Pumping station design 3rd ed

Contents Special Preface to the Third Edition of Pumping Station Design ................ vi Preface to the First Edition ......................................................................... xv Preface to the Second Edition .................................................................... xvii Preface to the Third Edition ........................................................................ xix Acknowledgments ...................................................................................... xx Authors and Contributors ............................................................................ xxi 1. Introduction ........................................................................................ 1.1 1.1 Authors and Contributors .................................................................... 1.1 1.2 Responsibilities of Project Engineers ................................................. 1.1 1.3 Units ................................................................................................... 1.2 1.4 Standards and Codes ......................................................................... 1.2 1.5 Manufacturers’ Recommendations ..................................................... 1.3 1.6 Safety ................................................................................................. 1.3 1.7 How to Utilize This Book ..................................................................... 1.3 1.8 How to Select Consulting Engineering Firms ..................................... 1.4 1.9 Value Engineering .............................................................................. 1.5 1.10 Ensuring Quality and Economy .......................................................... 1.6 1.11 Avoiding Litigation ............................................................................... 1.7 1.12 Library ................................................................................................. 1.8 1.13 Operator Training ................................................................................ 1.8 1.14 References ......................................................................................... 1.9 2. Nomenclature ..................................................................................... 2.1 2.1 Abbreviations ...................................................................................... 2.1 2.2 Definitions ........................................................................................... 2.8 viii Contents This page has been reformatted by Knovel to provide easier navigation. 2.3 Symbols .............................................................................................. 2.14 2.4 Supplementary Reading ..................................................................... 2.14 3. Flow in Conduits ................................................................................ 3.1 3.1 Fundamentals of Hydraulics ............................................................... 3.1 3.2 Friction Losses in Piping ..................................................................... 3.4 3.3 Pipe Tables ......................................................................................... 3.9 3.4 Headlosses in Pipe Fittings ................................................................ 3.11 3.5 Friction Losses in Open Channel Flow ............................................... 3.12 3.6 Energy in Pressurized Pipe Flow ........................................................ 3.14 3.7 Energy in Open Channel Flow ............................................................ 3.16 3.8 Unbalanced Hydraulic Forces ............................................................. 3.20 3.9 Field Measurement of Pipe Diameter and Friction Coefficient ........................................................................................... 3.23 3.10 Flow of Sludges .................................................................................. 3.32 3.11 Unsteady Flow .................................................................................... 3.32 3.12 Model Studies ..................................................................................... 3.33 3.13 Computational Fluid Dynamics (CFD) ................................................ 3.35 3.14 References ......................................................................................... 3.36 4. Piping .................................................................................................. 4.1 4.1 Selection of Exposed Pipe .................................................................. 4.2 4.2 Selection of Buried Piping ................................................................... 4.11 4.3 Ductile Iron Pipe (DIP) ........................................................................ 4.17 4.4 Steel Pipe ........................................................................................... 4.19 4.5 Plastic Pipe ......................................................................................... 4.21 4.6 Asbestos Cement Pipe (ACP) ............................................................ 4.24 4.7 Reinforced Concrete Pressure Pipe (RCPP) ...................................... 4.24 4.8 Design of Piping .................................................................................. 4.25 4.9 Special Piping and Plumbing .............................................................. 4.35 4.10 References ......................................................................................... 4.40 4.11 Supplementary Reading ..................................................................... 4.41 5. Valves ................................................................................................. 5.1 5.1 Designing for Quality .......................................................................... 5.1 5.2 Isolation Valves ................................................................................... 5.4 Contents ix This page has been reformatted by Knovel to provide easier navigation. 5.3 Sluice Gates, Shear Gates, Flap Valves, and Stop Plates ................. 5.14 5.4 Check Valves ...................................................................................... 5.15 5.5 Control Valves .................................................................................... 5.21 5.6 Valve Actuators ................................................................................... 