story of an engineer. - :: gbc :: · pdf filethis is a proprietary document of kirloskar...

This is a proprietary document of Kirloskar Brothers Limited31-Oct-13 1

New Trend In Pump efficiency


Story of an Engineer….

This is a proprietary document of Kirloskar Brothers Limited 3

Energy Saving Concepts…

31-Oct-13


What about PUMP ???


We have derived H,Q, Suction pressure , working pressure & RPM.

What else is left ?

Pump efficiency !!

This is a proprietary document of Kirloskar Brothers Limited

Study

6

• 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.

31-Oct-13

• As per HIS pump efficiency reduces by 1.5% to 2% ev ery year

Pump has a Life Cycle Cost in it…


Why does efficiency of pump decrease???


findings

8

• Chemical degradation – Corrosion

31-Oct-13

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%


Finding…elements of Life Cycle Cost

31-Oct-13


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

31-Oct-13

– Mn 120 approx. / for 10 years life


Contribution of Various Elements

85%

10%2% 3%

ENERGY COST

MAINTENANCE COST

INITIAL COST

OTHER COSTS

31-Oct-13

Majority of buyers negotiate hard on this 1% of th e Total cost.


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%


Pumps put in operation…

15

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

31-Oct-13


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..


Environment Effect

17

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

31-Oct-13


Benefits of Lowest Life Cycle Cost™

1831-Oct-13


Conclusion

19

ROI of 9 months to One year

“THIS IS A CRADLE TO GRAVE SOLUTION”With Minimum cost to Maximum Benefits

31-Oct-13


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


…..Sustainable Efficiency

New Trend In Pump efficiency

This is a proprietary document of Kirloskar Brothers Limited22

HIS …about efficiency drop in a pump..


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.)

31-Oct-13

Power tariff Considered : Rs 6/KWh


Tortuous path for corrosive ion Layers of glass flakes Coating

SUBSTRATE

Surface roughness comparison

31-Oct-13

Reducing chemical degradation

Glass flake fluiglide coating


Coating on Internal parts…

31-Oct-13


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

27

This is a proprietary document of Kirloskar Brothers LimitedThis is a proprietary document of Kirloskar Brothers Limited

28

Hard Metallic serrated

wearing


Precision casting in austenitic stainless steel as standard . Axially hydraulic balance of double suction design improves efficiency &Bearing Life.


� Externally removable

bearing housing

� Universal seal chamber

� API type double row

thrust bearing assembly

Reducing mechanical degradation and down time


Reducing down time

story of an engineer. - :: gbc :: · pdf filethis is a proprietary document of kirloskar...

Documents