38

CHAPTER 3

INFLUENCE OF STATOR SLOT-SHAPE ON THE ENERGY

CONSERVATION ASSOCIATED WITH THE
SUBMERSIBLE INDUCTION MOTORS

3.1 INTRODUCTION

The electric submersible-pump unit consists of a pump, powered by

a medium-voltage three-phase induction motor. The power transmission
system is integrated with riser-pipes. Pipe stacks are flanged together, and
consist of riser-pipe with the power transmission system, concentrically
mounted inside of each section. The power transmission system comprises a
protective pipe with the copper conductors mounted inside. The motor is
filled with water, and is being continuously circulated inside. The motor unit
has forced-water lubrication. The water is fed down to thrust bearings and the
mechanical seal through slots in the stator and returns to the surface through
the rotor-gap/stator-gap and transmission system.

3.2 ANALYSIS APPROACH

This chapter presents the performance improvement of

submersible-pump sets ranging from 3-HP to 7-HP, by increasing the
efficiency of squirrel-cage induction motor. For a three-phase induction
motor, the stator winding consists of p poles and are distributed in space. The
stator winding is usually connected to a three-phase balanced voltage source.
The resulting currents in the stator produce a rotating magnetic field. The
 39

rotor winding is often of squirrel-cage type with the number of poles equal to
the number of poles in the stator. The currents are induced in the rotor
conductive-bars. The interaction of the resultant magnetic field in the air-gap
with the currents in the rotor conductive-bars produces an electromagnetic
torque, which acts on the rotor in the direction of the rotation of the magnetic
field in the air-gap. The performance of a three-phase induction motor is
analyzed based on the equivalent circuit. Because of symmetry of the three
phases, a single-phase equivalent circuit is shown in Figure 3.1, it can be used
to analyze the characteristics of a three-phase induction motor.

Figure 3.1 Equivalent Circuit of a 3phase Induction Motor

R1 is the stator resistance, X1 is the stator leakage-reactance,

comprising of stator slot leakage-reactance, end-winding leakage-reactance,
and differential leakage-reactance. X2 and R2 are the rotor leakage-reactance
and the rotor resistance, respectively. X2 includes rotor slot leakage-reactance,
end-ring leakage-reactance, differential leakage-reactance, and skew-slot
leakage-reactance. Due to the saturation phenomena in the magnetic leakage
field, both X1 and X2 are non-linear parameters. All the parameters in the
equivalent circuit are dependent on the stator and the rotor currents. In the
exciting branch, Xm denotes the magnetizing-reactance, and R c denotes the
resistance corresponding to the iron-core losses. X m is a linearized non-linear
parameter, whose value varies with the saturation degree in the main magnetic
field. Given that V1 is the external phase voltage applied to the phase
terminals, the stator phase current I1 and the rotor current I2, which have been
 40

referred to the stator, can be easily computed by analysing the equivalent

circuit.

The equivalent circuit parameters can be derived from the

following geometrical and electrical parameters:

1) Geometrical Parameters:

a) Stator and Rotor diameters (inner and outer)

b) Axial core-length

c) Number of slots in the Stator and the Rotor

d) Geometrical shapes of the Stator and the Rotor slots

2) Electrical Parameters:

a) Number of Poles

b) Number of conductors in series per phase

c) Winding pitch

d) Cross-section of the conductor

e) Short-circuited Cage ring section

f) Skewing pitch of the Rotor slots

These data are derived from the electromagnetic design of the

machine. As shown in Figure 3.1, the actual rotor resistance R2 and the rotor
leakage-reactance X2 have to be referred to the stator using Equation (3.1) and
Equation (3.2), respectively.

= (3.1)

= (3.2)
 41

The coefficient K for referring the rotor parameters to the stator

side is shown in Equation (3.3). Nph is the number of stator conductors in
series per phase, kw1 is the stator-winding coefficient (for the air-gap
fundamental spatial harmonic), and Nbars is the number of the squirrel-cage
rotor bars.

(3.3)

It is important to note that any stator-phase-winding structure can

always be described by Nph conductors in series per phase with an equivalent
wire section (Awire) suitable to carry the phase current. This means that only
Nph and Awire are required for the equivalent circuit parameter computation,
even if some parallel paths are used for the phase-winding realization (i.e.,
single-wire-parallel or bobbin-parallel).

3.2.1 Stator and Rotor Resistances

The stator winding resistance can be evaluated using Figure 3.2 and
Equation (3.4).

Figure 3.2 Length of the Average-turn of a Winding

 42

.
= (3.4)

where is the resistivity of conductor material, Lavg.turn is the length of the

average-turn, and Awire is the cross-sectional area of the wire. Equation (3.4) is
quite simple in itself, but some care has to be taken to define the average-
turn length. As shown in Figure 3.2, this length is the addition of two
components, namely, the part of turn embedded in the slot (L core) and the
end-winding length (Lew). Equation (3.5) to Equation (3.7) gives the length of
the average- turn of the conductor in the stator winding.

. = 2( + ) (3.5)

= (3.6)

= 1 ( + ) (3.7)

where Dis is the inner diameter of the stator core, hs is the height of the
stator slot, and kew is the end-winding shape coefficient. The value of kew is
usually close to /2 for wire-windings, assuming a semi-circumference end-
winding shape with a diameter equal to w. Typically, kew is in the range of
1.5-1.6, depending on the actual end-winding length. nr is the pitch-shortening
defined in number of slots, Npole is the number of poles (defined by the air-gap
fundamental spatial harmonic), and Nss is number of the stator slots.

