Grundfos rethinking the In-Line pump GRUNDFOS IN-LINE

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1 Grundfos rethinking the In-Line pump GRUNDFOS IN-LINE

2 Rethinking the In-Line pumps means Grundfos is one of the world s leading suppliers of pump technology offering full-line solutions to the building industry, including In-Line pumps for heating, and airconditioning systems as well as the transportation of fluids in industrial processes. We are committed to working in partnership with our customers, thereby ensuring that our solutions meet all their requirements within this area of activity. The physical pumps, the application software, the control systems and the service and support. As part of an ongoing process of innovation, the Grundfos range of In-Line pumps has been rethought in every detail. The result is plenty of small improvements and significant increases in efficiency as well as reliability. A uniquely stable design of coupling and shaft reduces wear on e.g. bearings and shaft seal while increasing both efficiency and operating reliability. An optimised geometry of the impeller and pump volute minimises backflow and increases efficiency. Cataphoresis treatment, inside and out, increases corrosion protection as well as efficiency. EFF1 motors contribute to make Grundfos In-Line pump the most efficient and reliable in the market - not at least in partial load operation. The wide range of electronic speedcontrolled pumpsoffer the possibility of choosing an extremely energy saving solution in allmost any flowsystem. A compact design makes installation very easy and requiresless valuable floorspace.

3 3 Small improvements in hydraulics means significant increases in efficiency Optimised geometry The geometry of the impeller and pump volute, is designed to optimise the flow of water: This means that water flows through the pump without eddies being formed, and that back-flow in the pump is minimised. This aquadynamic design of the impeller and the pump volute is vital to the efficiency of the circulation pump. Perfect match between impeller and pump casing The interaction between the impeller and the pump casing is also essential to the efficiency and performance of the pump. However, individual improvements to these two elements are not enough. We have developed and adapted their geometries to derive the highest possible level of efficiency from their integration. Mechanically balanced and hydraulically alleviated impeller The impeller of the In-Line pump is balanced in much the same way as the wheels of a car to ensure as stable and smooth an operation as possible. Furthermore, a network of small holes reduces the strain on the motor bearings caused by the pressure, which arises naturally in the pump. Yet another two important contributors to a longer service life. The new Grundfos In-Line pump TPE Series Efficiency in % Specific speed The new Grundfos In-Line range Market average The result of Grundfos rethinking of the In-Line pumps is significant increases in efficiency.

4 4 The integration of coupling and shaft has traditionally been the weak point of the In-Line pump. Poor integration causes wear of motor bearings as well as the mechanical shaft seal. The coupling/shaft design of the new Grundfos In-Line pump addresses this problem: The coupling and the shaft are welded together by means of friction welding and make up a completely stable mechanical unit. The impeller of the In-Line pump is balanced in much the same way as the wheels of a car to ensure as stable and smooth an operation as possible.

5 5 The unique design of coupling and shaft means increased reliability Reduced distance between impeller and pump casing Thanks to the uniquely stable design of the coupling and shaft unit, irregular movements are eliminated. Due to this we have been able to reduce the distance between the impeller and the pump casing. This means that back-flow in the system is minimised which means higher efficience and less energy consumption. Improvements in the shaft seal environment The very rigid shaft and coupling design means that the shaft seal moves in a pure, rotating pattern. The rigid construction minimises cross motion, thereby reducing vibrations and wear, to an absolute minimum. A uniquely stable design of coupling and shaft The coupling and the shaft and their integration is traditionally the Achilles heel of the In-Line pump. We have therefore devoted considerable development resources to improving this area. The result is an exceptionally rigid construction, where coupling and shaft are welded together by means of friction welding, to produce a stable, mechanical stainless steel unit. This design reduces wear on the bearings and on the mechanical shaft seal, while at the same time, increasing both efficiency and operational reliability. Reducing wear on motor bearings Vibrations and other loads will invariably be transmitted to, and absorbed by, the motor bearings. The very rigid design and the reduction in vibrations ensues optimum protection to the motor bearings. The reduced the distance between the impeller and the pump casing means that irregular movements are eliminated. While back-flow in the system is minimised this means higher efficience and less energy consumption.

