indian pump industry @ 2016
TRANSCRIPT
Indian Pump Industry@2016
BY- Dhiraj Kumar
WELCOME
WELCOME
Background of agricultural pump industry in India
Growth of agricultural pump industry in India in past
Present and future production capacity of agricultural pump Industry in India
Scenario of energy efficient pump sets production in India Capacity of producing energy efficient pump sets in India Achievements of Indian pump industry in R&D; etc.
TOPICS TO BE COVERED
• IPMA was established in 1951
• No. of IPMA member – 120 nos.
• Total turnover of pump industry : Rs. 20,000 cr. - IPMA members – Rs. 11,000 cr. - Non-IPMA members – Rs. 9,000 cr.
INDIAN PUMP INDUSTRY – SCENARIO 2016
Product No. of licenses registered under BIS (as on 16.01.16)
No. of brands under BEE(as on 16.01.16)
Submersible pumpsets (IS 8034) 617 264
Open well Sub. Pump sets (IS 14220)
292 91
Electric Moonset Pumps (IS 9079) 114 10
Agriculture43%
Irrig. WS6%
Domestic30%
Industrial13%
Misc.9%
AgricultureIrrig. WSDomesticIndustrialMisc.
4
SECTORWISE DEMAND OF PUMPS IN INDIA
BACKGROUND – AGRO PUMPS IN INDIA
• The agriculture pump market in India is valued at about INR
8600 cr. in 2014-15, and is expected to grow @ 7 to 8 percent
annually.
• Agro pumps growth depends on Govt policy and investments
– Star labeled and solar pumps being at focus
• Due to Erratic monsoon climate and scarcity of water across
areas in the country, govt and manufacturers have to work
together for agricultural growth of the country
• Fluctuations in ground water level is also increased demand
of agricultural pump set in the market
CONTD…
•Rising population & urbanization boosts the demand for
pumps in the market
• Healthy economic outlook also motivates the growth of the
Indian pumps industry
• More than 600 manufacturers at large, medium and small scale
GROWTH OF AGRICULTURAL PUMP INDUSTRY IN INDIA
• In spite of several challenges, Pump manufacturers in India are continuously improving to enhance productivity, quality and service.
• There are lot of engineering expertise in pump manufacturing , so that we are able to offer a wide variety of very efficient products, from renowned manufacturers.
• Market for the Energy Efficient Agriculture Pumps Growing because of the 5 star rating promotion and subsidy benefits given to farmers with new connection.
• Water shortage Due to unreliable monsoons, deep ground water level
will fluctuate and it increase shortage of water• Electrification in Rural Areas it will boost the requirement of agricultural pump sets• Availability of agricultural land Tendency to convert wasteland to cultivating land• Price sensitivity Tough Price sensitivité remaniés high, Customer’
awareness incérasse towards quality and energy efficient
Product• Costs of raw materials Increasing raw material costs (e.g. copper,
aluminium, steel) impact pump prices
GROWTH OF AGRICULTURAL PUMP INDUSTRY IN INDIA
CHALLENGES TO AGRICULTURAL PUMP INDUSTRY IN INDIA
• Most unpredictable business hence difficult to maintain inventory specially to MSMEs
• Different site conditions in different states w.r.t. voltage band, water level, quality of water, etc.
• Poor selection of the pump sets with respect to head and discharge and poor maintenance
• Approval Process for standards and Departmental approvals , varies from department to department and State to state.
PRESENT AND FUTURE PRODUCTION CAPACITY
OF AGRICULTURE PUMP INDUSTRY Summary of Production Capacity
Product Type Star rated pumps
Approx. production /
year
Total present capacity (Approx.)
Monoset Pumps 1 L 3.5 L – 3 Ph9 L – 1 Ph
7L – 3 Ph18 L – 1 Ph
Openwell Submersible pumps 1.25 L 3.5 L 7 L
Submersible Pumps 1.5 L 9 L 19 L
Note : Production Capacity can be increased by investment of nominal capital and man power
FUTURE REQUIREMENT OF AGRICULTURAL PUMPSET IN INDIA
REGIONWISE POTENTIALITY OF SUBMERSIBLE PUMP IN INDIA
REGION STATE IN REGION POTENTIALITY IN QTY.
