ksb energy saving_fpg (send out)

Technology that makes its mark

KSB Energy SavingOur Technology, your success

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (Boiler Feed Pump)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (Quench Spray Tower Pump)

• Theory

• Design

4. Q&A

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (QSTP_KWP)

• Theory

• Design

4. Q&A

KSB GroupAbout Us

KSB is one of the world’s leading manufacturers of pumps and valves, providing a comprehensive range of service offerings.

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It All Began with an IdeaExperience since 1871

The global success story of KSB began over 140 years ago when Johannes laid the foundation for the company by inventing his “boiler feed apparatus”.

Production of Valves since 1872 Pumps since 1873

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KSB ProductsPumps

• Water

• Waste Water

• Energy

• Industry

• Building Service

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KSB ProductsValves

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1. Gate Valves

2. Globe Valves

3. Check Valves

4. Butterfly Valves

5. Diaphragm Valves

6. Globe Control Valves

KSB ProductsAutomation and drives

• IE4 high efficiency motor

• Frequency Invertor

• Monitoring Equipment

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Spare Parts Reverse-Engineering Inventory Management Installation / Commissioning /

Supervision Repair Extension of warranty Inspection Service Consultancy Retrofit TPM Frame Contracts

KSB Products

Service

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (KWP)

• Theory

• Design

4. Q&A

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TheoryPerformance Curve

Performance Curve Shutoff Head Point Best Efficiency Point Run Out Point

Performance Curve

0

10

20

30

40

50

60

70

0 10 20 30 40 50

Capacity (m3/hr)

Hea

d (m

) / E

ffici

ency

(%)

0

2

4

6

8

10

12

14

Pum

p In

put (

BK

W)

/ N

PS

Hr (

m)

Best Efficiency PointShutoff Head Point

Run Out Point

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TheoryPerformance Curve

• Allowable operating range

• Preferred operating range

• For example: (API)• 70% - 120%• 80% - 110%

Performance Curve

0

10

20

30

40

50

60

70

0 10 20 30 40 50Capacity (m3/hr)

Hea

d (m

) / E

ffici

ency

(%)

0

2

4

6

8

10

12

14

Rad

ial T

hrus

t

Run Out Point

Preferred operating range

Allowable operating range

Min. Continuous Stable Flow

Best Efficiency PointShutoff Head Point

Reducing Total Cost of Ownership also means:

Utilising the availability capabilities of the components

Ensuring normal operation = extending service life = saving costs

Source: Paul Barringer, Barringer & Associates, Inc.

Dis

char

ge h

ead

[%]

Flow rate [%]

Characteristic curveGood practice:

-30%..+15%

Better practice:-20%..+10%

Best practice = -10% ..+5% of BEP

10

100

Outletrecirculation

Inletrecirculation

Impeller wear

Short bearing & mechanical

seal life

Cavitation

Overheating

Short bearing & mechanical seal life

Cavitation

Service life [%]

Typicalefficiency curve

Cost of Ownership TheoryCost of Ownership – service (availability/reliability)

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TheoryAffinity Laws

Capacity Q

System Resistance Curve

B1

N1

N2

B2

B3H3

Q3 Q2 Q1

H2

H1

Effect of Speed on Pump Performance

Keeping Impeller diameter D constant

Q2 =N2

N1

x Q1

H2 =N2

N1

x H1

2

P2 =N2

N1

x P1

3

N3

TheoryLoad profile in practice

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Load profile with two or multiple operating points:

System design:Peak loading & Low loading

Example: peak loading = day time; low loading = night time

Pump is design to serve in day time

Throttleing control

Operating hours

Dis

char

ge h

ead

Flow rate

QBEP

TheoryLoad profile in practice

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Load profile with two or multiple operating points:

Pump is not properly sizing Running in partial loading Flow fluctuation due to process

Operating hours

Dis

char

ge h

ead

Flow rate

QBEP

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TheoryComparison of control types

