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IS 14536 (1998): Selection, installation, operation andmaintenance of submersible pump set - Code of practice [MED20: Pumps]

IS 14536 : 1998

Indian Standard

SELECTION, INSTALLATION, OPERAnON AND MAINTENANCE OF SUBMERSIBLE PUMPSET -

CODE OF PRACTICE

ICS 23.080

.

0 BIS 1998

BUREAU OF INDIAN STANDARDS MANAK BHAVAN. 9 BAHADlJR SHAH ZAFAR MARC

NEW DELHI I I(kNJ,?

Price Group 2

Pumps Sectional Committee, HMD 20

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Pumps Sectional Committee had been approved by the Heavy Mechanical Engineering Division Council.

A large number of borewell submersible pumpsets covered in IS 8034 are in use for supply of clear cold water. It was decided to fommlate an Indian Standard to provide guidelines on selection, installation operation and maintenance of submersible pumpsets which would be useful for the consumers to ensure trouble free operation of the pumpsets. Hence this Indian Standard has been formulated with this objective.

IS 14536 : 1998

k&an Standard

SELECTION, INSTALLATION, OPERATION AND MAINTENANCE OF SUBMERSIBLE PUMPSET-

CODE OF PRACTICE 1 SCOPE

This standard lays down general guidelines for selection, installation, operation and maintenance of borewell submersible pumpsets covered in IS 8034.

2 REFERENCES

The Indian Standards listed below are necessary ad.juncts to this standard:

IS No.

694 : 1990

1239 (Part 1) : I990

4984 : 1995

4985 : 1988

8034 : I989

9283 : 1995

10804 : I994

12231 : 1987

3 SELECTION

Title

PVC insulated cables for working voltages up to and including 1 100 V (third revision)

Mild steel tubes, tubulars and other wrought steel fittings: Part I Mild steel tubes (fifth revision)

High density polyethylene pipes for potable water supplies Cfourth revision)

Specification for unplasticised PVC pipes for potable water supplies (seco& revision)

Specification for submersible pumpsets @r-Q revision)

Motors for submersible pumpsets Cfirst revision)

Recommended pumping system for agricultural purposes (second revision)

UPVC (rigid) pipes for use in suction and delivery lines of agricultural pumps

CRITERIA FOR PUMPSET

The selection criteria are:

a) Bore well size, yield and depth;

h) Performance requirement namely pump flow rate and total head;

c) Type of pewer supply; and

d) Nominal speed.

4 ROREWELL SIZE

Major use of submersible pumpsets is by way 01 installation on bore wells and hence, the diameter

of the borewell determines the barrel size of pumpset according to its suitability with the borewell size.

Type of borewell like deepwell/shallow well and position of strainer pipe are to be mentioned by the purchaser, so that pumpset is not lowered against strainer pipe. Accordingly the lowering depth is decided.

For safe erection and removal of the submersible pumpsets and subsequently to maintain suitable suction flow velocity in remaining ring section between the unit and tubewell casing, maximum outside diameter of the pumpsets with respect to tubewell diameters are recommended as given in Table 1.

Table 1 Maximum Outside Diameter of Submersible Pumpset

Nominal Diameter Maximum Outside Corresponding of the Tubewell Diameter of Minimum Diameter

Submersible of Checking Pumpsets Mandrel

mn, mm mm

(1) (2) (3)

100 9x IO2

115 108 112

150 146 I so 200 I96 200

2.50 245 2.50

300 2% 301

NOTES 1 The six and straightness ofthe bore well should be checked hy 3. mandrel with ulinimum dia given in col 3 of Tnble I ahd of length minimum equal to the length of the pumpset. 2 The drill bit size used fur drilling the borehole should be such that the checking mandrel is lowered up IO the end of borehole and taken out of it ens~ly.

5 DISCHARGE

The yield of the borewell shall be tested by the drilling contractors and a report is furnished by them regarding the continuous availability of water and its level when a certain quantity of water is being pumped out from the borewell. To ensure longer life and optimum efficiency of the borewell, it is recommended that the rated discharge of the pump should be taken as approximately 85 percent of the yield of the borewell. Thus, the discharge of the pump is decided. From various types of pumps available in the manufacturing I-anpe, a suitnhlc type 01‘ pump is selected, hased on horewell size and required discharge, which g~vcs maximum efficiency at that particular point.

1s 14536 : 1YYS

. h TOTAL HEAD

‘I’he total hcact shall be worked out by considering the following aspects:

Level of water below the ground level when

the rated/desired discharge is being pumped

out.

Variation of water level taking place in season.

