Table of Contents

1. SCOPE............................................................................................................................................................. 2
2. REFERRED STANDARD .............................................................................................................................. 2
3. DEFINITIONS ................................................................................................................................................ 2
4. UNITS ............................................................................................................................................................. 5
5 QUALITY CONTROL MEASURES BY THE MANUFACTURER ............................................................ 5
6 INFORMATION TO BE FURNISHED BY THE PURCHASER/BUYER ................................................... 9
7 INFORMATION TO BE FURNISHED BY THE MANUFACTURER OR THE SUPPLIER .................... 11
8 STAGES OF INSPECTION AND CONTROL ............................................................................................ 12
9 COMPLAINT REDRESSAL ........................................................................................................................ 19
10 PRODUCTION PLAN .................................................................................................................................. 19
11 TEST METHOD AND ITS REQUIREMENTS ........................................................................................... 19
12 TEST REPORT PROFORMA FOR SUBMERSIBLE MOTORS AND SUBMERSIBLE PUMPSETS ..... 19
ANNEX A .............................................................................................................................................................. 20
ANNEX B 1 ........................................................................................................................................................... 23
ANNEX B 2 ........................................................................................................................................................... 25
ANNEX B 3 ........................................................................................................................................................... 27

1
 MANUAL FOR TESTING AND INSPECTION OF SUBMERSIBLE PUMP SETS
1. SCOPE
1.1 This manual highlights the key elements essential for the field inspection officers to ensure
the quality for submersible pump-sets procured by EESL in compliance with the requirements laid
out in the tender/bid document, thereby building credibility of the program and ensuring the
quality of the product.

This manual specifies guidelines for the bid evaluation, pre-delivery, and post-
delivery/verification inspection including the sampling methodology in carrying out the type,
acceptance and routine tests of submersible pump-sets commonly used in bore wells, tube wells
and open wells for handling clear, cold water, rated voltage up to and including 415V for three
phase and 240 V for single phase, 50 Hz ac, and rated output not exceeding 22 kW and 2.2 kW
for three phase and single phase respectively for application in agriculture, water supply etc.
covered under the scope of IS 8034. This manual also prescribes the levels of control at the
manufacturers end for specifies the performance requirements for submersible pump-sets.
Stepwise guidelines for the inspection of submersible pump-sets are given in Annex A of this
manual.

2. REFERRED STANDARD
2.1 The following standards shall be referred while using this manual:

IS No Title
1885 (Part 35) Electrotechnical Vocabulary Part 35 Rotating Machines
2223 Dimension of Flange Mounted AC Induction Motors
2500 : (Part 1) Sampling Procedure for Inspection by Attributes, Part 1 Sampling Plan
Indexed by Acceptance Quality Limit (AQL) For Lot by Lot Inspection
3073 Assessment of Surface Roughness
4029 Guide for Testing Three Phase Motors
5120 Technical Requirements for Roto-Dynamic Special Purpose Pumps
7572 Guide for Testing Single Phase AC and Universal Motors
8034 Submersible Pump-Sets
IS/ISO 9001 Quality Management System- Requirements
9283 Motors for Submersible Pump-Sets-Specification
11346 Code of Acceptance Tests for Agricultural and Water Supply Pumps

3. DEFINITIONS
All definitions given in IS 1885(Part 35), IS 8034, IS 9283 and IS 5120.shall apply. Some of the
important definitions relevant to this manual are given below:

3.1 Velocity Head

This is the kinetic energy per unit weight of liquid handled at a given section.

2
3.2 Static Suction Head
When the liquid level in an open vessel is above the pump datum, static suction head is the
difference in elevation between the pump datum and the liquid level in the suction vessel.

3.3 Total Suction Head (h)

Suction head exists when the total suction head is above atmospheric pressure head. This is equal
to the static suction head minus the friction and entrance losses in suction pipeline. Total suction
head as determined on test bed is the reading of a suction gauge at the suction nozzle of the pump
corrected to pump datum plus velocity head at the point of measurement.

3.4 Static Delivery Head

When the pump discharges into an open vessel, the static delivery head is the difference in
elevation between the pump datum and the highest point of delivery.

3.5 Total Delivery Head

This is the sum total of the static delivery head and the friction and exit losses in the delivery
pipeline. The total delivery head, as measured on the test bed is the reading of the pressure gauge
at the discharge of the pump corrected to pump datum plus the velocity head at the point of
measurement.

3.6 Total Head

This is the measure of the energy increase per unit mass of liquid imparted to it by the pump and
is, therefore, the algebraic difference of the total delivery head and the total suction head.

3.7 Net Positive Suction Head (NPSH)

This is the total suction head of liquid in meters, absolute, determined at the pump suction nozzle
and corrected to pump datum less the vapour pressure head of the liquid at pumping temperature,
at the suction nozzle in meters absolute.

3.8 Specific Speed

Specific speed is a term used for classifying pumps based on their performance and dimensional
proportions regardless of their actual size or the speed at which they operate. It is the speed
expressed in revolutions per minute of an imaginary pump geometrically similar in every respect
to the actual pump consideration and capable of raising 75 kg of water per second to a height of
one meter.

3.9 Driver Input

The power input to the prime mover expressed in kilowatts.

3.10 Pump Input

The power applied at pump shaft expressed in kilowatts.

3
3.11 Pump Output
The liquid power delivered by the pump expressed in kilowatts.

3.12 Pump Efficiency

The ratio of the pump output to the pump input.

3.13 Overall Efficiency

The ratio of the pump output to the driver input.

3.14 Static Water Depth

It is the depth of water level below the ground level when the pump is not in operation.

3.15 Rated Voltage

Voltage or voltage range specified in the relevant standard or assigned by the manufacturer or
responsible vendor.

3.16 Rated Frequency

The rated frequency shall be 50 Hz.

