In India, pumping systems have been predominantly used in various infrastructure sectors to facilitate the movement of fluids and gases. Sectors, including water and wastewater, agriculture and mining, and industries such as thermal, paper and pulp, textile and chemical have traditionally relied on conventional pumps. These pumps operate with a fixed mechanism and pattern, leading to inefficiencies and high maintenance costs. Despite these limitations, the demand for such pumps has been increasing rapidly across sectors. Therefore, these pumps are undergoing a technological overhaul, incorporating real-time monitoring and control systems, variable frequency drive (VFD)- and variable speed drive (VSD)-based systems, and innovations and advancements in submersible pumps, among others. The digital upgrade of pumping systems offers several benefits. These include a reduction in energy consumption, reduced operating costs, continuous tracking and adjustments in speeds or flow rates based on demand, and better predictive maintenance capabilities. In addition, these systems enable project implementing agencies to make effective data-driven decisions while improving the performance and operational efficiency of the pumps.
SCADA, IoT and RMS-based monitoring
There has been an uptick in the real-time monitoring of wastewater treatment projects undertaken by water utilities and irrigation projects in the agricultural sector. Monitoring efforts are being carried out through the adoption of the supervisory control and data acquisition (SCADA) system, internet of things (IoT)-enabled devices and remote monitoring systems (RMSs). Through this initiative, sensors are being installed along the water supply service chain, spanning from treatment plants, distribution stations, and the distribution network of pipelines to pumps and valves, enabling the tracking of operations. These built-in sensors collect critical information on various parameters such as the flow rate, pressure, temperature and vibration of the fluid. These patterns are then analysed at a centralised control system or a cloud-based platform to check for potential issues. For instance, the Bangalore Water Supply and Sewerage Board plans to leverage SCADA to monitor water supply at various pumphouses across the city. The system will help in recording multiple parameters, such as the quality of discharged water, water pressure, and the operational hours of each pump set. The Chennai Metropolitan Water Supply and Sewerage Board also has similar plans in progress. It will install sensors in all pumping facilities and water treatment plants to enable the real-time monitoring of water levels and their distribution. These sensors will facilitate the automation of pumping in sewage pumping stations once the water reaches the threshold level. They will be connected to a control centre, enabling the prompt identification of any blockages in pumps for immediate repair.
In the agricultural sector, the solar pumps being installed under Component C of the Pradhan Mantri Kisan Urja Suraksha evam Utthaan Mahabhiyan (PM-KUSUM) scheme are also being integrated with an RMS. This allows the transmission of data of the pumps’ operations to be transmitted to the server. This data includes information on the location and status of the solar pump, water discharge, pattern of the pump usage, its energy generation and capacity utilisation. Moreover, the government is pushing the universal solar pump controller technology under Component B of PM-KUSUM. It allows the full utilisation of stand-alone solar pumps. These controllers are monitored through a centralised system, helping farmers to optimise power usage and save energy costs.
VFD– and VSD-based pumps
Pumps account for 20-30 per cent of the total energy consumption by sewage treatment plants (STPs). This energy usage contributes to the majority (over 50 per cent) of the operational costs of STPs. To address this, energy-efficient VFD– and VSD-based pumps are being used in various industries, such as paper and pulp, textiles, and geothermal. For instance, in the paper and pulp industry, oversized pumps are employed to maximise operational capacity. However, these oversized pumps often face throttling, making them inefficient over time. To address this issue, many plants in the industry are installing VFD pumps. Moreover, around 25 kW of power can be saved by installing VFDs on the cooling fans of the plants along with fully opened dampers.
Pump maintenance in the critical safety environments of industries is expected to be facilitated through the integration of augmented reality and virtual reality.
Similarly, VSD pumps are being adopted for various applications in the textile industry. These include machinery processes, air treatment, and air conditioning in fibre and yarn production, as well as specialised applications such as dyeing, bleaching and finishing. KSB Limited offers VSD pumps equipped with specialised control systems. The VSD-based pump series, Etanorm is designed to enhance the plant’s long-term operational efficiency. Additionally, its Multitec VSD pump series is utilised in geothermal plants, featuring a multistage horizontal or vertical centrifugal pump design.
Other advanced pumps
There have been several advancements in submersible pumps, expanding their application to areas such as offshore and geothermal energy generation, groundwater level maintenance in opencast and underground mining, irrigation, water supply wells, and sewage treatment works. These pumps are undergoing several innovations. For instance, the KSB Group launched a new submersible borehole pump series called UPA S 250 in February 2023. With an optimised hydraulic design, this series achieves very high levels of efficiency, making it well suited for mine dewatering, water supply, groundwater management and general pressure-boosting tasks in various industries. Its components are made of high-grade stainless steel and the pump can achieve high flow rates ranging between 60 and 400 cubic metres per hour. Another advanced submersible pump is the electric type. This is used in geothermal applications and high-temperature reservoirs during the thermal recovery of heavy oils. An example of such pumps is Schlumberger Limited’s REDA Hotline electric submersible pump system, which is preconfigured for immediate deployment at the well site. It is designed to withstand significant temperature variations ranging from cool surface conditions to hot downhole operating temperatures.
Another advancement in pumps is the introduction of the explosion-proof pump, which has a specialised design to safely transfer gas in locations that are vulnerable to explosions. These pumps are prevalent in the oil and gas and chemical industries and are encased in stainless steel to prevent flammability. One such series of pumps is the Reliance Division 1 explosion-proof pump motor, offered by ABB Limited. It is built to contain any potential explosion inside the pump, preventing its release into the surrounding atmosphere.
The way forward
Going forward, there will be an increased emphasis on reducing the high energy consumption of pumps due to their substantial impact on operating costs and the environment. To enable this, the adoption of artificial intelligence (AI)-based predictive analytical tools would play a crucial role. The complex processes and equipment in the thermal power, chemical, and oil and gas industries can be effectively managed using AI-driven platforms. To this end, Sulzer Pumps India Private Limited and Siemens Large Drive Applications have collaborated to develop advanced digital pump solutions. In the future, pump maintenance in critical safety environments of these industries is expected to be facilitated through the integration of augmented reality and virtual reality technologies. The simulations will allow operators to troubleshoot pumps in a risk-free environment. Similarly, digital twin models for water supply systems, including gPROMS, SIWA Sewer, and SIWA Blockage Predictor offered by Siemens, will enable smooth pump operations. Furthermore, the integration of renewable energy is crucial to offload energy consumption from the grid. Meeting the targets set under PM-KUSUM for the installation of solar pumps and upgrading existing grid-connected pumps will be a significant milestone in this direction.
