560kW Horizontal Submersible Long Shaft Pump for a Large Reservoir Water Intake and Supply Project in Southeast Asia
2025-06-10
.gtr-container-a7b8c9 {
font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif;
color: #333;
line-height: 1.6;
padding: 16px;
max-width: 100%;
box-sizing: border-box;
}
.gtr-container-a7b8c9 p {
font-size: 14px;
margin-bottom: 1em;
text-align: left !important;
word-break: normal;
overflow-wrap: normal;
}
.gtr-container-a7b8c9 strong {
font-weight: bold;
}
.gtr-container-a7b8c9__section-title {
font-size: 18px;
font-weight: bold;
color: #26509F;
margin-top: 2em;
margin-bottom: 1em;
padding-bottom: 0.5em;
border-bottom: 1px solid #eee;
text-align: left !important;
}
.gtr-container-a7b8c9__subsection-title {
font-size: 16px;
font-weight: bold;
color: #26509F;
margin-top: 1.5em;
margin-bottom: 0.8em;
text-align: left !important;
}
.gtr-container-a7b8c9__sub-subsection-title {
font-size: 14px;
font-weight: bold;
color: #333;
margin-top: 1.2em;
margin-bottom: 0.6em;
text-align: left !important;
}
.gtr-container-a7b8c9__list {
list-style: none !important;
padding-left: 20px !important;
margin-bottom: 1em;
}
.gtr-container-a7b8c9__list li {
position: relative !important;
padding-left: 15px !important;
margin-bottom: 0.5em !important;
font-size: 14px !important;
text-align: left !important;
}
.gtr-container-a7b8c9__list li::before {
content: "•" !important;
position: absolute !important;
left: 0 !important;
top: 0.1em !important;
color: #26509F !important;
font-size: 1.2em !important;
line-height: 1 !important;
}
@media (min-width: 768px) {
.gtr-container-a7b8c9 {
padding: 24px 40px;
max-width: 960px;
margin: 0 auto;
}
.gtr-container-a7b8c9__section-title {
margin-top: 2.5em;
margin-bottom: 1.2em;
}
.gtr-container-a7b8c9__subsection-title {
margin-top: 2em;
margin-bottom: 1em;
}
.gtr-container-a7b8c9__sub-subsection-title {
margin-top: 1.5em;
margin-bottom: 0.8em;
}
.gtr-container-a7b8c9 p {
margin-bottom: 1.2em;
}
.gtr-container-a7b8c9__list {
padding-left: 25px !important;
}
.gtr-container-a7b8c9__list li {
padding-left: 20px !important;
}
}
1. Project Overview
① Project Background
This project is located at a major water conservancy reservoir in a tropical Southeast Asian country, serving three critical functions: municipal drinking water supply, centralized irrigation for tens of thousands of hectares of farmland, and industrial make-up water supply for a nearby industrial park.
Affected by seasonal rainfall patterns, the reservoir experiences water level fluctuations of up to 18 meters annually. The water contains seasonal sediment and aquatic vegetation. Traditional vertical pump stations have been constrained by flood-season inundation risks, high civil construction costs, and difficult maintenance procedures. The owner's original design based on vertical long shaft pumps required a large installation footprint and lengthy civil works, making it impossible to meet the project's compressed delivery schedule.
The project required a reliable water intake system capable of delivering a large and continuous flow rate over long distances to a water treatment plant. The equipment needed to accommodate wide water level variations, withstand tropical hot and humid outdoor environments, operate continuously 24 hours a day, simplify maintenance, and significantly reduce civil engineering investment.
② Operating Parameters
Pumped Medium: Reservoir surface water containing small amounts of sediment
Water Temperature: 22–38°C
Rated Flow Rate: 370 m³/h
Total Head: 310 m (including static lift, pipeline friction losses, and safety margin)
Motor Power: 560kW High-Voltage Submersible Motor
Installation Type: Horizontal submersible long shaft arrangement mounted on a floating intake platform
Operation Mode: Continuous year-round operation with VFD speed regulation to adapt to seasonal water level changes
Ambient Conditions: Tropical climate with humidity above 85%, frequent rainfall, and intense sunlight exposure
2. Selection Challenges and Customized Solution
① Three Major Project Challenges
Extreme Water Level Fluctuations
Low water levels during dry seasons reduce submergence depth, while rising water levels during rainy seasons can flood conventional pump houses.
Long-Distance Water Conveyance and High Head Requirements
Conventional multistage submersible pumps lack stability under ultra-high head conditions, while traditional vertical long shaft pumps suffer from excessive shaft length and vibration issues.