5.24 5.7 Air and Vacuum Valves ...................................................................... 5.27 5.8 Materials of Construction .................................................................... 5.29 5.9 Installation of Valves ........................................................................... 5.30 5.10 Corrosion Protection ........................................................................... 5.31 5.11 References ......................................................................................... 5.31 6. Fundamentals of Hydraulic Transients ............................................ 6.1 6.1 Introduction ......................................................................................... 6.1 6.2 Nomenclature ..................................................................................... 6.2 6.3 Methods of Analysis ............................................................................ 6.2 6.4 Surge Concepts in Frictionless Flow .................................................. 6.3 6.5 Slow Closure of Valves ....................................................................... 6.7 6.6 Surge Concepts in Flow with Friction ................................................. 6.10 6.7 Column Separation ............................................................................. 6.11 6.8 Criteria for Conducting Transient Analysis ......................................... 6.12 6.9 References ......................................................................................... 6.13 7. Control of Hydraulic Transients ....................................................... 7.1 7.1 Overview of Hydraulic Transient Control Strategies ........................... 7.1 7.2 Control of Pumps ................................................................................ 7.8 7.3 Control Tanks ..................................................................................... 7.9 7.4 Valves for Transient Control ............................................................... 7.11 7.5 Containment of Transients .................................................................. 7.13 7.6 Surge Control for Water Pumping Stations ......................................... 7.15 7.7 Surge Control for Raw Wastewater Pumping Stations ....................... 7.18 7.8 Pipeline Design ................................................................................... 7.19 7.9 Computer Analysis .............................................................................. 7.21 7.10 Transients in Distribution Systems ..................................................... 7.23 7.11 References ......................................................................................... 7.26 x Contents This page has been reformatted by Knovel to provide easier navigation. 8. Electrical Fundamentals and Power System Principles ................. 8.1 8.1 Definitions and Code References ....................................................... 8.1 8.2 Electrical Fundamentals ..................................................................... 8.2 8.3 Power and Control System Elements ................................................. 8.9 8.4 Standby Generators and Auxiliaries ................................................... 8.26 8.5 Grounding ........................................................................................... 8.29 8.6 Lighting and Power Outlets ................................................................. 8.32 8.7 Electrical Circuit Diagrams .................................................................. 8.35 8.8 Power and Control System Practices ................................................. 8.37 8.9 Reference ........................................................................................... 8.41 8.10 Supplementary Readings ................................................................... 8.41 9. Electrical Design ................................................................................ 9.1 9.1 Final Construction Drawings ............................................................... 9.1 9.2 Specifications ...................................................................................... 9.3 9.3 Contacting Utilities .............................................................................. 9.4 9.4 Construction Information to Utilities .................................................... 9.5 9.5 Load Estimation .................................................................................. 9.5 9.6 Overcurrent Protection and Conductor Sizing .................................... 9.8 9.7 Lighting ............................................................................................... 9.14 9.8 Power Factor ...................................................................................... 9.16 9.9 Engine Generators .............................................................................. 9.17 9.10 Short-circuit Current Calculations ....................................................... 9.20 9.11 Harmonics ........................................................................................... 9.22 9.12 Construction Service ........................................................................... 9.22 9.13 References ......................................................................................... 9.24 10. Performance of Centrifugal Pumps .................................................. 10.1 10.1 Classification of Centrifugal Pumps .................................................... 10.1 10.2 Pump Application Terminology, Equations, and Performance Curves ................................................................................................ 10.1 10.3 Pump Operating Characteristics ......................................................... 10.8 10.4 Cavitation ............................................................................................ 10.16 10.5 Pump Characteristic Curves ............................................................... 10.27 10.6 Pump Operating Regions ................................................................... 10.30 Contents xi This page has been reformatted by Knovel to provide easier navigation. 10.7 Elementary Pump System Analysis .................................................... 10.32 10.8 Practical Pumping System H-Q Curve Analysis ................................. 