CONSULTANCY SERVICES

Optimize Pump Performance. Reduce Energy Consumption. Improve Operating Efficiency.

Falcon Industrial Testing Laboratory Pvt Ltd provides measurement-based Pump & Motor Performance Assessment and Energy Audit Services to determine actual hydraulic and electrical performance, identify energy losses and recommend practical energy-saving opportunities.

Why Conduct a Pump Energy Audit

Pumping systems can consume significant electrical energy. Pumps may operate inefficiently because of oversizing or undersizing, operation away from the Best Efficiency Point (BEP), excessive throttling, improper pump sequencing, high system resistance, inefficient motors, incorrect operating pressure or flow, and unsuitable operating schedules.

Our Pump Performance & Energy Audit establishes the actual operating condition using field measurements and engineering analysis.

Our Pump Energy Audit Methodology

Actual Water Flow Measurement

Actual pump discharge flow is measured using a calibrated Ultrasonic Clamp-On Flow Meter.

Actual flow – m³/hr or LPS, as applicable
Pump-wise flow where technically measurable
Common-header flow, where applicable
Flow at different operating conditions/head, where the system permits
Comparison of actual measured flow with design pump flow

Electrical Power & Motor Performance Measurement

Pump motor electrical performance is measured using a suitable 3-phase Power / Power Quality Analyzer.

Voltage – V
Current – A
Active Power – kW
Power Factor
Frequency – Hz
Energy parameters required for performance calculation
Motor loading, where sufficient data is available
Voltage and current imbalance, where measurable

Measured input power is used to evaluate overall wire-to-water operating efficiency.

Pump Head Measurement

Pump suction and discharge pressures are measured using suitable calibrated pressure gauges or digital pressure measuring instruments.

Pump suction pressure
Pump discharge pressure
Differential pressure
Elevation/velocity corrections, where materially applicable
Actual Total Dynamic Head (TDH) – mWC

Pump Performance at Various Operating Conditions

Where the existing system safely permits changing operating conditions, readings may be taken at multiple operating points.

Actual flow

Suction pressure

Discharge pressure

Actual head

Input power – kW

Motor current – A

Power factor

Actual efficiency – %

Safety: No operating point will be intentionally created outside the safe operating limits of the pump/system.

Pump Efficiency Assessment

Hydraulic output power

Overall / Wire-to-Water efficiency

Pump-only efficiency where reliable motor output/efficiency information is available

Specific Energy Consumption, where applicable

Existing operating power

Annual operating hours

Estimated annual energy consumption

Hydraulic/system losses

OEM Pump Curve & Design Performance Comparison

Where OEM/design pump curves are provided, actual measured operating points are plotted and compared with the intended pump performance.

Design flow vs. actual flow

Design head vs. actual head

Actual operating point

Design/BEP region vs. actual operating region

Design efficiency vs. actual operating efficiency

Input power

Pump operating condition at various heads

Deviation from the intended operating point

Motor Performance Assessment

Rated motor kW vs. actual input kW

Rated current vs. actual current

Voltage condition

Voltage imbalance, where measurable

Current imbalance, where measurable

Power factor

Frequency

Percentage motor loading, where sufficient data is available

Abnormal loading or electrical conditions

Energy Performance Assessment

Actual pump operating efficiency

Specific Energy Consumption, where applicable

Existing operating power

Annual operating hours

Estimated annual energy consumption

Hydraulic/system losses affecting pump performance

Pump oversizing/undersizing indication

Throttling losses, if applicable

Potential VFD optimization

Pump operating sequence

Potential energy-saving opportunities

Design vs. Actual Performance

Parameter	Design / Rated	Actual	Deviation / Achievement
Water Flow	—	—	%
Pump Head	— m	— m	%
Motor Input Power	— kW	— kW	%
Current	— A	— A	%
Power Factor	—	—	—
Pump / Overall Efficiency	— %	— %	— %

Energy Optimization

Energy-Saving Opportunities & Recommendations

Pump operating-point correction

VFD speed optimization

Pump sequencing optimization

Reduction of unnecessary throttling

Impeller trimming assessment

Pump replacement / right-sizing

Reduction of system resistance

Pipeline/header improvement

Valve setting correction

Strainer cleaning

Elimination of air locks

Parallel pump operation optimization

Motor efficiency improvement/replacement

Operating schedule optimization

Other energy-conservation measures identified during the audit

Important Scope Note: Physical modification, servicing, alignment, impeller modification, valve replacement, VFD programming and electrical repair are outside the measurement scope and, where required, can be quoted separately.

Complete Package Includes

Pump Performance Assessment

Measurement-based assessment of actual pump operating performance under existing site conditions.

Includes: Actual water flow measurement, suction and discharge pressure measurement, pump head calculation, input power measurement, motor current, power factor, operating condition assessment, and actual efficiency evaluation.

Electrical & Motor Performance Assessment

Evaluation of motor electrical performance and operating loading to identify abnormal or inefficient conditions.

Includes: Voltage, current, active power, power factor, frequency, voltage imbalance, current imbalance, motor loading, rated versus actual power comparison, and identification of abnormal electrical conditions.

Pump Efficiency & Energy Assessment

Assessment of pump efficiency and energy consumption to identify performance losses and energy-saving opportunities.

Includes: Hydraulic output power, wire-to-water efficiency, pump efficiency where applicable, specific energy consumption, existing operating power, annual operating hours, estimated energy consumption, and hydraulic/system loss assessment.

OEM Pump Curve & Design Comparison

Comparison of measured pump performance against OEM or design pump characteristics to identify operating deviations.

Includes: Design flow versus actual flow, design head versus actual head, actual operating point, BEP region comparison, design versus actual efficiency, input power comparison, operating condition analysis, and deviation from intended operating point.

Energy Saving Opportunity Identification

Identification of practical opportunities to reduce pump energy consumption and improve overall operating efficiency.

Includes: Pump oversizing or undersizing assessment, throttling loss identification, VFD optimization opportunities, pump operating sequence review, system resistance assessment, inefficient operating conditions, and potential energy-saving measures.

Energy Savings & Payback Assessment

Quantification of potential energy and cost savings based on measured operating conditions and available site data.

Includes: Estimated energy savings in kWh/year, potential cost savings in ₹/year, estimated investment requirement, simple payback period, operating-hour analysis, electricity tariff consideration, and prioritized energy-saving recommendations.

Pump System Optimization Consultancy

Engineering recommendations to improve pump system operation, reliability, energy efficiency, and overall performance.

Includes: Pump operating condition review, system performance analysis, pump sequencing recommendations, VFD suitability assessment, operating-point optimization, energy-efficiency recommendations, and practical improvement measures.

Technical Report & Performance Documentation

Detailed technical documentation presenting measured data, calculated performance, findings, and recommendations.

Includes: Site measurement data, pump performance calculations, electrical measurement results, design versus actual comparison, efficiency assessment, energy-saving opportunities, recommendations, and technical performance report.

REPORT OUTPUT

Energy Audit Report / Deliverables

The final energy audit report presents measured field data, engineering calculations, performance comparisons, identified losses and practical energy-saving recommendations.

Pump-wise measured data

Actual water flow

Suction and discharge pressures

Actual pump head

Electrical input power

Voltage / Current / Power Factor

Actual hydraulic power

Actual operating efficiency

Various operating-point measurements

Design vs. actual comparison

Actual operating point vs. OEM pump curve

Energy-performance analysis

Identified losses / deviations

Energy-saving opportunities

Estimated energy and cost savings

Observations

Engineering recommendations

Final conclusion

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