28-30 NOVEMBER 2006

Institut Pembangunan Kompetensi JPS

(DICODE) IPOH
Bahagian Latihan dan Kemajuan Kerjaya
Jabatan Pengairan dan Saliran Malaysia,
Kampung Temiang,
31650 Ipoh, Perak.
I - PUMPIKG SYSTEM cSi FACILITIES
1. INTRODUCTION
The general construction of a t,ypical p~.!~nping inst~illat :m campiete with its
associated equipment is as outiined below. Depending on the application, location
and complexity ofthe installation required, some of the features may not be
applicable or provided.
(a) Intake System
(i) Inlet and Approach Char m!
(ii)
Screen and raking cq~:iptnent, j t opi ~g / pensock
(iii) Pump sump
(b) Discharge System
(i) Column pipe, discharge piping
(ii)
Valves - flap valve, check valve
(c) Building I Superstructure
(i)
Pump room 1 well (dry or wet pit)
(ii) Control room 1 office
(iii) Electric room - transformer room, HV room, LV room etc
(iv) Generator room
(v) Workshop / store
(vi) Toilet facilities
(d) Auxiliary Equipment
(i)
Electrical Equipment - HV i LV switchgear. tramdormer
(ii) Instrumentation - level, flow,
(iii) Supervisory and coiitrol / operation equipment
(iv) Generator set
(e) Pumping Equipment
(i)
Electrical pump set - submersible, non-submersible
(f) Ancillary Equipment
(i)
Lifting device / overhead cram
(ii)
Penstock / stoplog / gatcs
(iii) Trash removal equipmenr:
(iv) Fire fighting equipment
2. ELECTRICAL SUBMERSIBLE PUMPS
2.1 Pu~nps are devices used for transfering water from a relatively low ground area to
a higher ground level irrespective for irrigation or for drainage applications.
Depending on the type of installation, electrical pumps are classified into two (2)
categories.
(a)
Volute Casing Type i n which quick discharge coupler is used for p~111ip
installation or removal. It generally covers all radial flow type of punips
and mainly ised in sewage, waste and rain water drainage.
(b)
Diffuser Casing Type i n which the pump is securely rested at the hotto111
of the column pipe by its own weight. Axial flow and niised llow type ol'
pumps fall into this category. They are mainly used in storm water
drainage, tlood control and irrigation application.
2.2 Motors used i n electrical submersible pumps are generally of squirrel cage
induction type with Class F atator winding insulation and comply with IF'S8 or
1P68 enclosure protection. Motor is sealed fro111 liquid being pumps ed by e~nans
of mechanical seals. Protective features are:-
(i)
thermal detectors for stator winding
(ii)
leakage detector for mechanical seal leakage
(iii)
thermal detector for thrust bearing
3. AUXILIARY EQUIPMENT
Electric equipment for typical pumping installation consists of :-
(i) Incoming facility
(ii) Distribution facility
(iii) Supervisory and operation instru~nentation
(iv) Emergency standby generator set
(v) DC power source
3.1 Incoming Facility
Incoming facility normally covers TNB switchgear room and consunier
transformer room where high voltage incoming supply is being stepped dmcn to
lower voltage suitable for consumer's application.
3.2 Distribution Facility
It supplies power from the distribution board to the various loads. The whole
distribution board is nornially housed in the consun~er's control room where the
entire system operation can be centrally controlled.
Instrumentation includes devices used to monitor the pumping operation such as
water level sensor / indicator, salinity meter, tlownieter, thermometer etc.
3.4 Supervisory &: Monitoring Instrumentations
Supervisory and monitoring instrumentation is used to monitor the routing
operation of the pumps and their accesories so that a desired level of reliabilit)
can be achieved. The supervisory instruments include pressure instruments,
vibration monitoring devices etc.
3.5 Generator Set
Standard generator set is installed for the purpose of supplying power to the
puniping installation i n case of TNB power interruption where the service of the
pumping facility is of utmost importance.
3.6 DC Power Source
The Dc power source is the imit where AC power is converted to DC and stored i n
batteries. It is used as a backup for the control circuit. the major l'ailure circuit and
starter motor of the generator set.
I1 - GENERAL DESIGN & SELECTION GUIDE
A. PREPARATION AND PLANNING
1. GENERAL
Design of a pumping station shall satisfy the specified applications and
predetermined conditions. As such performances of related and auxiliary equipnient
should be well matched with each other. Well-planned design is pre-requisite to
efficient pumping installation.
SITE INVESTIGATION
r Site condition and its suitability in terms of accessibility
r Data collection such as water levels / fluctuation and water q~~ality analqsis
r Water duty requirement study
I Space availability
INFRMATION SOURCING
r Acq~~i re technicalinformation on mechanical and electrical eq~~ipment from
manufacturers and suppliers
I Discuss with suppliers on the details of various equipnient
THINGS TO LOOK FOR
Pumping station layout to ascertain space requirements
Suitability ofeach piece of equipment
Cost factor
Reliability and flexibility
Safety and protection system
Mode of operation
111 - SPECIFIC DESIGN & SELECTION GUIDE
PUMPlNG EQUIPMENT
ELECTRICAL SUBMERSIBLE PUMP
Pump Number determination
Factors to be considered:-
Equipment and operating cost
Capacity of water demand
Control of demand variations
Necessity of extra capacity for water demand
Reliability and critical situation
Site conditions realted to floor area, loads and ground bearing capacit},,
construction cost, adequacy of water depth etc.
Drainage Pumping I~istallations
Three (3) or more pumps are preferred
For multiple pumping installation, each pi~nip should have the capacitj, of
the total required capacity divided by the number of pumps being installed
For large pumping installation, all pumps should have the same capacitg
incorporated with one smaller capacity punipset to cater for low tlow
condition
If two ( 2) pumps are installed, each pump should be sized to pump no1 less
than 213 of the total capacity
Irrigation Pumping Installations
3 to 4 pu~iipsets are preferred for flexibility in operation
r If two (2) pumpsets are installed, each pump should be sized to punip not
less than 213 of the total capacity required
r Identical pumpsets are to be installed for standardization
r Standby set is not encouraged except for large pumping installations
r Sometimes additional smaller capacity pitnipset is installed to Sacilitate in
regulating water fluctuation at downstreani or use frequent) converter
1.2 Determination of Pumping Capacity
1.2.1 Irrigation
> The consumtive requirement of irrigation water should be estimated i n
accordance to DID Technical ~ a ~ e r ~ o . I as reference
r Capacity of pumping units shall be based on ~nasirnuni demand of the crops
planted
t- Recommended water duties for rice cultivation for single and double
cropping are tabulated below:-
InchesIMo~ith AcresK'i~sec
Double cropping system
Off-season
Presaturation period 40 days 15 4 8
Normal irrigation period 10 7 1
Main Season
Presati~ration period 40 days 13
Normal irrigation period 9
Single cropping system
Presaturation period 40 days
Normal irrigation period
r Shorter supply period during presaturation may increase water requiren~ent
eg. 34 acres per cusec for a 20 days supply period
r Other factors to be considered are soil type, method of planting (direct
seeding), future projection of planting acreage
1.2.2 Drainage
r For normal drainage, where excess ground water and effluent watcr ti-om
various sources are drained by pumping; pumping capacity shall be based on
actual measurements of existing flow
I For flood control or storln drainage where puniping is required to eliniinate
excess surface water originating from rainfall, determination of optimum
pumping capacity requires careful study on internal water level rise against
assumed run-off (Q = C i A)
1.3 Design Head Determination
1.3.1 Irrigation Pumping Stations
+ Head compi~tation should be based on design water level at [he p111iip sump
and the design water level at the downstrea~n canal
r Design intake water level should take into consideration of the ~iiinirni~ni and
masi~num intake water level. Attention should be given to mean \%ater Ion
water level during dry season.
h Design discharge water level normally refers to tlie canal fill1 supply level
1.3.2 Drainage Pumping Stations
For ordinary drainage services, design level is set at tlie difference in the
design suction and discharge water levels. but due consideration slio~~ld he
given to the mini~nim water levelk conditions.
i For flood control services, ~naxi~nuni actual head occurs at the discharge
highest water level but due consideration should be given to the minimum
water level conditions.
1.4 Pump Selection
1.4.1 Factors to be taken into account:-
Y System requirements
i System layout
;i Fluid characteristics
'i Intended service life
i; Materials of construction
i Equipment cost, operating cost and maintenance cost
1.4.2 General guide for pi~nip type selection
Where n = pimp speed (rpm)
Q = pump capacity (cu. meter per second)
H = total head (meter)
Pump Type
Radial
Mixed
r ~ x i a l
Specific Speed
NS = n S Q " ~
H.3/4
10-90
90- 160
160 - 300
Mead Pet- Stage
(Meter)
1
18 -300
i
i
-- - -
9 - 18
1
I
-.
7
Less than 9 I
2. PUMP SUMP HYDRAULIC DESIGN
2.1 General
i Standard open sump to be adopted where uniform approach tlow is necessary
> For non-uniform approachflow, closed intake or draft tube can be considered.
k Refer to standards and recomniendations from BMRA or pump n~anufacturers
'i. Sump model test is recommended for pu~nping stations where the geometry
differs from recommended standards.
r Major pumping stations exceeding 2.5 cubic meters per second and if multiple
combi~iations are used, model testing shall be carried out.
2.3 Su~np Configurations and Dimensions
i. Refer to standard guide on pump sunip dimensions (Attached)
3. DISCHARGE PIPING SYSTEM
3.1 General
r Discharge velocity shall be limited to 1 m/s to 2 mls for small size pipeline
and 2 m/s to 3 m/s for large bore installations
i; General guide for pipe size
k Steel pipes are commo~ily used for discharge piping sjrstem. csccpt \+hen
handling acidic or corrosive liquid as for drainage stations
> Ductile cast iron pipes are used when handling acidic liquid. because of
its highly coorosive resistant characteristics
Capacity Discharge Bore
% Where steel pipes are used. they are galvanised against rusting
Capacity
r General guide for mild steel col uni ~~ pipes wall thicltness
k General guide for mild steel discharge pipe wall thickness
Pump Capacity
(llsec)
400
Nominal Diameter
(mm)
Less than 700
800
900
----
Wall Thickness
(mm)
6
Wall Thickness
(mm)
6
7
8
9
10
I I
12
13
; Weight of the pipe can be calculated according to formula:
W = F x 10. 68xTx(D-T)Ib/ ft
Where W = weight of pipe (Iblft)
T = wall thickness (inches)
D = outside diameter (inches)
F = relative weight factor
For cast iron
For ferritic stainless steel
For austinitic S.S.
Fordee I
I . Introduction to Pumps
Chapter 1 Introduction to Pumps
1.1 Classification of Pumps
A pump i s a type of fluid machine which is
driven by a prime mover (usually, an electric motor
or an internal. combustion engine), used to impart
energy to fluids, and continuously feed "the re-
quired amount" of such fluid to "an intended height
or distance."
Pumps ar e broadly classified into turbo types,
positive displacement types, and other types on the
basis of pumping theory. Displacement type
pumps (including spiral screw pumps, gear pumps
and screw pumps) and other-type pumps (includ-
ing air lift pumps, hydraulic rams, and jet pumps)
are rarely used as pumps for irrigation and drain-
age, and so this handbook deals only with turbo
pumps.
The classification of turbo pumps is shown in
Fig. 1.1.
Turbo pumps supply energy to fluids by the ac-
tion of a rotating impeller and are divided into
three categories according to their operating prin-
ciple: O centrifugal pumps, Q mixed flow pumps,
and 0 axial flow pumps.
One parameter of any such pump is the specific
speed N,, which is derived from the law of hydrau-
lic similarity for the pump and expressed by equa-
tion (1.1).
where
: specific speed '
N : revolutions per minute
Q :
discharge quantity (m3/min), Q/ 2
for double suction
H : total head ( m) , per one stage for
multi-stage pumps
Specific spzed is usually determined for the per-
formance (discharge quantity and total head) a t
the best efficiency point, and remains at a constant
value for geometrically similar pumps, regardless
of their size and revolutions per minute. It is
therefore used as a guide in classifying pumps.
The specific speed (N,) of turbo pumps ranges ap-
proximately from 100 to 2500. As specific speed
increases, thn shape of the impeller changes (for
example, the ratio of outlet width to outside diam-
eter increases). Also as the specific speed in-
creases, t het ype of pump changes from centrifugal
through mixed flow to axial flow, as shown in Fig.
1.2.
. ,
1 Centrifugal pumps
Centrifugal pumps supply pressure and velocity
energy to water mainly by the centrifugal force
produced by the impeller. In centrifugal pumps,
water enters the impeller in a direction parallel to
(or at a small angle to) the pump shaft axis, and
exits in a radial direction. In volute pumps, veloc-
ity energy of the water flowing out of the impeller
Volute pumps
Centrifugal pumps
Difluser pumps
I
r : I
I
Axial flow pumps
I Turbo pumps
Fig. 1.1 Classification of turbo pumps
I
Volute type mixed flow pumps
Mi xed flow pumps
M ~ x e d flow pumps
i
Fundamentals of Pumping Equipment
Approximate value of specific apeed
(Ns) 100 200 300
400 Boo 1OOO 1200 and o v a
Fig. 1.2 Specific speed N, and impeller profiles
(a) Single volute casing (b) Double volute casing
Direction of rotation
Impeller
Vnlutc cuaing
Fig.
Discharge opening Q
\ + Ihrection of
Diffuser
(guide vane)
DifFuser
(guide vane)
Impeller
Q
- - -
casing
casing
Fig. 1.4 biffz&?'puliipp
is artially converted into pressure energy in t he
vo te casing.
olute casings ar e available a s single and dou-
bl types (Fig. 1.3). The double volute casing, used
t o educe t he radial thrust (t he radial force acting
to ard t he pump center line). has two volutes po-
sit,' ned 180" ~ 1 p 1 r 1 ~ ' ~ OI I I each ulhcr. which divide
- t h liquid into two equal quantities.
I
Generally speaking, double volute casings ar e
uscd whcn the radial t hrusi is so high as to i rnpo~c
high loads on t he main shaft and bearing. Diffuser
pumps, also called turbine pumps, convert the-ve-
locity energy into pressure energy through diffus-
e ~ - s (guide vanes) instiillcd nr-nuod t h t i n~pc~l l ( ~r
cilxulnler-e~~ce (Fi g- 1.4 j .
I . Inrrmluction to Pumps
Discharge quantity (%)
Fig. 1.5 Charact eri st i c curves for
a volute pump
Note . The absc~ssa represents the discharge quant~ty
percentage calculated when the d~scharge amount at
the best eficiency point is taken as loo%, and the
ordinates represent the total head, pump eficiency,
and shaft power calculated when these factors are
taken as 100% at the best eficiency point
Th e specific speed of volute pumps r anges ap-
proxi mat el y from 100 t o 700. Diffuser pumps,
which have a specific speed of approxi mat el y from
100 t o 250, a r e now sel dom used a s single-stage
pumps wi t h bores of 150 mm o r less, because of
t hei r complicated construction. They a r e usual l y
used as mul t i -st age pumps.
Th e r el at i onshi p bet ween di schar ge quant i t y
a nd t ot al head ( t he Q-H charact eri st i c) for volute
pumps descri bes a gr adual downward curve, t he
shut -off head being 120 t o 130% for low specific
speeds a n d 170 to 180% for high specific speeds.
Typical charact eri st i cs of a volute pump with a
specific speed of about 300 ar e shown in Fig. 1.5.
1.1.2 Mixed flow pumps
Mixed flow pumps suppl y pressure and velocity
energy t o wat er by t he centrifugal force of t he i m-
peller a n d t he lifting function. In pumps of t hi s
type, wat er ent er s t he impeller from a direction
parallel to t he shaf t axi s and exi t s in a n oblique
direction. Th e velocity energy of the liquid leaving
t he i mpel l er is converted into pressure energy by
ei t her O di ffusers (gui de vanes) or @ a volute cas-
ing. Pumps with a volute casi ng cont ai ni ng a
mixed flow type impeller a r e called volute t ype
mixed flow pumps.
Discharge
\ DiKiser (gwide vane)
Discharge quantity !TI
Fig. 1.6 Charact eri st i c curves for mixed
flow pumps wi t h specific speed
N, s 900
For mixed flow pumps, t here ar e two t ype i m-
pel l er vanes: fixed a nd movable. Th e specific
speed of mixed flow pumps is approxi mat el y from
700 to 1400, but ranges from approxi mat el y 400 to
1400 when a diffuser pump (i n which a rndi al flow
impeller is housed in a diffuser casi ng i n order to
pr ovi de a hi gh head ver t i cal s ha f t p u mp ) is
grouped with mixed flow pumps. The char act er i s-
tics or a mixed pump with a specific speed of
900 ar e shown in Fig. 1. 6.
I
Fundamentals of Pumping Equipment
Some ver t i cal ' shaft hi gh-head mi xed flow
umps ar e of t he multi-stage type in which two or
ore impellers ar e incorporated.
-1.3 Axial flow p u mp s
Axial flow pumps supply pressure and velocity
nergy to wat er by t he lifting action 2f t he impeller
anes. In axial flow pumps. water ent ers t he irn-
eller in a direction parallel to the pump shaft axis
nd
nel
i fft
exits in t he same direction. Some velocity
rgy is converted into pressure energy by the
i sers.
or axial flow pumps, a s for mixed flow pumps,
types of impeller vanes ar e available, fixed and
fable. Specific speeds of axial flow pumps are
I 1300 to 2500; pumps with a specific speeds
500 t o 1600 being t he most common. Charac-
3tics of a n axial flow pump with a specific speed
1
mscharge quantity 1 %)
g. 1.7 Characteristic curves for axial flow
pumps with specific speed
of 1500 ar e shown in Fig. 1.7. The Q-H character-
istic shows a sharp downward tendency; t hat is, a
smal l change in discharge quantity relates to a
large change in pump head. Higher shaft power
i s required as t he quant i t y of water decreases.
When t he discharge quant i t y is less t han 65 or 70%
of normal, or total head exceeds 140% of normal,
t he pump is unstable, with vibration or overload.
'
Therefore, axial flow pumps should not be operated
in t hi s range.
1.2 Pumping Theory
Though many type pumps ar e used for land i m-
provement through suppl y of irrigation wat er and
drai nage, main components of such pumps ar e t he
impeller and the casing.
They have complementary functions. The i m-
peller supplies energy t o t he water by its rotation.
The casing guides t he wat er to the entrance of t he
impeller, efficiently converts t he velocity energy of
t hc wat er flowing out of t he impeller into pressure
energy, and guides t he wat er to t he pump outlet.
Ther e ar e two theories used to determine "total
head" at t ai ned by a pump: O t he momentum t he-
ory a nd @ t he aerofoil theory. The former i s used
a s pumpi ng theory for centrifugal pumps and t he
l at t er Ibr axial flow pumps.
The morrientum theory is based on t he assurnp-
tion t hat a n impeller ha s an infinite number of
vanes and water flows along t he curved surface of
a vane a t all points, while t he aerofoil theory s t ar t s
from t he determination of how lift works on a si n-
gle aerofoil placed in a n uniform flow extending
infinitely.
( at Centrilugal type (bl Axial flow type
Fig. 1.8 Pump impellers
1.2.1 Theory of c e nt r i f uga l p u mp s
( 1) Centrifugal pump mechanism
When t he impeller is rotated within the pump
casing of a volute or diffuser pump, water is sub:
I abl e L 3ummar y 01 p u mp rypes a n 0 I nei r cnar acr er i sr ~cs
P u mp t ype
Cent r i l ugal
(high head, l ow f l ow)
E . I L X C ~ n o w
( n i e d ~ u m he a d, m c d ~ u m f l ow)
Axial n o w
( l ow head, high f l ow)
Not es
Th e pr essur e is devel oped mai nl y b y i mpar t i ng
a large whi rl ( t angent i al ) c ompone nt t o t he fl ui d
leaving t he i mpel l er . A doubl e s uct i on ar r angement
I S fairly c o mmo n in whi ch t he irnpcUer is similar
t o t wo single s uct i on irnpeUcrs placed back t o
back. Thi s has t he advant age o f bal anci ng t he axi al
t hr ust of t hc p u mp b u t it compl i cat es t he i nt ake
u r a n g c me n t wi t h ext r a pi pcwor k.
