Internship Report Done by NTAMBARA Sylvestre Owen On Solar Powered Submersible Pumps Used in Mukindo Water Project in Gisagara District

SCHOOL OF ENGINEERING
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

PROGRAM OF ELECTRICAL ENGINEERING
NYARUGENGE CAMPUS
NTAMBARA SYLVESTRE OWEN 215004285
INDUSTRIAL ATTACHMENT REPORT DONE

AT:
Prepared by;
Names: NTAMBARA Sylvestre Owen
Telephone: +250789469955 / +250727634011
E-mails: bsowen100@gmail.com / ntambara.owen@yahoo.com
Duration: 03rd July, 2017 – 30th August, 2017 Submission date: 10th October, 2017
Industrial Attachment NTAMBARA Sylvestre Owen 215004285
DEDICATION:
I dedicate this industrial attachment report to;

ALMIGHTY GOD
MY FAMILY RELATIVES
MY FRIENDS
MY COLLEGUES
MY LECTURERS
MY INDUSTRIAL TRAINING OFFICERS
UR-CST CAREER GUIDANCE
UR-CST i EEE/ELE 2017

DECLARATION:
I, NTAMBARA Sylvestre Owen a final year students at University of Rwanda-College of

Science and Technology, Nyarugenge Campus in Electrical Engineering, I do hereby declare that
this industrial attachment report is based on my original work except for quotations and citations
with a complete list of references that provides and indicates all the sources of information that
were quoted or cited.
I also declare that it has not been previously and concurrently submitted elsewhere for any other
academic award either at University of Rwanda or any other higher learning institutions for
publication or any other academic purpose.
Student Name: NTAMBARA Sylvestre Owen

REG No: 215004285
Sign ____________________ Date _____________
UR-CST ii EEE/ELE 2017

ACKNOWLEDGEMENT:
First and foremost, I thank the Almighty Omnipotent, Omniscient and Omnipresent God for
giving me the strength and courage throughout the period of my internship and for his guidance
and for helping me to complete this industrial attachment.
Secondly, I extend my heartfelt gratitude to EWB-Rwanda authorities that allowed me to have

internship in their organization in order to put the theoretical knowledge taken from class into
practice, especially Eng. Wellars BAHORANYE and Eng. Joseph NTWALI who despite their
many duties and agreed to lead my work, their guidance, remarks and relevant suggestions have
been there to carry out this industrial attachment.
I would like to acknowledge and thank the University of Rwanda for invaluable role in education
of putting this program of doing industrial attachment which in turn enhances the practices of the
theoretical work; we do always have in classes.
I would also like to thank all the people who supported me in its accomplishment; my family
relatives, my colleagues, my friends and my acquaintances, for their advices and encouragement.
My gratitude for the accomplishment of this industrial attachment merely goes to My Mum, my
trainee mates and my classmates especially; Ramy, Angel and Anselme for their shore up.
Finally, to any person or entity who has shown particular interest in my work.
I thank you all and God bless you all.
UR-CST iii EEE/ELE 2017

ABSTRACT:
This industry attachment report is a 20 credits module done at the end of third year class and it is
required for partial fulfillment of the award of the bachelors in Electrical engineering organized
by Ministry of Education through the program of University of Rwanda-College of Science and
Technology.
I participated on various activities carried out during implementation of MUKINDO WATER
PROJECT including civil, mechanical and electrical work.
This report includes company training practices, the conclusion of the trainees on the work done
and the recommendations suggested for the problem of fresh water to the population in
GISAGARA District specifically in Mukindo sector that was being solved through that project
initiated by EWB-Rwanda.
Our aim was to deepen our knowledge into electrical power system used in that project to pump
the water up the hill to the community and above all in the field of solar power system since
solar system is the one which was used to provide electrical energy for powering LORENTZ
PSk2 solar submersible pump systems.
I had also a chance of getting information filters that were being fabricated by EWB-Quebec
just for filtrating the rain water and unclean water from the dams. We had an overview on how it
is fabricated, equipments and materials used while making those filters i.e. the quality and the
quantity of the materials.
This industrial attachment was conducted at Gisagara district in Mukindo sector in the different
activities of the project that was being implemented by EWB-Rwanda stated above especially
for all activities concerned with electric power from 03/07/2017 up to 30/08/2017 with the
purposes of empowering student with the practical technical skills and to train and uphold the
student with practical working conditions after 3years of lecturers.
UR-CST iv EEE/ELE 2017

ABBREVIATIONS AND ACRONYMS:
EWB: Engineers without Boarders

UR: University of Rwanda
CST: College of Science and Technology
EEE: Electrical and Electronics Engineering
ELE: Electrical Engineering
USAID: United States Agency for International Development
MININFRA: Ministry of Infrastructure
ATM: Automated Teller Machine
PV: Photo Voltaic
PVC: Poly Vinyl Chloride
SW: Sun World
DC: Direct Current
AC: Alternating Current
STC: Standard Test Conditions
PS: PlayStation
COM: Common
NO: Normally On
NC: Normally Closed
LED: Light Emitting Diode
AWG: American Wire Gauge
VDC: Volts Direct Current
MNSPD: MidNite Solar surge protection device
IPM: Intelligent Power Module
PSU: Power Supply Unit
GND: Ground
PE: Protective Earth
MPPT: Maximum Power Point Tracking
NEMA: National Electrical Manufacturers Association
HDPE: High Density PolyEthylene
RPM: Revolution per Minute
UR-CST v EEE/ELE 2017

LIST OF FIGURES:
Figure 1: NTAMBARA Owen while standing at KAZABAGARURA Water Source ................................ 3

Figure 2: KAZABAGARURA Water Source ............................................................................................... 5
Figure 3: System Layout ............................................................................................................................... 8
Figure 4: Solar Panel ..................................................................................................................................... 9
Figure 5: Solar Panel Dimensions while Designing ..................................................................................... 10
Figure 6: I-V curve for the solar panel ........................................................................................................ 11
Figure 7: SunSwitch Front side Figure 8: SunSwitch Back side .................................................. 12
Figure 9: Mounting Sun Switch ................................................................................................................... 12
Figure 10: Connecting SunSwitch to a PS controller (with low light= OFF) ............................................. 13
Figure 11: Connecting SunSwitch to a PS controller with tank float switch (with low light = OFF) ........ 13
Figure 12: well probe .................................................................................................................................. 14
Figure 13: Well probe fixing ........................................................................................................................ 15
Figure 14: Float Switch ................................................................................................................................ 15
Figure 15: Float switch scheme .................................................................................................................. 16
Figure 16: Surge Protector .......................................................................................................................... 16
Figure 17: PV Disconnect 440-20-6 ............................................................................................................ 17
Figure 18: PV Disconnect dimensions while designing ............................................................................. 18
Figure 19: Operation of the Controller ....................................................................................................... 19
Figure 20: Controller dimensions for installation ....................................................................................... 20
Figure 21: Minimum spacing for wall mounting ........................................................................................ 21
Figure 22: Terminal block, numbering ....................................................................................................... 21
Figure 23: LORENTZ PSk2 solar submersible pumps ............................................................................... 23
Figure 24: Motor in borehole...................................................................................................................... 24
Figure 25: Preassembly of the pump .......................................................................................................... 24
Figure 26: Connection pump end with motor ............................................................................................ 24
Figure 28: connecting the next piece of pipe .............................................................................................. 25
Figure 27: Fixing of the motor cable at a joint (top) and a strait pipe (right) ............................................. 25
Figure 29: Bottom view of PSk2 controller: cable entries and external sockets......................................... 27
Figure 30: Filling, venting and drainage hole ............................................................................................. 28
Figure 31: Installation depth ....................................................................................................................... 30
LIST OF TABLES:
Table 1: Technical data of PSk2 controller ................................................................................................. 18
Table 2: Controller dimensions for installation .......................................................................................... 20
Table 3: Terminal explanation .................................................................................................................... 22
Table 4: Tightening torques for pump/motor connection ........................................................................... 25
Table 5: Additional weight per meter pipe length ...................................................................................... 26
UR-CST vi EEE/ELE 2017

Table 6: Mini plug sockets description ....................................................................................................... 27

