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    Do horizontal high-pressure multistage centrifugal pumps consume a lot of electricity? These few reasons are quite common.

    Publication Date:

    2026-02-27

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    In industrial fluid-transfer applications, the energy consumption of horizontal high-pressure multistage centrifugal pumps directly affects production and operational costs. Many enterprises encounter the challenge during operation of “surging electricity consumption without a corresponding increase in transfer efficiency.” This phenomenon is not accidental; rather, it results from the combined effects of factors such as operating condition matching, medium characteristics, and equipment maintenance. In this article, Centrifugal pump Manufacturer Changsha Zhonglian Pump Industry Senior after-sales engineer, Mr. Feng, draws on his many years of maintenance experience to identify several common causes of high power consumption in horizontal high-pressure multistage centrifugal pumps, for reference by user organizations.

     

    Horizontal multistage centrifugal pump

     

    I. Is power consumption remaining stubbornly high? 5 In-depth Analysis of the Core Reasons

    Operating condition deviation: Flow rate and head deviate from the design range.

    The efficient operation of a horizontal high-pressure multistage centrifugal pump depends on precise matching of operating conditions. If the actual flow rate and head deviate from the pump’s rated design parameters by more than... 15% This will cause the pump to operate in an inefficient range—either the flow rate is too high, resulting in “a big horse pulling a small cart,” or the head is insufficient, forcing the pump to run overloaded. Both scenarios will directly lead to a sharp increase in power consumption.

    Sudden change in medium properties: density / Viscosity exceeds the design threshold.

    When designing a pump, the pump body is typically based on specific medium parameters. If the density and viscosity of the actual medium being conveyed increase compared to the design values—for example, due to an increase in solid content or changes in medium temperature—this will lead to greater flow resistance within the pump and higher impeller load. As a result, the motor will need to output more power to maintain normal operation, thereby increasing energy consumption per unit of throughput. It’s important to note that significant impacts on energy consumption will occur only when the variation in medium parameters exceeds the design tolerance range; minor fluctuations generally won’t cause noticeable changes in power consumption.

    Equipment aging and lack of maintenance: Component wear leads to performance degradation.

    After prolonged operation, core components such as the pump impeller, seals, and bearings are prone to wear and corrosion, leading to increased clearances and reduced sealing performance. Impeller wear diminishes hydraulic efficiency, while enlarged clearances can cause internal leakage. All these issues result in the pump performing "useless work," ultimately manifesting as higher power consumption coupled with declining delivery efficiency. Moreover, failure to perform regular lubrication and maintenance, as well as untimely removal of impeller fouling, can further exacerbate energy waste.

    Motor operation anomalies: efficiency degradation or improper matching.

    As the power core of the pump, the motor’s operational status directly affects overall energy consumption. Issues such as coil aging, bearing damage, and declining insulation performance can all reduce the motor’s efficiency. Similarly, if the motor’s power output does not match the pump’s requirements—for example, using a “small motor to drive a large pump,” which leads to overloaded operation, or using a “large motor to drive a small pump,” resulting in power redundancy—this will also cause unnecessary energy waste.

    Excessive system resistance: Unreasonable design of pipelines and accessories.

    The layout of pipelines and the selection of valves in a conveying system directly affect the pump’s load. If there are too many pipe bends, the pipe diameter is too small, valves are not fully open, or filters become clogged and are not cleaned promptly, the system resistance will exceed the pump’s design capacity. As a result, the pump will have to consume additional energy to overcome this resistance, thereby increasing power consumption.

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