Enriched Efficiency with Cost effective Manufacturing Technique in 3.7 kW Submersible pump sets using DCR Technology

Abstract

This paper describes the overall efficiency improvement in Submersible pump sets with reduced cost by increasing the efficiency of the submersible motor using die cast rotor (DCR) technology. The important parameters responsible for the submersible motor characteristics like Efficiency, Locked rotor Torque, Slip etc., are compared with the existing Copper Fabricated Rotor (CFR) and proposed DCR in a 5HP 3phase wet type water cooled induction motors in accordance with IS 9283. The overall performance, possible efficiency improvements in Submersible pump sets and cost comparisons between the existing CFR and DCR's are also practically verified and reported in accordance with IS 8034. It is estimated that about 30 % to 40 % of electrical energy produced in India is consumed by motorized pump sets employed in agricultural sector (1). Pumps and pumping systems use 60% of the new motors in the OEM supply chain. Any improvement in efficiency of motor would therefore result in increased efficiency of the system at end use. Low-voltage motors of up to 37.5 kW consume most of the energy size, which offer maximum potential for energy savings. Most of the energy is consumed by low-voltage motors of up to 37.5 kW size which offer maximum potential for energy savings. One of the ways to address the problem of energy shortage is to reduce demand mainly by increasing end use efficiency. As motors are the largest users of the electrical energy, even small efficiency improvements can produce very large savings across the country, Energy conservation measures taken by individual consumers in this direction will increase the comprehenses of the national economy and benefit the environment on a global scale. The total number of irrigation pump sets in India during the year 2001 was 12.5 million. In the year 2002-03 the Annual power consumption was 118,059 GWh by Agri-pump sets, based on this information, the number of pump- sets works out to 15.7412 Million. The demand is seen to be increasing year after year and also the resulting shortage of electrical energy. In the states of Andhra Pradesh and Gujarat, the agricultural sector alone accounts for 37.45 % and 40 % of total power consumption respectively (2,3). Based on the statistics, the total electricity consumption during the year 2002-03 was 562,572 GWh and the consumption by Agri-pump sets was 118,029 GWh, which works out to only 20.98%. By considering the average connected load of the pump as 6.5 kW per pump set and 1800 pumping hours annually, the total power consumption by agri-sector will be 184,172 GWh, and the percentage works out to 32.7%, which reasonably matches with the other studies. Numerous field studies have revealed that 90% of the agri-pump sets used in India are far inefficient and are wasting power worth of Crores of Rupees. Because there is no energy classification for pumps due to large variety of pumping systems.