The p u mp casi ng can of t e n be made in t wo hal ves
(split casi ng) whi ch si mpl i l i es mai nt enance a nd
rcpai r.
The f l ow t hr ough t he i mpel l er is par t l y axi al
and par t l y r a b a l , giving char act er i st i cs haUway
bet ween a n axi al p u mp and a cent r i r ugal pump.
The desi gn l ends itself t o fhc vert i cal axi s sus-
pended p u mp ar r angement . It 1s t hen of t e n called
a bowl . r ype p u mp d u e t o t hc bul ge in t he casing
t o ~ c c o m m o d a ~ c t he par t l y radi al out f l ow f r om
t hc ~mpe l l e r .
' There are usual l y i nl et gui de vanes t o gui de t he
wat er axi al l y i nt o t he i mpel l er, and out l e t gui de
vanes l o r emove t he t angent i al vel oci t y c ompone nt .
However t hese f i xed gui de vanes ar e not a n essen-
tial l eal ur e of a n axi al f l ow p u mp . Th e headl di s-
charge cur ve f or t he axi al f l ow p u mp falls very
s t r cpl y, so t hc head cor r espondi ng t o ma x i mu m
cl r i cl ency ma y bc ax l i t t l e as o n e t hi rd of t hc head
at zer o di scharge.
Sket ch
t
Di scharge
/
Fi xed
b h d e s
/
l nl et
l nl et
H
'
H
- 10090
' erccnt Er f i c ~c nc y
head q
I
I
I 0
0 Per cent discharge I 0 0 Q
100
' r r ccnt
hced
5 0
0 Percent di scharge 100 Q
EUicle ncy
rl
0 Pcrcenr discharge 100 Q
Each pump has a performance curve, this graphs shows the performance of a pump.
Always verify that the curve you are using matches the pump. Verify pump model, size,
impeller diameter, R.P.M.
Revolutions Per Minute (R.P.M.) - This in combination with T.D.H. illustrates performance,
high and low parameters, in this case operating between 650 and 1350.
U.S. Gallons per Minute (G.P.M.) or Liters Per Minute - Starting at the left (zero flow) and
reading to the right (up to 3400 G.P.M.).
Total Dynamic Head q.D.H.) - This can be expressed in Feet of Water, Pounds per
Square Inch (P.S.I.) and Meters. This is read starting at the bottom zero pressure and
reading vertical (up to 130 Ft., 55.3 P.S.1.,38 Meters). EXAMPLE: Pump is turning 1 150
R.P.M. and our Total Dynamic Head is 70 feet, read up to 70 feet follow the line to the
right where it crosses 1150 R.P.M., follow that line down to the G.P.M. line and our
capacity will be 1,000 G.P.M. Where our Total Dynamic Head and our G.P.M. intersect
1 150 R.P.M., we are above the 30 horsepower line so we would need a 40 horsepower
motor, and our pump would be approx. 55% efficiency.
Efficiency - (the ratio between useful work performed and the energy needed in
producing that work) efficiency is noted and is labeled in terms of percentage (50%,
60%, 63%). Such data is used by engineers to pick the most efficient point at which to
operate the pump.
Horsepower (B.H.P.) - An amount of actual power required by the pump at a given
condition. Various B.H.P. is also indicated and is marked 7.5, 10, 15,20,25,30,40,50,
60,75 B.H.P.. This information is needed to select the correct size motor.
Net Positive Suction Head Required (N.P.S.H.R.) - Refers to the amount of atmospheric
pressure required to push water through the suction side of the pump. Read vertical
from flow, using our above example of 1,000 G.P.M. follow that line up to where it
intersects the N.P.S.H. line and read to the right. This pump requires 5 feet of N.P.S.H.
Operating range - Area in which the pump will safely operate within and not cause
damage to the pump. Some curves may not show this range. Instead, the operating
range will be reflected in the form of solid lines (R.P.M. or speed lines). And those areas
outside the operating range will be identified as dashed lines. Operation outside the
operating range will damage the pump. Conditions to the left of the operating range
will produce discharge cavition. Those items directly effected will be impellers, volutes,
bearings, seals, and shafts. Conditions to the right and sometimes across the bottom will
produce suction cavitation. Those items directly effected will be impellers, wear
plates, bearings, and suction heads.
Repriming Lifts -This represents the height that the pump is capable of repriming at the
noted speed. Example: 950 R.P.M the pump will reprime to 19 feet. Some curves may
note Dry Prime. This represents the height and spi?ed relationship for priming the pump
with a full volute casing of product and an empty suction pipe.
- Gem
!El!?%!
PUMP
?don 4 " Troubleshooting" "Ser." @ Copyright The Gorman-Rupp Company, 1993 Page 27
LI TRES P E R
I I
MI NUTE IN I
I 1 I I 1 I 1 I I I I
8 8 3 S 3 8 % 8
0 0
HUMDREOS $ b v-
T- r
8
.-
3
T-
HOW TO READ CURVES
Each pump has a performance curve. This graph gives the actual performance of a
submersible pump under different sets of conditions.
Always verify that the curve you are using matches the pump. Verify pump model, size.
impeller diameter.
Revolutions Per Minute (R.P.M.) - Speed of electric motor or impeller speed. A
submersible curve will note the performance of at the above noted speed.
Head/ capacity (H/Q) - Represents the pressure in relationship to flow at 1750 R.P.M.
US. Gallons per Minute (G.P.M,) - Starting at t he lefi (zero flow) and reading
io the right (up to 1000 G.F.M.).
Total Dynamic Head 0.D.H.) - This can be expressed in feet of water, or meters. This is
read starting at the bottom zero pressure and reading vertical (up to 120 Ft. or 36.2
Meters). EXAMPLE: Total Dynamic Head is 85 feet, read vertical to 85 feet follow the line
to the right where it crosses the H/Q, follow that line down to the G.P.M. line and our
capacity will be 500 G.P.M.
Efficiency - (The ratio between useful work performed and the energy needed in
producing that work) efficiency is noted and is labeled in terms of percentage. Such
data is used by engineers to pick the most efficient point at which to operate the
pump. To read efficiency, where our duty point intersects our H/Q Read up to where
you will intersect the efficiency line, then read to the right, our efficiency will be
approx. 64%.
Horsepower (B.H.P.) - An amount of actual power required by the pump at a given
condition. At 1750 R.P.M. is also indicated. To find brake horsepower. where
our duty point intersects our H/Q, read down to where you will interect the B.H.P. line,
then read to the right, our B.H.P. will be approx. 16 B.H.P. required.
Kilowatts (KW) -To find KW, where our duty point intersects our H/Q, read down to
where you will intersect the KW line, then read to the right, our KW will be approx. 14.2.
xtion 4 ' Troubleshooting" "Ser." 63 Copyright The Gorman-Rupp Company, 1993 Page 28
I
I Centrifugal Pump Troubleshooting "Ser.' Copyright The Gormon-Rupp Company, 1992 Page 29
NET POSITIVE SUCTION HEAD (N.P.S.H.)
The NPSH i s the difference between the inler total head (absolure) and the
head corresponding to the vapour pressure (absolute) of the liquid.
There are two values of NPSH to consider.
REQUI REDNPSN (NPSHR) i s a function of the pump design'(obtained
from pump manufacturer).
AVAILABLE NPSH (NPSHA) i s a function of the system in which the
pump operater. This can be calculated for any installation.
A simple example i s a glass of 95OC water. What i s the NPSHA maximum?
NPSHA = Absolute Pressure - Vapour Pressure
= 101.325 - 84.53
= 16.795 kPa (1.7 12m)
I f water temperature was increased to 10oC the NPSHA becomes zero.
i.e. absolute pressure equals vapour pressure.
For successful operation the NPSHA must be greater or equal'to the NPSHR.
When NPSHA i s less than NPSHR the pump wi l l cavitate. .'.:
When the liquid source i s above the pump:
NPSHA = Absolute pressure + Total suction head.
~n - Friction loss i n suction pipework.
metres - Vapour pressure of liquid.
When the liquid source i s below the pump :
NPSHA = Absolute pressure ---Total suction l i f t
in - Fridtion loss i n suction pipework
metres - Vapour pressure of liquid
DEFINITIONS
Absolute Pressure -.
Absolute pressure i s the true total pressure and i s equal to gauge pres-
sure plus atmospheric pressure.
Veloci ty Head
v2
Velocity head (29) in a pumping system i s an energy component that
represents the kinetic or "velocity" energy i n a moving mass of liquid
at the point being considered. It i s equivalent to the vertical distance
the mass of liquid would have t o fall to acquire the velocity.
Vapour Pressure
The vapour pressure of a liquid at a given temperature i s that pressure
at which i t wi l l flash inro vapour.
3. ~2 AFFINITY LAWS
Pumps requiring a reduced or increased performance can be achieved in the
following manner.
1)
Reduced performance i s achievkd by reducing the speed.
2 )
Increased performance i s achieved by increasing . . the speed.
The pump manufacturer must be consulted for the pump limitations in the
above respects.
The mathematical relationships between capacity, hea$, speed and power
' I
are known as the Affinity Laws. I #
. With the impeller diameter constant
where Q = Capacity N = Speed
H = Head P = Power .
An analogy of these laws i s when the i m~el l er diameter i s reduced and the
pump running speed held constant. The relationships are approximate only.
The reason I s that "slip" occurs reducing head and quantity and increases
power required,
Q1 Dl y = y , , 2<2L. J .
-=-
Q2 0 2 , Hz -
where D = Diametet of impeller.
To illustrate the use of these equations consider the following examples.
Submersible Pumps AFP 1000 - 8002 -. -
AFP Pumps -
for every application
the right
submersible pump
The AFP pumps are compact unit constructions.
which may be installed either wet or dry thanks to the
efficient cooling system. The flood-proof pumps are
suitable for all installation systems of modern water and
sewage technology and are suitable for every type of
installation whether for fixed or portable applications or
for horizontal or vertical installation.
There are four basic types of installation of the AFP
pumps:
Wet well i nst al l at i on
using the ABS automatic coupling system and single
guide rail. The pump is lowered along the guide rail and
automatically reaches its correct operating position on
the pedestal and seals itself at the discharge
connection.
Hori zont al dry i nstal l ati on
with motor and volute support. This type of installation i r
suitable for pump stations with a separate collection
sump or fitted to a tank.
This type of installation is a space and cost saving
alternative for the refurbishment of existing old pumping
stations.
Verti cal dry i nstal l ati on
with skirt base. This type of installation is suitable for
pump stations with a separate collection sump or fitted
to tank.
This type of installation is a space and cost saving
alternative for the refurbishment of existing old pumping
stations equipped with long shaft pumps
Portabl e appl i cat i ons
with support rmg, discharge eibow for hose- or plpe-
connect~on. For rapid installation In emergencies, for
service use and when constructing or repairing sewers
in Concrete Sump
... with free outflow
over a welr
in a Steel Pipe
... with free outflow
... with discharge elbow,
non-return valve, shut off valve and
discharge main
... with pressurized outflow
and non-return valve
... with discharge elbow, and
siphon pipe with venting
KUBUS
Rekabentuk
Sistem Pam
Pumps Technology
Ir Lim Lee Thon
Engine Driven Pump
Electric Motor
PUMP HOUSE PUMPS
rn Engine Driven
rn Electric Motor (long shaft)
rn Electrical Submersible
Radial flow (High head, low discharge)
Mixed flow (Medium head, medium
discharge)
Axial flow (Low head, high discharge)
Electrical Switch Board & Motor
I Typical Radial Pump System
Electrical Submersible
Radial Flow Pump
Engine Driven Portable Pump
Portable Pumps
rn Tractor PTO Driven
rn Engine
rn Hydraulic Power Pack
rn Electric Motor
Engine Driven Portable Pump On Trolley
( Portable Pump & Power Pack
Pump Sizes
rn Fixed Pump Houses
1 140 I/s - 5100 I/s
1 Head 2.5 m - 13 m
Portable Pumps
1 28 I/s - 560 I/s
1 Head6 m - 15 m
I
SPECIFIC SPEED
Q = pump capacity (cu. meter per minute)
H = total head (meter)
I Portable P u m ~ I
pump ~ p e
Radial
Mixed
1 Axial
SPECIFIC SPEED
n = pump speed (rpm)
Q = pump capacity (cu. meter per second)
H = total head (meter)
Specific Speed
Ns =
H"
100 - 800
400 - 1400
1400 - 2500
I PurnpType I Specific Speed I Head Per Stage /
Head Per Stage
(Meter)
18 300
9 - 18
Less than 9
Ns = (Meter)
I
Radial 10 90 18 - 300
Mixed 90 - 160
Axial
SPECIFIC SPEED (British Unit)
11 - &mp speed (rpm)
Q = pump capacity (igpm)
H = total head (ft)
(Feet)
Radial - 70 60 1000
1 Mixed 1 70 - 150 1 30 - 60 1
Axial 150 N 300 Less than 30
EXERCISE
Q = 1180 LJS, N = 750 rpm, H = 3.6 M,
Determine Specific Speed Ns and hence
suitable pump type (Axial, Mixed,
radial)
SYSTEM HEAD CURVE
PUMP TYPES
AND THEIR
CHARACTERISTICS
SPIRAL
SPIRAL SCREW PUMP
Advantages
rn Simple construction - easy to service &
repair
rn Less prone to clogging
rn Can operate with no load - will not burn
out
rn High reliability - low speed, less wear &
tear
Fig. 1.72 ConstrucLion of n spiral screw
pump
AFFINITY LAWS
Disadvantage
rn Unsuitable for high head application
Requires larger installation area
rn Lower pumping efficiency
EXCERCISE
Q, = 100 GPM, N, = 1750 rpm, HI = 44
ft, P, = 2.47 BHP, Dl = 6 718"
rn D Constant; N2 = 3450 rpm, determine Q2,
'421 P2
rn N3 remains at-3450 rpm, D3 = 6 l/zr';
determine Q3, H3, P3
m Relationship between capacity (Q), head (H),
speed (N) & power (P)
PUMP CURVE (VARIOUS PUMP SPEED)
PUMP CURVE (VARIOUS IMPELLER DIAMETER)
Pump
Installation
Configuration
(Axial Flow)
1
PUMP COMPONENT MATERIALS & APPUCATION
I m~el l er Materials
Fedtures ( Medlum Handled
Comml y used
I
River water, ram water
I I
Installation
I
Ductile Iron (370117 - B5
2789)
Carbon steel casting (A2,
A3 - BS3100)
Phosphor Bmnze (BS 1400)
Stanless steel wmng
(410C21.42009 - BS
Stainless steel casting
(30K15.316C16 - BS
1504)
Aluminum Bronze
I
PUMP COMPONENT MATERIALS & APPLICATION
Pump Casing Materials
I
PUMP COMPONENT MATERIALS & APPLICATION
Pump Shalt Materials
Possess higher strength
than gray wst iron
Possess hgher strength
and wear reststance
Po- higher wear
resistance than bronze
Possess h~gh abras~on
and COmxlOn reStstanCe
Possess high abras~on &
wear resistance - less
affected by cavitation
Gmd for acidic condnion
water
13 - chrome
stainless steel and corrosion water, sea water
20Cr13 and stainless
steel (ferrite) x 22Cr
River water, rain water
Water containing
sediment, sewage, ram
water, river water
Rlwr water, rain water,
sea water
Rwer water, ram water.
Sewage, a0ment
Sewage, sea water
Sewage
Kursus
Rekabentuk
Sistem Pam
Pengiraan Hidrolik
Ir Lim Lee Thon
CALCULATION OF HEAD LOSS
Equivalent Pipe Length Method
= Fitting losses is given as equivalent feet or meters
of straight pipe
Loss Coefficient Method
rn Hf = t; x V2/2g
rn H, = Head Loss (m)
t; = LossCoefficient for shape condition, fining
V = averagevelocity (mls)
g = Acceleration of free fall (9.8mls)
STATIC HEAD
m Static head (ha) = discharge head (hd)
+ suction head (h,)
m Capacity (Irrigated areal runoff)
n Head (system design)
n System layout & pump sump design
m Pump selection
rn type (axial, mixed, radial)
Material of construction
L HEAD
Tot al Head = Static Head + Friction
Head + Velocity Head
Head Loss on Piping
I
Darcy's Formula
rn Hf = f x LID x V2/2g
H, = Friction Head Loss (m)
f = friction coefficient
- 0.02 + O.OOOS/D (New Steel Pi pe)
- (0.020+ 0.M)OSD) x 1.5 (Regular Steel Pi pe)
L = Pi peLength(m)
D = InsidePi pediameter (m)
V = AverageVelocity (mls)
g = Acceleration of free fall (9 8mh)
Application - Rough value for plpe dla. < 2OOmm
rn Manning's Formula
Hf = f, x L/D x V2/2g
H, = Friction Head LOSS (m)
f, = hidion loss coefficient
- (124.6/D'n) x nz
- N - Roughness factor
L = Pipe Length (m)
= D = Inside Pipe diameter (m)
V = Average Velocity (m/s)
g = Acceleration of free fall (9 8mk)
Application -Sewage &rain water pumping system
Total Dynamic Head
Computation
EXERCISE 1
Calculate
1 T.D.H. CALCULATION
rn Williams-Hazen Formula
rn Hf = 10.666 x C-1.85 x D-4.87 x ql.85 x L
8 H, = Friction Head Loss (m)
C - Roughness Factor
rn D - Inside Pipe Dia. (m)
Q - Flow Rate (m3/s)
8 L - Pipe Length
Application - Water Works and water irrigation pumping
system
Equivalent Pipe Length Method
1. Obtain stat6 Head
2. Compute suction pipe length & fitting losses
3. Compute discharge pipe length & fitting
losses
4. Calculate total equivalent pipe length
5. Obtain C value for ty e of ipe & determine
multiplier value [(108/C)l4
6. Lookup friction loss per 100 feet pipe for
pipe sue & d~scharge
7. Calculate total friction loss
8. Compute Total Dynamic Head [(1)+(7)]
Loss Coefficient Method
1. For ipe materral obtam roughness
coe$clent C (table)
2. Compute Pipe Loss by:-
(a) H, = 10.666 x C-' x D487 x q1 x L
(b) From table knowing Q, D and C
3. Com ute Friction Head Loss for shape
condion
- obtain value from table
-
compute using formula H, = t; x V2/2g
4. Compute Total Dynamic Head = Static Head
+ Suction Loss + Discharge Loss
Net Positive Suction Head (N.P.S.H.)
m Refers to the amount of atmospheric pressure
that is available to push liquid into a pump
m Difference between inlet total head (absolute)
and vapour pressure
m N.P.S.H. required is a function of pump
design
N.P.S.H. available is a function of the system
NPSH EXCERCISE
m Pump Model T4A-B
340 GPM, 10" Static Lift, 25' 4" steel pipe
Pump altitude - 5000 ft above sea level
Liquid is sewage at 75OF
Compute NPSH available
Compare with NPSH required
Determine if acceptable (NPSH, > NPSH,)
I POWER CALCULATION EXCERCISE
m Determine the Water HP, Engine HP required
for Pump in Exercise 1 (assume transmission
efficiency of 95%, engine reserve of 25%)
Determine the Water kW, Motor kW required
for Pump in Exercise 2 (assume direct drive
transmission efficiency of 100%, motor
reserve power of 10%)
NPSH COMPUTATION
1. Equivalent Head at sea level (ft or m)
2. Reduction at altitude of job site (ft / m)
3. Head available at site [(I) - (2)]
4. Compute Total Dynamic Suction Head
5. Vapour Pressure of liquid at operating temperature
(ft 1 m)
6. Safety Factor of liquid (water = 1: petroleum = 23
7. Compute Total Deduction (4)+(5)+(6)
8. Compute NPSH available = (3) - (7)
9. Obtain NPSH Required from pump performance curve
10. Compare if (8)>(9) ok
PUMP FORMULAE
xH, xQ/ 550
rn Y = 62.4 lb/ft3, H, in ft, Q in cusec
Water hp = H, x Q / 3300
rn H, in ft, Q in igpm
m Water power = Sg x H, x Q / 102 kW
rn Sg = 1, H, in m, Q in 11s
Pump input power = water hplpump eff
Required Prime mover power = Pump
input power/Transrnission efficiency
m Engine / motor reserve power
-: PUMP SELECTION
4-
You will appreciate from reading the previous section of this booklet that
there are many different types of pumps made to suit a wide variety of
pumping applications.
