Global Training and
Support Guide
Smart Energy
Energy-Efficient Flow Solutions
For more than a century, Blackmer has been at the forefront of flow technology problem solving. From the first
positive displacement rotary vane pump to its patented cavitation/noise suppression innovation, Blackmer has
led the way in solutions for the safe, reliable and energy-efficient transfer of high-value and hazardous liquids
and gases in mobile and process applications worldwide.
Centrifugal
Pumps
Positive
Displacement,
Sliding Vane
Pumps
2
Peristaltic
(Hose) Pumps
Reciprocating
Gas Compressors
Smart Energy
Energy-Efficient Flow Solutions
Introduction
 High energy prices impose a competitive and
profit-robbing threat to every manufacturing operation,
large or small, worldwide
 Left unmanaged, energy expenditures can quietly
and quickly erode a company’s financial performance,
productivity, and competitive position
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Smart Energy
Energy-Efficient Flow Solutions
Smart “Energy Management” is the Key to:
 Driving productivity improvements that increase
financial performance
 Controlling energy expenses by reducing power
consumption without compromising output
performance
 Increasing operational reliability by emphasizing
the use of energy-efficient technologies that support
enhanced mechanical efficiency
 Reducing vulnerability to energy price volatility
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Smart Energy
Energy-Efficient Flow Solutions
Blackmer started its Smart Energy™ Flow Solutions
initiative to help educate companies on how they
can reduce energy consumption through the
use of positive displacement sliding vane
pump technologies.
Blackmer Smart Energy™ Flow Solutions Mission
Enable pump users to a gain a competitive business advantage through
the deployment of energy-saving positive displacement sliding vane
pump technology.
Blackmer will accomplish this mission by providing end-users, engineering
consultants, OEMs, and distributors with education, tools, and knowledge on
the energy-saving value and performance-enhancing advantages of positive
displacement sliding vane pumps.
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Smart Energy
Energy-Efficient Flow Solutions
A Global Opportunity
Worldwide industrial energy consumption is expected to increase
by 42%, or an average of 1.3% per year, from 2007 to 2035.
95% of the growth occurs in
developing nations.
Global energy consumption rose in
2010 at the fastest pace since 1973, as
rapidly growing developing nations led
a strong rebound from the Great
Recession.
China has now surpassed the United
States as the world’s biggest
consumer of energy, accounting for
20.3% of global demand compared
with 19% for the U.S.
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Smart Energy
Energy-Efficient Flow Solutions
Key Points to Ponder



Pumps represent 27% of the electricity used in industrial applications*
Energy is the single largest cost-of-ownership component of an industrial pump
system – representing between 50-90% of total life cycle costs, depending
on the technology
A reduction of energy consumption is a key component to controlling costs
– Using the right pump technology, properly sized for a specific
application, is an important step towards reducing pump
energy consumption
Industrial Energy
Consumption
*Source: Hydraulic Institute
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Smart Energy
Energy-Efficient Flow Solutions
Pumps – A Vital Part of an Energy-Efficient System
 There is a specific “best use” for every pump technology
– Understanding how pump efficiency, system
efficiency and overall energy efficiency are
measured and affected by the pumps and overall
system configuration is vital to developing a
successful energy-efficient pumping system
 Knowing the fundamental advantages and disadvantages
between pump technologies is necessary to selecting
the right pump for optimum performance and
energy-saving results
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Smart Energy
Energy-Efficient Flow Solutions
Choosing The Right Pump Technology Can Help a
Company Achieve Simultaneous Goals:
Reduce energy
consumption
Improve worker
safety
Reduce operations,
production and
maintenance costs
Improve capacity
utilization
Improve
productivity
Improve system
reliability
Improve product
quality
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Smart Energy
Energy-Efficient Flow Solutions
Published Reports confirm many opportunities for companies
to immediately improve bottom line performance through
energy-efficient pump system improvements
Source: Pump Systems Matter – U.S. Industrial Motor Systems Market Opportunities Assessment,
U.S. Department of Energy
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Smart Energy
Energy-Efficient Flow Solutions
A dollar saved on energy, maintenance or production is
equivalent to $17 in sales income (assuming a 6% gross margin)*
* SOURCE: Northwest Energy Efficiency Alliance / Industrial Efficiency Alliance – How Continuous Energy
Improvements Reduce Costs and Improve System Performance
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Smart Energy
Energy-Efficient Flow Solutions
Managing Global Energy Consumption
Global net electricity demand is projected to grow by 1.4%
per year between 2007 and 2035, with the strongest growth
in developing countries.
