How to select an industrial pump control systems for TCO

How to select industrial pump control systems for TCO

Environmental concerns and optimising energy costs are strong drivers for an end-user’s economic policy. As a consequence, Total Cost of Ownership (TCO) is an important factor when making investment decisions. System design is key to TCO and influences any purchasing decision, such as the design of a pump control system.

 Total Cost of Ownership (TCO)

The Total Cost of Ownership includes buying price and all operating costs through the life of the project. It is a financial estimate to help buyers and owners determine the direct and indirect costs of a project. It is a management accounting concept used in full cost accounting or ecological economics where it includes social costs.

When it comes to building an energy efficient pumping system, the choice of the motor control system is crucial. As a response to the EU regulations on Energy using Products, the EN 50598 series proposes a system-level approach.  Called the Extended Product Approach (EPA) it is used to select the most efficient combination of products.

Selecting a pump control system

When designing an energy-efficient pump control system there are several options available and the TCO depends on the application requirements. For example, using a  variable speed drive (VSD) to control the flow rate in variable flow applications allows the pump to operate at its Best Efficiency Point (BEP) and to avoid the energy loss associated with a throttling valve. Although a VSD is an energy efficient solution for variable flow, it is not the case for constant flow applications.

There are several options for a pump control system and selecting the wrong one has a big impact on both TCO and the application itself. For example, in constant flow applications, a direct-on-line starter and high efficiency motor (IE3) deliver the most energy efficient solution. There are fewer losses during nominal operation of the pump and no consumption of the motor starter during the stand-by.

Selecting a pump control system

The first step is to identify the nature of the flow of your pumping installation, for example does it need a constant or variable flow. Next, if you are dealing with a constant flow application you must determine if water hammer may be an issue. From here you are in position to choose between Direct-On-Line starter, Star-Delta starter, Soft starter or Variable Speed Drive. Finally, you can start to build your pump control system with the appropriate motor control solution and avoid over-sizing.

The Extended Product Approach allows you to optimise the choice of the motor control system. Thus, it ensures a high energy efficiency level for your  pumping system.

For more information and case studies, refer to the Schneider Electric Control Panel Technical Guide “How to select the appropriate motor control system for your pump




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