Pumps play a vital role in the transportation of fluids and gases in infrastructure projects, with a steady growth of their usage in India in recent times. Sectors such as water and wastewater, agriculture and irrigation, and mining, as well as industries such as thermal, paper and pulp, textile and chemicals, have traditionally relied on conventional pumps. The evolution of pumps and pumping technologies has been pivotal in addressing the high energy consumption and costs and operational inefficiencies of conventional pumping systems.
Sustainable solutions such as solar pumps, energy-efficient variable frequency drive (VFD) and variable speed drive (VSD) pumps, and advanced pumps such as screw pumps and vacuum pumps are improving the efficacy of pumping systems. Their integration with new-age technologies such as artificial intelligence (AI), supervisory control and data acquisition (SCADA), and internet of things (IoT) are revolutionising the landscape of pumping solutions.
Energy-efficient pumping systems
India has been witnessing a shift towards sustainable pumps and pumping solutions. Amidst rising concerns about climate change, carbon emissions and global warming, infrastructure sectors and end-user industries are prompted to adopt more sustainable practices, such as the use of clean energy. Thus, solar pumps are gaining momentum. These pumps use photovoltaic (PV) technology to convert solar energy into electricity and are increasingly being used across various sectors such as irrigation and agriculture, to effectively draw surface water and groundwater. Under the Pradhan Mantri Kisan Urja Suraksha evam Utthaan Mahabhiyan (PM-KUSUM) scheme, as of December 31, 2024, out of 131,640 total pumps sanctioned for individual solar pumps, 5,272 have been installed. In addition, of the total 3,435,874 sanctioned feeder-level solar pumps, 107,184 have been installed. The Maharashtra government aims to deploy around 3.5 million solar agricultural pumps by 2025 to facilitate sustainable agricultural practices under the PM-KUSUM scheme. In line with this, in December 2024, RMC Switchgears Limited secured a project to supply, install and commission 5,000 agricultural solar pumps across Maharashtra. This project worth Rs 900 million includes 3 horsepower (HP), 5 HP and 7 HP solar pump systems, with completion targeted by 2026. Similarly, other states are also picking up pace. For instance, in March 2024, Latteys Industries Limited was awarded a Rs 300 million project under PM-KUSUM, which involves the supply, installation, testing and commissioning of 1,000 off-grid solar PV water pumping systems in Rajasthan.
Additionally, energy-efficient solutions such as VFDs, VSDs and intelligent control systems/software enable real-time speed adjustments. This facilitates the customisation of pump performance to fluctuating demand, yielding significant energy savings. To this end, VFD-based pumps have been introduced to generate the required pressure at the nodes of the water network in Ayodhya to ensure a 24X7 water supply. Advanced software such as OpenFlows WaterGEMS has been employed, which allows hydraulic network modelling with an unlimited number of pipes and automated data integration. This enabled Geoinfo Services to easily generate digital analysis scenarios and obtain equal residual pressures of tanks. The use of these pumps is expected to result in energy savings of 1,082 million kilowatts per hour.
Advanced screw and vacuum pumps
Screw and vacuum pumps are advanced pumping solutions due to their unique characteristics, advantages and applications across diverse industries and infrastructure sectors. A screw pump is designed to effectively handle viscous fluids and high-pressure applications, such as in the oil and gas (O&G) industry. It uses a positive displacement mechanism, which ensures that the movement of fluid is consistent, steady and energy-efficient. There are various types of screw pumps, depending on the number of screws used in its operation. It can significantly improve efficiency and reduce the energy usage of the petrochemical industry for crude oil handling and transportation. Moreover, it is used for circulating water, fuel injection, hydraulics and lubrication in the construction sector. Players such as Netzsch Pumps and Systems in India offer NOTOS multi-screw pumps for different industry applications such as mining, oil and gas, and chemicals. Additionally, different kinds of screw pumps, such as single screw pumps, eccentric screw pumps and industrial screw pumps, offered by private players such as Heliflow Pumps, have applications across the chemical, electroplating and pharmaceutical industries.
Another type of pump is the vacuum pump, which is designed to effectively remove gas molecules from a sealed volume, creating a partial vacuum or a low-pressure environment. They help in creating controlled environments, allowing for chemical processes to occur at specific temperatures and pressure requirements. Key private players providing industrial vacuum pumps in the Indian market include Crompton, Flowserve Corporation, Kirloskar Brothers Limited and the Jyoti Group. Flowerserve, for example, offers SIHI KPH liquid ring compressor, a type of vacuum pump used in the pharmaceutical, steel and primary metal industries. This product is also used for midstream transportation and downstream processing in the O&G sector.
Integration of AI, IoT and SCADA
The use of AI and IoT in pumping systems has marked a paradigm shift in the handling of water, industrial fluids and gases. IoT-enabled sensors and monitoring devices gather real-time data on pump performance metrics such as temperature, pressure, vibration and energy consumption. This data can be analysed using algorithms, enabling the formulation of predictive maintenance strategies. Furthermore, the uptake of SCADA and remote monitoring systems has enabled the smart sensor-based tracking of operations across various water and sewage treatment plants, pipeline networks and other water systems. Recently, Wilo Mather and Platt Pumps Private Limited, a private player specialising in water management technologies, launched an axial flow submersible pumping system, aiming to mitigate flooding in densely populated urban areas. The system, integrated with an advanced SCADA system, can manage large water volumes and enable real-time monitoring, ensuring robust disaster preparedness. Similarly, KirloSmart is a smart solution offered by Kirloskar Brothers which has applications across end-user industries such as chemical, pharmaceuticals, steel, cement, coal and mining. This solution offers real-time reporting, analytical reports, data monitoring, maintenance alerts and other smart features for pump functioning.
A wide range of SCADA solutions are being offered by Emerson, a key player offering technological pumping solutions. These solutions have applications across different sectors, such as O&G, to streamline and integrate scattered assets through automation Realift Rod Pump Control systems, offered by Schneider Electric, can enhance energy efficiency and automation of oil and gas wells through advanced extraction controls. It has applications in industries such as O&G and energy management. Another example is the Nagalwadi irrigation project in Madhya Pradesh, which has deployed seven pumping stations controlled by the programmable logic controller and SCADA-based automation system. All pump stations can be remotely controlled and monitored, allowing real-time control of water levels, pressure and flow. Additionally, due to the integration with a long-range access wide area network-based communication system, operational data can be efficiently transmitted and monitored, even in remote areas.
The way forward
With the adoption of innovative technologies, pumps and pumping systems are poised to bring enhanced efficiency to various infrastructure sectors in the years to come. The adoption of AI-based predictive analytical tools and data analytics will play a crucial role in this. Moreover, the use of digital twins and infrastructure mapping across sectors will witness increased uptake in the coming years.
The government is undertaking active initiatives to expand innovations in pumps and pumping systems. For instance, in October 2024, the Ministry of New and Renewable Energy invited stakeholders to recommend suggestions for updating the standards of solar water pumping systems and incorporating technological advancements under PM-KUSUM. Through the integration of renewable energy, the operating cost of pumping systems is expected to reduce across other sectors as well.
Going forward, the research and development of energy-efficient pump designs, new advanced material coatings and additive manufacturing such as 3D printing are poised to increase the efficiency and durability of pumping systems in India. For instance, 3D-printed pumps that undergo the vapour smoothing process become stronger and are sealed against exposure to liquids and gases without degrading their mechanical properties. This enhances their durability for industries such as O&G.