate = 8%
• Non-energy inflation rate = 4%
• Lifetime = 5 years
Item: Motor Car Pump & Motor
Initial energy cost rate R 10.00 /ltr. R 1.00 /kWh
Energy inflation rate 10% /yr 10% /yr
Operating extent 32 000 km/yr 7 000 h/yr (80%)
Slide Courtesy of Oak Ridge National Laboratory

8
 Life cycle cost - example Motor Car
R 200,000 purchase, 10km/l, 32 000 km/yr

1st year energy cost:

R 32 000

9
 Life cycle cost - 200kW pump and motor
R 200 000 initial cost; R 30 000 /yr maintenance

First year energy cost

= 100kW x 7000hrs x R1/kWh
= R 700 000

(motor drawing 50% load)

10
Higher first cost 200kW pump and motor R 400 000,
lower service time (4 380 hrs/year)

First year energy cost =

R 438 000 (50% load)

11
Group Discussion on
LCC (Life Cycle Costs)

12
Systems Approach

13
 The System
Electric utility At each interface, there are
feeder inefficiencies. The goal should be to
maximize the overall cost effectiveness
Transformer
of the pumping, or how much flow is
Motor breaker/ delivered per unit of input energy.
starter
The adjustable speed drive VSD, when present,
will have an impact on the function of several
Adjustable elements.
speed drive
(electrical)
Fluid Ultimate
Motor Coupling Pump
system goal
Slide Courtesy of Oak Ridge National Laboratory

14
 Power Train & System Components
• Utility system - Line losses (minimal)
• Transformer – Typically efficient
• Breaker/starter - Negligible losses
• Adjustable speed drive (VSD) - To be discussed (briefly)
• Motor - To be discussed (briefly)
• Coupling - Losses should be minimal
• Pump - To be discussed
• System - To be discussed
• Ultimate goal - To be discussed
Slide Courtesy of Oak Ridge National Laboratory

15
 Motor & Electrical Losses

• Motor losses are generally small in pumping systems

~ 4-5%

• A VSD will increase the motor losses

(VSD’s can be around 97% efficient)

It is important to note that a high efficiency motor will run slightly faster
and hence consume more power
(Power α Speed³)

16
 Pump Losses
• Pump efficiencies can (and do) on the other hand vary
a lot;
From 0 to about 85%

• The pump efficiency depends strongly on where the

pump is operated on its curve

(Pump Curves and Best Efficiency Point are described later)

17
 It is essential to understand the ultimate
goal of the fluid system in order to be able to
optimize it
• Understand Why the system exists

• Understand what the pump & system is trying to Do

• Have clearly defined criteria for what’s Really needed

• Understand what's negotiable and what's not

Slide Courtesy of Oak Ridge National Laboratory

18
 Defining the system
Output = Flow Rate x Head x Constant

Flow
• Which flow rate? regulator
F2

• Which head?
By-pass
valve
Input
Flow
P F1 measuring
P
MCC

Shut off
valve Shut off
valve
Slide Courtesy of Oak Ridge National Laboratory

19
Pump System Fluid Relationships
&
Basic Hydraulics

20
 Pressure vs Head
• In Pump Systems Pressure is often referred to as ‘Head’
This is a measure using the height of a column of fluid
that would produce a specific pressure

P = 9.81 x Head x Specific Gravity

(P in kPa and Head in meters)

• Head is measured in meters or other similar and

Pressure is measured in bar, kPa or similar

• Typically 10m ‘Head’ = 100kPa (actually 98,04kPa for water

with SG = 0.999 @ 25°C)
Slide Courtesy of Oak Ridge National Laboratory

21
 The ability for pumps to move fluid is based on
the energy contained in a mass of fluid
• Pump output is measured in meters of head. The three common
terms used to express this energy in water is:
o Elevation / Pressure Head (Static Head or Hs)
o Velocity Head (Hv)
o Head loss due to Frictional Losses (Hf)

Total Head (TDH) = Hs+ Hv + Hf

• This means that the head created by the pump is used to overcome
friction, lift the fluid and to create kinetic energy in the fluid

22
 Using a simple pump system, what is the
elevation/pressure head (or Static Head)?

Head (m) = Pressure in kPa / 9.8

If the pump is not

HS (static head) running, and P = 98
kPa what is the static
head (Hs) in meters?
• Why is it important that the
P pump is not running?
• Will the static head change
if the pump is running?

