Customer Overview

Gharda Chemicals is one of India’s leading chemical manufacturing companies with large-scale industrial operations requiring highly reliable and energy-efficient pumping systems for continuous process applications.

For their Panoli plant project, Gharda had ordered 6 Nos. of UP250/30 utility pumps supplied through Kirloskar Brothers Limited and supported by Vijay Engineering and Machinery Pvt. Ltd..

Challenge Faced During Inspection

As part of the inspection process at VEMPL’s APOEM (Authorized Pumpset Original Equipment Manufacturer) testing facility located at Taloja, Maharashtra, all pumps were subjected to detailed internal performance testing before customer witness inspection and dispatch.

During the inspection of the UP250/30 pumps, the team observed:

• Actual Brake Kilowatt (BKW) values were marginally higher than the declared datasheet values.
• Pump efficiencies were lower than expected with respect to the declared efficiencies as per ISO 9906 Grade 2B permissible limits.
• Consistent positive-side power consumption was observed across all tested pumps.

Although the pumps were technically within ISO permissible tolerance limits, our team identified recurring higher-side power consumption trends during internal performance testing and proactively raised concerns for further technical evaluation.

The matter was subsequently escalated to Kirloskar Brothers Limited for detailed technical evaluation and resolution.

Initial Performance Observations

Root Cause Analysis & Technical Investigation

The VEMPL APOEM and QC teams jointly initiated a detailed technical investigation along with KBL engineers.

Several evaluations and comparative studies were conducted to identify the source of the performance deviation, including:

• Comparative testing using different motor brands
• Performance curve verification
• Power factor evaluation under varying load conditions
• Internal hydraulic component inspection
• Efficiency comparison under multiple operating conditions

During the investigation, the engineering team identified that optimization of the impeller hydraulic passage geometry could significantly improve the pump’s hydraulic performance and efficiency.

Additionally, it was observed that testing the pumps with the customer-specified CGL IE3 motors yielded better performance characteristics compared to the initially tested BBL motors.

Corrective Engineering Actions Taken

To improve the pump performance and achieve satisfactory operating parameters, several corrective engineering actions were implemented on the impeller hydraulics.

The impeller vanes underwent:

• Surface refinishing
• Precision grinding
• Hydraulic profile correction
• Deburring of vane edges
• Controlled polishing of flow passages

These corrective actions enhanced the hydraulic smoothness of the impeller flow passages, thereby reducing internal turbulence and hydraulic losses.

Additionally:

• Pumps were retested using CGL IE3 motors as specified by the customer.
• Power factor and efficiency behavior were analyzed across various duty points.

Testing & Validation

Following the hydraulic corrections and motor optimization, the customer team from Gharda Chemicals was invited to witness the revised performance testing at the VEMPL APOEM facility.

The revised testing demonstrated substantial improvements in efficiency and reduction in BKW consumption.

Observations After Correction

Key Improvements Achieved

• Efficiency improvement achieved up to 90.61%
• Significant reduction in BKW consumption after hydraulic correction
• Improved alignment with declared datasheet parameters
• Enhanced hydraulic stability and operational consistency
• Improved power factor performance with CGL motors
• Successful witnessed performance validation by the customer

The witnessed test results were found satisfactory by the Gharda technical team.

Final Outcome

After successful performance validation and customer witness testing:

• All 6 utility pumps were approved for dispatch
•  Pump performance aligned with customer expectations
• Efficiency and power consumption concerns were successfully resolved
•  Customer confidence was restored through transparent technical collaboration
• Formal dispatch clearance was issued by Gharda Chemicals

Key Highlights

• Comprehensive APOEM inspection and testing support by VEMPL
• Collaborative troubleshooting with Kirloskar Brothers Limited
• Successful impeller vane refinishing and hydraulic optimization
• Improved pump efficiency and reduced hydraulic losses
• Detailed performance validation and witnessed testing
• Customer-approved performance results and dispatch clearance

Conclusion

This project demonstrated VEMPL’s strong technical capabilities in pump performance diagnostics, hydraulic optimization, and customer-focused engineering support.

Through systematic investigation, close coordination with Kirloskar Brothers Limited, and precision corrective actions on the impeller hydraulics, the team successfully resolved a critical efficiency and power consumption concern for Gharda Chemicals.

The successful execution reinforced VEMPL’s commitment to delivering reliable, performance-oriented pumping solutions backed by strong engineering expertise, advanced APOEM testing capabilities, and responsive after-sales support.