Final Narrative Report

Project code: 2011IE12

Promoting energy efficient pumps

in industry in India: Addressing the
energy and climate change
problem
Prepared for

Shakti Sustainable Energy Foundation

India Energy Initiative, Climate Works Foundation

 The Energy and Resources Institute 2012

Suggested format for citation

T E R I. 2012
Promoting energy efficient pumps in industry in India: Addressing
the energy and climate change problem
New Delhi: The Energy and Resources Institute. 25pp.
[Project Report No. 2011IE12]

For more information

Project Monitoring Cell
TERI
Darbari Seth Block
IHC Complex, Lodhi Road
New Delhi 110 003
India

Tel. 2468 2100 or 2468 2111

E-mail pmc@teri.res.in
Fax 2468 2144 or 2468 2145
Web www.teriin.org
India +91 Delhi (0)11

Disclaimer
The views expressed in this document do not necessarily reflect the view of Shakti Sustainable Energy
Foundation. The organisation also does not guarantee the accuracy of any data included in this
publication nor does it accept any responsibility for the consequences of its use.

Contents

CHAPTER 1: PROJECT OVERVIEW ............................................................................................... 1

CHAPTER 2: TACTICS PURSUED AND OUTPUTS TO DATE .......................................................... 3
2.1 Background of pump industry in India ....................................................................... 3
2.2 Analysis of the existing policy environment and frameworks available ................ 6
2.3 Overview of pump industry in India ........................................................................... 8
2.3.1 Pump industry in Gujarat ..................................................................................... 9
2.3.2 Pump industry in Coimbatore ........................................................................... 10
2.4 Consultative workshops with stakeholders .............................................................. 11
2.5 National level dissemination workshop ................................................................... 13
CHAPTER 3: BARRIERS TO PROMOTION OF ENERGY EFFICIENT PUMP SETS AND LESSONS LEARNT
........................................................................................................................................... 15
CHAPTER 4: PRINCIPAL OUTCOMES........................................................................................ 19
CHAPTER 5: POSSIBILITIES OF FUTURE COLLABORATION AND KNOWLEDGE SHARING........... 23
REFERENCES: ............................................................................................................................ 25

Annexures
Annexure 2.1:

Estimated energy saving potential by adoption of energy efficient pumps in

different end-use sector

Annexure 2.2:

Agenda of the two consultative meets

Annexure 2.3:

Summary of discussions at the consultative meets

Annexure 2.4:

List of participants of consultative meets

Annexure 2.5:

Agenda of the national level dissemination workshop

Annexure 2.6:

List of participants at the workshop

Chapter 1: Project overview

Pumps are used to lift or convey water and other liquids in a variety of applications in
industries, agriculture (irrigation), municipalities (water supply and waste water),
automobiles and buildings (houses, commercial buildings and HVAC). About 10% of the
total electricity produced in the world goes into pumping. A substantial amount of the
energy consumed in pumping can be saved by adoption of energy efficient pump seta. TERI
had submitted a proposal undertaking a study on Promoting Energy Efficiency in Pump
Industry in India: Addressing the Energy and Climate Change Problem (submitted on 10
January 2011; revised 5 May 2011) to Shakti Sustainable Energy Foundation (SSEF) India
Energy Initiative of the Climate Works Foundation. The proposal was accepted by Climate
Works Foundation and a one year project was granted to TERI for undertaking the proposed
study.
The overall goal of the study is to identify policy instruments to accelerate the penetration of
energy efficient pump sets in India. The study aims to achieve the following objectives:
1.
Explore the possibilities and conditions for improving the efficiency of pumps used in
industries in India.
2.
Elaborate appropriate measures and policy instruments for enhancing the efficiency of
pumps used in industries in India.
3.
Stimulate cooperation and communication among energy specialists, pump
manufacturers and users, and government officials as a first step towards
strengthening the efficiency of pumps used in industries in the country.
This narrative report provides an overview of the pump industry in India and elaborates
action to promote energy efficient pump sets in India.

The term pumps set used in the report refers to the combined pump (hydraulic component) and electric motor
(drive component)

Chapter 2: Tactics pursued and outputs to date

TERI interacted with a cross-section of stakeholders including industry association
representatives, leading manufacturers of pumps, government representatives and industry
consultants in Ahmedabad, Rajkot and Coimbatore. The objective of the meetings was to
understand the market for energy efficient pumps in India and working of the BEE star
labelling scheme. Meetings were also conducted with leading pump manufacturers and
suppliers of castings to pump industry. Two regional consultative meets were also
organised under the project by TERI, one for the Western region at Ahmedabad in January
2012 and second for the Southern region at Coimbatore in April 2012. The findings from
these interactions are summarized in the following sections:

2.1 Background of pump industry in India

Pump sets are widely used to lift and transfer water in the agricultural, domestic, municipal
and industrial sectors. Pumps can be classified into different types such as submersible
(mixed and radial flow), open-well submersible (monoset), centrifugal monobloc, back pull
centrifugal, sewage pump and mud-pump. The major applications and types of pumps
manufactured in India are shown in figure 2.1a.
According to industry estimates, the Indian pump industry has more than 2,000
manufacturers, employs 120,000 people and produces about 4.5 million pumps per annum.
The United States, China, Germany, Japan and India are the major pump manufacturing
countries in the world. India also exports pumps to countries located in Africa, Middle East
and South Asia. The Indian pump industry is characterized by the coexistence of large
number of small and medium scale enterprises (SMEs), alongside some large Indian as well
as multinational manufacturers. A number of these SMEs are in the unorganised sector. The
turnover of the organized pump manufacturing industry ranges between Rs.3, 500 to 4, 000
crores. However, the turnover of the Indian pump industry as a percentage of the global
pump business is still small (just 1.75%) compared to the population (17.3% of the world
population). This low base coupled with the brisk pace of investments in the infrastructure
and industrial sectors promises to accelerate the growth of the Indian pump industry in the
future.
Studies and various pilot initiatives undertaken in the pump sector suggest that there is
considerable potential to save energy by stimulating the manufacture of energy efficient
pump sets and replacing the low inefficient pump sets operating in the field by more energy
efficient models. Apart from the design of the pump itself, other factors like pipes, cables,
panel boards and the quality of power impact the performance of pumps. Therefore, it is
critical to focus on the entire pumping system so as to achieve greater efficiency.

Promoting energy efficient pumps in industry in India

Chemicals
Special
applications

Food processing
Pharmaceutical

Construction

Mud
Centrifugal
monoblock
Peripheral
(self- priming)

Domestic
Submersible
Jet

PUMPS
Horizontal split
casing monoblock

Municipal

Sewage pump
Dewatering

Centrifugal
monoblock

Industry

Positive
displacement
Back pull

Submersible

Agriculture

Centrifugal
monoblock
Open-well
Submersible

Figure 2.1a Type of pumps used by various sectors

Promoting energy efficiency in pump industry in India

The electricity consumption by different sectors in India is shown in Figure 2.1b. The
agricultural sector in India is the third largest consumer of electricity in India after industry
and domestic sectors. The sector also accounts for the highest number of pumps (nearly
42%) used in India. A large number of pump manufacturers in India are in the unorganized

Figure 2.1b Electricity consumption by sector in India (2009-10)[1]

sector. The demand for pumps, and consequently the energy consumption in pumping has
been increasing rapidly in recent years. Depletion of groundwater level and scarcity of water
availability for different sectors has contributed to the growth in the energy consumption.
Different types of pumps are used depending on the water table ranging from small
centrifugal pumps in areas having shallow water levels to submersible pumps in areas
having a deep water table. The buying decision of pumps individual farmers is often
influenced by availability of cheap power and government subsidy schemes.
Use of submersible pumps is relatively a recent phenomenon. Since power to the some
sectors is either free or highly subsidised, the user is not concerned about energy efficiency
of the pump. Promoting energy efficient pump sets is beneficial in terms of lowering the
overall power demand and reducing the subsidy burden on the states without sacrificing the
service obligation to this sector. Promoting energy efficient pump is thus promising method
of targeting subsidy to the beneficiary farmers. A study commissioned by BEE, estimated
that the installed base of agricultural pumps in the year 2004 was 14.2 million and that it is
growing annually at the compounded annual growth rate (CAGR) of 6%. Assuming this
projected growth rate, this population would have grown to over 20 million in 2012. These
pump sets account for a significant percentage of the total electricity produced in India
(estimated at around 21% of total electricity production)[1].
At a national level, adoption of energy efficient pumps by different sectors could lead to a
huge saving in energy. A broad-brush estimate of the saving potential was made by TERI.
This estimate was based assuming that all the pumps used in relevant sectors of the
economy viz. agriculture, industry, domestic residences, public water works and
commercial buildings convert to energy efficient pumps. The estimate point to an electricity
saving potential of about 45,456 GWh per year which is equivalent to 8% of the total

Promoting energy efficient pumps in industry in India

electricity sold in India in 2009-10. Table 2.1 summarizes the total as well as sector-wise
energy saving potential by adoption of energy efficient pump sets. The energy saving
potential is equivalent carbon dioxide saving of nearly 37 million tons per annum.
Table 2.1 Energy saving potential by adopting energy efficient pumps in different end-use
sector
Sector
Agriculture
Industry
Domestic
Public Water Works
Commercial
Total

Energy consumption ( 200910) in GWh

119492
209209
141845
12552
58971
363606

Energy saving potential in

pump in GWh
34141
5230
2837
2069
1179
45456

The assumptions and basis of this estimated energy saving potential is provided in
Annexure 2.1.
The electricity consumption in pumping will be increasing briskly in the coming years.
Unfortunately, energy savings in pumps have largely been overlooked. Apart from some
attempts on pilot scale, there have hardly been any holistic plans to reduce energy
consumption and/or improve energy efficiency of pumps. One of the reason for lack of
initiatives in this area is that pumps are produced by a large number of small and medium
scale units and electricity for certain sectors is highly subsidised. Public procurement
schemes of state government can be designed to promote energy efficient pumps as
explained in Chapter 4.

