Take a look at the pie-chart below. As you can see, the pump's initial cost is the lowest expenditure over the pump's lifecycle. The two major expenses over the lifecycle of an industrial pump are – energy and maintenance costs.
Energy bills are the highest expenditures incurred during the lifecycle of a pump. Generally, an industrial centrifugal pump accounts for around 25 to 60% of the plant's total electrical energy. However, plant owners can significantly reduce energy costs by improving the efficiency of a pump. Matching pump performance to the system requirements can reduce energy costs by 20% in most cases.
Factors that Impact Pump Efficiency
Once the pump is installed, the major factors that affect the pump’s performance include:
- Overall system design
- The efficiency of the pump and system components
- Appropriate maintenance cycles
- Efficient pump control
Among other factors. Let’s take a look at how to boost pump performance and efficiency, reducing the costs of operating the pump.
Select a Pump that is Suited for the End Application
The first factor to consider is that you choose an appropriately sized pump for the required operating conditions. Choosing a pump that is not suited for your end application will result in lowered operating efficiency.
Whether you choose a centrifugal pump or any other roto-dynamic pump, there are pumps in a wide array of features and configurations to meet your specific requirements. For instance, pumps that are suited for handling slurries do not work well for less viscous liquids like water. A pump that handles high viscous liquids has a special design suited for that specific application.
Besides, the design differences, pumps made for specific applications have several other factors that play a crucial role in determining the efficiency. To give an example, take the case of a vertical turbine pump. The number of stages used depends on the end application.
So, the first step is to choose the right pump suited for your specific application.
Let’s take a look at the other factors that influence pump efficiency.
|Pump Description||Factors that Influence Efficiency|
|Slurry pumps (End suction)||Manufacturing considerations, hydraulics compromised to minimize wear and tear, transfer large solids|
|Solid-handling pumps (End suction)||The efficiency of the pump is compromised to pass solids|
|Submersible sewage pumps (End suction)||The efficiency of the pump is compromised to pass fibrous materials and large solids|
|Paper stock pumps (End suction)||The impeller is open for pumping fibrous air-trapped mixtures|
|Horizontal multi-stage pumps||Clearances, inter-stage bushings, surface finish, shaft stiffness|
|End suction pumps (not including self-priming pumps, and seal-less pumps)||Surface finish and clearances|
|Double suction pumps||Surface finish, large impeller ring clearances, large shaft diameter through the impeller eye, suction inlets|
Specific Speed of the Pump
The type and design of the pump is only one factor influencing the efficiency of the pump. The next significant factor to consider is the specific speed of the pump. The specific speed numerically measures how the flow enters and exits the impeller. Each pump has a pre-fixed optimal specific speed to attain maximum efficiency. This number varies depending on the pump design.
However, note that selecting a pump solely based on the optimal specific speed is not possible. This is because the end application dictates the specific operational speed of the pump.
Pumps that have a low specific speed discharge have a radial flow. These pumps generate higher head and lower flow rates compared to other similar pumps. On the other hand, pumps with higher specific speed have axial flows. These flows move axially while entering and exiting the pump. These pumps have a lower head and a higher flow rate.
Other Factors to Consider
Besides the two factors mentioned above, a few other factors determine the efficiency of a pump. They are pumpage, the viscosity of the pumped fluid, etc.
The efficiency of a pump plays a crucial role in determining its overall lifecycle cost. You need to ensure that your industrial pump is operating at its maximum efficiency. Choosing the right type of pump suited for your application is a crucial first step.
If you're having trouble finding the right type of industrial pump, get in touch with our sales team at Sintech, India's leading industrial pump manufacturer and exporter. Our team helps you analyse your requirements and suggest the best pump for your needs.