The challenge

A large global Engineering Consultancy that specialises in the design, development and integration of advanced internal combustion engines and electrified powertrain systems, had an old inefficient pump system feeding their test facility.

The old system was a 1990’s install of column pumps with very basic on/off control . With the forward movement in their company they had a demand for constant, consistent and reliable pressure. Their original requirements was to replace the pumps with a similar design with inverter drives . The major concern was minimal downtime.

The solution

Dura Pumps engineering team looked at the direct replacement and knew there was a better way to achieve the clients requirements. To provide a new improved and efficient system, and carry out the install with minimum downtime, required one of our bespoke skid mounted solutions.

A large skid frame manufactured at our premises, pre-assembled with 5 of KSB’s Etaline 18.5kw centrifugal pumps, a manifold with pipework, actuated valves, sensors and pressure vessels, with a separate control panel with integrated inverter controls.

The system was delivered to site ready for install To reduce downtime on site further and prevent any leaks, we carried out the installation using the latest pipe crimping systems. The system was switched over pump by pump to keep the processes up and running at all times. The downtime per pump switch over was reduced to 2 hours, but still keeping the remainder of the system operational.

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The results

The process now enjoys a new and efficient pump system, which is effectively optimised, thanks to the actuated valves controlling the flow and the triple pressure vessel configuration providing constant pressure and new pumps providing reliability. In addition to meeting the processes requirements, the system saves them near 500,000 kWh per year (that’s £ 50,000!) through greater pump efficiency, optimal pump specification and the inverter controls.

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