6 6 Cataphoresis treatment means increase in efficiency and corrosion protection Cataphoresis treatment inside and out The inside, as well as the outside, of the pump casing and the impeller have been subjected to cataphoresis treatment to provide a completely smooth and fully coated durable surface. In this way, the irregularities which invariably result from spray-painting even with two coats of paint are avoided. Electro-coated (Cataphoresis): Pump casing after 672 hours in salt fog, test mark: 6 How to test Temperature: 35 +/-2 C 50g/l +/- 10g/l Medie: ~ 5% +/- 1% NaCl ph: 6,5-7,2 Duration: 672 hours Standard ISO Painting: Pump casing after 24 hours in salt fog, test mark: 0 Protection rating (after 672 hours in saltfog) According to standard ISO (E) Area of defect No defect 10 <0,1 9 <0,1 <0,25 8 >0,25 <0,5 7 >0,5 <1 6 >1 <2,5 5 >2,5 <5 4 >5 <10 3 >10 <25 2 >25 <50 1 >50 0 Rating The 672-hour test An official test based on the ISO standard shows that the cataphoresis treatment gives Grundfos In-Line pumps a level 6 rating, while spray-painted surfaces consisting of two coats of paint are placed at level 2 (Zero=most defects; 10= no defects) after 672 hours in a salt fog. Furthermore, Grundfos has tested the In-Line pumps in accordance with the ISO standard, and these tests have placed the pumps in the C3 corrosion class. Cathodic application of Powercron The surface treatment consists of electro-coating the cathodic application of Powercron. Electro-coating ensures that the material of the pump casing and the impeller is coated by a completely smooth layer of Powercron, covering all irregularities and sharp edges to the entire surface. Zinc phosphating With a view to further increasing corrosion resistance and to optimising the adhesion of Powercron, all pump parts are given a basic coating of zinc phosphate. Reduced friction The smoothness of the cataphoresis treated surfaces reduces friction. Therefore, energy which would be lost in pumps with rough surfaces, is saved. Thereby increasing pump efficiency by 1-2%. Cataphoresis layer Cast iron The cataphoresis treatment offers a completely smooth coating of all surfaces. This reduces the friction thereby increasing pump efficiency by 1-2%. Powercron is applied by means of electro-coating and covers any surface irregularities.

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8 IN-LINE...

9 9 Full-line means there is allways a solution A one-stop pump supplier Grundfos is one of the world s leading manufacturers of In-Line pumps for heating and air-conditioning systems as well as the transportation of fluids in industrial processes. Our pumps and know-how span the entire spectrum from small to large-scale operations. Working with Grundfos thus offers the opportunity of reducing the number of pump suppliers required to one. A single supplier, who assumes responsibility for ensuring that the best components are selected and combined in the most optimum way possible. Full-line means that our products cover 2 and 4-pole up to 30 kw Single pumps/twin pumps Standard pumps/electronically speed-controlled pumps Flange sizes DN Series 2000 and Series 1000 up to 22 kw Temperatures of -25 C to +140 C PN6/PN10/PN16 PN25 (from DN 80) The two series of Speed Control pumps We offer two series of speed-controlled In-Line pumps with frequency converter, each series comprising a wide range of products. The Series 2000, which is pre-defined to continuously regulate pressure according to flow by means of a built-in pressure sensor. And the Series 1000, which accommodates any configuration and control method required (without integrated pressure sensor). System type Product type TPE Series 2000 (Electronic speed-controlled pump with integrated sensor) TPE Series 1000 (Electronic speed-controlled pump without sensor) TP Series (Constant speed pump) Main pumps Boiler shunts Mixing loops Heat surfaces Heat recovery Domestic hot water circulation Domestic hot water production Constant speed pump can be applied, but in most cases the speed controlled pump will be the optimum solution.

