Energy and cost-savings potential varies considerably by each site based on the current condition of equipment, operating hours, applied improvements, and the available utility incentives. The table below shows some selected examples of implemented projects in the irrigation and water/wastewater segments related to pumping systems efficiency improvements.
|Application||Description||Energy Saved (kWh)||$ Savings||$ Installation Cost||$ Utility Incentive||Payback (yrs)|
|Water District – Turbine Well Pump Improvement||350 HP turbine well pump OPE was improved from 57.5% to 76.8% by rebuilding the bowl assembly, column pipe and the tube and shaft assembly||281,244||$28,124||$88,544||$29,023||2.1|
|Municipal Water System – Pump and Well Rehabilitation||350 HP turbine well pump was rehabilitated. OPE was improved from 13.8% to 67.2%. The customer has treated the well with granular acid descale, bacteria controller and acid enhancer. The bowl assembly was replaced and the motor was overhauled.||1,135,213||$113,521||$103,766||$124,873||0.7|
|Irrigation District – Well Rehabilitation||100 HP turbine well pump OPE was improved from 44.1% to 69% by sonar jet cleaning, air lift well, cleaning blank areas; replace bowl assembly, tube and shaft.||155,100||$15,510||$68,029||$18,932||3.2|
|Municipal Water Company – Submersible Well Pump||Pump efficiency testing revealed that the OPE of the existing 125 HP submersible well pump increased from 50% to 66.3% by removing and replacing the pump, motor, and rebuilding the bowl assembly.||158,941||$15,894||$101,108||$17,483||5.3|
|Irrigation Customer 1||60 HP turbine well pump was rehabilitated. OPE was improved from 12.7% to 65%. The customer replaced the bowl assembly, tube and shaft.||90,768||$9,077||$26,578||$9,984||1.8|
|Irrigation Customer 2||Added VFD to a 200 HP constant speed pump which was operating at constant load and used throttling as the control. The pump was designed for 982 GPM and is currently being maintained at 900 GPM using VFD controls. The VFD maintains a discharge pressure of 50 psi which is the pressure required for low drip emitters.||53,031||$5,303||$22,550||$5,833||3.2|
|Water Utility – Distribution System Improvements Through Hydraulic Modeling||Water distribution system consisted of one 800 HP and two 600 HP booster pumps connected via more than 25 miles of pipes, water storage tanks and more than 3,500 feet difference in system head. Pumps were tested and a complete dynamic model of the system was developed. Work included pump efficiency improvements, addition of VFDs, replacement of pumps, and the expansion of water storage tank capacity.||1,396,440||$101,242||$1,000,624||$171,450||8.2|
|Large Water Company – Pump Sequencing||Identified and prioritized 82 well pumps as candidates for the well pump sequencing pumping groundwater into multiple zones which then feed into the distribution system. The study reviewed energy intensities of pumps throughout the system and recommended pump sequencing and filling selected reservoirs accordingly in order to more efficiently meet system demand.||2,533,208||$329,317||$323,900||$161,950||0.5|
|Water Utility – Distribution System Optimization Through Hydraulic Modeling||Lincus engineers developed a complete hydraulic model including a water treatment plant and multiple gravity feeding and pressurized zones that complete the system. We identified pressure adjustment opportunities between multiple hydraulic zones by the use of storage facilities, additional VFDs and by the better use of existing pump stations thereby reducing the need for the pressure reducing valves (PRVs).||415,599||$60,313||$500,000||$43,886||7.6|
|Large Municipal Wastewater Utility – Pump Station Improvements||Pump station consisting of two (2) 400 HP and two (2) 150 HP pumps operating at a constant speed to pump sewage out of the wet well. The energy retrofit project involved installation of (3) new 500 HP pumps with Variable Frequency Drives (VFDs). Substantial energy savings were achieved due to improved OPE, VFD installation and Pump Operational Optimization using the installed VFDs.||629,869||$94,480||$1,000,000||$75,380||9.8|
There are many qualified pump service companies in your area. Lincus can help you determine which one is best to provide the services you need. These companies can provide pump tests, and repair and installation services. As an example, shown below is a list of qualified pump service companies in Arizona:
Pumps are among the most widely manufactured items in the world and their many designs permit their use in a variety of applications. As a result, there are many pump types and sizes that can range from below 1 HP (such as medical infusion pumps), to over 5,000 HP (for diesel engine driven water pumps). They are utilized in everything from washing machines, refrigerators, cars and trucks, construction sites, wastewater treatment facilities, food-processing plants, irrigation, and water damns. While there are many different pumps for their vast application, the two general types of water pumps are centrifugal and positive displacement.