23
 Velocity head
Velocity head (Hv) is the amount of energy required to cause the water
to move at a given velocity. This is represented by the following
relationship:
Hv = V2/2g V = the velocity in meters/second
g = the acceleration due to gravity (9.8 m/sec2)

To determine velocity, the following equation can be used:

V = Q/A Q = flow in m3/sec
A = the area of the pipe in m2

Velocity head is usually below 0.5 m and can often be considered

minimal for many water pumping systems

24
 Head loss due to piping frictional losses
• Frictional Head loss (Hf) is the loss of energy due to the friction of the
piping materials and is expressed in meters of head. This can be
determined theoretically using:

The Darcy Weisbach Equation

or the
The Hazen-Williams Equation

• Hf can be determined more accurately in the field using actual

pressure measurements

25
 Pipe friction loss estimating formula
(Darcy-Weisbach)
This equation is very useful to understand what parameters
influence frictional losses in piping:

L V2
Hf = f x d x
2g
Hf = Pressure drop due to friction (ft or m)
f = Darcy friction factor
L = Pipe length (ft or m)
d = Pipe diameter (ft or m)
V2
= Velocity head (ft or m)
2g
Slide Courtesy of Oak Ridge National Laboratory

26
 How Each Factor Affects Friction Loss
Increasing Velocity = Increased Pressure drop
(proportional to V²)

Increasing Diameter = Reduced Pressure loss

Increasing Length = Increased Pressure loss

Increased Friction Factor = Increased Pressure loss

27
 What are some sources of friction for
piping components?
• Valves
• Elbows
• Tees
• Reducers/expanders
• Expansion joints
• Tank inlets/outlets
(In other words, almost everything that the pumped fluid
passes through, as well as the fluid itself)

28
 Specific Gravity / Relative Density
• Specific gravity is the relationship of the weight of a fluid referenced to
the weight of water at 4 °C. (water @ 4 °C has density = 1 000 kg/m³)

• For purposes of evaluating water pumping systems, a specific gravity

of 1.0 can be used at a temperature range of 0 °C to 26 °C . However,
if water temperature increases, the specific gravity will decrease and
decrease pump power. (if the SG is 1.5 then the pump will draw 50% more
power)
• If a fluid other than water is being evaluated, specific gravity of the
fluid must be included in pump calculations.

• If relative density is used instead of density the power will be

expressed in kW

29
Valve Types

30
 Ball
Valve

Globe
Butterfly Valve Valve

31
Gate
Valve

Globe
Valve

32
Tea Break
15 min

33
System Curves

34
A system-head curve is a graphical representation of the
relationship between flow and hydraulic losses in a given
piping system. ...

• A system curve will give an understanding of how a system

will perform under varying flow and pressure conditions.

• For example as the velocity of the flow increases we expect

the friction losses to increase proportionally to V²

• Increasing the pumping pressure supplied to the system will

increase the flow through the system

35
 A System head curve for an All Frictional system
50
Friction
40 only
Head (m)

30

20

10

Zero 0
Static 0 200 400 600 800 1000
Flow rate (m³/hr)
Figure Courtesy of Oak Ridge National Laboratory

36
 System head curve for All Static system
50

40 Static only
Zero
Head (m)

30 Friction

20

10

0
0 200 400 600 800 1000
Flow rate (m³/hr)
Figure Courtesy of Oak Ridge National Laboratory

37
 System head curve for Combined
static and frictional system
50

40
Friction Head
Head (m)

30

20
Total Head
10 Static Head

0
0 200 400 600 800 1000
Flow rate (m³/hr)

38
 The effect on the system head curve
when the static head changes
50
New System Curve
40 due to an increase in
static head
Head (m)

30

20
New System Curve
10 Static head due to a decrease in
static head
0
0 200 400 600 800 1000
Flow rate (m³/hr)

39
 The effect on the system head curve
when system friction changes
50
New System Curve due
40 to higher friction head
Head (m)

30

20
New System Curve due
10 Static head to lower friction head

0
0 200 400 600 800 1000
Flow rate (m³/hr)

40
 Two types of pump systems

Mostly
static
head

All
frictional
head

Figure Courtesy of Oak Ridge National Laboratory

41
 Group Discussion
• What factors would affect the shape of
the system curve (static and friction
component) ?

• Where would the different types of

valve be most suitable ?

