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Pumping Systems

The document provides an overview of centrifugal pumps and pumping systems, detailing components such as impellers, diffusers, and the relationship between hydraulic power, pump shaft power, and electrical input power. It discusses the importance of selecting the right pump based on system characteristics, efficiency curves, and the impact of impeller diameter and speed variations on performance. Additionally, it highlights energy conservation opportunities within pumping systems to optimize efficiency and reduce costs.

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Mahendra Aharwal
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© © All Rights Reserved
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19 views36 pages

Pumping Systems

The document provides an overview of centrifugal pumps and pumping systems, detailing components such as impellers, diffusers, and the relationship between hydraulic power, pump shaft power, and electrical input power. It discusses the importance of selecting the right pump based on system characteristics, efficiency curves, and the impact of impeller diameter and speed variations on performance. Additionally, it highlights energy conservation opportunities within pumping systems to optimize efficiency and reduce costs.

Uploaded by

Mahendra Aharwal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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6.

Pumps and Pumping Systems

Centrifugal Pumps
Impeller
Imparts velocity to the water
Diffuser (volute)
Converts velocity to pressure
Pressure (head) α Impeller
Dia
Capacity α Impeller width
What Is A Pump System?
• A Pump System comprises of all piping,
fittings and valves before and after a pump as
well as the motor and motor driver.
• There can be multiple pumps, motors and
drives, and they can be arranged to operate in
parallel or in series.
• Pump Systems can have static head (pressure),
or be circulating systems (friction only
systems)
First, Let's Get A Big Picture Perspective
Of Energy Flow in Pumping Systems
Electric utility
feeder
At each interface, there are
Transformer inefficiencies. The goal should be
to maximize the overall cost
Motor breaker/ effectiveness of the pumping, or
starter how much flow is delivered per
unit of input energy.
Adjustable
speed drive
(electrical)
Fluid Ultimate
Motor Coupling Pump system goal
4
Pump Performance Curve

Duty Point

Operating Range
Pump Performance Curve
Hydraulic power, pump shaft power and
electrical input power

• Hydraulic power Ph = Q (m3/s) x Total head, hd - hs (m) x  (kg/m3) x g (m2/s)


1000
Where hd - discharge head, hs – suction head,  - density of the fluid, g –
acceleration due to gravity

• Pump shaft power Ps = Hydraulic power, Ph


pump efficiency, Pump

• Electrical input power = Pump shaft power P


Motor
System Characteristics

Static Head Static Head vs. Flow


Dynamic (Friction) Head

Friction Head vs. Flow


System with high static head
System with low static head
Pump curve
Pump operating point
Selecting a pump

System Curve
Head
Meters

Flow (m3/hr)
Selecting a pump
Pump Curve at
Const. Speed

82%
Operating Point
System Curve
Head
Meters

500 m3/hr

Flow (m3/hr)
Selecting a pump
Pump Curve at
Const. Speed

82%
50 Operating Point
Head,
m System Curve

300 500

Flow (m3/hr)
Selecting a pump

Pump Curve at
Const. Speed Pump Efficiency
77%
Partially
70
closed valve 82%
50 Full open valve
Head,
m System Curves

300 500

Flow (m3/hr)
Selecting a pump
Pump Curve at
Const. Speed Pump Efficiency 77%

70 m Partially B 82%
closed valve
A
50 m
Full open valve
42 m
System Curves C
Head
Meters
Static Operating Points
Head
300 m3/hr 500 m3/hr
3
Flow (m /hr)
Efficiency Curves
31 kW

16.1 kW
If we select E, then the pump
efficiency is 60%
• Hydraulic Power = Q (m3/s) x Total head, hd - hs (m) x  (kg/m3) x g (m2/s)
1000

= (68/3600) x 47 x 1000 x 9.81


1000
= 8.7 kW

• Shaft Power - 8.7 / 0.60 = 14.5 Kw


• Motor Power - 14.5 / 0.9 = 16.1Kw
(considering a motor efficiency of 90%)
If we select A, then the pump
efficiency is 50%
• Hydraulic Power = Q (m3/s) x Total head, hd - hs (m) x  (kg/m3) x g (m2/s)
1000

(68/3600) x 76 x 1000 x 9.81


1000
= 14 kW

Shaft Power - 14 / 0.50 = 28 Kw


Motor Power - 28 / 0.9 = 31 Kw (considering a
motor efficiency of 90%)
Using oversized pump !
As shown in the drawing, we should be using impeller "E" to
do this, but we have an oversized pump so we are using the
larger impeller "A" with the pump discharge valve throttled
back to 68 cubic meters per hour, giving us an actual head of
76 meters.

