guide to excellence€¦ · t-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0...

42
Quantity of water Head losses in ordinary water pipes m3/h Litres/min. Litres/sec. Nominal pipe diameter in inches and internal diameter in [mm] 1” 27.00 1¼” 35.75 1½” 41.25 2” 52.50 2½” 68.00 3” 80.25 3½” 92.50 4” 105.0 5” 130.0 6” 155.5 3.0 50 0.83 1.460 13.14 0.830 3.403 0.623 1.719 0.385 0.544 0.229 0.159 6.0 100 1.67 2.919 46.49 1.660 11.90 1.247 5.972 0.770 1.875 0.459 0.542 0.329 0.244 0.248 0.124 9.0 150 2.50 2.490 25.11 1.870 12.53 1.154 3.903 0.668 1.124 0.494 0.506 0.372 0.256 0.289 0.140 12 200 3.33 3.319 42.75 2.493 21.36 1.539 6.624 0.918 1.901 0.659 0.855 0.496 0.431 0.385 0.234 0.251 0.084 15 250 4.17 4.149 64.86 3.117 32.32 1.924 10.03 1.147 2.860 0.823 1.282 0.620 0.646 0.481 0.350 0.314 0.126 18 300 5.00 3.740 45.52 2.309 14.04 1.377 4.009 0.988 1.792 0.744 0.903 0.577 0.488 0.377 0.175 0.263 0.074 24 400 6.67 4.987 78.17 3.078 24.04 1.836 6.828 1.317 3.053 0.992 1.530 0.770 0.829 0.502 0.294 0.351 0.124 30 500 8.33 3.848 36.71 2.295 10.40 1.647 4.622 1.240 2.315 0.962 1.254 0.628 0.445 0.439 0.187 36 600 10.0 4.618 51.84 2.753 14.62 1.976 6.505 1.488 3.261 1.155 1.757 0.753 0.623 0.526 0.260 42 700 11.7 3.212 19.52 2.306 8.693 1.736 4.356 1.347 2.345 0.879 0.831 0.614 0.347 48 800 13.3 3.671 25.20 2.635 11.18 1.984 5.582 1.540 3.009 1.005 1.066 0.702 0.445 54 900 15.0 4.130 31.51 2.964 13.97 2.232 6.983 1.732 3.762 1.130 1.328 0.790 0.555 60 1000 16.7 4.589 38.43 3.294 17.06 2.480 8.521 1.925 4.595 1.256 1.616 0.877 0.674 75 1250 20.8 4.117 26.10 3.100 13.00 2.406 7.010 1.570 2.458 1.097 1.027 90 1500 25.0 4.941 36.97 3.720 18.42 2.887 9.892 1.883 3.468 1.316 1.444 105 1750 29.2 4.340 24.76 3.368 13.30 2.197 4.665 1.535 1.934 120 2000 33.3 4.960 31.94 3.850 17.16 2.511 5.995 1.754 2.496 150 2500 41.7 4.812 26.26 3.139 9.216 2.193 3.807 180 3000 50.0 3.767 13.05 2.632 5.417 240 4000 66.7 5.023 22.72 3.509 8.926 300 5000 83.3 4.386 14.42 90° bends. slide valves 1.1 1.2 1.3 1.4 1.5 1.6 1.6 1.7 2.0 2.5 T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the velocity of water in m/sec. Lower figures indicate head loss in metres per 100 metres of straight pipes. The table is calculated in accordance with H. Lang’s new formula a = 0.02 and for a water temperature of 10° C. The head loss in bends, slide valves, T-pieces and non-return valves is equivalent to the metres of straight pipes stated in the last two lines of the table. To find the head loss in foot valves multiply the loss in T-pieces by two. THE GUIDE GRUNDFOS Holding A/S Poul Due Jensens Vej 7 DK-8850 Bjerringbro Tel: +45 87 50 14 00 www.grundfos.com The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. 97641818 0516/GMS WATER UTILITY/9782-BrandBox GRUNDFOS SP PUMPS GET THE FULL VALUE OF YOUR SUBMERSIBLE PUMP SYSTEM QUICK GUIDE to safe installation

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Page 1: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

Quantity of water Head losses in ordinary water pipes

m3/h Litres/min. Litres/sec.Nominal pipe diameter in inches and internal diameter in [mm]

