KIRLOSKAR HVAC PUMPING SYSTEMS

COMFORT WITH SAVINGS & SUSTAINABILITY

AIR CONDITIONING • HEATING • ENERGY MANAGEMENT

KIRLOSKAR BROTHERS LIMITED

 About Kirloskar Brothers Limited

Kirloskar Brothers Limited (KBL) is the flagship company of Kirloskar Group.

Established in 1888 and incorporated in 1920, KBL is the largest manufacturer and
exporter of pumps, valves and pumping systems in the country.

Pumps ranging from 0.18 kW to 26,000 kW

• Projects and Engineered Pumps

• Infrastructural Pumping Projects
• Industrial Pumps
• Agricultural and Domestic Pumps
• Valves
• Motors
• Hydroturbines
• Alternators

Biggest Pump

Smallest Pump

KBL proud manager standing at the discharge pipe of

KBL’s large pump and holding KBL’s smallest pump

Manufacturing Unit at Kirloskarvadi ‘YAMUNA’, Global Headquarters of Kirloskar Brothers Limited is among
Celebrating (1910-2010) the Greenest Buildings in India with LEED Certified Platinum Rating
 KBL Comprehensive Solution
to HVAC Industry

ZONE A ZONE B

Primary centrifugal pumps

Variable speed secondary centrifugal pumps

Balancing valve

Temperature control sensor

2 way valve

Chiller

Air handling unit (load)

DPT
Controller
Expansion tank
Variable
Frequency
Drives Air separator

Non return valve

Our Offerings:
• Primary and Condenser Pump Sets • Secondary Variable Speed Pumping System
• Tertiary Variable Speed Pumping System • Primary Variable Flow System
• District Cooling System

Listed - Packaged Pumping System

Approved – Pumps

Offerings

Pumps Long & Short Coupled Pumps, Single & Double Suction Pumps
Vertical Inline Single & Multistage Pump

Motors EFF2, EFF1 & Higher Efficient

Control Panel Wall & floor mounted panels

Energy Saving and Glass flake coating on Pumps, Valves, Tanks, Pipes etc.
Efficiency Sustainable Coatings

Accessories Valves, Differential Pressure Transducers, Condition Monitoring System,

Expansion Tank, Air Separator Tank, Pressurisation System

Service Backup 24x7 Service Backup, Energy Audit, O&M Contract, etc.
 Primary Variable Flow
Pumping System

FM Ts

BV BV BV

M
C
Chiller

Chiller

Chiller
DP 1

DP 2

DP 3

V AHU 1 AHU 2 AHU 3

DP 4
Chiller Panel

CV CV CV

CV1 CV2 CV3

ET

P1 P2 P3

AS
Tr

VFD VFD VFD Controller

Notifications-

FM : Flow Meter MCV : Modulating Control Valve

P1 : Pump 1 P2 : Pump 2
P3 : Pump 3 VFD : Variable Frequency
AS : Air Separator ET : Expansion Tank
AHU : Air Handling Units Ts / Tr : Temperature Sensors
BV : Balancing Valve
DP 1 / DP 2 / DP 3 / DP 4 : Differential Pressure Sensors
CV / CV 1/ CV 2 / CV 3 : Control Valves
 About Primary Variable Controller

Controller Features
• It is a specially designed modular controller for Primary Variable Flow System
• Standard I/Os are as below-
a) Analogue Inputs-12 Nos & Analogue Outputs-2 Nos
b) Digital Inputs-24 Nos & Digital Outputs-16 Nos
• However, digital and analogue input / output capability can be extended up to 1024
• Controller is with MODBUS for BMS communication
• Controller is having dedicated software to suit application needs; however can be modified
according to customer needs thus giving more flexibility in control system
• As a standard, Controller is capable of controlling up to 4 pumps in parallel and as an option
can be modified for up to 8 pumps
• Auto take over of pumps and VFDs is possible in case of pump/VFD failure
• Controller takes care of flow requirement by taking inputs from DP sensors across AHUs
• Controller also maintains chiller’s minimum and maximum capacity by taking inputs from DP
sensors across chiller and temperature sensors at entrance and return and modulating
bypass control valve thereby protecting chiller against freezing and allowing staging and de-
staging of chiller
• Optional feature like GSM and CDMA support is possible for web based monitoring
• Local/remote control operation is available
• Controller is having flexibility to work with any make of VFD
• Controller is interfaced with chiller panel for staging and de-staging of chiller
 Wide Range of Pumps

