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APROJECT REPORT IFF1749565 and
Password: 54669094
ONDESIGN AND TESTING OF SUBMERSIBLE PUMP
Submitted by
PRAJAPATI CHIRAG.A (090160119081)MERUTHA JATIN.R (090160119080)
MISTRI AJIT.C (090160119097)RAHEVAR SACHIN.S (090164119402)
In fulfillment for the award of the degreeof
BACHELOR OF ENGINEERINGin
MECHANICAL
GOVERNMENT ENGINEERING COLLEGEMODASA
Gujarat Technological University, Ahmadabad
Government Engineering College ModasaMechanical Engineering Department
2012-2013
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CERTIFICATETO WHOMSOEVER IT MAY CONCERN
This is to certify that Mr. PRAJAPATI CHIRAG AMRUT
BHAI(090160119081),MERUTHA JATIN RAMESH
BHAI(090160119080), MISTRI AJIT CHANDU
BHAI(090160119097), RAHEVAR SACHIN
SAMARSINH(090164119402) of B.E. (Mech.) Semester VIII has satisfactorily completed his8 th semester project work titled DESIGN AND TESTING OF SUBMERSIBLE PUMP in
fulfillment of Degree of Bachelor of Engineering from
Government Engineering College, MODASA under Gujarat
Technological University in the year 2012-13.
Date of Submission: (18 /04 /2013)
Project Guide Head of DepartmentProf. Dr P.K.BRAHMBHATT Prof.K.P.TRIVEDIMECHANICAL Dept, HOD MECHDept,
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GEC, MODASA. GEC, MODASA.
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ABSTRACT
With teaching our knowledge become good, training isdeveloping our habit.It assures that technical studies cannot
perform adroit without practical training. Hence the
practical training is exorbitant for Engineering student. The
actual objective of plant training is to get all detail about
organization and main enhance about all operation and
process, which are carried out practical knowledge. Its
inviting feature is to learn industrial management and
discipline. In this report of training we include all the
details related to our project as well as company.In this
report we have include pump detail and tried to acquire
knowledge about submersible pump.
Efforts are put up to design of submersible pump. A various
testing of submersible pump
has been ca rried out at DUKE PLASTO PVT LTD.
Performance of the submersible pump has been measured
critically.
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List of figure
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S.R.NO NAME OF THE FIGURE PAGENO
2.1.1 Detail drawing of submersible pump 15
2.2.2 Parts of the pump 17
2.2.3 Spare parts of motor 20
2.4.1 V-3 special submersible pump 22
2.4.2 V-4 submersible pump 24
2.4.3 V-6 submersible pump 262.4.4 DSP5MF 29
2.5.1 Installation of submersible pump 32
3.1.1 closed impeller 36
3.1.2 semi open type impeller 38
3.1.3 open type impeller 38
4.11.1 impeller 52
5.2.1 Characteristics curve of pump 62
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List of table
S.R.NO TABLE PAGENO
1 V-3 special submersible pump 23
2 V-4 special submersible pump 25
3 V-6 special submersible pump 274 Material for construction 33
5Characteristics of two phase three Pole
motor
34
6 Motor Testing table 57
7 Full load test 58
8 Temperature rise test at rated Voltage 58
9 High voltage Test 59
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CONTENTS
S.r.No. Particulars PageNo.
Acknowledgement 3
Abstract 4
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List of figure 5
TITLE OF CHAPTER
1 Chapter1.1 Introduction 10
1.2 Problems occur with submersible pump 11
1.3 What are the submersible pump 12
1.4 Why shaft break 13
2 Chapter
Brief history of work
2.1 Description of submersible pump 15
2.2 Main components of pump 16
2.3 Definition and brief 18
2.4Types of submersible pump andTheir
specification
21
2.5 How to remove submersible pump 30
2.6 Material of construction 33
3 Chapter 3.1 Impeller are used in submersible pump 36
Radial Flow Solids Handling Impellers
4 Chapter
Design of Submersible pump
4.1 Design Parameter 41
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4.2Properties of water for which submersible
pump is to be used
42
4.3 Voltage and frequency selection 434.4 Cavitation phenomenon of pump 44
4.5 Net positive suction head (NPSH) 45
4.6 Work done by impeller on water 46
4.7 Pump shaft design 47
4.8 Shaft subjected to twisting moment 48
4.9 Shaft subjected to bending moment 49
4.10 To achieve diameter of the shaft 50
4.11Pressure head development by pump
impeller
51
5 Chapter
5 Testing of Submersible pump 55
5.1. Motor Testing on submersible pump 56
5.1.1 Full load test 58
5.1.2 Temperature rise test at rated Voltage 585.1.3 High voltage Test 59
5.2 Performance test 60
6 Chapter
6.1 Result analysis 64
7 Chapter
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7.1 Conclusion 66
8 Reference 67
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(1)INTRODUCTION
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1.1Introduction
This project attempts to design submersible pump and
humble efforts are made to Testing of submersible pump.
