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KIRLOSKAR BROTHERS LIMITED,

DEWAS
UNDERSTNADING
PUMP


KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP
Pump is a machine, which imparts energy to
the liquid flowing through it.

This energy can be utilized EITHER to lift
water from a lower level to higher level OR to
circulate in a closed circuit.

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP

KIRLOSKAR BROTHERS LIMITED, DEWAS
CLASSIFICATION OF PUMP

KIRLOSKAR BROTHERS LIMITED, DEWAS
CLASSIFICATION OF PUMP

KIRLOSKAR BROTHERS LIMITED, DEWAS
CLASSIFICATION OF PUMP

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP
CA centrifugal pump converts energy of a prime
mover (a electric motor or engine ) first into
velocity or kinetic energy and then into pressure
energy of a fluid being pumped.
C The energy changes occur by two main parts of
the pump, the impeller and the volute or diffuser.
The impeller is the rotating part that converts driver
energy into the kinetic energy.
The volute or diffuser is the stationary part that
converts the kinetic energy into pressure energy.

KIRLOSKAR BROTHERS LIMITED, DEWAS
The energy created by the centrifugal force is
kinetic energy. The amount of energy given to the
liquid is proportional to the velocity at the vane tip
of the impeller. The faster the impeller revolves or
the bigger the impeller is, then the higher will be
the velocity of the liquid at the vane tip and the
greater the energy imparted to the liquid.

PRINCIPLE OF OPERATION

KIRLOSKAR BROTHERS LIMITED, DEWAS
This kinetic energy of a liquid coming out of an
impeller is harnessed by creating a resistance to
the flow. The first resistance is created by the
pump volute (casing) that catches the liquid and
slows it down. In the discharge nozzle, the liquid
further decelerates and its velocity is converted to
pressure according to Bernoullis principle.
Therefore, the head (pressure in terms of height of
liquid) developed is approximately equal to the
velocity energy at the periphery of the impeller.
PRINCIPLE OF OPERATION

KIRLOSKAR BROTHERS LIMITED, DEWAS
The liquid is filled in the pump casing and suction
pipe. This process is called Priming.
When the impeller rotates, it spins the liquid filled
between the vanes outward due to centrifugal
action.
As liquid leaves the eye of the impeller, a low-
pressure area ( vacuum ) is created at the eye of
impeller.
This creates Differential Pressure between water
source and impeller eye, causing liquid to flow
toward the inlet.
PRINCIPLE OF OPERATION

KIRLOSKAR BROTHERS LIMITED, DEWAS
PRINCIPLE OF OPERATION

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
Pumping system efficiency = Pump eff. x Motor eff. x Piping eff. x
Foot valve eff.

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
Static Suction Lift (hss) : It is the vertical distance from
liquid level to pump centre line. It exists when the source
of liquid is below the pump centre line and attracts a
negative sign.
Static Suction Head (hss) : It is the vertical distance from
liquid level to pump centre line. It exists when the source
of liquid is above the pump centre line and attracts a
positive sign.
Static Delivery Head (hsd) : It is the vertical distance from
pump centre line to the highest discharge point.

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
Total Static Head (hst) : It is the vertical distance from
liquid level to the highest discharge point. It is an algebraic
subtraction of static suction lift / head from static delivery
head.
Pump with suction lift : Total Static Head = hsd ( -hss)
hsd + hss
Pump with suction head : Total Static Head = hsd - hss
Total Head (H) : It is the sum of total static head and
frictional head ( required to overcome the resistance to
flow in the pipe and fittings ).
Total Suction Lift (Manometric Lift) Hm : It is the sum of
total static suction lift and frictional head in suction branch.