10 10 Grundfos solutions means value-for-money security Life Cycle Cost analysis as a selection tool By rethinking the In-Line pumps we have used the Life Cycle Cost analysis as a guideline to messure the value of the improvements. Besides, the Life Cycle Cost (LCC) analysis is an important tool in selecting the right In-Line pump for a given system. Using this method, the cost of a pump system can be calculated taking into account the cost of the initial technology, the installation and maintenance as well as energy consumption. What may have appeared a complex and tricky calculation has consequently become a comparatively simple procedure. LCC-analysis: Proves the value of speed controlling A 20 year old substation needs renovation, and at the same time the consulting engineer and the customer want more focus on low operation costs. Total heated area: 80,000 m2 Total heat demand: 6,000 kw The flow is calculated to : 129 m3/h The head is calculated to: 18 m H(m) mm 50 mm 40 mm 65 mm 90 mm 100 mm 125 mm 150 mm 200 mm Q(m 3 /h) H(m) and Q(m 3 /h) Grundfos In-Line range 4-pole/50Hz Grundfos In-Line range 2-pole/50Hz

11 11 Existing pump installation (20 years old): 1 constant-speed pump in operation and 1 standby pump (alternation between the 2 pumps). Life Cycle Cost will be based on 2 new alternatives: System 1: 1 constant-speed pump and 1 standby pump System 2: 2 speed-controlled pumps and 1 speed controlled standby pump Comparison/benefit: Depending on the energy price, there is a very short pay-back time on the extra cost or the speed-controlled pump system. Given a cost of 0,1 EURO per kwh, the pay-back time is approximately 1,7 year. Yearly saving in energy: 26,305 kwh/year = 50% LCC-analysis: The new TP single speed pumps pays back in one year! The pumps in a district heating system are operating for about 5000 hours/year at a flow of 40,7 m3/h and a head of 47,5 m. The enduser wants to reduce energy costs by upgrading the pumps to a more efficient type. Comparison/benefit: Even though there will be some initial costs for replacing pumps, the payback time will still be around 1 year. The reasons for the achieved energy savings are due to the use of both high efficiency pumps and motors. Yearly saving in energy: 14,150kWh/year = 22,6%

12 12 EURO 120, ,000 80,000 60,000 40,000 20,000 0 Energy consumption Year of operation Payback time Life Cycle Cost 20 years operation System 1 System 2 105,642 53,032 Energy cost 1,500 1,500 Maintenance cost 5,200 7,300 Initial cost System 1 1 constant-speed pump + 1 standby pump Selected pump: 2 x End Suction Control panel: Motor protection Access to system data: None Price index: 100 (4,500 EURO) Yearly energy consumption: 52,821 kwh/year System 2 2 speed-controlled pumps + 1 standby pump Selected pump: 3 x TPE Control: PMU Access to system data: Yes Price index: 162 (7,290 EURO) Yearly energy consumption: 26,516 kwh/year EURO 140, , ,000 80,000 60,000 40,000 20,000 0 Energy consumption Life Cycle Cost 20 years operation System 1 System ,000 96,700 Energy cost Year of operation 1, Maintenance cost Payback time 0 2,030 Initial cost System 1 1 constant speed pump Selected pump: LP80-200/ kw (old Grundfos pump) Motor type: EFF2 Price index: 0 Yearly energy consumption: 62,500 kwh System 2 1 constant speed pump Selected pump: Motor type: Price index: Yearly energy consumption: TP /2 11 kw EFF1 (high efficiency) 100 (2030 EUR, including installation) 48,350 kwh