2.2 Analysis of the existing policy environment and

frameworks available
In order to create awareness about energy efficient pumps among consumers, BEE has
launched a voluntary star labeling of pump sets in India. The BEE star labeling scheme is
the major policy framework for promoting energy efficient pump sets in India.
The focus of the BEE Star Labelling Program is to create awareness on the economic benefits
of energy efficient appliances, which provide quick payback on relatively higher capital
costs; to provide information on the energy performance of appliances so that
users/consumers can make informed choices at the time of purchase; and thereby, to spur
both demand for and manufacture of energy efficient appliances. At present star labelling is
mandatory for air conditioners, refrigerators, tubular fluorescent lamps and distribution
transformers and voluntary for products like pumps, TVs, fans, etc.
BEE drives star labelling scheme by activities at various levels by:

Setting standards for energy efficiency for different appliances

Motivating appliance manufacturers to obtain star labels for their products

Creating market demand for energy efficient (star labelled) products

Ensuring that star label parameters are met during the manufacturing process and in
finished products (through monitoring and inspection/testing)
6

Promoting energy efficiency in pump industry in India

The BEE energy labelling scheme for pump sets covers electric mono set pumps,
submersible pump sets and open well submersible pump sets. The star labelling is only
applicable for 3 phase pump sets from 1.1 kW (1.5 HP) to 15 kW (or 20 HP). The label is
linked to the energy efficiency of the specific pump model above Bureau of Indian Standards
(BIS) norm. The referred BIS are IS 9079:2002 for electric mono set pumps for clear, cold
water and water supply purposes, IS 8034:2002 for submersible pump sets, IS 14220:1994 for
open well submersible pump sets and IS 11346:2002 for testing purposes of the above
mentioned pump sets.
The link between star labeling and BIS norm is given in Table 2.2.
Table 2.2 BEE Star Rating Plan for pump set
No. of Stars
1
2
3
4
5

Overall energy efficiency above BIS norm*

Upto 5% higher
5 10 % higher
10 15 % higher
15 20 % higher
20 25 % higher

*Overall efficiency of the pump set is including the efficiency factor for induction motors. The overall efficiency is
calculated as per IS 14220:1998, IS 8034:2002 and IS 9079:2002 for pump sets and IS 12615:2004, IS: 4029 1967, IS
325: 1996 for induction motors.

The additional qualifications for BEE star labeling are as follows:

a.
BIS License mark certification for the product is mandatory.
b.
Quality Certification such as ISO 9000 shall be preferred.
c.
Only BIS/BIS approved lab/NABL approved lab test report is acceptable.
A sample of the BEE label to be affixed on the name plate of the pump is shown in figure 2.2.

Figure 2.2 Sample of BEE star label for submersible pump sets

A labeling fee is charged by BEE. The labeling fee includes a one-time registration fee, a fee
for each star labeled pump set produced.
7

Promoting energy efficient pumps in industry in India

There is a system to monitor and verify the performance of the pump sets by picking
samples from the field. BEE or its designated agency can pick-up samples for testing from
either manufacturing facility or warehouse or the dealer for testing on a random basis.
Parameters for verification and testing are guaranteed performance of nominal volume rate
of flow, nominal head and overall efficiency of the pump set at the duty point. However, the
sampling and testing from field samples is not happening regularly.

2.3 Overview of pump industry in India

The main pump manufacturing hubs in India are Ahmedabad and Rajkot in the state of
Gujarat and Coimbatore in the state of Tamil Nadu (see figure 2.3). Apart from these two
pump manufacturing hubs, pump sets are also produced by large-scale manufactures like
Kirloskar, Crompton, KSB, Grundfos, Matter & Platt, Jyoti, Shakti, Worthington, etc.
Meetings were conducted with pump manufacturers in Rajkot and Ahmedabad in Gujarat and
Coimbatore in South India to understand the barriers to promotion of energy efficient pumps.
An overview of the pump industry in these two regions is provided here.

Ahmedabad
Rajkot

Coimbatore

Figure 2.3 Main pump manufacturing hubs in India

Promoting energy efficiency in pump industry in India

2.3.1 Pump industry in Gujarat

In Gujarat, farmers have been facing severe water crisis in many area. A few enterprising
among them accepted the challenge to find a solution to the problem and started
manufacturing pump sets. It had begun with trial and error method with small scale
manufacturing and since 1994 it has geared up to a successful industry itself.
There are about 400 pump manufacturing units in Ahmedabad and about 200 pump
manufacturing units in Rajkot. However, majority of these units are in the unorganized
sector and are involved in assembling of pump-sets from bought-out parts. The unorganised
sector manufacturers are very small in size and cater to the local market requirements. These
units produce submersible pump sets mainly and centrifugal pumps.
Four main categories of submersible pump sets: V3 (i.e. for 3-inch bore well) V4 (for 4-inch
bore well), V6 (for 6-inch bore well) and V8 (for 8-inch bore well) are produced in these
clusters. For arid regions, large diameters like V8 and even V10 (for 10-inch bore well) are
also produced. The power rating of the electrical motor in commonly produced pumps
varies between a few horse power (HP) to 10 HP. However, power rating can go as high as
100 HP to 200 HP especially for the pumps used in arid areas where the water table in very
low.
While Ahmedabad manufactures cast iron (CI) pumps, Rajkot is the hub for production of
stainless steel (SS) pumps. There are just a handful of manufacturers of branded pump
manufacturers in these two clusters. The non-branded manufacturers concentrate on selling
pump sets as a commodity and at prices which are about 30% lower than branded
manufacturers. The non-branded manufacturers are not concerned about maintaining the
quality. While the branded pump manufacturers have their own hydraulic design and use
their own pattern for casted sub-components, the non-branded manufacturers use common
pattern produced in bulk by local foundries. The non-branded pumps are usually based on
the design of popular local branded pumps like Lubi or KSB.
Some of the leading manufacturers of branded pumps in Ahmedabad are the following:

Lubi

Varun

Sabar

Amrut

Ariant
Some of the major branded pump manufacturers in Rajkot are the following:

Falcon

Kiwi

Flowtech

Silver

Angel

Alidara

Topland

Gujarat Forging
Apart from submersible pumps, the pump manufacturing clusters in Gujarat also produce
centrifugal pumps, sewage pumps and mud pumps for different end-use sectors. Most of

Promoting energy efficient pumps in industry in India

the pumps manufactured in Gujarat are sold through distributors to end-users. The
government also procures pumps for distribution among farmers in backward areas. A
couple of years back, the Government of Gujarat through Gujarat Energy Development
Agency (GEDA) introduced a scheme to procure energy efficient pump-sets. The scheme
was aimed to promote energy efficient pump sets. Under the scheme, farmers were offered
replacement of old pump set with new energy efficient ones at a subsidised rate. Some of the
technical requirements for qualification under GEDA scheme were the following:

BIS certificate for pump set

The testing facility at manufacturers site to be as per the BIS requirement.

The efficiency of the pump set should be a certain percentage above BIS
The scheme was good and contributed to energy savings. However the scheme was
withdrawn since it suffered from some drawbacks. The drawbacks of GEDA scheme are
highlighted in Chapter 3.

2.3.2 Pump industry in Coimbatore

Coimbatore was a hub of textile industry, mainly cotton, in early twentieth century.
Although, man has been using pumps of some type or the other for 4000 years, electricity
driven pump was first manufactured in India in Coimbatore in 1930. By 1959, all the major
pump designs were introduced into commercial products. The industry has grown rapidly
in the region.
At present there are about 450 manufactures of pump sets in Coimbatore and the cluster
accounts for nearly 48% of the pump sets manufactured in India. Submersible pump sets
account for the major share of the pumps (about 65%) produced in the cluster followed by
pump sets for domestic applications. Most of the pumps manufacturers in the cluster
concentrate on high volume centrifugal and submersible segments. Hence there are
relatively few manufacturers in the cluster producing specialised pumps like concrete volute
pumps (for hydro power applications), drainage pumps, sewage pumps, split casing
centrifugal pumps and vertical turbine pumps. Most of the submersible pump sets
manufactured in Coimbatore use gun metal or SS impeller since they have better corrosion
resistance properties. Plastic impellers are also used especially for smaller clear water pump
sets.
The leading pump set manufactures in the cluster are the following:

Aquasub

Texmo/Tarro

CRI

Mahendra

Sugna

Best Engineers

Perfect Engineers

Deccan pumps

Sharp

V-Guard

Rievera pump

10

Promoting energy efficiency in pump industry in India

Some of the above mentioned manufacturers are OEM suppliers to reputed brands like
Crompton, KSB, Grundfos etc. Almost all the manufacturers are producing centrifugal
pumps for high head and low discharge. Axial flow pump typically have efficiencies upto
92%. Production of industrial axial flow pumps for low head and high discharge is not
common in Coimbatore. Other positive displacement pumps, particularly rotary types, used
for niche applications, peristaltic, progressing cavity and rotary lobe pumps are also not
produced in the cluster. The high development cost of specialised pumps for industrial use
and dominance of large pump manufacturers like Mather & Platt, Kirlosker, Jyoti,
Worthington and KSB in this segment have been the major deterrence to their production in
the cluster. The pump industry in Coimbatore needs to move beyond small sized
centrifugal pumps to higher value added production of industrial pump sets.

