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International cooperation success for concrete volute pumps in India
International cooperation successfor concrete volute pumps in India Termomeccanica Pompe, owned by Termomeccanica Holding, is an Italian company well known worldwide as producer of large, engineered centrifugal pumps for application in water transportation, power production, irrigation, oil and gas, and sea water desalination. Kirloskar Brothers Ltd (KBL) is the largest Indian manufacturer of a wide range of centrifugal pumps from half kW to 5000 kW.
The cooperation agreement signed a few years ago between the two companies provides that, following Termomeccanica Pompe’s design, the concrete volute pumps are manufactured partially in Italy and partially in India. Generally the impeller and the rotating parts of the pumps are supplied by Termomeccanica Pompe, which has also the role
www.worldpumps.com
of ‘Collaborating Engineering Partner’ for the whole project. Termomeccanica Pompe has very wide experience in designing concrete volute pumps, and has been suppfying this kind of pump for more than 30 years, mainly for power stations in Italy. The comparry is able to optimize the most suitable hydraulics for each specific project through computational fluid dynamics (CFD) calculations (see Figure 1) and tests on reduced-size model pumps. As a result of the cooperation between TM.P and KBL, four conCrete volute pumps are already in operation for the condenser cooling water system in the NTPC’s ‘power station at Vindhyachal STPP stage II, and a further five at Simhadri TPP stage I; six more pumps are now under construction for the nuclear power station of Tarapur.
WORLD PUMPS
January 2003
3s
order for the design, supply and erection of the five pumping station for the Saurashtra Branch Canal, which is a major branch of the main canal of the Sardar Sarovar Project (see World Pumps, January 2002, pp. 30-31) on the Narmada River in the north of India. A total of 26 concrete voiute pumps will be installed in those pumping stations. The rated capacity of each pump is 72 000 m?h. It is envisaged that an additional 39 identical pumps will be installed in a further stage to complete the project. The five pumping stations of the Saurashtra Canal have a similar arrangement. The general arrangement of one pumping station is shown in Figure 2. The main data for the pumping units are: Termomeccanica Model type: NV 3000 Flow rate: 72 000 m%h Total head: 11-16 m Electric motor rating: 4500 kW Figure 3 shows a cross-sectional drawing of a typical NV concrete volute pump. The impeller is of semiopen, mixed-flow type. The impeller is overhung, and supported by a pair of radial bearings. The lower bearing is lubricated by the pumped liquid; the upper one is installed in the oil bath bearing housing. The axial thrust is borne by the bearing of the reduction gear box, which is located between the pump and the electrical motor. The shaft seal is of the packed type; provisions are included to avoid ftooding of the pumping station during removal of the packing for maintenance.
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The discharge volute and the suction duct are made of concrete and are incorporated into the civil works. Some embedded metallic parts are provided
to support the impeller liner and the pump cover, and to reinforce and protect the volute tongue area. The concrete pouring method and several casting steps are defined through close cooperation between the pump designer and the civil engineers in order to optimize the forms in terms of materials and costs. Hydraulic performances of the pump, including the suction channel and the discharge siphon are validated by tests carried out on reduced dimension model pumps, using a test bed (Figure 4) at Termomeccanica Pompe’s laboratory Very extensive measurements have been performed in order to verify the behaviour of the impeller under cavitation conditions; visual examination of the flow fields on the impeller blades are recorded through stroboscopic examinations. In Figure 5, the increase of the bubble length on the suction side of the impeller blade, as a result of lowering the available NPSH, is shown at two different flow rates. Particular attention has been paid to the geometry of the discharge siphon in order to achieve minimum losses during the normal operation and to assure proper priming during pump start-up. For the Saurashtra canal project Termomeccanica Pompe’s scope of supply includes the design of the pumps, the engineering activities related to the whole pumping units (motor -gearbox - pump) and the manufacturing and supply of the pump rotors and impeller liners. Kirioskar Brothers’ scope includes the entire civil and electromechanical design/engineering and supply of the pumping stations (cranes, filters, control systems, and so on), together with the electrical motors and
36
WORLD PUMPS
January 2003
www.worldpumps.com
gearboxes. In addition, Kirloskar will manufacture in India the balance parts of the pumps in compliance with manufacturing drawings and instructions provided by Termomeccanica Pompe. The first set of pumps will be operational the end of 2003.
