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)