pump

efficiency
testing
and
monitoring

Almost 70% of the world’s electricity is consumed by the industry horses, commonly known as motors. Out of
this, 70% is used to drive roto-dynamic machines, which are primarily pumps, blower, fans and compressors.
These machines operate with varying degrees of efficiency (20 and 90%).
- Juned Ansari

G
reater the inefficiency of the consumption of these machines and common is the “conventional
machine, greater is the their systems in a plant. method”. This measures the input
energy wasted. It therefore To fulfil this need, two methods energy and output from the system.
becomes important to test, evaluate have been commonly used in the The second one, a more practical
and monitor the energy industry. The first and the most approach, is the thermodynamic

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method (an assessment of the losses). This
article talks about performance
monitoring of pumps using the
thermodynamic method.
Also importantly, the same method
can also be applied effectively for
monitoring of blowers, compressors and
hydro turbines with ease.
Introduction
Centrifugal pumps are found
operating with varying degrees of
efficiency and performance shortfalls.
Over the complete life cycle of the
pump, energy consumption is the
biggest contributor (amounting to
90-95%) to the total “Life Cycle Cost” of
P
the machine, . Even if a pump is
Pump operating at 70% efficiency, 30% of the
performance energy fed to it is wasted in the form of
heat, noise and vibration. For a 100 kW
testing and machine, 30 kW is simply unavailable for
monitoring any useful work. Over the life cycle of
the pump, many times, the value of the
shows asset loss is more than the cost of the machine
condition itself.
Obviously, only a certain part of the
and also
wasted energy (as no machine can be
helps in 100% efficient), can be saved by testing
averting , monitoring and corrective actions on
the pumps at regular intervals. Pump
catastrophic performance testing and monitoring
failures. shows asset condition and also helps in
averting catastrophic failures. A number
of pumps when monitored
simultaneously (Multi Pump Monitoring),
will give an insight to the way a station
is being operated and reveals any
operating deficiencies. This is critical,
especially in the process industry, where
along with reducing energy consumption
and implementing energy efficiency, the
Operations teams are equally concerned
about minimising downtime and the
direct impact on the total plant specific
energy consumption.
Thermodynamic Method
Unlike the conventional method
which involves flow measurement for
efficiency evaluation, thermodynamic
method measures the inefficiency of the
Pump Efficiency Testing and monitoring.indd 87
Pump Performance
machine and thus uncertainty of
measurement is very low. This makes the
method ideal and suitable even for
smaller machines. The method is based
on the first law of thermodynamics and
requires differential pressure and
temperature measurement across the
machine to evaluate the efficiency.
When this is combined with power
measurement, flow can be calculated
accurately. The basic equations are
shown below:
1 Pi xh m xh p
hp = Q=
txgxH
d1 + p n
C xDT
gxH
Where,
Cp= Specific heat of the fluid (KJ/Kg-K)
ΔT= Differential temperature across the
pump in mK (milli Kelvin)
H= Pump head in meters (m)
Pi= Input power to the motor in kW
ηp= Pump efficiency (%)
Q= Pump flow rate in m3/s
This method has been used extensively
on more than 12,000 pumps across the
world and the results were overwhelming.
Following studies will establish this fact.
Study 1
We have been engaged in permanent
monitoring of all of the pumps within a
number of pumping stations for a UK
water company. The initial monitoring
revealed that the combined average
operating efficiency of the station was low
(67%) and a better “operating” schedule as
presented. The new operating regime, if
followed, would improve the operating
efficiency to 82%. Such operating schedule
alterations do not need any capital
expenditure and are immediately accepted
by the management. The charts below
depict the case and are self explanatory.
The system has been operational for the
last 5 years, with an annual operating cost
reduction of 26%.
Study 2
This study on a pump, carried out in an
Indian chemical industry It has shown how
errors at the design stage can lead to trouble
Electrical IndiaMay 201087
4/29/2010 5:03:34 PM
 Pump Performance

Fig. 1: Pre and Post Implementation Charts

when plant begins operation. A Pre-Replacement Post-Replacement Relative % age

wrongly sized pump, with lower than Performance Performance Change
required flow through the system was
Flow Rate (I/s): 74.6 151.2 102.7
selected and this affected production.
A thorough investigation and pump Pump Head (m): 27.8 34.0 22.3
testing revealed that there was mis-
match between pump and the system. Power to Motor (kW); 60.6 98.6 62.7
To achieve the desired performance, a
Pump Efficiency (%): 43.9 67.4 53.9
recommendation for installing a
bigger impeller in the existing pump Pumping Cost (kWh/MI) 225.4 181.2 -19.6
was made. By implementing the
recommendation, the plant reduced Saving for same flow (Rs.) - 458,571 -
the specific power consumption of the
pump. The pump has Efficiency improvement is directly
been running efficiently related with energy and carbon
for last 9 months footprint reduction. Testing is
without any problems. recommended for pumps, blowers
and compressors for efficient running.
Conclusion We do not want to be blamed by
A thorough pump the future generations for not
and system testing and allowing them the use of these
analysis can reveal the scarce resources? Let us conserve
operating deficiencies energy, water and environment. 
and asset condition.
Thermodynamic
method for pump Juned Ansari is a gold medalist
testing delivers mechanical engineer and a
qualified energy auditor
accuracy better than
working as Energy Efficiency
±1% which is also Analyst in Secure Meters
verified by the Fluid Juned Ansari
Limited.The company's
Control Research website can be accessed at
Fig. 2 www.securetogether.com.
Institute (FCRI), India.

88May 2010Electrical India

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