Pump up the savings

RESPONSIBLE FOR moving fluids in a wide range of industries, pump systems are by nature energy-intensive, especially when conventional control methods like throttling valves or on-off systems are used. These older methods typically force pumps to operate at full capacity, regardless of the actual demand, wasting significant energy when the flow requirement is lower.

Additionally, on-off pumps, with their limited two-speed maximum or stopped functionality, contribute to mechanical wear. This can lead to premature failure and increased maintenance costs. VSDs offer critical protection and maintenance benefits by reducing wear on pipes and valves, as well as minimising excessive stress on the motor's windings.

VSDs slowly ramp up and gradually stop the pump mechanism, which minimises the risk of mechanical shocks or sudden pressure surges that can damage pipes, joints and seals. Additionally, they can be combined with pressure sensors to maintain a consistent pressure level across the system, regardless of demand fluctuations. This ability to regulate pressure automatically helps prevent both physical damage to components and short-term overloading of the electrical supply with each pump start.
 
Increased energy efficiency

Unlike traditional fixed-speed pumps, VSDs provide precise control over pump speed, adjusting energy input to match the system’s actual demand. Instead of forcing the pump to operate at its maximum capacity, a VSD allows gradual, optimised control, ensuring the pump runs only as fast as necessary. VSDs also offer significant efficiency improvements compared to throttling valves, which are commonly used to regulate flow and pressure in industrial systems. By using VSDs, companies can eliminate throttling valves and associated pipework, enhancing system efficiency. You may even opt for a lower-power, cheaper pump without compromising performance.

Throttling valves restrict flow, increasing pressure and causing energy loss. In contrast, VSDs control pump speed directly, eliminating the need for such restrictions and preventing energy waste. For example, when flow or pressure requirements decrease, the VSD slows the pump’s speed, cutting energy consumption. Over time, these savings add up to significant operational cost reductions and less frequent maintenance requirements.

The adoption of VSDs has already helped a wide range of industries make huge strides toward their sustainability goals by reducing energy usage, carbon emissions and environmental impact. However, to fully unlock the potential of this technology, pump systems also need intelligent control software to monitor and manage their operation.

Intelligent VSDs for pumping operations

Beyond slowing down or speeding up the pump, modern VSDs like those integrated with intelligent control systems — such as WEG's Pump Genius — offer even more sophisticated energy management features. These systems continuously monitor and adjust the pump’s operation based on real-time data, such as flow rate, pressure and fluid levels. This ensures optimal energy usage and improves system reliability by preventing issues like cavitation, overheating, or unnecessary wear on the pump.

For systems that use multiple pumps, Pump Genius is a highly advanced solution, capable of controlling up to six pumps in a coordinated system. This software balances wear and tear by rotating pumps in and out of operation and adjusting their speeds to meet system needs. It also provides real-time alerts of potential issues, such as overpressure or low flow, helping operators address problems before inefficiencies or unplanned downtime occur​.

Modern VSD systems offer the advantage of integrating intelligent motion controllers, which handle complex tasks that previously required programmable logic controllers (PLCs). This integration simplifies system design and improves performance by enabling each pump to operate autonomously within the overall network, reducing the need for high-performance communication systems.

David Strain is technical director at Technidrive

technidrive.co.uk