“Centrifugal Pump” is the general name for impeller-type pumps in volute or diffuser type casings. These can pump all sorts of liquids, with and without solids, and can handle the highest flow rates. It’s recommended to keep liquids air- and vapor-free for centrifugal pumps to avoid impeller damage. These pumps are best for lower viscosity liquids and high flow rates. Sizes can be found from 0.125 – 5,000 HP, pumping 5 – 200,000 GPM at 10 – 7,500 ft of head. The following table includes a list of centrifugal type pumps and the specifications within which they can be found:
|Pump Types||Flow Rate Ranges||Total Head Ranges||Power Ranges|
|API Process Pumps||10 – 10,000 gpm||50 – 7,500 ft||1 – 5,000 hp|
|Axial Flow Pumps||5,000 – 200,000 gpm||10 – 30 ft||10 – 1,500 hp|
|Booster Pumps||5 – 10,000 gpm||200 – 7,500 ft||1 – 5,000 hp|
|Canned Motor Pumps||5 – 1,500 gpm||25 – 400 ft||0.5 – 300 hp|
|Chopper Pumps||50 – 10,000 gpm||15 – 200 ft||1 – 500 hp|
|Circulator Pumps||5 – 750 gpm||20 – 180 ft||1 – 50 hp|
|Cryogenic Pumps||5 – 1,000 gpm||25 – 1,000 ft||0.5 – 500 hp|
|Drum Pumps||0.5 – 70 gpm||20 – 75 ft||0.25 – 1 hp|
|End Suction Pumps||5 – 7,000 gpm||10 – 750 ft||0.125 – 250 hp|
|Fire Pumps||20 – 5,000 gpm||100 – 1,200 ft||10 – 800 hp|
|Grinder Pumps||5 – 50 gpm||50 – 150 ft||0.5 – 5 hp|
|Horizontal Split Case Pumps||100 – 100,000 gpm||50 – 1,500 ft||3 – 5,000 hp|
|Jet Pumps||1 – 70 gpm||20 – 200 ft||0.5 – 5 hp|
|Magnetic Drive Pumps||5 – 4,000 gpm||25 – 1,000 ft||0.5 – 300 hp|
|Multistage Pumps||5 – 10,000 gpm||200 – 7,500 ft||1 – 5,000 hp|
|Regenerative Turbine Pumps||1 – 200 gpm||50 – 1,200 ft||0.5 – 75 hp|
|Slurry Pumps||10 – 30,000 gpm||30 – 250 ft||1 – 2000 hp|
|Self-Priming Pumps||5 – 7,000 gpm||10 – 350 ft||1 – 150 hp|
|Submersible Pumps||5 – 7,500 gpm||10 – 200 ft||0.25 – 250 hp|
|Trash Pumps||5 – 1,000 gpm||25 – 150 ft||0.25 – 50 hp|
|Vertical Sump Pumps||5 – 7,500 gpm||15 – 150 ft||0.5 – 250 hp|
|Vertical Turbine Pumps||50 – 150,000 gpm||15 – 2,000 ft||1 – 5,000 hp|
|Well Pumps||50 – 20,000 gpm||20 – 1,000 ft||1 – 3,000 hp|
Please contact us for more information of the advantages, disadvantages, and application of each pump type.
