Power Generation: Thermal:
The first ever, concrete volute pumps to pump sea water through a once-pass cooling water system of a 500 MW thermal power station were recently made and successfully commissioned. The capacity range for these types of pumps is 10,000 m3/hrto 120,000 m3/hr.
This was preceded by the design, development, and manufacture and commissioning of 2.2 m delivery size (30,000 m3/hr) vertical mixed flow pumps, with full-scale works-testing of the pumps with huge captive test-facilities for drive-ratings of the order of 3 MWe.
Boiler feed pumps, whether in ring-section or barre1-casing designs for pressure-ratings to the order of 420 bar are available from Indian manufacturers. Likewise, condensate extraction pumps of the encasent pattern for low NPSH have also been made since long.
Amongst the pumps of auxiliary systems, the Indian pump industry has been catering to the needs of ash-handling, abrasion-resistant pumps, pumps for raw water and other miscellaneous duties and screw and gear pumps for fuel-firing and lubrication systems, etc.
Complete pumping systems for captive power generation or co-generation are available indigenously. For industries like sugar, the power generation is often using waste like bagass as fuel.
Power generation - Nuclear:
The programme of nuclear power generation seems to be far less active now. Yet the successful manufacture and development of Moderator pumps, Primary System Feed Pumps, shut down Cooling pumps, Auxiliary Feed Pumps and pumps for emergency core-cooling system, etc., has progressed further with the development of a range of canned motor pumps up to 200 kW and most interestingly of the sodium-coolant pumps for the prototype fast breeder reactor of 500MWe capacity. Canned Motor Pumps for Heavy Water Plants for ratings of the order of 15 kW have been already supplied by the Indian pump industry.
Hydropower and pumped storage power generation:
The capabilities of the Indian pump industry to supply pumps and systems for hydro power and pumped storage power-generation are well established since long.
Oil and natural gas sector:
This being the unique core sector, most of the specialised needs of pumps from this sector have been developed in the Public sector enterprise-segment of the Indian pump industry. The developments have covered the sucker rod pumps, the multiplex mud pumps, Cementing Units, etc. These are supplemented by developments contributed also by the private sector, especially towards the injection pumps, fire-fighting pumps, sea-water handling pumps in duplex stainless steel for off-shore oil-exploration, 1 km long screw pumps, etc. For transmission of crude and refined petroleum products across long distances through pipelines, the high energy pumps upto 2000 kW rating have been produced in the country.
Refineries, fertilisers, lubricants and petro-chemicals sector:
The segment of the Indian pump industry, catering to the industries in this sector keeps itself well abreast of the periodic revisions being made in the Internationally well-recognized standards like 1502858, 150-5199, API-610, etc. and is quite prompt in adapting to the latest editions and practices. For the fertiliser industry, reciprocating carbamate and liquid Ammonia pumps are developed by the public sector pump manufacturer.
Mining and metal ore refining sector:
The coal mining is the most prominent amongst the mining activities, although there are activities of metal-ore mining, mining of diamond, mica, etc. The mining activity itself, whether opencast or underground is growing in size and technology. Accordingly, pumps of large capacities, of submersible and other types and for slurry transport of the mined outputs are coming into vogue. For aluminium production, single and double casing pumps in high hardness abrasion-resistant materials have been developed indigenously.
The steel sector, while being a core sector, operates at two prominent levels. If the primary level be considered to be the steel plants, then the secondary level can be the re-rolling mills and sponge iron plants and the like, producing the secondary products.
The pumping needs of the steel sector comprise pumping water as the one most important utility and also the pumping of other utilities like lubricating oils, furnace-oil, etc. Fluidizing and removal of the scale is another auxiliary activity, where pumps render a useful service.
The pickling and cleaning processes involve caustic and acidic solutions, for which pumps in non-metallic constructions and in lined constructions are employed. There are a good number of manufacturers specializing in making pumps in such constructions.
The significant aspect of paper-making is again the extent of fluidizing the paper-stock. Higher the percentage consistency, as much more economical is the process of paper-making, because all the fluidizing liquid has to be subsequently squeezed out during the calendaring. The solids-handling capacity of paper-stock pumps has over the years improved from 4 to 5 percent consistency to some 8 to 9 percent consistency.
Macerator pumps have also been made in India since long. Alongside, with pumps to handle liquors and bleaching solutions, which are akin to chemical-handling pumps, the Indian pump industry has had the capabilities to service the complete requirements of pumps for paper-making.