Xylem Water Solutions (India) Pvt. Ltd. PERFORMANCE TESTING OF - PowerPoint PPT Presentation

Xylem Water Solutions (India) Pvt. Ltd. PERFORMANCE TESTING OF VERTICAL TURBINE PUMPS FOR POWER PLANT APPLICATIONS Ron Sassoon Cell : + 91 7738083550 Email : ron.sassoon@xyleminc.com April 2012

Xylem Water Solutions (India) Pvt. Ltd., Transformation (November 2011) - The name Xylem is derived from classical Greek and is the tissue that transports water in plants, highlighting the engineering efficiency of our water-centric business by linking it with the best water transportation of all — that which occurs in nature Xylem is a premier pure-play water technology company � A singular focus on innovative solutions serving global water markets � Headquartered in White Plains, N.Y � 12,000 employees worldwide � Presence in more than 150 countries � 2011 revenues of $ 3.8 billion � More than a century of experience in the water industry Xylem [XYL] will be a leading global water technology provider, enabling customers to transport, treat, test and efficiently use water in public utility, residential and commercial building services, industrial and agricultural settings. 2

Xylem Water Solutions (India) Pvt. Ltd., Present scenario : - 3

Xylem Water Solutions (India) Pvt. Ltd., Need for change : - 1. Critical analysis of existing performance qualification methods. 2. Acceptance of pumps > 90% Efficiency. 3. Evaluate performance measurement with direct measurements. 4

Xylem Water Solutions (India) Pvt. Ltd., Leap forward for high efficiency system: - 5

Xylem Water Solutions (India) Pvt. Ltd., Testing pump for 90 % & above : - 6

Xylem Water Solutions (India) Pvt. Ltd., Testing pump for 90 % & above ( Multispeed ) : - 7

Xylem Water Solutions (India) Pvt. Ltd., Impact of efficiency on the pump operating cost : - Case I Case II Plant capacity 2 x 660 MW 2 x 660 MW Pump application Circulating cooling water Number of pumps 2 x 50 % ( 4 nos ) 2 x 50 % ( 4 nos ) Cooling Water required per unit 90,000 Cu.m / Hr 90,000 Cu.m / Hr Pump capacity @ head 45,000 Cu.m / Hr @ 25 MWC 45,000 Cu.m / Hr @ 25 MWC Pump efficiency 88 % 90 % Duty point pump input power 3481.51 KW per pump 3404.14 KW per pump Motor rating @ 15 % Margin 4004 KW per pump 3915 KW per pump Total duty point power ( 4 pumps 13,926.02 KW 13,616.56 KW ) Difference in duty point power 309.46 KW Cost of operating a low efficiency circulating cooling water pumps ??? 8

Xylem Water Solutions (India) Pvt. Ltd., Pump testing : - TRADITIONAL 2 WATT METER TESTING WITH JOB MOTOR 9

Xylem Water Solutions (India) Pvt. Ltd., Shortfalls in normal Performance testing method : - 1. Full column pipe length. 2. Calibrated job motor. 3. Full speed. 4. Indirect way of shaft power measurement. 5. Manual recording of reading # No data log. 6. Lack of verification of motor efficiency at full & part load. 7. Unavailability of performance at variable speed. 8. All the above results in shaft power measurement errors & inefficiencies. 10

Xylem Water Solutions (India) Pvt. Ltd., Suggested Performance testing method : - 1. SUPPLY WITH HIGH VOLTAGE VFD FOR 50/ 60 HZ CONSTANT 2. FREQUENCY IRRESPECTIVE OF VARATION OF GRID FREQUENCY VARIATION 3. STEPLESS OUT PUT VOLTAGE SELECTABLE FORM 3.3 KV TO 11 KV. 4. TORQUE TRANSDUCER BETWEEN PUMP AND MOTOR FOR ACCURATE SHAFT POWER MEASUREMENT. 5. DATA ACQUISITION SYSTEM TO ELEMENT MANUAL READING. 6. ACCURATE MEASUREMENT OF PUMP AND MOTOR POWER AND EFFICIENCY. 7. NO CALIBRATED MOTOR IS REQUIRED. 8. PUMP TESTING WITH FULL COLOUMN LENGTH AND FULL SPEED. 9. PUMP AND MOTOR POWER MEASUREMENT AT MULTI SPEED OPERATION. 11

Xylem Water Solutions (India) Pvt. Ltd., Advantage of power measurement by torque transducer : - 12

Xylem Water Solutions (India) Pvt. Ltd., Key features of the proposed system : - 1. Supply with high voltage VFD offering 50/ 60 HZ constant. 2. Stable frequency irrespective of variation of the grid frequency variation. 3. Step less output voltage selectable from 3.3 KV to 11 KV. 4. Torque transducer between pump & motor gives accurate shaft power readings. 5. Automated data acquisition system eliminates requirement of manual readings. 6. Accurate measurement of pump & motor power & efficiency. 7. Calibrated motor not required. 8. Pump to be tested with full column suspension length & at full speed. 9. Pump & motor power measurements can be had at multi speed operation. 13

Xylem Water Solutions (India) Pvt. Ltd., Schematic diagram of the proposed system : - 14

Xylem Water Solutions (India) Pvt. Ltd., Test facility specifications : - 1. Wet pit 45 mts x 7.9 mts x 10 mts deep for testing vertical turbine pumps. 2. Dry pit 25 mts x 8 mts x 7 mts deep for testing horizontal split case pumps & metallic volute pumps. 3. Overhead crane capacity 90 T & 40 T. 4. Variable frequency drive for testing of pumps at 50 Hz & 60Hz frequency. 5. Supply capacity up-to 7.3 MW. 6. Flow measuring capacity of up-to 1,20,000 m^3/hr 15

Xylem Water Solutions (India) Pvt. Ltd., Test facility instrumentation : - 1. Details of measuring instruments : 2. Output of all the instruments integrated thru DAS in control room. 3. No human intervention during testing process to eliminate any errors. 16

Xylem Water Solutions (India) Pvt. Ltd., Select reference of high efficiency pumps : - Sr. Client Year of Qty Model Type Discharge Head Speed Motor No. supply Cu.M/Hr M RPM HP Vertical 1 Yanpet, Saudi Arabia 1998 1 132 x 96 WCBR 60,046 20 212 5360 Column Korea Hydro & Nuclear Vertical 44,324 2 2003 8 100 x 84 WCA 15 293 3200 Power - Shin Kori Units 1 & 2 Column Southern Power Station, Vertical 3 1982 4 108 x 78 WCAR 41,328 15 330 3000 Israel Column Vertical 4 We Energies - Elm Road 2007 4 96 WCAX 46,597 5.9 225 1750 Column Vertical 5 Amergen - Clinton 2008 1 114 x 84 WMCC 43,089 29.8 320 5500 Column 17

Xylem Water Solutions (India) Pvt. Ltd., This is not special for us……. 18

Xylem Water Solutions (India) Pvt. Ltd., Registered Office & Factory : Plot no. 731, GICD Savli, Manjusar, Savli Road, Vadodara – 391 770 Telephone : +91-2667-265 700 Fax : +91-2667-265 764 Corporate office : Ground & First Floor, Vishnu Shivam Mall, Thakur Village, Kandivali (East), Mumbai 400 101 Telephone : + 91 22 40 370 370 Web : www.xyleminc.com / www.xylemindia.in 19

Xylem Water Solutions (India) Pvt. Ltd., THANK YOU 20