Table 7: Motor cable resistance .................................................................................................................. 29
Table 8: LED status .................................................................................................................................... 31
Table 9: indicator lights .............................................................................................................................. 31
Table 10: Inspection overview .................................................................................................................... 33
TABLE OF CONTENTS:
DEDICATION: .................................................................................................................................................. i
DECLARATION: .............................................................................................................................................. ii
ACKNOWLEDGEMENT: ................................................................................................................................. iii
ABSTRACT:.................................................................................................................................................... iv
ABBREVIATIONS AND ACRONYMS: ............................................................................................................... v
LIST OF FIGURES: .......................................................................................................................................... vi
LIST OF TABLES: ............................................................................................................................................ vi
I.INTRODUCTION: .......................................................................................................................................... 1
1.1. BACKGROUND OF EWB-RWANDA: ........................................................................................... 1
1.2. MISSION: .......................................................................................................................................... 1
1.3. VISION: ............................................................................................................................................. 1
1.4. GENERAL OBJECTIVE: ................................................................................................................. 2
1.5. SPECIFIC OBJECTIVES: ................................................................................................................. 2
II. MUKINDO WATER PROJECT: ..................................................................................................................... 3
1. BACKGROUND: .......................................................................................................................................... 4
2. PRELIMINARY ACTIVITIES DONE AT THE SITE: .......................................................................................... 5
2.1. Kazabagarura water source ................................................................................................................ 5
2.2. Water departure chamber ................................................................................................................... 6
3. APPURTENANCES USED AND CIVIL WORK: ............................................................................................... 6
3.1. Pipe material ...................................................................................................................................... 6
3.2. Catchment of the source and intake ................................................................................................... 6
3.3. Location of valve on water supply system ......................................................................................... 6
3.3.1. Air release valves ........................................................................................................................ 6
3.3.2. Blow offs valve ........................................................................................................................... 7
UR-CST vii EEE/ELE 2017

3.3.3. Gate valve ................................................................................................................................... 7

3.3.4. Non-return valves ........................................................................................................................ 7
3.3.5. Pressure reducing valve .............................................................................................................. 7
3.3.6. Line valve.................................................................................................................................... 7
3.4. Tap Stand point .................................................................................................................................. 7
3.5. Service connections ........................................................................................................................... 7
3.4. Water reservoir................................................................................................................................... 7
III. SOLAR SUBMERSIBLE PUMPING SYSTEMS:.............................................................................................. 8
3.1. General Description ........................................................................................................................... 8
3.2. SOLAR PANEL (PV Generator): ...................................................................................................... 9
3.2.1. Definition .................................................................................................................................... 9
3.2.2. Installation of solar panels .......................................................................................................... 9
3.2.3. Tilt angle ................................................................................................................................... 10
3.3. Shading effect to the solar panel ...................................................................................................... 10
3.4. Design and selection of the PV modules to be used in this Mukindo water project ........................ 10
3.4.1. Performance under standard test conditions (STC) .................................................................. 10
3.4.2. Thermal characteristics ............................................................................................................. 11
3.4.3. Component materials ................................................................................................................ 11
3.4.4. Advantages of using solar panels .............................................................................................. 11
3.4.5. Disadvantages of solar panels ................................................................................................... 11
4. SUN SWITCH:........................................................................................................................................... 12
4.1. Installation of SunSwitch light sensor ............................................................................................. 12
4.1.1. Mounting ................................................................................................................................... 12
4.1.2. Connecting SunSwitch to controller and float switch ............................................................... 12
4.2. Contact rating ................................................................................................................................... 13
4.3. Operation of the SunSwitch ............................................................................................................. 13
4.4. Solar panel for Sun Switch............................................................................................................... 14
4.5. Advantages of Sun switch ................................................................................................................ 14
5. WELL PROBE: ........................................................................................................................................... 14
5.1. Features ............................................................................................................................................ 14
5.2. Technical data .................................................................................................................................. 14
5.3. Possible solutions ............................................................................................................................. 15
UR-CST viii EEE/ELE 2017

6. FLOAT SWITCH: ....................................................................................................................................... 15

6.1. Features ............................................................................................................................................ 15
6.2. Technical data .................................................................................................................................. 16
6.3. Float switch requirements: ............................................................................................................... 16
6.4. Grounding shielded float switch cable ............................................................................................. 16
6.5. Operation of the float switch system................................................................................................ 16
7. SURGE PROTECTOR: ................................................................................................................................ 16
7.1. Features ............................................................................................................................................ 17
7.2. Technical data .................................................................................................................................. 17
8. PV DISCONNECT 440-20-6:...................................................................................................................... 17
8.1. Features ............................................................................................................................................ 17
8.2. Technical data .................................................................................................................................. 17
8.3. Wiring .............................................................................................................................................. 17
8.4. Optional lightning surge protector ................................................................................................... 17
9. PS9K2 PUMP CONTROLLER: .................................................................................................................... 18
9.1. Features the controller...................................................................................................................... 18
9.2. Operation of the Controller .............................................................................................................. 19
9.3. Installation and operation of the controller ...................................................................................... 19
9.4. Functions of the controller ............................................................................................................... 19
9.5. Controller Placement ....................................................................................................................... 20
10. LORENTZ PSk2 SOLAR SUBMERSIBLE PUMPS: ...................................................................................... 23
10.1. Features .......................................................................................................................................... 23
10.2. Pipe sizing ...................................................................................................................................... 23
10.3. Pipes with thread ............................................................................................................................ 24
10.4. Installation...................................................................................................................................... 24
10.5. Installation depth ............................................................................................................................ 25
10.6. Checking correct rotational direction ............................................................................................. 25
10.6.1. Check the rotational direction as follows: ............................................................................... 26
10.7. Removal of pumps ......................................................................................................................... 26
11. CABLE ENTRIES AND EXTERNAL SOCKETS: ............................................................................................ 26
12. GROUNDING: ........................................................................................................................................ 28
12.1. Why ground?.................................................................................................................................. 28
UR-CST ix EEE/ELE 2017

12.2. How to ground?.............................................................................................................................. 28

13. MOTOR WATER FILLING/REFILL: .......................................................................................................... 28
13.1. Resistance measurement ................................................................................................................ 29
13.2. Winding resistance ......................................................................................................................... 29
13.3. Insulation resistance ....................................................................................................................... 29
13.4. Loss insurance................................................................................................................................ 29
14. INDICATOR LIGHTS: ............................................................................................................................... 31
15. TROUBLE SHOOTING: ............................................................................................................................ 32
15.1. Time delays .................................................................................................................................... 32
15.2. PUMP OVERLOAD (PUMP ON light shows red instead of green)............................................. 32
15.3. Service and Maintenance of the Controller.................................................................................... 33
15.4. Requirement of inspection and maintenance: ................................................................................ 33
15.5. Main points for inspection and maintenance ................................................................................. 33
IV. TRAINING OUTCOMES: ............................................................................................................... 34
1. INDUSTRIAL ATTACHMENT CONTRIBUTION TO OUR KNOWLEDGE: .............................. 34
2. TRAINING BENEFITS AND MOTIVATIONS: .............................................................................. 34
V. CONCLUSION AND RECOMMENDATIONS: .............................................................................. 35
1. CONCLUSION: .................................................................................................................................. 35
2. RECOMMENDATIONS: ................................................................................................................... 35
VI. REFERENCES AND RESOURCES: ............................................................................................................. 36
1. Reference ............................................................................................................................................ 36
2. Resources ............................................................................................................................................ 36
VII. APPENDIX:....................................................................................................................................... 36
1. Training certificate .......................................................................................................................... 36
2. Weekly log books ........................................................................................................................... 36
UR-CST x EEE/ELE 2017

I.INTRODUCTION:
1.1. BACKGROUND OF EWB-RWANDA:
Engineers Without Borders (EWB-Rwanda) is a Non-Governmental Organization (NGO) that

uses engineering practices to improve the quality of life through education and implementation
of environmentally and economically sustainable engineering projects. It is established to partner
with EWB chapters from around the world, other organizations or institutions and local
communities, since 2005 some members in action (Wellars, Tuombe, Bonaventure and Joseph),
and 2013 officially founded at the University of Rwanda (former KIST).
Meeting, discussing and working with Engineers Without Borders from around the world;
having site and regional experience in needs; after analyzing the technical and managerial
capacity of the Rwandans with local potential in materials; it was required to have a Rwandan
group of Engineers to develop practical skills by giving solutions for identified problems into the
community, as per the mission, vision, and objectives here below mentioned.
Along the past years, Rwandan engineers and Experienced Advisors (namely Wellars
BAHORANYE, Dr GATABAZI Jean Damascene, Dr Leopold MBEREYAHO, SEKAMANA
Jean Damascene, Joseph NTWALI, KYAZZY Eduard, NIKUZE Joselyne , MUNYABUGINGO
Bonaventure, and MUGOROZI Theophile) sat together and analyzed the solutions as
contribution to sustainable development projects through engineering networking humanitarian
organization “Engineers Without Borders – Rwanda” in partnership with the Government,
NGOs, Institutions, Academics, Volunteers, Industries, and local communities.
EWB-RWANDA has been officially registered under the registration No78/RGB/NGO/2016

dated 27th January 2016, by Rwanda Governance Board (RGB) for mission, vision and
objectives as follows:
1.2. MISSION:
EWB-RWANDA has been founded with a mission to partner with developing communities to
improving the quality of life through education and implementation of engineering projects.
EWB-Rwanda gives to university students and engineering professionals’ members a unique and
life changing opportunity to participate in and improve the global community.
1.3. VISION:
EWB-RWANDA has a vision in which the communities have the capacity to sustainably meet
their basic human needs, and that our members together with our partners have the global
perspectives through the innovative professional educational opportunities.
UR-CST 1 EEE/ELE 2017

