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Energy efficiency of pumps and pumping systems Dr.-Ing. Fr.-W. Hennecke Pumpenfachingenieur GmbH Hannover 06.04.2011
Energy efficiencyof pumps and pumping systems
Dr.-Ing. Fr.-W. HenneckePumpenfachingenieur GmbH
Hannover 06.04.2011
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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
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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.
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Verbraucher/ Last
Reservoir
Rohre und Armaturen mit Strömungswiderstand
What is a pumping system?
Pumpe
Berge, KSB
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What is a pump unit?
Kupplung
Zulauf
Druckstutzen
Elektro-Motor
Strom-versorgung
Grundplatte
Hydraulik:Spiral Gehäuse
mit Laufrad
Berge, KSB
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Efficiency of the pump unit
• Hydraulic efficiency of the pump 20 - 95%
• Mechanical Losses 2 %
• Electrical Drives 70 – 95%
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Maximum efficiencies of pumps
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Efficiencies of electrical drives
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Efficiency of centrifugal pumpspump curves
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Pump system curves (1)
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Pump system curves (2)variable speed
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Pump and system curve (3)with efficiencies
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How to save energy
• Analyse the pumping system
• Select the right pump type and size
• Select the right control method
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Analyse the pumping system: fluid
• Water, oil, mud, food, pharma
• temperature, vapor pressure, density
• viscosity, solids, gas
• Corrosiveness
• Explosiv, toxic, cancerogenic
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Analyse the Pumping system: Flowrate
• Nominal flowrate
• Alternating flowrates– normal, minimum, maximum– continuously, discontinously, stop and go
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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)
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Select pump type and size
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Select the right control methode
• Regulation by
• Throttling• Reducing impeller diameter• By-pass• Speed regulation
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Select the right control methodDrosselregelung
M
Q
P
Einsparpotenzial
Q1Q2
Anlagen-kennlinie
Pumpen-kennlinie
Q
H
P
Drehzahlregelung
M~~~~~~
Q
P
Q1Q2
Anlagen-kennlinie
Pumpen-kennlinie
Q
H
P
Berge, KSB
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Kennlinie CBS 32-250 2900 U/min
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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
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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
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What happens outside optimum?
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Förderhöhe
Förderstrom
Nenn-Förderhöhe
Nenn-Förderstromgeringerer Bedarf
Auslegungspunkt(mit Reserve)
HäufigsterBetriebspunkt
Optimum for just one operating point
Realer Vollastpunkt
Centrifugal Pumps
