Lenntech GRUNDFOS

info@lenntech.com SP ENGINEERING MANUAL

www.lenntech.com
 
 Contents
1  Introduction
2  Water supply
2.1 Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.3.2 Well diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2 Groundwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.3.3 Well yield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2.1 Groundwater wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.3.4 Pump efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2.2 Riverbank filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.3.5 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2.3 Groundwater requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.3.6 Derating of submersible motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2.4 Required raw/well water and water treatment capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7.3.7 Protection against boiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2.5 Well yield and operational efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7.3.8 Sleeve cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Surface water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7.4 Riser pipe selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3.1 From fresh water sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7.5 Cable selection and sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3.2 From the sea and saltwater sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7.6 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.6.1 Pump / motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3  Applications 7.6.2 Cable splice/Connection of motor cable and drop cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.1 Freshwater supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7.6.3 Riser pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2 Dewatering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7.7 Pumps in parallel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2.1 Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7.8 Pumps in series operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3 Horizontal application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.9 No. of start/stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.4 Air/gas in water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.10 Pump start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Corrosive water (seawater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.11 VFD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6 Hot water and geothermal water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.12 Generator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Booster modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8  Communication
4  Pumps 8.1 General introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1 Pump principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8.2 Communications and Networking Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 8.3 SCADA systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Pump selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 8.3.1 SCADA main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.4 Pump curves and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8.3.2 SCADA functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.3.3 Web-hosted SCADA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5  Motors and controls 8.4 Networking basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.1 Motor types, general description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 8.4.1 Networking topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.2 Motor cables and joints, reference to drop cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 8.4.2 Communications protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.3 Motor protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 8.4.3 Functional profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.4 Reducing the locked-rotor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 8.4.4 The fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.4.1 Direct-on-line – DOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 8.5 GENIbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.2 Star-delta – SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 8.5.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.3 Autotransformer – AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.5.2 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.4 Primary resistor-type starter, RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.5.3 Cabling guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.4.5 Soft starter – SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.6 Grundfos GENIbus products for SP Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.4.6 Frequency converters (variable speed drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.5 Operation with frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 9  Troubleshooting
5.6 CUE varible speed drive for SP pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

6  Power supply 10  Accessories

6.1 Power generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.1 Cooling sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.2 Corrosion protection in seawater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.1  Voltage unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.2.1 Cathodic protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.2  Overvoltage and undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.2.2 Galvanic cathodic protection systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.3 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 10.2.3 Impressed current cathodic protection systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.4 Variable frequency drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 10.3 Drop cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.5 Grid connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 10.4 Cable joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.6 Current asymmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 10.5 Riser pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7  Installation & operation 11  Additional information

7.1 Wells and well conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 11 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.2 Pump setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.3 Pump and motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 12  Index
7.3.1 The duty point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 12 index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

 
 Introduction

Serving our common interests

This engineering manual has been created with a specific focus on one of Grundfos’ most recognisable and
popular pumps: the SP. When it was created in the late 1960’s, this breakthrough product set new standards
within durability, efficiency, and construction in thin-plate stainless steel. The numerous product types, sizes,
and configuration possibilities available today serve as a testament to the innovative nature of the original
SP pumps.

Working with SP pumps on a daily basis often gives rise to lots of different questions. We have created this en-
gineering manual to help you quickly and easily find the answers to a number of these questions. We serve our
common interests of providing the best possible SP solutions and service for all customers.

Please note that this engineering manual is a supplement to and not a replacement for product data booklets
and installation manuals. The newest editions of these publications are always the most valid and must be
adhered to.

We have taken considerable time and care to make the presentation as convenient and easy to use as possible.
We realise, however, that there is always room for improvement, and invite you to comment. Please contact your
local Grundfos representative if there are subjects you would like to see covered in future editions.

We sincerely hope that you find this manual a useful reference tool in your work with SP pumps.

Kenth H. Nielsen
Global program Director,
Grundfos Management A/S

1.
Introduction

 
 Water supply

2.1 Resources If groundwater levels are permanently lowered, a

The amount of water in the world is constant. It is water supply disaster with an increasing salinity and
changing position, quality, phase, etc., but it is con- other undesired substances can be expected.
stant. Seawater accounts for approx. 97.5% of all wa-
ter. Fresh water accounts for the remaining 2.5%. Two-
thirds of the fresh water is bound as glaciers, polar
ice, and snow cover. The remaining, less than 1% of all
water in the world, is somehow available in different
sources for mankind to use.

These sources are: Well head

• groundwater, shallow or deep underground aqui-

fers of water
• surface water, from rivers or lakes.
In case no fresh water is available, seawater or con-
taminated water is treated and used as fresh water. Pump

2.2 Groundwater Pump inlet

Redox layer

Groundwater is typically between 25 and 10,000 Gravel packing

years old. Before it reaches the aquifer, it has been fil-
tered and exposed to biological treatment on its way
Casing sealed
through the various layers of the ground. Groundwa- at layers of clay Submersible motor

ter is therefore usually of high quality and requires

little or no treatment before it is consumed.
Well screen

2.2.1 Groundwater wells

Irrigation and water supply systems serving up to Fig. 1 Groundwater well with submersible pump
500,000 consumers and the adjacent industries are
ideally supplied by groundwater. Pollution-free aqui- 2.2.2 Riverbank filtration
fers larger than 600 km2 are normal. 75 to 150 well-in- In riverbank filtration wells, the well is placed nearby
takes spread on the different aquifers will provide the a river. Using this method, the river water is filtered
most environmentally-friendly, safest and reliable through the ground. This process is a natural addi-
water sources. For waterworks serving more than 1 tion to a direct intake plant needing capacity enlarge-
million consumers, an additional source such as riv- ment. The easy-to-clean, pre-filtered water requires
erbank filtration, river dams, or desalination should less final treatment and extracts water from the aq-
be considered. uifer when the river level runs low.

The individual wells are to be extended into older After every wet period with high river water levels,
groundwater at pollution-free depths when extract- the mud/dung/sediments of the riverbed are washed
ing for drinking water. Irrigation wells can easily use downstream and partly replaced by new sediments.
water from the upper aquifer, the secondary aquifer, This natural process provides perfect conditions for a
with slightly polluted water quality. The groundwa- 90% reduction of human-induced enzymes, viruses,
ter level will vary over the seasons, but is to be re- bacteria, pathogens, and so on. Each wet period with
spected on the yearly basis, as the maximum remov- high river water levels also fills the aquifers around
2. able quantity is similar to what is created every year. the river with water, where it is stored and ready for

Water Supply

 
 Water supply Water supply

feeding the riverbank wells when the river water lev- To find the peak hourly consumption, please refer to Consumption
2.2.4 Required raw/well water and
el runs low in dry season. The storage of river water in the MPC-Booster section of Grundfos WinCAPS/Web- m3/h
water treatment capacity
aquifers causes less water stress on the river during CAPS or figures 4 and 5.
dry seasons. The relationship between water storage and daily
Pump-out requirement 100
consumption illustrates the percentage of the daily
Riverbank wells can be constructed like groundwater Water is used by many different types of consumers, consumption that is present in storage. With this
80
wells, or from 7-8m vertical casings dug down under each with a specific consumption pattern. There are Hotels
percentage, follow it horizontally in fig. 6 to find the
the riverbed. They can be supplemented with 8-12 many methods of calculating the maximum water necessary percentage for raw-water requirement.
60
horizontal injected steel screens or filters for sedi- requirement, both manual and computerised ones. The daily consumption multiplied by the percentage
Hospitals
ment-free water intake. 40
of raw-water requirement provides the necessary ca-
The table below can be used for rough calculation of pacity from the well fields.
the water requirement for: 20

• office buildings If a treatment plant has no cleanwater tank or water

• residential buildings incl. blocks of flats 0 tower, the raw-water and treatment capacity must
• department stores 0 200 400 600 800 1000
be equal to the maximum hourly consumption, i.e.
Number of beds
• hospitals Fig. 4 Peak water consumption Qraw-water = 345 m3/h in the example.
• hotels.
Fig. 2 Riverside well installations Consumption If the treatment plant has a clean-water tank or a wa-
m3/h
ter tower capacity of 2,760 m3, peak load situations
Averange 60
can be covered from the reservoir. This means that
Category Units
m /h
3
the raw-water pumps can run constantly around the
50
Dwellings 2,000 units 70 clock at 2,760/24 m3/h = 115 m3/h.
Office buildings 2,000 employees 30 40 Department
stores The effective volume of the clean-water tank and/or
Department stores 2,000 employees 55
30 Dwellings water tower and the maximum capacity of the treat-
Hotels 1,000 beds 110 ment plant are crucial for investment costs in con-
Hospitals 1,000 beds 80 20 nection with groundwater wells.
Office buildings
Maximum peak 345 10
In the example, there is a clean-water tank of 1,600
load (warm season)
m3. This means that the water reservoir comprises
0
0 400 800 1200 1600 2000
1,600/2,760 x 100 = 58% of the daily consumption.
Factors for calculating daily consumption: Number of
employees
• Minimum 100 consumers connected: Factor 8 Fig. 5 Peak water consumption At a maximum peak consumption of 345 m3/h and
• Minimum 30 consumers connected: Factor 4 a maximum consumption of 2,760 m3/day and with
• Minimum 10 consumers connected: Factor 2.5 Peak hourly consumption is stated, this can be con- an effective clean-water tank volume of 1,600 m3, the
The maximum daily consumption in the example verted into assumed daily consumption by using the raw-water capacity must be at least 2,760 x 7.6/100 =
Fig. 3 Riverbank filtration above will be factor 8 x 345 m3/h = 2,760 m3/day. factors 8/4/2.5. 210 m3/h. 7.6 is taken from fig. 2. This will give a maxi-
Bacteria, pathogens, etc. are trapped by the mum duty time of the raw-water pumps of 2,760/210
sediments. = 13 hours/day.
The 210 m3/h are split up between at least three to
2.2.3 Groundwater requirement four wells. In case of fewer wells, a standby installa-
The basis for determining the groundwater require- tion must be made.
ment from the well fields is to evaluate the relation-
ship between the water storage volume and the fin-
ished water production capacity compared to peak
and daily consumption.

10 11
 Water supply Water supply

An increase from 10 to 20 m3/h will consequently re- An increase from 80 to 90 m3/h will give an addi-
Clean-water tank size as a percentage of daily consumption sult in a lowering of the water level of approx. 1 m. tional drawdown of approx. 5m; from 80 to 100 m3/h
% An increase from 10 to 30 m3/h will give a lowering of approx. 11 m, i.e. much more than at moderate flows.
100
Clean-water tank size as a percentage the water level of approx. 2m. The most economic well load occurs at a flow where
90 of daily consumption: the drawdown curve goes from linear to progressive.
80
Tank volume (m3)
x 100 = % tank capacity At moderate flows, the drawdown curve will be close
Daily consumption (m3/24h)
to linear as the increased drawdown is due to flow If the well yield is not sufficient to meet the water
70 Raw-water requirement:
resistance in screen setting. requirement, even by prolonged operation, the fol-
Daily consumption (m3/24h)
60 58%
100 x = % raw-water requirement lowing should be done:
Mi Min
nim imu Parabolic drawdown at large flows • Have a specialist look at the problem.
Mi

50 um m1
00 c
nim

10 ons
0c um At increasingly large flows, a progressively increasing • Have a supplementary well drilled.
um

on ers
40 su con
me nec
10

rs ted frictional resistance in screen setting and aquifer will

0

co
co

30 nn
ect give a parabolic drawdown curve of the second de- Please note that rules and regulations may vary from
ns

7,6% ed
um

gree. This means a progressively falling water level in country to country.

ers

20
co
nn

the well with increased pumping.

ec

10
ted

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 %

Raw-water
requirement

55 Static water level

Fig. 6 Raw-water and treatment capacity (m3/h) as a The most common cause of overpumping of a well or
50
percentage af the daily consumption (m3/day) aquifer is increased water consumption. This is cov- Gradient: 10 cm/m3/h
ered by increased pump capacity or longer duty time 40
Increasing gradient
of the groundwater pumps without increasing the
2.2.5 Well yield and operational catchment area or the number of wells. 30

efficiency 20
Aquifer load
Each well has specific capacity, consisting of m3/h When pumping at constant capacity for several 10

for each metre of drawdown of the pumping wa- hours, the dynamic water level in the well should re-
ter level. With your raw-water requirement, you are main fairly constant. If the level is lowered consider-
able to load each well to obtain the lowest average ably, this means that the amount of pumped water
drawdown. The smaller the drawdown, the smaller exceeds the influx. If the level drops from year to year,
the total head. The smaller the voltage drop in power the quantity of pumped water should be reduced and Acceptable well load Overpumping

cables, the better the operational efficiency. water from other aquifers should be utilised.

• Overpumping will result in deep drawdown. This Well load

0 10 20 30 40 50 60 70 80 90 100 m⁳/h
gives room for oxidation, resulting in the formation During test pumping, the amount of pumped water
of ochre which may clog well screen and pump. is increased at fixed intervals which will result in a
This means increased service costs for well regen- lowering of the dynamic water level. If the draw- Fig. 7 Dynamic water-level variations by test pumping
eration and possibly reduced well life. down is plotted against increased pumping, a rough
parabola will result.
• Overpumping means lowering of the water level of
the aquifer which can result in chemical changes Linear drawdown at moderate flows
and precipitation of heavy metals. Infiltration of ni- At moderate flows, this means that typically an in-
trate and pesticides in the water may occur, result- creased amount of water of 1 m3/h will result in an al-
ing in increased expenses for water treatment. most linear increase in the drawdown of 10 cm/m3.

12 13
 Water supply Water supply

2.3 Surface water Using direct water intake and standard conventional
water treatment will only result in a microscopic di-
2.3.1 From freshwater sources verse biodynamic-balanced fauna entering the ac-
Surface water is usually taken from lakes or rivers. companying pipework and tank system. The fauna
Unlike groundwater, it is not protected from nature can range from single-celled organisms to millime-
or human activities, and treatment is therefore al- tre-sized predators. This fauna must be eliminated by
ways necessary. Surface water level and quality will dosing high levels of chlorine. Direct water intake at
vary over the seasons. For example, after heavy rain- a temperate climate will require chemical overdosing
fall, or snow melt, lots of solids and sand are washed during the coldest season of the year, when chemical
downstream. reactions have slowed to nearly inactivity.

These sharp and abrassive minerals as well as biode-

gradable materials are to be settled or screened off 2.3.2 From sea and saltwater sources
before pump intake to avoid negative effects on the Coastal seawater intake should be placed where the
final water treatment process. Submersible pumps lowest salt content is expected. In the coastal splash-
are ideal for these applications with periodic uncon- ing zone, a lot of water evaporates making the salt
trollably high water levels. Note that power cables concentration of remaining waters greater than out-
and electric equipment must be elevated to perma- side the splashing zone. In fact, it can be up to twice
nently dry locations. as great.

This makes it necessary to extend the seawater in-

take up to hundreds of meters from the splashing
zone to obtain the lowest salt content. This type of
intake structure is generally beneficial when intake
capacity exceeds 1,000 m3/h.

For intake capacities lower than 1,000 m3/h, cor-

rosion-safe beach wells and coastal bank filtration
wells are recommended. These installations can pro-
vide savings of up to 20% per year on costs related to
maintenance, repair, power consumption and chemi-
cals at the desalination plant.

Coastal bank filtration wells are constructed like riv-

erbank filtration wells, but in higher corrosion classes
to resist the impact from the present salts.

Fig. 8 Settling tank principle

For more permanent installations, indirect riverside

infiltration via sand or gravel bank fillings to intake
casings or riverbank wells are recommended. This
natural filtering improves the water quality and
saves up to 20% on power consumption, chemicals
and testing at final treatment.

14 15
 Applications

3.1 Freshwater supply

The supply of fresh water for drinking water, irriga-
tion and various industrial applications is the most
common application for submersible pumps. Pumps
of many different designs, and made from many dif-
ferent materials can be used with a reasonably good
result here.

Grundfos SP pumps made of stainless steel EN 1.4301/

AISI 304 are the obvious choice for this application. If
the well is made correctly and produces clean, sand-
free water, the pump can last for many years.

However, in some livestock watering and irrigation

applications, the water quality is so poor that pumps
made of standard stainless steel material do not sur-
vive very long. In these cases a pump in EN 1.4401/
AISI 316 or EN 1.4539/AISI 904L stainless steel can be
used.

Estimates for a timeframe for carrying out several

activities are found in the diagrams below. They in-
clude:
• the recommended service periods caused by wear
and tear
• the expected service repair cost
• the loss of efficiency in the service periods.

Please note that the diagrams do not reflect loss of ef-

ficiency caused by clogging from sediment or scale.
Service intervals for submersible pumps

Submersible pumps are subject to wear just like all

other pumps. Unfortunately, their placement under-
ground makes viewing this wear difficult. The dia-
gram here enables you to calculate the following:

· W  hen should I service my submersible pump?

· How much efficiency has been lost since the last
service?
· How much will a renovation cost (approximately)?

A number of things must be determined beforehand.

They include:
· Water velocity at the component you wish to test
· The conditions related to pump material and the
3. pumping environment
· The presence or absence of solids and aggressive
Applications carbon dioxide.

