Energy efficiency of pumps and pumping...

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Energy efficiencyof pumps and pumping systems

Dr.-Ing. Fr.-W. HenneckePumpenfachingenieur GmbH

Hannover 06.04.2011

6. April 2011 Hennecke 2

Dr.-Ing. Friedrich-Wilhelm HenneckeCurriculum vitae

• 1960-1972 Studies and research– Mechanical and Chemical Engineering at

Technical University of Hannover and University of Bristol

– Research at Max-Planck-Institute of Fluid Dynamics and at Technical University of Karlsruhe

• 1972- 2002 BASF Works Engineering– Plant engineer Ammonia plants– Maintenance Manager of a refinery– Manager Engineering Pumps and Motors– Member of the German Pump

Standardization Committee• 2002 retired

– Consultant Pumptechnology and Marketing

– Pumpforum Vogel Business Media– Pumpenfachingenieur GmbH

Energy consumption of pumps• Pumping systems

– nearly 20 percent of the worlds energy demand– 25 to 50 percent in certain industrial plants operation.

– domestic services, commercial and agriculturál services, infrastructuralservices, food processing, chemical, petrochemical, pharmaceuticalmechanical industries.

• Pumps are individual machines, but they provide service only whenoperating as a part of a system.

• The energy consumed by such a system depends on – the design of the pump,– the design of the installation and the selection the pump– the way the system is operated.

Verbraucher/ Last

Reservoir

Rohre und Armaturen mit Strömungswiderstand

What is a pumping system?

Berge, KSB

What is a pump unit?

Kupplung

Zulauf

Druckstutzen

Elektro-Motor

Strom-versorgung

Grundplatte

Hydraulik:Spiral Gehäuse

mit Laufrad

Berge, KSB

Efficiency of the pump unit

• Hydraulic efficiency of the pump 20 - 95%

• Mechanical Losses 2 %

• Electrical Drives 70 – 95%

Maximum efficiencies of pumps

Efficiencies of electrical drives

Efficiency of centrifugal pumpspump curves

Pump system curves (1)

Pump system curves (2)variable speed

Pump and system curve (3)with efficiencies

How to save energy

• Analyse the pumping system

• Select the right pump type and size

• Select the right control method

Analyse the pumping system: fluid

• Water, oil, mud, food, pharma

• temperature, vapor pressure, density

• viscosity, solids, gas

• Corrosiveness

• Explosiv, toxic, cancerogenic

Analyse the Pumping system: Flowrate

• Nominal flowrate

• Alternating flowrates– normal, minimum, maximum– continuously, discontinously, stop and go

Analyse the pumping system: Piping system

• Suction side– Geodetic suction head (alternating ?)– Pressure losses (valves, control instruments,

filters)• Pressure side

– Geodetic suction head (alternating ?)– Pressure in vessel– Pressure losses (valves, control instruments,

filters)

Select pump type and size

Select the right control methode

• Regulation by

• Throttling• Reducing impeller diameter• By-pass• Speed regulation

Select the right control methodDrosselregelung

Einsparpotenzial

Anlagen-kennlinie

Pumpen-kennlinie

Drehzahlregelung

M~~~~~~

Anlagen-kennlinie

Pumpen-kennlinie

Berge, KSB

Kennlinie CBS 32-250 2900 U/min

Elements of Life Cycle Costs (LCC)

LCC = Cic + Cin + Ce + Co + Cm + Cs + Cenv + Cd

Cic = initial cost

Cin = installation and commissioning cost

Ce = energy costs

Co = operating cost

Cm = maintenance and repair costs

Cs = down time and loss of production cost

Cenv = environmental cost

Cd = decommissioning and disposal cost

Summary

• A pump only works in a pumping system

• You can improve the efficiency of the pump unit by1, 2 or 5 percent

• You can improve the efficiency of the pump system by10, 20 or 50 percent

• But first at all the pump must be reliable and you mustconsider all elements of LCC

What happens outside optimum?

Förderhöhe

Förderstrom

Nenn-Förderhöhe

Nenn-Förderstromgeringerer Bedarf

Auslegungspunkt(mit Reserve)

HäufigsterBetriebspunkt

Optimum for just one operating point

Realer Vollastpunkt

Centrifugal Pumps

Energy efficiency of pumps and pumping...

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