Technical Support- LAXMI PUMPS PRIVATE LIMITED

Technical Support

Submersible pumps are installed in bores and are hardly accessible for visual inspection. However one can diagnose troubles by tuning one’s ear to the acoustical sound produced by discharge line. This can however be done by the user rather than a trained mechanic as frequency of sound is typical to a typical installation. It is advisable to touch one’s ear to delivery line and observe the sound emitted by the pump. In a daily routine inspection following points should be noted:

Sound emitted by the pump.
Voltage supplied to the pump.
Current drawn by the pump.
Visual discharge at the outlet of the pump.

The pump should not be operated for more than 2 Hrs. Panel must show voltage in the range 180 V-240 V for single phase and 350 V-440V for three phase. Any voltage outside this range is likely to harm the motor. Current drawn at different available voltages for a particular installation should be recorded and checked on a daily basis. Any abnormal current drawn by the pump set can be a possible cause of trouble. Visual discharges at outlet of the pump will depend on various factors like voltage availability on the site, the depth of water available, and periodic yield of the borewell.

Technical Support

General

The site safety regulations and statutory requirements if any, are to be taken care of and complied with, by the purchaser.

The motor and pump serial number, type and size, main operating data are stamped on the name plate of the pump set. Please quote these details while ordering the spares.

Storage

The unit is preferably to be stored in the vertical position. If the pump set is in operation and is required to be taken out for storage, after cleaning all external parts, the unit can be stored in a dry and dust free room. Thereafter whenever re-installation is taken up, verify that the pump shaft and motor shaft rotate freely by hand. If pump set is stored for long time, periodic inspection is advised.

Scope

Unless and otherwise contracted, our standard scope of supply is restricted to Motor unit, Pump unit & 3 mtr. long cable only. All other accessories are to be procured by purchaser separately.

Shut Down Period

The pump set should not be allowed to remain stationary for more than 7 days, otherwise lime, iron and other substances tend to settle in bearings and impeller gaps. If the conditions demand that the pump set has to remain shut down for a longer period, it is recommended that the pump set should run daily for at least 15 minutes to enable it to be in a healthy condition.

Minimun Flow Rate

If it is required to operate the pump set at the reduced discharges by throttling the delivery valve, the minimum rate of flow should not be less than 25% of rated flow to prevent over heating of the motor.

Receipt Of Packages At Site Verification Of Transit Damages (If Any)

After the goods are received at site, they are to be verified as per the dispatch documents. Transit damages, if any are to be reported immediately to the concerned supplier. The pump and motor are packed separately, and they are packed in a corrugated tube. Great care needs to be taken, while unpacking the goods especially the motor. DO NOT PULL THE MOTOR BY ITS CABLE AT ANY TIME. After removing the equipments from the respective packing, verify that both pump and motor shaft rotate freely.

Recommended Accessories

Cable

Every pump set supplied with 3 mtr. of cable length. Since pump sets are to be installed in borewell, an additional cable length is required to the electric supply located at ground level. The exact size of the cable is to be selected with the help of cable selection chart.

Control Panel

User is advised to use control panel with quality accessories to avoid future problems. Control panel should have following protective devices for trouble free operation of the pump set

Thermal relay with suitable current relay setting.
Single phasing preventor (For 3 phase pumps only)
Provision for water level guard/ Auto switch connection to avoid dry running of the pump set
Starting and running capacitors (as per specification on motor nameplate)
Overload / Under voltage protector.

Water Level Guard / Dryrun Control

It is recommended to install the pump set with water level guard / dryrun control of reputed make to protect the pump set against dry running at lower water levels. The water level guard consists of a cable & probe. This probe is to be installed at about 0.5 mtr. above N. R. V. top. When the water level in the bore gets lowered below the probe level, starter will get switched off automatically by the level sensing device.

Supporting Clamps

Two pairs of supporting clamps are required for installation of pump set. One pair is required permanently to hold the pump set in position. This clamp usually rests on girders or borewell casing pipe.

Cable Clips

It is necessary to fix a cable at every 3 mtr. length of delivery pipe to keep the cable in position. This minimizes the chances of damage to cable while lowering / taking out of pump set in to / form borewell. Care is to be taken while fixing these clips so that damage to the cable is avoided.

