Kirloskar PDF

AVENUES OF ENERGY
CONSERVATION IN ELECTRIC
PUMPING SYSTEMS
N.C. TIWARI
KIRLOSKAR BROTHERS LIMITED
PRESENT SCENARIO
! OVER 40% OF THE TOTAL ENERGY IS CONSUMED BY

ELECTRIC PUMPING SYSTEMS ALONE.
! OVER 15 MILLION ELECTRIC PUMPING SYSTEMS ARE
IN OPERATION.
! EVERY YEAR AROUND 800,000 NEW PUMPSETS ARE
INSTALLED.
! MAJORITY OF THE PUMPSETS (ALMOST 80%) ARE
INEFFICIENT - ARE OPERATING AT AS LOW AS 50 TO
70% OF ACHIEVABLE EFFICIENCY.
Continued..
1
PRESENT SCENARIO
! THIS LOW OPERATING EFFICIENCY IS A RESULT OF
WRONG SELECTION OF PUMPING SYSTEMS :
" PUMPSETS ARE SELECTED BASED ON PRIMEMOVER RATING
AND PIPE SIZE. NO CONSIDERATION TO RECOMMENDATION
OF IS:10804.
" INEFFICIENT PUMPING SYSTEMS ARE INSTALLED DUE TO
PRICE ADVANTAGE.
" A LOWER HP EFFICIENT PUMPING SYSTEM CAN DO THE JOB,
INSTEAD A HIGHER HP INEFFICIENT SYSTEM IS OFTEN
INSTALLED.
" IN THE EVENT OF HP BASED TARIFF AND SUBSIDY,
DERATING IS COMMON IN AGRICULTURE SECTOR.
" OBVIOUSLY, THERE IS HUGE POTENTIAL TO
CONSERVE BOTH POWER AND ENERGY.
POTENTIAL FOR ENERGY AND POWER

CONSERVATION
POTENTIAL FOR SAVING BY RECTIFICATION
TOTAL POWER GENERATED : 90,000 MW

POWER CONSUMED BY
AGRICULTURAL PUMPING : 36,000 MW
POWER BEING WASTED IN
AGRICULTURAL PUMPING : 10,080 MW
COST OF GENERATION,
TRANSMISSION & DISTRIBUTION
: 40,320 crores
OF EQUIVALENT POWER
2
POTENTIAL FOR ENERGY AND
POWER CONSERVATION
POTENTIAL FOR SAVING BY NEW SYSTEMS
NEW PUMPING SYSTEM BEING

INSTALLED EVERY YEAR : 800,000
POTENTIAL FOR SAVING BY

INSTALLING EFFICIENT PUMPING
: 896 MW
SYSTEMS
COST OF GENERATION,
TRANSMISSION & DISTRIBUTION
: 3,584 crores
OF EQUIVALENT POWER
PUMPING SYSTEM
Pumping system efficiency = Pump effi. x Motor effi. x

Piping effi. x Foot valve effi.
3
REASONS FOR LOW EFFICIENCY
Pump selection based on HP rating and

pipe sizes or HP rating and No. of stages
(in case of submersible pumps)
Buying decision on the basis of PRICE
alone.
Initial cost
5 - 10%
Operating cost
90 - 95%
4
Purchase price
Operating cost
Maintenance cost
FACTORS REASONS DESIRABLE
1. PUMP EFFICIENCY LOW AND STEEP HIGH PEAK AS WELL AS TOP

EFFICIENCY CURVE FLAT EFFICIENCY CURVE
2. SUCTION LIFT POOR HIGH
3. SELECTION OF SYSTEM NON MATCHING WITH SITE AS PER IS:10804.