10.37 10.9 Complex Pumping System H-Q Curves ............................................. 10.43 10.10 References ......................................................................................... 10.43 11. Types of Pumps ................................................................................. 11.1 11.1 General Classifications of Pumps ....................................................... 11.1 11.2 Classification of Centrifugal Pumps .................................................... 11.6 11.3 Construction of Centrifugal Pumps ..................................................... 11.7 11.4 Overhung-impeller Pumps .................................................................. 11.17 11.5 Impeller-between-bearings Pumps ..................................................... 11.25 11.6 Classification of Vertical Pumps ......................................................... 11.25 11.7 Construction of Vertical Pumps .......................................................... 11.27 11.8 Types of Vertical Pumps ..................................................................... 11.31 11.9 Positive-displacement Pumps ............................................................. 11.33 11.10 Special Pumps .................................................................................... 11.35 11.11 Summary of Typical Pump Applications ............................................. 11.40 11.12 References ......................................................................................... 11.41 11.13 Supplementary Reading ..................................................................... 11.41 12. Pumps: Intake Design, Selection, and Installation ......................... 12.1 12.1 Design of Pump Intakes ...................................................................... 12.2 12.2 Pump Intake Design Standards .......................................................... 12.2 12.3 Types of Pump Intake Basins ............................................................. 12.4 12.4 Model Study ........................................................................................ 12.11 12.5 Evolution of Trench-type Wet Wells .................................................... 12.12 12.6 Summary of Trench-type Wet Well Characteristics ............................ 12.26 12.7 Trench-type Wet Well Design ............................................................. 12.28 12.8 Wet Wells in Small Lift Stations .......................................................... 12.44 12.9 Principles of Pump Selection .............................................................. 12.47 12.10 Step-by-step Pump Selection and Installation Procedure .................. 12.54 12.11 Reducing Cost of Ownership .............................................................. 12.59 12.12 Installation Design .............................................................................. 12.61 12.13 References ......................................................................................... 12.81 xii Contents This page has been reformatted by Knovel to provide easier navigation. 13. Electric Motors ................................................................................... 13.1 13.1 General ............................................................................................... 13.1 13.2 Applications of Motors ........................................................................ 13.3 13.3 Fundamentals ..................................................................................... 13.6 13.4 Types of Motors for Pump Drivers ...................................................... 13.9 13.5 Characteristics of Squirrel-cage Induction Motors .............................. 13.12 13.6 Motor Speed ....................................................................................... 13.12 13.7 Motor Voltage ..................................................................................... 13.13 13.8 Enclosures .......................................................................................... 13.14 13.9 Insulation ............................................................................................ 13.15 13.10 Squirrel-cage Motors .......................................................................... 13.16 13.11 Frequency of Motor Starts .................................................................. 13.20 13.12 Miscellaneous Motor Features ............................................................ 13.21 13.13 Specifying Pumping Unit Drivers ........................................................ 13.23 13.14 Definite Purpose Induction Motors ...................................................... 13.24 13.15 Design Checklist ................................................................................. 13.28 13.16 References ......................................................................................... 13.29 14. Engines ............................................................................................... 14.1 14.1 Selecting an Engine Drive .................................................................. 14.1 14.2 Duty Cycle .......................................................................................... 14.2 14.3 Fuel for Engines .................................................................................. 14.4 14.4 Aspiration ............................................................................................ 14.7 14.5 Types of Engines ................................................................................ 14.7 14.6 Rich-burn or Lean-burn ....................................................................... 14.8 14.7 Application Criteria .............................................................................. 14.8 14.8 Starting Methods ................................................................................. 14.10 14.9 Cooling Methods ................................................................................. 14.10 14.10 Controls .............................................................................................. 14.10 14.11 Governors for Engine Control ............................................................. 14.11 14.12 Accessories for Engines ..................................................................... 14.12 14.13 Combustion Air ................................................................................... 