Borewell Cap

It is necessary to cover the borewell opening with this cap to avoid entry of any foreign material like dirty water, stones etc. in to the borewell there by avoiding damage to the pump set. Sometimes if a larger size stone falls into the borewell and is sandwiched between delivery pipe & borewell wall, it can damage the cable or may make it difficult to lift pump set outside.

Check Valve

The pump set operating point can be adjusted using the valve, there by avoiding the pump set operation at very low or high discharge flow.

Non Return Valve

It is recommended to protect the piping system in case of sudden power failures, causing water hammer by fitting N.R.V. in the delivery pipe.

Pressure Gauge

It is recommended to fix a Bourdon tube type pressure gauge in order to indicate the pressure developed by the pump set.

Required Tools For Installation

A tripod stand of 20 feet length.
A chain- pully block of 1 Ton capacity for bore upto 100m. depth & 2 Ton for above 100m. depth installation.
Chain spanner – 2 Nos.
A screw driver 8″, 12″, Insulating pliers, Spanners etc.
Megger 500 Mohm -1 No.
All plumbing material.

Check List Before Installation & Commissioning

Check the borewell for undersize, crookedness with the help of master size of pump set before actually loading the pump in the borewell.
The yield of borewell should be more than the discharge of the pump set.
Ensure that the N. R. V. top is at least 1 mtr. (3 feet) below maximum draw down level of water in the borewell. And also ensure that the pump set is lowered minimum 3-4 mtr. above the bottom of the borewell (check exact depth of borewell.)
Required electrical supply (1 phase or 3 phase) with appropriate voltage is available on sight

Provide proper earthing to reduce risk of electrical shock during operation of pump set.

The voltage drop at motor connection on account of power fluctuation and/or length and size of supply cable, should not be more than minimum specified voltage. The recommended minimum voltage at motor connection should not be less than 350 V for 3 phase and 180 V for single phase pump set. The recommended maximum voltage at motor connection should not be more than 440 V for 3 phase and 240 V for single phase pump set.
Motor & pump shaft rotate freely before coupling.
Motor is filled with cold, clear drinking water.

Do Not Fill Distilled Water In Motor

Check if the motor protection relay is proper.
Keep the delivery valve slightly open if it is provided.
Cable joining has been made properly as per the procedure given in this manual.
Verify that suitable control panel with following protective devices are provided and are in working condition :

Thermal Relay with suitable relay current setting.
Single phasing preventor/Auto switch (for three phase pump sets).
Provision for water level guard connection to avoid dry run of the pump set / over load protector.
Starting & running capacitors as recommended on nameplate of motor.
Motor & Pump coupling faces are clean. Remove rust preventor.

Cable Jointing Procedure

Good cable connection ensures a prefect water tight joint & at the same time gives reliable protection against mechanical damages to the joint. Select proper cable size with the help of Cable Selection Chart

Cut the motor & supply cable in a staggered manner.
Cut the outer black P.V.C. of both the cables.
Maintain projections of motor cable RED, YELLOW & BLUE conductors projecting outer black PVC by 50 mm, 75 mm & 100 mm respectively.
Remove insulation of all conductors to project copper wire approximately by 7.5 mm.
Coincide the copper wires of same colour conductor of both the cables. Insert copper wire of same colour conductor of both the cables in each crimping sleeve. Crimp each sleeve at three different points.
Clean the sleeve. Wrap two layers of approx. 6 mm. size MRF tape over each joint.
Wrap two layers of PVC adhesive tape over each sleeve.
Wrap each joint with two more layers of PVC Tape.
File both the outside Black PVC outer sheath of both the cables by rough file.
Wrap two layers of approx 8/10 mm size MRF tape and then wrap two layers of PVC Adhesive tape.
Keep the joint deep in water for some time & test it by meggar. If meggar value is 20 Mohm or more, then the joint is O.K.