AS WELL AS WELL.
4. ELECTRIC MOTOR INEFFICIENT EFFICIENT
OVER SIZED MATCHING WITH PUMP
5. PIPES UNDERSIZED AS PER IS:10804

TO MANY BENDS AS MINIMUM AS POSSIBLE
UNNECCESSARY LENGTH AS MINIMUM AS POSSIBLE
INFERIOR QUALITY OF PIPE PIPE MATERIAL AS SMOOTH
MATERIAL AS POSSIBLE
IMPROPER OR NO MAINT. SCHEDULED MAINTENANCE
6. MAINTENANCE REWINDING BY UNTRAINED REWINDING BY TRAINED
MECHANICS MECHANICS
5
COMPARISON OF EFFICIENCY LEVELS
RANGE OF RANGE OF
EFFICIENCY IN EFFICIENCY IN
COMPONENT
EFFICIENT PUMPING INEFFICIENT
SYSTEM PUMPING SYSTEM
1. ELECTRIC MOTOR 81% TO 85% 60% TO 80%
2. CENTRIFUGAL PUMP 61% TO 70% 40% TO 60%
3. PIPING SYSTEM I.E. FRICTION LOSSES AT FRICTION LOSSES AT

SUCTION AND 5% TO 10% OF PIPE 20% TO 40% OF PIPE
DELIVERY LINES. LENGTH. LENGTH.
4. FOOT VALVE K-VALUE < 0.8 K-VALUE - 2 TO 13
5. POWER 100% 80% TO 90%

TRANSMISSION (MONOBLOC) (COUPLED AND BELT
SYSTEM DRIVEN)
ENERGY
!ENERGY = kW x h
where;
kW - Power consumption
h - Operating hour
!Focus should be on reduction of kW
instead of reduction of h to :
!Conserve power as well as energy.
!To improve the voltage condition.
!Energize more no. of pumpsets from the same
transformer.
6
POWER CONSUMPTION
Reduce friction losses
HxQ
kW =
Kx pump
x

primemover
Use Efficient pump
and motor
For a given flow rate (Q), reduced Head (H)

and higher efficiency of pump &
primemover will result in lower kW
consumption.
TOTAL HEAD
Agriculutral pumping
H = hst + hfpiping + hffootvalve + Vd2/2g
Industrial pumping
H= hst + hfpiping + hfequip + Vd2/2g +(Hequip)
Reduction in friction losses in piping, foot valve

and equipment will result in reduced Head (H).
7
PIPE FRICTION
Friction Losses in Pipes is calculated by:

(1211 x 109) Q 1.852
hf = ________________ ____
d 4.87 C
Where,
hf = Friction losses %
d = Pipe inside dia. mm.
Q = Flow rate l/s.
C = Coefficient of friction
150 for RPVC pipes.
140 for new G.I. Pipes.
120 for old G.I. Pipes.
Effect of pipe size
SR. ORIGINAL REDUCED INCREASE IN

NO. PIPE SIZE mm PIPE SIZE mm FRICTION LOSS
01 30 25 3.75
02 40 30 2.00
03 50 40 3.14
04 65 50 3.54
05 80 65 2.20
06 100 80 3.60
For a given discharge rate and pipe material
8
RECTIFICATION MEASURES -
POTENTIAL FOR SAVINGS
ENERGY
Sr. No. RECTIFICATION MEASURES CONSERVATION
POTENTIAL
1. REPLACEMENT OF SUCTION PIPE AND 20% TO 25%
FOOT VALVE
2. REPLACEMENT OF SUCTION AND 30% TO 35%

DELIVERY PIPES AND FOOT VALVES
3. REPLACEMENT OF PIPING, FOOT 40% TO 45%

VALVE AND PUMP
4. REPLACEMENT OF COMPLETE 50% TO 60%

PUMPING SYSTEM INCLUDING PIPING,
FOOT VALVE AND MONOBLOC PUMP.
SOURCE: Dr SM PATELs REPORT
RECTIFICATION OF EXISTING PUMPING