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
STATIC
DELIVERY
HEAD
TOTAL
STATIC
HEAD
TOTAL HEAD = TOTAL STATIC HEAD
+ FRICTIONAL LOSSES IN SUCTION AND DELIVERY PIPE
STATIC
SUCTION
LIFT
STATIC
DELIVERY
HEAD

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
SUCTION LIFT SUCTION HEAD

KIRLOSKAR BROTHERS LIMITED, DEWAS
Understanding Pressure

KIRLOSKAR BROTHERS LIMITED, DEWAS
Understanding Pressure

KIRLOSKAR BROTHERS LIMITED, DEWAS
CHARACTERISTIC CURVE

KIRLOSKAR BROTHERS LIMITED, DEWAS
CHARACTERISTIC CURVE

KIRLOSKAR BROTHERS LIMITED, DEWAS
HEAD Vs DISCHARGE
FLAT CURVE
relatively rapid increase in discharge
with reducing head.
STEEP CURVE
relatively rapid increase decline in
head with increasing discharge.
STABLE CURVE (DESIRABLE)
one discharge corresponding to any
specified head.
UNSTABLE CURVE
two discharge corresponding to a
specified head.
DROOPING CURVE
relatively sudden drop in head at
particular discharge.






KIRLOSKAR BROTHERS LIMITED, DEWAS
POWER Vs DISCHARGE
NON-OVERLOADING CURVE 1
curve rises to a point and then falls as the discharge increases.
OVERLOADING CURVE 2
power increases continuously with the increase in discharge.
1
2

KIRLOSKAR BROTHERS LIMITED, DEWAS
EFFICIENCY Vs DISCHARGE
Efficiency curve rises to a peak value and then again
falls with increase in discharge.
BEP

KIRLOSKAR BROTHERS LIMITED, DEWAS
Types of impeller profile
Radial flow : Liquid enters the impeller at
the hub and discharging radially.

Francis vane : Radial flow impellers with
double curvature of the vanes at the inlet.

Mixed flow : Liquid enters axially and
discharging in an axial and radial direction.

Axial flow : Liquid enters axially and
discharging nearly axially.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Types of impeller
Closed Impeller : A closed impeller has
vanes between two shrouds. These
impellers are used for clear water.
Semi Open Impeller : A semi open impeller
has exposed vanes, but with a support
plate or shroud on one side. These
impellers are generally used for liquids
with small percentage of solids.
Open Impellers : Mostly open impellers are
used in axial flow pumps. These impellers
move lot of volume but not lot of head or
pressure.

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
SPECIFIC SPEED
By definition, Specific speed (Ns) is revolution per minute at
which a geometrically similar pump would run to deliver
ONE GPM discharge at a head of ONE foot. It is a
dimensionless index, which determine the profile of the
impeller and performance of the pump.

Where,
N - Speed, rpm
Q - Discharge at BEP, US GPM
H - Head per stage at BEP, feet

KIRLOSKAR BROTHERS LIMITED, DEWAS
SPECIFIC SPEED

KIRLOSKAR BROTHERS LIMITED, DEWAS
Comparison of impeller profile

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
Maximum attainable efficiency

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
EFFICIENCY
Energy input = Energy useful + Losses

Efficiency = Energy useful / Energy input

Losses = Mechanical + Volumetric + Hydraulic

bearings leakage friction
coupling (slip) entrance / exit
rubbing vortices
separation
disc friction

KIRLOSKAR BROTHERS LIMITED, DEWAS
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
The ENTRY LOSS caused by the liquid
streamlining past the vanes edge into the
impeller. This loss has a direct bearing on the
capability of the impeller to suck the specified
amount of liquid. Loss can be kept low by correct
vane shape and finish.

LEAKAGE LOSS across a pressure differential,
usually at the wear rings. This loss can be
minimized by running the pump with close but
not dangerously close clearance.
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
R
e
c
o
m
m
e
n
d
e
d

W
e
a
r
i
n
g

R
i
n
g

C
l
e
a
r
a
n
c
e

Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
DISC FRICTION is caused by the impeller
shrouds rotating in liquid. The loss can be kept
low by providing a good machining or casting
finish to the impeller walls. Reducing the volume
of liquid between impeller and volute walls is
also an advantage.

