Dsoy dk;Zky;hu mi;ksx gsrq

(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS

TROUBLE SHOOTING
AND
MAINTENANCE
OF
SUBMERSIBLE PUMPS

CAMTECH/ E/ 2018-19/ EP-09/ Submersible Pump/ 1.0

February, 2019
(DRAFT)

Maharajpur, GWALIOR - 474 005

 Trouble Shooting
And
Maintenance
Of Submersible Pumps

QUALITY POLICY
(DRAFT)
“To develop safe, modern and cost
effective Railway Technology
complying with Statutory and
Regulatory requirements, through
excellence in Research, Designs and
Standards and Continual
improvements in Quality
Management System to cater to
growing demand of passenger and
freight traffic on the railways”.
 PREFACE

Submersible pumps of various capacities have wide applications over

Indian Railways in pumping installations and their proper upkeep and
maintenance are essential for trouble-free supply of water for day to day
operations.

This handbook on "Troubleshooting and Maintenance of Submersible

pumps” is prepared with the objective to disseminate knowledge on pumps and
their selection, installation. This handbook comprises general description,
selection and installation along with troubleshooting for common troubles.
This handbook also comprises selection of cables for pumps, minimum
submergence etc.

It is clarified that this handbook does not supersede any existing

provisions laid down by Railway Board/ Zonal Railways/ RDSO, OEMs. This
handbook is for guidance only and it is not a statutory document.

I am sincerely thankful to all field personnel who helped us in preparing

this handbook. Technological up-gradation & learning is a continuous process.
Please feel free to write us for any addition/ modification in this handbook.

CAMTECH, Gwalior Manoj Kumar

Date: 22.02.2019 Joint Director /Mech
 CONTENT
Chapter No Description Page no.

Preface iii
Contents iv
1. GENERAL DESCRIPTION 01
1.1 PUMP 01
1.2 CLASSIFICATION OF PUMPS 01
1.3 SUBMERSIBLE PUMP 01
1.4 ADVANTAGES OF SUBMERSIBLE PUMP 02
1.5 DISADVANTAGES OF SUBMERSIBLE PUMP 02
1.6 APPLICATION OF SUBMERSIBLE PUMP 02
1.7 BASIC TERMINOLOGY OF PUMP 03
1.7.1 Head 03
1.7.2 Static Head 03
1.7.3 Total Head/ Total Dynamic Head 03
1.7.4 NPSH (Net Positive Suction Head) 03
1.7.5 Specific Gravity (S.G.) 03
1.7.6 Specific Speed 04
1.7.7 Vapour Pressure 04
1.7.8 Viscosity 04
1.7.9 Flow (Q) 04
1.7.10 Friction Loss 04
1.7.11 Friction 04
1.7.12 Shaft 05
1.7.13 Cavitation 05

2. SELECTION AND INSTALLATION OF PUMP 06

2.1 INSTALLATION 06
2.1.1 Positional Requirements 06
2.1.2 Liquid Temperatures/ Cooling 06
2.1.3 Maximum Liquid Temperature 06
2.2 ELECTRICAL CONNECTIONS 06
2.2.1 General Instructions 06
2.2.2 Motor Protection 07
2.2.3 Lightening Protection 08
2.2.4 Cable Sizing 08
2.2.5 Control of Single-Phase Motors 09
2.2.6 Connection of Single-Phase Motors 09
2.2.7 Connection of Three-Phase Motors 09
2.2.8 Direct-On-Line Starting of Motors 09
2.2.9 Star-Delta Starting of Motors 10
2.2.10 Connection in Case of Unidentified Cable Marking/Connection 10
Chapter No Description Page no.

2.2.11 Soft Starter 10

2.3 ASSEMBLY OF MOTOR, PUMP AND INSTALLATION 10
2.3.1 Assembly of Motor and Pump 10
2.3.2 Fitting of Submersible Drop Cable 12
2.3.3 Riser Pipe 12
2.3.4 Cable Fitting 12
2.3.5 Lowering The Pump 13
2.3.6 Installation Depth 13
2.4 START-UP AND OPERATION 14

3. TROUBLE SHOORING 15
4. MISCELLANEOUS 18
4.1 SELECTION OF CABLE SIZE 18
4.1.1 How to Choose Correct Cable Size According Pump? 18
4.1.2 Points to Take into Consideration When Selecting Cables 18
4.2 PUMP SELECTION 19
4.2.1 Application of Pump 19
4.2.2 Head Discharge 19
4.2.3 Power 20
4.2.4 NPSH (Net Positive Suction Head) 21
4.2.5 Efficiency 22
4.2.6 Pump Selection Curve 22
4.2.7 Head Flow Curve 23
4.2.8 Material 23
4.2.9 Fluid 24
4.3 INSULATION CLASS 24
4.3.1 Insulation Class A 24
4.3.2 Insulation Class B 25
4.3.3 Insulation Class F 25
4.3.4 Insulation Class H 25
4.3.5 Important Factors Selecting Insulation Class for Motor 25

5. MINIMUM SUBMERGENCE 26
5.1 INTRODUCTION 26
5.2 MINIMUM SUBMERGENCE 26
5.3 CAVITATION 27
5.4 VORTEXING 27
5.5 ENTRAINED GAS 28

REFERENCE 29
CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 1

CHAPTER 1

GENERAL DESCRIPTION

1.1 PUMP
 Pump is a mechanical device which raises the energy levels of various fluids by
converting kinetic energy imparted by its prime movers into hydraulic energy.
 Pump is a machine to transport the liquid from one place to another place usually
through a pipe.
 It imparts energy to a fluid passing through it to enable the fluid to move from one point
to another.
 It converts mechanical energy into kinetic energy.
 In practice, pumps change both the velocity and the pressure passing through them.
 A pump may, therefore, be defined as “a mechanical device which converts the
mechanical energy imparted to it from an external source (electric motor, diesel engine
or even manual energy) into hydraulic energy in the fluid handled by it”.
 As a consequence, the energy level of fluid handled by the pump or flowing through the
pump is augmented, making it possible for the fluid to move from a lower level to a
higher level, against gravity and friction.

