The Complete Guide to Submersible Cables: Everything You Need to Know

Electricity and water need to be separate in order to ensure safety, particularly in cases where electrical equipment is installed in environments with water below or around them. Such cables are known as submersible cables and are often used with submersible pumps which are installed in borewells, wells, water tanks, irrigation and industrial water systems.

Proper selection of cable is important due to the fact that submersible pump cables are always exposed to moisture and at times remain submerged in water for extended periods. It is essential that the cable chosen will offer proper insulation, protection and flexibility.

For customers buying cables for use in agricultural, domestic, commercial or industrial pumps, understanding various aspects of cables will prevent difficulties during the use of the cable after installation.

Neon Cables Pvt Ltd deals in cables used in different electrical applications. The following is a guide to the information customers need to know regarding submersible cables.

What Are Submersible Cables?

Submersible cables refer to the electrical cables that have been made with the intention of supplying power to any equipment that works in either undersea or wet conditions. Submersible cables are normally installed to feed the electricity needs of the submersible pumps which extract water from underground water sources.

Submersible cables differ from normal electrical cables by virtue of having insulation and structure that can cope with the continuous presence of water. Also, they should be capable of withstanding the load of electricity required by the pump without overheating.

Typically, a submersible cable will include:

• Conductors that conduct electricity
• Insulation of conductors
• Outer covering of the cable
• Flexible structure for ease of installation
• Construction for wet and tough conditions.

What Is the Difference Submersible Pump Cables Different From Regular Electrical Wires?

Cables laid within a borehole could end up staying immersed in water for long periods of time. The cables could also be subjected to pulling forces during installation and removal of the pump.

This makes it necessary that the cable offers:

• Water-proofing properties
• Electrical insulation
• Flexibility
• Mechanical strength
• Current carrying capacity
• Resistance to heat

Inappropriate use of cables can lead to insulation failures, electrical problems, voltage issues, and poor pump performance.

Where Are Submersible Cables Commonly Used?

Submersible cables are primarily employed where electrical pumps have to function underwater.

Applications where submersible cables are extensively utilized include:

• Pumps for borewells
• Irrigation pumps for agriculture
• Pumps for domestic water supply
• Borewells for domestic use
• Commercial establishments
• Industrial water pumping
• Water treatment plants
• Water extraction from underground
• Pumping stations
• Storage and distribution of water

The right cable specifications might differ significantly across these uses since the requirements of a small domestic pump and an industrial one might be completely different.

How Do Submersible Pump Cables Supply Power to a Pump?

Despite the fact that the motor is submerged under water, the submersible pump requires a secure electrical connection because the cable provides electrical power from the electrical source to the motor.

As for the installation process, the cable is properly fastened along the pump and delivery pipe during the installation process to prevent any damage to the cable when the pump is being lowered into the borehole.

It is essential to mention that the conductor size of the cable has to correspond to the requirements of the pump regarding the electric current.

This explains why customers should indicate the requirements of the pump including its power and voltage and the length of the cable and installation conditions.

How Do You Select the Correct Submersible Pump Cable?

Choosing a cable only by its physical size is not enough. Several technical factors should be checked before purchase.

Customers should use the manufacturer's recommended sizing guidelines and electrical design requirements rather than selecting a cable based only on price.

Why Is Cable Size Important for Submersible Pumps?

The size of the cable is directly related to the level of current flow that can be handled by the conductor.

An under-sized cable could result in overheating and high voltage drop. In cases where the pump installation is relatively deep and the cable run is lengthy, voltage drop could be a factor of great significance.

For instance, in case of pumps located in deep borewells, cables of greater lengths would be needed compared to the shallow ones. The electrical system design needs to take into consideration the total length of the cable, not just the section adjacent to the pump. The right conductor size can be calculated by a competent electrical engineer.

What Role Does Insulation Play in Submersible Cables?

The insulation protects the conductor from the environment and provides protection against undesirable electrical connection.

In case of usage in submerged systems, insulation becomes very crucial since the cable could be subjected to water permanently. The insulation material must be appropriate to the environment and voltage.

Proper insulation can ensure that safety in electricity will be maintained and breakdown of 

leakage will not occur.

Therefore, customers are advised to be concerned about the insulation specification rather than conductor specification of a cable.

How Does Flexibility Help During Pump Installation?

It is possible that the cable of the submersible pump will need to accompany the pump and the discharge pipes inside the borehole.

If the construction of the cable is too rigid, then it could become difficult for its installation and will be under greater stress.

The flexibility makes it possible to position the cable without putting any unnecessary stress on it.

This is especially necessary when:

• Lowering of the pump
• Removal of the pump
• Positioning of the cable
• Making connections
• Carrying out maintenance.

How Are House Wires Different From Submersible Cables?