2.4 Consultative workshops with stakeholders

In order to obtain the views of stakeholders, TERI and SSEF organized two interactive
meets, in Ahmedabad on January 25, 2012 and in Coimbatore on April 17, 2012. Pump
manufacturers and industry associations representing the Ahmedabad and Rajkot clusters in
Gujarat and Coimbatore cluster in Tamil Nadu were invited to the meeting. The agenda of
the two consultative meets are given in Annexure 2.2.
Both the workshops were well attended. Mr S P Garnaik, Energy Economist and in-charge
of the Standards and Labelling program, Bureau of Energy Efficiency (BEE) chaired the
panel discussion in the Coimbatore meet. The presentations and discussions focused on
issues related to BIS standards and BEE Star Labels for promoting energy efficient pumpsets. The major discussion points with industry are summarized below.

Providing incentives for adoption of energy efficient pump-sets

Need for incorporation of return on investment criteria rather than lowest capital cost
in government procurement schemes

Expansion of star labeling to cover all categories of pump sets and pump sets which
are more efficient than five star

Need to introduce traceability of BIS and BEE labeled pump sets

Policy advocacy to modify BIS standards with respect to testing, material of

construction and installation with the aim of improving efficiency of pumping systems

Need to strengthen NABL certified laboratories and reduce testing time period

Need to support innovation (R&D) of energy efficient pump models

Capacity building of pump-set users on energy efficient pump-sets

Conducting a study to monitor performance of pumps operating in the field jointly

with BEE, BIS and industry
Detailed summaries of discussions at the two workshops are presented in Annexure 2.3. The
list of participants of the two workshops is provided in Annexure 2.4.
Some photographs of the Ahmedabad meet are provided in Figure 2.4a and Coimbatore
meet are provided in Figure 2.4b.

11

Promoting energy efficient pumps in industry in India

Figure 2.4a Photographs of the consultative workshop at Ahmedabad

Figure 2.4b Photographs of the consultative workshop at Coimbatore

12

Promoting energy efficiency in pump industry in India

2.5 National level dissemination workshop

In order to disseminate the findings of the study, TERI, in partnership with BEE and SSEF,
organised a national level dissemination workshop on 30th July 2012. In order to attract
participation of all relevant stakeholders including leading pump manufacturers from
different parts of the country, BEE called an extraordinary meeting of their technical
committee for pumps under their standards and labeling programme on the day of the
national level workshop. The agenda of the workshop and list of participants are provided
in Annexure 2.5 and Annexure 2.6 respectively.
TERI made a detailed presentation of the findings of the study in the workshop. Mr S P
Garnaik, BEE moderated the discussions which followed. All the major recommendations
emanating from the study were deliberated in detail and accepted by the participants. BEE
complimented TERI and SSEF for taking up this study and coming out with good
recommendations which can be implemented. BEE also mentioned that it would be willing
to consider positively proposals developed by TERI, SSEF and industry taking forward
some of the recommendations of the study. Specifically, three of the activities which can be
taken-up for future investigation which were discussed at the workshop and found to be
acceptable to stakeholders are mentioned below.
1.
Study on quantification of energy losses in pumps as a result of poor quality of grid
supply power.
2.
A pilot study to test and compare the actual and design efficiency of pumps and
motors of BEE labelled pump-sets.
3.
An action research project development and demonstration of super-efficient pumps.
BEE indicated that it would be willing to consider funding such a proposal of
submitted jointly by a research/academic institute and industry association under
their R&D budget for supper-efficient appliances in the next five year plan.
The recommendations have been further elaborated in Chapters 4 and 5 of this report.
A few pictures of the event are provided in Figure 2.5.

13

Promoting energy efficient pumps in industry in India

Figure 2.5 Photographs of the National Level Dissemination Workshop

14

Chapter 3: Barriers to promotion of energy

efficient pump sets and lessons learnt
The major barriers to promote energy efficient pumps and some of the possible remedial
measures are highlighted here.
1.
Often the pumps perform poorly in the field because the right pump for the required
head and water quantity is not selected. There is also no standardisation of piping,
panel and cabling to be used with the pump. There is a need to focus on training and
capacity building of all stakeholders (pump users, distributors, dealers and so on) on
proper selection and installation of pump sets.
2.
Use of impellers fabricated from SS is not common. Fabricated SS pumps are light in
weight and have higher energy efficiency. Most of the manufacturers still use cast
impellers. Cast iron impellers lead to a sharp deterioration in pump efficiency over
time as highlighted in Box 3.0 [5].

Time:
Pump Type:
Application:
Location:

Box 3.0
Deterioration of performance with time with CI impellers
2 years
0.5Hp Self Priming Regenerative
Pumping well water to overhead tank
Goa

Field data

Date
15/06/06
15/09/06
15/03/07
15/10/07
15/06/08

Static
suction
head (m)
4
3.5
5.2
3.7
3.8

Static
delivery
head (m)
10
10
10
10
10

Time for
2000 liters
(hrs)
1.2
1.3
1.4
1.7
2.0

Power
input
watts
470
450
430
420
420

Energy
consumed
in filling
kW
0.56
0.60
0.62
0.70
0.82

Yearly
consumption
on kWh
168
180
187
210
247

%
increase
0.00
7.2
4.1
13.7
22.1

The energy consumption of the cast iron centrifugal pump lifting water increased by 22% within a
short time of two years. The result of field studies show that there is a sharp deterioration in the
performance of a pump using cast components over time.
The reason for the increase in energy consumption was the increase in clearances within the pump
due to corrosion of cast iron components. Use of thermoplastics like PEEK (Poly-Ether-Ether-Ketone)
with carbon fibres in place of cast iron leads to excellent wear and corrosion resistance and better
channel design leading to energy efficiency improvement by about 50%.

3.

A major barrier to adoption of energy efficient pump sets in the agriculture sector is
the fact that power is either free or highly subsidised for farmers in India. Hence, there
is little incentive for the farmers to pay more to install energy efficient pump sets.
Under this scenario, government bodies and state utilities must assume the major role
of developing innovative schemes which promote the manufacture and use of energy
efficient pump sets.

15

Promoting energy efficient pumps in industry in India

4.

5.

Drawbacks in present public procurement schemes. Interactions with the industry

revealed that some of the present public procurement schemes like that of GEDA
(Gujarat Energy Development Agency) suffered from many drawbacks which resulted
in the withdrawal of the scheme. Some of drawbacks of the scheme included improper
selection of manufacturers of energy efficient pumps, unrealistic monitoring and
verification procedures and unattractive payment terms for the manufacturers. Also,
the operating cost of energy over the lifetime of a pump if often not considered during
the selection of pumps. Good branded manufacturers are reluctant to participate in
government tenders.
Issues regarding BIS certification.
The industry felt that there are many lacunas in the present BIS certification scheme.
Since the BEE star labelling of pump sets is closely linked to BIS certification, these
issues also effect the growth of energy efficient pump manufacturing in India. These
issues are summarized below.
a.
The supply voltage at site often can dip to as low as 250V, as compared to
standard voltage conditions of 420V. Motors are not designed to withstand low
voltages, which also contributes to high rate of failures. The BIS certification
needs to incorporate testing as well as safety aspects of large fluctuations in
operating voltage.
b.
The durability of the pumps is not considered in BIS certification. Overloading
of motors is common leading to failures of the electric motor during operation.
Overloading happens due to less active materials like copper and poor quality of
stamping used in the electric motor. Field data was collected on the causes of
pump motor failures in the field in Rajkot cluster under a TERI-SIBDI project
(Providing project development support for enhancement of energy efficiency at
Pune, Kolhapur and Ankleshwar clusters). The common reasons of motor
failures reported in Rajkot cluster is shown in Figure 3.0.

Figure 3.0 Common causes of motor failures

c.

