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PDF Water Distribution Manual DL
PDF Water Distribution Manual DL
PDF Water Distribution Manual DL
WATER
DISTRIBUTION
MANUAL
Contents
SURFA
SUR FACE
CE WA
WATER
TER IN
INTTAKE
1) Intake pumping stations ......................................................................................................7
a) Rivers and lakes ................................................................................................................................7
b) Channel lift stations .......................................................................................................................8
c) Seawater pumping stations ........................................................................................................10
WATER DISTRIBUTI
DISTRIBUTION
ON
3) Pump pre-selection ....................................................................................................................15
a) Flow rate estimation ......................................................................................................................15
i) Pipe leakage ...................................
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ii) Wide operation range ........... ................................
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b) Pump head estimation .................................................................................................................18
i) Layout of a distribution network ................................
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ii) Pressure management ...................
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..
iii) Summary ....................
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c) Number and size of pumps .........................................................................................................24
i) Pump efficiency............................
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ii) Specific speed and impeller type ................. .....................................
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iii) Selecting for maximum attainable efficiency .................................................................................................
...................
iv) Pump determination, nq: a practical example: example: ..................
......................................
....................................
................
d) Summary of pump pre-selection ............................................................................................28
2
PUMPING
PUMPI NG ST
STA
ATIONS
8) Pumping station design .......................................................................................................49
a) Projects and solutions ..................................................................................................................49
b) Pump selection .................................................................................................................................50
i) Horizonal split-case versus end-suc end-suction tion pumps ....................
........................................
...................................
...............
ii) NPSHavailable and NPSHrequired ..................
.......................................
..........................................
.........................................
...................................
...............
iii) Design when using a vertical turbine ................... .......................................
.........................................
................................
...........
c) Optimising the costs of electrical equipment – AC motors, efficiency and VFDs54 VFDs54
i) AC Motors .......................................................................................................................................54
ii) Efficiency classes.........................................................................................................................55
classes.........................................................................................................................55
iii) Motor start method .................................................................................................................55
iv) Variable frequency drives (VFD) ..........................................................................................55
v) Summary.................
Summary.....................................
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..........................................
.........................................
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................................
...........
9) Design tips..........................................................................................................................................58
a) Reduce nozzle forces ......................................................................................................................58
b) Essential elements for suction and discharge pipes ......................................................58
.................................................. ....58
c) Recommended length of suction tubing ..............................................................................59
d) Air pockets in pipework ................................................................................................................59
e) Air-release valves..............................................................................................................................59
f) Isolation (stop) valves .....................................................................................................................60
g) Isolation valves for pressure and flow regulation .............................................................60
h) Check valves or non-return valves ...........................................................................................61
i) Chlorine disinfection ......................................................................................................................63
j) Pump monitoring
monitoring ..............
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.........64
..64
Local pumping
Booster systemsstations......................................................................................................................86
for local pumping stations ............................................................................90
3
OPTIMISED
WATER
SOLUTIONS
RAW WATER
WATER DRINKING WATER
INTAKE TREATMENT
4
You are guided through water intake pumping station layouts, for water sources ranging from rivers
and lakes to seawater
seawater.. We discuss how pump pre-selection and flow rate estimation are essential for
an optimised system, and show the importance of pressure management solutions for delivering
correct pressure at the end-user while reducing the risk of pipe bursts.
We present all the main equipment required for an optimised water supply system, and end with a
look at the comprehensive range of Grundfos
Grun dfos products and solutions.
6
7
8
9
Seawater intakes can be designed as beach wells, where a series of beach wells along the shoreline
becomes a beach wellfield. The benefit of beach wells as a solution compared to direct seawater intake
is that there are no algae, less bacteria and lower salt concentration in the wells compared to direct
intake from the off-shore
off-shore splash zone. However not all sea shores are sandy beaches.
10
Pumping station layouts can be for wet or dry installations with a wide range of combinations.
Pump and motor in dry pit Onshore wet pit with pump Wet pit with pump and motor
with suction from wet pit under water and motor under water
above water
Pump and motor in dry pit Pump and motor in dry pit Offshore with pump under
with long suction pipeline with suction direct from source water and motor above water
11
Pumping station
Wet pit installation
Pump types:
• Vertical turbine pump
• Submersible well pump
• Submersible sewage pump
12
Pumping station
Dry pit installation
13
14
3) Pump pre-selection
We will now look at pump pre-selection in a Factors used by planners for determining typical
water distribution pipe network system. To select demand for residential areas
the right pump, we need to know several factors: • ADC: Annual Average Daily Consumption,
also known as ‘design flow’
• An estimat
estimation
ion of tthe
he total flow ra
rate
te (Q) and • MDC: Annual Maximum Daily Consumption
head (H) – this figure is derived from the ADC
• The wate
waterr source composition, for the material • MDC/Peak hour: Peak hour consumption on
configuration of the pump the Annual Maximum Day
• The design of the pumping station, so we can • Fire flow: a measure of an exceptional
exceptional load case
select the pump type and number of pumps
required Flow (%)
300
At the early planning stage of a project, however
however,, C: MDC/Peak hour =2.5 ADC
250
no pump specifications are available, so this
200 B: MDC = 1.8 ADC
is initially an estimation. Grundfos offers 180
engineering support in the early planning phase, A: ADC
100
liaising with the owners, planners, operators,
consultants and civil and electromechanical
Time
engineers. 12 2 4 6 8 10 12 2 4 6 8 10 12 (Hours)
night noon night
15
Average water
water use per person per day
Spain (1998)
Norway (nd)
Netherlands (2000)
France (1995)
Switzerland (2000)
Luxembourg (2000)
Austria (1999)
Hungary (1999)
Denmark (1999)
Germany (1998)
Poland (1999)
Slovenia (1996)
Belgium (nd)
Estonia (2000)
Lithuania (nd)
i) Pipe leakage
16
ii) Wide operation range A much more complex task will be the selection
of any single pump within the system to cope
The reason for a flow rate estimation is so we can with the minimum flow (if not supplied by an
cover the expected wide range within which the elevated tank) and all intermediate operating
pumps will operate. points of the very wide operation range.