Continuity Test

To check the continuity between the three possible combinations of the power leads, connect one lead from meggar to (R) phase and another lead from meggar to (Y) phase of motor cable. Rotate the handle of meggar and note down the reading. Repeat this for (Y) and (B) phase and also for (B) and (R) phase. In all cases, readings should be zero and infinity value will indicate break in winding wire, cable or joint or loosening of joint, which is to be corrected.

Insulation Test

Check the insulation resistance of winding coils and cable. Join all the leads, twist them together and connect them to the line lead from meggar; Connect another lead from the meggar to a clean the surface of delivery pipe on meggar dial. The rotation of meggar handle should be enough to produce 500 volts D.C. The reading on meggar dial should never be less than 5 Mohm. Reading of 2 Mohm indicates that insulation has become weaker and (0) zero reading indicates shorting of windings/ cables or joints to the earth. In case of weaker insulation or Zero insulation, cut the cable at lead joint and again check the insulation of winding. If it is OK, then there is no fault in winding coils or else the motor is to be sent to the works for repairs.

Installation & Commissioning of 'Lada' V4 Slim Radial 82mm, V4 Radial 96mm, V4 Mix 96mm & V5 Radial 125mm Submersible Pump

Hold motor in vertical position and remove both A & B water filling plugs
Fill water from one of the water filling port A with cold, clean, fresh drinking water.
Hold motor carefully & shake it right & left to remove the air inside the motor.
Top up the water from one water filling port A till water comes out from other port B.
Check the insulation resistance of motor with 500 Volts. Megger should be minimum 100 Mega Ohms.
Connect the supply cable to motor cable strictly as per the cable joining procedure.
Remove the cable guard and strainer from the pump.
Couple the pump with motor. Check the play by lifting pump shaft with the help of screwdriver, it should be between 0.5-1 mm.
Adjust cable slot of suction piece of pump to fit suction sand protection provided on cable to prevent sand from going inside the motor.
After pump and motor surfaces are matched properly and perfectly, tighten the opposite nuts equally.
Cover the cable running on pump by cable guard and suction intel by suction strainer.
Connect first delivery pipe to pump outlet (N.R.V.) and lower the pump set in borewell by means of tripod chain – pulley block and supporting clamps.
Connect one by one delivery pipes likewise and lower the pump set to desired depth. Cable running with delivery pipe should not be kept loose. It should be clipped with delivery pipe at an interval of minimum 3 mtr. with cable clips.
Hold the last pipe on the borewell casing firmly by means of supporting clamps.
Connect bends, good quality of N.R.V. and check value on delivery pipe line.
Connect the cable leads to control panel.
Ensure that check valve is kept partially opened (1/3 of full open) before switching on the pump set, to avoid entry of large amount of sand/ mud along with rapid flow of water.
Check direction of rotation after installation (for 3 phase pump sets) Start the pump set and check discharge. Confirm both the discharge flow and the correct electric connection that gives required discharge flow.
In case of single phase pumpsets the direction of rotation will show correct direction of rotation irrespective of the mode of connection of the supply.
Check supply voltage/ current is appropriate or not. Run the pump set till clean and clear water is discharged continuously.
Don’t switch on / off for more than 15 times in an hour with minimum of one minute interval between two sucessive starts and stops to avoid motor overheating.
Rest delivery pipe approximate minimum 1 ft. above the ground level.
Use PVC pipe for under grounded supply cable.

Caution

Pumpset should not be run in dry condition in any case.
Before commissioning the pump set, Megger value should be checked & it should be 20 Mega Ohms minimum.

Installation & Commissioning of 'Lada' V6 Slim Radial 135mm, V6 Radial / Mix / 50 Feet per stage / Janata Model 142mm Submersible Pump

