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New Video: Grundfos shows SE/SL wastewater pumps
These pumps help you reduce energy consumption in wastewater applications by allowing to reduce the kW size of the pumps thanks to their high efficiency. The innovative Open S-tube impeller offers good operational reliability and saving money on maintenance. www.grundfos.com Read the full article
Steve SchofieldSteve Schofield, CEO at the British Pump Manufacturers’ Association, considers whether there is at last a change in attitudes towards energy efficiency amongst the general public. And if so, whether this can have a meaningful impact on decreasing the energy consumption across UK industry.The subject of energy, or rather energy efficiency, has long been a topic of vague disinterest among the vast majority of households and billpayers. Energy, or rather the complex business sector that produces and delivers it, has historically struggled with engagement. Energy efficiency, in particular, has more often than not been misrepresented as simply a penny-saving exercise involving the change of lightbulbs for modern replacements, and switching lights off when rooms are unoccupied. Boiling the kettle less, another suggestion often heard.However, with the huge global rise in the cost of energy, and its near constant headline coverage by the broadcast media, not to mention the financial pain we are all now enduring, perhaps 2023 has the potential to see a real change in attitudes. A change that could positively impact all aspects of energy use.Of course, greater autonomy in our energy provision is now understood and acknowledged as a stand out way to protect ourselves from market volatility caused by unstable regimes. But the drive for improved efficiency across all the avenues of energy use, will simply mean that the energy we do produce and secure as a country will go that much further. This will not only allow us to make big savings on our domestic bills and to ensure our homes stay warm through the winter months, it will also have a massive impact on the efficiency, and ultimately, the profitability of our commercial and industrial sectors.The British Pump Manufacturers Association (BPMA) has been a longstanding advocate of not only the need for improved energy efficiency across the UK’s vast installed base of pumps and pump systems, but also the massive opportunity it presents for significant energy use reduction.The operation of pumps and their associated systems accounts for around 20% of the world’s entire electrical energy consumption, and in some high-use industrial applications, this can be as much as 25-50% of the total electrical energy usage. Across the European continent pumps are the single largest user of electricity within industry, consuming over 300 TWhpa of electricity, which in turn accounts for over 65 Mton of CO₂ emissions.Unfortunately, the vast majority of pump systems operating today were not originally designed with energy conservation as a major consideration. It is now well documented that rotodynamic pumps, which account for 80% of the installed base across Europe are between 20-30% oversized. This is usually due to an in-built ‘safety factor’ allowing for potential future uprates, or any wear in the pump or fouling of the system. But this simply means they are using far too much energy for the required duty. As such, there is huge potential to save massive amounts of energy if these pumps are properly sized, operated and maintained. In fact, if pump systems are initially designed with energy use in mind, and the pumps are optimised for efficiency, a saving up to 50% in electrical energy can be achieved.In essence, it is important to know as much about the pump system as possible and to create a pressure/flow profile for the system, as the energy required to drive the pump is directly related to the flow and pressure required.Energy AuditsIt is also important to carry out regularly energy audits to help determine where energy use reduction measures can be employed, and in turn how operating costs can be lowered. The government has estimated that most companies can reduce their energy consumption by 10-20%, and energy audits carried out in accordance with ISO 14414 have shown that savings of 30-50% are not unusual. By reviewing utility bills, you can get an indication of the savings to be made and the investment that you should be prepared to put into the auditing process.Across most industrial sites, some two-thirds of the total energy consumption is used to power electric motors, an integral part of any pump system. The overall cost associated with operating these essential pieces of equipment throughout their entire life span can be broken down as follows; 5% accounts for the initial purchase/installation costs, 10% for ongoing maintenance and a massive 85% for the energy used to run them.Clearly, any reduction in the energy consumed by electric motors is important, and with modern designs, that reduction can be as much as 30%. It is also evident that many pumps and motors are constantly operated at full power, irrespective of process needs, something which can be managed with the addition of variable speed drives, and so across Europe’s installed base there is the potential for significant energy savings; savings which can in turn drop to the bottom line and increase the profitability of any business.Certified Pumps Systems Auditor SchemeGiven the amount of energy consumed by pumps in their normal operation, and the potential for energy efficiency gains within pump systems, the BPMA has developed the Certified Pump System Auditor Scheme (CPSA).Through the CPSA, pump engineers are being trained to correctly assess the efficiency of pump systems, and to provide appropriate