Evaluating the Potential Impact of Variable Frequency Drive Technology in Pumping Operations of Refined Petroleum Products in Kenya. A Case Study of Kenya Pipeline Company

Abstract

The research investigates the energy consumption patterns and potential for energy efficiency improvements within the Kenya Pipeline Company, focusing on the mainline pumping operations. With rising energy costs significantly impacting the company's operations, an analysis was conducted to evaluate the effectiveness of implementing variable frequency drives as an alternative to the current autotransformer, direct online, and soft starters used in pumps. The research highlights the energy consumption for pump stations on the eastern line, evaluates the current motor starters' energy efficiency, and calculates the potential economic benefits of transitioning to variable frequency drive technology. The research involved auditing the company’s major loads, distributing questionnaires, and reviewing electricity bills and throughput data for three years. The energy audit findings indicate that pumps are the main energy consumers, representing a significant portion of Kenya Pipeline Company's total energy expenses. The use of auto-transformer starters, though common, has been identified as inefficient due to high inrush currents and low power factors, resulting in significant energy losses and high operational costs. By replacing these starters with variable frequency drives, the company can modulate pump speeds based on real-time demand, significantly reducing equipment energy consumption and mechanical stress. The research presents a detailed techno-economic evaluation showing that implementing variable frequency drives could save approximately Ksh. 1,101,299,377 for the three years, with an average payback period of 5 months and energy consumption would reduce by 54,585,211 kWh. The study concludes that upgrading to variable frequency drives would align with national energy conservation goals and enhance the operational efficiency and economic viability of the Kenya Pipeline Company. Kenya Pipeline Company is recommended to prioritize this upgrade to mitigate the high energy costs and contribute to more sustainable energy management practices in the region. Further research is suggested to optimize variable frequency drive technology use and monitor its long-term benefits accurately. Keywords: Energy efficiency, motor starters, variable frequency drives,