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SUB MERSIBLE PUMP Russian oil delivery system engineer and inventor Armies Arutunoff successfully installed

the first submersible oil pump. In 1929, Pleuger Pumps pioneered the design of the submersible

turbine pump, the forerunner of the modern multi-stage submersible pump. In the mid-1960s

the first fully submersible deep-well water pump was developed.

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INDEX

SR NO. CONTENT Page no.

1 Basic of SUBMERSIBLE PUMP 3

2 Working Principal 4

3 Main Parts of SUBMESIBLE PUMP 7

4 Information about OIL FILLED PUMP SET (MOTOR + PUMP) 8

5 Steps of assembly of OIL FILLED MOTOR 9

6 Steps of assembly of PUMP 10

7 Information about WATER FILLED PUMP SET (MOTOR + PUMP) 11

8 Assembly of WATER FILLED MOTOR and component’s function 13

9 Difference between LOWER H.P. and HIGHER H.P. MOTOR 15

10 Assembly of PUMP and component’s function 16

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Basic of Submersible Pumps:

The submersible pump is a centrifugal pump. Because all stages of the pump end (wet end)

and the motor are joined and submerged in the water, it has a great advantage over other

centrifugal pumps. There is no need to recirculate or generate drive water as there is with jet

pumps; therefore, most of its energy goes toward “pushing” the water rather than fighting

gravity and atmospheric pressure to draw water.

Virtually all submersibles are “multi-stage” pumps. All of the impellers of the multi-stage

submersible pump are mounted on a single shaft and all rotate at the same speed. Each

impeller passes the water to the eye of the next impeller through a diffuser. The diffuser is

shaped to slow down the flow of water and convert velocity to pressure. Each impeller and

matching diffuser is called a STAGE. As many stages are used as necessary to push the water

out of the well at the required system pressure and capacity. Each time water is pumped from

one impeller to the next, its pressure is increased. The pump and motor assembly are lowered

into the well by connecting piping to a position below the water level.

In this way the pump is always filled with water (primed) and ready to pump. Because the

motor and pump are under water they operate more quietly than above ground installations

and pump freezing is not a concern.

To get more flow, the exit width of the impeller is increased and there will then be less

pressure (or head) that the pump will develop because there will be less impellers on a given

HP size pump. If the system demands more than a particular pump can produce, it will be

necessary to go up in horsepower; thereby, allowing more impellers to be stacked or to go to a

different design pump with wider impellers.

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Working principal: The submersible pumps used in ESP installations are multistage centrifugal pumps operating

in a vertical position. Although their constructional and operational features underwent a

continuous evolution over the years, their basic operational principle remained the same.

Produced liquids, after being subjected to great centrifugal forces caused by the high rotational

speed of the impeller, lose their kinetic energy in the diffuser where a conversion of kinetic to

pressure energy takes place. This is the main operational mechanism of radial and mixed flow

pumps.

The pump shaft is connected by a mechanical coupling at the bottom of the pump. Well

fluids enter the pump through an intake screen and are lifted by the pump stages. Other parts

include the radial bearings (bushings) distributed along the length of the shaft providing radial

support to the pump shaft turning at high rotational speeds. An optional thrust bearing takes

up part of the axial forces arising in the pump but most of those forces are absorbed by the

protector’s thrust bearing.

Applications: Submersible pumps are found in many applications. Single stage pumps are used for

drainage, sewage pumping, general industrial pumping and slurry pumping. They are also

popular with pond filters. Multiple stage submersible pumps are typically lowered down

a borehole and most typically used for residential, commercial, municipal and industrial water

extraction (abstraction), water wells and in oil wells.

Other uses for submersible pumps include sewage treatment plants, seawater handling,

firefighting (since it is flame retardant cable), water well and deep well drilling, offshore drilling

rigs, artificial lifts, mine dewatering, and irrigation systems.

Special attention to the type of submersible pump is required when using certain types of

liquids. Pumps used for combustible liquids or for water that may be contaminated with

combustible liquids must be designed not to ignite the liquid or vapors.

Use in oil wells:

Submersible pumps are used in oil production to provide a relatively efficient form of

"artificial lift", able to operate across a broad range of flow rates and depths. By decreasing the

pressure at the bottom of the well (by lowering bottom hole flowing pressure, or increasing

drawdown), significantly more oil can be produced from the well when compared with natural

production. The pumps are typically electrically powered and referred to as Electrical

Submersible Pumps (ESP).

