One of the most significant challenges for the pump industry is the urgent need to improve sustainability outcomes. Recognising this need, Grundfos has been working to reduce the financial and environmental costs of pump installation and maintenance.
Pumps can be quite costly to acquire, and it’s essential to consider the significant hidden costs that customers might not immediately realise. When factoring in the total lifetime costs of operating a pump, these expenses can significantly exceed the initial upfront cost of purchasing a new pump. This is primarily due to additional maintenance costs, which can quickly amount to twice the initial investment. The significant ongoing operational costs associated with running a pump must also be considered.
Currently, nearly 30 per cent of the world’s electricity is used in industrial activities, where at least 10 per cent of their total energy is used by pumps. As such, pumps play a significant role in industrial sustainability goals – but research suggests that over 70 per cent of pumps operate below maximum efficiency.
That’s why Grundfos has developed Energy Check Advanced (ECA). It seeks to determine how much energy (kWh) can be reduced by replacing an existing pump set with a new one and what the payback time would be. Grundfos ECA uses power sensors in addition to the equipment nameplate information. The measurement period depends on the system’s variability.
How does it work?
The Grundfos ECA process is an ongoing one that ensures any issues can be spotted and dealt with. It starts with the initial contact, which sees Grundfos assess the site for prequalification by discussing the relevant site information. It is followed by a premises inspection to draw up a list of performance data and installed pumps.
Grundfos then logs data to determine the pumps’ load profiles and develops a proposal for its client. The printed report contains the full details of the pump audit and recommendations, which can include offering a solution incorporating the right pumps for the site. These recommendations are based on optimal performance, energy efficiency and the cost savings that can be maximised from the recommended solution.
It’s important to remember that the Grundfos ECA requires follow-up to ensure the pumps are properly maintained and operated.
What can be achieved?
There are many possible outcomes when Grundfos run its ECAs. For example, following an ECA at one of the largest food manufacturers in the world, Grundfos recommended that investing in more energy-efficient pumps and completing several minor improvements would generate the potential for financial savings approaching $50,000. This would mean the pumps would be paid back in less than four years, saving over 400,000 kWh annually.
Similarly, a dairy factory found that its existing four-pump solution had an obsolete control panel and one failed pump. With the goal of peace of mind and reliability, a new four-pump solution saw nearly $120,000 saved per year, along with over 50,000 kWh.
A fibre manufacturer had been having issues with a boiler feed pump. Upgrading the pump delivered over $16,000 in annual savings in an initial investment of less than $14,000. The pump would generate significant financial and environmental savings with a payback time of less than nine months.
Investing in greener and more energy-efficient pump solutions can boost a business’s environmental profile by reducing carbon emissions, while also helping enterprises comply with the latest energy-saving regulations. By increasing the reliability of operations and reducing downtime, pump owners can see critical operational benefits.
Image: Grundfos
