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5 Abstract
6 This paper provides an insight into the selection of the most suitable configuration for closed
7 distribution systems (i.e., systems with no storage capacity). The analysis is developed using the
8 WaterGEMS software and considering a wide ranges of operational scenarios in terms of flows
9 and required heads. For each scenario, various design configurations are considered and
10 compared. Results show that using more than a minimum of pumps can have lower operational
11 and total costs, thanks to the pumps operating closer to their best efficiency point. Small
12 additional benefits in terms of operational and total costs may be obtained as a result of the
13 introduction of the variable speed drive in at least one of the station pumps. Similar costs are
14 obtained in the configuration where large pumps are flanked by a small “jockey” pump operating
15 at low demand times. The design solution made up of large pumps fitted with a downstream
16 hydropneumatic tank also represents a valid alternative option from the economical viewpoint
18
19 Keywords: closed distribution systems, fixed speed pumps, variable speed pumps, economic
20 analysis.
21
1
Bentley Fellow, Bentley Systems, Incorporated, 3 Brian’s Place, Nanticoke, PA 18634, USA.
E-mail: Tom.Walski@bentley.com
2
College of Engineering, Mathematics and Physical Sciences, University of Exeter, North Park
Road, Exeter EX4 4QF – UK. Email: E.F.Creaco@exeter.ac.uk
22 Introduction
23 The usual standard for pumping station design is that “With any pump out of service, the
24 remaining pump or pumps shall be capable of providing the maximum daily pumping capacity of
25 the system.” (GLUMRB, 1992). This standard has worked well and provides for acceptable
26 system reliability. There are essentially two types of water distribution systems: systems with
27 storage which allows pumps to be turned off and closed (dead end) systems which must run at
29 Systems with storage have a great deal of benefits in that they provide reliability in case of
30 power outages, can better dampen transients, can meet peak demand requirements such as during
31 fires and other emergencies and enable pumps to be run at efficient operating points to minimize
32 energy use. However, a system with storage is not always used because of cost, lack of
34 Systems without storage are often referred to as closed or dead-end systems. Pumps in closed
35 systems have some serious drawbacks in that they must meet the current demand which can vary
36 widely, making it difficult to keep the pumps running at an efficient operating point. When
37 constant speed pumps are used, there is a risk of over-pressurizing the system. The outflow can
38 be throttled to reduce pressure or water can be recirculated to the suction side of the pump. All of
39 these approaches tend to waste energy. Variable speed pumping, using variable frequency drives
40 (inverters), eddy current drives or some other technology, can reduce the waste in energy but it is
41 still not possible to ensure that the pumps will run at an efficient operating point. Variable speed
42 pumps can be expensive, with the drives costing almost as much as the pumps themselves.
43 From the standpoint of initial costs, the least expensive solution for a station is almost always
44 two pumps, each of which can deliver the peak design flow. Constant speed pumping is usually
46 While the two pump solution may be the least costly in terms of initial cost, when running pumps
47 continuously, energy costs are always much greater than initial cost in terms of present worth
48 life-cycle costs. Therefore, spending a little extra initially to save energy is usually justifiable, in
50 The loss of efficiency in pumping is related strongly to the extent to which the normal flows
51 differ from the peak flow. If the pump always ran at peak flow, then a single constant speed
52 pump would work well. However, normal flows vary widely and are usually a fraction of the
53 peak flow. That is the nature of “peak” flow. During a normal day, flows can vary from 25 to 75
54 percent of peak flow with peak flow only reached on rare peak times on peak days. In the early
55 buildout of the pressure zone being fed by the pump station, the demand may only be a tiny
56 fraction of the peak flow. Even with variable speed pumping, it is impossible to run pumps
57 efficiently when the speed is turned down significantly. While variable speed drives can have
58 efficiencies nearing 100% at full speed, the drives themselves also contribute to the loss of
60 Use of smaller pumps can enable the pumps to run at speeds closer to their best efficiency. Of
61 course, this means that two pumps in a station cannot meet the standard that design flow must be
62 met with the largest unit out of service. Therefore, if smaller pumps are used, at least three
63 pumps must be used at any station where the total flow of two pumps sized can meet the design
64 flow. Use of three pumps increases initial costs but as will be shown later, the savings in energy
67 utilities (AWWA, 2015; Leiby and Burke, 2011; US EPA, 2009; Walski, 2011; WEF, 2009), the
68 question of pump selection in closed systems has not been extensively studied. Nevertheless,
70 Walski (2001) presented an analysis showing that when the average flow is significantly less
71 than the peak design flow, three smaller pumps will have a lower life-cycle cost than two larger
72 pumps, even when equipped with variable speed drives. When the flows were very low, a
73 constant speed pump with a hydropneumatic tank would have the lowest life-cycle cost. The
74 analysis was limited to smaller pump stations with a design flow less than 30 L/s (500 gpm) and
75 a head difference between the suction and discharge side of the pump of 37 m (120 ft). The
77 Walski, Wu and Bowdler (2006) showed that for an example small pressure zone, two large
78 pumps with variable speed drives were more energy efficient only when the average flow was
79 close to the peak flow. Otherwise, three pumps were more efficient.