The HYDRAULIC LOSSES in the pump are
caused by friction and turbulence in all
passages. Losses can be kept low by smooth
finish, correct velocity and distribution of flow.
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
STUFFING BOX LOSSES must be kept low :
By cutting out all unnecessary turns of packing
By running the gland just right enough for a
satisfactory seal with adequate lubrication of packing
and,
In case of mechanical seal, by ensuring that no undue
friction horse power is consumed due to unsuitable
rubbing faces or too high face loading.
Conventional means should be used to ensure
low MECHANICAL LOSSES in bearings and other
rotating components.
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
Losses in Pumps

KIRLOSKAR BROTHERS LIMITED, DEWAS
POWER CONNSUMPTION
Motor input (IPkW) : The electrical input to the motor.
Pump input (BPkW) : The power delivered to the
pump shaft by the primemover through pump coupling
or through direct shaft.
Pump output (LPkW) : The power delivered by the
pump in the form of discharge at a given head.
Motor Input
Pump Input
Pump Output

KIRLOSKAR BROTHERS LIMITED, DEWAS
EFFICIENCY
Pump Efficiency
p = Liquid Power = H x Q
Pump Input 102 x BP
Motor Efficiency
m = Motor Output = BPkW
Motor Input IPkW
Overall Efficiency
o = Liquid Power = H x Q
Motor Input 102 x IP


KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
WHY SUCTION LIFT IS LIMITED ?
ATMOSPHERIC
PRESSURE
10.33 mWC
VACUUM 0
mWC
IDEAL SUCTION LIFT = 10.33 - 0
= 10.33 mWC

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
NET POSITIVE SUCTION HEAD (NPSH)
Related with the suction lift characteristic of the pump.
It takes care of the atmospheric pressure at the site and
the temperature of pumping liquid which affect the
pump performance.

NET POSITIVE SUCTION HEAD AVAILABLE (NPSHA) :
Related to pump installation.

NPSHA = Ha - Hvp - hss - hfs
where, Ha = atmospheric pressure in m
Hvp = vapour pressure of pumping liquid in m
hss = static suction lift in m
hfs = friction losses in suction branch including losses in
foot valve and bends in m

KIRLOSKAR BROTHERS LIMITED, DEWAS
PUMP TERMINOLOGY
NET POSITIVE SUCTION HEAD REQUIRED (NPSHR)
Related with pump design. It is the minimum energy
required at the pump inlet to exhibit the rated
performance as per the characteristic curve.

NPSHR = Ha - Hvp Hman + Vs
2
/2g
where, Ha = atmospheric pressure in m
Hvp = vapour pressure of pumping liquid in m
Hman = Manometric / Total suction lift in m
Vs
2
/2g = Suction velocity head m

At any Operating point NPSHA should be more than
NPSHR
In the operating range if NPSHR > NPSHA, the pump will
cavitate resulting in lower discharge and efficiency.

KIRLOSKAR BROTHERS LIMITED, DEWAS
When the pressure of the liquid is reduced to equal to or
less than its vapor pressure, the liquid begins to boil and
small vapor bubbles or pockets begin to form. As these
vapor bubbles move along the impeller vanes to a higher
pressure area above the vapor pressure, they rapidly
collapse.




Cavitation results in :
Noise.
Vibration.
Pitting of impeller and Devlivery casing.
Reduction in discharge and efficiency.
CAVITATION

KIRLOSKAR BROTHERS LIMITED, DEWAS
EFFECT OF SUCTION LIFT

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
Pump Speed
Discharge varies directly in proportion to speed.
Q N
Head varies in square proportion to speed
H N
2

Power varies in cube proportion to speed.
P N
3

Example :
1500 1800 2000 3000
Head (m) 16 23 28.4 64
Discharge (l/s) 16 19.2 21.3 32
Power (kW) 3.2 5.5 7.6 25.6
Prime Mover (HP) 5.0 8.0 12.0 40.0

KIRLOSKAR BROTHERS LIMITED, DEWAS
Impeller Diameter
Discharge varies directly in proportion to diameter.
Q D
Head varies in square proportion to diameter.
H D
2

