Advanced pump systems lower energy costs and streamline operations in high-pressure industrial applications.
From food processing to pulp and paper, industrial applications rely on high-pressure pumps to handle demanding washing and cleaning needs. While functional, traditional pump setups often have significant drawbacks: high maintenance, frequent downtime and mounting operational costs. Emerging technologies offer smarter, cost-effective solutions that address these challenges with precision and efficiency.
Advanced solutions
One of the most promising new solutions is Grundfos’ Hydro HP technology. This technology combines intelligent features designed to streamline high-pressure pumping systems. At its core, Hydro HP includes CR/CRN vertical multistage pumps, known for their reliability and ease of maintenance. These pumps can handle high- and low-flow needs, reducing energy consumption while delivering consistent performance.
“The system’s versatility also allows it to cater to varying industry demands,” a spokesperson said. “Our Hydro HP system is designed to accommodate different industrial pressures and flows without compromising energy efficiency or reliability. With this adaptability, it’s the answer to diverse and complex industrial needs.”
The ability to integrate variable-frequency drives (VFDs) into the system further boosts efficiency by automatically adjusting motor speed to meet specific flow requirements. This feature lowers energy consumption and reduces system stress, minimising the need for frequent maintenance.
Grundfos has developed the control system for Hydro HP to be centred around the CU 352 multi-pump controller. With seamless integration to plant SCADA systems, operations staff can monitor and manage the pumps’ performance in real time, streamlining maintenance and troubleshooting processes.
Facilities can set optimal operating conditions and observe valuable data points, such as system pressure, flow, and operational status.
Reducing operational expenditures
The cost of ownership of a pump system goes beyond its initial purchase price, representing only around 10 percent of the asset’s life. Traditional high-pressure systems often require expensive maintenance, especially in demanding industrial environments such as wastewater treatment. The Hydro HP system is built with wear-resistant materials and easy-to-replace components, significantly reducing the time and cost required for routine servicing.
The CR/CRN pumps within the Hydro HP are equipped with Grundfos-engineered cartridge seals, which enable fast, on-site replacement in under 30 minutes. By simplifying maintenance, these pumps help facilities save on parts and labour.
“Our goal is to minimise disruptions by designing a system that can be maintained in-house,” said the spokesperson. “Our cartridge seals and stack kits allow quick replacements, reducing downtime and lowering operational costs.”
The system offers energy-saving features that reduce energy consumption by 20 to 50 per cent compared to fixed-speed pumps, leading to long-term cost savings. Hydro HP uses variable frequency drives (VFDs) that automatically adjust motor speed, conserving energy and lowering overall costs. According to Grundfos, enhancing energy efficiency and simplifying maintenance can result in a positive return on investment within the first few years of operation.
The packaged approach
In addition to addressing operational pain points, the Hydro HP system integrates pumps, controls, and customisation options within a single, fully-engineered package. With its flexible configuration, the system can be tailored to meet specific operational demands or expanded for future growth while maintaining a compact footprint. It is factory-tested and has a two-year warranty, ensuring reliability and a streamlined installation process.
“We’re seeing an increased demand for systems that combine performance with ease of installation and support,” said the spokesperson. “Hydro HP meets this demand by delivering an integrated solution, providing facilities with dependable performance and the added security of comprehensive support.”
Hydro HP’s packaged pumping solution from Grundfos is a forward-thinking choice for facilities looking to boost efficiency and minimise long-term costs. Enhanced monitoring, efficient energy use, and low-cost maintenance provide a sustainable solution to modern industry demands.
For more information, visit https://product-selection.grundfos.com/au/industries