SYSTEMS
! REPLACEMENT OF PIPING SYSTEM FOR
ENERGY CONSERVATION IS IT THE RIGHT
SOLUTION ?
! REPLACEMENT OF EXISTING PIPING SYSTEM
WITH HIGHER SIZE RPVC PIPE & LOW
FRICTION FOOT VALVE IS LARGELY
PREFERRED DUE TO COST CONSIDERATION
THIS MEASURE, THOUGH CONSERVE ENERGY,
IS ASSOCIATED WITH TWO DRAWBACKS,
WHICH NEED DUE CONSIDERATION :
Continued...
9
SYSTEMS
! REDUCED FRICTION LOSSES AND HENCE REDUCED
TOTAL HEAD INCREASES THE FLOW RATE. THUS,
FOR THE SAME QUANTITY OF WATER, OPERATING
HOUR REDUCES RESULTING IN LEESER ENERGY
(kWh) OR DIESEL CONSUMPTION. BUT IT IS USUALLY
ASSOCIATED WITH INCREASED LOAD (kW) ON
PRIMEMOVER. THIS IS BECAUSE OF RISING POWER-
DISCHARGE CURVE OF PUMPS, NORMALLY USED
FOR AGRICULTURAL PUMPING.
! IF INCREASED FLOW RATE IS MORE THAN THE YIELD
OF THE WATER SOURCE, WATER LEVEL GOES DOWN,
SUCTION LIFT / TOTAL HEAD INCREASES WHICH MAY
AGAIN RESULT IN INEFFICIENCY.
RECTIFICATION OF PIPINGS AND FOOT

VALVE
10
SYSTEMS
SINCE, TRANSFORMERS ARE ALREADY

OVERLOADED RESULTING IN POOR VOLTAGE
/ FREQUENCY CONDITION. IF SUCH
RECTIFICATIONS ARE IMPLEMENTED,
VOLTAGE CONDITION WILL FURTHER
WORSEN.

SYSTEMS
THE RIGHT SOLUTION FOR RECTIFICATION OF

EXISTING PUMPING SYSTEMS WOULD BE TO
REPLACE COMPLETE SYSTEM WITH A
PROPERLY SELECTED EFFICIENT PUMPING
SYSTEM OF LOWER HP RATING. THIS WILL
NOT ONLY IMPROVE VOLTAGE CONDITIONS,
BUT WILL ALSO RELEASE POWER ON
TRANSFORMERS, WHICH CAN BE UTILIZED
FOR ENERGIZING ADDITIONAL PUMPSETS.
11
RECTIFICATION OF COMPLETE PUMPING
SYSTEM
EVALUATION OF RECTIFICATION
MEASURES
Sr. No. RECTIFICATION MEASURE ENERGY ** POWER

CONSUMPTION CONSUMPTION
kWh kW
1. REPLACEMENT OF SUCTION REDUCES INCREASES
PIPE AND FOOT VALVE
2. REPLACEMENT OF SUCTION REDUCES INCREASES

AND DELIVERY PIPES AND FOOT
VALVES
3. REPLACEMENT OF PIPING, FOOT REDUCES INCREASES
VALVE AND PUMP
4. REPLACEMENT PF COMPLETE REDUCES REDUCES

PUMPING SYSTEM INCLUDING
PIPING, FOOT VALVE AND
MONOBLOC PUMP.
** FOR PUMPING SAME QUANTITY OF WATER
12
SELECTION OF AN EFFICIENT PUMPING
SYSTEM - AGRICULTURE APPLICATION
! SELECT THE PUMP FOR FLOW RATE BASED
ON CROP PATTERN AND YIELD OF WATER
SOURCE, IF YIELD IS A LIMITING FACTOR.
! SELECT THE APPROPRIATE SIZE OF PIPE TO
LIMIT FRICTION LOSSES WITHIN 10%. FOR
LONG OFFSET PIPE LINES, LOSSES SHOULD
BE LIMITED TO MUCH LOWER VALUE BASED
ON COST ECONOMICS.
! WHEREVER INSTALLATION PERMITS, RPVC
PIPE SHOULD BE PREFERRED.
Continued...

