Manado – Variable Speed Drive (VSD) technology has been shown to significantly improve the energy efficiency of industrial centrifugal pump systems while substantially reducing electricity consumption. The finding was reported by Herotje Siwi, Paul M. Rumagit, Djefry P. Hosang, Tammy T. V. Pangow, and Fransiscus J. Tulung from Manado State Polytechnic in a study published in the International Journal of Scientific Multidisciplinary Research in July 2026. The research offers a practical solution for industries seeking to reduce operational costs while supporting sustainable energy management and carbon emission reduction efforts.
Industrial energy consumption continues to rise as manufacturing activities expand worldwide. Among the largest consumers of electricity in industrial facilities are centrifugal pump systems, which are widely used in water treatment plants, oil and gas operations, chemical processing, manufacturing, and heating, ventilation, and air conditioning (HVAC) systems. In many industrial settings, pumps rarely operate under their most efficient conditions, resulting in unnecessary energy losses and increased operating expenses. This challenge has created a growing demand for technologies capable of adjusting pump performance according to real operational requirements.
To address this issue, the researchers evaluated the application of Variable Speed Drive technology, which allows the rotational speed of a pump motor to be adjusted based on actual system demand. Unlike conventional fixed-speed systems that regulate flow using throttling valves, VSD directly controls motor speed, enabling more efficient energy utilization while maintaining the required hydraulic performance. This approach minimizes energy waste commonly associated with traditional flow control methods.
The study employed a quantitative experimental approach using a laboratory-scale centrifugal pump test rig equipped with a Variable Speed Drive controller, flow meter, pressure sensors, and electrical power measurement instruments. Experiments were conducted under steady-state operating conditions at multiple rotational speeds ranging from 100 percent to 60 percent of the rated speed. At each operating condition, the researchers measured flow rate, pressure head, electrical power consumption, and pump efficiency to evaluate the relationship between rotational speed and overall system performance.
Experimental results demonstrated that reducing pump speed gradually lowered flow rate and pressure head while significantly decreasing electricity consumption. More importantly, system efficiency increased until reaching an optimal operating point before declining slightly at lower rotational speeds. These findings indicate that maximum motor speed does not necessarily produce the highest operational efficiency in industrial pumping systems.
According to the research data, operating the pump at full speed resulted in an efficiency of approximately 68 percent with a power consumption of 10 kilowatts. When the rotational speed was reduced to around 70 percent, efficiency increased to 81 percent while power consumption declined to approximately 3.6 kilowatts. This demonstrates the existence of an optimal operating zone where hydraulic performance and energy usage are balanced most effectively.
The researchers also compared conventional fixed-speed operation with Variable Speed Drive operation. The comparison revealed that VSD reduced electrical power consumption from 10 kilowatts to approximately 5.8 kilowatts, representing an energy saving of about 42 percent. At the same time, system efficiency increased from 68 percent to 78 percent. The improvement occurred because VSD adjusts motor speed directly to match system demand instead of dissipating excess energy through throttling valves, which are commonly used in conventional pump systems.
Further analysis identified that the most efficient operating range lies between 70 and 80 percent of the pump's rated speed. Within this range, the system maintains the required hydraulic output while consuming substantially less electricity than at full-speed operation. The findings suggest that industrial pumping systems achieve their highest performance not by operating at maximum speed but by maintaining an optimal balance between production requirements and energy consumption.
According to Herotje Siwi and colleagues from Manado State Polytechnic, the study provides strong experimental evidence that Variable Speed Drive technology is an effective strategy for industrial energy management. Dynamic motor speed control not only lowers electricity consumption but also improves overall operational efficiency and supports more sustainable industrial practices. The experimentally validated optimization framework developed in this study also provides practical guidance for industries seeking to determine the most energy-efficient operating conditions for centrifugal pump systems.
The findings have broad implications for industries that rely heavily on pumping systems as part of their daily operations. Implementing Variable Speed Drive technology could reduce electricity costs, improve equipment reliability by minimizing unnecessary mechanical stress, and contribute to national and global energy efficiency targets. In addition, the research offers valuable insights for industrial managers, engineers, and policymakers aiming to develop more sustainable and cost-effective energy management strategies across various industrial sectors.
Author Profile
Herotje Siwi – Manado State Polytechnic
Paul M. Rumagit – Manado State Polytechnic
Djefry P. Hosang – Manado State Polytechnic
Tammy T. V. Pangow – Manado State Polytechnic
Fransiscus J. Tulung – Manado State Polytechnic
Research Source
Article Title: Optimization of Energy Efficiency in Industrial Centrifugal Pump Systems Using Variable Speed Drive Technology
Journal: International Journal of Scientific Multidisciplinary Research (IJSMR), Vol. 4, No. 7, 2026
DOI: https://doi.org/10.55927/ijsmr.v4i7.89
Journal Link: https://journalijsmr.my.id/index.php/ijsmr
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