The material of construction (MOC) of different pump parts (like impeller, shaft,
bearing bush, quality of thrust bearings and motor components stampings,
cooling medium) are not specified in the BIS standards. Failures in pump
components like bushes, bearings, etc. is high. For example, 15% failure of thrust
16

Promoting energy efficiency in pump industry in India

bearing was reported in submersible pumps where axial thrust is high. Bushes
are used in submersible pumps to act as sleeve between two impellers. There is
scope to improve the quality of the bushes. Possibility of incorporation of MOC
needs to be considered.
d.
There are a limited number of BIS/NABL accredited laboratories to test pumpsets in some regions like Gujarat. In addition, the testing capacities of the present
laboratories are limited. This leads to long waiting period in getting pumps
tested for BIS certification.
e.
BIS is also not adequately staffed in all regions. For example, there is one office at
Rajkot for certification of all ISI products for Saurashtra and Kutch Region. This
result in delays in the process of getting ISI certificate and BEE label. This can
considerably delay the launch of the product.
6.
Issues regards BEE star labelling scheme
a.
The BEE star rating is only limited to 3 phase pump-sets of up to 15 kW (or 20
HP) only. Hence a large number of single phase pumps and pumps higher than
20 HP are excluded from the ambit of star labelling scheme of BEE.
b.
There are no incentives for manufacturers to improve their efficiency beyond 5
star at present.
c.
The BIS standard for mixed flow submersible pump sets is very stringent as
opposed to a relaxed efficiency standard for radial flow submersible pumps.
Hence, most of the mixed flow submersible pumps, even of reputed
manufacturers, are having 2 or 3 star rating, while almost all the models of radial
flow submersible pumps are 5 star rated. This aspects needs to be looked into
while revising the standards.
d.
The manufacturers have to fill and upload the application forms for BEE
labelling online. The manufacturers are not well versed with the use of e-filing
and hence they are dependent on local service provider/consultants for this
work.
e.
The overall cost of the pump set goes up for BEE labelling due to higher product
cost. This can be a barrier to marketing of these pump sets.
f.
At present there is no traceability of BEE/BIS labeling of pumps which leads to
misuse of the labels.
7.
Barriers to get BIS/BEE label for tiny and small manufacturers of pump sets
a.
The manufacturers have to maintain testing facility at site and calibrate
instruments and gauges as per the specifications on the standard. Hence, the
manufacturing cost of the labels is increased as compared to non BIS products.
b. BIS certified units are exempted from excise duty till a turnover of Rs 1.5 crore but
non BIS-certified units are liable to pay 8 per cent excise duty on every pump set
produced. Hence small units, that have not availed BIS label, are forced to market
their products through formal channels. BIS licencing should be modified to make it
more attractive for tiny and small manufacturers. A cluster based approach can be
adopted for these units to bring them under the BIS fold.
c.
The application fee of BEE label can be a barrier for tiny and small
manufacturers.
d.
The manufacturers require technical support to upgrade their pump models.
e.
Sourcing of quality sub-components like stampings is a barrier for small scale
manufactures. The purity of copper may vary when procured from local
suppliers in small quantities.

17

Chapter 4: Principal outcomes

The demand for pump sets is rising rapidly in India. India is likely to emerge as the fourth
largest manufacturer of centrifugal pump sets. However, the growing usage of pumps in
India demands optimal energy efficient design for saving energy. Indian pump set industry
faces many challenges both with regard to improving the quality of pumps as well as
manufacturing of energy efficient pumps.
Some challenges in improving the energy efficiency of pump sets produced in India and
recommendations to improve the situation are highlighted in this chapter. The overall
observations and recommendations are summarised in Table 4.1.
Table 4.1 Observations and recommendations to promote manufacture and use of energy
efficient improve the quality of pumps and for manufacturing of energy efficient pumps
S.No.
1.

2.

Observations
Operating cost of energy over
the lifetime of a pump is far
greater than the cost of the
pump itself. Greater awareness
of the concept of life cycle
energy cost and pump
efficiency needs to be created
among policy makers, state
electricity boards and
consumers.

Recommendations
a. Public procurement programs of state governments
should be modified to encourage pump selection
based on lowest life cycle cost rather than lowest
capital cost.
b. State electricity boards/distribution companies
should introduce programs to replace existing
submersible agricultural pumps with energy efficient
stainless steel pumps. The energy saved by the new
pump will pay back its cost within a few months as
shown below:

Vast energy and cost savings

can be realised by raising the
efficiency and improving the
quality of pumps produced in
India through appropriate
legislations. These legislations
should be aimed at raising the
pump efficiencies over time

Average size of submersible pump

7.5
(kW)
Rating of equivalent EE stainless steel
5.5
pump (kW)
Saving by replacing conventional
2 kW
pump with EE pump (kW/hr)
Average operating time for pump
3,000
(hours/year)
Energy saving per pump (kWh/year)
6,000
Unsubsidized energy cost (Rs/kWh)
5
Monetary saving (Rs/year)
Rs 30,000
Cost of new energy efficient pump
Rs 20,000
Payback
8 months
India needs to emulate some of the successful policy
measures undertaken in other countries. For example,
BIS standard for radial flow (high head and low
discharge) pump set is quite lenient. Almost all the
major manufacturers are able to achieve five star
rating for their radial flow models. Consequently
there is no incentive for a pump manufacturer to
improve their pump models further and achieve a

a.

19

Promoting energy efficient pumps in industry in India

S.No.

3.

Observations
and to eliminate manufacture
of sub-standard quality pump
sets. Legislation for raising
pump efficiencies now exists in
Korea and China. The
European Commission, as part
of its Energy Using Products
Directive, has targeted the
raising of efficiencies of water
pumps. Europump, which has
been instrumental in assisting
the EC in this task has
proposed a method for
eliminating bad performers.

Recommendations
higher efficiency than that required to get a five star.
The BIS standards for pump sets needs to be revised
from the point of raising the efficiency bar for radial
flow pump-sets.

Development of new energy

efficient stainless steel pump
sets requires R&D. In addition,
manufacture of such pumps
requires considerable
investment in development of
tooling and manufacturing
processes.

b.

While revisiting the BIS standard, the reasons for

why manufacturers are not able to achieve more than
three star for mixed flow (low head and high
discharge) pump sets needs to be understood.
Technical support needs to be provided to
manufacturers of mixed flow pumps, if needed.

c.

The BIS licencing method should be modified to

adopt a cluster based approach for SME sector.

a.

Innovation centres should be established at cluster

level to strengthen R&D and provide technical
assistance to local industry. These innovation centres
should be established in partnership between
government, industry, and academic/research
institutes. International and national level expertise
should be pooled during conceptualisation,
development and implementation of these centres.
R&D focus areas should include assistance in design
and manufacture of (i) energy efficient stainless steel
submersible pump sets (ii) multi-stage centrifugal
pumps (iii) axial flow pumps (iv) submersible pumps
with vaneless diffusers (v) high specific speed pumps
(vi) variable speed drives (VSD) (vii) materials for
efficient pumps and (viii) training in advanced pump
design using simulation software like CFD.
State level energy benchmarking competitions should
be organised to promote interest in energy efficient
pump sets.

b.

4.

Material of construction
directly influences the
efficiency of the pump set. Use
of poor quality material result
in poor energy efficiency and
performance of the pump sets.
For example, motor efficiency is
a function of the quality of
stamping, grade of the copper
rod and winding wires used in
the electric motor. Use of less
active material like copper in
motor by reducing core length

a.

b.

Presently the BIS standard for pump sets does not

specify the grade/quality of the material of
construction to be used for different components.
This needs to be corrected in consultation with
technical experts.
Education of consumers is needed on selection and
installation of pump sets.

20

Promoting energy efficiency in pump industry in India

S.No.

5.

6.

7.

Observations
and thickness of winding wires
is common. This results in high
current density leading to faster
rise in temperature of the motor
with consequent reduction in
its operating life. Similarly, use
of cast iron impellers and poor
quality of bush results in faster
deterioration in pump
efficiency.
Overloading of the motor is
common to achieve a higher
star rating. In other words,
fitting a smaller sized motor
than what is needed to a pump,
results in higher overall
efficiency and this star rating.
Overloading of a motor not
only leads to high failure rates
resulting in financial loss for
the consumer it is a national
loss as well since an overloaded
motor results in reduction of
operational efficiency and life
of the motor.
Most of the manufacturers of
pump sets, especially those in
the small and medium scale,
compromise on quality
assurance and in-house testing.
Important tests like torque,
surge, high voltage and
humidity tests on motors and
dynamic balancing of bearing
for pumps are often not
followed. Hence, percentage of
motor failures due to winding,
torque and insulation are high.
Mechanical failures due to
failure of thrust bearing and
bush are also common.
The pump efficiency is defined
at a particular head for a
specified voltage. However
these parameters are seldom
achieved in the field.
Moreover, the water head for
submersible pumps varies

Recommendations

Instead of specifying overall efficiency of a pump, the star

rating criteria should specify that an energy efficient pump
should be coupled with an energy efficient motor. The
efficiency of both system (motor and pump) should be
notified on the nameplate separately.

BIS standards should incorporate reliability/durability

(deterioration of pump efficiency with time) criteria. To
ensure implementation, third party inspection and energy
auditing can be done on a sample basis for operating
pump sets.

Hence performance testing of pump sets should be made

mandatory over a range of head and voltage conditions.
This was included in the BIS standard in the past. It was
mandatory for all pumps to be tested over at least five
discrete points over a range of head and voltage (+/- 25%
of the duty point) for a specific speed. The variation in
efficiency over this range should be within 5-10%.

21

Promoting energy efficient pumps in industry in India

S.No.

Observations
between the summer and
monsoon season.
Low supply voltage leads to
higher current and hence
higher I2R losses in the pump
thus reducing the overall
energy efficiency of the
pumping system. This energy
loss can be minimised by
maintaining the quality of
power supply.

Recommendations

At present, no reliable data is available on the energy loss

occurring due to low voltage. A detailed study needs to be
undertaken to analyze in a holistic manner the economic
loss at the national level resulting from low voltages in
agricultural feeders. A study to analyse the impact of low
voltage on energy loss and also reduction life of the motor
needs to be initiated.

