Tomadaniel I

S c i e n t i f i c
WATER
a n d
SERVICES
Te c h n i c a l
AND
THE
NEW
C o n f e r e n c e
ENERGY
CHALLENGES
TITLE: Economic and Power Efficiency of Variable Speed Pump

Control Systems in Static Load Networks
AUTHOR: DANIEL TOMA, assist.prof.Ph.D.

JOSIF BARTHA, prof.Ph.D.
CRISTIAN SCRIPCARIU, Ph.D.stud.
Platinum Sponsor
Silver Sponsor
The content of the paper
1. INTRODUCTION
2. THEORETICAL ASPECTS
3. CASE STUDY: THE CHIRITA PUMPING STATION (THE CITY PUMPING PLANT)
4. RESULTS AND CONCLUSIONS
1. Introduction
Pumping stations that operate on water supply systems are important power consumers. According to the American
Energy Department, in the US electric motors that drive water pumps use around 25 % of all produced power.
Pumps
Pumps
22%22%
Other applications
35%
Fans
16%
Conveyors
2%
Cooling compressors
7%
Air compressors
18%
Estimated distribution of power consumption in EU
1. Introduction
Many times pumps operate at low efficiencies, much lower than the designed ones, fact that generates extra power
consumptions. Lately, there has been noticed an increasing awareness of public as regards the problem of energy efficiency.
Considering that the pumping sector offers an
important
potential
for
energy
savings,
the
optimization of energy consumptions becomes a

stringent current issue that is intensely studied
nowadays.
In order to exploit this energy saving potential the

most useful approach is the implementation of
variable speed drives on pump motors, instead of
controlling pumping processes by means of other

techniques (e.g. by varying fluid flows by discharge
valves).
For a single pumping plant the energy saving

Diagram of a variable speed pumping unit driven
by a static frequency converter
potential may range between 5 and 50 % in case that

pumps are equipped with static frequency converters.
2. Theoretical aspects
In order to ensure an objective analysis of the operation of pumping facilities, equipped with variable speed driven pumps,
in water supply systems, there is need for a research based on the following approaches and activities:
- based on in situ measurements, determining the pumps functional and energy characteristics at rated speed (head,
efficiency and energy);
- based on in situ measurements, determining the efficiency of the pump-motor systems and also the efficiency of the
frequency converter - motor - pump groups, at various speeds;
- the assessment of load losses characteristics for all components of a pressurized water conveying system, by considering all
geometrical and hydraulic characteristics of pumps suction and discharge hydraulic communications, and also for all main supply
and discharge pipelines;
- to determine the head variation domain, domain into which each system evolves, in relation to the geometric lifting heights
determined by the relative position of water levels into the tanks located in the two characteristic races (highest-discharge,
lowest-suction) and also in relation to head loss characteristics on the pumps discharge and suction pipes;
- performing an analysis of operating regimes of the system water tanks-pumps-network during various operational
situations (combinations of active pumps, the speed of a motor driven supplied by a static frequency converter), and determining
the power consumption and economical characteristics (pump efficiency, specific energy consumption Es and the unit specific
energy consumption esu), associated with typical operating regimes.
3. Case study: the Chirita pumping station (the CITY pumping plant)
Chirita water plant complex is located in the eastern southeastern part of Iasi, on Iasi Tutora road, and is designed to treat
water from the Prut River and Chirita Lake providing drinking water to about 100 000 people.
Chirita
PS
Chirita PS pumping process flow chart
General layout of the Chirita complex
The Chirita pumping station is equipped with three pumping plants, called by their serviced area, as it follows:
the CITY plant - pumps water from the filter station towards Iasi City distribution network;
the SOROGARI plant - pumps water from the filter station towards Sorogari water storage complex;
the INDUSTRY plant - pumps raw water drawn from Lake Chiria towards Iasi Citys industrial area.
The Chirita pumping station functional scheme
The CITY pumping facility is equipped with (2+1) pump+motor units that include:
WILO ASPV250C-185/4-R4-C1-EO-FC-ACH pump, rated for an efficiency = 87 %, a nominal flow Qo = 300 l/s, under nominal
head Ho = 48 mWC, and absorbing on shaft a nominal power Ppo = 166,1 kW, and driven at no = 1485 rot/min by a WEG315S/M
motor, with nominal power Pmo=185 kW and efficiency =95,5 %, motor rated for a voltage U = 400 V, and a nominal current In =
325 A, and power factor = 0,86.
Pumps P1, P2 i P3 are coupled in a parallel configuration and are driven by a static frequency converter, at nominal or variable
speed.
Chirita pumping station
CITY pumping plant
Static frequency converter

