Advantage by knowledge

Pumpen Intelligenz

Advantage by knowledge

Understanding Pump Performance by

Mather & Platt Pumps Ltd. Pune, India (A Subsidiary of WILO SE, Germany)
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Pumpen Intelligenz

ISHRAE- 2008

About us

Pump Fundamentals

Pumpen Intelligenz

ISHRAE- 2008

About us

Pump Fundamentals

Pumpen Intelligenz

Our Hof unit

Pumpen Intelligenz

Our Pune unit

Pumpen Intelligenz

Our Kolhapur unitwith State of art technology

Pumpen Intelligenz

ISHRAE- 2008

About us

Pump Fundamentals

Pumpen Intelligenz

Pump Fundamentals

Pump Classification
Classification based on Geometry, design, application , installation

Selecting right
Pump
Type, MoC, Operational zone

Pumpen Intelligenz

Pump Classification

Design

Construction

Installation

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Pumpen Intelligenz

Classification based on Design

Pumps Displacement

Dynamic
Specific Speed Suction Condition

Centrifugal
No. of Inlets Impeller Geometry

Axial Flow

Non Priming

Single Suction

Closed Impeller

Mixed Flow

Self Priming

Double Suction

Semi-open

Radial Flow

Open Impeller

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Pumpen Intelligenz

Specific speed & Suction Specific speed

Specific speed (NS) RPM x Qopt. on full impeller diameter NS =

(Head at Qopt. on full impeller diameter)

3/4

Metric Conversion factors from Metric units For British units = Multiply by 47.2 For American units = Multiply by 51.7 For Metric units : Q in m3/sec, For British units : Q in IGPM, head in m & NPSHr in m head in ft & NPSHr in ft

For American units : Q in USGPM, head in ft & NPSHr in ft

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Pumpen Intelligenz

Impeller Designs

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Pumpen Intelligenz

Impeller Designs

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Pumpen Intelligenz

Casing Designs

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Pumpen Intelligenz

Pump Classification

Design

Construction

Installation

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Pumpen Intelligenz

Classification based on Construction

Centrifugal

No. of Stages
Single Stage Multi Stage

Nozzles No., Position

Single / Multi SuctionL/R/V Del.- L/R/V Vertical Turbine

Feet Location Bottom Centre

Materials
Casing Impeller Shaft / Sleeve

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Pumpen Intelligenz

Type of Constructions
Single Stage Multi Stage Inline Bloc Vertical

Submersible

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Pump Classification

Design

Construction

Installation

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Pumpen Intelligenz

Classification based on Installation

Centrifugal Position Dry pit Wet pit Location Indoor Outdoor Mounting Horizontal Vertical Drive Coupled Bloc Motor on Top Cardon Shaft

Thro Pully
Fixed/variable Speed
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Pumpen Intelligenz

Selecting right pump

Liquid Details Site Conditions Understanding

Pump Performance
Buying Decisions

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Pumpen Intelligenz

Liquid Details
Specific gravity Temperature Vapour pressure Viscosity pH contents Nature - Crystalizing / Polymerising

Characteristics - toxicity / explosiveness

Solid contents - size of solids, nature of solids etc. Oxygen content Chlorine content

Sulphur content
Consistency Fiber contents - Nature of fiber, size & length of fiber etc.
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Pumpen Intelligenz

Parameters based on Application

Centrifugal

Water Quality Temperature

Chemicals Phy.Properties Solid Contents Chemical Properties

Sludge / Slurry Dry / Wet Solid Size Composition Abrasiveness

Petrochemicals Sealing type Centre Dewatering Composition Depth

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Pumpen Intelligenz

Selecting right pump

Liquid Details Site Conditions Understanding

Pump Performance
Buying Decisions

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Pumpen Intelligenz

Site Conditions
Relative position of Tanks Position / Negative : Suction / Discharge Pressure in tanks Pumping from / to tanks with Pressurised tanks/ vacuum/ atmospheric conditions Piping Size, Materials, Quality, no. of bends, valves

NPSH conditions
Available NPSH under different site conditions Location of installation Indoor / Outdoor