80 The present paper seeks to perform a more general analysis of several different alternative design
81 configurations for a closed system pump station. Life-cycle costs are compared over a wide
83
84 Methodology
85 In this study, nine alternative hydraulic configurations of pumping stations into a closed water
86 distribution system were evaluated in terms of life-cycle costs. Given a design flow of Q, the
91 4. two constant speed pumps each with flow Q and one constant speed with flow Q/4,
93 6. two constant speed pumps each with flow Q/2 and one variable speed pump with flow Q/2,
94 7. two constant speed pumps each with flow Q plus hydropneumatic tank to enable pumps to
95 cycle,
98 In particular, configurations 1-7 enabled comparison of the total costs associated with pumping
99 stations made up of 2 and 3 pumps, which are the configurations most frequently selected by
100 engineers. Configurations 8 and 9, instead, provided insight into the effects of more than 3
101 pumps.
102 The cost analysis included energy costs and pumping mechanical and electrical equipment costs.
103 It was assumed that building structural costs and operation and maintenance labor and
104 mechanical repairs would be roughly independent of the configuration. Hereinafter the equations
105 that enable evaluation of the costs of the various elements installed are reported. These equations
106 were derived by applying multiple linear regression technique to data reported on manufacturers’
107 catalogues. In particular, the cost of pumping mechanical and electrical equipment can be given
108 by:
110 where Qp = flow from individual pump, L/s and H = pump head, m. The previous equation is
111 compliant with the findings of Walski (2012) in terms of exponent values for Qp and H.
112 The additional cost for variable speed pumping is based on a variable frequency drive (inverter)
113 although other technology could be used (e.g. eddy current drives). The cost for a variable
114 frequency drive for a variable speed pump can be given by:
118 where V = volume of tank, m3. Cost obtained through the previous equation has to be increased
120 Hydropneumatic tanks are usually not built greater than 20 m3 because any larger size could not
121 be transported easily to the site for installation. Instead, multiple tanks would be used which is
123 The costs assume that costs such as land, building structure, SCADA equipment, maintenance
124 labor and other similar costs do not vary significantly between configurations. Therefore, the
125 costs that vary significantly between configurations would include pump mechanical and
126 electrical equipment, tanks (if needed) and most importantly energy.