Assuming the number of rotor phases to be equal to the number of

bars, the phase-resistance of the cage is referred to single bar and to two
adjacent ring sectors, as shown in Figure 3.3. The resistance contribution of a
single bar can be computed by Equation (3.8), while the resistance
contribution of one End-ring can be computed by Equation (3.9).
 43

= (3.8)

= (3.9)

where KR is the skin-effect coefficient for the bar resistance, Abar is the
cross-sectional area of the bar, Lbar is the bar length, Aa is the cross-sectional
area of the cage-ring, and Da is average diameter of the cage-ring.

Figure 3.3 Bar and Ring Currents in Rotor Cage

By using, Equation (3.8) and Equation (3.9), it is possible to

compute the equivalent rotor-phase resistance. As is well known, the
calculation of this equivalent resistance is based on the total rotor-cage joule-
losses. The phasor diagram for the current is shown in Figure 3.4, where, Ib is
the bar current and Ia as the ring current. The relationship between the ring
current and the end-bar current is given in Equation (3.10).
 44

Figure 3.4 Phasor Diagram of Ring and End-bar Current

(3.10)

As a consequence, the total joule-loss dissipated in the rotor cage (P jr) is

defined by Equation (3.11).

= + (3.11)

Since each rotor bar can be considered as a phase of a multi-phase winding,

the equivalent rotor-phase resistance is defined by Equation (3.12).

= + (3.12)

3.2.2 Classification of Magnetic Flux

To calculate the inductive parameters, it is important to classify the

magnetic fluxes through the machine. Figure 3.5 is used as a reference for this
classification.
 45

Figure 3.5 Flux-path in the Machine

The flux in a rotating machine can be classified into two categories:

A) With respect to the flux-path: The total flux linked ( total) with a
phase winding is the addition of two contributions, namely:

1) main, the main flux linked due to the magnetic field lines,
crossing the air-gap. This flux is produced simultaneously by
the stator and the rotor currents.

2) local, the local flux linked due to the following two components:

a) The field lines close to the conductors in the slot and the
two adjacent teeth ( sl).

b) The field lines around the end-windings ( hl).

B) With reference to the energy conservation: The total flux ( total)

linked with a phase winding is the addition of the following two

components:
 46

1) useful, the linked flux that is due to the fundamental distribution

of air-gap flux density, and is a component of the main flux.

2) leakage, the linked flux that does not give appreciable

contributions to energy conversion.

With those of the above two classifications, it is possible to write the

Equation (3.13) to Equation (3.15) for the total flux linked with the winding.

= + (3.13)

= + + (3.14)

= + (3.15)

As a consequence, the leakage-flux in the winding is calculated using

Equation (3.16).

= + + (3.16)

The actual speed is mainly governed by the first harmonic flux;

only the fundamental flux component is conventionally considered as useful
in the electromechanical energy conversion. Flux components of higher
orders are considered as leakage-components. As a consequence, with
reference to Equation (3.15), the quantity ( ) is defined as the
air-gap leakage-flux. This air-gap leakage flux is used for the calculation of
the leakage-inductance.
 47

3.2.3 Leakage-inductance

The slot leakage-inductance (both for the stator and the rotor) can
be calculated on the basis of the magnetic energy stored in the slot defined by
Equation (3.17).

E = L I (3.17)

where is the slot-leakage-coefficient, Lslot is the length of the

winding part inside the slot, and Islot is the total current in the slot. Obviously,
this current depends on the phase current (IPhase), and on the type of phase-
winding.

Figure 3.6 Distribution of Magnetic-Field in the Slot

Lslot is used as general symbol: It is equal to Lcore for the stator

winding and Lbar for the rotor cage. Assuming, the permeability of iron to be
infinite and that the magnetic field lines are parallel into the slot as shown in
Figure 3.6, the magnetic energy stored in the slot is given by Equation (3.18).

= ( ) ( ) (3.18)

Given the x-coordinate, the magnetic field and the slot current are calculated
by using Equation (3.19) and Equation (3.20).
 48

( ) ( )
( ) = (3.19)
( )

= ( ) ( ) (3.20)

As a consequence, the slot-leakage-coefficient is given by Equation (3.21).

( ) ( )
= (3.21)

Since the permeability of iron is considered infinite, Equation (3.21) cannot

be applied to closed rotor slots, because, the slot, the slot-leakage-coefficient
should be infinite too. In this case, taking into account the inevitable heavy
saturation of the slot closing magnetic wedge, an equivalent slot-opening has
to be considered. Unfortunately, the selection of the width of the slot-opening
is not a simple task and it can be done on the basis of the actual shape of the
slot-closing zone. Generally, some trial-and-error steps based on the
experience of the designer are required in order to obtain reasonable results.
The phase slot leakage-inductance can be obtained by Equation (3.22).

= (3.22)

Alternatively, the leakage-inductance (L ) of a machine can be obtained as the

sum of different leakage-inductances. According to the design-tradition of
electrical motors, the leakage-inductance (L ) can be thought of as made up of
the following partial leakage-inductances:

Air-gap leakage-inductance (Lg)

Slot leakage-inductance (Lu)

Tooth-tip leakage-inductance (Ld)

 49

End-winding leakage-inductance (L w)

Skew leakage-inductance (Lsq)

The leakage-inductance of the machine is the sum of these leakage

inductances as shown in Equation (3.23).

