Kirloskar lowest life-cycle cost pumps

On May 31, 2013

Mr. Prasad Kulkarni

The life cycle cost of pump is divided in Capital cost, Energy cost, Maintenance cost and Disposal cost. Traditionally market focus has been on capital cost which contribute hardly on 3- 5% of its life cycle cost. On the other hand, energy cost and maintenance cost contribute as much as 95-97% of the life cycle cost.

Kirloskar Brothers as the leading pump manufacturer and pumping solution provider has come out with new series that is unique and one of a kind , Lowest Life Cycle Cost (LLC ) series of pump in the Split casing and Vertical Turbine Pumps. This series specifically focused on energy and maintenance cost.

Hydraulic Institute Standard has mentioned about the deteriorationof efficiency.In normal cases, practically pump efficiency drops at 1% per annum due to erosion and corrosion. As the efficiency decreases, there is increase in the power and time consumption to deliver the same output. This degradation of pump efficiency leads to increased cost of operation. Evaluating the Life Cycle Cost (LCC) of a pump can be highly beneficial. LCC can evaluate and compare complex pumping systems to safeguard commercial interests while making decisions about purchasing pumping systems.

Studying the LCC of pumping systems has shown that efficiency of the pumps can be increased by specific changes in the design and thus the development of Lowest Life-cycle Cost (LLC) Pumps. Modifications in the traditional pump designs with an objective to reduce the downtime, replacement of components and to increase the cycle of planned maintenance have given rise to Lowest Life-cycle Cost (LLC) Pumps. LLC pumps help in the conservation of energy by maintaining wire to water (overall ) efficiency of the product over the years of wear. As compared to conventional products where there is a growing concern over energy depreciation.

Factors such as corrosion and natural erosion have been considered when discussing the LLC pumping system by KBL.

These have been improved by working on the following factors:

Improving design efficiency
Using low friction Hydrophobic coatings to reduce losses
Retain enhanced efficiency for longer periods bychanging the mechanical design.
Right Configuration of System
Changes suitable to variable head and flow

The efficiency of the pumps has been enhanced greatly and in a sustainable manner by the use of a special corrosion resistant and efficiency coating called ‘corrocoat’. Proper corrocoating has resulted in the reduction of friction in the KBL LLC pump and has improved the efficiency of the pumps.

Secondly new mechanical design is introduced in such a way that improved efficiency can be sustained over its life cycle. Similarly right configuration of system is used so as to maintain its wire to water efficiency.

Kirloskar Lowest Life CyclePumps
The designing of the LLC has been done at KBL with an aim to make the pumps energy efficient. Due to these modifications, LLC pumps save an additional energy cost and effectively reduce the degradation costs.

Types of Low Life-cycle Cost Pumping systems at KBL :
KBL has two major types of LLC pump series: Horizontal Spilt Case Pumps and the Vertical Turbine LLC Pumps. Enlisted below are some of the salient design features

Universal mechanical seal chamber so that customer specified seal can be accommodated.
Wear rings are designed to minimize the frictional losses.
Corrosion resistant stiff shaft.
API type bearing arrangement.
New design of volute casing to minimize load on bearing.
Externally removable mechanical seal.
Externally removable bearing &bearing housing
Efficiency enhanced and drinking water approved coating
High precision replicast stainless steel impeller.
Positively locked impeller and nut.
Special design throat bush to facilitate suction lift.
Special design base plate to minimize excessive down time
Compact design than conventional pump.

Long term benefits of LLC
A KBL LLC pump has a low life cycle cost as compared to the conventional pumps. The LLC pumps have a higher initial purchase cost, but they save tremendous amounts of energy and money in the long run.

This is the cumulative effect of the following salient features:

Reduced energy consumption leading to reduced energy costs
Reduction in the downtime which helps in cost cutting
Reduced maintenance costs due to robust design
Reduced cost of ownership on whole

This cumulative reduction in energy consumption will translate directly to cost saving and therefore increase the profitability of an organisation. Also the productivity increases due to lesser downtimes and the robust design which in turn is advantageous.

Conclusion
As the developed countries are becoming more aware of the effect of energy wastage the importance of efficient use of energy is evident.Increase in the efficiency of the pumps means reduction in the overall energy consumption. This translates directly in reduced emissions and preservation of natural resources effectively reducing the carbon footprint. Lowest Life-cycle Cost Pumps by Kirloskar Brothers Limited effectively reduce energy consumption and thereby increase the overall efficiency of the pumps. The LLC pump user will derive a benefit of guaranteed performance in a sustainable manner over the life time of the pump. Kirloskar Brothers Limited has used this concept effectively in their products in order to contribute to energy conservation.

For more information
Web: www.kirloskarpumps.com