Now a days most of organization is showing keen interest
in using submersible pump. The study about all operation
and process, which are carry out in practical knowledge. Its
inviting feature is to learn industrial management &
discipline. In this report I include types of pump they
manufactured, its application, analysis and design.
A properly installed check valve will prevent a backspin
with is when the pump begins moving in reverse direction.
This put a undo strain on mechanism. This prevents an up
thrust or leaking back into the well without check valve, the
reversal movement of water can cause hammering effect
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putting pressure on pipes and resulting in damaged
plumbing.
In submersible pump all horse power ratings are within theservice limits of motor and pump can be operated
continuously without fear of damage to motor bearing with
sand channel all bearing are water lubricated and have a
squared shape enabling sand particles if any to leave pump
together with pumped liquid.
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1.2 Problems occur with submersible pump are as
follow
1. Pump takes too much power.
Mechanical friction.
Misalignment.
Low voltage.
High specific gravity.
2.Less discharge.
Motor is running in reverse direction.
Gas in water.
Inadequate water level
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1.3 What are the submersible pump ?
A submersible pump is one of the type of centrifugal pump
that is designed to function the pump and motor submergedin the fluid to be pumped. The Motor is sealed in the way
that prevents even tiny amount of the fluid from seeping in
which would case the motor to short out. The main
advantage of submersible pump is that there is no motor
above grade so floor space is better utilization and the cost
of the installation may be reduced. They also tend to have
lower maintenance cost and create less noise than pump
which has motor mounted at the grid.There is no cancer for
priming this type of submersible pump and less cancer
about cavitations, since the impeller and casing are always
submerged and there is no suction pipe within it.
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1.4 Why shafts break?
The most prominent reasons for failure of shaft are they are
twisted and they are bend. Another reason for breakdown of
shaft is excessively worn out.
The information for salvation is given below.
1. Calculate the diameter of the shaft required carrying
maximum horsepower that any particular
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submersible pump could draw; this can be done by
adding factor of safety.
2. Bend the shaft until it breaks though not any pump wehave ever seen in any pump.
3. Shaft can wear out. This is the cause of the vast
majority of submersible pump shaft breakage.
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(2)
LITERATURE
SURVEY
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Brief history of work
2. 1Description
A submersible pump is a turbine pump close coupled to a
submersible electric motor. Both pump and motor are
suspended in the water, thereby eliminating the long drive
shaft and bearing retainers required for a deep well turbine
pump. Because the pump is located above the motor, water
enters the pump through a screen located between the pump
and motor.The submersible pump uses enclosed impellers
because the shaft from the electric motor expands when it
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becomes hot and pushes up on the impellers. If semi-open
impeller were used, the pump would lose efficiency. The
pump curve for a submersible pump is very similar to adeep well turbine pump.
Submersible motors are smaller in diameter and much
longer than ordinary motors. Because of their smaller
diameter, they are lower efficiency motors than those used
for centrifugal or deep well turbine pumps. Submersible
motors generally referred to as dry or wet motors. Dry
motor are hermetically sealed with a high dielectric oil to
exclude water from the motor. Wet motors are open to well
water with rotor and bearings actually operating in the
water
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Fig 2.1.1.Detail drawing of
submersible pump.
2.2MAIN COMPONENTS OF SUBMERSIBLE PUMP
1. Frame
2. Pump bowl
3. Stator
4. Non return valve
5. Vertical shaft
6. Bearing
7. Bearing bush
8. Impeller
9. Winding
Most submersible pumps are design for use in wells
with a minimum 8 inch inside diameter. There are some
available for use in wells with as small as 6 inch inside
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Fig.2.2.2 Parts of the pump
2.3Definition and brief view
1. Impeller:
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Impeller is the heart of the centrifugal pump. It rotates
the liquid mass with a peripheral speed of its vane tips. The
whirling movement of impeller imparts centrifugal force tothe liquid and increases its velocity head. Impeller does not
increase liquid pressure. But high velocity head is
converted in to pressure head in the volute. Increase in
velocity is directly proportional to the impeller diameter
and pump speed.
The impeller is mounted on the shaft which is
supported by bearings and driven through a flexible or
coupling by an electric motor or some times by a turbine
This impeller is made by foundry process by using
mold. The material used for impeller is cast iron. Plastic
impeller is also available.
Impeller may be classified on the basis of its
construction as
a) Closed or Shrouded Impeller
b) Semi open ( Semi closed) Impeller
c) Open type Impeller.
2.Bowl:
Bowl is also made by foundry process by using mold.
It is also available in plastic and cast iron material. It is
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a study part with pipe casing. Vane is also produced
inside of the bowl.
3.Shaft:Shaft is one of the rods with light machining with key
groove throughout. S.S. material is used for shaft. The
basic purpose of a shaft is to transmit the torques
encountered when starting and during operation while
supporting the impeller and other rotating parts. It must
do this job with a deflection less than the minimum
clearance between the rotating and stationary parts.
