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    Energy Savings of Pump Applications - General Industry

    Uploaded by

    Dave Duaso
    The document discusses potential energy savings from using variable frequency drives (VFDs) on pump applications instead of flow control valves. It states that VFDs can reduce energy usage by 25-50% by lowering pump speeds to match system demands. VFDs avoid wasting energy by preventing pumps from operating above needed levels. They also reduce wear and maintenance needs by lowering operating pressures on pumps. The document uses affinity laws to illustrate how slower pump and motor speeds from VFDs lower flow, head, power usage proportionately according to formulas provided.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Energy Savings of Pump Applications - General Industry

    Uploaded by

    Dave Duaso
    23 views13 pages
    The document discusses potential energy savings from using variable frequency drives (VFDs) on pump applications instead of flow control valves. It states that VFDs can reduce energy usage by 25-50% by lowering pump speeds to match system demands. VFDs avoid wasting energy by preventing pumps from operating above needed levels. They also reduce wear and maintenance needs by lowering operating pressures on pumps. The document uses affinity laws to illustrate how slower pump and motor speeds from VFDs lower flow, head, power usage proportionately according to formulas provided.

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    Vacon energy savings Pump

    Original Title

    Energy Savings of Pump Applications_General Industry

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    The document discusses potential energy savings from using variable frequency drives (VFDs) on pump applications instead of flow control valves. It states that VFDs can reduce energy usage by 25-50% by lowering pump speeds to match system demands. VFDs avoid wasting energy by preventing pumps from operating above needed levels. They also reduce wear and maintenance needs by lowering operating pressures on pumps. The document uses affinity laws to illustrate how slower pump and motor speeds from VFDs lower flow, head, power usage proportionately according to formulas provided.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    23 views13 pages

    Energy Savings of Pump Applications - General Industry

    Uploaded by

    Dave Duaso
    The document discusses potential energy savings from using variable frequency drives (VFDs) on pump applications instead of flow control valves. It states that VFDs can reduce energy usage by 25-50% by lowering pump speeds to match system demands. VFDs avoid wasting energy by preventing pumps from operating above needed levels. They also reduce wear and maintenance needs by lowering operating pressures on pumps. The document uses affinity laws to illustrate how slower pump and motor speeds from VFDs lower flow, head, power usage proportionately according to formulas provided.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 13

    Energy Savings on Pump Applications

    General Industry
    Compiled by: Arnold S. De Leon

    1 | Department (slide master)


    VFD - Variable Frequency Drive or
    FCV – Flow Control Valves?

    • In many flow applications a mechanical


    throttling device (FCV) is used to limit
    the flow.

    • Although this is an effective means of


    control, it wastes mechanical and
    electrical energy because of high losses
    in the form of heat.

    • As seen in figure to the right, the use


    of a Variable Frequency Drive (VFD)
    will result in cooler motor operation
    and energy use reduction.

    How much energy can be saved?

    2 | Energy Savings
    Department of Pump
    (slide master)
    Conventional Approach - Flow Control Valve

    • Throttling the System via Flow Control


    Valve to meet system demand (Q) will
    shift the curve to the left.

    • This will push the Pump to increase the


    operating pressure which can cause pipe
    leaks, rotating equipment vibration and
    increase wear and tear.

    • Use of Flow Control Valve, have a


    minimal impact on energy consumption
    of pump/motor system by less than 5%

    3 | Energy Savings
    Department of Pump
    (slide master)
    Pump Problem with Conventional Control

    Pipe Leaks
    Mechanical Seal
    Leakage or
    Early Wear and Tear

    Pump and Motor


    Alignment

    Impeller Wear
    Due to Cavitation

    4 | Energy Savings
    Department of Pump
    (slide master)
    Modern Solution– Variable Frequency Drive

    • Regulating the Flow via VFD to meet


    system requirement will change the Pump
    Performance curve, as if the pump is
    Variable.

    • VFD Control, shows the additional benefits


    of reduced operating pressure, thus
    reduced vibrations, mitigate leakage
    potential and lessen mechanical failures.

    • Use of VFD, have a greater impact on


    energy savings of pump/motor system by
    less than 25-50%.

    5 | Energy Savings
    Department of Pump
    (slide master)
    Comparison in Energy Consumption

    • If a throttling device is used to


    control flow, energy usage is as
    shown in the upper curve of figure
    on the right.

    • If a VSD is used the lower curve


    describes the energy usage. The
    difference is energy savings.

    How does this works?

    6 | Energy Savings
    Department of Pump
    (slide master)
    How VFD can save Energy?
    An overview about Affinity Law on Pumps and Fans
    Typical Pump Sizing using Performance Curve

    At the given Flow Rate or


    “Q”, the BHP of the motor
    increase with the Total
    Head Required “H”

    @ 1600 gpm vs 180 Feet


    BHP is between 75 and 100,

    What is Motor Capacity at


    90 BHP is estimated at,

    Motor HP = BHP  Efficiency


    Motor HP = 90HP/0.92
    Motor HP = 97.83HP

    Choose the next Available


    Motor at 100HP!

    8 | Energy Savings
    Department of Pump
    (slide master)
    Pump Sizing using Computed Value

    • Fundamental Formula

    • Brake Horse Power (BHP) = Flow (Q) x Total Dynamic Head (TDH) x Specific Gravity (SG)
    -------------------------------------------------------------------
    3960 x Pump Efficiency

    • BHP = 1600 GPM x 180 Feet x 1 / 3960 x 0.83


    • BHP = 87.62 HP

    • Motor HP = Brake Horse Power / Motor Efficiency

    • Motor HP = 87.62 HP / 0.92


    • Motor HP = 95.23 HP
    • Choose available motor at 100HP

    9 | Energy Savings
    Department of Pump
    (slide master)
    What is Affinity Law?

    The affinity laws of centrifugal pump performance express the effect on


    pump performance due to changes in certain application variables. The
    affinity law variables which affect pump performance are:

    1) Pump speed in pump revolutions per minute (RPM).


    2) Impeller diameter.

    Law 1: Impeller Diameter Change Law 2: for Motor Speed Change

    Q1 / Q2 = D1 / D2 Q1 / Q2 = N1 / N2

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

    BHP1 / BHP2 = (D1 / D2) 3 BHP1 / BHP2 = (N1 / N2) 3

    Please note the same effect in Trimming the Impeller and Changing the Motor Speed
    in FLOW, HEAD and POWER

    10 | Energy Savings
    Department of Pump
    (slide master)
    Affinity Law Curves

    Please note the same effect in Trimming the Impeller and Changing the Motor Speed
    in FLOW, HEAD and POWER

    11 | Energy Savings
    Department of Pump
    (slide master)
    Affinity Law Value in Energy Efficiency
    • Say a 100HP Pump – Motor.
    • @ 20% speed Reduction
    • Power = Speed 3

    • Power = (0.8) 3 = (0.512) * 100%


    • Power = 51% * 100HP = 51 HP or 39 KW
    • Savings = 100HP - 51HP = 49HP or 37KW

    • Say 300 Days Operation/Annum


    • Power Consumption without VFD:
    • 300 Days* 16 Hours*100HP *0.756
    • 544,320 KWH one year
    • Power Consumption with VFD:
    • 300 Days * 16 Hours * 51HP *0.756
    • 277,603 KWH one year

    Rough estimate : Say Energy Cost PHP 8/KWH

    With VFD, Potential Energy Savings per year,


    266,717 KWH or PHP 2,133,736.00

    12 | Energy Savings
    Department of Pump
    (slide master)

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