! SELECT A LOW FRICTION FOOT VALVE.
! COMPUTE THE OPERATING TOTAL HEAD FOR
THE RABI SEASON. ALSO WORK OUT
MAXIMUM TOTAL HEAD REQUIRED DURING
THE SUMMER.
! SELECT A PUMPSET SUCH THAT OPERATING
POINT DURING RABI IS CLOSE TO BEST
EFFICIENCY POINT. DO NOT SELECT A PUMP
WITH HEAD MUCH HIGHER THAN REQUIRED
IN THE WHOLE YEAR. IF POSSIBLE, USE
SEPARATE PUMP OF HIGHER HEAD DURING
THE SUMMER.
Continued...
13
! IN CASE, PUMP IS OPERATING AT SUCTION
LIFT, SELECT A PUMP WITH BETTER NPSHR.
! SELECT AN EFFICIENT PRIME MOVER OF
APPROPRIATE RATING.
SELECTION OF 35
30
PUMPSET 25
HEAD
20
15
10
5
0
0 2 4 6 8 10
3.0
2.5
2.0
POWER
1.5
1.0
0.5
0.0 Best Efficiency
0 2 4 6 Point
8 10
60
50
EFFICIENCY
40
30
20
10
0
0 2 4 6 8 10
DISCHARGE l/s
14
SELECTION OF 50
PUMPSET 40
Head m
30
20
10
60
5 0 5 10 15 20
4
BPkW
3
2
1
80
Pump Efficiency %
0
60 0 5 10 15 20
40
20
0
0 5 10 15 20
Discharge l/s
GUJARAT EXPERIENCE
TOTAL PUMPING SYSTEMS RECTIFIED : 1009

POWER (CONNECTED ANNUAL ENERGY
LOAD ) CONSUMPTION
KW KWh
1. BEFORE 9,328 1,72,18,190

RECTIFICATION
2. AFTER 4,955 80,13,651

RECTIFICATION
3. SAVINGS 4,373 92,04,539
4. PERCENTAGE 46.89% 53.46%

SAVINGS
15
RAJASTHAN EXPERIENCE
PARAMETERS EXISTING PUMP KIRLOSKAR PUMP

PRIMEMOVER RATING 7.5 HP 5.0 HP
SUCTION PIPE SIZE 50 mm 75 mm
DELIVERY PIPE SIZE 65 mm 75 mm
MATERIAL OF PIPE GI WHITE PVC
FOOT VALVE LOCAL KBL
DISCHARGE 3.68 l/s 5.03 l/s

INPUT POWER 6.18 kW 4.35 kW
INCREASE IN 36.7 %
DISCHARGE
REDUCTION IN INPUT 29.66 %
POWER
ENERGY INDEX 1.392 0.717
SAVING IN ENERGY 48.44 %
TAMIL NADU EXPERIENCE

MATERIAL OF PIPE GI WHITE RPVC
FOOT VALVE LOCAL KBL

INCREASE IN 32.28 %
DISCHARGE
POWER
16
NOIDA EXPERIENCE

MATERIAL OF PIPE GI GI
FOOT VALVE LOCAL LOCAL

INCREASE IN 25.3 %
DISCHARGE
POWER
MADHYA PRADESH EXPERIENCE

PRIMEMOVER RATING 3 HP 2 HP

REDUCTION IN INPUT 40.73%
POWER
ENERGY INDEX (Q/IpkW) 3.29 5.42
17
MADHYA PRADESH EXPERIENCE

INCREASE IN DISCHARGE 28.55%
REDUCTION IN INPUT 30.89%
POWER
ENERGY INDEX (Q/IpkW) 3.06 5.70

SYSTEM - INDUSTRIAL APPLICATION
!Select the pump with high efficiency and top flat
efficiency curve.
!Select the primemover of high efficiency.
Operating point should be close to the best
efficiency point (BEP).
!To reduce the flow rate, do not throttle but
consult and trim the impeller.
!Use multistage or multiple pumps in series in
case of high H / high pressure application.
!Use multiple pumps in parallel operation, where
flow rate requirement is varying. Continued..
18
SYSTEM - INDUSTRIAL APPLICATION
!Use Variable Speed Drive to meet the fluctuating
requirement.
!For multistoried building, use multiple pumps
with hydro-pneumatic arrangement.
SELECTION OF 35
30
PUMPSET 25
HEAD
20
15
10
5
0
0 2 4 6 8 10
3.0
2.5
2.0
POWER
1.5
1.0
0.5
0.0 Best Efficiency
0 2 4 6 Point
8 10
60
50
EFFICIENCY
40
30
20
10
0
0 2 4 6 8 10
DISCHARGE l/s
19
SELECTION OF 50
PUMPSET 40
Head m
30
20
10
60
5 0 5 10 15 20
4
BPkW
3
2
1
80
Pump Efficiency %
0
60 0 5 10 15 20
40
20
0
0 5 10 15 20
Discharge l/s
CHAMUNDA MILLS EXPERIENCE