The maximum flow in water distribution can For this reason, it is not unusual to find different
in many cases be 15-20 times higher than the pump sizes in parallel (cascade) operation in an
minimum flow. This depends on: existing pumping station, with some of them
equipped with variable speed drives to cope with
• Daytime (peak) consumption the varying demand.
• Seasonal changes
• The sy
system
stem dynamics and how demand For pump pre-selection, it is sufficient to take two
develops in the future pump sizes:
• A small pump fforor the minimum flow and to
The total flow rate estimation of a pumping pressurise the system. If the minimum flow
station can be determined by statistical rate is too low, we can apply a pressurised tank
information or by usual planning factors, with or a bypass with an orifice plate towards pump
the MDC/Peak level the relevant figure that gives suction side
us the total flow of the pumping station. The fire • Three to four pumps with 35 % of tthe
he MDC/
flow must be checked as well; it could be that peak flow – the pump selection will be
pumps running in overcapacity will cope with it. reviewed anyway at a later stage
17
18
H
Hmax Pump
Resulting characteristic
Pump Head H
Friction Hf
Static Hs
Q1 Q
System characteristic together with the pump performance curve for the open system.
19
Branch, tree or dead-end system Thus, this system also follows the grid iron
Tree systems have large mains supplying an area, system with the flow pattern similar in character
and smaller mains branching off from the large to that of dead-end system. So, determina
determination
tion of
main. In less-developed communities, it will be the size of pipes is easy, however determination
harder to avoid dead-ends in the system because of friction losses is not that easy.
there is less of a need for infrastructure. This is
The supply main is laid along peripheral roads, The disadvantage is that the exact calculation of
and sub-mains branch out from the mains. sizes of pipes is not possible.
21
22
<20 %
20 - 40 %
40 - 60 %
60 - 80 %
>80 %
23
Pumping stationsdirectly
(VFDs) pumping with variable
into thefrequency drives
distribution channels, it crashes
impeller causing against
shock theThe
losses. front edgesofofthe
surface the
network to maintain a suitable constant blade is rough – causing friction losses.
minimum pressure is the preferred method used
today. Volumetric losses are caused by the inner
Volumetric
recirculation from the discharge side to suction
side of the impeller inside the pump casing. As the
impeller rotates within the casing, we must allow
c) Number and size of pumps for a gap, and the pressure difference causes water
to pass through.
A common question asked by municipalities
at the planning stage is the number
nu mber of pumps
required. This is an iterative process, and the
starting point is energy efficiency
efficiency.. This is because
– when seen from the owners and investors
point of view – the operation costs during a
pump’ss lifetime are always greater than the
pump’
initial investment cost.
24
Characteristic curve
established from Euler equation
Q Design
Preferred operational
operational range when choosing an impeller
25
The specific speed of rotation (nq) characterises nq up to approx. 25 Radial high-head impeller
an impeller by the ratio between flow and head. up to approx. 40 Radial medium-head
Specific speed and pump size together determine impeller
the attainable efficiency. up to approx. 70 Radial-low head impeller
up to approx. 160 Mixed-flow impeller
This is a parameter derived from a dimensional approx. from
from 14
1400 to 400 Axial-flow
analysis which allows a comparison of impellers impeller (propeller)
of various pump sizes, even when their operating
data differ (flow rate Qopt, developed head Hopt,
rotational speed n at the point of best efficiency
ηopt).
n q
is defined
which as the theoretical
a geometrically rotational
similar impeller speed
would at
run
if it were of such a size as to produce 1 m of head
at a flow rate of 1 m 3/s at the best efficiency point.
It is expressed in the same units as the speed of
rotation:
Mixed-flow impeller
H
nd in
d
in rpm
m =
= Developed
Pump speedhead at ηopt
nq in metric units
Axial impeller
26
iii) Selecting for maximum attainable The figure shows that for a given specific speed,
efficiency an increase in pump size results in an increase in
expected best efficiency of that pump as we may
The expected efficiency of a centrifugal pump expect lower internal losses.
varies as a function of specific speed size of the
pump and operation near the BEP rate of flow. Similarly, for a given flowrate, the increase or
Similarly,
decrease of the designed specific speed of the
The theoretical values of maximum attainable pump may result in an increase in expected
efficiency from Europump (Association of
European Pump Manufacturers) provides a good pump efficiency,
efficiency, up to a point. The graphic can
indication of what is typically achievable in the be used as a guide to identifying the pump
centrifugal pump industry with good design and configurations that will yield the highest basic
manufacturing practices. efficiency.
27
We can use the chart to determine the nq. • The total flow rat
ratee is determined by the
authority – it may be based on statistic (past)
Two possible pump selections look promising: and prognostic (future) – if not given we may
estimate it applying recognised planning
2 x 450 m³/h with 1450 rpm (nq 42) factors.
5 x 180 m³/h with 2850 rpm (nq 50)
• The pump head equals the requir
required
ed system
Both cases are leading to an nq between 40 pressure plus the difference
d ifference in elevation
and 55 so should lead to a good efficiency
efficiency.. (static head)
The attainable efficiency for both cases is above • The static head usually can be ttaken
aken out of
maps when not given by the planner or the
85 % and case a) looks better than case b) – due to authority
the bigger size we can expect less internal losses.
