We were called on by one of the Auto Giants in the country in 1994. This company had plans for large-scale expansion, revolutionary in the country at that time. New mid-sized cars in Petrol and Diesel versions were planned to be produced and they had ambitious plans for launching a revolution in world's Automobile Arena.

They were about to buy an additional couple of centrifugal Compressors of 4000 and 5500 CFM and they wanted to ascertain the compressor capacity as well as Shop-wise consumption for their internal accountability. Their past experience with flow meters from other manufacturers was not good at all and they wanted high reliability for measuring Compressed Air accurately.

INCONEL's Approach:

We studied the application, their requirements, their operating culture conditions and the piping layout. It was found that they had in total, more than 125 km proposed pipelines in their plant. In the existing 96 km stretch there were heavy leakages in their headers and piping of the Plant.

It was observed that operators were misusing air for comfort cooling during summers! The existing flow meters were not working properly and providing incorrect and erratic readings.

There was always confusion about consumption of Air in the plant as the consumption and flow readings never matched, not even close to the Compressed Air Generation.

INCONEL's Stepwise Solution and Implementation:

We looked into the Project as an opportunity for us. We collected the facts, operating procedures and operating conditions. We carried out preliminary education for the operating staff and advised the management that not only accurate measurement but training personnel is also essential, as well as arresting all non-productive losses (leakages etc.)

Following steps were taken to provide a comprehensive solution:

• Project team was formed and operating personnel were trained with proper information.
• INCONEL Flow Meters were installed.
• Leakage Analysis was carried out using Flow Meters.
• Leakage causes were identified and fixed.
• Leakage Analysis was carried out another time to confirm lower leakage figures.
• Most efficient compressors in the Compressor House were identified using Flow Meters and operation of these was recommended.
• Specific Power per 1000 SCFM was calculated using Flow Meter and Electrical KW meter.
• Metered Flow v/s Production was charted to identify Compressed Air intensive products and operations.
• Air consumption for various plant-intensive processes was benchmarked and control was advised for further reduction in non-productive losses.
• Management Review and feedback from various departments was taken for further improvement of overall efficiency of shop and maximizing savings in utilization of Compressed Air.

Inference:

INCONEL Vortex Flow Meters provided the client with following advantages:

• Complete Accountability of Compressed Air Generation and Consumption within 3% (Present peak Generation is 47000 SCFM)
• Minimizing Header leakages from 12.5% to less than 1%
• Reducing non-productive leakages from 22.5% to between 7.5 to 10.5%
• Reduction up to 4 times as before in Compressed Air consumption in some product variants (Earlier cost per product was 4000 - 4300 INR reduced to 780 to 1100 INR depending on quantity produced)
• Most economical compressors were identified for specific production demands.

A Major Industrial Development Corporation, with chemical industrial estates spread over 1400 square kilometers and supply piping of more than 300 kms length; was trying to install reliable water flow meters for more than 15 years. Several consultants, manufactures, dealers were approached in the past but none were able to provide good results. The flow meters for major incoming and distribution pipelines were completely replaced more than five times, but there was no consistent data for the incoming water and distribution data could not be consequently recorded correctly.

The Industrial Development Corporation had literally become a museum of old flow meters! The irrigation authorities would levy a fine frequently as the agreements stated that water lifting charges shall be paid as per the metered quantity. If the meter failed, then 100% of the sanctioned quota would be charged; or 1.25 times the sanctioned quota would be charged if the meter was out of order and a properly functioning one was not installed within 30 days.

Major flow meter manufacturers were invited for discussion and the issue of correct water flow measurement was raised. The conditions laid down by the Industrial Development Corporation were that the manufacturer must provide free service & maintenance for 3 years and payment would be staggered in 50+20+10+10 % installments. Due to proposal of staggered payment terms, almost all manufacturers were hesitant to take on the project; moreover, no manufacturer/dealer would comply with the condition of free service and maintenance for 3 years!