3.17 Lot
The number of pumps of the same size, type and duty point offered for inspection at one time shall
constitute a lot.

3.18 Sampling
The selection of a portion of a lot with a view to taking a decision about the quality of the lot on
the basis of results obtained by inspecting the selected portion.

3.19 Sample Size

The number of pumps selected for inspection and/or testing from a lot.

3.20 Type test

Tests carried out to prove conformity with the requirement of the relevant specification. These are
intended to prove the general qualities and design of the given type of a product.

3.21 Acceptance test

Tests carried out on samples taken from a lot for the purpose of acceptance of the lot.

3.22 Routine test

Routine tests are intended to check the quality of the individual test unit. These tests are done to
ensure the reliability of test objects and consistency of the material used in their manufacture,
which are likely to vary during production.

4
3.23 Verification test
Verification tests are the evaluation of whether or not a product, service, or system complies with
a regulation, requirement, or imposed conditions.

4. UNITS
4.1 Volume
The standard units for volume shall be:
a) Litre, and
b) Cubic meter

4.2 Rate of Flow

The standard units for expressing rate of flow shall be:
a) Litres per minute,
b) Litres per second, and
c) Cubic meters per hour

4.3 Head
The standard unit for expressing head shall be the meter.

5 QUALITY CONTROL MEASURES BY THE MANUFACTURER

The manufacturer shall exercise suitable levels of control as described in 5.1 to 5.6 below.
5.1 In House Test Laboratory
The manufacturer shall have the requisite test facilities in house, which shall be suitably equipped
and staffed where different tests specified in the relevant standard shall be carried out in
accordance with the test methods prescribed in the standard.

5.2 Maintenance of Test Records

The manufacturer shall maintain all records of tests, inspection and calibration. All testing
equipment and measuring instruments shall be periodically checked and calibrated and records of
such checks/calibration shall be maintained. Copies of any records and other connected papers
that may be required by the EESL representatives shall be made available during the visit at the
manufacturing premises.

5.3 Quality System in the Organization

The manufacturer should implement proper Quality Management System in their organization in
accordance with IS/ISO 9001 as applicable to various day-to-day activities of the organization.

5
5.4 Marking on the Product
The marking on the submersible pump-sets shall be furnished in a permanent and legible manner
on either the product where it is accessible and visible and/or packaging or product data sheet/leaf-
let. The information on the meters shall be in accordance with clause 16.1 of IS 8034.
In addition, the meters shall carry BEE star label and/or BIS certification mark licence.
Any other additional information may be provided on the rating plate subject to agreement
between the manufacturer and EESL. Following information shall be furnished on the nameplate
affixed to each submersible pump-set:
a) Manufacturer’s name or trade mark (if any)
b) Model;
c) Serial No;
d) Number of stages;
e) Bore size, Min;
f) Head, at nominal duty point;
g) Discharge, at nominal duty point;
h) Overall efficiency;
i) Motor rating (kW);
j) Rated speed (rpm);
k) Maximum current (amp);
l) Rated voltage (v) or voltage range with variation;
m) Rated frequency (Hz);
n) Connection star/delta;
o) Type of duty (whether continuous or not);
p) Delivery size;
q) Head range for non-overloading requirements; and
r) BIS standard mark and BIS Licence number, if any and/or BEE star label

5.5 Raw Materials and Components

As far as possible, each consignment of the raw material and components should be accompanied
by a test certificate certifying its conformity to the relevant Indian Standard wherever exists or
else each lot of raw material shall be checked for its conformity as per the relevant standard, if
any.

5.6 Sampling and Frequency of Testing

The manufacturer shall carryout all the tests specified in IS 8034. The number of samples to be
subjected to various tests and the frequency of testing including the action that are required to be
taken by the manufacturer in case of failure of sample in any of the test or tests are given in Table
1 for submersible motors and Table 2 for submersible pump-sets. The tests, as specified in Table
1 and 2 and the levels of control specified therein, shall be carried out on the entire production of
the factory.

6
 Table 1
Sampling and Frequency of Testing

S. Test Requirements Test Methods No. of samples Frequency

No. of Testing
Clause Reference
Standards
1 General Construction 5.1 to 5.3 IS 9283 Each motor -
2 Earthing 5.4 -do- -do- -
3 Finish of 5.5 -do- One One sample
Bearings Rotor/shaft/slee per week
4 IS 3073 ve

4 Balancing of Rotor 5.6 IS 9283 Each Rotor -

5 Dimensions 7 -do- One Motor One sample
per day
6 Shaft Extension run 4 IS 2223 One Rotor Shaft -do-
out, concentricity of
mounting, and face
run out
7 Terminal markings 13 IS 9283 Each motor -
8 High Voltage test 20 -do- -do- -
9 Insulation resistance 21 IS 9283 Each Motor -
before & after HV
test
10 No load running of 8.1 IS 4029 or -do- -
Motor and reading of IS 7572
current and voltage
11 Locket rotor reading 8.3 IS 4029 -do- -
of Voltage, Current 8.2 IS 7572
and Power input
12 Reduced voltage 16.2 (e) IS 9283 -do- -
running up test at
no-load (for 3 phase
motors only)
13 Leakage Current 23 -do- -do- -
Test at rated voltage
14 Measurement of 7 IS 4029 or One Motor One sample
Stator Resistance IS 7572 per week
15 Full load reading of 8.8 IS 4029 -do- -do-
voltage, current 8.4 IS 7572
power input and Slip

7
 S. Test Requirements Test Methods No. of samples Frequency
No. of Testing
Clause Reference
Standards
16 Performance 17 IS 9283 -do- -do-
characteristics
17 Momentary 18.1 IS 9283 As per -
Overload Test agreement with
purchaser
18 Temperature rise test 19 IS 9283 One motor One sample
per week
19 Speed 22 IS 9283 One motor -do--
20 Efficiency 12.1 -do- -do- -do-
21 Power Factor 12.2 -do- -do- -do-

NOTE 1: The tests given in Table 1 are applicable when motor is manufactured in house. In case of motors procured
from outside sources, each consignment of the motors shall be accompanied by a test certificate about its conformity
with as per IS 9283. In such cases or if the motor carries BIS certification mark, the testing of motors specified in
Table 1 is not required to be carried out by the pump manufacturer.