16 17
 Applications Applications

The chart below is useful as a guideline to determine 4. Drop directly down (90°).The aggressive CO2 con- 3.2 Dewatering to the submersible pump, and high-grade stainless
the service intervals for submersible pumps. tent has increased the material loss to 0.25mm. Dewatering in connection with mining applications steel is recommendable.
Follow the steps below: Note the salinity level of the water (point 4). Draw or construction sites is often done with submersible A special mining application is leach mining, where
1. Note point 1 on Curve A. Pump material and media a horizontal line through this point; follow it to the pumps. The water quality determines whether the an aggressive liquid is used to dissolve the minerals
conditions are as indicated in the legend. left and read the results. pump can be a standard EN 1.4301 (AISI 304) pump, or to be mined. These are then pumped with the liquid
2. Draw a parallel line to the right. Impeller material 5. Recommended service intervals for your pump: Af- if it has to be stainless steel of a higher grade. to the surface and reclaimed.
loss is approx. 0.18mm per 1,000 hours of opera- ter every 6,000 hours of operation (point 5).
tion (point 2). 6. Loss of efficiency: Approx. 18% (point 6). When reducing groundwater levels, the aquifer is One way of doing this is described in the following:
3. Follow the parallel line until you reach the differ- 7. Estimated cost of renovating the pump: 75% of the exposed to oxygen, creating rust and other adhesive
entiation line that corresponds to aggressive CO2 price of a new pump (point 7). solids. They are washed out and penetrates the well 1. Find the chloride corrosion potential (chloride
and component material. Note the conditions in screen, then passing on to the pump inlet. equivalent = ppm chloride – (0.5 x ppm acid)).
the example (point 3). 2. With this chloride equivalent, use fig. 10 to find the
To maintain pump performance, the duty point is to minimum pH value acceptable for EN 1.4539 (AISI
be selected to the right of the best efficiency point. 904L) stainless steel. If the illustration indicates
Recommended service intervals for submersible pumps that there is a high corrosion risk, epoxy-coating of
Velocity at components
Differentiation line for water
qualities without aggressive
The higher the velocity inside the pump, the longer in- the motor is required.
carbon dioxide
Impellers Chamber bowls Valve strainers Water pipes Motor cooling tervals between service can be. A high velocity prevents 3. Most power cable materials and junction kits are
0 mg/l (all materials)
6
m/s 9 8 7 5 4 3 2 1
the pump from clogging up and losing performance. In unstable in acidic waters. If possible, use the blue
10 mg/l (cast iron only)
0.18
very adhesive mixtures, it can be beneficial to remove Grundfos TML motor cable in full length to the
Water containing 10 mg/l solids

1 2 3
20 mg/l (cast iron only)
0.16 the non-return valve from the pump to enhance back- junction box on the surface.
Curve A
0.14
40 mg/l (cast iron only)
wash of the pump and pipes after pump stoppage. 4. Install the pump centering device on your pump or
Curve B
0.12 motor to ensure perfect cooling of the entire sur-
0.10 Material loss per 1,000
face.
Curve C
0.08
hours of operation in [mm]
3.2.1 Mining 5. If corrosion occurs, install ion-exchange units to
Curve D
0.06
Mining is a typical dewatering application. However, bring down the chloride content, or install zinc an-
the water quality is very often aggressive in relation odes as cathodic protection.
Sand free water

Curve E 0.04
Corrosion due to chlorides on R-version pumps at 35°C
0.02
Curve F pH
0.40
0.04

0.48
0.08

0.44
0.20

0.36
0.28
0.24
0.16

0.32
0.12

Differentiation line for salinity

8
40% 20 200 mg salt/litre
Seawater,
800 mg salt/litre marine 7
50% 16 environment
Expected renovation in % of the price of a new pump

2,000 mg salt/litre

30,000 - Highest corrosive potential (seawater)

6
60% 12
ris
River mouth
sion
or coastal ro
or
5
Service intervals in 1,000 hours

70% 8
water c
lowering o k
n ris
7 6 5 4

r
eo on

Baltic/Mediterranean seawater
4
tl si
80% 4

Lit rro
%

co

Pacific/Atlantic seawater
gh
100% 2 Mining 3
25 20 15 10
Average efficiency loss during service period
5 waters
Hi
Brackish water Freshwater
2
Curve A: Curve B: Curve C: Curve D: Curve E: Curve F:
Material: Cast iron Material: Cast iron Material: stainless steel impeller Material: Cast iron Material: Cast iron Material: Bronze or
pH: 5 pH: 7 coated with hard chromium pH: 5 pH: 7 stainless steel impeller
Oxygen content: 7 ml/l Oxygen content: 2 ml/l or bronze impeller with Oxygen content: 7 ml/l Oxygen content: 2 ml/l pH: 5-8
Temperature: 30o C Temperature: 10o C hard chromium shaft Temperature: 30o C Temperature: 10o C Oxygen content: 0-10 ml/l 1
Solids content: 10 mg/l Solids content: 10 mg/l pH: 5-8 Temperature: 0-30oC
Oxygen content: 0-10 ml/l
Temperature: 0-30o C
Solids content 10 mg/l
0
0 500 5,000 10,000 20,000 50,000 100,000 300,000
Fig. 9 Recommended service intervals for submersible pumps
Freshwater Brackish water Seawater Brine ppm Cl-

Fig. 10 Corrosion due to chlorides

18 19
 Applications Applications

3.3 Horizontal application

Pumping water from a tank or reservoir is very often If more than one submersible pump is installed in a Vacuum pump Vacuum switch Vacuum gauge

done with a standard submersible pump. A submersible tank or reservoir the distance between the pumps Non-return
pump has many advantages compared to a dry-installed must equal the overall diameter of the pump and valve

pump such as: motor including cooling sleeve.

• Low noise level: The submersible pump is very si-
lent and does not disturb any neighbours. Submersible pumps used for fountain applications
• Theft proof: The pump is installed at the bottom of are often installed horizontally. Because of its low in-
the tank/reservoir. ertia, a submersible pump is able to start and stop
• No shaft seal: This eliminates the risk of leakage very fast. This makes it ideal for fountain applica- !xŠ
above ground. tions. Because of the high start/stop frequency, it is
recommended to use canned motors only. Rewind-
In horizontal installations, Grundfos always recom- able motors should never be used in connection with
mends that you include a flow sleeve and baffle plate an extreme number of starts and stops. !xŠ Šƒ||| Gas vacuum

at low water levels. Water level in casing

The large number of starts/stops is also hard on the

contactors, which have a limited lifetime. In order *Œ„‡ €…ƒ|‹
1x‹|‰ ƒ||ƒ
to protect the motor from failure in the contactors, Gas 5-7 m

Grundfos recommends that you install the phase-

Groundwater level
'€… êï „
failure relay between the overload relay and the mo-
tor.

Finally, it is important to size the pump and nozzle

together, so the pump never operates at maximum
Fig. 11 Flow sleeve on horizontally installed pump flow, but always as close to the best efficiency point Fig. 14 Gas evacuation Fig. 15 Vacuum wells
as possible.
Vacuum wells
If the well water contains so much gas in suspension pump to the vent pipe when the casing is hermetical-
x}}ƒ| ‡ƒx‹| 3.4 Air/gas in water that a sleeve is insufficient to meet the water quality ly sealed. This requires that the well casing is strong
0†‰‹|
If air/gas is mixed in the pumped water, the pump requirements, a vacuum must be created in the well enough to withstand the vacuum and that the NPSH
will underperform, and sometimes even stop pump- casing. This can be done by connecting a vacuum requirement is met.
ing. Air/gas greatly disturbs the hydraulic functions
of centrifugal pumps. To improve performance, the
pump must be submerged deeper into the well, thus
-||… }‰†„ xy†|
Fig. 12 Vortex baffle plate on horizontally-installed increasing the pressure.
pump (seen from above)
If that is not possible, the problem may be overcome
1x‹|‰ ƒ||ƒ by installing a sleeve around the pump, below the
0†‰‹| pump inlet. The sleeve should extend upwards as
far as possible, but never above the dynamic water
'€… êï „ level.
x}}ƒ| ‡ƒx‹|

‰†ŠŠ Š|z‹€†…
Fig. 13 Vortex baffle plate on horizontally installed
pump (cross-section)

20 21
 Applications Applications

3.5 Corrosive water (seawater) 3.6 Hot water and geothermal water
Submersible pumps are used for many seawater ap- PRE = (% Cr) + (3.3 x %Mo) Corrosion diagram Groundwater close to the surface will be close to the
EN 1.4301, 1.4401 and 1.4539
plications like fish farming, offshore industrial appli- 100
average annual air temperature in the region. Going
SPR 1.4539
cations and water supply for reverse osmosis-treated For comparison to other stainless steel types, which 90 SPN 1.4401 deeper, the temperature will increase 2 to 3  °C for
water. contain Nitrogen (N) the formula looks like below: CRN 1.4401 each 100m of well depth, in the absence of geother-
80 SP 1.4301
mal influence.
70
SP pumps are available in different materials and cor- PREN = (% Cr) + (3.3 x %Mo) + (16 x %N)

Temperature [°C]
60
rosion classes depending on the application of the In geothermal areas, this increase might be as high
50
pumps. The combination of salinity and temperature In addition to temperature and salinity, the corro- as 5 to 15  °C for each 100m of well depth. Going deep
40
is not favourable to stainless steel, and must always sion temperature is affected by the presence of other for water requires temperature-resistant elastomers,
be taken into consideration. metals, acids and biologocal activity. This is also indi- 30
electrical cables, connections and motors.
A good way to compare the corrosion resistance of cated in fig. 16. 20

stainless steel, is to compare its resistance against 10 Hot groundwater is used for general heating applica-
pitting. The figure used as a comparison is called: The chart below can be used for the selection of the 0 tions, and for leisure in many areas, especially those
0 200 400 600 800 1000 1200 1400 1600 1800 2000
‘Pitting Resistance Equivalent’ (PRE). proper grade of steel. with volcanic activity.
Chloride [ppm]
Fig. 16 shows the most common stainless steel types
used by Grundfos. Fig. 17 Corrosion diagram The motor liquid of your submersible motor has a
higher boiling point temperature than the well water
prevents the motor bearing lubrication from being
Corrosion diagram
EN 1.4301, 1.4401 and 1.4539 reduced due to the lower viscosity of the liquid. The
Corrosion resistance of seawater-submerged pumps 100
SPR 1.4539
motor must be submerged deeper to raise the boil-
35 SPN 1.4401 ing temperature as the table below.
Temperature of standard seawater (21,000 ppm Cl¯) - °C

90
Full-developed pitting Environmental impact CRN 1.4401
80
resistance equivalent in 60 days SP 1.4301
30 70 Vapour Kinematic
Critical crevice temperature in
Temperature pressure viscosity

Temperature (°C)
stagnant water 60
25  °C mWC mm2/s
50

Chlorine, sulphuric acids and chemicals

40 0 0.00611 1.792

decrease temp. acceptance by 8°C

20
increase temp. acceptance by 5°C
4 0.00813 1.568
Cast iron and mild steel anodes

Biological activity decreases 30

10 0.01227 1.307
Zink anodes increase temp.

20
15
temp. acceptance by 5°C

10 20 0.02337 1.004
acceptance by 15°C

10 0 30 0.04241 0.801
0 2000 4000 6000 8000 12000 16000 20000
40 0.07375 0.658
Chloride [ppm]
5 50 0.12335 0.554
Fig. 18 Corrosion diagram 60 0.19920 0.475
0
EN 1.4301/AISI 304 EN 1.4401/AISI 316 EN 1.4462/AISI 904L EN 4539/AISI 904L 70 0.31162 0.413
PRE = % Cr + 3.3 x % Mo PRE = % Cr + 3.3 x % Mo PRE = % Cr + 3.3 x % Mo PRE = % Cr + 3.3 x % Mo The elastomer components in the pump may also be 80 0.47360 0.365
= 7.5 = 24.3 = 33.5 = 34.9
damaged by poor water quality, for example if the 90 0.70109 0.326
Critical temperature for water has a high content of hydrocarbons and many
permanent still-standing water 100 1.01325 0.294
chemicals. In such cases the standard elastomer can
Pitting resistance 110 1.43266 0.268
be replaced by FKM rubber. The Grundfos SPE pumps
120 1.98543 0.246
are particularly designed to meet these requirements.
Fig. 16 Corrosion resistance For all other models, the pumps can be specified and 130 2.70132 0.228
delivered on request. 140 3.61379 0.212
150 4.75997 0.199
160 6.18065 0.188

22 23
 Applications Applications

Gas in the water is to be expected where there is geo-

thermal activity. To avoid reduced pump capacity in a
geothermal water installation where air is mixed in,
Grundfos recommends to install the pump a mini-
mum of 50m below the dynamic water level.

3.7 Booster modules

Grundfos pump types BM and BME are SP pumps
built into a sleeve. By connecting each unit in series,
a very high pressure can be obtained.

The pumps are primarily used for reverse osmosis ap-

plications, producing clean water from polluted wa-
ter or seawater.

Grundfos booster modules are also used for water

supply in distribution networks to boost water pres-
sure over long distribution lines. The main advantag-
es compared to conventional booster pumps are the
quiet operation, and there is no shaft seal that may
leak.

Fig. 19 Grundfos BM

24 25
 Pumps

4.1 Pump principle

The SP pump is a centrifugal pump, where the pump The pump consists in principle of an inlet (1), a
principle is to transform mechanical energy from the number of pump stages (2) and a pump outlet (3).
motor to velocity energy in the pumped medium, and Each pump stage creates a pressure difference, and
thereby creating a pressure difference in the media the more pressure needed, the more stages need to
between the pump inlet and outlet. be included.

A pump stage includes an impeller (4) where the im-

peller blades transfer energy to the water in terms
of a velocity and pressure increase. Each impeller is
fixed to the pump shaft (5) by means of a spline con-
nection or split-cone connection.
(3) Outlet

For submersible pumps, there are two general design

types:
• radial
• semi-axial.

(5) Shaft
The radial design is characterised by a large differ-
ence between the impeller inlet and the outlet diam-
eter of the impeller. It is suitable where a high head
is required.

(7) Guide vane

The semi-axial design is more suitable for larger flow
pumps.

(4) Impeller A seal ring (6) between the impeller inlet and the
(6) Seal ring chamber ensures that any back flow is limited. The
chamber includes a guide vane (7), which leads the
water to the next stage. It also converts the dynamic
(2) Stage (Chamber)
pressure into static pressure.

In addition to guiding the water into the first impel-

lers, the pump inlet is also the interconnector for the
motor. For most pumps the dimensions conforms to
the NEMA standard for 4”, 6” and 8”. For larger pumps
and motors there are various standards depending
(1) Inlet on the supplier. The pump inlet must be designed in
order to deliver the water to the first impeller in the
best possible way and thereby minimise the losses as
much as possible. For some radial designed impellers,
the inlet also includes a priming screw (fastened on
the pump shaft) in order to secure the water intake
and avoid dry running of the pump.

The pump outlet normally includes a non-return

4. Fig. 20 Submersible pump principle valve, which prevents back flow in the riser pipe,

Pumps

26 27
 Pumps Pumps

when the pump is stopped. Several benefits are ob- 4.4 Pump curves and tolerances H [m]
SP 60-8
Eta
[%]
120
tained such as: After estimating the necessary flow and head, pump ISO 9906 Annex A
Pumped medium = any viscous fluid

• Energy loss due to back flush is avoided. 3 4

selection can be performed by using Grundfos Win-
100
• A counter pressure is always ensured, when start- CAPS/WebCAPS or the corresponding pump data QH

ing up the pump again. This is essential in order to Flow (Q): 60 m3h
booklet. Both sources contain performance curves. 80
Eta, pump
80

make certain that pump performance remains on Pipe length of discharge pipe: 0 m
Eta, total
70

the pump curve. 2 In addition to the pump head, the required power 60 60
: 10 m
• Damage in the pump due to water hammering is consumption is also available in the data booklet, 50

limited. where the pump supplier distinguishes between the 40 Shaded

areas show
40
acceptable
• Contamination of the groundwater due to back : 50 m 1 Pipe length of riser pipe: 0 m motor shaft power output P1 (printed on the motor tolerances
30

20 20
flush is limited. nameplate) and the motor input power, P1. P1 is used
10

: 80 m 4
for sizing the electrical installations.
0 0
0 10 20 30 40 50 60 Q [m3/h]
4.2 Wear parts Head: 90 m Friction losses: 0 m
Please note that P4 is the hydraulic effect produced Fig. 23
Depending on the pumped media and the number of by the pump. P [kW] NPSH
[m]
years a pump has been in operation, a service inspec- 16
P1
8

tion of the pump is recommended. This includes re-

P4 : Hydraulic effect
12 6
placing all wear parts in the pump. The recommend- P2

ed service parts are: 8 4

NPSH
• bearings, radial 4 2

• valve seat 0 0

• neck rings 0 10 20 30 40 50 60 Q [m3/h]

• seal ring Fig. 21 Total head calculation Fig. 24
• upthrust ring.
When estimating the flow demand, the well yield Figures 23 and 24 Pump performance parameters
If extensive wear from sand has occurred in the must also be taken into consideration. Information P2 : Motor shaft power (=P3) including tolerances
pump, replacing the pump shaft and impellers may regarding the well yield is available from the well
also be necessary. drillers test report, which is made during well de- In the data booklet, information regarding pump ef-
velopment. If possible, the necessary flow must be ficiency is also available, and it can be shown as the
Renewing the wear parts in case of service is essen- reduced as much as possible. This will minimise the pump-end efficiency (based on P2 ) or as a complete
tial for maintaining a high pump efficiency and a low water table drawdown, and reduce total power con- pump efficiency including the motor (based on P1).
operating cost. sumption in terms of kwh/m3. In some cases, loses in non-return valves are not in-
cluded in the efficiency shown. The efficiency curves
For further service information, see the Grundfos P1 : Motor input power are used for the selection of pump size, where the
service instructions. best efficiency area matches the required flow. If the
complete pump efficiency is not shown, it can be cal-
Fig. 22 Power definitions culated by using the flow (Q), head (H) and power
4.3 Pump selection input P1:
Selection of a pump starts with estimating the flow Normally the power consumption is also shown as a
and pressure. The total head is the sum of the follow- function of the flow.
ing etatotal = (Q x H x 9.81)/( P1 x 3600)
• dynamic water table (1)
• lift above ground (2) The NPSH value stands for “Net Positive Suction
• discharge pressure (3) Head” and is a measure for required inlet pressure =
• losses in pipes, valve and bends (4) minimum water level above pump inlet.

