GRUNDFOS SP ENGINEERING MANUAL
Contents 1 Introduction Water supply 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2
Resour Resources ces.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Groundwa water. ter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwat Groundwaterwel erwells. ls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riverbank Riverbankltratio ltration. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwat Groundwaterre errequire quirement. ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requiredr Requiredraw/we aw/wellwa llwateran terandwat dwatertr ertreatme eatmentcap ntcapacity acity... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ .... Wellyiel Wellyieldando dandopera perationa tionaleci leciency. ency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suracewat Suracewater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromres Fromreshwat hwaterso ersources. urces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromthes Fromtheseaand eaandsaltw saltwater atersources. sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 9 9 9 10 11 12 14 14 14
Applications 3.1 3.2 3.2.1 3.3 3.4 3.5 3.6 3.7 3.7
Freshwater Freshwatersuppl supply. y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dewatering Dewatering.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mining. Mining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Horizontalappli applicatio cation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air/gasi Air/gasinwat nwater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosive Corrosivewate water(sea r(seawater water). ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hotwater Hotwaterandgeother andgeothermalw malwater ater.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boostermo Boostermodules. dules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 19 19 20 20 22 23 24
Pumps 4.1 4.2 4.3 4.4
Pumpprinciple. principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wearparts. Wearparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpselection. selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpcurvesandt curvesandtoler olerances ances.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 28 28 29
Motors and controls 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.5 5.6
Motortypes Motortypes,gene ,general raldescription. description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorcabl Motorcablesand esandjoin joints,re ts,reere erenceto ncetodro dropcabl pcables. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorprot Motorprotectio ectiondevi ndevices. ces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reducingt Reducingtheloc helocked-r ked-rotor otorcurr current. ent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct-onDirect-on-line– line–DOL. DOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Star-delta Star-delta–SD. –SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autotrans Autotransorm ormer–A er–AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primaryre Primaryresistor sistor-type -typestart starter, er,RR. RR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sotstarter Sotstarter–SS. –SS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Frequencyconverters converters(va (variabl riablespeed espeeddriv drive). e). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operationw Operationwithr ithrequenc equencycon yconverte verter. r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUEvaribl CUEvariblespeed espeeddriv driveor eorSPpu SPpumps. mps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 35 36 36 37 38 39 39 39 40 41 43
Powergener Powergeneration ation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage. Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltageu Voltageunbala nbalance. nce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltag Overvoltageandu eandundervo ndervoltage. ltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Variablerequencyd requencydrives. rives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gridconnec Gridconnection. tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Currenta Currentasymme symmetry. try. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wellsand Wellsandwellcondit wellconditions. ions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsetting. setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpandmotorse andmotorselecti lection. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thedutypoi Thedutypoint. nt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 57 57 60 60 61 61 62 63 65 65 65 66 66 66 67 67 67 67
8 Communication 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.5 8.5.1 8.5.2 8.5.3 8.6
Generalin Generalintrodu troduction. ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communica Communications tionsandN andNetwor etworking kingTechnol Technology. ogy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAsyst SCADAsystems. ems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAmai SCADAmainpart nparts. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAun SCADAunctions ctions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web-hosted Web-hostedSCA SCADA. DA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Networkingbasics. basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Networkingtopology. topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communica Communications tionsprot protocol ocol.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Functionalpro prole. le. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theeldbus. Theeldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENIbus. GENIbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backgrou Background. nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technica Technicaldesc ldescripti ription. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablinggu Cablingguidelin idelines. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GrundosGENI GrundosGENIbuspr busproducts oductsor orSPAp SPApplica plications tions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 71 72 72 72 73 74 74 75 75 75 76 76 76 77 78
9 Troubleshooting 9
Troub Troubles leshoo hootin ting. g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
47 47 47 47 48 48 49 50
10.1 10.1 Coolings Coolingsleeves. leeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Corrosion Corrosionprot protectio ectionins ninseawat eawater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 1 Cathodicp Cathodicprote rotection. ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 2 Galvanicc Galvaniccatho athodicpr dicprotecti otectionsy onsystems. stems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3 3 Impressedc Impressedcurren urrentcat tcathodic hodicprot protectio ectionsyste nsystems. ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 10.3 Dropcables. cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Cablejoin Cablejoints. ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 10.5 Riserpipes. pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 56 56 56
11
83 83 83 83 84 84 85 85
11 Additional inormation
7 Installat ion & operation 7.1 7.1 7.2 7.2 7.3 7.3 7.3.1 7.3.1
Welldiam Welldiameter. eter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyiel Wellyield. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpeciency. eciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watertem Watertempera perature. ture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deratingo Deratingosubm submersibl ersiblemot emotor. or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection Protectionagai againstboiling nstboiling.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleevecoo Sleevecooling. ling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpipeselecti pipeselection. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cableselec Cableselectiona tionandsiz ndsizing. ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling. Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump/motorasse /motorassembly. mbly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablesplic Cablesplice/Co e/Connecti nnectiono onomoto motorcab rcableand leanddrop dropcabl cable. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpipeconnect pipeconnections ions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinpa Pumpsinparall rallelope eloperati ration. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinser Pumpsinseriesop iesoperat eration. ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.ostar No.ostart/sto t/stops. ps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpstartup. startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VFDopera VFDoperation. tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Generatoroper operatio ation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Accessories
6 Power supply 6.1 6.2 6.2.1 6.2.2 6.3 6.4 6.5 6.6
7.3.2 7.3.2 7.3.3 7.3.3 7.3.4 7.3.4 7.3.5 7.3.5 7.3.6 7.3.6 7.3.7 7.3.7 7.3.8 7.3.8 7.4 7.5 7.5 7.6 7.6 7.6.1 7.6.1 7.6.2 7.6.2 7.6.3 7.6.3 7.7 7 7.8 7.8 7.9 7.9 7.10 7.10 7.11 7.11 7.12 7.12
Additional Additionalinormatio inormation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Index 12
index. index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents 1 Introduction Water supply 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2
Resour Resources ces.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Groundwa water. ter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwat Groundwaterwel erwells. ls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riverbank Riverbankltratio ltration. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwat Groundwaterre errequire quirement. ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requiredr Requiredraw/we aw/wellwa llwateran terandwat dwatertr ertreatme eatmentcap ntcapacity acity... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ .... Wellyiel Wellyieldando dandopera perationa tionaleci leciency. ency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suracewat Suracewater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromres Fromreshwat hwaterso ersources. urces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromthes Fromtheseaand eaandsaltw saltwater atersources. sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 9 9 9 10 11 12 14 14 14
Applications 3.1 3.2 3.2.1 3.3 3.4 3.5 3.6 3.7 3.7
Freshwater Freshwatersuppl supply. y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dewatering Dewatering.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mining. Mining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Horizontalappli applicatio cation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air/gasi Air/gasinwat nwater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosive Corrosivewate water(sea r(seawater water). ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hotwater Hotwaterandgeother andgeothermalw malwater ater.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boostermo Boostermodules. dules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 19 19 20 20 22 23 24
Pumps 4.1 4.2 4.3 4.4
Pumpprinciple. principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wearparts. Wearparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpselection. selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpcurvesandt curvesandtoler olerances ances.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 28 28 29
Motors and controls 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.5 5.6
Motortypes Motortypes,gene ,general raldescription. description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorcabl Motorcablesand esandjoin joints,re ts,reere erenceto ncetodro dropcabl pcables. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorprot Motorprotectio ectiondevi ndevices. ces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reducingt Reducingtheloc helocked-r ked-rotor otorcurr current. ent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct-onDirect-on-line– line–DOL. DOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Star-delta Star-delta–SD. –SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autotrans Autotransorm ormer–A er–AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primaryre Primaryresistor sistor-type -typestart starter, er,RR. RR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sotstarter Sotstarter–SS. –SS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Frequencyconverters converters(va (variabl riablespeed espeeddriv drive). e). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operationw Operationwithr ithrequenc equencycon yconverte verter. r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUEvaribl CUEvariblespeed espeeddriv driveor eorSPpu SPpumps. mps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 35 36 36 37 38 39 39 39 40 41 43
Powergener Powergeneration ation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage. Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltageu Voltageunbala nbalance. nce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltag Overvoltageandu eandundervo ndervoltage. ltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Variablerequencyd requencydrives. rives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gridconnec Gridconnection. tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Currenta Currentasymme symmetry. try. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wellsand Wellsandwellcondit wellconditions. ions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsetting. setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpandmotorse andmotorselecti lection. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thedutypoi Thedutypoint. nt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 57 57 60 60 61 61 62 63 65 65 65 66 66 66 67 67 67 67
8 Communication 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.5 8.5.1 8.5.2 8.5.3 8.6
Generalin Generalintrodu troduction. ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communica Communications tionsandN andNetwor etworking kingTechnol Technology. ogy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAsyst SCADAsystems. ems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAmai SCADAmainpart nparts. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAun SCADAunctions ctions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web-hosted Web-hostedSCA SCADA. DA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Networkingbasics. basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Networkingtopology. topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communica Communications tionsprot protocol ocol.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Functionalpro prole. le. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theeldbus. Theeldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENIbus. GENIbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backgrou Background. nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technica Technicaldesc ldescripti ription. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablinggu Cablingguidelin idelines. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GrundosGENI GrundosGENIbuspr busproducts oductsor orSPAp SPApplica plications tions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 71 72 72 72 73 74 74 75 75 75 76 76 76 77 78
9 Troubleshooting 9
Troub Troubles leshoo hootin ting. g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
47 47 47 47 48 48 49 50
10.1 10.1 Coolings Coolingsleeves. leeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Corrosion Corrosionprot protectio ectionins ninseawat eawater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 1 Cathodicp Cathodicprote rotection. ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 2 Galvanicc Galvaniccatho athodicpr dicprotecti otectionsy onsystems. stems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3 3 Impressedc Impressedcurren urrentcat tcathodic hodicprot protectio ectionsyste nsystems. ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 10.3 Dropcables. cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Cablejoin Cablejoints. ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 10.5 Riserpipes. pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 56 56 56
11
83 83 83 83 84 84 85 85
11 Additional inormation
7 Installat ion & operation 7.1 7.1 7.2 7.2 7.3 7.3 7.3.1 7.3.1
Welldiam Welldiameter. eter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyiel Wellyield. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpeciency. eciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watertem Watertempera perature. ture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deratingo Deratingosubm submersibl ersiblemot emotor. or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection Protectionagai againstboiling nstboiling.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleevecoo Sleevecooling. ling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpipeselecti pipeselection. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cableselec Cableselectiona tionandsiz ndsizing. ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling. Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump/motorasse /motorassembly. mbly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablesplic Cablesplice/Co e/Connecti nnectiono onomoto motorcab rcableand leanddrop dropcabl cable. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpipeconnect pipeconnections ions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinpa Pumpsinparall rallelope eloperati ration. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinser Pumpsinseriesop iesoperat eration. ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.ostar No.ostart/sto t/stops. ps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpstartup. startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VFDopera VFDoperation. tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Generatoroper operatio ation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Accessories
6 Power supply 6.1 6.2 6.2.1 6.2.2 6.3 6.4 6.5 6.6
7.3.2 7.3.2 7.3.3 7.3.3 7.3.4 7.3.4 7.3.5 7.3.5 7.3.6 7.3.6 7.3.7 7.3.7 7.3.8 7.3.8 7.4 7.5 7.5 7.6 7.6 7.6.1 7.6.1 7.6.2 7.6.2 7.6.3 7.6.3 7.7 7 7.8 7.8 7.9 7.9 7.10 7.10 7.11 7.11 7.12 7.12
Additional Additionalinormatio inormation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Index 12
index. index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents 1 Introduction Water supply 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2
Resour Resources ces.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Groundwa water. ter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwat Groundwaterwel erwells. ls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riverbank Riverbankltratio ltration. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwat Groundwaterre errequire quirement. ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requiredr Requiredraw/we aw/wellwa llwateran terandwat dwatertr ertreatme eatmentcap ntcapacity acity... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ .... Wellyiel Wellyieldando dandopera perationa tionaleci leciency. ency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suracewat Suracewater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromres Fromreshwat hwaterso ersources. urces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromthes Fromtheseaand eaandsaltw saltwater atersources. sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 9 9 9 10 11 12 14 14 14
Applications 3.1 3.2 3.2.1 3.3 3.4 3.5 3.6 3.7 3.7
Freshwater Freshwatersuppl supply. y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dewatering Dewatering.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mining. Mining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Horizontalappli applicatio cation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air/gasi Air/gasinwat nwater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosive Corrosivewate water(sea r(seawater water). ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hotwater Hotwaterandgeother andgeothermalw malwater ater.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boostermo Boostermodules. dules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 19 19 20 20 22 23 24
Pumps 4.1 4.2 4.3 4.4
Pumpprinciple. principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wearparts. Wearparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpselection. selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpcurvesandt curvesandtoler olerances ances.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 28 28 29
Motors and controls 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.5 5.6
Motortypes Motortypes,gene ,general raldescription. description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorcabl Motorcablesand esandjoin joints,re ts,reere erenceto ncetodro dropcabl pcables. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorprot Motorprotectio ectiondevi ndevices. ces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reducingt Reducingtheloc helocked-r ked-rotor otorcurr current. ent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct-onDirect-on-line– line–DOL. DOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Star-delta Star-delta–SD. –SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autotrans Autotransorm ormer–A er–AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primaryre Primaryresistor sistor-type -typestart starter, er,RR. RR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sotstarter Sotstarter–SS. –SS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Frequencyconverters converters(va (variabl riablespeed espeeddriv drive). e). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operationw Operationwithr ithrequenc equencycon yconverte verter. r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUEvaribl CUEvariblespeed espeeddriv driveor eorSPpu SPpumps. mps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 35 36 36 37 38 39 39 39 40 41 43
Powergener Powergeneration ation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage. Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltageu Voltageunbala nbalance. nce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltag Overvoltageandu eandundervo ndervoltage. ltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Variablerequencyd requencydrives. rives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gridconnec Gridconnection. tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Currenta Currentasymme symmetry. try. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellsand Wellsandwellcondit wellconditions. ions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsetting. setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpandmotorse andmotorselecti lection. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thedutypoi Thedutypoint. nt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 57 57 60 60 61 61 62 63 65 65 65 66 66 66 67 67 67 67
8 Communication 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.5 8.5.1 8.5.2 8.5.3 8.6
Generalin Generalintrodu troduction. ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communica Communications tionsandN andNetwor etworking kingTechnol Technology. ogy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAsyst SCADAsystems. ems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAmai SCADAmainpart nparts. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAun SCADAunctions ctions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web-hosted Web-hostedSCA SCADA. DA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Networkingbasics. basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Networkingtopology. topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communica Communications tionsprot protocol ocol.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Functionalpro prole. le. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theeldbus. Theeldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENIbus. GENIbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backgrou Background. nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technica Technicaldesc ldescripti ription. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablinggu Cablingguidelin idelines. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GrundosGENI GrundosGENIbuspr busproducts oductsor orSPAp SPApplica plications tions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 71 72 72 72 73 74 74 75 75 75 76 76 76 77 78
9 Troubleshooting 9
Troub Troubles leshoo hootin ting. g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
47 47 47 47 48 48 49 50
10.1 10.1 Coolings Coolingsleeves. leeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Corrosion Corrosionprot protectio ectionins ninseawat eawater. er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 1 Cathodicp Cathodicprote rotection. ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 2 Galvanicc Galvaniccatho athodicpr dicprotecti otectionsy onsystems. stems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3 3 Impressedc Impressedcurren urrentcat tcathodic hodicprot protectio ectionsyste nsystems. ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 10.3 Dropcables. cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Cablejoin Cablejoints. ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 10.5 Riserpipes. pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 56 56 56
11
83 83 83 83 84 84 85 85
11 Additional inormation
7 Installat ion & operation 7.1 7.1 7.2 7.2 7.3 7.3 7.3.1 7.3.1
Welldiam Welldiameter. eter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyiel Wellyield. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpeciency. eciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watertem Watertempera perature. ture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deratingo Deratingosubm submersibl ersiblemot emotor. or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection Protectionagai againstboiling nstboiling.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleevecoo Sleevecooling. ling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpipeselecti pipeselection. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cableselec Cableselectiona tionandsiz ndsizing. ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling. Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump/motorasse /motorassembly. mbly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablesplic Cablesplice/Co e/Connecti nnectiono onomoto motorcab rcableand leanddrop dropcabl cable. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpipeconnect pipeconnections ions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinpa Pumpsinparall rallelope eloperati ration. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinser Pumpsinseriesop iesoperat eration. ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.ostar No.ostart/sto t/stops. ps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpstartup. startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VFDopera VFDoperation. tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Generatoroper operatio ation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Accessories
6 Power supply 6.1 6.2 6.2.1 6.2.2 6.3 6.4 6.5 6.6
7.3.2 7.3.2 7.3.3 7.3.3 7.3.4 7.3.4 7.3.5 7.3.5 7.3.6 7.3.6 7.3.7 7.3.7 7.3.8 7.3.8 7.4 7.5 7.5 7.6 7.6 7.6.1 7.6.1 7.6.2 7.6.2 7.6.3 7.6.3 7.7 7 7.8 7.8 7.9 7.9 7.10 7.10 7.11 7.11 7.12 7.12
Additional Additionalinormatio inormation. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Index 12
index. index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Introduction
Serving our common interests ThisengineeringmanualhasbeencreatedwithaspecicocusononeoGrundos’mostrecognisableand popularpumps:theSP.Whenitwascreatedinthelate1960’s,thisbreakthroughproductsetnewstandards withindurability,eciency,andconstructioninthin-platestainlesssteel.Thenumerousproducttypes,sizes, andcongurationpossibilitiesavailabletodayserveasatestamenttotheinnovativenatureotheoriginal SPpumps. WorkingwithSPpumpsonadailybasisotengivesrisetolotsodierentquestions.Wehavecreatedthisengineeringmanualtohelpyouquicklyandeasilyndtheanswerstoanumberothesequestions.Weserveour commoninterestsoprovidingthebestpossibleSPsolutionsandserviceorallcustomers. Pleasenotethatthisengineeringmanualisasupplementtoandnotareplacementorproductdatabooklets andinstallatio andinstallationmanual nmanuals.Thenewestedit s.Thenewesteditionsothesepubl ionsothesepublicati icationsarealwa onsarealwaysthemostvali ysthemostvalidandmustbe dandmustbe adheredto. Wehavetakenconsiderabletimeandcaretomakethepresentationasconvenientandeasytouseaspossible. Werealise,however, Werealise,however,thatthereisalwaysroom thatthereisalwaysroomorimprovement,andinvitey orimprovement,andinviteyoutocomm outocomment.Pleasecontact ent.Pleasecontactyour your localGrundosrepresentativeitherearesubjectsyouwouldliketoseecoveredinutureeditions. WesincerelyhopethatyoundthismanualauseulreerencetoolinyourworkwithSPpumps.
KenthH.Nielsen GlobalprogramDirector, GrundosManagementA/S
1. Introduction 6
7
Introduction
Serving our common interests ThisengineeringmanualhasbeencreatedwithaspecicocusononeoGrundos’mostrecognisableand popularpumps:theSP.Whenitwascreatedinthelate1960’s,thisbreakthroughproductsetnewstandards withindurability,eciency,andconstructioninthin-platestainlesssteel.Thenumerousproducttypes,sizes, andcongurationpossibilitiesavailabletodayserveasatestamenttotheinnovativenatureotheoriginal SPpumps. WorkingwithSPpumpsonadailybasisotengivesrisetolotsodierentquestions.Wehavecreatedthisengineeringmanualtohelpyouquicklyandeasilyndtheanswerstoanumberothesequestions.Weserveour commoninterestsoprovidingthebestpossibleSPsolutionsandserviceorallcustomers. Pleasenotethatthisengineeringmanualisasupplementtoandnotareplacementorproductdatabooklets andinstallatio andinstallationmanual nmanuals.Thenewestedit s.Thenewesteditionsothesepubl ionsothesepublicati icationsarealwa onsarealwaysthemostvali ysthemostvalidandmustbe dandmustbe adheredto. Wehavetakenconsiderabletimeandcaretomakethepresentationasconvenientandeasytouseaspossible. Werealise,however, Werealise,however,thatthereisalwaysroom thatthereisalwaysroomorimprovement,andinvitey orimprovement,andinviteyoutocomm outocomment.Pleasecontact ent.Pleasecontactyour your localGrundosrepresentativeitherearesubjectsyouwouldliketoseecoveredinutureeditions. WesincerelyhopethatyoundthismanualauseulreerencetoolinyourworkwithSPpumps.
KenthH.Nielsen GlobalprogramDirector, GrundosManagementA/S
1. Introduction 6
7
Water supply
.1
Resources
Theamountowaterintheworldisconstant.Itis changingposition,quality,phase,etc.,butitisconstant.Seawateraccountsorapprox.97.5%oallwater.Freshwateraccountsortheremaining2.5%.Two- thirdsothereshwaterisboundasglaciers,polar ice,andsnowcover.Theremaining,lessthan1%oall waterintheworld,issomehowavailableindierent sourcesormankindtouse. Thesesourcesare: • groundwater,shallowordeepundergroundaquiersowater • suracewater,romriversorlakes. Incasenoreshwaterisavailable,seawaterorcontaminatedwateristreatedandusedasreshwater.
.
Groundwater
Groundwater is typically between 25 and 10,000 yearsold.Beoreitreachestheaquier,ithasbeenlteredandexposedtobiologicaltreatmentonitsway throughthevariouslayersotheground.Groundwateristhereoreusuallyohighqualityandrequires littleornotreatmentbeoreitisconsumed.
I groundwater levels arepermanently lowered, a watersupplydisasterwithanincreasingsalinityand otherundesiredsubstancescanbeexpected.
Well head
Pump
Pump inlet Redoxlayer Gravelpacking
Casing sealed atlayers ofclay
Submersible motor
Well screen
..1 Groundwater wells
. Water Supply 8
Irrigation andwatersupplysystemsservingup to 500,000consumersandtheadjacentindustriesare ideallysuppliedbygroundwater.Pollution-reeaquierslargerthan600km2arenormal.75to150well-intakesspreadonthedierentaquierswillprovidethe most environmentally-riendly, saest and reliable watersources.Forwaterworksservingmorethan1 millionconsumers,anadditionalsourcesuchasriverbankltration,riverdams,ordesalinationshould beconsidered.
Fig. 1 Groundwater well with submersible pump
Theindividualwellsare tobe extendedintoolder groundwateratpollution-reedepthswhenextractingordrinkingwater.Irrigationwellscaneasilyuse waterromtheupperaquier,thesecondaryaquier, withslightlypollutedwaterquality.Thegroundwaterlevelwillvaryovertheseasons,butistoberespectedontheyearlybasis,asthemaximumremovablequantityissimilartowhatiscreatedeveryyear.
Atereverywetperiodwithhighriverwaterlevels, themud/dung/sedimentsotheriverbedarewashed downstreamandpartlyreplacedbynewsediments. Thisnaturalprocessprovidesperectconditionsora 90%reductionohuman-inducedenzymes,viruses, bacteria,pathogens,andsoon.Eachwetperiodwith highriverwaterlevelsalsollstheaquiersaround theriverwithwater,whereitisstoredandreadyor
.. Riverbank ltration Inriverbankltrationwells,thewellisplacednearby ariver.Usingthismethod,theriverwaterisltered throughtheground.Thisprocessis anaturaladditiontoadirectintakeplantneedingcapacityenlargement.Theeasy-to-clean,pre-lteredwaterrequires lessnaltreatmentandextractswaterromtheaquierwhentheriverlevelrunslow.
9
Water supply
.1
Resources
Theamountowaterintheworldisconstant.Itis changingposition,quality,phase,etc.,butitisconstant.Seawateraccountsorapprox.97.5%oallwater.Freshwateraccountsortheremaining2.5%.Two- thirdsothereshwaterisboundasglaciers,polar ice,andsnowcover.Theremaining,lessthan1%oall waterintheworld,issomehowavailableindierent sourcesormankindtouse. Thesesourcesare: • groundwater,shallowordeepundergroundaquiersowater • suracewater,romriversorlakes. Incasenoreshwaterisavailable,seawaterorcontaminatedwateristreatedandusedasreshwater.
.
Groundwater
I groundwater levels arepermanently lowered, a watersupplydisasterwithanincreasingsalinityand otherundesiredsubstancescanbeexpected.
Well head
Pump
Pump inlet Redoxlayer
Groundwater is typically between 25 and 10,000 yearsold.Beoreitreachestheaquier,ithasbeenlteredandexposedtobiologicaltreatmentonitsway throughthevariouslayersotheground.Groundwateristhereoreusuallyohighqualityandrequires littleornotreatmentbeoreitisconsumed.
Gravelpacking
Casing sealed atlayers ofclay
Submersible motor
Well screen
..1 Groundwater wells
. Water Supply
Irrigation andwatersupplysystemsservingup to 500,000consumersandtheadjacentindustriesare ideallysuppliedbygroundwater.Pollution-reeaquierslargerthan600km2arenormal.75to150well-intakesspreadonthedierentaquierswillprovidethe most environmentally-riendly, saest and reliable watersources.Forwaterworksservingmorethan1 millionconsumers,anadditionalsourcesuchasriverbankltration,riverdams,ordesalinationshould beconsidered.
Fig. 1 Groundwater well with submersible pump
Theindividualwellsare tobe extendedintoolder groundwateratpollution-reedepthswhenextractingordrinkingwater.Irrigationwellscaneasilyuse waterromtheupperaquier,thesecondaryaquier, withslightlypollutedwaterquality.Thegroundwaterlevelwillvaryovertheseasons,butistoberespectedontheyearlybasis,asthemaximumremovablequantityissimilartowhatiscreatedeveryyear.
Atereverywetperiodwithhighriverwaterlevels, themud/dung/sedimentsotheriverbedarewashed downstreamandpartlyreplacedbynewsediments. Thisnaturalprocessprovidesperectconditionsora 90%reductionohuman-inducedenzymes,viruses, bacteria,pathogens,andsoon.Eachwetperiodwith highriverwaterlevelsalsollstheaquiersaround theriverwithwater,whereitisstoredandreadyor
.. Riverbank ltration Inriverbankltrationwells,thewellisplacednearby ariver.Usingthismethod,theriverwaterisltered throughtheground.Thisprocessis anaturaladditiontoadirectintakeplantneedingcapacityenlargement.Theeasy-to-clean,pre-lteredwaterrequires lessnaltreatmentandextractswaterromtheaquierwhentheriverlevelrunslow.
8
9
Water supply
eedingtheriverbankwellswhentheriverwaterlevelrunslowindryseason.Thestorageoriverwaterin aquierscauseslesswaterstressontheriverduring dryseasons. Riverbankwellscanbeconstructedlikegroundwater wells,orrom7-8mverticalcasingsdugdownunder theriverbed.Theycan besupplementedwith8-12 horizontalinjectedsteelscreensorltersorsediment-reewaterintake.
Water supply
Tondthepeakhourlyconsumption,pleasereerto theMPC-BoostersectionoGrundosWinCAPS/WebCAPSorgures4and5. Pump-outrequirement Waterisusedbymanydierenttypesoconsumers, eachwithaspecicconsumptionpattern.Thereare manymethodso calculatingthemaximumwater requirement,bothmanualandcomputerisedones.
.. Required raw/well water and water treatment capacity
Consumption m3 /h
Therelationshipbetweenwaterstorageand daily consumptionillustratesthepercentageothedaily consumption thatis present instorage.Withthis percentage,ollowithorizontallying.6tondthe necessary percentage or raw-water requirement. Thedailyconsumptionmultipliedbythepercentage oraw-waterrequirementprovidesthenecessarycapacityromthewellelds.
100
80
Hotels 60
Hospitals 40
Thetablebelowcanbeusedorroughcalculationo thewaterrequirementor: • ocebuildings • residentialbuildingsincl.blocksoats • departmentstores • hospitals • hotels. Fig. 2 Riverside well installations
20
0 0
200
400
600
800
1000
Number of beds
Fig. 4 Peak water consumption
Ithetreatmentplanthasaclean-watertankorawatertowercapacityo2,760m3,peakloadsituations canbecoveredromthereservoir.Thismeansthat theraw-waterpumpscanrunconstantlyaroundthe clockat2,760/24m3/h=115m3/h.
Consumption m3 /h
Averange m /h
Category
Units
Dwellings
2,000 units
70
O c e bu il di ng s
2 ,0 00 e mp lo ye es
30
Departmentstores
2,000employees
55
60
50
Department stores
40
1,000 beds
Hospitals
1,000 beds
Maximumpeak load(warmseason)
Theeectivevolumeotheclean-watertankand/or watertowerandthemaximumcapacityothetreatmentplantarecrucialorinvestmentcostsinconnectionwithgroundwaterwells.
Dwellings
30
Hotels
110 80 345
20
Oce buildings 10
0 0
Fig. 3 Riverbank ltration Bacteria, pathogens, etc. are trapped by the sediments.
.. Groundwater requirement Thebasisordeterminingthegroundwaterrequirementromthewelleldsistoevaluatetherelationshipbetweenthewaterstoragevolumeandthenishedwaterproductioncapacitycomparedto peak anddailyconsumption.
10
Factorsorcalculatingdailyconsumption: •Minimum100consumersconnected:Factor8 •Minimum30consumersconnected:Factor4 •Minimum10consumersconnected:Factor2.5 Themaximumdaily consumption in theexample abovewillbeactor8x345m3/h=2,760m3/day.
Iatreatmentplanthasnocleanwatertankorwater tower,the raw-waterand treatmentcapacity must beequaltothemaximumhourlyconsumption,i.e. Qraw-water=345m3/hintheexample.
400
800
Fig. 5 Peak water consumption
1200
1600
2 000
Number of employees
Peakhourlyconsumptionisstated,thiscanbeconvertedintoassumeddailyconsumptionbyusingthe actors8/4/2.5.
Intheexample,thereisaclean-watertanko1,600 m3.Thismeansthat thewaterreservoircomprises 1,600/2,760x100=58%othedailyconsumption. Atamaximumpeakconsumptiono345m3/hand amaximumconsumptiono2,760m3/dayandwith aneectiveclean-watertankvolumeo1,600m3,the raw-watercapacitymustbeatleast2,760x7.6/100= 210m3/h.7.6istakenromg.2.Thiswillgiveamaximumdutytimeotheraw-waterpumpso2,760/210 =13hours/day. The210m3/haresplitupbetweenatleastthreeto ourwells.Incaseoewerwells,astandbyinstallationmustbemade.
11
Water supply
Water supply
eedingtheriverbankwellswhentheriverwaterlevelrunslowindryseason.Thestorageoriverwaterin aquierscauseslesswaterstressontheriverduring dryseasons.
Tondthepeakhourlyconsumption,pleasereerto theMPC-BoostersectionoGrundosWinCAPS/WebCAPSorgures4and5. Pump-outrequirement Waterisusedbymanydierenttypesoconsumers, eachwithaspecicconsumptionpattern.Thereare manymethodso calculatingthemaximumwater requirement,bothmanualandcomputerisedones.
Riverbankwellscanbeconstructedlikegroundwater wells,orrom7-8mverticalcasingsdugdownunder theriverbed.Theycan besupplementedwith8-12 horizontalinjectedsteelscreensorltersorsediment-reewaterintake.
.. Required raw/well water and water treatment capacity
Consumption m3 /h
Therelationshipbetweenwaterstorageand daily consumptionillustratesthepercentageothedaily consumption thatis present instorage.Withthis percentage,ollowithorizontallying.6tondthe necessary percentage or raw-water requirement. Thedailyconsumptionmultipliedbythepercentage oraw-waterrequirementprovidesthenecessarycapacityromthewellelds.
100
80
Hotels 60
Hospitals 40
Thetablebelowcanbeusedorroughcalculationo thewaterrequirementor: • ocebuildings • residentialbuildingsincl.blocksoats • departmentstores • hospitals • hotels. Fig. 2 Riverside well installations
20
Iatreatmentplanthasnocleanwatertankorwater tower,the raw-waterand treatmentcapacity must beequaltothemaximumhourlyconsumption,i.e. Qraw-water=345m3/hintheexample.
0 0
200
400
600
800
1000
Number of beds
Fig. 4 Peak water consumption
Ithetreatmentplanthasaclean-watertankorawatertowercapacityo2,760m3,peakloadsituations canbecoveredromthereservoir.Thismeansthat theraw-waterpumpscanrunconstantlyaroundthe clockat2,760/24m3/h=115m3/h.
Consumption m3 /h
Averange m /h
Category
Units
Dwellings
2,000 units
70
O c e bu il di ng s
2 ,0 00 e mp lo ye es
30
Departmentstores
2,000employees
55
60
50
Department stores
40
Hotels
1,000 beds
Hospitals
1,000 beds
Theeectivevolumeotheclean-watertankand/or watertowerandthemaximumcapacityothetreatmentplantarecrucialorinvestmentcostsinconnectionwithgroundwaterwells.
Dwellings
30
110 20
80
Maximumpeak load(warmseason)
Oce buildings
345
Intheexample,thereisaclean-watertanko1,600 m3.Thismeansthat thewaterreservoircomprises 1,600/2,760x100=58%othedailyconsumption.
10
0 0
Factorsorcalculatingdailyconsumption: •Minimum100consumersconnected:Factor8 •Minimum30consumersconnected:Factor4 •Minimum10consumersconnected:Factor2.5 Themaximumdaily consumption in theexample abovewillbeactor8x345m3/h=2,760m3/day.
Fig. 3 Riverbank ltration Bacteria, pathogens, etc. are trapped by the sediments.
400
800
1200
1600
2 000
Number of employees
Fig. 5 Peak water consumption
Peakhourlyconsumptionisstated,thiscanbeconvertedintoassumeddailyconsumptionbyusingthe actors8/4/2.5.
.. Groundwater requirement Thebasisordeterminingthegroundwaterrequirementromthewelleldsistoevaluatetherelationshipbetweenthewaterstoragevolumeandthenishedwaterproductioncapacitycomparedto peak anddailyconsumption.
Atamaximumpeakconsumptiono345m3/hand amaximumconsumptiono2,760m3/dayandwith aneectiveclean-watertankvolumeo1,600m3,the raw-watercapacitymustbeatleast2,760x7.6/100= 210m3/h.7.6istakenromg.2.Thiswillgiveamaximumdutytimeotheraw-waterpumpso2,760/210 =13hours/day. The210m3/haresplitupbetweenatleastthreeto ourwells.Incaseoewerwells,astandbyinstallationmustbemade.
10
11
Water supply
Water supply
Anincreaserom10to20m3/hwillconsequentlyresultinaloweringothewaterleveloapprox.1m. Anincreaserom10to30m3/hwillgivealoweringo thewaterleveloapprox.2m.
Clean-water tank size as a percentage of daily consumption % 100 90
Clean-water tank size as a percentage of daily consumption:
80
Tank volume (m3) x 100 = % tank capacity Daily consumption (m3/24h)
70
Raw-waterrequirement:
60
Daily consumption (m3/24h) x = % raw-water requirement 100
58%
Atmoderateows,thedrawdowncurvewillbeclose tolinearasthe increaseddrawdownisdueto ow resistanceinscreensetting.
M M i M i n im u n i m i n i m 1 u m m 00 c 1 0 u m on s u m 0 c e rs o n 1 0 c on n s u 0 m e e ct e d c o r s c n s o n n e u m c t e 7,6% d e r s c o n n e c t e d
50 40 30 20 10
Parabolic drawdown at large fows Atincreasinglylargeows,aprogressivelyincreasing rictionalresistanceinscreensettingandaquierwill giveaparabolicdrawdowncurveotheseconddegree.Thismeansaprogressivelyallingwaterlevelin thewellwithincreasedpumping.
Anincreaserom80 to90 m3/hwillgiveanaddi3 tionaldrawdownoapprox.5m;rom80to100m /h approx.11m,i.e.muchmorethanatmoderateows. Themosteconomicwellloadoccursataowwhere thedrawdowncurvegoesromlineartoprogressive. Ithewellyieldisnotsucienttomeetthewater requirement,evenby prolongedoperation,theollowingshouldbedone: • Haveaspecialistlookattheproblem. • Haveasupplementarywelldrilled. Pleasenotethatrulesandregulationsmayvaryrom countrytocountry.
0 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
%
Raw-water requirement
Fig. 6 Raw-water and treatment capacity (m 3 /h) as a percentage a the daily consumption (m 3 /day)
.. Well yield and operational eciency 3
Eachwellhas speciccapacity, consisting om /h oreachmetreo drawdowno thepumpingwaterlevel.Withyourraw-waterrequirement,youare abletoloadeachwelltoobtainthelowestaverage drawdown.Thesmallerthedrawdown,thesmaller thetotalhead.Thesmallerthevoltagedropinpower cables,thebettertheoperationaleciency. • Overpumpingwillresultindeepdrawdown.This givesroomoroxidation,resultingintheormation oochrewhichmayclogwell screenand pump. Thismeansincreasedservicecostsorwellregenerationandpossiblyreducedwelllie. • Overpumpingmeansloweringothewaterlevelo theaquierwhichcanresultinchemicalchanges andprecipitationoheavymetals.Inltrationonitrateandpesticidesinthewatermayoccur,resultinginincreasedexpensesorwatertreatment.
1
Themostcommoncauseooverpumpingoawellor aquierisincreasedwaterconsumption.Thisiscoveredbyincreasedpumpcapacityorlongerdutytime othe groundwaterpumpswithoutincreasing the catchmentareaorthenumberowells. Aquier load When pumping at constant capacity or several hours,thedynamicwaterlevelinthewellshouldremainairlyconstant.Ithelevelisloweredconsiderably,thismeansthattheamountopumpedwater exceedstheinux.Itheleveldropsromyeartoyear, thequantityopumpedwatershouldbereducedand waterromotheraquiersshouldbeutilised. Well load Duringtestpumping,theamountopumpedwater isincreasedatxedintervalswhichwillresultina loweringo thedynamicwaterlevel.I thedrawdownisplottedagainstincreasedpumping,arough parabolawillresult.
Static water level
55 50
Gradient: 10 cm/m 3 /h Increasing gradient
40 30 20 10
Acceptable well load
0
10
20
30
40
Overpumping
50
60
70
80
90
100
m/h
Fig. 7 Dynamic water-level variations by test pumping
Linear drawdown at moderate fows Atmoderateows,thismeansthattypicallyanincreasedamountowatero1m3/hwillresultinanalmostlinearincreaseinthedrawdowno10cm/m 3.
1
Water supply
Water supply
Anincreaserom10to20m3/hwillconsequentlyresultinaloweringothewaterleveloapprox.1m. Anincreaserom10to30m3/hwillgivealoweringo thewaterleveloapprox.2m.
Clean-water tank size as a percentage of daily consumption % 100 90
Clean-water tank size as a percentage of daily consumption:
80
Tank volume (m3) x 100 = % tank capacity Daily consumption (m3/24h)
70
Raw-waterrequirement:
60
Daily consumption (m3/24h) x = % raw-water requirement 100
58%
Atmoderateows,thedrawdowncurvewillbeclose tolinearasthe increaseddrawdownisdueto ow resistanceinscreensetting.
M M i M i n im u n i m i n i m 1 u m m 00 c 1 0 u m on s u m 0 c e rs o n 1 0 c on n s u 0 m e e ct e d c o r s c o n s n n u m e c t 7,6% e d e r s c o n n e c t e d
50 40 30 20 10
Parabolic drawdown at large fows Atincreasinglylargeows,aprogressivelyincreasing rictionalresistanceinscreensettingandaquierwill giveaparabolicdrawdowncurveotheseconddegree.Thismeansaprogressivelyallingwaterlevelin thewellwithincreasedpumping.
Anincreaserom80 to90 m3/hwillgiveanaddi3 tionaldrawdownoapprox.5m;rom80to100m /h approx.11m,i.e.muchmorethanatmoderateows. Themosteconomicwellloadoccursataowwhere thedrawdowncurvegoesromlineartoprogressive. Ithewellyieldisnotsucienttomeetthewater requirement,evenby prolongedoperation,theollowingshouldbedone: • Haveaspecialistlookattheproblem. • Haveasupplementarywelldrilled. Pleasenotethatrulesandregulationsmayvaryrom countrytocountry.
