1. KIRLOSKAR BROTHERS LIMITED, DEWAS UNDERSTNADING PUMP

2. 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.

3. KIRLOSKAR BROTHERS LIMITED, DEWAS PUMP

4. KIRLOSKAR BROTHERS LIMITED, DEWAS CLASSIFICATION OF PUMP

5. KIRLOSKAR BROTHERS LIMITED, DEWAS CLASSIFICATION OF PUMP

6. KIRLOSKAR BROTHERS LIMITED, DEWAS CLASSIFICATION OF PUMP

7. KIRLOSKAR BROTHERS LIMITED, DEWAS PUMP   A 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.   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.

8. 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.centrifugal force PRINCIPLE OF OPERATION

9. 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 Bernoulli’s 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

10. 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

11. KIRLOSKAR BROTHERS LIMITED, DEWAS PRINCIPLE OF OPERATION

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

13. 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.

14. 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.

15. 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

16. KIRLOSKAR BROTHERS LIMITED, DEWAS PUMP TERMINOLOGY SUCTION LIFTSUCTION HEAD

17. KIRLOSKAR BROTHERS LIMITED, DEWAS Understanding Pressure

18. KIRLOSKAR BROTHERS LIMITED, DEWAS Understanding Pressure

19. KIRLOSKAR BROTHERS LIMITED, DEWAS C HARACTERISTIC C URVE

20. KIRLOSKAR BROTHERS LIMITED, DEWAS C HARACTERISTIC C URVE

21. KIRLOSKAR BROTHERS LIMITED, DEWAS H EAD Vs D ISCHARGE l FLAT CURVE  l relatively rapid increase in discharge with reducing head. l STEEP CURVE  l relatively rapid increase decline in head with increasing discharge. l STABLE CURVE (DESIRABLE)  l one discharge corresponding to any specified head. l UNSTABLE CURVE  l two discharge corresponding to a specified head. l DROOPING CURVE  l relatively sudden drop in head at particular discharge.     

22. KIRLOSKAR BROTHERS LIMITED, DEWAS P OWER Vs D ISCHARGE l NON-OVERLOADING CURVE 1 l curve rises to a point and then falls as the discharge increases. l OVERLOADING CURVE 2 l power increases continuously with the increase in discharge. 1 2

23. KIRLOSKAR BROTHERS LIMITED, DEWAS E FFICIENCY Vs D ISCHARGE l Efficiency curve rises to a peak value and then again falls with increase in discharge.  BEP

24. 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.

25. 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.

26. KIRLOSKAR BROTHERS LIMITED, DEWAS b b SPECIFIC SPEED

27. 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

28. KIRLOSKAR BROTHERS LIMITED, DEWAS SPECIFIC SPEED

29. KIRLOSKAR BROTHERS LIMITED, DEWAS Comparison of impeller profile

30. KIRLOSKAR BROTHERS LIMITED, DEWAS

31. Maximum attainable efficiency

32. KIRLOSKAR BROTHERS LIMITED, DEWAS b b EFFICIENCY

33. 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

34. KIRLOSKAR BROTHERS LIMITED, DEWAS Losses in Pumps

35. KIRLOSKAR BROTHERS LIMITED, DEWAS l l 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. l l 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

36. KIRLOSKAR BROTHERS LIMITED, DEWAS Losses in Pumps

37. KIRLOSKAR BROTHERS LIMITED, DEWAS b Recommended Wearing Ring Clearance Losses in Pumps

38. KIRLOSKAR BROTHERS LIMITED, DEWAS l l 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. l l 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

39. KIRLOSKAR BROTHERS LIMITED, DEWAS l l STUFFING BOX LOSSES must be kept low : l l By cutting out all unnecessary turns of packing l l By running the gland just right enough for a satisfactory seal with adequate lubrication of packing and, l l 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. l l Conventional means should be used to ensure low MECHANICAL LOSSES in bearings and other rotating components. Losses in Pumps