4.Pump Casing:
A casing is provided for housing the impeller and
supporting the bearings provided with the shaft. Also,
the casing has provision for connecting with the
suction and delivery pipe lines. As it handles liquids
with higher pressure, a stuffing box is provided to
prevent leakage from the gap between the pump casing
and the shaft. Also, closely fitted rings, called Wearing
Rings, are mounted on the impeller and fitted in the
casing to restrict leakage of high pressure liquid back
to the pump Suction.The efficiency of a pump depends
on the type of casing used. As such, a casing should
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not waste more energy due to eddy formation. To
minimize the energy loss in pump casing, three
common types of designs of casing are in use.These are:
a) Volute type Casing,
b) Vortex or whirlpool Casing,
c) Diffuser (-ring) type Casing or turbine Casing.
5. Suction
Suction is used to supply water to pump. It is made by
foundry process in three stage mold box. Cast iron is used
to made suction. Suction plate is provided between suction
and first impeller.
6. Sleeve:
Pump shafts are usually protected from erosion,
corrosion, and wear at the seal chambers, leakage joints,
internal bearings, and in the waterways by renewable
sleeves. Unless otherwise specified, a shaft sleeve of wear,
corrosion, and erosion-resistant material shall be provided
to protect the shaft. The sleeve shall be sealed at one end.
The shaft sleeve assembly shall extend beyond the outer
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face of the seal gland plate. (Leakage between the shaft and
the sleeve should not be confused with leakage through the
mechanical seal).
7. Coupling:
Couplings can compensate for axial growth of the shaft and
transmit torque to the impeller.
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2.4TYPES OF SUBMERSIBLE PUMP AND THEIR
SPECIFICATION
1. DSP3RF
Performance range
-Flow rate up to 80 l/m
-Head range up to 106m
Operating limits
-maximum fluid temperature 30c
-maximum sand content 50g/m
Pump application
This pumps are suitable for pumping clean water
or fluids with a sand content of not more than
50g/m.Their high performance and dependency make
them suitable for use in domestic, civil and
agriculture, irrigation, ponds, pressure boosting etc.
2. DSP4OF (oil filled)
Performance range
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- Flow rate up to 145 l/m
- Head range up to 216
3. DSP6RF(radial flow)Performance range
- flow rate up to 360 l/m
- head range up to 336m
4. V-3 special submersible pump
- H.P. range:.5-1.0
- Max discharge: 35-50 LPM
- Diameter: 73mm OD
Salient Features of V3 Submersible Pumps
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All components are precisely machined to give you
trouble free operation.
Motors are designed to withstand high voltagefluctuations.
All rotating components are dynamically balanced for
smooth and noise free operations.
Requires less space.
Easily rewind able.
Simple assembly for servicing.
Fig.2.4.1 V-3 special submersible pump
Application
Fountains. Cooling water Circulations.
Gardening and Nurseries.
Domestic water supply.
Housing, Complexes and General Industries.
Hospitals and Bungalows.
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Table -1:V-3 special submersible pump
PARTICULARS MATERIALS OFCONSTRUCTION
Motor Casing Stainless steelBearing Bush Leaded bronzeMotor Shaft Stainless SteelThrust Bearing Stainless steel & Graphite
carbon/TeflonHousing / Base Cast Iron / BrassStamping CRNGOScrews / Studs Stainless steelImpeller /Diffuser
Noryl GNF2 Techno polymer
Stage Casing Noryl GNF2 Techno polymer Pump Casing Stainless steelPump Shaft Stainless steelSuction / Delivery Cast Iron / Brass
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5.V-4 submersible pump
- H.P. range:.5-1.25
- Head range:20-122m
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- Max.discharge:20-55 LPM
- Diameter: 96mm OD
Salient Features of V4 Submersible Pumps Corrosion resistant stainless steel body.
Specially designed for low voltage working.
High electrical and mechanical efficiency.
Higher heat dissipation.
Dynamically balanced rotor and other rotating parts
for uniform clearance.
Specially designed bearing to withstand axial thrust
loads.
Designed for high voltage fluctuations.
High efficiency, Low power consumption.
Fig.2.4.2V-4 submersible pump
Application
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Drinking water supply, Domestic and community
water supply
Drip irrigation. Sprinkler irrigation and gardening. Housing-Complexes, Hospitals, High-rise buildings.
Fire fighting, landscaping, Fountains, Service stations.
Table-2:V-4 special submersible pump
PARTICULARS MATERIALS OFCONSTRUCTION
Motor Casing Stainless steelBearing Bush Leaded bronzeMotor Shaft Stainless Steel
Thrust Bearing Stainless steel & Graphitecarbon/Teflon
Housing / Base Cast Iron / BrassStamping CRNGO
Screws / Studs Stainless steelImpeller /Diffuser
Noryl GNF2 Techno polymer
Stage Casing Noryl GNF2 Techno polymer Pump Casing Stainless steelPump Shaft Stainless steel
Suction / Delivery Cast Iron / Brass
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V6 Submersible Pumps
Salient Features of V6 Submersible Pumps
Rotating parts dynamically balanced for uniform
clearance.