1.2 CLASSIFICATION OF PUMPS

PUMPS

Positive Displacement Pumps Centrifugal Pumps

Reciprocating Pumps Rotary Pumps

Gear Pumps
Piston Pumps
Lobe Pumps
Plunger Pumps Screw Pumps

Diaphragm Pumps Cam Pumps

Vane Pumps

1.3 SUBMERSIBLE PUMP

 This pump initially found most versatile use in naval applications and gained popularity
for deep well applications.
 Both pump and motor are installed deep inside the tube-well/ bore well.
 It makes, suction head minimum which makes it possible to lift water from depths as
low as 800 meters.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

2 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

 These pumps are coupled with wet type squirrel cage induction motor/ PMSM
(Permanent Magnet Synchronous Motors)/ IPMSM (Integrated Permanent Magnet
Synchronous Motors)/ BLDC (Brush Less D C motors). Both motor and pump operate
totally submerged below the surface of water.
 The motor winding is either wet or dry type.

1.4 ADVANTAGES OF SUBMERSIBLE PUMP

 Lower initial investment.
 Easy to install, as it requires no foundation.
 Lower operational and maintenance cost due to near perfect hydroelectric design and
perfect workmanship.
 Oiling or Greasing of bearing is not required, since the bearings are water lubricated.
 Long life: Sturdy construction protected against corrosion and abrasion.
 Pump is below water level, as such there is no suction trouble.
 Reliable: Motor winding designed to withstand normal fluctuation and normal overload.
 Noise and vibration free operation.
 Sleek design: More clearance between pump and bore casing pipe.
 Overall efficiency of pumping is highest in submersible pump.

1.5 DISADVANTAGES OF SUBMERSIBLE PUMP

 Motor is comparatively costlier than a vertical turbine pump.

 The water has to be perfectly clear, free from sand, as sand has an abrasive action on the
impellers.

 The supply voltage has to be perfectly good and fairly constant, since considerable
voltage drop occurs in the cable as the motor is under great depth.

 Rewinding and repair of the motor is a specialized job and it has to be absolutely
perfect.

1.6 APPLICATION OF SUBMERSIBLE PUMP

 Domestic
 Fountain
 High Rise Building
 Construction
 Agriculture
 Drip & Sprinkler Irrigation
 Irrigation
 Water Circulation
 Rural Water Supply Schemes
 Industrial Water Supply
 Process House

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 3

1.7 BASIC TERMINOLOGY OF PUMP

1.7.1 Head

The head of the pump is an expression of how much height the pump can lift the
liquid. This is measured in terms of meter of water column, independent on the liquid density.

1.7.2 Static Head

 The vertical height difference from surface of water source to centreline of impeller is
termed as static suction head or suction lift (‘suction lift’ can also mean total suction
head).

 The vertical height difference from centreline of impeller to discharge point is termed as
discharge static head.

 The vertical height difference from surface of water source to discharge point is termed
as total static head.

1.7.3 Total Head/ Total Dynamic Head

Total height difference (total static head) plus friction losses & ‘demand’ pressure
from nozzles etc. i.e. Total Suction Head + Total Delivery head = Total Dynamic Head.

1.7.4 NPSH (Net positive suction head)

Net positive suction head – related to how much suction lift a pump can achieve by
creating a partial vacuum. Atmospheric pressure then pushes liquid into pump. A method of
calculating if the pump will work or not.

Net Positive Suction Head or NPSH for pumps can be defined as the difference
between liquid pressure at pump suction and liquid vapor pressure, expressed in terms of
height of liquid column.

1.7.5 Specific Gravity (S.G.)

Specific gravity, weight of liquid in comparison to water at approximate 20°C (SG = 1)

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

4 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

1.7.5 Specific Speed

A number which is the function of pump flow, head, efficiency etc. Not used in day
to day pump selection, but very useful as pumps with similar specific speed will have
similar shaped curves, similar efficiency/ NPSH/ solids handling characteristics.

1.7.6 Vapour Pressure

If the vapour pressure of a liquid is greater than the surrounding air pressure, the
liquid will boil.

1.7.7 Viscosity

A measure of a liquid’s resistance to flow i.e. how thick it is. The viscosity
determines the type of pump used, the speed it can run at, and with gear pumps, the internal
clearances required.

1.7.8 Flow (Q)

Flow rate with which liquid is moved by the pump. Measured in m3/hr or GPM, LPD,
LPM or LPS.
Capacity depends on- liquid characteristics, pump size, inlet & outlet sections,
impeller size, impeller rotational speed RPM, size & shape of angles between vanes.

1.7.9 Friction Loss

The amount of pressure/ head required to ‘force’ liquid through pipe and fittings.