ESP systems consist of both surface components (housed in the production facility, for

example an oil platform) and sub-surface components (found in the well hole). Surface

components include the motor controller (often a variable speed controller), surface cables and

transformers. Subsurface components typically include the pump, motor, seal and cables. A gas

separator is cable down-hole. This cable had to be wrapped around jointed tubing and

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connected at each joint. New coiled tubing umbilical’s allows for both the piping and electric

cable to be deployed with a single conventional coiled tubing unit.

The ESP system consists of a number of components that turn a staged series of centrifugal

pumps to increase the pressure of the well fluid and push it to the surface. The energy to turn

the pump comes from a high-voltage (3 to 5 kV) alternating-current source to drive a special

motor that can work at high temperatures of up to 300 °F (149 °C) and high pressures of up to

5,000 psi (34 MPa), from deep sometimes installed.

The pump itself is a multi-stage unit with the number of stages being determined by the

operating requirements. Each stage consists of a driven impeller and a diffuser which directs

flow to the next stage of the pump. The motor used to drive the pump is typically a three

phase, squirrel cage induction motor.

New varieties of ESP can include a water/oil separator which permits the water to be re-

injected into the reservoir without the need to lift it to the surface. There are at least 15 brands

of oil field asps used throughout the world. Until recently, ESPs had been highly costly to install

due to the requirement of an electric wells of up to 12,000 feet (3.7 km) deep with high energy

requirements of up to about 1000 horsepower (750 kW). ESPs have dramatically lower

efficiencies with significant fractions of gas, greater than about 10% volume at the pump intake.

Given their high rotational speed of up to 4000 rpm (67 Hz) and tight clearances, they are not

very tolerant of solids such as sand.

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Main parts of submersible pump: 1. MOTOR

2. PUMP

Both are assemble together.

Function of Motor:

It converts ELECTRICAL ENERGY into MECHANICAL ENERGY.

Function of Pump:

It converts MECHANICAL ENERGY into PRESSURE ENERGY.

Two types:

1. OIL FILLED

2. WATER FILLED

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A. OIL FILLED These pumps have low power consumption. Designed for optimum efficiency these pumps

are suitable for oil & water filled motor. Less vibration and lower noise level due to dynamic

balancing of rotating parts makes these pumps very popular in Domestic and Industrial water

supply, Sprinkler and drip irrigation systems, Farm houses, Nurseries and gardening and Booster

systems. This is energy efficient, easy to install pump with corrosion and abrasion resistant

parts.

Technical Specifications

Head : 23 - 251 Meters

Capacity : 5 to 350 LPM

Rating : 0.37 Kw/ 0.5 HP to 4.1 Kw/ 5.5HP

Voltage Range: 1 Phase (180 to 240)

3 Phase (280 to 440)

FEATURES

Suitable for oil & water filled motor

Low power consumption

Corrosion and abrasion resistant part

Less vibration and lower noise level due to dynamic balancing of rotating parts

Light weight and compact size makes it easy to install

APPLICATION

Domestic and Industrial water supply

Booster systems

Farmhouse, Nurseries and gardening

1) MOTOR: It consist,

Stator, Rotor, Motor housing,

Motor base, Diaphram, Connector socket

Upper End Seal Types according to size(inch):

3, 4

Types according to H.P.:

0.5, 0.75, 1, 1.5, 2, 2.5, 3, 4, 5.5

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Types according to PHASE:

SINGLE PHASE

THREE PHASE

Test on motor:

1. Leak test 4. No load test 2. H.V. test 5. Locked rotor test 3. I.R. test 6. Low voltage test

a) STATOR:

It is stationary part of motor.

It may be of single or three phases and also depend upon H.P. It consist windings.

b) ROTOR:

Rotor is rotating part of motor.

It also depends upon H.P. It rotates inside portion of stator.

MECHANICAL SEAL:

It is act as slider bearing. It is used to prevent liquid under pressure from leaking out of

pump or from drawing air into the pump when vacuum condition.

c) MOTOR BASE:

It joins at lower portion of motor housing. Whole weight of motor housing is rest on

motor base. It consist,

Diaphram: it joins with motor base. It is used to maintain or release the pressure of

motor housing.

d) UPPER END SEAL:

It joins at upper portion of motor housing.

It consist,

Connector socket: The phase connection comes out from connector socket.

Fix part: It use to prevent sand flowing inside the motor body.

Steps of assembly of motor: 1. Insert STATOR in motor housing. Press it by hydraulic Pressure Machine.

2. Join MOTOR BASE and DIAPHRAM and join this couple to lower end of motor housing.

Press this assembly by pneumatic air pressure machine by matching hole to hole of

housing and motor base.

Fix rivets and nuts in hole.

3. Connect stator socket.

4. Insert ROTOR inside portion of stator. Air gap should be 0.3mm.

Must check that, rotor must be freely rotate.