ATV61HC22N4
4. Results and conclusions

Table Pumps that operate into the CITY pumping plant: Coefficients of analytical expressions
for pumps functional and energy characteristics (catalogue and experimental values)
(H=AH0 + AH1Q + AH2Q2 ; P=AP0 + AP1Q + AP2Q2 ; R=AR0 + AR1Q + AR2Q2 )
Coefficientsfor pumps functional and energy characteristics
Head
characteristics
Power characteristics
Efficiency characteristics
Pumps
Catalogue/
in situ
P1, P2
catalogue
57,59
-0,05
-100,50
49,73
433,77
-124,32
2,40
582,75
-994,17
P1
in situ
59,93
29,42
-221,50
100,68
367,50
-202,84
1,92
501,61
-859,80
P2
in situ
56,84
30,80
-225,38
100,85
312,23
-79,23
1,45
502,96
-890,05

Table Geometric and hydraulic characteristics of main pipeline and pumps communications
in the CITY pumping plant
Hydr. res. coeff.
Pumps
Hydraulic
communication
P1, P2
Main
pipeline
Suction
P1
Discharge
54,61
0,800
0,0006
Ic, 2xVf,4xCt
0,0187
2,877
0,8383
3,76
0,600
0,0006
Rf, Re, Ct, Vf
0,0201
2,166
1,4612
0,50
0,300
0,0006
Re
0,0236
0,083
1,2494
0,50
0,250
0,0006
Df
0,0247
0,318
7,7759
4,32
0,500
0,0006
Rc, Vf, Ct, Df, Cf
0,0209
4,023
5,5568
16,0433
Pump
Suction
P2
Discharge
Pump
1,32
0,600
0,0006
Rf, Vf
0,0201
0,720
0,4873
0,50
0,300
0,0006
Re
0,0236
0,083
1,2494
0,50
0,250
0,0006
Df
0,0247
0,318
7,7759
1,88
0,500
0,0006
Rc, Vf, Cf
0,0209
4,020
5,4184
14,9310

In order to highlight the energy advantage of a variable speed drive compared to the traditional adjustment techniques
(adjusting the flow rate by maneuvering the discharge valve) there has been considered two cases:
operation with two active pump units, the AP1 unit being driven at a variable speed in the range r.p.m via the static
frequency converter and the AP2 unit, supplied directly from power grid, being driven at nominal speed;
operation with two active pump units, both units being driven at nominal speed no = 1450 r.p.m, and supplied directly from
power grid, and P1 pump discharge valve being used for flow control (valve with various closing degrees).

Diagrama regimurilor de functionare
60
HP2o = f (Q, 1450)
55
HP1P2 = f (Q)
HR2 = f (Q, Ho2)
HP1 = f (Q, 1425)

HP2 = f (Q, 1450)
50
H [m]
45
40
HRm = f (Q, Hom)
35
HR1 = f (Q, Ho1)
30
HP1o = f (Q, 1425)
25
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8
Operational regimes of CITY pumping plant

(P1 operation at variable speed n = 1425 rpm; P2 operation at constant speed n = 1450 rpm)

60
HP2o = f (Q, 1450)
55
HP1P2 = f (Q)
HR2 = f (Q, Ho2)
50
HP1= f (Q, 1400)
HP2 = f (Q, 1450)
H [m]
45
40
HRm = f (Q, Hom)
35
HR1 = f (Q, Ho1)
30
25
HP1o= f (Q, 1400)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