Core with low watt loss laminations.
Low power consumption.
High efficiency.
Designed for high voltage fluctuations
Fig.2.4.3 V6 Submersible Pumps
Application
Landscaping, Service Stations
Booster Applications.
Domestic and Village Water Supply.
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Commercial complexes and High-rise Buildings Water
Supply.
Small Farms, Big Agriculture Lands and Hotels.
Table-3:V-6 special submersible pump
PARTICULARS MATERIALS OFCONSTRUCTION
Motor Casing Stainless steelBearing Bush Leaded bronzeMotor Shaft Stainless Steel
Thrust Bearing Stainless steel & Graphitecarbon/Teflon
Housing / Base Cast Iron / Stainless steelStamping CRNGO
Screws / Studs Stainless steelImpeller /Diffuser
Noryl /Cast iron / Stainless steel / Brass
Stage Casing Cast iron / Stainless steelPump Casing Cast iron / Stainless steelPump Shaft Stainless steel
Suction / Delivery Cast Iron / Stainless steel
6.V-8 submersible pump
- H.P. range:7.5-60
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- Head range :12-325m
- Max.discharge:850-1750 LPM
- Diameter: 128mm OD
7. DSP5MF
Performance Range
Flow rate up to 640 l/min (38.4 m/h)
Head range up to 130 m
Operating Limits
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60 Hz frequency
Sized for the connection to the motor according to
NEMA standard
Fig2.4.4 DSP5MF
Other commonly used submersible pumps are
listed below
- DSP4R/M (water filled)
- DSP4R/H (mix filled)
- DSP5M/F (mix filled)
- DSP6M/F (mix filled)
- DSP6R/H (radial flow high head)
- DSP7M/F (mix flow)
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- DSP8J/F (mix flow)
High performance submersible pump
- DSP8RF- DSP8MF
2.5 How to remove submersible pump?
Replacing a submersible pump is not a complicated
task if we understand the basics about a well system such as
the placement of the pump, how the submersible pump
operates and how it is installed in a wheel casing. An
advanced do it our self with knowledge of electrical wiring
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Installation of submersible pumpMount control on a vertical wall free vibration ensure
that cable entry is made completely dust proof by using
cable glands. Connect the supply to leads, motor leads and
electrode exactly according to connection diagram given
inside of box. Tighten all screw.Connect the earthing wire to the terminal so marked. It is
recommended that earthing connection should also be given
to delivery pipe of pump in coming switch fuse unit should
be near the control panel so as to enable to the operator to
operate with both switch fuse unit and control panel from
one place.
Operation
Put the incoming switch fuse to ON position. Now
phase indicating the lamps will glow observe that will use
glowing with about the same intensity otherwise do not
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start the panel. Voltmeter indicates supply voltage. If the
voltage indicated is below the rated do not start the panel.
Start the pump by processing the green button. Observesteady ammeater reading. It should not exceed rated
current. In case of star delta stator it is necessary to set the
timer use for change over from star to delta, first set timer
to maximum value. Start timer maximum value. Start the
motor and measure the time taken for motor to reach nearly
rated speed. Stop motor and set timer.
Do not start the pump in case of single phasing.
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Table:4
MATERIAL OF CONSTRUCTION
NAME OF
PARTS
MATERIAL USED
1Impeller/Diffuser Stainless steel 304/316 and
Graded cast iron
2 Pump Shell Stainless steel
3 Bearing bush Rubber/Bronze
4 Pump shaft Stainless steel 410
5 Hardware Stainless steel 304
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6 Bearing housing gray cast iron
7 Rotor electric sheet steel
8 Stator electro sheet steel
9Breather
diaphragm
Nitrile rubber
10 Thrust bearing Vulcanized rubber
11 Cable guard Nitrile rubber
12 Stator casing Gray cast iron
The pump has started at the same time after priming. The
discharge valve is opened slowly after the pump has started.
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Table-5
Performance characteristics of two pole three
phase submersible motors as per I.S. for bore
Rate
d o/p
Minimu
m full
load
If
in
am
p
Minimu
m
starting
Normal efficiency of
motor suitable for
bore size and
maximum o/p
100m 150m 200m
OR OR OR
96m
m
142m
m
192m
m
(1) (2) (3) (4) (5) (6) (7)1.1 2740 3.25 125 60 62.3 -
1.5 2760 4.5 125 65.2 70.4 -
2.2 2760 6.5 125 67.8 71.3 -
3 2780 8.5 125 68.7 72.3 73
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3.7 2780 10 125 - 73.9 75.7
4.8 2800 12 125 - 76.5 78.3
5.5 2820 14.5 160 - 77 79.17.5 2820 19.5 160 - 76.4 80
9.3 2840 25 160 - 79 80.9
11 2840 29 170 - 80 81.7
13 2840 34 170 - 80.9 82.2
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3.1Impellers are used in submersible pump
Radial Flow Solids Handling Impellers
Open type
Close type
Semi open type
The various members of the radial flow impeller
family include the closed, open,and semi open
designs. Depending upon capacity, each design may
incorporate rom one to four vanes. The vanes are not
straight, but describe a smooth curvethat begins at the
impellers eye and extends to its periphery. They may
also becurved upward at their entry as in the Francis
vane design shown in figure Theclosed impeller,
shown on the following page, looks very much like
anexaggerated version of the clear water impeller seen
earlier.
