• Indian Pump Industry has more than 500 manufacturers with worker strength of over 30,000 producing 1 million pumps valued at Rs.12 billion. During the period 1978-94 pump industry has maintained an average growth of 15% p.a. The pump manufacturers are able to meet 84% of the domestic market demand and export pumps worth Rs.2 billion in 1997-98. It services all sectors of the Indian Industry viz. Agriculture, Public Health Engineering, Water supply, Chemical and process industries, Refinery and Petrochemical, Paper, Steel, Mining, Power Generation, Food Processing pharmaceutical, Sewage and Effluent treatment etc.
   

• Pumps account for 30% of the power consumption in the country. Thus, efficient operation of pump system can yield substantial savings. The industrial Pump-motor system is a major determinant of cost of production in the industry by way of capital investment and running cost. Not only the pump and drive selected for optimal performance, but pump-motor system as a whole should be efficient and reliable and reliable.
   

• TIFAC has therefore, commissioned Techno-market survey on industrial pumps and motor systems. Selection of pump-motor system would differ from one industry to another due to changes in application parameters, process parameters and liquid characteristics. Hence, it will not be practical to cover all industries in a single study. In this study Municipal Wastewater Treatment industry is taken as the focus industry.
   

• Different pump technologies are available for transporting liquids under different operating conditions in the industry. The centrifugal pump technology, which works on a simple principle cover 85% of industrial applications. The high velocity head imparted to the liquid by rotation of impeller is converted into pressure due to increasing passage area of the volute.
   

• The popularly used variations of CENTRIFUGAL PUMP TECHNOLOGY are:

• POSITIVE DISPLACEMENT PUMPS have a positive sealing line formed between the pump elements and the liquid is displaced along this sealing line by movement of the pumping element. The pumping element may have reciprocating or radial motion. Different pumps working on this principle are;

• The capacity and pressure range as well as material options of different types of pumps described above is summarized in Annexure I. Table 5.3 & 5.4 compare total lifetime cost of different pumps for two typical applications in Sewage treatment industry.
   

• Presently, the Indian market for centrifugal pump for industrial application is estimated to be Rs.65 million growing at a annual rate of 8%. The awareness level amongst user industries regarding application of positive displacement pump is lower as compared to centrifugal pump technology. This is also depicted by the fact that in India share of positive displacement pump in the domestic market is approximately 10% which in international market is approximately 20%. Market for positive displacement pump in India is valued at Rs.1.2 million. Piston / Plunger Pump has the largest share in this market followed by Screw pumps and Gear pumps.

• Preliminary step for selecting a pump starts with estimation of capacity and differential head. Depending upon application, liquid and process parameters described above, type of pump is selected. This requires matching of different operating parameters with pump characteristics. Table 3.1 indicates type of pump to be used for commonly encountered liquids in different industries.

• Having decided the type of pump to be used, pump sizing is done. Usually, pump manufacturer does the Pump sizing from the sizes available in his production programme.
  
  For centrifugal pump, care is taken to select a pump size in which the duty point is close to the best efficiency point of the pump.
  
  For positive displacement pump, the limitation on pump speed is considered based on parameters of viscosity, abrasion or NPSHA. The pump size, which gives the desired capacity within the above speed limit, is selected.
   

• In both, Centrifugal as well as Positive displacement pump, the material of construction is determined by the chemical and abrasion characteristics of the liquid being handled at the pumping temperature. Appendix 1 lists variety of liquids and suitable material of construction options. Shaft sealing option is finalised in consultation with Packing / Seal manufacturer considering above factors.
   

• AC induction motors are the most widely used prime mover for industrial pumps. AC induction motors of different construction and mounting configuration are available. The motors can be foot, flange or wall mounted. Different motor enclosures are :

• Presently, selection of motor for driving the pumps is carried out with involvement of consultation 15% of cases pertaining to new projects. In 45% of cases, pump set complete with motor is procured from pump manufacturers while the balance purchases involve procurement of motor by the user organisations.
   

• Indian manufacturers are producing motors of all types, which are comparable to those in the international market. Abroad, development of high efficiency motors has helped reduce energy losses in the motor. Energy efficient motors cost 15% to 30% higher than comparable standard motors but depending upon the application, the higher initial cost can be recovered by savings in the cost of energy.
   

• Variable speed drive is used for pump having variation in discharge rate and provides power saving. Different types of variable speed drives are available, viz. Pulse Width Modulated inverter, Eddy current or slip coupling drive, Switched Reluctance Drive etc. Variable frequency drives are proven to be advantageous due to their higher efficiency, capability to integrate with drive control software.
   