Surrounding Conditions
Fumes, Temperature, Humidity, Dust, etc

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Pumpen Intelligenz

Selecting right pump

Liquid Details Site Conditions Understanding Pump Performance Buying Decisions

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Pumpen Intelligenz

Characteristic of pump

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Wilo-Basic technics of pumps

Figure of characteristics of pump: different steepness

> flat run > steep run
H0

= high changing of volume flow, little changing of pressure = little changing of volume flow, high changing of pressure

pumping head H m

H0 p

volume flow Q m/h

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Wilo-Basic technics of pumps

System characteristic / pipe system characteristic

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Wilo-Basic technics of pumps

Operation point
The pumping head matches the flow resistance of the pipe system.
both thermostatic valve are open

pumping head H m

intersecting point = operation point

volume flow Q m/h

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Wilo-Basic technics of pumps

Operation point
The pumping head matches the flow resistance of the piping system.
only one thermostatic valve is open

pumping head H m

intersecting point = new operation point

volume flow Q m/h

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Wilo-Basic technics of pumps

Efficiency of pump
Efficiency of pump

p =
> p

QH 367 P2
= efficiency of pump

> Q [m/h] = volume flow

> H [m]
> P2 [kW] > 367 > [kg/m] medium

=
= = =

pumping head
power at the pump shaft conversion factor density of the pumping

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Wilo-Basic technics of pumps

Efficiency of pump
Characteristic of pump and the behaviour curve of the efficiency

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Wilo-Basic technics of pumps

Impeller
Sort of impeller >charateristic in radial-flow impeller, semiaxial impeller, axial impeller >closed impeller: >front and rear cover

>open impeller:
>only rear cover

frame of impeller

open impeller with radial blades

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Wilo-Basic technics of pumps

Adjustment of the pumping capacity

Changing the impeller diameter
D1

Q1 Q2 H1

H2

( ) ( )
D2 D1

D1

D2 ~ D1 ~

Q2 Q1 H2 H1

D2

D2 ~ D1 ~

H1 D2 H2 pumping head H m

D1 D2

volume flow Q m/h

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Q2

Q1

Wilo-Basic technics of pumps

Adjustment of the pumping capacity

Changing the impeller diameter
>Changing the motor power

>mind the dimensioning of motor

>

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Wilo-Basic technics of pumps

Adjustment of the pumping capacity

Changing the speed
n1
H1

Q1 Q2 H1 H2 P1

n1 n2

n2

()
n1 n2

H2 pumping head H m

P2

()
n1

n2

Q2 Q1
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volume flow Q m/h

Wilo-Basic technics of pumps

Adjustment of the pumping capacity

Changing the speed
144 pumping head H % 121 100 81 64 49 36

1,2 n
1,1 n 1,0 n 0,9 n 0,8 n 0,7 n 0,6 n speed at approx. 40 Hz speed at 60 Hz

speed at 50 Hz

volume flow Q m/h

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Wilo-Basic technics of pumps

Adjustment of the pumping capacity

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Pumpen Intelligenz

Buying Decisions
Liquid Details Site Conditions Understanding Pump Performance Buying Decisions

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Pumpen Intelligenz

Understanding Buying Decision

Considerations Personal Level Fuel economy Safety Durability Cost of Acquisition

Utility
Maintenance Insurance Performance

Cost of Usage

Cost of Ownership

Cost of Disposal

Resell value
Price

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Pumpen Intelligenz

Why
Considerations Corporate Level
Cost of Procurement
(Product + Supplementary goods)

Installation & Commissioning Energy Cost Operating Cost (labor cost of normal system supervision) Maintenance (routine and predicted repairs) Downtime cost (loss of production) Resell / Scrap value
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Cost of Ownership (also known as Life Cycle Cost)

Pumpen Intelligenz

LCC
Life Cycle Cost
Installation 2% Down-time 6%

Energy 73%

Maintenance 9% Other 23%

Operating 6% Procurement 4%

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Pumpen Intelligenz

Achieving Cost effectiveness

Design Stage Exact identification of needs Better estimate of losses Minimise unwarranted requirements viz.MoC, Automisation, sealing, etc State complete parameters