The chemical industry made up 22% of the total world industrial energy
consumption in 2007. Energy represents 60% of this industry’s operating costs.
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Smart Energy
Energy-Efficient Flow Solutions
Managing Global Energy Consumption
Improving the energy efficiency of even one pump in a
manufacturing process could produce substantial financial
savings for any operation.
The table to the right
summarizes the electrical
costs of a continuously
operated centrifugal pump
(driven by a 100 HP motor)
at 10 cents per kWh.
Even a 10% reduction
in energy consumption
adds up to considerable
savings.
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Smart Energy
Energy-Efficient Flow Solutions
Geographic Opportunities
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Smart Energy
Energy-Efficient Flow Solutions
Geographic Opportunities
Americas
United States
 2.4 million pumps consuming 142 billion kWh annually
 Projected 25% reduction in industrial production energy use by 2017
Canada
 Projected 0.6% industrial energy consumption growth rate in next 20 years
Mexico
 1.9% annual industrial energy consumption growth rate
South America
 Brazil – 2.1% annual industrial energy consumption growth rate
Other Central & South American Countries
 20% projected growth rate between 2007-2035
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Smart Energy
Energy-Efficient Flow Solutions
Geographic Opportunities
EMEA
Europe
 Energy legislation mandating “Smart Meters” to gauge electric usage
Russia
 Least energy-efficient economy in the world
 0.2% annual projected industrial energy growth
Middle East
 2.2% annual industrial energy consumption growth rate
 Chemical sector is the largest consumer of energy
 Numerous petrochemical projects underway in Saudi Arabia, Qatar, Kuwait,
UAE, and Iran
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Smart Energy
Energy-Efficient Flow Solutions
Geographic Opportunities
Asia
China
 Industrial sector accounts for
75% of total energy consumption
 High demand for industrial pumps
due to infrastructure development
 Government mandates dramatic
energy reduction in the coming
decade
India
 Growth expected from light
manufacturing and services
 Opportunities are abundant as
government mandates industries
to develop efficiencies in energy
consumption
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Between 2003 and 2006, this market witnessed rapid growth driven by the huge
demand from industries such as water and wastewater treatment, power
generation, oil and gas, and chemicals and petrochemicals.
Smart Energy
Energy-Efficient Flow Solutions
How To Measure Energy Efficiency in Pumps


Pumps waste energy when they fail to convert the electric power they consume
into the fluid motion they were designed to provide
Critical measurement equations used to select a new pump or when analyzing a
pump system for energy efficiency:
Imparted Energy
Efficiency =
Inputted Energy
Energy Used
Specific Energy =
Pumped Volume
Energy Converted
Power =
Time Taken
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Smart Energy
Energy-Efficient Flow Solutions
How To Measure Energy Efficiency in Pumps
Horsepower
(alternating =
current)
19
kW x Efficiency
746
Smart Energy
Energy-Efficient Flow Solutions
Measuring & Managing Energy Consumption


When pumps operate at optimum levels they use less energy and increase
reliability, saving both energy and maintenance costs
The maintenance and productivity benefits of improving a pump system’s
performance are generally one to two times the value of the energy savings
Calculating Potential Energy Savings
Savings = kW (in input electric energy) x Annual Operating Hours x
(1 − Actual System Efficiency)
Optimal System Efficiency
EXAMPLE:
1) Operating Efficiency (300 HP pump = 55% Efficiency)
2) Optimal Operating Efficiency (300 HP = 78% Efficiency)
3) Pump draws 235 kW x 6,000 hours of service per year
Savings = 235 kW x 6,000 Hrs/Yr x
20
(1 - 0.55)
0.78
= 415,769 kWh per year @ 0.05 per kWh = $20,788 Savings
Smart Energy
Energy-Efficient Flow Solutions
Reducing Energy Waste Begins with
Proper Pump Selection for the Application
 Select the pump technology best
suited for the application
 Properly size pumps, control valves
and piping for real-time requirements
(avoid excessive margin of error
capacity and/or total pressure
or head)
 Reduce restrictions, turbulence
and frictional losses
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Smart Energy
Energy-Efficient Flow Solutions
Reducing Energy Waste Begins with
Proper Pump Selection for the Application
 Ensure proper motor alignment (poor alignment of motor
and load increases motor power consumption)
 Reduce flow rates = lower energy losses
 Lower operating pressures
 Maintain pumps and system components to avoid
efficiency loss (wear is a significant cause of decreased
pump efficiency; corrosion in pipes increases friction)
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Smart Energy
Energy-Efficient Flow Solutions
Consider Application When Choosing
Pumping Equipment
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1. HOW MUCH FLOW?