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Fig.3.1.1 closed impeller
This particular example consists of two vanes with frontand back shrouds. Theshrouds of the closed impeller
enclose the impellers vane passages from the eyeto the
periphery and are designed to accommodate the largest
possible diameter solids. The vanes themselves have large,
rounded leading edges to preventclogging by rags and
stringy material that could become entangled at the
vaneentry. On pumps with suctions up to 12, a two vane
(often referred to as a twoport ) design is typical while
larger pumps may utilize a three or four vane design. Most
closed impellers also incorporate pump out vanes on the
back side of theback shroud. These small, straight vanes
keep the sealing area free of debris andalso reduce the
unbalanced axial forces that can occur due to back
shroudslarger surface area.
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The major wearing surface of the closed impeller is the area
where the eyeprotrudes into the volute suction. Replaceable
volute wear rings are used tomaintain proper clearance andhydraulic efficiency. A typical rule of thumb callsfor wear
ring replacement when the factory set tolerance has
doubled.Very large sewage pumps often use a mixed flow
impeller for low head, highflow conditions. The mixed flow
design utilizes a double curvature vane thatprovides both
radial ( centrifugal ) and axial ( lifting ) flow characteristics.
Alsobecause of their extremely large through lets (4 and
greater) these larger pumpscan utilize sharpened vane
leading edges for greater efficiency.Another characteristic
of the closed solids impeller is that its diameter
seldomexceeds 80% of the volute cut water diameter as
compared with about 92% for astandard impeller. This
diameter is illustrated on the following page and
isrestricted, at the expense of slippage, in order to reduce
vibration and noiseespecially at lowerflows. This larger
than normal clearance also reduces cloggingin the area
where the impeller periphery is closest to the volute case.
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Another closed design is the singl e vane impeller. On
the positive side, it allows for the largest possiblethrough let and since there is only one vane, thereisonly one leading edge and thus potential clogging atthe vane entry isreduced.Unfortunately, due to its lack of symmetry, it is inherently out of balance. Unlike themultilane impeller, most cannot be trimmed and must
be replaced if hydraulic conditions change. The singlevane impeller also tends to produce rather steep headcapacity curve. Although this can be useful in someapplications, the flatter multilane curve generally hasgreater utility. The figure below is that of a semi open ,single vane impeller. In the closed version, the vane isenclosed by a front shroud.
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Fig.3.1.2 semi open type impeller
By definition, the true open impeller consists of
nothing more than vanes mounted to a hub that is
attached to the pump shaft. They are usually seen in
smaller pumps and are best suited for applications
involving stringy materials. Because they are shroud
less, it is less likely for material to become entrapped
between the impeller and the front and rear portions of
the pump case. A disadvantage is their structural
weakness and, because of this, they are often
Strengthened by a partial shroud on the back side. If
the back shroud covers the entire vane structure, the
impeller is designated as semi open .
Since one or both shrouds are missing from each
design, both are prone to wear at the vane edges and
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solids will create BEP (BestEfficiency Point) flows of 80 to
120 GPM. Increase solids size to 3 and the flowrange
increases to 400 to 700 GPM. With conventional pumpsflow can bereduced by throttling the discharge; however,
such a tactic is not acceptablewhen solids are involved.
This problem is exacerbated when a low flowapplication is
complicated by a high head requirement.
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CHAPTER-4(4)DESIGN OF
SUBMERSIBLEPUMP
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4.0 DESI GN OF SUBM ERSI BL E PUM P
4.1DESIGN PARAMETERS
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NAME OF PARTS BOREHOLE
SUBMERSIBLEPUMP
1. H.P. Range 0.5To3.0 H.P (Single phase
version)
2.o To 10 H.P.(Three phase
version)
2. Head Range up to 140 meters
3. Discharge at duty point 40-250 LPM
4. Max. Discharge 320LPM
5. Max. head / Stage 8 meters
6. Operating voltage 160-240 volt (Single phase)
300-440 volt (Three phase)
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100 ppm than pump should be of zinc with bronze or
stainless steel material.
Motor selection
Wet type motor
This type of motor is filled with clean water or mixture of
oil and water.
Resin filled motor
In this motor stator is enclosed with nonconductor and rest
of space is filled with
Oil or water.