= + + + + (3.23)

Air-gap inductance is given by Equation (3.24).

2 2
m T v
k wv
L o
DL ph (3.24)
g p v ,V 1 v

where 0 = Permeability of vacuum

m = Number of phases

g = Air-gap length

L = Effective core-length

D = Diameter of the core

Tph = Number of turns per phase in a winding

p = Number of pole-pairs

= Ordinal of the harmonic

kwv = Winding factor

The term v, when equal to 1, in the Equation (3.24), represents the

fundamental component, and thus the magnetizing-inductance (Lm) of the
machine.

The slot-inductance of a phase winding is obtained as follows:

 50

Figure 3.7 shows the equivalent circuit of slot-inductance, and its

value is determined by Equation (3.25).

Figure 3.7 Equivalent Circuit of Slot-Inductance

4m 2
Lu = o u (3.25)
Q

where Q = Number of slots

u = Permeance factor of the slot

Figure 3.8 Slot Model

Equation (3.26) is used to determine the permeance factor of the slot ( u),
using the dimensions of the slot model as shown in Figure 3.8.
 51

h4 h3 h1 h2 b4
u = 3b + b + b + b -b ln b (3.26)
4 4 1 4 1 1

Tooth-tip leakage-inductance is determined using Equation (3.27).

= (3.27)

d = Permeance factor of tooth-tip

End-winding leakage-inductance (Lw) calculation is given by Equation (3.28)

= (3.28)

lw = Average length of the end-winding

w = Permeance factor of end-winding

q = Number of slots per pole per phase

Equation (3.29) shows the Skew leakage-inductance (Lsq)

= (3.29)

where

= , the Leakage factor caused by skewing

ksq = skewing factor

=
 52

3.3 CALCULATION OF PERFORMANCE PARAMETERS

The magnetic energy stored in a slot can be calculated by using any

one of the Flux analysis softwares, namely, 2-D, RMxprt, and MotorPro, after
completion of the initial design using low-loss materials. The magnetic circuit
of the motor is constituted by the lamination of the stator, the rotor, and the
air-gap. The energy conversion is assisted by the flux in the air-gap, driven by
magneto-motive-force (mmf) produced in the stator winding. The mmf
required to drive the flux is influenced by the reluctance of the magnetic
circuit. The reluctance of the magnetic circuit is determined by the length and
the relative permeability of the material as given in Equation (3.30).

= (3.30)

where S = Reluctance

= Length of the magnetic circuit

= Permeability of free space
= Relative permeability
A = Area of the magnetic circuit

The mean length of the magnetic circuit is influenced by the shape

of the slot and the air-gap. Material composition of stamping influences the
relative permeability and the saturation factor coefficient. Reduced reluctance
circuit needs less mmf to force the flux, and hence results in less magnetizing
current. Hence, the output power, power factor, and efficiency improve
significantly. This could be understood from the equivalent circuit shown in
Figure 3.1, and Equation (3.31) to Equation (3.37).

The electromagnetic power (P m), otherwise called as the air-gap power, is

determined by Equation (3.31).

=3 (3.31)
 53

The electromagnetic torque (Tm) is calculated using Equation (3.32).

= (3.32)

where, denotes the synchronous speed in rad/s.

Equation (3.33) gives the mechanical shaft output torque (Tsh).

= (3.33)

where, Tfw denotes the frictional and windage torque.

The output power (Po) is shown in Equation (3.34).

= (3.34)

where r = (1 s) denotes the rotor speed in rad/s.

Equation (3.35) is used to calculate the input power to the motor (Pi).

= + + + + + (3.35)

where Pfw, Prc, Pcl, Psc, and Pl denote the frictional and windage losses, the
rotor copper loss, the iron-core loss, the stator copper loss, and the stray loss,
respectively.

The power factor is determined by Equation (3.36).

= (3.36)

Equation (3.37) is used to determine the efficiency.

= 100 (3.37)
 54

3.4 ANALYSIS USING ROTATIONAL MACHINE EXPERT

Rotational Machine Expert (RMxprt) is an interactive software

package from ANSOFT Corporation used for the design and analysis of
electrical machines. When a new project is started in RMxprt, the type of
motor is to be selected. The parameters associated with the selected machine
are given as input in the property window. The property windows are
accessed by clicking each of the machine elements; for example, stator, rotor,
and shaft under machine in the project tree. Solution and output options such
as the rated output, torque, and load current, etc., are set by adding a solution-
setup in analysis of the project tree. A 3-phase, 380 V, 2-pole submersible
induction motor with the power range 3-HP to 7.5-HP has been chosen, based
on the market requirement. (Source: TEXMO Industries, CRI Pumps,
DECCAN Industries, and PSG Industrial Institute). Different stator, rotor slot-
shapes have been considered for optimisation. The stator and rotor slot-
models used for simulation are shown in Figure 3.9 and Figure 3.10,
respectively.

Figure 3.9 Stator Slot-models used for Optimisation

 55

Figure 3.10 Rotor Slot-models used for Optimisation

The various dimensions of slots pertaining to Stator and Rotor are

shown in Table 3.1 and Table 3.2, respectively.