42
 Reducing Friction Losses With “Pigs”

Sources: http://www.pipepigs.com/services.htm
http://www.pipepigs.com/images/pigsmain.jpg
43
Short video on ‘Pigs’
10 min

44
Pump Performance
Characteristics

45
 The Pressure-Flow Relationship
• A pump adds energy to a fluid
• Pumping increases pressure
(energy) in the fluid
• Different Pumps deliver;
o High pressure / Low flow or
o High flow / Low pressure
(and everything in between)
• Reliability and energy use are
highly dependent on the
Operating Point of the pump

46
Pressure-Flow Relationship
(Pump curves will The Pressure-Flow
be explained later) Relationship is
Shown in the
Pump Curve
Operating Point
Head or Duty Point
or
Pressure

Flow
47
 Fluid Power Output of a Pump
Pressure-Flow Relationship
Fluid Power delivered
Head by the pump is
proportional to
Head x Flow
The fluid power
produced by Duty Point
the pump is
proportional to (Pump curves will
the size of this be explained later)
blue square
Flow

48
 Important fundamental relationships

Flow rate (l/s) x Head (m) x Density

Fluid Power =
102

Fluid Energy = Fluid power x Operating time

}
• Reduce the Operating time
• Reduce the Flow rate Reduce Energy Use & Cost
• Reduce the Head
Units Note: Using Flow in l/s and Head in meters will give Power in kW
Slide Courtesy of Oak Ridge National Laboratory

49
 Pump Curve
• All Pumps have a specific performance in terms of
Pressure, Flow and Power. Efficiency under various
operating conditions is also considered

• A pump manufacturer will specify the performance of

the pump as measured under laboratory conditions

• This pump curve can be used to determine how well a

pump is performing under its actual operating
conditions

50
 Pump nameplate data applies to
one particular operating point
50

40
Head (m)

30

20
Rated:
10 715 m3/hr @ 30 m

0
715
0 200 400 600 800 1000
Figure Courtesy of Oak Ridge National Laboratory
Flow rate (m³/hr)

51
 Efficiency added to the pump curve

50 100
40 80
Head (m)

30 60
Eff %
20 40
Rated:
10 715 m3/hr @ 30 m 20

0
715
0 200 400 600 800 1000
Figure Courtesy of Oak Ridge National Laboratory
Flow rate (m³/hr)
52
 Another characteristic curve of interest is the
shaft power as a function of flow rate
50 100

40 80

Shaft power (kW)

Head (m)

30 60

20 40

10 20

0 0
0 200 400 600 800 1000
Slide Courtesy of Oak Ridge National Laboratory
Flow rate (m³/hr)
53
Manufacturers
set of pump
curves
Performance curves for
different impeller sizes

Power curves for different

impeller sizes

Efficiency curves for

different impeller sizes

54
 Pump curve shapes vary:
Head curves for two pump designs
160
140
120
Head (m)

100
80
60
Shut off head
40
20 End of curve
0
0 1000 2000 3000 4000 5000
Flow rate (m³/hr)

55
 And finally, efficiency curves for the two pumps
100
Pump 1
80
Efficiency (%)

60
Pump 2
40

20

0
0 1000 2000 3000 4000 5000

Flow rate (m³/hr)