Power varies in cube proportion to diameter.
P D
3

Example :
200 210 220 230
Head (m) 16 17.6 19.4 21.2
Discharge (l/s) 16 16.8 17.6 18.4
Power (kW) 3.2 3.7 4.3 4.9
Prime Mover (HP) 5.0 6.0 8.0 8.0


KIRLOSKAR BROTHERS LIMITED, DEWAS
Speed And Diameter

KIRLOSKAR BROTHERS LIMITED, DEWAS
SYSTEM HEAD CURVE
Effect of Speed and Impeller Dia.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Effect of Speed and Impeller Dia.
P
O
W
E
R

k
W

E
F
F
I
C
I
E
N
C
Y

%

DISCHARGE l/s
Higher Speed / dia.
Lower Speed / dia.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Specific Gravity
Pump develops Same Head (in meters of liquid) independent
of specific gravity but the pressure in kg/cm2 is proportional
to the specific gravity.
Pump delivers the same quantity by volume independent of
sg but the quantity by weight will be proportional to the sg.
Efficiency is un-effected by the sg.
Power is directly proportional to sg.
Permissible lift varies with specific gravity. As sg increases,
suction lift decreases.
Example : SG = 1 Power = 3.2 kW
SG = 1.1 Power = 3.5 kW
SG = 0.9 Power = 2.9 kW

KIRLOSKAR BROTHERS LIMITED, DEWAS
Other parameters
ALTITUDE
Suction lift values are given at atmospheric pressure at
Mean Sea Level. Suction lift is reduced approx. by 1.2 m
for 1000 m altitude.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Other parameters
HOT LIQUIDS
Hot liquid vaporizes at higher absolute pressure than
cold liquids, therefore the suction lift must be reduced
when handling hot liquids.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Other parameters
VISCOSITY
As viscosity increases q
Discharge decreases+
Head decreases +
Power increases q
Efficiency decreases +


KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
FRICTION LOSSES IN PIPES
Friction Losses in Pipes is calculated by:
(1211 x 10
9
) Q
1.852
H
f
=

________________ ____
D
4.87
C
Where,
h
f
= Friction losses in 100 m pipe length
d = Inside dia. of pipe in mm.
Q = discharge in l/s.
C = smoothness coefficient of pipe material.
150 for RPVC pipes.
140 for new G.I. Pipes.
120 for old G.I. Pipes.

KIRLOSKAR BROTHERS LIMITED, DEWAS
FRICTION LOSSES IN PIPES
Material C Material C
Asbestos Cement 140 Glass 130
Brass 130 - 140 Lead 130 - 140
Brick sewer 90 - 100
Metal Pipes - Very to extremely
smooth
130 - 140
Cast-Iron - new unlined (CIP) 130 Plastic 130 - 150
Cast-Iron 10 years old 107 - 113 Polyethylene, PE, PEH 150
Cast-Iron 20 years old 89 - 100 PVC, CPVC 150
Cast-Iron 30 years old 75 - 90 Smooth Pipes 140
Cast-Iron 40 years old 64-83 Steel new unlined 140 - 150
Cast-Iron, asphalt coated 100 Steel
Cast-Iron, cement lined 140 Steel, welded and seamless 100
Cast-Iron, bituminous lined 140
Steel, interior riveted, no
projecting rivets
100
Cast-Iron, wrought plain 100 Steel, projecting girth rivets 100
Concrete 100 - 140 Steel, vitrified, spiral-riveted 90 - 100
Copper or Brass 130 - 140 Steel, corrugated 60
Corrugated Metal 60 Tin 130
Ductile Iron Pipe (DIP) 140 Vitrified Clays 110
Fiber 140
Wooden or Masonry Pipe -
Smooth
120
Fiber Glass Pipe - FRP 150 Wood Stave 110 - 120
Galvanized iron 120

