PUMPING STATIONS AWARENESS

BY ANDY FINN APRIL 2005

1.

PUMP TYPES
The types and sizes of pumps are dependent upon: Flows and heads Nature of liquid being pumped

Pump Type Plunger Screw Centrifugal Clean Water X Axial Flow Centrifugal Radial Flow Peristatic / Diaphragm Progressive Cavity Mixed Flow Volute Archimedian Screw Mixed Flow Bowl X X X X X X Vortex Impeller X X X X X X X X X X X X X X X X X X X

Raw Sewage, unscreened Raw, Sewage, screened Storm water with sewage Storm water (surface water only) Primary treated sewage Final effluent Primary sludge (>94% moisture) Primary sludge (<94% moisture) Humus sludge Digested sludge Activated sludge Supernatant liquid Grit removal

X X X X X X X X X X X X

X X X X X X

X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X

The most commonly used pumps are vortex impeller pumps and radial flow pumps. Vortex Impeller Pump the vortex impeller pump uses a forced vortex spiral flow through the pump such that liquid crosses across the face of the impeller; thus any solid entering the pump suction has a free and uninterrupted passage through to the discharge. Radial Flow Impeller Pump the double shrouded or channel impeller has a centrifugal pumping action such that liquid passes through the impeller radially into the pump casing and thence to the discharge. Other types of radial impellers include fully open and semi-open impellers with one, two or three vanes. Large size vortex impeller pumps are normally less efficient than similar radial flow impeller pumps. Large flow variations occur due to large changes in head in

relation to vortex impeller pumps. Advantages of vortex impeller pumps are reduced wear and improved freedom from choking.

2.

IMPELLERS

3.

PUMP MOTORS Aspects for consideration in determining most suitable motor for a pump include: Explosion proof Operational temperature of the motor Seals Bearings Motor protection devices include: Overheating Water intrusion Seal failure Bearing failure Winding insulation deterioration

4.

PUMP CONNECTIONS

5.

PUMP MATERIALS The most suitable material for the pumps is dependent upon: Corrosion resistance Wearing resistance Abrasive liquid

6. a)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

The pumps are located in a single wet chamber below ground level and are fully submersible types (ie the pumps are submerged under the liquid) with guide rails and low level coupling systems. The guide rail and coupling system allow the pump to be installed or removed quickly and easily from the surface. The pumps are fitted with permanent lifting chains attached to each pump with the top end attached to a bracket just inside the access cover, ready for use. A suitably rated removable lifting davit with winch or pulley block is used to withdraw the pumps. A floor socket is located in the top slab to receive the davit. Pumps are connected by flexible cables to a control panel mounted at ground level which incorporates the starters and control equipment for the pumps. The panel is mounted within a weatherproof kiosk. Isolating sluice valves and non-return valves are fitted within a separate valve chamber with access through a removable cover. Control of the pumps is normally by ultrasonic level sensors with backup using float type level regulators set to start and stop the pumps at high and low levels respectively. For pumping stations handling a large variation in flows (eg Combined sewers which may deal with only dry weather flow (DWF) at one time and heavy storm and dry weather flows at another time), this situation can be dealt with by using two pumps (ie DWF pump + storm pump) or by one variable speed pump.

6 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

6 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

7 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

7 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station) Design Considerations: i) ii) Requirement to stop flows entering the wet well to enable maintenance / repairs hence penstock on inflow The pumping station may breakdown allow for contingencies as appropriate. Eg a) Power failure consider use of temporary generator b) Pump failure switch over to standby pump c) Inflow exceeds capacity of wet well and pumps provide gravity overflow Operate as much as possible from the surface to avoid confined spaces. Preferably with a small cover over devices such that it can be operated by a single person and there is no risk of falling in. eg Small covers over level devices, spindles, etc. Access covers over pumps require to be sufficiently sized to enable removal of the pumps. In sizing the covers, consider the obstruction from the guide rails. Also consider the maximum weight of a cover (generally this should not exceed 25kg for a single person). A safety grid should be provided under the cover such that when the main cover is opened, personnel cannot fall into the wet well. Also the safety grid should be self closing such that when the pump has been pulled through it, it closes under its own weight. For ultrasonic levels, consider the spread of signal. ie It needs to pick up the water level and not get a reading from the benching, pipework or pumps as it will affect operation of the pumps There is some dead space under the pump inlet Get the benching arrangement checked by the pump manufacturer in order that the pump manufacturer in the future cannot state that failure of the pumps is down to the benching design Ducts for cables require to be sealed to prevent flammable gasses or water or vermin passing through them. (Remember electrics may be involved and therefore gases can explode, whilst vermin can eat through the cables) A check may be required in relation to the possibility of the wet well and valve chamber floating. The wet well should be considered empty for the check Depending upon the location of the wet well, odour mitigation may be required If there is a risk of differential movement between the wet well and valve chamber, consider having the two structures separate otherwise reinforcement will require to be designed to allow for settlement.