(End Suction, Back Pull Out Type Long Coupled Pumps)

MODEL: CPHM / DB / CE MODEL: KPD

• Delivery size: From 20 mm to 200 mm • Delivery size: From 20 mm to 200 mm

• Capacity: Up to 1900 m³/hr (8371 US gpm) • Capacity: Up to 750 m³/hr (3304 US gpm)
• Head: Up to 150 m (493 ft) • Head: Up to 225 m (728 ft)
• Temperature: (-) 30°C to 90°C • Temperature: (-) 50°C to 350°C
• 50 Hz / 60 Hz availability • Also available in vertical execution
• 50 Hz / 60 Hz availability

Zero Leakage Pump

W
NE

MODEL: iCP MODEL: DBL / MF

• Delivery size: From 20 mm to 200 mm • Delivery size: From 150 mm to 650 mm

• Capacity: Up to 180 m³/hr (793 US gpm) • Capacity: Up to 7000 m³/hr (30838 US gpm)
• Head: Up to 85 m (279 ft) • Head: Up to 35 m (119 ft)
• Temperature: (-) 30°C to 90°C • Temperature: (-) 10°C to 90°C
• Zero leakage without Mechanical seal / • 50 Hz / 60 Hz availability
Gland packing
• 50 Hz / 60 Hz availability
 Wide Range of Pumps

(Double Suction, Horizontal Axially Split Case Long Coupled Pumps)

MODEL: UP / UPLV / UPH / UPM

• Delivery size: From 50 mm to 1200 mm

• Capacity: Up to 25000 m³/hr (110000 US gpm)
• Head: Up to 180 m (591 ft)
• Temperature: (-) 10°C to 90°C
• 50 Hz / 60 Hz availability

MODEL: SCT / SCT EXTENDED

• Delivery size: From 50 mm to 350 mm

• Capacity: Up to 4500 m³/hr (19813 US gpm)
• Head: Up to 400 m (1313 ft)
• Temperature: (-) 10°C to 100°C
• Highly efficient pump
• 50 Hz / 60 Hz availability

W
NE
MODEL: iHT (High speed @ 2900 RPM)

• Delivery Size: From 50 mm to 300 mm

• Capacity: up to 1300 m³/hr (5727 US gpm)
• Head: Up to 250 m (820 ft)
• Temperature: (-) 10°C to 90°C
• Low down time: Quickly fixable
• Space saving as running at 2900 RPM
• Single / double stage pump
• Dual drive
• 50 Hz / 60 Hz availability
 Wide Range of Pumps

(Vertical Axially Split Single / Multistage Pumps)

MODEL: iHTV / UPV /SCTV (single/double stage pump)

• Delivery size: From 50 mm to 1200 mm

• Capacity: Up to 25,000 m³/hr (110000 US gpm)
• Head: Up to 160 m (512 ft)
• Temperature: (-) 10°C to 100°C
• 40% space saving against horizontal execution
• 50 HZ / 60 HZ availability

(Vertical Inline Single / Multistage Pumps)

MODEL: SINGLE STAGE (ILS / IN IL)

• Suction - Delivery size: Up to 200 mm

• Capacity: Up to 400 m³/hr (1750 US gpm)
• Head: Up to 90 meter (295 ft)
• Temperature: (-) 30ºC TO 90ºC
• Back pull-out design
• 50 Hz / 60 Hz availability

MODEL: MULTISTAGE PUMPS (IL / KCIL / KSIL)

• Delivery size: From 25 mm to 100 mm

• Capacity: Up to 110 m³/hr (480 US gpm)
• Head: Up to 250 m (820 ft)
• Temperature: (-) 15°Cto 120°C
• Pressed stainless steel components
• All wetted parts in SS304 or SS316
 Wide Range of Pumps