40. KIRLOSKAR BROTHERS LIMITED, DEWAS Losses in Pumps

41. KIRLOSKAR BROTHERS LIMITED, DEWAS Losses in Pumps

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

43. KIRLOSKAR BROTHERS LIMITED, DEWAS EFFICIENCY l Pump Efficiency  p = Liquid Power= H x Q Pump Input102 x BP Pump Input102 x BP l Motor Efficiency  m = Motor Output=BPkW Motor InputIPkW Motor InputIPkW l Overall Efficiency  o = Liquid Power = H x Q Motor Input 102 x IP Motor Input 102 x IP

44. KIRLOSKAR BROTHERS LIMITED, DEWAS b b SUCTION LIFT

45. 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

46. KIRLOSKAR BROTHERS LIMITED, DEWAS PUMP TERMINOLOGY l l 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. l l 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

47. KIRLOSKAR BROTHERS LIMITED, DEWAS PUMP TERMINOLOGY l l 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 l l At any Operating point NPSHA should be more than NPSHR l l In the operating range if NPSHR > NPSHA, the pump will cavitate resulting in lower discharge and efficiency.

48. 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 : l l Noise. l l Vibration. l l Pitting of impeller and Devlivery casing. l l Reduction in discharge and efficiency. CAVITATION

49. KIRLOSKAR BROTHERS LIMITED, DEWAS EFFECT OF SUCTION LIFT

50. KIRLOSKAR BROTHERS LIMITED, DEWAS b b PARAMETERS AFFECTING PUMP PERFORMANCE

51. KIRLOSKAR BROTHERS LIMITED, DEWAS Pump Speed l l Discharge varies directly in proportion to speed. Q  N l l Head varies in square proportion to speed H  N 2 l l Power varies in cube proportion to speed. P  N 3 Example : 15001800 20003000 Head (m) 16 23 28.4 64 Discharge (l/s) 1619.2 21.3 32 Power (kW) 3.2 5.5 7.6 25.6 Prime Mover (HP) 5.0 8.0 12.0 40.0

52. KIRLOSKAR BROTHERS LIMITED, DEWAS Impeller Diameter l l Discharge varies directly in proportion to diameter. Q  D l l Head varies in square proportion to diameter. H  D 2 l l Power varies in cube proportion to diameter. P  D 3 Example : 200 210 220 230 Head (m) 16 17.6 19.421.2 Discharge (l/s) 16 16.8 17.618.4 Power (kW) 3.2 3.7 4.3 4.9 Prime Mover (HP) 5.0 6.0 8.0 8.0

53. KIRLOSKAR BROTHERS LIMITED, DEWAS Speed And Diameter

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

55. KIRLOSKAR BROTHERS LIMITED, DEWAS Effect of Speed and Impeller Dia. HEAD m POWER kW EFFICIENCY % DISCHARGE l/s Higher Speed / dia. Lower Speed / dia.

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

57. KIRLOSKAR BROTHERS LIMITED, DEWAS Other parameters l l 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.

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

59. KIRLOSKAR BROTHERS LIMITED, DEWAS Other parameters l l VISCOSITY As viscosity increases   Discharge decreases   Head decreases   Power increases   Efficiency decreases 

60. KIRLOSKAR BROTHERS LIMITED, DEWAS b b FRICTION LOSS IN PIPING SYSTEM

61. KIRLOSKAR BROTHERS LIMITED, DEWAS FRICTION LOSSES IN PIPES l l Friction Losses in Pipes is calculated by: (1211 x 10 9 ) Q 1.852 H f = ________________ ____ D 4.87 CWhere, 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.

