KIRLOSKAR BROTHERS LIMITEDA Kirloskar Group Company
WARM WELCOME TO ALL THE DELEGATES
International Conference on HydropowerDehradun , Uttarakhand
D 05 07 F b 2015
15-Jan-14 This is a proprietary document of Kirloskar Brothers Limited 1
Date : 05-07 February 2015
Kirloskar Brothers Limited (KBL)
1888
Centrifugal pumps, Valves, Hydel turbines, P i P j
Core business
1920Incorporated
1888Established
Summary financials (FY: 2012 13)
Pumping Projects
Yamuna- Global Headquarter Kirloskar Brothers Limited ,IndiaINR 7786 MillionNet worth
INR 18724 Million Revenues
Summary financials (FY: 2012-13)
LEED Certified Platinum Rated Green Building
INR 159 Million Market cap
INR 719 Million Profit Before Tax
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Company Profile: Kirloskar Brothers Ltd.
• Mother company of Kirloskar Group : Diversified Engineering Conglomerate
Rich Culture - Strong Values - Futuristic VisionRich Culture Strong Values Futuristic Vision
• Pioneer of Indian engineering Industry - More than 125 Years of Experience
• The largest manufacturer of Centrifugal pumps in India.
• Manufactures the largest pumps in India by size and horsepower.g p p y p
• Commands the highest market capitalization among the pump
manufacturers in India.
• Largest exporter of pumps from India for the last 27 years.
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• Manufacturer of Hydro Turbines upto 20 MW Single unit.
Domestic Subsidiaries
KIRLOSKAR BROTHERS LIMITED
• Cross country & submarine pipelines
Karad Projects & Motors
• Cross country & submarine pipelines• Tunneling and underground caverns• Bridges and roads• Civil construction
Ltd.
• Manufacturing of stators, rotors & electric motors
The Kolhapur
Steel Ltd.
(2007)
• Large alloy steel castings foundry• Single piece casting of 14 Ton• 600 Tons / month capacity(2007) 600 Tons / month capacity
Kirloskar Systech Limited
System engineering for projects• Power• Water
- Focused engineering data for in-house use and outside contractors
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(2010) • Irrigation• Industry
- Patents and IP Creation
International Subsidiaries
KIRLOSKAR BROTHERS INTERNATIONAL B.V. (2008)
SPP Pumps Limited – UK (2003)
• Leading market presence in Fire Pump Packagesbusiness
• Lowest life cycle cost pump range• Assembly units in USA & South Africa
Kirloskar Brothers Europe BV – The Netherlands
(2008)
• Sales and Packaging of centrifugal pumps with focuson European markets
Kirloskar Brothers Thailand Ltd – Thailand
(2009)
• Sales and Packaging of centrifugal pumps with focuson South East Asian markets
Braybar Pumps Ltd. South Africa (2010)
• Manufacturing & Sales of high head multi-Stagepumps, Rubber lined slurry pumps and white metallined bearings
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Joint Ventures
Kirloskar Corrocoat Private Limited
Products:• Pump energy efficiency coatings• Corrosion Protection CoatingCorrosion Protection Coating• Sea water application• Single point solution provider
KEPL
Products:• API process pumpsAPI process pumps• Boiler feed pumps• Steam turbines upto 30 MW
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Human Resources
Empowered, responsive, motivated and competent human capital are a key asset of KBL.
Our TeamOur Team Team KBL is committed to create a value based organization with ethical practices, and lead
the company to excel in pursuit of its mission and vision.
