Submersible Pumps & MotorsSubmersible Pumps & Motors ... Pump... · Submersible Pumps &...

Submersible Pumps & MotorsSubmersible Pumps & Motors Preventative Maintenance

June 7, 2012Randy CowdenRandy CowdenSales Representative

Water & Wastewater

Submersible Pump Applications

Submersible Pumps Can Operate Submerged In A Submersible Pumps Can Operate Submerged In A Wet Well Or Permanently Mounted In A Dry WellWet Well Or Permanently Mounted In A Dry Welly yy y Pump Preventative Maintenance Should Include Pump Preventative Maintenance Should Include

The Pump Environment & Equipment, The Pump The Pump Environment & Equipment, The Pump Itself And The ControlsItself And The ControlsItself And The ControlsItself And The Controls Proper Preventative Maintenance Of The Well Will Proper Preventative Maintenance Of The Well Will

Increase The Longevity Of The PumpsIncrease The Longevity Of The Pumpsg y pg y p Regular Control Panel Checks Can Give Regular Control Panel Checks Can Give

Forewarning Of Potential ProblemsForewarning Of Potential Problems Annual Pump Inspections Can Increase The Life Annual Pump Inspections Can Increase The Life

Of The Pump And Prevent Catastrophic FailuresOf The Pump And Prevent Catastrophic Failures

Water & WastewaterSubmersible Pumps & Motor Preventative Maintenance

February 19, 2009

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Maintenance & Troubleshooting Safety

Follow All Safety Guidelines When Working Around Lift Stations And With Mechanical & Electrical Equipment

Check For Any Hazards Including Trip, Fall, Chemical And Dangerous Gases

Use Proper Safety Gear Including Proper Safety Shoes, Hard Hats, Harnesses, Gas Monitors And Gloves,

Only Qualified Service Personnel Should Perform Work And Should Never Work Alone

Do Not Ignore Health Hazards Observe Strict Cleanliness Do Not Ignore Health Hazards. Observe Strict Cleanliness

A First-aid Kit Must Be Handy

Use Lock-out Tag-out Procedures On Electrical Equipment


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Wet Well Preventative Maintenance

Properly Ventilate Well And Check For Gases Before Properly Ventilate Well And Check For Gases Before Observing Wet WellObserving Wet WellObserving Wet WellObserving Wet Well

Remove Debris From Top Of Wet Well Water LevelRemove Debris From Top Of Wet Well Water Level

Check Condition Of Power CablesCheck Condition Of Power Cables Check Condition Of Power CablesCheck Condition Of Power Cables

Check Guide RailsCheck Guide Rails


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Clean Level Sensors (Floats, Clean Level Sensors (Floats, Transducers) And Check For Proper Transducers) And Check For Proper OperationOperationOperationOperation

–– Clean Floats And Check By TiltingClean Floats And Check By Tilting

–– Check Transducers By Using KnownCheck Transducers By Using Known–– Check Transducers By Using Known Check Transducers By Using Known Water Height and Verify In ControlsWater Height and Verify In Controls

Check Pump Connection For Proper Check Pump Connection For Proper SealingSealing

–– If Water Swirls Or Sprays Around If Water Swirls Or Sprays Around Discharge Connection This Could IndicateDischarge Connection This Could IndicateDischarge Connection, This Could Indicate Discharge Connection, This Could Indicate Improper Sealing or Sludge Build Up Improper Sealing or Sludge Build Up Around PumpAround Pump


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Pump Lift Station Down And Clean Pump Lift Station Down And Clean Side Walls OffSide Walls OffSide Walls OffSide Walls Off

–– Flygt Pumps Can Be Operated Until Flygt Pumps Can Be Operated Until The Pumps “Snore” To Help Remove The Pumps “Snore” To Help Remove Debris And Decrease Build UpDebris And Decrease Build UpDebris And Decrease Build Up. Debris And Decrease Build Up. (Check Other Manufactures If Pumps (Check Other Manufactures If Pumps Can Be Operated Continuously This Can Be Operated Continuously This Low )Low )Low.)Low.)

–– Use Two Pumps To Pump Down Use Two Pumps To Pump Down Station To Increase Velocity In The Station To Increase Velocity In The Di h Pi i A d R dDi h Pi i A d R dDischarge Piping And Reduce Discharge Piping And Reduce Chance Of Clogging.Chance Of Clogging.


