Energy-efficient Centrifugal Pump Retrofitting

Transform existing pumps into high-efficiency assets with rapid ROI.
Energy-efficient centrifugal pump retrofitting involves upgrading or modifying an existing pump system to significantly reduce its energy consumption. EKG Malaysia provides turnkey retrofit solutions—from energy audits and hydraulic analysis to implementation—typically achieving 20–50% energy savings with payback periods of 6–24 months.

Common Retrofit Strategies We Implement:

1. Pump Hydraulic Optimization

• Impeller Trimming or Replacement: Downsizing the impeller to match the actual system head requirement, eliminating energy wasted on overcoming excess pressure.

• Installing a Correctly Sized Pump: Replacing a severely oversized pump with a smaller, high-efficiency model that operates at its Best Efficiency Point (BEP).

2. Drive & Control Upgrades

• Variable Frequency Drive (VFD) Installation: The most impactful retrofit. Replacing throttling valve control with variable speed control to match pump output directly to demand. Ideal for systems with varying flow requirements.

• High-Efficiency Motor Replacement: Swapping out standard motors (IE1/IE2) with IE3 or IE4 premium efficiency motors.

3. System Optimization

• Eliminating Throttling Valves: Bypassing or removing control valves that create artificial head loss.

• System De-Pressurization: Reviewing and resetting control setpoints (e.g., reducing differential pressure setpoints in HVAC systems) to the minimum required.

• Parallel Pump Optimization: Optimizing the operating sequence and control of multiple pumps.

Our Retrofitting Process:

Phase 1: Energy Audit & Assessment

• Data Logging: Measuring existing pump performance (flow, head, power) over a representative period.

• System Curve Analysis: Determining the actual system curve vs. the pump's operating point.

• Savings Potential Report: Quantifying energy and cost savings for each retrofit option with ROI calculations.

Phase 2: Solution Design & Implementation

• Detailed Engineering: Specifying the exact components (impeller size, VFD model, motor specs).

• Minimal-Dowtime Execution: Careful planning to implement changes during planned outages or with minimal disruption.

• Professional Installation: Precision work on pump modifications, VFD integration, and control reprogramming.

Phase 3: Verification & Commissioning

• Post-Retrofit Measurement: Verifying performance and energy savings.

• Control Tuning: Optimizing VFD parameters and system setpoints.

• Training & Documentation: Handing over system documentation and training facility staff.

Why Retrofit with EKG?

• We Focus on Root Cause: We don't just add hardware; we correct the hydraulic mismatch.

• Guaranteed Results: Our proposals are based on measured data, not estimates.

• Comprehensive Approach: We address the pump, drive, controls, and system.

• Ongoing Support: We ensure the retrofit continues to perform optimally.

Turn your biggest energy user into a savings generator.
A strategic retrofit is often the fastest, most cost-effective way to cut operational costs and carbon footprint.

Contact EKG Malaysia for a Pump Energy Audit and Retrofit Feasibility Study. Let us show you the measurable savings possible in your facility.