1.7.10 Friction

It is a form of resistance to the movement of

flow. This is depending on velocity and the area.
This is measured in terms of head in meters.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 5

1.7.11 Shaft

Shaft is a component that carries all the rotating pump parts and also provides power
to the impeller. The shaft has to withstand the rotating torque, axial and radial thrust.

1.7.12 Cavitation

If the pressure drops below the vapour pressure of the liquid at the operating
temperature, the liquid will vaporize.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

6 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

CHAPTER 2

SELECTION AND INSTALATION OF PUMP

2.1 INSTALLATION:
Before installation, read the installation and operating manual of OEM carefully for right
method of installation.

2.1.1 Positional Requirements

 Where it is accessible, the coupling must be suitably isolated from human touch.
 Depending on motor type, the pump can be installed either vertically or horizontally.
 If the pump is installed horizontally, the discharge port should never fall below the
horizontal plane.
 If the pump is installed horizontally, e.g. in a tank, it is recommended to fit it in a flow
sleeve.

2.1.2 Liquid Temperatures/ Cooling

 It is recommended to install them on or above the well screen in order to achieve proper
motor cooling
 In cases where the stated liquid velocity cannot be achieved, a flow sleeve must be
installed.
 If there is a risk of sediment deposition, such as sand, around the motor, a flow sleeve
should be used in order to ensure proper cooling of the motor.

2.1.3 Maximum Liquid Temperature

 Out of consideration for the rubber parts in pump and motor, the liquid temperature
must not exceed 40 °C (~105 °F).

 The pump can operate at liquid temperatures between40°Cand60°C (~105°Fand 140°F)

provided that all rubber parts are 140°F and provided that all rubber parts are replaced
every third year.

2.2 ELECTRICAL CONNECTIONS

Warning

Before connecting the pump supply, make sure that the electricity supply has been
switched ‘OFF’ so that it cannot be accidentally switched ‘ON’.

2.2.1 General Instructions

 The electrical connection should be carried out by an authorized electrician in
accordance with local regulations.
 The supply voltage, rated maximum current and power factor (cosø) appear from the
loose data plate that must be fitted close to the installation site.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 7

 The required voltage quality for submersible motors, measured at the motor terminals,
is –10%/+6% of the nominal voltage during the supply voltage and losses in cables.
 The pump must be properly earthed.
 The pump must be connected to an external mains switch with a minimum contact gap
of 3mm in all poles.
 The motors are wound for direct-on-line starting or star-delta starting and the starting
current is between 4 and 6 times the full load current of the motor.
 The run-up time of the pump is only about 0.1 second. Direct-on-line starting is
therefore normally approved by the electricity supply authorities.

2.2.2 Motor Protection

2.2.2.1 Single-phase Motors
 Single-phase submersible motors type 4” must be protected by a protective
device which can either be incorporated in a control box or separate.
2.2.2.2 Three-phase Motors
 Motors have no built in temperature transmitter. A PT-100 sensor is available
as an accessory. Motors with PT-100 sensor must be protected by means of:
 Motor starter with relay or connector(s)
2.2.2.3 Required Motor Starter Settings
 For cold motors, the tripping time for the
motor starter must be less than 10 seconds
at 5 times the rated maximum current of
the motor.
 In order to ensure the optimum protection
of the submersible motor, the starter
overload unit should be set in accordance
with the following guidelines:
1. Set the starter overload to the rated
maximum current of the motor.
2. Start the pump and let it run for half
an hour at normal performance.
3. Slowly grade down the scale indicator
until the motor trip point is reached.
4. Increase the overload setting by 5 %.

 The highest permissible setting is the rated

maximum current of the motor.
 For motors wound for star-delta starting, the starter overload unit should be
set as above, but the maximum setting should be as:
𝑺𝒕𝒂𝒓𝒕𝒆𝒓 𝒐𝒗𝒆𝒓𝒍𝒐𝒂𝒅 𝒔𝒆𝒕𝒕𝒊𝒏𝒈 = 𝑹𝒂𝒕𝒆𝒅 𝒎𝒂𝒙𝒊𝒎𝒖𝒎 𝒙 𝟎. 𝟓𝟖

 The highest permissible start-up time for star-delta starting or auto

transformer starting is 2 seconds.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

8 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

2.2.3 Lightening Protection

 The installation can be fitted with a special over voltage protective device to protect the
motor from voltage surges in the electricity supply lines when lightning strikes
somewhere in the area.
 The overvoltage protective device will not, however, protect the motor against a direct
stroke of lightning.
 The overvoltage protective device should be connected to the installation as close as
possible to the motor and always in accordance with local regulations.

2.2.4 Cable Sizing

 Make sure that the submersible drop cable can withstand permanent submersion in the
actual liquid and at the actual temperature.
 The cross-section (q) of the cable should meet the following requirements:
i. The submersible drop cable should be sized to the rated maximum current (I) of
the motor.
ii. The cross-section should be sufficient to make a voltage drop over the cable
acceptable.

Nominal Area in mm2

Current Rating at 40°C (Amp).
(for copper conductor)
1.5 14
2.5 18
4 26
6 31
10 42
16 57
25 72
35 90
50 115

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 9

2.2.5 Control of Single-Phase Motors

The single-phase submersible motor with motor protection(separate)which cuts out

the motor in case of excessive winding temperatures while the motor is still supplied with
voltage. Allow forth is, when the motor forms part of a control system.

2.2.6 Connection of Single-Phase Motors

The single phase motors are connected to the
mains via an operating capacitor which
should be sized for continuous operation.

