PRODUCTS & APPLICATION COURSE BOREHOLE SYSTEMS 9 th August 2018 1
Borehole Drilling: Borehole Drilling 2
Borehole Drilling Process Step 1 Hydro-geologists survey report & siting the borehole Step 2 - National & Local Authority Permits & Compliance. (KE WARMA, NEMA & County Approvals) Step 2 Drilling and Construction Step 3 Determining the yield of the borehole Step 4 Equipping the borehole 3
Static Water Level Water level before Pumping (SWL) Dynamic water Level Stable water level after 24hr test pumping (PWL) Draw down PWL - SWL TYPICAL BOREHOLE 4
BOREHOLE SURVEY DATA Borehole details Depth SWL Casing PWL Test Yield Flow Casing profile drawing Surface details Distance to delivery Pipe size & Material Elevation Power Supply Source: Mains/Solar Single or three Phase Generator Size Distances of: Power pt Panel Borehole - Panel 5
TEST PUMPING Well log should contain the result of a pumping test of at least 48-72hrs depending on PWL stability Over 24hrs, the PWL should be constant Low risk of over pumping Problems of Over Pumping Risk of dry running Risk of sand penetration and siltation Lowering of the PWL higher operating costs Deep draw down casing oxidation to form ochre which may clog well screen and pump Permanent lowering of aquifer levels chemical changes and heavy metal precipitation, infiltration of nitrates and pesticides resulting in pollution of the aquifer Most common cause of over pumping is increased water consumption, covered by increased pump capacity or longer duty of borehole pumps without increasing number of wells and catchment area 6
PUMP POSITIONING Submersible pumps are cooled by circulation of the pumped water around the motor Effective circulation and convection is achieved if the pump is located in a plain casing - below PWL above the main aquifer Motor cooling is key to its life pump position affects motor life Water temperature also affects motor life due to its effect on cooling When cooling conditions are not ideal Industrial motors Cooling Sleeve Derating of motors 7
CABLE SIZING Correct size Avoid excessive Vd (1-4%) Motor size, 1~, 3~ Length of distance run Ensure proper insulation Electrode cable, electrodes Earthing for safety Splicing, joints along length Protection of cable running along the ground Wiring professionally wired control panels 8
Cable Sizing Chart 9
TYPICAL BOREHOLE INSTALLATION 10
SYSTEM COST OF OWNERSHIP Includes procurement costs, purchase price, installation cost, Operating/Energy costs Also includes tools for product selection, after sales service, training and technical support, efficient logistics, documentation, wide product range and a stable organization Life Cycle Cost (LCC) Total sum of costs and benefits arising out a relationship with a supplier. Power, P = Q x H x 367x Energy Costs, E = c x h x P c = Specific energy cost / kwh h = Total running hours 11
SYSTEM COST OF OWNERSHIP Includes purchase price, installation cost, operating/energy costs Also includes:- i. Cost of after sales service, ii. training and technical support, iii. efficient logistics, iv. documentation, v. wide product range and vi. a stable organization 12
RECAP - KEY POINTS Insist on the provision of the Borehole Completion report! Get specific site details Discuss power availability(on Grid? 1, 3~? Genset, Solar?) Discuss delivery point (tank, Sprinklers etc) Discuss use of water Plants, animals, drinking, industrial Cables Look at the legislation what does the law say about borehole abstractions Consider LCC 13
BOREHOLE EQUIPMENT 14
BOREHOLE PUMPS Grundfos SP Dayliff DS Grundfos SQ Grundfos SQFlex Pedrollo 4SR Dayliff D3SP1/ DSP Lorentz PS/PSK 15
GRUNDFOS SP/DAYLIFF DS Multistage submersible pumps for installation with 4 & 6 diameters Clean thin non-aggressive liquids without components or fibres Entire pump Stainless Steel with water lubricated rubber bearings Handle sand content upto 50mg/l, where the pump efficiency will remain acceptable for up to 35,000 duty hrs Type Keys: SP3A 45 DS 3/45 16