In general, the NPSH value will increase for bigger

28 29
 Pumps Pumps

flows and if the required inlet pressure is not met, it

will result in evaporation of the water and a risk of
cavitation damage in the pump.

In general, there are many different local standards

for tolerances on performance curves. Pump per-
formance for Grundfos SP pumps is shown accord-
ing to ISO 9906, Annex A. QH curves printed in the
documentation show the nominal curve. According
to ISO 9906, Annex A, power curves only have an up-
per tolerance. For efficiency curves, only lower toler-
ances are shown. Please see the example shown in
fig. 23 and 24 above. The general conditions accord-
ing to ISO 9906 for the performance curves in this
illustration are:
• The measurements are made with airless water at
a temperature of 20  °C.
• Curves apply to a kinematic viscosity of
1 mm2/s. When pumping liquids with a higher
density, a higher motor output is required.

In addition to QH, Q-P, Q-eta curves, an axial load

curve is normally also available on request. The down
thrust load is created by the hydraulics and trans-
ferred to the motor thrust bearing. The total axial
load is calculated by multiplying the single-stage val-
ues by the number of stages. It can be used to check
whether the capacity of the motor thrust bearing is
sufficient.

( 5(|Ž‹†…7
ñêê
-* ðêë
ðê "‘
ïêðê "‘
ðêê

ïêê
ïê "‘
îêê

íêê

ìêê

ëêê

ê
ê ëê ìê íê îê ïê ðê ñê òê + 5„í7

ê ì î ð ò ëê ëì ëî ëð ëò ìê ìì ìî + 5ƒŠ7

Fig. 25 Single-stage axial-load curve, SP 60

30 31
 Motors and controls

5.1 Motor types, general description tors, few have plug systems. Oil-filled motors incor-
This chapter deals exclusively with submersible mo- porate a ball-bearing system.
tors, and controls for submersible motors. Submers-
ible motors are special because they are designed to Single-phase motors
run underwater. Otherwise, their operating principle There are several versions of single phase motors.
is the same as all other electric motors. They all have their distinctive advantages and disad-
vantages. Most types need a capacitor and some oth-
Please note that all Grundfos 4”, 6”, and 8” motors er accessories, which is built into a starter box. The
conform to NEMA standards. starter box is dedicated for starting a given motor at
specific voltage and frequency.
A submersible motor consists of a motor body and a
motor cable. The cable is detachable in a plug system. Permanent-split capacitor (PSC) motors
The cable is dimensioned for submerged use in order Simple and reliable, PSC motors have a run-type ca-
to minimise the spatial requirement along the pump. pacitor included in the circuit. The capacitor size is a
The motor cable is connected to the drop cable above compromise between adding starting torque and en-
the pump by use of a cable termination kit. The drop suring a high efficiency during operation.
cable used to raise and lower the pump. Pros: Simple, low-cost, reliable and silent.
Cons: Low locked-rotor torque and low efficiency.
Canned
In a canned motor, the windings are enamel wire (like PSC
in standard surface motors) hermetically sealed from L L
the surroundings and filled with embedding ma-
N N
terial in order to withhold the windings and at the
same time increase heat transfer. These motors have PE PE
a journal bearing system, consisting of upper and
lower radial bearings as well as upthrust and down-
thrust bearings. Thrust and journal bearings run hy-
drodynamically in the water-based motor liquid.
Switch

Wetwound (rewindable) Overload

Capacitor star
Wetwound motors have a special water resistance Capacitor Induction run
0,37 ... 0,75 kW
wire, and a watertight joint between the windings
and the motor cable. The joint is always inside the
motor, and no plug system is available.

The motor liquid mainly consists of clean water. The

liquid circulates around the entire motor, transfer-
ring heat away from windings and rotor and lubricat-
ing the bearing systems.
Lightning Main
arrestor
Oil-filled (optional)
An oil-filled motor is equipped with an impregnated Start

standard surface motor winding. Transformer oil is

filled into the motor and used as lubricant and cool-
ing. The oil can be mineral or vegetable oil with high Fig. 26 PSC
insulation resistance. The motor cable splice is typi-
5. cally made inside the motor as in a wetwound mo-

Motors and controls

32 33
 Motors and controls Motors and controls

Capacitor-start/induction-run (CSIR) motor Capacitor-start/capacitor-run (CSCR) motors Resistance-start/induction-run (RSIR) motor 3-wire motors:
The start-up capacitor boosts the torque during start This motor type has both a starting capacitor to This motor has a relay built directly into the motor • PSC motors if there is a capacitor in the starter box
up. Then it is disconnected by a switch. The CSIR mo- boost starting torque, and a run capacitor (PSC). This winding. The relay disconnects the starting phase on the ground.
tor type is typically used for smaller kW ratings. ensures a smooth operation and a good efficiency. when the motor is running. •  CSIR motors
Pros: Locked-rotor torque. The motor type combines the advantages of both of Pros: No need for capacitors (no control box), ease of •  CSCR motors
Cons: Noisy operation (true single-phase), relay the above types. installation.
needed to cut out the start-up capacitor. Pros: Good starting torque, high efficiency. Cons: Limited starting torque, limited kW ratings Motor derating
Cons: Price of control box. (only through 1.1 kW). Motor derating is where there are special require-
CSIR CSCR RSIR
ments to the motor, such as high water tempera-
L CSIR CSIR L CSCR CSCR L RSIR RSIR ture, voltage tolerances outside of acceptable in-
L
N L L
N L L
N L terval, or voltage unbalance. All of these situations
stress the motor winding more than what it has
N N N N N N
PE PE PE been designed for.
PE PE PE PE PE PE
The simplest solution is to use an oversized motor,
typically not more two output sizes above the re-
quired output. The result is an extended lifetime, but
Switch
Relais Relais the efficiency is not optimal, since the motor never
Switch Switch
Capacitor start Start
Relais
cap. Relais Capacitor start Start
Relais
cap. Relais operates at its optimal duty point. The power factor
Induction run Capacitor run
Capacitor start
0,37 ... 0,75 kW Capacitor start
Start
cap.
Start Capacitor start
1,1 - 3,7 kW Run
Capacitor start
Start
cap.
Start is normally be low due to the partial load on the con-
cap. cap. cap.
Induction run Induction run Capacitor run Capacitor run struction.
0,37 ... 0,75 kW 0,37 ... 0,75 kW 1,1 - 3,7 kW 1,1 - 3,7 kWRun
cap.
Run
cap.

A better solution is to have a motor specially wound

in a larger stack length. Due to the increased sur-
face, the electrical data and cooling capability are
improved. These motors are designed for higher tem-
Tmac
Lightning peratures, wider voltage tolerances, etc. Also, the ef-
arrestor Tmac Tmac
Lightning Lightning
ficiency of a standard motor is maintained or even
Main Main Overload
arrestor Main
arrestor increased.
Bimetal
Main Main Main Main Overload Overload
Main Main
Start Start Bimetal Bimetal
Start

tart Start Start Start Start

Start Start
5.2 Motor cables and joints, reference
to drop cables
Fig. 27 Schematic diagram of a CSIR motor Fig. 28 Schematic diagram of a CSCR motor Fig. 29 RSIR motor Submersible pump installation are designed to be
used with the submersible motor, the motor cable
Terminology; 2-wire and 3-wire motors and the joint between motor cable and drop cable
The terminology is related to the number of wires underwater. If for any reason the motor cable is not
needed in the installation excluding earth cable. 2- fully submerged, the current-carrying capacity must
wire motors must be supplied by three leads : phase, always be checked. See chapter 7.5 as well.
neutral end earth. 3-wire motors must be supplied by Therefore, the motor cable, joint and submerged part
four leads: phase, neutral, point between start- and of the drop cable have a relative large surface area
run- winding in motor + earth cable. that is in contact with the pumped media. It is im-
portant to choose the correct material for the given
2-wire motors: installation. You must also be aware of your local
•  PSC motors a capacitor is built into the motor. drinking water approval requirements.
•  RSIR.

34 35
 Motors and controls Motors and controls

5.3 Motor protection devices are several ways of reducing the impact on the mains, Type Reduced Price Features in Space Customer Reliable Reduced pressure surge Energy sav-
locked-rotor relation to requirement friendly ings during
The same type of motor-protective devices used for however not all of them are relevant to pumps. This current price
Mechanical Hydraulic
operation
standard surface motors can be used for submers- section covers several different ways of reducing the DOL No Low OK Low Yes Yes No No No
ible motors. It is important to secure and limit short- locked-rotor current, and information about running SD
circuiting currents and protect against phase-failures submersible pumps with frequency converters. Below 45 kW No Low Low Low Yes Yes No No No
above 45 kW Yes Low OK Low Yes Yes No No
as well as overload. AF Yes Medium OK Medium Yes/No Yes Yes/No No No
The following applies to radial and semi-radial RR
Most single-phase motors have a built-in thermal pumps, including Grundfos SP pumps. Axial pumps SS Yes Medium OK Medium Yes/No Yes/No Yes No Yes/No
FC Yes High OK Medium/ Yes/No Yes/No Yes Yes/No Yes/No
protector. If the protector is not built into the wind- are however not dealt with here. high
ing, it must be incorporated in the starter box. The
protectors feature automatic or manual reset. Ther- As the locked-rotor current of a pump motor is often
mal protectors are designed to match the motor 4-7 times as high as the rated current, there will the DOL motor starter gives the highest locked-rotor Example:
winding characteristics. be a considerable peak load of grid and motor for current, it will cause minimal grid disturbance. x operating current
a short period. In order to protect the grid, many
6
Pt100 and Pt1000 are linear resistors. Combined with countries have regulations for reducing the locked- Lots of submersible pumps use long cables, however.
a standard sensor device, they can indicate the tem- rotor current. Normally it is given as a maximum These long cables automatically trigger a reduction of
5
perature development over time. On canned-type load in kW or in Amps allowed to start Direct on Line the locked-rotor current due to the simple physics in-
motors, the sensor device is placed in the staybolt (DOL); The maximum load allowed varies quite a lot volved, as the resistance in the cable reduces the cur- 4
hole; on wet-wound versions, the sensor device is throughout the world, so you must be certain that rent. If, for example, the cable is long and designed for
Power consumption
placed in the motor liquid. you adhere to your local regulations. In some cases, a voltage drop of 5 % full load (amps), a reduction of 3
at startup

only specific methods for reducing the locked-rotor the locked-rotor current will occur automatically. The
Operating
PTC and NTC resistors are rarely used in submersible current are allowed. example below illustrates this point. 2
current
installations because they are not sufficiently fast
and reliable to protect the submersible motor. The following types are described in the following: 1

Grundfos offers a special temperature sensing device DOL - Direct-on-line 0

0 1/10 second Time
called Tempcon. It is a NTC-resistor built in near the SD- Star-delta
winding, and senses the temperature. The tempera- AF - Autotransformer Sine
periods
ture is converted into a high-frequency signal, trans- RR – Resistor starter
Typically 3 to 5 periods
mitted to the control panel by means of power-line SS - Soft starter
communication. From the control panel, the signal FC - Frequency converter
can be picked up by a signal converter, transmitted Before a choice is made, application, requirements Fig. 30 Current flow by DOL starting
to the MP 204 control panel and indicated as a tem- and local standards must be considered.
perature on the MP 204 control panel display. MP 204
is a advanced motor protector designed for the pro-
tection of the submersible motor against net distur- 5.4.1 Direct-on-line – DOL
bances. In DOL starting, the motor is coupled directly to the
grid by means of a contactor or similar. Assuming all
other aspects to be the same, DOL starting will always
5.4 Reducing the locked-rotor current give the lowest generation of heat in the motor, con-
The purpose of reducing the locked-rotor current is sequently providing the longest life span of motors up
to protect other equipment against power surges in to 45 kW. Above this size, the mechanical impact on
connection with high power loads. This also protects the motor will be so considerable that Grundfos rec-
the piping against excessive pressure surges. There ommends current reduction. Furthermore, although

36 37
 Motors and controls Motors and controls

5.4.2 Star-delta – SD Things are somewhat different for centrifugal pumps 5.4.3 Autotransformer – AT 5.4.4 Primary resistor-type starter, RR
The most common method for reducing the locked- with a greater diameter and mass, as they conse- In this starting method, the voltage is reduced by In this starting method, the voltage is reduced by
rotor current for motors in general is star-delta quently have a higher moment of inertia. Remember means of autotransformers. This principle is also means of resistors put in series on each motor phase.
starting. During start-up, the motor is connected that star operation for too long may result in consider- called the Korndorf method.
 †‡|‰x‹€…~ zŒ‰‰|…‹ The function is to increase the resistance during the
for star operation. When the motor is running, it able motor heating and a reduced life time as a result. start thus limiting the locked-rotor current flowing.
is switched over to delta connection. This happens ð A correctly dimensioned starter will reduce the start-
automatically after a fixed period of time. During Submersible installations with SD starters will often ing voltage (on the terminals of the motor) to ap-
*†Ž|‰ z†…ŠŒ„‡‹€†…
start-up in star position, the voltage on motor ter- be more expensive than other similar installations. ï
x‹ Š‹x‰‹Œ‡ proximately 70% of the line voltage.
minals is reduced to 58 % of the nominal starting Two supply cables (6 leads) are required for the mo-
voltage. This starting method is very well known in tor instead of one (3 leads) in the normal situation. î
The starter is cut out by means of a timer controlling
the market and relatively cheap, simple and reliable, The motor must also feature two sockets, making it a contactor which means that the reduced voltage
í
which makes it very popular. typically 5% more expensive than a traditional, sin- will only be present for the predefined time and that
x operating current
gle-socket motor. )‡|‰x‹€…~ the motor is energized the entire time.
ì
zŒ‰‰|…‹
6

Never have resistors connected for more than 3 sec-

ë
Power consumption .ë
5
at startup
onds, as it will reduce the starting torque with conse-
quently increased winding.
ê
4 ê ëëê Š|z†…{ .€„|
&ë .ë

Fig. 34 Current flow by autotransformer starting

,-#-.),
3
.î.ï.ð
Operating &ì .ì
2
current When the motor is to be started, it is first connected ,-#-.),
.í
to a reduced voltage, with full voltage following after- í *"-
1 ').),
.ì wards. During this switchover, part of the autotrans- &í .í
former is connected as a choke coil. This means that ,-#-.),

0
0 Time the motor will be connected to the grid the entire
time. Motor speed will not be reduced.
Fig. 31 Current flow by SD starting Fig. 32. Wye eonfiguration at start-up The power consumption when starting can be seen Fig. 36. Typical electrical diagram for a primary resis-
from fig. 34. tor reduced voltage starter
For SP pumps, and in general for pumps with a low After a pre-determined time, the starter electrically
moment of inertia, SD starting is not recommended switches the windings over to the Delta Configura- Autotransformer starters are relatively expensive, 5.4.5 Soft starter – SS
due to the fact that speed is lost during switching tion, shown in fig. 33. but very reliable. The locked-rotor current naturally A soft starter is an electronic unit which reduces the
from Y/D. A submersible pump goes from 0 to 2.900 depends on the characteristics of motor and pump, voltage and consequently the locked-rotor current
rpm within three cycles (0.06 s)! This also means that and varies considerably from type to type. by means of phase-angle control. The electronics
the pump stops immediately when the current is dis- .ë.ï unit consists of a control section, where the different
connected from the mains. Never have the autotransformer in the circuit for operating and protective parameters are set, and a
more than 3 seconds. power part with triacs.
When comparing the DOL and star-delta locked-ro-
tor current, star-delta starting reduces the current &ë
òê
ðï
ïê .ë
The locked-rotor current is typically reduced to 2-3
at the beginning. When switching over from star to times the operating current.
delta, the pump slows considerably, almost stopping .í.î .ì.ð
&ì
òê
ðï
ïê
.ì

completely. Afterwards, it has to start directly in delta .í

í *"-
').),

(DOL). The diagram shows that there is no real reduc- &í

òê
ðï
ïê

tion of the locked-rotor current.

