Energy-efficient HVAC Pump Retrofitting

Transform your existing system into a high-efficiency asset with rapid payback.
Energy-efficient HVAC pump retrofitting involves upgrading or replacing outdated pumps, motors, and controls to dramatically reduce energy consumption in your building's chilled water, condenser water, and heating systems. EKG Malaysia provides turnkey retrofit solutions that typically achieve 30–50% energy savings with payback periods of 1–3 years, improving comfort and system reliability.

Common Retrofit Opportunities We Target:

1. Constant to Variable Speed Conversion

• Action: Installing a Variable Frequency Drive (VFD) on an existing constant-speed pump motor.

• Savings Mechanism: Pump speed reduces to match real-time cooling/heating demand, following the Affinity Laws (power is proportional to the cube of speed).

• Ideal For: Systems with control valves that throttle flow, causing energy waste.

2. Pump Downsizing or Impeller Trimming

• Action: Replacing an oversized pump with a correctly sized unit or trimming the existing impeller.

• Savings Mechanism: Eliminates energy wasted on overcoming excess pressure created by an oversized pump.

• Ideal For: Systems where the pump operates far from its Best Efficiency Point (BEP), often with a bypass line in constant flow.

3. High-Efficiency Motor Replacement

• Action: Swapping out standard motors (IE1/IE2) with IE3 or IE4 premium efficiency motors.

• Savings Mechanism: Reduces motor losses, improving full-load and part-load efficiency.

4. Complete System Modernization

• Action: Replacing old primary-secondary systems with a Variable Primary Flow (VPF) system.

• Savings Mechanism: Eliminates secondary pumps and reduces primary pump energy by allowing variable flow through chillers.

Our Proven Retrofit Process:

Phase 1: Energy Audit & Assessment

• Data Logging: Measuring existing pump power, flow, and pressure over 1-2 weeks.

• System Analysis: Identifying the actual system curve vs. pump operating point.

• Savings Report: Quantifying energy/cost savings and ROI for each retrofit option.

Phase 2: Engineering & Implementation

• Detailed Design: Selecting exact components (VFD model, pump size, motor specs).

• Minimal-Dowtime Execution: Careful staging to keep the building operational.

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

Phase 3: Commissioning & Verification

• Control Tuning: Programming VFDs for optimal response and protection.

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

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

Why Retrofit with EKG?

• We Focus on System-Level Solutions: We correct the root cause, not just the symptom.

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

• Comprehensive Approach: We address pumps, motors, drives, controls, and piping.

• Ongoing Support: We ensure the retrofit delivers savings long-term.

Turn your biggest energy user into a savings generator.
An HVAC pump retrofit is often the single most cost-effective upgrade for reducing building operating costs.

Contact EKG Malaysia for a Free Pump Energy Audit and retrofit feasibility study. Let us show you the measurable savings hidden in your current system.