0 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
%
Raw-water requirement
Fig. 6 Raw-water and treatment capacity (m 3 /h) as a percentage a the daily consumption (m 3 /day)
.. Well yield and operational eciency Eachwellhas speciccapacity, consisting om3/h oreachmetreo drawdowno thepumpingwaterlevel.Withyourraw-waterrequirement,youare abletoloadeachwelltoobtainthelowestaverage drawdown.Thesmallerthedrawdown,thesmaller thetotalhead.Thesmallerthevoltagedropinpower cables,thebettertheoperationaleciency. • Overpumpingwillresultindeepdrawdown.This givesroomoroxidation,resultingintheormation oochrewhichmayclogwell screenand pump. Thismeansincreasedservicecostsorwellregenerationandpossiblyreducedwelllie. • Overpumpingmeansloweringothewaterlevelo theaquierwhichcanresultinchemicalchanges andprecipitationoheavymetals.Inltrationonitrateandpesticidesinthewatermayoccur,resultinginincreasedexpensesorwatertreatment.
Themostcommoncauseooverpumpingoawellor aquierisincreasedwaterconsumption.Thisiscoveredbyincreasedpumpcapacityorlongerdutytime othe groundwaterpumpswithoutincreasing the catchmentareaorthenumberowells. Aquier load When pumping at constant capacity or several hours,thedynamicwaterlevelinthewellshouldremainairlyconstant.Ithelevelisloweredconsiderably,thismeansthattheamountopumpedwater exceedstheinux.Itheleveldropsromyeartoyear, thequantityopumpedwatershouldbereducedand waterromotheraquiersshouldbeutilised. Well load Duringtestpumping,theamountopumpedwater isincreasedatxedintervalswhichwillresultina loweringo thedynamicwaterlevel.I thedrawdownisplottedagainstincreasedpumping,arough parabolawillresult.
Static water level
55 50
Gradient: 10 cm/m 3 /h Increasing gradient
40 30 20 10
Acceptable well load
0
10
20
30
40
Overpumping
50
60
70
80
90
100
m/h
Fig. 7 Dynamic water-level variations by test pumping
Linear drawdown at moderate fows Atmoderateows,thismeansthattypicallyanincreasedamountowatero1m3/hwillresultinanalmostlinearincreaseinthedrawdowno10cm/m 3.
1
1
Water supply
.
Surace water
..1 From reshwater sources Suracewaterisusuallytakenromlakesorrivers. Unlikegroundwater,itisnotprotectedromnature orhumanactivities,andtreatmentis thereorealwaysnecessary.Suracewaterlevelandqualitywill varyovertheseasons.Forexample,aterheavyrainall,orsnowmelt,lotsosolidsandsandarewashed downstream. Thesesharpandabrassivemineralsaswellasbiodegradablematerialsaretobesettledorscreenedo beorepumpintaketoavoidnegativeeectsonthe nalwater treatment process.Submersiblepumps areidealortheseapplicationswithperiodicuncontrollably high waterlevels.Notethatpowercables andelectricequipmentmustbeelevatedtopermanentlydrylocations.
Water supply
Usingdirectwaterintakeandstandardconventional watertreatmentwillonlyresultinamicroscopicdiverse biodynamic-balancedaunaentering theaccompanyingpipework andtanksystem.Theauna canrangeromsingle-celledorganismstomillimetre-sizedpredators.Thisaunamustbeeliminatedby dosinghighlevelsochlorine.Directwaterintakeat atemperateclimatewillrequirechemicaloverdosing duringthecoldestseasonotheyear,whenchemical reactionshaveslowedtonearlyinactivity.
.. From sea and saltwater sources Coastalseawaterintakeshouldbeplacedwherethe lowestsaltcontentisexpected.Inthecoastalsplashingzone,aloto waterevaporatesmakingthesalt concentrationoremainingwatersgreaterthanoutsidethesplashingzone.Inact,itcanbeuptotwice asgreat. Thismakesitnecessaryto extendtheseawaterintake upto hundredso metersromthe splashing zonetoobtainthelowestsaltcontent.Thistypeo intakestructureisgenerallybenecialwhenintake capacityexceeds1,000m3/h. Forintake capacitieslower than1,000 m3/h, corrosion-saebeach wells andcoastal bankltration wellsarerecommended.Theseinstallationscanprovidesavingsoupto20%peryearoncostsrelatedto maintenance,repair,powerconsumptionandchemicalsatthedesalinationplant. Coastalbankltrationwellsareconstructedlikeriverbankltrationwells,butinhighercorrosionclasses toresisttheimpactromthepresentsalts.
Fig. 8 Settling tank principle Formorepermanentinstallations,indirectriverside inltrationviasandorgravelbankllingstointake casingsor riverbankwells arerecommended.This natural ltering improves the water quality and savesup to20%onpowerconsumption,chemicals andtestingatnaltreatment.
1
1
Water supply
.
Surace water
..1 From reshwater sources Suracewaterisusuallytakenromlakesorrivers. Unlikegroundwater,itisnotprotectedromnature orhumanactivities,andtreatmentis thereorealwaysnecessary.Suracewaterlevelandqualitywill varyovertheseasons.Forexample,aterheavyrainall,orsnowmelt,lotsosolidsandsandarewashed downstream. Thesesharpandabrassivemineralsaswellasbiodegradablematerialsaretobesettledorscreenedo beorepumpintaketoavoidnegativeeectsonthe nalwater treatment process.Submersiblepumps areidealortheseapplicationswithperiodicuncontrollably high waterlevels.Notethatpowercables andelectricequipmentmustbeelevatedtopermanentlydrylocations.
Water supply
Usingdirectwaterintakeandstandardconventional watertreatmentwillonlyresultinamicroscopicdiverse biodynamic-balancedaunaentering theaccompanyingpipework andtanksystem.Theauna canrangeromsingle-celledorganismstomillimetre-sizedpredators.Thisaunamustbeeliminatedby dosinghighlevelsochlorine.Directwaterintakeat atemperateclimatewillrequirechemicaloverdosing duringthecoldestseasonotheyear,whenchemical reactionshaveslowedtonearlyinactivity.
.. From sea and saltwater sources Coastalseawaterintakeshouldbeplacedwherethe lowestsaltcontentisexpected.Inthecoastalsplashingzone,aloto waterevaporatesmakingthesalt concentrationoremainingwatersgreaterthanoutsidethesplashingzone.Inact,itcanbeuptotwice asgreat. Thismakesitnecessaryto extendtheseawaterintake upto hundredso metersromthe splashing zonetoobtainthelowestsaltcontent.Thistypeo intakestructureisgenerallybenecialwhenintake capacityexceeds1,000m3/h. Forintake capacitieslower than1,000 m3/h, corrosion-saebeach wells andcoastal bankltration wellsarerecommended.Theseinstallationscanprovidesavingsoupto20%peryearoncostsrelatedto maintenance,repair,powerconsumptionandchemicalsatthedesalinationplant. Coastalbankltrationwellsareconstructedlikeriverbankltrationwells,butinhighercorrosionclasses toresisttheimpactromthepresentsalts.
Fig. 8 Settling tank principle Formorepermanentinstallations,indirectriverside inltrationviasandorgravelbankllingstointake casingsor riverbankwells arerecommended.This natural ltering improves the water quality and savesup to20%onpowerconsumption,chemicals andtestingatnaltreatment.
1
1
Applications
.1 Freshwater supply Thesupplyoreshwaterordrinkingwater,irrigationandvariousindustrialapplicationsisthemost commonapplicationorsubmersiblepumps.Pumps omanydierentdesigns,andmaderommanydierentmaterialscanbeusedwithareasonablygood resulthere. GrundosSPpumpsmadeostainlesssteelEN1.4301/ AISI304aretheobviouschoiceorthisapplication.I thewellismadecorrectlyandproducesclean,sandreewater,thepumpcanlastormanyyears. However,in some livestockwatering and irrigation applications,thewaterqualityissopoorthatpumps madeostandardstainlesssteelmaterialdonotsurviveverylong.InthesecasesapumpinEN1.4401/ AISI316orEN1.4539/AISI904Lstainlesssteelcanbe used. Estimatesora timerameorcarrying outseveral activitiesareoundinthediagramsbelow.Theyinclude: • therecommendedserviceperiodscausedbywear andtear • theexpectedservicerepaircost • thelossoeciencyintheserviceperiods. Pleasenotethatthediagramsdonotreectlossoeciencycausedbycloggingromsedimentorscale. Service intervals or submersible pumps Submersiblepumpsaresubjecttowearjustlikeall otherpumps.Unortunately,theirplacementundergroundmakesviewing thisweardicult.The diagramhereenablesyoutocalculatetheollowing: · WhenshouldIservicemysubmersiblepump? · Howmucheciencyhasbeenlostsincethelast service? · Howmuchwillarenovationcost(approximately)?
. Applications 16
Anumberothingsmustbedeterminedbeorehand. Theyinclude: · Watervelocityatthecomponentyouwishtotest · Theconditionsrelatedtopumpmaterialandthe pumpingenvironment · Thepresenceorabsenceosolidsandaggressive carbondioxide.
17
Applications
.1 Freshwater supply Thesupplyoreshwaterordrinkingwater,irrigationandvariousindustrialapplicationsisthemost commonapplicationorsubmersiblepumps.Pumps omanydierentdesigns,andmaderommanydierentmaterialscanbeusedwithareasonablygood resulthere. GrundosSPpumpsmadeostainlesssteelEN1.4301/ AISI304aretheobviouschoiceorthisapplication.I thewellismadecorrectlyandproducesclean,sandreewater,thepumpcanlastormanyyears. However,in some livestockwatering and irrigation applications,thewaterqualityissopoorthatpumps madeostandardstainlesssteelmaterialdonotsurviveverylong.InthesecasesapumpinEN1.4401/ AISI316orEN1.4539/AISI904Lstainlesssteelcanbe used. Estimatesora timerameorcarrying outseveral activitiesareoundinthediagramsbelow.Theyinclude: • therecommendedserviceperiodscausedbywear andtear • theexpectedservicerepaircost • thelossoeciencyintheserviceperiods. Pleasenotethatthediagramsdonotreectlossoeciencycausedbycloggingromsedimentorscale. Service intervals or submersible pumps Submersiblepumpsaresubjecttowearjustlikeall otherpumps.Unortunately,theirplacementundergroundmakesviewing thisweardicult.The diagramhereenablesyoutocalculatetheollowing: · WhenshouldIservicemysubmersiblepump? · Howmucheciencyhasbeenlostsincethelast service? · Howmuchwillarenovationcost(approximately)? Anumberothingsmustbedeterminedbeorehand. Theyinclude: · Watervelocityatthecomponentyouwishtotest · Theconditionsrelatedtopumpmaterialandthe pumpingenvironment · Thepresenceorabsenceosolidsandaggressive carbondioxide.
. Applications 16
17
Applications
Applications
Thechartbelowisuseulasaguidelinetodetermine theserviceintervalsorsubmersiblepumps. Followthestepsbelow: 1. Notepoint1onCurveA.Pumpmaterialandmedia conditionsareasindicatedinthelegend. 2.Drawaparallellinetotheright.Impellermaterial lossisapprox.0.18mmper1,000hoursooperation(point2). 3.FollowtheparallellineuntilyoureachthedierentiationlinethatcorrespondstoaggressiveCO2 andcomponentmaterial.Notethe conditionsin theexample(point3).
4.Dropdirectlydown(90°).TheaggressiveCO2contenthasincreasedthe materiallossto 0.25mm. Notethesalinitylevelothewater(point4).Draw ahorizontallinethroughthispoint;ollowittothe letandreadtheresults. 5. Recommendedserviceintervalsoryourpump:Aterevery6,000hoursooperation(point5). 6.Lossoeciency:Approx.18%(point6). 7. Estimatedcostorenovatingthepump:75%othe priceoanewpump(point7).
. Dewatering Dewatering in connection withmining applications orconstructionsitesisotendonewithsubmersible pumps.The waterqualitydetermines whetherthe pumpcanbeastandardEN1.4301(AISI304)pump,or iithastobestainlesssteeloahighergrade. When reducing groundwater levels, the aquier is exposedtooxygen,creatingrustandotheradhesive solids.Theyarewashedoutandpenetratesthewell screen,thenpassingontothepumpinlet. Tomaintainpumpperormance,thedutypointisto beselectedtotherightothebesteciencypoint.
Dierentiationline forwater qualities withoutaggressive carbondioxide
Velocity at components Impellers m/s
9
Chamberbowls 8
7
Valvestrainers 6
5
Waterpipes 4
3
Motorcooling 2
0 mg/l (all materials)
1
10 mg/l c( astiron only)
0.18
s d i l o s l / g m 0 1 g n i n i a t n o c r e t a W
1
2
3
20 mg/l c( astiron only)
0.16 Curve A
40 mg/l (castirononly)
0.14 0.12
Curve B
0.10
Material loss per1,000 hours of operationin [mm]
Curve C 0.08 Curve D
r e t a w
..1 Mining Miningisatypicaldewateringapplication.However, thewaterqualityisveryotenaggressiveinrelation
0.06
Curve E
e e r f d n a S
Thehigherthevelocityinsidethepump,thelongerintervalsbetweenservicecanbe.Ahighvelocityprevents thepumpromcloggingupandlosingperormance.In veryadhesivemixtures,itcanbebenecialtoremove thenon-returnvalveromthepumptoenhancebackwashothepumpandpipesaterpumpstoppage.
0.04 0.02
Curve F
4 0 . 0
8 0 . 0
2 1 . 0
6 1 . 0
0 2 . 0
4 2 . 0
8 2 . 0
2 3 . 0
6 3 . 0
0 4 . 0
4 4 . 0
20
w e n a f 60% o e c i r p e h t f 70% o % n i 7 n o i t a v 80% o n e r
1. Find the chloride corrosion potential (chloride equivalent=ppmchloride–(0.5xppmacid)). 2.Withthischlorideequivalent,useg.10tondthe minimumpHvalueacceptableorEN1.4539(AISI 904L) stainless steel. I theillustration indicates thatthereisahighcorrosionrisk,epoxy-coatingo themotorisrequired. 3.Mostpowercablematerialsandjunctionkitsare unstableinacidicwaters.Ipossible,usetheblue GrundosTMLmotorcablein ulllengthto the junctionboxonthesurace. 4.Installthepumpcenteringdeviceonyourpumpor motortoensureperectcoolingotheentiresurace. 5. Icorrosionoccurs,installion-exchangeunitsto bringdownthechloridecontent,orinstallzincanodesascathodicprotection.
8
200 mgsalt/litre 800 mgsalt/litre
p 50% m u p
Onewayodoingthisisdescribedintheollowing:
pH
8 4 . 0
Dierentiationline forsalinity
40%
tothesubmersiblepump,andhigh-gradestainless steelisrecommendable. Aspecialminingapplicationisleachmining,where anaggressiveliquidisusedtodissolvetheminerals tobemined.Thesearethenpumpedwiththeliquid tothesuraceandreclaimed.
16
Seawater, marine environment
7
2,000 mgsalt/litre
k r i s i o n s r o o r o c k n r i s r o n e o i l s t r o L i t o r h c g i H
6 12
s r 8 u o h 0 0 5 0 , 1 n i s 4 l a v r e t n i e c i v r e 2 S
6
d e t c e p x 100% E
25 20 15 10 Average efciencyloss duringservice period
River mouth or coastal water lowering
4
5
4 %
Mining waters
5 Brackishwater
Freshwater
Curve A:
Curve B:
Curve C:
Curve D:
Curve E:
Curve F:
Material:Castiron pH: 5 Oxygencontent:7 ml/l Temperature:30 o C Solids content:10 mg/l
Material:Castiron pH:7 Oxygencontent:2 ml/l Temperature: 10o C Solids content:10 mg/l
Material:stainless steel impeller coated withhard chromium orbronze impellerwith hard chromium shaft pH:5-8 Oxygencontent:0-10 ml/l Temperature:0-30 o C Solids content10 mg/l
Material:Castiron pH:5 Oxygencontent:7 ml/l Temperature:30 o C
Material:Castiron pH:7 Oxygencontent:2 ml/l Temperature:10 o C
Material:Bronze or stainless steel impeller pH:5-8 Oxygencontent:0-10 ml/l Temperature:0-30 oC
3
2
1
r e t a w a e s n a e n a r r e t i d e M / c i t l a B
r e t a w a e s c i t n a l t A / c fi i c a P
) r e t a w a e s ( l a i t n e t o p e v i s o r r o c t s e h g i H 0 0 0 , 0 3
0 0
Fig. 9 Recommended service intervals or submersible pumps
500
Freshwater
5,000 1 0, 00 0
Brackish water
Seawater
2 0, 00 0
50,000
100,000
Brine
300,000
ppm Cl-
Fig. 10 Corrosion due to chlorides
18
19
Applications
Applications
Thechartbelowisuseulasaguidelinetodetermine theserviceintervalsorsubmersiblepumps. Followthestepsbelow: 1. Notepoint1onCurveA.Pumpmaterialandmedia conditionsareasindicatedinthelegend. 2.Drawaparallellinetotheright.Impellermaterial lossisapprox.0.18mmper1,000hoursooperation(point2). 3.FollowtheparallellineuntilyoureachthedierentiationlinethatcorrespondstoaggressiveCO2 andcomponentmaterial.Notethe conditionsin theexample(point3).
4.Dropdirectlydown(90°).TheaggressiveCO2contenthasincreasedthe materiallossto 0.25mm. Notethesalinitylevelothewater(point4).Draw ahorizontallinethroughthispoint;ollowittothe letandreadtheresults. 5. Recommendedserviceintervalsoryourpump:Aterevery6,000hoursooperation(point5). 6.Lossoeciency:Approx.18%(point6). 7. Estimatedcostorenovatingthepump:75%othe priceoanewpump(point7).
. Dewatering Dewatering in connection withmining applications orconstructionsitesisotendonewithsubmersible pumps.The waterqualitydetermines whetherthe pumpcanbeastandardEN1.4301(AISI304)pump,or iithastobestainlesssteeloahighergrade. When reducing groundwater levels, the aquier is exposedtooxygen,creatingrustandotheradhesive solids.Theyarewashedoutandpenetratesthewell screen,thenpassingontothepumpinlet. Tomaintainpumpperormance,thedutypointisto beselectedtotherightothebesteciencypoint.
Dierentiationline forwater qualities withoutaggressive carbondioxide
Velocity at components Impellers m/s
9
Chamberbowls 8
7
Valvestrainers 6
5
Waterpipes 4
3
Motorcooling 2
0 mg/l (all materials)
1
10 mg/l c( astiron only)
0.18
s d i l o s l / g m 0 1 g n i n i a t n o c r e t a W
1
2
3
20 mg/l c( astiron only)
0.16 Curve A
40 mg/l (castirononly)
0.14 0.12
Curve B
0.10
Material loss per1,000 hours of operationin [mm]
Curve C 0.08 Curve D
r e t a w e e r f d n a S
Thehigherthevelocityinsidethepump,thelongerintervalsbetweenservicecanbe.Ahighvelocityprevents thepumpromcloggingupandlosingperormance.In veryadhesivemixtures,itcanbebenecialtoremove thenon-returnvalveromthepumptoenhancebackwashothepumpandpipesaterpumpstoppage.
Curve E
..1 Mining Miningisatypicaldewateringapplication.However, thewaterqualityisveryotenaggressiveinrelation
0.06 0.04 0.02
Curve F
4 0 . 0
8 0 . 0
2 1 . 0
6 1 . 0
0 2 . 0
4 2 . 0
8 2 . 0
2 3 . 0
6 3 . 0
0 4 . 0
4 4 . 0
20
1. Find the chloride corrosion potential (chloride equivalent=ppmchloride–(0.5xppmacid)). 2.Withthischlorideequivalent,useg.10tondthe minimumpHvalueacceptableorEN1.4539(AISI 904L) stainless steel. I theillustration indicates thatthereisahighcorrosionrisk,epoxy-coatingo themotorisrequired. 3.Mostpowercablematerialsandjunctionkitsare unstableinacidicwaters.Ipossible,usetheblue GrundosTMLmotorcablein ulllengthto the junctionboxonthesurace. 4.Installthepumpcenteringdeviceonyourpumpor motortoensureperectcoolingotheentiresurace. 5. Icorrosionoccurs,installion-exchangeunitsto bringdownthechloridecontent,orinstallzincanodesascathodicprotection.
8
200 mgsalt/litre 800 mgsalt/litre
p 50% m u p w e n a f 60% o e c i r p e h t f 70% o % n i 7 n o i t a v 80% o n e r d e t c e p x 100% E
Onewayodoingthisisdescribedintheollowing:
pH
8 4 . 0
Dierentiationline forsalinity
40%
tothesubmersiblepump,andhigh-gradestainless steelisrecommendable. Aspecialminingapplicationisleachmining,where anaggressiveliquidisusedtodissolvetheminerals tobemined.Thesearethenpumpedwiththeliquid tothesuraceandreclaimed.
16
Seawater, marine environment
7
2,000 mgsalt/litre
i s k n r o i s r r o c o o k r i s r n o n e o i l s t L i t r r o c o h g H i
6 12
s r u 8 o h 0 0 5 0 , 1 n i s 4 l a v r e t n i e c i v r e 2 S
6
25 20 15 10 Average efciencyloss duringservice period
River mouth or coastal water lowering
4
5
4 %
Mining waters
5 Brackishwater
Freshwater
Curve A:
Curve B:
Curve C:
Curve D:
Curve E:
Curve F:
Material:Castiron pH: 5 Oxygencontent:7 ml/l Temperature:30 o C Solids content:10 mg/l
Material:Castiron pH:7 Oxygencontent:2 ml/l Temperature: 10o C Solids content:10 mg/l
Material:stainless steel impeller coated withhard chromium orbronze impellerwith hard chromium shaft pH:5-8 Oxygencontent:0-10 ml/l Temperature:0-30 o C Solids content10 mg/l
Material:Castiron pH:5 Oxygencontent:7 ml/l Temperature:30 o C
Material:Castiron pH:7 Oxygencontent:2 ml/l Temperature:10 o C
Material:Bronze or stainless steel impeller pH:5-8 Oxygencontent:0-10 ml/l Temperature:0-30 oC
3
r e t a w a e s n a e n a r r e t i d e M / c i t l a B
2
1
r e t a w a e s c i t n a l t A / c fi i c a P
) r e t a w a e s ( l a i t n e t o p e v i s o r r o c t s e h g i H 0 0 0 , 0 3
0 0
Fig. 9 Recommended service intervals or submersible pumps
500
Freshwater
5,000 1 0, 00 0
Brackish water
2 0, 00 0
50,000
Seawater
100,000
Brine
300,000
ppm Cl-
Fig. 10 Corrosion due to chlorides
18
19
Applications
Applications
. Horizontal application Pumpingwaterroma tank orreservoiris veryoten donewithastandardsubmersiblepump.Asubmersible pumphasmanyadvantagescomparedtoadry-installed pumpsuchas: • Lownoiselevel:Thesubmersiblepumpisverysilentanddoesnotdisturbanyneighbours. • Thetproo:Thepumpisinstalledatthebottomo thetank/reservoir. • Noshatseal:Thiseliminatestheriskoleakage aboveground. In horizontalinstallations,Grundos alwaysrecommendsthatyouincludeaowsleeveandbafeplate atlowwaterlevels.
Imorethanonesubmersiblepumpisinstalledina tankorreservoirthedistancebetweenthepumps mustequaltheoverall diametero thepumpand motorincludingcoolingsleeve.
Vacuumpump
Submersible pumpsusedorountain applications areoteninstalledhorizontally.Becauseoitslowinertia,asubmersiblepumpisabletostartandstop veryast.Thismakesit ideal orountainapplications.Becauseothehighstart/stoprequency,itis recommendedto usecannedmotorsonly.Rewindablemotorsshouldneverbeusedinconnectionwith anextremenumberostartsandstops.
Fig. 11 Flow sleeve on horizontally installed pump
Fig. 12 Vortex bae plate on horizontally-installed pump (seen rom above)
Gas vacuum Waterlevel incasing
Finally,itis importanttosizethepumpandnozzle together,sothepumpneveroperatesatmaximum ow,butalwaysasclosetothebesteciencypoint aspossible.
. Air/gas in water
Vacuumgauge
Thelargenumberostarts/stopsisalsohardonthe contactors,whichhave a limitedlietime. Inorder toprotectthemotorromailureinthecontactors, Grundosrecommendsthat youinstall thephaseailurerelaybetweentheoverloadrelayandthemotor.
Vacuumswitch Non-return valve
Iair/gasismixedinthepumpedwater,thepump willunderperorm,andsometimesevenstoppumping.Air/gasgreatlydisturbsthehydraulicunctions ocentriugal pumps.Toimprove perormance,the pumpmustbesubmergeddeeperintothewell,thus increasingthepressure.
Gas
5-7 m
Groundwaterlevel
Fig. 14 Gas evacuation
Fig. 15 Vacuum wells
Vacuum wells Ithewellwatercontainssomuchgasinsuspension thatasleeveisinsucienttomeetthewaterquality requirements,avacuummustbecreatedinthewell casing.Thiscanbedonebyconnectingavacuum
pumptotheventpipewhenthecasingishermeticallysealed.Thisrequiresthatthewellcasingisstrong enoughtowithstandthevacuumandthattheNPSH requirementismet.
Ithatisnotpossible,theproblemmaybeovercome byinstallinga sleevearoundthepump,belowthe pumpinlet.The sleeve should extend upwards as araspossible,butneverabovethedynamicwater level.
Fig. 13 Vortex bae plate on horizontally installed pump (cross-section)
0
1
Applications
Applications
. Horizontal application Pumpingwaterroma tank orreservoiris veryoten donewithastandardsubmersiblepump.Asubmersible pumphasmanyadvantagescomparedtoadry-installed pumpsuchas: • Lownoiselevel:Thesubmersiblepumpisverysilentanddoesnotdisturbanyneighbours. • Thetproo:Thepumpisinstalledatthebottomo thetank/reservoir. • Noshatseal:Thiseliminatestheriskoleakage aboveground. In horizontalinstallations,Grundos alwaysrecommendsthatyouincludeaowsleeveandbafeplate atlowwaterlevels.
Imorethanonesubmersiblepumpisinstalledina tankorreservoirthedistancebetweenthepumps mustequaltheoverall diametero thepumpand motorincludingcoolingsleeve.
Vacuumpump
Submersible pumpsusedorountain applications areoteninstalledhorizontally.Becauseoitslowinertia,asubmersiblepumpisabletostartandstop veryast.Thismakesit ideal orountainapplications.Becauseothehighstart/stoprequency,itis recommendedto usecannedmotorsonly.Rewindablemotorsshouldneverbeusedinconnectionwith anextremenumberostartsandstops.
. Air/gas in water
Iair/gasismixedinthepumpedwater,thepump willunderperorm,andsometimesevenstoppumping.Air/gasgreatlydisturbsthehydraulicunctions ocentriugal pumps.Toimprove perormance,the pumpmustbesubmergeddeeperintothewell,thus increasingthepressure.
Fig. 12 Vortex bae plate on horizontally-installed pump (seen rom above)
Gas vacuum Waterlevel incasing
Finally,itis importanttosizethepumpandnozzle together,sothepumpneveroperatesatmaximum ow,butalwaysasclosetothebesteciencypoint aspossible.
Fig. 11 Flow sleeve on horizontally installed pump
Vacuumgauge
Thelargenumberostarts/stopsisalsohardonthe contactors,whichhave a limitedlietime. Inorder toprotectthemotorromailureinthecontactors, Grundosrecommendsthat youinstall thephaseailurerelaybetweentheoverloadrelayandthemotor.
Vacuumswitch Non-return valve
Gas
5-7 m
Groundwaterlevel
Fig. 14 Gas evacuation
Fig. 15 Vacuum wells
Vacuum wells Ithewellwatercontainssomuchgasinsuspension thatasleeveisinsucienttomeetthewaterquality requirements,avacuummustbecreatedinthewell casing.Thiscanbedonebyconnectingavacuum
pumptotheventpipewhenthecasingishermeticallysealed.Thisrequiresthatthewellcasingisstrong enoughtowithstandthevacuumandthattheNPSH requirementismet.
Ithatisnotpossible,theproblemmaybeovercome byinstallinga sleevearoundthepump,belowthe pumpinlet.The sleeve should extend upwards as araspossible,butneverabovethedynamicwater level.
Fig. 13 Vortex bae plate on horizontally installed pump (cross-section)
0
1
Applications
Applications
. Corrosive water (seawater)
.6 Hot water and geothermal water
Submersiblepumpsareusedormanyseawaterapplicationslikesharming,oshoreindustrialapplicationsandwatersupplyorreverseosmosis-treated water. SPpumpsareavailableindierentmaterialsandcorrosionclassesdependingontheapplicationothe pumps.Thecombinationosalinityandtemperature isnotavourabletostainlesssteel,andmustalways betakenintoconsideration. Agoodwaytocomparethecorrosionresistanceo stainlesssteel,is tocompareits resistance against pitting.The gureused asa comparisonis called: ‘PittingResistanceEquivalent’(PRE). Fig.16showsthemostcommonstainlesssteeltypes usedbyGrundos.
Corrosion diagram
PRE=(%Cr)+(3.3x%Mo)
Groundwaterclosetothesuracewillbeclosetothe averageannualairtemperatureintheregion.Going deeper,thetemperaturewillincrease2to3°Cor each100mowelldepth,intheabsenceogeothermalinuence.
EN 1.4301, 1.4401 and 1.4539 100
Forcomparisontootherstainlesssteeltypes,which containNitrogen(N)theormulalookslikebelow:
SPR1.4539 SPN1.4401
90
CRN1.4401 80
SP1.4301
70
PREN=(%Cr)+(3.3x%Mo)+(16x%N) Inadditionto temperatureand salinity, thecorrosiontemperatureisaectedbythepresenceoother metals,acidsandbiologocalactivity.Thisisalsoindicateding.16.
] C ° [ e r u t a r e p m e T
60
Ingeothermalareas,thisincreasemightbeashigh as5to15°Coreach100mowelldepth.Goingdeep orwaterrequirestemperature-resistantelastomers, electricalcables,connectionsandmotors.
50
40
30
20
10
Thechartbelowcanbeusedortheselectionothe propergradeosteel.
0 0
20 0
4 00
60 0
8 00
1 00 0
1200
1 400
1 60 0
180 0
20 00
Chloride [ppm]
Fig. 17 Corrosion diagram
Themotorliquido yoursubmersiblemotorhasa higherboilingpointtemperaturethanthewellwater preventsthemotorbearinglubricationrombeing reducedduetothelowerviscosityotheliquid.The motormustbesubmergeddeepertoraisetheboilingtemperatureasthetablebelow.
Corrosion diagram EN 1.4301, 1.4401 and 1.4539
Corrosion resistance of seawater-submerged pumps C 35 ° ) ¯ l C m30 p p 0 0 0 , 1 25 2 ( r e t a w20 a e s d r a d 15 n a t s f o 10 e r u t a r e p 5 m e T
0
SPR1.4539 SPN1.4401
90
Environmental impact
Full-developed pitting resistance equivalent in 60 days
EN 1.4301/AISI 304
E N 1. 44 01 /A IS I 31 6
E N 1. 44 62 /A IS I 90 4L
E N 45 39 /A IS I 90 4L
PRE = % Cr + 3.3 x % Mo = 7.5
PRE = % Cr + 3.3 x % Mo = 24.3
PRE = % Cr + 3.3 x % Mo = 33.5
PRE = % Cr + 3.3 x % Mo = 34.9
Fig. 16 Corrosion resistance
SP1.4301
70
. p m e t e s C a ° e 5 r c 1 n y i s b e e d c o n a n t a p k e n c i c Z a
Pitting resistance
CRN1.4401 80
Critical crevice temperature in stagnant water
Critical temperature for permanent still-standing water
100
Hotgroundwaterisusedorgeneralheatingapplications,andorleisureinmanyareas,especiallythose withvolcanicactivity.
C ° s 5 e y d b o n e a c l n e a e t t p s e c d l c i a . m p d n m a e t n e o s r a i t e s r a c n C i
s l a c i m C e ° h 8 c y d b s n e e a c s a C s n e a r ° d t c 5 i c p e y a e d b i c c y e r c t c i u a . v n h p i t a l p c t m u e a p s t l e c , e a c e c a s i n a i g . e o p r o r l c o m l h e i e C B t d
) C ° 60 ( e r u t 50 a r e p m 40 e T 30
20
10
0 0
2000
4000
6000
8000
12000
16000
20000
Chloride [ppm]
Fig. 18 Corrosion diagram Theelastomercomponentsinthepumpmayalsobe damagedbypoorwaterquality,orexampleithe waterhasahighcontentohydrocarbonsandmany chemicals.Insuchcasesthestandardelastomercan bereplacedbyFKMrubber.TheGrundosSPEpumps areparticularlydesignedtomeettheserequirements. Forallothermodels,thepumpscanbespeciedand deliveredonrequest.
Temperature °C 0 4 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Vapour pressure mWC 0.00611 0.00813 0.01227 0.02337 0.04241 0.07375 0.12335 0.19920 0.31162 0.47360 0.70109 1.01325 1.43266 1.98543 2.70132 3.61379 4.75997 6.18065
Kinematic viscosity mm2/s 1.792 1.568 1.307 1.004 0.801 0.658 0.554 0.475 0.413 0.365 0.326 0.294 0.268 0.246 0.228 0.212 0.199 0.188
Applications
Applications
. Corrosive water (seawater)
.6 Hot water and geothermal water Corrosion diagram
Submersiblepumpsareusedormanyseawaterapplicationslikesharming,oshoreindustrialapplicationsandwatersupplyorreverseosmosis-treated water.
PRE=(%Cr)+(3.3x%Mo)
SPpumpsareavailableindierentmaterialsandcorrosionclassesdependingontheapplicationothe pumps.Thecombinationosalinityandtemperature isnotavourabletostainlesssteel,andmustalways betakenintoconsideration. Agoodwaytocomparethecorrosionresistanceo stainlesssteel,is tocompareits resistance against pitting.The gureused asa comparisonis called: ‘PittingResistanceEquivalent’(PRE). Fig.16showsthemostcommonstainlesssteeltypes usedbyGrundos.
PREN=(%Cr)+(3.3x%Mo)+(16x%N)
Groundwaterclosetothesuracewillbeclosetothe averageannualairtemperatureintheregion.Going deeper,thetemperaturewillincrease2to3°Cor each100mowelldepth,intheabsenceogeothermalinuence.
EN 1.4301, 1.4401 and 1.4539 100
Forcomparisontootherstainlesssteeltypes,which containNitrogen(N)theormulalookslikebelow:
Inadditionto temperatureand salinity, thecorrosiontemperatureisaectedbythepresenceoother metals,acidsandbiologocalactivity.Thisisalsoindicateding.16.
SPR1.4539 SPN1.4401
90
CRN1.4401 80
SP1.4301
70
] C ° [ e r u t a r e p m e T
60
Ingeothermalareas,thisincreasemightbeashigh as5to15°Coreach100mowelldepth.Goingdeep orwaterrequirestemperature-resistantelastomers, electricalcables,connectionsandmotors.
50
40
30
20
10
Thechartbelowcanbeusedortheselectionothe propergradeosteel.
0 0
20 0
4 00
60 0
8 00
1 00 0
1200
1 400
1 60 0
180 0
20 00
Chloride [ppm]
Fig. 17 Corrosion diagram
Themotorliquido yoursubmersiblemotorhasa higherboilingpointtemperaturethanthewellwater preventsthemotorbearinglubricationrombeing reducedduetothelowerviscosityotheliquid.The motormustbesubmergeddeepertoraisetheboilingtemperatureasthetablebelow.
Corrosion diagram EN 1.4301, 1.4401 and 1.4539
Corrosion resistance of seawater-submerged pumps C 35 ° ) ¯ l C m30 p p 0 0 0 , 1 25 2 ( r e t a w20 a e s d r a d 15 n a t s f o 10 e r u t a r e p 5 m e T
0
100
SPR1.4539 SPN1.4401
90
Environmental impact
Full-developed pitting resistance equivalent in 60 days
Hotgroundwaterisusedorgeneralheatingapplications,andorleisureinmanyareas,especiallythose withvolcanicactivity.
CRN1.4401 80
SP1.4301
70
Critical crevice temperature in stagnant water
. p m e t e s C a ° e 5 r c 1 n y i s b e e d c o n a n t a p k e n c i c Z a
EN 1.4301/AISI 304
E N 1. 44 01 /A IS I 31 6
E N 1. 44 62 /A IS I 90 4L
E N 45 39 /A IS I 90 4L
PRE = % Cr + 3.3 x % Mo = 7.5
PRE = % Cr + 3.3 x % Mo = 24.3
PRE = % Cr + 3.3 x % Mo = 33.5
PRE = % Cr + 3.3 x % Mo = 34.9
Critical temperature for permanent still-standing water Pitting resistance
Fig. 16 Corrosion resistance
s l a c i m C C e ° ° h 8 s 5 c y e y d b s d b o n e e n e a c s a c s n l n a e C ° d t a r e a t c 5 i c p e p t y a e e s e d b c c c d c y e i r c l i t c a i u a . . v n h p m a p p i t t d l c p m m a n e u e s t a t l e c , e a n e c c e s i a n o r s i a a g . i e o p r r t e l o c s r c i o m l a n h e e C i B t C d
) C ° 60 ( e r u t 50 a r e p m 40 e T 30
20
10
0 0
2000
4000
6000
8000
12000
16000
20000
Chloride [ppm]
Fig. 18 Corrosion diagram Theelastomercomponentsinthepumpmayalsobe damagedbypoorwaterquality,orexampleithe waterhasahighcontentohydrocarbonsandmany chemicals.Insuchcasesthestandardelastomercan bereplacedbyFKMrubber.TheGrundosSPEpumps areparticularlydesignedtomeettheserequirements. Forallothermodels,thepumpscanbespeciedand deliveredonrequest.
Temperature °C 0 4 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Vapour pressure mWC 0.00611 0.00813 0.01227 0.02337 0.04241 0.07375 0.12335 0.19920 0.31162 0.47360 0.70109 1.01325 1.43266 1.98543 2.70132 3.61379 4.75997 6.18065
Kinematic viscosity mm2/s 1.792 1.568 1.307 1.004 0.801 0.658 0.554 0.475 0.413 0.365 0.326 0.294 0.268 0.246 0.228 0.212 0.199 0.188
Applications
Applications
Gasinthewateristobeexpectedwherethereisgeothermalactivity.Toavoidreducedpumpcapacityina geothermalwaterinstallationwhereairismixedin, Grundos recommendstoinstallthepumpa minimumo50mbelowthedynamicwaterlevel.
.7 Booster modules Grundospumptypes BMand BMEareSP pumps builtintoasleeve.Byconnectingeachunitinseries, averyhighpressurecanbeobtained. Thepumpsareprimarilyusedorreverseosmosisapplications,producingcleanwaterrompollutedwaterorseawater. Grundosboostermodulesarealsoused orwater supplyindistributionnetworkstoboostwaterpressureoverlongdistributionlines.Themainadvantagescomparedtoconventionalboosterpumpsarethe quietoperation,andthereisnoshatsealthatmay leak.
Fig. 19 Grundos BM
Applications
Applications
Gasinthewateristobeexpectedwherethereisgeothermalactivity.Toavoidreducedpumpcapacityina geothermalwaterinstallationwhereairismixedin, Grundos recommendstoinstallthepumpa minimumo50mbelowthedynamicwaterlevel.
.7 Booster modules Grundospumptypes BMand BMEareSP pumps builtintoasleeve.Byconnectingeachunitinseries, averyhighpressurecanbeobtained. Thepumpsareprimarilyusedorreverseosmosisapplications,producingcleanwaterrompollutedwaterorseawater. Grundosboostermodulesarealsoused orwater supplyindistributionnetworkstoboostwaterpressureoverlongdistributionlines.Themainadvantagescomparedtoconventionalboosterpumpsarethe quietoperation,andthereisnoshatsealthatmay leak.
Fig. 19 Grundos BM
Pumps
.1 Pump principle TheSPpumpisacentriugalpump,wherethepump principleistotransormmechanicalenergyromthe motortovelocityenergyinthepumpedmedium,and therebycreatingapressuredierenceinthemedia betweenthepumpinletandoutlet.