1”27.00

1¼”35.75

1½”41.25

2”52.50

2½”68.00

3”80.25

3½”92.50

4”105.0

5”130.0

6”155.5

3.0 50 0.83 1.46013.14

0.830 3.403

0.623 1.719

0.385 0.544

0.229 0.159

6.0 100 1.67 2.91946.49

1.66011.90

1.2475.972

0.7701.875

0.4590.542

0.3290.244

0.2480.124

9.0 150 2.50 2.49025.11

1.87012.53

1.1543.903

0.6681.124

0.4940.506

0.3720.256

0.2890.140

12 200 3.33 3.31942.75

2.49321.36

1.5396.624

0.9181.901

0.6590.855

0.4960.431

0.3850.234

0.2510.084

15 250 4.17 4.149 64.86

3.117 32.32

1.924 10.03

1.147 2.860

0.823 1.282

0.620 0.646

0.481 0.350

0.314 0.126

18 300 5.00 3.740 45.52

2.309 14.04

1.377 4.009

0.988 1.792

0.744 0.903

0.577 0.488

0.377 0.175

0.263 0.074

24 400 6.67 4.987 78.17

3.078 24.04

1.836 6.828

1.317 3.053

0.992 1.530

0.770 0.829

0.502 0.294

0.351 0.124

30 500 8.33 3.848 36.71

2.295 10.40

1.647 4.622

1.240 2.315

0.962 1.254

0.628 0.445

0.439 0.187

36 600 10.0 4.618 51.84

2.753 14.62

1.976 6.505

1.488 3.261

1.155 1.757

0.753 0.623

0.526 0.260

42 700 11.7 3.21219.52

2.3068.693

1.7364.356

1.3472.345

0.8790.831

0.6140.347

48 800 13.3 3.67125.20

2.63511.18

1.9845.582

1.5403.009

1.0051.066

0.7020.445

54 900 15.0 4.13031.51

2.96413.97

2.2326.983

1.7323.762

1.1301.328

0.7900.555

60 1000 16.7 4.58938.43

3.29417.06

2.4808.521

1.9254.595

1.2561.616

0.8770.674

75 1250 20.8 4.11726.10

3.10013.00

2.4067.010

1.5702.458

1.0971.027

90 1500 25.0 4.94136.97

3.72018.42

2.8879.892

1.8833.468

1.3161.444

105 1750 29.2 4.34024.76

3.36813.30

2.1974.665

1.5351.934

120 2000 33.3 4.96031.94

3.85017.16

2.5115.995

1.7542.496

150 2500 41.7 4.81226.26

3.1399.216

2.1933.807

180 3000 50.0 3.76713.05

2.6325.417

240 4000 66.7 5.02322.72

3.5098.926

300 5000 83.3 4.38614.42

90° bends. slide valves 1.1 1.2 1.3 1.4 1.5 1.6 1.6 1.7 2.0 2.5T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0

Table of head lossesHead losses in ordinary water pipesUpper figures indicate the velocity of water in m/sec.Lower figures indicate head loss in metres per 100 metres of straight pipes.

The table is calculated in accordance with H. Lang’s new formula a = 0.02 and for a water temperature of 10° C.

The head loss in bends, slide valves, T-pieces and non-return valves is equivalent to the metres of straight pipes stated in the last two lines of the table. To find the head loss in foot valves multiply the loss in T-pieces by two.

THE GUIDE

GRUNDFOS Holding A/SPoul Due Jensens Vej 7DK-8850 BjerringbroTel: +45 87 50 14 00www.grundfos.com

