This is a proprietary document of Kirloskar Brothers Limited31-Oct-13 1
New Trend In Pump efficiency
This is a proprietary document of Kirloskar Brothers Limited31-Oct-13 2
Story of an Engineer….
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Energy Saving Concepts…
31-Oct-13
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What about PUMP ???
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We have derived H,Q, Suction pressure , working pressure & RPM.
What else is left ?
Pump efficiency !!
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Study
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• 1/5th of total power generated in the world is consumed b y
Pumps & Pumping Systems i.e. 20% of 21000 Tera Watt 20% of 21000 Tera Watt
Hour Hour (Source: enerdata.net 2010 Values) power produced.
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• As per HIS pump efficiency reduces by 1.5% to 2% ev ery year
Pump has a Life Cycle Cost in it…
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Why does efficiency of pump decrease???
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findings
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• Chemical degradation – Corrosion
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For standard pump wear ring clearance increase by least 2 times in run of 8000 hours.
• Mechanical degradation
Shaft deflection
� Mechanically erodes diametric clearances
� Reduction in mechanical seal life and bearing life
� Increases pump vibration owing to residual unbalance
Due to mechanical wear & tear
� Wear ring clearance increases
1.5 times of standard clearance = reduction in efficiency by 1.5 to 2.3%
2 times of standard clearance = reduction in efficiency by 2 to 6%
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Finding…elements of Life Cycle Cost
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Example
Let us consider a pump requiring 235 kW motor to d rive. Energy cost will be
– ` 1,410 / hour– ` 31,020/ day (22 hrs of operation) – ` Mn 0.93 / Month (30 days)– ` Mn 11 approx. / Year.
The initial cost of the pump motor equipment is about Mn 1.1 Only 1% of the running cost over its life period
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– Mn 120 approx. / for 10 years life
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Contribution of Various Elements
85%
10%2% 3%
ENERGY COST
MAINTENANCE COST
INITIAL COST
OTHER COSTS
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Majority of buyers negotiate hard on this 1% of th e Total cost.
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Need to develop new design with
•Reduce chemical degradation
•Improve efficiency
•Reduce mechanical degradation
•Reduce down time
• Sustain Efficiency
This is a proprietary document of Kirloskar Brothers Limited 1331-Oct-13
This is a proprietary document of Kirloskar Brothers Limited 1431-Oct-13
Efficiency Improves by 3% to 5%+
Efficiency reduction is 0.25% every Year..
Corrosion Restricted to 10+ years
Maintenance downtime reduces by 50%
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Pumps put in operation…
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1925 Head (M) 37 Sp gravity 1 26087% 90% 3.0%
22 Avaiability factior 100% 80303 Motor Effi 95.5% Currency INR Power Tarrif INR 6.00
Motot Input 234.81
Pumping Cost Pumping Cost
BKW Per Annum INR BKW Per Annum INR Power Cost (INR)
1 82.6% 234.81 1,885,497 11,312,982 85.61% 226.58 1,819,422 10,916,534 66,075 396,448 2 81.4% 238.38 1,914,210 11,485,261 85.39% 227.15 1,823,982 10,943,894 90,228 541,367 3 80.1% 242.01 1,943,361 11,660,164 85.18% 227.72 1,828,554 10,971,322 114,807 688,842 4 78.9% 245.70 1,972,955 11,837,729 84.97% 228.29 1,833,136 10,998,819 139,818 838,911 5 77.8% 249.44 2,003,000 12,017,999 84.75% 228.86 1,837,731 11,026,385 165,269 991,615 6 76.6% 253.24 2,033,502 12,201,015 84.54% 229.43 1,842,337 11,054,020 191,166 1,146,995 7 75.4% 257.09 2,064,469 12,386,817 84.33% 230.01 1,846,954 11,081,724 217,515 1,305,093 8 74.3% 261.01 2,095,908 12,575,449 84.12% 230.58 1,851,583 11,109,498 244,325 1,465,951 9 73.2% 264.98 2,127,825 12,766,953 83.91% 231.16 1,856,224 11,137,341 271,602 1,629,612 10 72.1% 269.02 2,160,229 12,961,374 83.70% 231.74 1,860,876 11,165,255 299,353 1,796,119
Input data By Customer Power Energy BILL Number of Pump In system 3 Kw INRTotal Saving in ten Years /pump 1,800,159 10,800,951 Total Saving in ten Years for the system 5,400,4 76 32,402,853
Motor rating KW
Power consumed Power consumed for Corrocoated Pump
TOTAL SAVING IN TEN YEARS
Over all Efficiency
Over all Efficiency
No of Years
POWER SAVING CALCULATION
Stnadard /Existing pumps Pumps with Corrocoat Coati ngs Reduction in Power consumtion & Pumping cost due to corrocoating
/Annum
Working Hrs per day
Flow Cum/hrStandard pump Pump with coating Improvement In efficiency
No of Working Hrs No of working Pumps
Pump efficiency
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This is a proprietary document of Kirloskar Brothers Limited31-Oct-13 16
REGULAR LLC Dif ference
BEP Head meter 37 37 -
BEP Discharge m³/Hr 1925 1925 -
Pump Ef f iciency % 86.5 89 2.5
Motor Ef f iciency % 95.5 96 0.5
Overall Ef f iciency % 82.6 85.4 2.8325
Motor Input kw 235 227 8.00
Total electricity Cost In 10 Years for 3 pump
INR 363,617,227 331,214,374 32,402,853
10,800,951
Total Energy Consupt ion In One Hour
235 227 kw-hr
Total Energy Consupt ion In 10 Years
20,200,957 18,400,799 1,800,158
kw-hr
kw-hr
Total electricity Cost In 10 Years for 1 pump
INR 121,205,742 110,404,791
Result is..