22

Chapter 5: Possibilities of future collaboration and

knowledge sharing
The study has revealed several interesting and insightful facts related to production, testing
and operation of pump sets in India. These insights have been used to develop some
practical recommendations to improve the policies which govern the performance of pump
sets. A substantial amount of energy savings will result if the recommendations are
implemented. For this, there is a need to engage into a dialogue with the concerned
stakeholders (government officials, industry associations, progressive manufacturers and
technical experts). This project was able to initiate the dialogue with relevant stakeholders.
However, the dialogue needs to be continued. This will help ensure that some of the
recommendations get incorporated in the policy framework governing pump set
manufacture in India.
Some of the other possible areas of future collaboration are mentioned below.
a.
Low supply voltage leads to higher current and thus higher I2R losses in pump sets
thereby reducing the energy efficiency of the motor. This is energy loss at a national
level. The energy loss due to low voltage can be minimised by maintaining the quality
of grid power supply. There is a need for conducting a study at a national level to
quantify the economic loss resulting from low voltages in agricultural feeders. The
study can be initiated by BEE and Shakti in collaboration with an industry association
(SIEMA) and a leading technical institute (TERI). The study should be based on field
work and aim at measurement and analysis of the impact of low supply voltage on
energy loss and life of the pump motor.
b.
Another observation during the study was the high rate of pump failures in the field
mainly on account of mismatching of the pump and the electric motors. Ideally, the
kW rating of the motor should be 10 % higher than what is required by the pump.
Overloading of electric motors leads to energy wastages as the current is restricted but
not the power drawn by the motor. This finding needs to be validated with actual
performance monitoring of pump sets. A pilot study aimed at testing of motors and
pumps separately should be undertaken in collaboration with BEE and BIS. Under the
study, a sample of leading 25-50 pumps of various brands can be collected from four
different regions. The efficiency and energy consumption of the individual pumps and
motors can be tested separately by an independent laboratory. The study will help to
establish clearly the performance of pump and motor separately and to validate the
premise that pump manufacturers are fitting undersized motors to pumps causing
overloading of the motor leading to higher current drawn and overheating of the
pumps and pump failures.
c.
Several issues related to modification in BIS standards have emerged from the TERIShakti study. For example, there are no clear guidelines on specification of material of
construction for pump sets. There is also scope for improving the performance
specifications of pump sets. Efficiency levels at different loads are specified for some
equipment like transformers. Similar standards can be introduced for pump sets too.
There is scope for incorporating standard installation procedures for pumps within
BIS. There is clearly a need for further consultation on these with industry and
policymakers. It is important that an independent agency continue to dialogue with
the relevant technical committees on pump sets of BEE and BIS in order to ensure that
23

Promoting energy efficient pumps in industry in India

some of these issues get deliberated and acted upon. This will catalyse manufacture of
quality and energy efficient pump sets in India in the future.
Sharing the knowledge with the concerned stakeholders has been an important component
of the project. To share the outcomes of the project, two consultative meets were organized
by TERI under the project in Ahmedabad in January 2012 and in Coimbatore in April 2012.
Both the consultative meets were well attended by all regional level stakeholders. In order to
interact with a wider range of stakeholders, TERI participated and made a presentation at
the National Conference on Motors and Pumps held in Coimbatore in November 2011. TERI
has also presented some of the project learnings at the 4th India-Japan Energy Forum held in
January 2012. In the future too, TERI proposes to continue sharing the learnings of the
project through participation and presentation at national and regional level knowledge
sharing platforms such as seminars and workshops related to pump industry and energy
efficiency. Efforts will also be made by TERI to sensitize policymakers on the need for
promoting energy efficiency in the pumping sector and to build upon some of the issues
identified under the study.

24

References:
1.

All India Electricity Statistics General Review 2011, CEA, Ministry of Power,
Government of India

2.

Rotodynamic pumps (Centrifugal and Axial), K.M. Srinivasan, New Age International
Publishers, 2008, 520 pp

3.

A brief history of pumps, World Pumps.com, 23 March 2009

4.

TERI-SIDBI study on Providing project development support for enhancement of

energy efficiency at Pune, Kolhapur and Ankleshwar clusters

5.

Keny Abhay, Centrifugal Pump Efficiency Improvement; Alternate Methods and

Design Methodology, 2009. Presentation at Conference on Motors & Pumps,
Coimbatore, 2009.

25

ANNEXURES

Annexure 2.1:
Estimated energy saving potential by adoption of
energy efficient pumps in different end-use sector

Electricity consumed in pumping and saving potential by adoption of

energy efficient pumps by different end-use sectors
Agriculture
Average efficiency of existing
pump sets
Efficiency improvement
potential
Average efficiency of improved
pump sets
Electricity consumption in agriculture 2009-10
Electricity consumption in agriculture after
adoption of improved pump set
Estimated energy saving potential
or
Public water works
Average efficiency of existing
pump sets
Efficiency improvement
potential
Average efficiency of improved
pump sets
Electricity consumption in municipalities 200910
Share of pumping energy in municipalities
Electricity consumption in water pumping
2009-10
Electricity consumed in water pumping after
adoption of improved pump set
Estimated energy saving potential
or
Domestic
Average efficiency of existing
pump sets
Efficiency improvement
potential
Average efficiency of improved
pump sets
Electricity consumption in
domestic sector 2009-10
Share of pumping energy in industry
Electricity consumption in water pumping 200910
Electricity consumed in domestic sector after
adoption of improved pump set

35%

(assumed)

40%

(assumed)

49%
119492
85351
34141

GWh

29%

GWh
GWh
of the total electricity consumption in
the agriculture sector

35%

(assumed)

30%

(assumed)

46%
12552
71%

GWh
(Assumed - 70% of expense is energy;
50% pumping; 20% lighting)

8966

GWh

6897
2069
16%

GWh
GWh
of the total electricity consumption in
the municipal sector

20%

(assumed)

25%

(assumed)

25%
141845
10%

GWh
(assumed)

14185

GWh

11348

GWh

Estimated energy saving potential

2837
or

Industry
Average efficiency of existing
pump sets
Efficiency improvement
potential
Average efficiency of improved
pump sets
Electricity consumption in industry 2009-10
Share of pumping energy in industry
Electricity consumption in pumping in industry
2009-10
Electricity consumed in industry after adoption
of improved pump set
Estimated energy saving potential
or
Commercial
Average efficiency of existing
pump sets
Efficiency improvement
potential
Average efficiency of improved
pump set
Electricity consumed in commercial sector 200910
Share of pumping energy in commercial sector
Electricity consumption in pumping in
commercial sector 2009-10
Electricity consumed in commercial sector after
adoption of improved pump set
Estimated energy saving potential
or
Total energy saving potential in pumps
or

2%

GWh
of the total electricity consumption in
the domestic sector

45%

(assumed)

20%

(assumed)

54%
209209
15%

GWh
(assumed)

31381

GWh

26151
5230

GWh
GWh
of the total electricity consumption in
the industry sector

3%

30%

(assumed)

25%

(assumed)

38%
58971
10%

GWh
(assumed)

5897

GWh

4718
1179

GWh
GWh
of the total electricity consumption in
the commercial sector
GWh
of total electricity sold in India

2%
45456
8.0%

Annexure 2.2:
Agenda of the Consultative Meets

Interactive meet on
Promoting energy efficient pumpsets in India
January 25, 2012
Venue:
Fortune Landmark
Ahmedabad

Objectives:
Discuss the technology and policy level barriers to promoting energy efficient pumpsets
Sharing of experiences between different stakeholders
Discussion on strategies on removal of barriers
AGENDA
Wednesday , 25th January 2012

13:00 14:00

Registration and Lunch

14:00 14:10

Welcome and meeting objectives

- Mr Girish Sethi, TERI
- Mr Shashank Jain, Shakti Foundation

14:10 14:40

Background Presentation:
Barriers and strategies for improving energy efficiency of pumpsets
- Mr Prosanto Pal, TERI

14:40 16:30

Panel Discussion:
Chairperson:
Mr Sivasubramanian Narayanaswamy
Discussants:
Experts and representatives from the pump manufacturers (4or 5)

16:30 17.30

Tea/Coffee

Interactive meet on
Promoting Energy Efficient Pumpsets
PROGRAMME

VENUE: Legend, Residency Hotel, Coimbatore

DATE: April 17, 2012

5:30 pm

Registration

6:00 pm 6:10 pm

Welcome

6.10 pm 6.20 pm

Overview of issues related to energy efficiency improvement of pump sets

Mr V Krishnakumar, Aquasub Group

6:20 pm 8:00 pm

Background Presentation
Mr Prosanto Pal, TERI
Chairperson
Mr S P Garnaik, Energy Economist, Bureau of Energy Efficiency (BEE)
Panel Discussion

