Energy-efficient Cooling Tower Pump Retrofit | Optimized Heat Rejection by EKG (Malaysia) Sdn Bhd
Transform Your Largest Cooling Energy Load into a Model of Efficiency
Cooling tower pumps are among the biggest energy consumers in a facility's HVAC system. A strategic retrofit modernizes this critical component, replacing oversized, constant-speed pumps with a right-sized, variable-speed system that intelligently matches flow to the exact heat rejection demand. EKG (Malaysia) Sdn Bhd delivers engineered retrofit solutions that slash energy use, reduce water consumption, and extend equipment life—providing a rapid, measurable return on investment.
Operating a fixed-speed pump for a variable cooling load results in:
Excessive Energy Consumption: Pumps running at full speed during low-load conditions (e.g., night, mild weather).
Wasted Water: Constant overflow at the cooling tower basin and excessive bleed-off due to uncontrolled flow.
Mechanical Wear: Throttling valves create back-pressure and cavitation, damaging impellers and bearings.
Poor Temperature Control: Inability to precisely control condenser water temperature, reducing chiller efficiency.
We replace the "always-on, full-blast" approach with intelligent, demand-based pumping.
1. Comprehensive System Audit & Data Logging
Measure existing pump power draw, flow rates, and system pressure.
Analyze cooling tower approach and chiller load profiles to establish a true operating baseline.
2. Right-Sized Pump & Variable Frequency Drive (VFD) Installation
Pump Replacement or Retention: We evaluate if the existing pump can be retained with a VFD or if a new, correctly sized high-efficiency pump is required.
VFD Integration: Install a dedicated VFD to control pump motor speed. The drive adjusts the speed in real-time based on a control signal.
3. Advanced Control Strategy Implementation
The retrofit's intelligence lies in its control logic. We program the system to optimize for:
Condenser Water Temperature Reset: Slowing the pump to allow the water to spend more time in the tower, achieving a lower temperature without extra fan energy.
Chiller Demand-Based Flow: Modulating flow based on actual chiller condenser pressure or load.
Wet-Bulb Temperature Tracking: Reducing pump speed when ambient wet-bulb temperature is lower, enhancing free cooling potential.
4. Ancillary System Upgrades
Install pressure-independent control valves at critical branches.
Upgrade strainers and install duty standby controls if not present.
5. Commissioning & Performance Verification
Test the system across its full operating range.
Measure and document post-retrofit energy consumption.
Provide a performance report showing achieved savings.
Energy Savings: 30% to 60% reduction in pump energy consumption is typical.
Water Savings: Reduced flow minimizes tower bleed-off and drift, lowering water and chemical treatment costs.
Extended Equipment Life: Reduced operating hours and softer starts increase the lifespan of pumps, motors, and tower fill.
Improved Chiller Efficiency: Optimal condenser water temperature improves chiller COP (Coefficient of Performance).
Reduced Maintenance: Elimination of throttling valves and reduced bearing wear lower long-term maintenance costs.
Turnkey Responsibility: We manage the entire project from audit to commissioning.
Performance-Based Design: Our solutions are engineered to meet specific savings targets.
Minimized Disruption: We plan and execute the retrofit to ensure continuous cooling tower operation.
Ongoing Support: We provide post-retrofit monitoring and optimization services.
This retrofit is ideal if your system has:
Pumps over 7-10 years old.
Constant-speed pumps with throttling valves.
High and unpredictable condenser water loop energy costs.
Goals for sustainability certifications (GBI, LEED).
Stop Wasting Energy on Fixed-Speed Pumping
A cooling tower pump retrofit is one of the highest-ROI projects in facility management.
Contact EKG (Malaysia) Sdn Bhd for a free feasibility assessment. We will analyze your current operation and provide a detailed savings projection and project proposal.
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