Case
Pump intelligence optimizes processes, saving 30% energy
CIDER MANUFACTURER
See how one of the world’s top cider producers has improved its industrial cooling processes with intelligent solutions from Grundfos.
30% ENERGY SAVINGS
FULL CONTROL
EASY OPERATION
One of the world’s top cider makers was experiencing a substantial rise in demand for its product. With its production increase, it needed more cooling capacity – both for the process of manufacturing cider and also for storing the final product. The company and their OEM supplier – one of the UK’s leading industrial cooling installers – were looking for a turnkey solution that would fit the cider manufacturer’s sustainable profile. They needed process efficiency, connectivity, system reliability and technology to accomplish more.
The solution
They chose Grundfos iSOLUTIONS intelligent pumps and controls for the cooling system. Variable speed, conventional end suction pumps are combined with intelligent multi-pump controllers, external Grundfos sensors and communication. This enabled the OEM customer to control and optimize their cooling production to optimum levels while adapting to changes in process demands through Grundfos technologies and communication capabilities.
The Grundfos system controls an array of different application sub-systems:
- Softened water for cooling tower
- Primary Chiller Pumps
- Secondary cooling distribution pumps
- Chiller condenser pumps
- Closed-loop circuited pressurization
- Condensing cooling tower fan motors and even the mechanical room ventilation fans
These systems are enabled by Grundfos CIM500 communication modules. This allows the OEM to obtain critical operational data that could either be used to determine system adjustment or inform the cider manufacturer on performance parameters like power consumption, cooling power, water consumption, alarms and more.
The outcome
The factory has better control of its cooling processes due to Grundfos iSOLUTIONS. Compared to a proposed competitor’s solution, the new Grundfos system saves an estimated 30% energy on pumps and chillers. In addition, since the condensing system is more efficient, the cooling towers need less water replacement. The company not only benefits from energy and water savings over conventional systems, but they get the insights into key data points. They can see how efficiently the system is operating, and they can make adjustments quickly if they have process changes. And the intelligence is also put into the building management system for full and transparent control and overview. The cider company achieves its goals in manufacturing quality cider for its customers while contributing to global sustainability.
The Grundfos iSOLUTIONS is a key element in this cider manufacturer’s continuous improvement for their cooling system, as it reacts immediately to process or demand changes.
Grundfos supplied
• CRIE vertical multistage pump with high-efficiency IE5 permanent magnet motor & inverter
• NB end-suction pumps featuring IE3 efficiency-rated motors
• CUE pump-dedicated variable speed drives
• Control MPC-EC featuring CU352 multi-pump controller & process PI&D
• RPI+T industrial direct relative pressure & temperature sensors
• CIM communication interface module featuring ethernet connectivity
• PHT pressurization unit
GRUNDFOS CONTROL MPC – CU 352
- Perfect cascade control, for 2 to 6 pumps in parallel
To achieve optimal operation of the system and minimum energy consumption, it is not enough to have high-efficiency pumps. The control of the system is just as important.
The MPC incorporates pump curve data for the best optimized system performance.
This information makes it possible for the system to calculate the optimal speed and number of pumps to be operating at any time.
The controller can estimate the flow based on pump curve data, without using a flow meter. This provides insight to the performance of the system and can indicate any irregular water consumption that could indicate a pipe burst, without having to invest in an expensive flow meter.
Grundfos Control MPC – CU 352
GRUNDFOS NBE SINGLE STAGE PUMP
The NBE combines pumps, motor, and frequency drive into a single product. Along with various sensors, these pumps allow for dynamic and intelligent solutions to many industrial applications such as cooling systems.
The NBE can be tailored to meet specific application needs. This makes it an excellent choice for a number of applications within heating, cooling, and industrial processes – each of which is characterized by varying demands, different control needs, and varying numbers of operating hours.