Industry

Pump and PumpDrive.The Ideal Combination.

Energy Efficiency2

Saving energy means saving money.

Plant owners and operators today are facing ever growing chal-

lenges. Against the backdrop of steadily rising energy prices, they

have no choice but to keep the overall cost of their systems to a

minimum. After all, any analysis of the total life cycle cost (or LCC)

of a system will show that approximately one third of the costs

incurred during a system’s service life are spent on energy. Fortu-

nately, these expenses also offer the greatest possibilities for savings.

Seek the support of your KSB partner to tap the full potential and

start saving money. Your system will operate at its best – and

you’ll notice the difference in your electricity bills.

For more information about KSB’s energy efficiency concept visit http://energy-efficiency.ksb.com

Life cycle costs Example: Industrial pump

9 % Operation

9 % Downtime

20 % Maintenance

Availability ~38 %

Initial investment ~30 % Energy ~32 %

9 % Installation

7 % Environment

14 % Pump

System Efficiency Service

Savings potential is identified

and solutions are proposed on

the basis of the precisely

calculated pump load profile.

Pump selection

The most important step towards saving

energy costs: hydraulic optimisation of

the system and selection of the best pump

for the job.

Speed control

PumpDrive adjusts the speed

of the motor to match demand.

Energy saved: up to 60 %

EFF1 motor

Standard at KSB.

Efficiency gain: up to 3.5 %

Trimmed impellers

The impeller is adapted to match the actual

operating point without any added costs.

Energy saved: over 10 % on average

KSB optimises not just individual components

but entire hydraulic systems.

3

Speed control with PumpDrive.

A key element of energy efficiency is speed control with

PumpDrive. Using PumpDrive makes sound economic sense

whenever energy costs are high, flow rate requirements keep

changing, intake pressures vary, and the number of operating

hours per year is high. Once the selected pump’s operating

parameters are set, PumpDrive precisely adjusts the motor

speed, and thus the head and flow rate of the pump, to match

current demand. The bottom line: energy savings of up to 60%.

This means your investment will pay for itself in a very short

time. Your KSB partner will be happy to calculate the potential

energy savings achievable in your plant.

Variable speed systems from KSB:making the right economies.

Just one example:

Etanorm PumpDrive 32-200/552.

A demand-based reduction of the

flow rate by just 30 % translates

into cost savings of 1,712 euros 

every 8000 operating hours (at

twelve euro cents per kilowatt hour).

m3/h

m

60

40

20

00 10 20 30 40

System curve(throttled)

System curve

Design point

2,900 1/min

2,050 1/min

Ener

gy

save

d

60 % of unused power input at fixed speed

Product Benefits4

If the speed of a pump is adjusted to match pump output to

actual demand, this will lead to a considerable cut in energy

costs and a marked increase in the system’s overall efficiency.

But that is not all KSB’s PumpDrive is capable of: due to the

square V(f) characteristic, PumpDrive can be depended upon

to precisely match the torque requirement of the centrifugal

pump – even at reduced speed. And, thanks to the dynamic

pressure set point compensation function, it is capable of

calculating the pipe friction losses, which vary with the flow

rate. This prevents the consumer being over-supplied at low

load and puts an end to electricity being wasted.

Apart from lowering energy costs, PumpDrive has more to offer

plant owners and operators. Pump and PumpDrive are perfectly

matched. As the units leave the factory ready for operation

and preset to the motor and pump they will be operated with,

commissioning could not be easier or faster! A higher operating

reliability and an improved process control are further advantages

of using PumpDrive. On top of everything else, PumpDrive is

easy to install.

Saving costs means increasing overall efficiency.

n The pump will operate within the permis-

sible operating range at all times. This

effectively prevents damage due to cavita-

tion. Characteristic curve control based

on the stored characteristic will make

sure of this.n Dynamic overload protection by reduc-

ing the pump speed prevents unnecessary

pump downtime.n Up to six pumps can be operated in parallel

without the need for a higher-level PLC.

Increased operatingreliability

Straightforward installation

n The motor-mounted model is available for

drive ratings up to 45 kW.n As it is independent of the motor used and

has an integrated cooling system, PumpDrive

is suitable for use with any motor brand and

will meet any works standard specifications.n Cost savings are possible with motor- or

wall-mounted units. There is no need for

high control cabinet mounting costs, long

cables or filtering measures.n If space is tight, the wall-mounted unit will

provide for easy access.n Cabinet mounting is available upon request.

Improved process control

n An integrated PI controller ensures that

exactly the required flow rate and pressure

are provided through speed control. n Integration into a process control system

is, for example, by means of a Profibus

system. The condition of the pump can be

visualised at any time at a central display.

5

Product Variants6

One solution for all applications.

PumpDrive Advanced

PumpDrive is available in two variants:

PumpDrive Basic for open- and closed-loop control of single pumps

or for an auxiliary pump in a multiple pump system. A graphical

control panel or a blanking plate preventing unauthorised use are

available as optional features.

PumpDrive Advanced offers optimum pump protection thanks to

integrated characteristic curve control and is suitable for controlling

multiple pumps systems without requiring additional hardware.

An easy-to-use graphical control panel is a standard feature.

PumpDrive Basic

Etanorm PumpDrive

Multitec PumpDrive

Etabloc PumpDrive

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Standard control panel Blanking plate

Standard

n Single pump control using a simple operating and display unit

Accessories

n Protection against unauthorised use

Graphical control panel

Standard

n Ease of parameterisation

n Single pump control with pump protection functions based on characteristic curve control

n Integrated multiple pump control mode for up to 6 pumps

Option

n Ease of parameterisation

n Single pump control

Etachrom PumpDrive CPKN PumpDrive

Movitec PumpDrive

Reference Projects8

A tailored solution for every application. A look at our list of reference projects reveals:

Many well-known companies are convinced of the benefits of a pump and PumpDrive combination.

