Submersible Pump Operation, Maintenance & Troubleshooting Manual

Submersible Pump Operation, Maintenance & Troubleshooting Manual

The purpose of this manual is to provide comprehensive guidance for the operation, routine
maintenance, and troubleshooting of submersible pumps. This manual aims to:
 Ensure safe and efficient operation of submersible pumps.
 Minimize downtime and operational failures.
 Provide clear step-by-step procedures for maintenance and troubleshooting.
 Standardize operational practices across personnel.
 Extend the service life of the pump and related equipment.

1. Copy No: 01___ August 2025

Submersible Pump Operation, Maintenance & Troubleshooting Manual

Document Title: Submersible Pump — Complete Procedure
Document No.: CP-OP-003
Revision: 01
Prepared by: Hamza Arif / Sr. Mechanical Technician
Date: 29 August 2025
Approved by: ____________________

2. Table of Contents
1. Introduction
1.1 Purpose of the Manual
1.2 Scope of the Manual
1.3 Intended Users
1.4 Safety Precautions Overview
1.5 Symbols and Abbreviations
1.6 References and Standards

2. Submersible Pump Overview
2.1 Definition and Applications
2.2 Types of Submersible Pumps
 2.2.1 Sewage/Submersible Effluent Pumps
 2.2.2 Water Submersible Pumps
 2.2.3 Slurry Pumps
2.3 Components of a Submersible Pump
 2.3.1 Motor
 2.3.2 Pump Shaft
 2.3.3 Impeller
 2.3.4 Pump Casing
 2.3.5 Bearings
 2.3.6 Mechanical Seals
 2.3.7 Cable Glands & Connections
 2.3.8 Guide Rail System (if applicable)

2.4 Principle of Operation
2.5 Pump Performance Parameters

3. Pump Installation
3.1 Pre-Installation Requirements
 Site Selection
 Foundation & Mounting Requirements
 Environmental Conditions

3. 3.2 Mechanical Installation
 Step 1: Unpacking and Inspection
 Step 2: Mounting and Alignment
 Step 3: Coupling Installation
 Step 4: Suction & Discharge Piping
 Step 5: Anchoring and Support

3.3 Electrical Installation
 Step 1: Power Supply Check
 Step 2: Motor Connection & Cable Laying
 Step 3: Grounding
 Step 4: Control Panel Setup

3.4 Initial Pre-Commissioning Checks
 Shaft Rotation Check
 Impeller Clearance Check
 Mechanical Seal Integrity

4. Pump Operation
4.1 Pre-Start Checklist
4.2 Starting Procedure
4.3 Monitoring During Operation
 Pressure & Flow Rate
 Voltage & Current
 Noise & Vibration
 Temperature
4.4 Normal Operating Parameters
4.5 Shutdown Procedure
4.6 Emergency Stop Procedures

4. 5. Routine Maintenance
5.1 Daily Maintenance
 Visual Inspection
 Pump Performance Monitoring
 Noise & Vibration Check

5.2 Weekly Maintenance
 Lubrication Check (if applicable)
 Electrical Connections Check
 Minor Leak Inspection

5.3 Monthly Maintenance
 Motor Insulation Testing
 Pump Alignment Verification
 Vibration Analysis

5.4 Quarterly Maintenance
 Mechanical Seal Inspection
 Bearing Inspection & Lubrication
 Impeller and Shaft Check
 Cable Condition Check

5.5 Annual Maintenance
 Complete Pump Overhaul
 Bearing Replacement
 Motor Windings Check
 Pump Performance Testing

5.6 Maintenance Log Templates
 Daily, Weekly, Monthly, Annual Checklists

5. 6. Troubleshooting Guide
6.1 Common Issues and Causes
 Pump Does Not Start
 Pump Runs but No Flow
 Low Flow / Pressure
 Excessive Vibration
 Motor Overheating
 Mechanical Seal Leakage
 Noise & Cavitation

6.2 Step-by-Step Troubleshooting Procedure
6.3 Corrective Actions for Each Problem
6.4 Emergency Troubleshooting Scenarios

7. Spare Parts and Accessories
7.1 Critical Spare Parts List
7.2 Recommended Spare Quantities
7.3 Handling and Storage of Spares
7.4 Replacement Procedure for Each Part

8. Safety Guidelines
8.1 Electrical Safety
8.2 Mechanical Safety
8.3 Handling Hazardous Fluids
8.4 Personal Protective Equipment (PPE)
8.5 Lockout / Tagout Procedures

9. Appendices
9.1 Wiring Diagrams
9.2 Pump Curve Charts
9.3 Torque and Fastening Specifications
9.4 Lubrication Schedule
9.5 Mechanical Seal Assembly Drawings
9.6 Glossary of Terms

