At manufacturing facilities, power plants, and other industrial facilities, pumps are employed for a variety of tasks. Therefore, regardless of the kind and scale of the industry, a pumping system is used. According to India Energy Outlooks, India is the 3rd largest energy-consuming country and about 250 to 1500 watts are consumed from one pump every day. Pumps consume a high amount of energy and higher investment which urges the need for cost-effective pump and pumping solutions. The energy consumption merely depends on the time period for which it is used and the type of motor pump you are using.
A pumping system’s efficiency may decrease due to a number of problems which include the ageing of the pump, inadequate maintenance, improper installation, and the wrong pump model. Therefore, understanding how to decrease energy usage and boost a pumping system’s effectiveness is crucial. In this blog, we are going to guide you through 7 cost-effective pump and pumping solutions you can use to keep a large pumping system in your industry or power plant.
7 cost-effective pump and pumping solutions
Nobody can deny the significance of water pumps in industries, agriculture, power plants and enterprises. Every pump, including centrifugal pumps, submersible pumps, and more, is crucial to keeping the facilities operational but these pumps give output at a high cost and use a lot of energy. However, there are a few methods by which you can manage the energy consumption of these pumps, saving money and non-renewable energy sources in the process.
Select a cost-effective and efficient pump
It is crucial to choose the proper pump and pumping system for an industrial facility because a poor choice leads to excessive electricity consumption and poor performance. According to a research-based study conducted in Finland, the average pump efficiency is less than 40%, and 10% of the pumps used in industrial facilities are 10% or less efficient.
Therefore, in order to choose the proper pumping system in consideration of its kind, size, speed, type of drive, and power requirements, a person who is permitted to choose the pump for an industrial facility must consider choosing an efficient pump for their work. A pump that is appropriately chosen for an industrial building will use less energy, function at its best, and endure longer.
Choose the proper pump size
Energy savings is greatly dependent on the size of the pump you choose. The smaller the size of the pump the less energy it consumes and the more cost-effective it is. However, depending on the motor’s load, the motor’s size is chosen. Therefore, it is recommended to always select a proper-sized pump.
To save energy, oversized pumps that produce too much pressure are the perfect pump size for a power plant. In case you have an oversized pump motor, you can significantly reduce the speed of the pumps by using gear or belt drives but this technique is very uncommon and not preferred.
Use multiple pumps for varying loads
There are basically two major types of pumping systems i.e. static and dynamic. In a static head-dominated system, the use of several pumps is frequently the most cost-effective and energy-efficient approach for variable loads. For dynamic systems, instead, variable speed drives might be taken into account for economic efficiency. Pumps running in parallel provide redundancy and improved dependability.
The multiple pumps and pumping system uses multiple pumps to operate and can save a lot of energy and money. The optimal performance of a parallel system with numerous pumps comes from running them mostly independently.
Regular Maintenance
A pumping system that has received routine maintenance will use less energy and function at its peak. Regular maintenance can reduce electricity expenditures by 7%, and it requires inspection of some components of a pumping system such as bearings, impellers, Packing seals, Mechanical seals, Motor alignment, etc. It is essential to immediately replace any of these parts if there is any sign of wear and tear. Proper maintenance involves:
- Replacement of damaged parts
- Checking lubrication in the system
- Inspecting and replacing all of the packaging and mechanical sealings
- Checking the alignment of the pump
- Inspection and repair of all the parts
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Monitoring the pumps regularly
Monitoring operations and maintenance can be used to identify issues and fix them to build a more effective system. It can reveal clearances that require adjustment, point out blockages, damage to the impeller, insufficient suction, functioning outside of preferences, clogged or gas-filled pumps or pipes, or worn-out pumps. Basically, Monitoring involves:
- Vibration analysis
- Pressure Analysis
- Current and power monitoring
- Temperature monitoring
- Distribution system inspection
Avoid unnecessary use
The unnecessary use of a pump or pumping device causes excessive power consumption and lowers the pumping device’s efficiency since each component works a lot more than required. As a result of this wasteful use, various pumping system components will become damaged or worn out which requires frequent maintenance or replacement costs. The pump must be turned off when not in use. This is done to reduce the cost and avoid wear& tear of pump parts.
Choosing proper pipe sizes and improving sealing
By optimizing pipe sizes, energy losses caused due to friction can be reduced and saved. Flow, pipe diameter, pipe length, pipe features (surface roughness, material, etc.), and fluid parameters all affect the frictional force that is needed to pump the water. Choose a wide diameter according to the requirement for saving energy.
Also, In certain applications, sealing failure causes up to 70% of pump failures. The power absorbed will depend on the sealing configurations of the pumps. Pump efficiency can frequently be improved through the use of gas barrier seals, balanced seals, and no-contacting labyrinth seals.
Conclusion
These are the 7 cost-effective pump and pumping solutions that will help you save money and improve the performance of your pump. You can use these solutions to enhance a pumping system’s lifespan. It also helps in reducing energy use and observing an increase in efficiency. Regular component inspections and preventative maintenance will also result in a decrease in energy usage.
You can also buy some best cost-effective pumps online that consume less energy and provide great efficiency. Contact Mentor Water Expects us today at 7351002123.
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