Sealed motor
In this motor where winding and rest of space is filled with
air and oil.
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4.3 Voltage and frequency selection
Voltage selection
Three phase motor: 415 V (standard voltage)
Single phase motor: 240 V (standard voltage)
Frequency
Standard frequency :50 HZ
Voltage and frequency variation
Motor is designed to give rated output
Voltage that is differ from rated value should not be more
than +/- 6% .
Frequency that is differ from rated value should not exceed
+/- 3%.
Output rating for motor in KW
For three phase motor: .75, 1.1, 1.5, 2.2, 3.3, 3.7, 4.5, 5.5,
9.3, 11.3.
For single phase motor: .37, .55, .75, 1.1, 1.5, 2.2, 3, 15.
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Speed
2 pole motor proper speed is : 3000 RPM/MIN.
4.4 Cavitation phenomenon of pump
Cavitation is defined as the phenomenon of formation
of vapour bubbles of flowing liquid in a region where the
pressure of the liquid falls below its vapour pressure and
the sudden collapsing of this vapour bubbles in a region
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higher pressure.
Cavitation in pump:
In pump the cavitation may occur at the inlet of the
impeller the pump, or at the suction of the pump, where
the pressure is considerably reduced. Hence if the
presssure at suction of thepump drops bellow the vapour
pressure of the liquid than the cavitation may occur. The
cavitation in a pump can be noted by a sudden drop in
efficincy and head. In order to determine wheather
cavitation will occur in any portion of the suction side of
the pump, the critical value is given by, following equation.
Where, H atm=Atmospheric pressure head in meter of water
Hv=Vapour pressure head in meter of water .
Hs= Suction pressure head in meter of water/
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H ls= Head lost due to friction in suction pipe.
H=Head developed by the pump.
4.5Net positive suction head (NPSH)
The term net positive suction head is defined as theabsolute pressure head at the inlet to the pump, minus thevapour pressure head , plus the velocity head.
NPSH Ha-h s-h fs)-H v
For any pump installation distinction is made between therequired NPSH and the available NPSH. The value of required NPSH is given by the pump manufacture. Thisvalue can also be determined experimentally. For determining its value the pump is tested and the minimumvalue of hs is obtained at which the pump gives maximumefficiency whithout any objectional noise (cavitation free).The required NPSH varies with the pump design, speed of
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the pump and the capacity of the pump. When the pump isinstalled the available NPSH is calculated from aboveequation.
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4.6 Work done by impeller on water
The expression for the work done by the impeller on water
is obtained by drawing velocity triangles at inlet and out of
the impeller.The water enters the impeller radially at the
inlet for best efficiency of the pump. Which means the
absolute velocity of water at inlet makes an angle of 90 with the direction if the motion of the impeller at inlet.
Submersible pump is the reverse of a radially inward flow
reaction turbines. But in case of radially inward flow
reaction turbine, the work done by the water on the runner per second per unit weight of the water striking per second
is given by this equation.
So work done by the impeller on the water per second per
unit weight of water striking per second
=-work done by the turbine
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Weight of water =gQ
Mechanical efficiency
The power at the shaft of the submersible pump more than
the power available at the impeller of the pump. The ratio
of the power available at the impeller to the power at the
shaft of the pump is known as mechanical efficiency.
5.7 Pump shaft design
A shaft is for rotating machine element which is used to
transmit to power from one place to another.
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Material used for shaft
1.It should have high strength.
2.It should have good machine ability.3.It should have low notch sensitivity factor.
4.It should have good heat treatment properties.
5.It should have high wear resistant properties.
The shaft may be designed on the basis of
1.strength,and 2.rigidity and stiffness.
In designing shaft on the basis of strength, the following
cases may considered
(a)Shafts subjected to twisting moment or torque only.
(b)shaft subjected to bending moment only.
(c)shaft subjected to combined twisting and bending
moment, and
(d)shaft subjected to axial load in addition to combined
torsionl and bending load.
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The above equation can be written as
The hollow shaft are usually used in marine work these
shaft are stronger per kg of material and they may be forged
on mandrel, this making the material more homogeneousthan would be possible for a solid shaft.
Twisting may be obtained by using following relation
4.9 Shaft subjected to bending moment
When the shaft subjected to a bending moment then the
maximum stress given as
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M= Bending moment
I = Moment of inertia of cross sectional area of the shaft
about the axis of rotation
b= Bending stressy = Distance from neutral axis to the outer most fibre
For solid shaft moment of inertia,
Therefore bending moment is given by
From this diameter of shaft is determined.
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4.10 To achieve diameter of the shaft
For obtaining power of 10HP shaft diameter can be derived
as follows
N=200 r.p.m
Shear stress = 42 Mpa
1HP=746W Shaft is designed against shear stress
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T=356.36*1000 N-mm
But
D=120mm
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4.11Pressure head development by pump impeller
Impeller is working part of the pump It increases the
velocity to kinetic energy The liquid flows into impeller
and leaves impeller at the same pressure. Pressure of vane
tip is same suction pressure. As high velocity liquid escapes
from the impeller and flows into volute, its velocity is
converted into feet of liquid and pressure the best part of the pump.
