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Page 1 company presentation 201223/11/2012 One Day National Workshop on Common Effluent Treatment Plants CII - Sohrabji Godrej Green Business Centre, Hyderabad.

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Presentation on theme: "Page 1 company presentation 201223/11/2012 One Day National Workshop on Common Effluent Treatment Plants CII - Sohrabji Godrej Green Business Centre, Hyderabad."— Presentation transcript:

1 Page 1 company presentation /11/2012 One Day National Workshop on Common Effluent Treatment Plants CII - Sohrabji Godrej Green Business Centre, Hyderabad Technical Session II: Treatment Technologies & Monitoring 23 November 2012 Energy Efficient Turbo Blowers for Aeration Kiron C. Pande - Godrej & Boyce Mfg. Co. Ltd. Energy Efficient Turbo Blowers for Aeration Kiron C. Pande - Godrej & Boyce Mfg. Co. Ltd.

2 Page 2 Effluent Water Treatment

3 Page 3 Positive Displacement type, Twin Lobe Air Blower

4 Page 4 VolumetricTurbo Multi stage Turbo blower Low speed Turbo - η Increase over 10% - No Volumetric pulsation Efficiency Increased over 40% Blower Direct driven High Speed - η Increase over 10% -η Increase over 20% - Increase stability Increasing Energy Efficiency High Speed Turbo High Gear Ratio Multi stage Turbo blower Roots blower PD

5 Page 5 Turbo Blowers

6 Page 6 Energy Efficiency certified by: Korea Energy Management Corporation

7 Page 7 User selectable Control Modes with KTurbo Constant Flow Constant Pressure Constant Power D.O. Control

8 Page 8 User Selectable Control Modes

9 Page 9 Core Components & Salient Features Permanent Magnet Motor: a) Power required only to rotate & not for magnetizing of rotor; b) Can be started & stopped any number of times; c) High Efficiency even at part load No Gear Box: No transmission loss due to direct drive & no lubrication required. Variable Speed Drive for achieving high speed, smooth starts (reduced starting current) & energy efficient capacity control as part of the Blower package. Air Foil bearing for high speed operation (used in Jet engines) Oil Free air Low Noise: 80 dB against 100 dB of PD blowers Entire range is air-cooled & no need of water for cooling.

10 Page 10 Comparison with PD Blowers ParameterPD BlowerKTurbo Blower Aero Efficiency55%77% Drive Efficiency (Motor+Coupling+Invertor)82%92% Total Efficiency at 100% Load45%70% Total Efficiency at 50% Load22.5%67% Starting Current compared to Rated Current250%Below 5% MaintenanceOverhaulAir Filters Life5 YearsSemi- permanent Foot PrintLargeSmaller Noise Level dBBelow 80 dB

11 Page 11 PD Blowers Performance

12 Page 12  Typical model at 1800 RPM; Average total efficiency is 45% PD Blowers Performance

13 Page 13 PD Blowers Performance

14 Page 14 Single Stage Turbo Blowers Performance

15 Page 15 High Speed Turbo & PD Blower Performance

16 Page 16 High Speed Turbo & PD Blower Performance

17 Page 17 KTurbo (Benefits with KTurbo ) 1) Discharge Temperature : Less than 20° C than Roots type. => Change Aerated water temperature: less than 3 ℃ than with Roots blower used earlier 2) Capacity control : Operating 1 ㎥ /min => Protect for excessive aeration 3) Oil-less System => 100% oil-less air 4) Reduce energy consumption: more 40% (Before using roots blower) 5) Noise level : 1m (as against earlier 105dB with Roots blower) Aeration: Coca Cola (Korea)

18 Page 18 SunRiver: North America installation Before : 2 Units of 100hp Multi Stage After: 1 Unit of TB (70% Operation)

19 Page 19 Control Configuration for DO (Dissolved Oxygen) Intrinsic Feedback control DO data ( 4 ~ 20mA) Flow Control ※ DO Sensor (Endress+Hauser Co.) Input: ~ 60 ppm Output: 4 ~20mA HMI Display

