Water plant modernisation brings multiple benefits

Energy savings of at least 50%, less downtime and cheaper maintenance were just some of the benefits realised by UK-based manufacturer Robert McBride, following a process water plant modernisation and pump replacement project undertaken by Process Installations on its behalf.

McBride's manufacturing site at Bradford is supplied with process water from a single bunded area located in its finished goods warehouse area. Deionised water, ambient process water and 80°C process water is pumped from three 20-tonne storage tanks on ring mains to the process areas, while a single loop of ambient water is pumped to the ESP dilution unit situated in a tank farm area.

Its old pumping system was operated through one large, integrated control panel, meaning that the whole system needed to be shut down in order to carry out maintenance.

Process Installations, in conjunction with sister company Pump Engineering, supplied eight new, energy-efficient high-flow centrifugal pumps that run at 4 bar pressure and installed them in pairs to operate as a duty and standby pump for each loop. This ensures that production time will not be lost in the case of single pump failure and, as both pumps run together, allows for increased output if required. The use of identical pumps simplifies maintenance issues.

The pumps are controlled individually via a remote panel that is accessible from outside the bund area. Features include variable speed control, which is modulated to maintain a constant pressure in each line.

John Holstead, of Robert McBride, estimated the company's energy savings at around £8,000 per annum, taking into account lost water and maintenance. "We particularly appreciate the variable speed drive pumps, the in-built standby feature of the installation and the hygienic standard achieved," he said.