2.2.7 Connection of Three-Phase Motors

 Three-phase submersible motors must be
protected.
 When a conventional motor starter is being used, the electrical connection should be
carried out as described below:

2.2.7.1 Checking of direction of Rotation

When the pump has been connected to the electric supply, determine the correct
direction of rotation as follows:
1. Start the pump and check the quantity of water and head developed.
2. In case of head not developed, stop the pump and interchange two of the phase
connections. In the case of motors wound for star-delta starting, exchange lead wire.
3. Again start the pump and check the quantity of water and head developed.
4. Stop the pump and compare the results taken under points 1 and 3, the connection
which gives the larger quantity of water and the higher head is the correct
connection.

2.2.8 Direct-On-Line Starting of Motors

The connection of submersible motors wound for direct-on-line starting appears

below:

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

10 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

2.2.9 Star-Delta Starting of Motors

The connection of submersible motors wound for star delta

starting appears below:

2.2.10 Connection in case of unidentified cable marking/connection

If it is unknown where the individual leads are to be connected to

the mains in order to ensure the correct direction of rotation, proceed as
follows:

2.2.10.1 Motors wound for direct-on-line starting

Connect the pump to the mains as is expected to be right.

Then check the direction of rotation as described in earlier section of
Checking of direction of rotation.

2.2.10.2 Motors wound for star-delta starting

The windings of the motor are determined by means of an ohmmeter,

and the lead sets for the individual windings are named accordingly.

If star-delta starting is required, the leads should be connected as

shown earlier.

If direct-on-line starting is required, the leads should be connected as

shown earlier. Then check the direction of rotation.

2.2.11 Soft Starter

The use of soft starters which control the voltage on all three phases and which are
provided with a bypass switch is recommended.

2.3 ASSEMBLY OF MOTOR, PUMP AND INSTALLATION

Warning
Before starting any work on the pump/motor, make sure that the electric supply has
been switched ‘OFF’ so that it cannot be accidentally switched ‘ON’.

2.3.1 Assembly of Motor and Pump

How to couple motor with pump:

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 11

The bolts and nuts securing the straps to the pump must be tightened diagonally to
the torques stated in the following table:

Table-1
Straps Bolt/Nut Torque [Nm]
M8 18
M10 35
M12 45
M16 120

Caution

Make sure that the coupling between the pump and motor engages properly. When
assembling the motor and pump, the nuts must be tightened diagonally to the torques stated
in the following table:

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

12 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

Pump/Motor Stay Bolt Size Torque [Nm]

M8 18
M12 150
M16 200
M20 300
Caution

Make sure that the pump chambers are aligned when assembly has been completed.

2.3.2 Fitting of Submersible Drop Cable

 Before fitting the submersible drop cable to the motor, make sure that the cable socket
is clean and dry.
 To facilitate the fitting of the cable, lubricate the rubber parts of the cable plug with
non-conducting silicone paste.
 Tighten the screws holding the cable to the torques stated:
Motor 4”: 1.5 Nm
Motor 6": 4.0-5.0 Nm
Motor 8": 15.0 Nm

2.3.3 Riser pipe

 If a tool, e.g. a chain pipe wrench, is used when
the riser pipe is fitted to the pump, the pump must
only be gripped by the pump discharge chamber.
 The threaded joints on the riser pipe must all be
well cut and fit together to ensure that they do not
work loose when subjected to torque reaction
caused by the starting and stopping of the pump.
 The thread on the first section of the riser pipe
which is to be screwed into the pump should not
be longer than the threads in the pump.

NOTE:
• Plastic pipes are recommended for 4” pumps only.
• When plastic pipes are used, an unloaded straining wire to be fastened to the discharge
chamber of the pump, should secure the pump. See figure.
• When connecting plastic pipes, a compression coupling should be used between the
pump and the first pipe section.
• Where flanged pipes are used, the flanges should be slotted to take the submersible drop
cable and a water indicator hose, if fitted.

2.3.4 Cable fitting

Cable clips must be fitted every 3 meters to fix the submersible drop cable and the straining
wire, if fitted, to the riser pipe of the pump.
• Cable clip set consists of a 1.5 mm thick rubber band and buttons.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 13

• Cable fitting: Cut off the rubber band so that the piece with no slit becomes as long as
possible.
• Insert a button in the first slit.
• Position the wire alongside the submersible drop cable,
• Wind the band once around the wire and the cable.
• Then wind it tightly at least twice around the pipe, wire and the cable.
• Push the slit over the button and then cut off the band.
• Where large cable cross-sections are used, it will be necessary to wind the band several
times.
• Where plastic pipes are used, some slackness must be left between each cable clip as
plastic pipes expand when loaded.
• When flanged pipes are used, the cable clips should be fitted above and below each
joint.

2.3.5 Lowering the Pump

• It is recommended to check the borehole by means of an inside caliper before lowering

the pump to ensure unobstructed passage.
• Lower the pump carefully into the borehole, taking care not to damage the motor cable
and the submersible drop cable.

Note:
Do not lower or lift the pump by means of the motor cable.

2.3.6 Installation depth

• The dynamic water level should always be above the suction interconnector of the
pump.
• Minimum inlet pressure is indicated in the NPSH curve for the pump.
• The minimum safety margin should be 1metre head.
• It is recommended to install the pump so that the motor part is above the well screen in
order to ensure optimum cooling.
• When the pump has been installed to the required depth, the installation should be
finished by means of a borehole seal.
• Slacken the straining wire so that it becomes unloaded and lock it to the borehole seal
by means of wire locks.

