performance increase grundfos solutionsnotes dual pump system at the cooling water plant. now, in...
TRANSCRIPT
>
Cooling 4
Process water 5
Condensate pumping 6
Precision dosing 7
Industrial wastewater 8
Water supply 9
>
Handling fibrous media 10
Customised solutions 11
High pressure 12
Handling aggressive media 13
Product range and service 14-15
industrial industrial
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 brochure inspire you to a closer cooperation
with Grundfos.
Grundfos solutions increase performance
How
111288 CASE brochure 06/11/02 14:55 Side 1
Processing water with flexible solutions
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 inter-
ruptions 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.
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
supply no less than 3,200
cooling water every hour.
precisely regulated using t
2000 unit.
Prior to this project, energy
tion was determined at
kWh/year. After the co
the energy consultants
savings of 920,000 kWh/ye
– resulting in an expected co
of 1,445,000 kWh/year in fu
The entire project has a
period of approximately th
if one includes the grant
Energy Agency.
Energy savings of 40%:920,000 kW/h per year!
6 NK end-suction pumps
Control 2000MF
>
4
plant service systems
- :
“Since we now have all these
means of control, the system today
is far more reliable. Should anyt-
hing happen to a pump in opera-
tion, the control unit makes sure
that another one is started.
We are highly dependent on the
cooling system. Without any coo-
ling water, we would have to stop
production, and the production in
process may be ruined.“A full year’s
energy savings is nothing compa-
red 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.”
emands more
n most manu-
e. When the
red of poor
old standard
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
Hydro 2000 booster system with
6 X CR 90-2
>
plant service systems
>
111288 CASE brochure 06/11/02 14:55 Side 3
are able to
m3/h of
They are
he Control
consump-
2,365,000
nversion,
expected
ar – 40%!
nsumption
ture.
payback
ree years,
from the
The textile industry d
from their pumps tha
facturers can handl
company finally ti
performance from its
5
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 perfor-
mance was no longer adequate to the
company’s needs.
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 Hydro Control 2000 system,
combined with the six-pump con-
figuration, makes for a highly flexible
solution with minimal risk of pressure
surges. The Grundfos booster solution
has now provided unmatched flexibi-
lity for more than two years, and the
client remains highly satisfied with
the marked increase in performance.
7
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 pres-
sures of 14 bar. The old pump, made by
another manufacturer, used external
cooling water to protect the shaft seal
against the high temperatures.
This protection was not, however,
adequate. Following repeated break-
down episodes, the engineer respon-
sible for day-to-day operation decided
to replace the inefficient pump with a
Grundfos CRN Air-Cooled Top pump,
featuring the air-cooled shaft seal
that is unique to Grundfos. This
pump is capable of handling water of
up to 180°C without needing any
external cooling water.
In special situations, particularly in
connection with start-up, the pump
may operate against lower counter
pressures which could cause cavitation.
To prevent this, the Grundfos CRN
pump is fitted with a special pre-
chamber and impeller, ensuring
that the NPSH value remains low
– irrespective of the flow.
The advantages outlined above
– a pump which successfully combines
high temperatures and high pressures
– resulted in a pump solution which
has now provided the client with a
whole year of trouble-free operation.
CRN pumps eliminated downtime for amajor manufacturer in the paper industry
plant service systems
CRN Air-Cooled Top>
–
A major sugar manufacturer had
similar needs, with identical con-
densate returns. In this case, losses
due to friction were 16 mWc. Until
recently, the system used compri-
sed six pumps made by another
manufacturer. These pumps needed
external cooling water to protect
the shaft seal against high tem-
peratures. When the plant was due
for renovation, the chief engineer
decided to replace the pumps with
six Grundfos NKG 125-250 pumps.
These pumps are fitted with
Burgmann Cartex double seals
which use glycol as coolant.
Temperature differentials are used
to circulate the glycol, ensuring
that even though the pump opera-
tes at 160°C, the glycol will never
reach a temperature higher than
70°C. Thus, the Grundfos solution
eliminated the need for external
cooling water.
Precision pumping: Getting exactly what you want with Digital Dosing
A leading textile dye works based in
Scandinavia supplies fabrics for the
automobile industry. The quality stan-
dards within this area are extremely
demanding: the colours need to be
100% consistent from batch to batch.
