
Save Energy on Pumping Systems: 12 Effective Strategies
Introduction
Pumping systems play a crucial role in various industries, including water treatment, food and beverage, and manufacturing. However, the energy consumption required to move fluids can be significant. In fact, pumping systems are responsible for a substantial portion of the world’s electrical energy demand. With rising concerns for the environment and the need to reduce costs, improving the energy efficiency of pumping systems has become a priority for many businesses.
In this article, we will explore 12 effective strategies to save energy on pumping systems. By implementing these strategies, you can reduce energy consumption, lower operating costs, and contribute to a more sustainable future.
Select the Right Pump Type for the Application

Choosing the most efficient pump type for your specific application is the first step towards saving energy. Many pumps, such as centrifugal pumps, are often oversized by 20-30% during the design phase. This oversizing leads to unnecessary energy consumption. By accurately selecting a pump that operates close to its Best Efficiency Point (BEP), you can significantly reduce energy usage. Collaborating with pump manufacturers or distributors can help optimize the pump selection process, taking into account factors such as size, power requirements, speed, type of drive, and ancillary equipment.
( Click here to know more about different types of water pumps and their application )
Right-Size the Pump
Pump size plays a crucial role in energy consumption. Oversized pumps consume more energy than necessary. Therefore, it is essential to right-size the pump to match the system’s requirements accurately. Over-sizing is a common practice that can result in higher energy and maintenance costs. By accurately determining the required flow and pressure parameters, you can avoid the unnecessary energy consumption associated with oversized pumps.
Trim the Impeller
If you find that your pump is oversized, trimming the impeller can be a cost-effective way to reduce pressure and flow. However, it’s crucial to consider the manufacturer’s guidelines and not trim the impeller below the minimum diameter specified on the pump curve. While impeller trimming is more energy-efficient than using throttling valves, it can decrease efficiency compared to a full-sized impeller. Alternatively, variable speed drives (VSDs) are often preferred for energy efficiency.
Implement Variable Frequency Drives (VFDs)

Variable frequency drives (VFDs) adjust the rotational speed of the motor to match the actual head and flow demand of the application. They are effective in reducing unnecessary energy consumption in two scenarios: reducing the speed of an oversized pump and accommodating different duty demands over time. By installing VFDs, you can optimize the pump’s performance and achieve significant energy savings. While there is an initial cost associated with VFD implementation, the long-term energy cost savings often justify the investment.
Optimize System Pipework to Minimize Pressure Loss
Optimizing system pipework is another effective way to save energy in pumping systems. Frictional pressure drop in pipework requires the pump to expend more power to overcome the losses. Minimizing the number of bends, expansions, and contractions in the pipework and selecting the appropriate diameter can help reduce pressure drop and improve energy efficiency. Additionally, using fittings and valves with low pressure drop can further optimize the system’s performance.
Utilize Proper Control Valves

Control valves play a crucial role in regulating flow and pressure in pumping systems. Throttling valves can increase pressure but also lead to energy inefficiency. By implementing proper control valves, you can minimize excess pressure and reduce energy losses. It is essential to use control valves that allow for precise flow regulation and minimize unnecessary energy consumption.
Consider Parallel Pumping Systems
In scenarios where the system has varying duty requirements, parallel pumping systems can be an alternative to VFDs. Using multiple pumps instead of a single large pump allows each pump to operate closer to its designed efficiency level. By turning on and off the pumps as needed, you can optimize energy consumption. Although parallel pumping systems may have higher initial costs, the long-term energy savings make them a viable option.
Optimize Demand and Usage
Reducing the demand and optimizing the usage of pumping systems can lead to significant energy savings. Holding tanks can help equalize flow over the production cycle, reducing the need for additional pump capacity. Eliminating bypass loops and unnecessary flows also contributes to energy efficiency. Additionally, reducing total head requirements by minimizing process static pressure and elevation changes can further optimize energy consumption.
Upgrade to More Efficient Pumps
Upgrading to more efficient pumps can result in substantial energy savings. Pump efficiency can degrade over time, leading to increased energy consumption. By replacing the pump with a newer, more efficient model, you can reduce energy use by 2% to 10%. Additionally, using higher efficiency motors can further enhance the efficiency of the pump system, resulting in energy savings of 2% to 5%.
Proper Pump Sizing for Current Needs
Correctly sizing the pump to match the current requirements is essential for energy efficiency. Operating a pump under throttled conditions or with a high bypass flow rate can lead to energy wastage. By carefully considering the peak loads and reducing pump size accordingly, you can optimize energy consumption. Alternative pump configurations and improved operations and management practices can also contribute to pump load reduction.
Regular Maintenance for Optimal Performance

Regular maintenance of pumping systems is crucial for maintaining optimal performance and reducing energy consumption. Inadequate maintenance can lead to decreased efficiency and increased costs. Proper maintenance includes activities such as impeller replacement, bearing inspection and lubrication, packing seal inspection and replacement, and pump/motor alignment checks. Preventive and predictive maintenance practices help detect and address deteriorating conditions before they lead to energy inefficiency.
Optimize Pump Seals and Minimize Leaks
Sealing systems in pumps can significantly impact energy efficiency. Leaks from static and dynamic seals waste fluid and contribute to energy losses. By selecting and maintaining proper pump seals, you can minimize leakage and improve energy efficiency. Monitoring and addressing wear and erosion of seals can help reduce energy consumption. Efficient sealing systems can often yield greater energy savings than other measures, such as variable frequency drives or impeller trimming.
Conclusion
Saving energy on pumping systems is crucial for reducing costs and promoting environmental sustainability. By implementing the 12 strategies discussed in this guide, you can optimize the energy efficiency of your pumping systems and achieve significant energy savings. From selecting the right pump type to regular maintenance and optimization, each step plays a crucial role in ensuring efficient and cost-effective operations. Invest in energy-saving measures today and contribute to a greener future.
References
- https://pumps-africa.com
- https://www.castlepumps.com
- https://electrical-engineering-portal.com
- https://www.foodprocessing.com