13 FULL-LINE

14 14 EFF1 motors means significant energy and maintenance savings EU-classified low-energy motors: EFF1 All Grundfos In-Line pumps are now designed with EFF1 motors, which are classified within the most efficient (i.e. with the lowest energy consumption) category in the new European norm, CEMEP. Together with the hydraulic improvements, the motors contribute to making Grundfos In-Line pumps the most efficient and reliable in the market as seen across a wide range of applications. This means higher efficiency than conventional motors especially during partial-load operation wich is almost always the reality in a pump system. Lower heat generation smaller ventilators The high level of efficiency means reduced heat generation and therefore a lower cooling requirement in the motor, which in turn means that a smaller ventilator is required. Efficiency Standard efficiency High efficiency % Shaft power 4 pole 30 kw. Typical pump operating area Low noise level long life of bearings With the fitting of a smaller ventilator, the noise level is reduced. At the same time, the motor bearings benefit from the low operating temperature, thereby prolonging their service life. Long lubrication intervals With the reduced heat generation, the motor requires less frequent lubrication. This saves both time and money in the maintenance budget. Simple and accurate adaptation of motor output The EFF1 Grundfos motors are stocked as standard product, this allows Grundfos to easily adapt motors to suit the conditions of any system. For example, in air-conditioning or cooling systems using glycol, where extra motor power is required to circulate more viscous liquid. Effiency in % 2-pole Effiency in % 4-pole ,1 2,2 4,0 7, Output power (kw) 75 1,1 2,2 4,0 7, Output power (kw)

15 15 And the compact design means easy installation In-Line pump Necassary floor space Norm pump No plumbing or concrete foundations required One of the most notable advantages of In-Line pumps is that they are small and compact and therefore easy to handle. As indicated by its name, the pump can be readily built into pipe systems. It can be upright with vertical integration of motors so you could say that the conventional pump has been raised! This means that the concrete foundations and complex plumbing solutions, which have previously been the order of the day in connection with the installation of pumps, are no longer required. At the same time, less valuable floor space is required to house the pumps. Also the critical proces of alligning pumps and motorshafts is taken care of by Grundfos. Grundfos In-Line pumps: From small to compact The systematic improvements of the hydraulics, mechanics and motor construction of the In-Line pump, which Grundfos has instigated, allows for a particularly compact design. Thanks to the marked increase in efficiency, smaller pumps can be used for applications which used to require much larger solutions. Twin pumps double benefits The Grundfos In-Line twin pump, with a spare pump head, provides extra reliability in case of breakdown. Here also, the vertical positioning of the motor means that the unit takes up height rather than precious floor space. The Grundfos speed-controlled In-Line twin pumps feature a built-in control unit as standard. In case of breakdown, the other speed controlled pump head will start up automatically.

16 16 User interface Frequency converter Filters Software Control Standard motor Sensor Serie 2000 Pump

17 17 Electronically speed-controlled pumps means optimal solution in any system The electronic speed control concept The idea behind speed control is to integrate all electronic components that makes each pump automatically adapt output to current conditions, thus ensuring that energy consumption will always be kept to a minimum. By automatically controlling its own speed, the pump will continuously regulate the pressure (head) so that it is optimally adapted to system conditions. Reducing energy by adapting to day to day and seasonal changes With this continuous adjustment to flow, the loss of energy that relates to changes in consumption throughout day to day and seasonal operation is eliminated. This ensures reliability of supply and a high degree of comfort. The easily installed all-in-one solution Grundfos speed-controlled In-Line pumps up to 22 kw in size come with a built-in motor, frequency converter and the necessary application software to achieve an all-in one solution. In addition to ensuring optimum adaptation in flow, and thus energy savings, the installation costs and the risks of errors are reduced as these components are dedicated to each other and already integrated. More than 22 kw: entire solutions with external frequency converter With large flow capacities and the parallel coupling of pumps, we design solutions with external frequency converters and control systems. Although these are not physical units, they are fully integrated with regard to their functionality, thus offer a true all-in-one solution. Proportional pressure Constant flow Temperature control The Series 1000 pumps have options for selecting any configuration and control method required: i.e. constant pressure, proportional pressure, temperature or flow control. The configuration can be de-fined to suit any specific operating conditions and can equally be amended to allow for ongoing changes. The two series: Series 2000 and Series 1000 We offer two series of speed-controlled In-Line pumps, each series comprises of a wide range of products. The Series 2000, which is pre-defined to continuously regulate pressure according to flow, and the Series 1000, which allows for any configuration and control method required: constant pressure, proportional pressure, temperature control or constant flow. Integrated twin pump control Both Series 1000 and Series 2000 twin pumps are equipped with an integrated control unit that allows the pumps to run in different modes, such as alternating operation where each pump runs 24 hours at the time to secure equal wear on each pump head. In case of breakdown, the other pump will start up automatically. The Series 2000 pumps are pre-configured to regulate the pressure continually in accordance with flow - through an inbuilt sensor. This eliminates the need for any initial programming, thus making the installation process extremely easy and straightforward. p Pumps with integrated sensors Pre-setting for circulation, constant and proportional pressure.