• Variable speed drive can regulate pump flow by consuming lesser energy in comparison to conventional method of using throttling valve on Pump discharge line. Savings in Power cost due to energy conservation by use of Variable speed drives can pay back the additional investment in cost of drive in a short span of time.
  Installation of variable speed drive requires that the site is well ventilated, free from corrosive fumes and radio frequency interference. Multiple pumps can be run by operating a single drive or individual drive with each pump can be installed.
   

• In India, use of variable speed drive with pumps is limited at present due to:

• Abroad, favourbale experience of variable speed drive for power conservation in high HP equipment has led to development of micro drives. These are low cost drives for lower power rating pumps.
   

• The pump and motor have to be matched for optimal performance. The torque-speed characteristics of the motor and pump should be matched to ensure availability of starting as well as running torque for the pump. The moment of inertia for the pump motor system ahs to be considered to determine the acceleration time for the motor to attain full speed. The starting torque of the motor is influenced by method adopted to start the motor. DOL starting provides higher starting toque in comparison to star delta starting.
   

• The pump and motor are connected through flexible coupling which transmits the power. The coupling while transmitting power, takes the load of axial misalignment. Different types of flexible couplings available in India include tyre type coupling, pin and bush coupling, gear type coupling, spider coupling, spacer coupling etc.
   

• Certain pumps are complete with motor like Submersible Pumps. The pump is close coupled with a motor, which is designed to operate while submerged in the liquid to be pumped. The motor is filled with oil and separated from the pumped liquid by a mechanical seal. This motor may be coupled to multi stage centrifugal pump or non-clog centrifugal pump for handling raw water, drinking water or sewage / effluents respectively.
   

• The shaft sealing is often a cause of concern to plant designers particularly when the liquid being handled is highly obnoxious / toxic or hazardous. Seal-less pumps have been developed to cater to the requirement of this market segment. There are two types.

• Seal-less pumps are used in nuclear power plants, refrigerant pumping, high temperature liquid handling, pumping of hazardous chemicals.

• Consultants and pump manufacturers perceive that 28% of users can effectively and independently select pump. Related to operation and maintenance of pump-motor system, the percentage of users in similar category is much higher (71% and 90%). Consultants have elaborate vender registration and evaluation procedure. In the bid evaluation process, different technical parameters are compared by Consultants. Some of the consultants apply price loading for higher power consumption to lay emphasis on pump-motor system efficiency and equate pumps having higher running cost with those having lower running cost. However for spares consumption, no such equalisation procedure is presently being adopted for bid evaluation.

The above practices need to be corrected to optimise performance of pump-motor system.

• Pump manufacturers should focus on application of new materials for manufacturing Pumps with better performance, in terms of efficiency as well as reliability. In the international market, variety of high performance alloys and Non-metallic pumps are offered. For corrosive duties, Plastic materials and for abrasive liquids, Ceramic coating or pumps in ceramic construction have proved successful.
  
  Pump manufacturers in co-ordination with Regional Research Laboratories / Defence Laboratories / Material Science Laboratories for developing pumps in non-conventional materials.
   

• Gear Pumps manufacturers should develop High precision Spinning pump, which are being imported at present and are required in large nos. by Man Made Fibre Industry Apart from design, manufacturers to focus on manufacturing aspects to achieve close tolerances for high metering accuracy.
  
  Gear Pump Manufacturers to work on this development and take assistance for machining from Tool rooms established with German collaborations.
   

• Use of submersible pumps in sewage industry should be increased. This decision can be taken where new pumping stations are being planned or replacement of existing pumps is contemplated.
  
  Sewage Board/Municipal Corporation – Drainage/Sewage Treatment Department
   

• Peristaltic Pump is not manufactured in India. Although manufacturing of this type of pump is not tricky, the material of hose or tube has to be such that it can withstand repetitive cyclic stresses for long service life. In long-term perspective, efforts to develop this pump should be directed towards solving this problem. In the short run, import of tube and manufacture of other components to produce it in India can be initiated.
  
  Pump manufacturer or other industrialist can venture into production based on feasibility study.
   

• Awareness of applicability of Positive Displacement pumps has been found to be low due to which centrifugal pump is preferred by users. Most positive displacement pump manufacturers in the country are small/medium scale units. Joint efforts should be undertaken by them to increase awareness as well as train users for their product range. Application Engineering support provided to users by some manufacturers like Roto Pumps Ltd., has received good response and helped in increased usage of Positive displacement pump.
  
  Manufacturers of Positive Displacement Pumps to plan promotional measures and provide application engineering assistance.
   

• Positive displacement pumps are manufactured and tested as per proprietary standards. Some of the consultants conduct testing of pumps as per API 676. Comprehensive standards & guidelines for PD Pumps should be published.
  
