THE MID WAY REPORT IS EXPECTED TO EXPLAIN

1. Work done
Includes the

 Study of IS standards used,

 Process involved in making of motor,

2. Observation and Results

Takes into account the ramifications of the test performed by me till date and
its conclusion

3. Major challenges
Describes the difficulties faced while analysing the working and
performance of the motor and finding changes which can be met to increase
its efficiency

4. Innovations
Highlights the methods and technologies proposed that are an upheaval in
themselves and are radically different from the existing methods and
technologies in use

5. Remaining work

Reminder of the plan of the completion of my project and what part has been
covered and what is still pending
 CHAPTER 1
IS STANDARDS USED FOR SUBMERSIBLE PUMPSETS

1.1 SUBMERSIBLE PUMP

A submersible pump is a unit combining a pump and a motor to an enclosed unit, suitable for
submerged installation. There are two types of submerged pumps:

 A submerged pump type with a submersible motor.

 A submerged pump with a dry motor,
which is connected to the pump by a long shaft.

Presently working on submerged pump type with a submersible motor and after midway
work will be done on submerged pump with a dry motor,

A submersible pump, also called an electric submersible pump, is a pump that can be fully
submerged in water. The motor is hermetically sealed and close-coupled to the body of the
pump.

1.2 SCOPE
Submersible motors for submersible pump sets are commonly used in bore holes (bore wells
or tube wells) and submersible pump sets commonly used in open wells for handling clear
cold and fresh water for application in agriculture, water supply etc.

1.3 TERMINOLOGY
1.3.1 Wet type water filled submersible motor

It is a motor which is completely filled with clear water, as shown in fig1.

1.3.2 Wet type oil filled submersible motors

It is a motor where winding as well as entire remaining space within the motor is filled with
nontoxic grade of oil and effectively sealed, see fig2.
1.3.3 Resin filled submersible motor

It is a motor where stator is in encapsulated and filled with an insulating compound. The
remaining portion is filled with water or oil(see fig 3)

1.4 CHARACTERISTICS OF CLEAR, COLD AND FRESH WATER

1.4.1 Clear, cold and fresh means water having characteristics specified below

a) Turbidity : 50 ppm (silica scale), Max

b) Chlorides : 500 ppm, Max

c) Total solids : 3000 ppm , Max

d) PH value : 6.5 to 8.5

e) Temperature : 33 degree

f) Specific gravity : 1.0004

1.5 CONSTRUCTION
Components and material used of motor consist of-

A) Stator: The stationary part of motor

a) Lamination Electrical sheet steel- IS 648

b) Winding wire Electro grade copper-IS 613

1) Conductor

2) Insulation: PVC or poly wrap copper conductor -IS 8783

3) Stator casing Grey cast iron or stainless steel sheet - IS 210,

B) Rotor: The rotating part of motor

a) Laminations Electrical sheet steel- IS 648

b) Conductor core Electro grade copper or-IS 613

die cast aluminium-IS 4026

C) Cable: IS 694

a) Conductor Electro grade copper

b) Insulation PVC or with polymer and /or sheathing

D) Motor shaft; The rotating axle attached along with rotor made of wrought steel IS 1873,
or Chromium steel IS 1570, Gr 04 Cr 13

E) Bearing housing which acts as the base is made of Grey cast iron IS 210 Gr FG 200

F) Bearing bush which acts as the protection is made of leaded tin bronze or rubber

The nomenclature of various components in the assembly of submersible pump set is given in
fig 1 to 3 the typical submission is given in fig 4 for information

The cable shall be insulated and sheathed with suitable polymer .It should be flexible 3 core
or 4-core flat type (or) with insulated leads. The size of the conductor shall be adequate and
suitable for continuous use under water.

The size of the conductor and the length of cable should be suitably selected so that the
voltage drop between the control panel and the motor terminals does not exceed three per
cent of the rated voltage.
 CHAPTER 2
AC INDUCTION MOTOR USED

2.1 DESCRIPTION
V4 (4″ bore size-single phase), V6 (6″ bore size-three phase), V8 (8″-three phase),
submersible motor is a squirrel cage, AC induction, water cooled and water lubricated
induction motor. The pumps are of mixed flow type pumps. Submersible pumps purify water
from deep wells. The bore well pumps are used for drawing water from 62-1500ft and can be
used for irrigation.

