Economical Retrofitting / Upgrade of Existing Hot Water Pumping System with Maximum Energy Conservation

Designed, Engineered, Supplied, Installed & Commissioned by Kinetic Flow Systems

Figure 1: Efaflu BMV Series Vertical Inline Hot Water Pump (right) Operating in Parallel with Old Pumps

Efaflu's BMV 32 series pump has recently been supplied by Kinetic Flow Systems (KFS) to Yunus Textile Mills on
their Caustic Recovery Plant - Hot Water Application. The pump is exactly equivalent to Grundfos CR series in
terms of performance parameters as well as dimensional interchangeability.
This was a retrofitting / upgrading job. We (KFS) conducted design & engineering, supply and supervisioning of
installation and commissioned the system. At the end of the paper, there are more pictures of the installation.
The existing customer installation included 02 pump sets (constant speed driven) x 11kW/2P (01 operating + 01
standby). The pumps are supplying hot water at +95degC to multiple machines. Once machine requirements are
met, their solenoid valve closes automatically. The original system came with a pressure tank and pressure
switches. So, when the requirement was finished, the pumps would stop at a preset pressure. However, the
bladder on hot water application was susceptible to frequent failures. Due to this customer was forced to use a
circulation valve on discharge header of their pumps to re-direct flow back to their source reservoir in case of low
and no flow conditions. The result was roughly 20amps of energy consumption round the clock for each pump in
operation.

Karachi Office: Plot C11, Suite 404, Marium Heights, Block 7/8, KCHS (Baloch Colony), Karachi.
Tel: +92-21-34540210 Fax: +92-21-34540210 Cell: +92-334-3546219
Lahore Office: 79-K, 1st Floor, Commercial Zone, Phase-I, DHA, Lahore. Tel: +92-42-35709913 Fax: +92-42-35709913
Wah Office: G-26, Street-14, Officers Colony, Wah Cantt. Tel: +92-51-4512040 Cell: +92-331-6322422
E-mail: info@kineticflowsystems.com | URL: http://www.kineticflowsystems.com

After site visit and detailed analysis, KFS proposed adding another pump to meet the expansion requirement;
however, the pump was proposed to be inverter driven while the existing two pumps were controlled by the
same inverter to switch on and off based on requirement (cascade / multi-motor operation).
Pressure was decided to be the feedback for system operation and a specialized high temperature pressure
transmitter (4~20mA) was installed to govern the VFD. The controller was also designed, engineering, supplied
and commissioned by KFS including of course the VFD.
During the process, customer's existing motor starters were utilized to keep the cost at minimum and we
retrofitted our VFD based controller with it. There was also provision built into our controller to shift the VFD to
one of the standby pump in case of failure of main pump!!
The job has been executed successfully and motor amps during low-flow condition were observed to be roughly
5amps. In no-flow (no demand) conditions, the inverter turns off the motor and goes in the standby mode thus
no power consumption. Pumps were governed by VFD and were switched on and off based on system demand.
Controller was built to provide protection against hunting of motors thereby system operated smoothly between
switching on/off of pumps.

Figure 2: KFS supplied Inverter Based Controller operating on pressure feedback (4~20mA) High Temperature Pressure Transmitter /
Transducer
Karachi Office: Plot C11, Suite 404, Marium Heights, Block 7/8, KCHS (Baloch Colony), Karachi.
Tel: +92-21-34540210 Fax: +92-21-34540210 Cell: +92-334-3546219
Lahore Office: 79-K, 1st Floor, Commercial Zone, Phase-I, DHA, Lahore. Tel: +92-42-35709913 Fax: +92-42-35709913
Wah Office: G-26, Street-14, Officers Colony, Wah Cantt. Tel: +92-51-4512040 Cell: +92-331-6322422
E-mail: info@kineticflowsystems.com | URL: http://www.kineticflowsystems.com

Karachi Office: Plot C11, Suite 404, Marium Heights, Block 7/8, KCHS (Baloch Colony), Karachi.
Tel: +92-21-34540210 Fax: +92-21-34540210 Cell: +92-334-3546219
Lahore Office: 79-K, 1st Floor, Commercial Zone, Phase-I, DHA, Lahore. Tel: +92-42-35709913 Fax: +92-42-35709913
Wah Office: G-26, Street-14, Officers Colony, Wah Cantt. Tel: +92-51-4512040 Cell: +92-331-6322422
E-mail: info@kineticflowsystems.com | URL: http://www.kineticflowsystems.com

Karachi Office: Plot C11, Suite 404, Marium Heights, Block 7/8, KCHS (Baloch Colony), Karachi.
Tel: +92-21-34540210 Fax: +92-21-34540210 Cell: +92-334-3546219
Lahore Office: 79-K, 1st Floor, Commercial Zone, Phase-I, DHA, Lahore. Tel: +92-42-35709913 Fax: +92-42-35709913
Wah Office: G-26, Street-14, Officers Colony, Wah Cantt. Tel: +92-51-4512040 Cell: +92-331-6322422
E-mail: info@kineticflowsystems.com | URL: http://www.kineticflowsystems.com

Karachi Office: Plot C11, Suite 404, Marium Heights, Block 7/8, KCHS (Baloch Colony), Karachi.
Tel: +92-21-34540210 Fax: +92-21-34540210 Cell: +92-334-3546219
Lahore Office: 79-K, 1st Floor, Commercial Zone, Phase-I, DHA, Lahore. Tel: +92-42-35709913 Fax: +92-42-35709913
Wah Office: G-26, Street-14, Officers Colony, Wah Cantt. Tel: +92-51-4512040 Cell: +92-331-6322422
E-mail: info@kineticflowsystems.com | URL: http://www.kineticflowsystems.com