recommendations in order to improve the efficiency of those systems. The CPSA accreditation is achieved by successfully completing a four-day residential course, followed by the satisfactory completion of a pump system audit. Only then can ‘Certified Pump System Auditor’ status be achieved.Within the full ESOS Guidance document, the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by "Lead Assessors" approved by the Environment Agency. Accordingly, it is hoped that CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company-wide energy audits.The next CPSA Training Course is scheduled for 9th-12th May 2023. For more detailed information, please visit http://www.bpma-cpsa.co.uk.In conclusion, it is hoped that with the heightened publicity around the cost of energy, and society’s growing appreciation of its importance to our very existence, we will begin to see far greater urgency in the adoption of energy reduction measures across our commercial and industrial sectors.Ultimately it’s a question of choice, and whether businesses are prepared to finally address the ‘Capex vs Opex’ argument and begin to enjoy the long term financial gains available through improved operational efficiency. The offer being; pay for the new equipment now, and recoup the cost through the energy savings made over its operational life. But either way, supported by the documented evidence that significant savings can be made through the correct selection and efficient operation of pumps and their related systems, the BPMA will continue its efforts to drive this clear and important message.Further information on the work carried out by the BPMA can be found through the website - https://www.bpma.org.uk/ - or for any specific enquiries, please email [email protected].
Given the global rise in energy costs, there has never been a better time to review and assess the efficiency of your pumping systems – whatever their size, complexity or indeed sphere of operation. Steve SchofieldIn this article, Steve Schofield, Europump Executive Council Member, and past Chair of the international working group responsible for ISO 14414 (Pump System Energy Assessment), offers some basic information and guidance on purchasing, maintaining and designing pump systems for optimum energy efficiency, maximum CO₂ reduction and best capital expenditure payback time.Pump systems account for 20 % of the worlds electrical energy demand and between 25 % - 50 % of the electrical energy usage in certain applications. Pumps are the single largest user of electricity within industry across the European Union, consuming over 300 TWhpa of electricity, which in turn accounts for over 65 Mton of CO₂ emissions.It is also well documented that rotodynamic pumps which account for 80 % of the installed base are between 20-30 % oversized. There is therefore a major potential to save energy if rotodynamic pumps are properly sized and operated.Where to start - Assess the potential for savingsUnderstand your pumping system:To identify if a pumping system is sized correctly make the following checks; - Are you wasting liquid flow? - Are you creating additional pressure? - What is the monitoring & controls philosophy? - Are there any oversized pumps installed for your required duty? - Are there any significantly old pumps employed in the system? - Is there excessive noise in the system? - Are there any throttling valves installed in the system? - Have you the correct size of pipework installed? - Inadequate maintenance lowers pump system efficiency, so what maintenance procedures are in place? - Are you adopting a proactive equipment replacement programme to current EU legislation Performance - Efficiency GraphAvailable Technology - Choosing the right equipmentUnderstanding Drive Technology:Use latest EU regulation to achieve best possible drive efficiency; - Variable speed drive (vsd) - Integrated control and monitoring - Permanent magnet technologySystem Design - Making the right choicesThe vast majority of existing pump systems operating today were not originally designed with energy conservation as a major consideration. If pump systems are initially designed on an energy efficient basis and pumps are correctly applied and sized the energy savings will often be in excess of 50 %.To design an energy efficient pump system all the following criteria should be considered: - Basic plant layout - Pipe size, configuration and restrictions to limited pipe work losses - Information on the liquid, (viscosity, density, aggressiveness, temperature) - System characteristics and pump selection - Pump/System control - Avoid oversizing of the pump units - Selecting the most energy efficient pumps at the best efficient point - Fitting VSD’s to match the system design & demandLow energy costs are a direct result of knowing what is the minimum flow and pressure that the system requires to operate successfully (system demand) and then selecting the correct sized pump and matching it to the system.When selecting a pump, it is important to determine the required flow and pressure to be generated by the pump. The flow may be determined by a process requirement, by the heating or cooling required in the system or by the peak water demand for utilities. The pressure required may be to elevate the liquid within the system or to overcome the pressure losses in the system created as liquid passes through it.It is important to know as much about the pump system as possible and to create a pressure/flow profile for the system. The energy required to drive the pump is directly related to the flow and pressure required. To generate high pressures generally leads to designs which may be inefficient and therefore it is important that neither the flow nor the pressure is over specified.Variable