HYDRAULIC RESEARCH CENTRE Introduction

In addition to being Indias largest pump manufacturer, exporter and Turnkey Contractor of pumping machinery, Kirloskar Brothers Limited is an undisputed leader and pioneer in the field of fluid handling in India. Kirloskar Brothers Limited, KBL has been able to achieve this success for more than seven decades, because of its pioneering spirit. Pioneer in pump manufacturing in India, and winner of export excellence awards for over a dozen times from the Government of India, KBL exports pumps to over 65 countries across five continents to USA, UK, Germany, Spain, Italy, Holland, Greece, Egypt, Sudan, South Africa, Kenya, UAE, Saudi Arabia, Oman, Iraq, Hong Kong, Malaysia, Indonesia, Singapore, Thailand, Laos, Vietnam, Australia and New Zealand. Some of our prestigious clients are Enron, Bechtel, ABB, Hyundai, GEC, Siemens, Rolls Royce, Mitsubishi and Alstom. KBLs global network includes offices and representatives posted in Germany, Egypt, South Africa, Kenya, Saudi Arabia, UAE, Nepal, Lao PDR, and Vietnam.

Hydraulic Research Centre (HRC) at Kirloskarvadi

KBL-Kirloskarvadi factory is the first multi-product engineering factory in India to get ISO-9001 accreditation in 1991. An ISO 9001 and ISO 14001 company, with four factories, it houses all manufacturing facilities under one roof - state of the art machining facilities, ferrous / nonferrous foundries, testing facilities with one of Asias largest hydraulic research centers with testing facility up to 4,000 kW, 11kV and discharge up to 50,000 m3/hr.

Pump Testing
Accurate test results are very important to the pump designers and for the smooth development of any product. Unfortunately, site tests seldom yield accurate results due to difficulties in installing precision measuring equipments and design information must therefore be gathered in the manufacturing stage. It is not always possible at site to demonstrate to customers that the contractual obligations are being fulfilled. The only satisfactory answer to such problems is to build a test house provided with accurate measuring equipment in which any pump up to the largest size can be run and tested at their design speed and output. The pumps manufactured at KBL, Kirloskarvadi are tested over a complete range to prove their hydraulic and mechanical performance for satisfactory operations prior to dispatch, conforming to HIS, BS, DIN, JIS and other international standards. The following tests are conducted at works, for this purpose. 1. ROUTINE TESTS Balancing of rotating components Hydraulic performance test over the complete range of operation on the prototype pump with Job/Lab motor Mechanical performance test on prototype 2. TYPE TESTS Closed circuit NPSH testing up to 500 kW Noise and vibration test Strip test Endurance test Cavitation and erosion test

Testing Facilities
The original facility of HRC, at KBL Kirloskarvadi was designed by and installed under the vigilance of Indian Institute of Science, I.I.Sc, Bangalore. Now this facility of HRC, at KBL Kirloskarvadi is upgraded and expanded in consultation with the world-renowned consultant British Hydromechanics Research Association, BHRA Group, UK. The test house is provided with a 50-Tonne and 20-Tonne crane with a lift of 18.5m. The HRC lab has four test loops and each loop is equipped with all precise measuring instruments connected to Data Acquisition System (DAS). Rapid assembly of test circuit is possible as all test pipes have special flanges and O rings. The testing is monitored from DAS control room. Computerized data processing, Graph plotting and Result generation is carried out with the help of advanced software, developed to meet all testing needs.

Layout of Large Pump Test Bed

Layout of Medium Pump Test Bed

Test Loop Facilities

HRC is equipped with four test loops for carrying out tests for different pump sizes and flow capacity. All test loop parameters are transmitted to main centralized Data Acquisition System DAS, where operation and calculation are monitored. The details of test loop are as under: Test Loop No. 1 Large Test Facility 50000 m3/hr This is the largest test loop consisting of an open channel, large sump with weir and magnetic flow meter in parallel circuit. The facility is used to measure maximum flow up to 50000 m3/hr. It is well equipped with 50-Tonne, 20-Tonne and 10-Tonne crane facility and available with H.T. supply through its main substation for 11 kV / 6.6 kV / 3.3 kV / L.T. supply. Pump driven by motor with maximum rating up to 4000 kW can be tested for its output.

