Modernising Cooling Water Systems with High-Efficiency Pumps for 24/7 Engine Test Cells

The site relied on 3 belt-driven pumps, operating on a 2-duty + 1-standby cycle, to circulate cooling water 24/7 across their high-demand engine testing infrastructure. The existing 45kW IE2 motors lacked efficiency, and the belt-driven setup imposed regular maintenance and mechanical losses. The client’s objectives were:

• To reduce energy consumption and operational costs
• To achieve regulatory compliance (IE3 minimum motor standards)
• To eliminate belt-drive inefficiencies and reduce downtime
• To ensure minimal disruption during the replacement, ideally over a scheduled shutdown weekend

To modernise cooling water systems already in place, we took into account the existing infrastructure and used our expertise to see how we could improve and streamline the process.

Tapflo’s team of engineers took to the drawing board and proposed 3x TECP 100-315 Centrifugal Pump (2 + 1 Duty / Backup arrangement), which would provide a high-performance solution, specifically selected for its efficiency, performance, and long-term reliability.

Key System Specifications:

This setup was selected to futureproof the system with performance headroom, account for general wear over time, and maintain high motor efficiency across varying flow rates.

We provided the client with a full-service replacement solution, encompassing design, supply, installation, and commissioning, to improve energy efficiency, reduce operational expenditure, and ensure compliance with current energy regulations. We were able to modernise the existing cooling water system infrastructure for the client for maximum energy efficiency and compliance.

Energy Efficiency & Operational Savings:

• Annual Energy Saving: 262,800 kWh
• Electricity Tariff Applied: £0.2463 / kWh
• Annual Cost Saving: £64,728
• 3-Year Projected Saving: ~£194,000

These electrical OPEX savings alone result in a buyback period of under 2 years before accounting for potential civil, control panel, or installation-related costs.

Maintenance & Reliability Improvements:

• Elimination of belt-drive assemblies reduces:
  • Mechanical losses
  • Alignment checks
  • Vibration-induced wear
• Longer bearing life and reduced maintenance frequency
• Eagle Burgmann Mechanical Seal Design ensures easier serviceability, with common available parts available in UK ex-stock

Environmental Impact:

• Annual CO₂e reduction of ~47.3 tonnes (based on 2024 UK grid emissions of 0.18 kg CO₂e per kWh)
• Contributes to corporate net-zero targets and energy efficiency standards

Regulatory Compliance:

• Full alignment with EU Regulation 2012/547 and UK MEPS (IE3 motors)

We offered a turnkey process package which included:

• The supply and delivery of all equipment.
• A on-site survey to assess civil works and installation feasibility.
• Full installation and commissioning, scheduled over a weekend shutdown to avoid disrupting test cell operations.

This upgrade transforms an ageing, inefficient pumping system into a high-efficiency, low-maintenance, future-ready solution with a rapid return on investment. With over £64k annual savings, improved reliability, and significantly reduced carbon impact, this project is a model of sustainable modernisation.

Whether you’re looking to improve process control, reduce energy usage, or integrate smart system automation, our team is ready to help you design a solution that fits your operational requirements.

Get in touch with Tapflo UK today, and our engineers will be happy to discuss your process challenges.