8:00 pm

Dinner

Annexure 2.3:
Summary of discussions at the
Consultative Meets

Summary of the Interactive Meet on Promoting energy efficient

pumpsets in India held on January 25, 2012 at Ahmedabad

Background
Pumps are energy-intensive equipment. About 10% of the total electricity produced in the
world goes into pumping. In India, the share of energy consumed in pumping is even larger.
A substantial amount of the energy consumed in pumping can be saved by adoption of
energy efficient pump-set. TERI is undertaking a study on Promoting Energy Efficiency in
Pump Industry in India: Addressing the Energy and Climate Change Problem on behalf of
Shakti Sustainable Energy Foundation India Energy Initiative of the Climate Works
Foundation. The study aims to understand the pump market in India and existing policy
environment and frameworks to promote energy-efficient pump-sets. In order to validate
the initial finding of the study and take views of stakeholders on ways to promote energy
efficient pump-sets interactive meet was organised in Ahmedabad on January 15, 2012. A
number of pump manufacturers from Rajkot and Ahmedabad clusters in Gujarat
participated in the workshop. A summary of the deliberations at the workshop is provided
below.
Summary of the workshop
In the welcome address, Mr Shashank Jain, Shakti Foundation mentioned that the objective
of Climate Works Foundation is to contain the global temperature rise to within 2 oC. Since
pumping accounts for substantial share of the total energy consumption, a high percentage,
it is important to find ways and means to reduce energy consumption in the sector by
adoption of energy efficient pumpsets. Improving energy efficiency of pumpsets will also
help local pump manufacturers to compete in the international market.
A background presentation was made by Mr Prosanto Pal of TERI. The following issues
were flagged off in the presentation on which the views of the industry were invited.
1. Long time for testing due to limited BIS accredited laboratories
2. Should BIS standard specify quality/grade of material
3. Should BIS standard incorporate durability (deterioration of efficiency with time)
aspects
4. Need to review the BIS standards/BEE standard for mixed flow pumps
5. Is there a need to revisit the BIS/BEE standard with regard to specify pump and motor
efficiencies separately
6. Public procurement policies to promote energy efficient pumpsets
7. Need for public funded R&D on energy efficient pump sets

The presentation was followed by an interaction session with the participants. The
discussions were moderated by Mr Sivasubramanian Narayanaswamy, a pump consultant
from Coimbatore cluster.
Mr Dhirajlal Suvagiya, promoter of Falcon Pumps, a leading pump manufacturer from
Rajkot cluster highlighted some of the challenges to promote energy efficient pump-sets in
India. Mr Mushtaq M Kadri of Sabar Enterprises, a leading pump manufacturer from
Ahmedabad also presented the views of accelerating energy efficiency in pump-sets in
India.
The major challenges which emerged from the discussion which followed for promoting
energy efficient pump-sets can be divided into three broad categories- market related,
supply power quality related and technology related.
The following market related challenges and solutions were mentioned by the industry.

Pump market in India is highly price sensitive. Adoption of BEE labeling add to the cost
of manufacturing due to the additional testing and raw material costs. Hence to promote
energy efficient pump-sets the government must subsidize BEE star rated pumps. The
amount of subsidy can vary between 2-5% depending on the pump rating (say 5% for
five star rating, 4% for four star rating and so on)

The industry felt that the application fee for BEE label (Rs 25,000 lumpsum plus Rs 1,000
per model) should be reduced.

Many agricultural DSM programs launched by states governments/utilities in Gujarat,

Haryana, Rajasthan and Punjab have not been concluded due to price factors. Most of
the government tenders have targeted turnkey replacement, including erection and
commissioning of existing agricultural pumpsets. However, these schemes do not take
into account the cost of pipes and cables. Manufacturers are also reluctant to enter into
the five year maintenance contact with farmers due to operational problems like
bypassing of control systems like earth leakage etc. provided with the pump-sets.

There are very few BIS approved testing laboratories. For example in Ahmedabad there
is only one laboratory and there is a queue of 8-9 months to get the pump tested there.

The following power supply related challenges to promoting energy efficiency in pump-set
were highlighted by the industry.

The low supply voltage commonly found in agricultural feeders leads in India lead to
huge wastage of electricity. A lower voltage reduces the operating efficiencies of pumpsets (sometime to as low as 20-25%) and increases line losses (due to high I2R losses). The
minimum supply voltage should be 350 V. The quality of power supply in Gujarat is
better than other states since Gujarat has a separate 11 kVA agricultural line.

The following technology related challenges were highlighted by the industry.

The site conditions should be carefully considered while selecting the appropriate model
of pumpset.

Right selection of cable size also contributes to energy savings. The cable should
preferably be of EC grade.

The pipe casing for agricultural pump-sets should preferably be smooth HDPE pipe of
the bigger size to reduce frictional losses. Proper installation guideline provided by
National Bank for Agriculture and Rural Development (NABARD) for agricultural
pumpsets should be followed.

Of the 6200 pump models which have obtained BEE label, majority are radial flow type
(having flow rate of in the range of 400-500 lit) while a relatively smaller percentage (2025%) are of mixed flow type (high flowrate 1200-1300 lit)

There is scope for R&D especially on energy efficiency improvement of mixed flow
pumps models. The design capacities of local manufacturers are limited since the design
optimization of vane angle etc. needs to be done using design softwares.

Writing of overall efficiency of the pumpset on the name plate must be compulsory

Material of construction needs standardization. Only SS should be used for impellers

and bowl. Use of cast iron impellers leads to fast deterioration in performance of the
pump. The deterioration is especially more in radial flow pumps.

BIS testing of pumps is presently for only a discrete point. The performance testing of
pumpsets should be done over a range of head and voltage (+/- 25% of the duty point)
for a specific speed.

There is scope to strengthen the test procedures followed by existing BIS laboratory and
introduce computerized and online testing methods.

Conclusions
The following are some conclusion of the deliberations:
1) BIS licensing method should be modified to make it more attractive for micro-scale units.
A cluster based approach can be adopted for these units to bring them under BIS fold
2) State level energy efficiency bench mark competition can be organized to promote
interest in energy efficient pumpsets
3) Material of specification should be specified in BIS standard. CI components should not
be used
4) Education of major users (farmers and industry) is required on selection and installation
of pumpsets
5) The pump must be tested over a range testing for award of BIS and BEE star rating
6) Government procurement scheme must be based on return on investment (ROI) criteria
rather than lowest capital cost.
7) Mentioning of the overall efficiency of the pumpsets must be made mandatory in the
name plate.

Summary of the Interactive meet on Promoting energy efficient

pumpsets in India held on 17 April 2012 held at Residency Hotel,
Coimbatore

Welcoming the participants, Mr Girish Sethi, TERI and Mr Shashank Jain, Shakti Foundation
provided an overview of the project objectives and the importance of saving energy in the
pumping sector.
Mr V Krishna Kumar, Aquasub Group provided an overview of the issues related to
promotion of energy efficient pump-sets in India. He mentioned that SIEMA also providing
inputs to BEE during formulation of energy efficiency norms for pump sets under the star
labeling program. He mentioned that there are no incentives provided by government to
five stat rated pump sets. Since agricultural power is highly subsidized and/or free, the
farmers are reluctant to pay a higher prove for energy efficient pump sets. He also
emphasized the importance of entire pumping system in improving the overall efficiency of
the pumping system.
Mr Prosanto Pal, TERI made a background presentation on the results of the TERI-Shakti
study. The present star labeling scheme is restricted to smaller pumpsets while in arid and
semi-arid regions large size of pumpsets (up to 100-200 HP) is also used. Also, there is little
incentive for the manufacturer to make a pumpset which is more than 20 percent more
efficient than BIS standard because of there is no star labeling scheme for such pump sets.
The background presentation was followed by a panel discussion consisting of senior
representatives from government organizations and industry. Mr S P Garnaik, BEE chaired
the panel discussion. In his opening remarks, Mr Garnaik emphasized that promoting the
use of energy efficient appliances is extremely important for India. He mentioned that the
Standards and Labelling (S&L) programme of BEE covers 14 products out of which labeling
in 4 products is mandatory and 10 product is voluntary. Presently out of 7,300 MW saving
through the S&L program, about 77% is on account of air conditioners and refrigerators
alone. There is a lot of scope of the pumping sector contributing to the energy saving under
the S&L programme. In this regard the low demand of 5 star rated pumps is a major
concern.
Mr Garnaik mentioned that public procurement policies of different state governments will
charge by December 2012 and they will adopt a LCA (life cycle analysis) of savings rather
than least procurement cost as is followed at present. The change will be initiated through
DG S&D. Hence one of the recommendations of the TERI-Shakti study has already been
accepted. Maintaining the quality of power supply as emphasized by the study is an

important aspect since low supply voltage leads to higher current and hence higher I2R
losses and lower pumping efficiencies. Having more HT lines rather than LT lines would
lead to improvement in power supply quality. Other factors like trimming of impeller, use
of corrocoating and VFD which lead to higher efficiency of the pumpset needs to be
promoted. He accepted the study recommendation that there is a need to consider the pump
efficiency over a range beyond the duty point only. However changing the standards for
testing of pumpsets is not the role of BEE. Regards the recommendations related to
specifying the material of construction, Mr Garnaik felt that BEE cannot define standards
like material selection. Regards the studys recommendation to provide support to R&D
through Centres of Excellence and award scheme for promotion of energy efficient
pumpsets, he suggested that these should be further elaborated. Mr Garnaik suggested that
SDAs should be given more role and responsibility.
Mr Lakshminarayanswamy, SIEMA felt that there is very little incentive for industry to
invest in development of energy efficient models. He suggested that Ministry of Power
should support industry associations in their R&D efforts. He agreed that testing time for
pumpsets should be reduced to eight days and hence there need for more NABL accredited
laboratories in the pump manufacturing clusters. He disagreed with the study findings that
failure of pumps is a major problem and said that India is not much behind USA in this
regard. Savings from pumps depends on installation e.g. undersized pipes wastes more
energy. Hence the energy savings estimated in laboratories cannot be translated to energy
saved in the field. He recommended that TERI , BEE and BIS should work more on
systems approach and not on pumpsets alone.
R Kalyanasundaram from Tamil Nadu Pump Manufacturing Association representing the
micro/tiny pump manufactures recommended the need for educating consumers (farmers)
as well as policy makers. With the sharp drop in ground water levels, farmers are forced to
use pumps of 10HP and above. He suggested that construction of check dams should be
undertaken by the government to ensure recharging of the ground water depletion. This
approach had been quite successful in Gujarat. The Government of Tamil Nadu had
launched a scheme to replace existing pumps with EE pump sets. However the scheme
suffered from many drawbacks since tenders were awarded to few favoured manufactures
and state electricity board did not have the capacity to evaluate and select EE pumpsets. The
scheme was withdrawn after smaller manufacturers made a petition before the High Court.
The BIS mark also has its drawback since there is no traceability of the BIS label. This can
potentially lead to misuse. TNEB has made it mandatory that new pumpsets installed under
government programs should be at least four star labelled. However lack of traceability of
BEE label can lead to manufacturers passing off their in-efficient models as star labeled. He
recommended that BEE should introduce traceability of their labels in the future. He also
recommended indirect fiscal incentives like duty waivers for energy efficient pumpsets