Table 3.1 Dimensions of Stator Slots

Dimension (mm)
Slot Type
BS0 BS1 BS2 HS0 HS1 HS2 RS1 RS2
A 3.90 6.03 9.50 1.00 0.80 13.20 - -
B 3.90 6.90 9.88 0.80 - 11.30 1.50 -
C 3.90 6.90 10.63 0.70 - 14.15 1.50 1.00
D 3.90 6.03 10.19 1.00 0.80 15.80 - 1.00
E 3.90 6.17 9.59 1.00 - 13.00 - -
F 3.90 6.25 10.36 0.52 - 15.60 - 1.00

Table 3.2 Dimensions of Rotor Slots

Dimension (mm)
Slot Type
BS0 BS1 BS2 HS0 HS1 HS2 RS
1 1.80 5.00 3.20 - 0.42 7.50 0.20
2 1.80 5.00 3.20 - 0.42 7.50 0.20
3 1.10 5.10 3.20 0.70 0.42 6.30 -
4 1.80 5.00 3.20 - - 4.60 -
 56

All the design values related to each section as mentioned in

Figure 3.11 have been configured in the software, namely, machine type,
main dimensions, material characteristics, BH and BP-curves for the
stamping, type of shaft material (SS-307), and body material (cast iron,
aluminium, and SS-304). The basic process in RMxprt is illustrated with the
help of the flowchart in Figure 3.11.

Start

Define Data for 3-phase Induction Motor

General Data Stator Data Rotor Data Solution Data

Machine type Outer diameter Outer diameter Duty-cycle

No. of Poles Inner diameter Inner diameter Type of Load
Stray loss Length Length Rated output
Friction loss Type of Steel Type of Steel Rated voltage
Windage loss Stacking factor Stacking factor Rated speed
Reference speed No. of slots No. of slots Operating
Slot-Model Slot-Model temperature
Slot dimensions Slot dimensions Winding
Winding details Winding details connection
Skew width Frequency
Rotor type

Analysis of Machine
Add a solution setup
Validation check
Analyse

Design Output of Machine

Design sheet
Performance table
Performance curves

Figure 3.11 Flowchart for Basic Process in RMxprt

The iterations have been performed, using the optimetrics tool

shown in Figure 3.12, by choosing different combinations of core-length,
number of turns per phase, and magnetic loading for 3-phase, 5-HP, 380 V
submersible induction motor.
 57

Start

RMxprt Model (initial design)

Define design variables and its

range of values

Add parametric setting

Define performance attributes needed

for calculation

Analyse

Apply optimum result for

initial design

RMxprt Model (optimised design)

Figure 3.12 Flowchart for Optimetrics Tool in RMxprt

Table 3.3 to Table 3.8 show the results obtained from the
simulation for different slot-model combinations. The parameters that
influence the magnetic circuit, namely, Stator Leakage-reactance,
Magnetizing-reactance, Rotor Leakage-reactance, Resistance corresponding
to Iron-core Loss, Stator Phase Current, and Magnetizing Current have been
considered for the selection of optimum slot-model.
 58

Table 3.3 Parameters for Slot-A Combination

Parameters Slot-1 Slot-2 Slot-3 Slot-4

Stator Leakage-reactance ( ) 1.42 1.29 1.38 1.36
Magnetizing-reactance ( ) 57.34 64.56 56.17 60.04
Rotor Leakage-reactance ( ) 5.94 5.16 5.34 6.23
Resistance Corresponding to
1879.34 1926.23 1902.74 1911.98
Iron-core Loss ( )
Stator Phase Current (A) 9.43 8.37 9.39 8.84
Magnetizing Current (A) 3.55 3.07 3.31 3.26

Table 3.4 Parameters for Slot-B Combination

Parameters Slot-1 Slot-2 Slot-3 Slot-4

Stator Leakage-reactance ( ) 1.53 1.42 1.31 1.33
Magnetizing-reactance ( ) 58.75 61.43 57.32 59.78
Rotor Leakage-reactance ( ) 6.37 6.12 5.87 6.03
Resistance Corresponding to Iron-
1849.56 1886.43 1842.53 1891.57
core Loss ( )
Stator Phase Current (A) 9.81 9.32 9.96 9.48
Magnetizing Current (A) 3.51 3.26 3.55 3.38

Table 3.5 Parameters for Slot-C Combination

Parameters Slot-1 Slot-2 Slot-3 Slot-4

Stator Leakage-reactance ( ) 1.51 1.36 1.45 1.38
Magnetizing-reactance ( ) 56.38 60.64 59.34 61.06
Rotor Leakage-reactance ( ) 6.06 6.13 5.76 6.57
Resistance Corresponding to Iron-
1889.26 1906.21 1898.89 1918.98
core Loss ( )
Stator Phase Current (A) 9.43 8.79 9.89 8.69
Magnetizing Current (A) 3.74 3.32 3.46 3.28
 59

Table 3.6 Parameters for Slot-D Combination

Parameters Slot-1 Slot-2 Slot-3 Slot-4

Stator Leakage-reactance ( ) 1.39 1.31 1.48 1.34
Magnetizing-reactance ( ) 58.76 61.63 59.17 60.46
Rotor Leakage-reactance ( ) 6.02 5.52 5.94 6.17
Resistance Corresponding to
1899.76 1912.43 1906.49 1910.38
Iron-core Loss ( )
Stator Phase Current (A) 9.37 8.89 9.24 8.91
Magnetizing Current (A) 3.74 3.39 3.61 3.45

