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Fans & Pumps

ADNAN JOUNI

RCREEE Energy Audit in Building Tunis, 1st 5th June 2010

Contents
1 General Introduction
2 Fans & Blowers 3 Pumps & Pumping systems

General Introduction
Pumps and fans are probably the devices the most frequently used in our life Both are necessary to move material and energy

General Introduction
In building sector their usage is essential to secure comfort and welfare Energy saving concerns 2 levels: The device itself The removed energy or material

Fans & Blowers

Equipment

Specific Ratio up to 1.11 1.11to 1.20

Pressure rise (mmWg) 1136 1136 2066


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Comparison

Fans Blowers

Contents
Introduction
Types of fans and blowers Energy audit of Fans

Introduction
What are Fan systems?
Any device that produces a current of air by the movement of broad surfaces can be called a fan Fans are similar in many respects to pumps. Both are turbo machines that transfer energy to a flowing fluid. It is easy to distinguish between fans and pumps: pumps handle liquids; fans handle gasses. Broadly speaking, the function of a fan is to propel, displace, or move air or gas.
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Introduction
Fan components
System resistance Fan curve Operating point Fan laws

Introduction
Fan Network Components
Turning Vanes (typically used on short radius elbows) Outlet Diffusers Heat Exchanger Baffles

Filter

Inlet Vanes Motor Controller Variable Frequency Drive Belt Drive Motor

Centrifugal Fan

Introduction System Resistance:


Sum of static pressure losses in system Increases with square of flow rate

Actual with system resistance

calculated

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Introduction

Fan Curves

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Introduction Operating Point


Fan curve and system curve intersection
Move to flow Q2 by closing damper (increase system resistance) Flow Q1 at pressure P1 and fan speed N1

Move to flow Q2 by reducing fan speed


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Introduction Fan Laws


Minimizing Energy through Fan selection

Fan Affinity Laws

Pre.

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Contents

Introduction

Types of fans and blowers


Energy Audit of Fans

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Types of Fans & Blowers


Type of Fan Peak Efficiency Range

Types of fans
Centrifugal Axial Types of blowers Centrifugal Positive displacement

Centrifugal fans: Airfoil, Backward curved/inclined Modified radial Radial Pressure blower Forward curved Axial fans: 79-83

72-79 69-75 58-68 60-65

Vane axial
Tube axial Propeller

78-85
67-72 45-50

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Types of Fans & Blowers


Centrifugal Fans
Advantages
High pressure and temp Simple design High durability Efficiency up to 75% Large running clearances

Disadvantages
Suited for low/medium airflow rates only
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Types of Centrifugal Fans

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Types of Fans & Blowers Example of Centrifugal Fans Backward-inclined


Advantages
Operates with changing static pressure Suited for high flow and forced draft services Efficiency >85%

Disadvantages
Not suited for dirty airstreams Instability and erosion risk
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Types of Fans & Blowers Axial Fans


Work like airplane propeller:
Blades create aerodynamic lift Air is pressurized Air moves along fan axis

Popular : compact, low cost and light weight

Applications
Ventilation (requires reverse airflow) Exhausts (dust, smoke, steam)
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Types of Fans & Blowers


Example of Axial Fans Tube axial fans
Advantages
Pressures to overcome duct losses Suited for medium-pressure, high airflow rates Quick acceleration

Disadvantages
Expensive Moderate noise Low energy efficiency 65%
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Types of Fans & Blowers Blowers


Difference with fans
Much higher pressures <1.20 kg/cm2 Used to produce negative pressures for industrial vacuum systems Types Centrifugal blower Positive displacement
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Contents
Introduction Types of fans and blowers

Energy Audit of Fans

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Energy Audit of Fans


Introduction
Example for the distribution of cost over the life cycle of fans

Fans are the main consumer for auxiliary Systems

Maintenance (5%)

Capital 8%)

In Most situations the potential of Energy Saving is more than 30%

Energy (87%)
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Energy Audit of Fans Steps Involved