20 Page 20 Schematic of KTurbo installation in WWTP plant

21 Page 21 Picture of KTurbo installation in WWTP plant

22 Page 22 Picture of KTurbo installation in WWTP plant

23 Page 23 KTurbo blowers supplying air to WWTP plant

24 Page 24 InverterPower In Controls Intake Silencer BOV Silencer Construction of Single & Twin Turbo Blowers / Comp

25 Page 25 PM Motor & Impellers 2 Pole permanent magnet (SmCo) with high strength retaining ring High performance electric core H Class Insulation winding Radial airfoil bearing Thrust disk & Thrust bearing Stainless steel casted Impeller Scroll Intake Discharge

26 Page 26 Core Technologies (1) Air foil bearings Self-acting hydrodynamic float on air Bump foil acting as a spring The first generation –Axially & circumferentially uniform elastic support elements The second generation –Variable axial OR circumferential compliance characteristics The third generation –Foil support in axial, circumferential AND radial direction

27 Page 27 History of Foil Bearings Simple Bump Reversed Multi-Layer Multi-Leaf High Capacity, High Speed, High Damping, High Temperature Multi-Pad Bump Third Generation Bump (KTurbo) Radial variation Circumferential variation Axial split/variation MiTi have made major research KTurbo has > 1000 units experiences KTurbo has TC series Teflon-S MoS2 High Temp Solid Lubricant -PS304 ; NASA -KOROLON1350F ; MiTi

28 Page 28 (2) High-speed & high-power PM motor/driver PM motors –High-speed & high-power (50 hp ~ 600 hp / 20,000 rpm ~ 70,000 rpm) –High efficiency (> 95%) Sensor-less Inverters –Cost-effective –High efficiency (> 97%) Core Technologies

29 Page 29 Why PM motor ?  No magnetizing power is necessary  Lower heat generation means less cooling loss.  Smaller rotor means less friction loss  No slip means high efficiency even at part load condition.

30 Page 30 Efficiency of PM motor & Induction Motor

31 Page 31 1.Stainless Steel SUS630, 17-4PH 2.Optimum Specific Speed Maximum efficiency 3.Optimum back sweep angle Maximum efficiency High Rise to surge Wide operating range 4.Splitter Blade Larger flow capacity Higher efficiency 5.Leaning Higher structural strength (3) Features of KTurbo Impeller Core Technologies

32 Page 32 Built-in Flow Meter Bell mouth is more accurate than Orifice, because it needs only one sensor.

33 Page 33 Discharge Duct Blow-off Valve Silencer Blower core Inverter Discharge pressure : P Discharge Temp : T2 Suction Flow rate dP : dP3 Suction Temp : T1 Filter Pressure Drop : dP1 Air Flow measuring Air in Air out Impeller Inlet Reducer T1 dP3 [Differential pressure] + Q ≈ Q (T1, Po, dP3) Measurement System

34 Page 34 HMI with touch screen

35 Page 35 HMI: Main Screen

36 Page 36 HMI: Operating Curves display

37 Page 37  CF memory is applied Data logging every 1 sec, 1 min, 1hour All event recording HMI: Data Logged every second

38 Page 38  CF memory is applied Data logging every 1 sec, 1 min, 1hour All event recording HMI: On-line trend display

39 Page 39 CCR (Central Control Room) SCADA or DCS or PLC MCP1 TB #1TB #2TB #3TB #4 MCP2 TB #1TB #2TB #3TB #4 Multi-Group Control

40 Page 40 Foundation Anchor bolting case-2 Anchor bolting case-1 Concrete pad

41 Page 41 Air Filters Pre 10 ㎛ 4-8 weeks Final 10 ㎛ or ㎛ 5-12 months ΔPΔP21-44mmWTR

42 Page 42 Customers

43 Page 43 Customers

44 Page 44 Thank You! Godrej & Boyce Mfg. Co. Ltd. Compressed Air Solutions Godrej | Electrical & Electronics Pirojshanagar, Vikhroli, Mumbai – India Tel.: to 2255 Fax: / s:


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