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MATERIALS HANDLING


In a hotel, for example, the water


requirement in the rooms is particularly high in the morning because the guests want to take a shower, but at noon it is comparatively low because there are hardly any guests in the hotel. However, the pump’s motor will consume as much electricity all day as it needs in the morning. If less is needed, the motor will be throttled. T e energy fi zzles out.


KEEPING AN EYE ON THE RIGHT COSTS “T e savings come from the fact that we regulate instead of throttle. So, we achieve the 35TWh saving by reducing waste,” says T omas Heng, who is responsible for series pumps at pump manufacturer KSB and sits on various working groups at Europump. T ese large energy savings therefore result from the ideal interaction of motor, frequency converter and pump. Consequently, it cannot be achieved by looking at the pump or the motor alone. So why is this saving hardly used


today? “Because consideration is often only given to the acquisition/installation costs and not the operation costs over the life span of the entire pump system. With the addition of a frequency converter, a pump costs are invariably lower than without one,” says Heng. In most cases, a standalone pump would pay for itself after about two to four years. But in industry, this is regarded as being too long, since an investment needs to pay for itself after just two years or even faster. So far, pump users have largely refrained from designing their pump systems to run as effi ciently as possible. T is problem is compounded


Pumps belong to a group of products that have the highest energy consumption


by the system planners’ desire to provide generous performance reserves and with it a tendency to over-spec. Pumps are specifi ed for the highest possible operating point, even if this is never achieved in practice. T ey want to be on the safe side. But if the pump is far too big for the application and is driven at full throttle, the waste of energy can be huge.


“Pumps are specifi ed


for the highest possible operating point, even if this is never achieved in practice”


PRODUCT APPROACH FALLS SHORT


Since pump manufacturers have determined to curb this waste, regulation is just what they want. However, there is a catch; the Commission is following a narrow product approach in the Eco-Design Directive adopted in 2009. T is is because the directive initially focused on new consumer products such as refrigerators, televisions and light bulbs. A light bulb is turned on or off . If it is on, it consumes electricity, if it is off , it does not. A light bulb is autarkic; a pump is not. Europump’s study found that if pumps


were looked at in isolation with a view to trimming their electrical consumption, savings of just 5TWh instead of 35TWh would only be possible with extreme design and production eff ort. In principle, the EU Commission is


Sulzer is invetigating how its pumps can make the biggest energy savings


46 www.engineerlive.com


prepared to consider the extended product approach as the basis for the effi ciency analysis. But it cannot decide this on its own. “T e problem is the member states. T ey say the extended product approach is too diffi cult for their market regulators to review,” says Frank Ennenbach, chairman of the Standards Commission at Europump and manager at pump manufacturer Sulzer. He adds, “T e critics’ argument is that if three diff erent product types – pump, motor and VSD – are combined and treated as one product or system, no one can check whether it has been confi gured correctly and that the savings are being achieved.”


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