Data collection

Observations and Analysis


Exploration for energy conservation measures Report preparation

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Energy Audit of Fans


Data Collection
Collect detailed design specification & operating parameters: Make, Type, Model, Fluid characteristics,
Rated Flow, Inlet pressure, Efficiency, motor characteristics, Regulation systems,

Collect Details of the fans and ducting system:


Collect the schematic diagram / network of the ducting system
Collect Performance characteristics of all fans Compile design, previous best and last energy audit values with respect to fans and draft system If the fans are operated in parallel then it is advised to collect the performance curve for the parallel operation Air quality and pressure equipments at the users as per the design requirements
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Energy Audit of Fans Instruments Required


Power Analyzer: Used for measuring electrical parameters such as kW, kVA, pf, V, A and Hz

Temperature Indicator & Probe


Stroboscope: To measure the speed of the driven equipment and motor Sling hygrometer or digital hygrometer Anemometer, Pitot tubes On line instruments (calibrated) Digital Manometer of suitable range and appropriate probes for measurement of pressure head and velocity head. Additional pressure gauges with appropriate range of measurement and calibrated before audit.
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Energy Audit of Fans Measurements & observations to be made


Energy consumption pattern of fans Motor electrical parameters (kW, kVA, Pf, A, V, Hz,) of fans Fan operating parameters to be measured/monitored for each Fan are: 1. Discharge flow rate 2. Pressure (suction & discharge)
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Energy Audit of Fans Measurements & observations to be made


3. 4. 5. 6. 7. 8. Damper position / guide vane position/ VSD Setting Temperature of fluid handled Load variation Fan operating hours and operating schedule Pressure drop in the system Pressure drop and temperature variation across the equipment 9. Fan /Motor speed Oxygen content, flow, temperature and pressure measurement across in exhaust gas path
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Energy Audit of Fans Energy consumption pattern


If the plant is monitoring the energy consumption, it is suggested to record the data and monitor the daily and monthly consumption pattern. (Collect data for 12 months) Work out the total consumption of fans to arrive at percentage to the total consumption of the auxiliary consumption If the energy meters are not installed to fans, instantaneous measurements can be carried out, based on the loading pattern daily consumption can be worked out.
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Energy Audit of Fans Fan Operating Efficiency Evaluation


The parameters to be studied in detailed are:
Air /gas rates of fans / main ducts Static pressure and dynamic pressure and total pressure Power consumption of fan (for estimating the operating efficiency of the fans) Monitor present flow control system and frequency of control valve operation if any (for application of variable speed drives)
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Energy Audit of Fans Fans Performance assessment


Static pressure
Potential energy put into the system by the fan

Velocity pressure
Pressure arising from air flowing through the duct. This is used to calculate velocity

Total pressure
Static pressure + velocity pressure Total pressure remains constant unlike static and velocity pressure

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Energy Audit of Fans Fan Operating Efficiency Evaluation


3/ s x static pr. developed by fan in mmwc Q in m Fan static kW = 102 Fan static kW x 100 Fan static efficiency % = Input kW to motor x m

Fan mechanical Efficiency % =


Parameter Q Static pressure Fan static/ total kW Input kW to motor m Total pressure Details Air flow rate

Fan total kW x 100 Input kW to motor x m


Unit m3/ s mmwc kW kW mmwc
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Difference between discharge & suction pressure Static / total power consumption of the fan Measured power consumption of the motor Efficiency of the motor at operating load Difference between discharge & suction pressure

Energy Audit of Fans Fan Operating Efficiency Evaluation


Corrected air density, =
273 X 1.293

273 + Air temperature in 0 C

Velocity in m / s =

Cp x 2 x 9.81 x Diff. velocity pr. in mmwc x


Unit 0.85 or as given by manufacturer

Parameter Details Cp Pitot tube constant

Density of air or gas at test condition

Kg / m3

Volumetric flow (Q), m3/s = Velocity, m/s x Area, m2


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Energy Audit of Fans Fan Performance Analysis


Compare the actual values with the design / performance test values if any deviation is found, list the factors with the details and suggestions to over come. The investigations for abnormality are to be carried out for problems. Enlist scope of improvement with extensive physical checks / observations. Based on the actual operating parameters, enlist recommendations for action to be taken for improvement, if applicable such asReplacement of fans, Impeller replacement, VFD application. Cost analysis with savings potential for taking improvement measures.