I n selecting the best type of pump for a given application, one must firstly
establish that the pump wi l l pump the liquid concerned within the intended
environment.
After this decision has been made, the pump duty i s then to'be determined
to enable the correct si ze of pump t o be chosen.
To determine the pump duty i s t o state:-
Rat e of fl ow requ~red, i.e., litres per second wh~ch are required to be
pumped.
Adjustable metering pump applications may require maximum and mi n-
imum f l ow rates.
The total head which the pump must generate when pumping the re-
quired flow.
The total head i s the sum of the vertical distance through which the
liquid i s to be pumped plus the friction losses in the associated pipe-
work. Reciprocating pumps may also generate a head due to the accel-
eration-of the liquid during the pumping and suction stroke which must
be considered part of the total head.
I t - i s usual when determining the total head for a pumping system t o
treat the inlet or suction side of the pump pipework separately from
t h e deliilery or pressure side.
The sum of these 'heads' i s the total head t o be generated by the pump.
Typical Head Calculations
A consideration of the heads required to cause fl ow in a system and the
definition of the terms used can best be understood by referring to the
following drawings and text.
FIG. 1-1 1. Pump operating with FIG. 1-12. Pump operating with
suction lift. Suction bay level below suction head. Suction- bay level above
centre llne of pump. Gauge reading at centre line of pump. Gauge reading at
suction flange - vacuum.
suction flange - pressure.
For Figure 1-1 1 - Pump under suction lif-t -
- H = hd + hs + fd + fs + vd2
-
29
For Figure 1-1 2 - Pump under suction head -
Where -
Total head i n metres = the total head delivered by the pump when
pumping the desired capacity.
Static discharge head i n metres = vertical distance between the
pump datum and the surface of the liquid in the discharge bay.
The datum shall be taken a t the centreline of the pump for hori-
zontal and double suction vertical pumps or a t the enrrance eye
Static suction head or lift in metres = vertical distance from sur-
face of water in suction bay t o the pump datum.
Friction head i n discharge i n metres = the head required t o over-
come friction i n the pipe, valves, fittings, turns, etc. in the dis-
charge system.
Friction head i n suction i n metres - the head required to over-
come friction i n the suction system.
The velocity head, in metres at the discharge nozzle of the
pump.
Since the velocity head i n most installations will be less than
one metre, on high head pumping installations it i s a relatively
sma4l part of the total head. However, on low head pumping
installations it i s a significant part of the total head.
The reason for separating these calculations i s to ensure that the suction I h
i s wi thi n the capability of the pump t o be selected, as explained in section
(cl .
Head i s usually expressed i n metres of liquid. Whilst it can be expressed in
pressure terms, i.e. kPa, MPa, the pump engineer wi l l always convert this
pressure to metres of liquid because a pump, being a dynamic machine, gen-
era:es a column of liquid (i.e. metres head) regardless of the fluid density.
Therefore, whilst the actual pressure ar the pump discharge will vary with
different densities of the liquid, t h e actual metres generated will not.
So that i f total head to be generated i s given in terms of pressure of the
liquid, density must be given to enable the equivalent metres liquid column
to be calculated.
(c) Whether the pump is to be placed above or below the surface of
the liquid to be pumped.
4
In this regard the suction l i f t capability of the pump (given on the
performance chart) must be studied to ensure that the pump i s
placed in the correct position relative to the liquid surface to en-
able i t to perform satisfactorily.
This' 'suction lift' capabiiity given on the'pump performance curve
is often given in an alternative form known as the NPSH perform-
ance of the pump. NPSH are the initials for NET POSITIVE SUC-
TION HEAD and is expressed in terms of absolute metres head.
Because the 'suction-lift' curve generally refers to the suction l i f t
of the pump when handling cold fresh water a t sea level, the pump
engineer requires a term that describes.the suction performance
for any liquid, hence the expression NPSH. For the basic defini-
tion of NPSH, refer section 2-2.
(d) Having established the quantity (llsec), the total head (metres) to
be generated by the pump and the suction l i f t or net positive
suction head (metres)' available, the next step i s to refer to the pump
performance curve to choose the pump thst suits all three of these
requirements.
I t i s usual for pump manufacturers to present the performance
curves of their pumps to h o w performance in several ways.
They can present this a t constant speed with several head-quantity
curves showing performance with :different impeller diameters or
alternatively at varying speeds with a particular diameter impeller.
In either case, they will also indicate pump efficiency, power ab-
sorbed by the pump, and suction lifr or NPSH required for the
flow range of the unit.
Therefore, i f the required flow, total head, and suction l i f t are plotted
directly on these curvki, the speed (rimin) and input power (kw) re-
quired are determined. The input power will usually be given for cold
clear water or liquid with a density of 1000, which means that liquid
intended to be pumped i s heavier or lighter than water, more or less
power will be required.
Having established the speed and power required, a suitable prime
mover can be selected.
Following sections give, in detail, the methods employed to determine
total head. suction lift or NPSH,' viscosity and density effect on perform-
ance and power required.
However, any pump manufacturer will be pleased to advise you on any
aspect of your pumping problems.
PUMP TOTAL DYNAMIC HEAD CALCULATION
' (EQUIVALENT PIPE LENGTH METHOD) '
Method
Obtain static head
Obtain suction pipe length and fitting losses (Sec 1, Pg 30 Table)
Obtain discharge pipe length and fitting losses (Sec 1, Pg 30 Table)
Calculate total equivalent pipe length
Obtain C value for type of pipe and determine multiplier value [(100/C)'8s](~ection 6,
Pg 9 Table)
Lookup fnction loss per 100 feet pipe for pipe size and discharge concern (Section 3, Pg
10 Table)
Calculate total friction loss from (4), (5) and (6).
Compute Total Dynamic Head from ( I ) and (7).
NPSH COMPUTATION
Method
From sea level altitude obtain Equivalent Head in feet of water (Section 3, Pg 9 Table)
Obtain reduction in feet at altitude concern (Section 3, Pg 9 Table).
Compute the feet head available at site from (1) and (2).
Compute Total dynamic suction head
Obtain Vapor Pressure of Liquid at operating temperature i n feet (Section 3, Pg 1 1 Table)
Obtain Safety Factor for liquid (water = 2', Petroleum = 3' )
Compute total deductions from (4), (5) and (6).
Compute NPSH available from (3) and (7).
Obtain NPSH required value from pump performance curve.
Compare if(8) > (9) ok.
90 Deg. - --\
Elbow S.R. \
r - -90 Deg.
\ Elbow S.R.
\
600 G.P.M.
All pipe and fittings 6
Valve
inch.
All elbows standard radius.
I
I I
v,
008
S
1
u
OOL
CSI
I vj
I
ELLS
I I I
I I STD. I LR. 1 TUBE TURN I
:tion 1 'Basic Centrifugal Pump Hyd." 'Ser.'
@copyright The Gorrnan-Rupp Company. 1991 Page 30
I N; U. PI PE 1 , 1
45 Deg. 90 Deg. 90 Deg.
STD.
45 l3eg.l 90 Deg.
LR-
45 Deg. 190 Deg.
hf = head loss due to friction in feet of liquid.
L = length of pipe including equivalent length for loss through fittings in feet.
C = friction factor for Hazen & Williams.
g.p.m. = gallons per minute.
d = inside diameter of pipe.
.. "
: ' 2 ' L ,
" a
HAZEN AND WILLIAMS -:FRICTION FACTOR c * .
" *
) . ) \ " *" . ^ i,
*.: f 4 & y ',~&~.ues of" c . ,
".. , * " <" \.d * + ; \ 8 - + , A
\+, 9. : ' " ' &' ;3.. Y
~cm~e; : ~i ~h= ~ornrn~nh/' &ed
b&t,;smooth ' 'e - f+ clea"; new Value for \design
well laid - low pipe ' PUrPo='S
poor or conoded
Cement - Asbestos - - - - - -
- -
Fibre - - - - - - - - - - - - - - - - -
Biturnastic - enamel - lined iron or steel
centrifugally applied - - - - - - - - - - - -
Cement - lined iron or steel centrifugally applied - - -
Cooper, brass. lead. tin. or brass pipe and tubing - - -
Wood - stave - - - - - - - - - - - -
Welded and seamless steel - - - - - - - - - -
Interior riveted steel (no projecting rivets) - - - - -
Wrought - iron, cast - iron - - - - - - - - - - -
Tor - coated cast - iron - - - - - - - - - - -
Grit - riveted steel (projecting rivets in girth seams only) -
- - - -
130
Concrete - - - - - - - - - - - - - - - -
152-85 1M
Full'- riveted steel (projecting rivets in girth &
horizontal seams) - - - - - - - - - - - - -
- - - -
115
Vitrified. spiral - riveted steel (flow w / lap) - - - - -
- - - -
110
Spiral - riveted steel (flow against lap) - - - - - -
- - - -
100
--
Corrugated steel - - - - - - - - - - - - -
1 I
I
Multiplier (Basic-C = 100)
I
'NOTE: The Hazen & Williams friction.factor 'C' must not be confused with t he
Darcy - Wejsback - Colebrook friction factor 'f'; t hese two friction
6.R
fact ors in no way related t o e a c h other.
!!z!E=
PUMPS
p c t i o n 6 'Miscellaneous' 'SerW 0 Copyright The Gormon-Rupp Company, 1991
Page 9
-
tlon 1 "Bosic Centrifugal Pump Hyd." 'Ser.' @copyright The Gorrnan-Rupp Company, 1991
Page 32
- -
k -
F
.L
I 1 I 1 1 I I 1 I I
2 &
0 cn 0 In 0 In 0 In 0 In
In w .o 01 7 -r a m m c.l
Section 3 'N.P.S.H." 'Sef." Copyr~ght The Gorman-Rupp Company, 1991 Page 12
HOW TO COMPUTE THE
NET POSITIVE SUCTION HEAD
Based on a model T4A3-B pump, compute the net positive suction head
(N.P.S.H.) for the following application.
550 G.P.M., 10' static lift, 25' of 4" D.I. pipe.
The. pump will be located in Denver, Colorado (5000 Ft. above sea level).
The liquid is sewage, 75 deg. F.
A
B
C .
- -
Atmospheric Pressure at Sea Level
- -
Atmospheric Pressure ( corrected to 5000 Ft.
- -
Atmospheric Pressure Available at Job Site
- -
Deductions From Available Atmospheric Pressure:
1. Total Dynamic Suction Lift
-
- Ft.
D
I G I N.P.S.H. Excess Available ( Subtract F From E )
I
2. Vapor Pressure of Liquid
-
- Ft.
3. Safety Factor (Atmospheric
Pressure Will Vary at Each
Location).
-
- Ft.
Total Net Deductions From Available
Atmospheric Pressure ( Total 1,2 & 3 )
E
F
I
Note '1: Items E and F cannot be determined until pump i s selected.
N.P.S.H. Available ( Subtract D From C )
N.P.S.H. Required ( See Performance Curve )
33.96 Ft.
Ft.
Ft.
Ft.
Ft.
Ft.
GR
EE!%!=
PUMPS
Sectlon 3 ' N.P S H.' 'Ser.' @ Copyright The Gorman-Rupp Company. 1991
Page 13
TEMPERATURE
P.S.I.
ABSOLUTE
VAPOR PRESSURE
KPa
ABSOLUTE
339 1
1.2280
1.767 1
2.5035
3.4950
4.8 140
6.5445
8.7909
1 1.6660
15.327 1
19.9191
25.6349
'32.6882
41.3136
5 1.7800
64.3905
79.4970
97.3546
1 18.52 16
FEET METERS
.0856
.I254
.I804
.2484
.3566
.I4913
.6678
-8967
1.1918
1.5682
2.0345
2.609 1
3.3360
4.2184
5.2883
6.5684
8.1229
9.9365
12.1006
SPECI FI C
GRAVITY
Section 3 ' N.P.S.H.' 'Ser.'
@ Copyright The Gorrnan-Rupp Company. 1 W 1 Page 11
'A"
.,,. ,... .
ALTITUDE
ABOVE SEk
LEVEL I N
FEET
0
1000
2000
3000
4000
5000
6000
7000
8000
ALTITUDE
4BOVE SEA
LEVEL IN
METERS
REDUCTION
TO MAXIMUM
PRACTICAL
DYNAMIC LIR
I N FEET
3AROMETERIC
READING
MILLIMETERS
MERCURY
REDUCTION
r0 MAXIMUM
PRACTICAL
I YNAMI C LIFT
I N METERS
0
.366
-725
1.076
1.41 1
1.74
2.054
2.362
2.664
EQUIVALENT
HEAD I N FEE1
OF WATER
BAROMETERIC
READING
INCHES OF
MERCURY
29.92 1
28.86
27.82
26.8 1
25.84
24.89
23.98
23.09
22.22
EQUIVALENT
HEAD I N
METERS OF
WATER
- (5,s
BORUlRV
PUMP!
Section 3 ' N.P.S.H.' 'Ser: @ Copyright The Gorman-Rupp Company. 1991 Page 9
PUMP TOTAL DYNAMIC HEAD COMPUTATION
. (LOSS COEFFICIENT METHOD)
1. From pipe material, obtain roughness coefficient C from table
2. Compute Pipe Loss by :-
(a) Formula : Hf = 10.666 * c- ' . ~' * D-~.*' * Q 1.85 * L or
(b) From table knowing Q, D and C obtain Hf per 100 unit and multiply by total
pipe length
3. Compute Friction Head Loss for shape condition by :-
(a)
Obtain K value for various shapes from table
(b)
Compute head loss using h u l a H = K x ~ ~ / 2 ~
4. Compute total Dynamic Head by adding Static Head with Suction Loss and
Discharge Loss
, - c F 3 : ) , , , d
-Total Head & Static Head
MTotal Head & St at i c Head
The total head IS obt a~ned by t he f ol l owmg formula
H = h a f h f
H . Total Head
h a ' Stat~c Head
h f Frtctlon Loss (Head)
- - - -- - >
-, - - i
---.>
~ d n - s u b m e r s i b l e Pu r n o s I
-, -
IS l ormed bul the manmum head
(cl osed val ve head) of the pump must
be more t h a n 'ha'.
Besides t he s t a t ~ c head r t IS neccessar y t o Incl ude t he frrctton l oss (head) t hat IS gener at ed
wh e n wat er f l ows t hrough pipes. bends and valves in t he cal cul ati on of t he t ot al head
. , . - -
I n case o f non- subr ner s~bl e pumps (mai nl y
hortzontal pumps). ~t i s advtsable t hat i t b e
HStatic Head
Installed at a pl ace wher e IS as near as t he
wat er l evel of s u c t ~ o n s~de. tn the poi nt of
-. -
prevention of cavttatron. J ' -
- - . ..
h~ : Suction Head
In case that the water level
( ~ n sucrlon t ank) I S above the pump
ha = M - hs
hd : Discharge Head
In case the water level (tn suct dn
l ank ) IS below I he pump.
ha = M i- hs
Total Head & St at i c Head
P]BI Su c t i o n Head and Di scharge
I h d 8
h p - hpd - hps
h f s :
h f d :
hp :
hps :
hpd :
Head
I tlptt I
ha - hd - hs
hp = hpd - hps
Friction Loss in Suction piping
Friction Loss in Dischalga piping
Pressure Head
Pressure Head on Suction Water Level
Pressure Head on Discharge Water Level
The"hp.'is zero (0) when the atomospheric
pressure acts on both of the suction and
discharge water level. However. when it
i s engaged to pump from a vacuum suction
tankpr to pump to a pressure discharge tank:
*
Pb : Pressure acts on the water level in
the discharge water tank
Ps : Plessure acts on the water level in
the suctlon water rank
n : Density of Water (kg f / e )
HSuct i on Characteristics
I t is generally recogni zed t hat t he maxi mum
avadable suction head at 20.c water temperature is
six ( 6) met er s. but this val ue varies accordi ng
t o t he temperature. I t is suggest ed t hat full
st udy and checki ng o n pump dat a be carri ed
out bef or e designing. as cavi t at ~on will be
likely t o occur by t he vari ati on of t he sat ur at ed
vapor pressure.
Tot al S u c ~ i o n Head Hs = hs-khfs-bps
HWat er Temperature and Total Su c t i o n Head .
(Re. NPSH 4 ml
Note : Include an aflo..~ance
in des~gnlng
Calculation of Loss Head
R c a k u l a t i o n o f ~ r i c f i o n Loss
I r Olstrtbut~on Loss
The energy of wat er i s decr eased by
m 1 Junctlon Loss
get t i ng In t ouc h wi t h t he pl pe wall. or by
n I Extr Loss ;,
t he bend( s) r educer ( s) and val ve(s) The o I Elbow L OSS
decr eased ener'gy of wa t e r 1s expr essed p F O I ~ Bend LOSS
by t he same uni t o f measur ement as t he a Tees LOSS
t ot al head
- L h
- r * Fold Elbow Loss
.., - 8
The f r ~c t i on l oss I ncr eases mor e as pi pe
. .
c -'I ,
l engt h get s l onger. or bends' and "alves ar e
2 ) open channel ~ ~ & ~ : - ~ ' q ' - ! i- :"Is
'
i nst al l ed mor e Accordi ngl y, -t he t ot al +.;--tcx<\
f r i c t ~on l oss is obt ai ned b y addl ng t he . - - I _. :
f r ~cf t on l oss- of bends: val ves and t he
1 1 formula of Frrct~on Coss on Straight PQO
change o f I nner pi pe c&dtti&-to t he
f ri ct t on l oss by t he l engt h of pi pe
a) Mannmg s Formula
The val ues are obta:ned-bf t he fol l owi ng^
Q - A - V
f ormul as
1
V -- - R'u - 1 ,
n
~ C a k u l a t i o n s '
1 ) Loss Head o n Pipirig
(Ii Formul as of Frictlon Loss on Stralght Pipe
Darcy's Formula
Manning's Formula .
L V'
.. .
Hf- fm . - - -
29
- -
Willlams Hazen's Formulp
Hf-10.666.C-1.85.0-4.87.Ol.35.L
12lForrnula~ of Friction Loss on Othors
a Suciton Loss ;I
b I Foot Valve Loss ;I
c I Bend Loss r b
d 1 Swmg Check Valve Loss r c v
e I flap Check Valve Loss ; f 1.
1 I Gale Valve Loss ;sv
g I Butterfly Valve Loss ;bv
I b) Ku!:er's Formula
Q - A - V
n
v -
I . &q
0 C O I E J ~ ~ -5 .'
1 - : 23 - -----
I
. - -
. R ;-
2 ) For mul as of Fr i c t ~o n Loss on Others
Formula of Screen Loss
. .
1 < r
Z F r i c t i o n Loss Head on S t r a i g h t Pi pe
1 ) Darcy' s Formula
L V'
C. Hf - f X - X -
0 29
H f : Friction Loss Head (m)
f : Frlcrion Coeffctent
L : Ptpe Leng th (m)
0 : lnstda D ~ J of Ptpe (m)
V : Average Veloc~ry (m!secz)
g : Acceleral~on of free fa11( 9 Bm/sec ')
vr. - Zg. Veloc~ry Head
h I Sudden Expanston Loss ;se
fI:Application
i ) SuddenConsrracrlon Loss r s c
I t IS appl~ed ro obt ~i nt ng rough val.~e
I Gradual Conlcal Exoans~on Loss Cge
~n lhe p~pe dm less than ?OOmm
Cal ucul ati on of Loss Head
0 F r ~ c t i o n Loss Coef f i ci ent
C) Roughness Fact or : n
New Steel Ppe
0.0005
f -0.020t--
0
Regular Steel Pipe
11 vanes depend~ng on the ktnd and
condition of oipe
GOt hers ex c ept Round Cut Sect i on
Pur the value of 0' instead of 0.
D.is obrained by the following formula.