Approximate DELIVERY
required in gallons/litres
per minute
5. HOW THICK?
Maximum VISCOSITY
of the liquid in Seconds
Saybolt Universal (SSU)
2. HOW MUCH PUSH?
Differential PRESSURE
required in pounds per
square inch (PSI) or Bar
6. HOW HOT?
Pumping TEMPERATURE
of the liquid in degrees
of Fahrenheit or Centigrade
3. WHAT LIQUID?
Type of LIQUID to
be handled
7. HOW MUCH PULL?
SUCTION conditions when
pumping in vacuum, or PSI/Bar
for pressure
4. HOW HEAVY?
Specific GRAVITY
of the liquid
8. HOW LONG?
Type of SERVICE, e.g., intermittent
duty, semi-continuous duty, or
continuous duty
Smart Energy
Energy-Efficient Flow Solutions
Many pump users do not know how to properly
select and apply pumps to a system, so pump
system operating costs are inadvertently
increased as a result.
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
Using pump selection
software programs can help
operators optimize pump
selection

Leading pump manufacturers
also provide applications and
engineering expertise, pump
specification and selection
programs, technical training
and support
allows users to select pump data and pump curves so
they can select the proper positive displacement or
centrifugal pumps for their application.
Smart Energy
Energy-Efficient Flow Solutions
Proper Pump Selection
Although the operating principles of positive displacement and
centrifugal pumps differ widely, both types of pumps can be used
to serve many of the same applications
Source: Schematic courtesy of
Chemical Processing Magazine
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Smart Energy
Energy-Efficient Flow Solutions
Proper Pump Selection
It’s time to put some energy into learning about the energy-saving
advantages of positive displacement sliding vane pumps
 There is no “one-pump-fits-all”
solution
 The right pump delivers
productivity gains and helps control
energy consumption
 Positive displacement sliding vane
pumps, by virtue of their inherent
energy and mechanically-efficient
designs, are uniquely suited to
offer manufacturers immediate
advantages in performance
and energy savings
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Smart Energy
Energy-Efficient Flow Solutions
Using LCC (Life Cycle Costs) for Proper Pump Selection


27
An analysis of Life Cycle Costs
(LCC) can dramatically reduce
waste and maximize efficiency
The NET cost savings based on
LCC will often justify a higher
initial price for a more energyefficient pump
Life-cycle costing helps identify
the lowest total cost of ownership
by considering:
– Initial equipment cost
– Installation and Commissions
– Energy costs
– Maintenance and Repairs
– Downtime costs
– Decommissioning costs
Total Life Cycle Cost (LCC)

LCC – Relative Comparison
Centrifugal vs. Positive Displacement (PD) Pumps
Centrifugals
Initial Pump Cost
Energy Cost
PD Pumps
Installation, maintenance,
operating, environmental
and downtime costs
Smart Energy
Energy-Efficient Flow Solutions
Basic Comparison – Centrifugal Pumps Vs. Positive Displacement Pumps
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Centrifugal
Positive Displacement
Mechanics
Imparts velocity to the liquid resulting in
a pressure at the outlet (pressure is
created and flow results)
Captures confined amounts of liquid and
transfers it from the suction to the
discharge port (flow is created and
pressure results)
Performance
Flow varies with changing pressure
Flow is constant with changing pressure
Viscosity
Efficiency decreases with increasing
viscosity due to frictional losses inside
the pump (typically not used on
viscosities above 850 cSt)
Efficiency increases with increasing
viscosity
Efficiency
Efficiency peaks at best-efficiency-point.