A consultant could take a mix: The tendency nowadays leads to apply more
1 x 450 m³/h and 3 x 180 m³/h smaller size pumps instead of a few bigger size
(one of them equipped with variable speed drive ones.
to cope with a very low minimum flow).
28
Hd
Qd
nq
29
The standard material configuration for pumped medium and what might happen if we
waterworks and
grey cast-iron water
casing distribution
with pumps is, and
a bronze impeller
impeller, a ignore the water.
– drinking characteristic of our pumped medium
in most cases this works fine.
Water is an oxidant, and we have to know the
Water
However, experience shows that drinking relevantt characteristics of water in order to
relevan
water applications can also be hazardous for measure its corrosive effects.
the pumps, so we will take a closer look at our
+
H H H
-
H + H H H + H
The rusting of iron is an electrochemical process When a corrosive electrolyte and two metallic
that begins with the transfer of electrons from materials are in contact (galvanic cell), corrosion
iron to oxygen via the water
water.. The iron is the increases on the least noble material (the anode)
reducing agent (gives up electrons) while the and decreases on the noblest (the cathode). The
increase in corrosion is called galvanic corrosion.
oxygen is the oxidising agent (gains electrons). The tendency of a metal or an alloy to corrode in
The rate of corrosion is affected by water and
accelerated by electrolytes, and acidity
acidity.. a galvanic cell is determined by its position in the
30
galvanic series. The galvanic series indicates the For mechanical engineers, a pump is a machine
relative nobility of different metals and alloys in a – from the chemical point of view it is a galvanic
given environment. The farther apart the metals cell – a battery.
are in the galvanic series, the greater the galvanic
corrosion effect will be. Metals or alloys at the Corrosion in a pump cannot be avoided with a
upper end are noble, while those at the lower end standard material configuration consisting of
are least noble. a bronze impeller (Cathode) in a grey cast-iron
casing (Anode). As the potential difference is
A galvanic cell, or voltaic cell, named after Luigi not to high and drinking water not a strong
Galvani, or Alessandro Volta respectively, is electrolyte, and last (but not least) the casing is
an electrochemical cell that derives electrical much bigger in volume than the impeller,
impeller, the
energy from spontaneous redox reactions taking velocity of the auto-destruction is slow.
place within the cell. It generally consists of two
different metals connected by a salt bridge. Vol Volta
ta However, this changes completely, if you use the
was the inventor of the voltaic pile, the first pump in, for example, seawater, or where a high
electrical battery. concentration
concentra tion of hypochlorite is injected on the
suction side.
+
Electric bridge
Current
OXIDATION REDUCTION
donation of electrons acceptance of electrons
Electrolyte
31
rather
be 10 tominimal. The
100 times rateofofgeneral
that penetration may
corrosion
depending on the aggressiveness of the liquid.
32
In water distribution, we are dealing with tap- When adding chlorine, a critical value is 5 mg/l,
water. Following a treatment process for raw which is the limit for ferritic material (steel). The
water in which specific chemical compounds chlorine content for drinking water usually is
are often taken out, the pH might be adjusted, about 10 times lower than that.
contaminants are removed, and chlorine may be When dosing with sodium and calcium
added to kill biological toxins. Local geological
conditions affecting ground conditions are hypochlorite:
determining factors for the presence of various • The usual content of 0.1-0
0.1-0.3
.3 mg/l refers to tap
ions, often rendering the water “soft” or “hard”. water and is harmless
• To raise the content level to 1.2 mg/l, inject on
Water is an oxidant: It can be Acid pH <7, Alkaline the suction side of the pump for better mixing
pH >7 and Neutral (pH= 7), it contains sufficient • Shock chlorinat
chlorination
ion (0
(0.6
.6 mg/l) means the
H3O+ -ions, and oxygen is always in solution. injection of 6-10 mg/l
i) Calcium Carbonate
Carbon ate (CaCOH) content
• If LSI is negativ
negative:
e: No potential tto
o scale, tthe
he
water will dissolve CaCO3. Lower than -0.5
indicates corrosive water
• If LSI is positiv
positive:
e: Scale can form and CaCO3
precipitation
precipitati on may occur
• If LSI is close to zer
zero:
o: Borderline scale poten
potential.
tial.
Water
Wat er quality or changes in temperature, or
evaporation
evapora tion could change the index
33
c) Corrosion protection
Now we will look at protecting the internal and To interrupt all electric flow, the casing must
wetted parts of the pump against corrosion, be 100 % covered to ensure electrical isolation.
using coatings. This means filling all gaps with an additional
machining of the pump casing, also casing-wear-
Usually, pumps for water distribution do not
Usually, rings, the casing must be painted below them,
require special material variants or coatings. and the paint must not be damaged when the
Natural surface water from lakes or rivers usually wear ring is replaced. TTake
ake similar care with the
is harmless, and acidic waters (moorland, for threads of the drain plugs.
example) are low in CaCo3 content.
Grundfos ensures effective resistance against
However, treated water can be critical. In sea
However, corrosion, erosion and chemicals with highly
water desalination plants, the pH is lowered advanced ceramic coatings, for reliable operation
in the RO process and the re-mineralisat
re-mineralisation
ion and long lifetime of pumps.
incomplete, and so often the treated water has
a very low CaCo3 content and is slightly acid. If the size of the pump is not
n ot too big, it could be
This also applies to salty well water treated with more economical to change the material to a
reverse osmosis. stainless-steel casing and
a nd impeller.
34
35
Main pumping stations which supply water Site development will depend upon a site
to the distribution system will be located near soils analysis showing adequate support for
the water treatment facility or a potable water foundations or possible groundwater problems,
storage facility and will pump directly into the and a grading and drainage plan for the area
distribution system or into transmission lines. showing that runoff away from the structures is
These pumping stations are normally rated for sufficient.
high flows and high heads.
