Reduce Cost of your Submersible Pumps
by using New Technology
polycot_winding_wire
Submersible Winding Wire

How it works !!
The author here in describes how cost of Submersible Motor can be reduced and efficiency can be increased by using PolyCot wire. These Triple taped low diameter winding wire have excellent. Electrical, Mechanical, Thermal & Chemical Properties. These wires withstand abrasion, frictional losses and work in every type of typical conditions.

For a given HP & RPM the product D2 L is obtained from the design calculations. Here D is the core diameter and L is the core length. Once D2 L is obtained, we have to split D & L. While there are options to split D & L for cost consideration or for obtaining the best power factor, none of these options are applicable for bore whole submersible motors. i.e., the diameter D is limited to the diameter of the bore hole. This limitation complicates the design because the smaller value of D restricts the stator yoke depth, the size & area of stator slots and in turn the rotor diameter. The stator conductor diameter is obtained for a given HP & current for the respective kW rating of the motor concerned. Then comes the thickness of the conductor insulation over and above the conductor diameter.

When PVC coated wires were used, the minimum coating thickness used to be in the order of 0.40 mm per side. This occupied a considerable amount of areas. Thus to accommodate the number of turns required for the power of motor, the designers used to increase the core length ā€˜Lā€™ much beyond what is required for developing the respective HPs.

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consultant_engineer
[wpex more=”Read more…” less=”…back”]Gopalakrishnan Ranganathan is a graduate in Electrical Engineering from PSG College of Technology Coimbatore. He has 45 years of rich and varied experience in the fields of design, development, standardization and quality assurance of rotating electrical machines. He had been heading the Coimbatore unit of the erstwhile multinational GEC ALSTOM INDIA Ltd. He is currently a consultant engineer of repute. He has contributed greatly in the design and development and energy efficiency improvements of asynchronous motors. He is the life member in various societies like IE (India), Institute of Standards Engineers, and National Institute of Quality and Reliability etc.
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cost saving
[wpex more=”Read more…” less=”…back”]As for example a core length of 300mm was used for an 1HP single phase motor using PVC wires. This can be brought down to 150mm by using the polywrap wire still developing the same required power. With the use of polywrap wire it was possible to develop 2 HP in a core length of 300mm. Thus the polywrap wires for submersible pump motors has revolutionized the design process, by reducing the active steel material and by saving atleast about 40% steel stampings. You can imagine the amount of saving on similar items on this score.
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higher efficiency
[wpex more=”Read more…” less=”…back”]Due to the reduction in core lengths, the length of mean turn gets reduced resulting in a smaller I2 R loss resulting in an improved efficiency of the motor. As stated earlier the improved yoke depth by using the polywrap wires results in less saturation of the core and hence results in reduction in core loss and in turn increases efficiency.
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reduced leakage current
[wpex more=”Read more…” less=”…back”]The smaller thickness of the insulation of the polywrap wires (almost half of the PVC insulation), renders smaller leakage currents (capacitance currents) leading to safer operation of the motors.
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life of motor
[wpex more=”Read more…” less=”…back”]The excellent heat transfer properties of the polywrap wires insulations results in a smaller temperature rise thus enhancing the life of the motor.
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concluding development
[wpex more=”Read more… less=”…back”]In case of a 5HP motor, the writer has designed a 6 inch submersible pump motors with 24 slots of each about 100mm2 slot area as against existing design of 150 mm2 for the same motor. The yoke depths was considerably increased, ultimately resulting in a very good efficiency.
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For design related further details & assistance please contact emgee201@gmail.com