C.R.S. Sundaram
Secretary, Southern India Engineering Manufacturing Association
Coimbatore, India
Pump industry in India
Special criteria for motor and pump design
Small industries testing and research centre (SITARC)
Product quality and performance
Types of pumps, performance range and price
Spares, accessories, availability and supply
Service assistance for installation and maintenance
Joint venture with local private people
Conclusion
Acknowledgements
India's economy is based mainly on agriculture and it is the backbone of the country. India's agriculture depends upon the timely monsoon and the amount of rainfall in any year. To avoid the uncertainty and vagaries of the monsoon, farmers in India resort to various methods of irrigation. India, being a vast country with much variation in geographical conditions, needs several irrigation techniques.
In areas of shallow water levels (1-6 metres head) axial flow or mixed flow pumps are used to lift water. Where water levels are at 6-40 metres head or on river sides, mostly radial flow pumps are used.
For deep bore wells submersible or jet or compressor pumps are used depending on head and discharge requirements and on availability of water in the bore well (yield).
The first electric motor in India was manufactured in Coimbatore in 1930 and thereafter the motor pump industry expanded rapidly there. Today 60% of India's requirements of domestic and agricultural pumpsets are made in Coimbatore. The Southern India Engineering Manufacturers' Association (SIEMA) (established in 1952) has 215 members, most of whom manufacture motors and pumps of various types. Indian pumps are made according to the specifications of the Bureau of Indian Standards (BIS). Coimbatore (with 1.2 million population) is also famous for Textile machinery manufacture and is rated sixth in the World. It is called the "Manchester" of South India due to the presence of hundreds of spinning mills, cloth and garment manufacturing units in and around Coimbatore. Besides Coimbatore, Ahmedabad, Baroda, Calcutta and Dewas are the other places where agricultural pump industries are situated. Similarly Rajkot, Agra and Kolhapur are famous for oil engines and Rajkot alone accounts for 50 percent of engine production.
Apart from the general requirements for motor and pump design such as rating, power factor, head, discharge and efficiency, the following factors are to be considered during design of pumpsets.
TABLE 1 Production particulars
|
Product type |
Quantity per year |
Value |
|
Single phase monoblock pumpsets 0.5 HP to 2 HP range |
2 million sets |
|
|
Three phase monoblock pumpsets 2 HP to 30 HP range |
600 000 sets |
$ 500 million |
|
Submersible pumpsets 3 HP to 30 HP range |
600 000 sets |
|
|
Diesel engines up to 10 HP |
200 000 engines |
|
|
above 10 HP |
12 000 engines |
|
1) In India, the three phase electricity power supply to villages varies from 240 - 450 volts with a 47.5 to 51 cycle frequency (standard 415 volt and 50 cycle frequency). Average power supply is 6 to 8 hours daily during summer and most of the time, power supply is around 240 - 300 volts. In the single phase, voltage varies from 140 - 250 volts.2) During summer the ambient temperature is 35° to 40 °C with dry humidity, when heat dissipation by motors or engines is poor. Hence pumpsets are designed for such extreme conditions.
3) The literacy level in Indian villages is very low as is the economy. Consequently, people cannot afford to spend on the maintenance of equipment.
Hence, motors, pumps and engines are designed for easy installation, trouble free operation, and easy maintenance for a long service period.
This Centre was set up in 1986 for testing motors, pumps, monoblocks, submersible pumps, raw materials and for calibration of instruments. SIEMA contributed an 8 000 m2 piece of land to SITARC where the testing centre is now functioning. The present cost of the land is approximately US$ 500 000.
SITARC has the following divisions and facilities:
Mechanical, electrical, materials testing and meteorology divisions
Research and development, design and engineering divisions
HRD/consultancy/information cell
Prototyping products and tools in model tool room
SITARC is approved as a research centre by the Ministry of Science and Technology, Government of India. It is accredited by NABL in the disciplines of mechanical, electrical, chemical and fluid flow and recognized by the Bureau of Indian Standards for ISI testing. Test certificates are recognized by the Export Inspection Agency, RITES, Ministry of Defence, State Electricity Board and the State Water and Drainage Board.
SITARC Pump Institute funded by UNDP, UNIDO, Government of India and the Government of Tamil Nadu, is in the process of setting up the most modern pump testing institute. The cost of the project is US$ 5 million.