Fig. 33. Delta Configuration motor Fig. 35 Typical electrical diagram for an autotrans-
former reduced voltage starter

38 39
 Motors and controls Motors and controls

Torque quency converters are the cheapest on the mar-

A new series/generation of soft starters has been in- ket, and are often employed.
troduced. They are equipped with a programmable
Operating
start ramp function for reducing the locked-rotor • The next step is the Vector-Controlled frequency
Start-up Stop
100%
current further, or for ramping high inertia loads. If converter. This frequency converter uses a model of
such soft starters are used, please use ramp times the motor, and calculates the output voltage based
55%
of max. three seconds. In general, Grundfos recom- on several parameters including the actual load. This
mends that you always install the soft starter with gives higher performance in controlling the shaft of
0
0
Max. 3 sec. Max. 3 sec.
Time a bypass contactor, enabling the motor to run DOL the motor, such as a higher accuracy of min-1, torque,
during operation. In this way, wear and power loss is etc. These drives are more expensive than the U/f
Fig. 37 Recommended start-up and stop time, max. 3 sec.
 †‡|‰x‹€…~ zŒ‰‰|…‹ avoided in the soft starter during operation. Fig. 39 Pump performance with different frequencies based drives, and are typically used for industrial ap-
x operating current
plications. However, they are also used in systems
ð
Please note that if ramping down is required, it might 1,5 where instabilities often occur. The more precise way
*†Ž|‰ z†…ŠŒ„‡‹€†… not be possible to use the bypass contactor solution 1.4 of controlling the shaft normally eliminates the prob-
ï 1.3
x‹ Š‹x‰‹Œ‡ for reducing the power consumption during normal lems caused by an instable pump, The vector-control-
1.2
operation. 1.1
led drives usually have a higher efficiency, or an auto-
î
1,0 matic energy optimizer function.
í
We recommend the use of frequency converters if 0.9 Operating
0.8 current
other ramp times are required. 0.7
The output section of a frequency converter can be
ì
)‡|‰x‹€…~ 0.6 made in two different ways: either with six or with
zŒ‰‰|…‹
Temperature readout of Grundfos motors with tem- 0.5 12 transistors.
0.4
ë perature transmitters is possible if the soft starter
0.3
has a bypass contactor. 0.2 This can also be referred to as 6-pulse and 12-pulse
ê 0.1 inverters. Six transistors are the most commonly
ê 'x í Š|z†…{ .€„| Soft starters may only be used on 3 phase submers- 0
found solution, as it is the cheapest and the sim-
0 3 seconds Typical start-up 30 seconds
Fig. 38 Current flow by soft starting ible motors. min. 30 Hz plest way of creating an output stage. To reduce the
Max. time for reduced voltage shall be limited not to Fig. 40 Current flow by frequency converter starting stress on motor insulation and increase the control
Other things being the same, this also gives a reduced exceed 3 seconds. performance, the 12-transistor output stage was
starting torque. The slow start may result in an in- Frequency converters are the most expensive of the introduced. 12-transistor operation is typically com-
creased heat generation in the motor, leading to a re- above-mentioned starting devices, and will primarily bined with advanced controls that are based on flux
duced lifetime. With short acceleration/deceleration 5.4.6 Frequency converters (variable be used in connection with operation at variable per- models of the motor. The advantage of a 12-transis-
times (such as three seconds), this is of no practical speed drive) formance. tor solution usually includes improved control at
importance. The same goes for SD and AT starting. low speeds and less stress on the motor. A 12-pulse
Frequency converters are the ideal device to control There are several types of frequency converters on frequency converter lies in the expensive range of
Grundfos therefore recommends following the accel- the performance of the pump, by adjusting the speed the market, each having its own characteristics. A frequency converters.
eration/deceleration times stated in the figure when of the motor. It is therefore also an ideal starter type, brief overview is presented here:
using a soft starter. It should not be necessary in con- both for reduction of the locked-rotor current and for The main selection factor for combining frequency
nection with Grundfos pumps to raise the starting reduction of pressure surges. • The simplest frequency converter is based on a converter and pump is the full load amps including
voltage above 55%. However if a particularly high voltage frequency curve. This converter is some- the overload factor. The frequency converter should
starting torque is required, the starting voltage may Note: a low frequency produces slow impeller rota- times called an U/f or V/f converter. They calcu- be chosen so it can deliver the required current all
be increased to achieve the required torque. tion, reducing pump performance. late the actual output voltage from the frequency, the time. For example, if the motor requires 9.7 A,
without taking the actual load into considera- chose a frequency converter with and output cur-
A soft starter will absorb a non-sinusoidal current tion. Different U/f or V/f curves can be chosen to rent at 9.7 A or higher.
and give rise to some grid noise. In connection with optimise for the actual application. Pumps will
very short acceleration/deceleration times, this is of typically use the Variable Torque curve. These fre-
no practical importance and does not conflict with
regulations concerning grid noise.

40 41
 Motors and controls Motors and controls

5.5 Operation with frequency vent electrical disturbances from the frequency If the points discussed above are met, the motor will 5.6 CUE variable speed drive for SP
converter converter from affecting other equipment on the have an acceptable lifetime. pumps
same mains. Normally there are three different
There are several things that should be considered levels of filters to select among: Please note that external frequency converters result
when using frequency converters together with sub- • No filter (Only for industrial use where filtering in power loss and transmits transients, they will:
mersible motors. Some of the conditions for running is done elsewhere)
submersible motors on frequency converters are • Filters for industrial applications • g enerate more heat in the motor compared to di-
found below. • Filters for domestic applications. rect on line operation
The version for domestic applications can be an • reduce the motor efficiency
1a. The frequency converter must have some kind of add-on for the industrial application, or it can be a • increase the power consumption of the motor.
output filter to limit voltage peaks (Upeak) and separate version. Because of this, an industrial motor should always
to reduce dU/dt (or dV/dt) which courses stress be used, as it has been built to compensate for these
on the insolation of the submersible motor. The It is mandatory to fulfil the requirements in the disadvantages.
maximum voltage (Upeak) should be reduced to a manuals for the frequency converter for keeping
level of less than 850 V (except for the MS 402); the CE mark on the product. If this is not done As far as the operating economy is concerned, the fol-
dU/dt should also be limited in accordance with properly the CE marking is not allowed. lowing should be taken into consideration:
the following table. • Frequency control of deep well submersible pumps
2. The flow rate past the motor must be at least will normally not result in improved operating
Max peak voltage and max dU / dt for Grundfos submersibles 0.15 m/s. The motor must be fitted with a cooling economy when installed in a well.
Motor series Max. Upeak voltage Max. dU / dt sleeve if the pumping does not create sufficient • It does, however, reduce the need for large tanks
MS402 650 V Phase - Phase 2000 V / micro s. flow past the motor. and space for these.
MS4000 850 V Phase - Phase 2000 V / micro s. • Frequency control of raw-water pumps reduces
MS6/MS6000 850 V Phase - Phase 2000 V / micro s. 3. With control of submersible motors in open sys- pressure surges in the pipe system and variations
MMS6/MMS6000 850 V Phase - Ground 500 V / micro s. tems with high static lift, the power consumption of the water level in the well at pump start and
MMS8000 850 V Phase - Ground 500 V / micro s. will change only moderately. This means that a stop.
MMS10000 850 V Phase - Ground 500 V / micro s. reduction of the pump performance will give in-
MMS12000 850 V Phase - Ground 500 V / micro s. creased generation of heat in the motor. A reduc- However where some kind of control is needed such as Fig. 41 CUE family
tion of the motor lifetime must therefore be ex- constant pressure, constant well water level, or simi-
 he typical output filters for frequency convert-
T pected. For operation with a frequency converter, lar, there might be different levels of improvement in CUE is a Grundfos frequency drive with a logical in-
ers are LC (also called sinus filters) or RC filters. Grundfos therefore always recommends using a using frequency converters. A frequency converter in- terface for easy setup and operation.
Frequency converter suppliers can supply data motor with spare capacity, i.e. an industrial motor cludes some logic input and output. It also typically in-
regarding Upeak and dU/dt for their different fre- or a derated standard motor. cludes a PID control section, for establishing control of With a CUE, it is possible to control pump perform-
quency converter series. Please see chapter 5.6. the application. In many cases additional equipment ance by changing the frequency. This allows you to
4.  The motor frequency: can be omitted, and the use of the frequency convert- program a smooth start up and stop of the pump.
 ormally, filters are also required if long motor ca-
N min.: 30 Hz er as a starter and as a part of the control system will This minimises the risk of damages on the pressure
bles are to be used together with the frequency max.:60 Hz improve the overall economic perspective. pipe and the entire pressure piping system. It also re-
converter. duces the stress from water hammer while minimis-
5. Temperature protection of Grundfos submersible The PID controller is widely used in control applica- ing the costs for valves and other regulating devices.
 he Upeak and dU/dt values should be measured
T motors with frequency converter is possible for tions, and frequency converter manufactures normal-
on the motor terminals. motors with a built-in thermocontacts. The motor ly gives some hints about how to optimize the use of Operation below 30 Hz is acceptable for no more
temperature cannot be read, but the protection is this feature. than three seconds. Above 30 Hz, there is no limita-
See table above for acceptable values of dV/dt. the same. An additional cable is required for the Please be aware of that an incorrectly programmed tion regarding operation time. This must always be
motor, but as operation of submersible motors PID controller could lead to an instable performance observed however, both during ramp-up and ramp-
1b. Frequency converters are normally designed for by means of frequency converters is usually used and excessive pressure on the system. down sequences.
use in an industrial environment. If a frequency in connection with tank application, this will not
converter is used in residential areas, it might be cause disturbances or additional costs. Please note that the ramp-up time to a minimum fre- The max. frequency is 60 Hz.
necessary to add some kind of input filter to pre- quency of 30 Hz may not take longer than 3 seconds.

42 43
 Motors and controls Motors and controls

The set-up data for the CUE is always current, and Mains cable Filter selection Setting guidelines
not kW, since submersible motors are often different This cable runs from the mains supply to the CUE Fig. 44 below shows how to select the correct filter • Ramp (up and down): maximum 3 seconds. This
from norm motors. unscreened. The cable between CUE and filter is for the installation. is to ensure the lubrication of journal bearings to
screened. The cable running from the filter to the limit wear, and prevent the winding from becom-
Functions pump motor is normally unscreened. The two exam- ing burnt out.
How to chose a
The CUE allows you to maintain the following pa- ples illustrate these setups. filter • Use temperature monitoring by PT100 (use of
rameters: screened cable can be needed).
• Constant pressure If the cable is used outside the well in a dry environ- • Heat kills the motor => low isolation resistance
• Constant level ment, a screened cable may be used with a cable con- => sensitive to voltage peaks.
• Constant flow rate nection to the submersible pump cable at the well Is the pump an • Motor recommendations:
SP/BM or BMB
• Constant temperature head. fig. 42 below shows how a cable selection can – For MS: use motors with 10% extra in given
• Constant curve. be used together with CUE and a filter. In the second duty point.
example, the connection box is located at the well – For MMS: always use motors that are PE2 – PA
Power cable head. NO Cable length YES wound.
A submersible pump power cable in a screened ver- <150m and • Remember to use a LC filter.
p> 11 kW
sion is not available. Normally, it is not required ac- Further information may be found in webCAPS on • Reduce peaks to max. 800 V.
cording to the EMC regulations due to the submerged www.grundfos.com. • Grundfos recommend Danfoss frequency invert-
installation. Use sine wave er, in combination with a LC filter.
Use dU/dt filter
filter
• Cables act as amplifiers => measure peaks at the
motor.
Fig. 44 Setting guidelines • Dimension it with respect for the current and not
the power output.
• Dimension the cooling provision for the stator
The main difference between dU/dt filters and sine tube at duty point with lowest flow rate. The
wave filters is: minimum flow m/s along the stator housing
CUE and Filter mounted close to well Both filters consist of coils and capacitors. The coils must be considered.
and the capacitors are small in value in the dU/dt fil- • Assure that the pump is used within the intend-
Unscreened cable screened cable Unscreened drop cable
Mains CUE Filter M ters compared to the values used in sine wave filters. ed range of the pump curve.
• Focus on the discharge pressure and sufficient
Grundfos offers a full range of filters to be used with NPSH, as vibrations will kill the motor.
Fig. 42 Submersible pump without connection box CUE.

screened screened Unscreened

Unscreened cable cable cable drop cable
Mains CUE Filter
Connection
box* M

* Both ends of the screened cable from the filter to the connection box must connected to earth

Fig. 43 Submersible pump with connection box and screened cable

44 45
 Power Supply

6.1 Power generation

The following will only focus on alternating current 6.2.2  Overvoltage and undervoltage
(AC) as this is the primary source of power for asyn- Power lines are expected to deliver a specific voltage.
chronous motors. Near the low voltage transformer, there will often
be an overvoltage of 3-5%. When the power lines are
Distribution loaded, a voltage drop will occur due to ohmic resist-
In order for generated power to be useful, it must be ance in periods of peak power consumption.
transmitted from the generating plant to the area
where consumption takes place. The challenge is to Most power lines are dimensioned so that undervolt-
have sufficient amount of energy available at the age of more than -10% will occur less than once a
time and place where work is demanded. year at the weakest point. But many consumers still
experience periods of considerable voltage drop.
The most efficient way to transfer energy from gen-
erating plant to consumption places is to increase Any motor will suffer if it does not receive the voltage
voltage while reducing current. This is necessary in stamped on the nameplate. If the voltage drops, the
order to minimize the energy loss as consequence motor torque will be reduced and the speed of the
of transmission. These losses are referred to as I2 x R loaded motor will consequently be reduced, too.
losses, since they are equal to the square of the cur-
rent times the resistance of the power lines. Once the As a result of this, the efficiency and induction resist-
electrical energy gets near the end user, the utility will ance of the motor will drop. This will make the power
need to step down the voltage to the level needed by consumption increase, resulting in increased genera-
the consuming machine. Each time, the voltage level tion of heat in the motor.
is changed, energy is lost, even in the most efficient
transformers. When a fully-loaded centrifugal pump motor receives
10% undervoltage, the power consumption will in-
6.2 Voltage crease by approx. 5%, and the motor temperature by
about 20%. If this temperature increase exceeds the
6.2.1  Voltage unbalance maximum temperature of the insulation material
Submersible motors are designed to operate on pow- around the windings, these will be short-circuited
er lines with given voltage and frequency. and the stator will be destroyed. In the submersible
motor, the temperature of the motor liquid is very
Voltage unbalance can be regulated at the regulating important for the lubrication of the journal bearings.
board of the transformer and/or the generator. The The load capacity as function of the temperature can
voltage unbalance shall be kept as small as possible, be seen on the diagram below.
as it is the primary source of current unbalance. This
&†x{  &†x{ zx‡xz€‹ †} Žx‹|‰ ƒŒy‰€zx‹|{ y|x‰€…~ Š ‹|„‡|‰x‹Œ‰|
leads to the creation of additional heat in the motor. ëêê

óê

òê

One possible cause of voltage unbalance is the un- ñê

equal distribution of single phase loads. These loads

ðê

ïê

vary over time. Voltage unbalance is subsequently îê

íê

very difficult to avoid if the net contains high per- ìê

centage of single phase consumption.

ëê

ê
ê ìê îê ðê òê ëêê

.|„‡|‰x‹Œ‰| ?

Use of two single phase transformers in so called

“open delta” connection is not recommended for Fig. 45 Diagram: Journal bearings load capacity as
6. three phase supply. function of motor liquid temperature.

Power Supply

46 47
 Power Supply Power Supply

This is critical if the motor is placed in a hot environ- It is customary to derate a standard motor to ensure Variable frequency drives (VFDs) are used to create Current:
ment and is badly cooled, or in case of voltage asym- long life if overvoltage or undervoltage of more than a “new” local net with a frequency different from Please note that dimensioning of variable frequency
metry, current asymmetry or voltage transients at +6/-10% can be expected at the motor cable entry. what the supply company is providing. This allows drives is done from the current value of the motor
the same time. Single-phase motors will often require capacitor the frequency and the motor (and pump) speed to – and that a submersible motor has higher current
adaption when exposed to low voltage supply. be regulated. values than similar output surface motor.
Usually, an increased winding temperature caused by Modern frequency drives can regulate in an interval
undervoltage will lead to faster aging of the insula- 6.3 Frequency between 0 and 400 Hz (or even more). Please remem- 6.5 Grid connection
tion, resulting in a reduced life. The frequency should always be kept at the nominal ber, as the speed goes up the load is also increasing Before connecting to grid, the characteristics of the
value. If the frequency is higher, the pump may over- eventually leading to risk of overloading the motor if grid shall be known: How is the quality of the net,
In case of overvoltage from the grid, the power con- load the motor. If the frequency is lower, pump per- not dimensioned correctly. what kind of earth is used and how good is the surge
sumption and heat generation in the motor windings formance will drop. and lightning protection?
will increase as well. Another important issue to remember is that the
„‡Š 6.4 Variable frequency drives frequency drive must not be used to boost voltage. • What voltage will be supplied and with what toler-
In order to make rational electric power distribution When you regulate the voltage, the frequency must ances?
îê utilities have agreed to use same frequency. This en- remain constant. • What frequency will be supplied and with what
able direct connection of different nets under condi- tolerances?
tion that the frequency and sequence of this is the Practical example: • What power is at disposition?
íê
same. Given net = 400 V, 50 Hz • How often can grid disturbances be expected?
The dominant frequencies used in the world today In order to have bigger regulation area, you choose • Is an own transformer foreseen or will a common
ìê are 60 Hz and 50 Hz. to dimension the pump set for 60 Hz operation. This transformer be used? If a common transformer is
gives recommended regulation area from 30 – 60 Hz. used, ask how even load of the net is assured (only
ëê
The frequency determines the speed of an asynchro- Hence you are not to boost voltage you have to applicable for 3-phase motors).
nous motor. Unfortunately it is very difficult to cal- choose a motor suited for running at 400 V, 60 Hz
culate exactly the speed of an asynchronous motor. (practically this will lead into choosing a 380 V, 60 Hz The supply from the grid to the motor is normally re-
ê
ëðê ëòê ìêê ììê ìîê ìðê ìòê 0†ƒ‹
This is determined by the speed of a synchronous motor hence this is a standard). ferred to as the net supply. Net supply is the power
motor minus the slip. line having the voltage for machine uses. Net quality
Fig. 46 Current variation as a function of over- and Filters: we divide into so called “stiff” or “soft” net.
undervoltage on a 230 V motor. Slip is defined as the difference in speed between Variable frequency drives is based on a technology
rotor and stator field. The slip is the product of the that switches (chops) in and out the voltage. This A given grid voltage is transformed into appropriate
Conclusion resulting torque – this means the greater the load, means that the resulting output from a variable fre- net voltage by use of a transformer.
1. For voltage variations of +6/-10% of the rated value, (torque) the greater the slip. In other words, the slip quency drive is only partly a sinusoidal curve. The The cheapest way of transforming a given grid volt-
measured at the motor terminals, normal life can of an asynchronous motor is load dependent. result is generation of noise on primary as well as age into appropriate net voltage is done through a
be expected when the power consumption is equal secondary side of the variable frequency drive. The so called autotransformer. Please note that this is not
to or less than the rated current stamped on the The synchronous speed can be calculated by use of primary side is regulated by authorities and/or utili- possible in all countries.
nameplate and if the motor cooling is sufficient and following formula: ties and demands RFI filter solutions. On the output
no transients or asymmetry occur. side, the challenge is the length, the type, the size and In order to protect the submersible motor, you need
2. For short/periodic voltage variations exceeding how the cables are placed in the installation. Long ca- a device that can isolate the motor from the net/grid
+6/-10% of the rated value, the reduction in life will Ns = 120 x f   bles increase the risk of creating high voltage peaks supply in case of problems. Grundfos recommends
P
be moderate until undervoltage/overvoltage varia- leading to deterioration of the insulation system of the use of electronic motor protector device MP 204.
tions are so considerable that the stator windings Ns = the speed of the rotating magnetic field. the submersible motor.
are short-circuited. 120 = constant.
3. With permanent or long lasting voltage variations f = frequency. Grundfos recommends the use of LC filters on the
exceeding +6/-10%, the motor should be derated or P = number of poles. secondary side of all variable frequency drives. If the
a Grundfos oversize motor chosen in order to ob- supplier of a VFD with a given cable configuration
tain acceptable life and efficiency. Control of motor will issue assurance that Upeak for given motor is
temperature is by use of Grundfos MP 204 electron- not exceeded at motor terminals this can be accept-
ically motor protector is always recommended. ed. See the table on page 42.