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Environment Effect
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Regular LLC Savings Regular LLC CO2 Reduction Ist Year 20,68,865 19,95,957 72,907 1,655 1,597 58
2nd Year 21,00,370 20,00,960 99,410 1,680 1,601 80 3rd Year 21,32,355 20,05,975 1,26,381 1,706 1,605 101 4th Year 21,64,828 20,11,002 1,53,826 1,732 1,609 123 5th Year 21,97,795 20,16,042 1,81,753 1,758 1,613 145 6th Year 22,31,264 20,21,095 2,10,169 1,785 1,617 168 7th Year 22,65,242 20,26,160 2,39,082 1,812 1,621 191 8th Year 22,99,738 20,31,239 2,68,500 1,840 1,625 215 9thn Year 23,34,760 20,36,329 2,98,431 1,868 1,629 239 10th Year 23,70,315 20,41,433 3,28,882 1,896 1,633 263
IN TEN YEARS 2,21,65,532 2,01,86,193 19,79,340 17,732 16,149 1,583
Power Consumption kW CO2 Tons Years
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Benefits of Lowest Life Cycle Cost™
1831-Oct-13
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Conclusion
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ROI of 9 months to One year
“THIS IS A CRADLE TO GRAVE SOLUTION”With Minimum cost to Maximum Benefits
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This is a proprietary document of Kirloskar Brothers Limited31-Oct-13 20
World wide Installations..
560+ in UK
28+ in Ireland8+ in Russia
6+ in France
18+ in Sweden
6+ in Belgium
16+ in Norway
40+ in India
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…..Sustainable Efficiency
New Trend In Pump efficiency
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HIS …about efficiency drop in a pump..
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Analysis of Pump Power Consumption Pattern
Per Day Per Year (Mn.)1 1st year 82.60 30,994 11.162 2nd year 81.36 31,466 11.333 3rd year 80.14 31,945 11.504 4th year 78.94 32,431 11.685 5th year 77.75 32,925 11.856 6th year 76.59 33,427 12.037 7th year 75.44 33,936 12.228 8th year 74.31 34,452 12.409 9th year 73.19 34,977 12.59
10 10th year 72.10 35,510 12.78Total 120
Sr. no No. of yearsOver all
EfficiencyPumping cost (in Rs.)
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Power tariff Considered : Rs 6/KWh
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Tortuous path for corrosive ion Layers of glass flakes Coating
SUBSTRATE
Surface roughness comparison
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Reducing chemical degradation
Glass flake fluiglide coating
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Coating on Internal parts…
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Anti Corrosion
Anti- Abrasion
Anti-Galvanic
Hydrophobic
Improves Efficiency
Features of Coating …
This is a proprietary document of Kirloskar Brothers LimitedThis is a proprietary document of Kirloskar Brothers Limited
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This is a proprietary document of Kirloskar Brothers LimitedThis is a proprietary document of Kirloskar Brothers Limited
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Hard Metallic serrated
wearing
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Precision casting in austenitic stainless steel as standard . Axially hydraulic balance of double suction design improves efficiency &Bearing Life.
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� Externally removable
bearing housing
� Universal seal chamber
� API type double row
thrust bearing assembly
Reducing mechanical degradation and down time
This is a proprietary document of Kirloskar Brothers Limited31-Oct-13 31
Reducing down time