BORELINE FLEXIBLE RISING MAIN > INSTALLATON

INSTALLATION : BEFORE YOU START

Read this manual thoroughly - then ensure you also have the following on site:

* These items are also required for pump retrieval.

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FITTING THE BORELINE COUPLING AND RISER TO THE PUMP

  1. Ensure that the ends of the riser are square - trimming with a sharp knife if necessary.
  2. Identify the lower Boreline coupling and ensure the Break-Off Plug is screwed in securely - then screw the coupling into the check-valve (non-return valve) located at the top of the pump. (If a Break-Off Plug is NOT being installed, screw either Boreline coupling into the check valve - in this case a 6mm (¼") hole should first be drilled in the non-return valve to allow draining before system removal and a vacuum relief valve should be fitted at the wellhead. Please check with the pump manufacturer before doing this as some do not condone drilling the check valve.)
  3. Push the Boreline riser over the coupling body making sure the riser end is flush with the shoulder at the threaded end of the coupling. Do not use any kind of lubricant.
  4. Fit the first ring with the three segments, over the rib closest to the threaded end of the coupling body. (For 8" hose this is the narrow ring.) Tighten all three screws evenly, ensuring the gaps between the segments are even. When fully tightened the gaps between these segments should be 1-2mm.
  5. Fit the second ring over the other rib positioning the gaps half way between the gaps of the first ring and tighten as above. (For 8" hose this is the wider ring - which will only fit over its rib one way round and will overlap the coupling body.)
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FITTING THE POWER CABLE

  1. The Boreline riser should be laid on the ground with the rib facing up. (All equipment for potable water boreholes must be kept clear of sources of bacterial contamination so the Boreline should be laid on a strip of new polythene sheeting - such as used for polytunnels or cloches - anchored to the ground.)
  2. Push a Boreline cable strap through the cable rib openings every metre (3 ft) along the entire length of the riser. Turn the riser over as you proceed to the next opening so that by the time all the cable straps have been inserted the rib of the riser is facing down. (A number of red cable straps are supplied - these should be used closest to the pump to serve as an indicator when the pump is being removed from the borehole.)
  3. Roll the power cable out next to the riser - allowing a little slack (5%).
  4. Fit a protective sleeve to act as a guard over the cable where it will pass over the coupling and secure with PVC tape. PVC reinforced hose or Polyethylene tube can be used.
  5. Connect the power cable to the pump motor. ( This work should be carried out by a qualified electrician only.)
    6. Fitting the Power Cable
  6. Starting from the end nearest the pump and allowing a little slack, lift the power cable onto the centre of the riser. Bring the first cable strap around the power cable, and secure using a Clove Hitch Knot . Pull tight ensuring the power cable is hard against the Boreline riser. Buckle the strap. The power cable will be on the opposite side of the Boreline to the support rib.
  7. Repeat the procedure for fastening each subsequent cable strap - starting with the red straps - until the 'top' end of the hose is reached. (Remember to snake the power cable along the entire length of the riser allowing approximately 5% slack : 50mm or 2" between each strap.)
  8. Any additional high / low level probes etc. can be attached directly to the power cable using standard cable ties. (Allow the same slack in the cable as for the power cable itself.)
  9. Bundle any loose cable ends and temporarily tape them to the hose until the headworks are fitted when installation is almost complete.
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BORELINE INSTALLATION PROCEDURE - using a VEHICLE

A tripod or crane will be required to lift the pump into the borehole. If a tripod is used it should be positioned directly above the borehole high enough to allow the pump and clamp to be lifted over the borehole.

Connect the Boreline coupling to the pump discharge or check-valve / non-return valve and / or Break-Off Plug assembly and then the Boreline riser to the coupling. (Do not attach the second Boreline coupling and headworks to the hose at this stage.)

Unroll the Boreline riser along the ground. Lay the power cable next to the riser along the length.

Connect the power cable to the pump motor. (This should only be carried out by a qualified electrician.) Use the Boreline cable straps to tie the power cable to the riser at the recommended intervals. (Remember to snake the power cable along the length allowing approximately 5% slack.) See 'Fitting the Power Cable' above.

Before installation inspect the pump, riser & cable and remove any loose mud & debris, washing as required with mains water. The pump and riser should be inspected during the installation process and any contamination removed before the assembly enters the borehole.

Some water suppliers may require the assembly to be disinfected during the installation operation - the appropriate procedures should be followed where this is specified. The maximum chlorine concentration should not exceed 5% to avoid damage to the hose.

Clamp the Boreline riser only ( not the power cable ) using a Boreline clamp approximately 500mm (18") above the pump.

Lift the pump using the clamp and lower it into the borehole until the clamp rests on the well head. Move the rolling wheel over the borehole ensuring that it is centrally positioned and secured. (An unsecured roller can move and cause damage to the hose - or injury to the operator.)

Lift the Boreline riser over the rolling wheel with the power cable fastened and positioned.

Attach the second Boreline clamp to the other end of the riser and secure it to the front of the installation vehicle. Reverse the vehicle so that the vehicle now takes the weight of the pump. Remove the first clamp. (The full load will now be taken by the vehicle and rolling wheel.)