Table 3.7 Parameters for Slot-E Combination

Parameters Slot-1 Slot-2 Slot-3 Slot-4

Stator Leakage-reactance ( ) 1.49 1.33 1.34 1.41
Magnetizing-reactance ( ) 56.37 61.32 57.46 61.08
Rotor Leakage-reactance ( ) 6.04 5.68 5.57 6.05
Resistance Corresponding to
1886.21 1912.47 1904.67 1908.43
Iron-core Loss ( )
Stator Phase Current (A) 9.38 8.78 9.27 8.89
Magnetizing Current (A) 3.72 3.39 3.58 3.44

Table 3.8 Parameters for Slot-F Combination

Parameters Slot-1 Slot-2 Slot-3 Slot-4

Stator Leakage-reactance ( ) 1.48 1.33 1.41 1.38
Magnetizing-reactance ( ) 56.46 62.45 57.34 60.57
Rotor Leakage-reactance ( ) 6.08 5.78 5.68 6.18
Resistance Corresponding to
1883.16 1912.06 1903.34 1907.43
Iron-core Loss ( )
Stator Phase Current (A) 9.38 8.85 9.24 9.07
Magnetizing Current (A) 3.55 3.23 3.47 3.31
 60

It could be concluded from the parameters in Table 3.3 to Table 3.8

that the combination of Slot-A type stator slot with Slot-2 type rotor slot
contribute to a good magnetic circuit. The advantages of this combination
are:

Reduced Stator and Rotor Leakage-reactances

Increased Magnetizing-reactance

Increased Resistance corresponding to Iron-Core Loss

Reduced Stator Phase Current

Reduced Magnetizing Current

The output power of the underwater motor can be increased by

reducing the magnetizing current. Reduced magnetizing current will improve
the operating power factor. A cumulative operation of more number of such
motors will lead to energy-saving and the load factor of the connected
distribution transformer will come down, resulting in good voltage regulation
and high Transformer utilization factor. Existing Slot-D type stator slot and
Slot-1 type rotor slot combination shown in Figure 3.13a are compared with
the proposed Slot-A type stator slot and Slot-2 type rotor slot shown in Figure
3.13b. Submersible motors with the ratings of 3-HP, 5-HP, 6-HP, and 7.5-HP
have been considered for optimisation.
 61

(a) (b)

Figure 3.13 Stamping Models (a) Slot-D Type Stator and Slot-1 Type
Rotor (b) Slot-A Type Stator and Slot-2 Type Rotor

For analysis in RMxprt, a 3-phase, 380 V, 2-pole, 50 Hz, and star-

connected submersible induction motor type has been considered with the
specifications given in Table 3.9.

Table 3.9 Specifications of the Motors

S.
Parameter 3-HP 5-HP 6-HP 7.5-HP
No.
1 Outer diameter of the Stator (mm) 137 137 137 137
2 Inner Diameter of the Stator (mm) 73 73 73 73
3 Length of the Stator core (mm) 105 180 205 225
4 Air-gap (mm) 0.5 0.5 0.5 0.5
5 Inner diameter of the Rotor (mm) 42 42 42 42
6 End-Ring Width (mm) 6 6.5 7.2 9
7 End-Ring Length (mm) 1 1 1 1
8 End-Ring Height (mm) 11 11 11 11
9 Number of Stator Slots 24 24 24 24
10 Number of Rotor Slots 18 18 18 18
11 Conductors per slot 52 31 27 24
 62

The stator and rotor stampings are common for the selected range
of motors. M43_29G-grade-stamping has been used for both the stator and the
rotor. The core-length has been varied based on the power rating of the motor,
the magnetic loading, and the electric loading values are adjusted to optimize
the core-length and other performance parameters. The electric loading value
is kept slightly higher for the submersible motor compared to the normal
industry-type motor because of the forced-water cooling. The number of
conductors per slot and End-Ring width have also been changed so as to meet
the design requirements.

3.5 SIMULATION RESULTS

With fixed operating conditions, the machines have been simulated

in RMxprt and the results are tabulated as shown in Table 3.10 and
Table 3.11. Following inferences could be made from Table 3.10 and
Table 3.11:

The leakage-reactance of stator and rotor, namely, Slot, End-

winding, Differential, and Skewing Leakage-reactance values
have got reduced.

Increased values of Iron-core Loss Resistance and

Magnetizing-reactance reduce the loss-component current and
the magnetizing current, resulting in improvement of the
operating power factor.

The stator phase current of the proposed slot type motor is

less, when compared to that of the existing slot type motor.

There is a significant improvement in the efficiency of the

motor with the proposed slot-shape.
63
64
 65

(a)

(b)

Figure 3.14 Flux Distribution (a) Existing Slot (b) Proposed Slot

Flux distribution in the Motor is shown in Figure 3.14. The flux

density with the proposed stator slot is found to be from 1.22 Tesla to
1.55 Tesla; but in the existing stator, it is from 1.20 Tesla to 1.70 Tesla. Since
the magnetic flux density is less in the proposed slot, there is a reduction in
the required magnetizing current.

