This is what PM told when he attended the G-8 –group of industrialised nation when the discussion was on reducing carbon emission

We nurture this reputation in everything we do .We also intend to be known as supplier who will

The above is for a double suction pumps

The above is for a double suction pumps

If the pump speed is reduced by one unit ,the energy consumption is reduced by 4 units.

The above is for a double suction pumps

A.LEFT OF BEP Temp rise to be restricted to 15F .2)Radial hydraulic thrust on impeller will be more (even @ 50% of flow at BEP).This will cause shaft deflection&breakage ,seal failure .3)Flow re circulation ( back-flow .rotating –stall ) at 50% flow of BEP .This will result in vibration,noise ,cavitation,mech damage. RIGHT OF BEP : 1) Run out condition .Increase in NPSHR. Cavitation will result .Liquid turns to vapour .Water boils at 100C at atm pressure .In pump casing vaccum is there hence water will boil even at room temp.

Imbalance causes vibration an thereby reduced bearing life.

A.LEFT OF BEP Temp rise to be restricted to 15F .2)Radial hydraulic thrust on impeller will be more (even @ 50% of flow at BEP).This will cause shaft deflection&breakage ,seal failure .3)Flow re circulation ( back-flow .rotating –stall ) at 50% flow of BEP .This will result in vibration,noise ,cavitation,mech damage. RIGHT OF BEP : 1) Run out condition .Increase in NPSHR. Cavitation will result .Liquid turns to vapour .Water boils at 100C at atm pressure .In pump casing vaccum is there hence water will boil even at room temp.

At higher suction specific speed suction recirculation will occur closer to the BEP rate of flow and sometimes even at the BEP. Suction recirculation in centrifugal pumps occurs when the flow through the pump is lower than that for which the impeller was designed. When this happens, a portion of the flow is forced back to the impeller inlet (suction) as shown in Figure

The above is for a double suction pumps

The above is for a double suction pumps

The above is for a double suction pumps

Electro coating 40 – 70 microns

The above is for a double suction pumps

The above is for a double suction pumps

to four pumps, but is normally not used for single-pump systems. Hydro 1000 covers an area of up to 10 bar and 500 m³/h.This is within the standard range. Hydro 2000 is also a booster system, for 1–6 CR pumps. The system is delivered on a base frame (control cabinet is available for wall-mounting). The pumps have a common discharge manifold and can also have a common suction manifold. On the discharge manifold there is a pressure transducer which controls the system together with a PFU 2000. Hydro 2000 is available in an MS version, i.e. without frequency converter, an MF version, i.e. with external frequency converter, and an ME version, i.e. with integrated frequency converter in the pumps. Hydro 2000 covers an area of up to 16 bar and 700 m³/h. This is within the standard range.

The above is for a double suction pumps

The above is for a double suction pumps

The above is for a double suction pumps

"Optimizing system performance - Role of pumps & pumping systems"

“A country on the road to development will get there quicker and more certainly ,if it chooses the more energy efficient route” -Dr Manmohan Singh

Emphasis on economical solution Improve efficiency of pumps. Optimum solution to fluctuating demand. Enhance reliability and service life of pumps Reliable pump monitoring solution towards preventive maintenance Customer expectation

Ensure pump functions as efficiently as possible Minimise life cycle cost. Provide optimum customer support. Remain a trustworthy and reliable long term partner. Suppliers compliance

Cost of Ownership - Trends Yesterday: The ideal pump was installed and left running with out trouble Today: Measurement of the cost to produce water in kWh/m3 or kWh/gall Tomorrow On-line monitoring Q Measurement ensures that you are operating in BEP and are driving down the total CoO. No measurement, meaning total CoO are increasing day after day Tomorrow – online monitoring, an ongoing optimisation Get the operation data when and where you want Yesterday Today System

Figure 1. Cumulative motor population and energy versus size. Vital Few Trivia Many

MOTOR - FACTS & FIGURES Cost of Motor is equivalent to its 40 days running cost,were it to run continuously. 10% decrease in efficiency ,increases operating cost by 15%. 10% undervoltage increases power consumption by 5% and Temp increase by 20%. 50% reduction in speed reduces power consumption by 87.5%

Thinking Buildings

Energy efficiency could be on account of Type of pumps Design of pumps System integration Motors