Employee Strength
Particulars Headcount
Total Employees 3510
Which include
Engineers 936
Application and Product engineers 125
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Kirloskar: Journey of Engineering Excellence
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Kirloskar Brothers Limited: Product Range
• Pumps : Vertical – Mixed/Axial Flow Concrete Volute and Metallic VoluteHorizontal Split CaseEnd Suction / InlineMultistage / Non Clogg gCanned Motor PumpCondensate Extraction PumpBoiler Feed Pumps.Fi Fi h i PFire Fighting Pumps
• Hydro – Turbines** : PeltonKaplanFrancis
(** Horizontal / Vertical)
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Kirloskar Brothers Limited: Product Range
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Kirloskar Brothers Limited Product Range
Valves : Butterfly (Hydraulic / Electrically operated)Valves : Butterfly (Hydraulic / Electrically operated)Sluice / GateNon Return / ReflexGate / Globe
Turnkey Project : Turnkey Project Involving Design, Engineering, ProcurementSupply, Installation, commissioning, testing, Civil - Constructions,Piping, Operation And Maintenance of Pumping Systemp g, p p g yIncluding Electro Mechanical Equipment, Control and HydelPower Generation
Anti Corrosion Products :Energy efficient anti corrosion and antiAnti Corrosion Products :Energy efficient, anti corrosion and antiabrasion coatings
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Manufacturing Facilities- India
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Manufacturing Facilities- Outside India
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KBL Across the Globe
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Certifications
• KBL has all the certifications required for International Market such as :
• QMS ISO 9001-2000
• QMS ISO 9001-2000 (Project)
• EMS ISO 14000
• OSHAS 1SO 18000
• CE Certifications
• ATEX
• FM approved / UL Listed fire packages
• ASME – N, NPT and MO stamp
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Awards
CII - Excellent Energy Efficient Unit award to Kirloskarvadi Plant
ISO 50001 Certification to Kondhapuri Plant
CII – GreenCo Silver Certification to Dewas Plant
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KBL Contribution to Hydroelectric Power – Way to Green Energy
• .
• Total installed capacity 100+ MW • 70 + Units delivered
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70 Units delivered
February 14, 2015
KBL in hydro power sector
• Committed to become a leader in micro, small and medium hydro turbine business and a preferredplayerplayer.
• Hydel Power turnkey solutions on “concept to commissioning” and “single window concept”basis.
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KBL: State-of-the-art Hydro Technology
• Design, Engineering, Manufacturing, Installation, Erection, Commissioning and Testing of Electro-Mechanicalitems for Hydro-electric projects
• Unique energy efficient solutions for variety of heads, discharge and power rating for different terrain
• DESIGN AND MANUFACTURING CAPABILITIES:
Francis / Kaplan / Pelton Turbines H i t l d V ti l C fi ti Horizontal and Vertical Configuration Single Unit capacity up to 20 MW
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KBL Hydro Turbines : Technical Capabilities
Horizontal Tubular Kaplan Turbine Vertical Kaplan / Francis Turbine
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Horizontal Francis Turbine Horizontal Pelton Turbine
KBL Hydro Turbines : Technical Capabilities
Fluid Flow Design and Optimization of Spiral Casing
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KBL Hydro Turbines: Technical Capabilities
Structural Stability & value Engineering throughStructural Stability & value Engineering through
• Natural Frequency Analysis
• Seismic Analysis
• Static and Dynamic analysis
• Torsion Analysis
• Rotor dynamics Analysis
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KBL Hydro Turbines: Manufacturing Facilities
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Birds Eye View of Manufacturing Facility at Kirloskarvadi
KBL Hydro Turbines: Manufacturing Facilities
Location
Connected By - Railway And Roady y
Nearest Railway Station - Kirloskarvadi , Dist: Sangli (Maharashtra)
Nearest Airport - Pune (250 Km)
Nearest Seaport Mumbai (450 Km)Nearest Seaport - Mumbai (450 Km)
Area
Total Area - 161,873 M2 (1742386 Ft2)
Factory Area - 103,598 M2 (1115120 Ft2)
Covered / Work Area - 129,498 M2 (1393905 Ft2)
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KBL Hydro Turbines: Manufacturing Facilities-Foundry
• Cast Iron Foundry • Alloy Cast Steel Foundry
KBL is the only turbine manufacturer in the country having its own Foundry. y y
• Non Ferrous Foundry y g y
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KBL Hydro Turbines: Manufacturing Facilities-Foundry
A large component being pouredA large component being poured
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A View of Sand Processing Plant
KBL Hydro Turbines: Manufacturing Facilities-Foundry
Metals Poured
Cast Iron Foundry Cast Iron, Cast Ni Resist, Austenitic Cast Iron, SG Ni Resist Austenitic Alloy Cast Iron
Alloy Cast SteelFoundry
Chromium Steel CA 15, CA6NM, Cast Steel WCB and LCB Grades Stainless steel CF 8M, CF 8C,CF3M,CN7MS, K-Monel, Duplex Stainless Steel, Super Duplex StainlessSteel Hastalloy B & CSteel, Hastalloy B & C
Non FerrousFoundry
Aluminium Bronze, Phosphor Bronze, Tin Leaded Bronze, Nickel Aluminium Bronze
Shop Capacity/MonthMax Weight of Single casting ( In - house )
Maximum Weight of single casting
Ton Ton Ton
CI & Heavy 1400 10 16 (TKSL)
Alloy Steel 225 4 6
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Alloy Steel 225 4 6
Non-Ferrous 75 0.8 Not required so far
KBL Hydro Turbines: Manufacturing Facilities-Machining
The Machine shop is equipped with following machines –
• CNC Vertical Turning Machines
CNC T i C t• CNC Turning Centres
• CNC Machining Centres
• Vertical Boring Machines (up to 8000 mm diameter x 6000 mm height)
• Various Special Purpose Machines
• Grinding Machines
• Honing Machines
• Drilling Machines
• Miscellaneous Machines such as Milling, Keyway cutting, Jig Boring Machines
• Maxi size of the job that can be turned 8000 mm diameter X 6000 mm L
• Maximum grinding capacity 250 mm diameter x 4000 mm length.