56
 Different motor loads for different types of
centrifugal pumps
100

80
Shaft power (kW)

60
Pump 2
40

20

0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

57
Pump Types

58
 Centrifugal pump systems account for 73% of
pump system energy consumption

Positive Displacement Pumps 27%

Centrifugal Pumps 73%

Data based on European Commission Save Study on Variable Speed Drives

59
 Pump types
End Suction
Split Case
Roto-Dynamic
Pumps Vertical Turbine
(Centrifugal) Special Pumps
• Jet Pumps
Pump • Vortex Pumps
Types • Regenerative turbines
Reciprocating
Displacement • Piston
Pumps • Diaphragm
Rotary
• Peristaltic
• Progressive Cavity
• Multiple Gear-Lobe

60
 Examples of centrifugal pump types

Split Case

Vertical, close
coupled
Submersible
Figures courtesy of ACR Publications
End Suction
61
 Pump types
End Suction Pump

62
 Pump types
End Suction Stock Pump

63
 Centrifugal pump flow
Common centrifugal pump flow configurations:

Radial Flow Mixed Flow Axial Flow

Figures courtesy of ACR Publications

64
 Centrifugal Impellers
Centrifugal impeller types:

Semi-open Open Closed

Figures courtesy of ACR Publications

65
 Examples of displacement pump types

Rotary Lobe Flexible Vane Flexible Tube

Horizontal Piston Screw Pump

Figures courtesy of Hydraulic Institute

66
 Pump Systems

Now let's hook a pump up to a system

67
 Pump Operating Point

The pump will always operate where the System and Pump
curves intersect, since at that point we have balance between
what the system demands and what the pump can deliver

68
 The intersection between the pump and system
head capacity curves defines the Operating Point
50

40
Duty Point
Head (m)

30
27.5

20

10 Operating point or Duty Point

= 800 m3/hr at 27.5 m head
0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

69
 The shaft power curve for this pump indicates
that the power at 800 m3/hr is about 75 kW
100

80
Shaft power (kW)

60

40
Note:
20 there is still Power being
consumed even at zero flow
0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

70
 The operating point is at a slightly greater flow than the
pump best efficiency point (BEP) flow rate
100

80
Efficiency (%)

60

40 BEP
(81% @ 715 m3/hr) Actual operating
point
20 (80% @ 800 m3/hr)

0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

71
 Pump Reliability is a function of operating point

Figure Courtesy of P. Barringer.

72
 Class Discussion on why
Operating Points would vary
from optimal ?

73
 Why duties vary from Optimal

• Incorrect system data and assumptions

• Safety factors added
• New system components
• Increased duty
• Changing suction head
• Dynamic process conditions
• System and pump wear
• Flow control

74
 Why Systems and not Components

• The following slides show test results from a throttled

system at a paper plant

• The different system curves refer to design, normal

operation and un-throttled operation

• Only delivered Fluid Power is considered

75
 Measured data at two operating points,
Max flow and with un-throttled system
Head

Flow

76
The Square is proportional to fluid power delivered
during normal operation
Selected pump

Design pump
Head

Flow
77
Necessary fluid power needed to deliver the same
flow if valve is opened
Head

Flow
78
 Delivered Fluid power is 270% of required !
Head

Flow
79
 Result of Test
• The pump is delivering 2.7 times more fluid power than
needed

• The difference in delivered fluid power dwarfs any

differences due to pump efficiency that could be obtained
by changing pumps

• Thus there is more to be gained from looking at the

system than at the components in this case

80
And you think this doesn’t
Paper Mill Pump
happen?

The valve
is on the
floor above
Note position of
gate valve

81
 Varying System Demand
Some system requirements may vary in time
(note the varying cost of electricity during those times)

Examples:
• Seasonal loads (chilled water, associated cooling
tower water, etc.)
• Industrial processes with variable output
• Potable and waste water, large daily variations

82
 Design parameters
vs
Actual operating conditions

• Centrifugal pumps and fans are typically designed to

handle peak flow/volume requirements that tend to
occur for only short periods
• As a result, they frequently operate at reduced
flows/volumes, often by being throttled