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GRUNDFOS SP PUMPS

GET THE FULL VALUEOF YOUR SUBMERSIBLE PUMP SYSTEM

QUICK GUIDE to safe installation

Page 2: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

Motor kW [A]Cos

100%Cable dimensions in mm²

1,5 2,5 4 6 10 16 25 35 50 70 95 120 150 185 240 3004" 0,37 1,4 0,64 462 767 - - - - - - - - - -4" 0,55 2,2 0,64 294 488 777 - - - - - - - - - -4" 0,75 2,3 0,72 250 416 662 987 - - - - - - - - - -4" 1,1 3,4 0,72 169 281 448 668 - - - - - - - - - -4" 1,5 4,2 0,75 132 219 348 520 857 - - - - - - - - - -4" 2,2 5,5 0,82 92 153 244 364 602 951 - - - - - - - - - -4" 3 7,85 0,77 69 114 182 271 447 705 - - - - - - - - - -4" 4 9,6 0,8 54 90 143 214 353 557 853 - - - - - - - - -4" 5,5 13 0,81 39 66 104 156 258 407 624 855 - - - - - - - -4" 7,5 18,8 0,78 28 47 75 112 185 291 445 609 841 - - - - - - -6" 4 9,2 0,82 55 91 146 218 359 566 867 - - - - - - - - -6" 5,5 13,6 0,77 40 66 105 157 258 407 622 850 - - - - - - - -6" 7,5 17,6 0,80 29 49 78 117 193 304 465 637 882 - - - - - - -6" 9,2 21,8 0,81 23 39 62 93 154 243 372 510 706 950 - - - - - -6" 11 24,8 0,83 - 34 53 80 132 209 320 440 610 823 - - - - - -6" 13 30 0,81 - 28 45 68 112 176 270 370 513 690 893 - - - - -6" 15 34 0,82 - - 39 59 97 154 236 324 449 604 783 947 - - - -6" 18,5 42 0,81 - - - 48 80 126 193 265 366 493 638 770 914 - - -6" 22 48 0,84 - - - 41 67 107 164 225 313 422 549 665 793 927 - -6" 26 57 0,84 - - - - 57 90 138 189 263 355 462 560 667 781 937 -6" 30 66,5 0,83 - - - - 49 78 119 164 227 307 398 482 574 670 803 9266” 37 85,5 0,79 - - 63 97 133 183 246 317 382 452 525 624 7148" 22 48 0,84 - - - 41 67 107 164 225 313 422 549 665 793 927 - -8" 26 56,5 0,85 - - - - 57 90 138 189 263 356 464 563 672 787 947 -8" 30 64 0,85 - - - - 50 79 122 167 233 314 409 497 593 695 836 9688" 37 78,5 0,85 - - - - - 65 99 136 190 256 334 405 483 567 682 7898" 45 96,5 0,82 - - - - - 54 83 114 158 213 276 334 396 462 553 6368" 55 114 0,85 - - - - - - 68 94 131 177 230 279 333 390 469 5448" 63 132 0,83 - - - - - - - 83 115 155 201 243 289 338 404 4668" 75 152 0,86 - - - - - - - 70 97 132 171 208 249 292 353 4098" 92 186 0,86 - - - - - - - - 79 107 140 170 204 239 288 3358" 110 224 0,87 - - - - - - - - - 89 116 141 169 198 240 279

10" 75 156 0,84 - - - - - - - 69 96 130 169 205 244 285 343 39610" 92 194 0,82 - - - - - - - - 79 106 137 166 197 230 275 31610" 110 228 0,84 - - - - - - - - - 89 116 140 167 195 234 27110" 132 270 0,84 - - - - - - - - - - 98 118 141 165 198 22910" 147 315 0,81 - - - - - - - - - - - 103 122 142 169 19410" 170 365 0,81 - - - - - - - - - - - - 105 122 146 16810" 190 425 0,79 - - - - - - - - - - - - - 106 125 14412" 147 305 0,83 - - - - - - - - - - - 105 125 146 175 20212" 170 345 0,85 - - - - - - - - - - - 92 110 129 155 18012" 190 390 0,84 - - - - - - - - - - - - 98 114 137 15812" 220 445 0,85 - - - - - - - - - - - - - 100 120 13912" 250 505 0,85 - - - - - - - - - - - - - - 106 123Max current for cable [A] 23 30 41 53 74 99 131 162 202 250 301 352 404 461 547 633