Speed Drives can save energyIt is now readily accepted that significant energy savings have already been made by using Variable Speed Drive and high efficiency motors. Generally, VSD’s are used to continually adjust the speed of the pump to the demand.The savings can be determined by the affinity laws: Q= Flow, H= Head, P = Power and n = Rotational SpeedWhen building a new pumping system, most pumps are selected with a "safety factor" in play to satisfy potential future uprates or to allow for wear in the pump or fouling of the system. Often there are many different parties involved in specifying and building a system and the safety factor can grow exponentially. This results in the pump delivering much higher flows than required. There may also be the need to vary the flow due to process conditions or varying heating and cooling needs within buildings.Traditionally, throttling is used to regulate flow in a pumping system. While throttling reduces the flow, the motor is still running at full speed and works even harder as it has to work against a restriction. By reducing the speed of the motor, the variable speed drive ensures no more energy than necessary is used to achieve the required flow. A centrifugal pump running at half speed consumes only one-eighth of the energy compared to one running at full speed. Using an electrical Variable Speed Drive is the simplest and most economical way of controlling the pump and matching it to the pump system.Here are some key considerations when looking to optimise the energy use in pumping systems:Has an alternative configuration been considered?In some cases, moving from an existing pump layout to an alternative can offer energy saving possibilities.Is the Pump Performance Monitored?By looking for early signs of pump wear which can include increased noise, vibration or power consumption, major energy and maintenance savings can be achieved.Has ease of maintenance been allowed for?When designing or replacing pumps, ease of future maintenance requirements should be considered.Variable Speed Drive Considerations When fitting VSD to a pumping system, output and input filters should be considered, along with insulated motor bearings.Maintenance When maintaining pumping systems, it is recommended to use original manufacturers’ recommendations and parts. Reliability / Security Efficient, well-maintained pumps are more likely to be reliable and unlikely to fail prematurely causing loss of production or services.Valves Valves are considered to waste energy within a pumping system, however if installed they should be checked for correct operation. Pumps not in use Stand by pump units or pumps with no demand should be switched off to save energy.Is the pump working most of the time close to its best efficiency point?Rotodynamic pumps operating away from BEP not only waste energy, but also reduce the life expectancy of the pump.System Alterations When upgrading, changing, or expanding a pumping system the demand may have changed and existing pumps may not be the most efficient solution.Purchasing the correct pump set When purchasing a pump set, price should not be the deciding factor. If a pump is sized correctly the return on investment is shorter, likewise if a pump is oversized and is wasting energy going forward you will have this additional cost for the anticipated life of the pump set.Has an energy check been undertaken on existing systems?The installed base of pumps is ten times the amount that are sold each year. Energy audits in accordance with ISO 14414 can identify substantial energy savings in existing pumping systems. When specifying a new pump, ask for a high efficiency motor to be fitted. If you are replacing or rewinding a motor, then evaluate the cost of fitting a high efficiency motor remembering to factor in the running savings which will pay back any increase in cost. Invest in conducting an energy audit. Review your utility bills and understand the energy you are using. Carry out an audit if: - Your energy bills are high - You have continuously operating pumps - You have many pumps in the system - You have processes with varying flows - You have throttled pumps - You have pumps which are on bypass - You have noisy valves or pipework - You have critical systems which have been subject to breakdownsThe purpose of an energy audit is to reduce operating costs by reducing energy consumption and the government has estimated that most companies can reduce their energy consumption by 10 % to 20 %. Energy audits carried out in accordance with ISO 14414 have shown that savings from 30 to 50 % are not unusual. When deciding whether or not to carry out an energy audit a good starting point is to assume that you will save at least 10 % of your current energy consumption. By reviewing utility bills, you can get an indication of the savings to be made and the investment that you should be prepared to put into the auditing process.Across most industrial sites, some two-thirds of the total energy consumption is used to power electric motors. Furthermore, the overall cost associated with operating these essential pieces of equipment throughout their entire life span can be broken down as follows; 5 % accounts for the initial purchase/installation costs, 10 % for ongoing maintenance and a massive 85 % for the energy used to run them. Clearly, any reduction in the energy consumed by electric motors is important, and with modern designs that reduction can be as much as 30 %. It is also evident that many pumps and motors are constantly operated at full power, irrespective of process needs, and so across Europe’s installed base there is the potential for significant energy savings; savings which can in turn drop to the bottom line and increase the profitability of any business.Further information on the work carried out by Europump can be found through the website - https://europump.net/ - or for any specific enquiries, please email the Europump secretariat - [email protected]