iii)

iv)

v)

vi) vii)

viii)

ix) x) xi)

7 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station) xii) Depending upon the size of inflow and the height of fall of the inflow, consideration should be given to whether a baffle arrangement is required on the end of the inlet pipe to the wet well. xiii) Due to the pipework arrangement and the land available, consideration may have to be given to the use of a rectangular shaped valve chamber rather than manhole rings. xiv) In determining the valve chamber arrangement, consider access for operation of the gate valves xv) Water may end up in the valve chamber (ie liquid from removal of pipe fittings, rainwater, etc), therefore consideration must be given to its removal. Options include: a sump in the base of the valve chamber to enable pumping out, a drain from the valve chamber to the wet well with a penstock or flap valve on it to prevent liquid from the wet well backing up into the valve chamber if the pumps fail) xvi) For large access openings, removable support beams may be required. If they are required, check to see if there is sufficient space for valves under them xvii) Any surfaces in contact with foul or combined sewage require to be sulphate resisting. This can either be done using sulphate resisting concrete or to use a granolithic (high strength concrete) layer over the concrete. xviii) Provide bauer connections to enable the hose from a tanker to be connected. For ease of operation, it is preferable for the bauer to be horizontal and above ground to avoid entry into a confined space. xix) On the emergency overflow, consider the requirements of the environmental authority and the need for a screen

8 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

Typical Site Layouts

MCC CABINET

WASH DOWN SET

8 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

MCC CABINET

WASH DOWN SET

15m

15m

15m

TYPICAL ARRANGEMENT FOR ACCESS OFF LOW CLASSIFIED ROAD

8 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station)

TYPICAL ARRANGEMENT FOR ACCESS OFF UNCLASSIFIED OR ESTATE ROAD

9 A)

TYPES OF PUMPING STATIONS WET WELL PUMPING STATION (also known as Submersible Pumping Station) Design Considerations for Site Arrangement i) ii) iii) Consider the types of vehicles (eg tankers, vans, lorries) and where they require to get to on site (eg to enable removal of the pumps from the wet well) Provide surfaced footpaths to items requiring regular maintenance or inspection. eg MCC Control, valve chamber, wet well. Maximise use of concrete and gravel (say 14mm or 20mm single sized clean stone) on filter fabric surfacing in order to minimise maintenance rather than having the area grassed. Also consider the consequence of contamination of the surface eg when pumps are removed or leakage from hoses connected to tankers In determining the sizes of kiosks, make doors large enough to enable removal of equipment, eg MCC. Check to see whether a surge vessel and compressors are required. Normally an electricity meter will be required on the site. Consider its location and provision of a separate compartment in order that the electricity company can read it without the requirement for the water authority personnel to be present. ie Ensure that the meter reader cannot have access to the pumping station controls. The control cabinet needs to be watertight, a flexible membrane may be required on the underside of the base to the superstructure and on top of the concrete. The control cabinet requires to be free of dust, therefore consider the need to seal the concrete Ensure an emergency stop is close to the wet well (normally it is sufficient for the stop to be incorporated in the control cabinet but in some cases an external stop may be required If a washwater system is to be provided to clean down, say pumps, consider where the contaminated water is going to end up. Eg Consider the provision of bunding (using road kerbs) and the drainage of the bunded area back into the wet well.

iv) v)

vi) vii) viii) ix)

B)

DRY WELL PUMPING STATION

The pumps are located in a dry chamber and draw from an adjacent wet sump through suction pipes. Usually pumps are vertical with extended flexibly jointed shaft drives to electric motors mounted at ground level; thus avoiding the dangers of motors becoming flooded. A building is usually constructed above ground to house electrical switchgear and pump motors. With dry well pumping installations, pumps can be inspected easily and serviced with regular checks on bearings, glands, etc.