2.2 FEATURES
 Complete Range- 0.5 HP to 2HP (single phase),5HP-20 HP(three phase)
 Stampings made of electric sheet provides better efficiency and low power
consumption.
 Dynamically balanced aluminium die cast squirrel cage rotor.
 Good performance in low voltage and withstand voltage fluctuation.
 Core components treated with corrosion resistant paint & varnish.
 Manufactured in quality assurance system compliance with IS 9001.
 Designed with class F, class B insulation which make it most preferred choice for
heavy duty application.
 Long run and works well even in toughest environmental conditions
 Shaft and terminal box are fitted with a seal to protect the motor from moisture
and dust particles.
 Temperature rise restricted to class B limit
 Both capacitor start capacitor run and capacitor run type in V4
 Self-starting in nature in V6 and V8
2.3 STANDARD SPECIFICATION
Type- Squirrel cage Induction Motor

Enclosure Totally enclosed, self-cooled

Power Range 0.5 HP to 2 HP (single phase), 5HP-20 HP (three phase)

Class of Insulation F/B

SYNC R.P.M. 3000 (2 Pole)

Supply Condition 200-240 (Single Phase), 400-415(three phase), 50 Hz ±5%

Ambient Temperature 50°C

Duty Continuous (SI)

2.4 TESTS PERFORMED

A) HIGH VOLTAGE TEST
 The high voltage test shall be applied between the windings and the frame only to
a new and completed motor with all of its parts in place filled with water. The test
shall be carried out at the conclusion of the temperature rise test of the motor
where such a test is carried out.
 The test voltage shall be of the supply frequency and shall be as near as possible
to sine wave form. The test shall be commenced at a voltage of not more than one
half of the full test voltage. The voltage shall then be increased to the full value
steadily or in the steps of not more than 5 percent of the full value, the time
allowed for the increase of the voltage from half to full value being not less than
10 s. The full test voltage of 1 500 V shall be maintained for 30 s.
 During the routine testing of motors of rated output up to and including 5.5 kW,
the 30 s test may be replaced by a test of approximately 5 s at the test voltage as
told above, following the same procedure.
B) INSULATION RESITANCE TEST
The insulation resistance when the high voltage test is applied shall be not less than
5 m Ω. The insulation resistance shall be measured with a dc voltage of 500 V applied for
a sufficient time for the reading of the indicator to become practically steady, such
voltage being taken from an independent source or generated in the measuring
instrument.

C) SPEED
The speed measurement may be conveniently taken by means of a slip coil .

D) LEAKAGE CURRENT TEST

The maximum leakage current value shall not be more than 50 mA at rated voltage at
no load. The motor shall be placed on either a rubber mat or a wooden base or any other
insulated base. A voltage equal to the rated voltage shall be applied to any supply line and
accessible outside metal parts of the motor. The resistance of the test circuit shall be 2000
± 50 Ω.

E) TEMPERATURE RISE TEST

The temperature rise test of the motor at rated voltage and supply frequency shall be
carried out with the motor coupled to a suitable pump for the full load current and the set
run continuously for 1 h till study state temperature is achieved. The set is stopped and
the temperature rise of the stator winding computed by the resistance method shall not
exceed 35°C at rated voltage and 45°C at 85 per cent of the rated voltage when the set is
run for 1 h soon after the test at rated voltage. During the test, the temperature of the
cooling water surrounding the motor may not exceed 45°C.

Determination of Temperature Rise of Winding by Resistance Method

The temperature rise (t2 – t1) may be obtained from the ratio of the resistance by the
formula:

t 2 – t a = ((R2-R1){(235 + t1 ) + (t 1 – t a ))}/R1

where, t2 = temperature of the winding at the end of the test in °C;

R2 = resistance of the winding at the end of the test measured within 30s after shut down;
t1 = temperature of the winding (cold) at the moment of the initial resistance
measurement, in °C; and

R1 = initial resistance of the winding (cold).

ta = temperature of cooling medium at the end of the test, in °C.

2.5 OBSERVATION AND RESULT

TROUBLE SHOOTING CHART

Sr
Problem Cause Suggested Remedy
No.

1 Pumps do not 1. Starting panel 1. Replace by new starter and

start. defective check for continuity.

2. Overload 1. Set relay properly.

protection out
3. Fuse blown off. 1. Replace with correct rating.

4. Low line 1. Use adequate size cable.

voltage 2. Wait till voltage recovers or
contact electricity board.

2 Fuse blows 1. Incorrect 1. Stabilise the voltage to rated

when voltage or and wait for adequate power
motor is inadequate power supply.
running supply.
1. Overload relay to be replaced
2. Overheated or adjusted to higher value.
overload 2. Replace starter if trips
protection box. repetitively.
 3. Defective 1. Defective electrical
control panel components to be replaced.
components
4. Damaged motor 1. Check continuity in cable
cable or winding. and wiring. Replace the cable.
Rewind the motor if required.
5. pump becomes
sand locked 1. Remove dismantel and clean
water passages inside the
motor. Change the motor thrust
pad if required.

