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© TEA. www.tea.ie 1
Performance Curves
© TEA. www.tea.ie 2
Performance Curve
Characteristics
© TEA. www.tea.ie 3
Performance Curve
Characteristics
© TEA. www.tea.ie 4
Operating Point
• The operating point of a centrifugal pump, also
called its duty point, is given by the intersection
of the pump characteristic curve with the
system curve.
• The flow rate Q and the developed head H are
both determined by the intersection.
• To change the operating point either the system
curve or the pump curve must be changed.
© TEA. www.tea.ie 5
Pump Operating Point
© TEA. www.tea.ie 6
© TEA. www.tea.ie 7
© TEA. www.tea.ie 8
Pump Range
© TEA. www.tea.ie 9
Parallel Pumping
© TEA. www.tea.ie 10
© TEA. www.tea.ie 11
Multi-Stage Pump Range
© TEA. www.tea.ie 12
Examples 2
© TEA. www.tea.ie 13
€252,585.63145093.0%185.369%680 @ 69 mExisting
Pumps
€223,300.81€67,033.10153596.4%250199.887.3%800m3/hr @
80m.E4
€0.00€55,759.15145096.0%200720m3/hr @
80m.D3
€222,099.22€55,301.74140596.7%250199.387.5%800m3/hr @
80m.C2
€225,125.73€62,425.00145095.4%250199.387.5%800m3/hr @
80m.B
€226,419.56€52,777.50145095.4%250200.487.0%800m3/hr @
80m.A
1
COST PER ANNUM
PRICESPEED
MOTOR EFF.
MOTOR KW
POWER ABSORBED
kW
PUMP EFF.
OUTPUTPUMP COMPANY
Coolcorcoran Pumphouse
Coolcorcoran Pumphouse
© TEA. www.tea.ie 14
Central Regional Water Supply
Coolcorcoran Station
© TEA. www.tea.ie 15
Electricity Cost /
Consumption Chart
© TEA. www.tea.ie 16
€325,507.
74145093.0%185.369%441050
Existing
Pumps
€298,179.
58€93,279.98135095.5%2503.9199.287.0%531,200D3
€296,626.
56€104,145.00132996.0%2504.6199.287.0%531,200C2
€296,342.
71
82855+1362
0145095.0%2505.8180.588.0%531,100B
€303,234.
40
102150
+13620145095.0%2504.2m181.486.0%531,080A
1
COST PER ANNUM
PRICESPEED
MOTOR EFF.
MOTOR KW
Pump N.P.S.H.
POWER ABSORBED
kW
PUMP EFF.
HEAD M.
OUTPUT M3/HR
PUMP
Lough Guitane Pumphouse
Lough Guitane
Pumphouse
© TEA. www.tea.ie 17
© TEA. www.tea.ie 18
Kilsarcon Pump Station
© TEA. www.tea.ie 19
© TEA. www.tea.ie 20
€29,516.52€66,587.053.66m29007556.278.6%150m3/hr @ 108m.H
€29,182.37€75,542.201.92m14507555.579.5%150m3/hr @ 108m.G
4
€30,129.85€63,348.892.1m14507557.377.0%150m3/hr @ 108m.F3
€29,516.52€54,820.503.66m29007556.278.6%150m3/hr @ 108m.E
€29,182.37€69,689.001.92m14507555.579.5%150m3/hr @ 108m.D
2
€29,516.52€61,026.703.66m29007556.278.6%150m3/hr @ 108m.C
€29,182.37€72,430.031.92m14507555.579.5%150m3/hr @ 108m.B
€30,129.85€54,888.602.1m14507557.377.0%150m3/hr @ 108m.A
1
COST PER ANNUM
PRICEPUMP NPSH SPEED
MOTOR KW.
POWER ABSORBED
kW
PUMP EFFICIENCY
OUTPUTPUMP
Crohane Pumphouse
Crohane Pumphouse
© TEA. www.tea.ie 21
Mid Kerry W.S.Crohane
© TEA. www.tea.ie 22
Mid Kerry W.S.Crohane
© TEA. www.tea.ie 23
Ballybeggan Water Supply
Existing Pumping Plant
Flow rate 140 m3/hr
Head 107 m.
Motor eff. 91%
Pump eff. 56%
Overall 51%
System hydraulic power 41 kW
Power consumed from ESB 83 kW
New Pumping Plant
164 m3/hr
113 M.
93%
78%
72%
51 Kw
74 Kw
ANNUAL ENERGY COST €25,023 €14,330
New Pumping Plant Cost
Payback Period
€27,554
2.5 years
© TEA. www.tea.ie 24
Ballybeggan
© TEA. www.tea.ie 25
Monitoring and Targeting
© TEA. www.tea.ie 26
Variable Speed
© TEA. www.tea.ie 27
Motor Principles
• The speed of an induction motor is normally fixed because the electricity supply frequency is fixed, as is the number of poles in the motor.
• The speed ( ignoring slip ) is calculated from the formula :
Speed(rpm) = 120 X frequency (HZ) / no of motor poles
• i.e.: - a 2 pole motor on 50 Hz supply has a speed of 120 x 50 = 3000 rpm
• Equally a 2 pole motor on a 60 Hz supply has a speed of 3600 r/min
• Therefore, by varying the frequency the speed can also be varied.