NOTE: For pumps fitted with plastic pipes, the expansion of the pipes when loaded
should be taken into consideration, when deciding on the installation depth of
the pump.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

14 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

2.4 START-UP AND OPERATION

• When the pump has been connected correctly and it is submerged in the water to be
pumped, it should be started with the discharge valve closed off to approximate 1/3 of its
maximum volume of water.
• Check the direction of rotation as described
earlier under “Checking of direction of
rotation”.
• If there are impurities in the water, the valve
should be opened gradually as the water
becomes clearer. The pump should not be
stopped until the water is completely clean,
as otherwise, the pump parts and the non-
return valve may choke up.
• As the valve is being opened, the drawdown
of the water level should be checked to
ensure that the pump always remains
submerged.
• The dynamic water level should always be
above the suction interconnector of the
pump.

Where:
L1: Minimum installation depth below
dynamic water level. Minimum 1 meter
is recommended.
L2 : Depth to dynamic water level.
L3 : Depth to static water level.
L4: Drawdown. This is the difference
between the dynamic and the static water
levels.
L5: Installation depth.
• If the pump can pump more than yielded by the well, it is recommended to fit the motor
protector, or some other type of dry-running protection.
• If no water level electrodes or level switches are installed, the water level may be drawn
down to the suction interconnector of the pump and the pump will then draw in air.
Caution

Long time operation without water or containing air may damage the pump and
cause insufficient cooling of the motor.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 15

CHAPTER 3

TROUBLE SHOOTING

S. Fault Probable Causes Suggested Remedial Measures

No.
1. The pump a) The fuses are blown. Replace the blown fuses. If the new
does ones blow again, the electric installation
not run. and the submersible drop cable should
be checked.
b) The ELCB or the Cut in the circuit breaker.
voltage- operated ELCB
has tripped out.
c) No electric supply. Contact the electricity supply
authorities.
d) The motor starter Reset the motor starter overload
overload has tripped out. (automatically or possibly manually). If
it trips out again, check the voltage. Is
the voltage OK, see items e) to h)
below.
e) Motor starter/contactor Replace the motor starter/contactor.
is defective.

f) Starter device is Repair/replace the starter device.

defective.
g) The control circuit has Check the electric installation.
been interrupted or is
defective.
h) The dry-running Check the water level. If it is OK, check
protection has cut off the the water level electrodes/level switch.
electric supply to the
pump, due to low water
level.
I) The pump/submersible Repair/replace the pump/cable.
drop cable is defective.
2. The pump a) The discharge valve is Open the valve.
runs but closed.
gives no b) No water or too low See item 3 a) below.
water. water level in borehole.
c) The non-return valve is Pull out the pump and clean or replace
stuck in its shut the valve.
position.
d) The inlet strainer is Pull out the pump and clean the strainer.
choked up.
e) The pump is defective. Repair/replace the pump.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

16 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

3. The pump a) The drawdown is larger Increase the installation depth of the
runs at than anticipated. pump, throttle the pump or replace it by
reduced a smaller model to obtain a smaller
capacity. capacity.

b) Wrong direction of See earlier section “Checking of

rotation. direction of rotation”.

c) The valves in the Check and clean/replace the valves, if

discharge pipe are necessary.
partly closed/blocked

d) The discharge pipe is Clean/replace the discharge pipe.

partly choked by
impurities (ochre).

e) The non-return valve of Pull out the pump and check/replace the
the pump is partly valve.
blocked.

f) The pump and the riser Pull out the pump. Check and clean or
pipe are partly choked replace the pump, if necessary. Clean
by impurities (ochre). the pipes.

g) The pump is defective. Repair/replace the pump.

h) Leakage in the pipe Check and repair the pipe work.

work.

i) The riser pipe is Replace the riser pipe.

defective.

4. Pump gives a) The differential of the Increase the differential. However, the
less than the pressure switch between stop pressure must not exceed the
rated the start and stop operating pressure of the pressure tank,
discharge pressures is too small. and the start pressure should be high
enough to ensure sufficient water
supply.

b) The water level Adjust the intervals of the

electrodes or level electrodes/level switches to ensure
switches in the reservoir suitable time between the cutting-in and
have not been installed cutting-out of the pump. If the intervals
correctly. between stop/start cannot be changed
via the automatics, the pump capacity
may be reduced by throttling the
discharge valve.

c) The non-return valve is Pull out the pump and clean/replace the
leaking or stuck half- non-return valve.
open.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 17

d) The volume of air in the Adjust the volume of air in the

pressure/diaphragm tank pressure/diaphragm tank in accordance
is too small. with its installation and operating
instructions.

e) The pressure/diaphragm Increase the capacity of the

tank is too small. pressure/diaphragm tank by replacing or
supplementing with another tank.

f) The diaphragm of the Check the diaphragm tank.

diaphragm tank is
defective.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

18 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

CHAPTER 4

MISCELLANEOUS
4.1 SELECTION OF CABLE SIZE

4.1.1 How to choose correct cable size according pump?

 Cable selection is a very important factor while selecting a pump and motor. If we did
not select a proper size cable so whether it can damage motor or gave a heavy electricity
bill.
 All cables are not appropriate to use in submersible motor because all the cables are not
able to stop water to enter in it periphery, submersible motor needs water proof cables.
 If waterproof cable will not be used, this condition can result in premature failure or
damage of cable, motor and control panel.