6. 10. References & Standards
10.1 ISO Standards
10.2 API Standards
10.3 ANSI Standards
10.4 Manufacturer Manuals & Technical Data Sheets

7. 1. Introduction
1.1 Purpose of the Manual
The purpose of this manual is to provide comprehensive guidance for the operation, routine
maintenance, and troubleshooting of submersible pumps. This manual aims to:
 Ensure safe and efficient operation of submersible pumps.
 Minimize downtime and operational failures.
 Provide clear step-by-step procedures for maintenance and troubleshooting.
 Standardize operational practices across personnel.
 Extend the service life of the pump and related equipment.
1.2 Scope of the Manual
This manual covers:
 All types of electric submersible pumps used in industrial, municipal, and water treatment
applications.
 Mechanical, electrical, and hydraulic aspects of submersible pumps.
 Installation, start-up, operation, routine maintenance, troubleshooting, and overhaul
procedures.
 Guidelines for safety, spare parts handling, and emergency situations.
1.3 Intended Users
This manual is intended for:
 Pump operators and plant technicians.
 Maintenance engineers and supervisors.
 Safety officers and electrical/mechanical engineers working with submersible pumps.
 Training personnel for operational guidance.
1.4 Safety Precautions Overview
Working with submersible pumps involves both mechanical and electrical hazards. Key safety points
include:
 Electrical Safety: Always isolate power before maintenance. Use proper grounding and follow
lockout/tagout procedures.
 Mechanical Safety: Avoid contact with moving parts, rotating shafts, and impellers.
 Fluid Hazards: Submersible pumps may handle hazardous fluids. Wear appropriate PPE
(gloves, goggles, chemical-resistant suits).
 Environmental Safety: Prevent contamination of surrounding area with lubricants, oil, or
pumped fluids.
 Emergency Procedures: Know location of emergency stops, fire extinguishers, and first aid
kits.

8. Symbols used in this manual:
 Warning: Risk of personal injury or equipment damage.
 Maintenance Tip: Important note for maintenance procedures.
 Electrical Hazard: Risk of electrical shock.
1.5 Symbols and Abbreviations
Symbol Meaning
L/min Liters per minute
RPM Revolutions per minute
kW Kilowatt
V Volts
Hz Hertz
PSI Pressure (Pounds per square inch)
Common Abbreviations:
 OEM – Original Equipment Manufacturer
 PPE – Personal Protective Equipment
 VFD – Variable Frequency Drive
 MC – Motor Current
 NPSH – Net Positive Suction Head

1.6 References and Standards
This manual follows international standards and guidelines:
 ISO 9906 – Pump performance testing.
 API 610 – Centrifugal pump standards.
 ANSI/HI 1.1-1.6 – Pump installation and maintenance guidelines.
 Manufacturer-specific manuals and technical data sheets.
 Electrical safety standards for motor-driven pumps.

9. 2. Submersible Pump Overview
2.1 Definition and Applications
A submersible pump is a pump that is designed to be fully submerged in the fluid it pumps. The
pump motor is hermetically sealed to prevent fluid ingress. These pumps are widely used for:
 Water supply from wells, tanks, or reservoirs.
 Sewage and effluent handling.
 Industrial and chemical fluid transfer.
 Flood control and drainage applications.
 Irrigation and agricultural water systems.
Key advantages of submersible pumps:
 Eliminates the need for priming.
 High efficiency due to submerged operation.
 Reduced cavitation risk compared to above-ground pumps.

2.2 Types of Submersible Pumps
Submersible pumps can be classified based on application and design:
2.2.1 Water Submersible Pumps
 For clean or slightly dirty water.
 Commonly used in water supply, irrigation, and fountains.
2.2.2 Sewage / Effluent Pumps
 Designed to handle solids and fibrous material.
 Equipped with vortex impellers to prevent clogging.
2.2.3 Slurry Pumps
 Handle abrasive or thick fluids containing particles.
 Constructed with wear-resistant materials.
2.2.4 Multistage Submersible Pumps
 Used for high-pressure applications.
 Consist of multiple impellers stacked on the pump shaft.

10. 2.3 Components of a Submersible Pump

A submersible pump is composed of several critical components. Each plays a key role in ensuring
proper operation.
2.3.1 Motor
 Submersible electric motor, typically water-cooled.
 Hermetically sealed to prevent fluid ingress.
 Rated for specific voltage, frequency, and current.
2.3.2 Pump Shaft
 Connects the motor to the impeller.
 Designed to handle torque and axial thrust.
 Supported by bearings to reduce wear.

