KIRLOSKAR BROTHERS LIMITED A Kirloskar Group of Company BHAGVATDAN - - PowerPoint PPT Presentation

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KIRLOSKAR BROTHERS LIMITED A Kirloskar Group of Company BHAGVATDAN GADHAVI EASC-KBL 09687641316,bhagvatdan.gadhavi@kbl.co.in Ahmedabad, Gujarat 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 1 Flow of Presentation

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1 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

BHAGVATDAN GADHAVI – EASC-KBL 09687641316,bhagvatdan.gadhavi@kbl.co.in Ahmedabad, Gujarat

KIRLOSKAR BROTHERS LIMITED A Kirloskar Group of Company

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2 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Flow of Presentation

1

Introduction - Energy Scenario

2

Why Energy Conservation

3

Pump and Pumping cost

4

Avenues of Energy Saving in Pumping

5

Case Study

6

Conclusion

7

Our Beneficiaries

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3 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Introduction about Energy Scenario

How the world has changed its attitude Left hand side-In 20th century smoke – sign of Prosperity and development Right hand side-In 21st century smoke – sign of lack of technology and hazard

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4 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Introduction about Energy Scenario

  • The process should be done some how
  • Usage of resources was not limited

19th Century

  • Competition increased in the market
  • Optimization of process to lower the cost

20th Century

  • Process is fully optimized. What Next..?
  • Energy is the next future

21st Century

Attitude of Industries regarding their process

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5 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Why Energy Conservation?

Cement 10% Power 20% Aluminium 10% Iron & Steel 10%

  • Chlor - Alkali

10%

  • Pulp & Paper

10%

  • Textiles

10%

  • Railways

20%

Energy Cost as % of Manufacturing Cost

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6 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

  • 85 % of the cost of running of a

pump is towards cost of electricity.

  • For e g A 20 kW pump requires

– 20 kWh/hr , i.e. Rs 90 / hr , (Energy Rate Rs. 4.5/kwh) – Rs 2,160/ day , – Rs. 64,800/ Month – Rs. 7,88,400/ Year. – Pump cost is Rs. 64,000 – 8 % of running cost

6

 Pumping system efficiency = Pump eff. x Motor eff. x piping eff.

Pump Cost and Pumping Cost

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7 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Facts Regarding Pump Power Consumption

7

The table below shows rise in pumping cost due to drop in efficiency for a 20 BKW pump set during the period of

  • peration.

Sr. No. No of Years Efficiency (* ) Pumping Cost Per Day Per Annum 1 1st Year 80 % 2160 788400 2 2nd Year 79 % 2187 798380 3 3rd Year 78 % 2215 808615 4 4th Year 77 % 2244 819117 5 5th Year 76 % 2274 829895 6 6th Year 75 % 2304 840960 7 7th Year 74 % 2335 852324 8 8th Year 73 % 2367 864000 9 9th Year 72 % 2400 876000 10 10th Year 71 % 2434 888338

 Normally pump efficiency drops at 1% per annum for

drinking water application due to erosion and corrosion.

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8 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Factors for taking the Right Decision

Purchase Price Running costs Maintenance costs 85%

10%

85% 10% 2.5% 2.5%

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9 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Pumping Costs

  • Many opportunities for reducing pumping costs are not recognized

because

  • Basic principles of pumping often misunderstood
  • Running pumps delivering sufficient water are considered to be

functioning satisfactorily

  • Production concerns outweigh pumping considerations
  • Lack of awareness of pumping costs
  • Life cycle costs (i.e. Initial costs plus running & maintenance cost) are

rarely considered at design stage

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10 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Typical Reasons for High Pumping Costs

  • Over Sizing
  • System Resistance not Matched with Pump Rated Parameter
  • Installation of Samll dia Pipes,Valves Than Required to save the initial cost.
  • Degradation & Lack of Maintenance
  • No measures for Variable liquid demand – Crude methods like bypass /

throttle

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11 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

The Way Forward

Energy Assessment & Solutions

Measurement Analysis Solutions for Energy Savings

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13 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Avenues of Energy Saving in pumping

1. Pump set :  Efficient Motors  High Efficiency IE2(High Efficiency), IE3(Premium Efficiency) motors  Efficient Pumps  LLC Series of pumps  Pumps with Corrocoat  Star Label pumps  Pump Selection  Pump set should be selected based on Discharge & Head requirements , not based on Suction & Delivery Sizes  The duty point Head & Discharge should be around best efficiency point  While selecting the Pumpset, change in needs based on peak & low demand also should be kept in mind

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14 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

  • 2. Pipes & Foot Valve :

 Pipe Size  Pipe material : smoother the material , lesser the frictional losses  Non Frictional Foot Valve : Preferably Non-frictional Foot Valve should be used for better results , it has larger impact

  • 3. Pumping Automation

 No of parallel pump operation wrt demand  VFD pumping

Avenues of Energy Saving in pumping

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15 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

  • Fully equipped with 12 sets of sophisticated instruments like

Ultrasound Flow Meter, Power Analyzer, Stroboscope, etc

  • Competent team 12 people Qualified Energy Audit Professionals
  • Having specialized Instruments for Hazardous area and for sewage

pumps .