•Hence, additional power drawn by A over E is 31 –16.1 = 14.9 kW.


•Extra energy used - 8760 hrs/yr x 14.9 = 1,30,524 kw.
= Rs. 5,22,096/annum
In this example, the extra cost of the electricity is more than the cost
of purchasing a new pump.
The affinity law for a centrifugal pump with the
speed held constant and the impeller diameter
changed
Flow:
Q1 / Q2 = D1 / D2
Example: 100 / Q2 = 8/6
Q2 = 75 m3/hr
Head:
H1/H2 = (D1) x (D1) / (D2) x (D2)
Example: 100 /H2 = 8 x 8 / 6 x 6
H2 = 56.25 m
Horsepower(BHP):
kW1 / kW2 = (D1) x (D1) x (D1) / (D2) x (D2) x (D2)
Example: 5/kW2 = 8 x 8 x 8 / 6 x 6 x 6
kW2 = 2.1 kW
Effect of speed variation
Power consumption with Throttling
Power consumption with VFD
Reducing impeller diameter

• Changing the impeller diameter gives a proportional change in


peripheral velocity
• Diameter changes are generally limited to reducing the diameter to
about 75% of the maximum, i.e. a head reduction to about 50%
• Beyond this, efficiency and NPSH are badly affected
• However speed change can be used over a wider range without
seriously reducing efficiency
• For example reducing the speed by 50% typically results in a
reduction of efficiency by 1 or 2 percentage points.
• It should be noted that if the change in diameter is more than about
5%, the accuracy of the squared and cubic relationships can fall off
and for precise calculations, the pump manufacturer’s performance
curves should be referred to
Impeller Diameter Reduction on Centrifugal
Pump Performance
Pump suction performance
(NPSH)
• Net Positive Suction Head Available – (NPSHA)
• NPSH Required – (NPSHR)
• Cavitation
• NPSHR increases as the flow through the pump
increases
• as flow increases in the suction pipework, friction
losses also increase, giving a lower NPSHA at the
pump suction, both of which give a greater chance
that cavitation will occur
Pump control by varying
speed:Pure friction head

• Reducing speed in the


friction loss system
moves the intersection
point on the system
curve along a line of
constant efficiency
• The affinity laws are
obeyed
Pump control by varying
speed:Static + friction head
• Operating point for the pump
moves relative to the lines of
constant pump efficiency when the
speed is changed
• The reduction in flow is no longer
proportional to speed
• A small turn down in speed could
give a big reduction in flow rate
and pump efficiency
• At the lowest speed illustrated,
(1184 rpm), the pump does not
generate sufficient head to pump
any liquid into the system
Pumps in parallel switched to
meet demand
Pumps in parallel with system
curve
Energy Conservation
Opportunities in Pumping Systems
1. Ensure adequate NPSH at site of installation
2. Operate pumps near best efficiency point.
3. Modify pumping system/pumps losses to minimize
throttling.
4. Adapt to wide load variation with variable speed drives
5. Stop running multiple pumps - add an auto-start for an on-
line spare or add a booster pump in the problem area.
6. Conduct water balance to minimise water consumption
7. Replace old pumps by energy efficient pumps
Air conditioning System
Resinoid plant
46 TR x 2nos in operation

Recirculated
cooled
air Hot Well

Resinoid Moulding Cold Well

Recirculated
cooled and
washed
air

NPC Preentation 35
Avoid Cold well Pumps
Resinoid plant
46 TR x 2nos in operation

Recirculated
cooled
air
Hot Well

Resinoid Moulding

Recirculated
cooled and
washed New line
air

NPC Preentation 36
Annual Savings –

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