5 Ways to Reduce the Energy Consumption of Your Pumps

Dirty water pumps can be energy-intensive assets, accruing a substantial energy bill and adding to the carbon footprint of your project. One of the best ways to reduce operational costs and improve sustainability is, therefore, to reduce the energy consumption of your pumps. In this article, we look at five ways to do this.

 

1. Understand your energy use patterns

Before you can reduce energy consumption, you need to understand how much is currently being used, and where. Pumps can account for a (surprisingly) large proportion of the site’s total electricity cost, and a lot of this goes on systems that are not properly optimised. For example, a pump that is too large for its application will operate inefficiently, consuming more power than needed. Similarly, an older or less efficient pump and poorly designed pipework all contribute to wasted energy.

A thorough energy audit of your pumping system is the best starting point to identify the best areas for improvement. You can also use smart monitoring systems and data logging to identify when and where your pumps are drawing the most power. These insights make it easier to spot inefficiencies, track performance trends, and take corrective action before energy is wasted.

 

2. Invest in the right pump for your application

Choosing the correct pump from the outset is fundamental to long-term efficiency and savings. Ideally, your pump should be in the ‘Goldilocks Zone’, powerful enough, but not too powerful for the application. Oversizing is a common and costly mistake in pump selection because when a pump is too powerful for the system’s requirements, it often operates away from its Best Efficiency Point (BEP), leading to wasted energy and increased wear and tear. It’s also essential to avoid throttling the discharge valve to control flow, and instead, adjust the pump speed or impeller diameter to meet your system’s true requirements.

Matching the pump type to your application is equally important. For instance:

• Centrifugal pumps are generally best for applications that require a high flow rate at relatively low pressure. However;
• Positive displacement pumps are a better choice for systems that need to move fluids at high pressure, regardless of the flow rate.

 

3. Fit your pump with a Variable Frequency Drive (VFD)

For pumping systems with fluctuating demand, variable frequency drives are one of the most effective tools for reducing a pump’s consumption.

A VFD controls the speed of the pump motor, allowing it to calibrate its output to match the real-time demands of the system. When combined with automated controls or sensors, VFDs can respond instantly to changes in system pressure or flow, maintaining optimal performance and energy efficiency without the need for manual intervention. So, instead of running at a constant speed, the pump can slow down whenever a lower flow or pressure is required. It’s the equivalent of not leaving engines idling when the construction plant is not in use, and the savings can be substantial.

Even a small reduction in average pump speed over time can deliver a significant (and disproportionate) drop in energy use, so that reducing pump speed by 20% can cut its energy costs by nearly 50%.

 

4. Commit to regular proactive maintenance

A well-maintained pump is a happy pump. Over time, wear and tear on components such as your seals, bearings, and impellers can increase friction and reduce system performance, forcing the pump to work harder and consume more energy in a game of diminishing returns. A consistent maintenance schedule should include:

• Checking and replacing worn seals: leaking seals not only waste product but also impact hydraulic efficiency.
• Lubricating bearings: proper lubrication reduces friction, allowing the pump to operate more smoothly and with less resistance.
• Cleaning impellers and casings: blockages or buildup on the impellers can disrupt fluid flow and significantly decrease
• Check, adjust or replace worn impellers: Fast flowing abrasive fluids can cause a dramatic increase in consumed power, as the gaps between the stationary and rotary parts increase. If your pumps are wearing too quickly, consider alternative ‘wet-part’ materials – or a different pump type altogether.

 

5. Minimise system losses

The pump itself is only one part of the efficiency equation. The entire pumping network contributes to the overall energy consumption of a pump. Friction losses within pipework, bends, and valves force the pump to generate more pressure to move the fluid, which requires more electricity. To minimise these system losses, make sure your pipework is correctly sized. Undersized pipes create high friction and require more energy to push fluid through. You should also use larger diameter pipes wherever possible, as this reduces fluid velocity and friction.

A simpler and more direct pipe layout, without as many bends and fittings, will also improve flow and reduce the load on the pump. A well-designed system makes it easier for the pump to do its job, directly lowering its energy consumption. Furthermore, regularly reviewing your piping design and monitoring pressure drops throughout the system will also help you pinpoint hidden areas of loss. Even small improvements in pipe layout or valve selection can yield measurable energy savings.

 

Take control of your pump energy consumption with Atlantic Pumps

Reducing the energy consumed by a pump is an achievable goal that can deliver significant cost savings and operational benefits. Our team of specialists are here to help. Please contact us today to discuss your requirements and find the perfect solution for your application.