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

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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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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 Introduction about Energy Scenario

Attitude of Industries regarding their process

19th • The process should be done some how

• Usage of resources was not limited
Century
20th • Competition increased in the market
• Optimization of process to lower the cost
Century
21st • Process is fully optimized. What Next..?
• Energy is the next future
Century

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 Why Energy Conservation?
Energy Cost as % of Manufacturing Cost

Cement
-Railways 10%
20%
Power
20%
-Textiles
10%
-Chlor - Alkali
Aluminium
10%
10%
-Pulp & PaperIron & Steel
10% 10%

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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.
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 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.

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Factors for taking the Right Decision

85%
Purchase Price

10%
10%

Running costs 2.5%

Maintenance costs

85%
2.5%

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 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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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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The Way Forward

Analysis

Solutions for
Measurement Energy
Savings

Energy
Assessment
& Solutions

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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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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

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 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
.

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 Infrastructure & Capabilities

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 Infrastructure & Capabilities

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Our Infrastructure

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Our Infrastructure

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Our Infrastructure

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 Unsupported stem length –
temperature probe in thermowell

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 Temperature Probe in Thermowell
-Continuous Monitoring

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 Unsupported Stem length – Direct
Immersion

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 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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Our Infrastructure

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 Arvind Mills, Ahemdabad, Gujarat

Raw Pump House No-2

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 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

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 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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 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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 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

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 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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 Observed Parameters(Verification
Audit)
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%

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 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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 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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 Appreciation Letters

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 Appreciation Letters

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 Certifications & Accreditations

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 Certifications & Accreditations

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 Saving
Rs. 12 Lacs
/Year in Cooling
Tower pumps

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 Saving
Rs. 990,000 units Rs.
60 Lacs /Year in 25
systems

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 Saving
Rs. 4.84 Lacs /Year
In paint shop
process

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Some of the Beneficiaries

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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………….

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