KIRLOSKAR BROTHERS LIMITED, DEWAS
SR.
NO.
ORIGINAL
PIPE SIZE mm
REDUCED
PIPE SIZE mm
INCREASE IN
FRICTION LOSS %
01 30 25 375
02 40 30 200
03 50 40 314
04 65 50 354
05 80 65 220
06 100 80 360
Effect of pipe size
For a given discharge rate and pipe material

KIRLOSKAR BROTHERS LIMITED, DEWAS
DISCHARGE
H
E
A
D

SYSTEM HEAD CURVE
Effect of pipe size
65 X 65 MM
50 X 50 MM

KIRLOSKAR BROTHERS LIMITED, DEWAS
FRICTION LOSSES IN PIPES - SOME FACTS
The longer the pipe, the greater the friction loss.
The smaller the pipe diameter, the greater the friction
loss.
The smoother the inner surface of pipe, the lesser the
friction loss.
The fewer fittings and valves on the pipe line, the lesser
the friction loss.
The lesser the no. of bends, the lesser the friction loss.
Friction loss is not affected by the angular position of
the pipe.
Friction loss is not affected by the pressure on the liquid
in the pipe.

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
SELECTION OF PUMPING SYSTEM
SYSTEM HEAD =
TOTAL STATIC HEAD
(hss + hsd)
FRICTIONAL LOSSES
(hfs + hfd)
VELOCITY HEAD
(Vd
2
/2g)
+
+

KIRLOSKAR BROTHERS LIMITED, DEWAS
Estimate Discharge
Choose suitable pipe to limit friction losses
to 10% max.
Choose suitable foot valve with K factor
less than 0.8.
Calculate total head.
Choose the type of pumpset to be used
monobloc, coupleset etc.
Select a suitable pump with maximum
efficiency at duty point i.e. matching of BEP
with OP
as well as Top flat efficiency curve
operating point should fall in the best
efficiency zone for the busiest season i.e.
RABI
ensuring that pump is suitable for
summer season.
0
5
10
15
20
25
30
35
0 2 4 6 8 10
H
E
A
D
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0 2 4 6 8 10
P
O
W
E
R
0
10
20
30
40
50
60
0 2 4 6 8 10
DISCHARGE l/s
E
F
F
I
C
I
E
N
C
Y
Best
Efficiency
Point
SELECTION OF PUMPING SYSTEM

KIRLOSKAR BROTHERS LIMITED, DEWAS
SELECTION OF PUMPING SYSTEM

KIRLOSKAR BROTHERS LIMITED, DEWAS
SELECTION OF PUMPSET

0
10
20
30
40
50
0 5 10 15 20
H
e
a
d

m
0
1
2
3
4
5
6
0 5 10 15 20
B
P
k
W
0
20
40
60
80
0 5 10 15 20
Discharge l/s
P
u
m
p

E
f
f
i
c
i
e
n
c
y

%

KIRLOSKAR BROTHERS LIMITED, DEWAS
ESTIMATION OF DISCHARGE
Following factors are to be considered, while estimating the
Discharge:
Yield of Water source
Crops / Area to be irrigated
Availability of electricity, which will decide the operating hours of
the pumpset
Any restriction of the electricity board for prime mover rating

Q = A x I x 28
R x H
where,
Q = Estimated Discharge in liters per second
A = Area of Crop to be irrigated (hectare or acre)
I = Intensity of Irrigation for crop (cm or inch) (1 hectare-cm = 1
acre-inch)
R = Rotation period in days
H = Operating hours of pump in hours/day

KIRLOSKAR BROTHERS LIMITED, DEWAS
H =
hss + hsd + hfs + hffv + hfd + Vd
2
/2g
hss - Static Suction Lift / head m
hsd - Static Delivery Head m
hfs - Friction losses in suction pipe m
hffv - Friction losses in foot valve m
hfd - Friction losses in delivery pipe m
Vd2/2g - Velocity head m
CALCULATION OF TOTAL HEAD

