Variable Speed Water Pump Technology: Enhancing Efficiency and Reducing Costs through Sensata Pressure Sensors

By Magazine Team Last updated Jun 15, 2025 148 0

Contents

1 Variabl speed water pump VS. Fixed speed water pump

2 How do a variable speed water pump work?

3 How can pump speed be controlled in a VSD system?

4 Benefits of variable speed drives

4.1 Reliability:

4.2 Energy efficiency:

4.3 Control Management:

5 Sensata Pressure Sensors

6 Development in Pressure Sensors

7 How pressure sensor works

8 Conclusion

9 References

In municipal systems, industry, and agriculture, water pumps are essential. However, traditional pumps are infamously inefficient. Due to old designs and materials, they frequently waste water and energy, which raises operating costs and harms the environment.

According to studies, inefficient water pumps may be responsible for as much as 20% of the world’s energy use in certain industries so new alternative water pump solution such as variable speed water pump (VSP) specially Sensata Pressure Sensors have been designed by pump and water system designers.

Variabl speed water pump VS. Fixed speed water pump

Depending on the flow circumstances, a fixed speed pump motor typically runs at its specified speed. The amount of water that the application requires determines the pressure that the pump is producing.

Compared to constant speed pumps, variable speed booster pumps offer a number of benefits, such as :

removal of high-head circumstances as flow drops and energy losses from pressure-reducing valves
longer motor life without continuous use and lower operating costs throughout the pump’s lifetime
reduced water hammer in the system, increased motor bearing and pump seal life, and new pump efficiency rates of up to 80%

The older constant speed split case, vertical turbine, and end suction pumps are far less common than variable speed pumps.

How do a variable speed water pump work?

The pump in a constant speed booster pumping system doesn’t alter its speed. Rather, pressure-reducing valves use resistance and friction to reduce head pressure. Water pressures and flow rates can be adjusted with a variable speed booster pumping system to meet the needs of the building or application at any given time.
The truth is that a booster pump runs at 20% capacity or less 80% of the time. In order for a variable speed pressure booster pump to benefit from pump and fan affinity laws, a variable speed control lowers the pump speed during periods of low demand.
Power decreases as the motor’s speed decreases. Typically, the head and flow on a pump curve change simultaneously. As flow increases, pressure capacity drops, and vice versa. By slowing down when the flow drops and the potential pump pressure rises, a variable speed water pressure booster pump lowers speed to match a constant discharge pressure. According to affinity laws, the energy used is lowered by a factor of eight when the pump slows down.

How can pump speed be controlled in a VSD system?

Sometimes the controller is just a basic control panel that is manipulated by hand. In some situations, a more sophisticated programmable logic controller (PLC) in conjunction with a variable frequency drive (VFD) can also be used to operate it.
The VFD changes the frequency to the pump motor, causing it to accelerate or decelerate in response to input from system variables like flow, level, or pressure.
Sensors collect information to determine when the variable speed pressure booster pump has to be accelerated in order to automate control.

Benefits of variable speed drives

For industrial and manufacturing machinery to operate correctly, there must be a constant water pressure. In order to lower the costs of continuous maintenance and repairs, water distribution systems must simultaneously improve installed systems’ dependability, efficiency, and water waste reduction.

VSDs are one of the best ways to improve the mechanics of water distribution systems. Most of the benefits can be categorized into three key areas :

Reliability:

Variable speed booster pumps often operate at lower rates and do not follow a stop/start cycle. As a result, the pump experiences less stress and is more reliable. The cost of maintenance can be lessened with a longer life cycle and less downtime.

Energy efficiency:

A variable speed water booster pump that uses pressure sensors to maintain a steady pressure production can be up to 30% more efficient than conventional technology, according to the U.S. Department of Energy.

Control Management:

Even in difficult situations, such as high-rise buildings, a variable speed water booster pump can maintain steady, dependable water pressure. Additionally, data collection and pressure supply modification (based on load and choice) are made simpler by digital technology.

Sensata Pressure Sensors

Sensata provide devices span a spectrum of pressure ranges, configurations and form factors:

High pressure (>750psi / 50bar). Micro Silicon Strain Gauge solutions provides rugged reliability and a hermetic seal for a wide variety of environments.
Mid pressure (100 to 750psi / 6 to 50 bar). Ceramic capacitive or MEMS solutions offer a wide range of solutions tailored to application needs at superior value.
Low pressure (inches of water to 100psi / 2mbar to 6 bar). MEMS solutions including TPMS offer extremely low power consumption and wireless connectivity.

Development in Pressure Sensors

For usage in industrial pumps where parts need durable, industrial housings, Sensata provides a variety of sensors. Its 60/70CP range pressure sensors, for instance, have demonstrated their applicability in various industries that demand the dependable pumping of liquids, including oil, with a high degree of dependability (10 million cycle life-span). Additionally, they are resilient enough to endure potentially harmful phenomena like hydraulic shock and pressure spikes.

Sensata recently introduced a more affordable pressure sensor family (116CP/126CP) for smaller home booster pumps in addition to the 60/70CP sensors. Automotive-grade pressure sensing technology that has been demonstrated to be dependable is the source of the patented 116CP/126CP sensor design. The plastic casing of the sensors makes them perfect for domestic and other low-cost pump applications, and it offers alternatives for usage in drinking water applications.

How pressure sensor works

The output pressure is controlled or maintained by the pump VFP using the electronic value that the pressure sensor transforms from the pressure signal. The sensor measurement pressure value is typically shown on the pump’s display, however occasionally users can view and track pressures using a tablet or smartphone app. A notice can also help with preventative maintenance and notify users of anomalies.

Conclusion

Water systems around the world require improvement, particularly as water supplies continue to deplete and become increasingly scarce. Access to clean, drinkable water will be the most important aspect of living in the coming century, according to several predictions made in light of climate change and global warming. Variable speed water pump could be a solution for the increase in the world’s population and water scarcity.

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https://aquaenergyexpo.com/