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SP ENGINEERING MANUAL

SP ENGINEERING MANUAL
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SP ENGINEERING MANUAL

Product catalog summary
Introduction
This document serves as a technical manual for Grundfos' SP pumps, highlighting their durability and efficiency. It complements existing product data and installation manuals, providing quick answers to common questions about SP pumps.
Water Supply
Resources: Only 2.5% of global water is fresh, with less than 1% available for human use. Groundwater: High-quality due to natural filtration, ideal for irrigation and water supply. Riverbank Filtration: Reduces treatment needs and maintains river levels. Surface Water: Requires treatment; submersible pumps recommended. Sea and Saltwater Sources: Intake should be positioned to minimize salinity.
Seawater Intake Structures
For capacities over 1,000 m3/h, extend intake far from the shore. For smaller capacities, use corrosion-safe wells to save on maintenance costs.
Applications of Submersible Pumps
Used for freshwater supply, dewatering, horizontal applications, corrosive water, and hot water. Material selection depends on water quality and conditions.
Service Intervals and Maintenance
Service intervals depend on water velocity, pump material, and environmental conditions. Efficiency loss and renovation costs are calculated accordingly.
Corrosion and Material Selection
Corrosion resistance is crucial, especially in seawater applications. The PRE formula helps determine the appropriate stainless steel grade.
Booster Modules
Enhance water pressure in distribution networks, offering quieter operation and eliminating leakage risks.
Pump Principle
SP pumps are centrifugal pumps that convert mechanical energy into velocity energy, increasing pressure through multiple stages.
Design Types
Radial designs are for high head requirements, while semi-axial designs suit larger flow pumps.
Wear Parts
Regular inspections are recommended to replace wear parts and maintain efficiency.
Pump Selection
Involves estimating flow and pressure, considering factors like dynamic water table and discharge pressure.
Pump Curves and Tolerances
Performance curves aid in pump selection, showing efficiency and power consumption.
Motors and Controls
Submersible motors conform to NEMA standards, with various types available for specific applications.
Motor Derating
Necessary for high water temperature or voltage tolerances, affecting efficiency.
Motor Protection Devices
Protect against short-circuiting, phase failures, and overloads.
Specifications and Features
Thermal protectors and temperature sensing devices like Tempcon are used for monitoring.
Reducing Locked-Rotor Current
Various methods are discussed, including DOL, SD, AT, RR, SS, and FC, each with specific advantages.
Operation with Frequency Converter
Output filters are necessary to limit voltage peaks and reduce motor stress.
Specifications and Requirements
Includes guidelines for frequency converters, motor flow rates, and temperature protection.
Operational Considerations
External frequency converters can lead to power loss and increased heat.
CUE Variable Speed Drive
Controls pump performance by changing frequency, minimizing damage risk.
Filter and Cable Guidelines
Filter selection depends on pump type and cable length.
Power Supply and Voltage Considerations
Voltage variations should be within +6/-10% of the rated value.
Specifications
Discusses the use of VFDs for motors and the importance of using filters.
Grid Connection
Understanding grid characteristics is crucial before connection.
Current Asymmetry
Maintaining low current asymmetry is essential for efficiency.
Voltage Transients and Lightning
Filters and lightning arresters are recommended for protection.
Installation and Operation
Emphasizes proper casing and filtering to prevent sand and silt entry.
Pump Setting and Selection
Advises on installation depth and aligning the duty point with required flow.
Well Design and Pump Performance
Proper design ensures water passes through the clearance, reducing turbulence.
Well Yield
Monitoring the water table is crucial to prevent overpumping.
Pump Efficiency
Peak efficiency occurs within a narrow flow range.
Water Temperature and Motor Cooling
Cooling is critical for motor longevity, with specific flow rate requirements.
Derating of Submersible Motors
Involves selecting a larger motor size based on a derating factor.
Protection Against Boiling
Motors should be installed below the dynamic water level.
Sleeve Cooling
Cooling sleeves ensure correct flow and prevent local heating.
Riser Pipe Selection
Depends on discharge pressure and friction loss.
Cable Selection and Sizing
Criteria include current capacity, voltage drop, and local regulations.
Voltage Drop and Cable Sizing
Formulas provided for calculating maximum cable length.
Water Quality and Temperature
Cable derating is required at temperatures above 30°C.
Installation and Operation
Grundfos motors come with drinking water-approved cables.
Cable Splice/Connection
Recommended methods for ensuring watertight connections.
Riser Pipe Connections
Various flange types are available for better handling.
Pumps in Parallel and Series Operation
Parallel operation suits variable consumption patterns.
Number of Start/Stops
Limiting starts maximizes pump life.
Generator Operation
Generators must be derated based on environmental factors.
Communication and Networking
Data communication is crucial for optimizing performance.
Communications and Networking Technology
Includes fiber optics and radio communication for automation systems.
SCADA Systems
Consist of a master computer, outstations, and a communications infrastructure.
SCADA Functions
Include system health monitoring, alarm logging, and control operations.
Web-hosted SCADA
Allows global access via web browsers.
Networking Basics
Common topologies include star, ring, and bus.
Communications Protocol
Protocols define data interchange rules between devices.
Functional Profile
Specifies a device's network interface.
Fieldbus
Connects sensors, actuators, and controllers in automation.
GENIbus
A proprietary fieldbus for water pump applications.
GENIbus Technical Summary
Specifications include a bus topology and data format details.
Data Link Layer
Includes timing specifications and medium access model.
Cabling Guidelines
Use twisted pair cables with shields and avoid long stubs.
Grundfos GENIbus Products for SP Applications
Include the MP 204 electronic motor protector for remote monitoring.
Troubleshooting
Common issues and solutions are provided.
Accessories
Cooling sleeves and corrosion protection systems are recommended.
Additional Information
Visit the Grundfos website for more details and product selection tools.
See more