GRUNDFOS SQ Electronically controlled high speed pump, 10,700rpm Both Stainless steel and composite material Electronic motor controller with Dry run protection No electrodes Soft Start design avoiding water hammer Over/Under Voltage protection Overload and high temperature protection No need for control panel cutting down installation cost Not repairable except replacement of impellers 3 pump fits in 80mm boreholes 17
PEDROLLO 4SR/6SR Multistage submersible pumps 4&6 pump Floating impellers to provide high resistance to sand content Impellers & diffusers are made of engineering plastic 1Ph Supplied c/w with a control box 3Ph require a DoL starter 19 models available Flow range 16m³/hr Max head 300m 18
DAYLIFF D3SP1 / DSP D3SP1 plastic impellers, 20m cable, 2 sizes, control included DSP Multistage submersible pumps 4 pump Clean thin non-aggressive liquids without components or fibres Floating impellers & Stainless Steel inlet/outlet chamber, casing Excellent sand handling capacity Supplied c/w with a control box Four models available Type Keys: DSP 1-15 19
CONTROL PANELS Provides protection and reliable controls for all electric pumps. Panels can be customized to suit customer requirement. Single Pump control Two pump control Multiple pump control
DAYLIFF DRYTEK Electronic pump controllers Fault and parameter setting done using push buttons Sizes up to 15kW (DOL) Digital display Incorporated PFR in 3~ panels Auto restart for fault signals 21
GRUNDFOS MP 204 UNIT Protects Against Dry running Overload Closed valve or frozen discharge Insufficient liquid circulation past the motor Too high temperature of Pumped liquid Deposits on the motor Over/Under Voltage Phase Asymmetry Motor Overheating Incipient motor failure 22
MP 204 WITH R100 Remote control R100 for wireless communication with MP204 uses infra red light Used for setting and resetting warning and stop limits of various operation parameters To check status displays MP 204 keeps a record of the last five faults recorded When communication with MP 204 is established motor Temperature flashes 23
POSSIBLE CAUSES OF FAILURE IN SUBMERSIBLE MOTORS Voltage un-balance Over/under-voltage Voltage spikes Mechanical overload due to pump wear High temperature hot water, loss of cooling (0.15m/s), mechanical overload, ochre/scale build up Over-pumping causing dry running Wrong size of cable excessive voltage drop Hydraulic loading water hammer 24
RECAP MOTOR PROTECTION Control Panel Ensure proper sizing of components, Wiring Cable Size Avoid excessive Vdrop Cable sizing charts available in tables Ensure Earthing is done properly- for safety of installation Ensure water temperature is within specs Above 7.5kW, use MP204 Unit for superior motor protection 25
DAYLIFF PVC BOREHOLE PIPES Traditional GI pipes PVC Stand Pipes Sizes available:- 1 ¼ 1 ½ 2 2 ½ 3 26
BENEFITS PVC PIPES Strong Non-corroding PVC, Long Life Deep Square Threads Strength Rubber Joint easy coupling and sure seal Smooth surface finish reduced hydraulic friction losses, better pump efficiency Light and easy to handle in 3m lengths Suitable for water temperature 70 deg C Economical to buy and install 27
Improving People s lives SOLAR PUMPING Solar water pumping- Cheaper, Cleaner, Sustainable
Solar Energy Principals Energy emitted by the sun Measured in Watts/m 2 ; at standard testing conditions of 25ºC, max solar irradiance is 1000W/m 2 Converted to thermal (e.g solar water heaters) and electrical (e.g. Photovoltaic modules) energy Varies throughout day and year
Solar Energy Basics Solar Energy Thermal Energy Electric Energy Solar Hot Water Systems Solar Power and Lighting Systems Solar Water Pumping Systems
https://youtu.be/5yqod1lbbjg
Water Supply a Global Challenge Increased demand for natural resources Climate change Energy required to access ground water Fossil fuels are expensive Grid power often not available or not reliable
Our alternative The Sun Sunshine is free It will deliver for another 5 billion years Africa has plenty of it!