KIRLOSKAR BROTHERS LIMITED, DEWAS
Bernoullis Theorem

KIRLOSKAR BROTHERS LIMITED, DEWAS
CALCULATION OF TOTAL HEAD

KIRLOSKAR BROTHERS LIMITED, DEWAS
CALCULATION OF TOTAL HEAD

KIRLOSKAR BROTHERS LIMITED, DEWAS
FRICTION LOSSES IN PIPES
Friction Losses in Pipes is calculated by:
(1211 x 10
9
) Q
1.852
H
f
=

________________ ____
D
4.87
C
Where,
h
f
= Friction losses in 100 m pipe length
d = Inside dia. of pipe in mm.
Q = discharge in l/s.
C = smoothness coefficient of pipe material.
150 for RPVC pipes.
140 for new G.I. Pipes.
120 for old G.I. Pipes.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Pipe fittings

KIRLOSKAR BROTHERS LIMITED, DEWAS
Pipe fittings

KIRLOSKAR BROTHERS LIMITED, DEWAS
Friction losses in foot valve can be given by
hf = kXVs
2
/2g
where,
k = Friction factor (0.8 max)
Vs
2
/2g = Suction Velocity head m
FRICTION LOSSES IN FOOT VALVE

KIRLOSKAR BROTHERS LIMITED, DEWAS
PERFORMANCE ADJUSTMENT

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
PRESENT SCENARIO
Over 40% of the total energy is consumed by
electrical pumping systems alone.
Over 15 million electric pumping systems are in
operation.
Every year around 800,000 new pumpsets are
installed.
Majority of the pumpsets (almost 80%) are
inefficient - are operating at as low as 50 to 70%
of achievable efficiency.
Continued..

KIRLOSKAR BROTHERS LIMITED, DEWAS
PRESENT SCENARIO
This low operating efficiency is a result of wrong selection
of pumping systems :
Pumpsets are selected based on primemover rating and
pipe size. No consideration to recommendation of
is:10804.
Inefficient pumping systems are installed due to price
advantage.
A lower hp efficient pumping system can do the job,
instead a higher hp inefficient system is often installed.
In the event of hp based tariff and subsidy, derating is
common in agriculture sector.
Obviously, there is huge potential to conserve both power
and energy.

KIRLOSKAR BROTHERS LIMITED, DEWAS
REASONS FOR LOW EFFICIENCY
Initial cost
Energy cost
Maintenance cost
Seeing beyond visible

KIRLOSKAR BROTHERS LIMITED, DEWAS
LIFE CYCLE COST

KIRLOSKAR BROTHERS LIMITED, DEWAS
REASONS FOR LOW EFFICIENCY
Pump selection based on HP and pipe
sizes or HP and No. of stages.
Buying decision on the basis of PRICE
alone.

KIRLOSKAR BROTHERS LIMITED, DEWAS
REASONS FOR LOW EFFICIENCY
FACTORS REASONS DESIRABLE
1. PUMP EFFICIENCY
2. SUCTION LIFT
3. SELECTION OF SYSTEM
4. ELECTRIC MOTOR
5. PIPES
6. MAINTENANCE
LOW AND STEEP
EFFICIENCY CURVE
POOR
NON MATCHING WITH SITE
AS WELL AS WELL.
INEFFICIENT
OVER SIZED
UNDERSIZED
TO MANY BENDS
UNNECCESSARY LENGTH
INFERIOR QUALITY OF PIPE
MATERIAL
IMPROPER OR NO MAINT.
REWINDING BY UNTRAINED
MECHANICS
HIGH PEAK AS WELL AS TOP
FLAT EFFICIENCY CURVE
HIGH
AS PER IS:10804.
EFFICIENT
MATCHING WITH PUMP
AS PER IS:10804
AS MINIMUM AS POSSIBLE
AS MINIMUM AS POSSIBLE
PIPE MATERIAL AS SMOOTH
AS POSSIBLE
SCHEDULED MAINTENANCE
REWINDING BY TRAINED
MECHANICS

KIRLOSKAR BROTHERS LIMITED, DEWAS
ENERGY
ENERGY = kW x h
where;
kW - Power consumption
h - Operating hour
Focus should be on reduction of kW instead
of reduction of h to :
Conserve power as well as energy.
To improve the voltage condition.
Energize more no. of pumpsets from the same
transformer.