(3) Outlet
The pump consists inprinciple o aninlet(1),a numberopumpstages(2)andapumpoutlet(3). Eachpumpstagecreatesapressuredierence,and themorepressureneeded,themorestagesneedto beincluded. Apumpstageincludesanimpeller(4)wheretheimpellerbladestranserenergytothewaterinterms oavelocityandpressureincrease.Eachimpelleris xedtothepumpshat(5)bymeansoasplineconnectionorsplit-coneconnection. Forsubmersiblepumps,therearetwogeneraldesign types: • radial • semi-axial.
(5) Shaft
(7) Guide vane
(4) Impeller (6) Seal ring
(2) Stage (Chamber)
(1) Inlet
. Pumps 6
Fig. 20 Submersible pump principle
Theradialdesignis characterisedbya largedierencebetweentheimpellerinletandtheoutletdiameterotheimpeller.Itissuitablewhereahighhead isrequired. Thesemi-axialdesignismoresuitableorlargerow pumps. Aseal ring (6)betweentheimpeller inlet andthe chamberensuresthatanybackowislimited.The chamberincludesaguidevane(7),whichleadsthe watertothenextstage.Italsoconvertsthedynamic pressureintostaticpressure. Inadditiontoguidingthewaterintotherstimpellers,thepumpinletisalsotheinterconnectororthe motor.Formostpumpsthedimensionsconormsto theNEMAstandardor4”,6”and8”.Forlargerpumps andmotorstherearevariousstandardsdepending onthesupplier.Thepumpinletmustbedesignedin ordertodeliverthewatertotherstimpellerinthe bestpossiblewayandtherebyminimisethelossesas muchaspossible.Forsomeradialdesignedimpellers, theinletalsoincludesaprimingscrew(astenedon thepumpshat)inordertosecurethewaterintake andavoiddryrunningothepump. The pump outlet normally includes a non-return valve, which preventsback owin theriser pipe,
7
Pumps
.1 Pump principle TheSPpumpisacentriugalpump,wherethepump principleistotransormmechanicalenergyromthe motortovelocityenergyinthepumpedmedium,and therebycreatingapressuredierenceinthemedia betweenthepumpinletandoutlet.
(3) Outlet
The pump consists inprinciple o aninlet(1),a numberopumpstages(2)andapumpoutlet(3). Eachpumpstagecreatesapressuredierence,and themorepressureneeded,themorestagesneedto beincluded. Apumpstageincludesanimpeller(4)wheretheimpellerbladestranserenergytothewaterinterms oavelocityandpressureincrease.Eachimpelleris xedtothepumpshat(5)bymeansoasplineconnectionorsplit-coneconnection. Forsubmersiblepumps,therearetwogeneraldesign types: • radial • semi-axial.
(5) Shaft
(7) Guide vane
(4) Impeller (6) Seal ring
(2) Stage (Chamber)
(1) Inlet
. Pumps
Fig. 20 Submersible pump principle
Theradialdesignis characterisedbya largedierencebetweentheimpellerinletandtheoutletdiameterotheimpeller.Itissuitablewhereahighhead isrequired. Thesemi-axialdesignismoresuitableorlargerow pumps. Aseal ring (6)betweentheimpeller inlet andthe chamberensuresthatanybackowislimited.The chamberincludesaguidevane(7),whichleadsthe watertothenextstage.Italsoconvertsthedynamic pressureintostaticpressure. Inadditiontoguidingthewaterintotherstimpellers,thepumpinletisalsotheinterconnectororthe motor.Formostpumpsthedimensionsconormsto theNEMAstandardor4”,6”and8”.Forlargerpumps andmotorstherearevariousstandardsdepending onthesupplier.Thepumpinletmustbedesignedin ordertodeliverthewatertotherstimpellerinthe bestpossiblewayandtherebyminimisethelossesas muchaspossible.Forsomeradialdesignedimpellers, theinletalsoincludesaprimingscrew(astenedon thepumpshat)inordertosecurethewaterintake andavoiddryrunningothepump. The pump outlet normally includes a non-return valve, which preventsback owin theriser pipe,
6
7
Pumps
whenthepumpisstopped.Severalbenetsareobtainedsuchas: • Energylossduetobackushisavoided. • Acounterpressureisalwaysensured,whenstartingupthepumpagain.Thisisessentialinorderto makecertainthatpumpperormanceremainson thepumpcurve. • Damageinthepumpduetowaterhammeringis limited. • Contamination othe groundwaterdue toback ushislimited.
Pumps
. Pump curves and tolerances 3
Aterestimatingthenecessaryowandhead,pump selectioncanbeperormedbyusingGrundosWinCAPS/WebCAPS or the corresponding pump data booklet.Bothsourcescontainperormancecurves.
4
Flow(Q):60 m3h
H [m] SP60-8 ISO9906AnnexA Pumpedmedium=anyviscousfluid
120
100 QH Eta, pump
80
80 Eta, total
70
Pipe length of discharge pipe:0 m
2 :10 m
: 50 m
1
:80 m
Pipe length of riser pipe: 0 m
4
Inadditionto thepumphead,the requiredpower consumptionis alsoavailablein thedata booklet, wherethepumpsupplierdistinguishesbetweenthe motorshatpoweroutputP1 (printedonthemotor nameplate)andthemotorinputpower,P1.P1isused orsizingtheelectricalinstallations.
60
60 50 Shaded areas show acceptable tolerances
40
Dependingonthepumpedmediaandthenumbero yearsapumphasbeeninoperation,aserviceinspectionothepumpisrecommended.Thisincludesreplacingallwearpartsinthepump.Therecommendedservicepartsare: • bearings,radial • valveseat • neckrings • sealring • upthrustring. Iextensive wear rom sand has occurredin the pump,replacingthepumpshatandimpellersmay alsobenecessary. Renewingthewearpartsincaseoserviceisessentialormaintainingahighpumpeciencyandalow operatingcost. Forurther service inormation, see the Grundos serviceinstructions.
. Pump selection Selectionoapumpstartswithestimatingtheow andpressure.Thetotalheadisthesumotheollowing • dynamicwatertable(1) • litaboveground(2) • dischargepressure(3) • lossesinpipes,valveandbends(4)
Head:90 m
Friction losses:0 m
PleasenotethatP4isthehydrauliceectproduced bythepump.
P4 : Hydraulic eect
40 30
20
20 10
0
0 0
. Wear parts
Eta [%]
10
20
30
40
50
60
Fig. 23
Q [m3 /h]
P [kW]
NPSH [m]
P1
16 12
8 6
P2
8
4 NPSH
4
2
0
0 0
Fig. 21 Total head calculation Whenestimatingtheow demand,the wellyield mustalso be takeninto consideration.Inormation regarding thewellyield isavailable rom thewell drillerstest report,whichis madeduring welldevelopment.Ipossible,thenecessaryowmustbe reducedasmuchaspossible.Thiswillminimisethe watertabledrawdown,andreducetotalpowerconsumptionintermsokwh/m3.
10
20
30
40
50
60
Q [m3 /h]
Fig. 24
P2 : Motor shaft power (=P3)
P1 : Motor input power Fig. 22 Power denitions Normallythepowerconsumptionisalsoshownasa unctionotheow.
Figures 23 and 24 Pump perormance parameters includingtolerances Inthedatabooklet,inormationregardingpumpeciencyisalsoavailable,anditcanbeshownasthe pump-endeciency(basedonP2)orasacomplete pumpeciencyincludingthemotor(basedonP1). Insomecases,losesinnon-returnvalvesarenotincludedintheeciencyshown.Theeciencycurves areusedortheselectionopumpsize,wherethe besteciencyareamatchestherequiredow.Ithe completepumpeciencyisnotshown,itcanbecalculatedbyusingtheow(Q),head(H)andpower inputP1:
etatotal = (Q x H x 9.81)/( P1 x 600) The NPSH value stands or “Net Positive Suction Head”andisameasureorrequiredinletpressure= minimumwaterlevelabovepumpinlet. Ingeneral,the NPSHvaluewillincreaseorbigger
8
9
Pumps
Pumps
whenthepumpisstopped.Severalbenetsareobtainedsuchas: • Energylossduetobackushisavoided. • Acounterpressureisalwaysensured,whenstartingupthepumpagain.Thisisessentialinorderto makecertainthatpumpperormanceremainson thepumpcurve. • Damageinthepumpduetowaterhammeringis limited. • Contamination othe groundwaterdue toback ushislimited.
. Pump curves and tolerances 3
Aterestimatingthenecessaryowandhead,pump selectioncanbeperormedbyusingGrundosWinCAPS/WebCAPS or the corresponding pump data booklet.Bothsourcescontainperormancecurves.
4
Flow(Q):60 m3h
H [m] SP60-8 ISO9906AnnexA Pumpedmedium=anyviscousfluid
120
100 QH Eta, pump
80
80 Eta, total
70
Pipe length of discharge pipe:0 m
2 :10 m
: 50 m
1
:80 m
Pipe length of riser pipe: 0 m
4
Inadditionto thepumphead,the requiredpower consumptionis alsoavailablein thedata booklet, wherethepumpsupplierdistinguishesbetweenthe motorshatpoweroutputP1 (printedonthemotor nameplate)andthemotorinputpower,P1.P1isused orsizingtheelectricalinstallations.
60
60 50 Shaded areas show acceptable tolerances
40
Head:90 m
Dependingonthepumpedmediaandthenumbero yearsapumphasbeeninoperation,aserviceinspectionothepumpisrecommended.Thisincludesreplacingallwearpartsinthepump.Therecommendedservicepartsare: • bearings,radial • valveseat • neckrings • sealring • upthrustring. Iextensive wear rom sand has occurredin the pump,replacingthepumpshatandimpellersmay alsobenecessary. Renewingthewearpartsincaseoserviceisessentialormaintainingahighpumpeciencyandalow operatingcost. Forurther service inormation, see the Grundos serviceinstructions.
Friction losses:0 m
PleasenotethatP4isthehydrauliceectproduced bythepump.
P4 : Hydraulic eect
20 10
0
0
Selectionoapumpstartswithestimatingtheow andpressure.Thetotalheadisthesumotheollowing • dynamicwatertable(1) • litaboveground(2) • dischargepressure(3) • lossesinpipes,valveandbends(4)
10
20
30
40
50
60
Fig. 23
Q [m3 /h]
P [kW]
NPSH [m]
P1
16 12
8 6
P2
8
4 NPSH
4
2
0
0 0
Fig. 21 Total head calculation Whenestimatingtheow demand,the wellyield mustalso be takeninto consideration.Inormation regarding thewellyield isavailable rom thewell drillerstest report,whichis madeduring welldevelopment.Ipossible,thenecessaryowmustbe reducedasmuchaspossible.Thiswillminimisethe watertabledrawdown,andreducetotalpowerconsumptionintermsokwh/m3.
10
20
30
40
50
60
Q [m3 /h]
Fig. 24
P2 : Motor shaft power (=P3)
P1 : Motor input power Fig. 22 Power denitions
. Pump selection
40 30
20
0
. Wear parts
Eta [%]
Normallythepowerconsumptionisalsoshownasa unctionotheow.
Figures 23 and 24 Pump perormance parameters includingtolerances Inthedatabooklet,inormationregardingpumpeciencyisalsoavailable,anditcanbeshownasthe pump-endeciency(basedonP2)orasacomplete pumpeciencyincludingthemotor(basedonP1). Insomecases,losesinnon-returnvalvesarenotincludedintheeciencyshown.Theeciencycurves areusedortheselectionopumpsize,wherethe besteciencyareamatchestherequiredow.Ithe completepumpeciencyisnotshown,itcanbecalculatedbyusingtheow(Q),head(H)andpower inputP1:
etatotal = (Q x H x 9.81)/( P1 x 600) The NPSH value stands or “Net Positive Suction Head”andisameasureorrequiredinletpressure= minimumwaterlevelabovepumpinlet. Ingeneral,the NPSHvaluewillincreaseorbigger
8
9
Pumps
Pumps
owsanditherequiredinletpressureisnotmet,it willresultinevaporationothewaterandarisko cavitationdamageinthepump. Ingeneral,therearemanydierentlocalstandards or tolerances on perormance curves. Pump perormanceorGrundosSPpumpsisshownaccordingtoISO9906,AnnexA.QHcurvesprintedinthe documentationshowthenominalcurve.According toISO9906,AnnexA,powercurvesonlyhaveanuppertolerance.Foreciencycurves,onlylowertolerancesareshown.Pleaseseetheexampleshownin g.23and24above.ThegeneralconditionsaccordingtoISO9906ortheperormancecurvesinthis illustrationare: • Themeasurementsaremadewithairlesswaterat atemperatureo20°C. • Curvesapplytoakinematicviscosityo 1mm2/s.Whenpumpingliquidswithahigher density,ahighermotoroutputisrequired. Inaddition toQH, Q-P, Q-eta curves,an axialload curveisnormallyalsoavailableonrequest.Thedown thrustload iscreatedbythe hydraulicsand transerredto themotorthrustbearing.The total axial loadiscalculatedbymultiplyingthesingle-stagevaluesbythenumberostages.Itcanbeusedtocheck whetherthecapacityothemotorthrustbearingis sucient.
Fig. 25 Single-stage axial-load curve, SP 60
0
1
Pumps
Pumps
owsanditherequiredinletpressureisnotmet,it willresultinevaporationothewaterandarisko cavitationdamageinthepump. Ingeneral,therearemanydierentlocalstandards or tolerances on perormance curves. Pump perormanceorGrundosSPpumpsisshownaccordingtoISO9906,AnnexA.QHcurvesprintedinthe documentationshowthenominalcurve.According toISO9906,AnnexA,powercurvesonlyhaveanuppertolerance.Foreciencycurves,onlylowertolerancesareshown.Pleaseseetheexampleshownin g.23and24above.ThegeneralconditionsaccordingtoISO9906ortheperormancecurvesinthis illustrationare: • Themeasurementsaremadewithairlesswaterat atemperatureo20°C. • Curvesapplytoakinematicviscosityo 1mm2/s.Whenpumpingliquidswithahigher density,ahighermotoroutputisrequired. Inaddition toQH, Q-P, Q-eta curves,an axialload curveisnormallyalsoavailableonrequest.Thedown thrustload iscreatedbythe hydraulicsand transerredto themotorthrustbearing.The total axial loadiscalculatedbymultiplyingthesingle-stagevaluesbythenumberostages.Itcanbeusedtocheck whetherthecapacityothemotorthrustbearingis sucient.
Fig. 25 Single-stage axial-load curve, SP 60
0
1
Motors and controls
.1 Motor types, general description Thischapterdealsexclusivelywithsubmersiblemotors,andcontrolsorsubmersiblemotors.Submersiblemotorsarespecialbecausetheyaredesignedto rununderwater.Otherwise,theiroperatingprinciple isthesameasallotherelectricmotors. PleasenotethatallGrundos4”,6”,and8” motors conormtoNEMAstandards. Asubmersiblemotorconsistsoamotorbodyanda motorcable.Thecableisdetachableinaplugsystem. Thecableisdimensionedorsubmergeduseinorder tominimisethespatialrequirementalongthepump. Themotorcableisconnectedtothedropcableabove thepumpbyuseoacableterminationkit.Thedrop cableusedtoraiseandlowerthepump. Canned Inacannedmotor,thewindingsareenamelwire(like instandardsuracemotors)hermeticallysealedrom the surroundings and lled with embedding materialinordertowithholdthewindingsandatthe sametimeincreaseheattranser.Thesemotorshave a journalbearingsystem,consistingo upper and lowerradialbearingsaswellasupthrustanddownthrustbearings.Thrustandjournalbearingsrunhydrodynamicallyinthewater-basedmotorliquid.
tors,ewhaveplugsystems.Oil-lledmotorsincorporateaball-bearingsystem. Single-phase motors There areseveral versionso single phasemotors. Theyallhavetheirdistinctiveadvantagesanddisadvantages.Mosttypesneedacapacitorandsomeotheraccessories,whichisbuiltintoastarterbox.The starterboxisdedicatedorstartingagivenmotorat specicvoltageandrequency. Permanent-split capacitor (PSC) motors Simpleandreliable,PSCmotorshavearun-typecapacitorincludedinthecircuit.Thecapacitorsizeisa compromisebetweenaddingstartingtorqueandensuringahigheciencyduringoperation. Pros:Simple,low-cost,reliableandsilent. Cons:Lowlocked-rotortorqueandloweciency.
PSC L N PE
Switch
Wetwound (rewindable) Wetwoundmotorshavea specialwaterresistance wire,and awatertightjointbetweenthe windings andthemotorcable.Thejointisalwaysinsidethe motor,andnoplugsystemisavailable.
Overload Capacitor
Themotorliquidmainlyconsistsocleanwater.The liquid circulatesaroundthe entire motor,transerringheatawayromwindingsandrotorandlubricatingthebearingsystems.
. Motors and controls
Oil-lled Anoil-lledmotorisequippedwithanimpregnated standardsurace motorwinding. Transormeroil is lledintothemotorandusedaslubricantandcooling.Theoilcanbemineralorvegetableoilwithhigh insulationresistance.Themotorcablespliceistypicallymadeinsidethemotorasinawetwoundmo-
Lightning arrestor (optional)
Main
Start
Fig. 26 PSC
Motors and controls
.1 Motor types, general description Thischapterdealsexclusivelywithsubmersiblemotors,andcontrolsorsubmersiblemotors.Submersiblemotorsarespecialbecausetheyaredesignedto rununderwater.Otherwise,theiroperatingprinciple isthesameasallotherelectricmotors. PleasenotethatallGrundos4”,6”,and8” motors conormtoNEMAstandards. Asubmersiblemotorconsistsoamotorbodyanda motorcable.Thecableisdetachableinaplugsystem. Thecableisdimensionedorsubmergeduseinorder tominimisethespatialrequirementalongthepump. Themotorcableisconnectedtothedropcableabove thepumpbyuseoacableterminationkit.Thedrop cableusedtoraiseandlowerthepump. Canned Inacannedmotor,thewindingsareenamelwire(like instandardsuracemotors)hermeticallysealedrom the surroundings and lled with embedding materialinordertowithholdthewindingsandatthe sametimeincreaseheattranser.Thesemotorshave a journalbearingsystem,consistingo upper and lowerradialbearingsaswellasupthrustanddownthrustbearings.Thrustandjournalbearingsrunhydrodynamicallyinthewater-basedmotorliquid.
tors,ewhaveplugsystems.Oil-lledmotorsincorporateaball-bearingsystem. Single-phase motors There areseveral versionso single phasemotors. Theyallhavetheirdistinctiveadvantagesanddisadvantages.Mosttypesneedacapacitorandsomeotheraccessories,whichisbuiltintoastarterbox.The starterboxisdedicatedorstartingagivenmotorat specicvoltageandrequency. Permanent-split capacitor (PSC) motors Simpleandreliable,PSCmotorshavearun-typecapacitorincludedinthecircuit.Thecapacitorsizeisa compromisebetweenaddingstartingtorqueandensuringahigheciencyduringoperation. Pros:Simple,low-cost,reliableandsilent. Cons:Lowlocked-rotortorqueandloweciency.
PSC L N PE
Switch
Wetwound (rewindable) Wetwoundmotorshavea specialwaterresistance wire,and awatertightjointbetweenthe windings andthemotorcable.Thejointisalwaysinsidethe motor,andnoplugsystemisavailable.
Overload Capacitor
Themotorliquidmainlyconsistsocleanwater.The liquid circulatesaroundthe entire motor,transerringheatawayromwindingsandrotorandlubricatingthebearingsystems. Oil-lled Anoil-lledmotorisequippedwithanimpregnated standardsurace motorwinding. Transormeroil is lledintothemotorandusedaslubricantandcooling.Theoilcanbemineralorvegetableoilwithhigh insulationresistance.Themotorcablespliceistypicallymadeinsidethemotorasinawetwoundmo-
. Motors and controls
Lightning arrestor (optional)
Main
Start
Fig. 26 PSC
Motors and controls
Motors and controls
Capacitor-start/induction-run (CSIR) motor Thestart-upcapacitorbooststhetorqueduringstart up.Thenitisdisconnectedbyaswitch.TheCSIRmotortypeistypicallyusedorsmallerkWratings. Pros:Locked-rotortorque. Cons:Noisyoperation(truesingle-phase),relay neededtocutoutthestart-upcapacitor.
CSIR
Capacitor-start/capacitor-run(CSCR) motors This motortypehasbotha startingcapacitorto booststartingtorque,andaruncapacitor(PSC).This ensuresa smoothoperationand agoodeciency. Themotortypecombinestheadvantagesobotho theabovetypes. Pros:Goodstartingtorque,higheciency. Cons:Priceocontrolbox.
Resistance-start/induction-run (RSIR) motor Thismotorhasarelaybuiltdirectlyintothemotor winding.The relay disconnects thestartingphase whenthemotorisrunning. Pros:Noneedorcapacitors(nocontrolbox),easeo installation. Cons: Limited starting torque, limited kW ratings (onlythrough1.1kW).
CSCR
L N PE
RSIR
L
L
N
N
PE
PE
Relais
l i
Start l icap.
Capacitor start Induction run 0,37 ... 0,75 kW
Capacitor start Capacitor run 1,1 - 3,7 kW
l i
Start cap. Run cap.
-
Tmac Main
Lightning i arrestor
i
i
i
Main
i
i Overload i
Start
i
l
Fig . 28 Schematic diagram o a CSCR motor
Bimetal Start
Fig. 29 RSIR motor Terminology; -wire and -wire motors Theterminologyisrelatedtothenumbero wires neededin theinstallationexcludingearthcable.2wiremotorsmustbesuppliedbythreeleads:phase, neutralendearth.3-wiremotorsmustbesuppliedby ourleads:phase,neutral,pointbetweenstart-and run-windinginmotor+earthcable. -wire motors: • PSCmotorsacapacitorisbuiltintothemotor. • RSIR.
Abettersolutionistohaveamotorspeciallywound ina largerstacklength.Dueto theincreasedsurace, theelectrical dataand coolingcapabilityare improved.Thesemotorsaredesignedorhighertemperatures,widervoltagetolerances,etc.Also,theeciencyoa standardmotoris maintainedor even increased.
Main
l
Start
Fig . 27 Schematic diagram o a CSIR motor
Motor derating Motorderatingiswheretherearespecialrequirementstothemotor,suchashighwatertemperature,voltagetolerancesoutside o acceptable interval,orvoltageunbalance.Allothesesituations stressthemotor winding morethanwhatithas beendesignedor. Thesimplestsolutionisto useanoversizedmotor, typicallynot more twooutputsizesabove therequiredoutput.Theresultisanextendedlietime,but theeciencyisnotoptimal,sincethemotornever operatesatitsoptimaldutypoint.Thepoweractor isnormallybelowduetothepartialloadontheconstruction.
Switch
Relais
l i
-wire motors: • PSCmotorsithereisacapacitorinthestarterbox ontheground. • CSIRmotors • CSCRmotors
. Motor cables and joints, reerence to drop cables Submersiblepumpinstallationare designedto be usedwiththesubmersiblemotor,themotorcable andthejointbetweenmotorcableanddropcable underwater.Ioranyreasonthemotorcableisnot ullysubmerged,thecurrent-carryingcapacitymust alwaysbechecked.Seechapter7.5aswell. Thereore,themotorcable,jointandsubmergedpart othedropcablehavea relativelargesuracearea thatisincontactwiththepumpedmedia.Itisimportanttochoosethecorrectmaterialorthegiven installation.Youmust alsobe aware oyour local drinkingwaterapprovalrequirements.
Motors and controls
Motors and controls
Capacitor-start/induction-run (CSIR) motor Thestart-upcapacitorbooststhetorqueduringstart up.Thenitisdisconnectedbyaswitch.TheCSIRmotortypeistypicallyusedorsmallerkWratings. Pros:Locked-rotortorque. Cons:Noisyoperation(truesingle-phase),relay neededtocutoutthestart-upcapacitor.
CSIR
Capacitor-start/capacitor-run(CSCR) motors This motortypehasbotha startingcapacitorto booststartingtorque,andaruncapacitor(PSC).This ensuresa smoothoperationand agoodeciency. Themotortypecombinestheadvantagesobotho theabovetypes. Pros:Goodstartingtorque,higheciency. Cons:Priceocontrolbox.
Resistance-start/induction-run (RSIR) motor Thismotorhasarelaybuiltdirectlyintothemotor winding.The relay disconnects thestartingphase whenthemotorisrunning. Pros:Noneedorcapacitors(nocontrolbox),easeo installation. Cons: Limited starting torque, limited kW ratings (onlythrough1.1kW).
CSCR
L N PE
RSIR
L
L
N
N
PE
PE
Relais
l i
Start l icap.
Capacitor start Induction run 0,37 ... 0,75 kW
Capacitor start Capacitor run 1,1 - 3,7 kW
l i
Start cap. Run cap.
-
Abettersolutionistohaveamotorspeciallywound ina largerstacklength.Dueto theincreasedsurace, theelectrical dataand coolingcapabilityare improved.Thesemotorsaredesignedorhighertemperatures,widervoltagetolerances,etc.Also,theeciencyoa standardmotoris maintainedor even increased.
Tmac Main
Lightning i arrestor
i
i
i
Main
i
i Overload
i
i
Start
l
Main
l
Bimetal
Start
Fig . 27 Schematic diagram o a CSIR motor
Fig . 28 Schematic diagram o a CSCR motor
Motor derating Motorderatingiswheretherearespecialrequirementstothemotor,suchashighwatertemperature,voltagetolerancesoutside o acceptable interval,orvoltageunbalance.Allothesesituations stressthemotor winding morethanwhatithas beendesignedor. Thesimplestsolutionisto useanoversizedmotor, typicallynot more twooutputsizesabove therequiredoutput.Theresultisanextendedlietime,but theeciencyisnotoptimal,sincethemotornever operatesatitsoptimaldutypoint.Thepoweractor isnormallybelowduetothepartialloadontheconstruction.
Switch
Relais
l i
-wire motors: • PSCmotorsithereisacapacitorinthestarterbox ontheground. • CSIRmotors • CSCRmotors
. Motor cables and joints, reerence to drop cables
Start
Fig. 29 RSIR motor Terminology; -wire and -wire motors Theterminologyisrelatedtothenumbero wires neededin theinstallationexcludingearthcable.2wiremotorsmustbesuppliedbythreeleads:phase, neutralendearth.3-wiremotorsmustbesuppliedby ourleads:phase,neutral,pointbetweenstart-and run-windinginmotor+earthcable. -wire motors: • PSCmotorsacapacitorisbuiltintothemotor. • RSIR.
Submersiblepumpinstallationare designedto be usedwiththesubmersiblemotor,themotorcable andthejointbetweenmotorcableanddropcable underwater.Ioranyreasonthemotorcableisnot ullysubmerged,thecurrent-carryingcapacitymust alwaysbechecked.Seechapter7.5aswell. Thereore,themotorcable,jointandsubmergedpart othedropcablehavea relativelargesuracearea thatisincontactwiththepumpedmedia.Itisimportanttochoosethecorrectmaterialorthegiven installation.Youmust alsobe aware oyour local drinkingwaterapprovalrequirements.
Motors and controls
. Motor protection devices Thesametypeomotor-protectivedevicesusedor standardsuracemotorscanbeusedorsubmersiblemotors.Itisimportanttosecureandlimitshortcircuitingcurrentsandprotectagainstphase-ailures aswellasoverload. Mostsingle-phasemotorshave a built-inthermal protector.Itheprotectorisnotbuiltintothewinding,itmustbeincorporatedinthestarterbox.The protectorseatureautomaticormanualreset.Thermal protectors aredesigned to match the motor windingcharacteristics. Pt100andPt1000arelinearresistors.Combinedwith astandardsensordevice,theycanindicatethetemperaturedevelopment over time.On canned-type motors,the sensordeviceis placedin thestaybolt hole; onwet-wound versions,the sensor device is placedinthemotorliquid. PTCandNTCresistorsarerarelyusedinsubmersible installationsbecause theyare notsuciently ast andreliabletoprotectthesubmersiblemotor. Grundosoersaspecialtemperaturesensingdevice calledTempcon.ItisaNTC-resistorbuiltinnearthe winding,andsensesthetemperature.Thetemperatureisconvertedintoahigh-requencysignal,transmittedtothecontrolpanelbymeansopower-line communication. Fromthe controlpanel, the signal canbepickedupbyasignalconverter,transmitted totheMP204controlpanelandindicatedasatemperatureontheMP204controlpaneldisplay.MP204 isaadvancedmotorprotectordesignedortheprotectionothesubmersiblemotoragainstnetdisturbances.
. Reducing the locked-rotor current Thepurposeoreducingthelocked-rotorcurrentis toprotectotherequipmentagainstpowersurgesin connectionwithhighpowerloads.Thisalsoprotects the pipingagainst excessivepressure surges.There
6
Motors and controls
areseveralwaysoreducingtheimpactonthemains, howevernotallothemarerelevanttopumps.This sectioncoversseveraldierentwaysoreducingthe locked-rotorcurrent,andinormationaboutrunning submersiblepumpswithrequencyconverters. Theollowingappliestoradialandsemi-radial pumps,includingGrundosSPpumps.Axialpumps arehowevernotdealtwithhere. Asthelocked-rotorcurrentoapumpmotorisoten 4-7timesashighastheratedcurrent,therewill beaconsiderablepeakloadogridandmotoror ashortperiod.Inordertoprotectthegrid,many countrieshaveregulationsorreducingthelockedrotorcurrent.Normallyitisgivenasamaximum loadinkWorinAmpsallowedtostartDirectonLine (DOL);Themaximumloadallowedvariesquitealot throughouttheworld,soyoumustbecertainthat youadheretoyourlocalregulations.Insomecases, onlyspecicmethodsorreducingthelocked-rotor currentareallowed.
Ty pe
R ed uc ed locked-rotor current
Pric e
DOL SD
No
Low
OK
Low
Yes
Yes
No
No
No
No Yes Yes
Low Low Medium
Low OK OK
Low Low Medium
Yes Yes Yes/No
Yes Yes Yes
No Yes/No
No No No
No No No
Yes Yes
Medium High
OK OK
Medium Medium/ high
Yes/No Yes/No
Yes/No Yes/No
Yes Yes
No Yes/No
Yes/No Yes/No
Below kW above kW
AF RR SS FC
Features in Space relation to requirement price
theDOLmotorstartergivesthehighestlocked-rotor current,itwillcauseminimalgriddisturbance. Lotsosubmersiblepumpsuselongcables,however. Theselongcablesautomaticallytriggerareductiono thelocked-rotorcurrentduetothesimplephysicsinvolved,astheresistanceinthecablereducesthecurrent.I,orexample,thecableislonganddesignedor avoltagedropo5%ullload(amps),areductiono thelocked-rotorcurrentwilloccurautomatically.The examplebelowillustratesthispoint.
Customer riendly
Reliable
Reduced pressure surge Mechanical Hydraulic
Energy savings during operation
Example: x operating current 6
5
4
Powerconsumption at startup
3
Operating current
2
Theollowingtypesaredescribedintheollowing:
1
DOL-Direct-on-line SD-Star-delta AF-Autotransormer RR–Resistorstarter SS-Sotstarter FC-Frequencyconverter Beoreachoiceismade,application,requirements andlocalstandardsmustbeconsidered.
0 0
1/10 second
Time Sine periods
Typically3 to 5periods
Fig. 30 Current ow by DOL starting
..1 Direct-on-line – DOL InDOLstarting,themotoriscoupleddirectlytothe gridbymeansoacontactororsimilar.Assumingall otheraspectstobethesame,DOLstartingwillalways givethelowestgenerationoheatinthemotor,consequentlyprovidingthelongestliespanomotorsup to45kW.Abovethissize,themechanicalimpacton themotorwillbesoconsiderablethatGrundosrecommendscurrentreduction.Furthermore,although
7
Motors and controls
Motors and controls
. Motor protection devices Thesametypeomotor-protectivedevicesusedor standardsuracemotorscanbeusedorsubmersiblemotors.Itisimportanttosecureandlimitshortcircuitingcurrentsandprotectagainstphase-ailures aswellasoverload. Mostsingle-phasemotorshave a built-inthermal protector.Itheprotectorisnotbuiltintothewinding,itmustbeincorporatedinthestarterbox.The protectorseatureautomaticormanualreset.Thermal protectors aredesigned to match the motor windingcharacteristics. Pt100andPt1000arelinearresistors.Combinedwith astandardsensordevice,theycanindicatethetemperaturedevelopment over time.On canned-type motors,the sensordeviceis placedin thestaybolt hole; onwet-wound versions,the sensor device is placedinthemotorliquid. PTCandNTCresistorsarerarelyusedinsubmersible installationsbecause theyare notsuciently ast andreliabletoprotectthesubmersiblemotor. Grundosoersaspecialtemperaturesensingdevice calledTempcon.ItisaNTC-resistorbuiltinnearthe winding,andsensesthetemperature.Thetemperatureisconvertedintoahigh-requencysignal,transmittedtothecontrolpanelbymeansopower-line communication. Fromthe controlpanel, the signal canbepickedupbyasignalconverter,transmitted totheMP204controlpanelandindicatedasatemperatureontheMP204controlpaneldisplay.MP204 isaadvancedmotorprotectordesignedortheprotectionothesubmersiblemotoragainstnetdisturbances.
. Reducing the locked-rotor current Thepurposeoreducingthelocked-rotorcurrentis toprotectotherequipmentagainstpowersurgesin connectionwithhighpowerloads.Thisalsoprotects the pipingagainst excessivepressure surges.There
areseveralwaysoreducingtheimpactonthemains, howevernotallothemarerelevanttopumps.This sectioncoversseveraldierentwaysoreducingthe locked-rotorcurrent,andinormationaboutrunning submersiblepumpswithrequencyconverters.
Ty pe
R ed uc ed locked-rotor current
Pric e
DOL SD
No
Low
OK
Low
Yes
Yes
No
No
No
No Yes Yes
Low Low Medium
Low OK OK
Low Low Medium
Yes Yes Yes/No
Yes Yes Yes
No Yes/No
No No No
No No No
Yes Yes
Medium High
OK OK
Medium Medium/ high
Yes/No Yes/No
Yes/No Yes/No
Yes Yes
No Yes/No
Yes/No Yes/No
Below kW above kW
AF RR SS FC
Theollowingappliestoradialandsemi-radial pumps,includingGrundosSPpumps.Axialpumps arehowevernotdealtwithhere. Asthelocked-rotorcurrentoapumpmotorisoten 4-7timesashighastheratedcurrent,therewill beaconsiderablepeakloadogridandmotoror ashortperiod.Inordertoprotectthegrid,many countrieshaveregulationsorreducingthelockedrotorcurrent.Normallyitisgivenasamaximum loadinkWorinAmpsallowedtostartDirectonLine (DOL);Themaximumloadallowedvariesquitealot throughouttheworld,soyoumustbecertainthat youadheretoyourlocalregulations.Insomecases, onlyspecicmethodsorreducingthelocked-rotor currentareallowed.
Features in Space relation to requirement price
theDOLmotorstartergivesthehighestlocked-rotor current,itwillcauseminimalgriddisturbance. Lotsosubmersiblepumpsuselongcables,however. Theselongcablesautomaticallytriggerareductiono thelocked-rotorcurrentduetothesimplephysicsinvolved,astheresistanceinthecablereducesthecurrent.I,orexample,thecableislonganddesignedor avoltagedropo5%ullload(amps),areductiono thelocked-rotorcurrentwilloccurautomatically.The examplebelowillustratesthispoint.
Customer riendly
Reliable
Reduced pressure surge Mechanical Hydraulic
Energy savings during operation
Example: x operating current 6
5
4
Powerconsumption at startup
3
Operating current
2
Theollowingtypesaredescribedintheollowing:
1
DOL-Direct-on-line SD-Star-delta AF-Autotransormer RR–Resistorstarter SS-Sotstarter FC-Frequencyconverter Beoreachoiceismade,application,requirements andlocalstandardsmustbeconsidered.
0 0
1/10 second
Time Sine periods
Typically3 to 5periods
Fig. 30 Current ow by DOL starting
..1 Direct-on-line – DOL InDOLstarting,themotoriscoupleddirectlytothe gridbymeansoacontactororsimilar.Assumingall otheraspectstobethesame,DOLstartingwillalways givethelowestgenerationoheatinthemotor,consequentlyprovidingthelongestliespanomotorsup to45kW.Abovethissize,themechanicalimpacton themotorwillbesoconsiderablethatGrundosrecommendscurrentreduction.Furthermore,although
6
7
Motors and controls
Motors and controls
.. Star-delta – SD Themostcommonmethodorreducingthelockedrotorcurrent or motors in general is star-delta starting.Duringstart-up,the motoris connected orstar operation.Whenthe motoris running, it isswitchedovertodeltaconnection.Thishappens automatically ateraxed periodotime. During start-upinstarposition,thevoltageonmotorterminalsisreducedto58%othenominalstarting voltage.Thisstartingmethodisverywellknownin themarketandrelativelycheap,simpleandreliable, whichmakesitverypopular.
Thingsaresomewhatdierentorcentriugalpumps with a greaterdiameter andmass,as they consequentlyhaveahighermomentoinertia.Remember thatstaroperationortoolongmayresultinconsiderablemotorheatingandareducedlietimeasaresult.
.. Autotransormer – AT
.. Primary resistor-type starter, RR
Inthis startingmethod,the voltageis reducedby meanso autotransormers. This principle is also calledtheKorndormethod.
Inthis startingmethod,the voltageis reducedby meansoresistorsputinseriesoneachmotorphase. Theunctionistoincreasetheresistanceduringthe startthuslimitingthelocked-rotorcurrentowing. Acorrectlydimensionedstarterwillreducethestartingvoltage(on theterminalso themotor)to approximately70%othelinevoltage.
SubmersibleinstallationswithSDstarterswilloten be moreexpensive thanother similarinstallations. Twosupplycables(6leads)arerequiredorthemotorinsteadoone(3leads)inthenormalsituation. Themotormustalsoeaturetwosockets,makingit typically5%moreexpensivethanatraditional,single-socketmotor.
6
Neverhaveresistorsconnectedormorethan3seconds,asitwillreducethestartingtorquewithconsequentlyincreasedwinding.
Powerconsumption at startup
5
4
Thestarteriscutoutbymeansoatimercontrolling acontactorwhichmeansthatthereducedvoltage willonlybepresentorthepredenedtimeandthat themotorisenergizedtheentiretime.
Operating current
2
1
0 0
Time
Fig. 31 Current ow by SD starting
Fig. 32. Wye eonguration at start-up
ForSPpumps,andingeneralorpumpswithalow momentoinertia,SDstartingisnotrecommended duetotheactthatspeedislostduringswitching romY/D.Asubmersiblepumpgoesrom0to2.900 rpmwithinthreecycles(0.06s)!Thisalsomeansthat thepumpstopsimmediatelywhenthecurrentisdisconnectedromthemains.
Aterapre-determinedtime,thestarterelectrically switchesthewindingsovertotheDeltaConguration,showning.33.
WhencomparingtheDOLandstar-deltalocked-rotorcurrent,star-deltastartingreducesthecurrent atthebeginning.Whenswitchingoverromstarto delta,thepumpslowsconsiderably,almoststopping completely.Aterwards,ithastostartdirectlyindelta (DOL).Thediagramshowsthatthereisnorealreductionothelocked-rotorcurrent.
Autotransormer starters are relatively expensive, but veryreliable. Thelocked-rotorcurrent naturally dependsonthecharacteristicsomotorandpump, andvariesconsiderablyromtypetotype.
Never havethe autotransormer in thecircuitor morethan3seconds.
Fig. 36. Typical electrical diagram or a primary resistor reduced voltage starter
.. Sot starter – SS Asotstarterisanelectronicunitwhichreducesthe voltageand consequentlythe locked-rotorcurrent by means o phase-angle control. The electronics unitconsistsoacontrolsection,wherethedierent operatingandprotectiveparametersareset,anda powerpartwithtriacs. Thelocked-rotorcurrentis typicallyreducedto 2-3 timestheoperatingcurrent.
Fig. 33. Delta Conguration motor
8
Whenthemotoristobestarted,itisrstconnected toareducedvoltage,withullvoltageollowingaterwards.Duringthisswitchover,partotheautotransormerisconnectedasachokecoil.Thismeansthat themotorwillbeconnectedto thegridtheentire time.Motorspeedwillnotbereduced. Thepowerconsumptionwhenstartingcanbeseen romg.34.