Procurement Stage

Buying Stage
Quoting stage

Match needs with performance

Process
Need

Offer right product to match the eeded performance

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Pumpen Intelligenz

Achieving Cost effectiveness

Buyer Seller

Process Knowledge Get complete need set Future Needs Understand & accomodate Operating Requirments Understand operational needs

Maintenence Requirements Ensure after sales support

Criticality of Operation Offer reliable solution/ alternative Down time needs Availibility of spares, service

Completeness of Requirements Offer complete package

Minimise indirect costs, avoid revisions, downtime costs, meeting the current & future needs
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Pumpen Intelligenz

Cost Drivers, Effects & Solutions

Extra margin on Head Increases no.of Stages & motor Seller rating

Extra Margin on flow

Estimated losses on higher side

Leads to higher pump model

Leads to higher model and power

Sealing arrangements
Application based MoC e.g. For Sea water Downtime Sourcing pump, motor, Accessories from Different suppliers
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Gland packing less expensive Mechanical Seal adds to cost

Select duplex Steel, why Titanium ? For lower downtime , opt for Hori. Split case or End Suction pumps Leads to Higher indirect cost, lack of synchronisation, higher invenrtory

Pumpen Intelligenz

Solutions for Building Sector

Federation Tower Moscow Asem Tower, Seoul

Commercial Building Services

Type of Construction

Commercial Complex Shopping Mall Hospitals / Hotels

World Trade Center, Dresden

Multiplex
IT Park

Township
SEZ
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Pumpen Intelligenz

Commercial Building Services

Type of Construction Pumping Solutions called for

Commercial Complex Shopping Mall Hospitals / Hotels

Hotels Multiplex IT Park Township SEZ

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Water Supply Dewatering Sewage HVAC Firefighting Utilities

- Swimming pools - Steam Generators - Waste Water Treatment Plant - Sewage Treatment Plant - Reverse Osmosis Plant

Pumpen Intelligenz

Solutions for Commercial Buildings

Fire fighting Sewage / Waste Water Air Conditioning

Utilities

Pressure Boosting

Solutions for Commercial Buildings

Fire fighting Sewage / Waste Water Air Conditioning

Utilities

Pressure Boosting

Fire fighting

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Pumpen Intelligenz

Solutions for Commercial Buildings

Fire fighting Sewage / Waste Water Air Conditioning

Utilities

Pressure Boosting

Utilities

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Pumpen Intelligenz

Solutions for Commercial Buildings

Fire fighting Sewage / Waste Water Air Conditioning

Utilities

Pressure Boosting

Sewage , Waste Water

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Pumpen Intelligenz

Solutions for Commercial Buildings

Fire fighting Sewage / Waste Water Air Conditioning

Utilities

Pressure Boosting

Pressure Boosting systems

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Pumpen Intelligenz

Solutions for Commercial Buildings

Fire fighting Sewage / Waste Water Air Conditioning

Utilities

Pressure Boosting

Air Conditioning

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Pumpen Intelligenz

Air Conditioning

A Typical layout
Load
Balancing Valve 2 Way Valve

Chillers

Panel with PLC & VFD`s Common Primary Pumps

Secondary Pumps

Air Separator

Expansion Tank

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Pumpen Intelligenz

Primary Circuits
Closed Circuit system
Constant Flow Produces Chilled water

Circuit includes

Chiller
Pumps Pump Controlling unit (Panel)

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Pumpen Intelligenz

Secondary Circuits
Circulation of Chilled water to load areas

Pumps Controlling Valve Temperature Sensor

Differential Pressure Sensors

Pump Controlling unit (Panel)

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Pumpen Intelligenz

Reasons for changes on Load

Seasonal demands - Annual Fluctuations in users - Population Changes in demand - hourly Atmospheric changes

Personal Needs

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Pumpen Intelligenz

Ways to save energy

Optimized System Design Use 2900 rpm pumps Usage of CI/CI Construction

Right selection of pumps

Minimum bends/ fittings Correct Piping Proper Care during usage

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Pumpen Intelligenz

Why Control ?
Increased Urbanisation
Increased demand for electricity GAP in Demand & Supply for Electricity Increasing tariff for electricity Energy saved = Energy generated Higher energy demands by Industry & Commercial Buildings

Continuous duty operations = larger scope for saving

Ways to control varies with the usage
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Pumpen Intelligenz