(Close Coupled Pumps)

MODEL: DBC (single stage)

• Delivery Size: 125 mm

• Capacity: Up to 350 m³/hr (1540 US gpm)
• Head: Up to 90 m (295 ft)
• Power Rating: 1.5 kW to 75 kW
• Suitable for 415 V ( +/- 10 % )
• Back pull out design
• Available in mechanical seal version

(Monobloc Single / Multistage Pumps)

MODEL: KDS+ (single stage)

• Delivery Size: 25 mm to 100 mm

• Capacity: Up to 176 m³/hr (778 US gpm)
• Head: Up to 76 m (250 ft)
• Power Rating: 1.5 kW to 22 kW
• Suitable for voltage fluctuation from 300 V to 440 V
• Gland pack / Mechanical seal fitted

MODEL: KDT (multi-stage)

• Delivery size: From 32 mm to 65 mm

• Capacity: Up to 72 m³/hr (318 US gpm)
• Head: Up to 110 m (361 ft)
• Power Rating: 0.75 kW to 15 kW
• Gland pack / Mechanical fittedseal
• Double Stage Pump
 Motors

EFFICIENT SILENT HEAVY-DUTY

Rotor Balancing Modern Type Testing Facility

Range and Specifications

• Range : 0.37 kW – 90 kW
• Voltage & Variation : 415 V ± 10%
• Frequency & Variation : 50 Hz ± 5%
• Combined Variation : ± 10%
• Suitable for Ambient Temp. : 50 deg. C
• Operating Duty : S1 Continuous
• Winding Temp. Rise : Limited to Class B
• Insulation : Class “F”
• Enclosure Protection Class : IP 55, TEFC
• Cooling : IC 0141,TEFC
• Mountings : Foot / Foot cum flange/ Flange

Salient Features
• Energy Efficient motors as per EFF1 / EFF2
• Built in efficiencies higher than average of competition in almost all the cases
• Savings on running expenses up to 85% of Total Life Cycle Cost (TLC)
 Wide Range of Valves

Check Valves / NRV (Cast Steel)

Sluice Valves / Gate Valves
• Manufacturing Standard: IS 5312 Part 1 & 2 / BS
• Manufacturing Standards : BS 5163 / IS14846
5153 (EN 12334)
• Type : Metal Seated
• Size Range : 50 to 1500 mm
• Size Range : (50 to 1400 mm)
IS 5312 : 50 to 1500 mm
• Pressure Ratings : PN 10, PN 16
BS 5153 : 50 to 600 mm
• End Connections : As per EN/DIN/BS/ANSI standards
• Pressure Ratings : PN 6, PN 10, PN 16
• Material of Construction : Cast iron, Ductile
• Material of construction : Cast Iron / Cast Steel /
Iron, Cast Steel, Stainless Steel
Ductile Iron / 2% NiCI

Butterfly Valves Ball Valve

• Manufacturing Standard: IS13095 / EN 593 • Design and Manufacturing Standard: EN ISO

(BS 5155)/ AWWA C504 17292 (BS 5351)
• Size Range: Up to 4500 mm • Size Range: 15 to 300 mm
• Design Pattern: Centric, Single Eccentric & • Pressure Rating: Class 150 and Class 300
Double Eccentric Type • Operation: Manual Hand Lever (Up to 100 mm)
• Pressure Ratings: PN 6, PN 10, PN 16 / AWWA Manual Gearbox (150 mm and above) Electrical
CL - 25, 75,150 & 250 and Pneumatic Actuators with accessories and
• End Connections: Wafer, Lug Wafer, Double Manual Override
Flanged – Short/ Long Pattern • End Connections: As per ASME B16.5 - 2003
• Material of Construction: Cast Iron / Cast Steel / Class 150 / 300
Ductile Iron / Fabricated Steel / 2 % Ni Cast
Iron / SG Ni Resist / Duplex Stainless Steel
 Floor Mounted Composite Control Panel