NOTE 2: For performance other than at rated voltage, the performance values shall be checked as per the guidance
given in note 3 under clause 17 of IS 9283.

NOTE 3: Momentary overload and sustained overload test shall be carried out as per the mutual agreement with the
purchaser.

Table 2
Sampling and Frequency of Testing

S. No. Test Requirement Test Methods No. of Frequency of

samples Testing
Clause Reference
Standards
1 Material of 6.2 IS 8034 3 One sample per
construction of week
various parts
(Mechanical test)
2 Impeller balancing 6.4.2 IS 8034 - Each impeller
3 Pump shaft or 6.4.1 -do- Three One sample per
protecting sleeve week
surface finish
4 Hydrostatic Test 9.1 -do- - Each pump set
5 Maximum Outside 11.2 -do- One One sample per
Diameter of day

8
 submersible pump
set
6 Temperature rise test 7.1.1.2 -do One -do-
at reduced voltage
7 Pump Test and 8 IS11346 one -do-
Verification of
Guarantees 14.1 IS 8034
8 Direction of Rotation 10 IS 8034 - Each pump sets
9 Guarantee of 15 -do- One One sample per
Performance week
10 Minimum Efficiency 15.2.2 -do- -do -do-
11 Submersible cable 8 IS 9283 -do- -do-

NOTE: In case of pump set, motor shall be tested for all routine tests as per clause 16.2 of IS 9283 and type tests
except full load test, performance characteristics, momentary overload and vibration test as specified in clause 16.1
of IS 9283. The frequency of tests and the number of samples to be tested shall be in accordance with Table 1 of this
manual.

In case the manufacture does not have requisite test facilities for any of the tests shown in Table
1 and 2 above, the same may be tested from any independent NABL accredited test labs except
for the tests, which are to be carried out on each submersible pump.
In case of failure of any motor or pump-sets in respect of tests carried out on each pump-sets,
cause of failure shall be identified and corrective action shall be taken to remove the non-
conformity.

In the case of failure of any sample, in respect of the tests conducted on each lot manufactured,
double the number of samples shall be taken for testing and no failure in those samples shall be
permitted. Otherwise, the lot shall be rejected. After corrective actions two consecutive lots shall
be tested as per the sample size and frequency indicated in the Table 1 and Table 2 for motors and
pump-sets respectively and then original frequency shall be restored if both the samples pass.

6 INFORMATION TO BE FURNISHED BY THE PURCHASER/BUYER

6.1 When enquiring or ordering submersible pump-sets to the prescribed standard as specified
in the contract, the following information in addition to those given in clause 12 of IS 8034 may
be furnished by EESL to the suppliers/manufacturers:
General information:
a) Name of the purchaser;
b) Address of the purchaser;
c) Name of the contact person and the contact details;
d) BIS certification Mark on the product and the copy of licence document;
e) In case of BEE star labeled product, relevant documents relating to approval of model
registration;

9
f) Total number of submersible pumps required; and
g) Location where the meters required to be supplied.
Technical information
a) Name of the purchaser;
b) Address of the purchaser;
c) Installation site;
d) Number of pumps required;
e) Spare parts required;
f) Pump operating conditions:
i) Capacity in l/min, l/s or m3/h
ii) Number of poles of motor
iii) Total head, alternatively, sketch of the pipeline giving information, such as static
delivery pipe diameter and length, distance between point of discharge pipe fittings
and valves used, etc., may be given
iv) Total depth of casing pipe
v) Static water depth
vi) Tube well capacity at predicted draw down
g) Description of the well:
i) Installation of the pump in:
 Open well
 Tube well
 Open well with a boring and
 Others
ii) Minimum inside diameter of the tube well or casing pipe
iii) Total depth of open well/deep well
iv) Total depth of casing pipe
v) Static water depth
vi) Well developed to...1/ min at...meter draw-down
h) Site conditions:
i) Height above mean sea level in meters, and
ii) Details of quality of water with respect to all characteristics as given in clause 4 of
IS 8034.
j) Power supply:
i) Type of supply (single-phase/three-phase)
ii) Frequency (Hz)
iii) Voltage (V) and
iv) Variation in voltage/frequency
k) Accessories (state whether the following items are required):
i) Sluice valve
ii) Reflux valve
iii) Pressure gauge
iv) Rising main pipe and delivery bend/elbow

10
 v) Type of installation stages in the entire system
vi) Water level indicator
vii) Voltage stabilizer
viii) Automatic starting and stopping device (optional)
ix) Starter-direct on the line or star-delta or indicate starting method
x) Voltmeter
xi) Ammeter
xii) Single phasing preventers
xiii) Water level guard and
xiv) Low voltage protector.