In addition to above KBL has dedicated vendors for carrying out specialized
operations.
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KBL Hydro Turbines: Manufacturing Facilities-Machining
4 Axis CNC machine for Profile machining of Runner blades and
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4 Axis CNC machine for Profile machining of Runner blades and Guide vanes
KBL Hydro Turbines: Manufacturing Facilities-Machining
i i l i hi iTubular Kaplan Casing Being Machined on Carnagee Machine
Francis Spiral Casing machining on SK 40 VTL.
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KBL Hydro Turbines: Manufacturing Facilities-Machining
Tubular Kaplan Casing Being Machined on WOTON CNC HBM
Sh ft St R li i F
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Shaft Stress Relieving Furnace
KBL Hydro Turbines: Manufacturing Facilities-Machining
Kaplan R nner H b machining on CNC VBM Francis Runner machining on CNC VBMKaplan Runner Hub machining on CNC VBM. Francis Runner machining on CNC VBM
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KBL Hydro Turbines: Manufacturing Facilities-Machining
Complete assembly check and functioning of Runner Blade Assembly at works
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at works
KBL Hydro Turbines: Manufacturing Facilities- Quality Assurance
Quality assurance facilities.
• Non-Destructive Testing facilities comprising of radiography, ultrasonic testing, magnetic particle testing and dye penetrate testing.
• Material testing laboratory conducting transverse, compression, shear & hardness tests and impact tests.
• This laboratory also has spectrometer for chemical analysis of materials .
• Standards room with instruments of international standards
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Scope of supply
Design, Engineering, Manufacture, Supply, Erection, commissioning and testing of complete electro-mechanical system on “Water to Wire” Conceptmechanical system on “Water to Wire” Concept.
This typically Includes:
•Inlet Valves•Turbine up to 20 MW Capacity•Gearbox•G t•Generator•EOT Crane•Governor•PLC-SCADA•Panels•Transformers•Switchyard Equipment
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Typical scope of supply
i f C i & i li i
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Supply and Erection of Draft Tube
Erection of Casing & Pit liner in progress at site
Typical scope of supply
Power House Crane Inlet pipes with BFV and dismantling joint
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dismantling joint
Typical scope of supply
Complete turbine with gear box and t
Control room, Panels
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generator
Typical scope of supply
Switch Yard
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Small Hydro Projects
References
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KBL : Contribution To Green Energy
Sr No Type of turbine No of Projects No of Units Total MW
1 Horizontal Francis 20 44 95.05
2 Vertical Francis 01 01 03.50
3 Horizontal Kaplan 12 24 37.10
4 Vertical Kaplan 04 06 30.11
5 Horizontal Pelton 01 02 04.00
TOTAL 38 77 169.76 MW
Total capacity addition by KBL : 169.76 MWTotal capacity commissioned by KBL : 100.86 MW
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Location map of KBL Hydro Sites
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2 X 2 MW Ranni Perunad Small HEPHorizontal S Type Tubular Kaplan Turbine
Head : 6.3M ( Gearbox-generator Assembly)
Discharge : 39 m3/sRunner Dia : 2800mmGenerator RPM : 750 RPM
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2 X 2.45 MW Darna Hydro Power PlantHorizontal S Type Tubular Kaplan Turbine
Head : 19.43mDischarge : 15.90 m3/s
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Runner Dia : 1600mmGenerator RPM : 750
2 x 2 MW Periyar Vaigai-I Hydro Power Plant Horizontal S Type Tubular Kaplan Turbine
Capacity : 2x2000 kW
