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KirlosKar PumPs, ValVes and TurbinesA Journey Towards A Green World

Published by Henley media Group ltd in association with the Commonwealth secretariat

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KirlosKar PumPs, ValVes and Turbinesa Journey Towards a Green world

Kirloskar brothers limited (Kbl) recognises that climate change will be one of the biggest drivers of economic change in the coming decade. it raises enormous strategic challenges for businesses of all kinds, as business operations are responsible for one third of global emissions while its products account for another third. it was the recognition of gravity of this issue that ushered Kbl on the path of ‘Going Green’ in all that it undertakes. From checking inefficiencies in fuel and water consumption, to manufacturing energy saving products in an energy efficient way; from adapting the ‘Zero discharge’ principle of recycling industrial waste water to use of renewable sources of energy, KBL has taken the Green mantra to heart. Standing testimony to this commitment is ‘Yamuna’ – KBL’s new business centre, constructed according to the guidelines specified by Leadership in Energy Environment (LEED), a rating system launched in India by Indian Green Building Council. This ‘green’ office building is located at Baner on Mumbai-Bangalore highway, commanding an impressive view.

LEED is an Indian rating system based on the one launched by ‘US Green Building Council’ (USGBC), Washington. Primarily, it ensures use of less energy, water and natural resources, creates less waste and improves conditions for people working within the premises. One could define a green building as a structure that uses clean, renewable energy, enables the efficient use of water, uses recycled and / or recyclable materials and provides a healthy atmosphere.

Yamuna has been so designed as to yield 40 to 50 per cent energy savings as well as 20 to 30 per cent water savings at the same time generating reduction in operating costs from day one. The construction of this building cost KBL only around 8 per cent more than a conventional building would have. Indeed, going green makes economic sense as it addresses the root cause of inefficient use of resources, besides saving operating costs.

enVironmenT ConsCious To The CoreStanding testimony to KBL’s commitment to health and safety is the prestigious international certification, OHSAS 18001, awarded to the Kirloskarvadi plant of KBL for ensuring and achieving occupational health and safety standards of people working in the plant. The Dewas and Shirval plants of KBL have also been certified, while it’s Kondhapuri plant is

preparing itself for the audit in the current year.Green is the way to be!

Green is the color of forests – the lungs of our planet; it is the color of ‘Go’, the hue of prosperity and the shade of life. It is to enrich this ‘Life’ that KBL is dedicated to.

Some of KBLs environment protection measures are as under–

imPlemenTaTion of beTTer enerGy manaGemenT TeChnique: sardar saroVar ProJeCTSardar Sarovar Narmada Nigam Limited, project in Gujarat, India, is the world’s largest pumping station. It was designed, manufactured, installed and commissioned by the expert engineers of KBL. The project, with 26 Concrete Volute and 22 Vertical Turbine pump sets, pumps out 640,000 litres of water per second, irrigating 540,000 hectares of farmland and providing drinking water to over 30 million people in 4620 towns and villages.

KBL’s ingenious ‘Siphon Creation and Siphon Breaking Arrangement for pumps’ that reduce motor rating and conserve energy. Kirloskar has been awarded a US patent for this unique technology used at the World’s Largest Irrigation Scheme of Sardar Sarovar project at Saurashtra Branch Canal At Dhanki District, Surendranagar in Gujarat.

The use of energy efficient siphon arrangement will

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provide the following benefits:Reduction in motor rating : 8.5 MWAnnual energy conservation : 34.96 million units Annual saving in electricity : worth Rs.122.3 million

imPlemenTinG beTTer enerGy manaGemenT TeChniques in all ProJeCTs underTaKen: deVadula – The world’s seCond hiGhesT lifT irriGaTion sChemeThe world’s second highest Lift Irrigation Scheme has the capacity of 8.5 MW to raise water through a lift of 130 m, which is the highest in the country. The scheme diverts 30 billion cubic meters (132 trillion gallons) of water from the Godavari river. The scheme provides drinking water to millions and irrigates 656,694 acres of land in the perennially drought prone regions of Andhra Pradesh.

Higher efficiencies of the Metallic Volute pumps embedded in concrete (93 per cent as against 85 per cent) will save 300 million units of power per year for the next one and a half decades at the Devadula irrigation scheme. Kirloskar Pumps provide irrigation to 25000 hectares of land in draught prone areas.

It is the first time in the country where such large capacities of motors have been installed for an irrigation pumping scheme. These pumps provide drinking water to millions and irrigate 656,694 acres of land in Warangal, Karimnagar, Nalgonda and Medak district, which were perennially drought prone and reeling under poverty.

KBL’s high capacity, high head Metallic Volute Pump, used in the Godavari Lift Irrigation project was selected for the ‘National Award for Excellence in Energy Management’ for 2008, under the category of ‘Innovative Product / Service Award’, in a competition instituted by Confederation of Indian Industry (CII).

Kbl unleashinG a Green reVoluTion aCross afriCa few PresTiGious referenCes of Kbl 1. eGyPT

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KBL’s foot prints in Africa go back to the 1930’s in Egypt, where today a pump is called a Kirloskar. More than 100,000 Kirloskar pump sets are working in Egypt across the Nile greening more than 200,000 Hectares of arid land. KBL is also proud to have more than 60 large pumping stations across the country taking care of both – Water Supply and Irrigation needs.

Cultivating and maximizing irrigation in farmland is the most important step to food sufficiency for any country and more so in Africa. This is where, KBL, with its TRIPLE A philosophy promoting Adaptable, Appropriate and Affordable pumping systems and pumping solutions, can meet the irrigation needs across Africa and achieve goals of food sufficiency through various phases.