Of course, this calls for exact dosing of
the dyes used. The old solution,
supplied by another manufacturer,
featured pumps that where time-
consuming and troublesome to cali-
brate. In fact, the problems rose to a
level where the company had to
allocate 1.5 full-time employees to
handle calibration at all times. The
task of ensuring precise dosing at the
plant is complicated further by the
fact that the pumps have to handle
varying inlet pressures.
As the overall problems with calibra-
tion became intolerable, the customer
wanted to replace its old system with
a simpler, less time-consuming, and
more accurate pump solution. The
obvious choice was a Grundfos Digital
Dosing system with its straight-
forward “what you set is what you
get” technology. This innovative tech-
nology eliminated all need for con-
tinuous calibration: Grundfos Digital
Dosing pumps provide customers
with fast and easy calibration and
accurate capacity setting, facilitating
smooth and even dosing action. In
addition to this, the user interface is
so simple that the need for specially
allocated staff disappeared overnight:
the desired volumes of dye are simply
set by means of the easy-to-use
digital control panel, and the pumps
do all the thinking.
The Grundfos Digital Dosing solution
has provided trouble-free operation
for more than 18 months – with
minimal calibration of the system.
Not only has this eliminated aggra-
vation and delays, it has also freed
up human resources for other tasks
within the company.
DME Digital Dosing pumps>
plant service systems
111288 CASE brochure 06/11/02 14:56 Side 5
This large-scale poultry abattoir gene-
rates 1.5 million litres of wastewater
every day. Being full of large chunks of
debris, this industrial wastewater
needs to be filtered before further
treatment. All of this means that
the company needs a solution which
is capable of handling huge volumes
while also providing highly specific
wastewater treatment.
At the abattoir, wastewater is gene-
rated from all production areas.
Consequently, pumps are called upon
to handle all kinds of waste and refuse
– including rubber gloves! The local
public wastewater plant will not
accept unfiltered wastewater, which
means that the abattoir has to carry
out an initial treatment to remove
all large solids from the water before
sending it on.
All wastewater is collected in a pump
pit and pumped onwards into a
mechanical screen, where all solid
waste is separated out. These solids
are then transported to a special
waste-disposal site. The first pit
contains two 100 mm S-type sewage
pumps with channel impellers, provi-
ding performance of 20 l/s x 25 mWc.
The 200 mm discharge line extends
to 500 m.
The pumps are mounted on complete
guide-rail systems, thus ensuring fast
and easy servicing. Frequency control
allows a continual adjustment to pit
levels, and the pumps are alternated
on a weekly basis.
Once the solids have been removed,
the wastewater is transferred to a
second, similar pit. From here, it is
pumped onwards to the public waste-
water treatment plant.
The chief engineer responsible for the
day-to-day operation of the abattoir is
very pleased with the new Grundfos
solution:
“since October 2000, all pumps and
controls have provided an admirable
performance in this unique and
demanding environment”.
Once again, Grundfos solutions prove
that they will match anything,
even highly specialised heavy-duty
applications.
For brewing beer, only the best pumps are good enough
9
Handling large quantities of abattoirwastewater the Grundfos way
plant service systems
S type wastewater pumps>
This 143-year-old brewery is the leading
domestic brand. It has reached this
dominant position on the basis of its
reputation for consistency and due to
its dynamic product development
strategy.
It is essential for both production and
for the end product that the water
supply system runs reliably and that
the quality of the supplied water is
consistent. A failure could bring
production to a standstill and harm
the quality of the beer.
There is also strong competition
among the breweries to continuously
decrease energy consumption.
Three Grundfos high-grade AISI 316
stainless steel CRN 64 pumps control-
led by a central PLC system supply all
brewery water. One CRN 8 serves as
jockey pump to maintain a constant
pressure in the system.
The versatile CR pumps are used not
only for the brewing water but also for
the cooling water, heating, cleaning etc.
The original CR range has three
decades’ reputation for reliability and
the maintenance procedures are quick
and simple.
Grundfos supplied highly efficient
hydraulics and drives as well as the
professional dimensioning tool Win-
CAPS to optimise the pump selection.
Now the system runs very reliably and
at optimum efficiency – reducing the
Cost of Ownership over the life cycle.
And maintaining that vital beer taste!
Brewing water – 3 x CRN 64
Cooling water
– 6x CRE 90.2 15kW
>
>
plant service systems
111288 CASE brochure 06/11/02 14:56 Side 7
Working with the customer for that special solution
This company manufactures chemicals.
During the manufacturing process it
is crucial to avoid leakage. The pumps
are often required to deal with liquids
at high temperatures, and to handle
vacuums, etc.
