Key points
Energy efficiency is a topic that should be on everyone’s agenda. Environmental concerns as well as the impact on business overheads means that reducing energy consumption is vital within industrial plants. With the US Department of Energy being quoted as finding that 16% of a typical industrial facility’s electricity costs are generated by its pumping systems, pumps have a large part to play in this. Here’s how industrial pump supplier Castle Pumps suggest you can improve the energy efficiency of your pump.
1. Avoid oversizing
Oversizing the pump during specification is common to cater for any uncertainties in the design process as to what duty the application required from the pump. However, as a higher performance in terms of flow and pressure requires the motor to run at a higher power, an oversized pump uses more energy than necessarily. For that reason, a pump should be selected than can be run as close to it’s Best Efficiency Point as possible.
2. Impeller trimming
If a pump has been oversized, then sometimes a throttling valve is used to achieve the lower duty requirements. This however is not as energy efficient as trimming the impeller, which is a relative cost-effective way of reducing the pressure and flow that is produced. In turn, impeller trimming is not the most energy efficient solution as when an impeller is shaved, the casing clearance gets larger. For that reason, variable frequency drives are often selected for peak efficiency.
3. VFDs
The purpose of a variable frequency drive is to vary the speed of the motor to achieve the actual performance requirements of the application as opposed to the maximum that the pump can provide. This enables them to reduce energy waste caused by the pump in two ways. Firstly, it can slow the motor on an oversized pump and secondly, it can control a pump in situations where there are differing duty requirements at different times i.e. sometimes it needs to operate at full speed and others it doesn’t. An example of this is a cooling pump, where the temperature of the component needing to be cooled may vary considerably.
4. Parallel pumping systems
Another energy efficient solution for an installation with differing performance requirements is the use of parallel pumping systems. When the occasional duty requirements are significantly higher than the standard operating conditions, a single pump could be operating a way off from its Best Efficiency Point for much of the time. By installing a second, smaller pump with lower power to meet the average system requirements, the larger, higher energy consuming pump would only need to be used when it warrants it.
5. Limit pipework pressure loss
The power of the pump required needs to account of pressure loss in the system. As the length, diameter, layout and internals of pipework all affect this, consideration should be given here when looking at energy efficiency. Bends and changes in the size of the pipework should be kept to a minimum, and the diameter should be carefully selected as smaller pipework results in more friction. Corrosion and rust can increase resistance reducing in pressure loss, which means cleaning and maintenance of pipework is important too.
6. Prevent unnecessary use
It might surprise you how often pumps are in operation when they aren’t actually doing anything, just due to lack of control. Control systems can be implemented to shut down pumps not in use, and using pressure switches, the number of pumps in service can be automatically adjusted as duty requirements vary.
7. Maintenance
Like any equipment, wear can reduce efficiency. A pump’s energy efficiency can degrade as much as 10-25% before it’s replaced, which is why routine maintenance is vital. It is vital to replace wearing parts such as wear rings, as leakages mean that the power requirements to produce the same flow is increased.
So, there you have it. If you’re concerned about your plant’s energy efficiency and are looking for ways to reduce it, then start with your pumps. These seven tips can help you reduce unnecessary energy consumption, but it is important to note that eventually the most energy efficient option is to replace it!
For more information on getting the right pump for you process, contact Castle Pumps Ltd.
www.castlepumps.com
Castle Pumps
- 01773 533 283
- sales@castlepumps.com
- https://www.castlepumps.com
- Office 1, Denby House Taylor Lane Loscoe Derbyshire DE75 7AB GB
About us
Castle Pumps Ltd are specialist suppliers of industrial pumps with over 10 years’ experience specifying pumping solutions to process engineers, operations managers and plant build consultants.
At Castle Pumps we understand that a pump that works isn’t necessarily the right pump. A pump that is pushed to it’s performance capabilities will result in more regular, costly maintenance, manual intervention from its operators, waste product and energy inefficiency. As a single source supplier of all of pumping technologies from centrifugal to air operated diaphragm to peristaltic to progressive cavity pump, we select the exact pump solution ideal for your application.
Whether you are looking to circulate water round a cooling system, dose ingredients on a production line, fill barrels of chemicals or transfer oil between tanks, contact Castle Pumps to deliver your process.
Where we supply to
UK Ireland, Europe, Africa, Asia, Australia, South America, North America
Industries we supply to
Energy and Power, Food and Beverage, Metals and Minerals, Paper and Pulp, Pharmaceutical Cosmetics Toiletries, Water and Wastewater
That is true that you don’t want to lose too much pressure. I need to get a plumber who can pump out a bunch of sludge. I’ll have to consider getting someone who has good certifications to do it for me.