Grundfos Solutions | Increasing performance in
PLANT SERVICE SYSTEMS
PLANT SERVICE SYSTEMS
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Grundfos is a leading international supplier of pumps and pump systems. We are rapidly moving into the
industrial market, bringing with us 50 years of experience, and a strong commitment to becoming the
preferred supplier of pumps for your business.
Grundfos pumps are some of the most reliable and efficient on the market. They meet nearly all user needs
for a wide variety of industrial systems: process, water supply, pressure boosting, heating, steam, cooling,
fire protection and wastewater.
We would like to share some of our experience with you. With a focus on the Grundfos solution and the
outcome for the customer, we have selected some case histories to show how we have responded to given
situations.
Let this newsletter inspire you to a closer cooperation with Grundfos.
industrial market, bringing with us 50 years of experience, and a strong commitment to becoming the
preferred supplier of pumps for your business.
Grundfos pumps are some of the most reliable and efficient on the market. They meet nearly all user needs
for a wide variety of industrial systems: process, water supply, pressure boosting, heating, steam, cooling,
fire protection and wastewater.
We would like to share some of our experience with you. With a focus on the Grundfos solution and the
outcome for the customer, we have selected some case histories to show how we have responded to given
situations.
Let this newsletter inspire you to a closer cooperation with Grundfos.
plant service systems | COOLING
Energy savings of 40%: 920,000 kW/h per year!
THE SITUATION
This multinational pharmaceutical company employs
approx. 15,000 people in 61 countries.
The cooling system at the company used to be
equipped with nine pumps operating at full power
around the clock.
Unfortunately, the only way of regulating the supply
was by using the manual on/off control. To make the
manual control run smoother, the pumps were
dimensioned for both full and half size. This resulted
in interruptions which caused damage and increased
energy consumption. However, the lack of control led
to a disproportionate consumption of energy in order
to maintain the desired level of supply.
In 1997, the company had an energy survey carried
out in order to analyse the scope for energy savings.
One of the proposals to emerge from this analysis
was the installation of an energy-efficient dual pump
system at the cooling water plant.
This multinational pharmaceutical company employs
approx. 15,000 people in 61 countries.
The cooling system at the company used to be
equipped with nine pumps operating at full power
around the clock.
Unfortunately, the only way of regulating the supply
was by using the manual on/off control. To make the
manual control run smoother, the pumps were
dimensioned for both full and half size. This resulted
in interruptions which caused damage and increased
energy consumption. However, the lack of control led
to a disproportionate consumption of energy in order
to maintain the desired level of supply.
In 1997, the company had an energy survey carried
out in order to analyse the scope for energy savings.
One of the proposals to emerge from this analysis
was the installation of an energy-efficient dual pump
system at the cooling water plant.
THE GRUNDFOS SOLUTION
Now, in the basement at the company six large NK
pumps supply the cooling water for production at
the factory.
The six NK pumps together are able to supply no
less than 3,200 m3/h of cooling water every hour.
They are precisely regulated using the Control 2000
unit.
THE OUTCOME
Prior to this project, energy consumption was
determined at 2,365,000 kWh/year. After the
conversion, the energy consultants expected
savings of 920,000 kWh/year – 40%! – resulting in
an expected consumption of 1,445,000 kWh/year in
future.
The entire project has a payback period of
approximately three years, if one includes the grant
from the Energy Agency.
Now, in the basement at the company six large NK
pumps supply the cooling water for production at
the factory.
The six NK pumps together are able to supply no
less than 3,200 m3/h of cooling water every hour.
They are precisely regulated using the Control 2000
unit.
THE OUTCOME
Prior to this project, energy consumption was
determined at 2,365,000 kWh/year. After the
conversion, the energy consultants expected
savings of 920,000 kWh/year – 40%! – resulting in
an expected consumption of 1,445,000 kWh/year in
future.
The entire project has a payback period of
approximately three years, if one includes the grant
from the Energy Agency.
SAYS THE MAINTENANCE ENGINEER AT THE
PHARMACEUTICAL COMPANY:
“Since we now have all these means of control, the
system today is far more reliable. Should anything
happen to a pump in operation, the control unit
makes sure that another one is started.
We are highly dependent on the cooling system.
Without any cooling water, we would have to stop
production, and the production in process may be
ruined. “A full year’s energy savings is nothing
compared to the production being at a standstill for
just one single day”.
“Consequently, we have to be fairly sure that our
suppliers – in this case Grundfos – possess both the
technical knowledge and the resources to fulfill this
assignment. They do! The system runs trouble free
and we are indeed satisfied with Grundfos.”
PHARMACEUTICAL COMPANY:
“Since we now have all these means of control, the
system today is far more reliable. Should anything
happen to a pump in operation, the control unit
makes sure that another one is started.
We are highly dependent on the cooling system.
Without any cooling water, we would have to stop
production, and the production in process may be
ruined. “A full year’s energy savings is nothing
compared to the production being at a standstill for
just one single day”.
“Consequently, we have to be fairly sure that our
suppliers – in this case Grundfos – possess both the
technical knowledge and the resources to fulfill this
assignment. They do! The system runs trouble free
and we are indeed satisfied with Grundfos.”
GRUNDFOS PRODUCTS USED
> 6 NK end-suction pumps
> Control 2000MF
> 6 NK end-suction pumps
> Control 2000MF
plant service systems | PROCESS WATER
Processing water with flexible solutions
THE SITUATION
The textile industry demands more from their
pumps than most manufacturers can handle. When
the company finally tired of poor performance from
its old standard pumps, Grundfos was ready to
supply a superior system.
