OPTIMISED WATER SOLUTIONS

Grundfos is a full-range supplier of intelligent pumps and systems for all

water supply and wastewater applications

• Maximum reliability and resource efficiency

• Tried and tested technology
• Years of expertise
Water intake

Surface Water
Pumping Stations

Underground Water
Pumping Stations
Water transport

Main Pumping Stations Booster Pumps

(Transfer and Distribution) (Transfer and Distribution)

Local Pumping Stations Water Towers

(Distribution) and Elevated Tanks
Water intake
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Maximum content of sand: 50 to 150 ppm

• More than 100 years of experience
• Light to Engineered-to-Order
• Wide Range of materials
• Global presence
 ENERGY SOURCE

PRODUCT

MGFlex motor RSI solar inverter

SQFlex submersible pump COMBINE WITH COMBINE WITH
High efficiency SQFlex solar
submersible pumps are ideal
CRFlex solar surface and The Grundfos Solar
for plug and pump, flexible,
MTRFlex solar Inverter (RSI) works with
low flow water supply
immersible pumps and almost any Grundfos
other conventional pump for large-scale
pumps use powerful water supply
MGFlex motors with an
integrated solar inverter
 DIS-G DOSING TANK DOSING SKID ISIA OXIPERM VACCUPERM SELCOPERM
DIA-G STATION STATION

DMX DMH DME SMART DIGITAL SMART DIGITAL XL

DDI
Main and local pumpings stations
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Wear ring
Replaceable wear ring design helps to solve
the efficiency drop problem after long-term
operation. The wear ring can be made from
different materials according to customer
requirements and the application.
Shaft and shaft sleeve
The strength and stiffness of
the shaft are strictly calculated
to withstand the stress under
the harshest operating
conditions. Replaceable
sleeves protect the shaft from
erosion and corrosion.
Pump casing
The split-casing enables
maintenance of rotating parts
without disturbing the pipe lines.
Impeller
The hydraulic design balances the axial force
and radial force, decreases the vortex and
recirculation in the volute, widening the high
efficiency range, and also meets the low NPSH
requirement at high flow. All this ensures
reliable operation under the entire performance
range, matching the water supply demands.
Bearing
Heavy duty bearing design is
for the most severe
environments, with the pump
lasting for no less than 50,000
hours.
Bearing housing
The bearing sleeve design
makes maintenance easier.
Compensated double volute design
The compensated double-volute design
virtually eliminates radial forces on the
shaft and ensures smooth performance
throughout the entire operating range.
Booster pumpings stations
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Wastewater transport

Wastewater
Flood control
discharge

Network pumping
Road discharge
station

Stormwater Main pumping

retention tank station
Grundfos in brief
Products Overview
ABCD
Wastewater discharge from buildings
Network pumping stations
Main pumping stations
Road drainage
Flood control
Stormwater retention tanks
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S-Range
– Installation types
S-Range
- Smart Trim
S-Range
- Smart Trim Factory set impeller clearance
Customer benefits
The SmartTrim system enables you to easily
restore factory-set impeller clearance, maintain
peak pumping efficiency, and keep operation
cost down.

Factory set impeller clearance

Decrease of pump efficiency in points

S-Range
- Smart Seal

• Flexible and replaceable

• Reduce re-circulation to
minimum
Flood
Control, Water Intake
Axial flow propeller pump
– KPL

BENEFITS
• With the Turbulence Optimiser™, for best-
in-class hydraulic efficiency of up to 86%
• High-voltage motors for low installation
costs
• High-precision one piece propeller with
back-swept design reduces clogging

TECHNICAL DATA VARIANTS

• Motor size: 11 - 700 kW • Propeller in stainless steel is standard;
(Up to 850 kW on request) other materials available on request
• Flow rate (Q): 9,200l/s (33,120 m3/h) • Sensors for monitoring the pump:
Applications: • Head (H): 10 m bearing and winding temperature,
RAW WATER INTAKE • Liquid temperature: 0 to +40 °C vibrations and water in oil
WASTEWATER TRANSPORT
• Discharge diameter: Up to 2200 mm
FLOOD CONTROL
• Insulation class: F
WASTEWATER TREATMENT
• Maximum installation depth: 20 m
• Maximum hydraulic efficiency: 86%
Mixed flow pump
– KWM

BENEFITS
• Simple pump design for long lifetime
• Robust, reliable and efficient, offering
maximum value for money
• High-voltage motors for low installation
costs