Delivery head above ground level that is

vertical height of the top most delivery point

of water from the ground level.

Frictional losses taking place in bend, nnnrcturn

valve, reducers, gate valve, column pipe and

delivcl-y pipe depending upon size and length

and type of pipe.

Addition 01’ all above gives the total head at which

the clcsired pumpset will be working.

7 STAGE AND RATING OF PUMPSET

For lhe desired head and with selected type of pump,

numhcr of stages required is known for the type of

pump. l’hc numhcr of stages give the corresponding

rating ot motor by Ircfcrring to the perfol-mance chart/

characteristic curves given by manufaclul-cr.

8 CARLE SELECTION

It is recommended that the cnblc size is sclccted from

the cable sclcction chart provided by the pumpsct

manufacturer, based on motor current and the length

01’ the cable rccluircd. If the chart is not provided

by the pumpsct manufacturer it is reoommcnded that

tlw maximum voltage drop li)r the molar current slw~iltl not cxccccl 3 pcrccnt of the supply voltage from llic control pnncl to the motor terminal. If, rluc to longer Icngth of cable for a particular current,

the point is at the end of boundary 01. selection chart

IOI- that size of cable, then next hi&r size uf cahlc

shall he sclcctcd. This will ennblc the motor to work

4atisI;tctorily as the voltage drop bclween supply point

and tnoro~~ tcrminnls will he minimal and overheating

01’ winding will IX reduced thereby increasing the

life 01’ motor.

NOI-mally ihc. n~inimurn SIAC of tlclivcry pipe sl~all

IX at Icast quivalent to the pumpsct nominal outlet

si;/c. Uut IO rccluce I’riclional losses 111 the p~pc.

hi$lcl- tliamctcr 01‘ pipes may hc used as provided

iii IS IOXO4. Accordin$y other supporting clamps

;~ntl cahlc clips shzll also hc sp’cciI‘ied depcndins up011 the diameter 01‘ the p~llc sclcctcd.

b) Overload,

c) Under and over voltage,

d) Single phasing in case of 3 phase pumpscts,

e) Dry running.

f) Short circuit/lightening protection, and

g) Proper indicating instruments.

All the above accessories shall be mounted on a

control panel.

10.2 Earthing

Earthing should he provided as per 5.4 of IS 928.3.

10.3 Protective Devices for Pump and Pipes

a) Control valve is recommended at the delivery line and ground Icvel.

b) Suitable devices like cheek val\,c, air valves.

surge tank, e~c, shall bc provided in the

delivery to avoid watcl- hammcl-in:.

11 INSTALLATION

A hoist or a winch of sufficient capacity is required

for lowering and installing the pumpsct in hnrcwell.

Suitable tools like pipe wrench and spanners, ctc, shall be available at the site l.or easy and quick

installation. The procedure for installation of ;I

submersible pump in bore well is as follows:

a )

b)

c)

Open the motor and pump packing cases,

check fol- any transit damage hclbre erection.

Keep the motor in vertical position.

Wherever liquid filling is required, filling 01 the motor with the liquid shall bc carried oui

as per the instructions of the manufaclurer.

Check li,r free rotation of motor shalt

manually.

Cheek the insulation rcsistancc of the mortar

by 500 V DC .mcggar and also check the

direction of rotalion by giving supply lo the

motor li)r few seconds.

Couple the pump IO the motor. Al’icr coupling.

check with ihc help of a suitahlc tool at ~trc

coupling whether the pump rotating asscmhly

gets lifted or not. II‘ it jicts lifted lhen the

ccjupling is correcl.

Note down pump and motel nameplntc Dada

li)r t’uture refcrcncc.

Join rcquiretl length ol cable il nccess;~~-y.

F~II- cahlc jointing, follow the I~;IIIU~‘~CILIICI ‘s I cct~mmcridation.

I.ower the unit without fcrk wilh pipes hy

means 01’ hoist/winch ;~ricl suppoi-liiig clalnp~

;rl~q with cartliin~ and anchor-:\,c!c (whercvcl-

apl~licahlc) and continue COIII~C~.IIII~ ihxYpc111 lcngtl1s 01 p1pc.

While lowering the unit without jerk, keep

on fixing the cable clips at every three meters length of pipe to keep the cable in position.

NOTE -Care is to be taken for prevention of any cable. danage during lowering of the unit.

Ensure that pump has been lowered along

with the submersible cable to the required

depth.

Fit the supporting clamps.

Check for insulation resistance of the motor

once again with a 500 V DC meggar.

Now connect the cable to the control panel.

