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GRUNDFOS WaterPRO - Energy-efficient pumps for commercial ...

GRUNDFOS WaterPRO JUNE 2009

GRUNDFOS WaterPRO

The new wave in water utility

MORE INSIDE…

Product Focus > Meet the New SL

Feature Article > Dedicated Controls for Network Pumping Stations

Tech Talk > Wastewater Pumps with Frequency Converters

International Project Reference > Controlling Vast Water Volumes at Dubai Drydocks

Local Project Reference > Grundfos Innovative Solutions Saves PBAPP Money and Space at Sg Dua WTP


ProductFocus

MEET THE NEW SL!

Long-lasting, service-friendly submersible wastewater pumps

“The newly extended SL range

is industrial design at its best.

Created to optimise performance

in your system, these pumps

minimise risk factors, reduce

maintenance requirements,

and last longer.


Like any Grundfos product, SL pumps are remarkably

durable. They employ innovative features-several of them

unique to Grundfos-to minimise known risk factors. The

SL pumps also let you plan service visits for maximum

efficiency-and keep those service visits shorter.

The SL (pumps) work with your system. They give you the choice-of impeller, of sensors, of speed control, etc.-that you need

for ideal pump set-up. And we can give you design advice to make the most of it.

SL PUMP PERFORMANCE

OVERVIEW

SuperVortex impeller

SuperVortex impeller pumps

(SLV) are available for free

passage of solids up to 100

mm. Ideal for liquids with

high content of solids, fibres,

or gassy sludge.

Channel impeller

Channel impeller pumps (SL1)

are available for free passage

of solids up to 100 mm. Ideal

for large flows of raw sewage.

H

[m]

50

40

30

20

15

10

8

6

5

4

3

2

SLV.80

SLV.65

SLV.65

SL1.50

SL1.50

SL1.80

SLV.100

SL1.100

50 Hz

5 10 15 20 30 40 50 100

Q[I/S]

20 40 60 80 100 200 Q[m 3 /h]

The entire range is available in explosion-proof versions. All DP and EF models and SL1 and SLV models with motors up to 1,5kW are provided with a II 2 G Ex c d IIB T4 explosionprotection

classification according to EN60079-0:2006 and EN60079-1:2007. All other SL1 and SLV models are provided with an II 2 G Ex c d IIB T4, T3, and for sensor versions,

an II 2 G c d mb IIB T4, T3 classification according to EN60079-1:2007, EN13463-5:2003, and EN60079-18:2004.


SL PUMP FEATURES

-and what they do for you

Moisture-proof plug

A two-component sealant

filling the plug prevents

moisture from entering the

motor via the cable core

Short rotor shaft

Compact motor

construction reduces

vibrations to protect

shaft seals and bearings

Double mechanical shaft seal

Primary and secondary seals are

combines into a single cartridge

to reduce maintenance time

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>

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>

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ProductFocus

Eff1-type motor

SL models have motors

based on Eff1 components,

improving motor efficiency

and prolonging pump life

Many sensor options

Larger SL models

available with integrated

analogue sensors

(motor temperature,

water in the intermediate

oil chamber, and motor

insulation resistance)

Easy-to-open clamp

Easy access for pump

maintenance. Enables

180˚ rotation of the

motor positioning


FeatureArticle

Grundfos

Dedicated Controls for

network pumping stations

For sewage networks

The Dedicated Controls are envisaged for use in

sewage pumping stations combining one or two

pumps and a mixer. This makes them obvious choices

for mains systems, commercial buildings, and similar

applications.

Expanded functionalities

The Dedicated Controls system builds on Grundfos’

experience with their own series of level controllers

for pump monitoring and control – specifically the

acclaimed LC series and Modular Controls system

– but greatly expands the functionalities available.

The Dedicated Controls range is developed for

those who want something extra. For example, the

monitoring functions have been expanded to include

pumped volume and overflow durations – and the

Grundfos, one of the

world’s leading pump

technology developers

and manufacturers, now

launches its Dedicated

Controls solution

– a sophisticated

monitoring and control

solution developed

specifically for network

pumping stations.

communication options have been expanded, too:

the Dedicated Controls system offers SCADA and BMS

communication using GSM/GPRS. Among other things,

this means that the options now also include a text

messaging service which allows users to control and

receive information from their pumping station on

their mobile phones.

Large graphic display

The large graphic display is another new feature. It was

created with the help of leading experts on interface

design for easy read-outs and easy operation. The

display shows a visualisation of the pumping station,

making it easy to find the information required – and

to adjust any settings. A Wizard function takes users

through the different functions step by step – in the

language of their choice.