NORTH INDIA
HARYANA 175000UTTAR PRADESH 150000PUNJAB 137500HIMACHAL PRADESH 25000JAMMU AND KASHMIR 12500TOTAL - A 500000
SOUTH INDIA
ANDHRAPRADESH 150000KARNATAKA 125000TAMILNADU 87500KERALA 25000TOTAL - B 387500
WEST INDIA
RAJASTHAN 150000MADHYAPRADESH 137500GUJARAT 137500MAHARASHTRA 125000CHHATISGARAH 75000TOTAL - C 625000
EAST INDIA
WEST BENGAL 112500JHARKHAND 75000BIHAR 75000ORISSA 75000AASAM 25000TRIPURA/SIKKIM 12500NAGALAND/MEGHALAYA 12500TOTAL - D 387500
TOTAL A+B+C+D 1900000NOTE - ABOVE SUBMERSIBLE PUMP POTENTIALITY COVERED 3" TO 10" DIA. BOREWELL SUBMERSIBLE PUMP
• According to Ministry of Agriculture it accounts for 14% of India’s GDP Project Details
• India`s Agriculture sector consumes about 140 billion units a year which is equivalent to around 18% of total National electricity consumption of India
• The average efficiency level of in-efficient non-star rated pump sets are in the range of 25%-30%
• Efficiency level of star rated energy efficient pump sets is 40%-45%
• Potential of 20% savings is estimated by mere replacement of in- efficient pump sets with star rated pump sets
SCENARIO OF ENERGY EFFICINT PUMPSET IN INDIA
SCENARIO OF ENERGY EFFICINT PUMPSET IN INDIA
LIST OF STAR RATED PUMP MANUFACTURERS IN INDIA HAVING MORE THAN 100 STAR RATED MODELSTOTAL MANUFACTURERS OF STAR RATING MODELS AS PER IS 8034 IN INDIA : 266 NOS.
SR.NO. COMPANY Total Star Rated Models (Nos.)
1 VARUNA 3282 PLUGA 2393 WATERMAN 2294 U-NEEL 2275 CROMPTON GREAVES 1916 AMRUT 1817 C.R.I.PUMPS 1708 TEXMO 1679 MBH PUMPS 148
10 SHAKTI 14611 FALCON 13812 OSWAL 13513 CHETAN 12414 SILVER 12115 UNNATI 10716 ANGEL 100
Source : BEE’s website (as on 21.12.2015)
• In 100 mm bore well dia. submersible pump sets, mass production technologies with noryl impellers• Innovation and cost effective manufacturing of Investment Casting and Fabricated stainless steel Pumps to increase the pump efficiency.• Development of 50ft and 60ft head per stage pumps.• Understanding the Voltage conditions and design pumps as per customer requirements• Burnishing process started to reduce friction losses in motor and hence to increase motor efficiency• Solar pumping system for farming• Submersible DC motors are developed for Solar Application• Sea water pumping system for power generation• Specialized pumps for Oil and Natural Gas Sector, Mining and Metal Ore refining sector, Steel, etc.• Sewage and waste water pump solutions in India
ACHIEVEMENTS OF INDIAN PUMP INDUSTRY IN R&D
Production capacity of producing energy efficient agriculture pump set : 50 lakhs pump set per year
IPMAer means;
Innovator, who sets new trends
Power conserver of the nation
Manufacturers of the pump of highest quality
Abiders of good engineering practices
CAPACITY OF PRODUCING ENERGY EFFICIENT PUMPSET AND ACHIEVEMENT
IN R & D
Methodology Proposed By
Indian Pump & Manufacturers’ Association
(IPMA)For successful
implementation of Ag-DSM Project
Ag-DSM - Pumping Program
Proposed by-Gov. of India
PRESENT SCENARIO OF AGRICULTURE PUMPING
•There are 2.1 Crore electrified pumps in India, being used for agriculture and consuming 92.33 Billion units energy every year, contributes approx 22% of total electricity consumption of India.
•Energy Saving potential in Agriculture Pumps is approx 27.79 Billion Units.
•At present Farmer is getting electricity either free or on very low cost (Flat Rate or Rs. 1 to 1.5/Unit) and that’s why farmer is not interested to improve efficiency of Pumps.
•Even after very low tariff or on flat rate there is huge theft of electricity in agriculture.
•The present average efficiency of the pumps installed is approx 22 to 30%
•There are two major reasons of pumping inefficiency the first one and most important is selection of pump set (Head and Discharge combination in terms of pump stage and model) and second one is inefficient commercial pumps.