TECHNICAL DATA VARIANTS

• Motor size: 11 - 700 kW • Impeller in cast iron is standard;
(Up to 850 kW on request) stainless steel available on request
• Flow rate (Q): 5,555 l/s (20,000 m3/h) • Sensors for monitoring the pump:
Applications: • Head (H): 20 m (Up to 400 m on request) bearing and winding temperature,
RAW WATER INTAKE • Liquid temperature: 0 to +40 °C vibrations and water in oil
WASTEWATER TRANSPORT
• Discharge diameter: column
FLOOD CONTROL
(FPV up to DN 2,200)
WASTEWATER TREATMENT
• Insulation class: F
• Maximum installation depth: 20 m
• Maximum hydraulic efficiency: 85%
Typical installations
– KPL, KWM
Accessories, engineering
– KPL, KWM
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WASTEWATER TRANSPORT
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Extremely durable tank
• Extremely durable tank
• GRP (Glass Reinforced
Polyester) is fully resistant
to tear and destructive
forces in wastewater
applications.
• Extreme reliability and long
lifetime compared to
concrete solutions
Unique pit design
• Spherical design ensures
optimum strength and
resilience to ground water
pressure.
• The design ensures that
wastewater is let to the
inlet of the pumps,
minimizing the risk of
sedimentation and odour
problems.
• Anchoring bolts for
attachment to a concrete
foundation comes
standard.
Lockable hatch with built-in
safety features

• The manhole comes with a

safety grid and is elevated
from the top for safety
reasons. It is locked with a
padlock.
• The design allows for for
ventilation through the top or
the side of the station.
• Control cabinet can be placed
on the top of the pumping
stations next to the manhole.
• Traffic covers can be supplied
up to Class D (40 ton).
Valves/valve chamber

• High quality non-return valves

and closing valves are an
integrated part of the
package.
• For easy service and
operation of the valves, we
offer integrated service
platforms.
• Optional valve chambers
means you do not have to
enter confined space to
service the valves.
• All valve chambers come with
a drainage pipe.
Flanged inlet or inlet sleeve

• All inlets are laminated into

the fiber glass wall to ensure
tight sealing.
• In case of high velocity or
large distance from inlet pipe
to bottom of stations, we offer
baffle plates to minimize the
risk of cavitation.
• Screen baskets for inlet sizes
up to DN 400 available.
Corrosion free and pressure-
tested pipework

• The design of the pipes and

manifold is done with focus on
service friendliness and low
friction losses.
• The pipework comes in stainless
steel (SS) or polyethylene (PE).
Vacuum breaker or manometer
for stainless steel available .
• Pipe diameters of up to 250 mm
for stainless steel and 160 mm
for polyethylene available.
The Grundfos range consists of
• Grundfos SMD direct drive mixers
• Grundfos SMG mixers
• Grundfos SFG flowmakers
• Grundfos SRG recirculation pumps

Benefits
• Hydrodynamic 2 or 3 blade propellers help ensure high
efficiency and non-clogging operation
• Full range of high-quality installation accessories
• Suitable for continuous and variable speed (CUE)
operation

Technical data
• Motor size: 1.5 - 18.5 kW
• Liquid temperature: 5 to 40 °C
• Propeller diameter: 450 - 2660 mm
• Propeller speed: 23 - 710 rpm
• Axial Thrust: 434 - 6440 N
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Technical data
• Disc diffusers 9″ & 12″
Maximum Qnominal 8.0 Nm3/h
• Tube diffusers 2″ & 3″
Maximum Qnominal- 34.0 Nm3/h
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Complex wastewater challenges

• Waste water content

• Growing populations
• Extreme weather conditions
Waste water content

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Growing populations
 Complex wastewater
…and Middle East... challenges

Dubai, 9th of March 2016

Gulf News
 Extreme weather conditions

Paris Karachi

Wikipedia
 Extreme weather conditions

Lahore

Wikipedia
Consequences of oversizing

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Right sizing of pumping station

To avoid
• Inefficient operation
• Breakdowns
• Odor formation
• Flooding
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Number of pumps

• Rule of thumb
m³/min m³/h l/s No. of Pumps
Flow below 100 6,000 1,667 3
Flow below 800 48,000 13,333 4
Flow above 800 48,000 13,333 >4
The Grundfos Pumping Station Creator lets
you design you own station in a matter of
minutes

• Specify size, features and functionalities

for your specific projects
• Choose from our wide range of pumps,
controls, pits, valves, and other parts
• Get full documentation including 3D
drawings
of your station
• All solutions available through the system
are fully CE-marked
Considerations in the sump
ANSI/HI 9.8-2012:
Rotodynamic Pumps
Hydraulic phenomena for Pump Intake Design
• Pre swirl
• Uneven velocity profile
• Air
• Vorticies

Waste
• What comes in must be pumped out
• Sedimentation
• Floating waste
• Wear
Preswirl

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Uneven velocity profile

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𝑣 −𝑣
𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑣𝑎𝑟𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = . 100%
𝑣
Air

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Wastewater

What comes in must be pumped

• Bottom sediments
• Floating debris
• Pump throughlet vs screen size
Solution

• Properly sized sump => floor velocities

• Properly sized screens
• Pump alternation
• Cleaning cycle
• Inbuilt features in Grundfos control
Grundfos PIT CREATOR
www.Grundfos.com/Grundfos Product Centre
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Wastewater controls
– Dedicated controls