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Energy Audit of Fans Fan Performance Analysis


Recirculation

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Damper IGV

P o w e r

75 50 25

Inlet Guide Vanes

VFD
Variable Frequency Drive

Ideal

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50

75

100
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Flow

Energy Audit of Fans Fan Performance Analysis

System characteristics and Fan curves

Impact of speed reduction


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Energy Audit of Fans Fan Performance Analysis


Visual survey of insulation & the ducting system:

Insulation status (measure the surface temperature with the aid of surface thermocouple / infrared pyrometer or by using thermal imaging cameras)
Bends and ducting status

Physical condition of insulation Identification of locations where action is required to improve the insulation (provide with detailed technoeconomics)
Improvement options for ducting systems if any
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Energy Audit of Fans


Exploration of Energy Conservation Opportunities Improvement of systems and drives:
Use of energy efficient fans Change of impeller with energy efficient impeller Correcting inaccuracies of the fan sizing Use of high efficiency motors

Fan speed reduction by pulley diameter modifications for optimization


Option of two speed motors or variable speed drives for variable duty conditions High Performance Lubricants: The low temperature fluidity and high temperature stability of high performance lubricants can increase energy efficiency by reducing frictional losses Use of energy efficient transmission systems (Use of latest energy efficient transmission belts)
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Energy Audit of Fans


Exploration of Energy Conservation Opportunities
Improvement in operations:
Minimizing excess air level in combustion systems to reduce fan load.
Minimizing air in-leaks in hot or cold flue gas path to reduce fan load Minimizing system resistance and pressure drops improvements in duct system / Insulation aspects Measures to up keep the performance

After the identification of energy conservation measures, detailed techno-economic evaluation has to be carried out
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Energy Audit of Fans


Case Study
A fan is used to draw air through a bag filter. Flow rate is 90 m3/s at a static pressure of 80 mm water column (WC) 65 mm WC is the static pressure across the bag filter Motor power drawn is 120 kW Motor efficiency is 86% Impeller diameter is 70 mm RPM is 1000

After consultation we decided to replace the bag filter with an electrostatic precipitator (ESP). Static pressure across the ESP is 20 mm WC Flow rate increased by 20% The flow rate can be brought back to 90 m3/s by two options: (a) Impeller trimming and (b) Reduced pulley diameter to reduce the RPM

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Energy Audit of Fans


Case Study
We must Calculate the following: 1. Fan static efficiency before installation of the ESP 2. The new impeller diameter if the impeller is trimmed, that would result in a reduction in fan efficiency of 5% 3. The new RPM that would result in a fan efficiency of 60% 4. Which of the two options is more energy efficient

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Energy Audit of Fans


Case Study
1. Fan static efficiency before installation of the ESP Power input at fan shaft = 120 x 0.86 = 103.2 kW Fan efficiency = 90 x 80/(102 x 103.2) = 68 %

2 New impeller diameter if the impeller is trimmed New fan static efficiency = 68% - 5% = 63% New static = 80 65 + 20 = 35 mm WC New flow rate Q = 90 m3/s x 1.2 = 108 m3/s Static pressure at a flow of 90 m3/s with ESP installed Q1 / Q2 = (H1/H2)2 result H2 = 32 mm Power required at the fan shaft Fan static efficiency: 0.63 = (90 x 32) / (102 x power) Power developed at fan shaft = 44.8 kW
New impeller diameter (D2) (D1 / D2) = (kW1 / kW2) 1/ 3 result D2 = 53 mm
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Energy Audit of Fans