Hold motor in vertical direction
Fill motor with fresh drinking water
Ensure that there is no water leakage from drain plug.
Hold motor carefully and shake it right and left to remove air inside the
Again fill the water
Check the insulation resistance of motor with 500 volts. Megger should be minimum 100 Mega ohms.
Remove the cable guard and strainer from the pump
Clean the pump and motor coupling face. Couple the pump with motor by matching coupling slot. Match the stud hole and cable hole of motor and pump. Set the pump till it fits in the motor adaptor.
Check the play by lifting the pump shaft with the help of screw driver, it should be between 0.5 mm to 1 mm
Take out the cable from cable slot and fit the strainer.
Join the cables as per instruction in cable jointing.
Fit the cable guard carefully.
Connect first delivery pipe to pump outlet(N.R.V) and lower the pump set in borewell by means of tripod stand, chain pulley block and supporting clamps.
Connect one by one delivery pipes and lower the pump to desired depth. Cable running with delivery pipe should not be kept loose. It should be dipped with delivery pipe at an interval of minimum 3 mtrs. with cable clips.
Fit the bore cap on bore casing
Hold the last pipe on the borewell casing firmly by means of supporting Clamping.
Connect bends, gate valve and good quality N.R.V.
Connect the cable leads to control panel.
Control panel must have thermal relay of proper current setting range, single phasing preventor and facility to connect the water level guard.
Keep the gate valve slightly open to avoid the entry of mud and soil while starting pump set.
Check the direction of rotation.
Check the supply voltage and current is appropriate or not. Run the pump set till clean and clear water is discharged continuously.
Don’t switch ON/OFF for more than 15 times in an hour with minimum of one minute interval between two successive starts and stops to avoid motor overheating.
Use PVC pipe for under grounded supply cable.
Rest delivery pipe approximate minimum 1 feet above the ground level.

Caution

Pumpset should not be run in dry condition in any case.
Before commissioning the pump set, Megger value should be checked & it should be 20 Mega Ohms minimum.

Periodic Inspection Chart

Breakdown Maintenance

Laxmi Pumps Pvt. Ltd. can supply you all the spares of your pump at reasonable price to carry out repairs at your local mechanics.However we insist that repairs to the pumps should be carried out by our authorized service stations or mechanics to save you from possible damage to your pump. Please quote the type and serial number of pump while ordering the spares of pumps. WE ASSURE TO SERVE YOU BETTER

Periodic Checks

It is better to carry out periodic checks to determine the health of Submersible Pump and possible troubles. This can be done in the following ways.

Install a Pressure guage (make provision while installation). Completely close the outlet of the pump by using a throttle valve. Record the pressure guage reading periodically. Any drop in pressure more than 15% of original value can suggest a problem in the pump. (Ref. Trouble shooting chart)
Periodic inspection should be carried out to determine the insulation resistance of winding.

Do’s

Ensure that the pump portion is kept resting on the N.R.V. and not on the coupling
Ensure that for prolonged storage, the motor is filled with cold drinking water (NOT DISTILLED WATER)
Run the pump for at least 1/2 an hour every week if the pump remains under shut down for a longer period, to resume instant service at any time
Do suspend the pump set 3-4 mtr. above the bottom in borewells.
Ensure that the pump is installed at least 1 mtr. below the lowest level of water.
Ensure proper coupling by lifting the shaft assembly with screw driver which should lift by 0.5 to 1.0 mm approximately
Run the motor for minimum 30 mins after commissioning until clear water starts flowing.
It is necessary to operate a submersible pump set against a throttle discharge valve. The minimum rate of flow should be at least 25% of the rate of flow at an optimum efficiency point on the chart to avoid overheating of the pump set
Use Overload Protection Relay
Ensure fitment of water level guard for low yield borewells.
Use the 500 volt D.C meggar only.

Don’ts

Don’t switch on/off for more than 15 times in an hour with minimum ol 1 min. interval between two successive start and stops to avoid damage to the motor.
Don’t use the pump if the water is sandy or acidic.
Don’t run the pump if any defect is observed.
Don’t run the pumpset in dry condition
Don’t run the pumpset against the closed discharge valve for more than 5 minutes to avoid over heating of the motor.
Don’t use new pumpset for developing or surging well or to free it from sand when the bore is a new one.
Don’t switch on the pumpset under any circumstances before filling the motor with drinking water.
Don’t start the pump without fitting sluice valve and water level guard.
Don’t operate the three phase pump in case of single phasing.
Don’t Lift the Motor with the help of its Cable.
Don’t bend the cable sharply
Don’t use extra washer in motor and pump coupling for extra play.