Fig. 34 Current ow by autotransormer starting
3
Fig. 35 Typical electrical diagram or an autotrans ormer reduced voltage starter
9
Motors and controls
Motors and controls
.. Star-delta – SD Themostcommonmethodorreducingthelockedrotorcurrent or motors in general is star-delta starting.Duringstart-up,the motoris connected orstar operation.Whenthe motoris running, it isswitchedovertodeltaconnection.Thishappens automatically ateraxed periodotime. During start-upinstarposition,thevoltageonmotorterminalsisreducedto58%othenominalstarting voltage.Thisstartingmethodisverywellknownin themarketandrelativelycheap,simpleandreliable, whichmakesitverypopular.
Thingsaresomewhatdierentorcentriugalpumps with a greaterdiameter andmass,as they consequentlyhaveahighermomentoinertia.Remember thatstaroperationortoolongmayresultinconsiderablemotorheatingandareducedlietimeasaresult.
.. Autotransormer – AT
.. Primary resistor-type starter, RR
Inthis startingmethod,the voltageis reducedby meanso autotransormers. This principle is also calledtheKorndormethod.
Inthis startingmethod,the voltageis reducedby meansoresistorsputinseriesoneachmotorphase. Theunctionistoincreasetheresistanceduringthe startthuslimitingthelocked-rotorcurrentowing. Acorrectlydimensionedstarterwillreducethestartingvoltage(on theterminalso themotor)to approximately70%othelinevoltage.
SubmersibleinstallationswithSDstarterswilloten be moreexpensive thanother similarinstallations. Twosupplycables(6leads)arerequiredorthemotorinsteadoone(3leads)inthenormalsituation. Themotormustalsoeaturetwosockets,makingit typically5%moreexpensivethanatraditional,single-socketmotor.
6
Neverhaveresistorsconnectedormorethan3seconds,asitwillreducethestartingtorquewithconsequentlyincreasedwinding.
Powerconsumption at startup
5
4
Thestarteriscutoutbymeansoatimercontrolling acontactorwhichmeansthatthereducedvoltage willonlybepresentorthepredenedtimeandthat themotorisenergizedtheentiretime.
Operating current
2
1
0
Time
0
Fig. 31 Current ow by SD starting
Fig. 32. Wye eonguration at start-up
ForSPpumps,andingeneralorpumpswithalow momentoinertia,SDstartingisnotrecommended duetotheactthatspeedislostduringswitching romY/D.Asubmersiblepumpgoesrom0to2.900 rpmwithinthreecycles(0.06s)!Thisalsomeansthat thepumpstopsimmediatelywhenthecurrentisdisconnectedromthemains.
Aterapre-determinedtime,thestarterelectrically switchesthewindingsovertotheDeltaConguration,showning.33.
WhencomparingtheDOLandstar-deltalocked-rotorcurrent,star-deltastartingreducesthecurrent atthebeginning.Whenswitchingoverromstarto delta,thepumpslowsconsiderably,almoststopping completely.Aterwards,ithastostartdirectlyindelta (DOL).Thediagramshowsthatthereisnorealreductionothelocked-rotorcurrent.
Whenthemotoristobestarted,itisrstconnected toareducedvoltage,withullvoltageollowingaterwards.Duringthisswitchover,partotheautotransormerisconnectedasachokecoil.Thismeansthat themotorwillbeconnectedto thegridtheentire time.Motorspeedwillnotbereduced. Thepowerconsumptionwhenstartingcanbeseen romg.34. Autotransormer starters are relatively expensive, but veryreliable. Thelocked-rotorcurrent naturally dependsonthecharacteristicsomotorandpump, andvariesconsiderablyromtypetotype.
Never havethe autotransormer in thecircuitor morethan3seconds.
Fig. 36. Typical electrical diagram or a primary resistor reduced voltage starter
.. Sot starter – SS Asotstarterisanelectronicunitwhichreducesthe voltageand consequentlythe locked-rotorcurrent by means o phase-angle control. The electronics unitconsistsoacontrolsection,wherethedierent operatingandprotectiveparametersareset,anda powerpartwithtriacs. Thelocked-rotorcurrentis typicallyreducedto 2-3 timestheoperatingcurrent.
Fig. 34 Current ow by autotransormer starting
3
Fig. 33. Delta Conguration motor
Fig. 35 Typical electrical diagram or an autotrans ormer reduced voltage starter
8
9
Motors and controls
Motors and controls
Torque Operating Start-up
100%
Stop
55%
0 0
Max. 3 sec.
Max. 3 sec. Time
Fig. 37 Recommended start-up and stop time, max. 3 sec.
Pleasenotethatirampingdownisrequired,itmight notbepossibletousethebypasscontactorsolution orreducingthepowerconsumptionduringnormal operation.
Anewseries/generationosotstartershasbeenintroduced.They areequipped witha programmable startramp unction orreducingthe locked-rotor currenturther,ororrampinghighinertialoads.I suchsotstartersareused,pleaseuseramptimes omax.threeseconds.Ingeneral,Grundosrecommendsthatyoualwaysinstallthesotstarterwith abypasscontactor,enablingthemotortorunDOL duringoperation.Inthisway,wearandpowerlossis avoidedinthesotstarterduringoperation.
quencyconvertersarethecheapestonthemarket,andareotenemployed.
Fig. 39 Pump perormance with diferent requencies 1,5 1.4 1.3 1.2 1.1 1,0
Werecommendtheuse orequencyconvertersi otherramptimesarerequired.
Operating current
0.8 0.7 0.6
TemperaturereadoutoGrundosmotorswithtemperaturetransmittersis possiblei thesotstarter hasabypasscontactor.
0.5
Fig. 38 Current ow by sot starting Otherthingsbeingthesame,thisalsogivesareduced startingtorque.Theslowstartmayresultinanincreasedheatgenerationinthemotor,leadingtoareducedlietime.Withshortacceleration/deceleration times(suchasthreeseconds),thisisonopractical importance.ThesamegoesorSDandATstarting. Grundosthereorerecommendsollowingtheacceleration/decelerationtimesstatedinthegurewhen usingasotstarter.ItshouldnotbenecessaryinconnectionwithGrundospumpsto raisethe starting voltage above 55%. However i a particularlyhigh startingtorqueisrequired,thestartingvoltagemay beincreasedtoachievetherequiredtorque. Asot starter willabsorba non-sinusoidalcurrent andgiverisetosomegridnoise.Inconnectionwith veryshortacceleration/decelerationtimes,thisiso nopracticalimportanceanddoesnotconictwith regulationsconcerninggridnoise.
Sotstartersmayonlybeusedon3phasesubmersiblemotors. Max.timeorreducedvoltageshallbelimitednotto exceed3seconds.
..6 Frequency converters (variable speed drive) Frequencyconvertersaretheidealdevicetocontrol theperormanceothepump,byadjustingthespeed othemotor.Itisthereorealsoanidealstartertype, bothorreductionothelocked-rotorcurrentandor reductionopressuresurges. Note:alowrequencyproducesslowimpellerrotation,reducingpumpperormance.
Theoutputsectionoa requencyconvertercanbe madeintwodierentways:eitherwithsixorwith 12transistors.
0.4 0.3 0.2 0.1
0
0.9
• The next step is the Vector-Controlled requency converter.Thisrequencyconverterusesa modelo themotor,andcalculatestheoutputvoltagebased onseveralparametersincludingtheactualload.This giveshigherperormanceincontrollingtheshato themotor,suchasahigheraccuracyomin-1,torque, etc.These drivesaremore expensivethan theU/ baseddrives,andaretypicallyusedorindustrialapplications.However, theyare alsoused in systems whereinstabilitiesotenoccur.Themorepreciseway ocontrollingtheshatnormallyeliminatestheproblemscausedbyaninstablepump,Thevector-controlleddrivesusuallyhaveahighereciency,oranautomaticenergyoptimizerunction.
0 0
3 seconds min. 30 Hz
Typical start-up 30 seconds
Fig. 40 Current ow by requency converter starting Frequencyconvertersarethemostexpensiveothe above-mentionedstartingdevices,andwillprimarily beusedinconnectionwithoperationatvariableperormance. Thereare severaltypeso requencyconverterson themarket,eachhavingits owncharacteristics.A brieoverviewispresentedhere: • Thesimplestrequencyconverteris basedon a voltagerequencycurve.ThisconverterissometimescalledanU/orV/converter.Theycalculatetheactualoutputvoltageromtherequency, withouttaking theactual load into consideration.DierentU/orV/curvescanbechosento optimise orthe actualapplication. Pumpswill typicallyusetheVariableTorquecurve.Thesere-
Thiscanalsobereerredtoas6-pulseand12-pulse inverters. Sixtransistorsare the mostcommonly oundsolution,asitisthecheapestandthesimplestwayocreatinganoutputstage.Toreducethe stressonmotorinsulationandincreasethecontrol perormance, the 12-transistor output stage was introduced.12-transistoroperationistypicallycombinedwithadvancedcontrolsthatarebasedonux modelsothemotor.Theadvantageoa12-transistorsolution usuallyincludes improved control at lowspeedsandlessstressonthemotor.A12-pulse requencyconverterliesintheexpensiverangeo requencyconverters. Themainselectionactororcombiningrequency converterandpumpistheullloadampsincluding theoverloadactor.Therequencyconvertershould bechosensoitcandelivertherequiredcurrentall thetime.Forexample,ithemotorrequires9.7A, chosearequencyconverterwithandoutputcurrentat9.7Aorhigher.
1
Motors and controls
Motors and controls
Torque Operating Start-up
100%
Stop
55%
0 0
Max. 3 sec.
Max. 3 sec. Time
Fig. 37 Recommended start-up and stop time, max. 3 sec.
Pleasenotethatirampingdownisrequired,itmight notbepossibletousethebypasscontactorsolution orreducingthepowerconsumptionduringnormal operation.
Anewseries/generationosotstartershasbeenintroduced.They areequipped witha programmable startramp unction orreducingthe locked-rotor currenturther,ororrampinghighinertialoads.I suchsotstartersareused,pleaseuseramptimes omax.threeseconds.Ingeneral,Grundosrecommendsthatyoualwaysinstallthesotstarterwith abypasscontactor,enablingthemotortorunDOL duringoperation.Inthisway,wearandpowerlossis avoidedinthesotstarterduringoperation.
quencyconvertersarethecheapestonthemarket,andareotenemployed.
Fig. 39 Pump perormance with diferent requencies 1,5 1.4 1.3 1.2 1.1 1,0
Werecommendtheuse orequencyconvertersi otherramptimesarerequired.
0.9
Operating current
0.8 0.7 0.6
TemperaturereadoutoGrundosmotorswithtemperaturetransmittersis possiblei thesotstarter hasabypasscontactor.
0.5
Fig. 38 Current ow by sot starting Otherthingsbeingthesame,thisalsogivesareduced startingtorque.Theslowstartmayresultinanincreasedheatgenerationinthemotor,leadingtoareducedlietime.Withshortacceleration/deceleration times(suchasthreeseconds),thisisonopractical importance.ThesamegoesorSDandATstarting. Grundosthereorerecommendsollowingtheacceleration/decelerationtimesstatedinthegurewhen usingasotstarter.ItshouldnotbenecessaryinconnectionwithGrundospumpsto raisethe starting voltage above 55%. However i a particularlyhigh startingtorqueisrequired,thestartingvoltagemay beincreasedtoachievetherequiredtorque.
Sotstartersmayonlybeusedon3phasesubmersiblemotors. Max.timeorreducedvoltageshallbelimitednotto exceed3seconds.
..6 Frequency converters (variable speed drive) Frequencyconvertersaretheidealdevicetocontrol theperormanceothepump,byadjustingthespeed othemotor.Itisthereorealsoanidealstartertype, bothorreductionothelocked-rotorcurrentandor reductionopressuresurges. Note:alowrequencyproducesslowimpellerrotation,reducingpumpperormance.
Asot starter willabsorba non-sinusoidalcurrent andgiverisetosomegridnoise.Inconnectionwith veryshortacceleration/decelerationtimes,thisiso nopracticalimportanceanddoesnotconictwith regulationsconcerninggridnoise.
Theoutputsectionoa requencyconvertercanbe madeintwodierentways:eitherwithsixorwith 12transistors.
0.4 0.3 0.2 0.1
• The next step is the Vector-Controlled requency converter.Thisrequencyconverterusesa modelo themotor,andcalculatestheoutputvoltagebased onseveralparametersincludingtheactualload.This giveshigherperormanceincontrollingtheshato themotor,suchasahigheraccuracyomin-1,torque, etc.These drivesaremore expensivethan theU/ baseddrives,andaretypicallyusedorindustrialapplications.However, theyare alsoused in systems whereinstabilitiesotenoccur.Themorepreciseway ocontrollingtheshatnormallyeliminatestheproblemscausedbyaninstablepump,Thevector-controlleddrivesusuallyhaveahighereciency,oranautomaticenergyoptimizerunction.
0 0
3 seconds min. 30 Hz
Typical start-up 30 seconds
Fig. 40 Current ow by requency converter starting Frequencyconvertersarethemostexpensiveothe above-mentionedstartingdevices,andwillprimarily beusedinconnectionwithoperationatvariableperormance. Thereare severaltypeso requencyconverterson themarket,eachhavingits owncharacteristics.A brieoverviewispresentedhere: • Thesimplestrequencyconverteris basedon a voltagerequencycurve.ThisconverterissometimescalledanU/orV/converter.Theycalculatetheactualoutputvoltageromtherequency, withouttaking theactual load into consideration.DierentU/orV/curvescanbechosento optimise orthe actualapplication. Pumpswill typicallyusetheVariableTorquecurve.Thesere-
Thiscanalsobereerredtoas6-pulseand12-pulse inverters. Sixtransistorsare the mostcommonly oundsolution,asitisthecheapestandthesimplestwayocreatinganoutputstage.Toreducethe stressonmotorinsulationandincreasethecontrol perormance, the 12-transistor output stage was introduced.12-transistoroperationistypicallycombinedwithadvancedcontrolsthatarebasedonux modelsothemotor.Theadvantageoa12-transistorsolution usuallyincludes improved control at lowspeedsandlessstressonthemotor.A12-pulse requencyconverterliesintheexpensiverangeo requencyconverters. Themainselectionactororcombiningrequency converterandpumpistheullloadampsincluding theoverloadactor.Therequencyconvertershould bechosensoitcandelivertherequiredcurrentall thetime.Forexample,ithemotorrequires9.7A, chosearequencyconverterwithandoutputcurrentat9.7Aorhigher.
0
1
Motors and controls
. Operation with requency converter Thereareseveralthingsthat shouldbe considered whenusingrequencyconverterstogetherwithsubmersiblemotors.Someotheconditionsorrunning submersible motors on requency converters are oundbelow. 1a.Therequencyconvertermusthavesomekindo outputlterto limit voltagepeaks(Upeak)and toreducedU/dt(ordV/dt)whichcoursesstress ontheinsolationothesubmersiblemotor.The maximumvoltage(U peak)shouldbereducedtoa levelolessthan850V(exceptortheMS402); dU/dtshouldalsobelimitedinaccordancewith theollowingtable. Max peak voltage and max dU / dt or Grundos submersibles Motors eries
Max.Upeakvoltage
Max.dU/dt
MS402
650VPhase-P hase
2000V/m icros .
MS4000
850VPhase-P hase
2000V/m icros .
MS6/MS6000
850V Phase-Phase
2000V /m icros.
MMS6/MMS6000
850VPhase-Ground
500V/micros.
MMS8000
850V Phase- Ground
500V /micros.
MMS10000
850V Phase- Ground
500V /micros.
MMS12000
850V Phase- Ground
500V /micros.
Thetypical outputltersorrequencyconvertersareLC(alsocalledsinuslters)orRC lters. Frequency converter suppliers can supply data regardingU peakanddU/dtortheirdierentrequencyconverterseries.Pleaseseechapter5.6. Normally,ltersarealsorequiredilongmotorcablesaretobeusedtogetherwiththerequency converter. TheUpeakanddU/dtvaluesshouldbemeasured onthemotorterminals. SeetableaboveoracceptablevaluesodV/dt. 1b.Frequency converters are normallydesigned or useinanindustrialenvironment.Iarequency converterisusedinresidentialareas,itmightbe necessarytoaddsomekindoinputltertopre-
Motors and controls
ventelectricaldisturbancesromthe requency converterromaectingotherequipmentonthe samemains.Normallythereare three dierent levelsolterstoselectamong: • Nolter(Onlyorindustrialusewhereltering isdoneelsewhere) • Filtersorindustrialapplications • Filtersordomesticapplications. Theversionordomesticapplicationscanbean add-onortheindustrialapplication,oritcanbea separateversion. Itismandatorytoulltherequirementsinthe manualsortherequencyconverterorkeeping theCE mark ontheproduct.Ithis isnotdone properlytheCEmarkingisnotallowed. 2.T he ow ratepast the motormustbe atleast 0.15m/s.Themotormustbettedwithacooling sleeveithepumpingdoesnotcreatesucient owpastthemotor. 3. Withcontrolosubmersiblemotorsinopensystemswithhighstaticlit,thepowerconsumption willchange onlymoderately.Thismeans thata reductionothepumpperormancewillgiveincreasedgenerationoheatinthemotor.Areductionothemotorlietimemustthereorebeexpected.Foroperationwitharequencyconverter, Grundosthereore alwaysrecommends usinga motorwithsparecapacity,i.e.anindustrialmotor oraderatedstandardmotor. 4.Themotorrequency: min.:30Hz max.:60Hz 5. TemperatureprotectionoGrundossubmersible motors withrequencyconverteris possibleor motorswithabuilt-inthermocontacts.Themotor temperaturecannotberead,buttheprotectionis thesame.Anadditionalcableisrequiredorthe motor, butas operationo submersiblemotors bymeansorequencyconvertersisusuallyused inconnectionwithtankapplication,thiswillnot causedisturbancesoradditionalcosts.
I the points discussed above are met, the motor will have an acceptable lietime.
.6 CUE variable speed drive or SP pumps
Pleasenotethatexternalrequencyconvertersresult inpowerlossandtransmitstransients,theywill: • generatemoreheatinthemotorcomparedtodirectonlineoperation • reducethemotoreciency • increasethepowerconsumptionothemotor. Becauseo this,an industrialmotorshouldalways beused,asithasbeenbuilttocompensateorthese disadvantages. Asarastheoperatingeconomyisconcerned,theollowingshouldbetakenintoconsideration: • Frequencycontrolodeepwellsubmersiblepumps willnormally notresult in improvedoperating economywheninstalledinawell. • Itdoes,however,reducetheneedorlargetanks andspaceorthese. • Frequencycontrol oraw-waterpumps reduces pressuresurgesinthepipesystemandvariations othewaterlevelinthewellatpumpstartand stop. Howeverwheresomekindocontrolisneededsuchas constantpressure,constantwellwaterlevel,orsimilar,theremightbedierentlevelsoimprovementin usingrequencyconverters.Arequencyconverterincludessomelogicinputandoutput.ItalsotypicallyincludesaPIDcontrolsection,orestablishingcontrolo theapplication.Inmanycasesadditionalequipment canbeomitted,andtheuseotherequencyconverterasastarterandasapartothecontrolsystemwill improvetheoveralleconomicperspective. ThePID controlleris widelyused incontrolapplications,andrequencyconvertermanuacturesnormallygivessomehintsabouthowtooptimizetheuseo thiseature. Pleasebe awareo thatan incorrectlyprogrammed PIDcontrollercouldleadtoaninstableperormance andexcessivepressureonthesystem. Pleasenotethattheramp-uptimetoaminimumrequencyo30Hzmaynottakelongerthan3seconds.
Fig. 41 CUE amily CUEisaGrundosrequencydrivewithalogicalinteraceoreasysetupandoperation. WithaCUE,itispossibletocontrolpumpperormancebychangingtherequency.Thisallowsyouto programasmoothstartupandstopothepump. Thisminimisestheriskodamagesonthepressure pipeandtheentirepressurepipingsystem.Italsoreducesthestressromwaterhammerwhileminimisingthecostsorvalvesandotherregulatingdevices. Operationbelow30 Hzis acceptableorno more thanthreeseconds.Above30Hz,thereisnolimitationregardingoperationtime.Thismustalwaysbe observedhowever,bothduringramp-upandrampdownsequences. Themax.requencyis60Hz.
Motors and controls
Motors and controls
. Operation with requency converter Thereareseveralthingsthat shouldbe considered whenusingrequencyconverterstogetherwithsubmersiblemotors.Someotheconditionsorrunning submersible motors on requency converters are oundbelow. 1a.Therequencyconvertermusthavesomekindo outputlterto limit voltagepeaks(Upeak)and toreducedU/dt(ordV/dt)whichcoursesstress ontheinsolationothesubmersiblemotor.The maximumvoltage(U peak)shouldbereducedtoa levelolessthan850V(exceptortheMS402); dU/dtshouldalsobelimitedinaccordancewith theollowingtable.
Max.Upeakvoltage
Max.dU/dt
MS402
650VPhase-P hase
2000V/m icros .
MS4000
850VPhase-P hase
2000V/m icros .
MS6/MS6000
850V Phase-Phase
2000V /m icros.
MMS6/MMS6000
850VPhase-Ground
500V/micros.
MMS8000
850V Phase- Ground
500V /micros.
MMS10000
850V Phase- Ground
500V /micros.
MMS12000
850V Phase- Ground
500V /micros.
Itismandatorytoulltherequirementsinthe manualsortherequencyconverterorkeeping theCE mark ontheproduct.Ithis isnotdone properlytheCEmarkingisnotallowed. 2.T he ow ratepast the motormustbe atleast 0.15m/s.Themotormustbettedwithacooling sleeveithepumpingdoesnotcreatesucient owpastthemotor.
Max peak voltage and max dU / dt or Grundos submersibles Motors eries
ventelectricaldisturbancesromthe requency converterromaectingotherequipmentonthe samemains.Normallythereare three dierent levelsolterstoselectamong: • Nolter(Onlyorindustrialusewhereltering isdoneelsewhere) • Filtersorindustrialapplications • Filtersordomesticapplications. Theversionordomesticapplicationscanbean add-onortheindustrialapplication,oritcanbea separateversion.
Thetypical outputltersorrequencyconvertersareLC(alsocalledsinuslters)orRC lters. Frequency converter suppliers can supply data regardingU peakanddU/dtortheirdierentrequencyconverterseries.Pleaseseechapter5.6. Normally,ltersarealsorequiredilongmotorcablesaretobeusedtogetherwiththerequency converter. TheUpeakanddU/dtvaluesshouldbemeasured onthemotorterminals. SeetableaboveoracceptablevaluesodV/dt. 1b.Frequency converters are normallydesigned or useinanindustrialenvironment.Iarequency converterisusedinresidentialareas,itmightbe necessarytoaddsomekindoinputltertopre-
3. Withcontrolosubmersiblemotorsinopensystemswithhighstaticlit,thepowerconsumption willchange onlymoderately.Thismeans thata reductionothepumpperormancewillgiveincreasedgenerationoheatinthemotor.Areductionothemotorlietimemustthereorebeexpected.Foroperationwitharequencyconverter, Grundosthereore alwaysrecommends usinga motorwithsparecapacity,i.e.anindustrialmotor oraderatedstandardmotor. 4.Themotorrequency: min.:30Hz max.:60Hz 5. TemperatureprotectionoGrundossubmersible motors withrequencyconverteris possibleor motorswithabuilt-inthermocontacts.Themotor temperaturecannotberead,buttheprotectionis thesame.Anadditionalcableisrequiredorthe motor, butas operationo submersiblemotors bymeansorequencyconvertersisusuallyused inconnectionwithtankapplication,thiswillnot causedisturbancesoradditionalcosts.
I the points discussed above are met, the motor will have an acceptable lietime.
.6 CUE variable speed drive or SP pumps
Pleasenotethatexternalrequencyconvertersresult inpowerlossandtransmitstransients,theywill: • generatemoreheatinthemotorcomparedtodirectonlineoperation • reducethemotoreciency • increasethepowerconsumptionothemotor. Becauseo this,an industrialmotorshouldalways beused,asithasbeenbuilttocompensateorthese disadvantages. Asarastheoperatingeconomyisconcerned,theollowingshouldbetakenintoconsideration: • Frequencycontrolodeepwellsubmersiblepumps willnormally notresult in improvedoperating economywheninstalledinawell. • Itdoes,however,reducetheneedorlargetanks andspaceorthese. • Frequencycontrol oraw-waterpumps reduces pressuresurgesinthepipesystemandvariations othewaterlevelinthewellatpumpstartand stop. Howeverwheresomekindocontrolisneededsuchas constantpressure,constantwellwaterlevel,orsimilar,theremightbedierentlevelsoimprovementin usingrequencyconverters.Arequencyconverterincludessomelogicinputandoutput.ItalsotypicallyincludesaPIDcontrolsection,orestablishingcontrolo theapplication.Inmanycasesadditionalequipment canbeomitted,andtheuseotherequencyconverterasastarterandasapartothecontrolsystemwill improvetheoveralleconomicperspective. ThePID controlleris widelyused incontrolapplications,andrequencyconvertermanuacturesnormallygivessomehintsabouthowtooptimizetheuseo thiseature. Pleasebe awareo thatan incorrectlyprogrammed PIDcontrollercouldleadtoaninstableperormance andexcessivepressureonthesystem. Pleasenotethattheramp-uptimetoaminimumrequencyo30Hzmaynottakelongerthan3seconds.
Fig. 41 CUE amily CUEisaGrundosrequencydrivewithalogicalinteraceoreasysetupandoperation. WithaCUE,itispossibletocontrolpumpperormancebychangingtherequency.Thisallowsyouto programasmoothstartupandstopothepump. Thisminimisestheriskodamagesonthepressure pipeandtheentirepressurepipingsystem.Italsoreducesthestressromwaterhammerwhileminimisingthecostsorvalvesandotherregulatingdevices. Operationbelow30 Hzis acceptableorno more thanthreeseconds.Above30Hz,thereisnolimitationregardingoperationtime.Thismustalwaysbe observedhowever,bothduringramp-upandrampdownsequences. Themax.requencyis60Hz.
Motors and controls
Motors and controls
Theset-updataortheCUEisalwayscurrent,and notkW,sincesubmersiblemotorsareotendierent romnormmotors. Functions TheCUEallowsyouto maintaintheollowingparameters: • Constantpressure • Constantlevel • Constantowrate • Constanttemperature • Constantcurve. Power cable Asubmersiblepumppowercableinascreenedversionisnotavailable.Normally,itisnotrequiredaccordingtotheEMCregulationsduetothesubmerged installation.
Mains cable Thiscablerunsromthemainssupplytothe CUE unscreened.The cablebetween CUE and lteris screened.Thecable runningromthe lter tothe pumpmotorisnormallyunscreened.Thetwoexamplesillustratethesesetups. Ithecableisusedoutsidethewellinadryenvironment,ascreenedcablemaybeusedwithacableconnectiontothesubmersiblepumpcableatthewell head.g.42belowshowshowacableselectioncan beusedtogetherwithCUEandalter.Inthesecond example,theconnectionboxislocatedatthewell head.
Filter selection Fig.44belowshowshowtoselectthecorrectlter ortheinstallation. How to chose a flter
Is the pump an SP/BM or BMB
NO
Furtherinormationmaybe ound inwebCAPS on www.grundos.com.
Cable length <150m and p> 11 kW
Use sine wave flter
YES
Use dU/dt flter
Fig. 44 Setting guidelines
CUE and Filter mounted close to well Mains
Unscreened cable
CUE
screened cable
Filter
Unscreened drop cable
M
Grundosoersaullrangeolterstobeusedwith CUE.
Fig. 42 Submersible pump without connection box
Mains
Unscreened cable
CUE
screened cable
ThemaindierencebetweendU/dtltersandsine waveltersis: Bothltersconsistocoilsandcapacitors.Thecoils andthecapacitorsaresmallinvalueinthedU/dtlterscomparedtothevaluesusedinsinewavelters.
Filter
screened cable
Connection box*
Unscreened drop cable
Setting guidelines • Ramp(upanddown):maximum3seconds.This istoensurethelubricationojournalbearingsto limitwear,andpreventthewindingrombecomingburntout. • UsetemperaturemonitoringbyPT100(useo screenedcablecanbeneeded). • Heatkillsthemotor=>lowisolationresistance =>sensitivetovoltagepeaks. • Motorrecommendations: –ForMS:usemotorswith10%extraingiven dutypoint. – ForMMS:alwaysusemotorsthatarePE2–PA wound. • RemembertouseaLClter. • Reducepeakstomax.800V. • GrundosrecommendDanossrequencyinverter,incombinationwithaLClter. • Cablesactasampliers=>measurepeaksatthe motor. • Dimensionitwithrespectorthecurrentandnot thepoweroutput. • Dimensionthecoolingprovisionorthestator tubeatdutypointwithlowestowrate.The minimumowm/salongthestatorhousing mustbeconsidered. • Assurethatthepumpisusedwithintheintendedrangeothepumpcurve. • Focusonthedischargepressureandsucient NPSH,asvibrationswillkillthemotor.
M
* Both ends o the screened cable rom the flter to the connection box must connected to earth
Fig. 43 Submersible pump with connection box and screened cable
Motors and controls
Motors and controls
Theset-updataortheCUEisalwayscurrent,and notkW,sincesubmersiblemotorsareotendierent romnormmotors. Functions TheCUEallowsyouto maintaintheollowingparameters: • Constantpressure • Constantlevel • Constantowrate • Constanttemperature • Constantcurve. Power cable Asubmersiblepumppowercableinascreenedversionisnotavailable.Normally,itisnotrequiredaccordingtotheEMCregulationsduetothesubmerged installation.
Mains cable Thiscablerunsromthemainssupplytothe CUE unscreened.The cablebetween CUE and lteris screened.Thecable runningromthe lter tothe pumpmotorisnormallyunscreened.Thetwoexamplesillustratethesesetups. Ithecableisusedoutsidethewellinadryenvironment,ascreenedcablemaybeusedwithacableconnectiontothesubmersiblepumpcableatthewell head.g.42belowshowshowacableselectioncan beusedtogetherwithCUEandalter.Inthesecond example,theconnectionboxislocatedatthewell head.
Filter selection Fig.44belowshowshowtoselectthecorrectlter ortheinstallation. How to chose a flter
Is the pump an SP/BM or BMB
NO
Furtherinormationmaybe ound inwebCAPS on www.grundos.com.
Cable length <150m and p> 11 kW
Use sine wave flter
YES
Use dU/dt flter
Fig. 44 Setting guidelines
CUE and Filter mounted close to well Mains
Unscreened cable
CUE
screened cable
Filter
Unscreened drop cable
M
Grundosoersaullrangeolterstobeusedwith CUE.
Fig. 42 Submersible pump without connection box
Mains
Unscreened cable
CUE
screened cable
ThemaindierencebetweendU/dtltersandsine waveltersis: Bothltersconsistocoilsandcapacitors.Thecoils andthecapacitorsaresmallinvalueinthedU/dtlterscomparedtothevaluesusedinsinewavelters.
Filter
screened cable
Connection box*
Unscreened drop cable
Setting guidelines • Ramp(upanddown):maximum3seconds.This istoensurethelubricationojournalbearingsto limitwear,andpreventthewindingrombecomingburntout. • UsetemperaturemonitoringbyPT100(useo screenedcablecanbeneeded). • Heatkillsthemotor=>lowisolationresistance =>sensitivetovoltagepeaks. • Motorrecommendations: –ForMS:usemotorswith10%extraingiven dutypoint. – ForMMS:alwaysusemotorsthatarePE2–PA wound. • RemembertouseaLClter. • Reducepeakstomax.800V. • GrundosrecommendDanossrequencyinverter,incombinationwithaLClter. • Cablesactasampliers=>measurepeaksatthe motor. • Dimensionitwithrespectorthecurrentandnot thepoweroutput. • Dimensionthecoolingprovisionorthestator tubeatdutypointwithlowestowrate.The minimumowm/salongthestatorhousing mustbeconsidered. • Assurethatthepumpisusedwithintheintendedrangeothepumpcurve. • Focusonthedischargepressureandsucient NPSH,asvibrationswillkillthemotor.
M
* Both ends o the screened cable rom the flter to the connection box must connected to earth
Fig. 43 Submersible pump with connection box and screened cable
Power Supply
6.1 Power generation Theollowingwillonlyocusonalternatingcurrent (AC)asthisistheprimarysourceopowerorasynchronousmotors. Distribution Inorderorgeneratedpowertobeuseul,itmustbe transmittedromthe generating plant tothe area whereconsumptiontakesplace.Thechallengeisto havesucient amount o energy availableat the timeandplacewhereworkisdemanded. Themostecientwaytotranserenergyromgeneratingplantto consumptionplacesis toincrease voltagewhilereducingcurrent.Thisisnecessaryin order tominimizethe energyloss asconsequence otransmission.TheselossesarereerredtoasI2xR losses,sincetheyareequaltothesquareothecurrenttimestheresistanceothepowerlines.Oncethe electricalenergygetsneartheenduser,theutilitywill needtostepdownthevoltagetothelevelneededby theconsumingmachine.Eachtime,thevoltagelevel ischanged,energyislost,eveninthemostecient transormers.
6. Voltage 6..1 Voltage unbalance Submersiblemotorsaredesignedtooperateonpowerlineswithgivenvoltageandrequency. Voltageunbalancecanberegulatedattheregulating boardothetransormerand/orthegenerator.The voltageunbalanceshallbekeptassmallaspossible, asitistheprimarysourceocurrentunbalance.This leadstothecreationoadditionalheatinthemotor.
6.. Overvoltage and undervoltage Powerlinesareexpectedtodeliveraspecicvoltage. Nearthelow voltagetransormer,there willoten beanovervoltageo3-5%.Whenthepowerlinesare loaded,avoltagedropwilloccurduetoohmicresistanceinperiodsopeakpowerconsumption. Mostpowerlinesaredimensionedsothatundervoltageomorethan-10%willoccurlessthanoncea yearattheweakestpoint.Butmanyconsumersstill experienceperiodsoconsiderablevoltagedrop. Anymotorwillsueriitdoesnotreceivethevoltage stampedonthenameplate.Ithevoltagedrops,the motortorquewillbereducedandthespeedothe loadedmotorwillconsequentlybereduced,too. Asaresultothis,theeciencyandinductionresistanceothemotorwilldrop.Thiswillmakethepower consumptionincrease,resultinginincreasedgenerationoheatinthemotor. Whenaully-loadedcentriugalpumpmotorreceives 10%undervoltage,the powerconsumptionwillincreasebyapprox.5%,andthemotortemperatureby about20%.Ithistemperatureincreaseexceedsthe maximumtemperatureo the insulation material aroundthe windings,thesewill be short-circuited andthestatorwillbedestroyed.Inthesubmersible motor,thetemperatureothemotorliquidisvery importantorthelubricationothejournalbearings. Theloadcapacityasunctionothetemperaturecan beseenonthediagrambelow.
Onepossiblecauseovoltageunbalanceistheunequaldistributionosinglephaseloads.Theseloads vary over time.Voltageunbalanceis subsequently verydicultto avoidi thenetcontains highpercentageosinglephaseconsumption.
6. Power Supply 6
Useo twosinglephasetransormersin socalled “open delta” connection is not recommended or threephasesupply.
Fig. 45 Diagram: Journal bearings load capacity as unction o motor liquid temperature.
7
Power Supply
6.1 Power generation Theollowingwillonlyocusonalternatingcurrent (AC)asthisistheprimarysourceopowerorasynchronousmotors. Distribution Inorderorgeneratedpowertobeuseul,itmustbe transmittedromthe generating plant tothe area whereconsumptiontakesplace.Thechallengeisto havesucient amount o energy availableat the timeandplacewhereworkisdemanded. Themostecientwaytotranserenergyromgeneratingplantto consumptionplacesis toincrease voltagewhilereducingcurrent.Thisisnecessaryin order tominimizethe energyloss asconsequence otransmission.TheselossesarereerredtoasI2xR losses,sincetheyareequaltothesquareothecurrenttimestheresistanceothepowerlines.Oncethe electricalenergygetsneartheenduser,theutilitywill needtostepdownthevoltagetothelevelneededby theconsumingmachine.Eachtime,thevoltagelevel ischanged,energyislost,eveninthemostecient transormers.
6. Voltage 6..1 Voltage unbalance Submersiblemotorsaredesignedtooperateonpowerlineswithgivenvoltageandrequency. Voltageunbalancecanberegulatedattheregulating boardothetransormerand/orthegenerator.The voltageunbalanceshallbekeptassmallaspossible, asitistheprimarysourceocurrentunbalance.This leadstothecreationoadditionalheatinthemotor.
6.. Overvoltage and undervoltage Powerlinesareexpectedtodeliveraspecicvoltage. Nearthelow voltagetransormer,there willoten beanovervoltageo3-5%.Whenthepowerlinesare loaded,avoltagedropwilloccurduetoohmicresistanceinperiodsopeakpowerconsumption. Mostpowerlinesaredimensionedsothatundervoltageomorethan-10%willoccurlessthanoncea yearattheweakestpoint.Butmanyconsumersstill experienceperiodsoconsiderablevoltagedrop. Anymotorwillsueriitdoesnotreceivethevoltage stampedonthenameplate.Ithevoltagedrops,the motortorquewillbereducedandthespeedothe loadedmotorwillconsequentlybereduced,too. Asaresultothis,theeciencyandinductionresistanceothemotorwilldrop.Thiswillmakethepower consumptionincrease,resultinginincreasedgenerationoheatinthemotor. Whenaully-loadedcentriugalpumpmotorreceives 10%undervoltage,the powerconsumptionwillincreasebyapprox.5%,andthemotortemperatureby about20%.Ithistemperatureincreaseexceedsthe maximumtemperatureo the insulation material aroundthe windings,thesewill be short-circuited andthestatorwillbedestroyed.Inthesubmersible motor,thetemperatureothemotorliquidisvery importantorthelubricationothejournalbearings. Theloadcapacityasunctionothetemperaturecan beseenonthediagrambelow.
Onepossiblecauseovoltageunbalanceistheunequaldistributionosinglephaseloads.Theseloads vary over time.Voltageunbalanceis subsequently verydicultto avoidi thenetcontains highpercentageosinglephaseconsumption.
Useo twosinglephasetransormersin socalled “open delta” connection is not recommended or threephasesupply.
6. Power Supply
Fig. 45 Diagram: Journal bearings load capacity as unction o motor liquid temperature.
6
7
Power Supply
Power Supply
Thisiscriticalithemotorisplacedinahotenvironmentandisbadlycooled,orincaseovoltageasymmetry, currentasymmetry orvoltagetransientsat thesametime. Usually,anincreasedwindingtemperaturecausedby undervoltagewillleadtoasteragingotheinsulation,resultinginareducedlie. Incaseoovervoltageromthegrid,thepowerconsumptionandheatgenerationinthemotorwindings willincreaseaswell.
6. Frequency Therequencyshouldalwaysbekeptatthenominal value.Itherequencyishigher,thepumpmayoverloadthemotor.Itherequencyislower,pumpperormancewilldrop.
6. Variable requency drives Inordertomakerationalelectricpowerdistribution utilitieshaveagreedtousesamerequency.Thisenabledirectconnectionodierentnetsunderconditionthattherequencyandsequenceothisisthe same. Thedominantrequenciesusedintheworldtoday are60Hzand50Hz.
Fig. 46 Current variation as a unction o over- and undervoltage on a 230 V motor. Conclusion 1. Forvoltagevariationso+6/-10%otheratedvalue, measuredatthemotorterminals,normalliecan beexpectedwhenthepowerconsumptionisequal toorlessthantheratedcurrentstampedonthe nameplateandithemotorcoolingissucientand notransientsorasymmetryoccur. 2. For short/periodic voltage variations exceeding +6/-10%otheratedvalue,thereductioninliewill bemoderateuntilundervoltage/overvoltagevariationsaresoconsiderablethatthestatorwindings areshort-circuited. 3. Withpermanentorlonglastingvoltagevariations exceeding+6/-10%,themotorshouldbederatedor aGrundosoversizemotorchoseninordertoobtainacceptablelieandeciency.Controlomotor temperatureisbyuseoGrundosMP204electronicallymotorprotectorisalwaysrecommended.
8
Itiscustomarytoderateastandardmotortoensure longlieiovervoltageorundervoltageomorethan +6/-10%canbeexpectedatthemotorcableentry. Single-phase motors will oten require capacitor adaptionwhenexposedtolowvoltagesupply.