Motor kW [A]Cos

100%Cable dimensions in mm²

1,5 2,5 4 6 10 16 25 35 50 70 95 120 150 185 240 3006" 4 9,2 0,82 95 158 252 377 623 984 - - - - - - - - - -6" 5,5 13,6 0,77 68 114 181 271 447 704 - - - - - - - - - -6" 7,5 17,6 0,8 51 85 135 202 333 526 805 - - - - - - - - -6" 9,2 21,8 0,81 41 68 108 161 266 420 643 882 - - - - - - - -6" 11 24,8 0,83 - 58 93 138 228 361 554 760 - - - - - - - -6" 13 30 0,81 - 49 78 117 193 305 467 641 887 - - - - - - -6" 15 34 0,82 - - 68 102 168 266 408 560 776 - - - - - - -6" 18,5 42 0,81 - - - 84 138 218 334 458 634 853 - - - - - -6" 22 48 0,84 - - - 71 117 185 283 389 541 730 949 - - - - -6" 26 57 0,84 - - - - 98 155 239 328 455 615 799 969 - - - -6" 30 66,5 0,83 - - - - 85 135 207 284 394 531 689 834 992 - - -6" 37 85,5 0,79 - - 109 168 229 317 425 549 661 782 908 - -8" 22 48 0,84 - - - 71 117 185 283 389 541 730 949 - - - - -8" 26 56,5 0,85 - - - - 98 155 238 328 456 616 802 973 - - - -8" 30 64 0,85 - - - - 87 137 210 289 402 544 708 859 - - - -8" 37 78,5 0,85 - - - - - 112 172 236 328 444 577 701 836 980 - -8" 45 96,5 0,82 - - - - - 94 144 197 274 368 477 577 686 800 956 -8" 55 114 0,85 - - - - - - 118 162 226 305 398 482 576 675 812 9418" 63 132 0,83 - - - - - - - 143 198 267 347 420 500 584 699 8078" 75 152 0,86 - - - - - - - 121 168 228 297 361 431 506 610 7088" 92 186 0,86 - - - - - - - - 137 186 242 295 352 414 499 5798" 110 224 0,87 - - - - - - - - - 153 200 244 292 343 415 483

10" 75 156 0,84 - - - - - - - 120 166 225 292 354 422 494 593 68510" 92 194 0,82 - - - - - - - - 136 183 238 287 341 398 476 54810" 110 228 0,84 - - - - - - - - - 154 200 242 289 338 405 46910" 132 270 0,84 - - - - - - - - - - 169 205 244 285 342 39610" 147 315 0,81 - - - - - - - - - - - 178 211 245 293 33610" 170 365 0,81 - - - - - - - - - - - - 182 212 253 29010" 190 425 0,79 - - - - - - - - - - - - - 183 217 24812" 147 305 0,83 - - - - - - - - - - - 182 216 253 303 34912" 170 345 0,85 - - - - - - - - - - - 159 190 223 268 31112" 190 390 0,84 - - - - - - - - - - - - 169 197 237 27412" 220 445 0,85 - - - - - - - - - - - - - 173 208 24112" 250 505 0,85 - - - - - - - - - - - - - - 183 212Max current for cable [A] 23 30 41 53 74 99 131 162 202 250 301 352 404 461 547 633

2

TOOLS

Cable dimensions for submersible motors at 3 x 400 V, star-delta starting.Voltage drop 3%

* At particularly favourable heat dissipation conditions.Maximum cable length in metres from motor starter to pump.

33

TOOLSTHE GUIDE

Bringing to siteTransport to site ...............................................................................6

On siteHandling .............................................................................................7Craning/Motor liquid check .........................................................8Assembly ............................................................................................9

Vibration impactExcessive flow ................................................................................ 10 Water hammer .............................................................................. 11 Insufficient inlet water level (NPSH) ...................................... 12 Eccentric installation in well or close to tank side ............. 13 Gas filled water ............................................................................. 14

Electric stressLightning and transients ............................................................ 15Water in cable connections ....................................................... 16Frequent starts and stops .......................................................... 17 Power failures ................................................................................ 18 Cabling current asymmetry ...................................................... 19 Generator power ........................................................................... 20 CUE .................................................................................................... 21

Importance of motor coolingFeeding from above the pump ................................................. 22 Water temperature above 15°C ............................................... 23 Silting up around motor ............................................................. 24 Horizontal and/or tank installation........................................ 25 Insufficient frequency ................................................................. 26

Solids in waterSand particles................................................................................. 27Iron bacteria ................................................................................... 28Iron and manganese .................................................................... 29 Marine life ....................................................................................... 30

