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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:
[email protected] | URL:
http://www.kineticflowsystems.com
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.
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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:
[email protected] | 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:
[email protected] | 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:
[email protected] | 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:
[email protected] | URL:
http://www.kineticflowsystems.com