11. 2.3.3 Impeller
 The rotating component that imparts velocity to the fluid.
 Types: Open, Semi-Open, Closed, or Vortex.
 Material selection depends on fluid properties (water, slurry, chemical).
2.3.4 Pump Casing
 Houses the impeller and directs fluid flow.
 Designed to withstand system pressure and minimize leakage.
 Typically made of stainless steel, cast iron, or corrosion-resistant alloys.
2.3.5 Bearings
 Support the shaft and reduce friction.
 Types: Sleeve bearings or ball bearings, depending on design.
 Proper lubrication is critical to prevent overheating and failure.
2.3.6 Mechanical Seals
 Prevent fluid from entering the motor.
 Usually double or single mechanical seals, depending on application.
 Seal materials vary (carbon, ceramic, tungsten carbide).
2.3.7 Cable Glands & Connections
 Electrical cables are sealed with glands to prevent water ingress.
 Ensure proper cable handling to avoid insulation damage.

2.3.8 Guide Rail System (if applicable)
 Used in vertical sump installations.
 Allows easy installation/removal of the pump without entering the sump.

2.4 Principle of Operation
The submersible pump operates on the centrifugal pumping principle:
1. Motor Rotation: The motor rotates the pump shaft.
2. Impeller Action: The impeller converts mechanical energy into kinetic energy, pushing fluid
outward.
3. Pressure Conversion: The pump casing converts kinetic energy into pressure energy.
4. Fluid Discharge: The pressurized fluid exits the discharge pipe for system use.

12. Key operational points:
 The pump must be fully submerged for proper cooling.
 Mechanical seals prevent leakage of pumped fluid into the motor.
 Adequate NPSH (Net Positive Suction Head) is required to prevent cavitation.

2.5 Pump Performance Parameters
Understanding performance parameters is critical for selection and operation:
Parameter Description Typical Range / Notes
Flow Rate (Q) Volume of fluid pumped per unit time L/min or m³/h
Head (H) Energy imparted to fluid m or ft
Power (P) Motor power requirement kW or HP
Efficiency (η) Ratio of hydraulic power to input power 50–90% depending on type
NPSH Required Minimum suction head to prevent cavitation m
Voltage & Current Motor electrical ratings V, A
RPM Impeller rotational speed Typically 1450–2950 RPM
Performance Considerations:
 Operation outside the designed range can cause overheating, vibration, and premature wear.
 Regular monitoring of flow, pressure, and motor parameters ensures long service life.

13. 3. Pump Installation
3.1 Pre-Installation Requirements
Before installing the submersible pump, ensure the following:
1. Site Selection:
o Ensure the pump location provides easy access for maintenance.
o Avoid areas prone to flooding (unless pump is designed for it).
o Check for proper ventilation if motor heat needs to dissipate.
2. Foundation & Mounting:
o Provide a level and solid foundation to prevent vibration.
o Ensure the base can support the pump and piping weight.
o For vertical installations, use guide rails or brackets as required.
3. Environmental Conditions:
o Confirm water temperature, chemical compatibility, and solids content.
o Ensure the sump or tank is clean and free of debris.

3.2 Mechanical Installation
Step 1: Unpacking and Inspection
 Remove the pump carefully from the crate.
 Check for shipping damage.
 Verify the pump model, serial number, and specifications against the order.
Step 2: Mounting and Alignment
 Place the pump on the foundation or guide rails.
 For vertical sump pumps, ensure proper alignment with guide rails.
 Ensure the pump sits plumb and level to avoid vibration.
Step 3: Coupling Installation
 Connect the pump shaft to the motor (if separate).
 Ensure proper alignment to prevent bearing and seal damage.
 Check coupling for correct clearance and tightness.
Step 4: Suction & Discharge Piping
 Connect suction and discharge pipes carefully to avoid stress on pump casing.
 Use flexible connectors if necessary.
 Ensure suction pipe is free of air leaks and fully submerged if required.
 Install valves (gate or check valves) per manufacturer recommendation.

14. Step 5: Anchoring and Support
 Tighten all foundation bolts to manufacturer torque specifications.
 Support all piping independently to prevent strain on pump casing.
 Ensure vibration isolators are installed if specified.

3.3 Electrical Installation
Step 1: Power Supply Check
 Verify voltage and frequency match the motor rating.
 Ensure proper phase sequence for three-phase motors.
Step 2: Motor Connection & Cable Laying
 Use cables rated for submersible pump voltage and length.
 Route cables away from sharp edges and heat sources.
 Avoid tight bends near the motor entry.
Step 3: Grounding
 Connect the motor frame to a reliable earth point.
 Use grounding conductors per local regulations.
Step 4: Control Panel Setup
 Verify all starter, protection, and monitoring devices are installed.
 Connect motor to starter or VFD as per wiring diagram.
 Check all protective relays (overload, phase failure, short circuit).