“Positive Displacement” pump is general name for pumps that do not have impellers, but instead rely on the change of volume to move liquids forward using rotating or reciprocating parts. The change in volume provides either a positive pressure or a vacuum for liquids to flow. Positive Displacement pumps may be favored over Centrifugal Pumps due to their ability to handle higher viscosity fluids, presence of fragile or shear sensitive solids, or low flow and high pressure. Sizes can be found from 0.5 – 5,000 HP, pumping 0.1 – 15,000 GPM at 10 – 100,000 psi of head. The following table includes a list of Positive Displacement type pumps and the specifications within which they can be found:
|Pump Type||Flow Rate Range||Total Head Range||Power Range|
|AODD Pumps||0.25 – 300 gpm||10 – 125 psi||0.25 – 30 hp|
|Concrete Pump||10 – 1,000 gpm||25 – 1,000 psi||10 – 500 hp|
|Diaphragm Pumps||1 – 1,800 gpm||25 – 15,000 psi||0.5 – 2,000 hp|
|Flexible Impeller Pumps||5 – 150 gpm||10 – 60 psi||0.25 – 10 hp|
|Gear Pumps||1 – 1,500 gpm||10 – 2,500 psi||0.5 – 2,000 hp|
|Lobe Pumps||25 – 3,000 gpm||50 – 450 psi||1 – 500 hp|
|Metering Pumps||.01 – 20 gpm||10 – 30,000 psi||0.125 – 60 hp|
|Peristaltic Pumps (Hose Pump)||0.2 – 200 gpm||10 – 250 psi||0.125 – 40 hp|
|Piston Pumps||5 – 700 gpm||50 – 5,000 psi||1 – 500 hp|
|Plunger Pumps||5 – 1,200 gpm||50 – 100,000 psi||1 – 5,000 hp|
|Progressive Cavity Pumps||10 – 2,400 gpm||50 – 2,000 psi||1 – 500 hp|
|Screw Pumps||50 – 15,000 gpm||50 – 4,500 psi||5 – 5,000 hp|
|Vane Pumps||5 – 2,500 gpm||20 – 200 psi||1 – 300 hp|
When looking for the right pump to match your application, there are many parameters to take into account. Contact us to discuss the type of pump you need, and we can provide you up with the correct pump manufacturer in your area.An example of agricultural pump manufacturers are provided below:
Alfa-Laval manufactures sanitary pumps, including the renowned Tri-Clover brand, for the dairy, food, beverage, pharmaceutical, and personal care industries.
Pump types available for selection – Single, multistage, and self-priming centrifugal pumps.
American Turbine Pump manufactures a broad range of vertical and submersible turbine pumps for the irrigation, industrial, municipal, commercial, mining, and golf course pumping markets.
Pump types available: Vertical and submersible turbines
Ampco Pumps Company’s centrifugal pumps are used in a variety of applications and industries including: food & beverage processing, CIP & COP systems, water treatment systems including reverse osmosis and desalination, military and commercial marine applications, and chemical processing.
Pump types available: Centrifugal
AnsiPro Pump Company manufactures ANSI chemical process pumps for a broad range of chemical process, industrial, municipal, irrigation and recreational applications.
Pump types available: ANSI process pumps
APV manufactures sanitary centrifugal pumps serving the food, dairy, brewery, beverage, chemical process, bio-pharmaceutical process industries.
Pump types available: Sanitary centrifugal pumps
Barnes Pumps manufactures submersiable pumps for water and wastewater applications including sump, sewage, effluent, grinders, non-clogs, self-priming, fountain and dewatering.
Pump types available: Centrifugal, fountain, grinders, non-clog, pressure sewer systems, sump and effluent, sewage ejectors, split case, condensate return systems, regenerative turbine, end suction, dewatering and vertical process.
If you’re looking to install a VFD on your existing system, there are many options on the market. First it’s important to know some basic facts about choosing the right VFD. Prior to reviewing your options, be sure to gather the following information about your system, which can usually be found on the motor’s nameplate:
It’s best to understand that sizing a VFD can be narrowed down by knowing the HP of the motor you want to control. For example, a 25 HP VFD can control up to 25 HP in power. Typically, this means that VFD’s can be slightly oversized, as in this case the same VFD can control a 20 HP motor. It’s best to get as close to the power requirements as possible to reduce the cost of the VFD purchased.1 However, knowing the FLA is much more critical, and is really the proper way to size a VFD. Comparing the FLA of the motor with the amp rating of the VFD is the best way to ensure that your VFD can provide the proper amperage to get your motor started. It’s best to give your motor a bit of cushion when choosing the VFD so that it can handle higher loads if need be. Being less conservative here pays off and is especially important if you have a constant torque load or a load that is difficult to get started. Although it may cost slightly more to purchase a drive with a higher amp rating, it will definitely pay off over time in reliability and functionality.
Understanding the voltage requirements is also necessary and will change if you have a three-phase input vs. a single phase input. A variable or constant torque type VFD can be distinguished as well. VFD’s installed for energy savings are usually Variable Torque VFD’s, while Constant Torque VFD’s are typically used for positive displacement pumps which need constant torque at all speeds. It’s also important to know if there are any special enclosure needs to meet certifications such as Ingress Protection (IP), NEMA, and UL Type Enclosures. These are just some basic facts when sizing a VFD and a more comprehensive guide should be used when going through a design phase. For more information, please contact us.
Lincus recommends the following popular manufactures when considering purchasing a VFD:
Prices for VFD’s can vary by type, size, and brand. Contact us for an estimate on installation costs, or review this online catalog.