14.15 14.14 Exhaust Silencing ............................................................................... 14.15 14.15 Pollution Control ................................................................................. 14.17 14.16 Vibration Isolation ............................................................................... 14.17 Contents xiii This page has been reformatted by Knovel to provide easier navigation. 14.17 Lubrication Oil Storage and Supply .................................................... 14.17 14.18 Fuel Oil Storage and Supply ............................................................... 14.18 14.19 Gaseous Fuel Storage and Supply ..................................................... 14.18 14.20 Service Piping ..................................................................................... 14.19 14.21 Building Envelope ............................................................................... 14.19 14.22 Ventilation ........................................................................................... 14.20 14.23 Maintenance ....................................................................................... 14.20 15. Variable-speed Pumping ................................................................... 15.1 15.1 Variable Speed versus Constant Speed ............................................. 15.2 15.2 Design Considerations ........................................................................ 15.4 15.3 Theory of Variable-speed Pumping .................................................... 15.4 15.4 Pump Selection ................................................................................... 15.9 15.5 Variable- and Constant-speed Pumps in Simultaneous Operation ............................................................................................ 15.12 15.6 Special Design Considerations ........................................................... 15.13 15.7 Analysis of Variable-speed Booster Pumping ..................................... 15.15 15.8 Minimum Flow Rate ............................................................................ 15.19 15.9 Operations in Booster Pumping .......................................................... 15.22 15.10 Simultaneous Operation of V/S and C/S Booster Pumps ................... 15.24 15.11 Adjustable- and Variable-speed Drives .............................................. 15.25 15.12 References ......................................................................................... 15.41 16. Pump-driver Specifications .............................................................. 16.1 16.1 Comparison of Two Approaches to Writing Specifications ................. 16.1 16.2 Methods for Specifying Quality of Equipment ..................................... 16.2 16.3 Nonrestrictive Specifications ............................................................... 16.2 16.4 Operating Conditions .......................................................................... 16.4 16.5 Mass Elastic Systems and Critical Speeds ......................................... 16.4 16.6 Pump Testing ...................................................................................... 16.4 16.7 Shipping Major Pumping Units ........................................................... 16.8 16.8 Submittals ........................................................................................... 16.8 16.9 Product Data ....................................................................................... 16.9 16.10 Seals ................................................................................................... 16.9 16.11 Pump Shafts ....................................................................................... 16.9 xiv Contents This page has been reformatted by Knovel to provide easier navigation. 16.12 Pump Shaft Bearings .......................................................................... 16.9 16.13 Vertical Drive Shafts ........................................................................... 16.9 16.14 Electric Motors .................................................................................... 16.9 16.15 Optimum Efficiency ............................................................................. 16.10 16.16 References ......................................................................................... 16.10 17. System Design for Wastewater Pumping ........................................ 17.1 17.1 Organization and Control of the Process ............................................ 17.1 17.2 Preliminary Engineering ...................................................................... 17.2 17.3 Detailed Layout ................................................................................... 17.6 17.4 Detailed Design .................................................................................. 17.10 17.5 Examples of Large Lift Stations .......................................................... 17.11 17.6 Examples of Medium-size Lift Stations ............................................... 17.18 17.7 Examples of Small Lift Stations .......................................................... 17.25 17.8 References ......................................................................................... 17.34 18. System Design for Water Pumping .................................................. 18.1 18.1 Types of Water Pumping Stations ...................................................... 18.1 18.2 Pumping Station Flow and Pressure Requirements ........................... 18.1 18.3 Raw Water Pumping from Rivers and Lakes ...................................... 18.5 18.4 Raw Water Pumping from Aqueducts ................................................. 18.16 18.5 Well Pumps with Elevated Tanks ....................................................... 18.24 18.6 Booster Pumping Stations .................................................................. 18.33 18.7 Retrofitting Large Pump Basins .......................................................... 18.44 18.8 References ......................................................................................... 18.46 18.9 Suggested Reading ............................................................................ 18.46 19. System Design for Sludge Pumping ................................................ 19.1 19.1 Hydraulic Design ................................................................................. 