Improving motor specification to boost the efficiency of submersible wastewater pumps
Electric motors in industrial applications, including those used in pumping systems, consume 30 to 40 percent of the world's electricity. For the past two decades, equipment manufacturers, users and regulators have been tackling excessive energy consumption. This has led to the development of higher efficiency standards for motors and the adoption of variable speed drive (VSD) technologies to better match energy use and demand. For motors designed for running in continuous duty applications (S1 operation), the International Electrotechnical Commission standard IEC-60034-30:2014 defines minimum energy efficiency specifications for four classes of motors: - IE1, Standard Efficiency; - IE2 High Efficiency, - IE3 Premium Efficiency and - IE4 Super Premium Efficiency. Each step up the IE efficiency ladder is associated with around a 20 percent reduction in motor losses, which translates directly into significant operating cost-savings. The 2014 update also includes 8-pole motors and has widened the rated power band to include 0.12 kW up to 1'000 kW motors. US NEMA efficiency standards use an almost identical approach. In Europe, the IE3 standard has been mandatory for new industrial motors rated between 0.75 kW and 375 kW since 2017. The European Commission estimates that the current efficiency regulations have reduced annual energy consumption by 57 TWh across the continent. Read the full article
Pumps for the largest smolt facility in Norway
Nordlaks is a Norwegian fully integrated company that produces, processes and sells Atlantic salmon and rainbow trout worldwide. It has recently completed the building of a new smolt facility for fish up to 500 grams at Innhavet in Hamarøy municipality. This RAS (Recirculating Aquaculture System) fish farm is the biggest of its kind in Norway, with a special focus on smolt welfare. The land-based facility has state-of-the-art equipment for optimal biosecurity and sustainability. At the heart of the RAS process, all recirculation pumps were supplied by Sulzer. The Innhavet RAS plant has 34 fish tanks of different capacities (350 to 1,000 m³) in 5 separate main sections. Each section is independent from the others and includes its own complete water treatment system in a semi-closed loop (98 % recirculation + 2 % make-up water). The brackish water from the fish tanks first flows by gravity to a rotating drum filter for the removal of the main suspended solid particles. It then falls into an MBBR (Moving Bed Biofilm Reactor) for TAN (Total Ammonium Nitrogen) reduction. After passing through a countercurrent degasser for the stripping of nitrogen and carbon dioxide, the treated water is finally pumped to some head tanks, prior to oxygenation and return to the fish tanks. In each fish tank, the water is fully renewed every half an hour. The well-being of the smolts is highly dependent on a constant flow of water through the facility. Read the full article
Europump: Maximising Energy Savings Through The Systems Approach
Various countries around the world have taken different approaches towards energy usage and possible energy reduction. Across Europe, the Commission has concentrated on components within the Energy Related Products Directive (ErP). The ErP focuses heavily on the efficiency of the products and the Commission has already implemented legislation to ensure that products with low efficiency are gradually phased-out across Europe. A significant step in the right direction for sure, although new ‘energy efficient’ components may still be required to operate within an inefficient system, impacting hugely on any possible efficiency gains. To evaluate the energy efficiency of a pumping system takes time, knowledge, and the will by both the pump system energy auditor and the pump’s operator (customer) to make a determined change. But the rewards are most definitely worth the effort. The potential energy savings throughout Europe are estimated at being between 40-50 TWh if the necessary changes to inefficient pumping systems are made. The Systems Approach First let us define what we mean by a system. A pumping system is defined as one or more pumps and those interacting or interrelating elements that together accomplish the desired task of moving a liquid. A pumping system generally includes pump(s), driver, drives, distribution piping, valves, controls, instrumentation, and end use equipment such as heat exchangers. Using the ‘systems approach’ involves comparing the need or demand to the supply. It is important to understand how the different components in a system interact and influence each other. A change to one component might improve or negatively impact other components. An example of this is replacing an old inefficient motor that is employed to drive a pump, with a modern high efficiency motor. The newer high efficiency motor will have less slip and will run faster than the old motor. When the pump is running faster, it will consume more energy and this increase in energy usage can be larger than the savings produced by the more efficient motor. To reap optimum savings from the change, the pump impeller might have to be trimmed. A system approach starts with defining the ’ultimate goal’ of the system. This includes determining the flow rates that the system must be able to deliver, whether there are flow variations and what kind of control is necessary. These requirements will influence the choice of piping size, control methods, pump size, motor size and so on.