Therequencydeterminesthespeedoanasynchronousmotor.Unortunatelyitisverydiculttocalculateexactlythespeedoanasynchronousmotor. Thisis determinedbythe speedo asynchronous motorminustheslip. Slipis dened asthe dierencein speedbetween rotorandstatoreld.Theslipistheproductothe resultingtorque–thismeansthegreatertheload, (torque)thegreatertheslip.Inotherwords,theslip oanasynchronousmotorisloaddependent. Thesynchronousspeedcanbecalculatedbyuseo ollowingormula: Ns = 10 x P Ns=thespeedotherotatingmagneticeld. 120=constant. =requency. P=numberopoles.
Variablerequencydrives(VFDs)areusedtocreate a“new”localnetwitharequencydierentrom whatthesupplycompanyisproviding.Thisallows therequencyandthemotor(andpump)speedto beregulated. Modernrequencydrivescanregulateinaninterval between0and400Hz(orevenmore).Pleaseremember,asthespeedgoesuptheloadisalsoincreasing eventuallyleadingtoriskooverloadingthemotori notdimensionedcorrectly. Another importantissue torememberis thatthe requencydrivemustnotbeusedtoboostvoltage. Whenyouregulatethevoltage,therequencymust remainconstant. Practical example: Givennet=400V,50Hz In orderto havebigger regulationarea, youchoose todimensionthepumpsetor60Hzoperation.This givesrecommendedregulationarearom30–60Hz. Henceyou are not toboost voltage you have to chooseamotorsuitedorrunningat400V,60Hz (practicallythiswillleadintochoosinga380V,60Hz motorhencethisisastandard). Filters: Variablerequencydrivesisbasedon atechnology thatswitches (chops)in andout thevoltage. This meansthattheresultingoutputromavariablerequency drive isonly partly a sinusoidal curve.The resultis generationo noise onprimaryas wellas secondarysideothevariablerequencydrive.The primarysideisregulatedbyauthoritiesand/orutilitiesanddemandsRFIltersolutions.Ontheoutput side,thechallengeisthelength,thetype,thesizeand howthecablesareplacedintheinstallation.Longcablesincreasetheriskocreatinghighvoltagepeaks leadingtodeteriorationotheinsulationsystemo thesubmersiblemotor.
Current: Pleasenotethatdimensioningovariablerequency drivesisdoneromthecurrentvalueothemotor –andthatasubmersiblemotorhashighercurrent valuesthansimilaroutputsuracemotor.
6. Grid connection Beoreconnectingtogrid,thecharacteristicsothe gridshallbeknown:Howisthequalityothenet, whatkindoearthisusedandhowgoodisthesurge andlightningprotection? • Whatvoltagewillbesuppliedandwithwhattolerances? • What requencywillbe suppliedand withwhat tolerances? • Whatpowerisatdisposition? • Howotencangriddisturbancesbeexpected? • Isanowntransormeroreseenorwillacommon transormerbeused?Iacommontransormeris used,askhowevenloadothenetisassured(only applicableor3-phasemotors). Thesupplyromthegridtothemotorisnormallyreerredtoasthenetsupply.Netsupplyisthepower linehavingthevoltageormachineuses.Netquality wedivideintosocalled“sti”or“sot”net. Agivengridvoltageistransormedintoappropriate netvoltagebyuseoatransormer. Thecheapestwayotransormingagivengridvoltageintoappropriatenetvoltageis donethrougha socalledautotransormer.Pleasenotethatthisisnot possibleinallcountries. Inordertoprotectthesubmersiblemotor,youneed adevicethatcanisolatethemotorromthenet/grid supplyin caseoproblems.Grundosrecommends theuseoelectronicmotorprotectordeviceMP204.
GrundosrecommendstheuseoLCltersonthe secondarysideoallvariablerequencydrives.Ithe supplieroaVFDwithagivencableconguration willissueassurancethatUpeakorgivenmotoris notexceededatmotorterminalsthiscanbeaccepted.Seethetableonpage42.
9
Power Supply
Power Supply
Thisiscriticalithemotorisplacedinahotenvironmentandisbadlycooled,orincaseovoltageasymmetry, currentasymmetry orvoltagetransientsat thesametime. Usually,anincreasedwindingtemperaturecausedby undervoltagewillleadtoasteragingotheinsulation,resultinginareducedlie. Incaseoovervoltageromthegrid,thepowerconsumptionandheatgenerationinthemotorwindings willincreaseaswell.
Itiscustomarytoderateastandardmotortoensure longlieiovervoltageorundervoltageomorethan +6/-10%canbeexpectedatthemotorcableentry. Single-phase motors will oten require capacitor adaptionwhenexposedtolowvoltagesupply.
6. Frequency Therequencyshouldalwaysbekeptatthenominal value.Itherequencyishigher,thepumpmayoverloadthemotor.Itherequencyislower,pumpperormancewilldrop.
6. Variable requency drives Inordertomakerationalelectricpowerdistribution utilitieshaveagreedtousesamerequency.Thisenabledirectconnectionodierentnetsunderconditionthattherequencyandsequenceothisisthe same. Thedominantrequenciesusedintheworldtoday are60Hzand50Hz.
Fig. 46 Current variation as a unction o over- and undervoltage on a 230 V motor. Conclusion 1. Forvoltagevariationso+6/-10%otheratedvalue, measuredatthemotorterminals,normalliecan beexpectedwhenthepowerconsumptionisequal toorlessthantheratedcurrentstampedonthe nameplateandithemotorcoolingissucientand notransientsorasymmetryoccur. 2. For short/periodic voltage variations exceeding +6/-10%otheratedvalue,thereductioninliewill bemoderateuntilundervoltage/overvoltagevariationsaresoconsiderablethatthestatorwindings areshort-circuited. 3. Withpermanentorlonglastingvoltagevariations exceeding+6/-10%,themotorshouldbederatedor aGrundosoversizemotorchoseninordertoobtainacceptablelieandeciency.Controlomotor temperatureisbyuseoGrundosMP204electronicallymotorprotectorisalwaysrecommended.
Therequencydeterminesthespeedoanasynchronousmotor.Unortunatelyitisverydiculttocalculateexactlythespeedoanasynchronousmotor. Thisis determinedbythe speedo asynchronous motorminustheslip. Slipis dened asthe dierencein speedbetween rotorandstatoreld.Theslipistheproductothe resultingtorque–thismeansthegreatertheload, (torque)thegreatertheslip.Inotherwords,theslip oanasynchronousmotorisloaddependent. Thesynchronousspeedcanbecalculatedbyuseo ollowingormula: Ns = 10 x P Ns=thespeedotherotatingmagneticeld. 120=constant. =requency. P=numberopoles.
Variablerequencydrives(VFDs)areusedtocreate a“new”localnetwitharequencydierentrom whatthesupplycompanyisproviding.Thisallows therequencyandthemotor(andpump)speedto beregulated. Modernrequencydrivescanregulateinaninterval between0and400Hz(orevenmore).Pleaseremember,asthespeedgoesuptheloadisalsoincreasing eventuallyleadingtoriskooverloadingthemotori notdimensionedcorrectly. Another importantissue torememberis thatthe requencydrivemustnotbeusedtoboostvoltage. Whenyouregulatethevoltage,therequencymust remainconstant. Practical example: Givennet=400V,50Hz In orderto havebigger regulationarea, youchoose todimensionthepumpsetor60Hzoperation.This givesrecommendedregulationarearom30–60Hz. Henceyou are not toboost voltage you have to chooseamotorsuitedorrunningat400V,60Hz (practicallythiswillleadintochoosinga380V,60Hz motorhencethisisastandard). Filters: Variablerequencydrivesisbasedon atechnology thatswitches (chops)in andout thevoltage. This meansthattheresultingoutputromavariablerequency drive isonly partly a sinusoidal curve.The resultis generationo noise onprimaryas wellas secondarysideothevariablerequencydrive.The primarysideisregulatedbyauthoritiesand/orutilitiesanddemandsRFIltersolutions.Ontheoutput side,thechallengeisthelength,thetype,thesizeand howthecablesareplacedintheinstallation.Longcablesincreasetheriskocreatinghighvoltagepeaks leadingtodeteriorationotheinsulationsystemo thesubmersiblemotor.
Current: Pleasenotethatdimensioningovariablerequency drivesisdoneromthecurrentvalueothemotor –andthatasubmersiblemotorhashighercurrent valuesthansimilaroutputsuracemotor.
6. Grid connection Beoreconnectingtogrid,thecharacteristicsothe gridshallbeknown:Howisthequalityothenet, whatkindoearthisusedandhowgoodisthesurge andlightningprotection? • Whatvoltagewillbesuppliedandwithwhattolerances? • What requencywillbe suppliedand withwhat tolerances? • Whatpowerisatdisposition? • Howotencangriddisturbancesbeexpected? • Isanowntransormeroreseenorwillacommon transormerbeused?Iacommontransormeris used,askhowevenloadothenetisassured(only applicableor3-phasemotors). Thesupplyromthegridtothemotorisnormallyreerredtoasthenetsupply.Netsupplyisthepower linehavingthevoltageormachineuses.Netquality wedivideintosocalled“sti”or“sot”net. Agivengridvoltageistransormedintoappropriate netvoltagebyuseoatransormer. Thecheapestwayotransormingagivengridvoltageintoappropriatenetvoltageis donethrougha socalledautotransormer.Pleasenotethatthisisnot possibleinallcountries. Inordertoprotectthesubmersiblemotor,youneed adevicethatcanisolatethemotorromthenet/grid supplyin caseoproblems.Grundosrecommends theuseoelectronicmotorprotectordeviceMP204.
GrundosrecommendstheuseoLCltersonthe secondarysideoallvariablerequencydrives.Ithe supplieroaVFDwithagivencableconguration willissueassurancethatUpeakorgivenmotoris notexceededatmotorterminalsthiscanbeaccepted.Seethetableonpage42.
8
9
Power Supply
Power Supply
6.6 Current asymmetry Lowcurrentasymmetrygivesthebestmotoreciencyandlongestlie.Itisthereoreimportanttohave allphases loaded equally. Beoremeasuring takes place,itshouldbecheckedthatthedirectionorotationothepumpiscorrect,i.e.theonewhichgives thehighestperormance.The directionorotation canbe changedby interchangingtwophases.The currentasymmetry should notexceed5%.I there isaMP204connected,10%willbeacceptable.Itis calculatedbymeansotheollowingtwoormulas: I (%) =
I (%) =
( (
Iphase max. – Iaverage Iaverage
Iphase – Iaveragemin. Iaverage
Step1
Step2
Connectio n1 UZ31A VX26A WY28A Totally85A Averagecurrent:
Connection2 Z30A X26A Y29A Totally85A
Connection3 Z29A X27A Y29A Totally85A
Totalcurrent 85+85+85 = =28.3A 3x3 3x3
Step3 Max.amps.dierenceromaverage: Connection1=31-28.3=2.7A Connection2=28.3-26=2.3A Connection3=28.3-27=1.3A Step4 %unbalance: Connection1=9.5%-nogood Connection2=8.1%-nogood Connection3=4.6%-ok
) x 100 [%]
Step5 Ithecurrentunbalanceisgreaterthan5%,thepower companyshouldbecontacted.Asanalternative,a deratedorindustrialmotorprotectedbyanMP204 shouldbeused. Ontheremotecontrol,youwillbeabletoreadthe actualcurrentasymmetry.Acurrentunbalanceo5% correspondstoavoltageunbalanceo1-2%.
) x 100 [%]
Themaximumvalueisusedasanexpressionothe currentasymmetry.The currentmust be measured onallthreephasesasillustratedbelow.Thebestconnection isthe onewhichgivesthe lowest current asymmetry.Inordernottohavetochangethedirectionorotationwhentheconnectionischanged,the phasesmustalwaysbemovedasillustrated.MP204 makesitpossiblenotonlytoprotectagainsttoohigh acurrentasymmetry,butalsotohavereadoutsothe actualvaluesiusedwithanR100.Thismakesiteasy tondtheoptimalconnection.
Example Seethediagraming.45andthetablebelow.
Evenasmallvoltageunbalancegivesalargecurrent unbalance.Thisunbalance,in turn, causes uneven distributionoheatinthestatorwindingsleadingto hotspotsandlocaloverheating.Thekeyresultsare illustratedgraphicallybelow.
ductorsononesideotheriserpipeandthenhave theearthleaddiagonallyopposite.
Current unbalance %
Voltage transients / lightning Powerlinesaresupposedtodeliversinusoidalshaped waves on allthree phases. Thesinusoidal shaped wavesproducedatthepowerstationareaddedto thetransientsinthedistributionsystem.
60
50
40
Sourcesotransients: 1. Frequencyconverterswithoutlters 2. Sotstarters 3. Contactorsorbigmachines 4.Capacitorsorprocessmachines 5.Lightning
30
20
10
0 0
2
4
6
%
8
Voltage unbalance
Fig. 48 Relationship between voltage and current unbalance Increases in winding temp. in hottest phase %
120
100
80
60
40
20
0
Fig. 47 Optimal connection
0
2
4
6
8
%
Voltageunbalance
Fig. 49 Relationship between voltage unbalance and temperature Currentunbalancecanbe createdby thepositioningothedropcables.Ijacketedcablesareused,no problemsshouldbeexpected.Isingleleadisusedit isalwaysrecommendtoplacethethreephasecon-
1. Frequencyconverters without lters ModernrequencyconverterswithanLCorRCltercanbe protectedso thatthey do not produce voltage peaksabove850Vinconnectionwithcablesoup to100mbetweenrequencyconverterandmotor. ThisisullyacceptableandanyGrundosmotor withcorrectratingandcoolingwillhaveanacceptablelie.Frequencyconverters othePWMtype (PulseWidthModulation)withoutLCorRClter yieldanoutputvoltagewhichdiersmuchrom theidealsinusoidalcurvewithtransientso600V at400VmainsanddU/dt:2000-2400V/us,measuredata cablelength o1m,dependingonthe make.Thesetransientswillincreasewithincreasingcablelengthbetweenrequencyconverterand motor.At200m,orinstance,thetransientswill bedoubleatthemotorcableplug,i.e.Upeakequals 1200VanddU/dt:1200V/us(400Vmains).Theresultwillbereducedlietimeothemotor.Because othis,requencyconvertersmustatleastcontain anRCltertoensureoptimummotorlie. 2.Aconnectedsotstarterwillabsorbanon-sinusoidalcurrentandgiverisetoacertaingridnoise.In connectionwithveryshortacceleration/decelerationtimes,thisisonopracticalimportanceand doesnotconictwithregulationsconcerninggrid noise.Ithestart-uptimeislongerthanthreeseconds,thenon-sinusoidaltransientswilloverheat themotorwindingsandconsequentlyaectthe littimeothemotor.
1
Power Supply
Power Supply
6.6 Current asymmetry Lowcurrentasymmetrygivesthebestmotoreciencyandlongestlie.Itisthereoreimportanttohave allphases loaded equally. Beoremeasuring takes place,itshouldbecheckedthatthedirectionorotationothepumpiscorrect,i.e.theonewhichgives thehighestperormance.The directionorotation canbe changedby interchangingtwophases.The currentasymmetry should notexceed5%.I there isaMP204connected,10%willbeacceptable.Itis calculatedbymeansotheollowingtwoormulas: I (%) =
I (%) =
( (
Iphase max. – Iaverage Iaverage
Iphase – Iaveragemin. Iaverage
)
Step1
Step2
Connectio n1 UZ31A VX26A WY28A Totally85A Averagecurrent:
Connection2 Z30A X26A Y29A Totally85A
Connection3 Z29A X27A Y29A Totally85A
Totalcurrent 85+85+85 = =28.3A 3x3 3x3
Step3 Max.amps.dierenceromaverage: Connection1=31-28.3=2.7A Connection2=28.3-26=2.3A Connection3=28.3-27=1.3A Step4 %unbalance: Connection1=9.5%-nogood Connection2=8.1%-nogood Connection3=4.6%-ok
x 100 [%]
Step5 Ithecurrentunbalanceisgreaterthan5%,thepower companyshouldbecontacted.Asanalternative,a deratedorindustrialmotorprotectedbyanMP204 shouldbeused. Ontheremotecontrol,youwillbeabletoreadthe actualcurrentasymmetry.Acurrentunbalanceo5% correspondstoavoltageunbalanceo1-2%.
) x 100 [%]
Themaximumvalueisusedasanexpressionothe currentasymmetry.The currentmust be measured onallthreephasesasillustratedbelow.Thebestconnection isthe onewhichgivesthe lowest current asymmetry.Inordernottohavetochangethedirectionorotationwhentheconnectionischanged,the phasesmustalwaysbemovedasillustrated.MP204 makesitpossiblenotonlytoprotectagainsttoohigh acurrentasymmetry,butalsotohavereadoutsothe actualvaluesiusedwithanR100.Thismakesiteasy tondtheoptimalconnection.
Example Seethediagraming.45andthetablebelow.
Evenasmallvoltageunbalancegivesalargecurrent unbalance.Thisunbalance,in turn, causes uneven distributionoheatinthestatorwindingsleadingto hotspotsandlocaloverheating.Thekeyresultsare illustratedgraphicallybelow.
ductorsononesideotheriserpipeandthenhave theearthleaddiagonallyopposite.
Current unbalance %
Voltage transients / lightning Powerlinesaresupposedtodeliversinusoidalshaped waves on allthree phases. Thesinusoidal shaped wavesproducedatthepowerstationareaddedto thetransientsinthedistributionsystem.
60
50
40
Sourcesotransients: 1. Frequencyconverterswithoutlters 2. Sotstarters 3. Contactorsorbigmachines 4.Capacitorsorprocessmachines 5.Lightning
30
20
10
0 0
2
4
6
%
8
Voltage unbalance
Fig. 48 Relationship between voltage and current unbalance Increases in winding temp. in hottest phase %
120
100
80
60
40
20
0
2
4
6
8
%
Voltageunbalance
Fig. 49 Relationship between voltage unbalance and temperature Currentunbalancecanbe createdby thepositioningothedropcables.Ijacketedcablesareused,no problemsshouldbeexpected.Isingleleadisusedit isalwaysrecommendtoplacethethreephasecon-
Fig. 47 Optimal connection
1. Frequencyconverters without lters ModernrequencyconverterswithanLCorRCltercanbe protectedso thatthey do not produce voltage peaksabove850Vinconnectionwithcablesoup to100mbetweenrequencyconverterandmotor. ThisisullyacceptableandanyGrundosmotor withcorrectratingandcoolingwillhaveanacceptablelie.Frequencyconverters othePWMtype (PulseWidthModulation)withoutLCorRClter yieldanoutputvoltagewhichdiersmuchrom theidealsinusoidalcurvewithtransientso600V at400VmainsanddU/dt:2000-2400V/us,measuredata cablelength o1m,dependingonthe make.Thesetransientswillincreasewithincreasingcablelengthbetweenrequencyconverterand motor.At200m,orinstance,thetransientswill bedoubleatthemotorcableplug,i.e.Upeakequals 1200VanddU/dt:1200V/us(400Vmains).Theresultwillbereducedlietimeothemotor.Because othis,requencyconvertersmustatleastcontain anRCltertoensureoptimummotorlie. 2.Aconnectedsotstarterwillabsorbanon-sinusoidalcurrentandgiverisetoacertaingridnoise.In connectionwithveryshortacceleration/decelerationtimes,thisisonopracticalimportanceand doesnotconictwithregulationsconcerninggrid noise.Ithestart-uptimeislongerthanthreeseconds,thenon-sinusoidaltransientswilloverheat themotorwindingsandconsequentlyaectthe littimeothemotor.
0
1
Power Supply
3.Bigmachines startingDOL orin star-delta connectionmaycreatesparksandsendconsiderable transientsbackto thegridwhenthe contactors areopened.Thesesurgescanharmthesubmersiblemotor. 4.Phasecompensationoprocessplantsmaycontaincomplicatedcontrolswithmanyandbigcapacitorswhichsendsurgesbacktothegrid.Surges canbeharmullorsubmersiblemotors. 5. Aseverestrokeolightningdirectlyona wellinstallation,starteror power supply willgenerally destroyalllivingorganismsandallelectricalinstallations.Thetransientsromsuchastrokeolightningwillbeatleast20-100kVandthegeneration oheatenoughtomelttheinsulationmaterials. Lightningstrikingthegridwillgeneratetransients whichwillpartlybeabsorbedbythelightningarrestersintgridsystem.Theunctionoalightning arresteris toleak theovervoltageto earth. Ia low-voltagegridis hitdirectly by lightningthere isa riskotransientso more than10-20kVat thepumpmotorstarter.Istarterandmotorare notcorrectlyprotectedbylightningarrestersand earthing,theinstallationmaybedamaged,asitis installed in electrically conducting groundwater, whichisthebestkindoearthingthereis.
Power Supply
I the power supply suers rom heavylightning transients,callthepowercompanytohavethemtest theirlightningarrestersatthetransormerstation. Iasystemhasbeenexposedtolightning,allcomponentsinthe starterboxshould bethoroughly tested.Thecontactormaybeburnedononephase whichmaygiverisetovoltageandcurrentunbalance inthe motor.The contactororthe thermal relaycanbeburnedonseveralphaseswhichmay causebothundervoltageandunbalance.Thethermalrelaymaybeburnedwhichmeansthatitcannottripandconsequentlycannotprotectthemotor windings.Onlysomeothemotorswhicharedamagedbylightningaredestroyedbythestrokeitsel; the rest are damaged by consequential eects. Grundos submersiblemotors type MS402 have aninsulationleveloupto15kV.Thisisthemaximumvoltagepeaks,whichthemotorisexposedto inpractice,e.g.inconnectionwithlightningclose totheinstallation.Lightningdirectlyonthepump installationis excluded here.Additionallightning protectionisthereorenotnecessary.
Damageto submersiblemotorsromlightningmay arisebothinconnectionwithpowersupplythrough overheadcablesandundergroundcables.Inareaswith requentlightning,thebestprotectionobothstarter andsubmersiblemotoristoinstalllightningarresters onthedischargesideothestartermainswitchand connectthemtogroundingrodsoripossibletothe risermainothewellithisismadeosteel. Attheborehole,lightningarrestersshouldbetted onthedischargesideotheisolationswitchgroundedtotherisermainandthewellcasingimadeo steel. Fordeep installations,lightningarresters can bettedinthemotorcable,too,astransientsdoublethevoltageina200mdropcable.Butingeneral, lightningarrestersshouldbepositionedsothattheir unctioncanbecheckedbyperiodicmeggingasthey wearoutwhen exposedto muchheavylightning.
Power Supply
3.Bigmachines startingDOL orin star-delta connectionmaycreatesparksandsendconsiderable transientsbackto thegridwhenthe contactors areopened.Thesesurgescanharmthesubmersiblemotor. 4.Phasecompensationoprocessplantsmaycontaincomplicatedcontrolswithmanyandbigcapacitorswhichsendsurgesbacktothegrid.Surges canbeharmullorsubmersiblemotors. 5. Aseverestrokeolightningdirectlyona wellinstallation,starteror power supply willgenerally destroyalllivingorganismsandallelectricalinstallations.Thetransientsromsuchastrokeolightningwillbeatleast20-100kVandthegeneration oheatenoughtomelttheinsulationmaterials. Lightningstrikingthegridwillgeneratetransients whichwillpartlybeabsorbedbythelightningarrestersintgridsystem.Theunctionoalightning arresteris toleak theovervoltageto earth. Ia low-voltagegridis hitdirectly by lightningthere isa riskotransientso more than10-20kVat thepumpmotorstarter.Istarterandmotorare notcorrectlyprotectedbylightningarrestersand earthing,theinstallationmaybedamaged,asitis installed in electrically conducting groundwater, whichisthebestkindoearthingthereis.
Power Supply
I the power supply suers rom heavylightning transients,callthepowercompanytohavethemtest theirlightningarrestersatthetransormerstation. Iasystemhasbeenexposedtolightning,allcomponentsinthe starterboxshould bethoroughly tested.Thecontactormaybeburnedononephase whichmaygiverisetovoltageandcurrentunbalance inthe motor.The contactororthe thermal relaycanbeburnedonseveralphaseswhichmay causebothundervoltageandunbalance.Thethermalrelaymaybeburnedwhichmeansthatitcannottripandconsequentlycannotprotectthemotor windings.Onlysomeothemotorswhicharedamagedbylightningaredestroyedbythestrokeitsel; the rest are damaged by consequential eects. Grundos submersiblemotors type MS402 have aninsulationleveloupto15kV.Thisisthemaximumvoltagepeaks,whichthemotorisexposedto inpractice,e.g.inconnectionwithlightningclose totheinstallation.Lightningdirectlyonthepump installationis excluded here.Additionallightning protectionisthereorenotnecessary.
Damageto submersiblemotorsromlightningmay arisebothinconnectionwithpowersupplythrough overheadcablesandundergroundcables.Inareaswith requentlightning,thebestprotectionobothstarter andsubmersiblemotoristoinstalllightningarresters onthedischargesideothestartermainswitchand connectthemtogroundingrodsoripossibletothe risermainothewellithisismadeosteel. Attheborehole,lightningarrestersshouldbetted onthedischargesideotheisolationswitchgroundedtotherisermainandthewellcasingimadeo steel. Fordeep installations,lightningarresters can bettedinthemotorcable,too,astransientsdoublethevoltageina200mdropcable.Butingeneral, lightningarrestersshouldbepositionedsothattheir unctioncanbecheckedbyperiodicmeggingasthey wearoutwhen exposedto muchheavylightning.
Installation & operation
7.1 Wells and well conditions Awellisahole,stretchingromthesuraceothe earthtotheundergroundaquier,wherethegroundwaterisound.Thedepthothewellmayvaryroma ewmeterstoseveralhundredmeters.
Wellsaretypicallydrilledwithspecialdrillingequipment,whichisabletopentratethevariouslayerso theground,suchassand,clay,bedrock,etc.Insidethe drilledholeacasing(pipe)istypicallyinstalled,which preventsthewellromcollapsingaroundthepump.
Belowthecasing,andinlinewiththeaquier,isanother‘casing’withneslots.Thisisthewellscreen, wheretheslotsallowsthewatertoenterthewell.It holdsbacksandandlargerparticlestryingtoenter thewell.Seeg.50.
Toimprovethelteringunction,theboreholetypicallyeaturesadiameterthatis2-3”largerthanthe casing.A nesand gravelpacklteris placed betweenthecasingandtheaquier,asshowng.45. Somecasings come witha pre-made gravelpack lter.Madecorrectly,thislteringmethodprevents sandandsiltromenteringthewell.
Fig. 50 Typical groundwater well components
7. Installation & operation
Recommendationson sandcontentvaries romone countrytoanother. TheNational GroundWaterAssociation (NGWA)in USArecommendsthe ollowingsandlimitsinwell water: • 1.10 mg/lin waterusedorood and beverage processing. • 2.50mg/linwaterorprivatehomes,institutions andindustries. • 3.10mg/linwaterorsprinklerirrigation,industrial evaporativecoolingandotherapplicationswhere a moderatecontento solids is notparticularly harmul. • 4.15mg/linwateroroodirrigation.
Installation & operation
7.1 Wells and well conditions Awellisahole,stretchingromthesuraceothe earthtotheundergroundaquier,wherethegroundwaterisound.Thedepthothewellmayvaryroma ewmeterstoseveralhundredmeters.
Wellsaretypicallydrilledwithspecialdrillingequipment,whichisabletopentratethevariouslayerso theground,suchassand,clay,bedrock,etc.Insidethe drilledholeacasing(pipe)istypicallyinstalled,which preventsthewellromcollapsingaroundthepump.
Belowthecasing,andinlinewiththeaquier,isanother‘casing’withneslots.Thisisthewellscreen, wheretheslotsallowsthewatertoenterthewell.It holdsbacksandandlargerparticlestryingtoenter thewell.Seeg.50.
Toimprovethelteringunction,theboreholetypicallyeaturesadiameterthatis2-3”largerthanthe casing.A nesand gravelpacklteris placed betweenthecasingandtheaquier,asshowng.45. Somecasings come witha pre-made gravelpack lter.Madecorrectly,thislteringmethodprevents sandandsiltromenteringthewell.
Fig. 50 Typical groundwater well components Recommendationson sandcontentvaries romone countrytoanother. TheNational GroundWaterAssociation (NGWA)in USArecommendsthe ollowingsandlimitsinwell water: • 1.10 mg/lin waterusedorood and beverage processing. • 2.50mg/linwaterorprivatehomes,institutions andindustries. • 3.10mg/linwaterorsprinklerirrigation,industrial evaporativecoolingandotherapplicationswhere a moderatecontento solids is notparticularly harmul. • 4.15mg/linwateroroodirrigation.
7. Installation & operation
Installation & operation
Itheconcentrationosandexceeds15mg/l,somuch materialwillberemovedromthewellthattheaquierandthestrataaboveitmaycollapseandthus shortenthelieothewell. Grundospermitsasandcontentonomorethan50 ppminthewellwater.Withasandcontento50mg/ l,thepumpeciencyandthelittimewillremainacceptableorupto25,000-35,000dutyhours,equalto approx.ouryearsooperationoreighthoursaday.
Installation & operation
Whenthepumpisinstalled,thedrawdownandthe dynamicwaterlevelmustalwaysbeknown.During operation,thewatermustneverallbelowtheinlet othepump.Theriskocavitationisnormallyvery smallwithsubmersiblepumps.However,NPSHo thespecicpumpinitsdutypoint,shouldalways bechecked. Minimumpumpinletsubmergenceinmeters:NPSH (m)–10(m).
Ithewellwaterhasasandcontenthigherthan 50mg/l,aspecialpumpandmotorisavailableon request. Beorethewellcanbeputintooperation,itmustbedeveloped.Anewwellwillalwaysproducesomesandand siltinthebeginning,andwelldevelopmentistheprocessopumpinganewwellreeromsandandsilt.Itis donebypumpingwithaveryhighow,whichdraws thene particlesin theaquierintothe ltero the well.Thisslowlymakestheltermoreeective.Ater approximatelyonedayopumping,thewellisnormally pumpedclean,andisreadyornormaloperation.
Thepumpusedorwelldevelopmentwearsoutrelativelyquicklybecauseothehighsandcontent,and itshouldthereorealwaysbe replacedwitha new pumpassoonasthewelldoesnotproduceanymore sand. Thepumpmustalwaysbeinstalledabovethescreen areaothe casing.Inthisway,youensurethatthe waterisorcedpastthemotor,providingadequate motorcooling.Ithepumpcannotbeinstalledabove thescreenlter, acoolingsleeveisalwaysrecommendedtocreatethenecessaryowalongthemotororpropercooling.Seechapter10.
7. Pump setting Pumpsettingisthedepthatwhichthepumphas beeninstalledbeneaththeground.Thepumpmust beabletolitthewaterromtheaquiertothesuraceanddeliveracertainminimumpressure.
6
7.. Well diameter
7.. Well yield
Ingeneral,thelargerthediameterothepump,the highertheeciency.
Manypumpsareabletooverpumpthewell,which meansitwillrundryinashortperiodotime.The pumpmustbeselectedwithduerespecttothecapacityo thewell,so overpumpingis avoided.We thereorerecommendmonitoringthewatertable.
However,thepumpmustbeabletotintothewell, anda certainminimumclearancebetweenmotor suraceand internalwelldiameteris thereore alwaysrequired. Inacorrectlydesignedwell,withthewellscreenbelowthepumpandmotor,thewaterhastopassthe clearancebetweenthecasingand themotor.This willcausearictionloss. Iatthesametimethemotoriseccentricpositioned inthewellwithonesideagainstthecasing,thesinglesidedinletowaterintothepumpwillcreateturbulencesandaecttheperormanceothepump. Fig.52showstherictionlossorclearancerom4to 16mmina6“well,andg.53isshowingthesame ora8”well. Boththeturbulenceandtherictionlosswillresultin pumpunderperormance,whichinsomesituations canbeextreme. Inwellswith well screenarea positionedabove thepump,thewaterhastopasstheclearancebetweenthepumpandthecasing,whichwillcause arictionloss.
Fig. 51 Static and dynamic water level
7. Pump and motor selection Pleaseseechapter4orsizingandselectionosubmersiblepumps.
7..1 The duty point Thedutypointothepumpistheowwherepump eciencyisbest.Thepumpmustbeselectedsothe requiredowisascloseaspossibletothedutypoint, orslightlytotherightothedutypoint.
Severalproblemsmayariseromoverpumping: • Dryrunningandpumpdamage • Inltrationonon-potablewater,i.e.seawater • Chemicalreactionsinthewellwhenoxygencontactsthedryaquier. Excessivedrawdownalsotriggersincreasedpower consumption,sinceitmustbecompensatedwithadditionalpumplit.
7.. Pump eciency Allpumpshavetheirpeakeciencyoverarelatively narrowowrange.Thisrangeis normallyusedto selectthepump.AGrundosSP46hasitspeakeciencyatandaround46m 3/how,justasSP60lies around60m3/h,andsoonorallotherSPpumps. Itheowrequirementallsbetweentwomodels,i.e. 66m3/h,bothanSP60andanSP77maybeusedwith thesameeciency.Someotheothercriteriacome intoplayasaresult: • Welldiameter(seechapter7.3.2) • Wellyield(seechapter7.3.3) • Sparecapacity.
Iatthesametimethepumpispositionedeccentric againstthecasing,itwillrestricttheinowathalo thesuctioninterconnecter.ThissinglesidedU-turn oinletwaterwillcreateinletturbulenceaecting theunctionothepump. Fig.54showstheworstcaseturbulence/rictionloss at6”pumpsin6”wellsodierentdiameters. Fig.55showstheworstcaseturbulence/rictionloss at8”pumpsin8”wellsodierentdiameters. Theturbulenceandrictionwillbeseenasunderperormanceothepump.
7
Installation & operation
Itheconcentrationosandexceeds15mg/l,somuch materialwillberemovedromthewellthattheaquierandthestrataaboveitmaycollapseandthus shortenthelieothewell. Grundospermitsasandcontentonomorethan50 ppminthewellwater.Withasandcontento50mg/ l,thepumpeciencyandthelittimewillremainacceptableorupto25,000-35,000dutyhours,equalto approx.ouryearsooperationoreighthoursaday.
Installation & operation
Whenthepumpisinstalled,thedrawdownandthe dynamicwaterlevelmustalwaysbeknown.During operation,thewatermustneverallbelowtheinlet othepump.Theriskocavitationisnormallyvery smallwithsubmersiblepumps.However,NPSHo thespecicpumpinitsdutypoint,shouldalways bechecked. Minimumpumpinletsubmergenceinmeters:NPSH (m)–10(m).
Ithewellwaterhasasandcontenthigherthan 50mg/l,aspecialpumpandmotorisavailableon request.
Beorethewellcanbeputintooperation,itmustbedeveloped.Anewwellwillalwaysproducesomesandand siltinthebeginning,andwelldevelopmentistheprocessopumpinganewwellreeromsandandsilt.Itis donebypumpingwithaveryhighow,whichdraws thene particlesin theaquierintothe ltero the well.Thisslowlymakestheltermoreeective.Ater approximatelyonedayopumping,thewellisnormally pumpedclean,andisreadyornormaloperation.
Thepumpusedorwelldevelopmentwearsoutrelativelyquicklybecauseothehighsandcontent,and itshouldthereorealwaysbe replacedwitha new pumpassoonasthewelldoesnotproduceanymore sand. Thepumpmustalwaysbeinstalledabovethescreen areaothe casing.Inthisway,youensurethatthe waterisorcedpastthemotor,providingadequate motorcooling.Ithepumpcannotbeinstalledabove thescreenlter, acoolingsleeveisalwaysrecommendedtocreatethenecessaryowalongthemotororpropercooling.Seechapter10.
7. Pump setting
7.. Well yield
Ingeneral,thelargerthediameterothepump,the highertheeciency.
Manypumpsareabletooverpumpthewell,which meansitwillrundryinashortperiodotime.The pumpmustbeselectedwithduerespecttothecapacityo thewell,so overpumpingis avoided.We thereorerecommendmonitoringthewatertable.
However,thepumpmustbeabletotintothewell, anda certainminimumclearancebetweenmotor suraceand internalwelldiameteris thereore alwaysrequired.
Severalproblemsmayariseromoverpumping: • Dryrunningandpumpdamage • Inltrationonon-potablewater,i.e.seawater • Chemicalreactionsinthewellwhenoxygencontactsthedryaquier.
Inacorrectlydesignedwell,withthewellscreenbelowthepumpandmotor,thewaterhastopassthe clearancebetweenthecasingand themotor.This willcausearictionloss. Iatthesametimethemotoriseccentricpositioned inthewellwithonesideagainstthecasing,thesinglesidedinletowaterintothepumpwillcreateturbulencesandaecttheperormanceothepump. Fig.52showstherictionlossorclearancerom4to 16mmina6“well,andg.53isshowingthesame ora8”well. Boththeturbulenceandtherictionlosswillresultin pumpunderperormance,whichinsomesituations canbeextreme. Inwellswith well screenarea positionedabove thepump,thewaterhastopasstheclearancebetweenthepumpandthecasing,whichwillcause arictionloss.
Fig. 51 Static and dynamic water level
7. Pump and motor selection Pleaseseechapter4orsizingandselectionosubmersiblepumps.
7..1 The duty point
Pumpsettingisthedepthatwhichthepumphas beeninstalledbeneaththeground.Thepumpmust beabletolitthewaterromtheaquiertothesuraceanddeliveracertainminimumpressure.
7.. Well diameter
Thedutypointothepumpistheowwherepump eciencyisbest.Thepumpmustbeselectedsothe requiredowisascloseaspossibletothedutypoint, orslightlytotherightothedutypoint.
Excessivedrawdownalsotriggersincreasedpower consumption,sinceitmustbecompensatedwithadditionalpumplit.
7.. Pump eciency Allpumpshavetheirpeakeciencyoverarelatively narrowowrange.Thisrangeis normallyusedto selectthepump.AGrundosSP46hasitspeakeciencyatandaround46m 3/how,justasSP60lies around60m3/h,andsoonorallotherSPpumps. Itheowrequirementallsbetweentwomodels,i.e. 66m3/h,bothanSP60andanSP77maybeusedwith thesameeciency.Someotheothercriteriacome intoplayasaresult: • Welldiameter(seechapter7.3.2) • Wellyield(seechapter7.3.3) • Sparecapacity.
Iatthesametimethepumpispositionedeccentric againstthecasing,itwillrestricttheinowathalo thesuctioninterconnecter.ThissinglesidedU-turn oinletwaterwillcreateinletturbulenceaecting theunctionothepump. Fig.54showstheworstcaseturbulence/rictionloss at6”pumpsin6”wellsodierentdiameters. Fig.55showstheworstcaseturbulence/rictionloss at8”pumpsin8”wellsodierentdiameters. Theturbulenceandrictionwillbeseenasunderperormanceothepump.