before
International markets and worldwide globalization necessitate increasingly greater and more effective cooperation amongst companies of different countries in order to approach specific market areas. The partners gain advantage from local company experience while achieving the highest competitiveness through a proper transfer of technologies and sharing of manufacturing activities. The positive results obtained through the cooperation agreement for concrete volute pumps between Kirloskar Brothers Ltd and Termomeccanica
New Delhi joined the crusade for energy conservation as the Confederation of Indian Industry (CR) hosted an Energy Efficient Motors Seminar cum Expo in the city on 24-25 July 2002. The principaI sponsor for the event, held at the Hotel Taj Mansingh, was Rockwell Automation, with Baldor Motors
& Drives and Kirlaskar Brothers Ltd as associate sponsors. Alstom, the ICPC, Crompton Greaves and Grundfos also lent their active support. Special Secretary, Ministry of Power, MS. Sisodia inaugurated the event with his impressive
speech on the importance of energy-efficient (BE) motors. He emphasized the point that EE motors are the key to low-cost capacity addition. Addition of one megawatt of new capacity requires an investment of a whopping Rs40 million (about PO.84 million), as against Rsl@-15
The cooperation agreement signed a few years ago between the two companies provides that, following Termomeccanica Pompe’s design, the concrete volute pumps are manufactured partially in Italy and partially in India. Generally the impeller and the rotating parts of the pumps are supplied by Termomeccanica Pompe, which has also the role
www.worldpumps.com
of ‘Collaborating Engineering Partner’ for the whole project. Termomeccanica Pompe has very wide experience in designing concrete volute pumps, and has been suppfying this kind of pump for more than 30 years, mainly for power stations in Italy. The comparry is able to optimize the most suitable hydraulics for each specific project through computational fluid dynamics (CFD) calculations (see Figure 1) and tests on reduced-size model pumps. As a result of the cooperation between TM.P and KBL, four conCrete volute pumps are already in operation for the condenser cooling water system in the NTPC’s ‘power station at Vindhyachal STPP stage II, and a further five at Simhadri TPP stage I; six more pumps are now under construction for the nuclear power station of Tarapur.
WORLD PUMPS
January 2003
3s
order for the design, supply and erection of the five pumping station for the Saurashtra Branch Canal, which is a major branch of the main canal of the Sardar Sarovar Project (see World Pumps, January 2002, pp. 30-31) on the Narmada River in the north of India. A total of 26 concrete voiute pumps will be installed in those pumping stations. The rated capacity of each pump is 72 000 m?h. It is envisaged that an additional 39 identical pumps will be installed in a further stage to complete the project. The five pumping stations of the Saurashtra Canal have a similar arrangement. The general arrangement of one pumping station is shown in Figure 2. The main data for the pumping units are: Termomeccanica Model type: NV 3000 Flow rate: 72 000 m%h Total head: 11-16 m Electric motor rating: 4500 kW Figure 3 shows a cross-sectional drawing of a typical NV concrete volute pump. The impeller is of semiopen, mixed-flow type. The impeller is overhung, and supported by a pair of radial bearings. The lower bearing is lubricated by the pumped liquid; the upper one is installed in the oil bath bearing housing. The axial thrust is borne by the bearing of the reduction gear box, which is located between the pump and the electrical motor. The shaft seal is of the packed type; provisions are included to avoid ftooding of the pumping station during removal of the packing for maintenance.
:
/, St
I,
)
The discharge volute and the suction duct are made of concrete and are incorporated into the civil works. Some embedded metallic parts are provided
to support the impeller liner and the pump cover, and to reinforce and protect the volute tongue area. The concrete pouring method and several casting steps are defined through close cooperation between the pump designer and the civil engineers in order to optimize the forms in terms of materials and costs. Hydraulic performances of the pump, including the suction channel and the discharge siphon are validated by tests carried out on reduced dimension model pumps, using a test bed (Figure 4) at Termomeccanica Pompe’s laboratory Very extensive measurements have been performed in order to verify the behaviour of the impeller under cavitation conditions; visual examination of the flow fields on the impeller blades are recorded through stroboscopic examinations. In Figure 5, the increase of the bubble length on the suction side of the impeller blade, as a result of lowering the available NPSH, is shown at two different flow rates. Particular attention has been paid to the geometry of the discharge siphon in order to achieve minimum losses during the normal operation and to assure proper priming during pump start-up. For the Saurashtra canal project Termomeccanica Pompe’s scope of supply includes the design of the pumps, the engineering activities related to the whole pumping units (motor -gearbox - pump) and the manufacturing and supply of the pump rotors and impeller liners. Kirioskar Brothers’ scope includes the entire civil and electromechanical design/engineering and supply of the pumping stations (cranes, filters, control systems, and so on), together with the electrical motors and
36
WORLD PUMPS
January 2003
www.worldpumps.com
gearboxes. In addition, Kirloskar will manufacture in India the balance parts of the pumps in compliance with manufacturing drawings and instructions provided by Termomeccanica Pompe. The first set of pumps will be operational the end of 2003.
before
International markets and worldwide globalization necessitate increasingly greater and more effective cooperation amongst companies of different countries in order to approach specific market areas. The partners gain advantage from local company experience while achieving the highest competitiveness through a proper transfer of technologies and sharing of manufacturing activities. The positive results obtained through the cooperation agreement for concrete volute pumps between Kirloskar Brothers Ltd and Termomeccanica
New Delhi joined the crusade for energy conservation as the Confederation of Indian Industry (CR) hosted an Energy Efficient Motors Seminar cum Expo in the city on 24-25 July 2002. The principaI sponsor for the event, held at the Hotel Taj Mansingh, was Rockwell Automation, with Baldor Motors
& Drives and Kirlaskar Brothers Ltd as associate sponsors. Alstom, the ICPC, Crompton Greaves and Grundfos also lent their active support. Special Secretary, Ministry of Power, MS. Sisodia inaugurated the event with his impressive
speech on the importance of energy-efficient (BE) motors. He emphasized the point that EE motors are the key to low-cost capacity addition. Addition of one megawatt of new capacity requires an investment of a whopping Rs40 million (about PO.84 million), as against Rsl@-15