The BIS assists exporters and industry to meet international standards and quality specifications for global acceptance through its standards formulation, certification, technical and other related activities. BIS is actively involved in the International Organization for
Standardization (ISO) and International Electro-Technical Commission (IEC) and also participates in various technical committees of ISO and IEC.
Product quality begins from the selection of raw materials. The BIS has defined materials specifications for each component of pumps and motors and has specified time schedules for calibration of gauges, meters and other tools used in regular testing of pumps. All industries are required to keep calibration records of their equipment and meters.
It is mandatory that qualified and properly trained technicians and inspectors are appointed to conduct testing. Most industries have their own quality control system which are used during the manufacturing stages of each component. A few SIEMA member units are beginning to obtain ISO 9001 and ISO 9002 system certification. Medium and large scale industries use the latest model CNC machines and fully computerized testing facilities to achieve the desired quality.
BIS has issued separate standard specifications for each type of pump. Similarly, testing facilities for agricultural, jet and submersible pumps are also specified by BIS to be followed by the industries.
Each pump manufactured will undergo the following testing procedure before despatch:
Routine test for Motor:
1) No load current, watts, speed (clock wise and anti clockwise)
2) Breakaway test to find starting torque
3) Full load test of watts, amps, speed, power factor, efficiency slip and temperature
4) For single phase motor, test for moisture proof and current leakage for user safety
Routine test for Monoblock in addition to motor test:
5) Test for overall efficiency of the monoblock
6) Test for guarantee of performance at duty point
7) Overload test in operational range
Because of such a stringent quality control system, pumpsets thus manufactured will have high reliability and superior performance.
1) Axial flow pumps
2) Monoblock pumps - single phase (240 Volts)
3) Jet centrifugal combination pumps
4) Monoblock pumps - three phase (415 Volts)
5) Submersible pumpsets
6) Direct coupled or belt driven centrifugal pumps
Axial flow pumps
Axial flow pumps or propeller pumps are used for a head range of 1-6 metres and give high discharge. No priming is necessary for this pump and it operates at 80-90 percent of pump efficiency.
|
Capacity |
Head Range (cm) |
Output Ips |
|
5 - 30 HP |
1 - 6M |
60/300 |
Prices for Axial flow pumps vary depending on the requirements of head and discharge.
Single phase 2880 rpm centrifugal monoblocks
These pumpsets are easy to install, lightweight, ruggedly built and designed for trouble free operation. They are of monoblock construction with a common shaft for the motor and pump. High efficiency of these pumps minimizes power charges. Numerous applications include irrigation of small land holdings, gardens, domestic water supply and circulating systems. Motors are made of TEFC body and covers are of cast iron with capacitor start and run, Class "B" insulation running at 2880 RPM and enclosures with protection IP44 & IP 55. Pumps are of end suction, centrifugal design. Casings are of cast iron. Impellers are bronze and dynamically balanced. These Monoblocks are fitted with high quality mechanical seals for long reliable life.
|
Capacity |
Head range (m) |
Output LPM |
Average price FOB Durban ($) |
|
0.5 HP |
6 - 20 |
220/70 |
105 |
|
1.0 HP |
6 - 25 |
400/75 |
135 |
|
1.5 HP |
6 - 30 |
440/90 |
165 |
|
2.0 HP |
8 - 30 |
480/150 |
182 |
Jet centrifugal pump combination sets
These pumpsets are used in borewells and openwells where suction depth is 8 - 60 metres. They are easy to install on borewells of 75 mm (3") and larger. As there are no moving parts inside the borewell jet units, maintenance is easier than with submersible pumps. Jet units are available in many sizes for various suction lifts.
|
Range |
Suction head range (m) |
Output LPH |
Average price FOB Durban ($) |
|
0.5 HP |
9/15 |
2000/1100 |
135 |
|
1.0 HP |
9/30 |
2700/1200 |
175 |
|
1.5 HP |
15/40 |
2500/1200 |
205 |
|
2.0 HP |
15/50 |
2900/1100 |
233 |
Three phase monoblock pumpsets
Motors are the TEFC 1440/2880 RPM squirrel case induction type. Pumps are the single stage, end suction type and are fitted with cast iron impellers and casings. Stainless steel bushes and brass impeller locking nuts are provided at the pump end. Gunmetal gland, stainless steel studs and brass nuts are fitted to avoid rusting and to make it easy to replace asbestos packing ropes. Various models are available in monoblock range for selection to meet specific requirements.