48 49
 Power Supply Power Supply

6.6 Current asymmetry Example ductors on one side of the riser pipe and then have
Low current asymmetry gives the best motor efficien- See the diagram in fig. 45 and the table below. Current unbalance
the earth lead diagonally opposite.
cy and longest life. It is therefore important to have Step 1 Connection 1 Connection 2 Connection 3 %
all phases loaded equally. Before measuring takes UZ 31 A Z 30 A Z 29 A Voltage transients / lightning
VX 26 A X 26 A X 27 A
place, it should be checked that the direction of rota- WY 28 A Y 29 A Y 29 A 60
Power lines are supposed to deliver sinusoidal shaped
tion of the pump is correct, i.e. the one which gives Totally 85 A Totally 85 A Totally 85 A waves on all three phases. The sinusoidal shaped
the highest performance. The direction of rotation Step 2
Average current:
Total current
=
85 + 85 + 85
= 28.3 A 50
waves produced at the power station are added to
can be changed by interchanging two phases. The 3x3 3x3 the transients in the distribution system.
current asymmetry should not exceed 5%. If there Step 3 Max. amps. difference from average:
40
Connection 1 = 31 - 28.3 = 2.7 A
is a MP 204 connected, 10% will be acceptable. It is Connection 2 = 28.3 - 26 = 2.3 A Sources of transients:
calculated by means of the following two formulas: Connection 3 = 28.3 - 27 = 1.3 A 30 1. Frequency converters without filters
Step 4 % unbalance: 2. Soft starters
Connection 1 = 9.5 % - no good
Iphase max. – Iaverage  3. Contactors for big machines
( ) Connection 2 = 8.1 % - no good 20
I (%) = x 100 [%]
I average
Connection 3 = 4.6 % - ok 4. Capacitors for process machines
Step 5 If the current unbalance is greater than 5%, the power 10 5. Lightning
company should be contacted. As an alternative, a
derated or industrial motor protected by an MP 204
Iphase – Iaverage min.  0 1. Frequency converters without filters Modern fre-
( )
should be used.
I (%) = x 100 [%] On the remote control, you will be able to read the 0 2 4 6 8 %
Iaverage actual current asymmetry. A current unbalance of 5% Voltage unbalance
quency converters with an LC or RC filter can be
corresponds to a voltage unbalance of 1-2%. protected so that they do not produce voltage
The maximum value is used as an expression of the Fig. 48 Relationship between voltage and current peaks above 850V in connection with cables of up
current asymmetry. The current must be measured Even a small voltage unbalance gives a large current unbalance to 100m between frequency converter and motor.
on all three phases as illustrated below. The best con- unbalance. This unbalance, in turn, causes uneven This is fully acceptable and any Grundfos motor
Increases in winding temp.
nection is the one which gives the lowest current distribution of heat in the stator windings leading to in hottest phase with correct rating and cooling will have an accept-
asymmetry. In order not to have to change the direc- hot spots and local overheating. The key results are %
able life. Frequency converters of the PWM type
tion of rotation when the connection is changed, the illustrated graphically below. (Pulse Width Modulation) without LC or RC filter
phases must always be moved as illustrated. MP 204 120 yield an output voltage which differs much from
makes it possible not only to protect against too high the ideal sinusoidal curve with transients of 600V
a current asymmetry, but also to have readouts of the 100 at 400V mains and dU/dt: 2000-2400V/us, meas-
actual values if used with an R100. This makes it easy ured at a cable length of 1m, depending on the
to find the optimal connection. 80 make. These transients will increase with increas-
ing cable length between frequency converter and
&ë &ë &ë
&ì
&í
&ì
&í
&ì
&í
60 motor. At 200m, for instance, the transients will
* * *
be double at the motor cable plug, i.e. Upeak equals
40 1200V and dU/dt: 1200V/us (400V mains). The re-
sult will be reduced lifetime of the motor. Because
20 of this, frequency converters must at least contain
/ 01 / 01 / 01
an RC filter to ensure optimum motor life.

0 2 4 6 8 %
* * * Voltage unbalance 2. A connected soft starter will absorb a non-sinusoi-
4 2 3 4 2 3 4 2 3
dal current and give rise to a certain grid noise. In
Fig. 49 Relationship between voltage unbalance and connection with very short acceleration/decelera-
' ' ' temperature tion times, this is of no practical importance and
í = í = í = does not conflict with regulations concerning grid
Current unbalance can be created by the position- noise. If the start-up time is longer than three sec-
Fig. 47 Optimal connection ing of the drop cables. If jacketed cables are used, no onds, the non-sinusoidal transients will overheat
problems should be expected. If single lead is used it the motor windings and consequently affect the
is always recommend to place the three phase con- lifttime of the motor.

50 51
 Power Supply Power Supply

3. Big machines starting DOL or in star-delta con- If the power supply suffers from heavy lightning
nection may create sparks and send considerable transients, call the power company to have them test
transients back to the grid when the contactors their lightning arresters at the transformer station.
are opened. These surges can harm the submers-
ible motor. If a system has been exposed to lightning, all com-
ponents in the starter box should be thoroughly
4. Phase compensation of process plants may con- tested. The contactor may be burned on one phase
tain complicated controls with many and big ca- which may give rise to voltage and current unbal-
pacitors which send surges back to the grid. Surges ance in the motor. The contactor or the thermal
can be harmfull for submersible motors. relay can be burned on several phases which may
cause both undervoltage and unbalance. The ther-
5. A severe stroke of lightning directly on a well in- mal relay may be burned which means that it can-
stallation, starter or power supply will generally not trip and consequently cannot protect the motor
destroy all living organisms and all electrical instal- windings. Only some of the motors which are dam-
lations. The transients from such a stroke of light- aged by lightning are destroyed by the stroke itself;
ning will be at least 20-100 kV and the generation the rest are damaged by consequential effects.
of heat enough to melt the insulation materials. Grundfos submersible motors type MS 402 have
Lightning striking the grid will generate transients an insulation level of up to 15 kV. This is the maxi-
which will partly be absorbed by the lightning ar- mum voltage peaks, which the motor is exposed to
resters int grid system. The function of a lightning in practice, e.g. in connection with lightning close
arrester is to leak the overvoltage to earth. If a to the installation. Lightning directly on the pump
low-voltage grid is hit directly by lightning there installation is excluded here. Additional lightning
is a risk of transients of more than 10-20 kV at protection is therefore not necessary.
the pump motor starter. If starter and motor are
not correctly protected by lightning arresters and
earthing, the installation may be damaged, as it is
installed in electrically conducting groundwater,
which is the best kind of earthing there is.

Damage to submersible motors from lightning may

arise both in connection with power supply through
overhead cables and underground cables. In areas with
frequent lightning, the best protection of both starter
and submersible motor is to install lightning arresters
on the discharge side of the starter main switch and
connect them to grounding rods or if possible to the
riser main of the well if this is made of steel.

At the borehole, lightning arresters should be fitted

on the discharge side of the isolation switch ground-
ed to the riser main and the well casing if made of
steel. For deep installations, lightning arresters can
be fitted in the motor cable, too, as transients dou-
ble the voltage in a 200m drop cable. But in general,
lightning arresters should be positioned so that their
function can be checked by periodic megging as they
wear out when exposed to much heavy lightning.

52 53
 Installation & operation

7.1 Wells and well conditions

A well is a hole, stretching from the surface of the #…Š‹xƒƒx‹€†… ‡€‹
earth to the underground aquifer, where the ground-
water is found. The depth of the well may vary from a
few meters to several hundred meters.

Wells are typically drilled with special drilling equip- -|xƒ€…~

ment, which is able to pentrate the various layers of
the ground, such as sand, clay, bedrock, etc. Inside the
†‰|†ƒ|
drilled hole a casing (pipe) is typically installed, which
prevents the well from collapsing around the pump.

Below the casing, and in line with the aquifer, is an- 1|ƒƒ zxŠ€…~
other ‘casing’ with fine slots. This is the well screen,
where the slots allows the water to enter the well. It
holds back sand and larger particles trying to enter
the well. See fig. 50.
ˆŒ€}|‰
To improve the filtering function, the borehole typi-
cally features a diameter that is 2-3” larger than the
casing. A fine sand gravel pack filter is placed be-
tween the casing and the aquifer, as shown fig. 45.
Some casings come with a pre-made gravel pack !‰x|ƒ ‡xz‚
-x…{ }€ƒ‹|‰
filter. Made correctly, this filtering method prevents
sand and silt from entering the well.
-z‰||… }€ƒ‹|‰

Fig. 50 Typical groundwater well components

Recommendations on sand content varies from one

country to another.
The National Ground Water Association (NGWA) in
USA recommends the following sand limits in well
water:
• 1.10 mg/l in water used for food and beverage
processing.
• 2.50 mg/l in water for private homes, institutions
and industries.
• 3.10 mg/l in water for sprinkler irrigation, industrial
evaporative cooling and other applications where
a moderate content of solids is not particularly
harmful.
7. • 4.15 mg/l in water for flood irrigation.

Installation & operation

54 55
 Installation & operation Installation & operation

If the concentration of sand exceeds 15 mg/l, so much When the pump is installed, the drawdown and the 7.3.2 Well diameter 7.3.3 Well yield
material will be removed from the well that the aq- dynamic water level must always be known. During In general, the larger the diameter of the pump, the Many pumps are able to overpump the well, which
uifer and the strata above it may collapse and thus operation, the water must never fall below the inlet higher the efficiency. means it will run dry in a short period of time. The
shorten the life of the well. of the pump. The risk of cavitation is normally very pump must be selected with due respect to the ca-
small with submersible pumps. However, NPSH of However, the pump must be able to fit into the well, pacity of the well, so overpumping is avoided. We
Grundfos permits a sand content of no more than 50 the specific pump in its duty point, should always and a certain minimum clearance between motor therefore recommend monitoring the water table.
ppm in the well water. With a sand content of 50 mg/ be checked. surface and internal well diameter is therefore al-
l, the pump efficiency and the lifttime will remain ac- ways required. Several problems may arise from overpumping:
ceptable for up to 25,000-35,000 duty hours, equal to Minimum pump inlet submergence in meters: NPSH •  Dry running and pump damage
approx. four years of operation for eight hours a day. (m) – 10 (m). In a correctly designed well, with the well screen be- •  Infiltration of non-potable water, i.e. seawater
low the pump and motor, the water has to pass the • Chemical reactions in the well when oxygen con-
If the well water has a sand content higher than #…Š‹xƒƒx‹€†… ‡€‹ clearance between the casing and the motor. This tacts the dry aquifer.
50 mg/l, a special pump and motor is available on will cause a friction loss.
request. Excessive drawdown also triggers increased power
If at the same time the motor is eccentric positioned consumption, since it must be compensated with ad-
Before the well can be put into operation, it must be de- -‹x‹€z in the well with one side against the casing, the sin- ditional pump lift.
Žx‹|‰
veloped. A new well will always produce some sand and ƒ||ƒ
gle sided inlet of water into the pump will create tur-
silt in the beginning, and well development is the proc- bulences and affect the performance of the pump.
…x„€z
ess of pumping a new well free from sand and silt. It is ‰xŽ{†Ž… Žx‹|‰ 7.3.4 Pump efficiency
†…| †} {|‡‰|ŠŠ€†… ƒ||ƒ
done by pumping with a very high flow, which draws Fig. 52 shows the friction loss for clearance from 4 to All pumps have their peak efficiency over a relatively
the fine particles in the aquifer into the filter of the 16 mm in a 6“ well, and fig. 53 is showing the same narrow flow range. This range is normally used to
well. This slowly makes the filter more effective. After for a 8” well. select the pump. A Grundfos SP46 has its peak effi-
approximately one day of pumping, the well is normally ciency at and around 46 m3/h flow, just as SP60 lies
pumped clean, and is ready for normal operation. Both the turbulence and the friction loss will result in around 60 m3/h, and so on for all other SP pumps.
ˆŒ€}|‰
pump underperformance, which in some situations
The pump used for well development wears out rela- can be extreme. If the flow requirement falls between two models, i.e.
tively quickly because of the high sand content, and 66 m3/h, both an SP60 and an SP77 may be used with
it should therefore always be replaced with a new In wells with well screen area positioned above the same efficiency. Some of the other criteria come
pump as soon as the well does not produce any more the pump, the water has to pass the clearance be- into play as a result:
sand. tween the pump and the casing, which will cause • Well diameter (see chapter 7.3.2)
a friction loss. • Well yield (see chapter 7.3.3)
The pump must always be installed above the screen • Spare capacity.
area of the casing. In this way, you ensure that the If at the same time the pump is positioned eccentric
water is forced past the motor, providing adequate Fig. 51 Static and dynamic water level against the casing, it will restrict the inflow at half of
motor cooling. If the pump can not be installed above the suction interconnecter. This single sided U-turn
the screen filter, a cooling sleeve is always recom- of inlet water will create inlet turbulence affecting
mended to create the necessary flow along the mo- 7.3 Pump and motor selection the function of the pump.
tor for proper cooling. See chapter 10. Please see chapter 4 for sizing and selection of sub-
mersible pumps. Fig. 54 shows the worst case turbulence/friction loss
at 6” pumps in 6” wells of different diameters .
7.2 Pump setting
Pump setting is the depth at which the pump has 7.3.1 The duty point Fig. 55 shows the worst case turbulence/friction loss
been installed beneath the ground. The pump must The duty point of the pump is the flow where pump at 8” pumps in 8” wells of different diameters.
be able to lift the water from the aquifer to the sur- efficiency is best. The pump must be selected so the
face and deliver a certain minimum pressure. required flow is as close as possible to the duty point, The turbulence and friction will be seen as underper-
or slightly to the right of the duty point. formance of the pump.

56 57
 Installation & operation Installation & operation

Wall side positioning Wall side positioning

Filter of well
Friction loss Friction loss in metres at each metre of motor length, when Turbulence loss/ U-turn inlet turbulence and friction loss in metres at each metre of
m Friction loss pump length for 6" SP-pumps in 6" wells, wall-side positioning
water is passing ∆D mm between motor and 6" casing Flow
m

60 D1 30
C1 C2 C3
D2 C1 PVC 160 casing
(delta) D1 = 4 mm Internal diameter: 145 mm Cable guard
50 (delta) D2 = 7 mm 25
C2 PVC 160 casing
(delta) D3 = 10 mm Internal diameter: 148 mm
(delta) D4 = 13 mm C3 PVC 160 casing
40 (delta) D5 = 16 mm 20 Internal diameter: 151 mm
C4 Steel casing Friction loss
D = 1 m of
∆ Internal diameter: 153 mm for each m of
30 motor length 15 pump length

C4
20 D3 Flow 10

Flow
10 D4 5
D5 m ∆ D P

0 0
0 10 20 30 40 50 60 70 80 m³/h 6" casing 0 10 20 30 40 50 60 70 80 m³/h 6" casing
Capacity
Fig. 52 Friction loss, 6” Fig. 54 U-turn, 6”

Wall side positioning Wall side positioning

Well screen
Friction loss Friction loss in m at each m. of motor length, when Turbulence loss/ U-turn inlet turbulence and friction loss in metres at each metre of
m Friction loss pump length for 8" SE-pumps in 8" wells, wall-side positioning
water is passing ∆D mm between motor and 8" casing m Flow
(delta) D1 = 7 mm
60 D1 30
(delta) D2 = 10 mm C1 C2 C3
(delta) D3 = 13 mm C1 PVC casing
(delta) D4 = 16 mm Internal diameter: 185 mm Cable guard
50 25
(delta) D5 = 22 mm C2 PVC casing
Internal diameter: 188 mm
(delta) D6 = 64 mm
C3 Steel casing
40 20 Internal diameter: 203 mm
D2 Friction loss
D = 1 m of
∆
for each m of
30 motor length 15 pump length

20 D3 Flow 10

Flow
10 D4 5
m ∆ D P
D5
D6
0 0
40 60 80 100 120 140 160 180 200 m³/h 8" casing 40 60 80 100 120 140 160 180 200 m³/h 8" casing
Capacity
Fig. 53 Friction loss, 8” Fig. 55 U-turn, 8”

58 59
 Installation & operation Installation & operation
ê
ê 'x í Š|z†…{ .€„|

Fig. 24b rettet.