Solar Irradiation Comparisons
Solar Module Pricing PV prices have dropped by 10x Almost any size of solar pump system is feasible For pumping ROI is fast, <3-5 years against a diesel generator
Price Per Watt Peak Solar Module Pricing 6.0 Retail Module Price Index Dec 2001 - Dec 2016 5.0 4.0 3.0 2.0 United States ($) Europe ( ) 1.0 0.0 2001 2008 2016 Period
Solar Pumping Overview SOLAR DIESEL ELECTRICITY Moderate Capital Cost Can be portable Extensive experience PROS Lower COO, Short RoI Fast, Simple installation High reliability & long life Low Maintenance Packaged, Modular Solution Unattended operation Clean, non-polluting Infinite and free Low capital costs Simple Installation Noiseless Extensive experience CONS Relatively high capital costs 6hr Pumping Lower output in cloudy day Space Demand (120W/M², 8m²/Kw) High COO Maintenance often inadequate reducing life Intermittent fuel Site operator necessary Noise, dirt and fume problems Finite High operation costs Unreliable Environment al effects 37
Solar Pumping Overview Cost Benefit Analysis The cost of solar pumping system will be equal to diesel water pumping system in around 5- years As the PV panel price goes down while oil price rises up, the benefit time will reduce
TWO IMPORTANT CONCEPTS Water per day Total water requirement for the application Pump water during daylight hours Store water not electricity Make water available when needed Simple and efficient
Components of a Solar Pumping System 40
PV Modules 1. Monocrystalline Efficiency: 16% Chemically stable Last long (25-yr warranty) 2. Multicrystalline Efficiency: 9-13% Long lifetime (20-yr warranty) Made from different silicon material than mono Have multiple colour tones and patterns 3. Amorphous Efficiency: 3-6% Most recent technology Most cheaply produced Don t use silicon in crystalline form Degrades over time Applications: where space not a limitation; <40W 41
Pump Controller (DC = AC) Dayliff Sunverter 1 Lorentz PSK Lorentz PSK2 42
Pump Controller (DC&AC = AC) Grundfos RSI Dayliff Sunverter 2 43
Protections/ Accessories Well Probe PV Disconnects Surge Protector 44
SOLAR PUMPING SOLUTIONS
D3 Solar Submersible Pumps Centrifugal and Helical type Permanent magnet, oil filled, brushless, DC motor, 120W 1000W Pumps are supplied complete with a controller, water level sensor and spare rotor or impellers depending on type Three models D3SOLAR120H 50m; 0.8m3/hr D3SOLAR500C 80m; 1.5m3/hr D4SOLAR1000C 90m; 4.0m3/hr
D4 Solar Submersible Pumps Centrifugal and Helical type, for borehole application Pumps are constructed principally from AISI 304 stainless steel Pumps are fitted with Permanent Magnet brushless high efficiency, maintenance free DC motors, 0.6kW 1.8kW Three models D4SOLARX600H 80m; 2.0m3/hr D3SOLARX1200C 180m; 1.6m3/hr D3SOLARX1800C 90m; 2.5m3/hr
Fluid Solar Dc Solar Submersible Manufacturer: Pedrollo Pumps Features a hydraulic end that incorporates floating centrifugal type impellers Pump and motor are an integral unit, with electronic control incorporated in the motor Motor Rating 750W, Input Solar Power Required 980W Min Input Voltage: 100VDC Head 60m; Flow 5.0m3/hr
Grundfos SQflex Pump Helical Rotor Pumps- 4 models for high heads and low flows (Heads up to 250m with flow from 600l/hr). Centrifugal Rotor Pumps- 6 models for low heads and high flows (Heads from 15m with flow upto18m3/hr).