SPEED 1440 RPM 2900 RPM
HEAD 24 m 20 m
DISCHARGE 37 l/s 36.5 l/s
REDUCTION IN INPUT POWER 28.5 %
RUNNING HOURS / DAY 20 20
ENERGY SAVING PER YEAR 28,470 kWh
SAVING PER YEAR Rs. 1,15,303
COST OF NEW PUMPSET Rs. 21,530
PAY BACK PERIOD 2 MONTHS 8 DAYS
20
SUBMERSIBLE PUMP V/S JET PUMP
PARAMETERS 4 OIL FILLED JET PUMP

SUBMERSIBLE PUMP
HP RATING 0.5 1.5
DEPTH TO LOW WATER LEVEL (M) 40 40
DISCHARGE (LPM) 25 16
TIME REQUIRED TO FILL 1000 0.67 1.04
LITRES TANK (HRS.)
CURRENT (AMP) 4.0 8.8
INPUT POWER (kW) 0.7 1.48
ENERGY CONSUMPTION PER 171 562
YEAR
ENERGY CHARGES PER YEAR @ 515 1686
Rs. 3 PER UNIT
SAVING IN RUNNING COST 69 %
OIL FILLED V/S WATER FILLED
PARAMETERS 4 OIL FILLED 4 WATER FILLED

SUBMERSIBLE SUBMERSIBLE
PUMP PUMP
HP RATING 0.75 0.75
LITRES TANK (HRS.)
YEAR
Rs. 3 PER UNIT
SAVING IN RUNNING COST 54%
21
OIL FILLED V/S WATER FILLED
SUBMERSIBLE PUMPS
PARAMETERS 4 OIL FILLED 4 WATER FILLED
SUBMERSIBLE SUBMERSIBLE
PUMP PUMP
HP RATING 0.75 0.75
LITRES TANK (HRS.)
YEAR
Rs. 3 PER UNIT
SAVING IN RUNNING COST 32%
RECOMMENDATIONS
! NEW PUMPING SYSTEMS :

! ENERGY DRAIN IN NEW PUMPING SYSTEMS SHOULD
BE STOPPED BY ENSURING THAT NEW PUMPING
SYSTEMS INSTALLED ARE EFFICIENT. MORE
STRINGENT NORMS SHOULD BE PREPARED AND
IMPLEMENTED FOR THIS PURPOSE.
! FOCUS SHALL BE ON POWER CONSERVATION
RATHER THAN ENERGY CONSERVATION ALONE. USE
OF SMALLER HP EFFICIENT PUMPSETS SHOULD BE
ENCOURAGED.
! AWARENESS SHOULD BE CREATED THROUGH
DEMONSTRATION OF SMALLER HP PUMPSETS
PERFORMING BETTER THAN HIGHER HP PUMPSETS.
22
RECOMMENDATIONS
! NEW PUMPING SYSTEMS :

! DEALERS AND USERS SHOULD BE TRAINED FOR
PROPER SELECTION OF PUMPSET AND PIPING
SYSTEM. HEAD SHOULD ALWAYS BE A CRITERIA FOR
SELECTING A PUMPSET RATHER THAN THE PRESENT
TREND OF HP & PIPE SIZE.
! MANUFACTURERS SHALL BE ENCOURAGED TO
IMPROVE THEIR PRODUCT EFFICIENCY BY PROVIDING
INCENTIVES SUCH AS TAX BENEFITS, SUBSIDY,
PREFERENCE IN PURCHASES ETC.
! DIFFERENTIAL TARRIF OF ELECTRICITY SHALL BE
IMPLEMENTED. HIGHER HP PUMPSET SHALL BE
CHARGED AT HIGHER RATE.
RECOMMENDATIONS
! EXISTING PUMPING SYSTEMS :

