annexure 18_tool for design of pumps with high efficiency_energy loading

8/8/2019 Annexure 18_Tool for Design of Pumps With High Efficiency_Energy Loading

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Details of Clear Water Pumpling Station

1 2 3 4

S.No. Details Value Units

1 Design Discharge 100 MLD

2 Pumping Hours 23 hours

3 FSL of CWR 236 m4 e! Le"e# of CWR 232 m

$ Si%e of D& Pipe#ine 300 'o 1000 mm

6 Leng'h of Pipe#ine 33(000 m

) C "a#ue a!op'e! for !esign purpose 140

* $0 m

+ 46 m

10 ,"erage -pera'ing Hea! for pumps 4* m .o'e/ Da'a in co#omn 3 'o e appropria'e# fi##e!

Maimum -pera'ing Hea! for pumps Difference in minimumsump #e"e# maimum !ischarge #e"e#5Maimum fric'ion hea!5#osses in specia#s( en'r ei'

Minimum -pera'ing hea! for pumps Difference in maimumsump #e"e# minimum !ischarge #e"e#5minimum fric'ion hea!5#osses in specia#s( en'r ei'



Pump Selection based on specific speed and maimum attainable efficienc!

Details

4670 m

$070 m

,"erage -pera'ing Hea! for pumps 4*70 m

Design Discharge 10070 MLD

Pumping Hours 23 hrs

Calculation of Specific Speed for Different Speeds " Number of Stages

8

9here : 8 Discharge in ;S ga##on<min

H 8 Discharge hea! in fee' per s'age

. 8 Mo'or Spee! in rpm

.o of S'ages Specific Spee!

1 1 1+1447+3 1$)74* 1$)74* 1$00 466*7)3

2 1 +$)2746 1$)74* 1$)74* 1$00 330172+

2 1 +$)2746 1$)74* 1$)74* 1000 22007*6

3 1 63*1764 1$)74* 1$)74* 1$00 26+$74+

2 2 +$)2746 1$)74* )*7)4 1$00 $$$270*

2 1 4)*6723 1$)74* 1$)74* 1$00 2334736

2 1 4)*6723 1$)74* 1$)74* 1000 1$$6724

Minimum -pera'ing hea! for pumps Difference in maimum sump #e"e# minimum !ischarge #e"e#5minimum fric'ion hea!5 #osses in specia#s( en'r ei'

Maimum -pera'ing Hea! for pumps Difference in minimum sump #e"e# maimum !ischarge #e"e#5Maimum fric'ion hea!5 #osses in specia#s( en'r ei'

Specific Spee! .s . :07$< H07)$

,s per ,merican .a'iona# S'an!ar! &ns'i'u'e H!rau#ic &ns'i'u'e .e9 =erse( 'he specific spee! for Pumps shou#! e in 'herange of 2000 'o 3000 for a''aining op'imum efficienc7 >herefore in 'he presen' case 'he !u' re?uiremen's are 'o e fie! insuch a 9a so 'ha' 'he specific spee! #ies in 'he ao"e range7

Calculation of Specific Speed #it$ different combinations%&tems 1 to ' are V( pumps and items )"* are DoubleSuction +SC pumps,

.o of Wor@ingPumps

Discharge perPump ;S

APM

PumpingHea! f'

PumpingHea! per

S'age fee'

Mo'or Spee!RPM

>hus sing#e s'age B> pump 9i'h a spee! of 1000 rpm an! Dou#e Suc'ion Cen'rfuga# pumps 9i'h 2 pumps 9or@ing ha"e 'hespecific spee! in 'he range of 20003000 rpm an! are 'hus 'he i!ea# choice7 , Sing#e s'age Ber'ica# >urine Pump ha"ingMo'or Spee! of 1$00 RPM 9i## ha"e specific spee! aroun! 3300( 9hich is s#igh'# higher 'hen upper #imi' of !esire! range