KIRLOSKAR BROTHERS LIMITED, DEWAS
For a given flow rate (Q), reduced Head (H)
and higher efficiency of pump &
primemover will result in lower kW
consumption.
kW =
K x
H x Q
pump
primemover
POWER CONSUMPTION
x

Reduce friction losses
Use Efficient pump
and motor

KIRLOSKAR BROTHERS LIMITED, DEWAS
H =
hst + hfpiping + hffootvalve + Vd
2
/2g
TOTAL HEAD
Reduction in friction losses in piping, foot valve
and equipment will result in reduced Head (H).
hst + hfpiping + hfequip + Vd
2
/2g +(Hequip) H =
Agriculutral pumping
Industrial pumping

KIRLOSKAR BROTHERS LIMITED, DEWAS
RECTIFICATION OF PIPINGS AND FOOT
VALVE

KIRLOSKAR BROTHERS LIMITED, DEWAS
RECTIFICATION OF COMPLETE PUMPING
SYSTEM

KIRLOSKAR BROTHERS LIMITED, DEWAS
EVALUATION OF RECTIFICATION
MEASURES
Sr. No. RECTIFICATION MEASURE ENERGY **
CONSUMPTION
kWh
POWER
CONSUMPTION
kW
1. REPLACEMENT OF SUCTION
PIPE AND FOOT VALVE
REDUCES INCREASES
2. REPLACEMENT OF SUCTION
AND DELIVERY PIPES AND FOOT
VALVES
REDUCES INCREASES
3. REPLACEMENT OF PIPING, FOOT
VALVE AND PUMP
REDUCES INCREASES
4. REPLACEMENT PF COMPLETE
PUMPING SYSTEM INCLUDING
PIPING, FOOT VALVE AND
MONOBLOC PUMP.
REDUCES REDUCES
** FOR PUMPING SAME QUANTITY OF WATER

KIRLOSKAR BROTHERS LIMITED, DEWAS
ACHIEVING ENERGY EFFICIENCY
To reduce the flow rate, do not throttle, but trim
the impeller.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Use Variable Speed Drive to meet the fluctuating
requirement.
ACHIEVING ENERGY EFFICIENCY

KIRLOSKAR BROTHERS LIMITED, DEWAS
Use multiple pumps in parallel operation, where
flow rate requirement is varying.
ACHIEVING ENERGY EFFICIENCY

KIRLOSKAR BROTHERS LIMITED, DEWAS
Use multistage or multiple pumps in series in
case of high H / high pressure application.
ACHIEVING ENERGY EFFICIENCY

KIRLOSKAR BROTHERS LIMITED, DEWAS

KIRLOSKAR BROTHERS LIMITED, DEWAS
Installation
Location: The pump should be located near to the water source to
minimize the suction lift.
Grouting: After the installation is completed, the foundation bolts
should be tightened evenly and grouting may be completed.
Sufficient time should be allowed for setting and seasoning of the
foundation.

KIRLOSKAR BROTHERS LIMITED, DEWAS
Piping
Pipe size should be as per the flange size to get higher
discharge.It is not recommended to reduce the pipe length.
The piping should be airtight. Any leakage in suction pipe may
drastically affect the performance of the pump.
The piping should be as short as possible for getting better
discharge.


KIRLOSKAR BROTHERS LIMITED, DEWAS
Piping
The horizontal length of the suction pipe should be straight to
avoid air trapping in pipe.
A check valve should be installed in the pipe line for delivery
pressure more than 20 meters.


KIRLOSKAR BROTHERS LIMITED, DEWAS
ELECTRICAL CONNECTIONS
Proper earthing connection should be made at the bolts
provided for earthing.
Proper size cable should be used between supply and
motor terminals to minimize voltage drop.
Nuts at terminal should be tightened properly.
No. of joints in cable should be as minimum as possible,
preferably joints should be avoided.
Wires and connections should be properly insulated. If
not, it may be lead to fatal shock.
Proper backup protection (reputed makes starter, main
switch and fuse) should be used.