5. Join UPPER END SEAL to motor housing and press it carefully by matching hole to hole.

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6. Do leakage test

First fill air in motor housing.

Keep this housing in water for a minute.

Check that, there is no any leakage from body or any other parts.

7. Clean the body of motor housing.

Do H.V. test and I.R. test

1.8 kV is applied for three phase.

1.5 kV is applied for single phase.

If all process are okay than,

8. Fill oil in motor housing.

It is used for cooling purpose and lubrication.

After filling oil, seal it.

9. Test on motor:

1. No load test:

Load is not given to the motor and start motor. At that time check how much

voltage it will take at running condition.

2. Locked rotor test:

Lock the rotor and then voltage supply is given to the motor.

At that time, check how much voltage it will take.

3. Low voltage test:

Low voltage is given to the motor.

Check how much voltage it will require to start the motor.

10. Etching on motor housing and stick a sticker.

Packing of motor body.

2) PUMP:

Main parts of pump: Suction strainer, strainer centering,

Lower Bracket Bowl,

Impeller, Diffuser,

Rotating shaft, shaft guide bearing,

Pump house, Discharge valve & Discharge bowl, Discharge nozzle,

Cable cover

Types according to stages (Impeller + Diffuser):

9, 11, 14, 18, 21, 28, 34, 40

Types according to diffuser’s series:

03, 07, 15, 25

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Steps of assembly of pump: 1. Assemble SUCTION STRAINER and STRAINER centering together. Join this assembly

with lower bracket. Join this assembly to pump housing.

2. Take no. of IMPELLERS & DIFFUSERS. Fix this pair into bowl.

Make no. of pair of such assembly that is known as STAGES.

3. Take one shaft and insert these stages in shaft according to pump rating.

NOTE: If there is more than 21 stages, than must insert one SHAFT GUIDE at middle to

prevent bending of shaft.

4. Take VALVE and DISCHARGE BOWL and assemble it and put it onto the stages.

5. Now, Fix NOZZEL BOWL at upper portion of pump house by nut runner. Then after

must check that shaft is rotate freely or not.

6. Send this assembly to drilling machine.

7. Fix CABLE CLAMP & CABLE COVER at the body of pump housing.

8. Stickers and packing of pump.

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B. WATER FILLED

There are 5 lines:

1. 6” motor line

2. 4” motor line

3. 4” pump line

4. 6” radial flow pump line

5. 6” mix flow pump line

1) 4” PUMP SET: These pumps have low power consumption and are designed for optimum efficiency. These

pumps can be used in booster systems, farm house, nurseries and gardening, dire-fighting

system and so on.

TECHNICAL SPECIFICATION:

Capacity: 400 to 10 l.p.m

Head: 7 to 178 m

Power Rating: 0.37 to 2.2kW (0.5 to 3 HP)

FEATURES:

Low power consumption

Designed for optimum efficiency

Less vibration and lower noise level due to dynamic balancing of rotating parts

Light in weight and compact size makes it easy to install

APPLICATION:

Domestic and Industrial Water Supply

Fire Fighting for small and medium size plants

Booster Systems

Nurseries and Gardening

2) 6” PUMP SET One of the best advantages of these pumps is huge saving in electrical consumption. These

are designed to withstand wide voltage fluctuations. Non overloading power characteristics

protect the motor. These pumps have dynamically rotating parts. These are mainly used in

firefighting application. These also find wide usage in continuous supply of water in farming.

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TECHNICAL SPECIFICATION:

Capacity: 2400 to 60 l.p.m

Head: 5 to 306 m

Power Rating: 2.2 to 33 kW (3 to 45 HP)

FEATURES:

Huge savings in electrical consumption

Capability to withstand wide voltage fluctuations

Operates equally well with Genset, great help during power cuts

Design of non-returnable valve reduces friction

CED coating cast iron components long life & rust free

APPLICATION:

Continuous water supply for farming application and irrigation projects

Fire Fighting

In 6”/7”/8” PUMP line. There is following models:

PUMP

MIXED FLOW RADIAL FLOW

6AA, 6B, 6C, 6C’

8D, 8E

HHN

HHF

1. MOTOR:

Types according to size(inch):

6, 8

Types according to H.P.:

1. Lower H.P.

3, 4, 5, 6, 7.5

2. Higher H.P.

10, 12.5, 15, 17.5, 20, 25

Types according to PHASE:

SINGLE PHASE

THREE PHASE

6D, 6F, 6G, 6J

7A, 7B, 7C, 7P

8A, 8B, 8P

9A, 9B, 9C

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Test on motor: 1. No load test 4. Locked rotor test

2. H.V. test 5. Low voltage test

3. I.R. test

Main parts of motor assembly:

Stator, Rotor, Motor base,

U.B.H. (Upper Bearing Housing)

L.B.H. (Lower Bearing Housing)

MOTOR assembly and component’s function:

1. STATOR: It energized by electricity. It is static part of motor. It consist windings. It produces e.m.f.

It may be of single phase or three phase.