3.6 REAL-TIME IMPLEMENTATION AND RESULTS

The stampings and the test setup are shown in Figure 3.15 and
Figure 3.16, respectively.
 66

(a) (b)

Figure 3.15 Stampings (a) Existing (b) Proposed

(a) (b)

Figure 3.16 Test Set-up (a) Testing Panel (b) Pump Loading

The performance test reports for 3-HP, 5-HP, 6-HP, and 7.5-HP
pump-sets, with the existing and the proposed motor slot-shape are shown in
Table 3.12 to Table 3.19.
 67

Table 3.12 Performance Test of 3-HP Submersible-pump-set with the

Existing slot-shape

Delivery Total Rise in Input Pump Overall

Speed gauge reading Time for Discharge Current
S.No. head Tank Power output efficiency
(rpm) rise (s) (lpm) (A)
(Kgf/cm )
2
(m) (cm) (kW) (kW) (%)

1 2851 0.00 1.90 30.00 54.69 331 5.35 2.49 0.10 4.11

2 2840 1.00 11.82 20.00 40.40 298 5.63 2.66 0.58 21.55

3 2828 2.00 21.76 20.00 45.16 267 5.92 2.83 0.96 33.40

4 2817 3.00 31.68 10.00 26.91 224 6.05 2.90 1.17 39.76

5 2836 4.50 46.58 9.80 40.81 145 5.66 2.68 1.11 40.96

6 2858 5.00 51.54 10.00 56.78 106 5.24 2.42 0.90 36.80

7 2899 5.50 56.51 5.00 78.03 39 4.32 1.79 0.36 19.79

8 2911 5.70 58.50 0.00 0.00 0 3.83 1.42 0.00 0.00

Table 3.13 Performance Test of 3-HP Submersible-pump-set with the

Proposed slot-shape

Delivery Total Rise in Input Pump Overall

Speed gauge reading Time for Discharge Current Power
S.No. head Tank output efficiency
(rpm) rise (s) (lpm) (A)
(Kgf/cm2) (m) (cm) (kW) (kW) (%)
1 2873 0.00 1.94 30.00 51.84 349 4.53 2.19 0.11 5.10

2 2865 1.00 11.88 20.00 37.15 324 4.90 2.37 0.63 26.75

3 2854 2.00 21.80 20.00 41.71 289 5.00 2.54 1.04 40.87

4 2844 3.00 31.72 10.00 24.71 244 5.10 2.63 1.27 48.51

5 2862 4.50 46.59 9.80 37.21 159 4.90 2.38 1.22 51.28

6 2883 5.00 51.55 10.00 51.98 116 4.44 2.13 0.98 46.17

7 2927 5.50 56.51 5.00 72.41 42 3.38 1.50 0.39 25.71

8 2939 5.70 58.50 0.00 0.00 0 3.00 1.12 0.00 0.00

 68

Head (m) Overall Efficiency (%)

Current (A) Motor Input (kW)
66 44
60 40
54 36
48 32
42 28
36 24
30 20
24 16
18 12
12 8
6 4
0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Discharge (lps)
(a)
Head (m) Overall Efficiency (%)
Current (A) Motor Input (kW)
66 60

60 55

54 50

45
48
40
42
35
36
30
30
25
24
20
18
15
12 10
6 5

0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5
Discharge (lps)

(b)

Figure 3.17 Pump Performance Curve: 3-HP (a) Existing (b) Proposed
 69

Current in the Proposed Design (A) Current in the Existing Design (A)
Discharge in the Existing Design (lpm) Discharge in the Proposed Design (lpm)
10 350
9 .
300
8
7 250

6
200
5
150
4
3 100
2
50
1
0 0
0 1 2 3 4 5 6
Delivery Gauge Reading (kgf/cm2)

(a)

Current in the Existing Design (A) Current in the Proposed Design (A)
pf in the Existing Design pf in the Proposed Design
10 . 1
9
8 0.8
7
6 0.6
5
4 0.4
3
2 0.2
1
0 0
0 1 2 3 4 5 6
Delivery Gauge Reading (kgf/cm2)

(b)

Figure 3.18 Performance Comparison Curve: 3-HP (a) Discharge and

Current (b) Current & Power factor
 70

Table 3.14 Performance Test of 5-HP Submersible-pump-set with the

Existing slot-shape

Delivery
Total Rise Time Input Pump Overall
Speed gauge in for Discharge Current
S.No. head Power output efficiency
(rpm) reading Tank rise (lpm) (A)
(m) (kW) (kW) (%)
(Kgf/cm2) (cm) (s)
1 2848 0.00 1.53 30.00 47.46 383 9.37 4.63 0.10 2.1
2 2843 2.00 21.41 30.00 53.81 338 9.63 4.84 1.21 25.01
3 2844 4.00 41.27 30.00 66.06 275 9.63 4.87 1.90 38.93
4 2851 5.00 51.22 30.00 74.34 244 9.47 4.73 2.08 44.05
5 2864 6.00 61.15 30.00 90.15 201 9.20 4.59 2.05 44.53
6 2875 7.00 71.07 20.00 85.38 142 8.47 4.01 1.67 41.64
7 2896 7.50 76.02 10.00 76.41 79 7.53 3.21 1.00 31.26
8 2929 7.90 80.00 0.00 0.00 0 6.37 2.23 0.00 0.00