Infrastructure & Capabilities

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16 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Infrastructure & Capabilities

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17 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Infrastructure & Capabilities

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18 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Our Infrastructure

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Our Infrastructure

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20 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Our Infrastructure

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Unsupported stem length – temperature probe in thermowell

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22 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Temperature Probe in Thermowell

  • Continuous Monitoring
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23 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Unsupported Stem length – Direct Immersion

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24 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Portable Unit - Tapping Point for Temperature and Pressure Probes

Direct immersion suitable up to about 30 bar pressure 15 mm gate valve T-piece Safety clip Temperature probe tip is 50 mm into fluid Pressure probe attached to T-piece via quick-connects

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25 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Our Infrastructure

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26 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Arvind Mills, Ahemdabad, Gujarat

Raw Pump House No-2

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27 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Soft Water Pump House No - 2 ( 2 Working)

Particulars Present System (P1, P2) Pump Make Submersible Type Total No of pumps 02

  • No. Of Working Pumps

02 Head (Mtrs) NA Discharge (m3/hr) NA Installed Power (KW) 15 + 24 = 39 KW Textile Industry – Arvind Mills, Ahmedabad, Gujrat

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28 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Observed Parameters:- P1(32 Hp), P2 (20 Hp)

Observed Parameters- P1 P2 Flow (m3/Hr) 130 111 Pressure Discharge ( Kg/cm2) 1.8 0.8 Discharge Head (Mtrs.) 18 8 Z Factor (Mtrs.) 2 2 Effective Head ( Mtrs.) 20 10 Input power to motor (KW) 22 KW 15.7 KW

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29 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Efficiency Calculations

Efficiency Calculations - P1 P2

Hydraulic output from the pump (Kw) 7.0 KW 3.0KW Input to the Motor (Kw) 22 KW 15.7 KW Overall Efficiency ( %) 31.81 % 19.10% Motor efficiency (From the name plate)

  • --%
  • -- %

Pump efficiency (considering above motor

efficiency )

  • ---%
  • --- %

Observations :-  Presently existing pumps Individual running point is 20 mtr. & 10 mtr head and 130 m3/hr & 111 m3/hr discharge. Overall Efficiency of the pumps is 31.81 % and 19.10 %. Presently water demand is relative to process requirements.  Suction and delivery valve is found fully open during measurement.  As per discussion with the clients, the water requirements are considered 250m3/hr and 30 mtr. head sufficient to the Present and future requirements.

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30 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Particulars Present Pump (Name Plate) Details

Pump Type UP 125/35 No of Pumps in Circuit 1 No of Working pumps 1 Head ( Meter ) 30 Discharge (M3/Hr) 250 Motor Rating (KW) 30 Speed (rpm ) 1450

Pump Detail

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31 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Present Working Details

Observations:-

  • In Existing Installation 1#Pump is Connected to cater the Raw water

requirement in the plant

  • Presently, 1#Pump is Running 24 hrs/day.
  • Pump is running on VFD to control the speed according to Pressure

requirement.

  • On average pump is running on frequency of 43 to 45 HZ.
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32 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Observed Parameters Pump

Flow (M3/Hr) 241 Discharge Pressure (Kg/cm2) 2.4 Discharge Head (Mtrs.) (A) 24 Suction Head (Mtrs.) (B) 1.04 P.Gauge Correction(Z-Factor)(Mtrs)(C) 0.4 Total Head (Mtrs.) (A+B+C) 25.44 Average Motor Input (kW) 21.41 Pump Hydraulic Out Put (kW) 16.70 Power Input to Pump(KW) 19.69 Motor efficiency (%) 92.0% Pump Efficiency(%) 84.81%

Observed Parameters(Verification Audit)

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33 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Saving Calculations(Recommended vs Actual)

Present Proposed Actual Installed Capacity ( Kw) 45 kw 30 kw 30 kw Power Consumption (Kw) 37.7 kw 26.48 kw 21.41kw Saving Calculations Estimated Saving (Kwh) 11.22 16.29 Estimated Saving in (%) 42.37 % 76.08 % Annul working days 365 365 Daily Working Hours 24 24 Annual working Hours 8760 8760 Estimated Annual Saving (Kwh) 98,287 1,42,700 Energy Rate (Rs./Kwh) 6.5 6.5 Estimated Savings /Annum (Rs.) 6,38,865 9,27,550

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34 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Pay Back Calculations

Investment for Replacement of 01 pump with motor (Rs.) 2,25,000 savings after modification (Rs.) 9,27,550 Simple Pay Back Period ( Years) 0.24

  • Approx. Pay Back Period in Months

2.91

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35 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Appreciation Letters

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36 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Appreciation Letters

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37 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Certifications & Accreditations

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38 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Certifications & Accreditations

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39 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Saving

  • Rs. 12 Lacs

/Year in Cooling Tower pumps

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40 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Saving

  • Rs. 990,000 units Rs.

60 Lacs /Year in 25 systems

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41 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Saving

  • Rs. 4.84 Lacs /Year

In paint shop process

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42 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

Some of the Beneficiaries

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43 This is a proprietary document of Kirloskar Brothers Limited 11-Jul-16

We believe in making the world a better place to live.

Come, let us join our hands together

 To conserve our nature  In the national interest  In the business interest

Leave your worries to us as a pump expert and rest assured that your saving’s account grows continuously………….