Case Study
3. Calculate the new RPM that would result in a fan efficiency of 60% Power required at fan shaft 0.60 = 90 x 32 / 102 x Power required at fan shaft Power required at fan shaft = 47 kW New RPM (N2): (N1 / N2) = (kW1 / kW2) 1/ 3 N2 = 769 RPM 4. Determine which of the two options is more energy efficient Power required by impeller trimming = 44.8 kW Power required by reducing RPM = 47 kW Therefore impeller trimming is the more energy efficient option.
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Pumps

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Contents

Introduction
Type of pumps Energy Audit of Pumps

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Introduction What are Pumping Systems


20% of worlds electrical energy demand Used for
Domestic, commercial, industrial and agricultural services
Municipal water and wastewater services

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Introduction What are Pumping Systems


Objective of pumping system
Transfer liquid from source to destination Circulate liquid around a system

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Introduction What are Pumping Systems


Main pump components
Pumps
Prime movers: electric motors, diesel engines, air system Piping to carry fluid Valves to control flow in system Other fittings, control, instrumentation

End-use equipment
Heat exchangers, tanks, hydraulic machines
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Introduction
Pumping System Characteristics
Head Resistance of the system Two types: static and friction Static head Difference in height between source and destination Independent of flow Static head at certain pressure Head (m) = Pressure (Pa) 1000xSpecific gravity
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Introduction Pumping System Characteristics


In most cases: Total head = Static head + friction head
Friction head Resistance in pipe and fittings Depends on size, pipes, pipe fittings, flow rate, nature of liquid Proportional to square of flow rate
System head
System curve

Friction head Static head

Flow 52

Introduction

Pumping System Characteristics


Pump performance curve Relationship between head and flow

Pump operating point


Duty point: rate of flow at certain head Pump operating point: intersection of pump curve and system curve
Head
Pump performance curve Pump operating point

System curve

Static head

Flow

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Introduction Pumping System Characteristics


Pump suction performance
Cavitation or vaporization: bubbles inside pump If vapor bubbles collapse Erosion of vane surfaces Increased noise and vibration Choking of impeller passages

Net Positive Suction Head (NPSH) NPSH Available: how much pump suction exceeds liquid vapor pressure NPSH Required: pump suction needed to avoid cavitation

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Introduction Pumping System Characteristic curves

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Introduction Pumping System Characteristics


Pumps in parallel: Curves

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Contents: Pumps

Introduction

Type of pumps
Energy Audit of Pumps

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Type of Pumps Pump Classification


Classified by operating principle
Pumps

Dynamic

Others (e.g.
Impulse, Buoyancy)

Positive Displacement

Centrifugal

Special effect

Rotary

Reciprocating

Internal gear

External gear

Lobe

Slide vane

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Type of Pumps Positive Displacement Pumps


For each pump revolution
Fixed amount of liquid taken from one end Positively discharged at other end

If pipe blocked
Pressure rises Can damage pump

Used for pumping fluids other than water

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Type of Pumps Dynamic pumps


Mode of operation
Rotating impeller converts kinetic energy into pressure or velocity to pump the fluid

Two types
Centrifugal pumps: pumping water in industry 75% of pumps installed Special effect pumps: specialized conditions
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Type of Pumps
Centrifugal Pumps How do they work?
Liquid forced into impeller Vanes pass kinetic energy to liquid: liquid rotates and leaves impeller Volute casing converts kinetic energy into pressure energy

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Type of Pumps Centrifugal Pumps Impeller

Main rotating part that provides centrifugal acceleration to the fluid


Number of impellers = number of pump stages Impeller classification: direction of flow, suction type and shape/mechanical construction

Shaft
Transfers torque from motor to impeller during pump start up and operation
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Impellers

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Contents: Pumps

Introduction Type of pumps

Energy Audit of Pumps

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Energy Audit of Pumps


Introduction
Example for the distribution of cost over the life cycle of a water-based pump system.