19.2 19.2 Types of Pumps .................................................................................. 19.9 19.3 Pumping System Design .................................................................... 19.13 19.4 Piping System Design ......................................................................... 19.23 19.5 Long-distance Pumping ...................................................................... 19.28 19.6 References ......................................................................................... 19.28 Contents xv This page has been reformatted by Knovel to provide easier navigation. 20. Instrumentation and Control Devices .............................................. 20.1 20.1 Reliability ............................................................................................ 20.1 20.2 Instrument Selection ........................................................................... 20.2 20.3 Level Measurements .......................................................................... 20.5 20.4 Pressure Measurements ..................................................................... 20.10 20.5 Flow Measurements in Pipes .............................................................. 20.13 20.6 Open Channel Flow Measurement ..................................................... 20.20 20.7 Chlorine Residual Measurement ........................................................ 20.20 20.8 Utility and Environmental Measurements ........................................... 20.20 20.9 Pumping Unit Monitors ....................................................................... 20.24 20.10 Control Equipment .............................................................................. 20.24 20.11 Control Logic ...................................................................................... 20.26 20.12 Altitude Valves .................................................................................... 20.27 20.13 Monitoring and Data Acquisition ......................................................... 20.27 20.14 Telemetry ............................................................................................ 20.29 20.15 Design Considerations ........................................................................ 20.34 20.16 References ......................................................................................... 20.35 20.17 Supplementary Reading ..................................................................... 20.35 21. Instrumentation and Control Applications ...................................... 21.1 21.1 Process and Instrumentation Diagrams .............................................. 21.1 21.2 Well Pump with Hydropneumatic Tank ............................................... 21.2 21.3 Booster Stations ................................................................................. 21.3 21.4 High-service Pumping Station ............................................................ 21.4 21.5 Small Wastewater Lift Station ............................................................. 21.5 21.6 Intermediate-sized Lift Station ............................................................ 21.7 21.7 Large Wastewater Pumping Station ................................................... 21.8 22. Vibration and Noise ........................................................................... 22.1 22.1 Problems of Vibration and Noise ........................................................ 22.1 22.2 Avoiding Vibration Problems ............................................................... 22.3 22.3 Troubleshooting Excessive Vibration .................................................. 22.11 22.4 Introduction to Vibration and Noise Calculations ................................ 22.19 22.5 Vibration and Noise Characteristics .................................................... 22.22 22.6 Applicable Codes ................................................................................ 22.25 xvi Contents This page has been reformatted by Knovel to provide easier navigation. 22.7 Equipment Vibration ........................................................................... 22.29 22.8 Vibration Isolation Theory ................................................................... 22.30 22.9 Vibration Isolators ............................................................................... 22.32 22.10 Piping Vibration ................................................................................... 22.35 22.11 Vibration of Drive Shafts ..................................................................... 22.46 22.12 Vibration of Structures ........................................................................ 22.50 22.13 Noise .................................................................................................. 22.52 22.14 Reducing Exterior Noise ..................................................................... 22.59 22.15 References ......................................................................................... 22.64 23. Heating, Ventilating, and Cooling ..................................................... 23.1 23.1 Need for Heating, Ventilating, and Air Conditioning ........................... 23.1 23.2 HVAC Design Criteria ......................................................................... 23.4 23.3 Odor Control ....................................................................................... 23.6 23.4 Dry Well Design Guidelines ................................................................ 23.11 23.5 Energy Use and Conservation ............................................................ 23.13 23.6 Corrosion Protection ........................................................................... 23.15 23.7 Sequence of Design Steps ................................................................. 23.16 23.8 Ventilating System Design .................................................................. 23.18 23.9 Design of Heating Systems ................................................................ 23.25 23.10 Design of Building Cooling Systems ................................................... 23.30 23.11 Design of Refrigerated Cooling Systems ............................................ 23.32 23.12 References ......................................................................................... 23.34 23.13 Supplementary Reading ..................................................................... 23.35 24. Designing for Easy Opera