7 INFORMATION TO BE FURNISHED BY THE MANUFACTURER OR THE

SUPPLIER
EESL may ask the manufacturer/supplier to furnish the following information while supplying the
submersible pump-sets complying with the relevant standard specified in the contract.
a) Name of the manufacturer;
b) Address of the manufacturer;
c) Organization structure;
d) Location of different manufacturing units, if manufacturing is done at more than one
locations;
e) Name and contact details of the responsible person in each units;
f) Details of the testing personnel;
g) Availability of complete test facilities at the manufacturing premises;
h) List of test equipment, measuring instruments and their accuracy class;
i) Details of calibration of each equipment/measuring instruments including their validity
period;
j) Whether any arrangements made with any outside test labs where test facilities for any
particular test (s) are not available with the manufacturer;
k) Whether the manufacturers lab is accredited by NABL and if yes what is the scope of
accreditation and its validity;
l) Accreditation of outsourced lab and the validity period;
m) Declaration in uncertainty in measurement; and
n) Whether the product (s) covered are BIS certified. If BIS certified what is the validity of
the licence and the varieties/types covered in the licence.
Additional Information
EESL may ask the manufacturer/supplier to furnish the following information while supplying the
pump-set complying with the relevant standard specified in the contract.
a) Type designation of pump and submersible motor;
b) Details of pump:

11
 i) Method of lubrication (normally the parts of the submersible pump-set are
lubricated by the pumped liquid itself. If any other type of lubrication is adopted,
it shall be indicated
ii) Minimum bore well diameter in mm
iii) Number of stages
iv) Outside diameter of the bowl, the maximum diameter of the pump fitted with non-
return valve and maximum overall diameter of the pump-set including the cable
guard, mm
v) Discharge ……l/s
vi) Total head …… m
vii) Speed …. rpm
viii) Overall efficiency at duty point..... percent and
ix) Minimum submergence at duty point...... m
c) Details of motor:
i) Rating …..kW
ii) Type.....in accordance with IS 9283
iii) Details of power supply
iv) Number of poles of motor and
v) Maximum current at rated voltage and frequency
d) Accessories:
i) Suitable starter
ii) Main switches
iii) Ammeter and voltmeter
iv) Pressure gauge
v) Water level indicating relays
vi) Automatic starting and stopping device
vii) Reflux valve and sluice valve and
viii) Erection clamps and special spanners, if any
e) Additional information to be furnished with the supply, if required.
i) Performance curves:
 Discharge vs head curve
 Discharge vs overall efficiency
 Discharge vs current
ii) Instructions for installation and maintenance and
iii) Weight of the pump motor together in kg and that of cables in kg/m length.

8 STAGES OF INSPECTION AND CONTROL

The inspection activities shall be undertaken in three different stages as follows:
Stage 1 – Bid Evaluation through document verification and Type Testing
Stage 2 – Production/Pre-Delivery
Stage 3 – Post-Delivery/Verification Testing
The detail procedure in respect of all the above three stages are described in 8.1 to 8.3.

12
8.1 Bid Evaluation
Bid evaluation shall comprise of type test certificate and the verification of relevant documents.
Manufacturers or bidders shall submit a declaration about the product details supported by type
test certificate from an independent third party NABL accredited laboratory against the specified
test standard. During the bidding phase, the pre-qualification of any manufacturer or bidder shall
be based on verification of the documents and test certificates submitted. In case of any change in
any design parameter, the complete type test shall be repeated. The manufacturer shall submit the
type test report along with other necessary supporting documents while submitting their bid, which
are subject to evaluation and scrutiny by EESL.

All the necessary information submitted by the bidder, as confirmation and declaration of quality
should comply with the prescribed guidelines of EESL and the stipulation of the prescribed test
standard. In case of non-compliance in any of the parameter, the bid shall be rejected.

8.1.1 Type Test

Manufacturer and/or the bidder shall get their product tested on two samples in an independent
accredited laboratory or in the manufacturers own lab accredited by NABL.
Before commencement of the tests, the submersible pump-sets shall be visually examined
including the components, parts and their assembly, constructions, mechanical hazards, marking
provision of suitable terminals for supply connections, earthing and the effectiveness of screws
and connection. The external surface finish shall be even and free from finishing defects. The
submersible pump-sets shall be subjected to the following type test as given in Table 3 for motors
and Table 4 for pump-sets.

Table 3
List of Type Test for Bid-Evaluation (Submersible Motors)

S. Test Requirements Clause Reference Test Methods

No. as per IS 9283
Clause Reference
Standards
1 General Construction 5.1 5.1 to 5.3 IS 9283
2 Earthing 5.2 5.4 -do-
5 Dimensions 7 7 -do-
6 Shaft Extension run out, 7.2.1 4 IS 2223
concentricity of mounting,
and face run out
7 Terminal markings 13 13 IS 9283
8 High Voltage test 20 20 -do-
9 Insulation resistance before 21 21 -do-
& after HV test

13
S. Test Requirements Clause Reference Test Methods
No. as per IS 9283
Clause Reference
Standards
10 No load running of Motor 8.1 8.1 IS 4029 or
and reading of current and IS 7572
voltage
11 Locket rotor reading of 8.3 8.3 IS 4029
Voltage, Current and Power
input 8.2 8.2 IS 7572
12 Reduced voltage running up 16.2 e) 16.2 (e) IS 9283
test at no-load (for 3 phase
motors only)
13 Leakage Current Test at 23 23 -do-
rated voltage
14 Measurement of Stator 7 7 IS 4029 or
Resistance IS 7572
15 Full load reading of voltage, 8.8 8.8 IS 4079
current power input and Slip 8.4 8.4 IS 7572
16 Performance characteristics 17.1 17 IS 9283
17 Momentary Overload Test 18 18.1 -do-
18 Temperature rise test 19 19 -do-
19 Speed 22 22 -do-

Table 4
Lis of Type Tests for Bid Evaluation (Submersible Pump-sets)

S. Test Requirement Clause Reference as Test Methods

No. Per
IS 8034 Clause Reference
Standards
1 Material of construction of 6.2 6.2 IS 8034
various parts (Mechanical
test)
2 Impeller balancing 6.4 6.4.2 IS 8034
3 Pump shaft or protecting 6.4 6.4.1 -do-
sleeve surface finish
4 Hydrostatic Test 9 9.1 -do-
5 Maximum Outside Diameter 11.2 11.2 -do-
of submersible pump set
6 Temperature rise test at 7.1.1 7.1.1.2 -do
reduced voltage