PUMP LIFE CYCLE
Pump Capital cost; 5%
Maintinance cost; 5%
Electrcity Cost; 90%
% Cost During Life Cycle
Pump Capital costMaintinance costElectrcity Cost
PRESENT AG-DSM METHODOLOGY
•The present Ag-DSM Projects invites bids from either Manufacturer or ESCO Company, for the “Design, Manufacture, Supply, Dismantling & Installation of 1,00,000 nos. of Agriculture Pumps with 1 Year Warranty and 4 to 5 years Repair & Maintenance.
Having Competencies to Manufacture Energy Efficient PumpNot Having Team to Manage Projects and 5 Year Maintenance
High Cost for 5 Year Maintenance
Only Manufactur
erCost of Pump Becomes High
Investment of Product and services is Difficult
Difficult to Find out all Kind of required Pumps
Only ESCOCompany
PROPOSED METHODOLOGY-1
EESL
ESCO (Execute the
Project , establish the saving, and
remote monitoring of EE Pumps)
Manufacturer
(Rate contract With EE Pump Manufacturer)
PROPOSED METHODOLOGY-1STEP-1
•By this No. Of Manufacturer will BID and PMC will get competitive price and required quantity at any time, which reduce the lead time of project execution.
EESL Will Float a Tender •For The Empanelment of EE Pump Manufacturer•Rate Contract will be done with No. of Manufacturer •For EE Pump with Controller with Defined Specifications & One year standard warranty only
Payment to the Manufacturer
•70% Payment will be made after supply of Pumps •20% After achieving of Required efficiency/Results•10% after successful completion of warranty period of one year
PROPOSED METHODOLOGY-1STEP-2
Option 1Separate Tender for ESCO – Based On Per site Cost
• Tender will be awarded based on less cost per site• Selection, Installation and Maintenance of EE Pumps • Achieve and sustain efficiency/saving• Establish and Maintain Remote Monitoring system
Payment to the ESCO Company – Per Site Basis
• Fix Cost Per site Basis• 60% After success full Installation and achieving the efficiency/saving • 10 % after Establishment of Remote Monitoring system• Balance 6% each year after success full completion, for 5 years
PROPOSED METHODOLOGY-1STEP-2
Option -2 Separate Tender for ESCO – Sharing Basis
• Tender will be awarded, who offer higher sharing to the EESL• Selection, Installation and Maintenance of EE Pumps • Achieve and sustain efficiency• Establish and Maintain Remote Monitoring system
Payment to the ESCO Company – Sharing Basis b/w EESL and ESCO Based on Tender
• 50% on deemed saving approach after achieving of efficiency/Saving and establishment of Remote Monitoring system
• Balance 10% each year after successful completion of a year for 5 years
PROPOSED METHODOLOGY-1
•This will be responsibility of the EESL to float tenders, investment, take payment from concerning DISCOM, awareness among farmers and other related issues.
•EESL/ESCO Shall also establish a common portal on which Manufacturer will provide the detail of star rated pumps with head and discharge with lead time of supply, so that ESCO Can select the pumps from them, as well as entire project shall be updated on the same at each step.
•By the remote monitoring system transparent data of power consumption can be obtain, further remote access (ON/OFF) of the pump through mobile may also be provided to farmer, farmer may also send complain through this.
2ND PROPOSALAGDSM-WITH SOLAR PUMP
AGDSM/ESCO Model For Solar Pump, will be workable for any Bidder with 6 years pay back and working Life for 20 Years. Consideration for ESCO-Solar Pump ModelSubsidy of 30% (Central Government) for Capital Investment
Power cost for Rs. 7/Kwh (After saving can be supplied to Industrial customer.
Interest On Capital 12.5%Detail Calculation ESCO SOLAR
BENEFITS OF SOLAR BASED ESCO
No capital investment to Generate Power plant and Transmission and Distribution Infrastructure which cost Rs. 30 to 40 Million Per MW, and approx 20 Million Per MW for T&D.
Life span of Solar Module is 25 Years, project can be design for 20-25 years.
No chances of Theft, Losses during T&D For Farmer, reliable electricity during Day Time, However in conventional electricity farmer get it mostly during Night Time
The saved electricity can be supplied to Industries. Need not to constant monitoring for energy saving achieved Additional Benefits can be taken By connecting Grid to obtain the power generated during non agriculture season.
