performance increase Grundfos solutionsnotes dual pump system at the cooling water plant. Now, in the basement at the company ... The Grundfos booster solution has now provided unmatched

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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

>


>


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


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>



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


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

>

>



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


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


>

>

>>

Technical data

Flow (m3/h): Max 120

Head (m): Max 480

Max operating pressure (bar): 40

Liquid temperature (°C): -40 to +180

>

>

>>

Technical data


Head (m): Max 150



/

>

>

>

>

>>

Technical data


Head (m): Max 800


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


1 4

>

>

>

>>

Technical data


Head (m): Max 650



>

>

>>

Technical data


Head (m): Max 160



>

>

>>

–

>

>>

>

Technical data

Flow (l/s): Max 2500

Head (m): Max 120

Discharge diameter:

DN 80 to DN 250


Technical data


Head (m): Max 60



>

2000

///

/

/


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

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How

to improve industry


Documents

performance increase Grundfos solutionsnotes dual pump system at the cooling water plant. Now, in the basement at the company ... The Grundfos booster solution has now provided unmatched