Maintenance (5%)

Capital 10%)

In Most situations the potential of Energy Saving is more than 30%

Energy (85%)
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Energy Audit of Pumps

Steps Involved
Data collection

Observations and Analysis


Exploration for energy conservation measures Report preparation

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Energy Audit of Pumps Data Collection


Collect detailed design specification & operating parameters: Make, Type, Model, Fluid characteristics, Rated Flow, Inlet pressure, Efficiency, motor characteristics, Regulation systems Collect the above information for all pumps in the water circuit Collect the Performance Characteristics curves of all pumps
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Energy Audit of Pumps

Data Collection
Compile design, previous best and last energy audit values of the pumping system being audited

If the pumps are operated in parallel, then it is advised to collect the performance curves for the parallel operation of the pumps
Schematic diagram of Water pumping network (which depict the source, pumps in operation & stand by, line sizes and users) Water and pressure equipments at the users as per the design requirements Brief description of the system, in which pumps are used
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Energy Audit of Pumps Instruments Required


Power Analyzer: Used for measuring electrical parameters such as kW, kVA, pf, V, A and Hz Temperature Indicator & Probe

Pressure Gauge: To measure operating pressure and pressure drop in the system
Stroboscope: To measure the speed of the driven equipment and motor Ultra sonic flow meter or online flow meter The above instruments can be used in addition to the calibrated online / plant instruments
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Energy Audit of Pumps Parameters to be measured


Energy consumption pattern of pumps (daily / monthly /yearly consumption) Motor electrical parameters (kW, kVA, Pf, A, V, Hz) for individual pumps

Pump operating parameters to be monitored for each pump


Discharge Flow, Head (suction & discharge), Valve position, Temperature, Load variation, Simultaneous power parameters of pumps, Pumps operating hours and operating schedule, Pressure drop in the system (between discharge and user point), Pressure drop and temperatures across the users (heat exchangers, condensers, etc), Pump /Motor speed, Actual discharge pressure and required / prevailing pressure at the user end, User area pressure of operation and requirement 70

Energy Audit of Pumps Observations & Measurements


Operating efficiency and performance evaluation of pumps Flow distribution

System Details: Detailed interactions (plant personnel) have to be carried out to get familiarization for system detail and operational details. The brief system should be briefed in the report
Energy consumption Pattern: If the plant is monitoring the energy consumption, it is suggested to record the data and monitor the daily and monthly consumption pattern

Collect the past energy consumption data (month wise for at least 12 months, daily consumption for about a week for different seasons, daily Consumption during the audit period)
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Energy Audit of Pumps


Efficiency & Performance Evaluation of the Pumps
Performance parameters for water pumps

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Energy Audit of Pumps


Efficiency & Performance Evaluation of the Pumps
Performance parameters for water pumps contd..

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Energy Audit of Pumps


Efficiency & Performance Evaluation of the Pumps
Pump hydraulic power can be calculated by the formula: Q x Total Head, (hd hs) x x g

Hydraulic kW =
Parameter Q Water flow rate Details

1000
Unit m3/s

Total head
g

Difference between discharge head, hd & suction head, hs


Density of water or fluid being pumped Acceleration due to gravity

m
Kg/m3 m2/s

Pump efficiency,

Pump

Hydraulic power Pump shaft power Hydraulic power x


Motor
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Pump shaft power =

Energy Audit of Pumps


Efficiency & Performance Evaluation of the Pumps

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Energy Audit of Pumps


Energy Conservation Opportunities
Compare the actual values with the design / performance test values if any deviation is found, list the factors with the details and suggestions to over come.

Compare the specific energy consumption with the best achievable value (considering the different alternatives). Investigations to be carried out for problematic areas..
Enlist scope of improvement with extensive physical checks / observations. Based on the actual operating parameters, enlist recommendations for action to be taken for improvement, if applicable such as: Replacement of pumps

Impeller replacement
Impeller trimming Variable speed drive application, etc
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Energy Audit of Pumps


Energy Conservation Opportunities

Avoiding Over sizing of Pump


Pump Curve at Const. Speed 70 m 50 m 42 m Head Meters Static Head 300 500
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Pump Efficiency 77%


Oversize Pump

B Partially closed valve

82%

A
Full open valve

System Curves

Required Pump

Operating Points

Flow (m3/hr)