20003000 for a''aining op'imum efficienc7Ho9e"er(Pumps Mo'ors 9i'h 1000 RPM spee! are more rous' compare! 'o1$00 rpm pumping se's7 >he CWR f#oor is 3m e#o9 AL an! in case of Hori%on'a# Sp#i' Casing pump( 'o pro"i!e posi'i"esuc'ion( pumps ha"e 'o e ins'a##e! e#o9 'his #e"e#7 >he main'enance an! shu' !o9n 'ime are #ess in HSC pumps7 ,s suchchoice is ei'her Sing#e s'age B> pumps 1000 rpm 9i'h 2W51S configura'ion or sing#e s'age !ou#e suc'ion HSC pump 1$00rpm 9i'h 2W51S configura'ion7 -'her a#'erna'i"es consi!ere! ao"e are no' sui'a#e on accoun' of "er high or #o9erspecific spee!s7 More"er using sing#e pump 9i'h fu## !ischarge has 2 !ra9ac@sa7 S'ar'ing curren' re?uiremen' is "er highma@ing 'ransformer( ca#e( s9i'chgear ra'ing high77 During ini'ia# ears of opera'ion( 9a'er !eman! 9i## e #ess7 >hus 'he pump sha## ha"e 'o opera'e a' fu## hea! for a #imi'e! perio! !uring 'he !a7



Suction Specific Speed

Suc'ionSpecific Spee! SS 8

9here : 8 Discharge in ;S ga##on<min

H 8 .e' Posi'i"e Suc'ion Hea! ,"ai#a#e in fee'

. 8 Mo'or Spee! in rpm

For presen' case

: 8 6037*6 #<s 8 +$)27$ ;S ga##on<min

. 8 1000 rpm

Net Positi-e Suction +ead -ailable %NPS+a, /e0uired ' Suction Specific Speed

.e' Posi'i"e Suc'ion Hea! 8 2670 fee'

8 )7+2 m

Suc'ion Lif' permissi#e8 271 m

8 ,'mospheric Pressure in m .PSH,

>hus pro"i!e minimum suermergence for o9# of B> pump

,s per ,merican .a'iona# S'an!ar! &ns'i'u'e H!rau#ic &ns'i'u'e .e9 =erse( 'he Suc'ion Specific Spee! for B7>7 Pumpsshou#! e in 'he "icini' of *$00 for a''aining op'imum efficienc7 >herefore in 'he presen' case 'he !u' re?uiremen's are 'o e fie! in such a 9a so 'ha' 'he Suc'ion Specific Spee! e aroun! *$007

. :07$< .PSHa07)$



ttainable fficienc! " nerg! oading

Specific Speed

8

9here : 8 Discharge in ;S ga##on<min per Pump

H 8 Discharge hea! in fee' per s'age

. 8 Mo'or spee! in rpm

: 8 6037*6 #<s 8 +$)27$ ;S ga##on<min

H 8 4*700 m per s'age 8 1$)7$ fee's

. 8 1000 rpm

8 22007*6

5enerall! ttainable fficienc!

Proposed oading for o#er fficienc!

i Ca#cu#a'ion of -"era## Efficienc of Pump Se'

Mo'or Efficienc 8 +470 ,ssuming energ efficien' mo'ors

Pump Efficienc 8 **

-"era## Efficienc 8 07+4 07**8 *27)2

8 *27$0

Specific Spee! .s . :07$< H07)$

For presen' case ofDou#e suc'ion Pump

Specific Spee! .s

,s per ,merican S'an!ar! for DS Cen'rifuga# Pumps issue! H!rau#ic &ns'i'u'e .e9 =erse( 'he specific spee! forPumps shou#! e in 'he range of 2000 'o 3000 for a''aining op'imum efficienc an! in 'he presen' case 'he specific spee! is9i'hin 'he range specifie! ao"e7

,s per ,merican S'an!ar! for Cen'rifuga# Pumps( genera## a''aina#e efficienc for DS Cen'rifuga# Pumps ha"ing!ischarge : 8 +$)2 g<min Specific Spee! .

s8 2200( is +0 as per Fig 1762,( page no7 *$7

For !ischarge : 8 +$)2 g<min( !e"ia'ion from genera## a''aina#e efficienc is 52 of a''aina#e efficienc as per Fig 1763 page no7 *$ 9hich gi"es efficienc range from +2 'o **7 >he efficienc of pumps is grea'# inf#uence! smoo'hnessof impe##er "anes( c#earance of impe##er ring( effec'i"eness of s'uffing o < mechanica# sea# an! suc'ion arrangemen'7 &n

"ie9 of 'hese fac'ors( 'he 5enerall! ttainable fficienc! ma! be ta6en as 77

.o cre!i' is propose! in 'he i! e"a#ua'ion for efficienc offere! eon! ** 9i'hou' nega'i"e 'o#erance7 Ho9e"er 9e can#e" compensa'ion for offering pumps 9i'h efficienc #ess 'han ** for each percen'age efficienc poin'7



ii Mo'or Po9er &npu' Re?uire!