2) Manni ng' s Formul a
~ v e r ~ g s ~l owng = A Cur Sect'on Fbw
Oeprh
S : Cucumferenclal Length o l ( m )
Flowtng CUI S e c w
(Example)
T - 7 1 A - W - H
Hf : Frtction Loss Head(m)
3) Williams-Hazen's Foumul a
f rn: Fnctlon Loss Coefflclent
I-! : . RCU+~P~S FEC! O, , .- HI-: 10.666 . C- I 85 . 0 - 4 87 , q1. 85
L
L : Total Ptpe Length(m)
Hf : Frtctton Loss Head(m)
D ). Ptpe Inner dla(rn) C ' Roughness Factor
V : Average Vel oc~t ~( m/ sec) D : Instde 01a of Pee
R : Accebtl on of free fall
q : Flow Rare (me /set)
D : P~pe Length(m)
Vz2g : Veloctty Head
S Application:
jX Appliption,,u
To obraln the value in wal er works and
water rrtgation.,J
To obt a~n the value tn sewage and ram water..
C Roughness Fact or : n
11 varres depending on the ktnd and condihon of
of pipe. Refer t o the followtng table.
~ o u ~ h n e s e ' ~ a - c t o r
. Standard Figure
Material of pipe
Condition
! . . . . . - . -- - - - - - - - - - . . - - . - -- . - . - - . - - - -- - . - - - .
i i n \.
. . . . . - - - - - . . . .
43
. - . . . -. . -- - .
Cast iron pipe New one
I 0.01 1 1 30
Old one
0.014 1 00
inner surface 0.016 70
. . . . . . . - - . . - - -. - -. - - - . . - - - -
St eel ptpe
. ._-
New one O. Gi i i JU
Ordinary one
Old one
Epoxy-tar linlng pipe
i
j
Mortar lining pipe
1
Hume concrete pipe
-
!
-9
Concrete pipe Polish treated inner surface :
Unueared inner sufface ;
----. .
0.015
- -
100
-- ..
Asbestos or cement ptpe
I
--.
0.01 I 140
- - -
PVC hard ptpe 0.0 10 140
n Mannmg r Roughness Coellc~enl c WJham Hdlon r no~qnnesr Coul f c. enr
Calculation of Loss Head
aFriction Loss Head for Shape Condition
b r Exlr l oss coeffic~ent : { o
1 ) Basi c Formula
HI : Loss Head(m)
Sharp edged 3 (o - I .O
t : Loss Coefficient
v : Average Veloc~ty(m 'sec)
g : Accelerat~on of Free Fa11( 9 8m/ secz)
1
-', r o- 1. 0
v * / z ~ : Velocrty Head(m) --I---'
2 ) Coeffi ci ent . -
a) Inflow coefficient : ci
Angular edge L
I
T i - 0 . 5
f -
Projected pipe [I-0.56-1 .O
acoef f i ci ent of Connections Pipe
1) Ga t e val ve : t s v
2 ) Swing c h e c k val ve : ( c v (Swing type)
3) Buttertly val ve : t b v
4 ) Flap c h e c k val ve : (fv
1 [ f ~ - 0.5 I Extt loss is excluded
Calculation of Loss Head
MSudden Contraction
6 ) Globe Valve : (gv , Loss Coefficient : < s ~
tiole) The velocaly head of !he rrnallet ptpe d.a
8s bppled lo lhal of the lormula
BSudden Expansion Loss
RI D ( Cb90- I tb60. / t M5. (b3O. I Cbl5.
0.5 11- 98 j 1.62 11.40 1 1 - 1 4 ! 0. 81
T Z T i T 5 8 10.47 0.41. i 0.33 10.24
1.0 0.29 10.24 0.21 10.170 0.120
1.5 0.170 0.139 0.121 10.098 0.070
Coefficient : [ se
2.0
2.5
5.0
- ,
Nore) The veloca~y nead of the smaller pqx d.a
PCoeffi ci ent of Pipe Fittings "" . IS appbed 10 that 61 !he tormula
Elbow
"L
Fcrtdon loss IS ezckrdad
R 0- 1 0 ti eauwslenl lo chat elbow
R 0- 1.5 8s mawvalenl to bng elbow
0.145
0.138
0.132
0,
Inside 0 1 a of the larger P,pe(rn)
0.119
0.112
0.107
0.059
0.056
0.1031 0.084
0.097 0.079
0.093 0.0761 0.054
9 P 0 0 . 0 0 9 0 0 - 0 ' 0 6 0 0 ' 0 : P W ' O ! 9 9 0 . 0 i E l - 0 P a l
- - - -
Z E 0 0 . 0 Z b 0 O . O E 9 0 0 - 0 I L E O - 0 1 9 P 0 . 0 I E 6 0 - 0 2 - 1
- - - - - - -
0 ~ 0 0 . 0 1 9 2 0 0 . 0 6 ~ 0 0 . 0 ' 6 1 0 - 0 1 8 2 0 . 0 1 L S O . 0 1 - 1
Calculation o! Loss Head
- v y . . I p I
89Loss Coeficient of Gradual coni cal Expansi on
Note) The veloctly head 01 the smaller pope dad a appbrd to thal ol the lorrnuld
GJunct i on Loss Coeficient 4-
he,! - 3 ) c j ,
I
0 , - 0, Junction Loss Head hr ( l 3 )
v i'
1 1 ~ ~ 1 . - I )
2a
Cal cul ati on of Loss Head
. .
BDi st r i but i on Loss Coef i ci ent .L .-
d, hel l - 31 d, I
) . . . . - .
-0, . 01;tribution . Loss Head ht(
.:. . . . .
, . : -,,.
. .;, ,
v
(T-," r *&. * ;!: :., . . . 5. : ,!
> . . . , ,
- ;. q . '< 7 ;:* ., ........ J
- Calculat~on Example usmg Formula -
H a - 1 l rn -- St at ~c Head
V =2. 5m/ sec - Vel oc~t y
1 Bore Sce 01 00(mm)=0 1 (m)
- 6.25 - V ' ' 2 . j ' ' ' -
2 St at ~c Head 1 1 (m)
--- 0.319m
29 2 9.8(m , sec' ) 19.6
3 Total P~pe Lengt h 48(m)
- ,
HI - HI, - tila--' tila -' HI.
-,I 1
4 Gale Valve 1 pmce I \ / I c
Check Valve 1 pmce Loss Head In Slraqhr Plpe HI,.-; f ; . -: (Dprcy s)
90' Elbow 4 pieces
0 2~
L : 48(rn) D : lOO(mm),~O.I(m)
,
5 Dtscharge Bore 100(mm) n M ~ C ' . , -
100A Check Valve V' ....
HI, -C, -
T I - 4XO.29-1 . l 6
2%
0.02
Accordngk. lolrl l os s head 8s as loflows
&
0.00785
Z.i(m /SKI
HI - 3.828+0.370 t 0. 045 t-0.383 - 4. 626n
V '
Tot al Head H - H a - HI . - -
H - 1 1 - 0 - 4.626 - 0. 319 - 15.945m 16m
29 Tot al h61a reauueo lor tne ourno ss 1 6 M
William-Hazen Formul a For Pipe Losses Hf = 10. 666"CA-1. 85' 0"-4. 87*QAl . 85*L
Value gi ven for every 100 metres of pi pe l ength (L=100) Roughness coeffi ci ent
Cusec mA31s
1.1 0.0300
Pipe Material C
C.I. (new) 130
C I. (average) 110
C.I. (old) 90
C.I. (old 8 rough) 70
MS. (new) 130
M.S. (average) 100
M.S. (old) 80
Epoxy-tar lined 130
A.C. 130
R.C. (polished) 140
R.C. (untreated 130
PVC hard 140
Rubber 140
Brick 100
Wood-stave 120
G.I. 130
William-Hazen Formula For Pipe Losses Hf = 10.666'CA.l.85*DA-4.87'QA1.85'L
Value given for every 100 metres of pipe length (L=100) Roughness coefficient
Cusec mA31s m m 60 70 80 90 100 110 120 130 140 150
6.0 0 1700 0.1750 2.55 10027 75.39 58 89 47.36 38 97 32.67 27 81 23.99 20.91 18 41
Pipe Mate C
C. I . (new) 130
C I (averae
C.I. (old)
C.I. (old 8
M. S. (new)
M.S. (aver;
M S. (old)
Epoxy-tar I
A.C
R.C. (polisl
R. C. (unlre
PVC hard
Rubber
Brick
Wood-stav
G I .
L a t e r hp WHP = Y X H t * Q/ 550 hp Q i n c u s e c , H t i n f t
Y ( s p . w t ) =62. 4 l b / c u f t
b a t e r power
WP = Sg * H t * Q/ 102 kw Q i n l / s , H t i n m
Sg = 1
: b o t o r o u t p u t
I ower
V = v o l t
A =amper e
c os # = P . f .
s -
n g i n e , Out put P = 8. 3*FC/ SFC hp FC = f u e l c ons umpt i on i n g a l / h k
ower SFC = S p . f u e l c o n s u mp t i o n o f ;
d i e s e l i n l b / b h p - h r
I
( De r a t i n g r e q u i r e d )
- .
c o s t p e r hc-m Cos L = $ l o , - OOO*~O~OO*FC*B/ ( ~ * 3 ) 6 0 0 )
- - . = $ 2778*FC*B/Q FC = u n i t of e l e c t r i c i ~ y i n G h r
B = cost of 1- u n i t of el ec. $n $
Q i n i / s > .
o s t p e r hc-rn Co s t = S 1 0 , 0 0 0 * 3 . 2 8 ^ 3 *FC *B/ ( Qk3600)
e n g i n e 1 = $98 *FC * B / Q FC i n g a l / h r
B i n $ per g a l
i
Q i n c u s e c
c o s t p e r a c - f t Co s t = $ 43560kFC*B/ ( Q*3600)
e n g i n e = S 12. 1RFC *B/Q FC i n g a l / h r
B i n S p e r g a l
Q i n c u s e c
I I SPe c i f i c Spe e d
1 c u s e c = 3 7 3 . 8
= 448 - 6
= 2 8 - 3 2
= 0. 02832
= 1 0 1 . 9 5
1 cumec = 3 5 . 3
= l o 0 0
1 l / s = 0 - 0353
B r i t i s h
Q IGPM
H f t
n
rPm
c o n v e r s i o n 47
I GPM
USGPM
l / s
c u me c
cu. m/ hr
c u s e c
l / s
c u s e c
r a d i a l 500 - 5000
mi xed - 3000 - 8000
a x i a l 7000 -15000
Ameri can
USGPM
f t
rpm.
52
m e t r i c
Cumec
m'
rpm
1
Selecting a suitable engine for
a Water pumping set ,
To determine the correct power of engine required the following details are needed, the
appropriate formula worked out from these details and allowances made for altitude and
avb~ent temperatures i n which the set wtll operate.
Details required
1 Water pump output in'gallons or litres per mi nute; 2 Water pump operating speed i n revolutions '
per minute; 3 Water pump overall efficiency. (Thi s i nformati on' shoul d be obtained from t he water
pump manufacturer.); 4 Altitude and ambient temperature the set will be operating in, allowing
for the highest temperatures reached during the year; 5 Total head i n feet or metres, which is the
height f rom the water level to the output.
Depending on whether these details are i n Imp. gallons or U.S. gallons and total head in feet, or
litres and total head i n metres, use one of the fol l owi ng three formulae.
Imp. gals/min. x Total head (ft) x
H.P. =
100
3300 Water pump efficiency O/o
U.S. galslmin. x Total head (ft) x
H.P. =
100
3960 Water pump efficiency O/O
Litreslmin. x Total head (metres) x
H.P. =
100
4578 Water pump efficiency O/O
The engine power output alters with different altitudes and ambient temperatures, so allowances
must be made for this. Typical deductions for altitude and temperature are as follows:
Al ti tude
Allow a 3'h0/o power loss for every 1000 feet above 500 feet, or 305 metres above 152.5 metres.
Ambi ent temperature
Allow a 2% power loss for every 10" F above 85" F or 5.6" C above 29.44" C.
Having found the H.P. required, an engine must then be .selected that can produce this power
on its continuous net rating and ensure i t is coupl ed to the water pump with the correct gear
ratio t o drive i t at its proper operating speed.
Water DUmO flow
Note. The above bhp lrgures are based on 100% pr / mp e l l ~ c ~ c n c y
NET BHP REQUI RED AT SEA LEVEL
1700
(374)
\ -
18 6
22 33
2 6 0 6
29 79
3 3 5 2
' 3725
4 0 9 8
4 4 7 1
48 44
52 17
\ ,.
\
1900
.(al e)
20 79
24 96
2913
3 3 3
3747
4164
4581
4998
54 15
58 32
700
(154)
7 6 5
9 18
1 0 7 1
1224
1-377
1 5 3
1683
1836
19 89
21 42
2100
(462)
2298
2759
3 2 2
3681
4142
4603
5064
5525
59 86
6s 47
900
(198)
9 84
11 81
1378
15 75
1772
1969
21 66
2363
25 6
27 57
1500
(330)
16 41
19 7
2299
2628
2957
3286
3615
3944
42 73
46 02
1100
(242)
1203
14 44
1685
1926
2167
2408
2649
2 8 9
31 31
33 72
1300
( 286)
14 22
17 07
1 9 9 2
22 77
2 5 6 2
2 8 4 7
31 3 2
3 4 1 7
37 0 2
39 87
LANTEC FAR EAST
WATER, WASTE WATER TREATMENT,
DRAINAGE & FLOOD CONTROL
arguments to choose between:
Archimedian Screw Pumps or Submersed Screw Centrifugal Pumps
Arcltimedian Screw Pzcmps
In brief the advantages of screw pumps can be described as follows:
+ Simple and Robust, low speed;
Probably the main and overall advantage of a screw pump is that this is a low speed, heavy duty
and robust pump that operates for years without trouble.
+ Capable of pumping raw water with floating debris.
A screw pump can pump raw sewage without the need for a coarse screen before the pump.
Floating debris and heavy solids are simply lifted up. This saves considerable on equipment costs
for a coarse screen or maintenance!
+ Can run without water
A screw pump can operate even when there is no water in the inlet. Therefore one does not need to
install expensive measures (level control etc) to prevent 'dry-running'.
No collection sump required, no cavitation possible
a screw pump can pump directly from te flat bottom of a
channel. In contrast with a centrifugal pump where a deeper
'collection pit' is required in order to ensure that the pump
always has a . . .cm coverage.
+ Constant high efficiency with variable
capacity
The efficiency-curve of a screw pump is
rather flat on the top. Due to that
efficiency characteristic, the screw pump
offers even high efficiency when it works
at 50% of it's capacity.
Centrifugal pumps on the other hand
show a very specific optimal point in
their efficiency curve; the efficiency
decreases strong at other capacities.
arguments to choose between Archimedian Screw Pumps or Submersed Screw Centrifugal Pumps
2 1 3
+ Pump capacity is self-regulating with incoming level
When incoming water-level goes down, at dry wheater flow, the screw pump 'automatically'
pumps less water. Ergo: no control system required to adapt pump performance.
+ 'Gentle handling' of biological floc
Because of the low rotational speed and large opening between the flights, screw pumps do not
damage the biological floc as much as high speed rotating centrifugal pumps. For this reason screw
pumps are almost always selected for return-of-activated-sludge pumping.
+ Easy maintenance (no 'high skilled' staff required)
Compared to (submersed) centrifugal pumps, a screw pump requires very little maintenance.
Besides that no 'high skilled' maintenance staff is required.
+ Long lifetime ( > 20-40 years)
Screw pumps with typical lifetimes of 20-40 years are no exception.
arguments to choose between Archimedian Screw Pumps or Submersed Screw Centrifugal Pumps
Submersed Screw Centrifugal Pumps
The comments below were received independently from various clients who operate both Screw
Pumps and the Submersed Screw Centrifugal system.
Their comments on the Submersed Screw Centrifugal Pumps are as follows:
High speed causes increased wear
the relatively high operational speed (450 - 950 rpm) causes wear and damage in the pump
housing, this is particularly so when pumping waste water containing sand and stones. This wear
results in regular expensive repairs to the housings.
High friction losses in pipes
High speed is required in the vertical discharge pipe in order to lift the solids with the waste water,
obtaining this high speed necessitates the use of small diameter piping. Using small diameter
piping causes high friction losses in the pipe which increases energy consumption.
Possible blockages at reduced capacities
At reduced capacities the speed in the vertical pipe reduces to such an extent that the solids fall out
of suspension to the bottom of the pipe causing blockages and stopping the pump.
&t Heavy solids cannot be pumped
Heavy solids cannot be pumped by the system, the sump eventually fills with the solids which have
to be removed by hand by maintenance staff. In the small confined area of the sump of a
prerotation pump this is a very difficult and unpleasant task for the maintenance personnel.
Alternatively one needs to install a coarse screen which increases the total equipment costs!
Q Floating debris is not pumped
Floating debris is not removed by the system, this collects in the sump and has to be removed in
the same manner as described above.
Moreover: at lower water levels in the sump when the spirals of the pump are not completely
covered, floating (wooden) debris can enter the conical spiral causing the pump to block. Repair is
difficult necessitating complete dismantling of the pump.
Kh Submerged motors cause more trouble than dry motors
The nature of the design requires the use of submerged motors, problems are encountered with
leakage and short circuiting.
Mechanical seals need regular adjustment
The mechanical seal between the pump and motor requires regular adjustment or replacement
which is time consuming (isolation and wash down required) and hence expensive.
45.h Lifting facilities required with each maintenance
Even low capacity pumps (100 11s) are too heavy to lift by hand, hence every time repair is
required a mobile crane must be used or permanent lifting facilities must be installed - either option
being expensive.
45.h Higher skilled maintenance staff required
The submerged pumps and motors require higher educational skill of both operators and
maintenance staff.
3. Compact Type
r /
Concrete Trough
c
Steel Trough-Liner
r l
Spaans Babcock
Compact Type
0
Also small capacities
....................a.
like 10 Ils !
TYPICAL INQUIRY FORM
PROJECT: Upgrading Of An Exisiting Drainage Canal
Client: Majlis Bandaraya Melaka Bersejarah
Scope of Works:
Supply & Install 1 unit of Concrete Trough Screw Pump
Pump Capacity:
400 literlsec
Contractor: Epilog Sdn. Bhd.
Completion Date: October 2006
Consultant:
Perunding O&L, Melaka
ans Babcock
PROJECT: Baling Kedah Irrigation Pump House
Client: Jabatan Pengairan & Saliran
Project:
Supply & Install 3 units of Concrete Trough Screw Pumps
Pump Capacity: 800 literslsec
~ornpl eti 6n ate:
Contractor:
Consultant:
2nd Quarter 2007
Wira Kerjaya
Peruding Zaaba
PROJECT: Kepala
Client:
Project:
Pump Capacity:
Completion Date:
Main Contractor:
Contractor:
Consultant:
Batas Flood Mitigation Scheme
Jabatan Pengairan & Saliran
Supply & Install 4 units of Concrete Trough Screw Pumps
2000 liters/sec
TBA
Pembinaan Kery
TBA
SMHB
Babcock
Narn Dinh City-Vietnam flooded twice a
year in the rainy season. The existing
pumping stations capacity was not
capable to keep the City dry. Spaans
Babcock designed and build a new screw
pumping station with 10 large screw
pumps to prevent the southern part of the
City from flooding.
CONTRACTING: Nam Dinh Drainage Pumping Station
Client: Nam Dinh City - Vietnam
Project: Turnkey
Capacity/Power: 4,400m3/hr - 950 kW
Year Of Completion: 1999
Consultant: Colenco-Switserland
Government of The Soci di st Republic of Vietnam
Swi ss Aaency - f or Development a nd Coopera-tion
-DIMH URBAN DEVELOPMENT PROJECT
FEASPBIhlTY STUDY
and PRELIMINARY
DESIGN FOR
MVESTMENT
DRAINAGE SECTOR
and
canal is 0.5 n1 higher, and its cross section considerably reduced, which will reduce
excavation volumes and costs. There will be no new bridge necessary for Routc 2 1 , and the
road and railway bridges on Route 10 are considered sufficient for the time being.
0.4 . Costs
Based on preliminary quotations for electromechanical equipment and preliminary designs for
the civil works, cost estimates have been prepared for two pump types, 1.e.
centrifugal, vertical shaft pumps, and
screw pumps
The cost estimates are summarised for both pump types i n the following table.
Screw pumps lteni
A. Pumping Station
General l [ems
Centrifugal,
verti crl pumps
Eanh and piling works
Concrete and brick works
Pumps incl. piping and control panels, tools
(USD)
'1,885,000
22.000
and spares
Other el.mech. equipment (dcwatering pump,
washing. lighting, lifting, penstocks, screens
ctc.)