Limited On-Site Construction Conditions
Large-scale underwater civil construction was not feasible, and local maintenance resources were limited, requiring an easy-to-service pumping solution.
② Customized Solution: 550QJ370-310-560kW Horizontal Submersible Long Shaft Pump
A customized horizontal long-shaft version of the QJ submersible pump series was selected to overcome these challenges.
Floating Platform Compatible Horizontal Configuration
The entire pump assembly operates fully submerged in a horizontal arrangement. The segmented modular shaft design allows the floating pontoon platform to rise and fall with changing reservoir levels, ensuring sufficient pump submergence at all times.
This design completely eliminates suction problems during dry seasons and prevents pump house flooding during rainy periods. Compared with traditional intake structures, civil construction costs were reduced by approximately 40%, while installation time was shortened by nearly 60%.
High-Pressure Multistage Hydraulic System
The large-diameter 550QJ hydraulic section incorporates precisely matched multistage impellers to achieve the rated flow rate of 370 m³/h under a total head of 310 meters.
The optimized hydraulic design maintains high efficiency under both low-water and high-water conditions through variable frequency operation, effectively avoiding overload and cavitation risks.
Wear-resistant ductile iron wetted components combined with silicon carbide double mechanical seals provide excellent resistance against sediment abrasion, making the system particularly suitable for reservoirs with high sediment content.
560kW Fully Sealed High-Voltage Submersible Motor
The motor features an IP68 protection rating and an internal circulating water cooling system capable of operating reliably in reservoir water temperatures up to 38°C.
High-temperature and moisture-resistant insulation materials protect the stator windings against tropical humidity and saline atmospheric conditions.
Integrated temperature, leakage, and vibration sensors enable real-time remote condition monitoring, making the system highly suitable for unattended overseas pumping stations.
Modular Long Shaft for Easy Maintenance
The segmented shaft incorporates flange-type quick coupling connections, eliminating the need for large underwater lifting equipment.
Only two technicians are required to replace impellers and sealing components. The modular design also simplifies containerized shipping and rapid on-site assembly, addressing common equipment limitations encountered at Southeast Asian construction sites.
3. Manufacturing, Delivery and Site Installation
Production and Export Delivery
To comply with the local 60Hz power supply standard, the motor windings and variable frequency control cabinet were specially customized.
Horizontal pump assembly
Segmented long shaft
High-voltage submersible cables
Integrated VFD control system
Floating platform mounting brackets
Water quality protection accessories
All equipment underwent hydraulic performance testing, pressure testing, and insulation testing before shipment.
The pumping system was packed in standardized export containers and delivered directly to the project port. Comprehensive English installation manuals and overseas technical support services were also provided.
Site Installation and Commissioning
Our overseas engineering team assisted with floating platform installation, underwater pump positioning, shaft alignment, waterproof cable laying, and VFD commissioning.
The pumping station was integrated with the reservoir PLC control system, enabling automatic water level-based speed adjustment. Pump speed increases automatically during low water conditions to maintain discharge head and decreases during high water periods to optimize energy consumption, achieving fully automated unattended operation.
4. Project Performance
After twelve months of continuous operation through both rainy and dry seasons, the pumping system has demonstrated excellent reliability.
The system consistently maintains the rated flow rate of 370 m³/h under a total head of 310 meters, ensuring uninterrupted municipal water supply, agricultural irrigation, and industrial water delivery.
Compared with the originally proposed vertical pump station, the horizontal submersible solution combined with variable frequency control reduced overall energy consumption by approximately 18%.
Maintenance requirements have been significantly lowered due to the absence of above-water shaft corrosion and the use of wear-resistant hydraulic components. Annual maintenance frequency has decreased by nearly 70%.
By eliminating the need for a large underwater pump station, the project was completed approximately three months ahead of schedule, substantially reducing labor and construction material costs.
5. Project Summary
The successful application of the 550QJ370-310-560kW Horizontal Submersible Long Shaft Pump demonstrates an innovative and reliable solution for overcoming major challenges associated with tropical reservoirs, including wide water level fluctuations, long-distance high-head water conveyance, and limited overseas maintenance capabilities.
This pumping system is highly suitable for floating platform water intake projects throughout Southeast Asia, large-scale river diversion schemes, lake water supply systems, mountainous high-head water transfer projects, and industrial raw water intake applications. It offers a mature and proven solution for high-head, large-capacity water intake systems where civil construction conditions are restricted, making it an excellent reference for future international water conservancy projects.