6
7
Installation & operation
Installation & operation
Wall side positioning
Wall side positioning Turbulence loss/ Friction loss m
Friction loss in metres at each metre of motor length, when water is passing ∆D mm between motor and 6"casing
Friction loss m
30
D1
60
50
40
C1
D2
(delta) D1 = 4 mm (delta) D2 = 7 mm (delta) D3 = 10 mm (delta) D4 = 13 mm (delta) D5 = 16 mm
20
15
Flow
10
∆
30
20
D3
10
D4 D5
C2
Flow
C3
C1 PVC 160 casing Internal diameter: 145 mm C2 PVC 160 casing Internal diameter: 148 mm C3 PVC 160 casing Internal diameter: 151 mm C4 Steel casing Internal diameter: 153 mm
25
D = 1 m of motor length
Filter of well
U-turn inlet turbulence and friction loss in metres at each metre of pump length for 6" SP-pumps in 6" wells, wall-side positioning
Cable guard
Friction loss for each m of pump length C4
Flow 5
m
∆
P
D 0
0 0
10
20
30
40 50 Capacity
60
70
m³/h
80
6" casing
0
Fig. 52 Friction loss, 6”
10
20
30
40
50
60
70
Turbulence loss/ Friction loss m
Friction loss in m at each m. of motor length, when water is passing ∆D mm between motor and 8"casing
Friction loss m
(delta) D1 = 7 mm (delta) D2 = 10 mm (delta) D3 = 13 mm (delta) D4 = 16 mm (delta) D5 = 22 mm (delta) D6 = 64 mm
50
m³/h
6" casing
Wall side positioning
Wall side positioning
60
80
Fig. 54 U-turn, 6”
D1
30
C1
20
D2 D = 1 m of motor length
15
Flow
10
C2
Flow
C3
C1 PVC casing Internal diameter: 185 mm C2 PVC casing Internal diameter: 188 mm Steel casing C3 Internal diameter: 203 mm
25
40
Well screen
U-turn inlet turbulence and friction loss in metres at each metre of pump length for 8" SE-pumps in 8" wells, wall-side positioning
Cable guard
Friction loss for each m of pump length
∆
30
20
D3
10
D4
Flow
m
D5 D6
0 40
60
80
Fig. 53 Friction loss, 8”
8
5
100
120 140 Capacity
160
180
200
∆
P
D 0
m³/h
8" casing
40
60
80
100
120
140
160
180
200
m³/h
8" casing
Fig. 55 U-turn, 8”
9
Installation & operation
Installation & operation
Wall side positioning
Wall side positioning Turbulence loss/ Friction loss m
Friction loss in metres at each metre of motor length, when water is passing ∆D mm between motor and 6"casing
Friction loss m
30
D1
60
50
40
C1
D2
(delta) D1 = 4 mm (delta) D2 = 7 mm (delta) D3 = 10 mm (delta) D4 = 13 mm (delta) D5 = 16 mm
20
15
Flow
10
∆
30
20
D3
10
D4 D5
C2
Flow
C3
C1 PVC 160 casing Internal diameter: 145 mm C2 PVC 160 casing Internal diameter: 148 mm C3 PVC 160 casing Internal diameter: 151 mm C4 Steel casing Internal diameter: 153 mm
25
D = 1 m of motor length
Filter of well
U-turn inlet turbulence and friction loss in metres at each metre of pump length for 6" SP-pumps in 6" wells, wall-side positioning
Cable guard
Friction loss for each m of pump length C4
Flow 5
m
∆
P
D 0
0 0
10
20
30
40 50 Capacity
60
70
m³/h
80
6" casing
0
Fig. 52 Friction loss, 6”
10
20
30
40
50
60
70
Wall side positioning Turbulence loss/ Friction loss m
Friction loss in m at each m. of motor length, when water is passing ∆D mm between motor and 8"casing
Friction loss m
(delta) D1 = 7 mm (delta) D2 = 10 mm (delta) D3 = 13 mm (delta) D4 = 16 mm (delta) D5 = 22 mm (delta) D6 = 64 mm
50
6" casing
Fig. 54 U-turn, 6”
Wall side positioning
60
m³/h
80
D1
30
C1
20
D2 D = 1 m of motor length
15
Flow
10
C2
Flow
C3
C1 PVC casing Internal diameter: 185 mm C2 PVC casing Internal diameter: 188 mm Steel casing C3 Internal diameter: 203 mm
25
40
Well screen
U-turn inlet turbulence and friction loss in metres at each metre of pump length for 8" SE-pumps in 8" wells, wall-side positioning
Cable guard
Friction loss for each m of pump length
∆
30
20
D3
10
D4
Flow 5
m
D5 D6
0 40
60
80
100
120 140 Capacity
160
180
∆
P
D 0
m³/h
200
8" casing
40
Fig. 53 Friction loss, 8”
60
80
100
120
140
160
180
m³/h
200
8" casing
Fig. 55 U-turn, 8”
8
9
Installation & operation
7.. Water temperature The limitingactoris the submersible motor and coolingothemotor.Coolingisthekeytoalonglietimeothemotor. Submersiblemotorsinstalledatmaximumacceptable watertemperaturemustbecooledataowrateoat least0.15m/s,whichensuresturbularow.Thisvelocityisensuredbynotlettingthepumpowdropbelow acertainminimumvalue.Seeg.56. Inlargediameterwellsortanksitmaybeneccessary touseaowsleevetoincreasetheowalongthe motortominimun0.15m/s.Seechapter10aswell. Inthediagrambelow,themotorisassumedtobepositionedabovethescreensetting. Maximum water temperature: Themaximumtemperaturesshownbelowarebased onowalongthemotoro0.15m/s MS 402 30 °C MS 4000 40 °C MS 4000I 60 °C MS 6000 40 °C MS 6000I 60 °C MS6T30 30 °C MS6T60 60 °C MMSwithPVCwire: 25°C MMSwithPE2/PAwire: 40°C
Installation & operation
Water temperatures above the temperature limit GrundosMS402motorsmustnotbeusedatliquid temperaturesabove30°C.OperationwithMS4000 andMS6ispossibleataliquidtemperatureabove thegiventemperaturelimit,ithemotorisderated (Seeg.57inchapter7.3.6). Ingeneral,however,thiswillshortenthelieothe motor.Itisimpossibletosaybyhowmuch,asthis dependsonanumberootherparameters,e.g.the voltagesupply,motorload,motorcoolingconditions, etc.Followingtherecommendationsinthismanual however,shouldprovideanacceptablelietime. Inthesecases,werecommendthatthepumpisservicedandallrubberpartsreplacedeverythreeyears inordertokeepconstanteciencyandensureanormallietime. Atoperationabovethetemperaturelimit,warranty issuesmustalwaysbeagreedupon.Nowarrantycan begivenwithoutderatingandMP204protection.
7..6 Derating o submersible motors Multiplythemotorsize(P2)withthederatingactor. ThisgivesthederatedmotoroutputP2.Thatisthe maximumloadthatmaybeappliedonthemotor. Inmanycasesthisresultsinamotorthatisonesize biggerthanoriginallycalculated.
Fig. 57 Derating o submersible motors
Fig. 58 Required water temperature/installation depth o MS 4000 and MS 6000
Example: AMS6T30withstandardrating,P2=30kW,isableto produce30x0.9=27kWin40°Cwateratacooling owrateo0.15m/s.Thesubmersiblemotorshould beinstalledattherecommendeddepth.
ForMS4000andMS6,thebestandsimplestprotectionagainst overloadand excessivetemperatures istomeasurethemotortemperaturebymeanso anMP204.Forothersubmersiblemotors,aPt100/ Pt1000maybeusedtomonitorthetemperature.
PleasenotethatderatingoMS4000IandMS6T60is notrecommended.
7..8 Sleeve cooling
7..7 Protection against boiling
Flowpastthemotormustbeaminimumo0.15m/s inordertosecurepropercoolingothemotor.
Inordertoprotectthemotoragainstboilingatpump stopandconsequentlyacoolingwaterstop,itshould beinstalled5mbelowthedynamicwaterlevel.This willraisetheboilingpoint.
Itheminimumowpastthemotorcannotbeobtainedthe naturalway,Grundosoersa rangeo coolingsleevesthatensurecorrectowandcooling, andareeasytoworkwith.Flowsleevesaretypically usedwhenthepumpisinstalledinareservoirortank, orinawell,wherethewaterowstothepumprom above,andthereoredoesnotcoolthemotor.There mustbereasonablespacingbetweenthecasingand theouterdiametertolimitthepressuredrop.
Fig. 56 Maximum ull-load cooling water temperature
60
61
Installation & operation
7.. Water temperature The limitingactoris the submersible motor and coolingothemotor.Coolingisthekeytoalonglietimeothemotor. Submersiblemotorsinstalledatmaximumacceptable watertemperaturemustbecooledataowrateoat least0.15m/s,whichensuresturbularow.Thisvelocityisensuredbynotlettingthepumpowdropbelow acertainminimumvalue.Seeg.56. Inlargediameterwellsortanksitmaybeneccessary touseaowsleevetoincreasetheowalongthe motortominimun0.15m/s.Seechapter10aswell. Inthediagrambelow,themotorisassumedtobepositionedabovethescreensetting. Maximum water temperature: Themaximumtemperaturesshownbelowarebased onowalongthemotoro0.15m/s MS 402 30 °C MS 4000 40 °C MS 4000I 60 °C MS 6000 40 °C MS 6000I 60 °C MS6T30 30 °C MS6T60 60 °C MMSwithPVCwire: 25°C MMSwithPE2/PAwire: 40°C
Installation & operation
Water temperatures above the temperature limit GrundosMS402motorsmustnotbeusedatliquid temperaturesabove30°C.OperationwithMS4000 andMS6ispossibleataliquidtemperatureabove thegiventemperaturelimit,ithemotorisderated (Seeg.57inchapter7.3.6). Ingeneral,however,thiswillshortenthelieothe motor.Itisimpossibletosaybyhowmuch,asthis dependsonanumberootherparameters,e.g.the voltagesupply,motorload,motorcoolingconditions, etc.Followingtherecommendationsinthismanual however,shouldprovideanacceptablelietime. Inthesecases,werecommendthatthepumpisservicedandallrubberpartsreplacedeverythreeyears inordertokeepconstanteciencyandensureanormallietime. Atoperationabovethetemperaturelimit,warranty issuesmustalwaysbeagreedupon.Nowarrantycan begivenwithoutderatingandMP204protection.
7..6 Derating o submersible motors Multiplythemotorsize(P2)withthederatingactor. ThisgivesthederatedmotoroutputP2.Thatisthe maximumloadthatmaybeappliedonthemotor. Inmanycasesthisresultsinamotorthatisonesize biggerthanoriginallycalculated.
Fig. 57 Derating o submersible motors
Fig. 58 Required water temperature/installation depth o MS 4000 and MS 6000
Example: AMS6T30withstandardrating,P2=30kW,isableto produce30x0.9=27kWin40°Cwateratacooling owrateo0.15m/s.Thesubmersiblemotorshould beinstalledattherecommendeddepth.
ForMS4000andMS6,thebestandsimplestprotectionagainst overloadand excessivetemperatures istomeasurethemotortemperaturebymeanso anMP204.Forothersubmersiblemotors,aPt100/ Pt1000maybeusedtomonitorthetemperature.
PleasenotethatderatingoMS4000IandMS6T60is notrecommended.
7..8 Sleeve cooling
7..7 Protection against boiling
Flowpastthemotormustbeaminimumo0.15m/s inordertosecurepropercoolingothemotor.
Inordertoprotectthemotoragainstboilingatpump stopandconsequentlyacoolingwaterstop,itshould beinstalled5mbelowthedynamicwaterlevel.This willraisetheboilingpoint.
Itheminimumowpastthemotorcannotbeobtainedthe naturalway,Grundosoersa rangeo coolingsleevesthatensurecorrectowandcooling, andareeasytoworkwith.Flowsleevesaretypically usedwhenthepumpisinstalledinareservoirortank, orinawell,wherethewaterowstothepumprom above,andthereoredoesnotcoolthemotor.There mustbereasonablespacingbetweenthecasingand theouterdiametertolimitthepressuredrop.
Fig. 56 Maximum ull-load cooling water temperature
60
61
Installation & operation
Therecommendedmin.spacingbetweencasingand owsleevemaybecalculatedromtheormulabelow: v = Q x (D – d ) v=m/s.Mustbemax.3m/stolimitheadloss Q=m3/h D=Casinginnerdiameterinmm d=Flowsleeveouterdiameterinmm. 1. Ithewellwatercontainslargeamountsoiron (andironbacteria),manganeseand lime, these substances will be oxidised and deposited on themotorsurace.Thisisapprox.5-15°Cwarmer thantheinuxwater.In caseoslowow past themotor,thisbuild-upoa heatinsulatinglayer o oxidized minerals and metals mayresult in hot spots in the motorwinding insulation. Thistemperatureincreasemayreachvalueswhich willreducetheinsulatingabilityandconsequently themotorlie.Acoolingsleevealwaysgivesaturbular owpastthe motor.Turbulentow gives optimumcoolingirrespectiveothecharactero thedeposits. 2. Ithegroundwaterisaggressiveorcontainschloride,thecorrosionratewilldoubleorevery15°C increasein water temperature.A coolingsleeve willthereorereducetheriskomotorcorrosion.
Installation & operation
oxidizedwaterwillmovetowardsthescreensetting. Whenusingacoolingsleeve,themotorwillrunat alowertemperatureandwhenthemotorstops,the coolingsleevewillabsorbtheresidualheatromthe motorandconsequentlypreventwaterrommoving upwardbecauseothethermaleectandoxidated waterrommovingdownward.Thiswillcontribute tolongerperiodsbetweenwellscalings. For these applicatio ns, the risk o local heating shouldbeconsidered,particularlyinconnectionwith horizontalinstallationsandwhereseveralpumpsare installednexttoeach other.In suchcases,cooling sleevesshouldalwaysbeused.
7. Riser pipe selection Thechoiceorisermaindependsonseveraldierent actors: • Dischargepressureandinstallationdepth • Theaggressivityothegroundwater • Frictionloss/operatingcost • Accessibilityandcostoalternative • Priorityoinitialcostsinrelationtoserviceandrepaircostsatalaterstage.
The thermal eect will make the heated water movetowardsthetopothewell.Atthesametime,
6
Thissolution isgenerally recommended asa riser pipeorsubmersiblepumps.Becauseothehosedesign,thediameterwillswellslightlywhenthehose ispressurised,andthusdecreaserictionloss.Atthe sametime,italsopreventsthebuiltuposcalingon thesurace,wheretheconstantchangeothediameterorcesthescalingtobreako.
InsuchcasestheWellmasterisrecommended. Seechapter10.
Thehosesolutionalsomakespumppullingaster compairedwiththetraditionalpipingsolution,and isthereorealsorecommendedwhenrequentpullingorservicehastobedone.
Friction loss in riser mains Frictionlossinpipesorhosescontributessignicantlytothepowerconsumptionoasubmersiblepump. Asmalldiameter steelpipeis cost-wiseattractive, butitcreatesalotointernalriction,andovertime thisisgoingtoincrease.Theresultishigherpower consumptionandcosts. Alargerdiameterstainlesssteelpipe represents a largerinvestment,butthelowerrictionlossrequires lessenergyorpumping.The smoothinternalsuraceisretainedeasier,requiringlessmaintenanceor cleaning. Example: Flowis54m3/h,or15l/s.
Pressure atground level [bar] 35
Frictionlossin100mo3”pipeand100mo4” pipeiscalculatedromarictionlosstable.
30
25
3. Atthetopothewell,oxidisedrawwaterisound. Eachtimethepumpstarts,thewaterlevelinthe wellislowered.Thisdrawsnewoxygenintothe well.Thisoxidationothetopewmetersisharmlessunlesstheoxygenreachesthescreen.Ithe inuxorawwaterthroughthescreenwithalow contentooxygenismixedwithwatercontaining reshoxygen,iron,manganeseandlimewilloxidizeandbedepositedinthescreenslots.Thiswill reducetheeciencyandconsequentlythecapacityothewell.Awarmsubmersiblemotorwithout coolingsleevewillheatupthesurroundingwater whenswitchedo.
PELorPEMrisermainsareprimarilyusedordomesticapplications.Incaseowaterwhichissoaggressivethatitwillattackeventhebeststainlesssteel, replaceablezincanodesshouldbettedinorderto protectmotorandpump.Insuchinstallations,itwill betooexpensivetoprotectstainlesssteelrisermains againstcorrosion.
20
3”pipe:14m 4”pipe:3.8m
P N 3 6
15 P N 2 4
10
Choosinga4”pipeinsteadoa3”pipesavesmore than10mheadper100mopipe. Theenergysavingsarecalculatedasollows:
P N 1 6
P N 1 0
5
P N 6
0 0
50
100
150
200
250
300
Installation depth[m]
Fig. 59 Required pipe pressure class at diferent installation depths and actual pressure at ground level Theaggressivityomostgroundwaterisso moderatethatcoatedorgalvanizedsteelpipeswillbeully acceptable.
kWh = Q x H = x 10. = . kWh 67xη 67x0.6 Flexiblehosesspeciallydesignedorpressurisedwater, like Wellmaster, arean alternative tostainless steelpipes.Sometypesareeven approvedoruse withpotablewater.
Neveruserehoses,nylonhosesorthelikewhich agequickly,and donothavetherequiredpressure rating.Thereisariskthatpumpandmotorwillall downintothewellwhichmayrequirethedrillingo anewwell.Remembertoattachawiretoallhose installationstopreventthepumpromallinginto thewell. Thedisadvantageo exible hose solutions isthat sometimes itis dicultto prevent thehosesrom gettingintocontactwiththeground.Thiscancause contaminationrombacteriaandgerms,whichcannotberemovedunlessyouemployexpensivespecial equipment.WhendimensioningrisermainsandrawwaterpipesbymeansodiagramsorPCprogrammes, remembertouseapipesuraceroughnesso1mm.
7. Cable selection and sizing Thedropcableis thecablerunningromthewell headtothemotorcablethatisattachedtothesubmersiblemotor. Normally,thedropcablehasourwires,whereoneis aground/PEwire.Insomelocalareas,aground/PE isnotrequired.Alwayschecklocalregulationabout groundingbeorecabletypeisselected. Othercriteriaordropcableselectionare: 1. Currentcarryingcapacity 2. Voltagedrop 3. Waterqualityandtemperature 4. Drinkingwaterapprovalrequirements 5. Regulations
6
Installation & operation
Therecommendedmin.spacingbetweencasingand owsleevemaybecalculatedromtheormulabelow: v = Q x (D – d ) v=m/s.Mustbemax.3m/stolimitheadloss Q=m3/h D=Casinginnerdiameterinmm d=Flowsleeveouterdiameterinmm. 1. Ithewellwatercontainslargeamountsoiron (andironbacteria),manganeseand lime, these substances will be oxidised and deposited on themotorsurace.Thisisapprox.5-15°Cwarmer thantheinuxwater.In caseoslowow past themotor,thisbuild-upoa heatinsulatinglayer o oxidized minerals and metals mayresult in hot spots in the motorwinding insulation. Thistemperatureincreasemayreachvalueswhich willreducetheinsulatingabilityandconsequently themotorlie.Acoolingsleevealwaysgivesaturbular owpastthe motor.Turbulentow gives optimumcoolingirrespectiveothecharactero thedeposits. 2. Ithegroundwaterisaggressiveorcontainschloride,thecorrosionratewilldoubleorevery15°C increasein water temperature.A coolingsleeve willthereorereducetheriskomotorcorrosion.
Installation & operation
oxidizedwaterwillmovetowardsthescreensetting. Whenusingacoolingsleeve,themotorwillrunat alowertemperatureandwhenthemotorstops,the coolingsleevewillabsorbtheresidualheatromthe motorandconsequentlypreventwaterrommoving upwardbecauseothethermaleectandoxidated waterrommovingdownward.Thiswillcontribute tolongerperiodsbetweenwellscalings. For these applicatio ns, the risk o local heating shouldbeconsidered,particularlyinconnectionwith horizontalinstallationsandwhereseveralpumpsare installednexttoeach other.In suchcases,cooling sleevesshouldalwaysbeused.
7. Riser pipe selection Thechoiceorisermaindependsonseveraldierent actors: • Dischargepressureandinstallationdepth • Theaggressivityothegroundwater • Frictionloss/operatingcost • Accessibilityandcostoalternative • Priorityoinitialcostsinrelationtoserviceandrepaircostsatalaterstage.
The thermal eect will make the heated water movetowardsthetopothewell.Atthesametime,
Thissolution isgenerally recommended asa riser pipeorsubmersiblepumps.Becauseothehosedesign,thediameterwillswellslightlywhenthehose ispressurised,andthusdecreaserictionloss.Atthe sametime,italsopreventsthebuiltuposcalingon thesurace,wheretheconstantchangeothediameterorcesthescalingtobreako.
InsuchcasestheWellmasterisrecommended. Seechapter10.
Thehosesolutionalsomakespumppullingaster compairedwiththetraditionalpipingsolution,and isthereorealsorecommendedwhenrequentpullingorservicehastobedone.
Friction loss in riser mains Frictionlossinpipesorhosescontributessignicantlytothepowerconsumptionoasubmersiblepump. Asmalldiameter steelpipeis cost-wiseattractive, butitcreatesalotointernalriction,andovertime thisisgoingtoincrease.Theresultishigherpower consumptionandcosts. Alargerdiameterstainlesssteelpipe represents a largerinvestment,butthelowerrictionlossrequires lessenergyorpumping.The smoothinternalsuraceisretainedeasier,requiringlessmaintenanceor cleaning. Example: Flowis54m3/h,or15l/s.
Pressure atground level [bar] 35
Frictionlossin100mo3”pipeand100mo4” pipeiscalculatedromarictionlosstable.
30
25
3. Atthetopothewell,oxidisedrawwaterisound. Eachtimethepumpstarts,thewaterlevelinthe wellislowered.Thisdrawsnewoxygenintothe well.Thisoxidationothetopewmetersisharmlessunlesstheoxygenreachesthescreen.Ithe inuxorawwaterthroughthescreenwithalow contentooxygenismixedwithwatercontaining reshoxygen,iron,manganeseandlimewilloxidizeandbedepositedinthescreenslots.Thiswill reducetheeciencyandconsequentlythecapacityothewell.Awarmsubmersiblemotorwithout coolingsleevewillheatupthesurroundingwater whenswitchedo.
PELorPEMrisermainsareprimarilyusedordomesticapplications.Incaseowaterwhichissoaggressivethatitwillattackeventhebeststainlesssteel, replaceablezincanodesshouldbettedinorderto protectmotorandpump.Insuchinstallations,itwill betooexpensivetoprotectstainlesssteelrisermains againstcorrosion.
20
Thedropcableis thecablerunningromthewell headtothemotorcablethatisattachedtothesubmersiblemotor.
15 P N 2 4
10
Choosinga4”pipeinsteadoa3”pipesavesmore than10mheadper100mopipe. Theenergysavingsarecalculatedasollows:
P N 1 6
P N 1 0
5
Normally,thedropcablehasourwires,whereoneis aground/PEwire.Insomelocalareas,aground/PE isnotrequired.Alwayschecklocalregulationabout groundingbeorecabletypeisselected.
P N 6
0 0
50
100
150
200
250
300
Installation depth[m]
Fig. 59 Required pipe pressure class at diferent installation depths and actual pressure at ground level Theaggressivityomostgroundwaterisso moderatethatcoatedorgalvanizedsteelpipeswillbeully acceptable.
Thedisadvantageo exible hose solutions isthat sometimes itis dicultto prevent thehosesrom gettingintocontactwiththeground.Thiscancause contaminationrombacteriaandgerms,whichcannotberemovedunlessyouemployexpensivespecial equipment.WhendimensioningrisermainsandrawwaterpipesbymeansodiagramsorPCprogrammes, remembertouseapipesuraceroughnesso1mm.
7. Cable selection and sizing
3”pipe:14m 4”pipe:3.8m
P N 3 6
Neveruserehoses,nylonhosesorthelikewhich agequickly,and donothavetherequiredpressure rating.Thereisariskthatpumpandmotorwillall downintothewellwhichmayrequirethedrillingo anewwell.Remembertoattachawiretoallhose installationstopreventthepumpromallinginto thewell.
kWh = Q x H = x 10. = . kWh 67xη 67x0.6 Flexiblehosesspeciallydesignedorpressurisedwater, like Wellmaster, arean alternative tostainless steelpipes.Sometypesareeven approvedoruse withpotablewater.
Othercriteriaordropcableselectionare: 1. Currentcarryingcapacity 2. Voltagedrop 3. Waterqualityandtemperature 4. Drinkingwaterapprovalrequirements 5. Regulations
6
6
Installation & operation
Current-carrying capacity Submersiblepumpdropcableisneverdimensioned orthelocked-rotorcurrent,asthemotorstartsup inless than1/10o asecond.Alwaysuse theull loadcurrentromthenameplateasthedimensioningcurrent.Theentirelengthothedropcableisnot submergedinwater,soadditionalcoolingromthe watermaybeencountered. Typicalguidelinesormax.ampsinsubmersibledrop cables: Dimension(mm2) 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300
Max .current (A) 18.5 25 34 43 60 80 101 126 153 196 238 276 319 364 430 497
Pleasealwayscheckthelocalguidelines,whichoverrulethetableabove. Voltage drop Thecablemustbesizedsothevoltagedropdoesnot exceed3%.Undernocircumstancesmustthevoltage atthemotorterminalsbelowerthantheminimum voltageorthemotor,whichistheratedvoltageminus10%. Themaximumlengthiscalculatedaccordingtothe ormulasshownbelow: Max. cable length o a single-phase submersible pump:
6
Installation & operation
U x ∆U L= [m] l x x 100 x (cos φ x + sinφ x Xl) Max. cable length o a three-phase submersible pump: U x ∆U L= [m] l x 1,7 x 100 x (cos φ x + sinφ x Xl) U =Ratedvoltage[V] U =Voltagedrop[%] I =Ratedcurrentothemotor[A] ρ =Specicresistance:0.02[mm²/m] q =Cross-sectionosubmersibledropcable[mm²] XI= Inductiveresistance:0.078x10-3[Ω/m] Water quality and temperature ThebestcablematerialorcleanwaterisEPR(EPM orEPDM).Thismaterialhasgoodelectricproperties combinedwithagoodresistancetowater.Thistype ocableisalwaysrecommendedwhenthepumped waterisnotcontaminatedwithhydrocarbons.EPR oersonlylimitedresistancetohydrocarbons,however. Inlighterhydrocarbonsolutions,aChloroprenecable maybeused. Inheavierconcentrationsohydrocarbonsitmaybe necessaryto usePTFE(Teon)jacketed cable.The SPEversionotheSPpumpscomesstandardwith PTFEmotorcable,andmakesitsuitableorpumpingwaterwithahighcontentohydrocarbons. A lower cost solution is a standard Chloroprene typeocable.Specicationsmaybeobtainedrom Grundos. Whenthe water temperature increases, thecable mustbederated.Thecurrentcarryingcapacityothe dropcablesisusuallyvalidat30°C.Athighertemperatures,thismustalwaysbecompensatedinaccordancewiththetablebelow.
Cable type
TML-A-B
H07RN
Insulation material
EPR
NR/SR
Ambienttemp. °C
Correctionactor
Correctionactor
10
1.18
1.29
15
1.14
1.22
20
1.10
1.15
25
1.05
1.05
30
1.00
1.00
35
0.95
0.91
40
0.89
0.82
45
0.84
0.71
50
0.77
0.58
55
0.71
0.41
60
0.63
-
65
0.55
-
70
0.45
-
Drinking water approval AllGrundosmotorsoutsideNorthAmericaandJapanaredeliveredromactorywithdrinkingwaterapprovedmotorcables.Ithepumpisusedorpumping potable water, Grundos always recommends alsousingadropcablethathasadrinkingwaterapproval. Regulations Localregulationsmustalwaysbecheckedandollowed.
7.6 Handling 7.6.1 Pump / motor assembly Grundos submersible pumps and motors are all madeinaccordancewithNEMAstandards.Theyare ullycompatiblewithpumpsandmotorsthatconorm tothese standardsas well.Grundos recommendsalwaysusingonlyaGrundospumptogether withaGrundosmotorandviceversa. Fordetailedassemblyinstructionspleaseseetheindividualinstallationandoperatinginstructionsor SPpumps.
7.6. Cable splice/connection o motor cable and drop cable Faultyorunapprovedcablejointsarerequentcauses oburned-outmotors.Grundos-recommendedproductsorproductsosimilarqualityshouldbechosen andthemanuacturer’sguidelinesollowed.Anycable jointmustbewatertightandhaveaninsulationresistanceominimum10megaohms,measuredinasubmergedstateater24hoursinwater.Inordertoobtain this,allcablepartsmustbe100%cleanandallother requirementsindicatedintheservicemanualandin servicevideo programmes observed.There areour waysomakingacablejoint. 1. Heat shrink Heatshrinkisaplastictubewiththeinsidecovered withglue.Whenexposedtoheat,itwillshrink,and thegluemelts,andmakesawatertightcablesplice. Ittakesalotopracticetoperormthiskindojoint. Furthermore,hightemeraturearerequiredorlarge cabletypes.Lightersandhobbyheatersarenotsucient.Theadvantageothisprincipleisthattheconnectiondoesnotrequiretimeordryingbutisready immediatelyatertting. . Resin Sealingwithresinistheoldestandbestknowntype ojoint.Itisalsothejointwhichissimplesttocarry outcorrectly.Itcanbeperormedintheeldwithout specialtools.Thedisadvantageisthatitmustharden oratleast24hours.Asarasthepriceisconcerned, thereisnodierencebetweenthisandshrinkex. . Tape Itis importantto usespecialtape orconnecting submersiblecables.Tapejointsshouldonlybeused atwaterpressuresbelow5m. . Plug connection Itisimportantnottousecablejointkitsortapewhich aremorethanthreeyearsold.Thisagelimitshould bereducedtooneyearistoredabove15°C.Always testthecablejointduringmaintenance. Motor cable plug Themotorcableplugmustalwaysbettedatthe torquestatedin thedocumentation.In caseolu-
6
Installation & operation
Current-carrying capacity Submersiblepumpdropcableisneverdimensioned orthelocked-rotorcurrent,asthemotorstartsup inless than1/10o asecond.Alwaysuse theull loadcurrentromthenameplateasthedimensioningcurrent.Theentirelengthothedropcableisnot submergedinwater,soadditionalcoolingromthe watermaybeencountered. Typicalguidelinesormax.ampsinsubmersibledrop cables: Dimension(mm2) 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300
Max .current (A) 18.5 25 34 43 60 80 101 126 153 196 238 276 319 364 430 497
Pleasealwayscheckthelocalguidelines,whichoverrulethetableabove. Voltage drop Thecablemustbesizedsothevoltagedropdoesnot exceed3%.Undernocircumstancesmustthevoltage atthemotorterminalsbelowerthantheminimum voltageorthemotor,whichistheratedvoltageminus10%. Themaximumlengthiscalculatedaccordingtothe ormulasshownbelow: Max. cable length o a single-phase submersible pump:
Installation & operation
L=
U x ∆U [m] l x x 100 x (cos φ x + sinφ x Xl)
Max. cable length o a three-phase submersible pump: U x ∆U L= [m] l x 1,7 x 100 x (cos φ x + sinφ x Xl) U =Ratedvoltage[V] U =Voltagedrop[%] I =Ratedcurrentothemotor[A] ρ =Specicresistance:0.02[mm²/m] q =Cross-sectionosubmersibledropcable[mm²] XI= Inductiveresistance:0.078x10-3[Ω/m] Water quality and temperature ThebestcablematerialorcleanwaterisEPR(EPM orEPDM).Thismaterialhasgoodelectricproperties combinedwithagoodresistancetowater.Thistype ocableisalwaysrecommendedwhenthepumped waterisnotcontaminatedwithhydrocarbons.EPR oersonlylimitedresistancetohydrocarbons,however. Inlighterhydrocarbonsolutions,aChloroprenecable maybeused. Inheavierconcentrationsohydrocarbonsitmaybe necessaryto usePTFE(Teon)jacketed cable.The SPEversionotheSPpumpscomesstandardwith PTFEmotorcable,andmakesitsuitableorpumpingwaterwithahighcontentohydrocarbons. A lower cost solution is a standard Chloroprene typeocable.Specicationsmaybeobtainedrom Grundos. Whenthe water temperature increases, thecable mustbederated.Thecurrentcarryingcapacityothe dropcablesisusuallyvalidat30°C.Athighertemperatures,thismustalwaysbecompensatedinaccordancewiththetablebelow.
Cable type
TML-A-B
H07RN
Insulation material
EPR
NR/SR
Ambienttemp. °C
Correctionactor
Correctionactor
10
1.18
1.29
15
1.14
1.22
20
1.10
1.15
25
1.05
1.05
30
1.00
1.00
35
0.95
0.91
40
0.89
0.82
45
0.84
0.71
50
0.77
0.58
55
0.71
0.41
60
0.63
-
65
0.55
-
70
0.45
-
7.6. Cable splice/connection o motor cable and drop cable Faultyorunapprovedcablejointsarerequentcauses oburned-outmotors.Grundos-recommendedproductsorproductsosimilarqualityshouldbechosen andthemanuacturer’sguidelinesollowed.Anycable jointmustbewatertightandhaveaninsulationresistanceominimum10megaohms,measuredinasubmergedstateater24hoursinwater.Inordertoobtain this,allcablepartsmustbe100%cleanandallother requirementsindicatedintheservicemanualandin servicevideo programmes observed.There areour waysomakingacablejoint. 1. Heat shrink Heatshrinkisaplastictubewiththeinsidecovered withglue.Whenexposedtoheat,itwillshrink,and thegluemelts,andmakesawatertightcablesplice. Ittakesalotopracticetoperormthiskindojoint. Furthermore,hightemeraturearerequiredorlarge cabletypes.Lightersandhobbyheatersarenotsucient.Theadvantageothisprincipleisthattheconnectiondoesnotrequiretimeordryingbutisready immediatelyatertting.
Drinking water approval AllGrundosmotorsoutsideNorthAmericaandJapanaredeliveredromactorywithdrinkingwaterapprovedmotorcables.Ithepumpisusedorpumping potable water, Grundos always recommends alsousingadropcablethathasadrinkingwaterapproval.
. Resin Sealingwithresinistheoldestandbestknowntype ojoint.Itisalsothejointwhichissimplesttocarry outcorrectly.Itcanbeperormedintheeldwithout specialtools.Thedisadvantageisthatitmustharden oratleast24hours.Asarasthepriceisconcerned, thereisnodierencebetweenthisandshrinkex.
Regulations Localregulationsmustalwaysbecheckedandollowed.
7.6 Handling 7.6.1 Pump / motor assembly Grundos submersible pumps and motors are all madeinaccordancewithNEMAstandards.Theyare ullycompatiblewithpumpsandmotorsthatconorm tothese standardsas well.Grundos recommendsalwaysusingonlyaGrundospumptogether withaGrundosmotorandviceversa. Fordetailedassemblyinstructionspleaseseetheindividualinstallationandoperatinginstructionsor SPpumps.
. Tape Itis importantto usespecialtape orconnecting submersiblecables.Tapejointsshouldonlybeused atwaterpressuresbelow5m. . Plug connection Itisimportantnottousecablejointkitsortapewhich aremorethanthreeyearsold.Thisagelimitshould bereducedtooneyearistoredabove15°C.Always testthecablejointduringmaintenance. Motor cable plug Themotorcableplugmustalwaysbettedatthe torquestatedin thedocumentation.In caseolu-
6
6
Installation & operation
bricationothecableplug,anon-conductivematerialshouldbeused(e.g.siliconepaste).Motorcable plugsthataremorethanthreeyearsoldshouldnot bereused,astheymayhavelosttheabilitytomakea sae,watertightconnection.
7.6. Riser pipe connections SubmersiblepumpsareavailablebothwithRPand NPTthreads,aswellasangesinvariousstandards. Ingeneral, however, Grundosrecommendstting a50cmlengthopipersttothepump.Thisgives goodhandlingothepumpduringtheinstallation, asthepumpdoesnotbecometoolong.Italsoleaves roomortheclampwhichholdsthepumpuntilthe nextpipehasbeentted. Asanalternativetoathreadedconnection,various ange typescan be oered:Grundosanges, JIS angesandDINanges. Pipe connections and installation Grundosstandardangesaremadeparticularlyor ttingintoawell.Thismeansthattheydonotcomplywith anynational norinternational standards; theyhavebeendimensionedtowithstandGrundos pumppressures.
Installation & operation
7.9 Number o start/stops
Theseproblemsaretypicallyavoidedbyusingoneo theollowing: 1. Severalsmallercascadeoperatedpumps(additionalpumpsstartsandstopsasdemandchanges) 2.F requency control othe pump via a pressure transducer 3. Acombinationo1and2.
The table below shows the recommended max. numberostartsordierentmotortypes:
Forcorrectpumpselection,thewell’scharacteristics mustbeknown,eitherromthewelllogor atest pumping.
7.8 Pumps in series operation Withpumpsettingdeeperthanthemax.headcapacityoastandardSPpump,itmaybecoupledin serieswithaBMpump(SPinsleeve).Seeg.60.
Min.starts peryear 1 1 1 1 1 1 1
Max.starts perhour 100 100 30 15 10 8 5
Max.starts perday 300 300 300 360 240 190 120
7.10 Pump start-up Detailed inormation aboutmethodsor reducing locked-rotorcurrent,seechapter5. Youshouldalwaysollowtheinstructionsoundin theinstallationandoperatinginstructionsoreach pumpregardingstartup.
Forpumpsinseriesconnections,remembertostart themin thecorrectsequence:thepump withthe lowestambientpressuremustbestartedrst. Forpumpsinparalleloperation,rememberthatair ventingpossibilitiesarealreadybuiltintothesystem. Thiswillpreventairlocking.
7.11 VFD operation
7.7 Pumps in parallel operation
66
Incl.N,RandRE versions MS 402 MS 4000 MS6/MS 6000 MMS 6000 MMS 8000 MMS 10000 MMS 12000
There are several advantages in using Grundos standardangesinsteadootheranges.Theyare notonly cheaper,and because otheir dimension theyareeasiertotintothewell. Grundoscan supply counterangesorGrundos anges,whichcanbeweldedontotherstpipe.
Parallelpumpingoperationisotenusedwithavariableconsumptionpattern.Asinglepumpoperation wouldrequireahighcapacitypump,wherethespare capacityisonlyusedinaveryshortperiod.Theinvestmentwouldbe veryhigh,andthe operational eciencytoolow.Thepeaksmayalsoresultinadditionaldrawdownothedynamicwaterlevelwitha numberowater-andwellqualityissuesasaresult.
Inordertogetamaximumlieoutothesubmersiblepumps,thenumberostartsmustbelimited.Itis usuallythemotorthatisthelimitingactor.Itisalso necessarytostartthemotoratleastonceperyearto avoiditromseizingup.
Seechapter5.
7.1 Generator operation
Fig. 60 Series coupled submersible pump
Enginedrivengeneratorsorsubmersiblemotorsare otenoeredaccordingtostandardconditions,e.g. • Max.altitudeabovesealevel:150m • Max.airinlettemperature:30°C • Max.humidity:60%.
67
Installation & operation
bricationothecableplug,anon-conductivematerialshouldbeused(e.g.siliconepaste).Motorcable plugsthataremorethanthreeyearsoldshouldnot bereused,astheymayhavelosttheabilitytomakea sae,watertightconnection.
7.6. Riser pipe connections SubmersiblepumpsareavailablebothwithRPand NPTthreads,aswellasangesinvariousstandards. Ingeneral, however, Grundosrecommendstting a50cmlengthopipersttothepump.Thisgives goodhandlingothepumpduringtheinstallation, asthepumpdoesnotbecometoolong.Italsoleaves roomortheclampwhichholdsthepumpuntilthe nextpipehasbeentted.
Installation & operation
7.9 Number o start/stops
Theseproblemsaretypicallyavoidedbyusingoneo theollowing: 1. Severalsmallercascadeoperatedpumps(additionalpumpsstartsandstopsasdemandchanges) 2.F requency control othe pump via a pressure transducer 3. Acombinationo1and2.
Inordertogetamaximumlieoutothesubmersiblepumps,thenumberostartsmustbelimited.Itis usuallythemotorthatisthelimitingactor.Itisalso necessarytostartthemotoratleastonceperyearto avoiditromseizingup.
The table below shows the recommended max. numberostartsordierentmotortypes:
Forcorrectpumpselection,thewell’scharacteristics mustbeknown,eitherromthewelllogor atest pumping.
Incl.N,RandRE versions MS 402 MS 4000 MS6/MS 6000 MMS 6000 MMS 8000 MMS 10000 MMS 12000
7.8 Pumps in series operation Withpumpsettingdeeperthanthemax.headcapacityoastandardSPpump,itmaybecoupledin serieswithaBMpump(SPinsleeve).Seeg.60.
Asanalternativetoathreadedconnection,various ange typescan be oered:Grundosanges, JIS angesandDINanges.
Min.starts peryear 1 1 1 1 1 1 1
Max.starts perhour 100 100 30 15 10 8 5
Max.starts perday 300 300 300 360 240 190 120
7.10 Pump start-up Detailed inormation aboutmethodsor reducing locked-rotorcurrent,seechapter5.
Pipe connections and installation Grundosstandardangesaremadeparticularlyor ttingintoawell.Thismeansthattheydonotcomplywith anynational norinternational standards; theyhavebeendimensionedtowithstandGrundos pumppressures.
Youshouldalwaysollowtheinstructionsoundin theinstallationandoperatinginstructionsoreach pumpregardingstartup.
Forpumpsinseriesconnections,remembertostart themin thecorrectsequence:thepump withthe lowestambientpressuremustbestartedrst.
There are several advantages in using Grundos standardangesinsteadootheranges.Theyare notonly cheaper,and because otheir dimension theyareeasiertotintothewell. Grundoscan supply counterangesorGrundos anges,whichcanbeweldedontotherstpipe.