HMI MOUNTED ON PANEL DOOR

• Two line 20 characters or four line 20 characters
• Blue backlit LED with white text self prompting
display
• Soft touch membrane keypad user friendly
display enables operator / maintenance personal
view
• Alarm messages and parameters like pump
status, run hours, kW, set pressure, actual
pressure etc.
• Setting of parameters like set pressure, pump
configuration other system parameters enables
engineer to set up the system

CONTROL PANEL ENCLOSURE

• Enclosure 16/14 gauge CRCA sheet
• Equivalent to IP42
• Removable gland plate for cable entry at bottom
• Ventilation by fan & air filters
• Phase reverse, Phase failure & under voltage relay
provided
• SMPS provided to take care of supply voltage
variations 85V - 265V Ac.
• Isolation transformer provided to take care of PLC
• Push in type connectors used for connecting field
cables for reliability
• LED indicators provided for main phase
indication, pump on & trip indication OUTER VIEW OF PANEL
• Individual Pump on/off push buttons are provided
for manual operation along with auto/manual
selector switch
Floor Mounted Composite Control Panel

VARIABLE FREQUENCY DRIVE (any make) Display of parameters

• Frequency
• UL listed PWM technology
• Voltage
• Adjustable acceleration / deceleration time
• Current KWH
• User friendly keypad / display unit
• Faults
• Enclosure IP 21 or IP 54
• Motor overload short circuit protection
• RS 485 port for PLC / BMS
• Communication information to BMS

PLC (PROGRAMMABLE
LOGIC CONTROLLER)
Compatible with any make VFD

• Modular PLC gives flexibility to add Inputs/

Outputs as per requirement
• Built in mod bus communications for BMS
connectivity. Others like N2 / Bacnet on
request
• Dedicated External PLC enables Lead / Log
pump alteration
• Auto takeover of other pump in case of failure
of working pump
• Number of DPTs can be added as required
speed variation by DID
• Provision to connect flow sensor proven
program safeguards against dry run, end of
curve, pump surge, hunting, over pressure
• Programmable set point with respect to time is
possible
• Can work with any make of VFD
• GSM/CDMA support
• Signals to BMS via communication
• Pump on/off status
• Individual analogue input
• Set points
• Actual pressure
• Speed, Current, KW, KWH, Run hours for
pumps

INNER VIEW OF PANEL

(SFU)
Switch Fuse Unit

BYPASS STARTER (Optional)

Wall Mounted HVAC Controller

Each VFD with inbuilt PLC (Degree of protection IP 54 and IP 21)

Multimaster PFC for redundant pump control

 Remote Condition
Monitoring of Pumpsets

Web based monitoring of following parameters -

• Flow • Pressures • Vibration • Bearing Temperature
• Voltage • Current • Energy Consumption • Winding Temperature etc.

AxisEYE
{ AxisREPORT
AxisNOTIFY
SUPERAxis
GSM/GPRS REMOTE Central Server

RTD
RTD
RS232 AI 4- 20 mA

Ethernet Port
AI 4- 20 mA
AI 4- 20 mA
Web
AxisScan

Modbus
Winding Temperature
Bearing Temperature

Vibration and Energy Data

Discharge Pressure
Suction Pressure

SMS
Pump Flow

Vibration Alerts
Monitor End User
Web access
Energy
Meter

Reports MIS
Trending
KBL and User
Management

Pump

Pump 2 TRIP
Check relay

Web Based GPRS Monitoring Alarm, Alerts and Tentative Action can be
(Weekly or Monthly reports can be send informed via sms / mail
for analysis purpose)
 Energy Saving Coatings

Why is it required?

1. Improvement of Pump efficiency guaranteed over 6. Prevents fungal / microbial growth on the wetted
the existing efficiency at duty point for new surfaces.
Pumps. This improvement will vary from 1 to 3
points based on type of pump and specific speed.
7. Saving in energy bill.

2. Consistency of higher efficiency over its life cycle.

8. Improvement in efficiency over and above the
achievable efficiency from Hydraulic point of view
3. Increase in equipment life by manifolds as these without changing the running clearance. The
coatings are Corrosion, Erosion & Galvanization, running clearances will remain standard without
abrasion resistant. effecting the reliability. Hence, efficiency
improvement is mainly because of reduction in
hydraulic losses. (Less friction loss, eddies and
4. High reliability, reduction in down time and spare
suppressed boundary layer).
parts requirement.