The Industrial Development Corporation wanted maintenance free flow meters which would easily integrate into their operating conditions. They were also ready to modify or completely change the pipelines for getting desired results. It was essential to get accurate meter readings so that the water lifting charges could be worked out correctly. Also the effluent discharge could be estimated for assessing the activities for statutory requirements.

INCONEL's Approach:

We approached the Industrial Development Corporation, reviewed the issues faced, studied the existing type of flow meter installed and determined the root cause of failure in these flow meters.

The major Head Works, Pump Houses, Treatment Plants were inspected and the operating conditions were taken into consideration. Failure pattern and causes were discussed with the client and we suggested appropriate remedies.

The pipelines and flow patterns in the pipelines was modeled and studied. Strategies were decided for avoiding future flow meter failure. It was also observed that at some locations pipelines were partially flowing. These being undesirable for metering, appropriate solutions were recommended to the client.

INCONEL's Stepwise Solution and Implementation:

We discussed the issues faced by the client and drafted an action plan. At first, all incoming raw water would be measured. Secondly, the quantum of treated water would be measured and lastly, water in major distribution pipelines would be measured.

Since air in partially filled pipelines causes faulty meter readings, the client was advised to modify such pipelines where flow measurement was planned. Optimal locations for the flow meters were selected and necessary arrangements were made for installation.

We requested the client for data such as pump operating procedures, pump specifications, pump capacities, water delivery times, water requirement patterns, estimation of water requirement in major industrial lines and valve operating sequence.

Following steps were taken to provide a comprehensive solution:

• It was observed that pumps of different heads were operated in parallel, hence wasting the energy without getting any substantial output from the low head pump. The pump operating sequences were changed and devised so that pumps running in tandem would have similar operating heads.
• Full flowing lines and partially flowing lines were identified. Partially flowing lines were made full flowing by providing throttling valves, humps, modifying pipeline by reduction to appropriate size, or other suitable arrangements.
• As a primary remedial step, installation locations which have the highest impact on water balance and measurement were selected. Flow meter locations were proposed on all rising mains for raw water from head works to treatment plant inlet, treated water outlets from treatment plants and Inlets of Elevated Service Reservoir (ESR).
• The client was requested to arrest all major leakages in the pipelines using suitable means so that contamination as well as wastage could be reduced.
• Flow meters were installed and water at respective outlets was volumetrically measured and verified. During this procedure, pump current and pressures were monitored at each pump outlets and at various strategic locations.
• Flow meter readings for raw water and treated water were compared, considering leakages, back wash and water evaporation losses. The figures matched to their expected water loss figures (22%). All Possible leakages, possible branches, interconnections were once again identified and leakages were arrested. Branches were closed off and identified as proposed flow meter installation sites. Volumetric test was conducted again and the difference in figures was hovering between 8 - 15% which was acceptable to the client.
• Locations with higher losses in pipeline stretches were identified and suitable data logging systems with half hourly logs and daily report printout capability were installed for macro analysis. Flow meters in series between 15 km stretches were recommended for calculating line losses, especially on underground lines or sites where regular maintenance was not easily possible.
• We recommended installation of suitable strainers to jack wells and pump foot valves in order to avoid regular pump maintenance due to blockages from debris such as plastic bags, tree branches, leaves, rags, gunny bags, entrapments etc.
• We interacted with the client with regards to a complete review of existing leakage loss figures and proposed comprehensive solutions for minimizing all leakages. This motivated the client to monitor the system closely; and we were successful in gaining their confidence in our flow meters.
• Owing to our efforts and proven problem-solving attitude, the client contracted us for metering of the entire industrial estate; our meters have been functioning without ANY maintenance till date (more than 10 years).

Inference:

INCONEL Vortex Flow Meters provided the client with following advantages:

• Water losses could be benchmarked anew and targets of 7.5 % losses were set and achieved by the client.
• Pumps with different heads and inappropriate pumps which were installed at various pump houses were identified; correct operation was recommended leading to annual energy savings of more than 1,360,000 INR.
• Several leakages were detected and fixed, leading to enormous savings in electricity and water bills.