Energy Audit of Pumps


Energy Conservation Opportunities

Avoiding Over sizing of Pump by impeller trimming 28.6 kW

14.8 kW

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Energy Audit of Pumps


Energy Conservation Opportunities

Provision of variable speed drive

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Energy Audit of Pumps


Energy Conservation Opportunities
Improvement of systems and drives.
Use of energy efficient pumps Replacement of inefficient pumps Trimming of impellers Correcting inaccuracies of the Pump sizing Use of high efficiency motors Integration of variable speed drives into pumps High Performance Lubricants: lubricants can increase energy efficiency by reducing frictional losses. Booster pump application Centralization/ decentralization Categorizing according to the pressure requirement
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Energy Audit of Pumps

Case Study
In a commercial Building a clear water Pump has:

Parameter Flow Q (m/h) Head H (m WC) Power P (kW) RPM

Design Operating 800 550 55 160 1485 24 (after delivery valve) 124 1485

Water flow rate varies from 500 m/h to 700 m/h. Pump flow rate has been reduced by partially closing the delivery valve. Motor efficiency is 93%.

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Energy Audit of Pumps Case Study 1. Calculate the operating efficiency 2. Explain what would be the best option to obtain the required flow rate variation 3. Calculate the power savings if the options suggested under question 2 would reduce the flow rate of the pump is 550 m/h
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Energy Audit of Pumps Case Study


SOLUTION

1. Calculate the operating efficiency Efficiency of the pump = (550 x 24 x 9.81) / (3600 x 124 x 0.93) = 0.3867 = 38.67% 2. Explain what would be the best solution The pump is operating at a poor efficiency of 38.67% due to throttling of the flow. Since the pump discharge requirement varies from 500 m/h to 700 m/h, the ideal option would be to operate with a variable speed drive (VSD).
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Energy Audit of Pumps Case Study


3. Calculate the power savings According to affinity laws: Relationship Q and RPM: Q1/Q2 = N1/N2 Relationship H and RPM: H1/H2 = (N1/N2)2 Relationship P and RPM: P1/P2 = (N1/N2)3 For a flow rate Q1 = 550 m/h, the reduced speed of pump (N1 in RPM) would be: N1 = 1021 RPM Power would be P1 = 52 kW Power saving = 124 kW - 52 kW = 72 kW
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Energy Audit of Pumps


Good Practices
GP1: A waste-fuelled heating plant fed two networks which supply an industrial area and a residential area.

An analysis of the pumps used to supply


networks showed that the pumps were all run continuously at high power, although the

pumping power required was often very low.


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Energy Audit of Pumps


Good Practices
System optimisation measures:
Complete separation of the pumps from the mains supply when they are switched off Replacement of existing pumps with smaller, highly efficient pumps Use of variable speed drive for operation at adjustable speeds Installation of high efficiency motors Installation of the new pumps and variable speed drive
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Energy Audit of Pumps


Good Practices

Energy savings and efficiency parameters


Electricity savings: 64 % or 325,000 kWh p.a. Cost savings: 32,500 p.a. Investment: 67,000 Payback period: 2.1 years

Return on investment: 48 %

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Energy Audit of Pumps


Good Practices
GP2:
A combined heat and power plant provides a district (houses, hospitals, welfare and handicapped facilities, commercial kitchen and a laundry ) heat via a district heating network. The energy audit focused on the optimization of the main district heating pumps in the power supply centre. The analysis showed considerable potential to optimize the pump control system, which until now has been regulated by hand.
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Energy Audit of Pumps


Good Practices

Systems optimisation measures:


Hydraulic alignment of the district heating network Installation of a proportional control system for the

pumps
Use of variable speed drive for operation at adjustable speeds

Replacement of the two network pumps


Use of high efficiency motors
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Energy Audit of Pumps


Good Practices Energy savings and efficiency parameters
Electricity savings: 39 % or 129,000 kWh p.a.
Cost savings: 14,100 p.a. Investment: 41,700 Payback period: 3 years Return on investment: 31 %

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THANK YOU
FOR

YOUR ATTENTION

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