As part of its environmentally friendly and highly
sophisticated operation processes, the company
uses large quantities of process water: up to 900
m3/h at approximately 25 mWc. To complicate
matters further, consumption of process water
varies enormously: from 100 m3/h to the absolute
maximum within very short periods of time.
The existing system comprised three standard
pumps, and their performance was no longer
adequate to the company’s needs.
The textile industry demands more from their
pumps than most manufacturers can handle. When
the company finally tired of poor performance from
its old standard pumps, Grundfos was ready to
supply a superior system.
As part of its environmentally friendly and highly
sophisticated operation processes, the company
uses large quantities of process water: up to 900
m3/h at approximately 25 mWc. To complicate
matters further, consumption of process water
varies enormously: from 100 m3/h to the absolute
maximum within very short periods of time.
The existing system comprised three standard
pumps, and their performance was no longer
adequate to the company’s needs.
THE GRUNDFOS SOLUTION
Wishing to reduce production times, the company
wanted to replace their old pump solution. Ensuring
the optimum supply of process water to production
facilities was a main concern, and consequently the
client chose a complete booster set from Grundfos,
comprising six CR 90-2 pumps. The solution came
equipped with the special Hydro Control 2000
system, which controls the activation of the pumps.
THE OUTCOME
The Hydro Control 2000 system, combined with the
six-pump configuration, makes for a highly flexible
solution with minimal risk of pressure surges. The
Grundfos booster solution has now provided
unmatched flexibility for more than two years, and
the client remains highly satisfied with the marked
increase in performance.
Wishing to reduce production times, the company
wanted to replace their old pump solution. Ensuring
the optimum supply of process water to production
facilities was a main concern, and consequently the
client chose a complete booster set from Grundfos,
comprising six CR 90-2 pumps. The solution came
equipped with the special Hydro Control 2000
system, which controls the activation of the pumps.
THE OUTCOME
The Hydro Control 2000 system, combined with the
six-pump configuration, makes for a highly flexible
solution with minimal risk of pressure surges. The
Grundfos booster solution has now provided
unmatched flexibility for more than two years, and
the client remains highly satisfied with the marked
increase in performance.
GRUNDFOS PRODUCTS USED
> Hydro 2000 booster system with 6 X CR 90-2
> Hydro 2000 booster system with 6 X CR 90-2
plant service systems | CONDENSATE PUMPING
CRN pumps eliminated downtime for a major
manufacturer in the paper industry
manufacturer in the paper industry
THE SITUATION
Manufacturing cardboard involves demanding processes, particularly as regards steam. This gave rise to
considerable problems for this major cardboard manufacturer, with several serious system crashes caused
by an unreliable pump solution.
Cardboard manufacturing involves plenty of steam, which is condensed after having been used for a
product treatment process. In this case the system is called upon to pump this return condensate –
condensed at approximately 160°C – back into the steam boiler, operating at pressures of 14 bar. The old
pump, made by another manufacturer, used external cooling water to protect the shaft seal against the
high temperatures.
Manufacturing cardboard involves demanding processes, particularly as regards steam. This gave rise to
considerable problems for this major cardboard manufacturer, with several serious system crashes caused
by an unreliable pump solution.
Cardboard manufacturing involves plenty of steam, which is condensed after having been used for a
product treatment process. In this case the system is called upon to pump this return condensate –
condensed at approximately 160°C – back into the steam boiler, operating at pressures of 14 bar. The old
pump, made by another manufacturer, used external cooling water to protect the shaft seal against the
high temperatures.
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Steel
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For food & beverage
industries
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Distribution | New
Thinking. New Technology.
Jun 3, 2012
Grundfos SE & SL ranges
| Submersible &
dry-installed waste water
pumps
Nov 1, 2011
Grundfos | Pumps for
paper industry
Sep 8, 2011
Grundfos Blueflux |
Advanced motor
technology for pumps
that reduces energy waste
Aug 22, 2011
CRN High Pressure
Programme
Jul 23, 2011
Grundfos CRT | Titanium
at work for industry
Jul 2, 2011
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Management |
Internet-based pump
monitoring
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Cooled Top
May 7, 2011
Grundfos | Buy the
Original
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Submersible and dry
installed pumps for
aggressive environments
Feb 19, 2011
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all the way
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Ownership
Nov 14, 2010
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Inside
Sep 3, 2010
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Steam Boilers
Jul 10, 2010
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Horizontal & vertical
double suction split case
pumps
Jun 21, 2010
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generation of horizontal
multistage pumps
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storm water pumps helps
BigB's house from
flooding?
Jun 8, 2010
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Pressure and Reliable
Drainage Pumps
May 14, 2010
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in Industrial Process
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Grundfos Solutions |
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in Plant Service Systems
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Grundfos Dosing &
Disinfection | Get the
right mix
March 12, 2010
Grundfos Direct Sensors
March 2, 2010
Grundfos Fire Protection
Solutions | Fire protection
you can count on
February 11, 2010
Grundfos in Burj Khalifa |
A towering achievement
Grundfos pumps secure
clean water for thousands
of people in Haiti
February 10, 2010
Tranter plate & frame
heat exchangers |
Bringing efficiency to heat
transfer
February 4, 2010
TRANTER Econocoil | An
efficient & versatile light
duty plate type heat
exchanger
January 29, 2010
TRANTER | Gasketed and
welded heat exchangers
for every need
January 22, 2010
Unilift CC | Multi-purpose
submersible drainage
pumps
January 14, 2010
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range of in-line choices
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range | Perfection under
high demands
January 1, 2010
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PRO - Effective and safe
disinfection with Chlorine
Dioxide
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broken
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