! LOOKING TO THE POTENTIAL FOR POWER
CONSERVATION, A LONG TERM (8 TO 10 YEARS)
PROGRAM MUST BE PREPARED AND IMPLEMENTED
TO RECTIFY THE INEFFICIENT PUMPING SYSTEM.
ADEQUATE FUNDS SHOULD BE ALLOCATED IN THE
BUDGET.
! RECTIFICATION OF PIPING AND FOOT VALVE SHOULD
BE DISCOURAGED AS IT INCREASES LOAD.
! RECTIFICATION OF PUMPING SYSTEM WITH AN
EFFICIENT SYSTEM OF SMALLER HP DELIVERING
SAME OR HIGHER DISCHARGE RATE IS THE RIGHT
SOLUTION. THIS MEASURE WILL NOT ONLY IMPROVE
VOLTAGE CONDITION, BUT WILL ALSO RELEASE
POWER FOR ENERGIZING NEW PUMPING SYSTEMS.
23
CONCLUSION
Power and more power is needed to keep the

nation self sufficient. EITHER spend lavishly for
generation of new power - and wait for more than
five years for the results OR make the new
pumping systems efficient and old ones
effective.The results are immediate and the cost is
a fraction. It does not require brilliant expositions
to understand a simple fact. What is needed is
determination and action - here and now.
THANK YOU
24

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AVENUES OF ENERGY

KIRLOSKAR BROTHERS LIMITED

! OVER 40% OF THE TOTAL ENERGY IS CONSUMED BY

KIRLOSKAR BROTHERS LIMITED

POTENTIAL FOR ENERGY AND POWER

TOTAL POWER GENERATED : 90,000 MW

KIRLOSKAR BROTHERS LIMITED

NEW PUMPING SYSTEM BEING

POTENTIAL FOR SAVING BY

KIRLOSKAR BROTHERS LIMITED

Pumping system efficiency = Pump effi. x Motor effi. x

Pump selection based on HP rating and

KIRLOSKAR BROTHERS LIMITED

REASONS FOR LOW EFFICIENCY

KIRLOSKAR BROTHERS LIMITED

KIRLOSKAR BROTHERS LIMITED

REASONS FOR LOW EFFICIENCY

FACTORS REASONS DESIRABLE

1. PUMP EFFICIENCY LOW AND STEEP HIGH PEAK AS WELL AS TOP

2. SUCTION LIFT POOR HIGH

3. SELECTION OF SYSTEM NON MATCHING WITH SITE AS PER IS:10804.

5. PIPES UNDERSIZED AS PER IS:10804

KIRLOSKAR BROTHERS LIMITED

2. CENTRIFUGAL PUMP 61% TO 70% 40% TO 60%

3. PIPING SYSTEM I.E. FRICTION LOSSES AT FRICTION LOSSES AT

4. FOOT VALVE K-VALUE < 0.8 K-VALUE - 2 TO 13

5. POWER 100% 80% TO 90%

KIRLOSKAR BROTHERS LIMITED

For a given flow rate (Q), reduced Head (H)

KIRLOSKAR BROTHERS LIMITED

Reduction in friction losses in piping, foot valve

KIRLOSKAR BROTHERS LIMITED

Friction Losses in Pipes is calculated by:

KIRLOSKAR BROTHERS LIMITED

Effect of pipe size

SR. ORIGINAL REDUCED INCREASE IN

KIRLOSKAR BROTHERS LIMITED

2. REPLACEMENT OF SUCTION AND 30% TO 35%

3. REPLACEMENT OF PIPING, FOOT 40% TO 45%

4. REPLACEMENT OF COMPLETE 50% TO 60%

SOURCE: Dr SM PATELs REPORT

KIRLOSKAR BROTHERS LIMITED

RECTIFICATION OF EXISTING PUMPING

KIRLOSKAR BROTHERS LIMITED

RECTIFICATION OF PIPINGS AND FOOT

KIRLOSKAR BROTHERS LIMITED

SINCE, TRANSFORMERS ARE ALREADY

KIRLOSKAR BROTHERS LIMITED

RECTIFICATION OF EXISTING PUMPING

THE RIGHT SOLUTION FOR RECTIFICATION OF

KIRLOSKAR BROTHERS LIMITED

KIRLOSKAR BROTHERS LIMITED

Sr. No. RECTIFICATION MEASURE ENERGY ** POWER

2. REPLACEMENT OF SUCTION REDUCES INCREASES

4. REPLACEMENT PF COMPLETE REDUCES REDUCES

KIRLOSKAR BROTHERS LIMITED

SELECTION OF AN EFFICIENT PUMPING