|
Capacity |
Head range (m) |
Output LPM |
Average price FOB Durban ($) |
|
2.0 HP |
6/20 |
400/220 |
220 |
|
3.0 HP |
6/24 |
1 580/380 |
280 |
|
5.0 HP |
8/30 |
2 000/500 |
330 |
|
7.5 HP |
8/42 |
3 200/500 |
455 |
|
10.0 HP |
8/53 |
3 720/480 |
560 |
|
12.5 HP |
8/62 |
4 000/560 |
640 |
|
15.0 HP |
8/72 |
4 000/520 |
695 |
|
20.0 HP |
20/80 |
2 300/420 |
890 |
|
30.0 HP |
30/80 |
2 500/900 |
1 260 |
Three phase submersible pumpsets
Submersible motors are designed to operate with 250/450 volts, 50 Hz, 3 phase AC supply. They are fitted with wet type, water-filled, water-lubricated squirrel cage induction motors. The motor casing is of stainless steel. The starter winding is made of PVC/Polyester film, wrapped around waterproof copper winding wires. The rotor laminations are fitted with electrolytic grade copper rods, and the ends are brazed with forged copper end rings, mounted on a stainless steel shaft, which is hardened and ground to ensure long life. The shaft is supported by two sets of leaded bronze journal bearings lubricated by water. The axial thrust generated by the pump is absorbed by a thrust bearing fitted at the bottom of the motor. The motor is seated on radial seal rings.
The pump is of multistage centrifugal design, with radial or mixed flow impellers which are of bronze and dynamically balanced. The diffusers are designed to give best possible efficiency and are built into the casings with replaceable guide bushes for easy maintenance. The pump shaft is made of stainless steel hardened and ground. A strainer is fitted at the inlet of pump to prevent entry of solid particles.
Single phase submersible pumpsets suitable for 100 and 115 mm borewells are also available.
Submersible pumps can be installed in bore wells and very deep wells for irrigation schemes, domestic uses and industrial requirements. Submersible pumps are versatile and are suitable for sprinkler irrigation schemes as booster pumps.
Submersible pumps suitable for 1 50 mm bore diameter
|
Motor HP |
Price FOB Durban |
Radial flow pump price |
Mixed flow pump price |
|
3.00 |
315 |
Basic 3 stage |
Basic 3 stage pump |
|
4.00 |
328 |
pump - $ 110 |
$ 188 |
|
5.00 |
350 |
Every additional |
Every additional |
|
6.00 |
390 |
stage cost extra - $ 18 |
stage cost extra |
|
7.50 |
450 |
can offer up to |
- $ 36 |
|
10.00 |
510 |
can offer up to |
can offer up to |
|
12.00 |
580 |
20 stage |
12 stages |
|
15.00 |
620 |
|
|
Direct coupled and belt driven centrifugal pumps
Direct coupled and belt driven centrifugal pumps are single stage, radial flow end, suction type with horizontal shaft and vertically split casings. Pumps are fitted with pulleys or with flexible couplings, to be driven by electric motors or diesel engines. Direct coupled pumps are supplied with a common base plate for fixing the drive units.
Direct coupled and belt driven centrifugal pumps
|
Size in |
HP reqd. |
Head range (m) |
Output LPM |
Average price FOB Durban ($) |
|
64 X 50 |
3.0 |
9/15 |
800/500 |
130 |
|
75 X 65 |
5.0 |
9/18 |
110/600 |
140 |
|
75 X 75 |
5.0 |
9/15 |
1 440/900 |
140 |
|
100 X 75 |
5.0 |
6/13 |
1 600/1 000 |
150 |
|
100 X 100 |
5.0 |
6/12 |
2 000/1 200 |
220 |
|
125 X 125 |
7.5 |
6/13 |
2 700/1 800 |
290 |
|
150 X 150 |
10.0 |
6/10 |
4 000/2 000 |
310 |
Diesel engine
Vertical four stroke cycle, single cylinder compression ignition "water cooled"/"air cooled" cold start diesel engine
Diesel engines are designed as prime movers for agriculture, with high efficiency, low fuel and lubricating oil consumption. Grade: 15 and Grade: 20 cast iron and EN 9 materials are used in the manufacture of these engines. Rigid inspection of components at every stage of the assembly makes every part easily interchangeable. Each engine is tested thoroughly for speed, output and fuel consumption according to the BIS specifications.
