KSB PIA 2015 Finalists

The Pump Industry Awards 2015 hope to encompass the full scope of success and innovation in the pump industry through their award ceremony. The event will be held on the 19th March at Chesford Grange Hotel, Kenilworth. KSB are proud finalists in two categories at the Pump Industry Awards 2015.

The categories that KSB have been nominated for are:

´Technical Innovation of the Year – Projects' and 'Environmental Contribution of the Year' categories with:

  • Pump as Turbine in place of Pressure Reducing Valve, KSB Ltd & Kier

In what ways is this product, system or service eco-friendly? Can you give details of energy or cost savings?

A “Pump as Turbine (PaT)” was introduced into South West Water’s Supply Network at a site called Watercombe to act in place of a Pressure Reducing Valve (PRV), thus capturing energy that would otherwise be wasted.

A PaT has many advantages over conventional hydro-turbine technologies, but the PaT’s ability to operate with a high outlet pressure is one key feature in this application. The PaT reduces pressure in a pipeline by extracting surplus energy and converting it to electricity (in this case 284MWh/annum), which can be fed back into the grid. This replaces the function of the pressure reducing valve which wastes that energy as noise and heat.

The technology can be rolled out to many similar applications across the UK and globally.

Please provide technical and application details:

The Watercombe site is located at the confluence of two pipelines carrying water abstracted from two rivers, the Yealm and the Erme. The combined flows pass into the main feeding Littlehempston WTW. The Erme source is around 100m higher than the Yealm, so pressure in the Erme pipeline has to be reduced by around 9 bar before it joins the system. At 55l/s this equates to a water power of 48.5kW which would traditionally be broken down by PRV. The inlet pressure at the PaT  is approx. 15 bar. The outlet pressure is approx. 6 bar which suits the capabilities of a pump-based hydroturbine. The PaT can function under the required operating conditions and harness the power that would otherwise be wasted by the PRV.

What has been installed and why was it chosen? Where and when did the installation take place?

The PaT, a multistage ring section pump, was selected to match the flows and pressures on site, to extract energy as efficiently and as quietly as possible. This is connected to a TEFV motor, functioning as an induction generator. Connection to the grid is via a turbine control panel. The turbine set, pipework, valves and controls are installed in a new building in a remote part of the Dartmoor National Park, near Ivybridge, hence the low noise requirement. The installation took place in 2013, being commissioned in October of that year. Successful proving has taken place throughout 2014.

How has this projects success been quantified? If it was a product replacement what improvements have been delivered? In what ways did it meet or exceed expectations? What are the long term expectations for its success?

Watercombe generates around 35kW when running, which is fed into the grid. Typical usage is 320 days/year (7680 hours) generating 284MWh/annum. This equates to some 200t CO2 saving (based on data given for UK’s fossil fuel electricity generation in the DECC publication “2013 UK Greenhouse Gas Emissions – release 27th Mar 2014). Previously, no useable energy was generated, so the site has entirely met expectations. Although the site itself generates a relatively small power output, the proof of concept is significant, in that it could be repeated at suitable sites on the water distribution networks throughout the country, generating further green electricity.

Environmental Contribution of the Year

  • PumpDrive 2 – The Latest Generation of KSB Speed Control Devices

Why is this product innovative, what new technology does it include and what makes it different from other products? When was it launched?

PumpDrive 2, launched in July 2014, is the latest generation of KSB's pump speed control systems. It ensures demand-driven pump operation and, hence, maximum energy savings. PumpDrive 2 continuously matches the speed of the pump to actual system demand, ensuring energy-efficient and reliable operation of pumps.

PumpDrive 2 has two main differences to other similar products, both are features which take the product beyond the current mainstream market

  • The drive is available in motor-mounted versions up to 55kW – extending beyond our main competitors.
  • The drive is capable of operation with next generation magnetless Synchronous Reluctance motors, giving IE4 potential today.

Please supply application details, particularly how it compares to other, similar or competitive products

PumpDrive 2 has the usual wide applications of similar variable speed drives, including the control features necessary to meet Enhanced Capital Allowance technical criteria.

We believe that PumpDrive 2 is not only unique, for the reasons given in the above text, but also delivered wider benefits as listed below:

  • Ready today for Synchronous Reluctance IE4 drive applications thanks to vector control method – Not a feature offered by our main competitors.
  • Motor-mounted models now up to 55 kW – this extends beyond main competitors.
  • PumpDrive 2 now in a robust metal housing.
  • Future-ready for Synchronous Reluctance IE4 drive applications thanks to vector control method.
  • Assistant for quick commissioning,  with wireless module with smartphone App.
  • New field bus modules: BACnet, Profinet and Ethernet.

What function does this product perform? Where and when, was it installed and how is it used?

PumpDrive 2 is a pump motor speed control device. The new drive lowers energy costs and reduces the pump's life cycle costs by controlling the pump input power. Speed control increases both the energy efficiency and the availability of pumps.

Associated compatible products such as the KSB PumpMeter and the KSB SuPremE® Synchronous Reluctance motor help in achieving even more energy savings with PumpDrive 2.

By means of continuous measurements and calculations as well as thanks to enhanced pump functions, KSB's new PumpDrive 2 optimises the operation of the system as a whole.

Since its release for sale in July 2014, the product has moved onto the traditional market against existing pump VSDs, and we expect it will gain wider appeal as the extended range comes into play and IE4 magnetless motor technology gains traction.

How has this products success been quantified and did it meet or exceed expectations? Why was it chosen, who are the clients and what do they do?

Unfortunately it is too early in the newly launched product’s lifecycle to cite particular user references, it is after all an innovative product. But the predecessor product was used to great success in combination with associated KSB products. Examples were Salzgitter – a steel maker in Germany who adopted KSB demand driven plant to gain a 55% reduction in power consumption and Heidelberg, a cooling lubricant supplier who used PumpDrive and SuPremE Sync. Rel. motors to deliver an incredible energy saving in the order of 90%

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