ToolsMaterial for aggressive water ................................................... 31

Instructions KMJoining motor and drop cable (KM type) .............................. 32

Page 3: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

3

THE GUIDE

Guide to excellenceDurability and long working life are essential for large pump sets, and obtaining excellence with submersible motors is a step towards prolonging the life of your pump set. Grundfos’ R&D experience and knowhow of common pitfalls when working with submersible motors have been converted into operational knowledge-sharing in this guide to excellence. The guide provides you with simple and easy-to-use instructions on how to avoid the most common mistakes during handling, installation and operation of your pump set. The guide covers high-risk areas only, and it is intend-ed merely as a supplement to the Grundfos installation and operation manual.

Page 4: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

4

THE GUIDE

4

How to use the GuideEnsuring a long product lifetime starts with proper installation of submersible pumps. This Guide provides the installer with practical recommendations that will help avoid the most common application and installation mistakes.

The contents of this Guide are categorised according to various causes of stress, for example “Electrical stress”. This makes it easy and quick to find the relevant recom-mendations. This “Guide to excellence” is based on experience accumulated by Grundfos over many years, drawn from our international network of companies and service partners.

Please do not hesitate to contact your Grundfos repre-sentative if you have any comments or questions arising from this Guide.

Page 5: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

5

GRUNDFOS PRODUCT CENTER

Grundfos Product CenterAt the online Grundfos Product Center, you can find all the information you need in one place.

• Retrieve relevant information such as pump sizes• Browse the product catalogue to find specific pump

information• Find appropriate replacement pumps• Find pumps for handling specific liquids• Browse pump curves, technical specs, CAD drawings,

available spare parts, installer guides, videos and other documentation

Visit product-selection.grundfos.com to see all your options.

On the product pages, you can download:• Installation and operation instructions• Data booklets• Service instructions• Quick guides• And much more

5

http://product-selection.grundfos.com

Page 6: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

6

Transport to sitePay attention to motor cables – do not cut or nail cables.

Block axial movements of motor shaft and pump set.

Support pump and motor to avoid disalignment and stress at suction interconnector (protect upper radial bearing of submersible motor).

Fold cables in a large diameter – do not bend in too small radius.

BRINGING TO SITE

Page 7: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

7

HandlingAvoid shock impacts when handling pump set.

Bring packaging as close to the installation site as possible before removing pump set.

ON-SITE

Page 8: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

8

Craning/Motor liquid checkHook up at advised points displayed on packaging.

Remove pump set from packaging in vertical position.

Check insulation resistance after connection of motor and drop cable.

ON-SITE

Page 9: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

9

AssemblyAssemble on site in vertical position, when pump and submersible motor are delivered in separate crates.

Do not connect discharge piping with pump set in hori-zontal position, as this may create disalignment when craning.

ON-SITE

Page 10: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

10

BEP (Best Efficiency Point).The longest service intervals is offered at performances to the right hand side of BEP.

Excessive flowReduce flow to data booklet limitations using a throttle valve or a flow control disk.

Excessive flow creates turbulence-induced vibration in the pump unit, which is transferred to the motor shaft. Heavy motor vibration may cause wear of winding insula-tion or collapse of journal bearings.

Min flow Max flow

Excessive flowDuty range

VIBRATION IMPACT

BEP

Recommended flow

Functional flow

Page 11: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

11

Water HammerWhen pump stops, the vertical water flow will stop flow-ing due to gravity.

The horizontal flow is stopped by vacuum at wellhead and swings back creating water hammer.

To eliminate - use membrane tank or soft start/stop.

15 min

Stop

Start

MEMBRANE TANK

RETURN VALVE

VIBRATION IMPACT

Page 12: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

12

Insufficient inlet water level (NPSH)Lower pump setting 3-10 m or reduce flow.

For maximum efficiency, the inlet submergence level in cold water is recommended to be at least 7 m with centric position. Lower pump in case of eccentric installation or excessive flow.

3m

If this is the water level - lower the pump an addtional 3 m

VIBRATION IMPACT

Page 13: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

13

VIBRATION IMPACT

Eccentric installation in well or installation close to tank sideInstall centraliser or distance positioner.

Eccentric installation may cause reduced efficiency in the first impellers due to inlet turbulence, resulting in reduced pump performance.