4.1.2 Points to take into consideration when selecting cables

 Selected cable shall be suitable for the field condition where it is to be used in.

 It shall be adequate in size to operate within the rated temperature of the cable and to
ensure the voltage drop within 3% from the point of supply to the motor terminals.

 Cable manufacturer rating is specifically specified for continuous use within a

submerged state.

 If simply someone took the same cable type to cover the distance from splice to
electrical panel, the cable would most likely to burn and so would submersible motor.
This is because the cable will get overheated in open air due to its small cross-section
area &also due to length of cable, it will generate a large voltage drop so the motor will
be under-supplied.

 For these reasons, borehole professionals will splice the motor short lead to a larger
cross-size “drop cable” that will safely carry the required current and supply the motor
with the desired voltage.

 Some important data needed for sizing the cable:

 Chemical properties of the water.
 Temperature of water inside bore hole.
 Temperature of air in the borehole and along the entire field where cable installed
 Max. submergence (or max pressure in booster applications)
 Agency approvals: water condition drinking water or non-drinking water
 Nominal operating voltage of load
 Nominal motor current
 Cos Ф (power factor) of motor
 Total length (from submersible motor to electrical panel)

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 19

4.2 PUMP SELECTION

General pump selection criteria based on following points:
1. Pump application
2. Head discharge
3. Efficiency
4. NPSH
5. Power
6. Material
7. Fluid

4.2.1 Application of Pump

It contains two major points field of usage whether industrial, agriculture or
domestic purpose and select a pump according to the nature of fluid used weather it is oil,
water or any other type of fluid.

Two major types of pumps are used

a. Surface pumps (pumps used on surface)
b. Submersible pumps (pumps used under water)

a. Surface Pumps
Surface pumps are designed to pump water from surface source like spring,
ponds, tanks or wells. Basically if we have water in reservoir then we use surface pump.
One more reason to use surface pump, if we head long suction head another reason for
selecting surface pump is cheap cost. Most of our surface pumps are either diaphragm
pump or rotary vane pump.

b. Submersible pump
Pump which merged in water with their motor are known as submersible pump.
They made up of steel which have high corrosion resistance properties below and that is
why it is costly than surface pump and one more thing this pump majorly used have low
suction head.

4.2.2 Head Discharge

Total Suction Head (TSH)

𝑇𝑜𝑡𝑎𝑙 𝑠𝑢𝑐𝑡𝑖𝑜𝑛 ℎ𝑒𝑎𝑑 = (𝑠𝑡𝑎𝑡𝑖𝑐 ℎ𝑒𝑎𝑑 + 𝑠𝑡𝑎𝑡𝑖𝑐 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 ℎ𝑒𝑎𝑑 + 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑙𝑜𝑠𝑠)

Static head: static head means height from water taken.

Static discharge head: head between the pump and the storage reservoir where water has
to pump or discharge.
Friction loss: it is loss which happens due to friction present in pipe and system.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

20 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

Head discharge

Head discharge basically a term which shows total fluid discharge from the
pump. It generally measures in meters.

Head and discharge curve

Fig: Head and discharge curve

The above curve shows relation between head and volume (discharge).
 Start at a point called the closed value head where the pump is the not doing any
work just generating pressure.
 It is a point where we don't want pump to work at all because it is simply churning
at the point.
 The flow rate then increase and the available head drop off.
The head of centrifugal pump is determined by impeller diameter and rpm.
 To select the point for operating point of the pump. It should be selected at duty
point because at duty point pump provide maximum efficiency.

4.2.3 Power

Pump power is nothing but basically it is a power of motor which used by pump to
transfer water from one place to other and it play a very important role in pump selection.
Power curve is provided below for better understanding.

Power curve

The power curve shows the power used by the pump at particular flow rate. The
selection of power for particular pump should at the point of maximum flow rate because if
the operator run the pump at greater than duty point then pump will not gave maximum
overall efficiency. If the power is selected at duty point, pump life and efficiency both will
be good.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 21

Fig: Power Curve

4.2.4 NPSH (Net Positive Suction Head)

NPSH means “Net Positive Suction Head”and it is further dividedin two categories.

i. NPSHR (net positive suction head required):It means the minimum pressure
required at the suction port of the pump to keep the pump away from cavitation.

ii. NPSHA (net positive suction head available): NPSHA is a function of installed
system and must be calculated, whereas NPSHR is function of pump and provided by
pump manufacturer.

NPSH Curve

Fig: NPSH Curve

The curve that is shown on this set is the NPSH (net positive suction head). It shows
the immersion that the pump impeller needs to avoid it get cavity and becoming damaged.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

22 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

For cavitation free operation of the pump NPSHA should be greater than NPSHR
to calculate NPSHAfollowing formula is used.

NPSHA = Ha –Hv +Hs - Hf

Where,
Ha = atmospheric pressure at sea level
Hv = vapor pressure of fluid at operating temperature
+Hs = suction head
-Hf = suction lift

4.2.5 Efficiency

In most of the cases, user neglects the efficiency of pump compared to price. But in
the simple way to understand effectively, “more efficiency more profit”.

Efficiency curve

The curve is shown below; it is an efficiency curve.

Fig: Efficiency Curve

The point on curve is a best efficiency point that is where one really want the
pump to run to achieve the beat overall solution for our particular system.

4.2.6 Pump selection curve

This curve contains all the curves of related parameter of pump and help to selecting
a good pump.