1.4. GENERAL OBJECTIVE:
To involve the concept and implementation of engineering assistance through which most of
Rwandan citizens have the opportunity to meet their most basic needs. For that, it will partner
with EWB chapters from around the world, other organizations or institutions and local
population.
All members of the organization EWB-Rwanda will have the priority in case of recruitment of
employees; they will professionally get trained for having the capacity to do so for others; for
those members’ fresh graduates, will have the priority and facilities for keeping one’s terms
according to their major of study.
1.5. SPECIFIC OBJECTIVES:
 Identification, implementation and ensuring the follow-up on the maintenance of

implemented projects
 Providing technical assistance to Rwandan Governmental and non-governmental
organizations or institutions and rural population in order to achieve millennium
development goals (EDPRS, VISION 2020…)
 Build the spirit of innovation and entrepreneurship in all sectors of activities with
professional training so that more Rwandans get capacity by exercising different
practices for improving living standards;
 Providing assistance to EWB-Chapters from around the world in implementation of their
projects in Rwanda;
 Working jointly with the Rwandan Government to identify the regions of greatest need
throughout the country and identify projects that will have the greatest impact to the
population in the Districts and Provinces;
 Organize fundraising activities in order to implement identified projects
 Implementation and maintenance of identified different projects;
 Establishing training center and provide professional trainings;
 Partner with EWB-International in the implementation of projects and capacity building
and in Rwanda.

II. MUKINDO WATER PROJECT:
Figure 1: NTAMBARA Owen while standing at KAZABAGARURA Water Source

1. BACKGROUND:
Nowadays, water supply and sanitation in Rwanda is characterized by a rapid increase in access
compared to the past years in rural area. Access to potable water has been increased, starting
from 44% in 2005 to 85% by 2015(water and sanitation sector, MININFRA, April 2006).
However, in Gisagara district where Mukindo sector is located, the increase of potable water at
above level has not been accomplished. This shows that the access on safe water supply in
Gisagara district specifically in Mukindo sector is low compared to the other rural areas in
Rwanda.
Although this sector have the spring water sources that can be exploited and transformed into
water supply systems but their identification and manner of their design are not taken into
considerations. Therefore, this issue has caused the quality of such water to be unsafe due to the
aspect of human activities.
It is that reason; Mukindo Water Project was developed by EWB-Rwanda and EWB-Rwanda is
Non-Governmental Organization of Engineers without Boarders, Rwanda chapter with the main
objective of provision and implementation of any essential engineering related project to the
populations for their good healthy and development in collaboration with the Government of
Rwanda.
This project was being implemented by EWB-Rwanda in partnership with EWB-Quebec from
Canada and the government of Rwanda particularly Gisagara District. It’s target was to supply
potable water to over 10 000 people who are living in Mukindo sector through a proper
development of Kazabagarura water source located in neighbouring sector Mugombwa sector
with a designed water supply and distribution system to the householders for their health
improvement.
Therefore, it is in that way, EWB-Rwanda designed a Gravitational and Solar powered Water
Pumping system for the supply of filtered, drinkable and clean water to Mukindo sector
especially Nyabisagara and Gitega Cells which are considered as vulnerable regions in terms of
accessing potable water.
The water from Kazabagarura water source flow at a rate of 1.48liters/second to the reservoir of
25m3 due to gravitational force in fact, water source in Mugombwa sector is elevated at 5m
compared to the location of the reservoir in Mukindo sector with 1125m distance apart.
The water from the reservoir is pumped uphill to the storage tanks of 50m3by solar submersible
pump system where the tanks are elevated at 156.2m with the distance 2128m from the reservoir.
This solar water pumping system is designed to provide 50m3 per day as quantity of water for the
distribution to the people in four villages namely; Kamasiga, Mukindo, Rebero and Gatunda.
The storage tanks of 50m3 in Mukindo center are to store water during the night or periods of
cloudy weather. When tanks are fully, they can provide water to the population within 2 or 3days
without using pump and that’s why the solar system used doesn’t involve any electrical storage
(Battery) for economic aspects.

2. PRELIMINARY ACTIVITIES DONE AT THE SITE:
2.1. Kazabagarura water source

Kazabagarura water source is located in Mugombwa sector; Kibayi cell, Rwahambi village and it
had been there for over 30 years. In 2004, it had been well constructed by the Government of
Rwanda (MININFRA) in partnership with USAID for the ease of the people to fetch water.
But, this water source is far from dwellings where the people from nearby regions either
Mugombwa sector or Mukindo sector make some hilly distance for them to reach where the
water source is located which make it too difficult for the people to get water and people who are
not able to go there are struggling to pay much money worthy 200Rwf/20litres to unsafe water
from different sources.
Figure 2: KAZABAGARURA Water Source

Due to high flow rate of about 1.48liters/second of water that come out of this source, it was
preferable for it to be well developed using pipes, solar pumping system and tanks for the supply
of water to the population in Mukindo sector who are living together in their respective villages
at low cost of about 20Rwf/20litres.

2.2. Water departure chamber
Water departure chamber is hydraulic structure built nearby the water source and it is made of
concrete or masonry for it to collect water from the source captured by one or several oil sump
filters and that constitutes the first work of regulation of the water adduction also, understand an
overflow that should be to proportion sufficiently to assure the evacuation of the maximal
discharge of source without provoking a retention to the level of the catchment.
This chamber is sized to 8m3 (2m x 2m x 2m) with an Inlet pipe from the water source, Overflow
pipe which helps the people near the water source to fetch water from the source and Outlet pipe
that carries water to the reservoir of 25m3 and this outlet pipe is a little bit lower than the inlet
pipe for the higher pressure of the water.
Water departure chamber with its overflow pipe helps to maintain the inlet of water and outlet of
the water at regulated pressure i.e. Inlet water flow rate must be equal to outlet flow rate and over
flow rate.
3. APPURTENANCES USED AND CIVIL WORK:

3.1. Pipe material
A pipe is a circular closed conduit through with which the water may flow either under gravity or
under pressure. When pipes do not run full, they run under gravity, such as in sewer lines
however, in supply, pipes mostly run under pressure.
Pipes used are of PVC type. The pipes were used on length of 1150m where more than 10 pipes
of 100m were installed in dug underground way for the whole system.
3.2. Catchment of the source and intake

Consist of collects the water of one or the sources in a hygienic manner while avoiding all kept
of the source and while avoiding the transportation of sand or other matters in suspension that
could possibly produce some deposits in the network. The catchment constitutes the very definite
starting point for the hydraulic calculation.
3.3. Location of valve on water supply system

Valves are in a water distribution system distinguished by the purpose, operation principle and
way of control. Generally, have the three tasks such as, flow and/or pressure regulation,
exclusion of the parts of the network due to emergence reasons, protection of reservoir and
pumps in the system.
3.3.1. Air release valves
This special type of valve intends to release air from pipeline interfering pipe capacity. Air
accumulation can occur during filling the pipeline but also in normal operation. The valves
consist of a flat arrangement contained in small chamber with an orifice vent. When water is
present in the chamber the orifice is closed by the pressure that initiate up thrust of the float.