83
Flow rate Daily flow fluctuation example

12 am 6 am 12 pm 6 pm 12 am
Time

84
 Average flow rate
Annual flow fluctuation example

1 2 3 4 5 6 7 8 9 10 11 12
Calendar month

Figure Courtesy of Oak Ridge National Laboratory

85
By tracking flow rate over time, a "flow duration" curve
is developed
Peak flow
Understanding how the flow
requirement varies over time is a
Flow rate

crucial element in optimizing fluid

systems

8 760 h/y
Annual hours above a certain flow rate

86
Optimisation Possibility Example

The following is an example of a possible solution

to a varying pump system demand;

87
 Using smaller pumps to handle low flows
• Diagram # 1 shows a pump operating for 2 500 hours per year at a flow
rate of 130 l/s – total flow is represented by the area under the curve.
• Diagram # 2 shows the same total flow pumped by two pumps. The 130 l/s
pump only operates 200 hours per year and a smaller pump rated for
70 l/s operates for 5 000 hours
150 150
Diagram #1 Diagram #2
Inflow and Pump

100 100
Flow (l/s)

50
50

0 0
Time (Hours) 0 2,500 10,000 200
5,000 0 5,000 10,000

88
 Handling Multiple Duties using
Variable Speed Pumps

• Handling variable flow demands

• Optimise pump duty for specific system
requirements

89
Lunch Break
60 min

90
 Pump Affinity Laws can be used to predict pump
curves for different speeds and impeller diameters
Speed Diameter
1 1
Q1 N1
( ) ( )
Q2
=
N2
Q1
( ) ( )
Q2
=
D1
D2

H1 N1 2 2
( ) ( )
H2
=
N2
H1
( ) ( )
H2
=
D1
D2

P1 N1 3 3
( ) ( )
P2
=
N2
P1
( ) ( )
P2
=
D1
D2
Q = flow rate; H = head; P = power; N = speed; D = diameter
Slide Courtesy of Oak Ridge National Laboratory

91
 Affinity Law Effects
Change of Speed = Change of Flow Rate

(Change of Speed)² = Change of Pressure

(Change of Speed)³ = Change of Power

Change of Diameter = Change of Flow Rate

(Change of Diameter)² = Change of Pressure

(Change of Diameter)³ = Change of Power

(Beware of systems with high Static Pressure)

92
 For Speed Changes, the efficiency lines
follow the affinity laws
Iso-efficiency lines can be overlaid onto head-capacity curves
50
40
50
60 80.5% (BEP)
40 70
75 78
80
Head (m)

30 80
78
75
20

10

0
0 200 400 600 800 1000 1200
Slide Courtesy of Oak Ridge National Laboratory
Flow rate (m³/hr)

93
 For multiple impeller diameters, the efficiency lines
do not follow the affinity laws
50
60
70
40 75
78
80
82
Head (m)

30 83
82
80
78
84 75
70
20

10

0
0 200 400 600 800
Flow rate (m³/hr)
(In most cases the 251mm impeller would be the largest)
Slide Courtesy of Oak Ridge National Laboratory

94
 Considerations for Affinity Laws
• It's fine to use the affinity laws to explore the possibilities
with impeller trimming for better pump and system
matching, but don't get carried away. Get actual
performance curves from the manufacturer, especially if
the trim change being considered is large.

• The affinity laws will generally not tell you where on the
curve the pump will operate or give you correct estimates
of possible energy savings, except for systems without
static head

95
Control Methods

96
 Pump System Energy Representation
Pump curve
Useful System curve with
energy Head valve fully open, S1
~Head x
Flow

Operating point

Flow
60 l/s

97
Throttling: Duty Point Moves to Left on the Pump Curve
System Curve with
valve throttled, S2

Wasted Energy S2 Pressure drop in the valve

S1
makes the friction losses
Head larger and the system
curve steeper. The system
curve gets steeper and
steeper as the valve
closes. 2 valve-positions
shown S1 & S2

Flow
30 l/s
Useful energy System curve with valve fully open

98
 Throttling: Duty Point Moves to Left on the Pump Curve
System Curve with valve
more throttled, S3
Head
Wasted Energy S3
Pressure drop in the valve
S1 makes the friction losses
larger and the system
curve steeper. The system
curve gets steeper and
steeper as the valve
closes. 2 valve-positions
shown S1 & S3