Mr Murgesan a freelance pump expert highlighted the challenges related to design of mixed
flow impellers, acceptance of EE pumps by farmers, and voltage and frequency variations.
He recommended TERI and Shakti to take up a study to analyze in a holistic manner the economic
loss at the national level as a result of low voltages in agricultural feeders. The study should be based
on ground level work and analyze the impact of low voltage on energy losses and the overall life of the
motor.
Mr P K Mukherjee, ex-BIS, highlighted the issues in the pump and motor separately. Voltage
supply in India is 230 V for single phase and 400V in three phases. This is the practice
internationally too. He agreed that there are no clear guidelines on specification of material
of construction for pumpsets. The reason for this is due to the lack of coordination between
metallurgical and electo-technical committees within BIS. There is scope for improving the
performance specifications of pumpsets. Installation standard for pumps should
incorporated and the instruction manual it should be part of both BIS and BEE schedules.
Different efficiency levels exists for transformers and can be introduced in the case of pump
sets too. To address deterioration of efficiency over the lifetime BIS standard has
specifications to measure the dimensions after dismantling a diesel engine after certain
number of operation. Something similar can be thought of for pump sets too. The issues
which are emerging from the TERI-Shakti study can be taken-up for discussion at the technical
committee on pump sets of BIS.
In his concluding remarks, Mr Garnaik said that the issues related to modification in
standard can be take-up by BEE and technical committee of BIS. He highlighted that there is
scope to increase the awareness among consumers. BEE and industry associations like
SIEMA can cooperate in this regard. There is need for better enforcement measures to stop
spurious labeling. He felt that the state government can also help in this regard. Mr Garnaik
suggested TERI, Shakti and BEE to take-up a follow-up study to evaluate the variations in efficiency
in the field based on real time data.

Annexure 2.4:
List of participants of consultative meets

Interactive meet on
Promoting energy efficient pumpsets in India
Ahmedabad
January 25, 2012

LIST OF PARTICIPANTS
Sr.
No.
1.

2.

3.

4.

5.

Contact Person

Phone/Fax/Mobile

Mr Dhirajlal L Suvagiya
CMD
Falcon Submersible Pumps Pvt Ltd
39/4, Vavdi Ind Area
B/h Hotel Krishna Park
Gondal Road, NH-8B
Vavdi, Rajkot-360004
Mr M B Bhesania
Rameshwar Pipe Industries
Vardhaman Industrial Area
Plot No 13, Survey No. 259/2
B/h Kothariya Solvent, Kothariya
Rajkot
Mr. Vinod K Asodariya
FLOTECh ENGINEERING PVT.
LTD.
Opp. Kaneria Oil Mill
Shapar Main Road,
At Shapar (Veraval),
Dist: Rajkot
Mr Shailesh Goswami
Labh Consultancy
108, Guruprasad Complex
Guruprasad Chowk
Near H J Doshi Hospital
Rajkot-360004
Mr Mushtaq M Kadri
Marketing Manager (Tech.)
Sabar Enterprises
603-605, 6th Floor
'B' Block "Atma House"
Near Times of India
Ashram Road
Ahmedabad380009

Phone: 91-281-2370 801/ 2/3/4/5

Fax: 91-281-2374422
Mobile: 98250 84787/
9727700566/7

Email
md@falconpumps.in

Phone; 91-281-2922522
Fax: 91-281-2331184
Mobile: 98252 07562

Phone: +91 (2827) 252509,

253309
Fax: +91 (2827) 253222
Mobile: +91 9979888435

info@flotech.in

Mobile: 99258 17928

labhconsultancy@gm
ail.com

Phone: 91-79-2658 4621-22-23,

30020540-41, 32920540
Fax: 91-79-26585491
Mobile: 9374077717

technical@sabarentris
es.com

21

Sr.
No.
6.

7.

8.

9.

10.

11.

12.

13.

Contact Person

Phone/Fax/Mobile

Mr Himanshu S Shah
Q A Incharge
India Electrical And Engineering
Co.10, Kothari Estate
Opp Rustom Mill Dudheswar Road
Ahmedabad-380004
Mr Mahendra Dhaduk Patel
Madhav Engineering Co.
B/h Perfect Auto
Opp Ayu Lab
Gondal Road, Vavdi
Rajkot-360004
Mr Subhashbhai Patel
Megha Pump Industries
Maruti Indutrial Area
Near Octroi Naka
B/h Ashish Eng., Gondal Road
Rajkot-360004
Mr Rasiklona
Texprint
Opp Adarsh Estate
Rkhial
Ahmedabad
Mr Deepak L Patel
La-Gajjar Machineries Pvt Ltd
4, Shrinath Estate
B/h Amba Estate
Navneet Prakashan Road, Rakhial
Ahmedabad-380021
Mr Vishal Modusarigu
La-Gajjar Machineries Pvt Ltd
4, Shrinath Estate
B/h Amba Estate
Navneet Prakashan Road, Rakhial
Ahmedabad-380021
Mr Rojnish R Joshi
Falcon Submersible Pumps Pvt Ltd
39/4, Vavdi Ind Area
B/h Hotel Krishna Park
Gondal Road, NH-8B
Vavdi, Rajkot-360004
Mr Ketan H Kakkad
Consultant
Gujarat Industrial and Technical
Consultancy Organisation Ltd
GITCO House, Opp. Sardar Patel
Stadium
Avrangpura
Ahmedabad-380009

Phone: 91-79-5623545, 5621510,

5624154, 5625646
Fax: 91-79-5624047
Mobile: 98246 95158

Email

Phone: 91-281-2363464, 6599024

Mobile: 98250 72797

info@madhavenginee
ring.com

Phone: 91-281-2925152
Mobile: 97261 86656, 97123
43784

Mobile: 98798 57889

Phone: 91-79-22748882/
22748883/ 22782490
Fax: 91-79-22782491
Mobile: 9898861932

lagajjarpumps@yaho
o.com

Phone: 91-79-22748882/
22748883/ 22782490
Fax: 91-79-22782491
Mobile: 92277 72824

lagajjarpumps@yaho
o.com

Phone: 91-281-2370 801/ 2/3/4/5

Fax: 91-281-2374422
Mobile: 9727700579

Phone: 91-79-26569617-4618,
2656 5333
Fax: 91-79-26565279
Mobile: 9898184581

khkakkad@gitco.co.i
n

22

Sr.
No.
14.

15.

16.

17.

18.

19.

20.

Contact Person

Phone/Fax/Mobile

Mr M C Varadarajan
Commercial Manager
Amrit Engineering Pvt Ltd
Post Box No. 4141, 2nd Floor
Motilal Centre, Near Dinesh Hall
Ashram Road,
Ahmedabad-380009
Mr Bharat Davda
Foundry Technologist
FBC 24x7- Foundry Business Center
3, Haridham Sarkari Karmachari
Society,
Before Shivaji Park, Raiya Road
Rajkot 360007, Gujarat
Mr N Sivasubramanian
No. 7, Alagu Nagar
Civil Aerodrome Post
Coimbatore-641 014
Mr Gaurav Panchal
Project Officer
Gujarat Industrial and Technical
Consultancy Organisation Ltd
GITCO House, Opp. Sardar Patel
Stadium
Navrangpura
Ahmedabad-380009
Mr R S Panchal
Gujarat Industrial and Technical
Consultancy Organisation Ltd
GITCO House, Opp. Sardar Patel
Stadium
Navrangpura
Ahmedabad-380009
Mr Vipul H Patel
Manager (QC)
La-Gajjar Machineries Pvt Ltd
Acidwala Estate
Nagarwel Hanuman Road,
Amraiwadi
Ahmedabad-380026
Mr Shashank Jain
Sr Programme Officer
Shakti Sustainable Energy
Foundation
Capital Court, 104B/2
Munirka Phase-III
New Delhi 110067

Phone: 91-79-27546710,
27546932, 27546058
Fax: 91-79-27546282
Mobile: 9898296700

Email
amrutpumps@gmail.
com

Phone 91-281-2455 776

Mobile 9978224704

Mobile: 09443181737

sivaskovai@gmail.co
m

Phone: 91-79-26569617-4618,
2656 5333
Fax: 91-79-26565279
Mobile: 9898002958

gnpanchal@gitco.co.i
n

Phone: 91-79-26569617-4618,
2656 5333
Fax: 91-79-26565279
Mobile: 9925064199

rspanchal@gitco.co.in

Phone: 91-79-22777485/
22777487
Fax: 91-79-22730872
Mobile 9227772918

vipul.patel@lgmindia
.com

Phone 91-11-47474007
Fax 91-11-47474043
Mobile 9868214441

shashank@shaktifou
ndation.in,

23

Sr.
No.
21.