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Submersible Dry Pit Preventative Maintenance

Follow The Same Guidelines For Follow The Same Guidelines For The Wet WellThe Wet WellThe Wet WellThe Wet Well

Check Ventilation EquipmentCheck Ventilation Equipment

Properly Ventilate Dry Well AndProperly Ventilate Dry Well And Properly Ventilate Dry Well And Properly Ventilate Dry Well And Check For Gases Before EnteringCheck For Gases Before Entering

Follow Safety Codes BeforeFollow Safety Codes BeforeFollow Safety Codes Before Follow Safety Codes Before Entering The Dry Well And Entering The Dry Well And Before Opening The Wet WellBefore Opening The Wet Well


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Submersible Dry Pit Preventative Maintenance

The Dry Well Needs To Be Checked The Dry Well Needs To Be Checked For Cracks And For Water Leaks InFor Cracks And For Water Leaks InFor Cracks And For Water Leaks In For Cracks And For Water Leaks In The WallsThe Walls

Sump Pump Needs To Be Checked Sump Pump Needs To Be Checked p pp pFor OperationFor Operation

Fittings Need To Be Checked For Fittings Need To Be Checked For TightnessTightness

Gate & Plug Valves Need To Be Gate & Plug Valves Need To Be O t d T P t S i i A dO t d T P t S i i A dOperated To Prevent Seizing And Operated To Prevent Seizing And Allow Full Closure When NeededAllow Full Closure When Needed


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Submersible Pump & Motor

Submersible Pumps And Motors Are One Unit (No Submersible Pumps And Motors Are One Unit (No Couplings, Impeller Is Directly Attach To The Motor Shaft)Couplings, Impeller Is Directly Attach To The Motor Shaft)

Mechanical Seals Isolate Motor From Pumped MediaMechanical Seals Isolate Motor From Pumped Media

Most Submersible Pumps Use Upper & Lower Most Submersible Pumps Use Upper & Lower M h i l S l Th t P id A S l Ch b FM h i l S l Th t P id A S l Ch b FMechanical Seals That Provide A Seal Chamber For Mechanical Seals That Provide A Seal Chamber For Lubricating & Cooling The SealsLubricating & Cooling The Seals

Mechanical Seal Failure Can Be Cause By Erosion, Mechanical Seal Failure Can Be Cause By Erosion, Vibration Or Thermal ShockVibration Or Thermal Shock

Water Intrusion Into The Motor Chamber Causes Motor Water Intrusion Into The Motor Chamber Causes Motor Failure, Leak Sensors Notify The Onset Of A LeakFailure, Leak Sensors Notify The Onset Of A Leak, y, y

Motor Failure Can Also Be Caused By Electrical Motor Failure Can Also Be Caused By Electrical MalfunctionMalfunction


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Typical Submersible Pump

C O

MOTOR

JUNCTION CHAMBER

MOTORCOMPARTMENT

SEAL OILHYDRAULIC

WET ENDCHAMBER


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Typical Small Submersible Pump

MOTORCOMPARTMENT

JUNCTION CHAMBER

HYDRAULICWET END

SEAL OILCHAMBER


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Flygt N-technology

Working together for higher efficiency

N-impeller

Insert ring

R li f

Guide pin

Relief groove

Pump housing


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6/22/2012 12Update Presentation Name or Confidentiality Status Under Footer Menu

“Compact Mixers/Pumps” 4600 - Series

Water & Wastewater

“Horizontal Axial Flow Pumps” PP4600 - Series

Water & Wastewater


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Pump Preventative Maintenance (Annually)

Run Pump And Listen For Any Unusual Noise In Upper & LowerUnusual Noise In Upper & Lower Bearings

Remove Pumps And Clean Off pBuild Up

Check For Build Up Around Power And Lifting Cables/Chain

Check Impeller Clearance

Check For Clogging


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PUMP DRAWS HIGH AMPS – MAY BE CLOGGED


February 19, 2009

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BBeaver


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Pump Preventative Maintenance (Annually) Remove Pump From Volute To Remove Any

Stringy Material From Around Impellers And Any Lodged Or Debris Build UpAny Lodged Or Debris Build Up

Check Oil Chamber For Oil Condition And Level Plus Change gOil (Properly Dispose Of Old Oil & Replace O-Rings)

Meggering The Power Leads– Insulation Check

W t I t i Ch k– Water Intrusion Check

– Cable Damage Check


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Checking A Pump With Multimeter

Check Each Power Lead To Pump Ground LeadGround Lead

– Open – Winding Is Not Grounded

– Resistance – Winding Is Groundedg

Check Between Power Leads To Determine

– Resistance Values Shows What Voltage Pump Is Wired For

Open Circuit Could Be Open Windings– Open Circuit Could Be Open Windings Or Cut Cable


February 19, 2009

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Checking A Pump With Megger

Disconnect Pump Power And Ground Leads

Check With A Cool Motor Check Power Lead To Pump Ground Lead

High Megohm Good Motor– High Megohm – Good Motor– Medium Megohm – Used Motor, Hot Motor

or Slightly WetLow Megohm Deteriorated Motor– Low Megohm – Deteriorated Motor Insulation, Bad Cable, Wet Windings