Flow
15 l/s
Useful energy Needed System curve with valve fully open
flow

99
 How a VSD saves energy
The Pump curve changes, not the System curve
NO
Wasted S3 System curve with valve fully open
Energy Head
S1
With a smaller pump or a
slowed down pump, the
same rate of flow can be
delivered without the large
losses in the valve

Flow
15 l/s
Useful energy the same as before. Valve
losses are eliminated
100
Lets review what happens if we operate a
pump at a reduced flow rate, with three
different system curves

101
 Change in speed for the All Frictional system results
in maintenance of constant pump efficiency
50
40
50
60 80.5 (BEP)
40 70
75 78
80
Head (m)

30 80
78
75
20

10
Zero Static
Head 0
System 0 200 400 600 800 1000 1200
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

102
 In a system with Static head, Pump efficiency does not
remain fixed as speed changes
50
40
50
60 80.5 (BEP)
40 70
75 78
Head (m)

80
30 80
78
75
20

Static + 10
Velocity
Head
System
0
0 200 400 600 800 1000 1200
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

103
 In a system with ONLY Static head, the effect
is even more dramatic
50
40
50
60 80.5 (BEP)
40 70 Static Head
75 78 Only
80 System
Head (m)

30 80
78
75
20
Deadhead
10 Pump

0
0 200 400 600 800 1000 1200
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

104
Let's pick a second flow condition for
our system:

Flow = 400 m³/hr

(half the original requirement)

105
 To develop 400 m³/hr in the all frictional system
speed is reduced to 50% of the original
50

40 Note:
Efficiency
remains
Head (m)

30 constant for
zero static
20 system

10 400 m3/hr, 6.9 m

6.9 (10.4 kWe)
0
0 200 400 600 800 1000
Flow rate (m³/hr) kWe = kW electric
Slide Courtesy of Oak Ridge National Laboratory

106
 To develop 400 m3/hr in the mixed static/frictional
system, speed is reduced to 78.5% of the original
50

40
Head (m)

30
21.9
20

10 400 m3/hr, 21.9 m

(34.6 kWe)
0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

107
 To develop 400 m3/hr in the all static head system
speed is reduced to 86.5% of the original
50

40
Head (m)

30
27.5

20
400 m3/hr, 27.5 m
10 (44.7 kWe)

0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

108
 Specific Energy (Es)

• The amount of energy needed to pump one unit volume

through the system.

• The Specific Energy varies with flow-rate

• A good way of comparing pump system performance

ie. how much “bang for your buck”

109
 Some Basic Equations
Fluid Power = Head (m) x Flow (m³/s) x Specific Gravity x 9.8 (m/s³)

Energy used
= Specific Energy
Pumped Volume

Pin  Time Pin

Es = =
V Q

110
 The power and ratio of volume per unit
energy or energy per unit volume
Static Head
m3/h Speed (%) Power (kW) m3/kWh Es= kWh/m3
(m)

0 800 100 79.5 10.1 0.099

0 400 50.0 10.4 38.5 0.026

20 800 100 79.5 10.1 0.099

20 400 78.5 34.6 11.6 0.087

27.5 800 100 79.5 10.1 0.099

27.5 400 86.5 44.7 8.9 0.112

Note 1) The power values for the 800 m3/hr assume the motor
being driven directly (ASD bypassed)
2) The increase in kwh/m3 at 27.5 m
111
Pumps Connected in
Parallel & Series
Combinations

112
 Parallel and series pumping “laws”, like the
Pump Affinity Laws apply to the Pump Curves Only

• Parallel Pumps - sum the Flow rates at a given Pressure

• Series Pumps - sum the Pressures at a given Flow rate

113
 Parallel pumps can help adapt to changing system
requirements and provide redundancy
50
Note:
This is for 3 x
40
identical pumps
Head (m)

30

20

10

0
0 1000 2000 3000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

114
 How about parallel pump
operation with different system
types?

115
 The effect of turning on a parallel pump also depends
on the nature of the system
50 925 m3/hr 1112 m3/hr
1600 m3/hr
40
Best result
with all
Head (m)