9. Most Effective Techno-Economic Solution.

5. The efficiency of the Pumps will be retained for a
longer period as compared to non-coated / epoxy
coated Pumps. The efficiency of the coated Pumps 10. Potable Water Certification available.
is expected to remain constant for atleast 3 years
whereas there will be drop in efficiency of
uncoated Pump by atleast @ 0.75 to 1% per year.

Casing Impeller

Valve Tank Pipes

 How it Benefits?

• Smoothens the surface from 18.8 µm to 0.08 µm, which reduces the frictional losses which in-turn
enhances and sustains the efficiencies of pumps.

Cast Iron Ra 18.8 µm

Mildly Rusted Steel Ra 5.0 µm

Mildly Rusted Steel Ra 5.0 µm

Fluiglide Ra 0.08 µm

• Hydrophobic in nature

Surface Contact
Line Contact
Water Droplet Point Contact Coating

Substrate

Surface with Semi Hydrophobic Hydrophobic Material

No Coating (Cast Iron) Material Coating Polymer Coating
(Ploypropylene) (Ester Resin)

Tortuous path for corrosive ion

Layers of glass flakes

Glass flake
coating

Epoxy Paint

SUBSTRATE
SUBSTRATE

Surface coated with Glass flake coro-coating

Epoxy Paint or C.E.D. coating
 Performance after Coating

ENERGY SAVING

Basic criteria for energy conservation

• To enhance the efficiency above the designed efficiency
• To retain the enhanced efficiency for longer period

A 30 kW Pumpset Case

No of Efficiency Pumping Cost Efficiency- Pumping Cost of Reduction in Pumping

Years (*) Corrocoated Corrocoated Pump Cost Due
Pump (*) to Corrocoating

` Per Annum ` Per Annum ` Per Annum

1 80% 16,06,793 82.00% 15,67,603 32,211
2 79% 16,27,133 81.90% 15,69,517 47,355
3 78% 16,47,993 81.80% 15,71,436 62,924
4 77% 16,69,396 81.70% 15,73,360 78,934
5 76% 16,91,362 81.60% 15,75,288 95,403
6 75% 17,13,913 81.50% 15,77,221 1,12,350
7 74% 17,37,074 81.40% 15,79,158 1,29,794
8 73% 17,60,870 81.30% 15,81,101 1,47,755
9 72% 17,85,326 81.20% 15,83,048 1,66,256
10 71% 18,10,472 81.10% 15,85,000 1,85,319
Total 10,58,301

Considering a project of minimum 10 pumps (30 kW each) working

for 10 years, savings would be more than ` 1 crore ($ 0.22 Mn) approx.

IMPROVED COMPONENT LIFE

Non Coated Impeller After 4 years

in a typical application

After Refurbishment Coated Impeller

with Corrocoat Corroglass After 7 Years Service
 Pumps for Green Buildings

Energy Efficient and

Low Maintenance Cost Series Pumps
Component Life Increased

Down Time Reduced Energy Cost Reduced Maintenance Cost Reduced

• Benefits generally post • Designed for 20 years • Universal Seal
installation of life Chamber as per
• All wetted parts with customer specified
• Bearing and
Glass Flake & Energy mechanical seals
Mechanical Seal
replacement in Saving Coatings • Designed to prevent
Horizontal Split Case • Pumps designed for overloading and motor
Pumps without higher efficiencies burning
removing top half and • Dynamically balanced
disturbing the rotating rotating parts ensuring
unit assembly minimum vibrations

REMOVE GUARD REMOVE PUMP COUPLING

REMOVE SPACER REMOVE BEARING HOUSING

Step 1 Step 2

REMOVE BEARING REMOVE BEARINGS AND

REASEMBLE FOR USE
RETAINING NUT REMOVE MECHANICAL SEAL

Step 4 Step 3
 District Cooling System

A District Cooling System consists of three primary components: the central plant, the distribution
network and the consumer system. The central plant may include the cooling equipment, power
generation and thermal storage. The distribution or piping network is often the most expensive
portion of the DCS and warrants careful design to optimize its use.