Highlight

Supported by PC tool

The Dedicated Controls system can be used with

Grundfos’ own PC tool created for on site service as well

as remote preparation, verification, and management.

The PC tool was also created for maximum userfriendliness.

It can be used for set-up and commisioning

of the pumping station – and to create backups of

your settings and parameters. You can even send your

settings via email to make commisioning simplier.

And once the station is up and running, the PC Tool

offers a full set of functionalities – on site or from a

remote location.

Part of a system approach

The Dedicated Controls system reflects how Grundfos

has moved from being primarily a pump manufacturer

to become a wide-ranging developer of pumping

systems and environmental technology.

Grundfos has always designed the products with a focus

on improving system performance. The main difference

is that over the last decade, Grundfos has gradually

started developing more and more system components

ourselves. Those components include everything a

client could need for a pumping station: “Grundfos

offers prefabricated and customised pumping station

on any scale, including all fitting, valves, and controls.

And pumps, of course. Everything fits together perfectly,

and the Dedicated Controls solution adds extra

functionalities for those who want them.”

Dedicated Controls at a glance

• Expands the scope of the Grundfos controls range

• Control one or two pumps

• Supplied as modules or as part of complete

panel range

• For motors up to 11 kW (direct on line) or 30 kW

(star/delta) or softstarter

• Analogue input 4+20 mA (pressure/

ultrasonic transmitters) and/or up to five

float switches

• Also control mixer/flush valve

• User-friendly display interface – includes

Wizard function

• Connect to all standard PLCs, SCADA, and

BMS systems

• Full data logs

• Customise your alarm scedule

• Text messaging – control pumps and receive

information via SMS

• Early warning

• Compatible with the Grundfos Remote

Management system

FeatureArticle

Dedicated Controls were created specifically for network

pumping stations

The Dedicated Controls system is available now.

Visit www.water-utility.grundfos.com


TechTalk

WASTEWATER PUMPS

OPERATED BY MEANS OF

FREQUENCY CONVERTERS

Why use

frequency

converters?

In general, frequency converters

are used to change the duty point

of a pump. In wastewater

applications, this means that they

are used to regulate the flow in

the system. Converting the initial

frequency from 50 Hz to another,

lower value will have consequences

for the flow, the head and the power

intake of the pump; consequences

that can be calculated by means

of these equations:

Q 1 = Q 0 x

H 1 = H 0 x

P 1 = P 0 x

f1 f0 f1 ( f) 0

f1 ( f) 0

NPSH 1 REQ = NPSH 0 REQ x

2

3

Cutting groove

f1 ( f) 0

2

Cutting groove


Consequences for pump cooling

From the power equation we learn

that the introduction of frequency

converters would not create any cooling

issues since the power intake decreases

to the third power.

An initial shaft power of P 0 = 30 kW

at f 0 = 50 Hz will be reduced to

P 1 = 15.36 kW at f 1 = 40 Hz. In the case

of pumps without cooling jackets, the

outer cooling surface and the material

mass inside the pump itself will easily

dissipate the heat.

However, when pumps are equipped

with a cooling jacket – inside which

the cooling water is provided by the

POSSIBLE JAMMING OF THE PUMP

AND INSTALLATION

Pump

When the motor frequency is lowered, the rotation speed

of the impeller will slow down and affect the velocities in the

impeller and the pump housing. Depending on the specific

hydraulic design of the pump in question, critical velocities

may be reached, causing impurities to settle in the pump

housing and in the impeller itself. Clogged impellers become

unbalanced, causing vibrations in the pump. The risk of

mechanical damage, wear, and excessive leakage from the

mechanical seals will shorten the lifetime of the pump.

Installation

When the flow is reduced due to lower speed, the velocity

in the pipe is also reduced. This presents a risk of particles

and fat settling. Therefore we recommend minimum

velocities for wastewater: 1 m/s in vertical pipes and 0.7 m/s

in horizontal pipes.

When sedimentation in the pipes occurs, the inner diameter

of the pressure pipe is reduced and the pump will operate at

a higher pressure (A1 to A2). The reduced inner diameter of

the pipes means that the flow will be reduced even further

(Q1 to Q2), which has the consequence of increasing velocity

(v1 to v2). The result is higher friction loss in the system.

pumped liquid moved by the impeller

– the heat transfer of the motor could

be a concern.

Slowing down the rotation speed of

the impeller decreases the flow in the

jacket. This reduced flow decreases

the velocity around the cooling jacket.

Bigger solids, fats, or long fibers in the

wastewater are at risk of settling when

the velocity reaches a critically low

value. After a while the cooling jacket

will become clogged, preventing any

water circulation at all.