In Commercial Building
Split the requirement Proper layout Use VFD for better control Avoid leakages Monitor power consumption Optimize performance Reduce losses Increased Energy Efficiency Conserve resources Helps to understand savings

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Pumpen Intelligenz

References :Inline pumps for HVAC

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Pumpen Intelligenz

ET ISO Operational Data

Flow up to 750 m3/hr Head up to 170 m Temprature up to 150 0C MoC : CI/ BZ/SS

Pumpen 69 Intelligenz

Split Case Operational Data

Flow up to 17000 m3/hr Head up to 220 m Temprature up to 150 0C MoC : CI/ BZ/SS

Pumpen 70 Intelligenz

Wilo-CronoLine-IL
Single-stage, low-pressure-centrifugal pump, Inline-design, with flange connection for the supply of cold and hot water (in accordance with VDI 2035) without abrasive substances in heating, cold water and cooling water systems >Single-head pumps with mechanical seal >High motor life due to series standard condensate drain holes in motor housings >With 4 or 2-pole three-phase current motors >Temperature range max. 140C

>Protection class IP55

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Product presentation

Wilo-CronoBloc-BL
Single-stage, low-pressure centrifugal pump in monobloc construction in accordance with EN 733 for the supply of cold and hot water (in accordance with VDI 2035) without abrasive substances in heating, cold water and cooling water systems >Tailored for the user with outputs and principal dimensions to EN 733 (DIN for norm pumps) >With 4 or 2-pole three-phase current motors >Temperature range max. 140C >High motor life due to series standard condensate drain holes in motor housings >Protection class IP55
Product presentation

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Wilo-CronoTwin-DL
Single-stage, low-pressure-centrifugal pump, Inline-design, with flange connection for the supply of cold and hot water (in accordance with VDI 2035) without abrasive substances in heating, cold water and cooling water systems >Reduction of space required and installation costs through twin-head pump design >Main/reserve operation (by means of additional external equipment) >Peak load operation (by means of additional external equipment) >Extended periods of use due to series standard condensate drain holes in motor housings. >Temperature range max. 140C
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Product presentation

References :Inline pumps for HVAC around Pune, Mumbai

Kamat Hotel, Jadhavgadi,Pune Ganga Retreat Countryside, Pune Deepak Fertilizers, Pune Seasons Service Apartment, Pune Venkateshwara Hatcheries, Pune Solitaire Corporate Park, Mumbai Whistling Woods International, Mumbai Rubi Hall, Pune Cipla, Goa Mars Enterprises, Mumbai Thomson Press, Mumbai Nanavati Hospital, Mumbai
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Pumpen Intelligenz

Control Panels for HVAC

HVAC PANELS ( 4 KW to 110 KW)
Panel : With & Without Bypass Starter. Switch Gears: Schneider Electric / ABB. Controller: Wilo VR HVAC Controller. VFD : One Per Pump . VFD : Danfoss VLT 2800 Up to 18.5KW and Danfoss FC HVAC series > 18.5KW. Differential Pressure Transmitters : Rosemount. Motor Rating 4 to 90KW.

Panel Features

Panel Features
Product advantages

The following bus systems can be connected (via optional modules): Profibus, CC Link (Asia), CAN bus, IEC 60870-5-101, IEC 60870-5-104, Ethernet HTML, Ethernet TCP/IP, Modbus RTU (RS 232), RK 512, ASCI II, MEWTOCOL Slave, LON Program updates via mobile telephone Remote fault reset via mobile telephone XY Graph display of measured values Measured value simulation program Emergency pump operation without PLC

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CC Booster

Panel Features
Product advantages

Touchscreen provides maximum ease of control and operation Fully graphics-capable touchscreen with user-programmable symbols Touchscreen has 3 different backlighting colours to indicate system status Multilingual operating unitup to 15 different languages, with European or Asian characters, can be programmed Three password-protected levels of system access Password can be configured by user as desired

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YOU ARE INVITED TO VISIT

OUR PLANTS
Contact : Milind Karve, Pune (M) : 9881739956 Amit Bhatt, Baroda (M) : 9825030929
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Pumpen Intelligenz

Thank You