DANONE, Ferrières-en-Bray, France

Product

Etanorm PumpDrive 80-200

Technical data

Flow rate: 210 m3/h, head: 43 m,

Drive rating: 45 kW

Danone, the French food and beverages manufacturer, employs

some 90,000 employees at 120 locations around the world. It

produces a total of about 110,000 tonnes of dairy products per

year at its production plant in Ferrières-en-Bray, France, alone.

At its Ferrières-en-Bray site, the company relies on a combination

of pump and PumpDrive to optimise its water supply. PumpDrive

ensures demand-based water supply to the production facilities

and makes a significant contribution towards process optimisa-

tion whilst improving the reliability of production.

Product

2 Etabloc PumpDrive GN 40-160/402 G11, motor-mounted,

of which 1 PumpDrive Basic, 1 PumpDrive Advanced

Technical data

Flow rate: 35 m3/h per pump, head: 25 m per pump,

Drive rating: 4 kW per pump

VION Food Group, Crailsheim GmbH, Leutkirch site, Germany

Europe’s leading producer of meat for butcher shops, meat whole-

salers and food retailers slaughters around 1,000 heads of beef

a week and processes several hundred pig and beef carcasses into

high-quality meat products and sausages. To warrant optimum

cooling of their vacuum-packed meats, VION Crailsheim relies

on a combination consisting of a KSB pump fitted with PumpDrive

variable speed system. PumpDrive controls the supply of refrig-

erant which varies according to the meat processing operations

taking place in each room. The supply of water with added anti -

freeze agent to the various cold storage areas is matched precisely

to the actual demand of each room. This saves energy and costs.

9

ArcelorMittal Steelworks, Eisenhüttenstadt, Germany

The Arcelor Group is one of the leading steel manufacturers in

the world. By integrating PumpDrive in their existing production

system, Arcelor uses the benefits provided by material-dependent

process pressure control.

This KSB automation product allows fast, precise and continuously

variable speed control to match pump performance to actual

demand. PumpDrive helps to control the process pressures of the

cooling system, which vary according to the type of material the

cooling agent has to be sprayed on. This treatment stage improves

the surface quality of a wide range of materials.

Product

2 Movitec PumpDrive VSF 18/12

(1 standby pump)

Technical data

Flow rate: 12 m3/h, head: 150 m,

Drive rating: 15 kW

These and many more companies rely on a pump and PumpDrive combination.

n Robert Bosch GmbH, Bambergn Heidelberger Druckmaschinen GmbH,

Brandenburg/Haveln Knoll Maschinenbau GmbH, Bad Saulgaun Novartis Nutrition GmbH, Osthofenn Saarstahl AG, Völklingenn Max Planck Institute for Plasma Physics,

Greifswaldn JT International Germany GmbH, Colognen AG der Dillinger Hütte, Dillingen/Saarn ZF Sachs AG, Schweinfurtn Huhtamaki Forchheim, Forchheimn Ideal-Standard GmbH & Co. OHG, Wittlichn Invista Deutschland GmbH, Östringenn Gebr. Gampert GmbH & Co. KG,

Weissenbrunn/Kronachn Dosch Messapparate GmbH, Berlin

Our services for your success.

Saving energy and providing full power at the same time requires special expertise. Our specialists will provide

support before and during the planning phase, and will thus help you achieve the largest possible energy and cost savings.

As well as individual consultancy support, we can offer you a range of other services and software products:

Service10

Services & Software

KSB Service

Total life cycle costs largely depend on a number of services

rendered at the start or in the course of a system’s useful life.

Some of the more traditional services are initial installation,

commissioning, repair, inspection and maintenance inspec-

tion. Whenever you need us, please feel free to contact one of

the more than 120 service centres or one of our service part-

ners all over the world. For more information, please visit

www.ksb.com/service

Automation Hotline

If you have technical questions relating to automation issues,

please call +49 6233 86-2042 for detailed information.

LearningCentre

Our seminars will allow you to expand your knowledge in

the field of automation technology. This will provide you

with the competitive edge you need to meet the ever growing

challenges of the market faster and more effectively. Please

contact: sascha.kunz@ksb.com

KSB EasySelect® selection software

Finding the right pump the easy way. The customer version

of our straightforward selection software is now available

in several languages. Select pumps yourself on the basis of

your application parameters, then download the relevant

documentation. Any time and any number of times you like:

www.ksb.com/easyselect

LCC-Software

As the only supplier of LCC software to date, KSB has developed

LCC-Comp for calculating the costs of a system during its entire

life cycle. Using the examples of several pumping systems, it

makes potential savings transparent as early as in the planning

phase. You can ask your KSB partner for details, or test our

Interactive Calculator online. http://energy-efficiency.ksb.com

PumpDrive Demonstrator

Using the example of a cooling system for an injection

moulding plant, the PumpDrive Demonstrator shows how

PumpDrive can be used to optimise a production process.

The user interface works exactly like the real product. You

will find the Demonstrator in the Download Centre of our

web site at www.ksb.com/downloads by clicking on the

Software section.

PACTware

PACTware is a vendor- and fieldbus-independent software

for operating field devices which KSB uses as a standardised

service tool for automation products. You will find the profes-

sional parameterisation standard in the Download Centre of

our web site at: www.ksb.com/downloads

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KSB AktiengesellschaftJohann-Klein-Straße 967227 Frankenthal (Germany) www.ksb.com

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