Appearance of the air in the chamber depresses the water level uncovering the orifice. The air
leaves out until normal water pressure in the chamber is established again. Valves used are
operated manually.
3.3.2. Blow offs valve
A blow off assembly is used to flush out accumulated sediments at low spots and dead-ends of
pipelines and for draining pipelines for repairs, maintenance, and inspection.
Blow off discharge are directed away from the pipeline into a nearby storm drain or other non-
erodible surface drainage channel.
3.3.3. Gate valve
Gate valve is the valve which is used for shut off the supplies whenever needed.
3.3.4. Non-return valves
These are valves through which flow of water can proceed in one direction only. An opposite
flow direction clauses the valves to close and remain closed until the flow is re-established in the
same direction. Hence the valves operate in on/off position, fully closed or opened by the flow
itself. The non-return valves are installed in pumping stations as a back-flow prevention
sometimes they may be found in distribution systems and as a past of service connection
3.3.5. Pressure reducing valve
Pressure reducing valves are normally used to control the pressure in isolated parts of networks if
it becomes too high. When the pressure upstream of the valve grows above the pre set value, the
valve will start closing until the downstream pressure is equal to the preset pressure. If the
upstream pressure is below the pre set value, the valve operates as fully opened.
3.3.6. Line valve
In general, line valves are installed in distribution and transmission pipelines to isolate and
depressurize pipeline segments for repairs, modifications, inspections or maintenance.
Valves are placed on all branches of crosses and tees and at each street intersection on the main
prior to the branch and on each branch of the water system.
3.4. Tap Stand point

For most users, the tap stands are the points of provision in drinking water, and must answer to a
certain number of criteria as robust construction, lasting equipment and easy cleaning seen their
daily company by the users
3.5. Service connections

Service connections link users with the distribution system. The standard set-up consists of:
connection, service pipe, outdoor and indoor-stop valve and water meter. In newer installations,
a non-return valve may be added as well.
3.4. Water reservoir

This water reservoir is built with stones, cement, sand and concrete with size of 25m3 as its
capacity. The reservoir was made circular for the economic reasons since the circle has the least
perimeter in terms of area enclosed, and a major portion of the structural action is in loop
tension.

The detail and performance of the joint between the side wall and bas slab have a significant
effect on the structural behavior of the wall.
The reservoir is elevated to provide water pressure. When a water tank is elevated, gravity forces
press water downward as it drains through a small pipe. It is the weight of the water pressing
down on itself due to gravity that creates the pressure. This allows the water to be forced through
the water system at high speeds and provides enough momentum for the water to reach homes
that are located many miles from the water tank.
III. SOLAR SUBMERSIBLE PUMPING SYSTEMS:

3.1. General Description
Water from the reservoir is pumped up the hill to the storage tanks by the solar powered system.
With reduction in cost of photovoltaic modules (solar panels) and improved control technology,
solar power has become logical solution for off-grid water pumping installations.
Previously systems used only DC input motors but recent advances in controller design has
facilitated the inversion of DC to AC power thus enabling standard AC pumps to be used in large
motor sizes providing much higher output.
The system is composed of a PV generator array, a pump and a solar pump controller.
Based on the design philosophy that it is more efficient to store water rather than electricity,
there is no energy storing device such as storage battery in the system.
The PV generator, an aggregation of PV modules connected in series and in parallel, absorbs
solar irradiation and converts it into electrical energy, providing power for the whole system.
The pump controller controls and adjusts system operation and converts the DC produced by the
PV generator into AC to drive the pump, and adjusts the output frequency in real-time according
to the variation of sunlight intensity to realize the maximum power point tracking (MPPT).
Figure 3: System Layout

3.2. SOLAR PANEL (PV Generator):
3.2.1. Definition
Solar panel is a group of solar cells that work together. Solar cell is a device that can make
electricity directly from the sun light (sun shines).
Figure 4: Solar Panel
Solar cell doesn’t give off any gases and it doesn’t even make noise, therefore solar cells and
solar panels have a lot of applications including; calculators, watches and flash lights.
They are also solar powered equipment like toys, radios, MP3players, cell phones and pagers.
Solar panels are sometimes used to make electricity to light up road signs and bus stops, roadside
emergency phones and ATM machines
Solar panels can also provide power for all kinds of machines, buildings including homes,
schools, hospitals and other institutions. It can also be used as backup in case of the utility power
fails to work. These solar cells that are used to convert sun light energy into usable electricity are
also known as PHOTOVOLTAIC simply Photo means Light and Voltaic refers to Electricity.
A single simple solar cell makes little electricity for this reason; cells are often linked together in
group known as solar modules. And when more power is needed, modules can be joined
together to form a large solar array.
These solar modules and arrays are sometimes called Solar panels, and whatever you call a
group of solar cells the fact remains that the more cells you link together the more electricity you
make.
3.2.2. Installation of solar panels

These solar modules have a frame that holds the cells. Some modules are several feet long and
wide and this combination of solar cells can help in production of few hundred watts of
electricity. Since the current and the power output of photovoltaic modules are proportional to
the sun light intensity. At a given intensity modules output current and operating voltage are
determined by the characteristics of the load.
For the solar panels to receive maximum sun light at any instant from the sun. They are different
ways of installing solar panels namely: placing them at a rotating treackers, installing them at
magnetic declination angle and tilt angle but here solar panels were installed using Tilt angle
method.

3.2.3. Tilt angle

To capture maximum amount of solar radiation energy, solar array should be tilted at an angle
approximately equal to site’s latitude and facing within 150 of due south.
For the winter performance, solar modules can be tilted 150 more than the latitude angle.
For summer performance, solar panel must be tilted 150 less than the latitude angle.
3.3. Shading effect to the solar panel

PV modules are sensitive to shading where shading obstructions is any soft or hard sources of
tree branch, roof vent, chimney or other item is shading from the distance, the shadow diffuse or
dispersed. The soft sources reduce the amount of reaching the light the cells of the modules.
Hard sources are those sources that stop the sun light from reaching the module i.e. blanket, tree
branch, dropping or sitting directly on the top of the glass.
For example, if one cell is hard shaded, voltage of that module will drop to half of its unshaded
value to protect itself.
3.4. Design and selection of the PV modules to be used in this Mukindo water project
Sun module, SW 250 mono / Version 2.0 and 2.5 Frame was used which is manufactured by an
American Company called solar world. This sun module has the following characteristics
Figure 5: Solar Panel Dimensions while Designing
3.4.1. Performance under standard test conditions (STC)

SW 250
Maximum power Pmax 250 Wp
Open circuit voltage Voc 37.8 V
Maximum power point voltage Vmpp 31.1 V
Short circuit current Isc 8.28 A
Maximum power point current Impp 8.05 A

3.4.2. Thermal characteristics

NOCT 46 °C
TC Isc 0.004 %/K
TC Voc -0.30 %/K
TC Pmpp -0.45 %/K
Operating temperature -40°C to 85°C
Figure 6: I-V curve for the solar panel

3.4.3. Component materials
Cells per module 60
Cell type Mono crystalline
Cell dimensions 6.14 in x 6.14 in (156 mm x 156 mm)
Front tempered glass (EN 12150)
Frame Clear anodized aluminum
Weight 21.2Kg
3.4.4. Advantages of using solar panels

 The silicon used in most of them is very common materials like sand.
 The fuel used is sunshine which is free.
 It is a renewable resource that will last nearly forever.
 Solar panels can make electricity right at the place where it is used with no more cables
or wires for carrying electricity.
 No water pollution and production of hazardous wastes by solar system.
 Solar power plants can be usually be build more quickly than oil, diesel, coal or nuclear
power plants and if more power is needed they are easier to expand than any other type of
power plant.
3.4.5. Disadvantages of solar panels

 They work best when sunshine is bright, when the sky is cloudy, they make less
electricity.
 It needs batteries to store electricity for future use.
 In case of expansion, it requires more land.
 Moderate costly.

4. SUN SWITCH:
Sun switch is an automatic Solar Level Switching Device.
The LORENTZ Sun Switch is designed for use with the LORENTZ pump controllers. It can also
be used for any application where you need to switch depending on solar light intensity. It is an
autonomous working unit that supplies itself with power from the solar cells on its back side.
Figure 7: SunSwitch Front side Figure 8: SunSwitch Back side

Solar pumps are only effectively pumping water when a minimum solar irradiation is available.
When there is not enough irradiation, the pump starts to rotate but does not deliver any water. In
this case the pump can heat up and wear off prematurely.
It has light sensor that allows in setting of irradiation level at which the pump is switched on.
This stops the solar pumps from pumping water at minimum solar irradiation, by stopping the
pump when the irradiation is not enough and this helps to reduce heating up of the pump and this
increases its life span.
4.1. Installation of SunSwitch light sensor
4.1.1. Mounting
Sun switch is mounted close to the solar panel
The device must stay in the same orientation as the solar panels.
For mounting the Sun Switch light-sensor on the frame of the
solar panel you can use the provided C-bracket to clamp it to the
frame. Alternatively, you can drill two holes into the frame and
fix the Sun Switch light-sensor with machine screws.
Figure 9: Mounting Sun Switch
4.1.2. Connecting SunSwitch to controller and float switch

The Sun Switch has two potential-free double throw contacts.
To operate the Sun Switch with a PS Controller, connect one COM and NO to the terminals 4
and 5 of the PS-Controller (COM and NC). The polarity does not matter. In this case, the PS
controller will start the pump when the irradiation is sufficient.