Catalog excerpts

SP ENGINEERING MANUAL-1

GRUNDFOS SP ENGINEERING MANUAL

 Open the catalog to page 1
SP ENGINEERING MANUAL-3

Contents 1  Introduction 2  Water supply Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Groundwater wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riverbank filtration . ....

 Open the catalog to page 3
SP ENGINEERING MANUAL-4

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 engineering...

 Open the catalog to page 4
SP ENGINEERING MANUAL-5

Water supply The amount of water in the world is constant. It is changing position, quality, phase, etc., but it is constant. Seawater accounts for approx. 97.5% of all water. 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: •  groundwater, shallow or deep underground aquifers of water •  surface water, from rivers or lakes. In case no fresh water is available, seawater or contaminated...

 Open the catalog to page 5
SP ENGINEERING MANUAL-6

Water supply feeding the riverbank wells when the river water level runs low in dry season. The storage of river water in aquifers causes less water stress on the river during dry seasons. Riverbank wells can be constructed like groundwater wells, or from 7-8m vertical casings dug down under the riverbed. They can be supplemented with 8-12 horizontal injected steel screens or filters for sediment-free water intake. Water supply To find the peak hourly consumption, please refer to the MPC-Booster section of Grundfos WinCAPS/WebCAPS or figures 4 and 5. Pump-out requirement Water is used by many...

 Open the catalog to page 6
SP ENGINEERING MANUAL-7

Water supply Water supply An increase from 10 to 20 m3/h will consequently result in a lowering of the water level of approx. 1 m. An increase from 10 to 30 m3/h will give a lowering of the water level of approx. 2m. Clean-water tank size as a percentage of daily consumption % 100 90 Clean-water tank size as a percentage of daily consumption: Tank volume (m3) x 100 = % tank capacity Daily consumption (m3/24h) If the well yield is not sufficient to meet the water requirement, even by prolonged operation, the following should be done: •  Have a specialist look at the problem. •  Have a supplementary...

 Open the catalog to page 7
SP ENGINEERING MANUAL-8

Water supply Surface water 2.3.1 From freshwater sources Surface water is usually taken from lakes or rivers. Unlike groundwater, it is not protected from nature or human activities, and treatment is therefore always necessary. Surface water level and quality will vary over the seasons. For example, after heavy rainfall, or snow melt, lots of solids and sand are washed downstream. These sharp and abrassive minerals as well as biodegradable materials are to be settled or screened off before pump intake to avoid negative effects on the final water treatment process. Submersible pumps are ideal...

 Open the catalog to page 8
SP ENGINEERING MANUAL-9

The supply of fresh water for drinking water, irrigation and various industrial applications is the most common application for submersible pumps. Pumps of many different designs, and made from many different 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, sandfree 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...

 Open the catalog to page 9
SP ENGINEERING MANUAL-10

4. rop directly down (90°).The aggressive CO2 conD tent has increased the material loss to 0.25mm. Note the salinity level of the water (point 4). Draw a horizontal line through this point; follow it to the left and read the results. 5. ecommended service intervals for your pump: AfR ter every 6,000 hours of operation (point 5). 6. oss of efficiency: Approx. 18% (point 6). L 7. stimated cost of renovating the pump: 75% of the E price of a new pump (point 7). to the submersible pump, and high-grade stainless steel is recommendable. A special mining application is leach mining, where an aggressive...

 Open the catalog to page 10
SP ENGINEERING MANUAL-11

Pumping water from a tank or reservoir is very often done with a standard submersible pump. A submersible pump has many advantages compared to a dry-installed pump such as: • ow noise level: The submersible pump is very siL lent and does not disturb any neighbours. • heft proof: The pump is installed at the bottom of T the tank/reservoir. • o shaft seal: This eliminates the risk of leakage N above ground. In horizontal installations, Grundfos always recommends that you include a flow sleeve and baffle plate at low water levels. If more than one submersible pump is installed in a tank or reservoir...

 Open the catalog to page 11
SP ENGINEERING MANUAL-12

Submersible pumps are used for many seawater applications like fish farming, offshore industrial applications and water supply for reverse osmosis-treated water. SP pumps are available in different materials and corrosion classes depending on the application of the pumps. The combination of salinity and temperature is not favourable to stainless steel, and must always be taken into consideration. A good way to compare the corrosion resistance of stainless steel, is to compare its resistance against pitting. The figure used as a comparison is called: ‘Pitting Resistance Equivalent’ (PRE). Fig....

 Open the catalog to page 12

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