127 Cost varies widely between locations and the details of design in terms of type of pump, details
128 of pump curves, available voltages, extent to which equipment can be located outdoors,
129 variations in energy tariff, seasonal and long term variation of demand, type of structure,
130 requirement for backup generators and other factors. However, those contingencies should affect
131 each configuration to roughly the same extent so that the analyses in the paper should be
132 relatively general. Nevertheless, design engineers should verify local costs when making
136 1 – design of each of the 9 configurations indicated above and assessment of installation costs;
138 3 – calculation of daily energy costs with the WaterGEMS program (Bentley Systems, 2014);
139 4 – calculation of operational costs during a reference period of time; conversion into present
141 In the applications, it was taken into account that the variable speed drives are not perfectly
142 efficient and tend to lose efficiency as the speed decreases. The values reported in Table 1 were
143 used to account for this although the loss of efficiency tends to be greater for smaller drives. For
144 variable speed pumping, the pumps were controlled to maintain a head at the discharge point of
146 The applications were carried out in three phases, considering ranges of flow and pressure values
148 In the first phase, costs were calculated over a wide range of average flows including 1.25, 2.5,
149 12.5, 25, 50, 100, 200 L/s (0.33, 0.67, 3.3, 6.7, 13.3, 26.6, 53.2 cfs). Two head values, equal to
150 25 m and 40 m (82 and 131 ft) respectively, were considered. The diurnal demand pattern used
151 for the first phase is pattern 1 shown in Figure 1. Since the peak demand multiplier in pattern 1 is
152 equal to 2, the previous average flows lead to the following values of maximum daily flow: 2.5,
153 5, 25, 50, 100, 200, 400 L/s (0.67, 1.34, 6.7, 13.4, 26.6, 53.2, 106.4 cfs). In all cases, design flow
154 was obtained by multiplying the maximum daily flow by 2. Cost comparisons were based on the
155 initial cost of mechanical and electrical equipment plus the present worth of energy cost for a 10
156 year period. Results are presented with a discount rate (interest rate) of 3%. An energy cost of
158 A second phase followed in order to analyze the extent to which the choice of diurnal demand
159 pattern affects results. In this part, costs were calculated in only one scenario, which considered
160 an average flow equal to 7.5 L/s (2 cfs) and pattern 2 in Figure 1 (with peak demand multiplier
161 equal to 3.33). This resulted in a maximum daily flow and in a demand flow equal to 25 L/s and
162 50 L/s respectively. In this case, a single head value equal to 40 m (131 ft) was considered. Costs
163 were calculated as in the first part of the work, i.e. by considering mechanical and electrical
164 equipment plus the present worth of energy cost for a 10 year period, as well as discount rate
166 A third phase was dedicated to assessing the influence of the discount rate (interest rate) R. For
167 two design configurations of the first part of the work, i.e. configurations 3 and 5 designed in the
168 scenario with Q=100 L/s – H= 40 m, costs were re-calculated considering various values of R
170
171 Results
172 Model runs were made for a wide range of flows and head as described above. The results in
173 terms of total present worth cost for the first phase of the applications are summarized in Figures
174 2 and 3, for heads equal to 25 and 40 m respectively. In general the present worth of energy costs
175 was on a similar order of magnitude to initial costs for the smaller flow rates. However, as the
176 flows increased, the energy cost could become as much as an order of magnitude larger than
177 initial cost. This is because energy costs are roughly proportional to flow and head while there is
178 a great deal of economy of scale associated with initial cost. (Doubling the pump flow rate does
180 In general, the solutions involving three pumps were superior to those involving two pumps
181 because with the smaller pumps, it was possible to operate the pumps much closer to the pump’s
182 best efficiency point, especially during low flow periods. The savings in energy more than paid
183 for the extra pumping equipment. Use of variable speed pumping, made a very big difference in
184 costs for the two pump configurations but a much smaller difference for the three pump
185 configurations. Very low present worth costs, close to solutions with three pumps fitted with
186 variable speed drive, were obtained in the case of the configurations with two large pumps
187 flanked by a small “jockey” pump. In these configurations, the operation of the small “jockey”
188 pump at low demand times enabled the large pumps to be kept off when they would have been
189 far away from their Best Efficiency Point (BEP). This resulted in a large decrease in the
190 operational costs. Use of a hydropneumatic tank made it possible to greatly reduce the cost for
191 the two pump configuration for small flow rates, resulting in comparable results to the
192 configuration with 3 small pumps fitted with variable speed drive. However, this configuration
193 with hydropneumatic tank was only considered up to the design with Q=50 L/s, which entailed
194 installing a tank volume as large as 20 m3 (maximum feasible volume as was explained above).