3.4 Initial Pre-Commissioning Checks
Before starting the pump for the first time, perform the following:
1. Shaft Rotation Check:
o Manually rotate the shaft (if possible) to ensure smooth movement.
o Check for obstructions or tight spots.
2. Impeller Clearance Check:
o Verify correct clearance between impeller and casing per manufacturer.
o Ensure no contact with pump casing or wear rings.
3. Mechanical Seal Integrity:
o Inspect mechanical seals for damage or leaks.
o Confirm proper lubrication (if seal requires oil or water flush).

15. 4. Electrical Check:
o Measure insulation resistance with a megger.
o Verify correct phase sequence and voltage.
o Confirm control panel settings, overload, and protection devices.
5. Valve and Pipe Check:
o Ensure suction and discharge valves are properly positioned.
o Fill suction pipe with water (for priming, if required).
o Check for air pockets in the system.

3.5 Commissioning Steps
1. Ensure all safety interlocks are active.
2. Close discharge valve initially.
3. Start the pump at low speed if variable speed control is available.
4. Gradually open the discharge valve to the desired flow.
5. Monitor:
o Pump current and voltage
o Flow rate and pressure
o Noise, vibration, and temperature
6. Record initial operating parameters for baseline reference.
7. Verify there are no leaks, unusual noises, or overheating.

16. 4. Pump Operation
4.1 Pre-Start Checklist
Before starting the submersible pump, ensure the following:
1. Power Supply:
o Confirm voltage and frequency match motor specifications.
o Check phase sequence (for three-phase motors).
2. Mechanical Inspection:
o Ensure pump is properly aligned and anchored.
o Check for visible damages, leaks, or loose bolts.
o Verify pump shaft rotates freely (if manually possible).
3. Valves & Piping:
o Ensure suction and discharge valves are positioned correctly.
o Check suction pipe is fully submerged and free of air pockets.
o Ensure all pipe supports are properly secured.
4. Lubrication & Seals:
o Check mechanical seals for proper installation.
o Verify any lubrication points are filled as required.
5. Control & Safety Systems:
o Verify control panel is functional.
o Check protection devices: overload, short circuit, phase failure.
o Ensure emergency stop is accessible.
6. Environment Check:
o Ensure the pump sump or tank is clean and free from debris.
o Confirm no personnel are near rotating parts.

4.2 Starting Procedure
1. Close the discharge valve partially to prevent hydraulic shock.
2. Turn ON the power supply at the control panel.
3. Start the pump using the starter switch or automatic control system.
4. Observe the pump rotation to ensure correct direction (if visible or applicable).
5. Gradually open the discharge valve to the desired flow rate.
6. Monitor current, voltage, flow rate, and pressure.
7. Listen for abnormal noise or vibration; stop immediately if present.

4.3 Monitoring During Operation
Continuous monitoring ensures the pump operates safely and efficiently:
1. Pressure & Flow Rate:
o Check against pump performance curve.
o Abnormal drop indicates blockage, air in suction, or pump wear.

17. 2. Motor Current & Voltage:
o Current should remain within rated limits.
o Voltage fluctuations indicate supply issues.
3. Noise & Vibration:
o Excessive vibration may indicate misalignment, impeller damage, or cavitation.
o Unusual noise often signals mechanical problems.
4. Temperature Monitoring:
o Pump casing and motor should not exceed manufacturer limits.
o Overheating may damage seals or bearings.
5. Fluid Leakage:
o Observe mechanical seals for leaks.
o Immediate action is required if fluid enters the motor.

4.4 Normal Operating Parameters
Parameter Typical Range Notes
Flow Rate As per pump curve L/min or m³/h
Discharge Pressure As per design PSI or bar
Motor Current Within rated limits A
Motor Voltage ±10% of rated V
Vibration < 2.8 mm/s RMS ISO 10816 standard
Temperature Motor winding < 90°C Depends on motor insulation class

4.5 Shutdown Procedure
1. Gradually close the discharge valve to reduce pressure shock.
2. Turn OFF the pump via control panel.
3. Record operating parameters in the pump logbook.
4. Inspect the pump for:
o Leakage
o Excessive vibration or noise
o Overheating
5. If the pump will be idle for a long time:
o Drain the pump and suction line (if applicable).
o Ensure motor is isolated and locked out.

