Download - KSB Energy Saving_FPG (Send out)
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Technology that makes its mark
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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
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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
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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
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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
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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
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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
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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
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DesignKSB Design - Retrofit
Pump Motor
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DesignKSB Design - Retrofit
Pump Voith Motor
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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
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PhotosKSB - Retrofit
Preparation for equipment removal
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PhotosKSB - Retrofit
Motor Removed
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PhotosKSB - Retrofit
Marking of shaft center line elevation in near by column
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PhotosKSB - Retrofit
Demolition of baseframe & foundation at motor sided
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PhotosKSB - Retrofit
Progress on foundation modification
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PhotosKSB - Retrofit
Casting new extended foundation
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PhotosKSB - Retrofit
New pockets in new foundation
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PhotosKSB - Retrofit
Leveling sole plate installed in foundation
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PhotosKSB - Retrofit
Cooler installation
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PhotosKSB - Retrofit
Placing new baseframe on new foundation
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PhotosKSB - Retrofit
Installing Voith Hydraulic Coupling
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PhotosKSB - Retrofit
Motor Installation
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PhotosKSB - Retrofit
Alignment
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PhotosKSB - Retrofit
Lubrication piping fabrication
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PhotosKSB - Retrofit
Grouting
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PhotosKSB - Retrofit
Grouting finished
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PhotosKSB - Retrofit
Lub. oil piping flushing by temporary arrangement
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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
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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
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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
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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
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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!