Head : 11.5 m
Discharge : 20.7 cumecs
Runner Dia : 2050 mmRunner Dia : 2050 mm
Rated Speed : 250 RPM
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2 x 6.5 MW Ankhe Ka Nak HEP,Vietnam : Vertical Kaplan Turbine
Capacity : 2 x 6500 kWRunner Dia : 1750 mmRated Head : 36.5 mRated Speed : 428 rpm
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Rated Speed : 428 rpmDischarge : 20.78 cumecs
3-D Model of complete turbine
2 X 5.50 MW Konal Hydro Power Plant Vertical Kaplan Turbine
Capacity : 2 x 5500 kWDesign Head : 50 mDesign Head : 50 mMax Head : 60 mDischarge : 12.7 m3/sec Rated Speed : 600 rpm
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Runner assembly during installationView of Generator with Oil Header
Vertical Kaplan Turbine-Kasari HEP
Capacity : 1x 2500 kWHead : 34 mDischarge : 9.2 cumecsRated Speed : 600 rpm
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Runner Blade assembly at Works Generator Top with Oil Header
1 x 3607 KW Zho Suwei Hydro Power PlantVertical Kaplan Turbine - Taiwan
Head : 13.86 mDischarge : 29.95 m3/sRunner Dia : 2440 mmRunner Dia : 2440 mmRated Speed : 240 RPMType of turbine : Vertical Kaplan
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Horizontal Francis Turbine
Nugu II HEPSechi HEP Nugu -II HEP2 x 750 kW Horizontal Francis Runner Dia. 780mm, Head 28 m
Sechi HEP2 x 2250kW Horizontal Francis Runner Dia. 660mm, Head 134.85 m
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Horizontal Twin Jet Pelton Turbine
Twin Jet Pelton Turbine 2 MW Panavi HEP
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2 MW Panavi HEP Bucket PCD-1386 mm
New Concept : Pump as Turbine (PAT)
Pump as Turbine (PAT) is a cost-effective solution forgeneration of power instead of actual turbines mainly fordecentralized power generation.
For small Hydro in the range of 5 to 100 kW, KBL hasdeveloped the capability of supplying “Pump as Turbine”with generator set in stand alone mode.
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Pump as Turbine (PAT)
Different configurations of PAT
Benefits of PAT:Lower initial cost as it is a standard pump (almost half thecost of conventional hydro-turbine of equivalent size)
Off the shelf product
Simple and sturdy construction
Easy maintenance as pumps have fewer parts than turbines
Maintenance personnel experience in pumps operation can aswell be used
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Kirloskar Brothers Limited: Butterfly Valves for Hydro Power Stations
3000 mm Turbine Inlet Valve 2100 mm Turbine Inlet ValveCustomer : Tamil Nadu Electricity Board
Periyar Vaigai HEP ( 2 x1.25MW ,Stage II,III & IV)
Y f S l 2009
2100 mm Turbine Inlet ValveCustomer : DLI Power (India) Pvt. Ltd.Darna HEP ( 2 x 2.45MW )Year of Supply :2010
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Year of Supply :2009
Kirloskar Brothers Limited: Butterfly Valves for Hydro Power Stations
Size : 1800 mm Butterfly ValveProject : MWRA,USAApplication : Turbine Inlet and Turbine by passYear of Supply: 2005
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Kirloskar Brothers Limited:Largest Butterfly Valves for CW System
Size : 3800 mmProject : JP NigreeApplication : CWSYear of Supply : 2013
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KBL USPs for Small Hydro Projects
• Good range of hydraulic models in Francis, Kaplan and Pelton turbines
• Highly efficient turbine models with proven design and robust performance
• Wider Sales and service Network and Strong Brand image to leverage upon
• Total hydro power solution available under one roofy p
• In-house design, Engineering and manufacturing facilities with Asia’s largest hydraulic testingcentre with TQM Approach
• Strategic tie-up with major OEM’s for efficient back up
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Website - www.kirloskarpumps.comE-mail - [email protected]
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