Forpumpsinparalleloperation,rememberthatair ventingpossibilitiesarealreadybuiltintothesystem. Thiswillpreventairlocking.
7.11 VFD operation
7.7 Pumps in parallel operation
Seechapter5.
Parallelpumpingoperationisotenusedwithavariableconsumptionpattern.Asinglepumpoperation wouldrequireahighcapacitypump,wherethespare capacityisonlyusedinaveryshortperiod.Theinvestmentwouldbe veryhigh,andthe operational eciencytoolow.Thepeaksmayalsoresultinadditionaldrawdownothedynamicwaterlevelwitha numberowater-andwellqualityissuesasaresult.
7.1 Generator operation Enginedrivengeneratorsorsubmersiblemotorsare otenoeredaccordingtostandardconditions,e.g. • Max.altitudeabovesealevel:150m • Max.airinlettemperature:30°C • Max.humidity:60%.
Fig. 60 Series coupled submersible pump
66
67
Installation & operation
Itheselimitsareexceeded,thestandarddieselengineandpossiblythegeneratorhavetobederatedin ordertogivethemotorsucientpowersupply. Whenordering a generator set, altitude, airinlet temperatureandmaximumhumidityshouldbegiventothemanuacturertohavethegeneratoractory derated.Generatorsetsorthree-phasesubmersible motorsmustbeabletowithstand35%voltagereductionduringstart-up. Forthe selectiono internallyregulated generators available, stick tothe tables beloworcontinuous breakkW orsingle-phase andthree-phase motors withDOLstart. Exampleso deratingactorsor standarddieselengines
Exampleso deratingactorsor standardgenerators
Altitude: Altitude: 3.5%orevery300mabove 2.5%orevery300mabove 150mabovesealevel(2.5%or 1000mabovesealevel. turbo-chargedengines). Air inlet temperature: 2%orevery5.5°Cabove 30°C(3%orturbo-charged engines). Humidity: 6%at100%humidity.
Air inlet temperature: 5%orevery5°Cabove40°C.
Installation & operation
Submersible motorrating orsinglephaseand three-phase versions[kW]
Generator rating
Elevationo max.150m andahumidityo100%
Elevationo max.750m andahumidityo100%
Dieselengineratingatan ambienttemperatureo [kW][kW] 30°C40°C 30°C40°C [kW][kW] [kW][kW]
0.25 0.37 0.55 0.75 1.1 1.5 2.2 3.7 5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0 90.0 110.0 132.0 150.0 185.0
1.5 2.0 2.5 3.0 4.0 5.0 7.0 11.0 16.0 19.0 28.0 38.0 50.0 55.0 75.0 95.0 1 10 .0 135.0 185.0 220.0 250.0 313.0 344.0 396.0
1.0 1.25 1.3 1.5 2.0 2.1 2.0 2.5 3.1 2.5 3.0 3.1 3.0 4.0 4.2 4.0 5.0 5.2 6.0 7.0 7.3 9.0 10.0 10.4 12.5 14.0 14.6 15.0 17.0 17.7 22.0 25.0 26.0 30.0 35.0 36.0 40.0 45.0 47.0 45.0 50.0 52.0 60.0 65.0 68.0 75.0 83.0 86.0 9 0. 0 100.0 104.0 110.0 120.0 125.0 150.0 165.0 172.0 175.0 192.5 200.0 200.0 220.0 230.0 250.0 275.0 290.0 275.0 305.0 315.0 330.0 365.0 405.0
1.4 2.3 2.8 3.4 4.5 5.6 7.8 11.1 15.6 1 9.0 2 8.0 3 9.0 50.0 56.0 72.0 92 .0 111.0 133.0 183.0 215.0 244.0 305.0 335.0 405.0
1.43 2.3 2.86 3.44 4.58 5.73 8.0 11.5 16.0 2 0. 0 2 9. 0 40. 0 52.0 57.0 75.0 9 5. 0 115.0 137.0 189.0 220.0 250.0 315.0 345.0 415.0
Ithegeneratoranddieselenginearederatedaccordingtothetable,theollowingcriteriaapply: 1 . Thevoltagedropatthegeneratorwillnotexceed 10%duringstart-up.Thismeansthatitispossibletouseeventheastestundervoltageprotectiononthemarketinthestarterboxothepump motor. 2.Generatorand dieselenginewillhavea normal lieasthenewullyrun-inengineisonlyloaded approx.70%withcontinuouspumpmotorrated current.Adieselenginewilltypicallyhavemaximumeciency(lowestuelconsumptionperkW output)at70-80%omaximumload.
68
3. B y autotransormer start or installation o a GrundosMP204orundervoltageprotection,it ispossibletochoosebothageneratoranddiesel enginethanare20%smallerthanstatedinthetable.This,however,meansrequentmaintenance oairlterandinjectionnozzles,cleaningothe coolerandchangeooil.Furthermore,itwillresultinavoltagedropduringstart-upoupto20%. Ithelossinthedropcableandmotorcableo upto15%isadded,thetotalvoltagelosswillbe morethan35%atthemotor.Thisisnoproblem orthree-phasemotors,butsometimesorsinglephasemotors,whichwillotenrequireanoversize startingcapacitororlowstart-upvoltages.
Generatoroperation Alwaysstartthegeneratorbeorethemotorisstartedandalwaysstopthemotorbeorethegeneratoris stopped.Themotorthrustbearingmaybedamaged igeneratorsareallowedtocoastdownwiththemotorconnected.Thesameconditionoccurswhengeneratorsareallowedtorunoutouel.
Therearetwotypesogenerators:internallyandexternally-regulated. Internally-regulated generators have an additional windinginthegeneratorstatorandarealsocalled sel-excited.The extra winding sensesthe output currentandincreasestheoutputvoltageautomatically. Internally-regulated generatorsnormally show the bestrunningeciency. Externally-regulated generators use an externally mountedvoltage regulatorthat senses theoutput voltage.Asthevoltagedipsatmotorstart-up,theregulatorincreasestheoutputvoltageothegenerator. Anexternally-regulatedgenerator is to be dimensionedapproximately50%higherinkW/kVArating todeliverthesamestartingtorqueasaninternally regulatedgenerator. Generator requencyisall importantasthe motor speedvarieswiththerequency[Hz].Duetopump anitylaws,apumprunningat1to2Hzbelowmotornameplaterequencywillnotmeetitsperormancecurve.Conversely, a pumprunning 1or 2Hz highermaytriptheoverloadrelay.
69
Installation & operation
Itheselimitsareexceeded,thestandarddieselengineandpossiblythegeneratorhavetobederatedin ordertogivethemotorsucientpowersupply. Whenordering a generator set, altitude, airinlet temperatureandmaximumhumidityshouldbegiventothemanuacturertohavethegeneratoractory derated.Generatorsetsorthree-phasesubmersible motorsmustbeabletowithstand35%voltagereductionduringstart-up. Forthe selectiono internallyregulated generators available, stick tothe tables beloworcontinuous breakkW orsingle-phase andthree-phase motors withDOLstart. Exampleso deratingactorsor standarddieselengines
Exampleso deratingactorsor standardgenerators
Altitude: Altitude: 3.5%orevery300mabove 2.5%orevery300mabove 150mabovesealevel(2.5%or 1000mabovesealevel. turbo-chargedengines). Air inlet temperature: 2%orevery5.5°Cabove 30°C(3%orturbo-charged engines).
Air inlet temperature: 5%orevery5°Cabove40°C.
Humidity: 6%at100%humidity.
Installation & operation
Submersible motorrating orsinglephaseand three-phase versions[kW]
Generator rating
Elevationo max.150m andahumidityo100%
Elevationo max.750m andahumidityo100%
Dieselengineratingatan ambienttemperatureo [kW][kW] 30°C40°C 30°C40°C [kW][kW] [kW][kW]
0.25 0.37 0.55 0.75 1.1 1.5 2.2 3.7 5.5 7.5 11.0 15.0 18.5 22.0 30.0 37.0 45.0 55.0 75.0 90.0 110.0 132.0 150.0 185.0
1.5 2.0 2.5 3.0 4.0 5.0 7.0 11.0 16.0 19.0 28.0 38.0 50.0 55.0 75.0 95.0 1 10 .0 135.0 185.0 220.0 250.0 313.0 344.0 396.0
1.0 1.25 1.3 1.5 2.0 2.1 2.0 2.5 3.1 2.5 3.0 3.1 3.0 4.0 4.2 4.0 5.0 5.2 6.0 7.0 7.3 9.0 10.0 10.4 12.5 14.0 14.6 15.0 17.0 17.7 22.0 25.0 26.0 30.0 35.0 36.0 40.0 45.0 47.0 45.0 50.0 52.0 60.0 65.0 68.0 75.0 83.0 86.0 9 0. 0 100.0 104.0 110.0 120.0 125.0 150.0 165.0 172.0 175.0 192.5 200.0 200.0 220.0 230.0 250.0 275.0 290.0 275.0 305.0 315.0 330.0 365.0 405.0
1.4 2.3 2.8 3.4 4.5 5.6 7.8 11.1 15.6 1 9.0 2 8.0 3 9.0 50.0 56.0 72.0 92 .0 111.0 133.0 183.0 215.0 244.0 305.0 335.0 405.0
1.43 2.3 2.86 3.44 4.58 5.73 8.0 11.5 16.0 2 0. 0 2 9. 0 40. 0 52.0 57.0 75.0 9 5. 0 115.0 137.0 189.0 220.0 250.0 315.0 345.0 415.0
Ithegeneratoranddieselenginearederatedaccordingtothetable,theollowingcriteriaapply: 1 . Thevoltagedropatthegeneratorwillnotexceed 10%duringstart-up.Thismeansthatitispossibletouseeventheastestundervoltageprotectiononthemarketinthestarterboxothepump motor. 2.Generatorand dieselenginewillhavea normal lieasthenewullyrun-inengineisonlyloaded approx.70%withcontinuouspumpmotorrated current.Adieselenginewilltypicallyhavemaximumeciency(lowestuelconsumptionperkW output)at70-80%omaximumload.
3. B y autotransormer start or installation o a GrundosMP204orundervoltageprotection,it ispossibletochoosebothageneratoranddiesel enginethanare20%smallerthanstatedinthetable.This,however,meansrequentmaintenance oairlterandinjectionnozzles,cleaningothe coolerandchangeooil.Furthermore,itwillresultinavoltagedropduringstart-upoupto20%. Ithelossinthedropcableandmotorcableo upto15%isadded,thetotalvoltagelosswillbe morethan35%atthemotor.Thisisnoproblem orthree-phasemotors,butsometimesorsinglephasemotors,whichwillotenrequireanoversize startingcapacitororlowstart-upvoltages.
Generatoroperation Alwaysstartthegeneratorbeorethemotorisstartedandalwaysstopthemotorbeorethegeneratoris stopped.Themotorthrustbearingmaybedamaged igeneratorsareallowedtocoastdownwiththemotorconnected.Thesameconditionoccurswhengeneratorsareallowedtorunoutouel.
Therearetwotypesogenerators:internallyandexternally-regulated. Internally-regulated generators have an additional windinginthegeneratorstatorandarealsocalled sel-excited.The extra winding sensesthe output currentandincreasestheoutputvoltageautomatically. Internally-regulated generatorsnormally show the bestrunningeciency. Externally-regulated generators use an externally mountedvoltage regulatorthat senses theoutput voltage.Asthevoltagedipsatmotorstart-up,theregulatorincreasestheoutputvoltageothegenerator. Anexternally-regulatedgenerator is to be dimensionedapproximately50%higherinkW/kVArating todeliverthesamestartingtorqueasaninternally regulatedgenerator. Generator requencyisall importantasthe motor speedvarieswiththerequency[Hz].Duetopump anitylaws,apumprunningat1to2Hzbelowmotornameplaterequencywillnotmeetitsperormancecurve.Conversely, a pumprunning 1or 2Hz highermaytriptheoverloadrelay.
68
69
Communication
8.1 Purpose o communication and networking
thesystemperormanceandespeciallythatitisnot alimitingactorortheuturegrowthandexibility.
Therearetwomainpurposesousingdatacommunicationandnetworkinginrelationtoequipment andmachineryinallindustrialinstallationsorin processinginstallationslikewatersupplyplants:
8. Communications and networking technology
To centralise supervision and control Itiswelldocumentedthatmostautomationsystems canbenetsubstantiallyromcentralisationocontrolandsupervision.Theissuesthataremostoten mentionedare: • Optimiseperormance (e.g.e nergyand material savings) • Optimiseprocessquality(correctiveactions) • Bettermaintenance(serviceondemand) • Reductionorunningcosts(e.g.stacutting) • Organised/quick reaction to aults (minimise downtime) • Easyaccesstocurrentdataandthepossibilityto storedataindatabases(reportgeneration) Systems orthis kindo central managementare calledSCADA systems(SupervisoryControlandData Acquisition) To realise distributed systems Manyotoday’sautomationsystemswouldneverbe realisablewithoutdatacommunication.Inanautomationsystem,discreetdevices,whicharephysically separated,havetoexchangedata.Thesearetypically intheormomeasuredphysicalvalues,commands andsetpoints. Thediscreetdevicesworktogethertoullasuperior purpose(e.g.supplyingwater)andbydoingsothey constitutewhatiscalledadistributed system.Each deviceislikeacomponentinalargerentity,contributingtotheoverallperormance,eciencyandreliabilityothesystem. Thenumbero discreetdevicescan oten be very hugeandsocanthedistancebetweenthem.Inthese casesthecommunicationand networkingin itsel becomesthemostimportantandvulnerableparto thesystemanditsabilitytoullitspurpose.
8. Communication 70
It is importantthat theselectiono network and communicationsprotocolisnotalimitingactoror
Theuseocommunicationandnetworkingis inevitableinmodernautomationsystems,butthe kindosystemandtheusedtechnologyisvery diversied.Systemsmadebeore1995wherealmost alwaysbasedonelectricalcables,whereasthetechnologytodayoerberopticsorradiocommunicationasanalternative(orcombined)solution. Opticalbersareexibleandcanbebundledascables.Itisespeciallyadvantageousorlong-distance communications,becauselightpropagatesthrough theberwithlittleattenuationcomparedtoelectricalcables.Additionally,the lightsignalspropagatinginthebercanbemodulatedatratesashighas 40Gb/s,andeachbercancarrymanyindependent channels,each bya dierentwavelength olight. Fiberisalsoimmunetoelectricalintererence,which alsomeansimmunitytodamagingvoltagesurges inducedbylightning–abigadvantagewhenusing long-distancecablinginoutdoorinstallations. Communication using radio signalsalls in two categories:Shortdistanceandlongdistanceradio communication.Weknowthetechnologyoshort distanceradiocommunicationromwirelessLANs. Mostieldbussesoerwirelessrepeaterstoextend the ieldbus communication distanceover relativelyshortrangesortoavoidusingcableswhere cablingwouldbecostlyorimpractical(e.g.moving devices). Long distanceradio communicationcan be based onprivateradiotelemetry.TheUHFband between 400MHz to 500MHz has become internationally adopted orlow power license-reeuse ordigital dataandtelemetrysystems.Ithastheadvantageo propagatingindirectlineosightandwillpenetrate conventionalbuildingmaterials.Fordistancesabove 1000m,radioswithhigherpowerrequiringalicensed channelistypicallyneeded.
71
Communication
8.1 Purpose o communication and networking
thesystemperormanceandespeciallythatitisnot alimitingactorortheuturegrowthandexibility.
Therearetwomainpurposesousingdatacommunicationandnetworkinginrelationtoequipment andmachineryinallindustrialinstallationsorin processinginstallationslikewatersupplyplants:
8. Communications and networking technology
To centralise supervision and control Itiswelldocumentedthatmostautomationsystems canbenetsubstantiallyromcentralisationocontrolandsupervision.Theissuesthataremostoten mentionedare: • Optimiseperormance (e.g.e nergyand material savings) • Optimiseprocessquality(correctiveactions) • Bettermaintenance(serviceondemand) • Reductionorunningcosts(e.g.stacutting) • Organised/quick reaction to aults (minimise downtime) • Easyaccesstocurrentdataandthepossibilityto storedataindatabases(reportgeneration) Systems orthis kindo central managementare calledSCADA systems(SupervisoryControlandData Acquisition) To realise distributed systems Manyotoday’sautomationsystemswouldneverbe realisablewithoutdatacommunication.Inanautomationsystem,discreetdevices,whicharephysically separated,havetoexchangedata.Thesearetypically intheormomeasuredphysicalvalues,commands andsetpoints. Thediscreetdevicesworktogethertoullasuperior purpose(e.g.supplyingwater)andbydoingsothey constitutewhatiscalledadistributed system.Each deviceislikeacomponentinalargerentity,contributingtotheoverallperormance,eciencyandreliabilityothesystem. Thenumbero discreetdevicescan oten be very hugeandsocanthedistancebetweenthem.Inthese casesthecommunicationand networkingin itsel becomesthemostimportantandvulnerableparto thesystemanditsabilitytoullitspurpose. It is importantthat theselectiono network and communicationsprotocolisnotalimitingactoror
8. Communication
Theuseocommunicationandnetworkingis inevitableinmodernautomationsystems,butthe kindosystemandtheusedtechnologyisvery diversied.Systemsmadebeore1995wherealmost alwaysbasedonelectricalcables,whereasthetechnologytodayoerberopticsorradiocommunicationasanalternative(orcombined)solution. Opticalbersareexibleandcanbebundledascables.Itisespeciallyadvantageousorlong-distance communications,becauselightpropagatesthrough theberwithlittleattenuationcomparedtoelectricalcables.Additionally,the lightsignalspropagatinginthebercanbemodulatedatratesashighas 40Gb/s,andeachbercancarrymanyindependent channels,each bya dierentwavelength olight. Fiberisalsoimmunetoelectricalintererence,which alsomeansimmunitytodamagingvoltagesurges inducedbylightning–abigadvantagewhenusing long-distancecablinginoutdoorinstallations. Communication using radio signalsalls in two categories:Shortdistanceandlongdistanceradio communication.Weknowthetechnologyoshort distanceradiocommunicationromwirelessLANs. Mostieldbussesoerwirelessrepeaterstoextend the ieldbus communication distanceover relativelyshortrangesortoavoidusingcableswhere cablingwouldbecostlyorimpractical(e.g.moving devices). Long distanceradio communicationcan be based onprivateradiotelemetry.TheUHFband between 400MHz to 500MHz has become internationally adopted orlow power license-reeuse ordigital dataandtelemetrysystems.Ithastheadvantageo propagatingindirectlineosightandwillpenetrate conventionalbuildingmaterials.Fordistancesabove 1000m,radioswithhigherpowerrequiringalicensed channelistypicallyneeded.
70
71
Communication
Forradiocommunicationinareasthatarecoveredby existingoperator networkslikeGSMtheeasiest(but notalwaysthecheapest)wayoestablishingremote communicationisbysubscriptiontothisservice.It isuptothecustomer(orthesystemintegratorhe isusing)toexamineandassessithedemandsor communicationspeed,responsetimeandreliability areullled. InrecentyearsEthernetnetworkingtechnology,with thecommunicationsprotocolTCP/IP,whichhastraditionallybeenusedorLANsandwhichhasbecome totallydominatingwithinthateld,hasstartedto migratetoeldbusapplications.Hereitnowenters into competition with the traditional eldbusses likeDeviceNet,Probus,Modbus,etc.,butinsteado representingonecoherentprotocol,EthernetTCP/IP showsupinmanyincompatiblestandardslikeEthernetIP (aDeviceNet variant), Pronet(a Probus variant),ModbusTCP(aModbusvariant)andsimilar standardsthatarebasedon(andcompatiblewith) correspondingold eldbusses.The actthat some newEthernetstandardslikeEtherCatthatarespeciallydesignedtoutilizethehighspeedadvantages oEthernethave alsoemerged hasnot madethe choiceand compatibilitysituation within networkingoautomationsystemseasier.
Communication
theSCADAsystemisbroken,thesubsystemisableto keeponoperatingaloneandstillulllingitspurpose (e.g.supplyingwatertoa tank).Theoverallsystem design(choiceotechnologyandequipment)should aimatsubsystemautonomywheneverpossibleand alwayswithoutexception ensure thatsubsystems areailsaeandwillreturntoapredictablewell-denedandsecurestateicommunicationwithSCADA isbroken.Theoutstationwilltypicallybe: • APLC(ProgrammableLogicController) • ADDC(DedicatedDigitalController) • Agatewaytoanother(underlying)network . A communications inrastructure Thisiswhattiesitalltogether.Amixotechnologies willotenbeusedasnosingletechnology(network orprotocol)spansalldemandsinmorecomplexapplications. LAN/WAN HMI Human Machine Interface
8. SCADA systems 8..1 SCADA main parts ThethreemainpartsoatypicalSCADAsystemare: 1. A master computer Thecomputer(e.g.aPCrunningWindowsorUnix) hasHMI(HumanMachine Interace) sotwareand adatabase.NumerousspecializedthirdpartyHMI/ SCADAsotwarepackagesareavailable.SomeexamplesareiFixromGEFanuc,CitectSCADAromCitect, SIMATICromSiemensandWonderwareromInvensys. . A number o outstations Anoutstationotenrepresentsanautonomous subsystem.Autonomousmeansthatitheconnectionto
7
Storage
Computer
(database)
(SCADAsoftware)
Communication infrastructure MPC Outstation (DDC)
Outstation (PLC)
Media Converter RX TX L i nk
PWR
Link
Subsystem
Subsystem
Fig. 61 Illustration o the main parts o a SCADA system
8.. SCADA unctions Belowisalistotheunctionsthatistypicallyound inSCADAsystemsotwarepackages.Thelistisprioritizedwiththemostimportantunctionsatthetop.
SCADAsystemsotwareotenhasnetworkservercapability,meaningthatithehostPCisconnectedto aLANortotheinternet,itwillbepossibletologon tothesystemremotelyromanothernetworkconnectedPC.TheSCADAsystemsotwareisastandard package(availablerommanydierentsotwarevendors),butwithahighdegreeocustomizedadaptation(data,unctions,graphics,etc). 1. Establishthehealthothesystem – IssystemOK(operatingasintendedandulllingitspurpose)? – Doesthesystemneedservice(causeandkind)? – Isthesystembrokendown(cause)? 2. Displaysystemvariables/conditions – Conditions(likeon/o)illustratedwithgraphics andcolors – Importantsystemvariablesdisplayedonsystem drawing(pressure,ow,etc.) – Importantsystemvariablesshowngraphically 3. Alarmloggingandalarmrouting – Managingdutyrosters – Routingomessages(e.g.SMS) 4. Datalogging/Retrievalologgeddata – Interacetodatabase(e.g.MicrosotSQL) – Dataprocessing/Datastoring/Graphicalvisualization 5. Control – Manuallyoperation – Automaticoperation – Closedloopcontrol(rare) 6.Setup – Displaymainsetupparameters – Changingomainsetupparameters 7. Maintenanceinormation – Maintenanceplanandhistory – Sparepartslist – Manuals,photos,instructivevideos 8. Expertsystem – Articialintelligence – Faultdiagnostics – Decisionsupport 9. InteracingtoEnterpriseResourcePlanning(ERP).
hosted SCADA system.Alldatais accessibleviathe internetbytheuseoaweb-browser(e.g.Internet Explorer). Thesubsystemscanbemonitoredandoperatedrom anyPCinanylocationwithinternetaccessallover theworld.Thereisnoneedtoinstallanexpensive sotwaresystemononeormorePC. TheSCADAsystemsotwareandallthedataresides onthewebserver,whichcouldbeoperatedbyacontractor(systemintegrator)orbythecustomer(e.g.a centralwebserveroracompletemunicipality). Thecustomer/userdoesn’thavetoworryaboutinormation,communication and sotware/hardware technologybutcanconcentrateonthepracticaluse othedataandthepracticalmaintenanceothesubsystem. Passwordsensurethatonlyauthorisedpersonnelrecievesaccesstooperatespecicsubsystems.
Server/computer
WWW
Client
Client
Client Subsystems
Fig. 62 Illustration o the princible in web-hosted SCADA
8.. Web-hosted SCADA ASCADAsystemsotwarewhichrunsonawebserver insteadoonanormalWindowsPCiscalleda web-
7
Communication
Forradiocommunicationinareasthatarecoveredby existingoperator networkslikeGSMtheeasiest(but notalwaysthecheapest)wayoestablishingremote communicationisbysubscriptiontothisservice.It isuptothecustomer(orthesystemintegratorhe isusing)toexamineandassessithedemandsor communicationspeed,responsetimeandreliability areullled. InrecentyearsEthernetnetworkingtechnology,with thecommunicationsprotocolTCP/IP,whichhastraditionallybeenusedorLANsandwhichhasbecome totallydominatingwithinthateld,hasstartedto migratetoeldbusapplications.Hereitnowenters into competition with the traditional eldbusses likeDeviceNet,Probus,Modbus,etc.,butinsteado representingonecoherentprotocol,EthernetTCP/IP showsupinmanyincompatiblestandardslikeEthernetIP (aDeviceNet variant), Pronet(a Probus variant),ModbusTCP(aModbusvariant)andsimilar standardsthatarebasedon(andcompatiblewith) correspondingold eldbusses.The actthat some newEthernetstandardslikeEtherCatthatarespeciallydesignedtoutilizethehighspeedadvantages oEthernethave alsoemerged hasnot madethe choiceand compatibilitysituation within networkingoautomationsystemseasier.
Communication
theSCADAsystemisbroken,thesubsystemisableto keeponoperatingaloneandstillulllingitspurpose (e.g.supplyingwatertoa tank).Theoverallsystem design(choiceotechnologyandequipment)should aimatsubsystemautonomywheneverpossibleand alwayswithoutexception ensure thatsubsystems areailsaeandwillreturntoapredictablewell-denedandsecurestateicommunicationwithSCADA isbroken.Theoutstationwilltypicallybe: • APLC(ProgrammableLogicController) • ADDC(DedicatedDigitalController) • Agatewaytoanother(underlying)network . A communications inrastructure Thisiswhattiesitalltogether.Amixotechnologies willotenbeusedasnosingletechnology(network orprotocol)spansalldemandsinmorecomplexapplications. LAN/WAN HMI Human Machine Interface
Storage
Computer
(database)
(SCADAsoftware)
8. SCADA systems
Communication infrastructure
8..1 SCADA main parts ThethreemainpartsoatypicalSCADAsystemare: 1. A master computer Thecomputer(e.g.aPCrunningWindowsorUnix) hasHMI(HumanMachine Interace) sotwareand adatabase.NumerousspecializedthirdpartyHMI/ SCADAsotwarepackagesareavailable.SomeexamplesareiFixromGEFanuc,CitectSCADAromCitect, SIMATICromSiemensandWonderwareromInvensys. . A number o outstations Anoutstationotenrepresentsanautonomous subsystem.Autonomousmeansthatitheconnectionto
MPC Outstation (DDC)
Outstation (PLC)
Media Converter RX TX L i nk
PWR
Link
Subsystem
Subsystem
Fig. 61 Illustration o the main parts o a SCADA system
8.. SCADA unctions Belowisalistotheunctionsthatistypicallyound inSCADAsystemsotwarepackages.Thelistisprioritizedwiththemostimportantunctionsatthetop.
SCADAsystemsotwareotenhasnetworkservercapability,meaningthatithehostPCisconnectedto aLANortotheinternet,itwillbepossibletologon tothesystemremotelyromanothernetworkconnectedPC.TheSCADAsystemsotwareisastandard package(availablerommanydierentsotwarevendors),butwithahighdegreeocustomizedadaptation(data,unctions,graphics,etc). 1. Establishthehealthothesystem – IssystemOK(operatingasintendedandulllingitspurpose)? – Doesthesystemneedservice(causeandkind)? – Isthesystembrokendown(cause)? 2. Displaysystemvariables/conditions – Conditions(likeon/o)illustratedwithgraphics andcolors – Importantsystemvariablesdisplayedonsystem drawing(pressure,ow,etc.) – Importantsystemvariablesshowngraphically 3. Alarmloggingandalarmrouting – Managingdutyrosters – Routingomessages(e.g.SMS) 4. Datalogging/Retrievalologgeddata – Interacetodatabase(e.g.MicrosotSQL) – Dataprocessing/Datastoring/Graphicalvisualization 5. Control – Manuallyoperation – Automaticoperation – Closedloopcontrol(rare) 6.Setup – Displaymainsetupparameters – Changingomainsetupparameters 7. Maintenanceinormation – Maintenanceplanandhistory – Sparepartslist – Manuals,photos,instructivevideos 8. Expertsystem – Articialintelligence – Faultdiagnostics – Decisionsupport 9. InteracingtoEnterpriseResourcePlanning(ERP).
hosted SCADA system.Alldatais accessibleviathe internetbytheuseoaweb-browser(e.g.Internet Explorer). Thesubsystemscanbemonitoredandoperatedrom anyPCinanylocationwithinternetaccessallover theworld.Thereisnoneedtoinstallanexpensive sotwaresystemononeormorePC. TheSCADAsystemsotwareandallthedataresides onthewebserver,whichcouldbeoperatedbyacontractor(systemintegrator)orbythecustomer(e.g.a centralwebserveroracompletemunicipality). Thecustomer/userdoesn’thavetoworryaboutinormation,communication and sotware/hardware technologybutcanconcentrateonthepracticaluse othedataandthepracticalmaintenanceothesubsystem. Passwordsensurethatonlyauthorisedpersonnelrecievesaccesstooperatespecicsubsystems.
Server/computer
WWW
Client
Client
Client Subsystems
Fig. 62 Illustration o the princible in web-hosted SCADA
8.. Web-hosted SCADA ASCADAsystemsotwarewhichrunsonawebserver insteadoonanormalWindowsPCiscalleda web-
7
7
Communication
Communication
8. Networking basics 8..1 Network topology Reerstothewayinwhichthenetworkocommunicatingdevicesisconnected.Eachtopologyissuited tospecictasksandhasitsownadvantagesanddisadvantages. Fig. 64 Ring topology Ina star network,allwiringisdoneromacentral point(e.g.ahuboracentralcontroller).Ithasthe greatestcablelengthsoanytopologyandthususes themost amounto cable. Ethernetnetworks are usuallybasedonthestartopology.
Advantages
Disadvant ages
•Equalaccessoralldevices
•Costlywiring
•Eachdevicehasullaccess speedtothering
•Dicultandexpensiveconnections
•Onlyslightperormancedrop withincreasedno.odevices.
Fig. 63 Star topology Advantages
Disadvant ages
•Easytoaddnewdevices
•Hubailurecripplesalldevicesconnectedtothathub
•Centralizedcontrol,network/hubmonitoring
Aring network,isanetworktopologyinwhicheach networkdeviceconnectstoexactlytwootherdevices,ormingacircularpathwayorsignals.Datatravelsromdevicetodevice,witheachdevicehandling everypacket.TheoldIBMLANstandardTokenRing andtheindustrialeldbusInterbusarebothusing theringtopology.
Inabus network,alldevicesconnecttothesamecablesegment.Wiringisnormallydonepointtopoint ina chain ashionor viadropcables.The cable is terminatedat eachend.Messagesare transmitted alongthecablearevisibletoalldevicesconnectedto thatcable.Mosteldbusses(e.g.Probus,DeviceNet, GENIbus)usethebustopology,butdespitethename, eldbussescanalsobebasedonothertopologies. Drop cable fashion
Daisy chain fashion
thenetwork,whenthedeviceisusedinapplications. Itdocumentstherelationbetweenthedeviceunctions,thedataitemsandthebehaviourotheapplication/systeminwhichthedeviceisoperating.
8.. Communications protocol
Devicesthatusethesamecommunicationsprotocol andexchangedataaccordingtoadenedandshared unctionalprolearesaidtobeinteroperable.
The communications protocol coversthe rulesthat speciyhowaunctionaldeviceconnectedtoanetworkcaninterchangedatawithotherdevicesthat arepart othe network.It species details inthe physicalhardwarelikeimpedanceandelectricalsignals.Itspeciesdetailsinthedatatranserlikebaud rate,timinganddatapacketormatanditspecies howaddressingodevices,requestingodataand replyingtorequestsshouldwork. Thecommunicationsprotocolisthemanagerothe communicationline.Theprotocolrulescontrolwho isallowedtotransmit,howmuchandorhowlong. In master/slave protocols (like GENIbus, Modbus, Probus)thearbitrationrulesotheprotocolcontrol whoismasterandwhoisslave. Itistheresponsibilityotheprotocolthateverything works reliably and thatdata gets communicated withouterrors.Butincaseswheresomethinggoes wrong,inprotocoltermscalled exceptions ,itisalso theresponsibilityotheprotocoltodetecttheseexceptions,to react uponthem(e.g. errorreporting, retransmission,etc.)andnallytorecoverromany errorcondition includingrom acomplete network breakdown.
8.. Functional prole Fig. 65 Bus topology Advantages
Disadvant ages
•Easytoimplement
•Limitsoncablelengthand devicenumbers
•Lowcost
•Diculttoisolatenetwork aults •Acableaultaectsall devices •Networkslowsdownwith increasedno.odevices
7
Veryotenacombinationothesethreebasictopologiesisused–thenwetalkaboutmixed topology .I thenetworking technologyused allowsconnection inanytopology–thenwetalkabout ree topology .
The unctional prole oa networkdevice means thespecicationo itsunctional interaceto the network.Thisisprimarilyadescriptionotheinput andtheoutputdatao thedevice.Thesedataare mostotenreerredtoasthedatapointsorthedata itemsothedevice.Theunctionalproledescribes thedataitems–whatormattheyhave(8bit,16bit, etc.),theirscaling(resolutionandrange),limitations andmutualrelation.
8.. The eldbus Thekindonetworksthatareusedinindustrialautomationsystemstoconnectsensors,actuatorand controllersarecalled eldbussesasopposedtonetworksusedoradministrativepurposesinoceenvironments,whicharegenerallyreerredtoas Local Area Networks (LANs). Fieldbussesaredesignedtoworkinharshenvironments–outintheeldsotospeak-anduseindustrialgradeequipmentandcabling.Moreoveraeldbus protocol generally promotes other characteristics thanaLANdoes,becausethedemandsarequietdierent. The eldbus typically transerssmall amounts o data, but the datais transerred requently(high sampleratescanotenbearequirement).Alsothe eldbusmust beable tohandletime criticaldata transer,meaningithastoullhardtimingrequirements(lowdelaysinbusaccessanddatareplyand astdataprocessing). TheLAN,ontheotherhand,transershugeamounts odata(les,etc.)between computersand servers, butthesedataaretranserredseldom.Alsothereactionneednotbeveryast,becauseitinteractswith humansandnotwithtime-criticalphysicalprocesses.
Apartromthedataitemdescription,theunctional prolealsodescribeshowtooperatethedevicevia
7
Communication
Communication
8. Networking basics 8..1 Network topology Reerstothewayinwhichthenetworkocommunicatingdevicesisconnected.Eachtopologyissuited tospecictasksandhasitsownadvantagesanddisadvantages. Fig. 64 Ring topology Ina star network,allwiringisdoneromacentral point(e.g.ahuboracentralcontroller).Ithasthe greatestcablelengthsoanytopologyandthususes themost amounto cable. Ethernetnetworks are usuallybasedonthestartopology.
Advantages
Disadvant ages
•Equalaccessoralldevices
•Costlywiring
•Eachdevicehasullaccess speedtothering
•Dicultandexpensiveconnections
•Onlyslightperormancedrop withincreasedno.odevices.
Fig. 63 Star topology Advantages
Disadvant ages
•Easytoaddnewdevices
•Hubailurecripplesalldevicesconnectedtothathub
•Centralizedcontrol,network/hubmonitoring
Aring network,isanetworktopologyinwhicheach networkdeviceconnectstoexactlytwootherdevices,ormingacircularpathwayorsignals.Datatravelsromdevicetodevice,witheachdevicehandling everypacket.TheoldIBMLANstandardTokenRing andtheindustrialeldbusInterbusarebothusing theringtopology.
Inabus network,alldevicesconnecttothesamecablesegment.Wiringisnormallydonepointtopoint ina chain ashionor viadropcables.The cable is terminatedat eachend.Messagesare transmitted alongthecablearevisibletoalldevicesconnectedto thatcable.Mosteldbusses(e.g.Probus,DeviceNet, GENIbus)usethebustopology,butdespitethename, eldbussescanalsobebasedonothertopologies. Drop cable fashion
Daisy chain fashion
Veryotenacombinationothesethreebasictopologiesisused–thenwetalkaboutmixed topology .I thenetworking technologyused allowsconnection inanytopology–thenwetalkabout ree topology .
thenetwork,whenthedeviceisusedinapplications. Itdocumentstherelationbetweenthedeviceunctions,thedataitemsandthebehaviourotheapplication/systeminwhichthedeviceisoperating.
8.. Communications protocol
Devicesthatusethesamecommunicationsprotocol andexchangedataaccordingtoadenedandshared unctionalprolearesaidtobeinteroperable.
The communications protocol coversthe rulesthat speciyhowaunctionaldeviceconnectedtoanetworkcaninterchangedatawithotherdevicesthat arepart othe network.It species details inthe physicalhardwarelikeimpedanceandelectricalsignals.Itspeciesdetailsinthedatatranserlikebaud rate,timinganddatapacketormatanditspecies howaddressingodevices,requestingodataand replyingtorequestsshouldwork.
8.. The eldbus Thekindonetworksthatareusedinindustrialautomationsystemstoconnectsensors,actuatorand controllersarecalled eldbussesasopposedtonetworksusedoradministrativepurposesinoceenvironments,whicharegenerallyreerredtoas Local Area Networks (LANs).
Thecommunicationsprotocolisthemanagerothe communicationline.Theprotocolrulescontrolwho isallowedtotransmit,howmuchandorhowlong. In master/slave protocols (like GENIbus, Modbus, Probus)thearbitrationrulesotheprotocolcontrol whoismasterandwhoisslave.
Fieldbussesaredesignedtoworkinharshenvironments–outintheeldsotospeak-anduseindustrialgradeequipmentandcabling.Moreoveraeldbus protocol generally promotes other characteristics thanaLANdoes,becausethedemandsarequietdierent.
Itistheresponsibilityotheprotocolthateverything works reliably and thatdata gets communicated withouterrors.Butincaseswheresomethinggoes wrong,inprotocoltermscalled exceptions ,itisalso theresponsibilityotheprotocoltodetecttheseexceptions,to react uponthem(e.g. errorreporting, retransmission,etc.)andnallytorecoverromany errorcondition includingrom acomplete network breakdown.
The eldbus typically transerssmall amounts o data, but the datais transerred requently(high sampleratescanotenbearequirement).Alsothe eldbusmust beable tohandletime criticaldata transer,meaningithastoullhardtimingrequirements(lowdelaysinbusaccessanddatareplyand astdataprocessing). TheLAN,ontheotherhand,transershugeamounts odata(les,etc.)between computersand servers, butthesedataaretranserredseldom.Alsothereactionneednotbeveryast,becauseitinteractswith humansandnotwithtime-criticalphysicalprocesses.
8.. Functional prole Fig. 65 Bus topology Advantages
Disadvant ages
•Easytoimplement
•Limitsoncablelengthand devicenumbers
•Lowcost
•Diculttoisolatenetwork aults •Acableaultaectsall devices •Networkslowsdownwith increasedno.odevices
The unctional prole oa networkdevice means thespecicationo itsunctional interaceto the network.Thisisprimarilyadescriptionotheinput andtheoutputdatao thedevice.Thesedataare mostotenreerredtoasthedatapointsorthedata itemsothedevice.Theunctionalproledescribes thedataitems–whatormattheyhave(8bit,16bit, etc.),theirscaling(resolutionandrange),limitations andmutualrelation. Apartromthedataitemdescription,theunctional prolealsodescribeshowtooperatethedevicevia
7
7
Communication
Communication
8.. GENIbus GENIbus,theGrundosElectronicsNetworkIntercommunicationsbusisaproprietaryeldbusdevelopedby Grundostomeettheneedordatatranserandnetworkingintypicalwaterpumpapplicationsinbuildings,watersupply,waterpuricationandindustry.