2. seneGal

In April 2005 KBL proposed the implementation of food sufficiency programme to the Honourable President of Senegal who approved the programme in its entirety. As a result Senegal is on its way to food sufficiency with phase one of the programme (over 2000 pump sets and accessories) already commissioned in November 2008, with the rice production going up by over 250,000 tonnes! (Prior to 2005/6- the

production was less than 100,000 tonnes, now after phase one of the KBL project, production stands at 360,000 tonnes).

Senegal will achieve food sufficient by 2012/13. As the Senegalese Minister of Agriculture, Hamath Sall told Afrol News on 16 April 2009, “By 2012, Senegal will not import a single grain of rice.” Record harvests in the River Senegal valley indicate that the country is on the right course.

3. anGola

KBL completed phase one of food sufficiency programme in April 2005 and it is looking forward to implementing phase two this year.

deVeloPinG eCo-friendly ProduCTs The founders of KBL were acting on energy efficiency products when the world did not attach the word ‘green’. Taking many countries towards food sufficiency is another way of turning a barren land into a green plantation.

Low Life Cycle Cost Pumps: KBL’s LLC pumps have achieved an operational achieved of 90 per cent.

ü Star Attraction: A unique, energy efficient, 7.5 HP KBL Monobloc Surface Pump with a ‘Five Star’ rating given by the Bureau of Energy Efficiency (BEE). It lifts 16 liters of water per second (4 liters more) compared to any other pump of similar HP. It consumes 7.6 amperes of electricity as against 12 amperes consumed by other makes. BEE and Ministry of Power plan to launch a scheme to replace all old and energy guzzling pumps on farms with this pump on all India basis, free of charge and thus save 47 per cent energy.

ü Solar Pumps: KBL has developed solar submersible pumping systems which have been appreciated by farmers country-wide as well as experts from the Ministry of Non-conventional

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Energy Sources (MNES).ü Pictorial display system: A unique pictorial display system with

an image processing system enables checking leak tightness as well as working condition of internal parts of valves in a closed condition.

ü Improved packaging: KBL modified the packaging of its domestic and agricultural pumps by eliminating the wooden base to cut consumption of wood

ü Recognition received: KBL’s environment and energy conservation initiatives have been recognized time and again by CII, The Energy and Resources Institute (TERI), the Marico Foundation, MNES and similar professional bodies.

ü Corrocoat: In order to enhance more efficiency we provide corrocoating solutions to our products which increased the resistance to corrosion and life of the product to 2 to 5 per cent.

inVesTinG in Green infrasTruCTure in Kbl’s manufaCTurinG PlanTs and offiCesKBL’s manufacturing plants have an internal competition with all other plants within the group companies. This is another important aspect of reducing the carbon footprint.

ü 4000 W solar panels have been installed at KBL Dewas in Madhya Pradesh, for testing solar pumping systems. During non-testing period, the panels are used for charging pumps at the ETP, saving electricity.

ü KBL plants and other premises are well equipped with sewage treatment plants, biogas plants, opting for certification by OHSAS and ISO 14001 standards.

ü KBL plants at Dewas and Kirloskarvadi are ‘Zero water discharge units where 100 per cent of waste water and effluent water is treated and used for gardening and maintenance of lush green lawns and plants.

ü The plant at Kirloskarvadi has bagged the National Award for Excellent Water Efficient Unit’ in recognition of its persistent efforts towards conserving this scarce resource.

ü Recognizing the importance of sustainable business growth and dwindling stock of natural resources, KBL has committed itself to the attainment of ten ‘Natural Capital Commandments’ proposed by CII.

We also have a full fledged ‘Energy auditing cell’ working with different industrial sectors, residential building, agricultural pumping and municipal corporations for auditing pumping systems.

PromoTinG enVironmenT ConserVaTion CulTure

ü Influencing the young: The Kirloskar School at Kirloskarvadi natures love for nature amongst students. The same message is communicated to students from other schools through ‘Clean and Beautiful School Contest’ which the Kirloskar Foundation conducts.

ü Energy Audit: KBL is the first pump manufacturing company in India to register its products for five Star marking with BEE. KBL has a full fledged Energy Auditing Cell working with different industrial sectors, residential buildings, and municipal corporations for energy auditing pumping systems. KBL is also working with various State Electricity Boards to improve energy conservation by using energy efficient pumps in agriculture sector.

ü Interaction: With farmers, mechanics and other end user’s visits our manufacturing facilities are organized to create awareness about energy efficient options offered by KBL. Training is also imparted to hone their technical skills. An energy conservation award has been instituted by the Kirloskar Group for its members to encourage efficient use of energy in plants. Energy Conservation Week is observed regularly at various KBL locations to promote energy efficiency.

ü Enriching Lives: KBL believes in continuous improvement and innovation. It’s Corporate Research Development and Engineering Centre contributes constantly to adding new products to an already existing wide range in order to suit new market trends and customized requirements. In a power-starved continent like Africa, KBL’s newly developed Solar Pumping System is an energy efficient solution for today’s time. With power cuts on the rise, especially in the African continent, diesel engine driven pump sets are almost inevitable. With pumps running on solar energy, you not only save conventional power, but also the fuel cost. Today, energy saved is energy produced.

That’s KBL for you – Enriching Lives’ while addressing ecological and environment impacts in a holistic manner and at the same time offering tremendous economic benefits.

Contact:

Kirloskar Brothers Limited‘Yamuna’, Survey No. 98/3 to 7, Baner,Pune – 411 045 (INDIA)

Phone: +91 20 2721 4444Fax: +91 20 2721 1117E-mail: kblin@kbl.co.inWebsite: www.kbl.co.in

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CrediTs

Henley Media Group Ltd.