14
 S. Test Requirement Clause Reference as Test Methods
No. Per
IS 8034 Clause Reference
Standards
7 Pump Test and Verification 8 8 IS11346
of Guarantees
14.1 14.1 IS 8034
8 Direction of Rotation 10 10 IS 8034
9 Guarantee of Performance 15 15 -do-
10 Minimum Efficiency 15.2.2 15.2.2 -do-
11 Submersible cable 8 8 IS 9283

8.1.2 Document Verification

The following documents shall be submitted by the manufacturers/bidders for verification and
scrutiny by EESL. A detail scrutiny of the documents listed below is essential to verify the
authenticity and validity of each documents submitted.
a) Copy of valid BIS certification marks Licence, if the product carries BIS certification
mark;
b) Document relating to BEE approval for star rating label;
c) Type test report in original from a NABL accredited testing laboratory as per IS 9283 for
motors and IS 8034 for pump-sets;
d) Copy of test certificates of important raw materials and components, wherever applicable;
e) Copy of valid NABL certificate of accreditation of manufacturers lab and independent lab;
and
f) Warranty certificate for guarantee of performance of minimum as prescribed by EESL.

8.2 Production/Pre-Delivery Inspection

The production/pre-delivery inspection shall be carried out by EESL or their authorized
representatives. The sample shall be supplied free of cost by the manufacturer. The testing charges
for all the type tests shall be borne by EESL. The schedule of test for pre-delivery inspection prior
to shipment from the manufacturer’s premises or their warehouse shall comprise of the following:
a) Type test
b) Acceptance test
c) Routine Test

The production/pre-delivery inspection shall be carried out at the manufacturer’s premises on

samples selected at random from their finished stock or their warehouse.

To ensure the production of quality products in a continuous manner, verify the proper levels of
control in the manufacturing process by the manufacturer. These include presence of an in house
accredited test facility, trained and competent testing personnel, maintenance of test records,

15
inspection and calibration, proper Quality Management System measures in accordance with
IS/ISO 9001.

8.2.1 Type Test

For the purpose of type tests, two samples of submersible pump-sets of each type and design shall
be selected from the lot offered. Sample drawn for type tests shall be tested at a NABL approved
manufactures or third party test lab.

The tests given in the Table 3 for motors and Table 4 for pump-sets as given below shall constitute
the type tests and shall be carried out on the selected samples for type tests. The sample shall be
representative of a manufacturer’s production selected from the finished stock at the
manufacturers end or in their warehouse.

Before commencement of the type tests, the pump-sets shall be visually examined including the
components, parts and their assembly, constructions, mechanical hazards, marking provision of
suitable terminals for supply connections including the provisions for earthing. The external
surface finish shall be even and free from surface defects.

The samples shall successfully pass all the type tests for proving conformity with the requirements
of the standard. If the sample fails in any of the type tests, EESL at its discretion, may call for
fresh samples not exceeding twice the original number and subject them again to all tests or to the
test (s) in which failure (s) had occurred. No failure is permitted in the repeat test.

The type test report shall also contain the nameplate or rating plate particulars of the submersible
pumps for purposes of identification.

Type test may be waived off in case tender document originally lays out the requirement of BIS
certification mark, if any.

8.2.2 Acceptance Test

To ensure the quality of products supplied by the manufacturer, acceptance test shall be carried
out by EESL on each lot offered for inspection.
Samples shall be selected at random to ensure proper representation of a lot from the factory or
their warehouse/stockyard for necessary testing in the manufacturers own lab duly accredited by
NABL in the presence of EESL representatives. The method employed for random selection
should be in accordance with IS 4905 to ensure proper representation of a lot. The sample size and
acceptance quality level (AQL) shall be as laid down in IS 2500 (Part 1).
The samples selected from the lot shall be checked for any visual defects including the
components, parts and their assembly, constructions, mechanical hazards, marking provision of
suitable terminals for supply connections including the provisions for earthing as well as the
external surface finish for any surface defects.

16
In case of failure of sample in any of the tests specified in the standard/inspection manual, reject
the lot and send a written communication to the manufacturer. The manufacturer may after
rectifying the necessary corrective measures can reoffer the lot for inspection.

Three inspection levels, I, II and III, are given in Table 1 of IS 2500 (Part 1) for general use. Unless
otherwise specified, level II shall be used. Level I may be used when less discrimination is needed
level III when greater discrimination is required.
Table 1 of IS 2500 (Part 1) provides the information about the lot size and corresponding
inspection level. For the purpose of lot inspection by EESL, single sampling plan with normal or
tightened or reduced inspection as given in Table 2A, 2 B and 2 C of IS 2500 (Part 1) may be
followed. The different level of AQL specifying the acceptance and rejection number of the lot as
given in Tables 2 A to 2 C shall be at the discretion of EESL.
Special levels, S-1, S-2, S-3 and S-4 given in Table 1 of IS 2500 (Part 1) may also be used where
relatively small sample sizes are necessary and larger sampling risks can be tolerated.
NOTE: A third party inspecting agency can be employed for inspection of the lot offered by the manufacturers and
submit test reports in the prescribed format as given in Annex B and duly approved by EESL for scrutiny and approval.

The nature of tests and the relevant test standard for the acceptance tests for submersible pump
sets are given in Table 5.