At higher or lower pressures, efficiency
decreases.
Efficiency increases with increasing
pressure
Inlet Conditions
Liquid must be in the pump to create a
pressure differential. A dry pump will not
prime on its own
Negative pressure is created at the inlet
port. A dry pump will prime on its own
Smart Energy
Energy-Efficient Flow Solutions
Comparing Centrifugal Pumps to
Positive Displacement Pumps
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If the system calls for:
The best pump to use
is:
Pressurized network of piping with a constant pressure
requiring constant flow rate
Centrifugal
Constant flow at various pressures
Positive Displacement
Constant flow at various viscosities
Positive Displacement
Constant flow at high viscosities (Particularly above 850 cSt)
Positive Displacement
Line stripping
Positive Displacement
Dry running – short duration
Positive Displacement
Priming
Positive Displacement
Shear sensitive
Positive Displacement
Entrained gases
Positive Displacement
High flow/low head
Centrifugal
Low flow/high head
Positive Displacement
Smart Energy
30
Energy-Efficient Flow Solutions
Smart Energy
Energy-Efficient Flow Solutions
Consider Positive Displacement Pumps
over Centrifugal Pumps when:
1. Working fluid is highly viscous (over 850 cSt)
2. Flow rate must be predictable over a wide
flow range (flow must be metered or
precisely controlled)
3. Flow rate must remain constant under varying
system pressures
4. System requires high-pressure, low-flow
5. Line stripping is required (some PD technologies)
6. Suction lift or self-priming is required
7. Working fluid is shear-sensitive
8. Energy-savings/efficiency is a primary concern
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Smart Energy
Energy-Efficient Flow Solutions
Positive Displacement Pumps Are Not Created Equal


PD pumps make up approximately 15% of industrial pump population
There are significant differences between PD pump types
PD Pump
Features
Viscosity Range
Flow Rates
Sliding
Vane









Very thin (LPG,
Refrigerants,
Solvents, Fuel
Oils, Gasoline,
Liquid Carbon
Dioxide,
Ammonia,
etc.) to high
viscosities up to
50,000 cSt
3.79 to >7,580 L/min
(1 to > 2,000 GPM)
Internal
Gear
 Differential pressure to 200 psi (higher pressures are
attainable)
 Speed to 3,600 RPM
 Metal-to-metal gear wears and slips over time, resulting in
efficiency degradation and higher energy consumption
High viscosities up to
1,000,000 cSt
1.8 - 5,685 L/min
(0.5 - 1,500 GPM)
Exceptional for thin liquids
Excellent on thick liquids at slow speeds
Exceptional efficiency at low flow rates
Excellent suction lift and line stripping capabilities
Self-adjusting vanes provide substantial energy savings
High mechanical efficiency = energy savings
Differential pressure to 200 psi
Speed to 3,600 RPM
Low energy consumption
Improper pump selection can cost money in downtime,
lost production, maintenance costs and energy consumption.
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Smart Energy
Energy-Efficient Flow Solutions
PD Pump
Features
Viscosity Range
Flow Rates
External Gear
 Do not perform well under critical suction conditions,
especially with volatile liquids
 Good for high pressure applications such as hydraulics
 Differential pressure to 3,000 psi+
 Speed to 3,600 RPM
 Metal-to-metal gear design subject to efficiency degradation
 Must be rebuilt or replaced
 No clearance adjustments for wear which results in slip,
efficiency degradation and higher energy consumption
High viscosities up to
1,000,000 cSt
Drops per minute to
5,685 L/min
(Drops per minute to
1,500 GPM)
Lobe
 Used frequently for food-type products due to sanitary nature
and ease of cleaning
 Vertical drain port reduces efficiency by 15-20%
 Sanitary models: Differential pressure to 200 psi
 Non-sanitary models: Differential pressure to 400 psi
Low viscosity with
diminished performance
up to 1,000,000 cSt
19 - 11,370 L/min
(5 - 3,000 GPM)
Air Diaphragm
(AODD)
 No bearings or rotating shaft
 Can handle a wide range of shear-sensitive, abrasive and
non-abrasive liquids as well as solids
 High pressure operation can cause excessive wear around
valve seats as the check valve closes
 Variable speed flow operation
 Requires air compression system. Electricity is used to run
compressors.