© TEA. www.tea.ie 28
Fan Affinity Laws(Applies to all centrifugal loads)
� Flow proportional to the speed
� Pressure proportional to the speed squared
� Power proportional to the speed cubed
Speed (%)
Input Power (%)100
0
80
60
40
20
010 20 30 40 50 60 70 80 90 100
© TEA. www.tea.ie 29
Pumping Water
Variable Speed Flow Control
• The performance of a pump is directly related to its
speed in rpm, providing there is no cavitation. The law
of similarity may be used.
• For example, doubling the Pump Speed
• Flow x 2
• Head x 4
• Power consumed x 8
© TEA. www.tea.ie 30
Speed Change Formulas
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© TEA. www.tea.ie 35
VSDMethods of control
There are two methods of control:
• Open Loop. The speed is simply controlled by a
potentiometer. The speed is set either by a person, or
perhaps by simple controls allowing perhaps 2-4
speeds, depending on the situation.
• Closed Loop. This is much more powerful, with the
user setting the flow, temperature, pressure, or
whatever else it is that they want to control. Using a
sensor, the VSD adjusts the speed automatically to
maintain this parameter. This will always give
optimum results, as long as it is set up properly!
© TEA. www.tea.ie 36
Variable speed drive
control
• VSD allows you to vary the speed of a motor to match precisely the demands of a system.
• Control a booster pump to operate in a variable flow situation and still maintain a minimum pressure in a distribution main.
• Allows you to use full size impellers in pumps to get maximum efficiency.
• Unequal sized pumps can operate in parallel.
• Soft starting and stopping to minimize surges in water mains.
• Precise control of oxygen level in a waste water treatment plant.
© TEA. www.tea.ie 37
Joint benefits of system
improvements
• Fitting a VSD not only saves energy, but also:– Reduced speed means less frictional wear, longer bearing and seal life.
– It reduces water hammer and resulting damage.
– Improved pressure control reduces leakage
© TEA. www.tea.ie 38
© TEA. www.tea.ie 39
© TEA. www.tea.ie 40
Motor Efficiency
© TEA. www.tea.ie 41
Motor Efficiency
Reservoir
Source
Motor (4)
Real
work
Done
Pipe
losses
Pump
losses
Motor
losses
© TEA. www.tea.ie 42
The European Efficiency
Labeling Scheme (2002-2010)
2 pole
4 pole
% Efficiency
kW
1.1 90
© TEA. www.tea.ie 43
IEC 1-4
© TEA. www.tea.ie 44
Motors and Legislation
Commission Regulation (EC) No 640/2009 (Directive 2005/32/EC)
In detail:
– IE2 by June 16, 2011
– IE3 by January 1, 2015 (for motors >=7.5 to 375 kW) and IE2 only in combination with an adjustable speed drive
– IE3 for all motors by January 1, 2017, (for motors from 0.75 to 375 kW) and IE2 only in combination with an adjustable speed drive.
© TEA. www.tea.ie 45
© TEA. www.tea.ie 46
Repair Replace - HEM
Cost €1,233 €1,595
2 yr running cost €38,663 €37,622
Total cost €39,895 €39,217
The Real Cost of
Rewinding a Motor
HEMsaving - €679Original - 90.5%
Repair - 90.0%
HEM - 92.5%
© TEA. www.tea.ie 47
Pipe Design
© TEA. www.tea.ie 48
Suction/Inlet
Pipework Layout
© TEA. www.tea.ie 49
Flow Velocities
• Suction pipes – 1 to 2 m/s
• Inlet pipes – 1.5 to 2.5 m/s
• Discharge pipes – 2 to 3 m/s
• The same velocities apply to
gate non-return and foot valves.
© TEA. www.tea.ie 50
Pump Connections
• The right pipe size is a compromise between pipe cost and
excessive friction loss. Do the calculations and insure that the
pipe losses and velocities are at acceptable levels. Do not depend
on the size of the pump flanges, in most cases larger pipes and
valves are required. Use long radius bends and radial tees.
• A small pipe will initially cost less but the friction loss will be higher
and the pump energy cost will be greater. If you know the cost of
energy and the purchase and installation cost of the pipe you can
select the pipe diameter based on a comparison of the pipe cost
vs power consumption.
© TEA. www.tea.ie 51
Control Systems
© TEA. www.tea.ie 52
Flow Control by Throttling
• Changing the flow rate Q by operating a throttle valve
is the simplest flow control method not only for a
single adjustment of the flow rate but also for its
continuous control, since it requires the least
investment.
• But it is also the most energy wasting method, since
this method simply increases the head to reduce the
flow and thereby increases the energy consumed.
© TEA. www.tea.ie 53
Reservoir Level Control
• Stop / Start
• PID
• Step Control
• Day / Night
© TEA. www.tea.ie 54
Pressure Control
• Continuous Pumping.
• Control with 2 to 3 fixed speed pumps
• On /Off with Pressure Tank.
• Variable Speed Control – PID and Step
Control
© TEA. www.tea.ie 55
Pump Protection
• Low Water Protection
• Loss of Prime - No-flow
• Burst Main
• High Pressure
• Bearing Over Heat
© TEA. www.tea.ie 56
Motor Protection
• Over / Under current
• Overheat
• Voltage
• Power Factor
• Bearing Over Heat
© TEA. www.tea.ie 57
Thank You!