A Comparative Review of Operational and Advanced Control Strategies for Enhancing Hydraulic and Energy Efficiency in Centrifugal Pumping Systems

Abstract

Centrifugal pumping systems are widely used in industrial processes, water-supply networks, irrigation systems, cooling circuits, wastewater facilities, and building services. Their overall performance is influenced not only by the nominal efficiency of the pump but also by the interaction between the pump and system curves, the operating point relative to the Best Efficiency Point (BEP), static and friction head, flow and pressure requirements, rotational speed, valve position, motor and drive efficiencies, demand variability, and the number of pumps in operation. This study presents a structured narrative review with a comparative analysis of operational and control strategies to improve the hydraulic and energy performance of centrifugal pumping systems. The evidence base comprised 26 publications issued between 2016 and 2026, including 12 core comparative studies. The reviewed strategies included BEP-oriented operation, discharge-valve throttling, variable-speed control, pressure and flow optimization, parallel-pump sequencing, demand-based scheduling, sensorless monitoring, online optimization, and digital-twin-based multi-objective control. The evidence was evaluated according to system configuration, hydraulic duty, static- and friction-head characteristics, demand profile, baseline control strategy, validation method, reported performance indicators, and reliability implications. Across the principal system-level studies, practical energy savings generally ranged from approximately 7.9% to 57.6%. Higher values were reported under specific comparator-dependent or theoretical conditions, including savings of up to 80% relative to outlet-valve throttling and theoretical savings approaching 70% for optimized storage-pumping operation. These values should not be interpreted as a direct ranking of the investigated strategies, as they were obtained under different system configurations, operating conditions, performance indicators, and baseline strategies. Variable-speed control generally provided the greatest benefit in variable-demand, friction-dominated systems, whereas its effectiveness was more limited in systems with a substantial static-head component. In parallel-pump stations, coordinated pump selection, sequencing, speed allocation, and switching-point optimization were found to be essential for minimizing inefficient partial-load operation. Advanced online and digital-twin-based approaches further supported adaptive and multi-objective operation by considering energy consumption together with hydraulic stability, pressure transients, equipment reliability, and service life. The review concludes that no single operational or control strategy is universally optimal. Strategy selection should therefore be based on the specific hydraulic characteristics, demand profile, baseline operating condition, technical constraints, implementation feasibility, and reliability requirements of each pumping system rather than solely on the highest reported energy-saving percentage.