Number of stages
One impeller could theoretically deliver an enormous head.
The tips speed would, however become very high. Thiswould cause excessive wear at the tip of the impeller, so
effectively the impeller diameter is limited by the speed and
the allowable tips speed. The simple solution is to put
another impeller in series. The software calculates the
number of stages that will deliver the required total
pressure without exceeding the tips speed.
Complete impeller design
The program in fact calculates all the important impeller
dimensions such as angles, suction and tip diameter, the
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width so on to conclude the characteristics. The
dimensionless parameter that is used for the shape of the
impeller is the specific speed.
Where N s=specific speed N=impeller speed in r.p.m
Q=volumetric flow rate in gpm
H=head in meter
These are used to calculate performance of pump.
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The figure below is that of a typical, clear water, Francis
vane ( radial flow ) Impeller. Its major parts the eye, vane
leading edges, and shrouds are labeled. The vane exits can be seen between the shrouds.
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4.11.1 Impeller
Although the mathematics that define the operation of animpeller can be complex (it is the stuff of Bernoulli and
Euler), its purpose is straight forward. An impeller is
designed to impart energy to a fluid so that it will flow or, if
it is already flowing, undergo some increase in its elevation
or pressure. It accomplishes this by increasing th e fluids
velocity as it travels through its vanes from the their leading
edges, located at the eye to their exits at the periphery. The
ever increasing radius of the vanes results in an increasing
rotational velocity that reaches some maximum at the
periphery. The resulting linear velocity of the fluid, at the
vane exit, is then converted to pressure in the volute.
If one were to set out to design a typical radial vane
impeller, several guidelines would be followed quite
closely. For instance, the overall diameter of the impeller
would closely match the volute and cut water diameters in
order to reduce slippage of the pumped fluid in these areas.
Also, depending upon the desired hydraulic characteristics,
four or more vanes would be incorporated to smooth flow
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at the vane exit. And, their leading edges would be
sharpened to reduce losses due to friction and turbulence.
Unfortunately, if one followed these same guidelines whendesigning a solids handling impeller, the outcome would be
doomed to failure. Unlike the typical radial vane impeller,
those designed to accommodate solids violate many of the
standard design rules. Small to medium sized sewage
pumps are often referred to as non clogs and their impellers
are designed to try to live up to that name. Although many
factors contribute to an impellers ability to pass solids
without clogging, one of the more important is its through
let size.
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(5)TESTING OF SUBMERSIBLE
PUMP
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Testing in submersible pump: -
5.1Various types of test for submersible pump
Various Motor Testing Given Below:
(1) High voltage test
(2) Stator resistance measurement(3) Low voltage test
(4) Temperature rising test
(5) Vibration test
(6) Rated voltage current test
Various Performance test
(1) Power and Head Calculation
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we will assume you have a 3/4 hp 230V single phase 3 wirewith ground submersible motor in the well.
According to the manual the MAIN winding should have areading of between 3.0 and 3.6 ohms between theYELLOW and BLACK wires, which are the main windingreadings.
The START windings are the reading between theYELLOW and RED wires. The range should be between10.7 and 13.1 ohms.
Check below for the Single Phase Motorabout other motors.
Table :6
HP Voltage 2 or 3WirePlus
Ground
MainWinding
Yellow &Black
Resistance
in Ohms
StartWinding
Yellow &Red
Resistance
in Ohms
F&WPart #
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4" 2 Wire + Ground Submersible Pump Motors(No Control Box Needed since controls are in the motor)
1/2
HP
115V 2 Wire 1.0 - 1.3
Ohms
137412
1/2HP
230V 2 Wire 4.2 - 5.2Ohms
137414
3/4HP
230V 2 Wire 3.0 - 3.6Ohms
137416
1HP
230V 2 Wire 2.2 - 2.7Ohms
137418
4" 3 Wire + Ground Submersible Pump Motors(Must Use Control Box to run these 3 wire motors)1/2HP
115V 3 Wire 1.0 - 1.3Ohms
4.1 - 5.1Ohms
137426
1/2HP
230V 3 Wire 4.2 - 5.2Ohms
16.7 - 20.5Ohms
137428
3/4
HP
230V 3 Wire 3.0 - 3.6
Ohms
10.7 - 13.1
Ohms
137430
1HP
230V 3 Wire 2.2 - 2.7Ohms
9.9 - 12.1Ohms
137432
1-1/2HP
230V 3 Wire 1.7 - 2.2Ohms
8.0 - 9.7Ohms
137434
2
HP
230V 3 Wire 1.8 - 2.3
Ohms
5.8 - 7.2
Ohms
137435
3HP
230V 3 Wire 1.0 - 1.5Ohms
4.0 - 4.9Ohms
139422
5HP
230V 3 Wire .68 - 1.0Ohms
1.8 - 2.2Ohms
137456
6" 3 Wire + Ground Single Phase Submersible PumpMotors
5HP
230V 3 Wire .55 - .68Ohms
1.3 - 1.6Ohms
126551
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7-1/2HP