Table 3.15 Performance Test of 5-HP Submersible-pump-set with the

Proposed slot-shape

Delivery
Total Rise Time Input Pump Overall
Speed gauge in Discharge Current
S.No. head for Power output efficiency
(rpm) reading Tank (lpm) (A)
2 (m) (cm) rise (s) (kW) (kW) (%)
(Kgf/cm )
1 2872 0.00 1.76 30.00 39.53 460 8.40 4.38 0.13 2.99
2 2867 2.00 21.57 30.00 45.64 399 8.87 4.52 1.44 30.75
3 2869 4.00 41.36 30.00 57.83 315 8.83 4.56 2.17 46.13
4 2876 5.00 51.28 30.00 65.56 277 8.90 4.44 2.36 51.81
5 2885 6.00 61.19 30.00 80.15 226 8.57 4.32 2.30 51.97
6 2913 7.00 71.09 20.00 76.48 158 7.30 3.68 1.86 49.53
7 2930 7.50 76.03 10.00 69.51 87 6.63 2.84 1.10 37.76
8 2959 7.90 80.00 0.00 0.00 0 5.17 1.96 0.00 0.00
 71

Head (m) Overall Efficiency (%)

Current (A) Motor Input (kW)
90 45

80 40

70 35

60 30

50 25

40 20

30 15

20 10

10 5

0 0
0 1 2 3 4 5 6 7
Discharge (lps)

(a)

Head (m) Overall Efficiency (%)

Current (A) Motor Input (kW)
90 60
80
50
70
60 40
50
30
40
30 20
20
10
10
0 0
0 1 2 3 4 5 6 7 8 9
Discharge (lps)

(b)

Figure 3.19 Pump Performance Curve: 5-HP (a) Existing (b) Proposed
 72

Current in the Proposed Design (A) Current in the Existing Design (A)
Discharge in the Existing Design (lpm) Discharge in the Proposed Design (lpm)
12 500
.
10
400

8
300
6
200
4

100
2

0 0
0 1 2 3 4 5 6 7 8
Delivery Gauge Reading (kgf/cm2 )

(a)

Current in the Existing Design (A) Current in the Proposed Design (A)
pf in the Existing Design pf in the Proposed Design
15 1
.
0.8

10
0.6

0.4
5

0.2

0 0
0 2 4 6 8 10
Delivery Gauge Reading (kgf/cm2 )

(b)

Figure 3.20 Performance Comparison Curve: 5-HP (a) Discharge and

Current (b) Current and Power factor
 73

Table 3.16 Performance Test of 6-HP Submersible-pump-set with the

Existing slot-shape

Delivery
Total Rise Time Input Pump Overall
Speed gauge in for Discharge Current
S.No. head Power output efficiency
(rpm) reading Tank rise (lpm) (A)
(m) (kW) (kW) (%)
(Kgf/cm2) (cm) (s)
1 2898 0.00 2.06 20.00 45.37 266.03 8.06 3.380 0.091 2.68
2 2883 2.00 22.01 20.00 50.25 240.54 8.58 3.780 0.878 23.22
3 2874 4.00 41.96 20.30 58.50 209.84 9.05 4.135 1.461 35.34
4 2867 6.00 61.92 10.00 33.29 181.65 9.41 4.389 1.867 42.54
5 2866 8.00 81.87 10.00 42.94 140.77 9.40 4.424 1.911 43.20
6 2873 9.00 91.85 10.00 53.12 113.77 9.24 4.270 1.732 40.57
7 2889 10.00 101.82 5.00 38.90 77.62 8.64 3.830 1.308 34.15
8 2913 11.00 111.80 2.00 38.09 31.68 7.65 3.033 0.585 19.29

Table 3.17 Performance Test of 6-HP Submersible-pump-set with the

Proposed slot-shape

Delivery
Total Rise Time Input Pump Overall
Speed gauge in for Discharge Current
S.No. head Power output efficiency
(rpm) reading Tank rise (lpm) (A)
(m) (kW) (kW) (%)
(Kgf/cm2) (cm) (s)
1 2908 0.00 2.15 20.00 39.25 308.99 7.12 3.171 0.110 3.46
2 2898 2.00 22.12 20.00 46.34 297.34 7.67 3.570 1.091 30.55
3 2889 4.00 42.06 20.30 53.65 266.68 8.09 3.918 1.862 47.52
4 2887 6.00 62.01 10.00 28.43 215.88 8.52 4.168 2.221 53.28
5 2896 8.00 81.94 10.00 38.32 174.69 8.44 4.211 2.373 56.36
6 2906 9.00 91.89 10.00 47.17 148.67 8.29 4.052 2.265 55.89
7 2912 10.00 101.84 5.00 33.16 94.81 7.75 3.620 1.598 44.14
8 2921 11.00 111.80 2.00 34.22 34.39 6.71 2.812 0.635 22.58
 74

Head (m) Oveall Efficiency (%) Current (A) Motor Input (kW)
130 45
120
40
110
100 35
90
30
80
70 25
60 20
50
40
15
30 10
20
5
10
0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Discharge (lps)
(a)

Head (m) Oveall Efficiency (%) Current (A) Motor Input (kW)
140 60

120
50

100
40
80
30
60

20
40

20
10

0 0
0.0 1.0 2.0 3.0 4.0 5.0
Discharge (lps)

(b)