195 The good performance of this configuration is a result of the ability to turn pumps off when a
196 tank is involved which is not an option for the other configurations. This is supported by the
197 observation that hydropneumatic tanks are almost never used for storage in large systems while
198 they are almost always used for individual home wells.
199 Apart from adoption of variable speed pumping and installation of the small “jockey” pump or of
200 the hydropneumatic tank, another possibility to reduce the total costs is by adopting
201 configurations with more than 3 pumps, such as configurations 8 and 9 made up of 4 and 5
202 identical pumps respectively. These configurations were very beneficial for two reasons:
203 1 – in the initial phase, water utilities do not have to spend much money to pay for the spare
205 2 –using a large number of pumps ensures that each pump always works close to its BEP.
207 respectively) shows that there is benefit in increasing the number of installed pumps up to 5.
208 However, the benefit is smaller and smaller as the number of installed pumps increases: in other
209 words, it is large when passing from 2 to 3 pumps, smaller when passing from 3 to 4 or from 4 to
210 5. Furthermore, some aspects associated with the installation of numerous pumps, such as the
211 increased probability of mechanic failure in the pumping station, additional mechanical
212 maintenance or the increased size of the station itself, may discourage practitioners to select
214 Results relative to the second phase of the applications are reported in Figure 4. The total costs of
215 the 7 configurations designed considering Q=50 L/s, H=40 m and pattern 2 are compared with
216 those designed considering Q=50 L/s, H=40 m and pattern 1 on the one hand and Q=50 L/s,
217 H=25 m and pattern 1 on the other hand. The figure shows that, ceteris paribus, a decrease in the
218 average flow, like that corresponding to adoption of pattern 2 instead of pattern 1, leads to lower
219 total costs. Since the installation costs for each configuration are the same (design flow does not
220 change), this difference is ascribed to a reduction in operational costs. This reduction is larger for
221 configurations 4, 7, 8 and 9. The reason for the reduction in configuration 4 is that, when the
222 average flow is reduced, the small “jockey” pump in the station works alone for a longer period
223 of time in the day. The reduction in configuration 7 is ascribed to the fact that, when the average
224 flow is reduced, the pumps can be kept off for a longer time in the day, taking advantage of the
225 storage in the tank. Finally, the reason for the reduction in configurations 8 and 9 is that, when
226 the average flow is reduced, a lower number of pumps, all operating close to their BEP, is active
227 on average in the system. The reduction in total cost derived from the change in pattern never
228 equals that caused by the reduction in head from 40 m to 25 m (which also entails changing
230 The effect of discount rate on the relative importance of initial vs. operating cost is well known.
231 Higher values tend to reduce the importance of future operating costs. This is illustrated in
232 Figure 5 relative to the third part of the applications. With a low discount rate, the solution with
233 the lower energy cost (configuration 5 - three variable speed pumps) is significantly better than
234 the constant speed solution (configuration 3 - three constant speed pumps). However, as the
235 discount rate increases, the present worth of the advantage of the variable speed pumps is
237
238 Discussion
239 The key to pump selection to minimize energy use in a closed distribution zone is to select
240 pumps which will operate most of the time at or near their best efficiency point (BEP). However,
241 in a closed system with no floating storage, the pump must discharge the exact demand in the
242 system and must therefore move to operating points away from the BEP. Pump selection should
243 be driven based more on actual average flows than peak flows since life-cycle costs are driven by
246 the system head curve and the pump head characteristic curve but the system head curve is more
247 nearly vertical in this type of system (Walski, Hartell and Wu, 2010).
248 The relationship of efficiency to flow for a constant speed pump is shown in Figure 6. The
249 chance of the demand occurring at the BEP of 100 L/s is small. The efficiency at, for example, a
250 flow of 50 L/s would be 53%. In addition, when the demand is less than 100 L/s, the head
251 produced and its energy is high while when it is greater than 100 L/s, it is not producing
252 adequate head. Having several smaller constant speed pumps reduces but does not eliminate this
253 problem.