8..1 Background GENIbuswasrstintroducedtothemarketin1991as aeldbusinteraceortheGrundoscirculatorpump typeUPE.Thispumpbecametherstwaterpumpin the worldwith integratedrequency converterand alsotherstwithintegratedeldbusinterace. TheoriginalpurposeotheGENIbusinteracewasto enable networking othe speedcontrolled circulatorpumpsintosubsystems,whereacentralmaster couldhandleseveralcontrolloopswithpumpsconnected hydraulicallyparallelandat thesametime makeimportantpumpdatalikepressure,owand alarmsavailableonadisplay. SincethenGENIbushasdevelopedintoanadvanced andyet costeective de-actoGrundosstandard andisavailableoralmostallGrundosproductswith electronics.Itsmainareaoapplicationis: • Networking between pumps, auxiliary devices andcontrollersinGrundossubsystems(e.g.HydroMPC) • Integrationin automationsystems(e.g. SCADA) viagateways • ConnectiontoPCtoolsviaadapterorconguration,aultnding,valuemonitoring,datalogging,etc.
8.. Technical description
8.. Cabling guidelines Havingbeendevelopedandnowbeingmaintained byasinglecompanyinsteadobyanindependent userorganization makes GENIbus a so-called pro prietary eldbus.Howeverthestandardisopenor anyonetouse,whichhasresultedintheemergence oseveralthirdpartygatewaysenablingtheconnectionoGENIbusdevices(e.g.pumps)tocontrollers ootherbrandsandogateways,whichcanconnect GENIbustoaewrecognizedeldbusstandards.
Ingeneral • Usetwistedpaircableswithshield • Connecttheshieldinbothends • Daisy chaining is the preerred wayto connect multipleunits • Avoidlongstubs • Keepwiresasshortaspossible • Separatebuswiresrompowercablesipossible.
Below isa GENIbus technicalsummary. ThecompleteGENIbusprotocolspecicationisavailableon request. Physicallayer(hardware) Topology
Bus
Transmitter
EIARS485,h al duple x
Data ormat
Startb it(=0),8databitsw ithl east signicantbitrst,stopbit(=1)
B au d ra te
9 60 0 bi ts /s Somedevicessupportprogrammable baudraterom1200-38400bits/s
Distance
Daisychain:1200m Multidrop:500m Twistedpaircablewithshieldisrecommended.Notermination.
No.obusu nit s
Max.32
Datalinklayer(timing,verication) InterB yteDelay
<=1.2ms
InterTelegramDelay
>=3ms
ReplyDelay
[3ms;50ms] Somedevicessupportprogrammable minimumreplydelay[3ms;2.5s]
Cyclicredundancy checking
16bitCCITT
Mediumaccess
Master/Sla ve
Physicaladdress range
Masteraddressrange:[0;231] Slaveaddressrange:[32;231] Connectionrequestaddress:254 Broadcastaddress:255
M
M
M
max. 500 m
S
GENIbus • Donotuseterminatingresistors • Acommunicationdistanceupto1200misnormallynotaproblem • Thedistancecanbeextendedwithrepeaters • Iyouexperienceproblemswithnoise,trydisconnectingtheshieldthatisoundatoneendperbus unit.
S
Bus unit #1
S
max. 1200 m
S
S
Bus unit #2
S
max. 1200 m
S
S
S
Bus unit #3
A
A
A
Y B
Y B
Y B
Daisy chaining, the ideal way o cabling GENIbus
Likemostothereldbusses,GENIbussupportsthe mechanisms or single-casting (single-addressing), multicasting (group addressing) and broadcasting (globaladdressing).AuniqueeatureoGENIbusis theConnection Request ,whichmakesitpossibleor amasterdevicetorecognizeallconnectedunitsona networkwithouthavingtopollthroughallpossible addresses.
76
77
Communication
Communication
8.. GENIbus GENIbus,theGrundosElectronicsNetworkIntercommunicationsbusisaproprietaryeldbusdevelopedby Grundostomeettheneedordatatranserandnetworkingintypicalwaterpumpapplicationsinbuildings,watersupply,waterpuricationandindustry.
8..1 Background GENIbuswasrstintroducedtothemarketin1991as aeldbusinteraceortheGrundoscirculatorpump typeUPE.Thispumpbecametherstwaterpumpin the worldwith integratedrequency converterand alsotherstwithintegratedeldbusinterace. TheoriginalpurposeotheGENIbusinteracewasto enable networking othe speedcontrolled circulatorpumpsintosubsystems,whereacentralmaster couldhandleseveralcontrolloopswithpumpsconnected hydraulicallyparallelandat thesametime makeimportantpumpdatalikepressure,owand alarmsavailableonadisplay. SincethenGENIbushasdevelopedintoanadvanced andyet costeective de-actoGrundosstandard andisavailableoralmostallGrundosproductswith electronics.Itsmainareaoapplicationis: • Networking between pumps, auxiliary devices andcontrollersinGrundossubsystems(e.g.HydroMPC) • Integrationin automationsystems(e.g. SCADA) viagateways • ConnectiontoPCtoolsviaadapterorconguration,aultnding,valuemonitoring,datalogging,etc.
8.. Cabling guidelines Havingbeendevelopedandnowbeingmaintained byasinglecompanyinsteadobyanindependent userorganization makes GENIbus a so-called pro prietary eldbus.Howeverthestandardisopenor anyonetouse,whichhasresultedintheemergence oseveralthirdpartygatewaysenablingtheconnectionoGENIbusdevices(e.g.pumps)tocontrollers ootherbrandsandogateways,whichcanconnect GENIbustoaewrecognizedeldbusstandards.
Ingeneral • Usetwistedpaircableswithshield • Connecttheshieldinbothends • Daisy chaining is the preerred wayto connect multipleunits • Avoidlongstubs • Keepwiresasshortaspossible • Separatebuswiresrompowercablesipossible.
Below isa GENIbus technicalsummary. ThecompleteGENIbusprotocolspecicationisavailableon request. Physicallayer(hardware) Bus
Transmitter
EIARS485,h al duple x
Data ormat
Startb it(=0),8databitsw ithl east signicantbitrst,stopbit(=1)
B au d ra te
9 60 0 bi ts /s Somedevicessupportprogrammable baudraterom1200-38400bits/s
Distance
Daisychain:1200m Multidrop:500m Twistedpaircablewithshieldisrecommended.Notermination. Max.32
M
S
Bus unit #1
S
max. 1200 m
S
S
Bus unit #2
S
max. 1200 m
S
S
S
Bus unit #3
A
A
A
Y B
Y B
Y B
Daisy chaining, the ideal way o cabling GENIbus
Datalinklayer(timing,verication) InterB yteDelay
<=1.2ms
InterTelegramDelay
>=3ms
ReplyDelay
[3ms;50ms] Somedevicessupportprogrammable minimumreplydelay[3ms;2.5s]
Cyclicredundancy checking
16bitCCITT
Mediumaccess
Master/Sla ve
Physicaladdress range
Masteraddressrange:[0;231] Slaveaddressrange:[32;231] Connectionrequestaddress:254 Broadcastaddress:255
8.. Technical description
M max. 500 m
S
Topology
No.obusu nit s
M
GENIbus • Donotuseterminatingresistors • Acommunicationdistanceupto1200misnormallynotaproblem • Thedistancecanbeextendedwithrepeaters • Iyouexperienceproblemswithnoise,trydisconnectingtheshieldthatisoundatoneendperbus unit.
Likemostothereldbusses,GENIbussupportsthe mechanisms or single-casting (single-addressing), multicasting (group addressing) and broadcasting (globaladdressing).AuniqueeatureoGENIbusis theConnection Request ,whichmakesitpossibleor amasterdevicetorecognizeallconnectedunitsona networkwithouthavingtopollthroughallpossible addresses.
76
77
Communication
Communication
8.6 Grundos GENIbus products or SP applications BytheusageotheelectronicmotorprotectorMP 204(describedinchapter10,“Accessories”)itispossibletomonitortheSPpumpremotely: • 3-phasecurrentandvoltages • 3-phasevoltageanglesandcos(θ) • Startcurrent • Currentasymmetry • Insulationresistance • Powerandenergyconsumption • Supplyrequency • Motortemperature • Presentalarmsandwarnings • Loggedalarms • Powerontimeandrunningtimecounter • Startcounter(totalandperhour) • Re-startcounter(totalandperday) • OperatingmodeoMP204motorprotector.
Mainnetworkconnection (to PLCor SCADA) power powerMNC powerGENI GENITxD GENIRxD Fault
DCD RTS TxD1 RxD1 TxD2 RxD2
G100Gateway
GatewayG100
3~ MP204
MP204
MP204
MP204
MP204 Motorprotector
GENIbus
Contactor
Fig. 66 Illustration o the remote monitoring and control o SP pump installations
ByoperatingtheelectronicmotorprotectorMP204 asanon/oactuator,itispossibletostart/stopcontroltheSPpumpremotely.Itisalsopossibletoreset alarms,loggedalarmsandvariouscounterslikerunninghoursandstartcounters. Bytheusageotheinput/outputIO111device(describedinchapter10,“Accessories”)aloneortogetherwithMP204itispossibletomonitortheollowing values: • ValueoPT100temperaturesensor • Valueopulsecounterinput • Valueoanalogue4-20mAinput • Alarmlimitexceeded(ortheaboveinputs) • Powerontime • Loggedalarms. MP204andIO112bothhaveGENIbusinterace.MP 204 issupported bythe GrundosgatewayG100 (datasheetavailableviaWEBcaps),whichcanhandle simultaneousconnectionoupto32MP204devices andsupportscommunicationviaModbus(RS232,radioorGSM)orviaProbus.Italsohasabuildindata logger with a capacity o approximately 300,000 timestampedloggings.
78
79
Communication
Communication
8.6 Grundos GENIbus products or SP applications BytheusageotheelectronicmotorprotectorMP 204(describedinchapter10,“Accessories”)itispossibletomonitortheSPpumpremotely: • 3-phasecurrentandvoltages • 3-phasevoltageanglesandcos(θ) • Startcurrent • Currentasymmetry • Insulationresistance • Powerandenergyconsumption • Supplyrequency • Motortemperature • Presentalarmsandwarnings • Loggedalarms • Powerontimeandrunningtimecounter • Startcounter(totalandperhour) • Re-startcounter(totalandperday) • OperatingmodeoMP204motorprotector.
Mainnetworkconnection (to PLCor SCADA) power powerMNC powerGENI GENITxD GENIRxD Fault
DCD RTS TxD1 RxD1 TxD2 RxD2
G100Gateway
GatewayG100
3~ MP204
MP204
MP204
MP204
MP204 Motorprotector
GENIbus
Contactor
Fig. 66 Illustration o the remote monitoring and control o SP pump installations
ByoperatingtheelectronicmotorprotectorMP204 asanon/oactuator,itispossibletostart/stopcontroltheSPpumpremotely.Itisalsopossibletoreset alarms,loggedalarmsandvariouscounterslikerunninghoursandstartcounters. Bytheusageotheinput/outputIO111device(describedinchapter10,“Accessories”)aloneortogetherwithMP204itispossibletomonitortheollowing values: • ValueoPT100temperaturesensor • Valueopulsecounterinput • Valueoanalogue4-20mAinput • Alarmlimitexceeded(ortheaboveinputs) • Powerontime • Loggedalarms. MP204andIO112bothhaveGENIbusinterace.MP 204 issupported bythe GrundosgatewayG100 (datasheetavailableviaWEBcaps),whichcanhandle simultaneousconnectionoupto32MP204devices andsupportscommunicationviaModbus(RS232,radioorGSM)orviaProbus.Italsohasabuildindata logger with a capacity o approximately 300,000 timestampedloggings.
78
79
Troubleshooting
Fault
9. Troubleshooting 80
Cause
Solution
Loudnoisesinpipeworkinhomeor Waterhammeratpumpstartand Fita50-litrediaphragmtankwhere building. stop. therisermainandthehorizontal dischargepipemeet. Pressuregaugesstopworkingater shorttime. Waterromthisdiaphragmtank willbedischargedwhenthepump Blow-outinpipingandttings isswitchedoandthusprevent theormationothevacuum. Airpenetratingsuctionpipingas Waterhammercreatingvacuum Introducesot-start/stop,-VFDor wellaspressurisedpiping. pressuretankshockabsorption. Arapiddeclineinpumpperorm- Wearandtearduetosand/silt Detecttheproblematicwells,seal ance. penetratingintowell otheproblematicsectionothe wellorreducepumpperormance tolessthanhalotheproblematic capacity. Contactorsailtoooten, Highstartingrequency Reducepumpcapacity,installa andmotorsconsumeexcessive VFDorlargertankcapacity. kWhperm3pumped. Powerconsumptionbythemotor Upthrus t Throttle pump perormance to isexcessive,andshat/coupling aroundthebesteciencypointor splinesweardown. reducethenumberoimpellerson thepump. Wornu pthrustbearings UpthrustbyON/OFFoperation Establishthenecessaryowc ontrolatstart-up. Thrustbearingsoncannedtype Cav it at ion Re mov e ow re st ri ct io ns t o pu mp motorsail andcheckorperormancearound thebesteciencypoint. Insulationresistanceonrewindablemotorsails. Motortemperatureincreasesover Deposits(Calcium,Iron,etc)onmo- Pullthepumpandmotororcleantime;pumpperormancealls. torsuraceandinhydraulicparts ing;cleanthepiping,welllterand opump. installacoolingsleeveonmotor. Pumpperormanceallso Aggressivewater(Corrosiono Pressuretestpipingromground pumpandpipes) level.Ileakagesoccur,pulland replacethepumpandpipeswitha highercorrosionclass. Waterdisappearsdownthepiping Risermainspipecorrosion Pullthepumpandreplacethepipwhenthepumpisstopped ingmaterialwithahighercorrosionclass. Pumpperormanceistoolow.The Gasevacuation Lowerthepumpwhenequipped motorconsumesinsucientkWh. withgasevacuationsleeve. Thewaterlevelinthewelliscon- Welloverpumping Reducepumpcapacityuntilthe stantlybecominglower. waterlevelremainsconstantover thecourseoayear. Drillmorewellsatotheraquiers.
81
Troubleshooting
Fault
9. Troubleshooting
Cause
Solution
Loudnoisesinpipeworkinhomeor Waterhammeratpumpstartand Fita50-litrediaphragmtankwhere building. stop. therisermainandthehorizontal dischargepipemeet. Pressuregaugesstopworkingater shorttime. Waterromthisdiaphragmtank willbedischargedwhenthepump Blow-outinpipingandttings isswitchedoandthusprevent theormationothevacuum. Airpenetratingsuctionpipingas Waterhammercreatingvacuum Introducesot-start/stop,-VFDor wellaspressurisedpiping. pressuretankshockabsorption. Arapiddeclineinpumpperorm- Wearandtearduetosand/silt Detecttheproblematicwells,seal ance. penetratingintowell otheproblematicsectionothe wellorreducepumpperormance tolessthanhalotheproblematic capacity. Contactorsailtoooten, Highstartingrequency Reducepumpcapacity,installa andmotorsconsumeexcessive VFDorlargertankcapacity. kWhperm3pumped. Powerconsumptionbythemotor Upthrus t Throttle pump perormance to isexcessive,andshat/coupling aroundthebesteciencypointor splinesweardown. reducethenumberoimpellerson thepump. Wornu pthrustbearings UpthrustbyON/OFFoperation Establishthenecessaryowc ontrolatstart-up. Thrustbearingsoncannedtype Cav it at ion Re mov e ow re st ri ct io ns t o pu mp motorsail andcheckorperormancearound thebesteciencypoint. Insulationresistanceonrewindablemotorsails. Motortemperatureincreasesover Deposits(Calcium,Iron,etc)onmo- Pullthepumpandmotororcleantime;pumpperormancealls. torsuraceandinhydraulicparts ing;cleanthepiping,welllterand opump. installacoolingsleeveonmotor. Pumpperormanceallso Aggressivewater(Corrosiono Pressuretestpipingromground pumpandpipes) level.Ileakagesoccur,pulland replacethepumpandpipeswitha highercorrosionclass. Waterdisappearsdownthepiping Risermainspipecorrosion Pullthepumpandreplacethepipwhenthepumpisstopped ingmaterialwithahighercorrosionclass. Pumpperormanceistoolow.The Gasevacuation Lowerthepumpwhenequipped motorconsumesinsucientkWh. withgasevacuationsleeve. Thewaterlevelinthewelliscon- Welloverpumping Reducepumpcapacityuntilthe stantlybecominglower. waterlevelremainsconstantover thecourseoayear. Drillmorewellsatotheraquiers.
80
81
Accessories
10.1 Cooling sleeves Ingeneral,coolingsleevesarerecommendedwhen themotorcoolingisinsucient.Thisisnormalin tankapplications.Itcanalsobenecessaryindeep wellapplications,wherethereisariskthatthewaterwillowtothepumpinletromaboveandnot automaticallypassalongthemotor.
Metalscanbe listedinordertotheirrelativeactivityin seawaterenvironment.I the metal surace becomestheanodeintheelectrochemicalcell,corrosiontakesplace.
Otherapplicationswherea owsleeveshouldbe used: • Themotoris exposed toa highthermalload, suchasduetoahighambienttemperature,currentunbalanceoroverload. • Aggressiveliquidsarepumped,sincecorrosionis doubledorevery10°Cincreaseintemperature. • Sedimentationordepositsoccuraroundand/or onthemotor.
Cathodicprotectionisatechniquetocontrolthecorrosionoagivenmetalsuracebypurposelymaking thissuraceintothecathodeotheelectrochemical cell. Thiscanbedoneintwoways: • Galvanic:byuseosacricialmetal • ImpressedCurrent:by useo DCpowersupply andaninertanode.
Byusingthecoolingsleeves,theowalongthemotorwillminimizethemotortemperatureandtherebyextendthemotorlie.
10.. Galvanic cathodic protection systems
10..1 Cathodic protection
10. Corrosion protection in seawater Stainlesssteelcanbedamagedbycreviceorpitting corrosionwhenimmergedintochlorinatedwater. Thelikelihoodocorrosiondependson: • Thegradeomaterialused(GG–AISI304–AISI 316–AISI904L) • Chlorideconcentrationinthewater • Electrochemicalpotentialothemetalexposed tomedia • Temperature • Oxygenconcentration • Velocityothemediaincontactwiththemetallicsurace • ThepHvalue.
10. Accessories 8
Whenmetalissubmergedintowater,itormsan electrochemicalcell,withananodeandacathode immergedinto anelectrolyte(ex.chlorinatedwater).Thisisalsoreerredtoasbeingagalvaniccell. Theanodecanbereerredtoastheactivepartand thecathodeasthenoblepart.
Fig. 67 Submersible pump set with sacricial zinc anodes.
8
Accessories
10.1 Cooling sleeves Ingeneral,coolingsleevesarerecommendedwhen themotorcoolingisinsucient.Thisisnormalin tankapplications.Itcanalsobenecessaryindeep wellapplications,wherethereisariskthatthewaterwillowtothepumpinletromaboveandnot automaticallypassalongthemotor.
Metalscanbe listedinordertotheirrelativeactivityin seawaterenvironment.I the metal surace becomestheanodeintheelectrochemicalcell,corrosiontakesplace.
Otherapplicationswherea owsleeveshouldbe used: • Themotoris exposed toa highthermalload, suchasduetoahighambienttemperature,currentunbalanceoroverload. • Aggressiveliquidsarepumped,sincecorrosionis doubledorevery10°Cincreaseintemperature. • Sedimentationordepositsoccuraroundand/or onthemotor.
Cathodicprotectionisatechniquetocontrolthecorrosionoagivenmetalsuracebypurposelymaking thissuraceintothecathodeotheelectrochemical cell. Thiscanbedoneintwoways: • Galvanic:byuseosacricialmetal • ImpressedCurrent:by useo DCpowersupply andaninertanode.
Byusingthecoolingsleeves,theowalongthemotorwillminimizethemotortemperatureandtherebyextendthemotorlie.
10.. Galvanic cathodic protection systems
10..1 Cathodic protection
10. Corrosion protection in seawater Stainlesssteelcanbedamagedbycreviceorpitting corrosionwhenimmergedintochlorinatedwater. Thelikelihoodocorrosiondependson: • Thegradeomaterialused(GG–AISI304–AISI 316–AISI904L) • Chlorideconcentrationinthewater • Electrochemicalpotentialothemetalexposed tomedia • Temperature • Oxygenconcentration • Velocityothemediaincontactwiththemetallicsurace • ThepHvalue. Whenmetalissubmergedintowater,itormsan electrochemicalcell,withananodeandacathode immergedinto anelectrolyte(ex.chlorinatedwater).Thisisalsoreerredtoasbeingagalvaniccell. Theanodecanbereerredtoastheactivepartand thecathodeasthenoblepart.
10. Accessories
Fig. 67 Submersible pump set with sacricial zinc anodes.
8
8
Accessories
Accessories
Grundosoersaseriesosacricialzincanodesor thesubmersiblepump andmotor.For metallicriser pipes,standardsolutionsorpipesarerecommended.
DCpowersupply Insulated Anode Cable
4e�
Theuseosacricialanodeshasanenvironmental impactthatshouldalwaysbetakenintoaccount.The eectsothesaltsbeingormedinthegalvanicprocessmustalwaysbetakenintoaccount. Thesystemneedstobemonitoredinordertond thecorrecttimeorreplacingthesacricialanodes.
Negative returncable (Structure Connection) 4Cl�
Forbiggerandmorecomplexsystems,engineeringis neededinordertomakethecorrectchoiceconcerningcorrosionprotection.Aspectstoconsiderinclude • Materialosacricialanode • Shape • Extension • Connection.
8
10. Cable joints Nomatterthetypeoseal,theadhesionbetweenthe sealantandthecableisthekeytoawatertightseal. Asstatedunder10.3Dropcables,acleanandoil-ree suraceonthecableisnecessary.
2Cl₂ O₂ + 2H₂O 4CH�
Theadvantageisthatthesystemisselregulating –the deteriorationothe sacricialanodereects theneedsorprotectionothesystem.
Seawater
possibletoremoveromthesurace,makingawatertightsealalmostimpossibletocreate.
Impressed CurrentAnode Protected structure
muchspace.Itswellswhenpressurised,whichminimisestheeventualgrowthodepositsontheinner diameter. A high pumping eciency is thereore maintained. Wellmaster is primarily usedin combination with aggressivewaterasanalternativetostainlesssteel pipes.Someend-userspreertouseWellmasterinall theirinstallationsduetotheeaseoinstallationand pulling,andthehighqualityhose.
Solventsmustneverbeapplied,asitmaydamagethe cablepermanently.Onlymechanicalcleaningmaybe used,suchasdryingwithacleancloth,orsandpaper grindingtocreateavirginmaterialsurace.
Fig. 68 Principle o impressed current cathodic system
10. Drop cables Grundoscandeliverdierentdropcabletypesdependingontheapplicationthepumpisgoingtooperatein.Generalguidelineshavebeendescribedin chapter7.5.
10.. Impressed current cathodic protection systems
Thereare cablesspeciallydevelopedto beused in connectionwithsubmersiblepumps.Severalothem areapprovedortransportingdrinkingwater.Numerousmanuacturersproducethesecableswhichmay beusedwithsubmersiblepumps.
ThisrequiresuseoaDCpowersupplyandknowledgeoactualpotentialbetweenthemetalthat needsprotectionandareerenceelectrode.Itis necessarytotakeintoaccounttheriskoorganic growthonthemetalpartthatovertimecanchange thepotentialdierence.
Acommonlyused typeis theH07RN-F, which isa generalpurposecable.Inmostcasesthiscableisadequateorusewithsubmersiblepumps.Pleasenote thatwaterresistanceotheconductorinsulationis notalwaysgoodenough.
ThesesystemsrequireindividualdesignandGrundos reers toexternal suppliers othesekinds o equipment wheredesign and advices can beobtained.ThenormalrangeotheDC supplywill be 50Vwith10-100A.
Grundos always recommends having the cable manuacturerguaranteethat thecable canulil GrundosstandardGS418A0010,whichisan additionalinsulationresistance testwith the cable submergedinwater.
Theadvantageothismethodisthatitisinert,meaningthatitdoesnotreleaseanychemicalagentsto theenvironment.Theprocessrequiresenergyinthe ormoapowersupply.
Theunctionalityothecableisdependantonthe watertight seal. Thesealing compound must be abletoadheretothesuraceothecableandthe individualwires.Cleaningothesuracebeorethe sealingisdoneisthereorevital.Somecablemanuacturersuseuidlubricantssuchassiliconoilin theirinternalprocesses.Theseuidsarealmostim-
Grundosoersanapprovedrangeo cablejoints: bothresintypeandheatshrinkjoints.Whenusing anon-Grundosjoint,we alwaysrecommendedto makea‘sot’joint,i.e.whenusingaresintomake thejoint,itmustbeasotresin.Polyurethaneusually ullsallrequirementsorawatertightandexible joint.InSection7.6.2describestheprosandconsor thevarioustypesojoints.
10. Riser pipes GrundosoerstheWellmaster,aexibleriserpipe, asanalternativetostandardsteelandplasticpipes. Thisiswovenhosehasapolyurethanelining,isapprovedoruseindrinkingwaterinseveralareas,and comesinsizesrom1-8”.Itisavailableinlengthsup to200metres.
Fig. 69 Cross-section o wellmaster hose Wellmasteriseasytohandle,anddoesnottakeup
8
Accessories
Accessories
Grundosoersaseriesosacricialzincanodesor thesubmersiblepump andmotor.For metallicriser pipes,standardsolutionsorpipesarerecommended.
DCpowersupply Insulated Anode Cable
4e�
Theuseosacricialanodeshasanenvironmental impactthatshouldalwaysbetakenintoaccount.The eectsothesaltsbeingormedinthegalvanicprocessmustalwaysbetakenintoaccount. Thesystemneedstobemonitoredinordertond thecorrecttimeorreplacingthesacricialanodes.
Negative returncable (Structure Connection) 4Cl�
Forbiggerandmorecomplexsystems,engineeringis neededinordertomakethecorrectchoiceconcerningcorrosionprotection.Aspectstoconsiderinclude • Materialosacricialanode • Shape • Extension • Connection.
10. Cable joints Nomatterthetypeoseal,theadhesionbetweenthe sealantandthecableisthekeytoawatertightseal. Asstatedunder10.3Dropcables,acleanandoil-ree suraceonthecableisnecessary.
2Cl₂ O₂ + 2H₂O 4CH�
Theadvantageisthatthesystemisselregulating –the deteriorationothe sacricialanodereects theneedsorprotectionothesystem.
Seawater
possibletoremoveromthesurace,makingawatertightsealalmostimpossibletocreate.
Impressed CurrentAnode Protected structure
muchspace.Itswellswhenpressurised,whichminimisestheeventualgrowthodepositsontheinner diameter. A high pumping eciency is thereore maintained. Wellmaster is primarily usedin combination with aggressivewaterasanalternativetostainlesssteel pipes.Someend-userspreertouseWellmasterinall theirinstallationsduetotheeaseoinstallationand pulling,andthehighqualityhose.
Solventsmustneverbeapplied,asitmaydamagethe cablepermanently.Onlymechanicalcleaningmaybe used,suchasdryingwithacleancloth,orsandpaper grindingtocreateavirginmaterialsurace.
Fig. 68 Principle o impressed current cathodic system
10. Drop cables Grundoscandeliverdierentdropcabletypesdependingontheapplicationthepumpisgoingtooperatein.Generalguidelineshavebeendescribedin chapter7.5.
10.. Impressed current cathodic protection systems
Thereare cablesspeciallydevelopedto beused in connectionwithsubmersiblepumps.Severalothem areapprovedortransportingdrinkingwater.Numerousmanuacturersproducethesecableswhichmay beusedwithsubmersiblepumps.
ThisrequiresuseoaDCpowersupplyandknowledgeoactualpotentialbetweenthemetalthat needsprotectionandareerenceelectrode.Itis necessarytotakeintoaccounttheriskoorganic growthonthemetalpartthatovertimecanchange thepotentialdierence.
Acommonlyused typeis theH07RN-F, which isa generalpurposecable.Inmostcasesthiscableisadequateorusewithsubmersiblepumps.Pleasenote thatwaterresistanceotheconductorinsulationis notalwaysgoodenough.
ThesesystemsrequireindividualdesignandGrundos reers toexternal suppliers othesekinds o equipment wheredesign and advices can beobtained.ThenormalrangeotheDC supplywill be 50Vwith10-100A.
Grundos always recommends having the cable manuacturerguaranteethat thecable canulil GrundosstandardGS418A0010,whichisan additionalinsulationresistance testwith the cable submergedinwater.
Theadvantageothismethodisthatitisinert,meaningthatitdoesnotreleaseanychemicalagentsto theenvironment.Theprocessrequiresenergyinthe ormoapowersupply.
Theunctionalityothecableisdependantonthe watertight seal. Thesealing compound must be abletoadheretothesuraceothecableandthe individualwires.Cleaningothesuracebeorethe sealingisdoneisthereorevital.Somecablemanuacturersuseuidlubricantssuchassiliconoilin theirinternalprocesses.Theseuidsarealmostim-
Grundosoersanapprovedrangeo cablejoints: bothresintypeandheatshrinkjoints.Whenusing anon-Grundosjoint,we alwaysrecommendedto makea‘sot’joint,i.e.whenusingaresintomake thejoint,itmustbeasotresin.Polyurethaneusually ullsallrequirementsorawatertightandexible joint.InSection7.6.2describestheprosandconsor thevarioustypesojoints.
10. Riser pipes GrundosoerstheWellmaster,aexibleriserpipe, asanalternativetostandardsteelandplasticpipes. Thisiswovenhosehasapolyurethanelining,isapprovedoruseindrinkingwaterinseveralareas,and comesinsizesrom1-8”.Itisavailableinlengthsup to200metres.
Fig. 69 Cross-section o wellmaster hose Wellmasteriseasytohandle,anddoesnottakeup
8
8
Additional inormation
For urther inormation about Grundos, please visit: www.grundos.com Hereyoucanlearnmuchmoreaboutthecompany, ourvaluesandndtheGrundosservicecentrenearesttoyou.Furthermoreyoucanvisitourextensive productselectiontoolWebCAPS,whereyoucannd exactlythepumpyourequire.
CAD drawings The“CADDrawings”sectionissel-explanatory.This iswhereyougotondCADdrawingsotheproductsyouareinterestedin–justnavigatethesimple menusto download theinormationyou needto yourcomputer.
WebCAPS WebCAPSisGrundos’onlineproductselectiontool thatgivesyoueasyaccesstoawealthoinormation.ShortorWeb-basedComputer-AidedProduct Selection,theWebCAPSinteraceiseasytouseand lets you choosebetween24 languagesormaximumuser-riendliness.Itincludesaullcatalogue otheproductsavailableinyourcountryaswellas accesstoliterature,CADdrawings–andevenservicevideos. Sizing unction that asks all the relevant questions ThesizingunctionisakeyeatureoWebCAPS,designedtohelpyouselecttherightpumporthejob. Theprogrammeguidesyoustepbystep,askingorall therelevantinormation.Iyouareunsureospecic guresorhowtocalculatethem,simplyclickonthe “calculator”icon.WebCAPSwillthenhelpyoucarry outallthecalculationsnecessarytoensurethatyou getexactlywhatyouneed.Everyactorwillbetaken intoaccount,andyouwon’thavetoworkhardtocollectinormationrst. Replacingapump?Seewhatwewouldrecommend! The “Replacement” unction is a clever little eatureoranyoneabouttoreplaceanexistingpump –whetheritcomesromGrundosoranothersupplier.Here,youcansearchoryourexistingpumpin thedrop-downmenus,applyvariousadditionalcriteriaiyouwish,andclick“submit”.Youthenhavea completelistotheGrundospumpswewouldrecommendasreplacements.
11. Additional inormation 86
87
Additional inormation
For urther inormation about Grundos, please visit: www.grundos.com Hereyoucanlearnmuchmoreaboutthecompany, ourvaluesandndtheGrundosservicecentrenearesttoyou.Furthermoreyoucanvisitourextensive productselectiontoolWebCAPS,whereyoucannd exactlythepumpyourequire.
CAD drawings The“CADDrawings”sectionissel-explanatory.This iswhereyougotondCADdrawingsotheproductsyouareinterestedin–justnavigatethesimple menusto download theinormationyou needto yourcomputer.
WebCAPS WebCAPSisGrundos’onlineproductselectiontool thatgivesyoueasyaccesstoawealthoinormation.ShortorWeb-basedComputer-AidedProduct Selection,theWebCAPSinteraceiseasytouseand lets you choosebetween24 languagesormaximumuser-riendliness.Itincludesaullcatalogue otheproductsavailableinyourcountryaswellas accesstoliterature,CADdrawings–andevenservicevideos. Sizing unction that asks all the relevant questions ThesizingunctionisakeyeatureoWebCAPS,designedtohelpyouselecttherightpumporthejob. Theprogrammeguidesyoustepbystep,askingorall therelevantinormation.Iyouareunsureospecic guresorhowtocalculatethem,simplyclickonthe “calculator”icon.WebCAPSwillthenhelpyoucarry outallthecalculationsnecessarytoensurethatyou getexactlywhatyouneed.Everyactorwillbetaken intoaccount,andyouwon’thavetoworkhardtocollectinormationrst. Replacingapump?Seewhatwewouldrecommend! The “Replacement” unction is a clever little eatureoranyoneabouttoreplaceanexistingpump –whetheritcomesromGrundosoranothersupplier.Here,youcansearchoryourexistingpumpin thedrop-downmenus,applyvariousadditionalcriteriaiyouwish,andclick“submit”.Youthenhavea completelistotheGrundospumpswewouldrecommendasreplacements.
11. Additional inormation 86
87
Index Alphabetic index
Index chapter
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additionalinormation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air/gasin water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autotransormer–AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boostermodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablejoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cableselectionandsiz ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablesplice/Connectionomotorcableanddropcable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablingguidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cathodicprotection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CommunicationsandNetworkingTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CommunicationsProtocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolingsleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosionprotectioninseawater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosivewater(seawater). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUEvariblespeedd riveorSPpumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Currentasymmetry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deratingosubmersiblemotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dewatering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct-on-line–DOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dropcables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequencyconverters(variable-speeddrive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freshwatersupply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromreshwatersources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromtheseaandsaltwatersources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functionalprole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Galvaniccathodicprotectionsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generalintroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generatoroperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENIbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gridconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwaterrequirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwaterwells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GrundosGENIbusproductsorSPapplications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontalapplication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hotwaterandgeothermalwater.... .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. Impressedcurrentcathodicprotectionsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation&operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorcablesandjoints,reerencetodropcables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorprotectiondevices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motortypes,generaldescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorsandcontrols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
10 11 3.4 3 5.4.3 8.5.1 3.7 10.4 7.5 7.6.2 8.5.3 10.2.1 8 8.2 8.4.2 10.1 10.2 3.5 5.6 6.6 7.3.6 3.2 5.4.1 10.3 6.3 5.4.6 3.1 2.3.1 2.3.2 8.4.3 10.2.2 8.1 7.12 8.5 6.5 2.2 2.2.3 2.2.1 8.6 7.6 3.3 3.6 10.2 .3 7 1 3.2.1 5.2 5.3 5.1 5
page 83 87 20 17 39 76 24 85 63 65 77 83 71 71 75 83 83 22 43 50 60 19 36 84 48 40 17 14 14 75 83 71 67 76 49 9 10 9 78 65 20 23 84 53 7 19 35 36 33 33
Alphabetic index
chapter
Networkingbasics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networkingtopology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.ostart/stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operationwithrequencyconverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltageandundervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powergeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powersupply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PrimaryResistor-typeS tarter,RR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protectionagainstboiling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump/motorassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpandmotorselection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpcurvesandtolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpeciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpprinciple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpselection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpstartup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinparalleloperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinseriesoperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reducingthelocked-rotorcurrent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requiredraw/wellwaterandwatertreatmentcapacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpip ec onnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpip es election. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpip es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riverbankltration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAmainparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleevecooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sotstarter–SS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Star-delta–SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suracewater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technicaldescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thedutypoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theeldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variablerequencydrives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VFDoperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltageunbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watersupply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watertemperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wearparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web-hostedS CADA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welldia meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyieldandoperationaleciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellsandwellconditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 8.4.1 7.9 5.5 6.2.2 6.1 6 5.4.4 7.3.7 7.6 .1 7.3 4.4 7.3.4 4.1 4.3 7.2 7.10 4 7.7 7.8 5.4 2.2.4 2.1 7.6 .3 7.4 10.5 2.2.2 8.3.2 8.3.1 8.3 7.3.8 5.4.5 5.4.2 2.3 8.5.2 7.3.1 8.4.4 9 6.4 7.11 6.2 6.2.1 2 7.3.5 4.2 8.3.3 7.3 .2 7.3.3 2.2.5 7.1
page 74 74 67 42 47 47 47 39 61 65 56 29 57 27 28 56 67 27 66 66 36 11 9 66 62 85 9 72 72 72 61 39 38 14 76 56 75 73 48 67 47 47 9 60 28 73 57 57 12 55
89
Index Alphabetic index
Index chapter
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additionalinormation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air/gasin water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autotransormer–AT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boostermodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablejoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cableselectionandsiz ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablesplice/Connectionomotorcableanddropcable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cablingguidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cathodicprotection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CommunicationsandNetworkingTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CommunicationsProtocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolingsleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosionprotectioninseawater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosivewater(seawater). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUEvariblespeedd riveorSPpumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Currentasymmetry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deratingosubmersiblemotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dewatering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct-on-line–DOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dropcables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequencyconverters(variable-speeddrive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freshwatersupply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromreshwatersources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fromtheseaandsaltwatersources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functionalprole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Galvaniccathodicprotectionsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generalintroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generatoroperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENIbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gridconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwaterrequirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwaterwells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GrundosGENIbusproductsorSPapplications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontalapplication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hotwaterandgeothermalwater.... .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. Impressedcurrentcathodicprotectionsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation&operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorcablesandjoints,reerencetodropcables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorprotectiondevices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motortypes,generaldescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motorsandcontrols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 11 3.4 3 5.4.3 8.5.1 3.7 10.4 7.5 7.6.2 8.5.3 10.2.1 8 8.2 8.4.2 10.1 10.2 3.5 5.6 6.6 7.3.6 3.2 5.4.1 10.3 6.3 5.4.6 3.1 2.3.1 2.3.2 8.4.3 10.2.2 8.1 7.12 8.5 6.5 2.2 2.2.3 2.2.1 8.6 7.6 3.3 3.6 10.2 .3 7 1 3.2.1 5.2 5.3 5.1 5
page 83 87 20 17 39 76 24 85 63 65 77 83 71 71 75 83 83 22 43 50 60 19 36 84 48 40 17 14 14 75 83 71 67 76 49 9 10 9 78 65 20 23 84 53 7 19 35 36 33 33
Alphabetic index
chapter
Networkingbasics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networkingtopology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.ostart/stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operationwithrequencyconverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltageandundervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powergeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powersupply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PrimaryResistor-typeS tarter,RR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protectionagainstboiling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump/motorassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpandmotorselection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpcurvesandtolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpeciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpprinciple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpselection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpstartup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinparalleloperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumpsinseriesoperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reducingthelocked-rotorcurrent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requiredraw/wellwaterandwatertreatmentcapacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpip ec onnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpip es election. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riserpip es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riverbankltration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAmainparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCADAsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleevecooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sotstarter–SS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Star-delta–SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suracewater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technicaldescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thedutypoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theeldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variablerequencydrives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VFDoperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltageunbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watersupply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watertemperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wearparts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web-hostedS CADA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welldia meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellyieldandoperationaleciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wellsandwellconditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 8.4.1 7.9 5.5 6.2.2 6.1 6 5.4.4 7.3.7 7.6 .1 7.3 4.4 7.3.4 4.1 4.3 7.2 7.10 4 7.7 7.8 5.4 2.2.4 2.1 7.6 .3 7.4 10.5 2.2.2 8.3.2 8.3.1 8.3 7.3.8 5.4.5 5.4.2 2.3 8.5.2 7.3.1 8.4.4 9 6.4 7.11 6.2 6.2.1 2 7.3.5 4.2 8.3.3 7.3 .2 7.3.3 2.2.5 7.1
page 74 74 67 42 47 47 47 39 61 65 56 29 57 27 28 56 67 27 66 66 36 11 9 66 62 85 9 72 72 72 61 39 38 14 76 56 75 73 48 67 47 47 9 60 28 73 57 57 12 55
88
89
90
91
90
91
Being responsible is our oundation Thinking ahead makes it possible Innovation is the essence
