Pumps and Pumping Stations

Presented by Ned W. Paschke, PE University of Wisconsin-Madison

Outline of this Session

Pumps and Pumping Stations
1. Pump Types and Features

2. Estimating Flows and Differential Heads

3. Pump Performance Curves and System Curves 4. Types of Pumping Stations 5. Wet-wells, Sumps, Suction Chambers 6. Piping, Valves, Screens, and Other Features

1. Pump Types and Features

A. Centrifugal End-Suction

Installed in a dry pump room

Horizontal or vertical shaft Volute elevation is below water surface Impeller is outside of bearings Stress on shaft, due to impeller Wide performance selection available

B. Centrifugal Double-Suction, Split Case

Usually horizontal, but can be vertical Installed in a dry pump room

Impeller is supported between the bearings, symmetrical.

Flow splits and enters impeller from both sides.

High efficiencies available. For clean water, not solids handling.

C. Submersible
Motor is integrally sealed to pump. Always vertical. Pump + motor operates submerged in the sump or reservoir Advantage: small footprint, no separate pump room needed.

A popular, growing trend

especially for small - medium size facilities

D. Vertical Turbine Pumps

Ideal for groundwater wells.

Or can be mounted above reservoirs and sumps

Motor above, pump below.

Small footprint area. Saves space. A series of impellers, directly in series. Can develop high differential heads.

E. Archimedes Screw Pumps

Probably the oldest type of pump (circa 250 BCE)
Handles a variety of flow rates at constant speed Can be open or closed design. Non-clogging, good at solids handling.

F. Progressing Cavity Pumps

For handling viscous sludges, difficult fluids, high solids.
A positive displacement pump, flow not affected by head. More expensive, lower efficiencies than centrifugal pumps. High wear, stator replacements. Low speeds are best.

G. Other Special Purpose Pumps

Chopper pump, with cutter blades

Self-priming, suction-lift pump. Mounted above water level

Recessed impeller vortex pump, for solids and rags

and many others!

Looking for a Centrifugal Pump?

1. 2. 3. 4. 5. 6. 7. 8. 9. Manufacturer with a strong experience record Good operating performance at desired flows & heads High efficiency - saves energy and reduces wear Solids handling capacity - to pass at least a 75mm sphere (but this will reduce efficiency somewhat) Low-speed rpm preferable to high-speed rpm. Less wear. High-speed is smaller and less costly, though. Minimal shaft deflection (less than .05mm is good) Inspection/ cleanout ports at suction & discharge Nominal pump size = connection size at discharge (note: suction diameter is often larger) Compare bare pump weights - heavy is good
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Key Pump Components

Casing (volute) Shaft

Discharge Impeller

Suction

Bearings Mech. seals or packing

N. Paschke 2011

Wear rings 11

2. Estimating Flows & Differential Heads

Lets Start with Typical Average Flow Rates
Note: Use actual local flow data if possible. Flows can vary greatly between different regions and cities. Trend: Water use per person is declining in the US.

Flowrate Variation an Important Aspect

Selecting a peak design flow: Not an easy decision. Involves both engineering and policy. It greatly affects the remaining design.

A Wastewater Pumping Example

Selecting Peak Design Flows

Facilities must handle a wide range of flows: Time-of-day, present vs. future, dry-weather vs. wet Wastewater peaks: governed by wet weather events. Drinking water peaks: governed by dry weather demands, fire flow requirements, and storage availability. Selecting the Peak Flow. Different methods are in use: Peak/average ratios (often 2.5 to 5, sometimes more) Historical experience & probability analysis Dynamic computer modeling, incl. storage & travel times Note: Define the duration and frequency of the peak Final design requires both engineering and policy: How big is big enough? How much can we afford?
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Differential Pumping Head and its Components

DISHARGE VALVE & FITTING LOSSES SLOPE OF PIPE FRICTION LOSS

Hp
STATIC HEAD

EXIT LOSS

N. Paschke, Univ. of Wisconsin-Madison 2011

Note: There are 3 Components of Pumping Head

Estimating Pipe Friction Losses

(each formula has its own empirical roughness factor)

Darcy - Weisbach

where

L V2 Loss = f D 2g

L = pipe length D = pipe inside diameter V = velocity = Q/A = flowrate / pipe area g= gravity = 32.2 ft/s2 =9.81m/s2 f = friction factor from Moody diagram

See tables for typical pipe roughness values

Hazen Williams (metric units)

where R = hydraulicradius = area wetter perimeter

V 0.849 C R

0.63

0.54

pr 2 r = = for circular pipes flowing full 2pr 2

V or Loss 0.63 0 . 849 C R

1.85

where S = friction slope = Loss / Length Common C values in pipes: 150 smoother 100 rougher

Friction Losses are proportional to V2 or V1.85

3. Pump Performance Curves and aaSystem Curves

Pumping head (feet) (1 ft. = 0.3048 m)

shut-off head operating point

Components of the system curve:

pipe friction losses

valve & fitting losses static head

static head

N. Paschke 2011

Flow rate (gal/min) (1 gal/min = 3.785 liters/min)

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Sensitivity to Static Head Ranges

Pumping head (feet) (1 ft. = 0.3048 m)

Pump operating range

What are some examples of a changing static head?