Drive the vehicle slowly forward allowing the pump and riser to be lowered into the borehole. Joiners, couplings and clamps must not pass over the rolling wheel. When the vehicle is close to the rolling wheel, clamp the riser above the wellhead. Lower the riser slightly so that this clamp now rests on the wellhead and remove the other clamp from the vehicle.

Attach the second Boreline coupling to the headworks and then the free end of the riser to the coupling. Release bundled cable(s), feed them through the surface plate and secure the loose ends neatly.

Raise the headworks using the tripod or crane until the weight of the whole assembly is taken, remove the clamp and lower the assembly onto the borehole.

Attachment of discharge pipework & final wiring up ( by a qualified electrician ) will complete the installation.

Where the water is to be used for a drinking water system, the pump discharge should be run to waste for half an hour on first start-up ( or whenever the pump has not been used for a while ) - to flush the components - before directing to the treatment system for further treatment and disinfection of water before entering the water supply.

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BORELINE INSTALLATION PROCEDURE - using a CRANE

Connect the Boreline coupling to the pump discharge or check-valve / non-return valve and / or Break-Off Plug assembly and then the Boreline riser to the coupling. (Do not attach the second Boreline coupling and headworks to the hose at this stage.)

Unroll the Boreline riser along the ground. Lay the power cable next to the riser along the length.

Connect the power cable to the pump motor. (This should only be carried out by a qualified electrician.) Use the Boreline cable straps to tie the power cable to the riser at recommended intervals. (Remember to snake the power cable along the length allowing approximately 5% slack.) See 'Fitting the Power Cable' above.

Before installation inspect the pump, riser & cable and remove any loose mud & debris, washing as required with mains water. The pump and riser should be inspected during the installation process and any contamination removed before the assembly enters the borehole.

Some water suppliers may require the assembly to be disinfected during the installation operation - the appropriate procedures should be followed where this is specified. The maximum chlorine concentration should not exceed 5% to avoid damage to the hose.

Calculate the maximum height that the eye of the crane can achieve above the wellhead. Clamp the Boreline riser only (not the power cable) using a Boreline clamp approximately 1000mm (3 ft) less than the crane maximum height from the base of the pump.

Connect the clamp to the crane hook and lift the Boreline to the maximum height of the crane, guiding the pump as it is moved into the vertical position over the borehole.

Lower the pump down the borehole until the clamp rests on the wellhead.

Secure the second clamp at the maximum lifting height to the Boreline riser less 1000mm (3 ft), raise this clamp to take up the slack and release the first clamp off the well head. Once the top clamp has taken all the weight remove the lower clamp. Repeat this operation to continue lowering the pump down the borehole. BORELINE INSTALLATION PROCEDURE - using a CRANE

When ready to make the last lift, attach the second Boreline coupling to the headworks and the free end of the riser to the coupling. Release bundled cable(s), feed them through the surface plate and secure the loose ends neatly.

Raise the headworks until the weight of the whole assembly is taken, remove the clamp and lower the assembly onto the borehole. The Boreline and cable must not be dragged over the edge of the casing as this will cause damage.

Attachment of discharge pipework & final wiring up (by a qualified electrician) will complete the installation.

Where the water is to be used for a drinking water system, the pump discharge should be run to waste for half an hour on first start-up (or whenever the pump has not been used for a while) - to flush the components - before directing to the treatment system for further treatment and disinfection of water before entering the water supply.

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BORELINE INSTALLATION PROCEDURE - by HAND

1", 1½" & 2" Boreline only. A minimum of three people required

Connect the Boreline coupling to the pump discharge or check-valve / non-return valve and then the Boreline riser to the coupling. (Do not attach the second Boreline coupling and headworks to the hose at this stage.)

Unroll the Boreline riser along the ground. Lay the power cable next to the riser along the length.

Connect the power cable to the pump motor. (This should only be carried out by a qualified electrician.) Use the Boreline cable straps to tie the power cable to the riser at the recommended intervals. (Remember to snake the power cable along the length allowing approximately 5% slack.) See 'Fitting the Power Cable' above.

Before installation inspect the pump, riser & cable and remove any loose mud & debris, washing as required with mains water. The pump and riser should be inspected during the installation process and any contamination removed before the assembly enters the borehole.

Some water suppliers may require the assembly to be disinfected during the installation operation - the appropriate procedures should be followed where this is specified. The maximum chlorine concentration should not exceed 5% to avoid damage to the hose.

Clamp the Boreline riser only (not the power cable) using a Boreline clamp approximately 600mm (2') from the free end.

Lift the pump and lower it gently until the majority of the Boreline is in the borehole and the clamp rests on the well head. The Boreline and cable must not be allowed to drag over the edge of the casing as this will cause damage.

BORELINE INSTALLATION PROCEDURE - by HAND

Attach the second Boreline coupling to the headworks and then the free end of the riser to the coupling. Release bundled cable(s), feed them through the surface plate and secure the loose ends neatly.

Whilst two people lift the headworks, until the weight of the whole assembly is taken, the third should remove the clamp so that the assembly can be lowered onto the borehole.