Figure 10: Connecting SunSwitch to a PS controller (with low light= OFF)

It is also possible to connect a tank float switch in a storage tank. In the following example, the
float is closed when up (i.e. tank full, fig. 4).
Figure 11: Connecting SunSwitch to a PS controller with tank float switch (with low light =
OFF)
Both, the SunSwitch and the float switch can stop the PS controller. In other words, the pump
will only run if the irradiation is sufficient and the tank is not full.
4.2. Contact rating

Max. Voltage 250 V AC / 220 V DC
Max. Current 2A
Max. Power 60 W / 62.5 VA
4.3. Operation of the SunSwitch

 Connect SunSwitch to the PS controller and mount it at the PV modules.
 The scale of the adjustment ranges from 15% to 55%. 100% is equivalent to 1,000 W/m²;
accordingly, the SunSwitch light sensor can set the pump startup point between 150
W/m² to 550 W/m². The hysteresis of the SunSwitch light-sensor is approx. 40 W/m².
 Adjustment should be done in the afternoon as irradiation levels reduce.
 Set the level to minimum (15%) and watch the flow rate of the pump.
 When the flow reduces to below a useful level increase the setting until the pump stops.
Due to the hysteresis, the pump will now start with slightly more power and stops at the
set irradiation.
 When the SunSwitch light-sensor allows the pump to operate, the “active” LED lights
up.
 If the pump starts too early or too late it is possible to modify the startup value at any
time during operation.

4.4. Solar panel for Sun Switch

The PSk2 controller is supplied with a special small 1.5 Wp PV module (pre-wired for
crimping). This PV module is used to measure the solar irradiation and allows you to set
irradiation dependent start / stop values for the pump.
Mount the PV module with the same alignment as the solar array that powers the pump system.
For example, if the solar array is tilted at an angle of 15°, the PV panel for the Sun Switch should
be tiled the same. You can ensure this by mounting the PV module on the frame of the PV
module array. The plug of the small solar panel for Sun Switch has a red (positive +) and a black
(negative –) cable.
4.5. Advantages of Sun switch

 reduced wear on the pump and motor since the pump only starts when it will continue to
run;
 no water heat-up inside the pump due to too insufficient power in low light situations
where the pump spins but cannot produce a flow up to the delivery point; and
 Pump will only run when minimum flow rates or pressure levels can be achieved which
are required by certain applicators.
5. WELL PROBE:
It is Mechanically Activated Device for Dry Run Protection in Applications with LORENTZ
Solar Pump Systems
The switch can be used to detect the water level within a well. When the
water level in the well dropped below the level of the well probe, the
LORENTZ Controller will stop the pump and indicates Source Low
LED.
Figure 12: well probe
5.1. Features
 Reliable dry run protection
 Simple to install
 Trouble free operation
 Corrosion-free
 Splicing kit included
5.2. Technical data

 Max. operating temperature 55 °C
 Enclosure class: IP68
 Submersion depth: max 50 m
 Cable length: 1.5m
 Wire size: 2x 0.75mm² or AWG 19, waterproofed
 Mounted in vertical position

Splice the two probe wires using the splice kit components that are
packed with the probe. The assembly procedure is the same as the
main pump link. Wiring to the controller – The dry run protection
must be connected to the controller via plug at slot B8, Potential
problems with the low-water probe in surface water – The probe has
a moving float. It is highly resistant to deposits and debris. However,
it may stick under some extreme conditions, especially from algae or
Figure 13: Well probe fixing water creatures (snails, etc.) that may be present in surface water.
5.3. Possible solutions

 Hang the probe independently of the pump and pipe (clamped to a weight, but not to the
drop pipe). This way, it can be pulled up for inspection or cleaning without the need to
pull up the pump.
 Pull the probe out periodically (with the pump, if necessary) for testing and inspection.
The pump should stop at the moment the probe leaves the water.
 Wrap the probe in a protective screen (fiberglass window screen, for example). Substitute
a different type of float switch. You can use any switch that makes contact on rise
 Use an encapsulated switch instead of the well probe if there is enough space for it to
operate properly, for example the LORENTZ float switch.
6. FLOAT SWITCH:
Float switch is a mechanically Activated Device for Water Level Detection in Applications with
LORENTZ Solar Pump Systems
The switch can be used to detect the water level within a tank. When the water
level in the tank reaches the maximum, the LORENTZ Controller will stop the
pump and indicates Tank Full LED.
Figure 14: Float Switch
6.1. Features
 Reliable water level detection
 Simple to install
 Trouble free operation
 Not sensitive to rotation
 Corrosion-free
 Three wires for normally open and normally closed application

6.2. Technical data

 Operating temperature: -10°C to 55°C
 Storage temperature: : -10°C to 55°C
 Cable length: 3m, waterproof
 Wire size: 3x 1.0mm² or AWG 18
6.3. Float switch requirements:

(1) A switch must be used, not wet electrodes.
(2) The preferred system requires a float switch to OPEN contact on rise to turn the pump OFF.
This is called “normally closed” (N.C.).
(3) Two wires are needed.
(4) Minimum wire size 1 mm2 [AWG 18]. This is good for a distance as far as 600m
(5) The cable must be suitable for its environment.
(6) If it must run a long distance, use twisted-pair shielded cable to reduce the chance of damage
from lightning induced surges.
Figure 15: Float switch scheme

6.4. Grounding shielded float switch cable
If you use shielded cable, connect the shield to ground at the controller only. DO NOT ground
the shield at the float switch. This will reduce surges induced by nearby lightning.
6.5. Operation of the float switch system

When the water level is high, the float switch will stop the pump.
The TANK-FULL indicator on the controller will light up.
When the water level drops, the float switch will signal the controller. The indicator light will go
out, and the pump will restart if sufficient power is available.
7. SURGE PROTECTOR:
Device to Protect LORENTZ Pump Accessories from Voltage Spikes
Figure 16: Surge Protector

7.1. Features
 Reliable surge protection for all LORENTZ pump accessories
 Can be installed inside the PS Controller
7.2. Technical data

 Max. voltage: 14 VDC
 Max current 8/20μs: 500 A
 Ambient temperature: max. 50°C
 Wire size: 2x 1.5mm² or AWG 16
8. PV DISCONNECT 440-20-6:
Connection box with DC Disconnect Switch and optional lightning surge protection
8.1. Features
 Designed for PS pump systems
 PS150 – PS4000
 For professional installation of pumping Systems
 Lightning surge protection device available (optional)
Figure 17: PV Disconnect 440-20-6
8.2. Technical data

Max. Voltage 440 V DC
Max. Current per string 10 A
Max. Total current 20 A
Max. No. of strings 6
String cable size 2.5 - 4mm²
Output cable size 4 - 10mm²
8.3. Wiring
 Wiring up to 6 PV-strings in parallel
 DC rated disconnect switch enclosed
 Enclosure class IP 54
8.4. Optional lightning surge protector

 Connects through an existing mounting hole in the PV connect housing
 Proper grounding of the device is mandatory to achieve protection

Figure 18: PV Disconnect dimensions while designing
9. PS9K2 PUMP CONTROLLER:

The heart of all AC solar pumping systems is the controller and PS controllers combine high
levels of functionality with high efficiency and reliability. It converts DC to AC and adjusts the
output frequency in real time.
9.1. Features the controller

 MPPT (maximum power point treacking) technology to maximize the power output at all
irradiation levels.
 Digital control for fully automatic operation, data storage and protection functions.
 IPM (intelligent power module) for the main circuit.
 LED display and control panel.
 Two sets of control input terminals just for low level, high level or remote sensing
control.
Table 1: Technical data of PSk2 controller

Model Pump Pump motor Solar Max. DC MPP Output Frequency Dimensions (mm) Weight
voltage input input voltage current (Hz) (Kg)
Motor (VDC) power voltage (VDC) (A)
power (KWP) (VDC)
(KW) W1 H1 D2 W2 H2 D1 d
PS9K2 7.5 380-440 9 850 500-600 18 0-60 320 450 250 290 405 220 9 17

9.2. Operation of the Controller
Figure 19: Operation of the Controller

9.3. Installation and operation of the controller
PS controller are surface mounted and should be provided with a housing for water and heat
protection. They must also be provided with DC disconnect switch between the PV modules and
controller. Due to high operating voltages proper earthing is essential.
All PV powered solar pumping systems should be provided with solar module array with
nominal output equal to the pump size. The arrays should be wired in a combination of series and
parallel connections to ensure that the correct voltage is available in the inverter.
The pump system must be equipped with a proper sized DC disconnect switch. The switch must
be installed between the solar generator and controller.
It must meet the following requirements:

 minimum 850 V DC
 continuous current rating according to maximum current of pump controller or higher
 the switch must be rated for DC current, NOT AC
9.4. Functions of the controller

 Settable minimum and maximum speed to provide continuous water delivery and
overload avoidance.
 Selectable display of operating including input/output amperage, power and voltage,
pump speed and temperature.
 Data logging of operating parameters including running time, starting/stopping time,
maximum power/voltage of day and total energy generated in the day where the data can
be recalled for reference.
 Automatic reset after well probe stops pump
 Inbuilt sun-switch sensor that protects the pump from running when the sun intensity is
sufficient.
 Inbuilt fan which efficiently cools the controller.