  BIS may undertake the work in consultation with Positive Displacement manufacturers.
   

• Presently Magnetic Drive pumps are available indigenously through one or two manufacturers only. These manufacturers have collaboration with foreign manufacturers. This technology holds promise in future and indigenous capability should be built in this field. At first, pumps operating at normal temperatures may be developed by utilising experience of eddy current drive manufacturers.
  
  Centrifugal Pump manufacturers to develop Magnetic drive pumps in association with Eddy Current drive manufacturers for normal temperature and simple liquids.
   

• Canned Motor pumps are being manufactured in the country by only one manufacturer at present. More manufacturers should enter this field. Since cost and time required for development of technology would be high, route of technical collaboration with foreign manufacturers may be explored.
  
  Pump manufacturers or other industrialists should put up facilities after feasibility study and tie up with foreign manufacturer.
   

• Development of high efficiency motors should be undertaken by Indian motor industry. For development of better grade of steel for stampings to reduce losses, help from material research laboratories and steel industry can be taken.
  
  The motor manufacturers in consultation with IIT and Material Laboratories / Regional Research Laboratories / Defence Laboratories and help from steel industry.
   

• A cooperative effort in Research and Development has been initiated in Coimbatore, where SiTarc (Small Industries Testing and Research Centre) has been set up to provide services to small units. Based on this expereience, a cooperative Research & Development organisation for Pumps may be initiated since majority of Pump manufacturers are in small scale and cannot afford their own R&D facility.
  
  Indian Pump Manufacturers Association can take the lead role to set up such a unit in consultation with Si Tarc and Pump and Pump manufacturers.
   

• Whereas many units of organised sector have adopted ISO 9000 Quality Assurance systems, in the small-scale sector, it needs to be adopted at a fast pace. This would go a long way in improving quality of pumps of small-scale units and enable them to enter International market as well.
  
  Indian Pumps Manufacturer Association can canvass amongst it s members and arrange awareness cum training course in association with Si Tarc or other Quality Management Consultancy organisations.
   

• The user industries should re-evaluate the duty parameters for pumps installed in their plant. In a big process plant, such an exercise will be costly as well as time consuming. It is suggested that based on annual power consumption of the Pumps, an ABC analysis may be applied. Top 10% of Pumps (by number), that consume maximum power on annual basis, should be taken up in the first phase for energy conservation exercise. Wherever feasible, pump and motor should be modified to operate close to their best efficiency point.
  
  User Industries to undertake such exercise in association with Pump manufacturers to optimise performance of existing Pump-Motor systems.
   

• Awareness regarding incorporation of Variable speed drive with Pump should be accelerated. Suitable duty concessions to reduce price of Variable speed drives may be considered. Pumping applications, where variations in load characteristic are known to occur should be identified. All new procurements of pump for such applications should include variable speed drives. Wherever, Pumps for such applications are operating with fixed speed motors, a time bound plan for incorporating the variable speed drive has to be drawn up.
  
  Variable speed drive manufacturers to take the lead for canvassing use of VSD. User Industries to undertake the exercise in association with Pump manufacturers to identify potential applications for using variable speed drive. Govt. of India to consider duty concessions for Variable speed drive manufacturers.
   

• User industry should adopt predictive techniques like vibration anlaysis for pre-empting pump-motor system breakdown. Further, use of spurious spares should be avoided to achieve better efficiency and higher service life of Pump-Motor system.
  
  Maintenance wing of user industries should undertake this exercise.
   

• Presently the procurement procedure of many users lays emphasis on purchase price. Appropriate weightage for technological factors should be incorporated for technological factors should be incorporated. Total Life Cycle criteria should be used for bid evaluation so that Pump-Motor efficiency, Spares consumption, reliability etc. of different makes of pumps are properly assessed and compared.
  
  User Industries and Consultants to modify existing bid evaluation process.
   

• Pump manufacturers should impart training to actual operators in user organisation, so that he understands the significance of various parameters affecting Pump-motor performance. This would ensure proper installation, operation and maintenance of Pumps, reduce occasions of Pump misuse / abuse and reduce downtime.
  
  Pump manufacturers to organise training modules at work site / manufacturing unit with the help of user organisations.
   

• Government of India has made it mandatory for Limited companies to declare Energy conservation measures undertaken by the company in their annual financial statements. This has put Energy conservation measures in the agenda of top management level. However, it has to pervade down to all levels. It would be apt to consider implementation of energy audits at periodic intervals by independent organisations to have more focussed action in this regard.
  
  Government of India to formulate policy in consultation with Industrial bodies like CII, ASSOCHAM, FICCI.