254 For a variable speed pump, the pump curves shift to meet the target head which in this case is 40
255 m (see Figure 7). Let us consider the case where the demand is 50 L/s at 40 m. The head and
256 discharge change with pump speed to a relative pump speed of 0.9 (full speed = 1.0). The
257 efficiency is essentially the same as a constant speed pump, although the discharge head and
259 The results of this analysis show that having more pumps in a station enables the pumps to run
260 closer to their peak efficiency points, even though the initial costs may be greater. They also
261 show that the present worth of energy cost is very likely to be much higher than the initial cost
263 The configuration with the hydropneumatic tank may be the best solution for smaller systems. It
264 is especially attractive in that the tank can provide some storage during a power outage and allow
265 time for a backup generator to start. Systems without storage will almost always have some time
266 and customers where the pressure drops to zero (Walski, Sharkey and Pflanz, 2011). The tanks
267 also have value in dampening transients when flows change. Hydropneumatic tanks are also
268 preferred in systems where there are extended periods of low demand such as camp grounds, golf
269 courses, ski resorts stadiums and other places where there are seasonal periods with little or no
271 When two different size pumps are used, it is important to set the flow at which the pumps
272 switch to maximize efficiency. Figure 8 shows an example where the switching point between a
273 25 and 100 L/s pump is at 40 L/s. At flows below that, the smaller pump is more efficient. Above
274 that flow, the larger is more efficient. The smaller pump may need a slightly oversized motor if it
276 With a large number of pumps, the operator can select the exact number of pumps to operate near the
277 peak efficiency at all times. For example, In Figure 9, three pumps would be the most efficient number to
278 run at demands between 65 and 85 L/s. The downside of this operation would be frequent pump starts,
279 which can affect motor life, if demands change frequently. There would need to be delay before switching
281 With the hydropneumatic tanks and the constant speed pump, it is not possible to exactly achieve
282 the design discharge pressure as the tank fills and drains or the pumps move along their curves.
283 With variable speed pumping, the desired discharge pressure can be consistently met.
284 Systems with fire demand much larger than normal demands can require a dedicated fire pump
285 but this pump will almost never be used and its life cycle energy cost will be negligible.
286 With constant speed pumps, it is possible to develop very high pressures during periods of low
287 demand which could lead to increased leakage. If modeling shows this to be an issue, a pressure
288 reducing valve or recycling some flow back to the suction side of the pump may be used to
289 reduce pressure. However, the alternative of recirculating flow would represent a waste of
291
292 Conclusion
293 There are numerous configurations of pumps that can meet design requirements in a closed
294 distribution system. The least costly from an initial cost standpoint is usually not the least cost in
295 terms of life-cycle costs. When the energy costs are included, the life-cycle costs can usually
296 favor a larger number of smaller pumps. In closed systems, variable speed pumping can
297 marginally reduce life-cycle costs but for small flows, configurations made up of large pumps
298 fitted with a downstream hydropneumatic tank or flanked by a small “jockey” pump may be
300 Using a large number of pumps is also beneficial from the standpoint of total costs. However,
301 some issues, such as the increased probability of pumping failure, frequent pump starts and the
302 increased size of the station, may discourage engineers from opting for configurations with
304 Costs and design details vary based on the location and the preferences of the engineers and
305 operators. Values presented in this paper need to be viewed as providing insight into the problem