Our Solutions

3
Capacity: Up to 25000 m /hr (110000 US gpm) Capacity: Up to 7000 m3/hr (30838 US gpm)
Head: Up to 400 m (1313 ft) Head: Up to 35 m (119 ft)

Butterfly valve with corocoating Pipes with corocoating

Central Controller
 Major HVAC Customers

Major National Customers

STERLING

WILSON

H O S P I TA L S
T O U C H I N G L I V E S

Major International Customers

Middle East Region: • Saudi Japanese Textile Mills • Modern Bakery
• Seidco General Contracting LLC • Al Fanar LLC
South East Asia Region: Primary Variable Flow Customers
• OCBC Bank • G-Energy Consultants
• Turf City • Aircon Network
• Great World City • Guthrie Engg
• Bedok Theatre • Great Resources Construction
 After Sales Service

24X7 Service Backup

Warranty Period Operation and

Maintenance Maintenance
Management

On Call Services Spares and

Consumables

Overhauling Energy Cum

System Audits

AMC Economy Club

Facility Equipment System

Management Modification Upgradation
 Our Manufacturing Facilities
at a glance

Stainless Steel Borewell

Industrial & Engineered Pumps Agricultural & Domestic Pumps Submersible Pumps Valves

Kirloskarvadi – Western India Dewas – Central India Shirval – Western India Kondhapuri – Western India

Reading, UK Colford, UK Atlanta, USA South Africa

Foundry & Machining Facilities

A large pump component CNC vertical borer Fully automatic twin spindle, Horizontal machining Vertical machining center
being poured with milling spindle twin turret machine center with pallet hanger
KBL GLOBAL NETWORK
USA Netherlands South Africa Kenya
Kirloskar Brothers LLC Kirloskar Brothers Europe B.V. Kirsons Trading (S.A.)(Pty.) Ltd. Kirloskar Kenya Ltd. Nairobi,
Miami, USA Johannesburg South Africa Kenya

UAE Thailand Lao PDR Cambodia

Kirloskar Middle East FZE Kirloskar Brothers (Thailand) Ltd. Kirloskar Brothers Ltd. Kirloskar Brothers Ltd.
Ajman, UAE Bangkok, Thailand Vientiane, Lao PDR Phnom Penh, Kingdom of Cambodia

Indonesia Oman Egypt Saudi Arabia

Kirloskar Brothers Limited Kirloskar Middle East FZE Kirloskar Brothers Limited Cairo,
Egypt Singapore

As we are constantly endeavoring to improve the performance of our products/ equipment, we reserve the right to
make alterations from time to time and as such our products/ equipment may differ from that detailed in this
publication. For latest information you may get in touch with our Regional Sales Offices.

ISO 9001:2008 ISO 14001:2004

Pumps | Valves | Motors | Hydro Turbines | Turnkey Projects

Corporate & Marketing Office : "Yamuna", Survey No. 98 / 3 to 7 Baner, Pune - 411 045 Maharashtra, (India)
•Phone: +91 - 20 - 2721 4444 • Web Site : www.kbl.co.in
W
o
r
k
s:
India: Kirloskarvadi, Shirwal, Kondhapuri, Dewas
Ove
rseas :Ajman, Cairo, Johannesburg, Nairobi, Phnom Penh, Miami, Vientiane, Bangkok, Amsterdam, Dakar
Reg
ional SalesO ff
ices:India: Ahmedabad, Bangalore, Bhubaneswar, Kolkata, Chennai, Jaipur, Kochi, Lucknow,
Mumbai, Nagpur, New Delhi, Pune, Ranchi, Secunderabad
No 20100816
Paradigm Plus

AUTHORIZED DISTRIBUTOR
PT RAGAM TEKNIK NAMORA
Ruko Paramount Blitz Blok A No.CC.1.
Gading Serpong - Tangerang. Banten. lndonesia. 15811
Ttp.[62]21-5462655 - 57 Fax. [62]21- 5462657
Website : www.ragamtekniknamora.co.id
Email :[email protected]
mobile : 081289816255