View of Large Vertical Pump Type BHR on Test Bed Flow 13000 m3/hr, Motor 1500 kW
Test Loop No. 2 Test Facility 300 3500 m3/hr This facility uses an open sump, which has high-level connection to the large test loop. The flow is measured through the flow meter / orifice meter. It has a facility where this loop can be combined with the closed loop tanks for cavitation / NPSH testing. It also enjoys the facility of crane and power as that for test loop No. 1. Test Loop No. 3 Test Facility 300 2500 m3/hr This test facility is well designed and equipped for NPSH and cavitation tests in the closed loop circuit. It has two tanks of 60 m3 capacity with controlled temperature of water up to 35oC with a cooling system. This facility is developed for sodium pump model for its critical NPSH and cavitation condition in addition to the model test on split case and end suction pump. In the test loop we can apply positive pressure / vacuum through compressed air and vacuum pump. The pump up to 500 kW L.T. supply can be very well tested with electric soft starter.

Pump Model With 500 kW L.T. Motor 1450 rpm Under Visual Cavitation Study

Test Loop No. 4 Test Facility 2500 12500 m3/hr Small to medium size, horizontal pumps as well as vertical turbine pumps can be tested on this test loop. This test loop has wet pit sump of size 14m Long X 3.6 m Wide X 3m Deep and dry pit sump of 9m Long X 5m Wide X 3m Deep. Dry pit sump is constructed for testing pumps with positive suction arrangements. This test bed has a 10-Tonne crane capacity and L.T. and H.T. supply independently from the substation. Very recently, High Head Horizontal Pump Under Test Head 195 m with 1500 kW 6.6 kV Motor, was tested using this facility.

Data Acquisition System

HRC has a Centralized Data Acquisition Control Room. On line and off line testing of pumps is carried out through window-based software, from control room. Various pump test parameters are sensed directly from the field by data sensors and are interfaced to the computer system. Thus test results, graph, test report, etc. can be made available during the test.

Reliable Performance
These pump test facilities ensure that pump performance meets specification before installation, irrespective of the size or type of the KBL pump. They also provide a rigorous testing ground for new pump design, development and improvement of existing pumps.

Sump Model Studies

KBL undertakes sump model study for satisfactory operation of pumps. Analysis using Computational Fluid Dynamic Techniques, (CFD) for prediction in advance is also possible without conducting sump model study. The study includes pumps for lift irrigation schemes, cooling water pumps, jackwell water supply, etc. KBL has already carried more than 100 experimental sump model studies and verified the results using CFD techniques. Now more and more customers are preferring sump flow studies by CFD.

Sump model study for Simhadri 2 x 500 MW Concrete Volute Pump

Sump model study Almatti Lift Irrigation Scheme

C.W. Pump 5 Nos., Flow 22000 m3/hr with 2175 KW 6.6 kV Motor for Dabhol Power Station

Test facility at a glance

SR. NO. 1 2 3 PARAMETER 1 Flow, m3/hr Head, m Power Supply 3 Ph 50 Hz 50000 120 11 kV (HT) 6.6 kV (HT) 3.3 kV (HT) 2 3500 800 4500 kW 2500 kW 1500 kW TEST LOOP NO. 3 2500 250 6.6 kV (HT) 3.3 kV (HT) 440 V (LT) 4 10000 200 2500 kW 1500 kW 500 kW

Crane Facility

10/50 Tonne (crane hook height 18.5 m) 15 Tonne (crane hook height 18.5 m) 2 Tonne (crane hook height 4 m)

10 Tonne (crane hook height 12 m)

KIRLOSKAR BROTHERS LIMITED

Enquiries may be directed to the nearest Regional Sales Office.

Regional Sales Offices : Ahmedabad, Bangalore, Baroda, Bhubaneswar, Calcutta, Chennai, Jaipur, Kochi, Lucknow, Mumbai, Nagpur, New Delhi, Pune, Ranchi, Secunderabad.
HRC 09210

KIRLOSKAR BROTHERS LIMITED PRINTING DIVISION, PUNE 411 038.

CORPORATE OFFICE : UDYOG BHAVAN, TILAK ROAD, PUNE - 411 002 (INDIA) PHONE : (020) 444 4444 FAX : (020) 4444198, 4440156 Email : kblin@kbl.co.in Web Site : http://www.kirloskars.com WORKS : KIRLOSKARVADI 416 308. DIST. SANGLI PHONE : (02346) 22301 TO 22305 FAX : 22311