Installation, testing, commissioning, training,
(USD)
1,564,000
32.000
1 40,000
2 10,000
996,000
O&M manuals
Roofing. metal works, painting, doors etc.
Water supply, surrounding' works, inlet Sr
I B. Transformer station
I
I 275.000 1 275.000 I
122,000
142.000
826,000
52,000
100,000
outlet works
Contingencies 10%
27.000
92,000
50,000
145,000
I C. Office. worksllou and staff llousc
I I
1 36.000 I 36,000 I
40,000
140.000
170,000
Ci vi l works
Electromechanical Equipment
Contineencies 10%
I
I TO'I'AL COST ESTI MATE I 2,196,000 ( 1,875,000
(Note: These are preliminary estimates, subject to change)
143,000
0.5 Recomniendation
36,000
2 14,000
25.000
Based on a detailed comparison of the two basic pump types (Appendix I), the consultanr
recommends that tendering process and detailed design be based on screw pumps.
36,000
2.14,000
25.000
Feasibility Study and Preliminary Dcsign of Invcstmcnts Dr ~ i n a ~ c Sector
Dmft 12/03/37 3:76 PM
Nam Dlrih Urbm Dcvcloprnent Project
4.2 Pump Type Options
, 4.2.1 Technical Options
There are different technical solutions available. In principle, there are two main
technologica1 options:
a) Centrifugal pumps
b) Screw (Archimedian) pumps
Alternative pump layouts are shown in Figure 4.2. There are general advantages and
disadvantages ofboth solutions as shown in Table 4.2-1.
Centrifugal
Pumps
Screw .
(Archl-
median)
Pumps
Table 4.2-1
Advantages
Compact construction
Moderate initial investment (at least when
submersible pumps are selected)
Wide range of pump sizes and discharge
heads available
Dry or wet, vertical or horizontal
installation possiblc
Choice of various designs (e.g. impeller)
High dynamic head and pumping over
long distance is possible (not required in
Kenh Gia)
Simple and solid construction (no ,.high-
technology'' product)
Composed of few parts which are simple
to service
Tolerant with solids in the pump flow.
Removal of long objects like steel pipes,
bicylce chains etc, is simple in casc of
blockage
Low wear and tear due to low rotational
speed (only 20-50 rpm).
Long expected lifespan with little
maintenance required (25 or more)
Low maintenance cost
Tolerant to extendcd periods of no flow
No cavitation or burnout at low or no
flow
No accessories (piping, valves etc.)
Shallow suction pool; no dcsludging
requirements for pump sump
. .
Coursc screening required only
Disadvantages
*
Hig'h rate of wear and tear of impellers when
flow contains sand or othcr abrasive materials
Rake andlor screen rcquircd to reduce risk 01
blockage by larse solids or textiles
r Skilled maintenance staff requircd in casc ol
blockage (disassembling of pump casing)
Expensive accessories (piping. valves)
Sufficiently deep suction pool requircd tc
prcvent cavitation effects
0 Dry run protection required
Special maintenance requirements in case 0 1
extended periods of no flow
Regular desludging of pump sump required
Each screw customized to fit existing
conditions
Heavy lifting equipment for installatior
required
No pumping into pressure systems possiblc
. (not required in Kenh Gia)
Corrosion resistant protection required, witt
regular maintenance renewal
Centrifugal versus Screw Pumps: General Advantages and Disadvantages
Note: Centrifugal pumps exist in many layouts and designs (see also attached report
"Comparison of Pump Types"). Thcre is considerable variety in the design of the pump
impellers. For mixed flow applications (as in a combined drainage1 sewerage system), i t is
important to choose impellers which have a large free flow passage to reduce the risk of
blockage.
One impeller design of particular ingenuity is the screw type impeller, manufactured by e.g.
Hidrostal or Flygt. I t has an extraordinarily large free flow passage, is tolerant to solids in the
Feas~bility Study and Preliminary Design of Investments Drainage Scctor
Draft 12i03137 3:25 PM
Nam Dinh Urban Dcvcl opment Project
water and has still a relatively high efficiency. It thus combines advantages of both
centrifugal and screw pumps.
When differentiating some basic layouts for centrifugal pumps, the main options available for
Kenh Cia are:
Vertical shaft centrifugal pumps (dry motor installation; dry or wet for pump)
Horizontal shaft dry installation (dry well, or elevated with suction pipe)
Wet well (bearing frame) installation with submersible motor
-Suspended submersible installation (pump and motor suspended in large diameter
discharge pipe)
Screw pump installation (Archimedian screw)
The following schematic shows the different layout principles.
1 . vertical (dry or wet well)
n
3. Wet Well Submersible
(Bearing Frame)
I
2. Horizontal (Dry Well)
+
14. Suspended Submersible
I I
5. Screw Pump
Figure 4.2 Basic Layout Principles
Fcasib~lity Study and Preliminary Dcsign of lnvcstmcnts Drainage Scctor
Draft 12/03/97 3:28 PM
Nam Dinh Urban Dcvcloprncnt Project
Table 4.2-2 lists some advantages and disadvantages of the different layouts specific to the
Kenh Gia pumping station (for general comparison between centrifugal and screw pumps,
with their general advantages and disadvantages, see Table 4.2-1).
Simple installation
Moderate costs for equipment
Moderate costs for accessories (no
valves required with low heads)
Pump Type
Vertical,
(dry motor I
wet pump)
Horizontal
(dry well or
elevated)
submersible Least expensive equipment and
construction cost
Advantages
Easy access to motor
Long lifespan expected (20-25 years)
Technology well known in Vietnam
Pump type manufactured also in Viet
Nam
Easy access to motor and pump for
maintenance
Long lifespan expected (20-25 years)
I
Screw I No accessories
I Easy access to motor and screw
I
Lowest power requirements
Longest expected lifespan (225 years)
Early pump start allows maximum
water level draw down in anticipation
of heavy rains
Minimum excavation depth (no
restrictions from dyke protection zone)
Disadvantages
Highest cost for elcctro-mechanical
equipment
Penstocks for pump well required if pump
mounted wet on bearing frame
Dry well design: waterproof construction
required, risk of flooding of motors
Elevated design: limited suction head
High cost electro-mechanical equipment
Pump size requires fixed insiallation on
bearing frame 3 penstock for pumpwell
required for maintenance
Special motors require special rnainten-
ance skills and spares
Considerable a$ditional risks of blockage
because of guidinglfixation plates for
pump i n discharge pipe
Special motors require special mainten-
ance skills (technology is l i t t l e known in
Viet Nam)
Shortest lifespan expected (15-20 years)
Highest quality standard for civil
co&truction and installation of screws
required
Potential corrosion problems for screws in
Vietnamese climate
System little known i n Vietnam
Table 4.2-2 Some specifid AdvantagesIDisadvantages of different Layouts
4.2.2 Comparative Equipment Costs
The preliminary quotations indicated the following comparative costs for electromechanical
equipment (excl. control panels, power supply and installation supervision) for different
pump systems:
Table 4.2-3 Comparative Equipment Costs
Feasibility Study and Preliminary Design of lnvcstrncnts Drlrinnge Scctor
Draft 1 ?/O3/W 3:ZS PM
Costs in USD '
1,296,000
390.000
650,000
769.000
900,000
724,000
504,000
643,000
approx. S00,000 '
approx. 600,000 '
Manufacturer
Ebara Hai Duong
I-l idrosral
Sulzcr/Spaans
ABB
CIF Iiaiphong or Ex fiictory i n VN ' part of total package price for all
Pump Type
Centrifugal Vertical (5 pumps)
Centrifugal Horizontal (5 pumps)
Centrifugal Submersiblc Suspcndcd (5 pumps)
Centrifugal Vertical ( I I punips)
Centrifugal Vertical (8 pumps)
Centrifugal Submersible (fixed frame) ( I I pumps)
Centrifugal Subniersiblc Suspended ( I I pumps)
Screw ( I 0 pumps)
Centrifugal vertical (8 pumps)
Screw ( I 0 pumps)
Nam D~nh Urban Developnlent Project
4.3 Pre-Selection of Pump Types to be Further Irlvestigated
As for the lowest cost option (submersible pumps suspended in column pipe), 'one supplier
has explicitly confirmed the consultants reservations as to the adequacy of the pump type for
the present application. The guiding and fixation plates for the pump inside the rising column
tend to accumulate solids like textiles or other fibrous material, which may lead to shortened.
service and maintenance cycles and deficiencies in pump availability.
Additionally, submersible motors of the required size have special technology and'rnainten-
ance requirements which are not readily available in Viet Nam. For these reasons, it has been
decided in consultation with the National Project Director and the municipal authorities that
no submersible motors should be considered forjrrdrer preliminary design.
Consequently, it was decided to do the preliminary design stage for two options, namely
A. Vertical centrifugal pumps
B. Screw pumps
/
This allowed for a more detailed assessment of the civil construction cost component and the
accessories required for each option.
For the two preselected pump types, a detailed te'chnical and comm'ercial comparison has
been undertaken (see attached report "Comparison of Pump Types"). The conclusions and
recommendations from this evaluation are summarised in Section 7 of this. report.
Feasibility Study and Preliminary Dcsign of lnvestrncnts Dra~nage Scctor
Draft 12/03/97 3 2 8 PM
Nam Dinh Urban Dcvcloprnent Project
4.4
Preliminary Layout and Design of Kenh Gia Pumping Station
4.4.1 Pump Layout Parameters
A. For Vertical Centrifugal Pumps
The layout and design is based on centrifugal pumps with screw type impellers
. No. of pumps: 8
, . . Discharge per pump 1500 11s
Discharge total 12000 11s
kW
kW
kg
Electrical motor
Total power required
Weight of motor
Impeller passage
Diameter suction inlet
Diameter discharge
Weight of pump
Casing dimensions
B. For Screw Pumps
No. of pumps:
Discharge per pump
Discharge total
Electrical motor
Total power required
Weight of motor
Diameter of screw
Length of screw
Weight of screw
Inclination of screw
x 1970 x 900 (LxWxH), excl. Mota
mm
mm
kg
degrees
4.4.2 Pump Sump Basin Depth '
A. Vertical Centrifugal Pumps
Centrifugal pumps require that a minimum water level be maintained above the bellmouth of
the suction pipe to prevent air vortex development. If air is' sucked' into the pump, there is a
risk of pump damage due to cavitational effects. Pump basins therefore must be sufficiently
deep. The minimum water level depends on the velocity of the water entering the suction
pipe. The larger the bellmouth, the smaller the entrance velocity and the minimum water
level.
As a rule, minimum water level z,,,~,, above the bellmouth entrance should satisfy the following
criterion:
z,,,~,, = v2/2g
v = water velocity at suction pipe entrance (bellmoi~th)
g = gravitational constant
Feasrbillty Study and Preliminary Design oflnvcsrments Druinagc Sector
Draft 12/03/97 3 2 6 PM
Nam Dinh Urban Development Projcct
The proposed pumps have a discharge capacity of 1.5 m3/s. To reduce the pump sump depth,
the pumps should be fitted with bellmouth pipes (bellmouth diameter 1000 mm), making z,,,;,,
10. 25 m. With a reasonable safety allowance, select z,,,;,, = 0.50 m.
The minimal distance fiom the pump basin bottom to the suction pipe entrance, for the
proposed pump type is s,,,, 2 0.25 m. Select s,,,~,, = 0.50 m..
The pump stop water level is selected at HI,,,,, = k0.00 m.
The pump sump bottom level then is .B 5
- z,,,~,, -
5 -1.00 m
B. Screw Pumps
There are no special requirements for the pump basin of a screw pump facility. Basically the
interceptor canal or inlet basin just ends at the foot end of the screws. To allow access to the
bottom screw bearings, the concrete walls separating the screw troughs are extended slightly
into the pump basin and fitted with vertical grooves for the insertion of stop logs.
Preliminary Design Plans c
The plans submitted with this study (see Appendix) show the main features of pump house
structure and equipment 1ayout.for the two pump type options, i.e. centrifugal vertical pumps
and screw pumps.
Feasibility Study and Preliminary Design of lnvcstmcnts Dra~nage Sector
Draft l2/O3/Yl 3:78 PM
Nam Dinh Urban Development Projcct
6 Cost Estimates for Project Investment Items
6.1 Kenh Gia Pumping Station
Cost estimates have been prepared for the two technical options selected for preliminary
design, i.e. centrifugal vertical pumps and screw pumps.
For the pumps and the transformer station equipment, the cost estimate is based on
preliminary quotations received from foreign and joint Viernameselforeign suppliers. The
costs of civil works have been estimated with quantities and local unit prices based on the
p~eliminary design plans. For accessories, price lists of various foreign and local suppliers
have been consulted, or standard unit prices for Viet Nam have been used.
In summary, following costs have been estimated for the two technical options:
Item I Centrifugal, Screw pumps
A. Pumaine Station
. -
General Items
Ehrth and piling works
Concrete and brick works
Pumps incl. piping and control panels, tools
vertical pumps
(USW
1.885.000
and spares
Other el.mech. equipment (dewatering pump,
washing, lighting, lifting, penstocks, screens
(USD) ,
1,564,000
. .
22,000
140,000
2 10,000
996,000 .
etc.)
Installation, testing, commissioning, training,
O&M manuals
I
outlet works I I
Contingencies 10% 170.000 140,000
. -
32,000
122,000
142,000
826,000
52,000
Roofing, metal works, painting, doors etc.
Water supply, surrounding works, inlet &
27,000
100,000 92,000
50.000
B. Transformer station
.Civil works
Electromechanical Equipment
Contineencies 10%
(Note: These are preliminary estimates, subject to change)
40,000
C. Office, workshop and staff house
including contingencies
6.2 Interceptor Canal
145,000 1 150,000
275,000
36,000
2 14,000
25.000
For the interceptor canal, no detailed cost estimates have been prepared so far. The budget
provision for Phase I is USD 0.3m, funded by the Vietnamese ~ovkrnment .
275,000
36.000
2 14,000
25.000
36,000
6.3 Related Structures
36,000
No detailed cost estimates have been prepared yet. The budget provision for Phase I is USD
0.3m, funded by the Swiss Government.
Feasibility Study and Preliminary Design of Investments Dra~nage Sector
Draft 12/03/97 3:28 PM
Narn Dinh Urban Developnlcnt Projccr
7 Recommendations and Conclusions
7.1 Pump Type Recommendation for Detailed Design
Based on the technical and cost findings, the two preselected pump types have been further
evaluated based on a list o f basic comparative indicators (see attached report entitled
"Comparison of Pump Types for the Flood Control Pump Station Kenh Gia"). The consultant
recommends that before preparation of detailed design plans, the pump type be selected and
pertinent tenders be called from interested bidders.
Methodology
A decision matrix methodology is used to find the preferred pump type for the present
application. The decision matrix serves to prioritise the 10,comparison criteria selected
(weighting). The rating (degree of fulfilment of the different criteria for the two pump types)
is based on comparing a number of sub-criteria (see attached report).
Result of the Evaluation j
The comparison resulted in the following score:
Centrifugal 515 points (73%) - ,
Archimedian screw , 708 points (100%)
The Archimedian screws were found to be better suited than centrifugal vertical pumps to the
application.
Recommendation
Based on the results of the comparison, the consultant recommends that screw pumps be
installed for the new Kenh Gia ~ u m ~ i n e station.
The consultant proposes to proceed with detailed design based on screw pumps, and to call
bids for pumps fiom screw pump suppliers only.
Feasibility Study and Preliminary Design of Investments Drainage Sector
Draft 12/03/97 3:28 PM
Nam Dinh Urban Development Project
Annex 1
WEIGHTING OF THE COMPARISON CRITERIA
Weights
W=Pxf
Points
P
Factor
Z C .
1 operational reliability y-;, 1 1 1
2 accident safcty during operation and 1: 1 1
. .
mamtenance
, -8. ( r
.: 5 '
3 maintenance and operating ,.friendliness" ' 1 0
T $.a
';'?
. .
4 operating costs .
5 capital costs
6 experience and references
7 operating life span
g ease of installation and construction
9 process flexibility
* factor "f' is introduced as a distribution factor to
create a weighting percentile.
TOTAL
I
Pump 'Type Comparison Page A - I
Last ed~red 08112/97 2:4 1 I'hl
Narn Dinh Urban Development Project
Annex 2
8 ease of installation and construction
9 process flexibility
., - ,., , - ,A+'
Detailed breakdown of the Performance Rating " , , , ,.,2 . 33..,.-+-T,- >\ . - ,- 7, : Centrifugal
I
Pump Type Comparisor~ Page A - 2
Last ediled 081 12/97 Z 4 I I'M
Screws I
1 operational reliability t o t a ~ F [ r a ~ e t o t a l ~ ~ ~ o o d
a. low suscept ~b~l i t y to breakdou n average good
b. high avaibbllity average good
c. proicn t c c hnol a ~ :\\ itlurk thr: i ndi ~i du~l mnlponcnts average very good
d Ion sensitiv~t) to changes in the water content or quality average very good
e. o\ crall s)stern compl ei ~t y average 7 good
2 accident safety duri ng operation and maintenance average
a. small damage potential due to incorrect operation. average
b. small damage potential due to blockage. average
c lo\\ r i A to opcratrng personnel during operation and maintenance. average
3 maintenance and operating ,,friendlinessw average Iota1
a rcgular v~sual inspections average
b. normal daily maintenance \\ark
c condlt~ons during oper'ltion average
4 operating costs t o t a l ~ ' v e r a g e t o t a l r / g o o d
a. Electrical poner average
good
b Consumable operating requirements average
good
c 1,oca.l operating st afcost s 7 good
good
d bl a~n~endnce and costs of the slec~rical/mechanicaI components. 4 fair 7 good
5 capital costs average
a Cost of the electr~cal and mechanical equlprnent. a%erage
1) Co\i of the dww, t ~e d pump hnuw average
6 e\ i )eri cnre and r ef er encc~ [ T i v e r y go& 1-l foor
7 operating life span
v [ ( a v e r a g e r ] . l e o o d
8
8
8
7
good
i w d
good
a g d
Nam Dinh Urban Development Project
Annex 3
Comparison Table (Final Rating)
I.
Pump Type Comparison Page A - 3
Last edited 0811 2/97 2:4 1 I'M
Comparison criteria +. $ " . ,
,,
4 , A, : , " , +',+
G A L 5%.
. r c
CAL 'SHAFT TYPE:
Percentage total of all weighted criteria 99
Comparison in % to show difference
\
7 9
;*
I S \
. ARCH~ EDES SCREW
. <Y
. SCREW TYPE '
I
731 100
1 operational reliability
2 accident safety during operation and maintenance .
3 maintenance and operating .,friendliness"
4 operating costs
5 capital costs
-
6 experience and r'eferences
7 operating life span
8 ease of~nsl al l at ~on and uonsttuction
9 process flexibility
Sum of the product of criteria and weights
Information
. ,
W
20
18
9
11
7
4
13
2
15
--
Information R
8
6
7
7
2
8
5
8
R
5
5
5
5
5
9
6
8
4
R*W
160
108
8 - 69
- *-
8 0
4 9
8
104
10
130
-
708
RhW
100
90
42
ti r
58
,S'T
3 5
3 6
78
16
60
- I-~-
5151
N a ~ n Dinti Urban Development Proiect
Annex 4
METHODOLOGY FOR COMPARISON OF PUMP TYPES
1 Methodology
The decision matrix methodology has been used in order to arrive at a logical choice. This
system has the advantage that not only the judgment, but also the proofs used are easily
,
recognized and clearly developed. It will therefore be easy to evaluate the sensitivity to any
changes in design parameters which may occur during fut,ure development (detailed design,
tender process etc.).
The following steps are necessary:
1. Definition of the contparison crirerki: these are detined based on the project goals,
boundary conditions, and local requirements. The project goal is to achieve the maximum
flood protection available with maximum reliability.
C
2. Priori~ization (weighting;) of the comparison criteria: Important criteria will receive a
higher weight than less important criteria
3. Ruling of comparison criteria: For each process (pump type), the degree of fulfilment of
the criteria are rated.
4. Comparison of the processes (pump types): Each of the processes is compared based on the
defined criteria and the assigned weights (prioritization). A final summarized score is
developed for each option.