6 C)

TYPES OF PUMPING STATIONS ON-LINE PUMPING STATION

6 C)

TYPES OF PUMPING STATIONS ON-LINE PUMPING STATION

7 C)

TYPES OF PUMPING STATIONS ON-LINE PUMPING STATION

7 C)

TYPES OF PUMPING STATIONS ON-LINE PUMPING STATION DESIGN NOTES 1) The flooring shall be manufactured in sections suitable for manual lifting by one person and shall be suitably clamped in position. 2) The drawings above are examples only and may require amending to suit detailed design of pipework / pumps and the utilitys requirements. Notwithstanding this, the station may need to be extended if surge equipment is required. 3) The access door should be large enough to enable removal of equipment including the MCC. 4) The drawing depicts a bottom entry MCC cabinet with cable ducts in the floor. As an alternative, the use of top entry MCC cabinets and wall mounted cable trays may be used. (A cable tray is the steelwork used to support cables see below) 5) The noise levels of the pumps require checking and if necessary the pumps may require to be placed in an acoustic enclosure. 6) An opening with small cover shall be provided in the wall to enable a cable from an emergency generator to be fitted from the outside. 7) Louvres shall be incorporated in the walls and sized to suit the pumping units in order to assist with cooling the pumps. The louvres (and building) should be designed such that it is watertight. Conversely heaters (and insulation) may be required in the building to keep it warm in cold weather when the pumps are not operating.

PHOTOGRAPHS OF VARIOUS ELEMENTS OF A PUMPING STATION

Cable Tray

MCC

PHOTOGRAPHS OF VARIOUS ELEMENTS OF A PUMPING STATION

MCC

Small Control Kiosk

PHOTOGRAPHS OF VARIOUS ELEMENTS OF A PUMPING STATION

Float Switch

Pump and Guide Rail

PHOTOGRAPHS OF VARIOUS ELEMENTS OF A PUMPING STATION

Standby Generator

Davit

PHOTOGRAPHS OF VARIOUS ELEMENTS OF A PUMPING STATION

Bauer Connection

Pumping Station Site

PHOTOGRAPHS OF VARIOUS ELEMENTS OF A PUMPING STATION

6.

PUMP SUMP It is useful to obtain the agreement of the pump manufacturer regarding the sump arrangement. The following comments are for guidance only. The functions of a pump sump or wet well are: To receive or hold incoming sewage A control for the pumps (ie its volume will dictate the frequency which the pumps will be operated). The maximum number of starts that can be tolerated by electric motors is dependent upon size and type of motor but a reasonable rule of thumb is 10 times per hour. The start level is normally below the invert level of the lowest incoming sewer with some freeboard. This is to prevent sewage backing up the sewer system. The stop level is dependent upon the required capacity of the wet well, size of pump and frequency of operation of pump. The sumps should have benching to direct solid matter towards the pump suctions and prevent solids build up. Minimum slope of benching > 450. The positions of the suction bellmouths in sumps can affect the pump performance. Normally allow the distance between the floor of the sump and the opening of the bellmouth to be D / 2 where D = diameter at the opening of the bellmouth (ie not the pipe diameter) > 80mm. The distance between bellmouths = between 2D and 3D. Incoming sewers should be positioned so that they distribute flow evenly to the sump. Large drops should be avoided as they will cause severe aeration of the liquid and possible cavitation in the pumps.

7.

PUMPING HEAD FRICTION HEAD Amount of head required to overcome the friction caused by the liquid passing through the pipes and valves to the point of delivery STATIC HEAD The vertical distance between the water level on the suction side of the pump to the highest level on the delivery system.

Max water level, B1 Level, C Mean water level, B2 Min water level

Max water level, A1 Mean water Level, A2 Min water level, A3 Pump

Mean static head = B2 A2 Max static head = B1 A3 Min static head = C A1

PUMP CASING CENTRE LINE BELOW WATER LEVEL

Max water level, B1

Level, C Min water level

Pump casing level, D Max water level, A1 Mean water level, A2 Min water level, A3

Mean static suction lift = D A2 Max static suction lift = D A1 Min static suction lift = D A1 Total suction lift = static suction lift + total friction head < suction capability of the pump = Nett Positive Suction Head

PUMP WORKING ON SUCTION LIFT

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USEFUL HELP a) b) c) d) Sewers for Adoption published by WRc Sewers for Scotland published by WRc Grundfos Pumps Ltd ITT Flygt Ltd