307
308 Acknowledgement
309 The authors would like to thank the reviewers for their helpful comments on the initial submittal
312 American Water Works Association, 2015, “Energy Management for Water Utilities,” AWWA,
315 Great Lakes and Upper Mississippi River Board of State Public Health and Environmental
316 Managers (GLUMRB), 1992, “Recommended Standards for Water Works,” Albany, NY.
317 Leiby, V. and Burke, M. (2011) “Energy Efficiency Best Practices for North American Drinking
319 US EPA (2009) “Ensuring a Sustainable Future: An Energy Management Guidebook for
320 Wastewater and Water Utilities,” US Environmental Protection Agency Office of Wastewater
322 Walski, T.M., 2001, “Don’t Forget Energy Cost when Selecting Pumps,” AWWA Annual
324 Walski, T.M., 2011, “Practical Tips for Reducing Energy Use,” Computing and Controls in the
326 Walski, T.M., 2012, “Planning-Level Capital Cost Estimates for Pumping,” J. Water Resour.
328 Walski, T.M., Hartell, W. and Wu, Z. Y., 2010, “Developing System Head Curves for Closed
330 Walski, T.M., Sharkey, M. and Pflanz, M., 2011, “What Happens when your Pump Loses
332 Walski, T.M., Wu, Z.Y., and Bowdler, D., 2006, “Finding Thieves in Your Water System,”
336
337 Tables
342 Figure 2. Present worth cost comparison for H=25 m (a). Zoom in peak design flows smaller
344 Figure 3. Present worth cost comparison for H=40 m (a). Zoom in peak design flows smaller
346 Figure 4. Present worth cost in the various configurations in three different demand scenarios
348 Figure 5. Effect of interest rate on present worth cost for the design with Q=100 L/s and H=40
349 m.
350 Figure 6. Pump head H and efficiency e for Constant Speed Pump.
351 Figure 7. Pump head H and efficiency e for Variable Speed Pump.
354
355
4.0
pattern 1
demamd multiplier
pattern 2
3.0
2.0
1.0
0.0
0 4 8 12 16 20 24
Time (hs)
356
357 Figure 1
2 000
Present worth 2 pumps
cost (k$)
2 pumps (2 VSP)
3 pumps
1 000 3 pumps (3VSP)
3 pumps (1VSP)
3 pumps (1 small)
2 pumps + hyd. tank
0 4 pumps
0 100 200 300 400 500 600 700 800 5 pumps
Peak design flow (L/s)
358
359 (a)
200
Present worth 2 pumps
cost (k$)
2 pumps (2 VSP)
3 pumps
100 3 pumps (3VSP)
3 pumps (1VSP)
3 pumps (1 small)
2 pumps + hyd. tank
0 4 pumps
0 10 20 30 40 50 5 pumps
Peak design flow (L/s)
360
361 (b)
362 Figure 2
3 000
Present worth 2 pumps
cost (k$)
2 pumps (2 VSP)
3 pumps
2 000
3 pumps (3 VSP)
3 pumps (1 VSP)
3 pumps (1 small)
1 000
2 pumps + hyd. tank
4 pumps
0
5 pumps
0 100 200 300 400 500 600 700 800
Peak design flow (L/s)
363
364 (a)
200
Present worth 2 pumps
cost (k$)
2 pumps (2 VSP)
3 pumps
3 pumps (3 VSP)
100 3 pumps (1 VSP)
3 pumps (1 small)
2 pumps + hyd. tank
4 pumps
5 pumps
0
0 10 20 30 40 50
Peak design flow (L/s)
365
366 (b)
367 Figure 3
200
Present worth H=40 m - pattern 1
cost (k$) H=25 m - pattern 1
H=40 m - pattern 2
100
3 pumps (1 small)
2 pumps+hydro
3 pumps
2 pumps
4 pumps
5 pumps
3 pumps (1VSP)
3 pumps (3VSP)
2 pumps (2VSP)
368 configurations
369 Figure 4
250
Present worth 3 pumps
cost (k$) 3 pumps (3 VSP)
200
150
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
Interest rate
370
371 Figure 5
80
373 Figure 6
80
375 Figure 7
Pump Head H; Efficiency e, 70 H (m) Large Pump
e (-) Large Pump
60
H (m) Small Pump
50 e (-) Small Pump
40
%
30
20
10
0
0 50 100 150 200
376 Flow (L/s)
377 Figure 8
378
80
1 Pump
70
2 Pump
3 Pump
60 4 Pump
5 Pump
50
Efficiency, %
40
30
20
10
0
0 50 100 150 200 250
Flow, L/s
379