Fig: Pump selection Curve

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 23

Now, for selecting a pump, first we see best efficiency point on curve. Compare that
point with the duty point .If the best efficiency point close to our pump duty point which is
on head discharge curve. Then our system is ideal for selection and gives better result to add
better performance.

BEP (Best Efficiency Point)

It is a point which lies on efficiency curve and it is a maximum efficiency point

where pump give maximum efficiency and profit.

Duty Point
It is a point on which we select our pump, we compare our pump's duty point with
BEP which present on efficiency curve.

According to that duty point we select the power used to run the pump.

4.2.7 Head Flow Curve

This curve shows, if your duty point lies in between point A1 and point A2 on the
following place then your pump will get maximum performance, shows this type of
characteristic which shows on plotted curve.

Fig: Head Flow Curve

4.2.8 Material

Material plays a vital role in pump selection and it clearly affects the application and life of
pump. So following basic properties of material should be considered for material selection
 Corrosion resistance
 Abrasive-wear resistance
 Cavitation resistance
 Strength
 Casting and machining properties
 Cost

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

24 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

Material preference according cost and properties rank wise order from high material
properties to low material properties in both surface & submersible pump.

 Nickel aluminum bronze alloy

 Titanium
 Bronze
 Stainless steel 304
 Stainless steel 316
 Cast iron
 Brass
 Mild steel

4.2.9 Fluid
Fluid is another important parameter in pump selection because you might need to
specify a pump that delivers 10 bars of pressure. But if you do not consider the pumped
liquid properties, it is highly unlikely you will make the right choice.

If you don't account differing viscosity and density of liquid,you may end up with
too big a pump, which is overly expensive to buy and run. if the pump is too small you
simply burn out the motor of pump. The denser liquid need more power to transfer liquid
and at different temperature the liquid change it density so keep this in mind while selecting
pump.

CONCLUSION

It is concluded that if we consider given points in above discussion that we can select
a appropriate pump for our application. The most important point of pump selection is duty
point where we measure all the parameters related to pump.

4.3 INSULATION CLASS

Critical factor in the life of electrical equipment is heat. The type of insulation used
in a motor depends on the operating temperature that the motor will experience. Average
insulation life decreases rapidly with increase in motor internal operating temperatures.
NEMA (National Electrical Manufacturers Association) has established safe maximum
operating temperatures for motors based on an average 20000 hour lifetime.

These maximum temperatures are the sum of the ambient and maximum temperature
rise ratings of the motor. There are four NEMA insulation classes based thermal endurance
of the system for maximum temperature rating purposes. These are listed on the Motor's
name-plate and are either A, B, F, or H. These codes indicate the maximum temperature the
motor insulation can withstand without failure.

4.3.1 Insulation Class A

In class ‘A’ maximum permissible winding temperature is 105°C. Insulation class

‘A’ consists of insulating materials such as cotton, silk, and paper suitably impregnation or
coated or immersed in dielectric liquid.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 25

4.3.2 Insulation Class B

In class ‘B’ maximum permissible winding temperature is 130°C. Insulation class

‘B’ consists of insulating materials or combinations of materials such as mica, fiber,
asbestos, etc. bonded together with varnishes or oil-modified synthetic resins, bitumen,
shellac and Bakelite.

4.3.3 Insulation Class F

In class ‘F’ maximum permissible winding temperature is 155°C. Insulation class ‘F’
consists of insulating materials or combinations of materials such as mica, fiber, asbestos,
etc. bonded together with epoxy, poly-esterimide (polyamide or polyimide), polyurethane or
other resins having superior thermal stability.

4.3.4 Insulation class H

In class ‘H’ maximum permissible winding temperature is 180°C. Insulation consists

of materials or combinations of materials such as mica, fiber, asbestos, etc. with suitable
bonding, impregnation or coating substance such as appropriate silicone resins or silicone
elastomers.

4.3.5 Important Factors Selecting Insulation Class for Motor

Operating temperature
When considering suitable operating temperature for motor, the temperature at the
hottest point is important, this temperature is referred to as “Hot spot” temperature. In Motor
winding hot spot is somewhere near the center of winding.
Temperature rise
In operation of a continuous duty motor occurs a condition when motor temperature
become steady while generating heat from windings, magnetic cores and friction losses and
dissipating heat to surrounding at same time. The difference between this steady temperature
and cooling medium temperature is the temperature rise. This rise is always the same
regardless the temperature of cooling medium temperature.
High value temperature rise limit the value of ambient temperature (installation site
temperature).
For each 10°C rise in operating temperature of motor above the rated temperature of
insulation class motor life will reduce by one-half.
Insulation class ‘A’ only used for fractional power motors. Insulation class ‘B’ used
for small integral power motor. Insulation Class ‘F’ used in most of the motors but by using
higher insulation class such as class ‘H’ motor can be made in compact size.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

26 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

CHAPTER 5

MINIMUM SUBMERGENCE
5.1 INTRODUCTION

Minimum submerge is the condition of water level above the inlet of pump to satisfy
pump operating conditions. Submergence is the distance between liquid levels and
submerges setting. In order to insure proper hydraulic performance, the pump manufactures
minimum submerge should be followed. Submergence is necessary to maintain prime,
prevent vortexing and may be provided to the pump NPSH requirement.

Submergence should not be confused with NPSH, as it is a term used to relate

liquid level to the intake setting level. In the case of a conventional submersible pumps
some submergence, in addition to the NPSHR, is necessary to maintain prime and
prevent vortex formation on the liquid supply surface.