Thermo - Syphen or a fresh water system is used for water cooled engines. A blower is attached with a fly wheel for air cooled engines. Single cylinder diesel engines are manufactured up to 10 HP and for above 10 HP, multi cylinder diesel engines are manufactured according to specifications.
|
Single Cylinder Water Cooled Engine |
Average Price FOB Durban ($) |
|
5.0 HP 1 500 RPM |
420 |
|
6.5 HP 1 500 RPM |
430 |
|
7.5 HP 1 500 RPM |
480 |
|
10.0 HP 1 500 RPM |
615 |
|
Single Cylinder Air Cooled Engine: | |
|
5.0 HP 1 500 RPM |
480 |
|
6.5 HP 1 500 RPM |
495 |
|
7.5 HP 1 500 RPM |
560 |
|
10.0 HP A500 RPM |
690 |
|
Double Cylinder Water Cooled Engines | |
|
10 HP |
930 |
|
13 HP |
960 |
|
15 HP |
990 |
|
Double Cylinder Air Cooled Engines | |
|
10 HP |
1010 |
|
13 HP |
1030 |
|
15 HP |
1060 |
Electrical Starters and Switches
Starters for direct-on-line or manually operated Star-Delta models are suitable for 220 and 440 v - 50 Hz, three phase or single phase - A.C. These are built-in with over load and single phase protection with bimetal relay arrangements, silver oxide bimetal contacts and other standard features to protect the electric motor from varying supply conditions.
|
|
Product Average Price FOB Durban $ |
|
Three Phase Direct ON line starters to suit 3 to 10 HP range |
39 |
|
Single Phase Direct ON line starters to suit 0.5 - 2 HP range |
24 |
|
Star Delta air break manually operated motor starters 3 to 10 HP range |
58 |
|
12.5 - 15 HP range |
64 |
Star Delta Oil dash pot manually operated motor starters
|
3 - 10 HP range |
101 |
|
12.5 - 15 HP range |
106 |
Three Phase Iron clad switches (rewireable):
|
Capacity rating |
Average Price FOB Durban ($) |
|
16 amps |
16 |
|
32 amps |
30 |
|
63 amps |
69 |
|
100 amps |
140 |
For each pump, a trouble shooting and repairing manual, installation and maintenance hand book and spare parts catalogue is supplied to help the customer understand the procedure to follow in dismantling, reassembling and ordering spare parts. Centrifugal, monoblock, jet and submersible pumps consume minimum spares during their lifetime.
The manufacturer will specify the required spares for each pump or batch of pumps ordered and these spare parts, can be supplied with the consignment. As most of the items are in regular production, any requirement can be met at short notice and delivery can be arranged.
Centrifugal pumps are easy to install and run. For submersible arid jet pumps, an installation guide book is provided with each pump.
Proper training can be provided for a few mechanics at the suppliers' premises. SITARC will also have training facilities for pump assembly, testing as well as installation techniques which can also be utilized.
Further a few engineers can be made available to train local people at various centres by organizing seminars and classes.
In India economic reforms have been in progress since 1991. Joint ventures, either in India or with African countries are encouraged, depending on the requirements. Joint venture in Africa is possible when the requirement of pumpsets by value is US$ 3 to 4 million per year. Interested parties can contact SIEMA.
It is hoped that the above information is useful. The similarity between India and Southern and East African countries in respect of soil, monsoon pattern, climate, water table, literacy levels, electric system and user method, makes Indian pumps ideal one for African countries.
ANNEXURES
1) Performance curves for single phase monoblocks
2) Performance curves for three phase monoblocks
3) Performance curves for submersible pumpsetsi) Radial Flow Pumps
ii) Mixed Flow Pumps
SIEMA is grateful to FAO for providing the opportunity to present their industrial scenario to the developing countries in Africa. Members of SIEMA also express their gratitude to Dr. R.K. Sivanappan for his cooperation and support without which this presentation would not be possible.
PERFORMANCE CURVES FOR SINGLE PHASE MONOBLOCKS (a)
PERFORMANCE CURVES FOR SINGLE PHASE MONOBLOCKS (b)
PERFORMANCE CURVES FOR THREE PHASE MONOBLOCKS
PERFORMANCE CURVES FOR SUBMERSIBLE PUMPSETS SUBMERSIBLE PUMPSET RADIAL FLOW PUMP SELECTION CHART
PERFORMANCE CURVES FOR SUBMERSIBLE PUMPSETS SUBMERSIBLE PUMPSET MIXED FLOW PUMP SELECTION CHART