30 static
system
20

10

0
0 500 800 1000 1500 2000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

116
Parallel Pump Systems

117
Pumps in Parallel
Ethanol Plant Example

118
 Reboiler Pumps #1 and #2
Beer
Column Reboiler

BC Boiler Pump
Energy Use:
6m
32m #1 = 119.6 kWe
1.1m

3.6m 1 #2 = 120.4 kWe

2 (kWe = Electrical
Power)
Energy Cost for Pump #2 : 120.4 kWe x 8 500 hours =
1 023 400 kWh @ R1.00/kWh = R 1 023 400/ year

119
 Reboiler Pump Curves
Operating two pumps
instead of one only
increases flow by 6% Actual Head 32m
in this case, but
increases system
annual energy costs
by R 1,023,400 Two
Pumps
Efficiency point of 40 One
each pump when 30 Pump
2 are running 20
10 Flow increase w/ 2nd
pump: ~ 20 l/s

120
Pumps in Series

121
 Identical pumps in series; add head at a given flow rate
to estimate overall performance
150

125

100
Head (m)

75

50

25

0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

122
Multi-stage Pumps

123
 Two identical pumps in series with system curve
150
Pressure and flow
125 increase for 2
pumps in series Best result
100
Head (m)

with all
friction
75
system
50

25

0
0 200 400 600 800 1000
Flow rate (m³/hr)
Slide Courtesy of Oak Ridge National Laboratory

124
 Motor
Considerations

125
 Typical high efficiency motor curves
Older motor
efficiency curve
(150 kW (200hp), 4-Pole)

126
Effect of an oversized motor
(virtually nothing)

127
 The difference in power consumption for
oversized motors is trivial
Electrical
power

128
Tea Break
15 min

129
Pump System Energy Use

130
 From the water or hydraulic power, to kW delivered by
the MCC
l/s x m x relative density
Hydraulic power =
102
Pump Pump input power (kW) = Hydraulic power
(shaft power or Pump efficiency
motor output)
Motor

Motor output power

Motor input power (kWe) =
Motor efficiency

And finally, the cost of running the motor =

Motor input power x operating hours x per unit electricity cost
Slide Courtesy of Oak Ridge National Laboratory

131
 Expanding the equation…

Flow (l/s) x Total Head (m) x Relative Density

kW =
102 x ηp x ηm x ηvfd

Flow System-level
Total Head Opportunities

ηp = pump efficiency
Component-level
ηm = motor efficiency
Opportunities
ηvfd = VSD efficiency

kWh = kW x Hours

132
 Calculating Electrical Costs Accurately
(This section can be studied in your own time)

When reducing energy consumption it is critical to

know what the ‘real’ cost per kWh or kVA is.
This is so that the value of the reduction can be
accurately assessed.
The effect & benefit of the optimisation project can
then be correctly established.

133
 What Information is Required ?

It is important to gather the following information;

• 12 months of actual electricity billing (rather than

accounting records)
• Some sense of the typical load profile of the
company or client - i.e.. When is the pump
system being used ?

134
 Where to Start ?
Determine the type of tariff that the client is
currently on;

• This can be one of very many alternatives from

municipalities and Eskom, with sometimes quite subtle
variations which can lead to calculation errors
• Actual bills rather than accounting records are important
so that the information can be checked against Eskom or
Municipality Tariff sheets (generally all of these are
available on the Internet)

135
• If the energy consumption (kWh) or demand (kVA) is to
be reduced, then it is important to look at the existing
cost of electricity during the hours when the reduction
will take place.
• Take special note of the client’s usage profile – for
example are they closed on weekends ?
• When analysing the billing information take careful note
of the billed items which are not affected by kWh usage
or KVA Demand.
• A common mistake is to take the whole billed total and
divide it by the number of kWh used to get an average
R/kWh cost of electricity

136
There are many items on a typical bill which will not be
affected when reducing the consumption of the existing
system.
Examples of these are;
▪ Service Fees
▪ Network charges
▪ Connection fees etc.