Grundfos SQflex Pump Motor One size of 1400W MSF 3 motor for all pumps Can be powered using Ac or DC voltage within the range of 30-330VDC Control Units IO 100 Manual Solar System IO 101 Solar/Generator System IO 102 Wind System CU 200 Solar System with High Level Control and Hybrid System monitoring. 50
Grundfos SQF Mini Pump SQF mini is a multistage submersible solar pump designed for water supply for boreholes and wells with low daily flow requirements. Built in MPPT, maximum power point tracking, software and motor protection Dry running protection Head 40m, Flow 2,000l/hr, Power 300W 51
Lorentz Solar Pumps <$1,000 Selling Price 450m Head 500m 3 / hour
Lorentz Solar Pumps DC Range: PS150 to PS4000 Nominal power 150W-4kW Submersible: centrifugal & Helical rotor; Q up to 70m³/Hr; H up to 450m Surface: Centrifugal ; Q up to 60 m3/h, H up to 150m AC Range: Upto 30kw Centrifugal pumps Submersible:Q up to 130m³/Hr; H up to 160m Surface-Q up to 315 m3/h, H 90m 53
Lorentz System Components Solar generator or Solar array Controller + pump unit = Pump System Pump end Controller ECDRIVE Motor Pump end + motor = Pump Unit
Lorentz DC Pump Controller Contains the electronics making them easy to service and replace Control and monitoring of the pump Maximum Power Point Tracking (MPPT) Overheat and overload protection Well probe / float switch connections Outdoor housing (IP 54) Shadowed installation Manual pump capacity adjustment Reduced flow rate of the well Maximum efficiency up to 98% Maintenance free
Ac Pump Controllers For use with AC submersible/surface pumps DC to 3-phase AC inverter MPPT technology Compatible to motor of rated voltage 3ph 3 types of controllers Dayliff Sunverter: 2.2kW-18.5kW Grundfos RSI: 3kW-37kW Lorentz PSk2: 5.5kW- 30kW 56
Dayliff Sunverter Controller MPPT Voltage: 530-600VDC Max DC Input Voltage 750VDC Output frequency 0-60Hz. Sizes:-1.5KW AND 2.2KW Single Phase Sizes:- 2.2KW-18.5KW Three Phase 57
Grundfos RSI Controller DC to 3-phase AC inverter MPPT technology Compatible to Motor of rated voltage 3ph Maximum input DC voltage 800V Minimum MPP Voltage 400V Output frequency 0-60Hz Output Voltage 415VAC Digital input for dry running and level switch IP66 enclosure rain, dust, sand 11 sizes available up to 37kw AC/DC Compatible
Lorentz PSk2 Controller DC to 3-phase AC inverter MPPT technology Compatible to Motor of rated voltage 3ph Maximum input DC voltage 850V Output frequency 0-60Hz Digital input for dry running and level switch 6 sizes available upto 30kw motor Blue housing, New naming - PSk2-40 Full support for smart Solution via smart PSU More detailed analysis Full system diagnostics and error reporting through PumpScanner 59
Lorentz Smart PSU Provides DC power to PSk2 pump controllers from AC source from grid or generator PSk2 will automatically and seamlessly manage power changes and blending of solar and other power sources. Constant flow and constant pressure onboard applications plus a daily amount feature Supports PSk2 controllers from 7-40k 380-400V 3 phase AC input (50-60Hz) Max 850V DC input, 560V DC output Controlled by PSk2 controller, both timed & on available solar power 60
Lorentz Accessories Well Probe detect water level within a well (source Low) Float Switch - tank water level detection (Tank Full) Pressure Switch tank water level detection (Tank Full) Liquid Level Sensor water level in tank/well Liquid Pressure Sensor pressure in a pipe Water meter with pulse cable Surge Protector voltage spikes PV Disconnect Professional Strings connection PV Combiner Connection Box for Parallel wiring PV Protect Electrical surges SmartStart- Remote control
Lorentz Remote Monitoring 62
idayliff System 63
SUCCESSFUL INSTALLATIONS 64
Kenya Red Cross Dertu Farm in Garissa 65
Dadaab Refugee Camp Water Supply 66
Kasha Water Supply, Garissa 67
Oxfam Nabulon LOWASCO Water Supply 68
LOWASCO Hybrid Water Supply 69
JICA Marsabit Hybrid Water Supply 70
Glory Outreach Farming in Lodwar 71
RVWSB Napuu, Lodwar 72
RVWSB Napuu, Lodwar 73
KRCS Oloitokitok Community Water Supply 74
Any closing Question? 75