There are generally two types of pumps used for
Pumps which pump into transmission lines also main potable water pumping stations:
are called main pumps or high-lift
high -lift pumps. • The vertical turbine pump
pump,, with line shaf
shaftt
• The cen
centrifugal
trifugal horizontal or vvertical
ertical split
split-case
-case
Site location will be determined from evaluation pump designed for waterworks service
of a topographic survey and flood plain
analysis to determine if there are any flooding If the pump station and intake structure are
probabilities for the proposed plant site. The site located within a surface or underground
must not be subject to flooding. reservoir,, vertical turbine pumps with the
reservoir
column extending down into the reservoir will
Major planning factors are: be a logical choice. If the pump station is located
• Availabil
Availability
ity of electric power at an above-ground storage facility
facility,, split-case
• Roadway access for maintenance and double-suction centrifugal pumps will be the
operation purposes preferred
preferred selection. These pumps are normally
• Security horizontal but vertical split-case pumps are
• Adverse iimpact,
mpact, if any
any,, upon surrounding common where there is limited space.
occupancies
PUMPI NG STATION
LOCAL PUMPING STATION
BOOSTER SYSTEM
36
37
Pumping to
elevated storage
Steady state
Pump trip Customers experience low or negative pressures (due to downsurge)
Negative pressure
Growth of vapour cavity
Flow reversal
Vapour cavity collapses High pressure spikes can damage the pipeline and the seals which
will make the distribution system vulnerable to low pressure
Pressure spike
38
i) Downsurge and water hammer this force can cause damage and we have
protection elements no opening to release it. It may enter the
pressurised tank and compress the air cushion
There are several elements that protect against in there.
downsurge and water hammer. • We ccan
an also by
bypass
pass the pump check valve and
the pump towards pump suction side with a
small orifice (and a rupture disc). Remember:
A vacuum breaker is a cheap solution with we need to lead away pressure and not flowflow..
big effect: it opens and lets air into the pipe
destroying the vacuum, with the disadvantage of
A simple option is also a spring-loaded
troublesome air entering the pipe, and not only
overpressure valve. However, this brings with
in cases of downsurge, but also when the valve,
it similar problems as the vacuum breaker.
due to dirt or a worn seat, is not closing properly
properly..
Another means of reducing the downsurge/
A surge vessel is a better remedy,
remedy, injecting vacuum after a pump trip is to install a fly wheel.
water to fill the vacuum. The pipe system A fly wheel is a solid mass installed on the pump
keeps hermetically closed, and it works in both or motor shaft that will increase the inertia,
directions: prolonging the rotating time of the pump before
• When, afafter
ter a short period, a counte
counter-reaction
r-reaction coming to full stop.
starts, a so-called
so- called pressure wave returns
(remember a wave is energy transmission A pump bypass pipe with a check valve as shown
without material transmission; it is not below can also be implemented to reduce the
movement of water but a discharge of its down surge.
inner tension). In a closed pipe system,
Surge
tank
Delivery
reservoir
Surge (air)
vessel
Air release/
Reservoir vacuum valve
Pump
station
Pressure
relief valve
39
Surge is inevitable when pumping water; it can Small-sized tanks and vessels are easy to operate;
occur when the flow rate of pumps at a pumping they have a bladder separating the air cushion
station is altered, valves opened or closed along of the water the vessel can be pre-loaded with
the pipeline, or uncontrolled pump stop due to a hand pump.
power cuts. These can lead to extreme pressure
fluctuations which, if not controlled, can lead to Larger-sized vessels and tanks do not have a
Larger-sized
disastrous consequences, including burst pipes, bladder,, as the air is in contact with the water
bladder
unnecessary water loss and supply disruptions. and gets dissolved. These tanks/vessels need
Negative pressures are far more prevalent measurement and control of the water level;
than high pressures, and considerably more in the case of the surge vessel, the water level
destructive. can be adapted by increasing or decreasing the
air pressure inside, requiring a compressor to be
A surge vessel is a pressurised tank with connected permanently.
permanently. The water level in a
compressed air inside (nitrogen sometimes used non-pressurised tank can be adapted by using
in pre-charged vessels). It is connected through a a float valve.
check valve held close by the pipe pressure with
a bypass with an orifice plate, for tank filling and
a nd Dimensioning the surge vessel and surge tank
overpressure discharge into the tank. In case of is complex: The water volume in the tank must
a pressure drop in the pipeline, the check valve exceed the water volume “running away in the
opens and water is injected into the pipeline. pipeline”,, which is about the running-out time of
pipeline”
the pump, depending on the moment of inertia
A surge tank is a storage reservoir situated at of the water
water-filled
-filled pump impeller, and the size,
a high point of a closed aqueduct, to absorb the length and the slope of the transmission line
sudden rises of pressure, as well as to quickly and the flow velocity.
provide extra water
water during a brief drop
d rop in
pressure when the water column runs away or a A surge analysis or transient flow calculation is
pressure wave causes an over or under pressure. done by computer simulation.
Air
Air
Bladder or
Diaphragm
Water
Compressor
40
d) Pipe pressure
The graph shown on this page is the result of a surge simulation by a computer program. Three cases
are indicated to illustrate the effect of an immediate pump stop with and without protective elements:
16
With 60
6000 m3 vessel
vessel
14
12
>
r
a
b
< 10
l
WITHO
WITHOUT
UT safe
safe ty devi
ty device
ce
e
v
e
L
e 8
d
o
N
t 6
a
e
r
u
s 4
s Vessel + Bypass DN 500
e
r
P
2
-2
-4
0 25 50 75 10 0 12 5 150 17 5 200 225 250 275 300 325 350 375 40 0
Time <s>
41
6) Water
Water towers or elevated tanks
A water tower is an elevated structure supporting a water tank constructed at a height sufficient to
pressurise a water supply system for the distribution
d istribution of potable water,
water, and to provide emergency
storage for fire protection. Water towers play a special role within distribution systems; however,
however, the
correct expression is ‘elevated tank’.