2. ROTOR: It is rotating part of motor. It is bar of aluminum or copper. Due to stator e.m.f. it

rotates and rotates the shaft.

3. MOTOR BASE: It is base of motor. Whole weight of motor assembly is rest on motor base.

It consists: Diaphram:

It is used to maintain/release pressure generated.

Cover plate:

Diaphram is covered and fix by cover plate.

Rocker:

Bearing is rest on rocker. So it provides support to bearing.

Collar plug:

It is used to release water from motor.

4. U.B.H. (upper bearing housing) It rest at upper side of motor. The stator connection comes out from U.B.H.

5. It consists: Stud:

It is used to lift up the motor and to fix the pump.

Bush:

It works as bearing and protect rotor and casting.

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Oil seal:

It used to resist water leakage.

Sand guard:

It used to resist sand flowing inside to motor.

Grommet:

It used to resist water leakage from upper side of motor.

6. L.B.H. (Lower Bearing Housing) It fix at lower side of motor before motor base.

It consists: Thrust bearing:

It is used to balance rotor bar.

Thrust plate:

It rest on rocker and thrust bearing placed on the plate.

7. Other important components used in motors.

Gasket

Washers:

‘O’ ring washer

Spring washer

Plane washer

Brass washer

Grommet:

1.5 (up to 5 H.P.)

2.5 (5> &<=10 H.P.)

4.0 (>10 H.P.)

SAND GUARD:

Sand fighter model – rubber

Non-Sand fighter model—brass

Cable clamp, Nut, Bolt, Key, Circlip

Air plug

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Difference between LOWER H.P. & HIGHER H.P. MOTORS:

LOWER H.P. MOTOR HIGHER H.P. MOTOR

3 H.P. to 7.5 H.P. (3, 4, 5, 6, 7.5)

10 H.P. to 25 H.P. (10, 12.5, 15, 17.5, 20, 25)

U.B.H. without adaptor. U.B.H. with adaptor.

Stator has one wire. Stator has three wires.

L.B.H. has less length. L.B.H. has more length.

It has non-fixed thrust plate. It has fixed thrust plate.

Stator stud: L.B.H. side: 180mm U.B.H. side: 150mm

Stator stud: L.B.H. side: 250mm U.B.H. side: 180mm

Motor may 1- phase or 3- phase. Motors are only 3-phase.

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2. PUMP:

Types according to size(inch):

6, 7, 8, 9

Types according to H.P.:

1. Lower H.P.

3, 4, 5, 6, 7.5

2. Higher H.P.

10, 12.5, 15, 17.5, 20, 25

Main parts of pump assembly:

Suction, Shaft, Bowl or Casing,

Diffuser, Impeller,

D.O.L. (Discharge Outlet)

N.R.V. (Non-Return Valve)

PUMP assembly and component’s function:

1. SUCTION & STRAINER:

It is used to suck water. Strainer is used to resist garbage flowing inside the pump.

2. SHAFT:

It is used to maintain the components such as impellers & diffusers to their respective

position.

3. BOWL OR CASING:

It is used to place diffuser in it. It generates pressure of water.

4. DIFFUSER:

It is set of stationary vanes that surround impeller.

It is used to increase efficiency by allowing more gradual expansion and less turbulent

area for liquid to reduce velocity.

5. IMPELLER:

It spins with shaft. Due to its design it generate vacuum and when water fill inside the

impeller, it throw the water forcefully to upper portion of stages. It is used to generate

head.

6. D.O.L. (Discharge Outlet):

It is used to take up water inside it and throw outside from pump.

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7. N.R.V. (Non-Return Valve)

It resists the water, when motor will stop and that time water falls down towards the

pump, it will damage the pump and motor.

At that time, due to return water the valve will rest on rubber ring.

8. COUPLING:

It couple the rotor shaft of motor and shaft of pump.

9. CABLE GUARD:

It guards the cable and prevents to damage by external sources.

It provides mechanical supports to the cable.

10. SUCTION with SAND FIGHTER:

One gun metal bush is placed inside the suction housing. Which resist the sand to

flowing inside the pump.

11. OTHER IMPORTANT COMPONENTS USED IN PUMP:

Adaptor plate

Wearing ring

Shaft sleeve

Grub screw

Stud

Bush

o Gun metal

o Rubber