62. KIRLOSKAR BROTHERS LIMITED, DEWAS FRICTION LOSSES IN PIPES

63. KIRLOSKAR BROTHERS LIMITED, DEWAS Effect of pipe size For a given discharge rate and pipe material

64. KIRLOSKAR BROTHERS LIMITED, DEWAS (hss + hsd) (hfs + hfd) DISCHARGE HEAD SYSTEM HEAD CURVE Effect of pipe size 65 X 65 MM 50 X 50 MM

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

66. KIRLOSKAR BROTHERS LIMITED, DEWAS b b SELECTION OF PUMPING SYSTEM

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

68. KIRLOSKAR BROTHERS LIMITED, DEWAS l l Estimate Discharge l l Choose suitable pipe to limit friction losses to 10% max. l l Choose suitable foot valve with ‘K’ factor less than 0.8. l l Calculate total head. l l Choose the type of pumpset to be used monobloc, coupleset etc. l l Select a suitable pump with maximum efficiency at duty point i.e. matching of BEP with OP l l as well as Top flat efficiency curve l l operating point should fall in the best efficiency zone for the busiest season i.e. RABI l l ensuring that pump is suitable for summer season. Best Efficiency Point SELECTION OF PUMPING SYSTEM

69. KIRLOSKAR BROTHERS LIMITED, DEWAS SELECTION OF PUMPING SYSTEM

70. KIRLOSKAR BROTHERS LIMITED, DEWAS SELECTION OF PUMPSET

71. KIRLOSKAR BROTHERS LIMITED, DEWAS ESTIMATION OF DISCHARGE l l Following factors are to be considered, while estimating the Discharge: l l Yield of Water source l l Crops / Area to be irrigated l l Availability of electricity, which will decide the operating hours of the pumpset l l 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

72. 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

73. KIRLOSKAR BROTHERS LIMITED, DEWAS Bernoulli’s Theorem

74. KIRLOSKAR BROTHERS LIMITED, DEWAS CALCULATION OF TOTAL HEAD

75. KIRLOSKAR BROTHERS LIMITED, DEWAS CALCULATION OF TOTAL HEAD

76. KIRLOSKAR BROTHERS LIMITED, DEWAS FRICTION LOSSES IN PIPES l l Friction Losses in Pipes is calculated by: (1211 x 10 9 ) Q 1.852 H f = ________________ ____ D 4.87 CWhere, 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.

77. KIRLOSKAR BROTHERS LIMITED, DEWAS Pipe fittings

78. KIRLOSKAR BROTHERS LIMITED, DEWAS Pipe fittings

79. KIRLOSKAR BROTHERS LIMITED, DEWAS l l 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

80. KIRLOSKAR BROTHERS LIMITED, DEWAS PERFORMANCE ADJUSTMENT

81. KIRLOSKAR BROTHERS LIMITED, DEWAS b b ENERGY EFFICIENCY IN PUMPING SYSTEMS

82. 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..

83. 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.

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

85. KIRLOSKAR BROTHERS LIMITED, DEWAS LIFE CYCLE COST

86. 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.

87. KIRLOSKAR BROTHERS LIMITED, DEWAS REASONS FOR LOW EFFICIENCY

88. 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.

89. 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

90. 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

91. KIRLOSKAR BROTHERS LIMITED, DEWAS RECTIFICATION OF PIPINGS AND FOOT VALVE

92. KIRLOSKAR BROTHERS LIMITED, DEWAS RECTIFICATION OF COMPLETE PUMPING SYSTEM

93. KIRLOSKAR BROTHERS LIMITED, DEWAS EVALUATION OF RECTIFICATION MEASURES

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

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

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

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

98. KIRLOSKAR BROTHERS LIMITED, DEWAS b b INSTALLATION & TROUBLE SHOOTING

99. 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.

100. 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.

101. 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.

102. 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.

103. 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

104. 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

105. 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

106. 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

107. 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

108. 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 0not 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 5protect against the powder protect against the access with a wire 6totally protect against the powder protect against the access with a wire

109. 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

110. KIRLOSKAR BROTHERS LIMITED, DEWAS Class of Insulation

111. KIRLOSKAR BROTHERS LIMITED, DEWAS THANK YOU

112. KIRLOSKAR BROTHERS LIMITED, DEWAS Centrifugal Force

113. KIRLOSKAR BROTHERS LIMITED, DEWAS Packing Selection