5.2 MINIMUM SUBMERGENCE

Minimum submergence requirements are commonly provided by the pump

manufacture and should be used for design purposes when required. In the absence of this
information, submergence requirement can be approximated using one of the following rules
of thumb which fits the application:
1. Can / De-watering application. 1.5 feet above the pump intake plus 1 feet additional
submergence for each 500 gpm of flow. (i.e. min. submergence at 1000 gpm should
be not less than 3.5 feet.
2. Sump application 3 feet above the pump intake plus 1 feet additional submergence
for each 1 liter per second (lps) in approach piping inlet velocity.

Following situations arise due to insufficient submergence of the pump which are:
i. Cavitation
ii. Vortexing
iii. Entrained Gas

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 27

5.3 CAVITATION

Cavitation is the condition at which the suction pressure at inlet of pump is below the
vapour pressure of the liquid. Cavitation can be generally avoided by providing the NPSHR
of the pump at the maximum flow requirement and water temperature anticipated. The
following analysis should be performed during the pump selection process.
i. Determine the maximum flow requirement under all possible operating condition
and select the pump which handles the maximum flow requirement within the
published performance curves.
ii. Calculate NPSHA for the application and compare with maximum NPSHR of the
selected pump at maximum flow point established in point 1 above. NPSHA must be
greater than NPSHR to prevent cavitation.
iii. The submersible pump intake must always be submerged for proper operation. In
some cases, the minimum submergence requirement is dictated by the NPSHR needs
of the pump. The minimum submergence should be not less than 3 feet (or as
specified by the manufacture) at the lowest possible pumping level at maximum
flow.

Favorable factors for cavitation

Factors which may create/ contribute to conditions favourable for cavitation, which are
often overlooked at the design stage, are:
i. Entrained (free) gas.
ii. Sudden drop in discharge head that significantly increase pumps flow.
iii. Insufficient submergence (dewatering/improper low level shut-off point).

5.4 VORTEXING

Vortexing is a term
frequently used to describe
flow patterns which result in
formation of vortices, causing
loud rumbling noise. A vortex
is a whirlpool caused by a
combination of factors such as
sump design, inlet velocity,
and direction of flow,
submergence and position of
intake. Air entering the pump
through these vortices is
responsible for noise and
vibration, but not cavitation.

Vortexing is rare in
submersible pump application;
however, when it does occur,
it is generally a result of
improper submergence.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

28 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

5.5 ENTRAINED GAS

Most liquid carry small amounts of air or other gases completely dissolved in the
liquid. Entrained gas is typically not a problem until it exceeds approximately 1-2% of the
total pumped volume of the fluid.

The presence of entrained gas is usually noted by:

1) Noise
2) Deterioration of H-Q (Head-Discharge) performance and efficiency.

The two most common entrained gas problems encountered in water well
applications involving submersible pumps are cascading water (falling water) and formation
of gases.

Effect of Entrained Air

The build-up of entrained air specifically affects the performance of centrifugal

pumps as shown in below figure. Centrifugal force throws heavier liquid outward from the
impeller eye. The lighter air remains behind and will gradually build into a bubble as big as
the impeller inlet (“eye”) area, which chokes off the intake flow. This is called “air locking”.

Air Entrainment and H-Q Performance

Increase submergence to reduce potential vortexes and/ or to increase the

submergence pressure on entrained gas in order to keep it in solution.

February, 2019 Trouble Shooting and Maintenance of Submersible Pumps

CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0 29

REFERENCE
1. Data and literature collected from M/s Shakti Pumps (I) Limited, Pithampur – 454774
Distt. Dhar, (M. P.).

2. Data and literature collected from M/s Texmo Pumps, Mettupalayam Road, Coimbatore
(TN).

3. Data collected from Railway units and field study.

4. Comments and suggestions received during the seminar held on 14.12.2018 at

CAMTECH, Gwalior.

Trouble Shooting and Maintenance of Submersible Pumps February, 2019

30 CAMTECH/E/2018-19/EP-09/Submersible Pumps/1.0

OUR OBJECTIVE

To upgrade maintenance technologies and

methodologies and achieve improvement in
productivity and performance of all Railway assets and
manpower which inter-alia would cover reliability,
availability, utilisation and efficiency.

CAMTECH is continuing its efforts in the documentation and up-

gradation of information on maintenance practices of electrical assets.
Over the years a large number of publications on electrical assets have
been prepared in the form of handbooks, pockets books, pamphlets &
video films etc. These publications have been uploaded on the internet
as well as rail net.
For downloading these publications please do following:
1. On internet visit : www.rdso.indianrailways.gov.in
Go to Directorates  CAMTECH  Publications for download
Electrical Engineering
2. On Railnet visit RDSO website at 10.100.2.19
Go to Directorates  CAMTECH  Publications for download 
Electrical Engineering

For any further information regarding publications please contact:

Director (Elect.) – 0751- 2470740 (O) BSNL, 9752447030 (CUG)
SSE/Electrical - 9755549297 (CUG)
E-mail at [email protected]
Fax to 0751- 2470841
Write at : Director (Electrical)
Indian Railways,
Centre for Advanced Maintenance technology,
In front of Hotel Adityaz,
Airport Road, Maharajpur,
Gwalior, Pin code – 474 005
February, 2019 Trouble Shooting and Maintenance of Submersible Pumps