2 Definition of the Comparison Criteria
The comparison criteria have been defined based on the project goal (the reliable reduction of
flooding on the city of Nam Dinh), local conditions and boundary limits as:
1. Operational reliability: The following qualities were considered as integral content to the
operational safety:
2. susceptibility to breakdown
3. availability
4. proven technology within the individual components
5. sensitivity to changes in the water content or quality
6. complexity of the overall process
' 7. Accident safety during operation and maintenance. The following sub-criteria are included
here:
8. damage potential due to incorrect operation
9. risk to operating personnel during operation and maintenance
10, risk to operating personnel during blockages
7
, 11. Maintenance and operating ,,friendlinessa. In this Eriterion the separate types of work
performed by the operating personnel are evaluated based on the conditions in which the
tasks must be performed.
12. regular visual inspections
13. normal daily maintenance work
14. Conditions during operation (noise level, vibration of equipment, temperature of surfaces, -
etc.)
Annex 4
METHODOLOGY FOR COMPARLSCIN OF HJMY TYPES
1 Methodology
I he decision matrix methodolo_ry h;~s bee11 used in order to anive at ;I logicnl~choice. This
system has the :~dvr\ntnge that not only tlic judgment. hut also the proofs usecl i11.e easily
recognized i d clearly developed. It will therefore be easy to evnli~ate the se~lsitivity to any
changes i n dcsign parmeless which mi~y occur :lurir~g future developnlcnt (detailed design,
tender process etc.).
The following steps are necessary:
I . Definition of the ~.ottrl)o~.i.so~~ c.ri/rricr: thcsc arc de-i'iwd based on the project goals,
bounda~y conditions. :!r\c.l locd sec\uire~nenrs. The project goal is to achieve the p nu xi mum
flood protection nvaila!:!e wit.11 r nns i ni ~~~~i reliability.
3. Rtr!iirgc: of i~otttpcrrisort r.ri/~v.itr: For cnch I~IT,(:CSS ( punlp type), the degree of f111 f i l went of
the criteria are raled.
4. Comparison of the processes (pump types;: Ex h tsf t!w processes is compared based 011
the defined csiterin and the ossigned weigh~s (piosi~izntion). A final sum~nari ~ed score is
developed t'ov each option.
2 Definition of the Comparison Criteria
The,comparison criteria have been detiuecl based on the project goal (the reliable reduction of
flooding on the city of Naln Dinh), loc:tl conditions and boundary limits as:
I . Operalional seliabiliry: 'The rollowir~g qualities werk considered as integral content to the
' operat iond safety:
susceptibility to breakdown
avnilabiliry .
*
proven technology within the intlivitluil! co~iipot;ents
sensitivity to chmgcs i l l the water conte~tt or quality
complexity of rlw ov~:~.all pluxs:;
regular visual i~~spzctic:~~?:
norrnd daily ~i l a i n~c ~~; u~c c work
4. Operating ~ P S I S . I'l.iese cos t ~ arc. esli:iia~cd ; ~si ng rn;lthern;~tic:~l averages based on actual
bids nncl i i i cl ~~de:
0 Electrical power
Cons~lmable oper:!ting requir.eme~~ts (li~bric:~r~ts and cooling/~;lshing wclcr)
Local opcratine staff' costs
Maintenance and repair costs of the ~lccir~~c:il/tr~ecli:~~~icnl components. ,
5. Cal)it;ll costs. Thc c;ipiiul costs arc: esti1n:~tes Ixwd 011 average within the. pre-
liminary bids as well as es~irniltes bosecl or1 the civil constn~ction requi~wnctnts for the
enlire pnniping statio:].
Cosl of the e1ectric:d and mec11;wic;il eqr~ipn~enr
Cost of the ;\ssoci;~letl pump house
6. Experience and lefisrcnces. in hi s criterion i t is il-nporl;j~;t 'to consider the ability of the
local representative' (anti represer~ted cornp;lnyi ro supply after s:~les services. These
services are comprised of not only :;pare parts clelivery ;uid m:~inten;lnce work, but also
training of local operating staff.
C
7. Operaling life spun. This factor i s c\ al u: ~~ed bascd upon the chosen materials, known wear
factors and overdl robust ch:lr;~ctct of' ~ h c tlesign.
8. Eilse of installation ;rnd construction. 111 this 'crirerion the design requiring the fewest
special considerntiow; of tl:e'local infrartrwtrtre is considered most rtdvant:rgeous.
9. Process flexibility:
adaptation of punrp regime to seasonal flow cotiditions
' tlexihility in low tlow conciitions
3 Prioritisation of the Criteria
It is most advuntagcous to outline the prio~.itizlrio~i (weighling) of the criteria by limiting ex11
decisioll to a conipiwison of two single. criteria.
A decision matrix is made i n order to cany out this process. Each criterion is separately
cornpiwed with each of the other ill order to ascertain which of the two is more. important. E.g.
criterion No. I i s first compared with No.?, theri wi ~h N0.3 etc. hen the procedure id repeated
for criterion No.2, which is progresively co~nprecl to Nos 3. 43 etc.
The fomiul:~rion of the question is nlw;~ys: "Whic!; criterion is more important ?". The niore
import:rnt of the criteria receives a "1" i n tlle lio~izvntal row. The diagonal of [he matrix is
automatically always tilled with a "1".
Question: The firs1 qucstio~l to be uskecl is: "Is operalionul reliabilty niore imporlnn't
t l l r ul uccicie~~l s;1fctyr?"
( Answer: "yes", tlierchre n " I " i s cn~cl-cd illto row I , colurnll 3.
J
-
2"' Example
uestion: "Are exlwr-ience i~nd refcl-el-tccs riw~-c i ~np~r - t a ~~t than opwating life SP~I I ~' ?"
Answer: "IIO". this requires the entry of 11 "0" into row 6, column 8 (and so on.).
The weightit~g of 11ie criteri;~ is ca!cu!i~~ctl hy su~iirning the ~ i u ~ n l ~ c r of "1's" witllil~ the
horizor~tal (row occ~~pi cd by tlw criteria) AND tllc 11~1rnlxr. of "0's" withiti the \wtic:~l column
above the diagon;~l ccl! l ~crt ; t i r~i n~ to the ~r i t e r i o ~~ C ~ I I S ~ C ~ C I ~ C ~ ~ .
New Development
based on:
> Disstress (dS)
PDecibel (dB)
xock
he S
Acoustic Emission Technology
CM System
+ Reliable for low-speed applications (also high speed)
+ for all rotating machines: pumps, compressors, blowers, fans.. .
+ Continuous monitoring of rotating equipment
+ 24 hr Automatic generated alarm by SMS, Pager, Phone ...
+ Early stage detection of bearing- and lubrication problems
+ Predict machine degradation
+ Simple reported values: PPi
+ optional: daily reporting via (secured) internet
Kursus I 1 GENERAL DESIGN & SELECTION
Rekabentuk
Sistem Pam
Pump Station & Sump
Design
IrLim Lee m0n
Pumping station layout to ascertain
space requirement
Suitability of equipment
Cost factor
Reliability and flexibility
Safety and protection devices
m Mode of operation
I DESIGN & SELECTION
Number of pumps required
(IrrigationIDrainage)
m Capacity (Irrigated area/ runoff)
Head (system design)
System layout & pump sump design
Pump selection
rn type (axial, mixed, radial)
rn Material of construction
IRRIGATION PUMPING STATION
B 3 to 4 pumps preferred for flexibility of
operation
w Preferable to have identical pumpset for
standardisation
w Standby set only for large pumping stations
8 If two(2) pumps, each should be not less
than 213 total capacity
w Additional smaller capacity pump or use of
frequency converter to facilitate regulating
water level downstream
DRAINAGE PUMPING STATION
Three (3) or more pumps preferred
B Preferable to have equal capacity for each
Pump
w One smaller capacity pumpset to cater for low
flow condition
w I f two(2) pumps, each should be not less
than 213 total capacity
w Standby generator set should be considered
I Determination of Pumping Capacity
Determination of Pumping Capacity
(Drainage)
8 Normal drainage
m Based on actual measurement of flow
(ground & effluent water)
8 Flood Control or storm drainage
rn Requires careful study of internal water
level rise against assumed run-off (needs
hydraulic study)
DESIGN HEAD (Drainage)
8 Normal Drainage
Set at difference in design suction and
discharge water levels
Due consideration for min. water level
Flood Control
m Max. head occurs at highest discharge
water level
Due consideration for rnin. water level
conditions
DESIRABLE FLOW CONDITION
Uniform flow - the velocity (magnitude
&direction) is same at all points across
the section
Steady flow - velocity (magnitude &
direction) does not change with time
m Single phase - no entrained air, vapour
or other gases.
DESIGN HEAD (Irrigation)
Based on normal water level at pump
sump and designed full supply level at
discharge canal
Consider max. and min. intake water
level
rn Define min. efficiency at all three intake
levels
PUMP SELECTION
I . Factors to consider
System requirernenk
System layout
Fluid characteristics
Intended service life
Materials of construction
m Equipment cost, operating cost &
maintenance cost
FLOW CONDITIONS I N
SUMP CAUSING
RABLE EFFECTS
THE PUMP
AIR GULPING
I I I
SUBMERGED VORTICES & SWIRLING FLOW
GOOD SUMP DESIGN
(BHRA GUIDELINE)
luo", , ' A
I
ie
AERATED J
FLOW
d
P
-
AIR
ENTRAINING ,
VORTICES
*I, .",,.I .I nllln,
I",...
LI*. MII. - , I--
---* ; I",
Figure 23
Bask sump desiws b r multiple Dumps, vet wl l arrnnpemenf
EXERCISE
(pump Inlet Chamber Dimension)
rn ABS Pump in steel riser
Q = 1180 I/s@ 3.6 m
ND = 1000 mm
rn Determine all dimensions
(submergence, width of chamber,
length of separation etc) indicated in
the format
UNDESIRABLE SUCTION
SUMP SHAPE
AND
IMPROVEMENT
Dimonrio~oftk pumpinlet shank
h ~ m. ' Pqu-X*
- ------ A'-____ .
PUMP SYSTEM LAYOUT
WITH SUCTION INTAKE GATE
TYPICAL LAYOUT WITH INTAKE CONDUIT
Wg. 1.23 Pumping slst~on and suction intoke ga(c Ftg. 1.14 Intake conduil, duction lump and pump
SINGLE FLOOR
Fig. 2.27 Vertical shell remi.two floor m i d flow pump
SEMI TWO FLOOR
Fig. 2.27 Vertical shah %mi-two noor mired flow pump
. . . . " . . . . , .
ANCILLARY EQUIPMENT
rn Lifting equipment - overhead / gantry crane
for pumps, valves, stop log etc
rn Screens - static or mechanized
rn Sand trap - collect sand &gravel
rn Stop logs or gates - inspection and
maintenance of pumps
rn Buildings Facilities
rn Ventilation
rn Access -facilitate installation, servicing &
repair
I
TWO FLOOR
I
Pi. 2.26 Vertiul shaR two Rmr mired flow pump
THREE
FLOOR
CHECKLIST ON VElTING SPECIFICATION
rn System configuration & pump combination
rn Pump material, type, speed, head, efficiency
and discharge; NPSH
rn Specification for pumped fluid
rn Pump inlet, sump and outlet design
Pump column design & sizing
Flow measurement, SCADA etc
rn Witness & model testing
Building dimensions & arrangement &
facilities
Ancillary equipment - overhead crane,
trash screen, stop loglgate, flap valve
Electrical facilities - starting system,
switch gear & safety protection devices,
cable sizing & reserve, prime mover
power & reserve
5. Pr ef er r ed sump and i nt ake desi gns
5.1.1 We t we l l
a r r a n g e me n t s
I t is relatively easy to de t e r r n~ne a standard des~gn for a s ~ngl e s ump, but I ( becomes 1nucl1 Illorc
d~f f i cul t for multtple pump arrangement s because of the many ways o f arranging pumps In a
gve n s ump The mul t ~pl e pump cases shown are elther of u n ~ r ~ s e d deslgn ( I e placmg scvcral
s ~ngl e pump cells s ~ d e by si de) or all the pumps are together in an open sump The best l ayout
for a glven pumpi ngst at l on may be different from the st andar d des ~gns shown, but t he pri nct -
ples ~nvol ved prov~de t he right b a s ~ s for the des ~gn. For purnpl ng st at i ons u,hich use r ~ d i c a l
depart ures ftom the st andar d de s ~gns , there I S usually a need t o fi nal ~se the det a~l s of the s unl p
geomet ry by experiments in a reduced scale hydraulic model .
Section 6 gives details o f t he principles and practice of modeUing pump sumps.
5.1 SINGLE PUMP SUMPS
A basic design for a simple rectangular sump suitable for vertical spindle axial or bowl t ype
pumps is shown in Figure 20. The dimensions are given in t er ms of t he bellmouth di amet er D,
since most manufacturers use similar ratios of be l l mouh d ~ a me t e r t o pump inlet dl ar net er ,
typically this ratio D/d is bet ween 1 .S and 1.8. Tolerances on these recommended di mens i ons
cannot be defined, but t hey are not critical t o about +- 20%. The distance X = $ D, bet ween
the bellmouth and the back wall, may have t o be increased for medi um size pumps (say 3 m3/ s
t o 7 m3 Is) t o provide access for maintenance.
It may be conveni ent t o make t he end wall in the f or m of a circular arc rather t han t o us
c ome r fillets. As long as t he principle o f about :D mi ni mum space between the bel l mout h a nd
t he wall is maintained, t he design proves satisfactory. Thus, in Figure 20, ( b) and (c) ar e al t er n;
tives t o the standard shape s hown in (a). These designs are applicable if there is uni f or m s t eady
single-phase flow t hrough t he channel cross-sectlon upst ream of t he bellmouth as descr i bed i n
Sect i on 1.2.1. The di st ance o f t hi s plane o f uniform flow f r om t he bellmouth cent r e l i ne is
about 3 0 .
F i g u r e 20 \I
Basic design f or single
plane of --I "*
pump, wet well sump -
wi t h a vertical intake (c)
5.1.2 Dry we l l
a r r a n g e me n t s
When s~gnrfi cant vanatlonsoccur the vel oc~t y and turbulence d r s t r ~ b u t ~ o n at t h ~ s s e c t ~ o n ,
all the problems d~scussed ~n Section 3 be pn t o occur For mddly non un~f or r n c o n d ~ t ~ o n s
I
(which, in practice, occur In many sumps), rernedldl measures Include Increds~ng t he submergence
(depth of l l qu~d over the bellmouth) and by the use of further structures such as cones, splrtrer~,
or crosses underneat h the bellmouth
The basic arrangement should be used i f the Intake is in the end wall of the s ump. For a honzor
tal intake (Figure 21(a)), the comer fillets are omi t t ed. The bel l mout h may be omi t t ed over
part of its circumference thus aUowing the i nt ake t o be set with its cent re Line fd above the
sump floor.
The t urned down bellmouth shown in Figure 2l ( b) is the more c ommon arrangement .
5.1.3 Mean ve l oc l t i e s Assum~ng a typical bellmouth d~amet er to pump inlet d~ar net er o i D / d = 1.75 and a pump ml el ,
mean velocity of 4 m/ s (which is typical for a moder n axial flow pump), we have:
Ta b l e 3 Typical mean velocities in a basic sump
Minimum
water level
Section
Pucr;lp inlet (d)
Bellmouth (D)
Approach channel
(20 x I+D)
Mi ni mum
Mean velocity m/ s
4 .O
1.3
0.3
(minimum)
T
As a rough guide, t he mean velocity o f the flow approachi ng a bellmouth i nt ake shoul d be
0.3 mls or less.
To
Fi g u r e 21 pump
Basic design for single
pump, dry well sump
(a) Horizontal intake
S
(mi
water level g
well
-
( b) Tu r n e d d o wn bel l mout h
I
5.1.4 Lengt h of
appr oach channel
Fi gure 22
Recommended
approach channel
lengths
In F ~ g u r e 22(a), an almost f ul l - wdt h band screen 1s s hown wt 1 1 ~h hel ps t o s mo o t h our any U P
st r eam flow d~s t ur bance and s o L ma y be rel at ~vel y short Th e mor e usual ( UK p r a c t ~ ~ ~ )
exampl e shown ~n F~gur e 22( b) w ~ r h a larger area contraction needs a l onger dppr oach lengtll
If t he area ratlo, a / A I S less t han a bout 0.5, or t he flow e nt e r s t he channel f r om t he s d e , s o me
f or m o f bafflmg I S needed and t he l engt h L depends very mu c h o n t he e f f e c t ~ve ne s s of t he
baffles or fl ow screens Model t est s ar e adv~sabl e t o d e t e r m~ n e o p t ~ r n u m appr oach l engt h a n d
baffle arrangement s.
Tabl e 4 Minimum sump lengths
less than 0.5
L
LID Cor nmen ts
Full wi dt h ba nd screen n o
obs t r uct i ons
As above, s o me obs t r uc t i on
(see Fi gure 22( a ) )
Typi cal UK ba nd scr een ( see
Fi gur e 22(b))
Baffles needed
L(= 6 0 as s h o wn )
( S u mp fl oor t o be level f or t hi s l engt h)
I
o / A = 0 . 5
(as s h o wn )
I L( = IOD as s h o wn ) '1
I ( Sump floor t o be level f or t h ~ s l engt h)
5.2 MULTIPLE PUMP SUMPS
5.2.1 We t we l l
a r r a n g e me n t s
The basic des~gns shown in Fi gur e 23 provlde t wo al t ernat i ve ways o f i ns~al l i ng t hree pumps in
a s ump where uniform s t eady fl ow occurs just upst r eam o f the intakes. Where t he appr oach
fl ow IS less uniform t han t he ideal case, Figure 23( b) is preferable t o Figure 23(a) These de s ~gns
give the preferred way of def i ni ng the final part of t he s ump, Zone 111.
However, in most cases t hi s i nformat i on wiU be insufficient t o produce a compl et e design
since it ignores the appr oach t o t he s ump, ' Zone II' , ot he r than t o state that the flow must be
1
uni form and steady. The s u mp designs given in Figure 23, show three pumps, but are sui t abl e
f or ot her numbers of pumps b y increasing or reduci ng t he wi dt h and keeping similar i nt er-pun1
spacing. Great care is needed i n appl yi ng the open s u mp t o a compl et e system. Thi s pomt is
discussed again in Sect i on 5.2.3.
Plane of uni f or m flow 4
( a) Open sump
Top of dividing
walls above rnax.
water level I
I
. I
I
-
I S = l . S D " 1
( mi n)
I
I
(b) Unitised sump
t
Figure 23 Basic sump designs for multiple pumps, wet wel l arrangement
5.2.2 Dry wel l The wet well standard d e s ~g n s shown in F~gur e 23 can be easily adapted for dr y well ~nsr al l at l on
a r r a n g e me n t s o f the pumps The plan d~r nensi ons should be the same whet her the intake is a t ur ned down
bellrnouth ( F~gur e 4(c)) or a horizontal Intake t hrough t he end wall (Figure 4( b) ) . The corner
fillets or (ad11 need n o t be used i f the intakes are horizontal.
For a gven de pt h o f water above the highest pol nt of the Intake bel l mout h, a horizontal
mt ake In the end wall glves s l ~ght l y better flow c o n d r t ~o n s t han a vertical Intake However , a
ver t ~cal Intake gives a l ower rnlnlmum operarlng wat er dept h than a hon7onral ~nr a l , e , and t h l ~
account s for the c ommon use of a turned-down be l l ~nout h for dry well ms t al l at ~ons
More vanation is possible in the positioning o f t he pumps , and the t ype of p u mp s , in a
dr y well than in a wet well, but the main advantage of a dr y well is the ease of u n d e r t a k ~ n g
p u mp maintenance.
5.2.3 Approaches Examples of multiple s u mp design which include t he appr oach t o the sump. are s h o wn in
to t h e s u m p F~g u r e 24 These are not basic dcslglls, bur rhey ~r l di i a t c u . ~ y s o r ~ ~ l c o r p o r a t l ~ i g tllz upt . ~i S U I I I ~ )
design and the unitised design i nt o an overall syst em. Th e probl em of providing s t e a dy, uni f or m
flow t o a multiple s u mp is made more difficult because, in t he majority of appl i cat i ons, t he
in takes must function satisfactorily with all possible combi nat i ons of pumps in oper at i on.