Throttling Speed control

M~~~

~~~

Q

M

Q

P

Q1Q2

Systemcurve

Pumpcharacteristic

Q

H

Savingspotential

P

Q1Q2

Systemcurve

Pumpcharacteristic

Q

H

P

• Power consumption

• Saving potential

• Affinity Law

Operating hours

Number of pumps

Q/Qopt ratio

Source: ReMain research project, 65 pumps, 21 May – 10 June 2009

0

50

100

150

200

250

300

350

400

450

0.250.5

0.751.0

1.251.5 0

10

20

3040

5060

70

Only few pumps are operated at the best efficiency point

TheoryOperating point

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TheoryVoith Hydraulic Coupling

Reference simulationReference video

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (QSTP_KWP)

• Theory

• Design

4. Q&A

DesignKSB Design - Retrofit

Pump Motor

DesignKSB Design - Retrofit

Pump Voith Motor

DesignKSB Design - Retrofit

Pump Motor

Emergency Installation

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (KWP)

• Theory

• Design

4. Q&A

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Retrofit in practice FCFC G8 & SK3

Equipment (G8)– KSB BFP HGC 5/7– Voith 487 SVTL 12.1– TECO AECW-S2001

Caption, Arial, 10 pt, black Caption, Arial, 10 pt, black

PhotosKSB - Retrofit

Preparation for equipment removal

PhotosKSB - Retrofit

Motor Removed

PhotosKSB - Retrofit

Marking of shaft center line elevation in near by column

PhotosKSB - Retrofit

Demolition of baseframe & foundation at motor sided

PhotosKSB - Retrofit

Progress on foundation modification

PhotosKSB - Retrofit

Casting new extended foundation

PhotosKSB - Retrofit

New pockets in new foundation

PhotosKSB - Retrofit

Leveling sole plate installed in foundation

PhotosKSB - Retrofit

Cooler installation

PhotosKSB - Retrofit

Placing new baseframe on new foundation

PhotosKSB - Retrofit

Installing Voith Hydraulic Coupling

PhotosKSB - Retrofit

Motor Installation

PhotosKSB - Retrofit

Alignment

PhotosKSB - Retrofit

Lubrication piping fabrication

PhotosKSB - Retrofit

Grouting

PhotosKSB - Retrofit

Grouting finished

PhotosKSB - Retrofit

Lub. oil piping flushing by temporary arrangement

PhotosKSB - Retrofit

Project finished

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos (Reference 2)

3. KSB Service: Retrofit (QSTP_KWP)

• Theory

• Design

4. Q&A

SES in PracticePower station

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SES in PracticePower station

Initial situation Operation of two 10-stage high pressure pumps

– Flow rate Qopt. 340 m3/h

– Discharge head Hopt. 1,743 m

– Power PW 1,785 kW– Speed of rotation n 2,985 min-1

– Density ρ 914 kg/m3

Identification of possible savings to reduce the energy costs of the pumps

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SES in PracticePower stationOptimisation - Solution A Hydraulic coupling High peripheral costs due to pump base plate modifications

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No need for extra cooling

Mechanical driven design

SES in PracticePower stationOptimisation - Solution B Variable Speed Drive / Invertor Extra cooling is required No need for peripheral modification Electrical driven machanism

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SES in PracticePower stationOptimisation - Solution C Blind stages (stages 9 und 7) Designed operating point changed for good

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (QSTP_KWP)

• Theory

• Design

4. Q&A

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TheoryKSB Service: Retrofit (KWP)

Current Operating Condition KSB RPK

– 2800 CMH / 53.5 m– 6 pole motor / 615 kW– Serious wear & tear – Cavitation

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TheoryKSB Service: Retrofit (KWP)

KSB Solution KWP

– Wear resistant material– Non-clogging channel

impeller– Lower NPSHr– Higher efficiency up to

90%– No need for civil work

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KSB Energy Saving

Outline

1. Company Introduction

2. KSB Service: Retrofit (BFP)

• Theory

• Design

• Photos

3. KSB Service: Retrofit (QSTP_KWP)

• Theory

• Design

4. Q&A

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DesignKSB Service: Retrofit (KWP)

Comparison DWG Pump Length Discharge Flange Motor (6 pole & 8 pole)

RPK

KWP

RPK & KWP 比較表RPK KWP

材質 A532 標準不鏽鋼KSB 特殊耐磨耗材料 Noriloy® with Cr-Carbides 由我司工廠特

殊鑄造由 KSB 材料實驗室開發，專為耐磨蝕狀況設計，於 FGD 相關製程

有大量實績。轉速 6 極馬達 : 1150 rpm 原始設計 8 極馬達 : 890 rpm

較低轉速可以降低磨耗速度，延長使用壽命。

NPSHr 9.5 m 原始設計 5.5 m 較低的 NPSHr 可以避免氣蝕，延長葉輪使用壽命。

效率 615 kW, 86% 原始設計 520 kW, 90% 馬達較小，消耗功率較少，操作費用大幅降低。

設計 背拉式設計 原始設計 背拉式設計 一般相較於他牌的渣漿泵設計，背拉式在保養上較為簡易。

磨耗保護 耐磨環 原始設計 耐磨板耐磨板較不易卡住，且在日後若有效率下降，可以利用特殊設計回覆

一定效率。葉輪設計 密閉式葉輪 原始設計 不阻塞型葉輪 增加葉輪前後距離，以利顆粒通過

葉輪，並保持高效率。

施工- - 中心支撐 減少改造工程，換裝容易。- - 底座 舊有底座延續使用，將提供新的馬

達座給新設備。- - 基礎 無須重新製作基礎

KSB Energy Saving Tool

Sonolyzer, Datalogger, Pumpmeter, PumpDrive

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• Sonolyzer Quick detect saving potential

• Datalogger Logging operating data.

Analyze by KSB professionals

• Pumpmeter Logging operating conditions,

displaying energy status in time

• PumpDrive Control your pump performing

in best efficiency

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Q & A

Thank you for your attention!