Energy Efficient Pumpset & Pumpset Selection Page 1
Pumpset : 5HP motor means it can deliver up to 5HP brake horse power output power. 5HP pump means it required a minimum of 5HP brake horse power input power. P1 MOTOR P2 P3 PUMP 5 HP 5 HP P1 = Electrical power = Motor input, kw P2 = Motor output = Pump input = BHP P3 = Fluid power = Q in lps X H in m (HP) 75 Pump Efficiency, p = Fluid power output Pump input BHP Motor Efficiency, m = Motor output Motor Input Set Efficiency, s = Pump Efficiency X Motor Efficiency Page 2
Electric Motor Performance Improvement Usage of low watt loss stampings with high magnetic properties Usage of high conductivity winding wires with good insulation resistance Usage of high purity rotor conductors Usage of rotor system having uniform air gap with dynamic balancing Usage of bigger diaphragm and increased cooling Page 3
Electric Motor Performance Improvement Usage of low coefficient of friction journal bearing materials Optimum clearance between the bearings Usage of highly grounded /polished bearing surfaces with low friction Page 4
Electric Motor Performance Improvement Usage of low coefficient of friction thrust bearing materials combination. Usage of highly lapped / polished bearing surfaces nearest to 1 or 2 light bands. Page 5
Pump Performance Improvement Usage of highly efficient hydraulic components (Impellers and diffuser in case of radial flow pumps and bowls in case of mixed flow). Recirculation losses in hydraulic components can be minimized by using latest hydraulic design software and CFD tools. Page 6
Pump Performance Improvement Usage of impellers in complete machined condition wherever possible to reduce disk friction losses. Various permanent coatings can be employed to get better surface finish in all other surfaces (Impellers, diffusers and bowl) Page 7
Pump Performance Improvement Clearance between impeller and diffuser housing & impeller and wear ring to be optimum to minimise volumetric losses. Selection of Proper wear ring material so that the clearance is maintained for longer period. Design of the stage (diffuser /bowl) bearings in such a way to minimise volumetric losses. Page 8
Pump Performance Improvement Usage of non return valve designed with minimal loss. Suction area of impeller is smoothly rounded off to prevent entry losses Minimum Entry Loss design in the Suction Bracket Page 9
Pump Performance Improvement Usage of Various casting methods to achieve better surface finish for the cast hydraulic components. Core design is in such a way that the parting lines are easy to clean. Core shifting in radial and axial direction are to be prevented by using appropriate core prints which results in desired hydraulic profiles without major deviation. Page 10
Pump Performance Improvement Continuous monitoring of Impeller, bowl and Diffuser vane Gap. Proper Geometrical and Dimensional Tolerance (GD&T) control in production Continuous Monitoring the hydraulic performance by SQC methods Continuous monitoring of critical parameters during machining by process capability analysis Page 11
Pump System Performance Improvement Pumpset to be designed in a way operate in wide voltage fluctuations Pumpset to be designed in way to operate wide head range with optimum efficiency instead of single point operation with highest efficiency Usage of the adequate size drop cables to minimise the voltage drop Usage of the optimum delivery pipe size to minimise the frictional losses Page 12
Pumpset selection based on Field condition Performance Curve Page 13
Pumpset selection based on Field condition Performance Curve System Curve At Starting of pumpset Page 14
Pumpset selection based on Field condition System Curve Performance Curve After Stable Operation Page 15
selection of pump set based on the field System Curve Performance Curve After Stable Operation Maximum Efficiency Point Page 16
Pumpset selection based on Field condition Page 17
BEE Star Marking For BEE star marking ISI efficiency is considered as base and is considered as 1 STAR For 2 STAR the pumpset has to be 5% more efficient than ISI efficiency For 3 STAR the pumpset has to be 10% more efficient than ISI efficiency For 4 STAR the pumpset has to be 15% more efficient than ISI efficiency For 5 STAR the pumpset has to be 20% more efficient than ISI efficiency Page 18
Sample Saving Calculation as per BEE norms: Power saving of a 5 star rated 15 kw pumpset having 320 m head and 2.5lps discharge is calculated as follows: ISI minimum requirement efficiency for 320m head and 2.5 lps pumpset 39.8% The same pumpset to get 5 star marking it should have 20% more efficienct than minimum ISI requirement. i.e 39.8 x 1.2 times 47.8 % If the 320 m head pump and 2.5 lps pump is having only ISI efficiency the power drawn will be the same pump if it is having a 5 star efficiency of 47.8% the input power will be 19.7 kw 16.4 kw The number of hours of operation is considered as 8 hours in a day and the operation is considered for 250 days then the saving will be Power saving = (19.7 16.4) x 8(hours) x 250 (days) = 6600 kwh per pumpset per year. Page 19
Thank you Page 20