9.5. Controller Placement

The controller must be protected from water, moisture and animals.
Place the controller in a dry and sufficiently ventilated environment.
Place the controller close to the solar array, not the pump. This will reduce the risk of lightning
damage. Explanation: The controller’s input circuitry is more sensitive to surges than its output.
It is safest to minimize the length of the input wiring.
Electronic devices are most reliable when they are protected from heat.
Mount the controller where it is shaded from the midday sun. An ideal location is directly under
the solar array, on the North side of the mounting structure. If no shade is available, cut a piece
of sheet metal and bolt it behind the top of the controller. Bend it over the controller to provide
shade. This is especially important in extremely hot locations. Extreme heat may trigger a
thermal function in the controller causing it to reduce the power consumption or turn it off.
Figure 20: Controller dimensions for installation
Table 2: Controller dimensions for installation
Weight
Model Dimensions (mm) (Kg)
W1 W2 H1 H2 H3 D1 D2 D
PS9K2 320 290 500 450 425 220 250 9 17
Fit all screws; leave about 10 mm / 0.4 spaces between the screw’s head and the wall. Hang the
controller on the wall. Finally, tighten all screws.
PSk2 controllers can be mounted side by side.

Figure 21: Minimum spacing for wall mounting
Figure 22: Terminal block, numbering

Table 3: Terminal explanation

Termin Terminal Clamping
Socket al Connection Function Range
14 AWG- 4
Ground GND Connect to protective ground wire (PE) Grounding AWG
1.5 - 16mm2
POWER 14 AWG- 4
IN + Connect to positive terminal of PV module The following conditions apply; AWG
- Connect to negative terminal of PV module technical data of PS9K2 controller 1.5 - 16mm2
Water Connect water detection sensor for 26 AWG-
Detection 1 Connection to NC surface 12AWG
pumps for submersible pumps, a
Sensor 2 Connection to COM jumper wire 0.5 - 2.5 mm2
is needed between 1 + 2
26 AWG-
3 Connect positive (+) 4 - 20mA signal 12AWG
Pressure
Sensor 4 Connect negative (-) sensor supply Voltage +24V 0.5 - 2.5 mm2
load impedance 100Ohms
Input impulse- reed switch; max- 26 AWG-
5 Connect to signal rating 1kHz 12AWG
setting range: adjustable by Pump
Flow meter 6 Connect to COM scanner 0.5 - 2.5 mm2
Application
26 AWG-
12AWG
PSU
control 7 Connect positive (+) Refer to smart PSU manual 0.5 - 2.5 mm2
8 Connect negative (-)
26 AWG-
12AWG
IN 24V 9 Connect positive (+) For service purpose- use only 0.5 - 2.5 mm2
10 Connect negative (-) if instructed by the manufacturer
L1 Connect to the L1 phase of the motor
AC output L2 Connect to the L2 phase of the motor 14 AWG - 4 AWG
Connect to the L3 phase of the 1.5 - 16mm2
L3 motor
The following conditions apply;
Connect to protective motor ground technical data of PS9K2 controller
GND wire (PE)

10. LORENTZ PSk2 SOLAR SUBMERSIBLE PUMPS:

LORENTZ PSk2 solar submersible pump systems are vertical multi stage pumps designed to
efficiently deliver the highest volumes of water across a wide range of lifts.
PSk2-C-SJ submersible pumps are typically used in irrigation projects and for wide area like
drinking water applications where they reliably meet the most demanding requirements,
economically, without pollution and without a grid connection or diesel generator.
The PSk2 controller converts the DC power from the solar array to digitally created AC signal to
run the motor. Motor speed (RPM) is proportional to the signal frequency. The frequency starts
low (about 20 Hz), and increases gradually to a maximum about 60 Hz.
The PSk2 C-SJ pumps are centrifugal pumps, driven by a 3-phase water cooled AC motor.
Each system consists of a pump, pump motor and a controller, this modular concept keeps all
electronics above ground, simplifying servicing and lowering cost of ownership.
Figure 23: LORENTZ PSk2 solar submersible pumps

10.1. Features
LORENTZ PSk2-C-SJ series has the following features:
 Engineered in Germany using high quality non corrodible materials
 IP54 / NEMA 3A corrosion resistant housing
 0 – 60Hz motor speed control
 Wide range of inputs to influence pump behaviour
 Integrated monitoring and management including on board recording of 5 years
performance data.
 Inbuilt irradiation measurement and pump control based on power available
 Integration with the LORENTZ Smart PSU for grid / generator connection and power
blending
10.2. Pipe sizing

LORENTZ pump systems are extremely efficient. It is important to keep this efficiency
throughout the entire system. A main reason for loss of efficiency is pipe pressure loss caused by
friction. Make sure that you have included the pipe pressure losses during the sizing process of
your system.

10.3. Pipes with thread

If you use pipes with a thread instead of a flange the installation is basically the same.
The threads must be sealed with hemp- or Teflon tape.
Make sure that the threads cannot work loose over time
10.4. Installation
To connect the pump end and the motor you must set the motor
with the clamps in the bore hole to fix it.
Figure 24: Motor in borehole
Make sure that the clamps rest on a sufficient stable support

structure, for example the well casing. If the structure is not strong
enough to carry the weight a support structure must be built that is
suitable for the installation process.
Figure 25: Preassembly of the pump
Lower the pump end carefully onto the motor and fix it
with the supplied screws. It is very important to avoid
heavy impact when the pump end is mounted onto the
motor.
For correct connection pay attention to the following
table with tightening torques. The screws must be
tightened diagonally.
Figure 26: Connection pump end with motor

Table 4: Tightening torques for pump/motor connection
Torque
Pump/Motor Torque (Nm) (Ibxft)
M8 18 13
M12 70 52
M16 150 110
During the process of lowering the pump into the well the motor cable
must be fixed properly to the pipe as figure 27 shows.
Where a plastic pipe is used, the longitudinal stretch of the pipe under
load must be considered by leaving a sufficient gap between the pipe
and the cable. The cable should be fixed with water-resistant tape. It is
a good installation practice to form a loop with the motor cable near the
pump and repeat it about every 40 m along the riser pipe.
Figure 27: Fixing of the motor cable at a joint (top) and a strait pipe (right)
This will keep any tensile forces away from the motor cable.
Round off the edges of a flange to prevent damage to the cable. Do not fix the cable tightly.
Leave space for the pipes to expand. The cable needs to get fixed every 3 m.
Figure 28: connecting the next piece of pipe

10.5. Installation depth
Make sure that the pump unit is suspended properly and is not in contact with sand and mud
from the well bottom. It is recommended to install the pump above the filter zone of the well to
keep the sand content in the water low and ensure proper cooling of the motor
10.6. Checking correct rotational direction

The submersible pump must be submerged in water before checking the correct rotational
direction. The correct rotation direction for submersible pumps is counter-clockwise, viewed
from the top. It is also labeled with an arrow on the pump end.

10.6.1. Check the rotational direction as follows:

1. Connect the pump to the controller and power supply.
2. Start the pump and check the delivered flow rate.
3. Stop the pump, disconnect the power supply and change two of the three phase leads (e.g. red
and yellow).
4. Start the pump again and check the delivered flow.
5. Stop the pump, disconnect the power supply and compare the flow rates from point 2 and 4.
The wiring with the better flow rate has the right rotational direction.
10.7. Removal of pumps

If you want to remove the pump system it is the same principle as the installation in the other
direction. When removing the pump, the pipes will be full of water and will be heavier.
In the table below you can see the additional weight of the water per meter pipe length.
Table 5: Additional weight per meter pipe length
Pipe diameter Additional weight

(In) (Kg/m) (Ib/ft)
2 2.0 14.5
2.5 3.2 23.1
3 4.6 33.3
4 8.2 59.3
5 12.7 91.9
6 18.4 133.1
11. CABLE ENTRIES AND EXTERNAL SOCKETS:

There are cable glands and plug sockets in the bottom of the controller. The sockets for the plug
connections are pre-wired and pre-assembled in the controller housing.
Three plugs are included in the delivery. The plugs are used to connect the pump accessories low
water sensor, remote float switch and solar panel for Sun Switch.
Accessories which use cable glands B1-B6 must be fixed tightly in the glands for strain relief
and sealing. Preparing plugs – Cut the wire of the plug in half and splice the cables of the
corresponding pump accessory to it.
Exception for solar panel for SunSwitch– The plug of the solar panel for SunSwitch has a red
(positive +) and a black (negative –) cable. Ensure you have the correct polarity.
A voltage reversal will lead to damage of the controller. The Plug has a plastic pin that fits into a
groove in the socket for the plug to ensure correct plug installation.

