Product Innovation of the Year Award 2009: Grudfos Pumps' Multi-Stage CR-H


Written by:
Alexandra Ferretti

Innovation

Introduced to the market on June 8, 2009, the Multi-Stage CR-H provides a retrofit option for industrial users of traditional ANSI pumps. The CR-H can be used in a wide range of clean fluid pumping applications, throughout industrial manufacturing plants and in applications serviced by oversized ANSI pumps.

This plug-and-play solution fits in existing pump and piping footprints and offers optimized duty points to maximize pump efficiency and minimize internal wear. A CR-H retrofit requires no re-piping and the pump end can bolt directly to the existing baseplate. Standard ANSI pumps must be disassembled and realigned when replacing mechanical shaft seals. The CR-H cartridge seal is accessed without pump removal or disassembly, and the motor and pump are self-aligned. Pressure ranges can be expanded beyond traditional ANSI pump limitations without piping changes.

mulit-stage CR-H pump family

Mulit-Stage CR-H pump family

Statistical Data

At 100 gpm and 290 ft of head, a traditional 1.5 X 3-8 AB ANSI B73.1 pump offers 50 percent efficiency at a break horsepower of 14.65 hp. For the same application, a CR20-5 H will offer 72.1 percent efficiency and require 10.1 hp, which is 31 percent less horsepower. The annual energy cost for the traditional ANSI pump based on continuous operation (and 10 cents/kWh) is $9,547, but the CR-H equivalent will only cost $6,600, a 31 percent savings.

At 60 gpm and 300 ft of head, a traditional 1 X 1.5-8 AA ANSI B73.1 pump offers 40 percent efficiency with a break horsepower of 11.36 hp. For the same application, a CR10-9 H offers 67.6 percent efficiency and requires 6.89 hp-39.3 percent less horsepower. Continuous operation for the traditional ANSI pump costs $7,424 annually, but the CR-H costs $4,503, a 39.3 percent annual savings.

End User Testimony

Mac Del Incorporated, Richmond, Ind.

A truck wash facility in Richmond, Ind., required a pump that could produce appropriate flow and pressure to operate the nozzle in a process involving hot caustic water and various cleaning and rinsing cycles for cleaning the inside of large tanker trucks. Originally, the pumps specified were traditional ANSI pumps with 100 hp motors. A review of the application prompted Grundfos to propose that the same duty could be achieved with a CR pump with a 30 hp motor, so the lower HP model was installed. The 30 hp CR outperformed the 100 hp model, so Mac-Del replaced an additional seven pumps with the CR-H during an eight-month period.
Some of the facility's customers also included trucks carrying ink. This posed a problem to the vertical design of the former pumps because at start-up the abrasive ink would collect at the bottom bearing, causing pump failure in two months or less. When the CR-H (horizontal model) was introduced, the abrasive materials settled away from the bearings, minimizing the wear of the pump and prolonging its life.

The CR-H has performed with a single seal and stack change out during a one year period, versus the former bimonthly seal changes. The savings included $10,000 in maintenance costs, combined with nearly $3,000 in energy cost savings. Mac-Del, Inc. is pleased with the payback that the CR-H offers.

Water Treatment Plant, Olathe, Kan.

The Olathe Water Treatment Station #2 in Olathe, Kan., agreed to participate in a field test, and with the assistance of Grundfos Distributor, Pump & Power of Lenexa, Kan., the Multi-Stage CR-H was installed in April 2009 in a backwash application for membrane wash. The Multi-Stage CR-H pump (15 hp), along with another pump brand (end suction, 20 hp), alternate operation in a system where a flush occurs approximately 10 times per hour and lasts two to five minutes. In this continuous operation, each pump is used equally.

Pumping System Assessment Tool (PSAT) is used to demonstrate the energy usage information. The data from PSAT showed that the 15 hp CR-H uses 13 kWh and the end suction 20 hp pump uses 17.1 kWh. At 4,380 hours of operation annually, and an average of three minutes of run time per start, the end suction averages an energy consumption of 74.8 MWh, and the CR-H averages 57.9 MWh. The CR-H offers 16.9 MWh in energy savings compared to the end suction, which results in an annual energy savings of $1,700.

Olathe Station #2 is also pleased with the CR-H's integrated cartridge seal technology. Maintenance Supervisor Brian Brennan said, "It's great not to have to worry about potential leaking associated with the additional plumbing to flush the shaft seal because the CR-H doesn't require the additional plumbing to flush, so leakage is not an issue." The CR-H cartridge seal virtually eliminates the parts and problems that are associated with other end suction pump seals. "In addition," adds Brennan, "this is a maintenance and cost-saving feature that makes everyone happy at our facility."


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Upstream Pumping Solutions

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