Figure 3.21 Pump Performance Curve: 6-HP (a) Existing (b) Proposed
 75

Current in the Existing Design (A) Current in the Proposed Design (A)
Discharge in the Existing Design (lpm) Discharge in the Proposed Design (lpm)
10
. 350

300
8
250

6 200

4 150

100
2
50

0 0
0 2 4 6 8 10 12 14
Delivery Gauge Reading (kgf/cm2)

(a)

Current in the Existing Design (A) Current in the Proposed Design (A)
pf in the Existing Design pf in the Proposed Design
10 1.0

8 0.8

6 0.6

4 0.4

2 0.2

0 0.0
0 2 4 6 8 10 12 14
Delivery Gauge Reading (kgf/cm2)

(b)

Figure 3.22 Performance Comparison Curve: 6-HP (a) Discharge and

Current (b) Current and Power factor
 76

Table 3.18 Performance Test of 7.5-HP Submersible-pump-set with the

Existing slot-shape

Delivery
Total Rise Time Input Pump Overall
Speed gauge in for Discharge Current
S.No. head Power output efficiency
(rpm) reading Tank rise (lpm) (A)
(m) (kW) (kW) (%)
(Kgf/cm2) (cm) (s)
1 2880 0.00 2.20 30.00 54.50 331 13.94 6.12 0.12 1.95
2 2873 2.00 22.15 20.00 39.09 308 14.27 6.37 1.12 17.65
3 2864 4.00 42.09 20.00 42.84 282 14.57 6.61 1.96 29.61
4 2856 6.00 62.04 10.00 23.53 257 14.79 6.78 2.64 38.85
5 2851 8.00 81.98 10.00 26.78 226 14.96 6.90 3.06 44.40
6 2849 10.00 101.93 10.00 32.00 189 14.89 6.89 3.20 46.48
7 2853 12.00 121.88 10.00 41.13 147 14.49 6.60 2.98 45.17
8 2861 13.00 131.85 5.00 25.75 118 13.86 6.16 2.58 41.94
9 2903 14.50 146.80 0.00 0.00 0 10.96 3.65 0.00 0.00

Table 3.19 Performance Test of 7.5-HP Submersible-pump-set with the

Proposed slot-shape

Delivery
Total Rise Time Input Pump Overall
Speed gauge in for Discharge Current
S.No. head Power output efficiency
(rpm) reading Tank rise (lpm) (A)
(m) (kW) (kW) (%)
(Kgf/cm2) (cm) (s)
1 2898 0.00 2.48 30.00 48.43 427 12.24 5.94 0.17 2.92
2 2891 2.00 22.61 20.00 33.16 413 12.93 6.17 1.52 24.71
3 2882 4.00 42.77 20.00 36.57 379 13.28 6.46 2.65 41.04
4 2874 6.00 63.10 10.00 18.37 367 13.56 6.63 3.79 57.08
5 2870 8.00 83.24 10.00 21.45 320 13.92 6.74 4.35 64.57
6 2868 10.00 103.72 10.00 27.34 259 13.78 6.81 4.39 64.51
7 2873 12.00 124.10 10.00 36.27 204 13.23 6.54 4.14 63.29
8 2881 13.00 134.36 5.00 21.37 179 12.61 6.08 3.93 64.54
9 2924 14.50 149.30 0.00 0.00 0 9.13 3.48 0.00 0.00
 77

Head (m) Overall Efficiency (%) Current (A) Motor Input (kW)
160 50

140 45
40
120
35
100 30
80 25

60 20
15
40
10
20 5
0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Discharge (lps)

(a)

Head (m) Overall Efficiency (%) Current (A) Motor Input (kW)
160 70

140 60

120
50
100
40
80
30
60
20
40

20 10

0 0
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0

Discharge (lps)

(b)

Figure 3.23 Pump Performance Curve: 7.5-HP (a) Existing (b) Proposed
 78

Current in the Proposed Design (A) Current in the Existing Design (A)
Discharge in the Existing Design (lpm) Discharge in the Proposed Design (lpm)
20 450

. 400

15 350
300
250
10
200
150
5 100
50
0 0
0 2 4 6 8 10 12 14 16
Delivery Gauge Reading (kgf/cm2)

(a)
Current in the Existing Design (A) Current in the Proposed Design (A)
pf in the Existing Design pf in the Proposed Design
16 1

14 .
0.8
12

10 0.6
8

6 0.4

4
0.2
2

0 0
0 2 4 6 8 10 12 14
Delivery Gauge Reading (kgf/cm2)

(b)

Figure 3.24 Performance Comparison Curve: 7.5-HP (a) Discharge and

Current (b) Current and Power factor
 79

Performance Comparison Curves for 3-HP, 5-HP, 6-HP, and

7.5-HP, Pump-sets have been depicted in Figure 3.17 to Figure 3.24. From the
performance curves, the following inferences have been made:

The current drawn from the supply gets reduced by 1 to 1.7 A,

and the power factor has also got significantly improved.

Input power consumed by the pump-set gets significantly

reduced by 130 to 300 W.

There is an increase in speed of the pump-set by 15 to 30 rpm,

and this results in increase in the discharge of water by 30 to
70 lpm.

The overall efficiency of the pump-set has gone up by 3 to 7 %.

Therefore, the adoption of these motors in the agriculture field can

give immense benefits to the user, as well as to the country and the global
environment at large.