Gm-1232 Project Report

7/27/2019 Gm-1232 Project Report

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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


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.
http://www.jalgangapumps.com/images/submersible-pumps-big/v6%20submersible-pumps.jpg


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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


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/

Documents

Gm-1232 Project Report