7.3.5 Water temperature Water temperatures above the temperature limit

 †‡|‰x‹€…~ zŒ‰‰|…‹ |‰x‹€…~ }xz‹†‰Š #…Š‹xƒƒx‹€†… {|‡‹
The limiting factor is the submersible motor and Grundfos MS 402 motors must not be used at liquid
cooling of the motor. Cooling is the key to a long life- temperatures above 30 °C. ðOperation with MS 4000 
5„7
time of the motor. and MS6 is possible at a liquid temperature above ëî
the given temperature limit, ï if the motor is derated ë ëí
ëì
Submersible motors installed at maximum acceptable (See fig. 57 in chapter 7.3.6). ëë
water temperature must be cooled at a flow rate of at î êó ëê
ó
least 0.15 m/s, which ensures turbular flow. This veloc- In general, however, this will shorten the life of the ò
í êò
ity is ensured by not letting the pump flow drop below motor. It is impossible to say by how much, as this ñ
ð
a certain minimum value. See fig. 56. depends on a number of other ì
parameters, e.g. the )‡|‰x‹€…~
êñ ï
*†Ž|‰ z†…ŠŒ„‡‹€†… x‹ Š‹x‰‹Œ‡ zŒ‰‰|…‹
voltage supply, motor load, motor cooling conditions, î
í
In large diameter wells or tanks it may be neccessary etc. Following the recommendations
ë in this manual êð ì

to use a flow sleeve to increase the flow along the however, should provide an êï acceptable lifetime. êï
ë
ê
motor to minimun 0.15 m/s. See chapter 10 as well. In these cases, we recommend ê that the pump is serv- ê ê îê îï ïê ïï ðê ñê ?
ê í Š|z†…{ ‹‡€zxƒ Š‹x‰‹Œ‡ íê Š|z
iced and all rubber parts replaced every three „€… ìï "‘years
ê 'x
‰x‹|{
ëê¢ ìê¢ íê¢ 1x‹|‰
‹|„‡ ¢

Fig. 25 rettet.
‹|„‡
In the diagram below, the motor is assumed to be po- in order to keep constant efficiency and ensure a nor- Fig. 58 Required water temperature/installation
sitioned above the screen setting. mal lifetime. Fig.
Fig. 27 rettet.
57 Derating of submersible motors depth of MS 4000 and MS 6000

Maximum water temperature: At operation above the temperature limit, warranty Example: For MS 4000 and MS6, the best and simplest protec-
The maximum temperatures shown below are based issues must always be agreed upon. No warranty can A MS6T30 with standard rating, P2 = 30 kW, is able to tion against overload and excessive temperatures
on flow along the motor of 0.15 m/s be given without derating and MP 204 protection. produce 30 x 0.9 = 27 kW in 40 °C water at a cooling is to measure the motor temperature by means of
MS 402 30 °C flow rate of 0.15 m/s. The submersible motor should an MP 204. For other submersible motors, a Pt100/
MS 4000 40 °C be installed at the recommended depth. Pt1000 may be used to monitor the temperature.
MS 4000I 60 °C 7.3.6 Derating of submersible motors
MS 6000 40 °C Multiply the motor size (P2) with the derating factor. Please note that derating of MS 4000I and MS6T60 is
MS 6000I 60 °C This gives the derated motor output P2. That is the not recommended. 7.3.8 Sleeve cooling
MS6T30 30 °C maximum load that may be applied on the motor. Flow past the motor must be a minimum of 0.15 m/s
MS6T60 60 °C In many cases this results in a motor that is one size 7.3.7 Protection against boiling in order to secure proper cooling of the motor.
MMS with PVC wire: 25 °C bigger than originally calculated. In order to protect the motor against boiling at pump
MMS with PE2/PA wire: 40 °C stop and consequently a cooling water stop, it should If the minimum flow past the motor cannot be ob-
'x€„Œ„ }Œƒƒƒ†x{ z††ƒ€…~ Žx‹|‰ ‰|„‡|‰x‹Œ‰| be installed 5m below the dynamic water level. This tained the natural way, Grundfos offers a range of
1|ƒƒ {€x„|‹|‰
will raise the boiling point. cooling sleeves that ensure correct flow and cooling,
ëò

and are easy to work with. Flow sleeves are typically

used when the pump is installed in a reservoir or tank,
ëð

or in a well, where the water flows to the pump from

ëì
„†‹†‰
ëî

above, and therefore does not cool the motor. There

ëê
„†‹†‰
must be reasonable spacing between the casing and
ëì
the outer diameter to limit the pressure drop.
ò
„†‹†‰

ëê

ò
ð
„†‹†‰
x„‡ƒ|
 '- ðêêê €… x ëì
Ž|ƒƒ Žx‹|‰ ‹|„‡|‰x‹Œ‰| îê?
‰|ˆŒ€‰|Š x }ƒ†Ž †} íì „í €} {|‰x‹€…~ †‰ x z††ƒ€…~
ð
Šƒ||| €Š ‹† y| x†€{|{
î
„†‹†‰

ê ëê ìê íê îê ïê ðê ñê òê „í

Fig.
Fig. 26 rettet.
56 Maximum full-load cooling water temperature

#…Š‹xƒƒx‹€†… {|‡‹
1x‹|‰ ƒ||ƒ
60  61
5„7
 Installation & operation Installation & operation

The recommended min. spacing between casing and oxidized water will move towards the screen setting. PEL or PEM riser mains are primarily used for domes- This solution is generally recommended as a riser
flow sleeve may be calculated from the formula be- When using a cooling sleeve, the motor will run at tic applications. In case of water which is so aggres- pipe for submersible pumps. Because of the hose de-
low: a lower temperature and when the motor stops, the sive that it will attack even the best stainless steel, sign, the diameter will swell slightly when the hose
cooling sleeve will absorb the residual heat from the replaceable zinc anodes should be fitted in order to is pressurised, and thus decrease friction loss. At the
v = Q 2x 354 
(D – d2) motor and consequently prevent water from moving protect motor and pump. In such installations, it will same time, it also prevents the built up of scaling on
upward because of the thermal effect and oxidated be too expensive to protect stainless steel riser mains the surface, where the constant change of the diam-
v = m/s. Must be max. 3 m/s to limit head loss water from moving downward. This will contribute against corrosion. eter forces the scaling to break off.
Q = m3/h to longer periods between well scalings.
D = Casing inner diameter in mm In such cases the Wellmaster is recommended. The hose solution also makes pump pulling faster
d = Flow sleeve outer diameter in mm. For these applications, the risk of local heating See chapter 10. compaired with the traditional piping solution, and
should be considered, particularly in connection with is therefore also recommended when frequent pull-
1. If the well water contains large amounts of iron horizontal installations and where several pumps are Friction loss in riser mains ing for service has to be done.
(and iron bacteria), manganese and lime, these installed next to each other. In such cases, cooling Friction loss in pipes or hoses contributes significant-
substances will be oxidised and deposited on sleeves should always be used. ly to the power consumption of a submersible pump. Never use fire hoses, nylon hoses or the like which
the motor surface. This is approx. 5-15 °C warmer A small diameter steel pipe is cost-wise attractive, age quickly, and do not have the required pressure
than the influx water. In case of slow flow past but it creates a lot of internal friction, and over time rating. There is a risk that pump and motor will fall
the motor, this build-up of a heat insulating lay- 7.4 Riser pipe selection this is going to increase. The result is higher power down into the well which may require the drilling of
er of oxidized minerals and metals may result The choice of riser main depends on several different consumption and costs. a new well. Remember to attach a wire to all hose
in hot spots in the motor winding insulation. factors: installations to prevent the pump from falling into
This temperature increase may reach values which • Discharge pressure and installation depth A larger diameter stainless steel pipe represents a the well.
will reduce the insulating ability and consequently • The aggressivity of the groundwater larger investment, but the lower friction loss requires
the motor life. A cooling sleeve always gives a tur- • Friction loss / operating cost less energy for pumping. The smooth internal sur- The disadvantage of flexible hose solutions is that
bular flow past the motor. Turbulent flow gives • Accessibility and cost of alternative face is retained easier, requiring less maintenance for sometimes it is difficult to prevent the hoses from
optimum cooling irrespective of the character of • Priority of initial costs in relation to service and re- cleaning. getting into contact with the ground. This can cause
the deposits. pair costs at a later stage. contamination from bacteria and germs, which can-
Example: not be removed unless you employ expensive special
Pressure at ground level [bar]
2. If the groundwater is aggressive or contains chlo- 35 Flow is 54 m3/h, or 15 l/s. equipment. When dimensioning riser mains and raw-
ride, the corrosion rate will double for every 15 °C water pipes by means of diagrams or PC programmes,
increase in water temperature. A cooling sleeve 30
Friction loss in 100m of 3” pipe and 100m of 4” remember to use a pipe surface roughness of 1 mm.
will therefore reduce the risk of motor corrosion. pipe is calculated from a friction loss table.
25

3. At the top of the well, oxidised raw water is found. 20 PN 3” pipe: 14 m 7.5 Cable selection and sizing
36
Each time the pump starts, the water level in the 4” pipe: 3.8 m The drop cable is the cable running from the well
well is lowered. This draws new oxygen into the 15 head to the motor cable that is attached to the sub-
well. This oxidation of the top few meters is harm- mersible motor.
PN

Choosing a 4” pipe instead of a 3” pipe saves more

24

10
less unless the oxygen reaches the screen. If the than 10 m head per 100 m of pipe.
PN
16

influx of raw water through the screen with a low The energy savings are calculated as follows: Normally, the drop cable has four wires, where one is
PN

5
10

content of oxygen is mixed with water containing a ground/PE wire. In some local areas, a ground/PE
PN
6

fresh oxygen, iron, manganese and lime will oxi- 0 is not required. Always check local regulation about
0 50 100 150 200 250 300 Installation
dize and be deposited in the screen slots. This will grounding before cable type is selected.
kWh = Q x H  = 54 x 10.2  = 2.45 kWh
depth [m]
reduce the efficiency and consequently the capac- 367xη 367x0.6
ity of the well. A warm submersible motor without Fig. 59 Required pipe pressure class at different instal- Other criteria for drop cable selection are:
cooling sleeve will heat up the surrounding water lation depths and actual pressure at ground level Flexible hoses specially designed for pressurised wa- 1. Current carrying capacity
when switched off. ter, like Wellmaster, are an alternative to stainless 2. Voltage drop
The aggressivity of most groundwater is so moder- steel pipes. Some types are even approved for use 3. Water quality and temperature
The thermal effect will make the heated water ate that coated or galvanized steel pipes will be fully with potable water. 4. Drinking water approval requirements
move towards the top of the well. At the same time, acceptable. 5. Regulations

62 63
 Installation & operation Installation & operation

Current-carrying capacity 7.6.2 Cable splice/connection of

Submersible pump drop cable is never dimensioned
L= U x ∆U  [m] Cable type TML-A-B H07RN motor cable and drop cable
for the locked-rotor current, as the motor starts up l x 2 x 100 x (cosφ x + sinφ x Xl) Insulation EPR NR/SR Faulty or unapproved cable joints are frequent causes
in less than 1/10 of a second. Always use the full material of burned-out motors. Grundfos-recommended prod-
load current from the nameplate as the dimension- Max. cable length of a three-phase submersible Ambient temp.  °C Correction factor Correction factor ucts or products of similar quality should be chosen
ing current. The entire length of the drop cable is not pump: 10 1.18 1.29 and the manufacturer’s guidelines followed. Any cable
submerged in water, so additional cooling from the 15 1.14 1.22 joint must be watertight and have an insulation resist-
water may be encountered. 20 1.10 1.15 ance of minimum 10 megaohms, measured in a sub-
L= U x ∆U  [m]
l x 1,73 x 100 x (cosφ x + sinφ x Xl) 25 1.05 1.05 merged state after 24 hours in water. In order to obtain
Typical guidelines for max. amps in submersible drop 30 1.00 1.00 this, all cable parts must be 100% clean and all other
cables: U = Rated voltage [V] 35 0.95 0.91 requirements indicated in the service manual and in
U = Voltage drop [%] 40 0.89 0.82 service video programmes observed. There are four
Dimension (mm )
2
Max. current (A) I = Rated current of the motor [A] 45 0.84 0.71 ways of making a cable joint.
1.5 18.5 ρ = Specific resistance: 0.02 [mm²/m] 50 0.77 0.58
2.5 25 55 0.71 0.41
q = Cross-section of submersible drop cable [mm²] 1. Heat shrink
4 34
XI = Inductive resistance: 0.078 x 10-3 [Ω/m] 60 0.63 - Heat shrink is a plastic tube with the inside covered
6 43
65 0.55 - with glue. When exposed to heat, it will shrink, and
10 60
70 0.45 -
16 80 Water quality and temperature the glue melts, and makes a watertight cable splice.
25 101
The best cable material for clean water is EPR (EPM It takes a lot of practice to perform this kind of joint.
35 126
or EPDM). This material has good electric properties Furthermore, high temerature are required for large
50 153
70 196 combined with a good resistance to water. This type Drinking water approval cable types. Lighters and hobby heaters are not suffi-
95 238 of cable is always recommended when the pumped All Grundfos motors outside North America and Ja- cient. The advantage of this principle is that the con-
120 276 water is not contaminated with hydrocarbons. EPR pan are delivered from factory with drinking water­- nection does not require time for drying but is ready
150 319
offers only limited resistance to hydrocarbons, how- approved motor cables. If the pump is used for pump- immediately after fitting.
185 364
240 430
ever. ing potable water, Grundfos always recommends
300 497 also using a drop cable that has a drinking water ap- 2. Resin
In lighter hydrocarbon solutions, a Chloroprene cable proval. Sealing with resin is the oldest and best known type
Please always check the local guidelines, which over- may be used. of joint. It is also the joint which is simplest to carry
rule the table above. Regulations out correctly. It can be performed in the field without
In heavier concentrations of hydrocarbons it may be Local regulations must always be checked and fol- special tools. The disadvantage is that it must harden
Voltage drop necessary to use PTFE (Teflon) jacketed cable. The lowed. for at least 24 hours. As far as the price is concerned,
The cable must be sized so the voltage drop does not SPE version of the SP pumps comes standard with there is no difference between this and shrink flex.
exceed 3%. Under no circumstances must the voltage PTFE motor cable, and makes it suitable for pump-
at the motor terminals be lower than the minimum ing water with a high content of hydrocarbons. 7.6 Handling 3. Tape
voltage for the motor, which is the rated voltage mi- It is important to use special tape for connecting
nus 10%. A lower cost solution is a standard Chloroprene 7.6.1 Pump / motor assembly submersible cables. Tape joints should only be used
type of cable. Specifications may be obtained from Grundfos submersible pumps and motors are all at water pressures below 5 m.
The maximum length is calculated according to the Grundfos. made in accordance with NEMA standards. They are
formulas shown below: fully compatible with pumps and motors that con- 4. Plug connection
When the water temperature increases, the cable form to these standards as well. Grundfos recom- It is important not to use cable joint kits or tape which
Max. cable length of a single-phase submersible must be derated. The current carrying capacity of the mends always using only a Grundfos pump together are more than three years old. This age limit should
pump: drop cables is usually valid at 30 °C. At higher tem- with a Grundfos motor and vice versa. be reduced to one year if stored above 15 °C. Always
peratures, this must always be compensated in ac- test the cable joint during maintenance.
cordance with the table below. For detailed assembly instructions please see the in-
dividual installation and operating instructions for Motor cable plug
SP pumps. The motor cable plug must always be fitted at the
torque stated in the documentation. In case of lu-

64 65
 Installation & operation Installation & operation

brication of the cable plug, a non-conductive mate- These problems are typically avoided by using one of 7.9 Number of start/stops
rial should be used (e.g. silicone paste). Motor cable the following: In order to get a maximum life out of the submersi-
plugs that are more than three years old should not xyƒ| ble pumps, the number of starts must be limited. It is
z†……|z‹€†…
be reused, as they may have lost the ability to make a 1. Several smaller cascade operated pumps (addition- usually the motor that is the limiting factor. It is also
safe, water tight connection. al pumps starts and stops as demand changes) necessary to start the motor at least once per year to
2. Frequency control of the pump via a pressure avoid it from seizing up.
transducer
7.6.3 Riser pipe connections 3. A combination of 1 and 2. The table below shows the recommended max.
Submersible pumps are available both with RP and number of starts for different motor types:
NPT threads, as well as flanges in various standards. For correct pump selection, the well’s characteristics
must be known, either from the well log or a test Incl. N, R and RE Min. starts Max. starts Max. starts
versions per year per hour per day
In general, however, Grundfos recommends fitting pumping. MS 402 1 100 300
a 50 cm length of pipe first to the pump. This gives ††Š‹|‰ „†{Œƒ| MS 4000 1 100 300
good handling of the pump during the installation, Ž€‹ -* ‡Œ„‡ MS6/MS 6000 1 30 300
as the pump does not become too long. It also leaves 7.8 Pumps in series operation MMS 6000 1 15 360
MMS 8000 1 10 240
room for the clamp which holds the pump until the With pump setting deeper than the max. head ca- MMS 10000 1 8 190
next pipe has been fitted. pacity of a standard SP pump, it may be coupled in MMS 12000 1 5 120
series with a BM pump (SP in sleeve). See fig. 60. .‰|x{|{ †‰ }ƒx…~|{
z†……|z‹€†…
As an alternative to a threaded connection, various
flange types can be offered: Grundfos flanges, JIS 7.10 Pump start-up
flanges and DIN flanges. Detailed information about methods for reducing
locked-rotor current, see chapter 5.
Pipe connections and installation
Grundfos standard flanges are made particularly for You should always follow the instructions found in
fitting into a well. This means that they do not com- the installation and operating instructions for each
ply with any national nor international standards; pump regarding start up.
-Œy„|‰Š€yƒ|
they have been dimensioned to withstand Grundfos ‡Œ„‡
pump pressures. For pumps in series connections, remember to start
them in the correct sequence: the pump with the
There are several advantages in using Grundfos lowest ambient pressure must be started first.
standard flanges instead of other flanges. They are
not only cheaper, and because of their dimension For pumps in parallel operation, remember that air
they are easier to fit into the well. venting possibilities are already built into the system.
Grundfos can supply counter flanges for Grundfos This will prevent air locking.
flanges, which can be welded onto the first pipe.