3 Pumps 1. Motor running 1. Check voltage / frequency.

operates but lower than raled Replace cable with higher size.
delivers little speed.
water.
1. Dismantels the pump and
2. Strainer /
clean strainer and water
impeller / stage
passage of impeller and stage
casing may be
casing if necessary replace
clogged.
them.

3. Defective rising
1. Check the piping joints for
main (leakage)
leakage / choking.

4. System
1. Replace pipes with higher
resistance of the
size.
pumpset is higher
2. Replace the pumpset with
than estimated.
higher size.

5. Yield of the
1. Lower the unit further if
bore is not
possible or throttle the sluice
sufficient.
 valve adjusting to flow rated.
6. Damaged pump 1. Replace correct components
parts. e.g. Impeller / Diffuser /
Bushes / Sleeves / Neckring
etc.
2. Check slit / sand content of
water to avoid premature wear.

4 Pump does 1. Water level in 1. If possible lower the unit

not deliver borewell may have further
any water. gone below level 2. Stop the unit until water
of pump. level rises sufficiently.
3. Operate the pumpset with
throttle valve.

2. Total head of 1. Replace with suitable

the system is pumpset for higher head.
higher than 2. Ensure that flow is not
designed head of obstructed due to foreign
pumpset. bodies in valve or inferior
quality of valve.

3. NRV sand 1. Check the flow direction

blocked / Wrongly arrow on the NRV body .
connected NRV on 2. Check for sand blockage
delivery pipe. clean and replace.

4. Motor does not 1. Check cable connection.

start. 2. Check for correctness of
incoming power supply.
3. Check for backup protection.
 5. Motor starts but 1. Check voltage / frequency.
doesn't pickup the Replace cable with higher size
rated speed. if necessary.

5 Fuse blow off 1. Defective 1. Repair / replace as per

or circuit control panel instruction.
breaker trips a) Defective 2. Replace and reset the starter
when motor wiring. only for checking the current
is started b) Incorrect fuse drawn. Make sure that
component. abnormal current is not drawn.

1. Rewind motor / replace

2. Defective relay.
cable.

1. Remove, dismantel and clean

3. Damaged motor
water passages inside the pump
winding or cable.
and ressemble.
4. Pump is sand
locked.

5. Pumpset might 1. Move the unit and put

have blocked in straight and then strat otherwise
crossed well. shaft would have bend.

6. Pump and motor

1. Check and realign coupling
not coupled
and see freeness
properly

6 Fluctuating 1. Check water 1.Replace damaged pipe or

Motor level or system repair leaks. Lower down the
Current. leakage. pump to get water

2. Foreign object
1. Take out the pump and repair
between casing
ring and impeller
or bearing parts
inside p

3. Abrasion of
thrust and bush 1. Take out and replace the
bearing inside worn out components.
motor.
2.6PRECAUTION

2.6.1DO' S:

1. Check the water quality before filling in the motor.

2. Always suspend the pump set at least 2 metres above the bottom of the bore.

3. The pumps must be installed 1 metre below the water level surface.

4. Always check the cable joints and vertical play after coupling the pump set.

5. Always use a good quality control panel.

6. Bending of cable must be avoided

2.6.2DON' T' S:

1. Don't run the pump if any of the following defects is observed.

o › Water is sandy or acidic.

o › If there is no water.

o › If the problem of single phasing arises.

2. Don't pull the motor with the help of cable.

2.7 MAJOR CHALLENGES

 Study of each and every part of motor and design it according to IS standards
purposed.
 If fault found in any of the tests performed then dis assembling it and rewinding
it again consuming both time and labor.
 Balancing of rotor : making of weight of both sides of rotor equal at an proper
angle so that in future least problems occur.
 Find the materials which can be used instead of existing ones for better
operation.

2.8 INNOVATION

 Suggest measures for better design to host mentor so that the submersible pump
which consume huge amount of electricity, increase its efficiency, and if we
design pumping system it will be of great help in present as well as future.
A solar-powered pump is a pump running on electricity generated by photovoltaic panels
or the radiated thermal energy available from collected sunlight as opposed to grid
electricity. The operation of solar powered pumps is more economical mainly due to the
lower operation and maintenance costs and has less environmental impact.

2.9 WORK LEFT

 Study of new technologies on international and national level .

 Do research on submersible pumps to make it more efficient and operational.
 After designing it
o Find changes which industry needs to take for implementation.
o How economical it is
o Its payback period
 Full-fledged study, design and analysis of monopole motors.