Modern systems are pressurised directly by pumps, anda nd elevated tanks are kept for emergency supply,
supply,
in case of power cut or to offer an overcapacity in case of fire flow. These tanks are used to deliver a
minimum flow too low to start a pump.
42
43
Pressure-reducing/pressure-regulating
Pressure-reducing/pressure-regula ting valves
(PRV) automatically reduces a higher inlet
pressure to a steady lower downstream pressure,
regardless of changing flow rate and/or varying
inlet pressure. PRVs are installed in water
distribution systems throughout the world
and are known for their superior performance,
reliability and long service life. There are many
variations on the basic pressure-reducing valve.
44
45
46
Local stations are usually located remote from Diagram of an inline booster pump
the main pump station, as in hilly topography,
where pressure zones are required or to handle
h andle
peak flows in the outskirts of a municipality
municipality..
a) Booster systems
A booster system is needed to provide a minimum or a constant water pressure in a distribution
system, when the pressure of the water supply system is insufficient or oscillating too much.
47
48
In this section, we will look at the overall design Often our contact with stakeholders takes
of a pumpinvolved
elements station. in
W
Weedesigning
will consider the critical
a pumping another form:
station, including the role of Grundfos in • EPC Contractor
selecting the correct products and as a solution Consulta
Consultant
nt and Contractor in one entity,
provider. open for smart solutions (spend to save)
49
50
i) Horizonal split-case versus The building for the end-suction pump will be a
end-suction pumps lot cheaper, the cross beams of precast concrete
in standard length of 20 ft or 6 m is sufficient,
The pump selection determines the overall costs, and the overhead crane span will also be less.
and the pump dimensions affect the engineering
design. Beyond this, the pump type and its • Depth required as per NPSHrequired :
Horizontal split-case pump: 4.3 m
suction and discharge pipe add costs. End-suction pump: 6.5 m
From our pre-selection pump example in Section
d elivery of 250 l/s (900 m3/h)
3, we saw that the delivery If the water suction tank is not elevated, the
into a system pressurised with 3 bar can be done foundation level for the end-suction pump
with: may need to be below ground level (requiring
excavation),
excav ation), while the horizontal split-case pump
• 2 pumps - 450 m3/h and 1450 rpm = Nq 42 could be fixed to a simple concrete foundation at
(Horizontal split-case), or ground level.
• 5 pumps - 180 m3/h, 2900 rpm = Nq 50
(end-suction pumps)
51
To work out NPSHavailable and NPSHrequired , it is If costs for the ground area (footprint) of the
necessary to look at where the water is coming pumping station are prohibitive to an extent that
from, and then select a pump with a NPSHrequired the increased operating costs balance out, then
less than the NPSH available. a solution using a vertical turbine pump could
be relevant, specifically in pressure boosting
Without question, it is cheaper to optimise the solutions.
NPSH required of the pump than having to lower
the ground level of the pumping station: However, although a narrow borehole for the
However,
pump is a plus, some critical aspects to consider
• A horizontal
horizontal split-case pump with double with vertical turbine pumps include:
suction impeller needs less suction pressure • Vibra
Vibration
tion resonance
resonance frequency
frequency when speed is
than an end-suction pump reduced by a variable speed drive
• A bigger
bigger pump with the same flow and head • High maintenance
maintenance costs
costs due to the
but actuated with a lower speed motor, for requirement for a crane to raise the pump, and
example with a 4-pole motor instead a 2-pole time consuming disassembly and reassembly
52
53
(motion), the(move)
stator rotate magnetic fields
with littleofslippage
the rotor and
(near
synchrony).
54
55
56
57
9) Design tips
The following section presents some advice and
tips to ensure the smooth operation of the pump
b) Essential elements for
and pumping station. It is certainly an advantage suction and discharge pipes
to consider these issues in the planning and
design stage: A proper pump connection is essential for a
smooth operation of the pump, the following
• How to cconnect
onnect a pump elements must be included on a drawing for a
• The suction pipe pumping station:
• Valves in pumping sta
stations
tions
• Disinfection (Chlorination) Minimum length of suction pipe (distance
• Monitoring between pump and next functional element)
• SCADA and control solution The suction pipe must be of sufficient length
and correct diameter
d iameter.. The flow is pre-accelerated
before entering the pump; for a 3600-rpm pump,
this is from 0 m/s in the tank, to 1 m/s in the
Forces – very high nozzle forces – are defined, Pipe support and thrust block (fix point) to limit
and then these API Norms ae applied to water horizontal and vertical nozzle forces
distribution projects. Suspend the pipe and ensure
en sure a massive fix point
(concrete block) near the pump on discharge
Instead of foreseeing support-points for the side.
water-filled
water -filled pipe and thrust-blocks to bind lateral
pipe forces from accelerating the water column, Dismantling pieces and bellows lockable
they calculate all pipe forces with a sophisticated against lateral movement
softwaree and state this as resulting nozzle forces
softwar Pipe expansion joints must be restrained
to be taken by the pump. This may work for small (3-flange type), to ensure all pipes are tied back
pumps and flow rates; however
however,, for larger pumps to the fix support point.
in waterworks, a non-restrained expansion joint
58
59
60
61
62
Right
Wrong
63
64
• Inlet/outle
Inlet/outlett pressure Power consumption calculated from the Amperage,
- Dysfunction (cavitation) measured together with the characteristic curve,
- Calculate efficiency can prove (or contradict) that the pump is running
- Load profile well. If the acquired data is inconsistent, the flow
• Bearing temperatur
temperaturee must be measured.
