Submersible pumps are now widely used for irrigation, industrial applications, domestic uses, and municipal water supply systems. Unnati Pump designs these pumps with specific electrical features to operate efficiently underwater. However, frequent voltage fluctuations due to unstable power supply may cause damages in the pump motors. It is essential to maintain the voltage within a certain range to run the submersible pumps safely for a long time. If the voltage drops below that limit, the motor needs to draw more current, heating up the pump body very soon. If the voltage is much higher than normal, it causes stress and saturation at the core.
Possibilities of Damages in a Submersible Pump Caused by Low Voltage
Low voltage is a common problem in rural areas that often causes problems in submersible pumps. A pump struggles to operate normally when the voltage is much lower than the usual limit, resulting in the following damage.
Use of more current
When the voltage level is too low, the motor of a submersible pump needs to draw more power to maintain its required output. The entry of excessive current causes the accumulation of heat in the motor body, which can gradually melt the insulation of the motor windings and decreases its dielectric strength.
Decrease in the pump speed
The usual speed of the motor of a submersible pump may decrease to a large extent when the voltage is too low. The flow rate and the liquid pressure also reduce because of low speed, resulting in slower delivery of water by that pump. In that case, users need to run the pump for a longer time, leading to more electricity consumption and faster wear and tear of the pump.
Failure in the suction of water
If the voltage is too low, it may not be possible for the pump to maintain the required suction pressure. If the pump runs dry for a long time due to inadequate water flow, its impellers and seals can be severely damaged.
Probable Damages Caused Due to High Voltage in a Submersible Pump
Too high voltage is also destructive for a submersible pump. This electrical condition can cause the following damage in the electrical components of the pump motor.
Stress on the motor windings
Higher voltage causes electrical stress on the insulation of the motor windings, leading to breakdown of the insulation. If the motor windings burn due to short circuits, the motor stops functioning, and the entire winding needs replacement.
Too much heat production
Due to the high voltage, the pump motor is forced to run at higher magnetic flux levels. Hence, extra heat is produced inside the core of the pump body. The motor will burn out very soon because of this excessive heat, which also reduces the longevity of all critical components of a submersible pump.
Frequent electrical tripping
A sudden increase in voltage can cause a circuit break or overloading of the circuit, resulting in damage to the electrical components of the pump. Repeated tripping of the pump motor disrupts the operation of the submersible pump, making it inefficient for the desired function.
Mechanical Damages Caused In a Submersible Pump Body by Voltage Fluctuations
Apart from the electrical components of a submersible pump, repeated voltage fluctuations can cause damage to its mechanical parts too, resulting in mechanical failures of the pump.
Vibration in the motor parts
Voltage fluctuations can cause irregularity in the speed of the submersible pump motor. Thus, various motor parts, like the impellers, motor shaft, and bearings, experience frequent vibrations, shocks, and mechanical stress. The efficiency and the longevity of a submersible pump rapidly decrease due to severe vibrations of the pump parts.
Fast wear of pump parts
The movable parts of a submersible pump, like bearings and seals, experience uneven loading due to the fluctuations in the voltage. Thus, these parts wear out much faster and need replacement more frequently.
Direct Impact of Voltage Fluctuation on Pump Efficiency
The operation of a submersible pump is adversely affected by frequent voltage fluctuations. The following problems can arise in this situation.
Less water output
A submersible pump cannot function at its stipulated speed because of an unstable voltage condition. Hence, it fails to deliver the required amount of water due to lower flow rate and fluid pressure.
More energy consumption
The submersible pump is forced to consume more energy to operate at a normal pace, due to the rapid voltage fluctuations. Thus, the running of this pump becomes more expensive in such electrical conditions. Moreover, more maintenance is another factor that makes the use of the pump costlier.
Preventive Measures That Can Decrease Voltage Fluctuations
Users of submersible pumps can minimize the risk of voltage fluctuations by applying certain methods as mentioned below.
Install a voltage stabilizer
It is essential to install a voltage stabilizer with a submersible pump. This stabilizer regulates the voltage of the incoming electricity to ensure that it remains within a safe limit. An automatic voltage regulator (AVR) may also be used to protect the pumps from voltage fluctuation.
Use cables of proper sizes
The installer of a submersible pump always makes sure to use high-quality cables of accurate sizes to keep the voltage stable. If undersized cables are used in wiring a submersible pump, increased resistance leads to voltage drops.
Installation of protective devices
It is wise to install certain devices to safeguard the submersible pumps from voltage spikes or drops. A voltage monitoring relay can be used to check for abnormal voltage conditions and disconnect the pump in cases of overvoltage, low voltage, phase loss, or phase imbalance. A Single Phase Protector (SPP) can be installed to protect submersible pumps from voltage issues when used in industrial or municipal systems.
Regular checkup of electrical parts
All the electrical connections, wirings, and control panels of a submersible pump should undergo regular inspection to detect voltage problems immediately. Loose connections and damaged cables can lead to voltage issues in the pump.
Conclusion
One of the most common issues faced by users of submersible pumps is voltage fluctuation. Maintaining a stable power supply is essential for smooth operation and longer motor life.
Unnati Pumps designs its pumps and motors to perform reliably under varying conditions, but proper electrical setup and voltage protection are important to ensure optimal performance and durability.