Page 14: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

14

Gas filled waterLower installation depth of pump and inlet.

Gas/air in the water will cause reduced efficiency in the first impellers. Remove non-return valve in pump and lower the pump to at least 30 m below water level to reduce bubble size.

VIBRATION IMPACT

Page 15: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

15

ELECTRIC STRESS

Lightning and transientsInstall arrestor.

Transients in the power lines will reduce insulation life. Install ground wires on motor and ground at well head.

ARRESTOR

Page 16: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

16

Water in cable connectionsUse Grundfos-approved cables (TML) and heat shrink termination.

PVC winding and H07RNF motor cables are acceptable for cold water (10° C) and shallow settings. For deep settings, use PE/PA winding and TML B motor cable.

Check insulation resistance after connection of motor and drop cable.

If the insulation resistance is less than 0.5 MΩ the motor should be pulled out for motor or cable repair.

ELECTRIC STRESS

Page 17: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

17

ELECTRIC STRESS

Frequent starts and stopsKeep start/stop frequency at a minimum to prolong the lifetime of the pump set. The motor wil consume 6 x nor-mal power at start-up, causing overheating of windings. Frequent start/stop will affect winding insulation.Protection against frequent start and stops When pressure tanks controls the storage volumen between start and stop, make sure that:1. You have the right tank size:

2. You test precharge pressure (air volumen) twice a year. If you experience frequent start/stop, install MP204 controller for motor temperature protection.

15 min

Stop

Start

STOPSTART

V = Q x 1000 (1 + cut - in) +Δp x 1 4 x nmax x Δp k

V = Tank volume [litres]Q = Mean flow [m3/h]Δp = Difference between cut-in and cut-out pressureCut-in = Cut-in pressure (lowest) [bar]nmax = Max. number of starts/stops per hourk = Constant for diaphragm tank pre-charge pressure: k = 0.9

Page 18: Guide to excellence€¦ · T-pieces, non-return valves 4.0 5.0 5.0 5.0 6.0 6.0 6.0 7.0 8.0 9.0 Table of head losses Head losses in ordinary water pipes Upper figures indicate the

18

Power failuresInstall proper motor protection.

Voltage imbalance will create hotspots in motor windings and lead to increased motor liquid temperature. Rotate the three wires at terminal to minimise unbalance and install motor protection MP 204.

MP 204

ELECTRIC STRESS

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19

Cabling current asymmetryGenerator Earthing - It is important that the aquifer where the pumpset is installed is used as reference earth potential for the generator.

Two possible causes:Voltage asymmetry results in current assymetry.Arrangement of (long) drop cables on the riser can in-crease current assymetri. Recommendation is to arrange earth cable on the riser opposite the three phase leads.

ELECTRIC STRESS

U UV V

W

W

Earth Earth

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20

ELECTRIC STRESS

Generator powerAvoid oversynchronous frequencies and coasting down of generators at pump stop.

Periodic oversynchronous frequencies will cause over-loading/overheating of the motor. Remove impellers or oversize motor in case of oversynchronous frequencies.

Synchronous frequency

(50/60 Hz)

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21

CUE• Parrallel operation of more wells.• External frequency converters type CUE.• Hydro MPC-EF maintains a constant pressure through

continuously variable adjustment of the speed of the pumps.

• The performance is adjusted to the demand through cutting in/out the required number of pumps and through parallel control of the pumps in operation.

• Pump changeover is automatic and depends on load, operating hours and fault.

• All pumps in operation will run at equal speed.

Hydro MPC-EFHydro MPC booster set with three SP pumps connected to external frequency converters in the control cabinet.

On SP pump connected to an external frequency converter in operation

ELECTRIC STRESS

PT

Q

H

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22

IMPORTANCE OF MOTOR COOLING

Feeding from above the pumpInstall flow sleeve.

Feeding from above will cause overheating of the motor surface. The overheated motor surface will scale up with organic and inorganic (lime) deposits, reducing the lifetime of the motor.

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23

Water temperature above 15° CIn case of rewindable motors, use PE/PA windings.Two-layer PE/PA winding increases the lifetime of the motor.

For temperatures from 40-60° C use canned type or special hot water motors.

