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 1 Introduction - Energy Scenario Why Energy Conservation 2 Pump and Pumping cost 3 Avenues of Energy Saving in Pumping 4 Case Study 5 Conclusion 6 7 Our Beneficiaries 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 2
Introduction about Energy Scenario How the world has changed its attitude Left hand side-In 20 th century smoke – sign of Prosperity and development Right hand side-In 21 st century smoke – sign of lack of technology and hazard 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 3
Introduction about Energy Scenario Attitude of Industries regarding their process 19 th • The process should be done some how • Usage of resources was not limited Century 20 th • Competition increased in the market • Optimization of process to lower the cost Century 21 st • Process is fully optimized. What Next..? • Energy is the next future Century 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 4
Why Energy Conservation? Energy Cost as % of Manufacturing Cost Cement 10% -Railways 20% Power 20% -Textiles 10% -Chlor - Alkali Aluminium 10% 10% Iron & Steel -Pulp & Paper 10% 10% 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 5
Pump Cost and Pumping Cost • 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 Pumping system efficiency = Pump eff. x Motor eff. x piping eff. 6 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 6
Facts Regarding Pump Power Consumption The table below shows rise in pumping cost due to drop in efficiency for a 20 BKW pump set during the period of operation. Sr. No of Years Efficiency (* ) Pumping Cost No. 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. 7 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 7
Factors for taking the Right Decision 85% Purchase Price 10% 10% 2.5% Running costs Maintenance costs 85% 2.5% 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 8
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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 9
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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 10
The Way Forward Analysis Solutions for Measurement Energy Savings Energy Assessment & Solutions 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 11
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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 13
Avenues of Energy Saving in pumping 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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 14
Infrastructure & Capabilities • 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 . 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 15
Infrastructure & Capabilities 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 16
Infrastructure & Capabilities 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 17
Our Infrastructure 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 18
Our Infrastructure 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 19
Our Infrastructure 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 20
Unsupported stem length – temperature probe in thermowell 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 21
Temperature Probe in Thermowell -Continuous Monitoring 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 22
Unsupported Stem length – Direct Immersion 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 23
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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 24
Our Infrastructure 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 25
Arvind Mills , Ahemdabad, Gujarat Raw Pump House No-2 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 26
Textile Industry – Arvind Mills, Ahmedabad, Gujrat 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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 27
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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 28
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. 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 29
Pump Detail Present Pump Particulars (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 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 30
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. 11-Jul-16 This is a proprietary document of Kirloskar Brothers Limited 31
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