4.6 Emergency Stop Procedures
1. Press the emergency stop button immediately if abnormal operation is detected.
2. Isolate power supply at the main breaker.
3. Do not attempt to open pump casing or discharge valve until the pump has fully stopped.
4. Follow troubleshooting procedures to identify and correct the problem.

18. 5. Routine Maintenance
Routine maintenance ensures the submersible pump operates efficiently, reliably, and safely while
extending its service life. Maintenance should be documented in a logbook.

5.1 Daily Maintenance
Purpose: Detect early signs of failure and ensure safe operation.
Steps:
1. Visual Inspection:
o Check for visible leaks from mechanical seals.
o Inspect the pump and motor for corrosion or damage.
o Ensure all bolts and fasteners are tight.
2. Performance Monitoring:
o Observe flow rate and discharge pressure.
o Record motor current and voltage.
o Check for unusual vibration or noise.
3. Safety Check:
o Ensure emergency stop and interlocks are functional.
o Confirm no debris or obstruction in the pump sump or suction area.

5.2 Weekly Maintenance
Purpose: Maintain electrical and mechanical reliability.
Steps:
1. Lubrication Check:
o Verify bearing lubrication (if grease-lubricated).
o Top-up as required per manufacturer specification.
2. Electrical Connections:
o Inspect terminal connections for looseness or corrosion.
o Tighten as needed.
3. Leak Inspection:
o Examine mechanical seals and cable entries for leaks.
4. Logbook Entry:
o Record weekly operational data, observations, and actions taken.

19. 5.3 Monthly Maintenance
Purpose: Detect issues not visible in daily or weekly checks.
Steps:
1. Motor Insulation Testing:
o Measure insulation resistance using a megger.
o Compare with manufacturer limits; typically >1 MΩ.
2. Pump Alignment Verification:
o Check alignment between motor and pump shaft.
o Adjust if misalignment is detected.
3. Vibration Analysis:
o Measure vibration levels at pump bearings.
o Investigate abnormal vibration (> ISO 10816 limits).
4. Impeller Check:
o Inspect for wear, erosion, or clogging.

5.4 Quarterly Maintenance
Purpose: Prevent mechanical failures and maintain efficiency.
Steps:
1. Mechanical Seal Inspection:
o Check for leaks or wear.
o Replace if necessary.
2. Bearing Inspection & Lubrication:
o Check bearing play and noise.
o Relubricate or replace bearings as per manufacturer.
3. Impeller and Shaft Check:
o Inspect for damage or misalignment.
o Clean or replace as needed.
4. Cable Condition Check:
o Examine cable insulation and entry points for damage.
o Repair or replace if necessary.

20. 5.5 Annual Maintenance
Purpose: Full inspection and overhaul to ensure long-term reliability.
Steps:
1. Complete Pump Overhaul:
o Disassemble pump and motor.
o Inspect all components (impeller, shaft, casing, motor).
2. Bearing Replacement:
o Replace worn or damaged bearings.
3. Motor Windings Check:
o Measure resistance and insulation.
o Perform any necessary electrical repairs.
4. Mechanical Seal Replacement:
o Replace all seals regardless of wear if recommended by manufacturer.
5. Pump Performance Testing:
o Verify flow rate, pressure, and motor current match specifications.
6. Reassembly & Documentation:
o Reassemble pump following alignment and torque specifications.
o Record all maintenance activities in the logbook.

5.6 Maintenance Log Templates
Daily Log Example:
Date Pump ID Flow Rate Pressure Motor Current Observations Action Taken Operator
Weekly, Monthly, Quarterly, Annual Logs follow a similar format but include additional
inspections, such as mechanical seal condition, lubrication, vibration readings, and electrical test
results.

21. 6. Troubleshooting Guide
Troubleshooting is a systematic process to identify and correct operational issues. This section
provides guidance to maintain pump reliability and minimize downtime.

6.1 Common Issues and Causes
Problem Possible Cause
Pump does not start
Power supply failure, blown fuse, tripped breaker, motor starter fault, control
panel issue
Pump runs but no
flow
Closed discharge valve, suction blockage, air in suction line, impeller damage
Low flow / pressure Worn impeller, clogged pump, suction pipe leak, wrong pump selection
Excessive vibration Misalignment, bearing failure, cavitation, unbalanced impeller, loosened bolts
Motor overheating Overvoltage/undervoltage, overcurrent, blocked cooling, bearing failure
Mechanical seal
leakage
Worn seal, improper installation, dry run, excessive pressure
Noise or cavitation Air in suction, high NPSH requirement, partially closed valve, impeller damage

6.2 Step-by-Step Troubleshooting Procedure
Step 1: Initial Observation
 Stop the pump if necessary and isolate power.
 Inspect for visible leaks, loose connections, and damaged components.
Step 2: Check Power Supply
 Verify incoming voltage and phase sequence.
 Check fuses, breakers, and motor starter.
Step 3: Inspect Suction & Discharge
 Ensure valves are open as required.
 Check suction line for blockages or air pockets.
 Inspect discharge for restrictions.
Step 4: Motor & Pump Inspection
 Measure motor current and voltage under start-up conditions.
 Listen for unusual noise or vibration.
 Check bearings and impeller for wear or damage.