When this happens, the accumulated

sludge and remaining water in the

cooling jacket creates an insulating

H

H

H1

A

v > v1

TechTalk

layer around the stator. Even at lower

frequencies, this could overheat the

motor. This is not a problem with

Grundfos pumps. Thanks to Grundfos’

integrated cutting system, fibers and

large solids are cut into small pieces

before entering the jacket. These small

particles remain suspended, preventing

them from clogging up the jacket.

A1

Q Q1 Q

Depending on the stagnant time and running hours

at lower speed, such clogging in the pump and pipes can

permanently disturb the functionality of the complete

installation.


TechTalk

Recommendations

The clogging phenomenon caused by reduced wastewater

velocities has an adverse impact on the operation of the

pump and the system.

Therefore, we do not recommend the use of frequency

converters for unscreened sewage unless velocities are kept

under control in every section of the entire pipe system.

Regularly speeding up the pumps to their full speed will

clean the pump hydraulics and the pipes. These cleaning

sequences can be pre-programmed in the controller. The

best interval between such cleaning sequences depends

entirely on the consistency of the sludge and can only be

determined by experience. However, we recommend that

you set the pumps to perform a cleaning sequence once

a day.

Flow regulation can be safely and easily obtained by

increasing the number of pumps. This configuration also

increases the reliability of the system.

H

Q1 Q Q Q Q Q Q

Q total=Qn

H

Q1

Q total=n x Q1

If you decide to work with frequency converters, all velocities

in the different parts of the system must be checked.

We recommend that you involve the pump manufacturer

in the design process in order to be informed about the

hydraulic limits of the pumps and the most appropriate

control system.


CONTROLLING VAST

WATER VOLUMES AT

DUBAI DRYDOCKS

InternationalProject Reference

PROJECT DATA

Customer: Dubai Drydocks

Dubai, United Arab Emirates: The Dubai Drydocks have moved on from their early beginnings in 1971 to become one of the

leading ship repair yards in the world – and the premier yard between Europe and the Far East.

Since beginning operation in earnest in 1983, the shipyard has repaired over 5,000 vessels of all types and sizes. Many of

those vessels are ULCCs and VLCCs, representing a large proportion of world’s tanker fleet. The yard employs over 5000 skilled

employees, a workforce which is supplemented by up to 1,500 workers from local subcontractors when required.

The Situation

In 2005, the Dubai Drydocks decided to strengthen their position within the markets for marine ship repairs, conversions,

and shipbuilding. This was to be done by upgrading the yard to include launching facilities for new-built ships

as well as for large fabricated steel structures and offshore modules. The expansion would allow the Dubai

Drydocks to build vessels and/or hull sections of 120x60m. To bring about the upgrade, the Drydocks launched

the so-called Safina project, a USD 60 million undertaking with the objective of creating a new building facility. The new

complex was to include a sea-water pumping system for an innovative hydrolift to handle ship launches.


10 InternationalProject Reference

The hydrolift explained

The hydrolift is used to safely transfer large sections of hull

from land to sea, and then into the drydock for final assembly.

First, the hull sections are transferred via rails from the

manufacturing area onto a platform within a walled basin.

A gate located across the transfer route enables the basin

to be pumped full of water, causing the hull section to float.

The hull section is then manoeuvred into a deeper part of the

basin from where it can be taken out to sea after the water

level is lowered and the main seaward gate is opened.

The project involved the construction of diaphragm quay

walls, impounding walls, a concrete transfer platform, massive

entrance abutments and two gates, including a floating steel

caisson weighing in excess of 1,400 tonnes.

The hydrolift system will enable the launching of hull sections

up to 120m x 60m. As an added benefit, the transfer process

can also be used in reverse with ships being recovered onto

the platform for general repairs.

Large-scale pumping requirements

The hydrolift required large-scale pumping capacities. The

tender materials specified four mixed-flow propeller pumps,

each with a nominal capacity of 2200 l/sec at a 10m head.

The pumps are installed in chambers on the seaward face

of new dock gate, while the installation was designed with

the discharge pipe located below the sea level. The overall

dimensions of the floatout basin are 131 x 66m, bringing the

total volume of water to be pumped up to 122,050 m 3 . The

installation was designed with the discharge pipe located

below the sea level.

The Grundfos Solution

When it was time to select the specific pumps used to fill

the hydrolift’s basins, the consultant, Royal Haskoning U.K.