8 +7*1:H < n

9here : 8 Discharge in LPS

H 8 Discharge hea! in m

n 8 -"era## Efficienc of Pump Se'

8 6037*6 +7*1 4* < 07*2$ 1000

8 344766 GW

8 34$ GW sa

iii Ca#cu#a'ion of ,!!i'iona# Po9er Charges

8 Differen'ia# GW ,nnua# Wor@ing hours Po9er >ariff

Differen'ia# GW 8 Prescrie! Eff >en!ere! Eff GW inpu' of Mo'or < >en!ere! Eff

8 ,!!i'iona# ,nnua# Po9er charges ,nnui' Fac'or

1 Life of Pumpse's is 1$ rs as per CPHEE- mannua#7

2 Pumping hours per !a 8 23 hrs7

,nnua# Hours of opera'ion of each pump 8 13733 36$72$ 8 4*6*7)* hrs

3 ,nnui' Fac'or

,nnui' Fac'or 8 0

9here n 8 no of ears 81$ rs R 8 !iscoun'ing ra'e 8 10

,nnui' Fac'or 8 )7606

4 Po9er >ariff 8 Rs7 47)$ per uni'

For 1 #ess effiecienc

Differen'ia# GW 8 *27$ *17$ 34$ < *27$

8 471*1* GW

8 471*1*4*6*7)*47)$

8 +6)12 Rs7

8 +6)12 )7606

8 )3$$+) Rs7 For each percen'age poin' of #ess efficienc7

,!!i'iona# ,nnua# Po9ercharges for #o9er efficienc

Capi'a#ise! ,!!i'iona# Po9ercharges for #o9er efficienc

.o9 as &ni'ai# Discharge 8 $+ MLD Fina# Discharge 8 *0 MLD 'herefore ,"g Discharge 8 6+7$ MLD ,"erage pumpinghours for each pump 86+7$23<*081+7+* hours

Ho9e"er as 3 uni's of pumps are pro"i!e! 2 9or@ing 5 1 s'an!( 'herefore pumping hours for sing#e pump 9i## e 1+7+*

2 < 3 8 13733 hrs

15Rn 1< R 15Rn

,!!i'iona# ,nnua# Po9ercharges for #o9er efficienc

Capi'a#ise! ,!!i'iona# Po9ercharges



8otor /ating

Pump Discharge 8 6037*6 LPS

Design Hea! 8 4*70 m

Mo'or Efficienc +470 ,ssuming energ efficien' mo'ors

Pump Efficienc 8 **

-"era## Efficienc 8 07+4 07**

8 *27)2

Mo'or Po9er &npu' Re?uire!

8 +7*1:H < n

9here : 8 Discharge in LPS

H 8 Discharge hea! in m

n 8 Pump Efficienc

8 3437)4 GW

8 344 GW sa

>he mo'or ra'ing sha## e higher of 'he fo##o9ing

17 110 of &npu' Po9er re?uiremen' a' !u' poin'727 Maimum Po9er re?uiremen' in 'he en'ire 9or@ing range of 'he pump7

>he Mo'or ra'ing re?uire! as per firs' a#'erna'i"e is 3)*711 GW7 >hus 9e go for ne' a"ai#a#e ra'ing of 39W.



Crane Capacit!

a, Static oad of Pump 8otor Set

i Weigh' of pump assem# from Gir#os@ar ca'a#oge appro 8 2$$0 @g

ii Weigh' of 3*0 @W mo'or 8 2$00 @g

b, Crane Capacit!

Maimum 9eigh' 'o e han!#e! crane 8 Area'er of i ii

8 2$$0 Gg

Consi!ering 2$ o"er #oa!ing 8 31*)7$ @g

sa 8 $000 @g

Pro-ide crane of ' 6g % '. ( , safe #or6ing load.

annexure 18_tool for design of pumps with high efficiency_energy loading

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