12 OPERATION

A)

b)

C)

(1)

Cl

S)

Switch on the supply and check for the

incoming voltage which should be the rated

voltage.

In case of 3 phase submersible pumpset, check whether all three phase supply voltage is

halancctl OI- not. II’ not, do not start the pump.

Ensure proper carthin, u is done at the ground

level.

If above parameters arc checked and found

all right, then the pump is ready to start.

Start the pump and check for the discharge.

Rated discharge will show the correct direction

of rotation.

Throttle the delivery valve LIP to approximately

l/3 of rated discharge. Do not stop the pump till cicar water starts coming out. Open the

delivery valve li~lly aftci- clear water is

obtained.

If MAINTENANCE AND TROUBLE SHOOTING:

‘I’(, CIISLII-c proper operation of the pumpset. the ground

lcvcl protcclion devices should be periodically

chcokctl. The common trouhlcs arid probable reasons

arc given in 13.1 to 13.7.

13.1 Less Discharge

il)

11)

C)

11)

c.1

I’)

F )

II)

Opcr;ltional system head is more than rated

plllllp l1cml.

Yicltl of horcwcll riot adcquale.

Lower xpcccl of motor tiuc to low vollage/

low l-i-c(lLl”ii”y/oxot’ssivc Iriction.

C’hoking of’ ctraincl-/illlpclIcr/piyes.

Dclivcry valvc/NRV/Chcck valve nc~t 1.~111~ 0pL’nL’d.

Improper (III-ccticrn 01’ rolalion ~LIC to change

in phase scqucncc of power supply.

I.eaka!$ Ill dcllvery

Gxccssivc al~~~asivc

conlponcllls.

IS 14536 : 1998

13.2 Pump Draws Excessive Power/Current

4

b)

cl

4

e)

f _,

g 1

h)

.i)

k)

Misalignment of pump and motor.

Higher speed of motor due to higher supply frequency/excessive supply voltage.

Duty point of the system not matching.

Rubbing of rotating parts with stationery parts.

Bearings worn out.

One defective fuse, single phasing.

Change in the actual static head.

Low voltage.

Cable in defective condition.

Loose connection of input supply.

13.3 Excessive Vibration

a )

b)

cl

d)

c)

0

0”)

h)

.i)

k)

Improper alignment.

Inadequate water level.

Bearings worn out.

Shaft bent.

Abrasive wear of pump bearings after

prolonged operation or due to operation in

water of higher sand content or corrosiveness.

Foreign bodies lodged in impellers.

Pump resting improperly on borewell bed.

Air or gas inclusion in water.

Dry running of pump.

Reverse rotation.

13.4 Zero Discharge

Failure of power supply.

Operating head is beyond the range ot

pumpset.

Pump not properly suhmergcd in water.

Straincr/impcllcr/dclivcry valve/check valve/

NRV/pipc fully choked.

Coupling broken.

13.5 Pump Seizure

a) lmpropcr ;ilignmcnt.

h) Dry running 01’ pump.

C) 13end in 4~1.1.

d) Pump remains rinuscd for prolonged pcr~otl

C) Clog$ng 01 torcign mailer.

1.) Bcar~n!~ WOI n out.

13.6 Wearing Out ot’ Parts

;I) Ml5atlgnrrlcnt

IS 14536 : 1998

h) Presence of sand particles.

c) Improper selection of material.

d) Frequent dry running.

c) Quality of water.

13.7 Pump Does not Start

a) Tripping of overload relay.

b) Low supply voltage.

c) Pump seized.

d) No power supply.

c) Blown fuse.

f) Failure of protection devices.

g) Failure of cables/cable joints.

NOTE - To ensure correct opentiou it is necessary to have comx~ information given hy various measuring instruments instdled on control panel. Periodical checking and calibration of the measuring instruments atx necessary for proper and conecr feedback.

14 CABLE JOINTING

The cable jointing is a critical parameter for performance, safety and service life of the pump. The cable jointing shall be done strictly as per pump manufacturer’s instructions and the insulation resistance and the strength of the joint is thoroughly checked.

Bureau of Indian Standards

BIS is a statutory institution established under the Bureclu of In&an Stcr/l&rr/ Act, 1986 IO promote harmonious development of the activities oi standardization, marking and quality certification of goods and attending to connected matters in the country.

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Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also revicwccl periodically; a standard along with amendments is reaffirmed when such review indicates that no cl~npes arc needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue ol’ ‘BIS Handhook’ and ‘Standards: Monthly Additions’.

This Indian Standard has been developed from Dot : NO. HMD 20 (0322).

Amendments Issued Since Publication

Amend No. Date of’ Issue Text Affected

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