Wiring of houses and submersible pumps are used for different applications. Housing wiring is meant for distribution of electricity within housing and such like structures. The Flexible House Wire is usually preferred where easy maneuvering of wire is needed for indoor electrical installations.

The submersible cables, however, are meant for use with apparatus that run under wet or submerged condition. It should not be assumed by either business people or individuals that housing wires can substitute submersible wires just because both are used for electrical purposes.

What Should You Know AboutHouse Wire Manufacturers?

In the acquisition of residential wires, buyers tend to compare the different House Wires of different manufacturers. This rule is the same in the case.

The following factors should be considered when selecting a house wire:

• Electrical load
• Voltage demand
• Mode of installation
• Size of conductor
• Type of insulation
• FLEXIBILITY
• Cable length required
• Standards applicable

But these are not necessarily suited for submersible pump application. Submersible pumps need wires suited to the environment.

What Problems Can Occur When the Wrong Submersible Cable Is Used?

The use of the wrong cable will affect the electricity safety as well as the operation of the pump.

These include:

• High voltage drop
• Cable overheating
• Deterioration of insulation
• Electricity leakage
• Problems with starting the pump
• Poor pump performance
• Short cable life
• Need for more maintenance

Not all problems will be noticed straight away. The cable may function well at first, but it will deteriorate if it is not made for use in water or the amount of electricity needed.

This is why it is vital to choose the right cable.

How Should Submersible Cables Be Installed?

Just as the quality of cable is important, so too is the installation quality. Even a good cable could be ruined if the installation process is done poorly.

When installing cables, the customer must make sure that:

• The right sized cable is used for the pump.
• There are no sharp objects that could damage the insulation.
• Too much force is not applied to pull the cable.
• The cable is not bent needlessly or crushed.
• The electrical connections are done by skilled individuals.

How Can Customers Choose the Right Cable Supplier?

A cable supplier must be able to offer details regarding the construction of the cable, its electrical rating, applications, and available sizes.

One must inquire about:

• Conductors used
• Sizes of conductors
• Rated voltage
• Type of insulation used
• Cable construction
• Suitability for applications
• Testing and quality control
• Lengths available
• Technical data
• After-sale support

In some cases involving agriculture, commercial, and industrial projects, the consistent supply of the correct cable becomes as critical as the initial selection of the product.

Why Consider Neon Cables Pvt Ltd for Cable Requirements?

Neon Cables Pvt Ltd meets the needs of clients seeking electrical cable solutions for various applications. In case the client is seeking cables for submersible pumps, the emphasis must be on the selection of a cable that matches the rating of the pump and its installation environment.

What Maintenance Is Required for Submersible Pump Cables?

Submersible cables usually have minimum requirements for routine maintenance when installed properly, but it is important that they are checked each time the pump goes under maintenance.

The items on the maintenance checklist include:

• Insulation of the cables
• Joints of the cables
• Connections
• Damage to the cables
• Moisture infiltration to the connections
• Securing arrangement
• Pump electrical performance

A cable with visible damage needs to be checked by an expert before the pump starts operating again.

Key Takeaways

Submersible cables are meant for electrical connections in wet or submerged conditions especially with borewell pumps and water pumping systems.

• Submersible cables supply electricity to pumps running underwater.
• Submersible pump cables need proper insulation for underwater use.
• Proper size of cables will depend on electrical load of the pump and length of the cable.
• For long cables, voltage drop should be considered.
• Flexibility comes in handy while installing and removing pumps.
• It should not be assumed that normal house wires are always good enough for such uses.
• Flexible House Wires are meant for electrical wiring uses and have different considerations from submersible pump cables.
• House Wires Manufacturers and Submersible cables manufacturers meet different application requirements.
• Proper installation is very important for performance of the cables.
• Neon Cables Pvt Ltd can assist you in evaluating your cable needs based on application.

Frequently Asked Questions

Can we use an ordinary electrical wire for a borewell pump?

An ordinary electrical wire cannot be used just because it will take the required amount of current. A borewell pump cable must be specially designed for being submerged in wet conditions.

Does the depth of borewell have any impact on the selection of cable?

Yes. Increased installation depth will mean increased length of cable to be installed. Thus complete installation of electrical circuitry must be taken into consideration.

How do I know about the cable size that my pump needs?

Cable size depends on many factors including power of the pump, operating voltage, operating current, cable length, installation conditions, and voltage drop that is permissible.

Can submersible cables be used in all types of water pumps?

Submersible cables are used in the application in which cables are required to operate in wet and submerged condition. But the specific cable can be selected depending on the pump, voltage, and installation environment.

Why does the submersible pump cable need to have a flexible structure?

There may be some situations where the cable must bend according to the arrangement of the pump installation. It makes easy positioning, lowering, and raising of the pump while decreasing the unnecessary strain on cable.