IMPORTANCE OF MOTOR COOLING

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24

IMPORTANCE OF MOTOR COOLING

Silting up around motorInstall flow sleeve.

Deposition of solids and silt around motor and shaft will cause wear of shaft seal. Installation of a flow sleeve ensures flow rates higher than 0.5 m/s, preventing deposition of solids and silt around motor and shaft.

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25

Horizontal and/or tank installationInstall flow sleeve.

Installation of a flow sleeve will prevent scaling on motor surface and give better cooling, cf. page 19.

IMPORTANCE OF MOTOR COOLING

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26

IMPORTANCE OF MOTOR COOLING

Insufficient frequencyInstall flow sleeve and never regulate below 30 Hz, or minimum flow requirement.

A cooling sleeve is a prerequisite for obtaining 0.15 m/s cooling flow at low frequencies.

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27

Sand particlesUse Sic/Sic shaft seal and flow sleeve.

Replacing standard shaft seal with silicon carbide seal (Sic/Sic) will minimise the amount of abrasive sand entering the motor interior.

SOLIDS IN WATER

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28

SOLIDS IN WATER

Iron bacteriaDisinfect well.

Iron bacteria can be killed with acid and disinfection agents.

HCL

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29

Iron and manganeseInstall flow sleeve.

Reduce surface temperature with flow sleeve in case of scale deposits on motor surface.

SOLIDS IN WATER

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Marine lifeDisinfect intake structure.

Marine life blocking the pump inlet can be killed with chlorine or other disinfection agent.

Cl2

SOLIDS IN WATER

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Materials for aggressive waterTe

mp

erat

ure

(°C

)

Chloride (ppm)

100

90

80

70

60

50

40

30

20

10

02000 4000 6000 8000 12000 16000 20000

Corrosion diagramW.nr. 1.4301, 1.4401 and 1.4539

SPR 1.4539

SPN 1.4401

CRN 1.4401

SP 1.4301

Tem

per

atu

re (°

C)

Chloride (ppm)

100

90

80

70

60

50

40

30

20

10

0200 400 600 800 1200 1600 2000

Corrosion diagramW.nr. 1.4301, 1.4401 and 1.4539

SPR 1.4539

SPN 1.4401

CRN 1.4401

SP 1.4301

Seaw

ater

Tem

pera

ture

(°C)

Chloride (ppm)

30

20

10

012 24 36 48 60 72 84 96 Hours

Recommended maximaldeactivation in seawater when without

zinkanodes

TOOLS

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Joining motor and drop cable (KM type)

INSTRUCTIONS KM

2 - 3

4 - 5

6 - 7

8 - 9

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33

INSTRUCTIONS KM

x 1

x 1

x 1

x 4

x 4 x 8 x 8

x 2

A

B

C

D

E

F G H

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12 cm

12 cm9 cm6 cm3 cm

9 cm 6 cm 3 cm

12 cm9 cm6 cm3 cm

12 cm9 cm6 cm3 cm

L1L2

L3H x 4

3

4

6

12 cm1

12 cm

2

12 cm

12 cm

12 cm

12 cm

5

2

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35

3

A

7

9

13

8

11

14

10

12

½

A C

C

CC

DE

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36

4

1 2

5 6

x 4

7

12 cm

8

12 cm

12 cm

4

312 cm

L1

L2 L3

G x 4

B

C

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5 12 cm

12 cm9 cm6 cm3 cm

9 cm 6 cm 3 cm

12 cm9 cm6 cm3 cm

12 cm9 cm6 cm3 cm

12

14

16 17 18

9 10

11

15

14

H x 4

½

DE

A

GH

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6

2

7

5

12 cm

3

12 cm

1

12 cm

4

12 cm

6

L1

L2

L3

L1

L2

L3

C

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39

7

8 10

11 12

13

9

F

D

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40

8

12 cm8

12 cm

9

12 cm

1 2

5 6

12 cm

4

312 cm

L1

L2 L3

x 4

7

G x 4

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9 12 cm

12 cm9 cm6 cm3 cm

9 cm 6 cm 3 cm

12 cm9 cm6 cm3 cm

12 cm9 cm6 cm3 cm

13

15

17 18

10 11

12

16

14

H x 4

D

A

A

GH

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42

* At particularly favourable heat dissipation conditions.Maximum cable length in metres from motor starter to pump.