7.11 VFD operation

7.7 Pumps in parallel operation See chapter 5.
Parallel pumping operation is often used with a vari-
able consumption pattern. A single pump operation
would require a high capacity pump, where the spare 7.12 Generator operation
capacity is only used in a very short period. The in- Engine driven generators for submersible motors are
vestment would be very high, and the operational often offered according to standard conditions, e.g.
efficiency too low. The peaks may also result in ad- •  Max. altitude above sea level: 150 m
ditional drawdown of the dynamic water level with a •  Max. air inlet temperature: 30 °C
number of water- and well quality issues as a result. Fig. 60 Series coupled submersible pump •  Max. humidity: 60%.

66 67
 Installation & operation Installation & operation

If these limits are exceeded, the standard diesel en- 3. By autotransformer start or installation of a Generator operation
Submersible Generator Elevation of Elevation of
gine and possibly the generator have to be derated in motor rating rating max. 150 m max. 750 m Grundfos MP 204 for undervoltage protection, it Always start the generator before the motor is start-
order to give the motor sufficient power supply. for single- and a humi­ and a humi­ is possible to choose both a generator and diesel ed and always stop the motor before the generator is
phase and dity of 100% dity of 100% engine than are 20% smaller than stated in the ta- stopped. The motor thrust bearing may be damaged
When ordering a generator set, altitude, air inlet three-phase ble. This, however, means frequent maintenance if generators are allowed to coast down with the mo-
Diesel engine rating at an
versions [kW]
temperature and maximum humidity should be giv- ambient temperature of of air filter and injection nozzles, cleaning of the tor connected. The same condition occurs when gen-
en to the manufacturer to have the generator factory [kW] [kW] 30 °C 40 °C 30 °C 40 °C
cooler and change of oil. Furthermore, it will re- erators are allowed to run out of fuel.
derated. Generator sets for three-phase submersible [kW] [kW] [kW] [kW] sult in a voltage drop during start-up of up to 20%.
motors must be able to withstand 35% voltage reduc- If the loss in the drop cable and motor cable of
0.25 1.5 1.0 1.25 1.3 1.4 1.43
tion during start-up. 0.37 2.0 1.5 2.0 2.1 2.3 2.3 up to 15% is added, the total voltage loss will be
0.55 2.5 2.0 2.5 3.1 2.8 2.86 more than 35% at the motor. This is no problem
For the selection of internally regulated generators 0.75 3.0 2.5 3.0 3.1 3.4 3.44 for three-phase motors, but sometimes for single-
available, stick to the tables below for continuous 1.1 4.0 3.0 4.0 4.2 4.5 4.58 phase motors, which will often require an oversize
1.5 5.0 4.0 5.0 5.2 5.6 5.73
break kW for single-phase and three-phase motors starting capacitor for low start-up voltages.
2.2 7.0 6.0 7.0 7.3 7.8 8.0
with DOL start.
3.7 11.0 9.0 10.0 10.4 11.1 11.5
5.5 16.0 12.5 14.0 14.6 15.6 16.0 There are two types of generators: internally and ex-
Examples of Examples of
7.5 19.0 15.0 17.0 17.7 19.0 20.0 ternally-regulated.
derating factors for derating factors for
11.0 28.0 22.0 25.0 26.0 28.0 29.0
standard diesel engines standard generators
15.0 38.0 30.0 35.0 36.0 39.0 40.0 Internally-regulated generators have an additional
Altitude: Altitude: 18.5 50.0 40.0 45.0 47.0 50.0 52.0
winding in the generator stator and are also called
3.5% for every 300 m above 2.5% for every 300 m above 22.0 55.0 45.0 50.0 52.0 56.0 57.0
150 m above sea level (2.5% for 1000 m above sea level. self-excited. The extra winding senses the output
30.0 75.0 60.0 65.0 68.0 72.0 75.0
turbo-charged engines). 37.0 95.0 75.0 83.0 86.0 92.0 95.0 current and increases the output voltage automati-
Air inlet temperature: Air inlet temperature: 45.0 110.0 90.0 100.0 104.0 111.0 115.0 cally.
2% for every 5.5 °C above 5% for every 5 °C above 40 °C. 55.0 135.0 110.0 120.0 125.0 133.0 137.0
30 °C (3% for turbo-charged 75.0 185.0 150.0 165.0 172.0 183.0 189.0 Internally-regulated generators normally show the
90.0 220.0 175.0 192.5 200.0 215.0 220.0
engines). best running efficiency.
110.0 250.0 200.0 220.0 230.0 244.0 250.0
Humidity:
132.0 313.0 250.0 275.0 290.0 305.0 315.0
6% at 100% humidity.
150.0 344.0 275.0 305.0 315.0 335.0 345.0 Externally-regulated generators use an externally
185.0 396.0 330.0 365.0 405.0 405.0 415.0 mounted voltage regulator that senses the output
voltage. As the voltage dips at motor start-up, the reg-
ulator increases the output voltage of the generator.
If the generator and diesel engine are derated accord-
ing to the table, the following criteria apply: An externally-regulated generator is to be dimen-
sioned approximately 50% higher in kW/kVA rating
1. T
 he voltage drop at the generator will not exceed to deliver the same starting torque as an internally
10% during start-up. This means that it is possi- regulated generator.
ble to use even the fastest undervoltage protec-
tion on the market in the starter box of the pump Generator frequency is all important as the motor
motor. speed varies with the frequency [Hz]. Due to pump
affinity laws, a pump running at 1 to 2 Hz below mo-
2. Generator and diesel engine will have a normal tor nameplate frequency will not meet its perform-
life as the new fully run-in engine is only loaded ance curve. Conversely, a pump running 1 or 2 Hz
approx. 70% with continuous pump motor rated higher may trip the overload relay.
current. A diesel engine will typically have maxi-
mum efficiency (lowest fuel consumption per kW
output) at 70-80% of maximum load.

68 69
 Communication

8.1 Purpose of communication and the system performance and especially that it is not
networking  a limiting factor for the future growth and flexibility.
There are two main purposes of using data commu-
nication and networking in relation to equipment
and machinery in all industrial installations or in 8.2 Communications and networking
processing installations like water supply plants: technology
The use of communication and networking is
To centralise supervision and control inevitable in modern automation systems, but the
It is well documented that most automation systems kind of system and the used technology is very
can benefit substantially from centralisation of con- diversified. Systems made before 1995 where almost
trol and supervision. The issues that are most often always based on electrical cables, whereas the tech-
mentioned are: nology today offer fiber optics or radio communica-
• Optimise performance (e.g. energy and material tion as an alternative (or combined) solution.
savings)
• Optimise process quality (corrective actions) Optical fibers are flexible and can be bundled as ca-
• Better maintenance (service on demand) bles. It is especially advantageous for long-distance
• Reduction of running costs (e.g. staff cutting) communications, because light propagates through
• Organised/quick reaction to faults (minimise the fiber with little attenuation compared to electri-
down time) cal cables. Additionally, the light signals propagat-
• Easy access to current data and the possibility to ing in the fiber can be modulated at rates as high as
store data in data bases (report generation) 40 Gb/s, and each fiber can carry many independent
channels, each by a different wavelength of light.
Systems for this kind of central management are Fiber is also immune to electrical interference, which
called SCADA systems (Supervisory Control and Data also means immunity to damaging voltage surges
Acquisition) induced by lightning – a big advantage when using
long-distance cabling in outdoor installations.
To realise distributed systems
Many of today’s automation systems would never be Communication using radio signals falls in two
realisable without data communication. In an auto- categories: Short distance and long distance radio
mation system, discreet devices, which are physically communication. We know the technology of short
separated, have to exchange data. These are typically distance radio communication from wireless LANs.
in the form of measured physical values, commands Most fieldbusses offer wireless repeaters to extend
and set points. the fieldbus communication distance over rela-
The discreet devices work together to fulfil a superior tively short ranges or to avoid using cables where
purpose (e.g. supplying water) and by doing so they cabling would be costly or impractical (e.g. moving
constitute what is called a distributed system. Each devices).
device is like a component in a larger entity, contrib-
uting to the overall performance, efficiency and reli- Long distance radio communication can be based
ability of the system. on private radio telemetry. The UHF band between
The number of discreet devices can often be very 400 MHz to 500MHz has become internationally
huge and so can the distance between them. In these adopted for low power license-free use for digital
cases the communication and networking in itself data and telemetry systems. It has the advantage of
becomes the most important and vulnerable part of propagating in direct line of sight and will penetrate
the system and its ability to fulfil its purpose. conventional building materials. For distances above
1000 m, radios with higher power requiring a licensed
It is important that the selection of network and channel is typically needed.
8. communications protocol is not a limiting factor for

Communication

70 71
 Communication Communication

For radio communication in areas that are covered by the SCADA system is broken, the subsystem is able to SCADA system software often has network server ca- hosted SCADA system. All data is accessible via the
existing operator networks like GSM the easiest (but keep on operating alone and still fulfilling its purpose pability, meaning that if the host PC is connected to internet by the use of a web-browser (e.g. Internet
not always the cheapest) way of establishing remote (e.g. supplying water to a tank). The overall system a LAN or to the internet, it will be possible to log on Explorer).
communication is by subscription to this service. It design (choice of technology and equipment) should to the system remotely from another network con- The subsystems can be monitored and operated from
is up to the customer (or the system integrator he aim at subsystem autonomy whenever possible and nected PC. The SCADA system software is a standard any PC in any location with internet access all over
is using) to examine and assess if the demands for always without exception ensure that subsystems package (available from many different software ven- the world. There is no need to install an expensive
communication speed, response time and reliability are failsafe and will return to a predictable well-de- dors), but with a high degree of customized adapta- software system on one or more PC.
are fulfilled. fined and secure state if communication with SCADA tion (data, functions, graphics, etc).
is broken. The outstation will typically be: The SCADA system software and all the data resides
In recent years Ethernet networking technology, with • A PLC (Programmable Logic Controller) 1. Establish the health of the system on the web server, which could be operated by a con-
the communications protocol TCP/IP, which has tra- • A DDC (Dedicated Digital Controller) – Is system OK (operating as intended and fulfill- tractor (system integrator) or by the customer (e.g. a
ditionally been used for LANs and which has become • A gateway to another (underlying) network ing its purpose)? central web server for a complete municipality).
totally dominating within that field, has started to – Does the system need service (cause and kind)?
migrate to fieldbus applications. Here it now enters 3. A communications infrastructure – Is the system broken down (cause)? The customer/user doesn’t have to worry about in-
into competition with the traditional fieldbusses This is what ties it all together. A mix of technologies 2. Display system variables/conditions formation, communication and software/hardware
like DeviceNet, Profibus, Modbus, etc., but instead of will often be used as no single technology (network – Conditions (like on/off) illustrated with graphics technology but can concentrate on the practical use
representing one coherent protocol, Ethernet TCP/IP or protocol) spans all demands in more complex ap- and colors of the data and the practical maintenance of the sub-
shows up in many incompatible standards like Eth- plications. – Important system variables displayed on system system.
ernet IP (a DeviceNet variant), Profinet (a Profibus drawing (pressure, flow, etc.)
LAN/WAN
variant), Modbus TCP (a Modbus variant) and similar – Important system variables shown graphically Passwords ensure that only authorised personnel re-
standards that are based on (and compatible with) HMI
3. Alarm logging and alarm routing cieves access to operate specific subsystems.
corresponding old fieldbusses. The fact that some Human Machine Storage – Managing duty rosters
Interface Computer (database)
new Ethernet standards like EtherCat that are spe- (SCADA software) – Routing of messages (e.g. SMS)
cially designed to utilize the high speed advantages 4. Data logging / Retrieval of logged data
of Ethernet have also emerged has not made the – Interface to database (e.g. Microsoft SQL) Server/computer

choice and compatibility situation within network- – Data processing / Data storing / Graphical visu-
ing of automation systems easier. alization WWW
5. Control
– Manually operation
8.3 SCADA systems – Automatic operation
Communication
infrastructure – Closed loop control (rare) Client Client Client

6. Setup Subsystems

8.3.1 SCADA main parts MPC – Display main setup parameters

The three main parts of a typical SCADA system are: – Changing of main setup parameters Fig. 62 Illustration of the princible in web-hosted
Outstation (DDC) Outstation (PLC)
7. Maintenance information SCADA
1. A master computer Media Converter – Maintenance plan and history
RX
The computer (e.g. a PC running Windows or Unix) TX – Spare parts list
Link PWR Link
has HMI (Human Machine Interface) software and – Manuals, photos, instructive videos
a database. Numerous specialized third party HMI/ Subsystem Subsystem 8. Expert system
SCADA software packages are available. Some exam- – Artificial intelligence
ples are iFix from GE Fanuc, CitectSCADA from Citect, Fig. 61 Illustration of the main parts of a SCADA – Fault diagnostics
SIMATIC from Siemens and Wonderware from Inven- system – Decision support
sys. 9. Interfacing to Enterprise Resource Planning (ERP).
8.3.2 SCADA functions
2. A number of outstations Below is a list of the functions that is typically found 8.3.3 Web-hosted SCADA
An outstation often represents an autonomous sub- in SCADA system software packages. The list is priori- A SCADA system software which runs on a web server
system. Autonomous means that if the connection to tized with the most important functions at the top. instead of on a normal Windows PC is called a web-

72 73
 Communication Communication

8.4 Networking basics Very often a combination of these three basic topolo- the network, when the device is used in applications.
gies is used – then we talk about mixed topology. If It documents the relation between the device func-
8.4.1 Network topology the networking technology used allows connection tions, the data items and the behaviour of the appli-
in any topology – then we talk about free topology. cation/system in which the device is operating.
Refers to the way in which the network of communi-
cating devices is connected. Each topology is suited 8.4.2 Communications protocol Devices that use the same communications protocol
to specific tasks and has its own advantages and dis- The communications protocol covers the rules that and exchange data according to a defined and shared
advantages. specify how a functional device connected to a net- functional profile are said to be interoperable.
Fig. 64 Ring topology work can interchange data with other devices that
In a star network, all wiring is done from a central are part of the network. It specifies details in the
point (e.g. a hub or a central controller). It has the Advantages Disadvantages physical hardware like impedance and electrical sig- 8.4.4 The fieldbus
greatest cable lengths of any topology and thus uses • Equal access for all devices • Costly wiring nals. It specifies details in the data transfer like baud The kind of networks that are used in industrial au-
the most amount of cable. Ethernet networks are • Each device has full access • Difficult and expensive con- rate, timing and data packet format and it specifies tomation systems to connect sensors, actuator and
usually based on the star topology. speed to the ring nections how addressing of devices, requesting of data and controllers are called fieldbusses as opposed to net-
• Only slight performance drop replying to requests should work. works used for administrative purposes in office en-
with increased no. of devices.
vironments, which are generally referred to as Local
The communications protocol is the manager of the Area Networks (LANs).
communication line. The protocol rules control who
In a bus network, all devices connect to the same ca- is allowed to transmit, how much and for how long. Fieldbusses are designed to work in harsh environ-
ble segment. Wiring is normally done point to point In master/slave protocols (like GENIbus, Modbus, ments – out in the field so to speak - and use industri-
in a chain fashion or via drop cables. The cable is Profibus) the arbitration rules of the protocol control al grade equipment and cabling. Moreover a fieldbus
terminated at each end. Messages are transmitted who is master and who is slave. protocol generally promotes other characteristics
along the cable are visible to all devices connected to than a LAN does, because the demands are quiet dif-
Fig. 63 Star topology that cable. Most fieldbusses (e.g. Profibus, DeviceNet, It is the responsibility of the protocol that everything ferent.
GENIbus) use the bus topology, but despite the name, works reliably and that data gets communicated
Advantages Disadvantages fieldbusses can also be based on other topologies. without errors. But in cases where something goes The fieldbus typically transfers small amounts of
• Easy to add new devices • Hub failure cripples all de- wrong, in protocol terms called exceptions, it is also data, but the data is transferred frequently (high
vices connected to that hub Drop cable fashion the responsibility of the protocol to detect these ex- sample rates can often be a requirement). Also the
• Centralized control, net-
work/hub monitoring ceptions, to react upon them (e.g. error reporting, fieldbus must be able to handle time critical data
retransmission, etc.) and finally to recover from any transfer, meaning it has to fulfil hard timing require-
error condition including from a complete network ments (low delays in bus access and data reply and
A ring network, is a network topology in which each break down. fast data processing).
Daisy chain fashion
network device connects to exactly two other devic-
es, forming a circular pathway for signals. Data trav- The LAN, on the other hand, transfers huge amounts
els from device to device, with each device handling 8.4.3 Functional profile of data (files, etc.) between computers and servers,
every packet. The old IBM LAN standard Token Ring The functional profile of a network device means but these data are transferred seldom. Also the reac-
and the industrial fieldbus Interbus are both using Fig. 65 Bus topology the specification of its functional interface to the tion need not be very fast, because it interacts with
the ring topology. network. This is primarily a description of the input humans and not with time-critical physical processes.
Advantages Disadvantages and the output data of the device. These data are
• Easy to implement • Limits on cable length and most often referred to as the data points or the data
device numbers items of the device. The functional profile describes
• Low cost
• Difficult to isolate network the data items – what format they have (8 bit, 16 bit,
faults
etc.), their scaling (resolution and range), limitations
• A cable fault affects all
and mutual relation.
devices
• Network slows down with
increased no. of devices Apart from the data item description, the functional
profile also describes how to operate the device via