The company had a particular problem:
In connection with a distillation pro-
cess, a CRN pump with a double seal
circulates the liquid. This process is
carried out under a 95% vacuum, and
as the pump is placed approximately 2
m below the water surface, we are in
problem territory for pump suppliers.
Vacuum operation typically causes the
following problems:
1. The seal opens up, which means
that air is drawn into the plant. This
can ruin the seal when the pump is
restarted, and air may also have an
adverse effect on the process. This is
solved by using a double seal.
2. When it comes to a stop, the pump
is drained and cannot be restarted
without being primed. This is solved
by applying a vacuum pipe directly
at the top of the pump and by using
the re-circulation function in the
pump suction chamber.
All in all, the company needed a
product that was 100 per cent
adapted to customer requirements.
The company has always been very
satisfied with Grundfos’ pumps, which
they use for supplying heat and water
to the factory. In 2001, they collabo-
rated with Grundfos on a process-
oriented solution to the problem
above. This would require a different
type of pump.
The answer was a stainless steel
centrifugal pump (CRN) fitted with
O-rings that are resistant to chemicals.
This version has a double mechanical
shaft seal that can withstand liquid
temperatures of up to 120°C inde-
finitely. There is also a barrier fluid
chamber that prevents leakage, mee-
ting the company’s environmental
requirements of a leak-free pump
that would perform perfectly under
the specified conditions in the plant.
The collaboration between this
company and Grundfos is typical
of the partnerships that have solved
individual companies’ problems and
led to Grundfos developing a wide
range of special solutions. In this case
for handling “difficult”:
> aggressive or corrosive liquids
> particle-carrying liquids
> poisonous or explosive liquids
> extremely high pressures
> extremely high or low temperatures
Large amounts of fibrous water – but no clogging
7 CRN pumps>
:
“Our production plant has perfor-
med like a dream – with minimal
downtime. The new Grundfos
pumps, seven in all, replace nine
old pumps that were no longer
financially viable. The Grundfos
solution cost only a fraction of a
traditional pump solution, but even
so, the purchase price was not the
main benefit. We saw much better
performance with the new pumps.
And of course the fact that energy
consumption was down by 50 per
cent was also important”.
A large-scale potato flour factory
processes approximately 180,000
tonnes of potatoes each season.
Besides potato flour, the end products
include potato protein and pulp for
feed. Naturally, energy efficiency is a
key consideration at the facility – part-
ly because reductions in energy con-
sumption make the company eligible
for public-sector subsidies for certain
projects. A hydrocyclone system sepa-
rates the raw material – the potato –
into media of varying viscosity, and
these substances need to be trans-
ported in an efficient manner with
minimal downtime.
Grundfos installed 7 CRN centrifugal
pumps, which fulfil a crucial function
by pumping the various media to
be transported.
As will be evident from the feedback
quoted above, the Grundfos pumps
have proven that they are equal to the
task of transporting even very fibrous
media with no problems whatsoever.
And of course the energy savings are
always welcome. Two more reasons
why prospective clients can be sure
that Grundfos is the right supplier for
them.
CRN – stainless steel
centrifugal pump with:
Double mechanical shaft seal
>
process
>
process
> Double shaft seal
1 0 1 1
111288 CASE brochure 06/11/02 14:56 Side 9
New centrifugal pumps for demandingindustrial applications
This company has been manufactu-
ring cardboard for over 90 years. The
factory produces 70,000 tons of grey
board and 90,000 tons of duplex card-
board; up to 320 metres of cardboard
rolling off the conveyors every minute!
These days, the main raw material is
no longer straw, but recycled paper.
The paper is mixed with large quan-
tities of water and pulped using large
cutters. This pulp is then transported
via conveyor belts over a filter or a
sieve to remove the surplus water. In
order to prevent the filter becoming
blocked, it must be cleaned conti-
nuously, which is done using high-
pressure water jets. Previously, the
traditional submersible pumps were
used in order to achieve the required
pressure.
However, this system had a number
of drawbacks: high energy consump-
tion, high purchase and maintenance
costs and leakages.
Therefore, the decision was taken to
use a Grundfos CRN 16 pump in com-
bination with a Grundfos CRN 16-
160/15SF high-pressure pump, which
is able to supply a pressure of 40 bars.
The CRN pumps have proven extre-
mely reliable. They are easy to
maintain and service-friendly. The
new system also provides substantial
energy-savings compared to the sub-
mersible pumps. The savings over the
life of the pumps will be substantial.