Ltd, invited bids from major companies such as Grundfos,

Flygt, KSB, ABS, and WEIR. Based on a thorough assessment of

the task at hand, Grundfos recommend a mixed-flow pump

– specifically the 1000KWM300 12T4, a KWM pump with a

nominal power rating of 300 kW and a 425 RPM motor. Like all

K-range pumps, these pumps would be adapted to perfectly

match the intended application. In this case, highlights include

an epoxy coating and zinc anodes for additional corrosion

protection – and the inclusion of all monitoring devices.

Grundfos package proved most attractive

While most bidders were rejected on technical grounds, a

non-Grundfos European manufacturer seemed most likely

to get the order, having been involved in the project from an

early stage. However, in the end the customer was convinced

that the Grundfos package offered convincing arguments.


PRODUCT DATA

1000KWM300 12T4

11 InternationalProject Reference

Grundfos input counteracted cavitation

A key point behind the final decision to use K pumps

was the fact that Grundfos offered more than just the

product. For example, the Grundfos team took at good

look at the tender specification and then recommended

what they would change. With the original design, the

pump would have been subjected to cavitation caused

by a siphoning effect created by the fact that the

discharge end of the pipe was located below sea level.

The Grundfos engineers suggested some modifications

to the discharge pipe; changes which were accepted

by the consultant. Grundfos also provided detailed

information on how to create the best possible cable

and chain supports system.

The Outcome

Completed in 2006, new hydrolift system is now

working perfectly, with vast water volumes controlled

reliably by the KWM pumps. Distinctive features such

as the pumps’ low RPM and excellent NPSH help ensure

efficient operation as well, adding more benefits

to a project in which Grundfos is very proud to have

taken part.

Read more about the Grundfos pump range at

www.grundfos.com


1 LocalProject Reference

GRUNDFOS INNOVATIVE

SOLUTIONS SAVES PBAPP

MONEY AND SPACE AT

SG DUA WTP

Sungai Dua Water Treatment Plant is currently the largest WTP in Penang. It is able to produce 770 million litres per day (MLD).

500 MLD of the production is distributed to Mainland (Seberang Perai) and the balance of 270 MLD is distributed to Penang

Island. Sungai Dua WTP is taking charged by Perbadanan Bekalan Air Pulau Pinang (PBAPP).

The Situation

There are 18 nos. of filter beds at Sungai Dua WTP and they require a total of 0.57

million litres water and 21m head for every backwash process, 7 times per day. If

PBAPP is going to tap from the treated water line, then the pressure of distribution

line to the customer would be greatly affected. On top of that, a lot of post

chemicals (Chlorine, Hydrated Lime and Sodium Silico Fluoride) would be wasted if

the treated water is used for filter backwashing process.

In order to overcome these problems, they have decided to use water from the

storage tank after the filtration process instead of using the treated water. To

serve that purpose, PBAPP needs 2 nos. of split casing pumps to be installed to the

existing system. But then the space constraint would be another issue that they

need to solve.

The Solution

PBAPP has found a solution with Grundfos when we recommended our PACO

vertical split casing pump to them. The KPV model is a vertical split casing pump

which requires very minimal ground space. For PBAPP, this was the first ever vertical

split casing pump being installed. With the right pump installed, PBAPP has saved

averagely RM100,000 per annum on the operation cost that consume chemicals

and also energy cost on the treated water. On top of that, the ROI was just 6 years

and the pumps are running fine until now.

The Outcome

PBAPP commented that they are very satisfied with the pump efficiency and the

robust design of the motor stool. It helps to reduce the upthrust load and the

alignment issue during operation. They are very pleased as well with the minimum

maintenance throughout the operation period.

GRUNDFOS PUMPS SDN BHD ( 0 -A)

7, Jalan Peguam U1/25

Glenmarie Industrial Park

40150 Shah Alam

Selangor, Malaysia

Tel : +603 5569 2922

Fax : +603 5569 2866

Email : gfosmy1@grundfos.com

www.grundfos.com

Cert No: KLR0 0 0

BRANCH OFFICE

Northen & East Coast

10, Ground Floor,

Jalan Todak 4,

Bandar Sunway,

13700 Seberang Jaya,

Penang, Malaysia

Tel : +604 818 3779

Fax : +604 818 3848

East Malaysia

Lot 8, Lorong Industri Warisan 1,

Taman Industri Warisan Indah,

Mile 7, Old Tuaran Road,

88450 Inaman, Kota Kinabalu,

Sabah, Malaysia

Tel : +6088 380 663/+6088 383 663

Fax : +6088 383 621

PROJECT DATA:

Customer:

Perbadanan Bekalan Air Pulau Pinang

PRODUCT DATA:

KPV 1015-3/4

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