Fig. 1 Pump system interaction curve Figure 1 uses the pump and system performance curves to determine pump operating conditions and to evaluate methods of flow control. To determine the efficiency of a system, the minimum energy to fulfill the process demand is compared to the actual energy used. Figure 2 illustrates the difference between looking at components and looking at systems. The diagram shows a remarkably simple system pumping a liquid from one tank to another. When looking on a component perspective we compare the input power to the motor from the MCC to the liquid output from the purple square around the motor and the pump. This analysis could indeed yield an excellent result. If we broaden the view a bit, we can see a re-circulating line going back to the first tank. The flow rate coming out of the purple square in is hence smaller than in green square. The power input is however the same.
Fig. 2 Efficiency of a pump measured on a component basis (purple box) based the ratio between input and output indicated by the purple box. The system view includes a re-circulation line as shown by the green box. Looking at the complete pumping system using a total system approach is illustrated by the red box Finally, we take a complete system view and include the losses in the recirculation line as well as the losses in the regulating valve on the line to the second tank. What might have looked as a reasonably good system on the components in the purple square can be viewed as an extremely low efficiency system when looked at using the systems approach illustrated by the red outline. To do this we need to define the system demand, i.e. the minimum pressure, flow rate and subsequent energy for the pumping system to work. To understand the knowledge and tools required to assess the system, industry spent many years developing the international standard ISO 14414 – Pump System Energy Assessment. Conclusion There are many exciting energy use improvement programs being developed around the world, but in Europe we have the Energy Efficiency Directive which mandates energy audits in Systems. For the electrical energy savings identified in pumping systems to be fully achieved, there needs to be a far stronger emphasis on the ‘systems approach’ and a commitment to make this happen from both the pump industry and its final end users – those that will ultimately benefit from lower energy bills. Europump would like to thank Steve Schofield, CEO, British Pump Manufacturers’ Association for his help in compiling this article. www.europump.org Read the full article
Dynamic Control moves the circulator operating point down from the currently selected control curve until…
KSB specialists developed a new function for its circulator pumps of the Calio and Calio S type series. The new function, called Dynamic Control, is an intelligent programme that helps cut pump input power by up to 20 percent compared with conventionally controlled pump sets. Modern circulators change their speed to match current demand. They adjust their flow rate and head, based on an algorithm, moving the operating point along a programmed control curve. The minimum system curve describes the friction loss when all thermostatic valves are fully opened. As the minimum system curve is usually unknown, plant designers select a control curve for conventional systems that is clearly above the minimum system curve. This uses more power than necessary and can also cause disturbing noises at the radiators’ thermostatic valves.
The latest Calio S generation comes with the new Dynamic Control function already integrated, resulting in energy savings of up to 20 percent. (© KSB SE & Co. KGaA) Dynamic Control moves the operating point down from the currently selected control curve until the minimum system curve is reached. Should the latter be undercut the algorithm re-sets the pump to its original control curve, thus ensuring sufficient supply. Safe recognition of the minimum system curve by means of a flow rate signal rules out undersupply. This ensures that the building is supplied with sufficient heat. As the implementation is purely based on software, no additional costs will be incurred by further sensors or actuators. The pump automatically gathers all required information from its internal signals. The installer no longer needs to make time-consuming settings since the pump is able to determine the system curve itself. The operator benefits from lower energy costs and less noise. Reducing energy also has a positive effect on the carbon footprint. The new function is already integrated in the current Calio and Calio S type series and can be installed as an update in pumps of the third generation of this type. www.ksb.com Read the full article