Their ability to handle large volumes of
water means that Grundfos pumps can
be used in a wide variety of situations.
Multistage centrifugal pumps for cardboard manufacture
This company manufactures and dyes
textiles for the automotive industry
and for a number of other applica-
tions. The company uses cutting-edge
dying technology, and the production
process is designed for high quality
and environmental friendliness.
The process makes high demands on
the pumps. The dye contains acids and
is used at a temperature of some
140°C and a pressure of 4.5 bars.
Before a new production run can be
started up, a colour test is made in the
lab. The dying machines previously
used for the test have been mounted
with stainles steel free pumps with
single mechanical shaft seals which
have caused trouble.
An ordinary pump is typically not suit-
able for liquids at 140°C. And the acid
dyes destroy the shaft seal’s sliding sur-
faces.
Hence the choice of a CRN pump with
a MAGdrive. The pump is made of
acid-proof stainless steel and has a
magnetic drive. This drive type handles
high temperatures without problems
and makes the shaft seal redundant.
The in-line design of the CRN pump
and the high overall reliability meet
the customer’s requirement for few
service intervals.
The pump is hermetically sealed.
Therefore, the dye is very unlikely to
leak and the process is much safer for
the employees – and environmentally
responsible. The fact that the pump
features a magnetic drive rather than
a traditional shaft seal provides the
very hard-wearing and compact
solution that was demanded.
The CRN MAGdrive pumps are un-
matched for use in industrial processes
that involve aggressive, volatile or
environmentally hazardous liquids.
CRN 16-SF high pressure>
CRN MAGdrive>
process process
> MAGdrive
1 2
111288 CASE brochure 06/11/02 14:56 Side 11
>
>
>>
Technical data
Flow (m3/h): Max 120
Head (m): Max 480
Max operating pressure (bar): 40
Liquid temperature (°C): -40 to +180
>
>
>>
Technical data
Flow (m3/h): Max 2000
Head (m): Max 150
Max operating pressure (bar): 16
Liquid temperature (°C): -10 to +160
/
>
>
>
>
>>
Technical data
Flow (m3/h): Max 215
Head (m): Max 800
Max operating pressure (bar): 60
Liquid temperature (°C): 0 to +60
Global servicenetwork
industrial
The Grundfos name is synonymous
with dependable, high quality pumps
that are highly unlikely to cause trouble.
If you need service, rest assured that
the Grundfos service network is gea-
red to move fast. You can get in touch
with a Grundfos approved service
partner around the clock.
Improving industry
The process is the heart of any factory
and reliable operation is of the utmost
importance as standstills will result in
very high costs. Together with our cus-
tomers, we are constantly developing
and optimising our range of products to
cover all aspects of the actual process.
We are listening to our customers,
knowing their demands and under-
stand the industrial process. And by
understanding the need for cost effec-
tive industrial production and proces-
sing, we are constantly thriving to
minimise the Cost of Ownership.
And even more important – we are
thriving to cover all your needs, to
ensure that our partnership will be of
benefit to your business.
1 5
Pumps used in industrial applications
Technical data
Flow (l/h): Max 48
Head (m): Max 180
Liquid temperature (°C): 0 to +50
1 4
>
>
>
>>
Technical data
Flow (m3/h): Max 470
Head (m): Max 650
Max operating pressure (bar): 60
Liquid temperature (°C): 0 to +60
>
>
>>
Technical data
Flow (m3/h): Max 720
Head (m): Max 160
Max operating pressure (bar): 16
Liquid temperature (°C): 0 to +70
>
>
>>
–
>
>>
>
Technical data
Flow (l/s): Max 2500
Head (m): Max 120
Discharge diameter:
DN 80 to DN 250
Liquid temperature (°C): 0 to +40
Technical data
Flow (m3/h): Max 600
Head (m): Max 60
Max operating pressure (bar): 20
Liquid temperature (°C): -25 to +140
>
2000
///
/
/
111288 CASE brochure 06/11/02 14:56 Side 13
Being responsible is our foundationThinking ahead makes it possible
Innovation is the essence
Grundfos Management A/SPoul Due Jensens Vej 7DK-8850 BjerringbroPhone +45 87 50 14 00
www.grundfos.com
GRUNDFOS INDUSTRY
96
49
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14 1
1 0
2
How
to improve industry
111288 CASE brochure 06/11/02 14:56 Side 15