Energy saving

Aspects to be taken note of Hydraulics NPSH Operating range Impeller diameter & Speed Surface finish

NPSH

Attainable efficiency NS= N X Q.5 / H.75 Where: N=RPM Q=Flow (GPM) H= Head (feet of water) Speed

Effect of speed Peripheral velocity related to speed. Affects suction performance of pump. Energy saving thru speed control. Affinity Law Flow2 = Flow1(Speed2/ Speed1) Head2 = Head1(Speed2/ Speed1)2 BKW2 = BKW1(Speed2/ Speed1)3

System Design Consideration The Affinity Laws. The table below indicates clearly the effects of the changes. back

Suction specific speed – How to predict cavitation using Suction Specific Speed

3. BKW2 = BKW1(Dia2/ Dia1)3 Effect of impeller diameter Typically, the allowable minimum diameter, as a percentage of its maximum diameter, is as follows radial impellers                80% mixed flow impellers       90% axial flow impellers          95%

Importance of Diameter

Reliability - Impeller Hydraulic balancing reduces the axial forces by using holes in impeller Longer bearing lifetime back

Importance of operating range

Problems with low flow recirculation Arrow = Velocity Colour = Pressure back Avoid whirling motion

Suction recirculation Avoid selecting pumps designed with high suction specific speed impellers to reduce this potential problem

The factors which determine minimum allowable rate of flow include the following: Temperature rise of the liquid -- This is usually established as 15°F and results in a very low limit.  However, if a pump operates at shut off, it could overheat badly. Radial hydraulic thrust on impellers -- This is most serious with single volute pumps and, even at flow rates as high as 50% of BEP could cause reduced bearing life, excessive shaft deflection, seal failures, impeller rubbing and shaft breakage. Flow re-circulation in the pump impeller -- This can also occur below 50% of BEP causing noise, vibration, cavitation and mechanical damage. Total head characteristic curve – Some pump curves droop toward shut off, so operation in such regions should be avoided.

Minimise leakage – both internal & due to wear Floating seal ring => No gap => No leakage Very tight tolerance

Effect of internal wear on centrifugal pump head-capacity curve Back

Surface coatings

Painting: Pump casing after 24 Hours in salt fog, test mark: 0 Electro- coated (Cataphoresis): Pump casing after 24 hours in salt fog, test mark: 6 back

Source : DOE office of Industrial technology , US motor systems

A Symptoms Approach to Identifying Efficiency Improvement Opportunities Throttled valves. Open bypass lines Multiple parallel pumps with the same number of pumps always operating Use Energy efficient (Class 1) motor instead of Eff 2 or 3 or std motor.

A Symptoms Approach to Identifying Efficiency Improvement Opportunities

Variable speed

A Symptoms Approach to Identifying Efficiency Improvement Opportunities

Multiple parallel pumps with the same number of pumps always operating

Use Energy efficient (Class 1) motor instead of Eff 2 or 3 or std motor.

Guide to pump efficiency for single stage centrifugal pumps Long coupled pumps

Close coupled pumps

Split casing pumps

10 Ways to Select a trouble free Pump Only select pumps with suction specific speeds less than 11,000-less than 9,000 is ever better. Select your pump so it never operates below 70% to 80% of its best efficiency point. Remember that 1450 rpm pumps are usually more reliable than 2900rpm pumps. Hydraulic efficiency peaks at specific speeds between 2000 and 3000 and drops dramatically below a specific speed of 500. Higher efficiency means less vibration and noise and lower energy bills. Use double suction impeller sparingly . They are less stable at off- design conditions tan single suction impellers. For a single stage pumps , never select a pump with maximum diameter impeller. You may need to increase the impeller diameter in the future. Select a driver that allows you to operate to the end of the pump curve. Use hydraulic stability, not temperature rise, as criteria for setting the minimum acceptable pump flow. Incorporate a healthy NPSH margin or ratio, i.e. NPSHr/ NPSHa into your selection. This ratio should be anywhere from 1.1 to 2.0 depending on the fluid, critically and suction energy level. A higher value is always better. . A robust pump, with a low L3/D4, is still your best protection against seal and bearing premature failure when the pump is operating off of its best efficiency point. Keep the following in the mind as you select your pump.

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