Table 5
List of Acceptance Test for Pre-Delivery Inspection (Submersible Pump Sets)

S. Test Requirements Clause Reference Test Methods

No. as per IS 9283
Clause Reference
Standards
1 Earthing 5.2 5.4 -do-
2 Terminal markings 13 13 IS 9283
3 High Voltage test 20 20 -do-
4 Insulation resistance before 21 21 -do-
& after HV test
5 No load running of Motor 8.1 8.1 IS 4029 or
and reading of current and IS 7572
voltage
6 Locket rotor reading of 8.3 8.3 IS 4029
Voltage, Current and Power
input 8.2 8.2 IS 7572
7 Reduced voltage running up 16.2 e) 16.2 (e) IS 9283
test at no-load (for 3 phase
motors only)
8 Leakage Current Test at 23 23 -do-
rated voltage

17
 S. Test Requirements Clause Reference Test Methods
No. as per IS 9283
Clause Reference
Standards
9 Measurement of Stator 7 7 IS 4029 or
Resistance IS 7572
10 Full load reading of voltage, 8.8 8.8 IS 4079
current power input and Slip 8.4 8.4 IS 7572
11 Performance characteristics 17.1 17 IS 9283
12 Momentary Overload Test 18 18.1 -do-
13 Temperature rise test 19 19 -do-
14 Speed 22 22 -do-
15 Direction of Rotation 10 10 IS 8034
16 Submersible cable 8 5.3 IS 9283
17 Hydrostatic Test 9 9.1 IS 8034

8.2.3 Routine Tests

In case production routine tests are to be repeated at the time of procurement, then where agreed
to between EESL and the manufacturer, the tests may be carried out at the manufacturer’s works;
alternatively, the tests may be repeated at the place specified by EESL provided that all the
arrangements for tests are made by EESL at the specified place.
Routine tests are the tests that would be conducted on each unit after completion at the
manufacturer’s work.
The following shall constitute the routine tests.
S. Test Requirements Clause Reference as Test Methods
No. per IS 9283
Clause Reference
Standards
1 Earthing 5.2 5.4 -do-
2 Insulation resistance 21 21 -do-
3 No load running of Motor and 8.1 8.1 IS 4029 or
reading of current and voltage IS 7572
4 Speed 22 22 -do-
5 Direction of Rotation 10 10 IS 8034

8.3 Post Delivery Inspection/Verification Testing

For verification testing, the sample shall be drawn from open market or manufacturer’s
warehouse/stockyard. EESL shall bear the cost of the sample as well as the cost of testing.
Verification tests shall cover all the type tests for submersible pump tests as mentioned in Table 3
and Table 4 of this manual. The type testing shall be carried out in an independent test laboratory.

18
9 COMPLAINT REDRESSAL
Whenever a complaint is received after the submersible pump sets have been delivered/used and
the complaint is proved to be genuine and the warranty period (where applicable) has not expired,
the defective goods or their components shall be replaced or repaired free of cost by the
manufacturer. The final authority to judge the conformity of the product to the relevant standard
specified in the contract shall be with EESL. In the event of any damages caused by the
submersible pump or claim filed by the user against the supply made by the manufacturer as per
the contract and also non- compliance of the product to the relevant standard specified in the
contract, entire liability arising out of such non-compliant product shall be with the manufacturer
and EESL shall not in any way be responsible in such eventualities.
The manufacturer shall give a guarantee for the soundness of construction and performance of the
submersible pumps, and shall be responsible for putting right any manufacturing defects free of
charge for a period of 12 months right from the date of sale or date of installation whichever is
later. Such repairs or replacements of defective parts shall be carried out at manufacturer’s works,
or his authorized agent at site or at service shop.

10 PRODUCTION PLAN
The manufacturer shall provide advance information about their production plan and readiness of
the lot to be offered for inspection to EESL.

11 TEST METHOD AND ITS REQUIREMENTS

The method of tests and its requirements shall be in accordance with IS 8034 and IS 9283.

12 TEST REPORT PROFORMA FOR SUBMERSIBLE MOTORS AND

SUBMERSIBLE PUMPSETS
The test report format given in Annex B1 to B 4 shall be used by the manufacture, testing
laboratory or EESL while submitting their test reports.

19
 ANNEX A
STEPWISE GUIDELINES FOR THE INSPECTION OF SUBMERSSIBLE PUMP-SETS
1. Introduction
This inspection manual elaborates the quality assurance process for submersible pump-sets
procured by EESL. This will ensure compliance of the procured products with the requirements
laid out in the tender document, thereby building credibility of the program and ensuring the
quality of the product.
To ensure procurement of quality products, proper inspection should be carried out by EESL. The
inspection activities are divided in three different stages:

Step 1 – Bid Evaluation before finalization of the bid

Step 2 – Production/Pre-Delivery
Step 3 – Post-Delivery/Verification Testing

2. Bid Evaluation
For bid evaluation, manufacturer shall submit the test report from an NABL accredited lab against
the relevant standard along with other necessary supporting documents (show the list in red below)
while submitting their bid. The test report should include type tests on safety and performance.

All the necessary information submitted by the bidder should comply with the prescribed
guidelines of EESL and relevant test standard. In case of non-compliance in any of the parameter,
the bid shall be rejected.
a) Copy of valid BIS certification marks License, if the product carries BIS certification
mark;
b) Type test report in original from a NABL accredited testing laboratory as per the relevant
standard;
c) Copy of test certificates of important raw materials and components;
d) Copy of valid NABL certificate of accreditation of the test lab issuing the test
certificate/report; and
e) Warranty certificate for guarantee of performance of minimum number of years prescribed
by EESL.

2. Prerequisite for Inspection at the manufacturers premises

Before undertaking the inspection, the EESL inspecting officers should ensure the following:
a) Opening meeting with the concerned officials and the testing and quality control personal
to discuss and planning to undertake the required task
b) Visit to the test laboratory to check the following:
 Availability of requisite test facilities as per the prescribed standard and its
workability
 Calibration detail and the validity of each instruments and test equipment

20
  Verification of test records and other relevant records related to in process quality
control including the manual and procedure for ISO 9001 certification
 Verification of testing facilities at the production line if applicable
After ensuring the compliance of all the requirements mentioned above, the inspecting officers
shall draw samples for acceptance and type tests from the lot offered for inspection by the
manufacturers. For acceptance tests the sampling plan and AQL shall be as per IS
2500 (Part 1). Routine tests shall be carried out on the entire lot.
After the completion of all the tests as per the specified standard, the test report shall be prepared
on the prescribed format as given in Annex B of this manual. The test reports shall be signed by
the inspecting officer from EESL and the authorized person from the manufacture.