22.

Contact Person

Phone/Fax/Mobile

Mr Prosanto Pal
Senior Fellow
TERI, New Delhi
Mr Gaurav Sharma
Research Associate
TERI, New Delhi

Phone: 011-24682100

Phone: 011-24682100

Email
prosanto@teri.res.in

Gaurav.sharma@teri.
res.in

24

Interactive meet on
Promoting Energy Efficient Pumpsets
Coimbatore
April 17, 2012
LIST OF PARTICIPANTS
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.

Name

Organization

Sri R R Ranghanthen
Sri T C Thiagarajan
Sri V Lakshminarayanasamy
Sri K K Rajan
Sri Jayakumar Ramdass
Sri G Rajendran
Sri S Murugesan
Dr Subramanian
Sri M Mohan
Sri A Santhosh Raja
Sri C Jayakumar
Sri A Narayanasami
Sri A Mohan Raj
Sri M Chennanaicker
Sri K Kumar
Sri Ravichandran
Sri P Manoharan
Sri G Senthil Kumar
Sri V Senthi Kumar
Sri A V Vijaya Kumar
Sri P Sakthivel
Sri R Loganathan
Smt Sripriya C G
Sri T Parthiban
Sri P Prabhu
Sri P R Periyasamy
Sri R Bharath
Sri K Gunabal
Sri A M Selvaraj
Sri Kamlesh B Patel
Sri Vijayakumar
Sri L Narayanasamy
Sri K Ravichandran
Sri P Ravikumar
Sri G Sampath Kumar
Sri R Surendran
Sri C Murugesan
Sri P Ramesh
Sri G Ranganathan

President
Vice President
Vice President
Vice President
Immt. Past President
Past President
Technical Co-ordinator, SIEMA
Technical Co-ordinator, SIEMA
Perfects Engineers
Perfects Engineers
Kirloskar Brothers Ltd
C R I Pumps Pvt Ltd
C R I Pumps Pvt Ltd
C R I Pumps Pvt Ltd
Viking Industries
Sharp Industries
Pioneer Products
Pioneer Products
V Guard Industries
V Guard Industries
Mehala Machines India Ltd
Mehala Machines India Ltd
Best Engineers Pumps P Ltd
Best Engineers Pumps P Ltd
Sri Dhanalakshmi Foundry
Sri Dhanalakshmi Foundry
KMP Industries
SiTarc
SiTarc
Vardaan Engineers
Challenger Pumps India Pvt Ltd
PSG Industrial Institute
PSG Industrial Institute
PSG Industrial Institute
V R Industries
Aquasub Engineering
Aquasub Engineering
Aquasub Engineering
Consultant
25

Sl.
No.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.

Name

Organization

Sri Pichumani
Sri P Murugan
Sri S Arun Kumar
Sri M Natarajan
Sri C Palanisamy
Sri P Santhosh
Sri B Udayakumar
Sri Ganesh
Sri Doraisamy
C Soundararaj
Ramakrishnan
V Krishna Kumar
R Bharath Arun
S Wilter
Mudiarasan B
D Devaraj
C Kanagaraj
Sri Hari
Sanjeev Deshak
N Sivakumar
D Jaya Prakash
N Shajadan
N Ravi Kumar
S Ramakrishnan
S Rajendran
Jaaintha Joseph
N Subramanian
M Sathish
I E Tamdlarasan
R Kalyanasundaram
J Vicks
S S Raman
R Ramesh
K P Shanmukgarajan
N Sivasubramanian
K Jayachandra
S P Garnaik
Shashank Jain
Girish Sethi
Prosanto Pal

C R I Pumps Pvt Ltd

C R I Pumps Pvt Ltd
C R I Pumps Pvt Ltd
C R I Pumps Pvt Ltd
Omparasakthi Industries
Omparasakthi Industries
Laxmi Forgings P Ltd
Perfect Engineers
Shree Natthji Engg Co
CEC Pump Sets
Best Engineers
Aquasub Engineering
K M P Industries
Kay Jay Sharp Trendys
Kay Jay Sharp Trendys
Bindhu Engg Industries
Coimbatore Pump Products
Yath Pumps
Orbits
Texmo Industries
Texmo Industries
Texmo Industries
Texmo Industries
Mahendra Sub. Pumps Pvt Ltd
Mahendra Pumps Pvt Ltd
Mahee Engg P Ltd, Unit
Norton Industries
Anchor Engg Co
Anchor Engg Co
Tapmaa
Sharp Pumps
Sharp Pumps
Harson Pumps
Prabhu Industry
TERI Consultant
Sri Amman Industries
BEE
Shakti Sustainable Energy Foundation
TERI
TERI

26

Annexure 2.5:
Agenda of the
National Level Dissemination Workshop

27

National Level Dissemination Workshop

Promoting energy efficiency in pump industry in India
July 30, 2012
Venue:
Board Room, The Oberoi Hotel, Zakir Hussain Marg, New Delhi
Time
10.00 a.m. 12.00 noon

AGENDA
10.00 11.00

Welcome and Opening Remarks

[Mr S. P. Garnaik, Energy Economist, Bureau of Energy Efficiency (BEE)]
Moderated Discussion by BEE on

Problems being faced by pumps manufacturers in S&L program of BEE

Proposal for shifting voluntary programme of pumps to mandatory phase

11.00 12.00

Background of TERI-Shakti study to promote energy efficiency in pump industry in

India
[Mr Shashank Jain, Sr Programme Officer-Industry, Shakti Sustainable Energy
Foundation]
Background presentation on TERI-Shakti study on Promoting energy efficiency in
pump industry in India
[Mr Prosanto Pal, Senior Fellow, TERI]
Question Answer
Vote of Thanks

12.30 14.00

Lunch

N.B. The workshop is being held in conjunction with the Technical Committee Meeting for Pumps
under the Standards and Labeling Programme of BEE

29

Annexure 2.6:
List of participants of the National Level
Dissemination Workshop

31

National Level Dissemination Workshop

Promoting energy efficiency in pump industry in India
July 30, 2012

List of participants
S
No.
1.

Name

Organisation

Contact details

Mr Anil Akole,

Crompton Greaves Limited

Pumps Division
KSB Pumps Ltd

Mobile. 9765550303
Email. Anil.akole@cgglobal.com
Mobile. 9871159488
Email. ksb.nd-subp@ksb.co.in
Email.
siema.vicepresident2@gmail.co
m
Mobile. 9823886003
Email.
shashirekha.goramane@cgglob
al.com

2.

Mr Ashok Choudhary,

3.

Mr V Krishnakumar,

Aquasub Engineering/
SIEMA/ SiTarc

4.

Ms Shashirekha Goramane

Crompton Greaves Limited

Pumps Division

5.

Mr Hemanth Kumar

ICPCI

6.

Mr S P Garnaik

7.

Mr Shashank Jain

Bureau of Energy
Efficiency (BEE)
Shakti Sustainable Energy
Foundation

8.

Mr Gaurav Kumar Gupta

Duke Plasto Technique Pvt

Ltd

9.

Mr Deepanshu Ahuja

10.

Ms Vineeta Kanwal

11.

Mr Surinder Singh Kalsi

Bureau of Energy
Efficiency
Bureau of Energy
Efficiency (BEE)
Kalsi Metal Works (P) Ltd.

12.

Mr Hardik Vyas

Falcon Pumps Pvt Ltd

13.

Mr Milind Raje

ICPCI

Mobile. 9582236644
Email.
Hemanth.kumar@copperallianc
e.asia

Mobile 9868214441
Email.
shashank@shaktifoundation.in
jainshashank97@rediffmail.com
Mobile. 9414055912
Email.
gkgupta@dukeplasto.com
Email. dahuja@beenet.in
Mobile. 9871729299
Email. vkanwal@beenet.in
Mobile. 9872900602
Email.
surinderkalsi@hotmail.com
Mobile. 9727700583/
9727700577
Mobile. 9820611816
Email.
Milind.raje@copperalliance.asia

33

S
No.
14.

Name

Organisation

Contact details

Mr Ashish Sharma

EESL

15.
16.
17.

Mr Gaurang Meher Diljun

Mr Chetan Yadav
Ms Alpana Jain

TERI
TERI
Shakti Foundation

18.
19.

Mr Prabhash Kumar
Mr Jaykumar

20.
21.

Mr J Ramdass
Mr S L Abhyankar

Data Analyst
Bureau of Energy
Efficiency (BEE)
Mahindra Pumps
IPMA

Mobile. 9560810808
Email. asharma@eesl.co.in
Email. gaurangm@teri.res.in
Email. chetan.yadav@teri.res.in
Email.
alpana@shaktifoundation.in
Email. pkumar@beenet.in
Mobile. 7428299639
Email. jaykumar@beenet.in

22.

Mr Jignesh Patel

23.

Mr Prosanto Pal

Rajkot Engineering
Association
TERI

24.

Mr Girish Sethi

TERI

Mobile. 9757215527
Email. Ipma.org@gmail.com
Mobile. 9824221874
Mobile. 9811799933
Email. prosanto@teri.res.in
Email. Girishs@teri.res.in

34