- Dysfunction
Bearing temperature and vibration monitoring are
- Wear detection related to the preventative maintenance concept;
• Vibration
however, they can be used for supervising operation.
- Dysfunction (cavitation)
Partial load operation
operation can increase both bearing
- Misalignment
temperature and vibration level. The loss of proper
- Wear (bearings)
alignment – caused by water hammer, for example –
• Amperage (power consumption) can also be detected.
- General function
- Calculate efficiency Visual inspection
inspection
- Wear detection (wear rings) A slow but constant increase of vibration, bearing
• 3-phase supervision temperature and power consumption (Amperage)
- Damage prevent
prevention
ion with unchanged hydraulic data can indicate wear
of bearings and an increase of the gap between
• Motor winding temperatur
temperaturee impeller and casing wear rings. This can be
- Damage prevent
prevention
ion
confirmed by a visual inspection.
For each measurement, two values need to be
defined and programmed into the plc: SCADA systems
• Alarm A Supervisory Control and Data Acquisition (SCADA)
• Trip (switch off) system is not only used for the visualisation of
a plant in a SCADA System but is also the most
For pump performance, monitoring should ideally powerful format in pump station design; the
cover five parameters: ‘process and instrumentation diagram’, also called
• Suction pressure ‘single line diagram’. This is especially the case at the
• Discharge pressure concept stage.
65
66
67
GRUNDFOS PRODUCTS
I N WA
WATE
TERR SU
SUPP
PPLLY
Pumps
Pumps Remote
Communication Polymer Dosing Systems
Dosing Remote
Accessories Communication
Pumps
Remote
Communication Mixers &
Flowmakers
Controls & Monitoring
Groundwater Rivers & Lakes Flocculation & Aeration Filtration & Backwash
Solar
Pumping Dosing Accessories
Disinfection Systems
68
Remote Communication
Lime Preparation System Pumps
Dosing Pumps
Disinfection Systems
Dosing Accessories
Controls &
Monitoring Controls & Monitoring
DisinfectionSystems
Water Distribution
Remote Communication
Booster Systems
69
70
GRUNDFOS
iSOLUTIONS
Intelligent system optimisation is offered by Grundfos
iSOLUTIONS. Built up around our comprehensive control
and communication offerings, you get an intelligent water
supply system offering savings from lower non-revenue
water (NRW), greater efficiency and lower energy costs.
We offer easy integrations and commissioning with your
71
PUMP MONITORING
MONITORING AND
AND
MANAGEMENT
GRUNDFOS REMOTE
MANAGEMENT
With the Grundfos remote management solution, you get
remote monitoring, analysis and control included in a low-
cost subscription. There
There is no initial cost and no additional
hardware and software costs. All data are stored in secure
facilities with access only to subscribing users. Different
user profiles can be set up for different levels of access,
depending on your system’s complexity.
• Access from
from phone, tablet
tablet or PC, and quickly see and
review the status of your pumps and locations
• Reduce maintenance costs by moving to a predictive
workflow and go from routine service checks to planned
and effective maintenance only when required
• Timely warnings enable preventive service before alarms
occur, reducing costly breakdowns, and with access to
key data, you can plan for service and maintenance
• Group pumps,
pumps, change
change configuration
configuration parameters
and monitor pump data
• Descriptive error codes make trouble shooting easy
and intuitive
• Time saving, with quick links to documentation,
replacementt tool, and automatic updates
replacemen
72
MULTIPUMP CONTROLLER
MULTIPUMP CONTROLLE R
MPC
Grundfos Control MPC is a control cabinet with a CU
352 controller that permits monitoring and control of
up to six identical pumps connected in parallel. The
Control MPC is easy to install and configure and offers
standby pump allocation,
allocation, forced pump changeover
changeover
and dry-running protection to help increase system
reliability, reduce downtime and costly maintenance.
Soft pressure build-up minimises risk of water ham-
mer, reducing the risk of leakage and costs of pipe
maintenance.
• Intelligent
Intelligent cascade controller
controller based on pump
efficiency
• Pump cut-in/cut-out
cut-in/cut-out is based on detailed pump
curve data
• Leakage detection
detectio n in non-return valves, protecting
protectin g
against water loss
• Reduced wear due to cavitation
(pump outside duty range feature)
73
EXTERNAL FREQUENCY
CONVERTERS
CUE
A complete range of external frequency converters
designed for speed control of a wide range of Grundfos
pumps for water supply, wastewater and irrigation appli-
cations. A special start-up guide will lead you through
the set-up of the CUE.
FIELDBUS
COMMUNICATION INTERFACES
CIM/CIU
The Grundfos fieldbus concept is the ideal solution for
complete control of pumps and pump systems. The
Communication Interface Module (CIM) and the Com-
munication Interface
Interface Unit (CIU) enable data communi-
cation via open and interoperable networks.
74
75
PUMPING
INTAKE
STATIONS
The key characteristic for intake pumping
pumping
stations is the suction water level varia-
tion. The requirement is for low NPSH from
submersible non-priming pumps.
76
SUBMERSIBLE PUMPS
SP
Complete range of submersible pumps for
groundwater
groundw ater applications built to deliver optimum
efficiency during periods of high demand, with long
product life and easy maintenance.