Flow rate (gal/min) (1 gal/min = 3.785 liters/min)

N. Paschke 2011

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Sensitivity to Static and Friction Ranges

Pumping head (feet) (1 ft. = 0.3048 m)

Possible pump operating range

Old pipes can become more rough, due to pipe corrosion, and interior deposits.

Flow rate (gal/min) (1 gal/min = 3.785 liters/min)

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Sensitivity to Pump Wear

Pumping head (feet) (1 ft. = 0.3048 m)
original new pump curve

pump is badly worn

Possible pump operating range

How would we know if our pump is wearing?

Flow rate (gal/min) (1 gal/min = 3.785 liters/min)

N. Paschke 2011

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Series and Parallel Pumping

Pumping head (feet) (1 ft. = 0.3048 m)

2 pumps in series
add pump curves vertically

System curve

2 pumps in parallel
add pump curves horizontally

1 pump

Flow rate (gal/min) (1 gal/min = 3.785 liters/min)

Pump Performance Curve: Lots of Info.

Size Speed Flow Head Impeller Vanes Efficiency Max. Solids Power required NPSHR
= 150mm

Net Positive Suction Head Available (NPSHA)

NPSHA is a property of the system, not the pump.
Note: NPSH problems use absolute pressure, not gage pressure

NPSHA = Ha + (Z1 Z2 ) Losses 1-2 Hv

Ha = atmospheric pressure head = 10.3 m at sea level = 8.6 m at elevation 1500 m

It indicates the net absolute head available at the suction side of the pump impeller, point 2 .

Hv = vapor pressure (absolute) 0.12 m at 10o C 0.24 m at 21o C

EXAMPLE. Estimate the NPSHA, Given Elev. 1 = 100 m., Elev. 2 = 98 m, Estimated suction losses = 1m, Temp = 100 C, Elev. = sea level. NPSHA = 10.3 m + (100 m 98 m) 1 m losses 0.12 m vapor = 11.2 m

4. Types of Pumping Stations

TYPES OF STATIONS

Dry-well Stations
Also called dry-pit or conventional Pump room (or dry well) houses the pumps DRY-WELL STATION Separate chamber (wet-well, or sump) stores incoming wastewater

Submersible Stations

Pumps/motors are submerged within the wet well No separate pump room exists UsesSUBMERSIBLE separate valve vault and STATION 24 control room

Advantages of Dry-well Stations:

A long experience record A wide selection of pumps Easy access to pumps Visual, hands-on inspection Chosen for most large stations

Advantages of Submersible Stations:

Lower cost, no dry well Less piping & valves Frequent access not needed Technology has improved 25 Valves accessible in vault

Examples of Pump Rooms in Dry-well Stations

Inside a Control Room on the ground floor Down in a Pump Room

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Examples of Pumping Station Exteriors

A Large Dry-well Station in Profile

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Same Station in Plan View

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Dewatering the site

Starting an excavation

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Constructing the base slab

Constructing the walls

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A large booster station in Virginia

Location: Kempsville Pressure Reducing Station, Hampton Roads Sanitation District, Virginia

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A deep lift station in Arizona

Submersible pumps installed in dry-well station. Variable frequency drives, emergency generator on grade floor, odor control, architectural design.

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Location: City of Glendale, AZ

A large circular submersible station in Texas

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In the discharge chamber

On the surface deck

Location: Houston, Texas
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A small, factory-built submersible station

A factory-built steel dry-well station

Two pumps (duplex) are most common Usually circular shape Typical diameters: 8-ft. to 12-ft. Oval or peanut shapes for three or more pumps Plus pre-cast concrete wet-well on field-poured base slab
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Example of a factory-built steel station

A self-priming suction-lift station

Pumps mounted above the water surface level Pump must include self-priming vacuum-break, to lift water into impeller Easy pump access, close to surface Low cost station 40 But may be less reliable

5. Choosing the Size and Number of Pumps

Pumping stations must handle a wide range of flows.
Minimum, average, peak. Present vs. future.

Objectives:
Must be large enough to handle the peak
Must be reliable and efficient for normal daily operation

Overlapping Considerations
How many total pumps? Variable-speed or constant? How to handle the peak? Parallel pumping? Future expansions?

Selecting a Team of Pumps

A Two-pump Constant-speed Station?
Common approach for smaller stations Each unit is sized for peak. Lots of cycling. High energy use.

A Three-pump (or more) Constant-speed Station?