230V 3 Wire .36 - .50Ohms
.88 - 1.1Ohms
126553
10HP
230V 3 Wire .27 - .33Ohms
.80 - .99Ohms
134134
15HP
230V 3 Wire .17 - .22Ohms
.68 - .93Ohms
136361
Table:7
5.1.1 F ul l L oad Test
F ul l L oad Test
A full load test Can be carried out as per IEC Standerd
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5.1.2Temperatur e r ise test at r ated Voltage Table :8
5.1.3H igh voltage Test Table :9
H igh voltage Test Requirement asper specification
Obtain Value
CL.no. 20 of IS:9283-1995
Motor should beable to with stand
WITHSTOOD
Full Load Test Requirementas perspecification
Obtain Value
CL.no. 16.1(g) of IS:9283-1995
Voltage (V) 240Current (I) 2900 2909Slip (%) 42.0 48.98Power factor 0.967
Temperature r ise test at rated Vol tage
Requirementas perspecification
Obtain Value
CL.no. 19 of IS:9283-1995Current 12.48Cooling Medium temp
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1.5KV for 30sec
A High voltage test shall be applied between the Windingand frame with the core and connected to the frame.
5.2 Performance test
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Head and power calculation of submersible pump
A pipe have 12cm diameter and 20m length. Pump
discharge is1500lpm at 18m height overall efficiency of
pump is 70%. power And head calculation can be derived
as below.
Length of pipe:20m
Diameter of pipe:0.12mDischarge:1500lpm
Efficiency:0.70
From the design formula power is
velocity of water in pipe
V=Q/A
=4Q/d 2
=(0.025)(4)()(0.12) 2
=2.21m/s
Head =height (suction+delivery head)+friction losses +K.E
of liquid
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=18 +h f +V 2/2g
=18 + 4flV 2/2gd +V 2/2g
= 18+ (4)(0.015)(20)(2.21) 2 +(2.21) 2
(2)(9.81)(.12) (2)(9.81)
Head =20.74m
= (9.81)(1000)(0.025)(20.74)
0.70
=7266.40 W= 9.74 H.P.
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5.2.1 characteristics curve of pump
Understanding of pump system characteristics
curve
A system head curve or system curve for a piping shows
variation of pressure required with flow rate. As flow rate
increases head required increases .Pump operating point is
the point where pump head curve need system head curve.
Pump curve are generated while testing pump using cold
water as liquid the curve is fixed for particular speed,
impeller diameter and water. When any of this charges the
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pump flow and head generated will differ.
The curves can be corrected to obtain performance
map without retesting pump with modified condition.
Minimum flow of pump.
There are at least four main factor possibly determining
pump flow. They are (1) fluid
(2)temperature rise (3)internal circulation(4)thrust capacity.
(6)RESULT
ANALYSIS
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6.1Result analysis
Many other parameter are important for pump design such
as
1.impeller angles and velocity triangles
2.slip(difference between real and ideally guided fluid
velocity)
With this design of pump meets following requirement.
In case of overheated control or stator this design allows
easily ventilate or shade the box or remove from source of
heat.
In case of defective components it can be measured using
ohmmeter and determine resistance across disconnected
starting capacitor when contact is made and replace
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defective components.
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7.1 Conclusion
This pumps are suitable for pumping clean water or fluids
with a sand content of not more than 30g/c.m their high
performance and dependability make them suitable for uses
in domestics, civil and agricultural irrigation, ponds,
(7)CONCLUSION
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pressure boosting etc. It is easily installed and no need for
foundation. There is no problem in suction because it is
arranged in water. There is less maintenance needed in it.The unit work with less noise.The power consumption are
less. Its operation cost are less.
Fast self priming can be possible with this design of pump.
Both cast iron and aluminum motor body. Shielded body
bearing for long life lubrication. This type of submersible
pump is also suitable for transferring water from one tank
to another tank for multistoried building.
The motor, pump, well and fluids operates as an intricately
balanced system in actual operation, an equilibrium point
will be reached which reflects this relationship.
We have to work on design of submersible pump . A
design carried out of shaft which has been use in
submersible pump. We have also to design carried of
impeller with respect to required head and discharge. A
testing is carried out of submersible pump .In testing same
size of five or six mode are tested .
This report covered detailed design of submersible pump as
different required capacity. Work sampaling is utilized in
testing.
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References
Company website (www.dukeplasto.com )
IS-8034-2002
Mechanical handbook by S. C. Sharma
A text book of Fluid mechanics and hydraulic machines
by Dr R K Bansal
http://www.dukeplasto.com/http://www.dukeplasto.com/Recommended