3. Production/ Pre-Delivery Inspection

The field-inspecting officer shall draw samples at random from the finished stock of the lot offers.
The number of samples for acceptance tests shall be as laid down in IS 2500 (Part 1) using a
suitable AQL.
The production/pre-delivery inspection shall be carried out by field inspecting personnel from
EESL or their authorized representatives at the manufacturer’s premises on samples selected at
random from their finished stock or their warehouse for testing. The sample shall be supplied free
of cost by the manufacturer. The manufacturer shall provide advance information about their
production plan and readiness of the lot to be offered for inspection to EESL. Pre dispatch
inspection tests include type, acceptance and routine tests.
Before commencement of the type tests, the submersible pump-sets shall be visually examined
including the components, parts and their assembly, constructions, mechanical hazards, marking
provision of suitable terminals for supply connections including the provisions for earthing. The
external surface finish shall be even and free from surface defects.

3.1 Type Tests

The sample selection for type testing shall be based on random sampling. The number of samples
for type testing shall be two drawn from the finished stock of the lot offered by the
manufacturer/supplier. Sample drawn for type tests shall be sent to an NABL approved test labs.
The testing charges for all the type tests shall be borne by EESL.

The samples shall successfully pass all the type tests for proving conformity with the requirements
of the standard. If the sample fails in any of the type tests, EESL at its discretion may call for fresh
samples not exceeding twice the original number and subject them again to all tests or to the test
in which failure had occurred. No failures are permitted in the repeat test. EESL may waive off
the type test on the lot offered by the supplier/manufacturers in case the submersible pup-sets
carries BIS certification mark and/or BEE energy efficiency level. The list of type tests shall be as
given in Table 3 for submersible motors and Table 4 for submersible pump-sets.

21
3.2 Acceptance Tests
To ensure the quality of products supplied by the manufacturer, acceptance test shall be carried
out by EESL on each lot offered for inspection. The manufacturer shall supply, free of charge, the
samples from the factory or their warehouse/stockyard for necessary testing in the manufacturers’
accredited lab in presence of EESL representatives.
Samples shall be selected at random from the lot offered by the manufacturers/supplier from the
finished stock using IS 4905 to ensure proper representation of a lot. The sample size and
acceptance quality level (AQL) shall be as per IS 2500 (Part 1). In the absence of test facilities for
any particular test, the testing personnel deputed by EESL shall draw the samples from the
manufacturing premises or from manufacturers ware house/stockyard and send the same to an
NABL approved test labs for the required tests.

In case of failure of sample in any of the tests specified in the standard/inspection manual, the lot
shall be rejected and a written communication to this effect shall be made to the manufacturer.
The manufacturer may after rectifying the necessary corrective measures can reoffer the lot for
inspection.

A third party inspecting agency can be employed by EESL for inspection of the lot offered by the
manufacturers and submit test reports in the prescribed format given in the inspection manual.

The list of acceptance tests shall be as given in Table 7 of this manual.

3.3 Routine Test

In case production routine tests are to be repeated at the time of procurement, then where agreed
to between EESL and the manufacturer, the tests may be carried out at the manufacturer’s works;
alternatively, the tests may be repeated at the place specified by EESL provided that all the
arrangements for tests are made by EESL. The routine tests shall be carried out on each
submersible pump-sets from the lot offered for inspection. In case of failure in any of the tests, the
sample under tests shall be either rejected or reworked/rectified and retested.
The list of routine tests is given in section 8.2.3 of this manual.

4. Post Delivery Inspection/Verification Testing

Verification testing is a vital crosscheck mechanism to ensure quality products reach the end
users/consumers post-delivery. For verification testing, the sample shall be drawn from open
market or manufacturer’s warehouse/stockyard. EESL shall bear the cost of the sample as well as
the cost of testing in an independent NABL accredited lab. The verification testing shall include
all the type tests specified in IS 9283 for submersible motor and IS 8034 for submersible pump-
sets Table 3 for submersible motors and Table 4 for submersible pump-sets in an NABL accredited
lab. The samples shall successfully pass all the type tests for proving conformity with the
requirements of the standard. If the sample fails in any of the type tests, EESL at its discretion,
shall draw the sample may call for fresh samples not exceeding twice the original number and
subject them again to all tests or to the test in which failure had occurred. No failures are permitted
in the repeat test. In case of failure of samples in repeat testing, EESL shall take appropriate action
against the manufacturers.

22
 ANNEX B 1
TEST REPORT PROFORMA FOR SUBMERSIBLE MOTORS AND SUBMERSIBLE
PUMPSETS

The test report for the motor testing shall be on prescribed format as given below.

1 Name and address of the manufacturer

_____________________________________________________________

2 Name of the Purchaser _____________________________ Test Certificate No.

__________________________________________

3 Purchase Order No. ________________ Order Acceptance No. ________________

A. SUBMERSIBLE MOTORS

1 Name Plate Data

a) Motor S. No.
b) Voltage _________ Volts
c) Output ________ kW
d) Frequency _______ Hz
e) Speed ________ rpm Current _________ amp
f) Bore Well Size __________ mm

2 TESTS
The details test results in accordance with IS 9283 shall be reported on the prescribed format given
in Table C1 of this Annex.

Test conducted on Motor No. ______________ Approved By

Tested by: On: Date:

B. SUBMERSIBLE PUMPS
1 Name Plate Data
a) Manufacturer’s name or trade mark (if any)
b) Model,
c) Serial No
d) Number of stages;
e) Bore size, Min;

23
 f) Head, at nominal duty point;
g) Discharge, at nominal duty point;
h) Overall efficiency;
i) Motor rating (kW);
j) Rated speed (rpm);
k) Maximum current (amp);
l) Rated voltage (v) or voltage range with variation;
m) Rated frequency (Hz);
n) Connection star/delta;
o) Type of duty (whether continuous or not);
p) Delivery size;
q) Head range for non-overloading requirements; and
r) BIS standard mark and BIS License number, if any.

