Case Studies

Case 1:  Performance Monitoring at MIDC Rawet Water works
Case 2:  Performance Evaluation at Sudarshan Chemical Industries Ltd.
Case 3:  Performance simulation for Sudanese Sugar Corporation
Case 4:  Energy Conservation at Parvati Water Works


Case 1: Performance monitoring at MIDC Rawet water works

The Client

The Maharashtra Industrial Development corporation (MIDC) is one of the largest industrial infrastructure development agencies in India. Pimpri-Chinchwad industrial area is a large industrial area under MIDC and Rawet water works having a processing capacity of 80 MLD provides water supply to this area.

The Challenge

Datamatrix had developed a software-based solution for performance optimisation of large pumping networks and MIDC, Pune extended all the support for detailed testing of the software. The Datamatrix system was effectively utilised at MIDC, Rawet water works for monitoring the performance of the plant and bringing out the major performance optimisation opportunities. The plant monitoring was earlier carried out manually through various standalone instruments without effective co-ordination or interface with the machine capabilities and operating environment. Due to wide fluctuations in water supply, it was difficult to manually coordinate and respond to the fluctuating demands without compromising on the plant operating efficiency. The annual energy cost of the pump house is around Rs. 30 million.

The Solution

Datamatrix has established 100% metering of all plant operating parameters and each data log was interpreted with the machine characteristics and the operating environment. Our system could highlight all the major saving opportunities and this was taken up for implementation in a phased manner. The possible savings during a period of one year are indicated below with a one-time implementation cost.

Areas for Improvement

Saving Opportunities spotted (Annual)

Total Implementation cost

Operational improvements

Rs. 2.2 million

Nil

Retrofits

Rs.0.8 million

Rs. 0.4 million

Machine replacement

Rs. 1.0 million

Rs.1.4 million

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Case 2: Performance Evaluation at Sudarshan Chemical Industries Ltd.

The Client

Sudarshan Chemical Industries Ltd is the largest pigment manufacturing company in India having plants at Pune and Roha in Maharashtra.

The Challenge

Datamatrix conducted random trials at their Pune plant and could highlight substantial opportunities in optimising the performance of the pumping machinery. Accordingly, an order was placed with Datamatrix for evaluating the performance and highlighting the opportunities with various improvement options right from rescheduling the machines to retrofits and replacements at the main plant at Roha, Maharashtara.

The Solution

The Datamatrix system was used as an offline tool to simulate the performance levels of various machines brought under the scheme. It also assessed the various retrofit options within the existing machinery and quantified the scope for improvement. Replacements were opted wherever necessary after taking into account the attractive payback period. Fifty of the largest machines of the plant were brought under the ambit of the Datamatrix solution and the optimisation options were as follows:

Energy consumption of the plant pumping machinery = 11064000 KWH /year
Performance optimisation opportunities identified were as follows:

Areas for Improvement

Saving Opportunities spotted  (Annual)

Total Implementation cost

By operational improvements and retrofits

366960 KWH

Nil

By Machine replacements

 

5256000KWH

Rs. 1.2million

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Case 3: Performance simulation for Sudanese Sugar Corporation

The Client

Sudanese Sugar Corporation is the largest government owned industrial conglomerate in Sudan having large sugarcane fields along the river Nile, and several sugar plants. Kirloskar- Ebara had supplied large capacity pumps for the irrigation of the sugar cane fields. The consultants for the project had engaged Datamatrix for performance evaluation and final inspection clearance of the pumps.

The Challenge

Sudanese Sugar Corporation had decided to go in for new pumps at their Guneid Sugar Factory mainly because the existing pumps used to cavitate when the Nile water level was low at about 380 mtr. from mean sea level. The delivery of the Kirloskar- Ebara pump was delayed and the suppliers were not able to test the pump as scheduled in the summer when the Nile River is at the lowest level. Datamatrix was engaged by the consultants for the project and had a challenging task of simulating the pump performance and evaluating the same for final inspection clearance based on the test data at the available water level.

The Solution

The Datamatrix representative visited the site with the software-based solution and simulated the performance of the machines under various conditions, although the test could be carried out only at a specific level of the river Nile. Datamatrix made the following observations.

 Performance of the pump was found satisfactory.  It was observed that even though the new pumps were able to operate at 91% efficiency at its BEP considerably higher than the existing pumps beyond a certain water level and demand conditions, the older pumps operate at a better efficiency and it was advisable to operate the older pumps during such conditions for better plant performance. It was observed that this pump house had a monthly energy bill of 40million Sudanese Dinars and it is possible to reduce the energy bill by 5 million Sudanese Dinars every month with the help of pump monitoring. A pump monitoring solution capable of indicating the efficiency of the pump dynamically will enable the operator to switch on the most efficient pump at that moment.

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Case 4: Energy Conservation at Parvati Water Works

The Client

Pune Municipal Corporation is one of the large municipalities in India catering to a population of around 2 million people. The Pune municipal corporation treats and supplies around 400 MLD water through various pump houses. The bulk of the treatment is done at Parvati Water Works.

The Challenge

Pune Municipal Corporation has engaged Datamatrix for performance optimisation and energy conservation of the pumping networks. The program is to be implemented at Parvati water works Pump House No. 1 as the pilot project and is to be extended to the other pump houses The annual energy cost for pumping is estimated to be around Rs. 350 million and a saving of around 10 percent of the energy cost is expected after full scale implementation.

The Solution

Datamatrix has implemented the performance monitoring and optimisation solution at Parvati Water Works, Pump house No.1 as the pilot project. The system is able to highlight all the operating parameters and machine performance at a central point and help the operator to sequence the machine for optimum performance. The performance levels are continuously monitored and any decline in the performance level is immediately analysed and corrective action is taken. The machine retrofit options are being studied thoroughly in the light of the data generated and interpreted by the system with respect to the characteristic behavior curves of the machines and the best options are being implemented. The asset management program has become much more effective as the system is able to track all the saving opportunities continuously and arrive at the optimum replacements based on the availability of funds and return on investment.  

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