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CP Pump Systems Service Catalog

CP is constantly looking for new ways to further improve energy efficiency. This goes hand in hand with meeting the highest safety standards. We are happy to pass on our outstanding knowledge in this area in special consultations.

CP customers enjoy comprehensive services: Energy efficiency consultations, tests and measurements are carried out on state-of-the-art, constantly evolving equipment, and technical documentation is complete and available on a long-term basis. All these services ensure trouble-free operation of the high-tech pumps.

Do you have any questions about our services? Contact our customer service!

Energy Efficiency Services and Consulting

As a trend scout in the field of energy efficiency, CP specializes in sealless magnetic drive pumps and pumps with double mechanical seals and offers a wide range of services: comprehensive consulting, in-depth system analysis and careful design.

CP customers benefit from tailored solutions that reduce costs and CO2 emissions in the long term. We act out of an inner conviction because we share present concerns about the current state of our planet. CP is convinced that sustainable research, thinking and acting pays off for all partners at all times. That is why our slogan is: cleaner pumps, cleaner planet.

Based on our rich and long experience, we are today providing advice and support to customers from the private and public sectors. Among them are owners and operators of process plants for liquids in the chemical and pharmaceutical industries as well as in various other branches of industry.

  • Fluid handling systems
  • Rotodynamic pumping system
  • Variable speed pumping systems
  • Energy efficient pumping
  • Pump life cycle costs
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Fluid handling and rotodynamic pumping systems

Energy Efficient System Planning
Pumping systems are designed to meet many requirements, energy efficiency not always being one of them. As a result, some plants are built with poor system design where pumps are not properly matched to the system, pipe diameters are incorrectly sized and flow velocities are too high. Bad plant layout resulting in inefficient routing of pipes frequently exacerbates the situation as well. As all these factors increase frictional resistance, larger pumps than necessary are needed to deliver liquid to the required service.

  • Calculation and design services providing clear and authoritative data to increase energy efficiency.
  • Consulting and system analysis delivering clear and authoritative data to optimise energy consumption.

Existing systems
Changing a running system already in place is often difficult. Sometimes pumps, valves and measuring instruments are modified, for example to optimise a system’s available net positive suction head (NPSH), gather measurement information or change suction and/or discharge flanges, when retrofitting differently sized new pumps. Due to the heavy expenditure for engineering and materials, such modifications are usually limited in scale and often have little impact on the energy efficiency of an existing system.

One significant exception is to employ variable speed pumping solutions that can be retrofitted into a system already in service. Another viable option is to check whether any duty points can be subsequently rescaled, because each system is designed with safety margins added to the calculated system curves to ensure that sufficiently large pumps are selected for the job. As a result, the pumps installed are often oversized and then operate at excessive flow rates or in throttled conditions, increasing energy usage and reducing pump life.

New systems
Competent planning of new pumping systems to minimise energy consumption is one of the keys to reducing life cycle costs (LCC). Some energy use may not be output-dependent. For example, a control system sensing output changes may itself generate a constant energy load, whereas a variable speed drive can consume different levels of energy at different operating settings. Throttle valves, pressure relief mechanisms and flow bypasses used for control will all reduce operating efficiency and increase energy consumption. Additional costs may be caused by cooling or heating circuits, liquid flush lines or fluid barrier arrangements. While such costs often do not vary for different types of systems, they can be influenced by the selection of materials and designs.

Carefully selected pumping systems will reduce energy costs. A system’s overall frictional resistance can be minimised and the monetary savings maximised if attention is paid to the following points:

  • Pumps must be optimally matched to the system in an early stage.
  • Variable speed drives should be chosen, pipe diameters and distances correctly selected and flow velocities optimally designed for each position where they will help reduce energy consumption.
  • Correctly determined pipe diameters and distances.
  • Conveying speeds must be optimally aligned.

Drehzahlgeregelte Pumpensysteme

Variable speed pumping systems

Energy Efficient Drives
Many pump systems are designed without variable speed drives because only one duty point is planned. Most electric motors are oversized and pump flow is regulated by a valve. This increases friction, so energy is wasted.

  • Advice on designing, specifying and operating energy-saving variable speed pumping systems by reducing motor power consumption.

CP pumps with variable speed drives
The relationship between a pump’s speed and its energy requirement is known as affinity law because the need for power increases with the cube of the speed. This means that a small increase in pump speed requires a lot more power, but also that a modest speed reduction can yield significant energy savings. Using a variable speed drive, a pump running at half speed consumes only one-eighth of the energy compared to one running at full speed.