 Energy accounts for 70% of compressed air life cycle cost - air
is not free.
 High energy costs.
Medium viscosity to
26,000 cSt
3.79 - 1,895 L/min
(1 - 500 GPM)
Improper pump selection can cost money in downtime,
lost production, maintenance costs and energy consumption.
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Smart Energy
Energy-Efficient Flow Solutions
Sliding Vane Pumps vs. Internal Gear Pumps
Sliding Vane and Eccentric Disc Pumps vs. Gear and Lobe Pumps
Sliding Vane Pumps
 Superior mechanical performance
 Less mechanically efficient
 Provides greater energy savings
 Consume more energy than sliding
vane pumps
 24% more efficient than gear pumps
 Sliding vanes automatically adjust to maintain
near perfect clearances throughout operating life
 Energy-wasting turbulence and slippage are
minimized and high volumetric efficiency and low
energy consumption are maintained
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Internal Gear Pumps
 The metallic gears wear over time resulting
in wider clearances. This increases energyrobbing slippage and significantly decreases
volumetric efficiency
 In order to compensate for performance
degradation, pump speed is increased which
requires greater energy consumption
Smart Energy
Energy-Efficient Flow Solutions
Energy Cost Comparison
Vane/Lobe/Gear
Mechanical Efficiency
From the lowest to the highest viscosity, sliding vane technology
provides the highest level of mechanical efficiency which equates
into the lowest energy consumption.
90
80
70
60
50
40
30
20
10
0
Vane
Lobe
Gear
4
160
530
Viscosity (cSt)
35
1620
189 - 379 L/min (50-100 GPM);
3.45 - 6.90 Bar (50-100 PSI);
4-1,620 cSt viscosity;
same model on all viscosities
Smart Energy
Energy-Efficient Flow Solutions
Sliding Vane Pumps vs. Internal Gear Pumps
Sliding vane pump technology
not only reduces energy costs
but helps to create an overall
more efficient pumping system,
providing solutions for seals,
suction, product shear, and
volumetric efficiency problems.
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Smart Energy
Energy-Efficient Flow Solutions
Sliding Vane Pumps vs. Internal Gear Pumps
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Smart Energy
Energy-Efficient Flow Solutions
Summary
 Left unmanaged, energy costs can quietly erode profits
 Pumps account for 27% of total electrical use in the
industrial sector
 Pump system improvements – such as using the proper pump for
the application – can help to reduce energy consumption
 Positive displacement sliding vane pumps are inherently energyefficient and offer advantages over centrifugal pumps and other
PD pumps in specific applications
 “A dollar saved on energy, maintenance or production is
equivalent to $17 in sales income (assuming a 6% gross margin).”
– Northwest Energy Efficiency Alliance
 Energy-saving advice is available from:
–
Blackmer Smart Energy™ Initiative (www.BlackmerSmartEnergy.com)
–
U.S. Department of Energy (Industrial Technology Program)
–
Hydraulic Institute (Pump Systems Matter)
–
Northwest Energy Efficiency Alliance
Smart Energy
Energy-Efficient Flow Solutions
Blackmer’s Commitment to Sustainability
Blackmer Smart Energy®
Solutions
We are proud to provide customers
with products that enable them to
reduce energy consumption and
preserve natural resources.
Blackmer cares deeply about
pioneering new technologies and
processes that allow our partners
to promote sustainability for our
world.
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Smart Energy
Energy-Efficient Flow Solutions
A Valuable Resource
www.blackmersmartenergy.com