60
HP2o = f (Q, 1450)
55
HP1P2 = f (Q)
HR2 = f (Q, Ho2)
50
HP2 = f (Q, 1450)
HP1= f (Q, 1375)
H [m]
45
40
HRm = f (Q, Hom)
35
HR1= f (Q, Ho1)
30
25
HP1o = f (Q, 1375)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


60
HP2o = f (Q, 1450)
55
HP2 = f (Q, 1450)

HP1P2 = f (Q)
HR2 = f (Q, Ho2)
50
H [m]
45
40
HRm= f (Q, Hom)
35
HR1= f (Q, Ho1)
30
HP1 = f (Q, 1350)
25
HP1o = f (Q, 1350)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


60
HP2o = f (Q, 1450)
55
HP2 = f (Q, 1450)
HP1P2 = f (Q)
HR2 = f (Q Ho2)
50
H [m]
45
40
HRm= f (Q, Hom)
35
HR1= f (Q , Ho1)
30
HP1 = f (Q, 1325)
25
HP1o= f (Q, 1325)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


60
HP2o= f (Q, 1450)
55
HP2 = f (Q, 1450)
HP1P2 = f (Q)
HR2 = f (Q, Ho2)
50
H [m]
45
40
HRm= f (Q, Hom)
35
HR1= f (Q, Ho1)
30
HP1 = f (Q, 1300)
25
HP1o = f (Q, 1300)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


60
HP2o = f (Q, 1450)
55
HR2 = f (Q, Ho2)
HP2 = f (Q, 1450)
50
HP1P2 = f (Q)
H [m]
45
40
HRm = f (Q, Hom)
35
HR1 = f (Q, Ho1)
30
HP1= f (Q, 1200)
25
HP1o = f (Q, 1200)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


60
HP2o = f (Q, 1450)
55
HP2 = f (Q, 1450)
HR2 = f (Q, Ho2)
50
45
H [m]
HP1P2= f (Q)
40
HRm = f (Q, Hom)
35
HP1 = f (Q, 1100)
HR1 = f (Q, Ho1)
30
25
HP1o = f (Q, 1100)
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8


65
60
HP1P2 = f (Q, niui)
55
H [m]
50
45
HR1 = f (Q, Ho1)
HP1 = f (Q, 1450)
40
35
HP1o = f (Q, niui)
HP2 = f (Q, 1450)
30
HP2o = f (Q, 1450)
25
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8
Operational regimes of the CITY pumping plant at minimum static head Ho1
(P1 - constant speed operation with discharge valve in various closing positions;
P2 constant speed operation, speed n = 1450 rpm)

65
60
HP1P2 = f (Q, niui)
55
50
H [m]
HRm= f (Q, Hom)
45
40
HP1 = f (Q, 1450)
35
HP1o = f (Q, niui)
HP2 = f (Q, 1450)
30
HP2o = f (Q, 1450)
25
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8
Operational regimes of the CITY pumping plant at minimum static head Hom

65
60
HP1P2 = f (Q, niui)

HR2 = f (Q, Ho2)
55
H [m]
50
45
40
HP1= f (Q, 1450)
35
HP1o= f (Q, niui)

HP2 = f (Q, 1450)
30
HP1P2 = f (Q, 1450)
25
20
0.1
0.2
0.3
0.4
Q [mc/s]
0.5
0.6
0.7
0.8
Operational regimes of the CITY pumping plant at minimum static head Ho2
9,811
=
3,61
9,812
=
3,62
1 =
2 =

Pumping plant energy efficiency coefficient KEsv (%) of pumping installation
Pump speed P1 (rpm)
1350
1325
1300
Discharge valves closing degree
1425
1400
1375
1200
1100
0,683
0,676
0,662
0,650
0,634
0,620
0,543
0,434
by discharge valve
341,9
344,0
348,7
352,9
359,2
365,5
417,2
686,4
variable speed
328,0
323,3
318,7
317,6
315,9
312,9
315,1
444,8
4,07
6,02
8,60
10,00
12,05
14,39
24,47
35,20
0,617
0,609
0,592
0,578
0,560
0,540
0,443
by discharge valve
361,3
364,3
371,2
377,3
387,0
399,8
523,4
variable speed
345,7
342,2
338,7
338,0
336,6
337,9
378,6
4,32
6,07
8,76
10,42
13,02
15,48
27,67
0,539
0,530
0,509
0,493
0,472
0,442
by discharge valve
390,5
395,1
406,7
417,2
434,6
467,3
variable speed
372,4
370,7
369,8
371,2
373,1
387,9
4,64
6,18
9,07
11,03
14,15
16,99
Adjustment
method
KEsv
KEsv
KEsv