Max. current for cable [A]*

Motor

TOOLS

Motor kW [A]Cos

100%Cable dimensions in mm²

1,5 2,5 4 6 10 16 25 35 50 70 95 120 150 185 240 3004" 0,37 1,4 0,64 462 767 - - - -4" 0,55 2,2 0,64 294 488 777 - - -4" 0,75 2,3 0,72 250 416 662 987 - -4" 1,1 3,4 0,72 169 281 448 668 - -4" 1,5 4,2 0,75 132 219 348 520 857 -4" 2,2 5,5 0,82 92 153 244 364 602 9514" 3 7,85 0,77 69 114 182 271 447 7054" 4 9,6 0,8 54 90 143 214 353 557 8534" 5,5 13 0,81 39 66 104 156 258 407 624 8554" 7,5 18,8 0,78 28 47 75 112 185 291 445 609 8416" 4 9,2 0,82 55 91 146 218 359 566 867 1186 16406" 5,5 13,6 0,77 40 66 105 157 258 407 622 850 11736" 7,5 17,6 0,80 29 49 78 117 193 304 465 637 8826" 9,2 21,8 0,81 23 39 62 93 154 243 372 510 706 9506" 11 24,8 0,83 - 34 53 80 132 209 320 440 610 8236" 13 30 0,81 - 28 45 68 112 176 270 370 513 690 8936" 15 34 0,82 - - 39 59 97 154 236 324 449 604 783 9476" 18,5 42 0,81 - - - 48 80 126 193 265 366 493 638 770 9146" 22 48 0,84 - - - 41 67 107 164 225 313 422 549 665 793 9276" 26 57 0,84 - - - - 57 90 138 189 263 355 462 560 667 781 9376" 30 66,5 0,83 - - - - 49 78 119 164 227 307 398 482 574 670 803 9266” 37 85,5 0,79 - - 63 97 133 183 246 317 382 452 525 624 7148" 22 48 0,84 - - - 41 67 107 164 225 313 422 549 665 793 927 1113 12878" 26 56,5 0,85 - - - - 57 90 138 189 263 356 464 563 672 787 947 10978" 30 64 0,85 - - - - 50 79 122 167 233 314 409 497 593 695 836 9688" 37 78,5 0,85 - - - - - 65 99 136 190 256 334 405 483 567 682 7898" 45 96,5 0,82 - - - - - 54 83 114 158 213 276 334 396 462 553 6368" 55 114 0,85 - - - - - - 68 94 131 177 230 279 333 390 469 5448" 63 132 0,83 - - - - - - - 83 115 155 201 243 289 338 404 4668" 75 152 0,86 - - - - - - - 70 97 132 171 208 249 292 353 4098" 92 186 0,86 - - - - - - - - 79 107 140 170 204 239 288 3358" 110 224 0,87 - - - - - - - - - 89 116 141 169 198 240 279

10" 75 156 0,84 - - - - - - - 69 96 130 169 205 244 285 343 39610" 92 194 0,82 - - - - - - - - 79 106 137 166 197 230 275 31610" 110 228 0,84 - - - - - - - - - 89 116 140 167 195 234 27110" 132 270 0,84 - - - - - - - - - - 98 118 141 165 198 22910" 147 315 0,81 - - - - - - - - - - - 103 122 142 169 19410" 170 365 0,81 - - - - - - - - - - - - 105 122 146 16810" 190 425 0,79 - - - - - - - - - - - - - 106 125 14412" 147 305 0,83 - - - - - - - - - - - 105 125 146 175 20212" 170 345 0,85 - - - - - - - - - - - 92 110 129 155 18012" 190 390 0,84 - - - - - - - - - - - - 98 114 137 15812" 220 445 0,85 - - - - - - - - - - - - - 100 120 13912" 250 505 0,85 - - - - - - - - - - - - - - 106 123Max current for cable [A] 23 30 41 53 74 99 131 162 202 250 301 352 404 461 547 633

Cable dimensions for submersible motors at 3 x 400 V, 50 Hz, Direct On Line.Voltage drop 3%

* At particularly favourable heat dissipation conditions.Maximum cable length in metres from motor starter to pump.