F i g u r e 24
Examples of mul ti pl e
Downslope not
- I <
213 W
mor e than 10' ' ~ e v e l floor
( a) Example of open s u mp design
I - - L( = 1 OD as s hown)
- - I
pump sumps, including 1
Penstocks
the approach works t o
t he sump (plan views) ( b ) Example or unitised s ump design
The flow patterns in an open sump vary appreciably as they depend on the number and
cornblnar~on of pumps in operation. [n general, a uni t ~sed des~gn s~rnilar t o that shown in
F~gure 24(b) would function correctly, slnce the approach length (L) o f each ' u n ~t ' can be a
conservative value based on the single pump deslgn illustrated in Figure 22.
The open sump design shown in F~gure 24(a) may well require baffles or splitters or a
grid in order to distribute the flow evenly to all the pumps. Since the need for these devices
and the s ~t i ngof them depends on the specific design under consideration, no basic deslgn
details can be given. The best way to determine the details is with the aid of a reduced scale
hydraulic model.
5.3 MINIMUM SUBMERGENCE
The cho~ce oi the rrunmurn submergence of a pump sump 1s usually a crrtical des~gn decmon,
since it defines the lowest point of the pumping station and thus a major part of t he civil
engineering costs. The minimum water level (MWL) in a pumping station is more oft en than not
defined by external conditions, such as the level of the incoming pipe or culvert, or the NPSH
requirements of the pump. Thus the sump floor level is defined by
Sump floor level = MWL - ( C + S )
The c l e a h c e ( C) between the bellmouth and the sump floor is an opt i mum at about c=+D,
and so the submergence ( S ) should be kept as small as possible t o reduce the cost of the civil
engineering works.
A limited amount of experimental data is available for the minimum submergence (S,&)
of pumps installed in sumps similar t o the basic designs of this publication. The mi ni mum sub-
mergence usually defined as the submergence when airentraining vortices form, is found t o
depend on the intake mean velocity ( VB) (1.e. flow rate (Q) divided by bellmouth area (770'14))
and the bellmouth size (D). The general trend is that s , ~ / D increases as VB increases and that
for a given VB, Smh/ D is slightly less for larger intakes than for smaller intakes. However, for
most practical applications the range of D is limited t o about 10: 1 and VB is usually similar for
all fixed speed pumps, so that the value of Smi, = 1.5 D quot ed in this publication represents a
reasonable compromise. For variable delivery pumps, where VB is smaller than normal for some
operating conditions, Smh can be less than 1.5 D for these conditions.
In general the submergence o f an intake should be large enough to reduce t he possible
occurrence ofai r entraining vortices, swirling flow and the effects of any surface waves whc h
may arise. There is, therefore, a conflict in that a conservative hydraulic design with a deeply
submerged intake costs more than a design in which the minimum submergence is only just
adequate. The minimum submergence values quoted for the basic designs of Figures 20. 2 1 and
23 assume that the approach flow to the bellmouth is the ideal as defined in Section 1.2.1.
Slight departures from this ideal condition can be offset by increasing the minimum submer-
gence, but obviously i t would be very expensive to compensate In this way for very poor
approach conditions.
PUMP INTAKES
Ideally, the flow of water into a pump should be
uniform, stezdy, without swirl and without air,
either entrained from a free surface or released
from local low pressure regions. Lack of uniform-
ity can lead to reduction of efficiency. Unsteady
flow will result in fluctuating loading of the pro-
peller;, leading to noise and vibration. Swirl in the
intake can cause a change in flow, efficiency and
power. It may also result in vortices leading from
the free surface or from a bounding solid surface
into the pump. These vortices can become strong
enough for the cores to be air filled or cavitating.
Vortices from the water surface can draw air con-
tinuously into the pump; solid suface vortices,
often called submerged vortices, provide discon-
tinuities in the flow around the propeller blades.
Various types of vortices are shown below.
Entrained air can result in a reduction of flow,
fluctuation of load with noise, as well as vibration
and consequent physical damage.
The flow in the approach channel or from a
reservoir has a significant or even dominant ef-
fect on the behaviour of the flow into the pump.
Vorticity or swirl and poor velocity distributions
can be amplified as speed increases towards the
pump. Excessive resistance to flow, either up-
stream or downstream, will increase the head on
the pump. In practice, some non-uniformity and
unsteadiness are inevitable but a properly de-
signed intake configuration will minimize these
and also avoid air entrainment as well as air core
Development of surface vortices
Surface dimple Deeper di mpk
Axisymmetric vortices
formation. Obviously, the intake should be as
inexpensive to build as possible.
An intake can be designed according to estab-
lished codes-design guides such as those of the
American Hydraulic Institute or the British Hy-
dromechanics Research Association and many
published technical papers give details. All these
recommend the use of long, straight approach
channels with dimensions based on a characteris-
tic pump dimension, such as the column or bell-
mouth diameter. Obstructions that create bound-
ary layer separations and vortex shedding should
be avoided. Stagnation regions, which can cause
boundary layer separations even on straight walls,
should be minimized. Minimum submergence
(depth below the free surface) of the final intake
pipe or entry to the pump, which will ensure satis-
factory flow without air entrainment, is also de- .,
e
fined. For multiple pump installations, individua-
lized "cells" are frequently employed to avoid
interactions between pumps, especially where
they are not intended to operate simultaneously.
It is often impossible to design an intake in this
way. However, once a design departs from the
well documented ground rules, the behaviour of
the flow is uncertain. It is therefore a regular re-
commendation of the design guides that, in order
to achieve acceptable operation of the system,
model tests of the intake should be camed out in
advance.
Intermittent airdm wing Continuous airdrawing
vortex ~iortex
Submerged vortices
3
Wall Vortex
Axi-.yym metric vortex
Extreme axi-symmetric ~lortex
Air releasinglcauitating
floor vortex
CORRECnVE MEASURES
The simple designs previously described will
generally work well in practice. However, in cer-
tain applications (perhaps due to limitations of
space, ins tallation of new pumps in old stations,
or when there are difficult approach conditions),
not all the requirements for a good, simple design
can be satisfied, and some vortexing or swirl or
both may occur. Sometimes it may be impossible
to provide adequate submergence. Corrective
measures must 'then be undertaken to eliminate
the undersirable features of the flow.
The problems can be broadly divided into
three groups-those associated with excessive'
swirl around the pump pipe, those of air entrain-
ing surface vortices, and those of submerged vor-
tices which are difficult or sometimes impossible
to observe from above the free surface.
Swirl around the pump pipe is usually caused
by an asymmetrical velocity distribution in the
approach flow. Initially, attempts must be made
to improve the symmetry of the flow. This can be
achieved quite often by subdivision of the inlet
flow with dividing walls. In addition, better direc-
tion of the flow into the inlet can be obtained by
trying to minimize higher velocity regions. The
introduction of some varied flow resistance by
grading the separation distance of screen bars is
sometimes used.
Relatively small flow asymmetry may be cor-
rected by insertion of a divider plate between the
column and the back wall of the sump, to block
swirl around the pipe. The provision of a floor
anti-swirl plate or splitter underneath the pump
11help to reduce the swirl into the pump. It is
not always safe to adopt this measure without
making a model test, as it may lead to the gener-
ation of submerged floor or wall vortices.
S~uirl b1ock~rrgplnte.s Back ~cal l vortex caused
byJ7oor splitter on&
Air entraining vortices
These vortices may form in the wake of the
column or upstream of it. They may form in the
wake if the inlet velocity is too high, perhaps
because of too small a depth of flow. They may
form upstream of the pipe if the velocity is too
low and the flow is generally too calm. In either
case, these vortices can be eliminated by intro-
ducing some extra turbulence into the flow by
the placement of a transverse beam or a baffle in
the water surface. Such a beam should enter the
water to a depth of about one quarter of the col-
umn diameter at about 1.5-2.0 diameters up-
stream of the column. The effectiveness of the
beam is limited to there being only small varia-
tions in the water depth; a floating beam can be
effective over a wider range of depths.
Surface bnjj7efor vortex supp7,essio?z
I I
7 - t - r r a - ,
Sometimes, provision of a floating raft upstream
of the column will eliminate air entraining vor-
tices. This raft may be continuous or in the form
of a grid. In both forms it impedes the formation
of surface vorticity,
An alternative, which allows for varying water
levels is to use an inclined plate similar to that
shown in sump configuration C.
Submerged vortices
Submerged vortices can form on any boundary
surface of the sump and are difficult to detect
from above the free surface of the water; their
existence may be revealed only by some rough
running of the pump or from the presence of ero-
sion damage to the propeller blades at an inspec-
tion. They can be detected during model tests
since observation is much easier. They can be
eliminated by disturbing the formation of stagna-
tion points in the flow. This can be achieved by
altering the flow pattern, for example by the
addition of appropriate extra surfaces, such as
center cones under the pump or additional fillets
between adjoining walls.
GENERAL CONSIDERATIONS
I
I
The layout, shape and design of a pumping
station depend very much on:
the nature, composition and general quality of
the liquid to be pumped,
site location and ground conditions,
11
environmental requirements and local regula-
1. %?practices and needs,
economic considerations.
When these arbitrarily chosen constraints which
influence the design of a pumping station are
t
taken into account, it is obvious that any two
pump installations with the same type, capacity
and number of pumps will differ considerably,
E
not only from country to country but also within
mparatively small district. However, the
mon objectives should be:
o utilize the well documented advantages of
Flygt submersible pumps,
to facilitate installation and service work,
I* to ensure reliable operation and satisfactory
performance,
to guarantee safe operation and public safety.
hese can be achieved only by careful design of
the whole pumping station. Not only the pumps
but all other parts of the station have to be con-
I sidered in order to ensure satisfactory perform-
ance and safe operation of the system.
I
A discussion of all possibilities would go far
beyond the scope of this brochure but some im-
portant items to be considered are listed below.
I
Liftngequipment should be adequate for hand-
ling not only the pumps but also valves, stop logs
.SUMP DESIGN PRl NCl PLES
I
Ideally, the flow of water into any pump should
be uniform, steady, without swirl and without air
either entrained from a free surface or released in
local low pressure regions. Lack of uniformity can
lead to the impeller operating locally away from
the optimum condition and reducing the hydraulic
'efficiency. Unsteady flow will cause fluctuating
I
load on the impeller, leading to noise and vibration,
possibly with consequent bearing problems.
Swirl in the intake can cause a significant change
in the operating point of the pump with a change
I
in the flow capacity, power and efficiency. It can
also result in local "tornado" type pressure reduc-
tions with an air core extending into a pump.
This air and any entrained air can cause reduc-
tion in water flow, rotor load fluctuation with
and other relatively heavy components. To be de-
pendent on the services of a mobile crane can be
costly and may not be readily available.
Screens are necessary to protect the pumps from
clogging when large quantities of weed, leaves,
rag, etc., are anticipated, e.g. during heavy rains.
In open sumps, a bar screen is also a good protec-
tion against personal accidents.
A sand trap is recommended to collect sand and
gravel (stones) before they can enter into the
pumps and damage them. Sand traps should be
easy to clean.
Stop logs orgates are used to close off the pump-
ing station or parts of it for inspection and repair
of the structure or fixed components. In particu-
lar, large stations should be subdivided to ensure
partial pumping capability at all times.
Buildings, although not necessary for the opera-
tion of the pumps, are required where service
and repair work has to be carried out on the spot,
and to provide rooms for personnel, sometimes in
response to local regulations.
Ventilation is important, not only in sewage
pumping stations but also in other situations, to
prevent the collection of toxic andor explosive
gases in the sump. Heating and ventilation will
be required for the buildings at the site.
Access is important in order to facilitate installa-
ti.on, servicing and overhaul. The well-planned
location of covers, ladders and handling equip-
ment can save many working hours and contrib-
ute to accident prevention.
noise and vibration, local impact loads on various
parts of the system and consequent physical
damage.
In order to design a satisfactory sump, the fol-
lowing points need to be considered:
Flow of water from the sump entrance should
be directed appropriately towards the pump in-
lets, so that the flow into the inlets is achieved
with a minimum of swirl and hydraulic loss.
In order to eliminate air-entraining surface vor-
tices in the sump; walls must be placed so that,
as far as possible, stagnation regions in the flow
are avoided. In the immediate neighborhood of
the pump inlet, it is often desirable to have a
wall close to the inlet to reduce any tendency to
localized swirl and vorticity which can cause
local air-cored or cavitating vortices. To avoid
surface vortices, water depth must be greater
than a certain minimum value.
Although excessive turbulence or large eddies
are to be avoided, some turbulence is useful in
preventing the development and growth of
persistent vortices.
Sediment, which could become foul, must not
accumulate within the sump. Stagnant or very
low velocity regions, where sedimentation
might occur, are to be avoided. A sloping floor
and fillets or benching are often used to assist
in preventing sedimentation.
Surface scum, floating sludge or general small
debris could remain in any relatively quiet re-
gion of the water surface; such material must be
pumped away. The water level should be low-
ered as much as possible at intervals so that
velocities and turbulence will be increased,
provided that air is not drawn into the pump.
This will also assist in preventing any tendency
for the accumulation of sediment on the floor.
In some cases, partition walls may be required
between pumps in a multi-pump installation.
These walls will follow the general principle of
being close to the pumps on either side.
Many sumps receive inflow from the sewer at a
relatively high elevation. The liquid will then
have to fall a significant distance into the sump.
This will especially be the case whenever the
pumps have lowered the liquid level in the sump
to the point at which all pumps are about to be
switched off. It is necessary to ensure that the
amount of air entrained is minimal and it has
the opportunity to rise to the surface and es-
cape before the flow reaches the pumps, there-
fore a sufficiently long flow path between the
sump entrance and the pump inlets must be
provided. The energy of the fall should be dissi-
pated to some extent since otherwise exes-
sively high velocities could exist within the
sump. These requirements can be met for
example by arranging that the inflowing water
strikes a target or baffle wall.
In some circumstances, pumping may be virtu-
ally continuous; in others, the pump(s) may
operate intermittently or relatively infrequently,
with a minimal inflow to the sump. Some
sumps will receive water at a relatively high
elevation and others will receive it at the low ele-
vation of the sump floor.
The sump should be as small and as simple as
possible in order to minimize the cost of con-
struction. However, a minimum volume of the
sump may be specified for other reasons, in
order to provide for a minimum retention time,
or to ensure that there are not more than a cer-
tain maximum number of pump starts per hour
allowed. In addition to pump hydraulic require-
ments, which should include consideration of
NPSH, it may be necessary to design the sump
to deal specifically with sedimentation problems
and to allow for occasional total drainage.
Principles to be adopted in the design of any
sump are given in a number of design guides or
"codes of practice" -for example the American
Hydraulic Institute and the British Hydrome-
chanics Research Association both have pub-
lished such guides (see bibliography). Neverthe-
less, it is not always easy to adopt the principles
exactly and therefore, whenever a new design
departs significantly from established practice, i$
is usually recommended that model tests of the
sump and its approaches be undertaken.
--
- . . - . . -. . . - . -. - - - . . - - - . --- -. -- - - - . . . . . ..
-!
Undesirable suction sump lniprovernent j
-. - --- -
Turbulent In flow
behlnd suctlon plpe
I f the back wall
clearance is ewces
sive. vortexes de-
velop and grow a t
the rear of s uct ~on I
pipe.
I
I
- e-:r
; Back wall clearance
Same as above I
1 should be about 1.50
Swirling flows de-
velop
!
! Suction pipe i s shifted to
t he cent er of suction sump
I - I
,
. 1 - I The cent er of t he i nt ake
-----../
-
i channel shoul d be aligned
Same as above '
with fie cent er oi the suc-
-----
.
i .
.
1 1 tion s u mp
Swirling flows de-
velop
Swirling flows de-
A swi rl i ng flow prevention
velop in a circular
wall shoul d be installed.
suction sump.
: G A l ami nar flow
protection device
should be ~ns t al l ed
i upst r eam 01 the
I s u c t ~o n s ump
Q The s u c t ~o n p q e s
' should be separat ed
' suf l i aent l y
2 Flow vel oc~t y
should be decreased
- 1
Turbulent flows de-
velop ar ound t he
downstream suc-
Lion pipe.
One suct i on pipe 1s
slightly shi ft ed i n t he
t r ansver se direction,
* 1 Se e note in text.
Fig. 3. 13 Undesirable suction s ump layouts and t hei r i mprovement s (1)
-
Undesirable suction sump shape Improvement
hr bul ent flows develop
around the right and
,eft suction pipes
Laminar flow protectton
walls or partition walls
should be installed
Partition walls should
be installed to control
the flow velocity in the
suction sump and t he
flow velocity to t he
bellmouth.
Vortexes develop readily
when the pump ar r ange
ment widens t he suc-
tion sump.
Direct outlet into the
suction sump produc&
turbulent flow and ai r
entrainment.
The intake channel
should be. sloped.
Inflow pipe I
The inflow pipe level
should be lowered and
the intake channel
should be sloped.
Same as above
Air pocket
A vent pipe should be
installed or t he front o
the sump should be ta-
pered.
The flow should be
changed to ordinary
flow.
Supercritical flow
Water should be re-
leased below sump sur-
face.
Above water release
causes air ent rai nment
Fig. 3.13 Undesirable suction s ump shapes and their improvements ( 2)
Table 1 Summary of fl ow conditions in a sump which cause undesirable affects on the pump
R o w condl t l on
A. Air gulping
8, Aerat ed fl ow
C. Alr ent rai ni ng
vortices
Descri pt i on and cause
Wlth t he wal cr level al , or onl y just above, t he t op
o f t he i nt ake t here will be a t endency for air t o be
drawn i n t o t he i nt ake ei t her conl i nuous l y o r inter-
ml t t ent l y in t he f or m of ' gulps' . There may be dlr.
t l nct local depression in t he wat cr surface adJnccnt
t o t he i nt ake, descrlbed as ' dr awdown' . whi ch may
accent uat e t he probl em. High i nt ake velocities will
also cause increased air fl ow rat es i nt o t he i nt ake.
The basic reason f or this condi t i on is t hat t he s u mp
wat er level is t o o l ow wi t h insufficient cover. S.
above t he i nt ake. See Sect i on 5. 3 for r ecommended
suhmergence.
Alr bubbl es may exist in the wat er o f a s u mp for a
variety of r e a l ons , but t hey arc usually due t o a
falllng wat er jet as t he wat er ent ers t he aump f r om
a welr or culvert t hat is abovc the wat er level In t he
s ump. If t here is i ns uf f i c ~e nl t i me for t hem t o rlsc
l o t he wat er surface beforc t h e y arc carri ed close
t o t he i nt ake sect i on, t hey will ent er t he i nt akc and
may be carried i nt o t he p u mp .
It I8 bast t o avoid hlph levcl ent ry Into t he s ump
but I f lhls la not p o ~ ~ l b l c . t h c , ~ one s houl d provlds
sufl l cl ent scparat l on of thc source o f scrat l on
f r om t he i nt akc t o allow t he air bubbl cs t o rise t o
the surface of the wat er in the s ump. Appr oxi mat e
cal cul at i ons based on the mcan hor l r ont al velocity
in t he s u mp , t he mi ni mum rl w velocity o f the alr
bubbl es, a n d t he wat er dept h in s ump, can be used
t o det er mi ne t he scpsrat i on di st ance. A typlcai
mi ni mum figure f or t he ri w velocity is 0.2 m/s.
based o n air bubbl es o f bet ween 2 t o 5 mm din.
Obvi ousl y, larger bubbl es will rise faster and so
reach t h e wat er surface beforc the smaller bubbl es.
(However, t here is an i mpor t a nt class of i nt ake used
l or sewerage where this procedure c a nnot always
be used and so s ome air ent r ai nment i nt o the p u mp
may .have t o bc accept ed. )
The e xt r e me case of a st eady vort ex wl t h an air
cor e bet ween t he wat cr surface and t he Intake
feeds air dl rcct i nt o t he p u mp . In less severe cases.
t he air may ent er onl y i nt cr mi f t enl l y 4 t h the
vort ex being unst eady and less devel oped. Even If
n o air is dr awn i n. Ihe swirling flow associated wl t h
t he s ur f ace can cause probl ems.