Variation of specific energy consumption as a function of control method, flow and static load
700
Variation of energy efficiency coefficient as a function of relative flow and static load
40
Es = f (disc. valve, Q, Ho1)
KEsv = f (Q/Q1max, Ho1)
theoretical values
650
theoretical values
35
Es = f (disc. valve, Q, Hom)
KEsv = f (Q/Qmmax, Hom)
theoretical values
600
theoretical values
30
Es = f (disc. valve, Q, Ho2)
KEsv = f (Q/Q2max, Ho2)
theoretical values
550
theoretical values
Es =f (variable speed, Q, Ho1)
25
KEsv [%]
Es [Wh/mc]
experimental values
500
Es = f (variable speed, Q, Hom)

experimental values
450
Es = f (variable speed, Q, Ho2)

experimental values
20
15
400
10
350
300
250
0.4
0.45
0.5
0.55
0.6
0.65
0.7
0.75
0.8
Q [mc/s]
Variation of specific energy consumption as a

function of control method, flow and static head
0
0.6
0.65
0.7
0.75
0.8
0.85
0.9
0.95
Q/Qmax [-]
Variation of energy efficiency coefficient as a

function of relative flow and static head
Thank you for your attention!

Tomadaniel I

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S c i e n t i f i c

TITLE: Economic and Power Efficiency of Variable Speed Pump

AUTHOR: DANIEL TOMA, assist.prof.Ph.D.

The content of the paper

4. RESULTS AND CONCLUSIONS

Estimated distribution of power consumption in EU

optimization of energy consumptions becomes a

In order to exploit this energy saving potential the

controlling pumping processes by means of other

For a single pumping plant the energy saving

potential may range between 5 and 50 % in case that

energy consumption esu), associated with typical operating regimes.

Chirita PS pumping process flow chart

General layout of the Chirita complex

The Chirita pumping station functional scheme

Chirita pumping station

CITY pumping plant

Static frequency converter

4. Results and conclusions

4. Results and conclusions

Rf, Re, Ct, Vf

Rc, Vf, Ct, Df, Cf

4. Results and conclusions

4. Results and conclusions

HR2 = f (Q, Ho2)

HP1 = f (Q, 1425)

HRm = f (Q, Hom)

Operational regimes of CITY pumping plant

4. Results and conclusions

HR2 = f (Q, Ho2)

HP2 = f (Q, 1450)

Operational regimes of CITY pumping plant

4. Results and conclusions

HR2 = f (Q, Ho2)

HP1= f (Q, 1375)

Operational regimes of CITY pumping plant

4. Results and conclusions

HP2 = f (Q, 1450)

HR2 = f (Q, Ho2)

Operational regimes of CITY pumping plant

4. Results and conclusions

Operational regimes of CITY pumping plant

4. Results and conclusions

HR2 = f (Q, Ho2)

Operational regimes of CITY pumping plant

4. Results and conclusions

HR2 = f (Q, Ho2)

HP2 = f (Q, 1450)

HRm = f (Q, Hom)

Operational regimes of CITY pumping plant

4. Results and conclusions

HR2 = f (Q, Ho2)

HR1 = f (Q, Ho1)

Operational regimes of CITY pumping plant

4. Results and conclusions

HR1 = f (Q, Ho1)

HP1 = f (Q, 1450)

HP2 = f (Q, 1450)

4. Results and conclusions

HP1P2 = f (Q, niui)

HRm= f (Q, Hom)

HP1 = f (Q, 1450)

HP1o = f (Q, niui)