18 18 Rethinking In-Line pumps also means reliable air-conditioning systems Shaft seals Advice concerning the choice of materials for the shaft seal, specifically adapted to suit the system in which the pump is to operate, comes as part of Grundfos experience and know-how within the field of In-Line pumps. Grundfos recommends the use of special shafts seals for systems containing glycol and other anti-freeze agents. With a view to ensuring tight seals in such medias, the shaft seals for Grundfos air-conditioning pumps are made of silicon carbide. At the same time, the area of the sliding surfaces has been reduced so that the pressure between these is increased. Easy adaptation of motor capacity When the density and viscosity of the liquids used in an air-conditioning or cooling system make particularly heavy demands in the form of motor power. The original motor, for which the pump was designed, can easily be replaced by a larger one on the assembly line. The low-energy EFF1 motor is a standard motor and is stocked by Grundfos. Protection against condensation The cataphoresis-treated surface of the Grundfos In-Line pumps offers particularly valuable protection against corrosion in air-conditioning systems, due to the formation of condensation of the outside of the pump. The cataphoresis treatment thereby contributes to ensuring particularly reliable and trouble-free operation.

19 19 Grundfos allways means reliability, service and support Reliability a hallmark of Grundfos pump technology Reliability means many things with Grundfos: operational reliability, durability, energy efficiency and a long service life. In rethinking our In-Line pumps, we have increased the level of reliability of all these crucial aspects. Examples of this are the uniquely stable design of the coupling and shaft unit and the improvements to the geometry of the pump casing. Ease of Service Service issues have also been brought into the design of In-Line pumps. For example, the cataphoresis-treated pump casing is lined with bronze slide rings. This means that the pump casing itself is protected against wear only the slide rings need to be replaced. Order handling within 24 hours Grundfos reliability not only refers to the quality of the pumps themselves. Highly developed distribution and service functions are also included. For example, pumps are dispatched within 24 hours of Grundfos receiving an order. System knowledge and Flow Thinking Each single pump is vital to ensuring optimal flow in a system. We know, however, that the quality of the pump can only be assessed in its proper context. The value of a pump, speed-controlled or not, is derived from its interaction with the rest of the system. This is why Flow Thinking is our working philosophy. It means taking a holistic approach and ensures we create solutions which embrace the entire pump solution. Visit The comprehensive Grundfos System Guide provides an overview of different systems in commercial buildings. It is intended as a source of ideas and information with regard to offering dimensioning solutions. Grundfos WinCAPS is our efficient electronic selection tool. Here, you can select pumps on the basis of technical criteria. You can perform a Life Cycle Cost analysis and obtain detailed information about each pump. This tool includes drawings and wiring diagrams. A simpler version of WinCAPS is WebCAPS, is accessible from our website

20 Being responsible is our foundation Thinking ahead makes it possible Innovation is the essence