• State-of-the-art
State-of-the-ar t hydraulics provide high efficiency
and low operating costs
• Made entirely
entirely of stainless steel to ensure high
reliability and long lifetime,
lifetime, even in corrosive
environments
• One supplier
supplier of the pump,
pump, motor and
H
[m] controls for an optimal pumping system
600
400
TECHNICAL DATA
200
• Motor size: 0.37 kW to 250 kW
100 • Flow rate (Q): Maximum 470 m3/h
60
40
• Head (H): Maximum 670 m
• Liquid temperature: 0 °C to +60 °C
20
• Discharge diameter: 1″ to 6″
10
1 2 4 10 20 40 100 200 600 • Diameter
Diam eter:: 4", 6”,
6”, 8”
8”,, 10”, 12”
Q [m3/h]
77
VERTICAL
VERTICAL TURBINE PUMPS
VT RANGE
The VT pump range is for deep wells and has a dry
motor connected to the submersed pump body using
a line shaft. These pumps are robust and built for
reliability and longevity. They are oil-lubricated and
typically used in areas where noise is not an issue.
• For applications
applicatio ns requiring low NPSHrequired, high flow
and high head
• Engineered- and configured-to-or
configured-to-order
der for highly
specific application requirements
requirements
• Hydraulic range from 4” to 72” with flexible and
customised performance
H
[m] TECHNI
TECH NICAL
CAL DATA
DATA
• Flow, Q: 25,000 m3/h
50
• Head, H: 700 m
• Power: max. 2 MW
1
1 10 100 1,000 10,000 100,000
Q [m3/h]
H
[ft]
1000
100
10
1
1 10 100 1,000 10,000 100,000
[Q gpm]
78
WATER TRANSFER
TRANSFER PUMPS
S RANGE
These powerful raw water transfer pumps are selected
for their strength, their durability,
durability, and for innovative
features such as the SmartTrim
SmartTrim impeller clearance
adjustment system and the Smart Seal for leakage
prevention.
• High efficiency
efficiency and durable water transfer pumps
• Patented SmartTrim
SmartTrim system
system for
for extremely
extremely easy
impeller adjustment keeps performace high and
lifecycle costs low
• The SmartSeal auto-coupling
auto-coupling gasket provides a
completely leak-proof
leak-proof connection between the pump
H
[m]
and the base unit
100
TECHNICAL DATA
60
• Motor size: Up to 520 kW
40
• Flow rate (Q): 2500 l/s (9000 m3/h)
20 • Head (H): 116 m
• Liquid temperature: 0 °C to +40 °C
10
• Discharge diameter: 80 to 600 mm
6
• Free passage: Up to 145 mm
4
10 20 40 1 00 20 0 4 00 1000 3000 • Insulation class: F (H on request)
request)
Q [l/s]
• Maximum system pressure: PN 10
• Maximum hydraulic
hydraulic efficiency: 85
85 %
79
80
MIXEDFLOW PUMP
KWM
Submersible mixed-flow pump designed for the high flow
at low head requirements of raw water transfer
transfer and other
heavy-duty pumping applications.
• With Turbulence Optimiser™, for best-in-class
best-in-class
hydraulic efficiency up to 86 %
• High-voltage motors for
for low ionstallation costs
• Robust, reliable
reliable and efficient, offering
offering maximum
maximum value
value
for money
TECHNICAL DATA
H • Motor size: 11 to 700 kW
[m]
25
20 (Up to 850 kW on request)
15 • Flow rate
rate (Q): 5,555 l/s (20,000 m3/h)
l/s (20,000
10 • Head (H): 20 m (Up to 400 400 m on request)
6 • Liquid temperature: 0 °C to +40 °C
4 • Discharge diameter: column
3
(FPV up to DN 2,200)
2
• Insulation class: F
1 • Maximum installation depth: 20 m
120 300 400 700 2000 4000 8000
Q [l/s] • Maximum hydraulic
hydraulic efficiency: 8585 %
81
MAIN
PUMPING
STATIONS
For main pumping stations, the key characteristics is
bulk transport. The requirement is for heavy duty and
high efficiency pumps that can handle high flow.
82
83
40
TECHNI
TECH NICAL
CAL DATA
DATA
• Motor size: 1.1 to 630 kW
20
• Flow rate (Q): 2500 m3/h
• Head (H): 148 m
10
20 40 100 200 400 1000 3000 • Liquid temperature: 0 °C to +100 °C
Q [m3/h]
• Discharge diameter: DN 50 to DN 450
• Maximum system pressure: 16 bar
• Maximum hydraulic efficiency: 90 %
84
30
• Double volute reduces radial
radial forces and minimises
20 noise and vibration
15
10
5
TECHNICAL DATA
4
3
• Motor size: 1.1 to 2,240
2,240 kW
kW
2
2 3 4 5 678 1.5 2 3 4 5 7 1.5 2 3 4 6 8 1 .5 2
• 12,000 m3/h
Flow rate (Q): 12 to 12,000
1x10 1x100 1x1000 1x10000
85
86
PUMPING
LOCAL
STATIONS
A local pumping station is characterised by flow
and pressure variation. The pumping system
must offer variable speed control.
87
SINGLESTAGE ENDSUCTION
STANDARD PUMPS
NB/NBG/NBE/NBGE
Multi-purpose end-suction pumps for reliable and cost-
efficient applications such as water supply.