Various combinations of sizes and/or parallel pumping Allows smaller, medium pump(s) for typical daily flow.

Fewer cycles. Can save energy.

A Variable-Speed Station?

Can provide flow flexibility with fewer total pumps

But must account for variable pump efficiencies and VFD losses

Is Storage Available, to Reduce the Pump Range?

Pump Cycling Examples

for a mid-sized wastewater station

Example: two equal pumps, constant-speed, peak capacity

Example: multi pump (3 or more) graduated-capacity, constant speed system. Small unit sized for 2 ft./sec.

Flat system curve example: One pump = 16,000 gpm Two pumps = 30,000 gpm

Steep system curve example: One pump = 16,000 gpm Two pumps = 18,000 gpm

Parallel pumping is most useful when system head curve is fairly flat.

Variable-speed Pumping Example

Pumping head (feet) (1 ft. = 0.3048 m)

Flow rate (gal/min) (1 gal/min = 3.785 liters/min)

Variable-Frequency Drives, Pros and Cons

Pros of VariableSpeed Inflow = Outflow. Allows smaller storage. Provides smoother discharge to downstream process Fewer starts and stops. Saves mechanical wear and reduces water-hammer Some energy savings, if system head-loss is large Can satisfy flow range with fewer total pumps. Cons of VariableSpeed Equipment is more costly.

More complex. It could fail.

Useful lifespan is more limited (10-15 years) Some extra energy losses within equipment Additional space needed in control room

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6. Suction Chambers (Wet-wells, Sumps)

Suction Chambers Serve Multiple Purposes:
Providing a storage volume
Inflow rate is different than outflow rate (pump discharge)

Electric motors have limited allowable starts per hour

Example: Maximum 6 starts/hour = Minimum 10 minute cycle time

Protecting against swirls, vortices, air entrainment

These can disrupt the pump performance

Avoiding solids deposition

To reduce problems with cleaning, odors, and corrosion

Examples of small circular designs

Separate dry-well type

Submersible

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Suction Chambers with Baffles (to reduce swirls and vortices)

Submersible

Separate dry well.

Source: Flygt ITT pumps

Selecting Depths, Volumes, & Cycle Times for Suction Chambers

1. 2. Establish allowable hi-water elevation Compute required live storage volume*

1 Pump Q CycleTimeAllowed 4
3. 4. Provide submergence to prevent vortices in pool Allow clearance below suction flare for entry Check that volute remains flooded
*for single step ON-OFF stations

5.

Flared Suction Entrance Pipe in Suction Chamber

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Submergence depths for pump inlet, to prevent swirls and vortices.

Examples
Source: Flygt ITT pumps

Self-Cleaning Trench Suction Chamber

5. Piping, Valves, Screens, Other Features

Ductile iron

PVC

Common Materials for Underground Piping

Ductile Iron A standard product, AWWA C150, C151 Push-on gasket joints 6 meter lengths Up to 50 deflection Same o.d. for all thickness classes Poly wrap for corrosion protection Plastics: PVC, HDPE, Fiberglass Excellent corrosion resistance Pressure ratings good, but less than ductile or steel Cracking? PVC may crack when coring holes under load Flexible pipe depends on soil to prevent deflection good bedding + compaction needed

Reinforced Concrete Pressure Pipe (RCPP) Custom built for your pressure & cover depth Steel wire for strength + steel cylinder for watertightness 55 Available in very large sizes. ( > 4 m dia. available)

Types of Isolation Valves Eccentric Plug Valve

Resilient Seated Gate Valve

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Check Valve, with Oil Cushion Chamber

600mm

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Combination Air Valves

Installed at high points in pipeline
To release air trapped in pipeline

Also to admit air into pipeline to relieve vacuums

ARI type

VENT-O-MAT type

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Screen Example: Perforated Plates with 6mm holes

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Emergency Power & Backup Options

1. 2. 3.
4.

5.

6.

Connect station to two independent electric power feeds Provide onsite generator in auto standby Provide portable generator to connect outside of station Provide onsite diesel or gasdriven pumps, capable of peak flow Provide portable pumping units (and connections) capable of peak flow, or Holding facility for 24-hours storage
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Summary: Pumps and Pumping Stations

Many different pumps to choose from
Submersible or dry-well Centrifugal, vertical turbine, Archimedes, positive displacement

Pump performance characteristics

Flow, head, efficiencies, speed NPSH, solids handling, power required

Choosing a set of pumps

Size and number, individual, parallel, or series Constant speed or variable speed

Station types, sump geometry, other features

Submersible, dry-well, sump sizes, baffles Valves, screens, emergency power

Questions, Discussion? Thank You!

Ned W. Paschke, PE Univ. of Wisconsin-Madison 432 N. Lake Street Madison, WI USA 53706 608-263-4705 paschke@engr.wisc.edu