In addition, pump sets may carry a separate BEE star label.

2 TESTS
The details test results in accordance with IS 9283 shall be reported on the prescribed format given
in Table C2 of this Annex.

3 Performance Test and Verification of Guarantee

The details test results shall be reported on the prescribed format given in Table C3 of this
Annex.

Result: Pass/Fail

Test conducted on Motor No. ______________ Approved By

Tested by: On: Date:

24
 ANNEX B 2
TEST REPORT OF SUBMERSIBLE PUMP SETS AS PER IS 9283
Srl. Nature of Reference Clause Verification Remarks
No. Test Test Reference for test (Pass/Fail or
Standard records/test Satisfactory/Unsatisfactory/Observed
(IS) certificate Value)
1 Construction 9283 5.1

2 Submersible -do- 5.3

Cable

3 Provision for -do- 5.4

Earthing

4 Finish of -do- 5.5

Bearing

5 Balancing of -do- 5.6

Rotor

6 Measurement -do- 6.4

of Speed

7 Dimension -do- 7.1 and 7.2

8* Temperature -do- 9.1 and 19

rise test
Loading Condition

Volts Amps Watts Load Percentage Power Efficiency

Slip Factor
No Load

Full Load

Conditions of Test

Hours Run Line Line Current Input Calculated Temperature Rise

(H) Voltage A watts Output ºC
V kW kW
At Rated
Voltage*
At 85 Percent
of Rated
Voltage*
9 Breakaway Torque and Starting Current (Clause 16.1 e) and 16.3 of IS 9283)

Breakaway Torque (Locked) with Voltage Applied Breakaway Starting Current (Locked Rotor)
and Power Input (Locked Rotor) with Volts
Applied

25
 V Kg.m V W A

S. Nature of Reference Clause Verification Remarks

No. Test Test Reference for test (Pass/Fail or
Standard records/test Satisfactory/Unsatisfactory/Observed
(IS) certificate Value)
10 Measurement 9283 16.1 e)
of Stator
Resistance
11 No load Test -do- 16.1 d) and
16.3 c)
12 Full Load Test -do- 16.1 g)
13 Reduced -do- 16.1 e) and
Voltage 16.3 e)
Running Test
14 Performance -do- 17
Test *
15 Power Factor -do- 12.2
16 Efficiency -do- 12.1
17 Terminal -do- 13
Marking
17 Overload Test
Momentary -do- 18.1
Overload*
Sustained -do- 18.2
Overload
18 High Voltage -do- 20
Test
19 Insulation -do- 21
Resistance
Test
20 Measurement -do- 22
of Speed
21 Leakage -do- 23
Current

*NOTE: In case of submersible pump sets, motors need not be subjected to the following test specified in relevant
clause of IS 9283

a) Full load test {16.1g)}

b) Performance test {16.1 h)},
c) Momentary overload Test {16.1 m)}
d) Temperature rise at rated voltage and reduced voltage {16.1 j)} and {16.1 k)}

26
 ANNEX B 3
TEST REPORT OF MOTORS FOR SUBMERSIBLE PUMP SETS AS PER IS 8034
S. Nature of Test Reference Clause Verification for Remarks
No. Test Reference test (Pass/Fail or
Standard records/test Satisfactory/Unsat
(IS) certificate isfactory/Observed
Value)
1 Material and 8034 6.21
Construction
2 Design Features -do- 6.3
of Components
for Pump
3 Requirements 8034 6.4
for Components
11723 6.3
4 Temperature 8034 7.1.1
Rise Test
5 Submersible -do- 8
Cable
6 Hydrostatic Test -do- 9
7 Direction of -do- 10
Rotation
8 Guarantee
Guarantee of -do- 15.1
Workmanship
and Material
Guarantee of -do- 15.2
Performance
9 Verification of -do- 15.3
Guarantee

27
 ANNEX B 4
TEST REPORT ON PERFORMANCE FOR SUBMERSIBLE PUMP SETS
Pump Set Record Sheet Sheet Number
Graph Number
Nature of test - Performance test as per IS 8034
Pump type .. .. . . .. . . . ... .. . .Pump S1No,. . . . .. Motor rating . . . . ...kW/HP.......... Motor S1No.........-
. ... . .. . . . .. . .. . . . . .. .........
Suction .......... . . .... mm Delivery .. . . .. . . .. . Voltage . . . ... .. . Full load current, Amps . . . .. . . ..- . . .
...rnm
Material of the impeller Meter constant: Ax ......kWx ......Rated frequency. ..........
Suction lift measured by: Hg manometer vacuum gauge Capacity measured by - Vee-
notch/volumetric tank/Flowmeter

Delivery head measured by: Hg manometer/pressure gauge Class of accuracy of measuring instrument -
One
Wattmet Performance
er converted at rated
Volume l/time(s)(in case of volumetric tank)

reading frequency
W W2
1
Velocity head correction, m
Delivery gauge reading, m

Gauge distance, Z.m

(in case of v-notch)

Overall efficiency,
Head over notch,
Frequency, Hz

Total head, m

Discharge l/s

Motor input

Pump Input
Current, A

(LP), kW
(IP) kW

IP,kW
S. No

(%)
H,

Q,
m

Pump certified for: Date …………….. Tested by………………….

i) Total Head in m Remarks……………………………………..

.................................................................
ii) Discharge in l/s ………………
Frequency ...........................................
iii) Overall efficiency percent . . ...
Motor input, kW ................
iv) Head range in
m..................................................................
H . . . ........ Q.. ...... . ...Guarantee factor
............................

28
Overall efficiency at duty point, percent
.............

General requirements –
Satisfactory/Unsatisfactory

29