Frequency converters are very cost-effective and often deliver a payback in a matter of months on energy savings alone. In addition, by matching the speed to the needs of the process, users often find they get better product quality and reduce maintenance costs. Companies, not least small and medium-sized enterprises, that are reluctant to take the financial risk of replacing drives can often benefit from energy efficiency incentives that are offered in many countries to help lessen the initial financial burden.

Variable speed drives not only cut your energy costs but also improve process control, increase production capacity, reduce maintenance costs and require less reactive power.

Other advantages include:

  • Smooth starting reduces maintenance.
  • Infinitely variable speed control provides accurate process control.
  • Full motor protection prevents many cable and motor faults.
  • Soft starting and stopping minimises mechanical wear in the process.
  • A wide range of speed, torque and power gives accurate speed control, resulting in process optimisation and better product quality.
  • Improved power factor helps maintain motor efficiency at reduced load.
  • EMC protection prevents interference with other sensitive equipment.
  • Productivity increases as motor speed is correctly matched to load requirements.

Variable speed drives reduce energy wastage in all phases of operation. Changing production volumes by mechanical means is very inefficient. With variable speed drives, this can be achieved by adjusting the motor speed. Particularly in pump applications, that saves a lot of money because the shaft power is proportional to the flow rate. CP partners with various drive manufacturers so that our customers can benefit from a wide choice of drives.

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Energy efficient pumping and pump life cycle costs

Energy Efficient Pumps
Pumps are often selected according to technical and commercial specifications that do not sufficiently take into account life cycle costs (LCC). As a result, energy consumption is frequently one of the major cost components and may dominate the LCC, especially if pumps run more than 2,000 hours per year. A 1 kW power difference at the pump’s projected duty point can consume more than €10,000 worth of electricity over a 10-year operating life at 10 cent per kWh.

  • Selection and specification of energy efficient pumps.
  • Analysis and methodology to calculate the impact of energy efficient pumping systems and cut costs by reducing energy consumption.

Installed pumps
When pumps are already installed, you need to consider separate data showing the performance of each pump system over the output range. Performance can be measured in terms of the overall efficiency of the pump or the energy used by the system at the different output levels. Two important power requirements should be evaluated most carefully: the power consumption at the pump’s intended (rated) duty point and at its intended maximum flow rate. When pumps with high power consumption fail, many plant managers send them out to be repaired although the problem of energy wastage will not be solved. One solution is to adopt a pump management policy giving clear guidelines on when to purchase new pumps with minimal power requirements. As a rule, pumps with long running hours and those with larger motor sizes should be replaced. Pumps that run only occasionally and those with smaller motor sizes can be repaired. In case of doubt, asking your pump supplier for a quote indicating the above-mentioned power consumption at your duty point will help you find out how much your company could save with more efficient pumps. Sometimes, replacement of a fully functional pump can even be justified on energy grounds alone.

Selecting new CP pumps
Competent selection of new pumps to minimise energy consumption is one of the keys to reducing pump life cycle costs (LCC). Choosing sealless magnetic drive pumps over pumps with mechanical seals not only offers significant safety advantages; they often consume less energy as well, especially when fitted with non-metallic containment shells that eliminate eddy current losses. CP offers a wide range of different pump models and casings, containment shells and bearing materials to best suit the most diverse system requirements, while ensuring maximum safety and energy efficiency.

CP provides comprehensive advice to help you carefully select energy efficient CP pumps.

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Tests and Measurements

CP tests all pumps prior to delivery to ensure they meet the high quality and performance standards our customers expect. With our flexible, state-of-the-art pump testing facilities continuously updated to current needs, we can provide comprehensive analyses and technical assessments.

We offer:

  • performance data checks according to EN 9906
  • power and efficiency measurements
  • pressure tests according to ISO 5199 for pumps and heating chambers
  • gas tightness and hydrostatic tests
  • NPSH measurements
  • analysis of suction conditions of self-priming pumps
  • performance data checks at variable speed
  • temperature measurements
  • acoustic emission measurements
  • vibration measurements
  • construction materials tests

Tests with water or other fluids and with air or gases:

  • Q up to 1300 m3/hr
  • H up to 230 m
  • pressures up to 40 bar
  • temperatures up to 350°C
  • motor voltages up to 500 V
  • motor power up to 200 kW
  • power supply through frequency converters up to 60 Hz

CP supports you with individual consulting

Our Sales Department Manager, Mr. Khalil Fallah, and his team are at your disposal to find the exact right solution for your needs.