137
 Typical Eskom Bill

Make sure to identify and understand each and every item on the bill so as
to be able to accurately assess the impact of any interventions
The above example is a ‘Seasonal Time of Use Tariff’

138
 City of Cape Town Bill

The above is an example of a ‘Demand Tariff’ where the client is being

charged for Maximum Demand.

139
 Some Tariff Terms
Time of Use – this means the billing rate is different for
usage during different periods of the day, night and
weekend (these times vary for Winter & Summer)

140
Seasonal Time of Use – there can be different charges
depending on the time of the year. This is due to the higher
demand for power during certain times of the year.
Generally called ‘High’ season and ‘Low’ season
Seasons are:
‘Low’ Season - September to May (Summer)
‘High’ Season - June to August (Winter)
The ‘High’ season charges are generally more expensive
due to high demand in the Winter months
Off peak Standard Peak
High Season (R/kWh) R 0.3838 R 0.7069 R 2.3333
Low Season (R/kWh) R 0.3324 R 0.5238 R 0.7612

141
• Demand charges - these can be charged according to the
actual maximum Demand of the client – measured in KVA,
or by the amount of kWh used during ‘Peak’ and ‘Standard’
times (see previous diagram) Also sometimes calculated
according to the kWh consumption during different periods.
• Maximum Demand - measured in KVA relates to the
highest power drawn value measured for the whole month.
This is a single charge where the month is divided into half-
hour intervals and the highest average power drawn for any
of those intervals will be the one used to calculate the cost
(it is basically a punitive charge levied by the supplier for
having to make available this high power even when not
utilised)

142
 Sample Facility Demand Profile
4/28/95 to 5/31/95

5/14 5/15 5/16 5/17 5/18 5/19 5/20

400

300

D
E
M
200
A
N
D
100

Sun Mon Tues Wed Thurs Fri Sat

DAY OF WEEK

143
Note:
• Remember that KVA may look similar to kW but it is not
the same. (Power Factor comes into play here)
• It is critical to ensure that the Power Factor is as close to
Unity as possible as this can affect the monthly costs.
Unity meaning that the Power used (kW) is equal to the
Power cost (kVA) being levied.
• Installing Power Factor correction can be the most cost
effective savings for any client being billed on a Demand
tariff

144
 Calculating the Actual Energy Cost
• Firstly – Remove all items from the monthly bill that
are not directly related or charged according to energy
consumption or demand charges

• Secondly – Analyse the energy usage profile to see

which time periods (Off-Peak, Standard or Peak) are
affected

• Thirdly - Take account of the 3 months of ‘High’

season and the 9 months of ‘Low’ season

145
 Summary
&
Introduction to the 2 Day
End User Training

146
 Optimisation Projects - What
to Consider

Financial Justification:
• Is it financially beneficial ?
• What can a business afford ?
• What is the investment in time & money ?
• How much does it actually cost in the long run ?
• How long to pay back the investment ?

147
 Prescreening an Optimisation Project
The DOE Best Practices Program encourages a three
tiered prescreening and assessment approach that
includes:
• Initial - Prescreening based on size, running time and
pump type
• Secondary - Prescreening to narrow the focus to
systems where significant energy saving opportunities
are more likely.
• Thirdly - Evaluating the opportunities and quantifying
the potential savings.

Slide Courtesy of Oak Ridge National Laboratory

148
 Primary & Secondary Prescreening
Primary
Secondary

Slide Courtesy of Oak Ridge National Laboratory

149
• Determine the type of pump
• Determine the control method and valve type if any
• Determine the system requirements
• Establish the operating hours and costs
• Calculate the annual cost of operation
• Check on the method of operation and management
• Draft a system diagram showing all components
• Establish where any inefficiencies may occur
• Calculate the losses where possible
• Estimate the possible savings

150
Introduction to what is covered in
the 2 Day End User Course

151
 Key Take-Away

• My key take-away about identifying and qualifying pump

system optimization opportunities is:

• After participating in this training, I believe that there ___

[is] ___ [is not] potential in my facility for pump
optimization.

152
 Evaluation Sheet
Instructions:

Please complete the Evaluation Sheet

Thank you

153