22. Step 5: Mechanical Seal Check
 Inspect seals for leakage or wear.
 Ensure proper alignment and lubrication.
Step 6: Corrective Action
 Address the specific issue based on the observed cause.
 Replace worn or damaged components.
 Re-align pump and motor if required.
 Clear blockages and refill lubrication or seal fluid.
Step 7: Restart & Test
 Restart the pump under monitored conditions.
 Gradually open discharge valve.
 Observe flow, pressure, vibration, and current.
 Record operational parameters in logbook.

6.3 Corrective Actions for Common Problems
Problem Corrective Action
Pump does not start Reset breaker, check starter, repair control panel, verify power supply
Pump runs but no flow Open valves, clear suction line, remove air pockets, check impeller
Low flow / pressure Clean pump, replace worn impeller, repair suction leaks
Excessive vibration
Tighten bolts, check shaft alignment, replace bearings, inspect impeller
balance
Motor overheating Correct voltage, reduce load, check cooling, replace faulty bearings
Mechanical seal
leakage
Replace seal, ensure proper alignment, maintain lubrication, avoid dry running
Noise / cavitation
Ensure sufficient NPSH, open valves fully, remove air from suction, repair
impeller

6.4 Emergency Troubleshooting Scenarios
Scenario 1: Pump Failure During Operation
 Stop the pump immediately.
 Isolate power supply and close suction and discharge valves.
 Inspect for blockage, leakage, or electrical failure.
 Apply corrective action based on cause.

23. Scenario 2: Sudden Overheating
 Stop the pump immediately.
 Check current and voltage; allow motor to cool.
 Inspect bearings, seals, and lubrication.
 Restart only after corrective actions are completed.
Scenario 3: Excessive Noise or Vibration
 Stop the pump.
 Inspect pump alignment, impeller condition, and shaft bearings.
 Replace damaged components or re-align pump as needed.

24. 7. Spare Parts and Accessories
Proper management of spare parts is essential to minimize downtime, reduce repair time, and ensure
smooth pump operation.

7.1 Critical Spare Parts List
Component Description Notes
Mechanical Seals
Prevent fluid ingress into
motor
Replace annually or if leaking
Bearings Support pump shaft Replace if worn, noisy, or high vibration
Impeller Rotates to pump fluid Replace if worn, eroded, or damaged
Shaft Connects motor to impeller Inspect for wear and alignment
Wear Rings Maintain pump efficiency
Replace if clearance exceeds manufacturer
limits
Couplings Connect pump and motor Inspect for misalignment and wear
O-rings / Gaskets Sealing components Replace when worn or damaged
Cable & Glands Electrical connection Check insulation and replace if damaged
Control Panel
Components
Fuses, relays, contactors Keep spares for quick replacement
Lubricants Bearing grease or oil Keep manufacturer recommended type

7.2 Recommended Spare Quantities
Part
Recommended
Quantity
Notes
Mechanical Seals 1–2 sets per pump Depends on pump type and operating hours
Bearings 1 set per pump Includes motor and pump bearings
Impeller 1 spare per pump For high wear applications, keep 2
Couplings 1 spare For emergency replacement
Gaskets / O-rings Multiple sizes Ensure full set for pump overhaul
Electrical Fuses / Relays As required For immediate electrical repair
Keep spares in dry, dust-free, and temperature-controlled storage to avoid deterioration.

25. 7.3 Handling and Storage of Spares
1. Mechanical Parts:
o Store in a clean, dry area.
o Protect shafts, impellers, and seals from scratches or dents.
2. Electrical Components:
o Store in anti-static bags if sensitive.
o Keep fuses, relays, and wires away from moisture.
3. Lubricants and Seal Fluids:
o Store in original containers.
o Avoid contamination with dirt or water.
4. Inventory Management:
o Maintain a spare parts logbook with quantity, purchase date, and expiration (if
applicable).