Attachment of discharge pipework & final wiring up ( by a qualified electrician ) will complete the installation.

Where the water is to be used for a drinking water system, the pump discharge should be run to waste for half an hour on first start-up (or whenever the pump has not been used for a while) - to flush the components - before directing to the treatment system for further treatment and disinfection of water before entering the water supply.

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BORELINE RETRIEVAL PROCEDURE - using a VEHICLE

Stop the pump. If a 6mm (¼") hole has been drilled into the check valve allow the water to drain down to the static water level - allow 30 seconds per metre ( 10 seconds per foot ). If a Break-Off Plug has been installed open the access port in the wellhead and drop the anvil tube to fracture the plug - when the water level drops allow 30 seconds per metre (10 seconds per foot) to completely drain down - meanwhile, recover the anvil tube using the attached cord.

Disconnect the electrical supply and discharge pipe-work.

Using the tripod or crane lift the Boreline out of the borehole and clamp the riser with the Boreline clamp. Do not clamp the cable. Lower the Boreline so that the clamp rests on the casing and takes the complete weight.

Place the rolling wheel against the borehole ensuring that it is centrally positioned and secured. (An unsecured roller can move and cause damage to the hose - or injury to the operator.) Lift the Boreline and fold it over the rolling wheel and attach it to the vehicle using the second clamp. Ease the vehicle away from the borehole so that it takes the weight of the assembly and remove the first clamp.

Drive the vehicle slowly away from the borehole lifting the Boreline and pump.

As the pump approaches the top of the borehole, clamp the riser and allow the clamp to rest on the borehole. (Proximity of the pump will be indicated by the red cable ties.)

Use the tripod or crane to lift the pump out of the borehole.

Please note. If the Boreline and pump have to be removed while full of water the column will be considerably heavier than normal. In this case make sure to allow for the extra weight when using lifting devices and vehicles.

See the full specification table, above, for nominal weights of the Boreline and water column per metre. The addition of pump, cable and accessories weights will give the total weight of the column to be lifted.

BORELINE RETRIEVAL PROCEDURE - using a VEHICLE

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BORELINE RETRIEVAL PROCEDURE - using a CRANE

Stop the pump. If a 6mm (¼") hole has been drilled into the check valve allow the water to drain down to the static water level - allow 30 seconds per metre (10 seconds per foot ). If a Break-Off Plug has been installed open the access port in the wellhead and drop the anvil tube to fracture the plug - when the water level drops allow 30 seconds per metre (10 seconds per foot) to completely drain down - meanwhile, recover the anvil tube using the attached cord.

Disconnect the electrical supply and discharge pipe-work.

Lift the headplate off the borehole using the crane and slings to approximately 3m (10 ft) above the well head. Clamp the riser using a Boreline clamp at the wellhead level. Lower the riser to allow the clamp to take the full load. Lower the headplate to the ground and remove it from the riser. Do not clamp the cable.

Once the headplate has been removed the Boreline can be drawn from the borehole to the maximum height allowed by the crane and clamped, again, using the other clamp at the well head.

This procedure is repeated until the pump is lifted clear of the borehole.

Please note. If the Boreline and pump have to be removed while full of water the column will be heavier than normal. In this case make sure to allow for the extra weight when using lifting devices and vehicles.

See full specification table, above, for nominal weights of the Boreline and water column per metre. The addition of pump, cable and accessories weights will give the total weight of the column to be lifted.

BORELINE RETRIEVAL PROCEDURE - using a CRANE

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BORELINE RETRIEVAL PROCEDURE - by HAND

1", 1½" & 2" Boreline only. A minimum of three people required

Please Note. If the Boreline and pump have to be removed while full of water the column will be considerably heavier than empty and it may not be possible to lift it by hand - this must be checked before attempting the lift.

See the full specification table, above, for nominal weights of the Boreline and water column per metre. The addition of pump, cable and accessories weights will give the total weight of the column to be lifted. ( Revised Work Practices Guide for Manual Lifting, published by the National Institute for Occupational Safety and Health (NIOSH) in 1991 recommends a maximum weight to be lifted, under perfect lifting conditions, of 51 pounds or 23 kilograms.)

Stop the pump and disconnect the electrical supply & discharge pipe-work.

Whilst two people lift the headworks off the borehole the third should clamp the riser with the Boreline clamp. Do not clamp the cable. Lower the assembly so that the clamp rests on the casing and takes the weight of the pump & riser. The headworks can then be lowered to the ground - there is no need to disconnect it from the Boreline.

Raise the rest of the Boreline from the borehole ( being careful not to damage it on the edge of the casing ) until the pump is retrieved.

BORELINE RETRIEVAL PROCEDURE - by HAND

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Cable Strap Clove Hitch

Cable Strap Clove Hitch

Pass the running end of the strap in front of the power cable and around it.
Cable Strap Clove Hitch Then bring the running end forward over its own standing part. Pass the running end once more around the power cable and bring the running end in between the strap and the power cable.
Cable Strap Clove Hitch Tighten the Clove hitch by pulling on the running end.
Cable Strap Clove Hitch Push the loops closer together.
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