FEATURE Drives, controls & motors


Energy saving in pumping applications


David Strain, Technical Director of systems integrator, Technidrive, takes a deep dive into the energy savings potential of pumping applications


E


ffi ciency is not just a buzzword. For industrial businesses, improving the effi ciency of electrical systems is crucial for


reducing expenditure – particularly in an environment where the energy costs remain high.


When it comes to energy consumption, centrifugal pumps are among the guilty culprits. For sectors like oil, gas, water and wastewater treatment, pumps can consume over 15% of a facility’s total energy use. A common cause is the use of traditional fi xed-speed motors in pumping applications; essentially, using a motor that runs consistently, regardless of the actual demand.


Variable control


For most industries, the demand for fl uid fl ow varies over time. For instance, water treatment plants might experience lower demand during off -peak hours. Fixed- speed pumps are unable to adapt to these changes, leading to wasted energy and increased costs. To better manage energy consumption in pumps, installing a variable speed drive (VSD) is the perfect solution. A VSD’s core functionality lies in


Pump intelligence Energy savings can also be made by using intelligent control software alongside a drive system. This can control pump performance through real-time monitoring and adjustments. Metrics such as pressure and fl ow are measured to ensure the pump speed adjusts correctly and effi ciently. Global motor and drive manufacturer


and Technidrive partner, WEG, off ers the Pump Genius platform for these applications. The system is available in three versions: Pump Genius Simplex, Multiplex and Multipump – each for a diff erent scale of pumping operations. The tool enables a standard VSD to become dedicated for pumping systems


22 March 2024 | Automation


adjusting the frequency and voltage supplied to the motor, therefore enabling precise control over its rotational speed. This allows for variable control of the pump’s output, meaning it never runs at full power unnecessarily. Moreover, many VSDs are now supplied with smart technologies that can collect and analyse data from the drive, motor and pump, allowing operators to monitor energy consumption in real time.


These systems bring substantial benefi ts compared to soft starters – equipment that facilitates a gentle ramp-up of motor speed during the start-up phase. Thanks to the ability to set specifi c parameters, VSDs are a far better option where energy savings are concerned.


WEG Pump Genius Simplex with CFW-11 VSD


and provides operators with greater opportunities for improving reliability and saving costs.


By equipping the inverter with intelligent features, the system can detect issues such as dry pumps and pump cavitation remotely. Upon identifi cation, the drive sends an automated alert to the operator via the HMI and can shut down the motor if necessary. Likewise, the system can also react in instances of increased demand. Should an application require a larger pump, the system can automatically instruct the jockey pump to pause, to enable the larger pump to continue operations.


For systems operating multiple pumps, the Pump Genius Multiplex enables forced rotation to ensure equal use of all pumps on site. Not only does this improve overall effi ciency, but reduces excessive wear and tear on individual pieces of equipment.


Maintenance


Following installation, the effi ciency of a pump should also be monitored over time, since its overall eff ectiveness is likely to reduce. Regular maintenance, such as identifying and addressing leaks, clogs and other issues promptly will ensure that the system is operating optimally – all achievable through smart technologies. Another key advantage of WEG’s Pump Genius is its ability to perform some maintenance automatically. Cleaning of the impeller, also known as deragging, is particularly important in wastewater settings – both for pump effi ciency, maintenance and spillage control. With pumps consuming large volumes


of energy use in industrial facilities, these systems should be a primary target for facility managers hoping to improve effi ciency and reduce costs.


automationmagazine.co.uk


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