74 75
 Communication Communication

8.5. GENIbus 8.5.3 Cabling guidelines

GENIbus, the Grundfos Electronics Network Intercom- Having been developed and now being maintained
munications bus is a proprietary fieldbus developed by by a single company instead of by an independent In general GENIbus
Grundfos to meet the need for data transfer and net- user organization makes GENIbus a so-called pro- •  Use twisted pair cables with shield • Do not use terminating resistors
working in typical water pump applications in build- prietary fieldbus. However the standard is open for •  Connect the shield in both ends • A communication distance up to 1200 m is normal-
ings, water supply, water purification and industry. anyone to use, which has resulted in the emergence • Daisy chaining is the preferred way to connect ly not a problem
of several third party gateways enabling the connec- multiple units • The distance can be extended with repeaters
tion of GENIbus devices (e.g. pumps) to controllers • Avoid long stubs • If you experience problems with noise, try discon-
8.5.1 Background of other brands and of gateways, which can connect • Keep wires as short as possible necting the shield that is found at one end per bus
GENIbus was first introduced to the market in 1991 as GENIbus to a few recognized fieldbus standards. • Separate bus wires from power cables if possible. unit.
a fieldbus interface for the Grundfos circulator pump
type UPE. This pump became the first water pump in Below is a GENIbus technical summary. The com-
the world with integrated frequency converter and plete GENIbus protocol specification is available on M M M
also the first with integrated fieldbus interface. request. max. 500 m max. 1200 m max. 1200 m

The original purpose of the GENIbus interface was to Physical layer (hardware)
enable networking of the speed controlled circula- Topology Bus S S S S S S S S S
tor pumps into subsystems, where a central master Transmitter EIA RS485, half duplex
could handle several control loops with pumps con- Data format Start bit (=0), 8 data bits with least
nected hydraulically parallel and at the same time significant bit first, stop bit (=1)

make important pump data like pressure, flow and Baud rate 9600 bits/s Bus unit #1 Bus unit #2 Bus unit #3
Some devices support programmable
alarms available on a display. baud rate from 1200-38400 bits/s
Distance Daisy chain: 1200 m
A A A
Since then GENIbus has developed into an advanced Multidrop: 500 m
and yet cost effective de-facto Grundfos standard
Twisted pair cable with shield is recom- Y Y Y
mended. No termination.
and is available for almost all Grundfos products with No. of bus units Max. 32 B B B
electronics. Its main area of application is:
Daisy chaining, the ideal way of cabling GENIbus
Data link layer (timing, verification)
• N etworking between pumps, auxiliary devices
Inter Byte Delay <=1.2ms
and controllers in Grundfos subsystems (e.g. Hy-
Inter Telegram Delay >=3ms
dro MPC)
Reply Delay [3ms; 50ms]
• Integration in automation systems (e.g. SCADA) Some devices support programmable
via gateways minimum reply delay [3ms; 2.5s]

• Connection to PC tools via adapter for configu- Cyclic redundancy 16 bit CCITT
checking
ration, faultfinding, value monitoring, data log-
Medium access Master/Slave
ging, etc.
Physical address Master address range: [0; 231]
range Slave address range: [32; 231]
Connection request address: 254
8.5.2 Technical description Broadcast address: 255

Like most other fieldbusses, GENIbus supports the

mechanisms for single-casting (single-addressing),
multicasting (group addressing) and broadcasting
(global addressing). A unique feature of GENIbus is
the Connection Request, which makes it possible for
a master device to recognize all connected units on a
network without having to poll through all possible
addresses.

76 77
 Communication Communication

8.6 Grundfos GENIbus products for

SP applications
Main network connection (to PLC or SCADA)
By the usage of the electronic motor protector MP power
power MNC
power GENI
GENI TxD
GENI RxD
DCD
RTS
TxD1
RxD1
TxD2

204 (described in chapter 10, “Accessories”) it is pos-

Fault RxD2

G100 Gateway

sible to monitor the SP pump remotely:

Gateway G100
• 3-phase current and voltages 3~

• 3-phase voltage angles and cos (θ) MP 204 MP 204 MP 204 MP 204

MP 204 Motor protector

• Start current GENIbus

• Current asymmetry Contactor

• Insulation resistance
• Power and energy consumption
• Supply frequency
• Motor temperature
• Present alarms and warnings
• Logged alarms
• Power on time and running time counter
• Start counter (total and per hour)
• Re-start counter (total and per day) Fig. 66 Illustration of the remote monitoring and
• Operating mode of MP 204 motor protector. control of SP pump installations

By operating the electronic motor protector MP 204

as an on/off actuator, it is possible to start/stop con-
trol the SP pump remotely. It is also possible to reset
alarms, logged alarms and various counters like run-
ning hours and start counters.

By the usage of the input/output IO 111 device (de-

scribed in chapter 10, “Accessories”) alone or togeth-
er with MP 204 it is possible to monitor the following
values:
• Value of PT100 temperature sensor
• Value of pulse counter input
• Value of analogue 4-20mA input
• Alarm limit exceeded (for the above inputs)
• Power on time
• Logged alarms.

MP 204 and IO 112 both have GENIbus interface. MP

204 is supported by the Grundfos gateway G100
(data sheet available via WEBcaps), which can handle
simultaneous connection of up to 32 MP 204 devices
and supports communication via Modbus (RS232, ra-
dio or GSM) or via Profibus. It also has a build in data
logger with a capacity of approximately 300,000
time stamped loggings.

78 79
 Troubleshooting

Fault Cause Solution

Loud noises in pipework in home or Water hammer at pump start and Fit a 50-litre diaphragm tank where
building. stop. the riser main and the horizontal
discharge pipe meet.
Pressure gauges stop working after
short time. Water from this diaphragm tank
will be discharged when the pump
Blow-out in piping and fittings is switched off and thus prevent
the formation of the vacuum.
Air penetrating suction piping as Water hammer creating vacuum Introduce soft -start/stop,- VFD or
well as pressurised piping. pressure tank shock absorption.
A rapid decline in pump perform- Wear and tear due to sand/silt Detect the problematic wells, seal
ance. penetrating into well off the problematic section of the
well or reduce pump performance
to less than half of the problematic
capacity.
Contactors fail too often, High starting frequency Reduce pump capacity, install a
and motors consume excessive VFD or larger tank capacity.
kWh per m3 pumped.
Power consumption by the motor Upthrust Throttle pump performance to
is excessive, and shaft /coupling around the best efficiency point or
splines wear down. reduce the number of impellers on
the pump.
Worn upthrust bearings Upthrust by ON/OFF operation Establish the necessary flow con-
trol at start-up.
Thrust bearings on canned type Cavitation Remove flow restrictions to pump
motors fail and check for performance around
the best efficiency point.
Insulation resistance on rewind-
able motors fails.
Motor temperature increases over Deposits (Calcium, Iron, etc) on mo- Pull the pump and motor for clean-
time; pump performance falls. tor surface and in hydraulic parts ing; clean the piping, well filter and
of pump. install a cooling sleeve on motor.
Pump performance falls off Aggressive water (Corrosion of Pressure test piping from ground
pump and pipes) level. If leakages occur, pull and
replace the pump and pipes with a
higher corrosion class.
Water disappears down the piping Riser mains pipe corrosion Pull the pump and replace the pip-
when the pump is stopped ing material with a higher corro-
sion class.
Pump performance is too low. The Gas evacuation Lower the pump when equipped
motor consumes insufficient kWh. with gas evacuation sleeve.
The water level in the well is con- Well overpumping Reduce pump capacity until the
stantly becoming lower. water level remains constant over
the course of a year.
9. Drill more wells at other aquifers.
Troubleshooting

80 81
 Accessories

10.1 Cooling sleeves

In general, cooling sleeves are recommended when Metals can be listed in order to their relative activ-
the motor cooling is insufficient. This is normal in ity in seawater environment. If the metal surface
tank applications. It can also be necessary in deep becomes the anode in the electrochemical cell, cor-
well applications, where there is a risk that the wa- rosion takes place.
ter will flow to the pump inlet from above and not
automatically pass along the motor.
10.2.1 Cathodic protection
Other applications where a flow sleeve should be Cathodic protection is a technique to control the cor-
used: rosion of a given metal surface by purposely making
• The motor is exposed to a high thermal load, this surface into the cathode of the electrochemical
such as due to a high ambient temperature, cur- cell.
rent unbalance or overload. This can be done in two ways:
• Aggressive liquids are pumped, since corrosion is • Galvanic: by use of sacrificial metal
doubled for every 10  °C increase in temperature. • Impressed Current: by use of DC power supply
• Sedimentation or deposits occur around and/or and an inert anode.
on the motor.

By using the cooling sleeves, the flow along the mo- 10.2.2 Galvanic cathodic protection
tor will minimize the motor temperature and there- systems
by extend the motor life.

10.2 Corrosion protection in seawa-

ter
Stainless steel can be damaged by crevice or pitting
corrosion when immerged into chlorinated water.

The likelihood of corrosion depends on:

• The grade of material used (GG – AISI 304 – AISI
316 – AISI 904L)
• Chloride concentration in the water
• Electrochemical potential of the metal exposed
to media
• Temperature
• Oxygen concentration
• Velocity of the media in contact with the metal-
lic surface
• The pH value.

When metal is submerged into water, it forms an

electrochemical cell, with an anode and a cathode
immerged into an electrolyte (ex. chlorinated wa-
ter). This is also referred to as being a galvanic cell. Fig. 67 Submersible pump set with sacrificial zinc
The anode can be referred to as the active part and anodes.
10. the cathode as the noble part.

Accessories

82 83
 Accessories Accessories

Grundfos offers a series of sacrificial zinc anodes for DC power supply

possible to remove from the surface, making a wa- much space. It swells when pressurised, which mini-
the submersible pump and motor. For metallic riser tertight seal almost impossible to create. mises the eventual growth of deposits on the inner
Insulated
pipes, standard solutions for pipes are recommended. Anode Cable diameter. A high pumping efficiency is therefore
Seawater
maintained.
10.4 Cable joints
4e�
The use of sacrificial anodes has an environmental
impact that should always be taken into account. The Negative return cable No matter the type of seal, the adhesion between the Wellmaster is primarily used in combination with
(Structure Connection)
effects of the salts being formed in the galvanic proc- 4Cl�
sealant and the cable is the key to a watertight seal. aggressive water as an alternative to stainless steel
ess must always be taken into account. As stated under 10.3 Drop cables, a clean and oil-free pipes. Some end-users prefer to use Wellmaster in all
surface on the cable is necessary. their installations due to the ease of installation and
2Cl₂
The system needs to be monitored in order to find pulling, and the high quality hose.
the correct time for replacing the sacrificial anodes. O₂ + 2H₂O Impressed
Solvents must never be applied, as it may damage the
4CH�
Current Anode
cable permanently. Only mechanical cleaning may be
The advantage is that the system is self regulating Protected
structure
used, such as drying with a clean cloth, or sandpaper
– the deterioration of the sacrificial anode reflects grinding to create a virgin material surface.
the needs for protection of the system. Fig. 68 Principle of impressed current cathodic system
Grundfos offers an approved range of cable joints:
For bigger and more complex systems, engineering is 10.3 Drop cables both resin type and heat shrink joints. When using
needed in order to make the correct choice concern- Grundfos can deliver different drop cable types de- a non-Grundfos joint, we always recommended to
ing corrosion protection. Aspects to consider include pending on the application the pump is going to op- make a ‘soft’ joint, i.e. when using a resin to make
• Material of sacrificial anode erate in. General guidelines have been described in the joint, it must be a soft resin. Polyurethane usually
• Shape chapter 7.5. fulfils all requirements for a watertight and flexible
• Extension joint. In Section 7.6.2 describes the pros and cons for
• Connection. There are cables specially developed to be used in the various types of joints.
connection with submersible pumps. Several of them
are approved for transporting drinking water. Numer-
10.2.3 Impressed current cathodic ous manufacturers produce these cables which may 10.5 Riser pipes
protection systems  be used with submersible pumps. Grundfos offers the Wellmaster, a flexible riser pipe,
This requires use of a DC power supply and knowl- as an alternative to standard steel and plastic pipes.
edge of actual potential between the metal that A commonly used type is the H07RN-F, which is a This is woven hose has a polyurethane lining, is ap-
needs protection and a reference electrode. It is general purpose cable. In most cases this cable is ad- proved for use in drinking water in several areas, and
necessary to take into account the risk of organic equate for use with submersible pumps. Please note comes in sizes from 1-8”. It is available in lengths up
growth on the metal part that over time can change that water resistance of the conductor insulation is to 200 metres.
the potential difference. not always good enough.

These systems require individual design and Grund- Grundfos always recommends having the cable
fos refers to external suppliers of these kinds of manufacturer guarantee that the cable can fulfil
equipment where design and advices can be ob- Grundfos standard GS418A0010, which is an ad-
tained. The normal range of the DC supply will be ditional insulation resistance test with the cable
50 V with 10-100 A. submerged in water.

The advantage of this method is that it is inert, mean- The functionality of the cable is dependant on the
ing that it does not release any chemical agents to watertight seal. The sealing compound must be
the environment. The process requires energy in the able to adhere to the surface of the cable and the
form of a power supply. individual wires. Cleaning of the surface before the
sealing is done is therefore vital. Some cable manu-
facturers use fluid lubricants such as silicon oil in Fig. 69 Cross-section of wellmaster hose
their internal processes. These fluids are almost im- Wellmaster is easy to handle, and does not take up

84 85
 Additional information

For further information about Grundfos,   CAD drawings

please visit: The “CAD Drawings” section is self-explanatory. This
is where you go to find CAD drawings of the prod-
www.grundfos.com ucts you are interested in – just navigate the simple
menus to download the information you need to
Here you can learn much more about the company, your computer.
our values and find the Grundfos service centre near-
est to you. Furthermore you can visit our extensive
product selection tool WebCAPS, where you can find
exactly the pump you require.

WebCAPS
WebCAPS is Grundfos’ online product selection tool
that gives you easy access to a wealth of informa-
tion. Short for Web-based Computer-Aided Product
Selection, the WebCAPS interface is easy to use and
lets you choose between 24 languages for maxi-
mum user-friendliness. It includes a full catalogue
of the products available in your country as well as
access to literature, CAD drawings – and even serv-
ice videos.

Sizing function that asks all the relevant questions

The sizing function is a key feature of WebCAPS, de-
signed to help you select the right pump for the job.
The programme guides you step by step, asking for all
the relevant information. If you are unsure of specific
figures or how to calculate them, simply click on the
“calculator” icon. WebCAPS will then help you carry
out all the calculations necessary to ensure that you
get exactly what you need. Every factor will be taken
into account, and you won’t have to work hard to col-
lect information first.

Replacing a pump? See what we would recommend!

The “Replacement” function is a clever little fea-
ture for anyone about to replace an existing pump
– whether it comes from Grundfos or another sup-
plier. Here, you can search for your existing pump in
the drop-down menus, apply various additional cri-
teria if you wish, and click “submit”. You then have a
complete list of the Grundfos pumps we would rec-
ommend as replacements.

11.
Additional information

86 87
 Index Index

Alphabetic index chapter page Alphabetic index chapter page

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 83 Networking basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 74
Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 87 Networking topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 74
Air/gas in water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 20 No. of start/stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 67
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 17 Operation with frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 42
Autotransformer – AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 39 Overvoltage and undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2 47
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 76 Power generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 47
Booster modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 24 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 47
Cable joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 85 Primary Resistor-type Starter, RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 39
Cable selection and sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 63 Protection against boiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.7 61
Cable splice/Connection of motor cable and drop cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.2 65 Pump / motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.1 65
Cabling guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3 77 Pump and motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 56
Cathodic protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 83 Pump curves and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 29
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 71 Pump efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.4 57
Communications and Networking Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 71 Pump principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 27
Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 75 Pump selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 28
Cooling sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 83 Pump setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 56
Corrosion protection in seawater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 83 Pump start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 67
Corrosive water (seawater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 22 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 27
CUE varible speed drive for SP pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 43 Pumps in parallel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 66
Current asymmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 50 Pumps in series operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 66
Derating of submersible motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.6 60 Reducing the locked-rotor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 36
Dewatering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 19 Required raw/well water and water treatment capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.4 11
Direct-on-line – DOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 36 Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 9
Drop cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 84 Riser pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.3 66
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 48 Riser pipe selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 62
Frequency converters (variable-speed drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.6 40 Riser pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 85
Freshwater supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 17 Riverbank filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 9
From freshwater sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 14 SCADA functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2 72
From the sea and saltwater sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 14 SCADA main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 72
Functional profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3 75 SCADA systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 72
Galvanic cathodic protection systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 83 Sleeve cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.8 61
General introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 71 Soft starter – SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.5 39
Generator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 67 Star-delta – SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 38
GENIbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 76 Surface water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 14
Grid connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 49 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 76
Groundwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 9 The duty point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 56
Groundwater requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 10 The fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.4 75
Groundwater wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 73
Grundfos GENIbus products for SP applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 78 Variable frequency drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 48
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 65 VFD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 67
Horizontal application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 20 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 47
Hot water and geothermal water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 23 Voltage unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 47
Impressed current cathodic protection systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3 84 Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9
Installation & operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 53 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.5 60
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 Wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 28
Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 19 Web-hosted SCADA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.3 73
Motor cables and joints, reference to drop cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 35 Well diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2 57
Motor protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 36 Well yield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3 57
Motor types, general description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 33 Well yield and operational efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.5 12
Motors and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 33 Wells and well conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 55

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