• High efficiency
• O-ring seal
seal between pump housing and cover
cover means
no risk of leakage
• Housing, impeller
impeller and wear
wear ring in different
different mate-
mate-
rials for improved corrosion resistance, no sticking
elements
• Also available
available with
with a permanent
permanent magnet
magnet MGE motor
up to 11 kW with built-in variable frequency drive
and IE5 efficiency
H
[m] TECHNICAL DATA
200 • Motor size: 0.55 to 200 kW
100 • Flow rate (Q): Up to 2200 m3/h
• Head (H): 210 m
30
• Liquid temperature: -25 °C to +140 °C
NB/NBG
Cast iron • Discharge diameter: DN32 to DN250
DN250
6 • Free passage: 4 to 34 mm
• Maximum system pressure: 16/25 bar
2
• Maximum hydraulic efficiency: 88.5 %
1
4 10 20 50 100 200 500 110
000
3
Q [m /h]
H
[m]
150
80
40
20
NB/NBG
Stainless steel
8
4
4 10 20 50 100 200 500 1000 1500
Q [m3/h]
88
SINGLESTAGE ENDSUCTION
STANDARD PUMPS
NK/NKG/NKE/NKGE
Multi-purpose end-suction pumps for reliable and cost-
efficient applications such as water supply and irriga-
tion. Back pull-out design enables removal of the motor,
coupling, bearing bracket and impeller without disturbing
the pump housing or pipework; these long-coupled pumps
comply fully with either EN733 or ISO2858.
• High efficiency
• O-ring seal between pump housing and cover means
no risk of leakage
• Back pull-out
pull-out design for
for easy dismantling
dismantling for service
service
• Also available
available with
with a permanent magnet MGE motor
H
up to 11 kW with built-in variable frequency drive and
[m] IE5 efficiency
200
TECHNICAL DATA
100
• Motor size: 0.55 to 460 kW
30
• Flow rate (Q): Up to 2200 m3/h
NK/NKG • Head (H): 210 m
Cast iron
10 • Liquid temperature: -25 °C
°C to +200 °C
• Discharge diameter: DN32 to DN250
DN250
3
• Free passage: 4 to 34 mm
1 • Maximum system pressure: 16/25 bar bar
4 10 20 50 100 20 0 500 1000
Q [m3/h] • Maximum hydraulic efficiency: 88.5 %
H
[m]
150
80
40
20
NK/NKG
Stainless steel
8
4
4 10 20 50 100 20
200 500 1000 1500
Q [m3/h]
89
BOOSTER
SYSTEMS
FOR LOCAL
PUMPING
STATIONS
At the booster pumping station, the key
characteristic is pressure increase.
This requires inline and compact pumps.
90
VERTICAL
VERTIC AL INLIN
I NLINEE VOLUTE
VOLUTE PUMPS
– TP/TPE
Single-stage, in-line centrifugal volute pumps with
standard motors and mechanical shaft seals. Compared
to end-suction pumps, in-line pumps allow a straight
pipework and thus often reduced installation costs and
space. TP pumps up to 22 kW are available as TPE pumps
with built-in Variable Frequency Drive.
TECHNICAL DATA
20
• Motor size: 0.12
0.12 to 630 kW
10 • Flow rate (Q): 4500 m3/h
• Head (H): 140 m
5
10 40 100 200 400 1000 4000
• Liquid temperature: -25 °C
°C to +150 °C
Q [m3/h] • Discharge diameter: DN 25 to DN 500
• Maximum system pressure: 25 bar
• Maximum hydraulic
hydraulic efficiency: 90 %
91
• Also available
available with
with a permanent
permanent magnet MGE motor
up to 11 kW with built-in variable frequency
frequency drive and
H
IE5 efficiency
[m]
• Multi-flange fits a variety
variety of standard
standard connections
connections for
200
a more flexible solution
150
• Uniquely designed
designed cartridge shaft seal increases relia-
100
bility, reducing downtime
60 TECHNI
TECH NICAL
CAL DATA
DATA
40 • Motor size: 0.37 to 75 kW
• Maximum 180 m3/h
Flow (Q): Maximum
20
• Head (H): Maximum 500 m
1 2 4 6 10 20 40 100 200 • Liquid temp.:
temp.: -40 °C to +180 °C
Q [m3/h]
(240° C, Thermal oil)
• Operating pressure: Maximum 50 bar
• Discharge diameter: Up to DIN 150
• Maximum efficiency: 80 %
92
HYDRO MPC
These pressure-boosting systems minimise energy
consumption and cut energy costs straight out of the
box. They are built on Grundfos CR and CRE centrifu-
gal pumps and available with application-optimised
functions for perfect performance in any given applica-
tion. Hydro MPC booster systems are easy set-up and
operate with monitoring and communication via BUS,
SCADA
SCAD A or Grundfos Remote Management. Systems are
built using high precision stainless steel manifolds and
H engineered precisely to your installation and system
[m]
150
design needs.
TECHNICAL DATA
20 • 2 to 6 pumps
5 10 20 50 100 200 500 1000
Q [m3/h] • Motor size: 0.55 to 75 kW
• Flow rate (Q): 1080 m3/h
• Head (H): 146 m
• Liquid temperature: 0 °C to +70 C
• Discharge diameter: Up to DN 350
• Enclosure class: IP 54
• Maximum system pressure:
PN16 (standard) (up to PN 40 on request)
• Maximum hydraulic
hydraulic efficiency: 80 %
• Ambient: 0 °C
°C to +40 °C
93
NOTES
94
NOTES
95
x
o
B
d
n
a
r
B
-
0
8
5
2
1
/
Y
T
I
L
I
T
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R
E
T
A
W
/
8
1
3
0
5
3
8
6
1
4
9
9
.
e
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o
d w
a
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r r
e e
e
t s
s e
i r
s
g t
e
r h
e g
r i
r
a l
l
e A
t .
a
v k
o r
a
n m
n n
i
k e
n D
i
h ,
t S
/
e A
b s
o
d f
n d
a
, n
o u
r
g G
o
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s o
o S
f
d /
n A
u
r g
n
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e d
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h
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, H
s s
o f
f o
d d
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r u
r
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T o
96