KIRLOSKAR BROTHERS LIMITED, DEWAS
TROUBLE SHOOTING
Failure to deliver water
Wrong direction of rotation
Pump not primed or filled with liquid
Air or vapor pocket in suction line
Suction pipe insufficiently submerged
NPSHA too low suction lift too high
Pump not upto rated speed
Air leaks in suction line or stuffing box

KIRLOSKAR BROTHERS LIMITED, DEWAS
TROUBLE SHOOTING
Pump does not deliver rated discharge
Air or vapor pocket in suction line
NPSHA too low suction lift too high
Power supply is not correct
Air leaks in suction line or stuffing box
Foot valve too small
Foot valve clogged
Viscosity greater / lower than rated
Wear rings worn
Impeller damaged
Speed different than specified

KIRLOSKAR BROTHERS LIMITED, DEWAS
TROUBLE SHOOTING
Pump does not prime
Pump and suction line not filled with liquid
Air leaks in suction line or stuffing box
Gas or vapor in liquid

Pump losses water after start
Air or vapor pocket in suction line
NPSHA too low Suction lift too high
Air leaks in suction line or stuffing box
Gas or vapor in the liquid


KIRLOSKAR BROTHERS LIMITED, DEWAS
TROUBLE SHOOTING
Pump does not deliver rated head
Wrong direction of rotation
NPSHA too low suction lift too high
Viscosity greater / lower than rated
Wear rings worn
Impeller damaged
Speed different than specified
Gas or vapor in the liquid

KIRLOSKAR BROTHERS LIMITED, DEWAS
TROUBLE SHOOTING
Pump overloads prime mover
Pump running beyond lower recommended head.
Lower pump efficiency

Stuffing box overheats
Gas or vapor in liquid
Gland packing too tight
Gland packing not lubricated
Wrong grade of packing
Insufficient cooling water

KIRLOSKAR BROTHERS LIMITED, DEWAS
Degrees of Protection IP
FIRST NUMBER : protection against the contact of external solid bodies and
against the access to dangerous parts
numb. protection of the material protection of the persons
0 not protect
1
protected against solid bodies of
superior dimensions to 50 mm.
protect against the access with the
back of the hand
2
protected against solid bodies of
superior dimensions to 12 mm.
protect against the access with a
finger
3
protected against solid bodies of
superior dimensions to 2.5 mm.
protect against the access with a
tool
4
protected against solid bodies of
superior dimensions to 1 mm.
protect against the access with a
wire
5 protect against the powder
protect against the access with a
wire
6 totally protect against the powder
protect against the access with a
wire

KIRLOSKAR BROTHERS LIMITED, DEWAS
Degrees of Protection IP
SECOND NUMBER : protection against the penetration of the liquids
numb. protection of the material
0 not protect
1 protect against the vertical fall of water drops
2 protect against the fall of water drops with inclination max of 15
3 protect against the rain
4 protect against the water sprays
5 protect against water jets
6 protect against big waves
7 protect against the effects of the immersion
8 protected against the effects of the submersion

KIRLOSKAR BROTHERS LIMITED, DEWAS

Class of Insulation
Particulars A Class E Class B Class F Class
Temperature withstanding
capacity
105C 120C 130C 155C
Frame size Bigger Moderate Smaller Smallest
Weight of motor Very Heavy Heavy Moderate Light
Cost of motor Very high High Low High
Copper Used Very high High Moderate Low
Heat Dissipation Factor Poor Fair Good Excellent
Resistance to Flame Poor Fair Good Better
Effect of Moisture & Humidity Very high High Low Very low

KIRLOSKAR BROTHERS LIMITED, DEWAS
THANK YOU

KIRLOSKAR BROTHERS LIMITED, DEWAS
Centrifugal Force

KIRLOSKAR BROTHERS LIMITED, DEWAS
Packing Selection

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