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WASTEWATER TRANSPORT

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Energy optimization
– Pump grouping

Start 4
Start 3
Water level
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Start 2
• Start 1

Stop 3-4 P3 P4
Stop 1-2 P1 P2

Group 1 Group 2
Efficiency

Example
• 40 000 m³ pumped from A to B
• H geo = 10 m

Alternative 1: Small pump low Alternative 2: Large pump high

efficiency efficiency
• Htot = 20m • Htot = 42m
• Q = 20 l/s • Q = 40 l/s
• tot = 50% • tot = 70%
• Energy = 4360 kWh • Energy = 6540 kWh
• 50% more despite higher efficiency
Anti-seizing

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Energy optimization
– VFD utilization

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VFD Operation

PROS CONS
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VFD Operation

Check List
 minimum speed
• clogging
• pipe velocities
• specific energy
• flush the pipes
 control strategy
• up to full speed before start/stop
• consider reverse if clogging
 Usually not good in propeller pump systems / pure lift systems when ≈ Hgeo > 0.5 of
total losses
 Cooling system
 Wastewater: enough starting torque
Anti-blocking
– flushing the system

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Anti-blocking
– reverse mode

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Daily emptying

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START

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Ajman case story, UAE

O&M COMPANY ACHIEVED

• Overall energy consumption reduced by approx. 20%
• Number of site visits and breakdowns have been
reduced significantly
• Complete overview of operating information is now
available via web & SMS (GRM), making continuous
optimization and monitoring of the entire network
possible

WHAT WE DID
• Replaced existing controls systems in all 22
wastewater pumping stations with Grundfos
Dedicated Controls CU352 with advanced features
(energy optimization, anti-clogging, flushing) with
VFD’s
• Implemented Web based monitoring system -
Grundfos Remote Management (GRM)
Support
• Grundfos Product Centre GPC
• Prefabricated Pumping Station Configurator
• Pit creator
• Mike Urban Water and Sewer Network
• Pressurized Network Simulation Tool
• NPSH Calculation Tool
• Hytran – Water Hammer Analysis
• Computational Fluid Dynamics - CFD
Main interested areas for using CFD:
• Pump stations
• Water Intakes
• Waste Water Treatment plants
• Mixer/ Flowmaker applications
• Water Treatment plants (Mixing)

CFD can be used when:

- Design needs deviation from normal standard recommendations (e.g. ANSI/HI 9.8)
- Specific flow conditions analysis is required (e.g. low water level)
- You have refurbishment cases with changed conditions
- Troubleshooting in existing systems
Overall aim for the CFD simulation of process tanks is to investigate and analyze the
presence or risk of the following phenomena:

• Adequate Mixing, Homogeneity

• Efficient Installation
• Velocity distribution
• Average Velocity
• Bulk flow Velocity
• Aeration flow pattern
• Dead Zones
• Shortcut
• Risk of sedimentation
Overall aim for the CFD simulation of pump stations is to investigate and analyze the
presence or risk of the following phenomena :

• Submerged vortices
• Free-Surface vortices
• Excessive pre-swirl of flow entering the pump
• Non-uniform velocity distribution at the impeller eye
• Excessive variation in velocity and swirl with time
• Entrained air or gas bubbles into the pump
• Risk of sedimentation
• Risk of cavitation
• Risk of erosion
• Pump failure
Original design indicates surface vortex after starting the pump
We could catch this complex phenomenon one to one in CFD!
We improved design and CFD results showed surface vortex is omitted.
New design got implemented on site and results are impressively confirm the CFD!
 Required attached data to your inquiry?

- Drawings of structure (2D/3D)

- Water Level(s)
- Solid Content (WWTP)
- Description of function / Specific demand
- Selection of products and Product data
- Position of product
- Duty point(s), # of simultaneous operating machines
- Required warranties (Homogenity, velocity, flow, head, power, efficiency)
- Special required Standards (if any)
– Initial analysis and considerations
– Nine stage process

Stage 1 Flow patterns and boundary geometry

Stage 2 Pump size and quantity

Stage 3 Pump selection

Stage 4 Placing the pumps

Stage 5 Minimum water level

Stage 6 Determine slope

Stage 7 Velocity

Stage 8 Cross-flow velocity

Stage 9 Dimensions
– Input data SPS

Q = 2160 m³/h = 600 l/s

H=8m
– Input data WPS

Q = 4320 m³/h = 1200 l/s

H = 18 m
– Head loss calculations
– Pumps selections
– Pipe velocities
– Submergence and clearance
– Units configuration
– CFD analysis, SPS
– CFD analysis, WPS
– Installation and commissioning, SPS
Complete Solution

Pum Switchgear Remote

Pumps & accessories Controls System design
ps Management expertise
Remote management
– GRM

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WASTEWATER TRANSPORT

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i-SOLUTIONS
– GRM
Support