7.4 Replacement Procedure for Each Part
Mechanical Seal Replacement:
1. Isolate power and drain pump.
2. Remove the pump from the sump or guide rails.
3. Disassemble the pump casing and impeller.
4. Remove old mechanical seal carefully.
5. Inspect seal seat and mating surface; clean thoroughly.
6. Install new seal per manufacturer instructions.
7. Reassemble pump and check alignment.
Bearing Replacement:
1. Disassemble motor or pump shaft.
2. Remove worn bearings using proper pullers.
3. Clean shaft and bearing housing.
4. Install new bearings using correct fit and lubrication.
5. Reassemble pump and check shaft alignment.
Impeller Replacement:
1. Remove pump casing or cover plate.
2. Detach old impeller from shaft.
3. Inspect pump casing and shaft for wear.
4. Install new impeller and secure per manufacturer torque.
5. Reassemble and align pump.

26. Cable & Gland Replacement:
1. Isolate power supply.
2. Remove old cable and gland.
3. Install new cable ensuring proper sealing and routing.
4. Verify insulation resistance before energizing.
Gaskets / O-Rings Replacement:
1. Remove old gasket or O-ring.
2. Clean sealing surfaces.
3. Install new gasket/O-ring.
4. Reassemble pump and tighten bolts to torque specifications.

27. 8. Safety Guidelines
Safety is paramount when operating and maintaining submersible pumps. Adhering to safety
procedures prevents accidents, equipment damage, and downtime.

8.1 Electrical Safety
1. Power Isolation:
o Always disconnect power at the main breaker before maintenance.
o Use lockout/tagout (LOTO) procedures to ensure power cannot be accidentally
restored.
2. Grounding:
o Ensure the pump and motor are properly grounded.
o Verify grounding connections periodically for continuity.
3. Voltage and Phase Checks:
o Confirm voltage and frequency match the motor rating.
o Check phase sequence for three-phase motors.
4. Control Panel Safety:
o Do not bypass protective devices such as overload relays or fuses.
o Use insulated tools when working near live components.
5. Cable Handling:
o Avoid sharp bends, cuts, or abrasion of electrical cables.
o Keep cables away from high-temperature sources and moving parts.
Warning: Never attempt to operate the pump with damaged insulation or exposed wires.

8.2 Mechanical Safety
1. Moving Parts:
o Keep hands, clothing, and tools away from rotating shafts, impellers, and couplings.
o Use guards or shields where provided.
2. Alignment and Lifting:
o Ensure proper alignment of motor and pump during installation.
o Use hoists or lifting equipment rated for the pump weight.
3. Fasteners and Supports:
o Verify all bolts and support structures are tight and secure.
o Check vibration isolators regularly.

28. 8.3 Handling Hazardous Fluids
1. Chemical Compatibility:
o Verify pump materials are compatible with the fluid being pumped.
o Avoid exposure to corrosive or toxic fluids without proper protection.
2. Spill Prevention:
o Ensure piping connections are secure.
o Maintain drip trays or containment for hazardous fluids.
3. Drainage and Cleaning:
o Follow proper procedures for draining pump and suction lines.
o Dispose of fluids according to environmental regulations.

8.4 Personal Protective Equipment (PPE)
Recommended PPE for Pump Operation and Maintenance:
 Safety goggles or face shield for chemical splash protection.
 Gloves (chemical-resistant or mechanical) depending on fluid and task.
 Safety shoes or boots to prevent injury from heavy equipment.
 Hearing protection if operating in noisy environments.
 Protective clothing (coveralls or lab coats) as required.

8.5 Lockout / Tagout Procedures
1. Preparation:
o Notify all personnel of maintenance work.
o Identify all energy sources (electrical, hydraulic, mechanical).
2. Isolation:
o Disconnect and lock power sources.
o Tag with maintenance information.
3. Verification:
o Attempt to start the pump to confirm power is isolated.
o Ensure all stored energy (pressure, rotation) is released.
4. Maintenance:
o Perform maintenance safely.
o Do not remove lockout/tagout devices until work is complete.
5. Restoration:
o Remove tools and debris.
o Reassemble and verify pump is ready for operation.
o Remove LOTO devices and restore power carefully.

29. 9. Appendices
The appendices provide reference material, technical data, and supporting diagrams to assist
operators and maintenance personnel in safe and efficient pump operation.

9.1 Wiring Diagrams
 Include full electrical wiring diagrams for:
o Direct-on-Line (DOL) starters
o Star-Delta starters
o Variable Frequency Drive (VFD) connections
 Key points to highlight:
o Phase sequence
o Protective relays
o Emergency stop connections
o Grounding points
Usage:
 For troubleshooting electrical issues.
 Ensures correct installation of new pumps or replacement motors.

