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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CONTENT
Basic of SUBMERSIBLE PUMP
Working Principal
Main Parts of SUBMESIBLE PUMP
Information about OIL FILLED PUMP SET (MOTOR + PUMP)
Steps of assembly of OIL FILLED MOTOR
Steps of assembly of PUMP
Information about WATER FILLED PUMP SET (MOTOR + PUMP)
Assembly of WATER FILLED MOTOR and components function
Difference between LOWER H.P. and HIGHER H.P. MOTOR
Assembly of PUMP and components function

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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.

 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
protectors 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 umbilicals 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 reinjected 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.

 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

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
2. H.V. test
3. I.R. test

a)

4. No load test
5. Locked rotor test
6. Low voltage test

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 diffusers 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
6D, 6F, 6G, 6J
7A, 7B, 7C, 7P
8A, 8B, 8P
9A, 9B, 9C

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
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 Test on motor:
1. No load test
2. H.V. test
3. I.R. test

4. Locked rotor test

5. Low voltage 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 components 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 modelbrass

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)
U.B.H. without adaptor.
Stator has one wire.
L.B.H. has less length.
It has non-fixed thrust plate.
Stator stud:
L.B.H. side: 180mm
U.B.H. side: 150mm

10 H.P. to 25 H.P.
(10, 12.5, 15, 17.5, 20, 25)
U.B.H. with adaptor.
Stator has three wires.
L.B.H. has more length.
It has fixed thrust plate.
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 components 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

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