– Low-No Megohm – Burnt Motor, Grounded Leads, Soaked Cable or Motor,

Do NOT Megger Pump If It Has Internal Contactors Or Capacitors (Single Phase)


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Check Pump Sensor Leads

Check Manufacture’s Ratings For Sensor Leads And To DetermineSensor Leads And To Determine Proper Test Procedure And Function

Usually Sensor Leads Are Checked yby Resistance (1200 – 1550 normal)

Open Resistance Will Show Fault, Possible Open Thermals (~)

Resistance Values On Leak Sensors Can Determine If A Leakage HasCan Determine If A Leakage Has Occurred (300)


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MOISTURE IN PUMP


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Control Panel Preventative Maintenance

Check InCheck In--Coming PowerComing Power

Ch k R Ti M t A dCh k R Ti M t A d Check Run Time Meters And Check Run Time Meters And Compare Previous Run TimesCompare Previous Run Times

Check Operating Amps For EachCheck Operating Amps For Each Check Operating Amps For Each Check Operating Amps For Each Pump And Compare To Previous Pump And Compare To Previous Readings & Full Load Ratings Readings & Full Load Ratings

Check All Electrical Components Check All Electrical Components And All Connections Including And All Connections Including S rge Arrestors AlternatorsS rge Arrestors AlternatorsSurge Arrestors, Alternators, Surge Arrestors, Alternators, Relays And Pump SensorsRelays And Pump Sensors


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Control Panel Preventative Maintenance

Check Alarm Light & Horn Check Alarm Light & Horn OperationOperationOperationOperation

DeDe--energize Panel, Check And energize Panel, Check And Tighten All ConnectionsTighten All Connectionsgg

Check Conduit For Tightness And Check Conduit For Tightness And Sealing (Replace Sealing When Sealing (Replace Sealing When Floats Or Pumps are Pulled Floats Or Pumps are Pulled Through)Through)

Use A Mild Protecti e Spra OnUse A Mild Protecti e Spra On Use A Mild Protective Spray On Use A Mild Protective Spray On The Door Gasket To Ensure The Door Gasket To Ensure Watertight IntegrityWatertight Integrity


February 19, 2009

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Pump Troubleshooting

Pump is operating but not pumping– Air Locked (Pump will pull lower than usual amps)– Air Locked (Pump will pull lower than usual amps)– Pump Is Not Sitting On The Discharge Connection Properly– Valves stuck or closed (Pump will pull lower than usual amps)– Debris in front of inlet pipe (Can possibly hear cavitation or rattling

in pump)– Wear Ring is worn out or Impeller clearance needs adjustedWear Ring is worn out or Impeller clearance needs adjusted– Pump is turning backwards (Three Phase Only) (Pump may

vibrate more)L B k I ll (P ill ll l th l )– Loose or Broken Impeller (Pump will pull lower than usual amps)

– Verify check valve on opposite side is closed (Will see return flow around pump)


February 19, 2009

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Pump Troubleshooting

Pump will not operate– Check phase monitor is tripped– Check for thermal/leak sensor is

tripped– Check Starter overloads– Check for “Low Level Shut” off

Pump will operate but motor t ti t iprotection trips

– Check the impeller– Check incoming power (out ofCheck incoming power (out of

phase)– Megger the pump for wet or burnt

motor


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motor

OVERHEATED MOTOR


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Types of Electrical Motor Failures

Winding Single-PhasedA single-phased winding failure is the result of an

i h f th l t thopen in one phase of the power supply to the motor. The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections.bad co ec o s

Phase Damage Due to Unbalanced Voltage Thermal deterioration of insulation in one phase of the stator winding can result from unequal g qvoltage between phases. Unequal voltages usually are caused by unbalanced loads on the power source, a poor connection at the motor terminal or a high resistance contact (weakterminal, or a high resistance contact (weak spring).Note: A one-percent voltage unbalance may result in a six- to ten-percent current unbalance.


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Winding Damaged Due to OverloadThermal deterioration of the insulation in all h f th t t i di t i ll iphases of the stator winding typically is

caused by load demands exceeding the rating of the motor.Note: Under-voltage and over-voltage g g(exceeding NEMA standards) will result in the same type of insulation deterioration.

Damage Caused by Locked Rotor g ySevere thermal deterioration of the insulation in all phases of the motor normally is caused by very high currents in the stator winding due to a locked rotor condition It may alsodue to a locked rotor condition. It may also occur as a result of excessive starts or reversals.


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This types of insulation failures is typically caused by contaminants, abrasion, vibration or voltage surges.

Winding Grounded at Edge of Slot

Winding Grounded in the Slot

Winding Shorted Phase-to Phase

Sh d C i d h Sh d C l


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Shorted Connection Winding with Shorted Coil


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Questions

Any Questions?


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