9.2 Pump Curve Charts
 Display flow rate (Q) vs. head (H) for each pump model.
 Include efficiency curves to identify optimal operating points.
 Notes:
o Do not operate pump outside recommended range.
o Check curves for changes after impeller wear or replacement.
Usage:
 For selecting pump for system requirements.
 For monitoring performance degradation.

30. 9.3 Torque and Fastening Specifications
Component Torque Specification Notes
Pump casing bolts Manufacturer-specific Nm Ensure uniform tightening
Coupling bolts Manufacturer-specific Nm Check after initial run
Flange bolts As per ANSI / DIN standards Use torque wrench
Bearing housing bolts Manufacturer-specific Nm Prevent misalignment
Usage:
 Ensures proper assembly and avoids misalignment or damage.

9.4 Lubrication Schedule
Component Lubricant Type Frequency
Bearings Grease (per manufacturer) Daily / Weekly check; Re-lubricate quarterly
Mechanical seals Oil / seal flush (if applicable) Per manufacturer recommendation
Couplings Lubricating grease (if required) Annually or after inspection
Notes:
 Use only manufacturer-recommended lubricants.
 Avoid over-lubrication to prevent overheating or seal damage.

9.5 Mechanical Seal Assembly Drawings
 Detailed diagrams showing:
o Seal faces orientation
o Spring placement
o Shaft and stationary seat alignment
 Include exploded views for proper assembly and maintenance.
Usage:
 Guides assembly during replacement or overhaul.
 Ensures seal integrity and prevents leaks.

31. 9.6 Glossary of Terms
Term Definition
NPSH (Net Positive Suction Head) Minimum pressure required at pump suction to prevent cavitation
Impeller Rotating component that imparts energy to fluid
Mechanical Seal Device preventing fluid leakage into motor
Flow Rate (Q) Volume of fluid moved per unit time
Head (H) Energy imparted to fluid expressed as height
RPM Rotations per minute of pump shaft
VFD Variable Frequency Drive for speed control
OEM Original Equipment Manufacturer
PPE Personal Protective Equipment

32. 10. References & Standards
This section lists the standards, codes, and technical references used to design, operate, and maintain
submersible pumps safely and efficiently. Adherence to these standards ensures reliability, safety, and
regulatory compliance.

10.1 International Standards
Standard Title / Description Relevance
ISO 9906 Pump acceptance tests – Hydraulic performance
Ensures pump meets rated
performance and efficiency
ISO 5199 Technical specifications for centrifugal pumps
Provides guidelines for design and
operational reliability
ISO 1940 Mechanical vibration balance standards
Ensures minimal vibration in
rotating machinery
ISO 13709
(API 610)
Centrifugal pumps for petroleum,
petrochemical, and natural gas industries
Standardizes design, testing, and
materials
ISO 13709 /
API 610
Multistage and submersible pump design
Guides material selection and pump
safety

10.2 Electrical & Safety Standards
Standard Title / Description Relevance
IEC 60034 Rotating electrical machines Motor design, efficiency, and safety
IEC 60204-1
Safety of machinery – Electrical
equipment
Electrical safety of pumps and control panels
NFPA 70
(NEC)
National Electrical Code
Proper wiring, grounding, and protection in
installations
OSHA
Standards
Occupational Safety and Health
Administration
General workplace safety, PPE, and
lockout/tagout procedures

33. 10.3 Pump Design and Maintenance References
Reference Description Relevance
Manufacturer
Manuals
OEM-specific operation and
maintenance instructions
Ensures correct installation, lubrication,
and operation
ANSI/HI 1.1 – 1.6 Hydraulic Institute pump standards
Pump installation, maintenance, and
testing guidelines
API 682
Mechanical seals – Shaft sealing
systems
Proper selection and maintenance of
mechanical seals
Pump Curves &
Catalogs
Performance curves for each pump
model
Used for monitoring performance and
troubleshooting

10.4 Additional References
 Lubrication Standards: ISO 6743 for greases and oils used in bearings and seals
 Vibration Monitoring Guides: ISO 10816 for vibration evaluation in rotating equipment
 Environmental Standards: Local regulations for wastewater discharge, chemical handling,
and fluid containment

10.5 Notes on Standard Compliance
1. Installation Compliance: Follow ANSI / HI and OEM installation standards to prevent
premature pump failure.
2. Safety Compliance: Follow IEC, NFPA, and OSHA standards for electrical safety, grounding,
and PPE.
3. Maintenance Compliance: Adhere to API, HI, and manufacturer manuals for mechanical seal,
bearing, and impeller maintenance.
4. Performance Verification: Use ISO 9906 or API 610 test procedures when verifying pump
performance after installation or repair.