Figure 29: Bottom view of PSk2 controller: cable entries and external sockets
Table 6: Mini plug sockets description

B Normally close
Remote float switch 7 Connection to NC (NC)
is bypassed to
Connection to COM COM
B Normally close
Low water sensor 8 Connection to NC (NC)
is bypassed to
Connection to COM COM
B
9 Connect positive (+) wire
from sunswitch panel to RED wire of
the plug Connected to
Solar panel for Connect negative (-) wire from solar panel for
sunswitch sunswitch sunswitch
panel to BLACK wire of the plug

12. GROUNDING:
12.1. Why ground?
Before starting to work on the electrical system make sure that all components are disconnected
from the power source. Only switch on the system when you have finished all work.
Grounding is mandatory to protect the users from potentially fatal electric shocks. It also protects
against electric charging or a short circuit inside the device. This is accomplished through
clamping, bolting or other mechanical means to provide an effective grounding path to the earth
to ensure safe operation at all time.
The grounding is also important to the system for lightning protection. In general, it is meant for
indirect lightning strikes and induced electrical potentials during operation of the pump system.
12.2. How to ground?

A protective earth connection for the controller must be connected to the left GND terminal. The
right GND terminal, next to the motor phases (L1, L2, L3), is for the protective earth wire of the
motor. Insufficient ground source, where there is an inadequate ground source you can use a
grounding rod. A grounding profile rod should be located about 4 – 5m from the controller. The
cable must not carry any mechanical loads.
The rod must be completely buried in the ground (0.5 m below ground level). The grounding
cable should be a copper cable with a cross section of not less than 16 mm2 (AWG 6).
13. MOTOR WATER FILLING/REFILL:

The submersible motor is factory-filled with water, but the motor filling must be checked before
installation. The motor must be filled in vertical position (coupling showing upwards, see figure
below, “Figure 30: Filling, venting and drainage hole”).
To fill the motor with water, remove the filling and venting screw. Fill clean drinking water in to
the motor until the water flows out continuously without bubbles.
NOTE: Do not fill the motor using a high-pressure source such as a tap or hose as this will cause
unwanted bubble formation. This may cause unwanted bubble formation.
To refill the motor, open the filling, venting and drainage screws to allow water to exit from the
drainage hole. Refill the motor with clean drinking water as described above.
Figure 30: Filling, venting and drainage hole

13.1. Resistance measurement

We recommend checking the winding and insulation resistance before connecting the pump to
the controller. For a submersible pump, these measurements should be done BEFORE lowering
the pump into the well.
To measure the winding and insulation resistance disconnect all motor leads from the controller.
A good quality Multimeter is necessary to measure the phase-to-phase resistance with accuracy
to the first decimal place (“0.1 Ohms”). It is also advisable to consider the resistance of the
multimeter leads when measuring very low values:
 Hold the tips of the multimeter together and note the value.
 Always subtract this value from your motor resistance measurements.
13.2. Winding resistance

1. Set the multimeter to “resistance measurement” and select the lowest measuring range.
2. All PSk2 motors are 3-phase motors. Measure the resistance of phase-to-phase: L1-L2, L2-L3
and L3-L1. Make sure there is good contact between the probes and the cable.
3. The deviation between the phases should be within 10 %. If the deviation is too high, the
reason is likely a damaged submersible cable or a faulty cable splice.
4. The absolute value is made up of the resistance of the motor winding and the submersible
cable. The resistance of the submersible cable depends on its length and size. For copper cable,
the values are shown in table 7 below.
Table 7: Motor cable resistance
Cable Resistance (Ω/100m)

4mm2/AWG11 0.4
6mm2/AWG9 0.25
10mm2/AWG7 0.17
16mm2/AWG5 0.1
13.3. Insulation resistance

Use a Megaohmmeter at 500 –1000 V.
Measure each phase to ground. Connect one test prod to the phase hold the other test prod to the
pipe work, or if plastic pipes are used to the ground wire.
If the insulation resistance is below 0.5 MΩ, the motor cable must be checked for damage.
13.4. Loss insurance

We recommend the use of a safety rope as loss insurance.
If the pipe breaks because of start-up torques of the motor, too much weight, pipe corrosion or
wrong installation a safety rope can prevent the total loss of the pump system and damage to the
well. Choose a safely rope that can handle the weight of the whole installation and the water
inside the pipes. The rope material must be water-resistant.

Figure 31: Installation depth
14. Automatic control for full-tank shutoff

We recommend the use of a float switch or other means to prevent overflow of your tank.
This will stop the pump when the tank is full, then reset when the level drops. This conserves
ground water, prevents overflow, and eliminates unnecessary pump wear.
PSk controllers allow the use of small diameter signal cable to a remote float switch, even if the
tank is a long distance away.
Figure 32: Water meter installation and dimensions

Table 8: LED status
14. INDICATOR LIGHTS:

 System (green) – the controller is switched on and the power source is present. in low-
power conditions, the light may show even if there is not enough power to run the pump.
 Pump on (green) – motor is turning. Sequence of flashing indicates pump speed. pump
speed (rpm) can be read off by the flashing sequence of the pump on led:
Table 9: indicator lights
Hz
1 flash >25
2 flashes >30
3 flashes >35
4 flashes >40
5 flashes >45
 Source low (red) – the water source has dropped below the level of the low-water probe
or the water sensor has detected air in the suction pipe. after the water level recovers or
the suction pipe has been re-filled with water, the pump will restart after a delay of 15
minutes.
 Tank full (red) – pump is turned off by action of the remote float switch (or pressure
switch or manual switch, whichever is wired to the (“remote float switch” terminals.)

 Tank full (flashing red) – the pump is turned off because the solar irradiation is below the
trigger point setting. The pump will start working when the set conditions are met.
15. TROUBLE SHOOTING:

Please read this section before calling for help. If you call for help, please refer to the model and
serial numbers. If the pump does not run – Most problems are caused by wrong connections (in a
new installation) or failed connections, especially where a wire is not secure and falls out of a
terminal.
The System ON light will indicate that the system is switched on and connected to the controller.
It indicates that VOLTAGE is present but (in a solar-direct system) there may not be sufficient
power to start the pump. It should attempt to start at intervals of 240 seconds.
When solar power is insufficient – When solar power on the array is present, but too weak for
the pump to run, it will attempt to start about every 240 seconds.
During each attempt, you will see the PUMP ON light come on. When pump stops from a
sudden shadow on the solar array – If a shadow suddenly passes over the array, e.g. if you walk
in front of it, the controller will lose track of the input voltage. It may make rapid on/off noises
and a high-pitched noise, then stop. This does not indicate a problem. The pump will attempt to
restart after the normal delay.
15.1. Time delays

(1) After the pump stopped due to insufficient sunshine – 240 seconds;
(2) After full-tank float switch resets – 2 to 3 seconds;
(3) After low-water probe regains contact with water in the source – 15 minutes, but the indicator
light will slowly flash for the rest of the solar day, or until power is disrupted or the controller is
turned off/on; Force a quick start – To test or observe the system, you can bypass the normal
time delays. Switch the POWER switch off then on again. The pump should start immediately if
sufficient power is present.
15.2. PUMP OVERLOAD (PUMP ON light shows red instead of green)

The system has shut off due to an overload. This can happen if the motor or pump is blocked or
very difficult to turn and is drawing excessive current (hard to turn). This can be caused by a
high concentration of solids in the pump, high water temperature, excessive pressure due to high
lift or a restriction in the pipe, or a combination of these factors. The controller will make 3start
attempts before shutting down the system.
The System ON LED will be OFF and the red OVERLOAD LED ON.
The system will not re-set until the ON/OFF switch is turned OFF and ON again.
Pump attempts to start every 240 seconds but does not run – The controller makes a slight noise
as it tries to start the pump. The pump will start to turn or just vibrate a little.
(1) There may be insufficient power reaching the controller.
A solar-direct system should start if there is enough sun to cast a slight shadow.
(2) If the pump was recently connected (or reconnected) to the controller, it may be running in
reverse direction due to wiring error.
(3) If the motor shaft vibrates, but does not turn, it may be getting power on only two of the three
motor wires. This might happen if there is a broken connection or if you accidentally exchanged
one of the power wires with the ground wire.
(4) The pump or pipe may be packed with mud, clay, sand or debris.

15.3. Service and Maintenance of the Controller

Routine inspection and maintenance – To make the controller run stably, a periodic inspection
must be performed every year.
15.4. Requirement of inspection and maintenance:

 The inspection must be performed by professional technical personnel.
 If necessary, cut off the power supply of the controller first.
 Avoid leaving any metal components in the controller, or else they might cause damage
to the equipment.
 An electric insulation test has been made on the controller before it has left factory. A
further test is not necessary.
 Do not use the mega ohmmeter to test the control circuit.
 When conducting any insulation test on the motor, you must dismantle the connection
between motor and controller.
15.5. Main points for inspection and maintenance

Please use the controller under the environmental conditions of this manual. Inspect and maintain
as per the following table.
Table 10: Inspection overview
Inspect
Frequency Inspection item Inspection content Judgement standard
Regular
Running
environment 1. temperature 1. temperature <50oC
2. dust, gas 2. humidity <90%, no dew condensation,
no pecular smell, flammable, explosive gas
1. excellent ventilation in installation
Cooling system 1. installation system environment
2. radiator 2. radiator air duct not blocked
1. vibration, temperature 1. stable vibration, normal temperature of the
Controller body rise shell
2. noise 2. no abnormal noise and pecullar smell
3. lead, terminal 3. fastering screws not loose
1. vibration, temperature
Motor rise 1. steady running and normal temperature
2. noise 2. no abnormal and uneven noise
Input and output 1. input voltage 1. input voltage in the specified scope
Parameter 2. outputcurrent 2. output current under the rated value

IV. TRAINING OUTCOMES:

1. INDUSTRIAL ATTACHMENT CONTRIBUTION TO OUR KNOWLEDGE:
This industrial attachment was very important to my knowledge in different ways such as:
practical knowledge, theoretical knowledge and social knowledge. In practical part, I have learnt
how to install solar panels with its accessories like controller, sun switch, float switch, PV
disconnect and well probe and other mechanical equipment such as pump, pipes, construction of
tap stand.
This knowledge, I got from this internship will help me to deal with some problems as far as
electrical engineering and other engineering field is concerned in my country and also will help
me to be competitive at work.
2. TRAINING BENEFITS AND MOTIVATIONS:
I learnt how to make the normal life easy based on the existing materials.
I learnt how to turn the theories learned in classes into practices.
I became a professional graduate through the knowledge got from this internship
I developed my engineering career through hands on skills from the site of internship
I knew how I might Solving some problems that might arise in the society daily life
I also knew how I could cooperate with my fellow engineers in case, we are doing similar job
thus helping each other.

V. CONCLUSION AND RECOMMENDATIONS:
1. CONCLUSION:
In this internship, EWB-Rwanda in partnership with EWB-Quebec from Canada and the
government of Rwanda particularly Gisagara district tried to solve the problem of unclean water
by delivering uncontaminated water to e more than 10 000 people who are living in Mukindo
sector through that Water Project like other projects implemented by EWB-Rwanda like
Building Bridges in different part of Rwanda.
Through solar system used as a source of electricity to provide electrical energy to the pump
system used in the project to uphill the water from reservoir up to the storage tanks I got a great
experience that I mark the best starting of my carrier in electrical engineering.
I acquired practical skills that match with some of theories learnt in classroom about solar
system. And how I could make a simple costly electrical related project to help the vulnerable
community in Rwanda either provision of electrical energy or provision of safe water using the
knowledge of filters or any other field of engineering through cooperation.
Before my internship at EWB-Rwanda, things seemed to be magic and mysterious but now are
clear, evident, real and true.
Therefore, I can confidently assure you that I understand what a duty of an engineer at field is.
2. RECOMMENDATIONS:
I would like to recommend EWB-Rwanda to:
1. Make Cooperation with institutions having students studying electrical and other engineering
courses to have internships in some projects that EWB-Rwanda is under the control so that
students can be familiar with their field of study for future benefits of EWB-Rwanda, the
community, Rwanda as country and the world.
2. To make seminars to the engineering students and other engineers so as to have the required
skills for implementing the projects in different fields of engineering.
3. To have strong collaboration with other Engineers Without Boarders (EWB) from different
countries so as to share experience about different projects.
4. To have training center to its members so as to be skillfully and expertly in their respective
field of engineering.
5. To collaborate with government of Rwanda for easy implementation of those projects.
I would like to recommend UR-CST:
Our college but particularly the Electrical and Electronics Department to strength its relationship
with EWB-Rwanda , Government Institutions and Private Companies because they have a lot
that benefits the students in terms of practical work. However more, it is better the internship is
done before the final year even several times during their school life in order to help students to
find many helpful ideas from different sites during their final year projects researches.

VI. REFERENCES AND RESOURCES:

1. Reference
 25 LORENTZ SunSwitch Manual

 Appendix E_Sizing of Water Piping System
 Davis and Shirtliff documents and specifications
 lorentz_psk2_manual_en
 sunmodule-solar-panel-250-mono-ds
 water and sanitation sector, MININFRA, April 2006
2. Resources
 www.davisandshirtliff.com
 www.ewb-international.com/countries/rwanda
 www.ewb-rwanda.org
 www.lorentz.de
 www.solar-electric.com
VII. APPENDIX:
1. Training certificate
2. Weekly log books

Internship Report Done by NTAMBARA Sylvestre Owen On Solar Powered Submersible Pumps Used in Mukindo Water Project in Gisagara District

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Internship Report Done by NTAMBARA Sylvestre Owen On Solar Powered Submersible Pumps Used in Mukindo Water Project in Gisagara District

Загружено:

Авторское право:

Доступные форматы

SCHOOL OF ENGINEERING

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

NTAMBARA SYLVESTRE OWEN 215004285

INDUSTRIAL ATTACHMENT REPORT DONE

I dedicate this industrial attachment report to;

UR-CST i EEE/ELE 2017

I, NTAMBARA Sylvestre Owen a final year students at University of Rwanda-College of

Student Name: NTAMBARA Sylvestre Owen

UR-CST ii EEE/ELE 2017

Secondly, I extend my heartfelt gratitude to EWB-Rwanda authorities that allowed me to have

UR-CST iii EEE/ELE 2017

UR-CST iv EEE/ELE 2017

ABBREVIATIONS AND ACRONYMS:

EWB: Engineers without Boarders

UR-CST v EEE/ELE 2017

Figure 1: NTAMBARA Owen while standing at KAZABAGARURA Water Source ................................ 3

UR-CST vi EEE/ELE 2017

Table 6: Mini plug sockets description ....................................................................................................... 27

UR-CST vii EEE/ELE 2017

3.3.3. Gate valve ................................................................................................................................... 7

UR-CST viii EEE/ELE 2017

6. FLOAT SWITCH: ....................................................................................................................................... 15

UR-CST ix EEE/ELE 2017

12.2. How to ground?.............................................................................................................................. 28

UR-CST x EEE/ELE 2017

Engineers Without Borders (EWB-Rwanda) is a Non-Governmental Organization (NGO) that

EWB-RWANDA has been officially registered under the registration No78/RGB/NGO/2016

UR-CST 1 EEE/ELE 2017

1.4. GENERAL OBJECTIVE:

1.5. SPECIFIC OBJECTIVES:

 Identification, implementation and ensuring the follow-up on the maintenance of

UR-CST 2 EEE/ELE 2017

II. MUKINDO WATER PROJECT:

Figure 1: NTAMBARA Owen while standing at KAZABAGARURA Water Source

UR-CST 3 EEE/ELE 2017

UR-CST 4 EEE/ELE 2017

2. PRELIMINARY ACTIVITIES DONE AT THE SITE:

2.1. Kazabagarura water source

Figure 2: KAZABAGARURA Water Source

UR-CST 5 EEE/ELE 2017

2.2. Water departure chamber

3. APPURTENANCES USED AND CIVIL WORK:

3.2. Catchment of the source and intake

3.3. Location of valve on water supply system

UR-CST 6 EEE/ELE 2017

3.4. Tap Stand point

3.5. Service connections

3.4. Water reservoir

UR-CST 7 EEE/ELE 2017

III. SOLAR SUBMERSIBLE PUMPING SYSTEMS:

Figure 3: System Layout

3.2. SOLAR PANEL (PV Generator):

Figure 4: Solar Panel

3.2.2. Installation of solar panels

UR-CST 9 EEE/ELE 2017

3.2.3. Tilt angle

3.3. Shading effect to the solar panel

Figure 5: Solar Panel Dimensions while Designing

3.4.1. Performance under standard test conditions (STC)

UR-CST 10 EEE/ELE 2017

3.4.2. Thermal characteristics

Figure 6: I-V curve for the solar panel

3.4.4. Advantages of using solar panels