As ymme t r y or pre-rol at i on in t he f l ow appr oach-
ing an i nt akc. coupl ed wi t h st agnant r e d o n s of
wat er above or near t he i nt nke, increase t he chances
of alr. entraining vortices formi ng. For exampl e, a
s u mp design wi t h suffl cl cnt de pt h t o give t he mini.
mu m s ubmer gence specified In Sect i on 5 may give
r i m t o vor t ex f or mat i on If t here is very much s s y m
Large quant i t i es
-db T O P ~ ~ P
Alr entrained
by falllng jet few: :.
\ Alr e n t e n
l nt ake
Ty Sur f ace barely detectable di mpl e
i L
,ylF Well defi ned -
surface di mpl e
-
- I - Air dr awn
- i nt er ml t t cnl l y Alr core ext ends
9 f r om b0' '
I nl o i nl ake l ful l v
. .
-
- I - Air dr awn
- i nt er ml t t cnl l y Alr core ext ends
f t o m bot r om o f
i nt o i nl ake (fully
vort ex i nt o Int ake
devel oped ent rai ni ng vorte T 1
E f f e c t ~ o n p u mp and ryrt em
- -
In t he ext r eme case, the pump may dcpri me ~ n d
the delivery fall t o zero. If the p u mp doas cont i nue
t o dellver wat er It Al l also ducharge large quant l -
ties of air whlch may cause serious probl ems in the
syst em. For exnmpl e, the pump may be supplying
cool i ng water t o a condenser where air would cause
overheat i ng o f t he t ubes. Large quant i t i es o f nlr
passing t hrough a p u mp impeUer will cause uneven
loading. resulting in vi br a t ~on, rough runni ng, and
probabl y damage t o t he bearings In I fairly short
t i me.
Al t hough there Is not much published d a t ~ o n
changer in performance due t o air ent r ai nment . It
Is known t hat alr In qui t e small quantities teadc t o
a reduction In di s chuge end loss In effl cl cncy. ( I n
a typlcai case, s centrifugal pump 4 t h 3% free rlr
s howed & dr op in erflclency o l 11%) Act ual
flgures depend very much on the t ype 01 pump.
*xial pump* bclng more s e n~l t i vc t o ent rai ned ~ l r
t hnn conlrilugal pumps. Normal d a ~ l g n practlce
s houl d be t o excl ude rll alr and t h b lmpllea t hat
t here s houl d be n o a1r.entralnlng v o r t i c e ~ at the
i nt ake and t hat t here shoul d be n o alr ent rai ned
In the appr oach fl ow t o the Intake due t o ot her
cause1.
Similar t o A above, the severity depcndl ng on the
quant i t y of air and the pump t ype.
Similar t o A above, the scvcrity depending on rhc
quant i t y o l air a nd the pump rype. There arc also
effcct s llmilar l o D a nd E bel ow, l he sevent y
dependi ng on the vortex strength and the pump
t ype
I n o w condi t i on
D. Submcrgcd
vortlccs
!
F. Largc.scale
turbulence
Dcrcri ptl on and c a u r Sketch Effects on pump and (ystem
These yorticcs originate f rom the side walls and
floor o f the sump rather than the water surface. I n
models. the vortex corc can be seen by injecting
dye i nt o the wnter near wherc a vortex is antici.
paled. Sometimes the vortex may be visible as
small air bubbles i n the watcr which arc ccnt r~f ugcd
I nt o the core. There is also the possibility that air
in solution can be released by the very l ow pressurc
in the rapidly rotati ng core.
There i s not a greal deal known about the origin of
subrncrged vortlccs excepl that they probably stcm
from swirl i n the approach f l ow and vorti ci ty In
the boundary layers on the sump fl oor and sides.
The presrncc of R submerged vortex core indicates
that there is appreciable swirl as well.
- - -
Swlrllng fl ow 1% usually causcd b y large.scale rota
tlon I n the bul k of the fl ul d In the sump whtch Is
then ampllfled as the fl ow converges i nt o the In-
take. I n many casos, the swirl may be accompanied
by a rapidly rotati ng Inner core avon I f them is no
surface vortex v~s~bi c.
This is where the eddy size is the same order of
magnitude as the Intake cross-section area. Un.
steady fl ow patterns arising f rom obrtructi ons i n
the sump or poor inlet conditions i nt o the sump
are a pri mary cause. Vortex shedding f rom pillars
or other pumps arc a common source o f trouble.
This can occur for a variety of reasons. but is
generally causcd by some form of uneven di sl ri bu-
ti on or the fl ow i nt o the sump. The velocity distri-
but i on across (he fl ow in the sump then shorn, for
example, a higher value on one side than the other.
or a higher value a1 the floor than the surface. This
uneven di st r i bul ~on may be stcsdy i n time, but it
can be a prime reason for swirl and vortex forma-
tion at the intake.
Large areas o f watcr above or behind an intake arc
almost stationary. The onl y movernenl wi t hi n ihesc
stagnanl areas is caused by the shear gcncrated
across the 'surface' separating them f rom the main
flow i nt o the intake.
Some such stagnunt regions are unavoidable. but
(heir extent can he rcduccd by careful design and
fllllng.ln wi t h solid rnaleriut ut the more obvious
places.
PLAN
Second pump d r a w water
I
f r om turbul cnt region
Wake caused
by flrst pump
ELEVATl ON SECTION ' AA'
Jet at ' 8' caused by gate at ' A' al l achcs t o one
side wall onl y. This produces a distorted
velocity profile ' C' at i ntake 'D'.
/ay- -.I St a~nant region
ELEVATI ON
Rapid changer i n local prcssure on the pump
Impeller as a vortex corc i s ingested can causc
severe vl brati on and cavitation. Axi sl pumps are
generally more susceptible t o damage f rom vortices
than other pump types.
Sever e rwi rl l ns flow Is Idonticsl l o D above, but
there 11 an addltlonal affect whcn the swirl I s on a
Iargor and l eu intenar scale but Is cantred on the
pump axis. I n thia Iattor case. t hr r r can br a gain
or r r ducl l on I n Iha pump parl ormwi cr dr pr ndi nt
on the r el ~t l ve dlrectlons o f the swlrl and the
pump Impeller. This effect 1s most notlccable In
axial and mi xed f l ow pumps.
Uneven blade loading, changing wi t h l i me, wi l l
causc vibration and noise i n Ihe pump. This effect
wi l l be wane whcn the pump i s very close t o t h ~
intake section as i n a vertically suspended wct.well
Installation. I f there is a moderate length of con.
dui t between the intake and the pump (say more
than I 0 dlametcrs) or i f there are several bends
and changes of cross-sectlon. the i nl t i al turbulence
may not be so i mportant in defining the flow
conditions at the pump Inlet flange. I n thls latter
case, the f l ow conditions will be set by the
geometry of the pipework leading to the pump
inlet flange.
The main effect is to promote swirl and vortex
formati on at the intake section, wi t h the results
described In D and E above. However, effects
similar t o F nbove coul d arise w i h the pump near
the Intake section, where the non-uni f orm vcloclty
distribution coul d lead to aaymmetrlc loads on the
pump Impeller (Al t hough thts Table dlscvsaes fl ow
condi tl onr i n the sump. di l t orl ed velocity proflles
may be caused by bends and changes In section of
the pl pework between the intake seclion and Ihe
pump. i f the pump i s not silcd very clore to the
intake.)
- --- ~
The boundaries belween stagnant regions and the
main f l ow tend t o be unstable and fluctuate i n
position. These regions promote unsteadiness i n
the main f l ow and Increase Ihe chances of alr
entraining vorticcs forming.
CHART OF RECOMMENDED MINIMUM
SUBMERGENCE VS. VELOCITY
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6
Inadequate su6mergence will lead to
vortex formation. In extreme cases, the vortex
tail will trail from suction inlet permitting air
entry into the pump suction see Figure 1.
Entrained air in pumped liquid will cause a
reduction in pump delivery. Noisy operation
and vibration usually accompanies this condi-
tion. Broken impeller shafts may occur in
extreme cases due to uneven loading of
impeller. Motor loads may be increased or
decreased.
Well developed vortices are visable on the
surface. However, just because they cannot
be seen does not mean that this condition
cannot be present and affecting the pump
performance.
VELOCITY IN FEET PERSEC. = G.P.M. x -4085
D2
NTRIFUGAL
Recognizing & Preventing Air Entrainment
Centrifugal pumps are not designed to operate on a mixture of liquid and gases.
Such operation leads to series mechanical trouble, shorten life and unsatisfactory
performance. Reduced capacity results from the presence of even small quantities of
air. For example, only two percent free air can cause ten percent loss in capacity.
In addition to serious loss in efficiency and wasted power, pumps handling a mixture
of liquid and gases are noisy, with destructive vibration. Shaft breakage, loss of prime
m d accelerated corrosion are other frequent results of entrained air.
Improperly packed stuffing boxes, inadequate seal on suction lift, leaky suction lines
3 r inadequate submergence may lead to the presence of air in the liquid being
x~-nped. The remedies for these conditions are obvious, and while considerable effort
s often expended to correct them, all too freauently another common source of air is
2eglected --- free discharge of liquid above the surface, at or near the pump suction
nlet pipe.
i
Air Entrainment
In Figure 1 , liquid falling directly on to the suction inlet would carry air into the
wt i on line and could result in the pump losing its prime. To minimize air entrainment,
~affles allow the air to separate before entering the pump suction. Figure 2 illustrates a
3ump with flooded suction. While the depth of air penetration may appear to be
~egligible, water current and unseen vortices can draw a considerable amount of air
nto the pump, and pump operation would undoubtedly be noisy. I
' - I
Suction Pipe
UMPS
Pipe
Figure 2
ction 4 ' Troubleshooting' 'Ser.' @ Copyright The Gorman-Rupp Company, 1993
Page 36
SUBMERGENCE
In suction lines, inadequate submergence will lead to ilortex formation. In extreme
cases, the vortex tail ill trail from suction inlet permitting air entry into the pump suction
see Figure 1, (page 2 ). Entrained air in pumped liquid will cause a reduction in pump
delivery. Noisy operation and vibration usually accompanies this condition. Broken
impeller shafts may occur in extreme cases due to uneven loading of impeller. Motor
loads may be increased or decreased.
Well developed vortices are visable on the surface. However, just because they can-
not be seen does not mean that this condition cannot be present and affecting the
pump performance.
35-
Figure 1, table 1 ( pagem show the recommended submergence in feet versus the
entrance velocity in feet/second.
Since available fall, excavation costs, retention time and existing structures all influ-
ence the available submergence; the recommended procedure for self-priming
pumps is to increase the line diameter adjacent to suction inlet.
As an example, determine the suction inlet configuration for a 8' pump at 1500
G.P.M. with a three foot available submergence. Following the recommendation of
minimum suction line diameter for favorable reprime performance, the 8" suction line
should be used.
Velocity in this 8" line is
G.P.M. x .41 - 1500 x .41 = 9.6, F.P,S.
-
Pipe Dia. 2 8 2
From the submergence Table 1, we should have 6.1 1 feet submergence. However.
since we only have 3 feet submergence available, the inlet velocity should be reduced
to 6 F.P.S.
The area of 8" diameter pipe is 50 in.
To'determine the new required inlet, we first determine the required area:
9.61 F.P.S. = 50 In. 2
= 80 In.
2
6 F.P.S.
Converting this area to a diameter;
( &) ~ 2 = 5 0 6 ~ 2 = 10.12 ID.
We require a 10" x 8" reducer
The required suction inlet configuration is shown in figure 1
Section 4 " Troubleshooting" "Ser." @ Copyright The Gorman-Rupp Company, 1993
Page 37
1 Documentation VUP-H
mnm
[ a i m E
\
I
I
I Ins tallation
I
Notes on pump inflow chamber
1:
m'
Axial pumps are very sensitive to turbulence in the inflow area.
For this reason it is essential that when designing the pump sump a
separate inflow chamber is provided for each unit.
The inflow chamber improves the flow to the pump and should fulfill
the following conditions:
- No swirls
- Avoidance of airdrawing vortex
- Free from cavitation
- Avoidance of submerged floor and wall vortices
- Even flow profile
ABS has carried out tests in technical scale using pumps of the series
VUP-H 400 in order to optimize the design of the pump inflow chamber
During this the following points were considered:
Reduction of minimum submergence
The minimum submergence (HZm. ) is the minimum water level which
has to remain in the pump sump in order to avoid the development of
vortices or cavitation.
The results are shown in the diagram 4.6 .
I
Optimization of the suction behaviour
A specific profile for the back wall was developed and the optimum
.
position for the pump in the inflow chamber was determined.
The suction inlet of the pump should be located as closely as possible to
the back wall. This arrangement prevents the development of swirls and
results in a more even flow. The water surface shows little turbulence and
the pump runs silently.
1 Documentation VUP-H ,
z 4 j
Installation
Procedure for the design of the pump inflow chamber
I
,
This procedure allows to determine the dimensions for the pump inflow
chamber for a specific VUP-H pump. With the design data a form can be
completed and attached to the tender.
Select type of installation
- Installation in steel riser pipe
- Installation in concrete well
From sheet 4.3 or 4.4 and 4.5 the fixed dimensions
for the relevant pump type are entered into the form.
Based on the flow Q the minimum submergence
HZmin is determined.
The minimum submergence HZmin plus the minimum
installation height Hmin determines the minimum water
level in the pump sump. Enter the values into the form
Based on the flow Q -, the chamber width B
and
the length of the dividing wall L- between two chambers
is determined. The length of the dividing wall should be
rounded up to an even dimension.
Enter the values into the form. 4.7
Based on the chamber width Bmin select the dimension
K for the profiled back wall.
Enter the value into the form. 4.8
Check that the form is fully and correctly filled out.
Documentation VUP-H 2 '
max wl.
Maximum water level
I
7 in the pump sump
---
Definitions
L
'
(back-up level)
The switching points are located
between n
water leve
laximum and minimum
1
Minimum water level
in the pump sump
Minimum submergence
HZmin
in order to keep the
propeller fully flooded.
Installation height b i n
(allowable tolerance +I- 30mm)
1
[zrn 4 )[F;
I Documentation VUP-H 3
I
! f
1
\
Installation in steel riser pipe
i
I ' -.
Section through the pump inflow chamber
,
Dimension
Riser pipe-ND
Radius to
back wall
Gap dimension A
Sump bottom to top
bf coupling ring
B
Height of
coupliag ring
Dimensions in ma '
Hydraulic section 11
* For flows above 4500 Us a riser pipe ND 1600 is recommended.
1 Documentation VUP-H
[ 4 ]I-
I
4 . 1
I I
Installation in concrete well
* !
: i
I
Section through pump inflow chamber
Dimension
Circular diameter A
Radius to back wall R1
Annular gap C
Sumpbottom to
supporting surface D
Height of chamber
(Minimum !)
E
Support flange F
Depth of riser well G
Hydraulic section
s
/
I
.
Abschnm GZr----
j Documentation VUP-H page 5
I
I (
1
! I
8 3
1 !
Installation
,
Top view on pump inflow chamber
\
,
I
Dimension
Radius to
back wall R1
Radius R2
I
Width of chamber B,,
I Length of separation
walls
L,,
Dimensions in mm
Hydraulic section
according to diagram page 8
- according to diagram page 7
according to diagram page7
Documentation VUP-H
/
Submergence for 3- and 4-blade hydraulic section
I
i and minimum installation height
Installation in concrete well or steel tube
Submergence
Hz,min [mm]
uXX) 3000 so00 7000
Discharge Q Pump [I/s]
Hydraulic section
1 Min. Inst. height [mm] 1 250 1 300 1 350 1 450 1 600 1 750 ]
f 7 I
Documentation VUP-H D re Page 7 J
f
7
I
I
1
Width of chamber and length of separation hal l s
I
Installation in concrete, well or steel riser pipe
Width of chamber
Length of separation wa
Note: The horizontal branches of the curve (with the names of the hydraulic sizes)
give the minimum pump inflow chamber width.
Documentation VUP-H
[-)(mi
Section
\ :I
I
Dimension K
The dimension K gives the distance of the radius R2 to the back wall.
This value is suitable for the construction of the pump inflow chamber.
Therefore values given for the Radius R2 have to be observed.
500 750 iw 1 3 0 is00 1750 2000 mo zoo nso 3000 3250 3500 3750
Width of chamber B [mm]
; Dimensions of the pump inlet chamber
Installation in steel tube
Pump type :
I
I Project :
I
I
I Project-No:
j
I
Discharge Q= US I prep.by :
Head
!
H= m j Date :
L
Section
Heigth of backwall [
; profile : I
i
min.wl. + 1000 mm 1
All dimensions I
TOP view
1 Dimensions of the pump inlet chamber
I Installation in concrete well
i I
i I
; I Pump type :
. I
1 Project :
I
!
! Project-No.:
i
I i
I I Discharge Q=
i 1
Head
! i H=
I Prepby :
I
1 Date :
Section
I
Modelling of the I
backwall profile in
the suction chamber i
/ AU dimensions 1
Top view
Kursus
Rekabentuk
Sistem Pam
Pengujian Pam
I r Lim Lee Thon
Pump Performance Test
= Measure or Calculate
Discharge Capacity
8 Total Head
Pump Speed
Motor Input Power
Pump Shaft Power
Pump Efficiency
Measurement for at least three different
discharge capacities
Test Results
rn Guaranteed Duty Point
rn XQ Flow Tolerance Value 0.07%
rn X, Head Tolerance Value 0.04%
rn[HcxX,)2+IqcxQ2>= 1
(dW2 (dQI2
ESTING
Pump performance test (Flow, Head,
Efficiency)
BS 5316 /IS0 2548 Class C
Pump sump model test (hydraulic flow)
British Hydromechanics Research Association
recommendation
m Local Universities
rn Site commissioning test (actual performance
at site) - flow @ head, operational condition
rn Take average of a few readings for
each point (10 readings)
rn Adjust to design pump speed figures
using affinity laws
rn Plot result and produce Test Report
rn The pump is approved i f its
performance curve falls within the
tolerance
Pump Test Bay (Open Channel Type)
-
/ Pump Perfomno, t ul according Lo I S0 2548, clrrr C
1 - Strodud Ten(-
L - .--.
Pump-
pcrfamsncc
Discharge Q
I
Discharge Volume XQ =+I- 7 56 Of Q .u
D , s c ~ . ~ ~ ~ e a d XH = +I- 4 C a ll,.,d
Pump House Model Test
rn Purpose
Check intake condition promote best possible
operation
Check Pump operation condition (vibration,
cavitation) at head &flow at various water levels
Recommend modification to intake and sump
design
rn ScopefExtent - upstream screen to sump
(penstock, stop log groove etc to be included)
rn Factors t o look into
Air entrainment, vortex formation, intrusion
of sediment
Swirl (unbalanced flow in sump)
rn Poor velocity / flow distribution
rn Scale - 1h to 1/25 (normally 1/10)
rn Flow similarities
rn Geometric 1:10
rn Flow 1:316.22
Velocity 1:3.162
rn Final Test
Effect of trash screen design & blockage
= Effect of sudden pump shut-off
Effect of varying flow rate with
submergence (various water levels -
Normal, Low, Minimum, Cut-off, Max.)
rn Observe -
surface vortex,
submergence flow,
rn velocity/velocity distribution
PROCEDURE
rn Observe flow at various water levels
rn Measure flow velocity at approach
(distribution)
Maintain sump water level
rn Perform test on wont case for several
pump combinations
Observe vortex formation
rn Carry out modification as necessary
MODEL TEST REQUIRED
Recommended for pumping stations where
the geometry differs from recommended
standards
Major pumping stations > 2.5 cumec
Upgrading of pumps with greater discharges
onto existing pump sump
Sumps have obstructions close to the pumps
Multiple pumps combinations are used
SCHit3ATIC LAYOUT OF M O E L TEST SIG F1GU-E 3 01
Documentation VUP-H
Pump Performance test according to IS0 2548, class C
- Standard Test -
Head
H
The guarantee for the discharge data is met, if :
I \
Discharge Q
Permissible tolerances within the IS0 2548, class C
Discharge Volume XQ = +/- 7 % of Q rated
Discharge Head XH = +/- 4 % of Hrated
Hydraulic efficiency +/- 5 % of rated efficiency
The duty point is equivalent to the rated data Q Nenn , HNCM
and rated efficiency. I i
TEST / PROTECTION
Some orot ecrl on
available
So me or me a t on
ava~l abl e
Prol ecred agal nsr
s ol ~d obrect s l arger
1 than 5 0 mm 1e.g.
accidenml cont act
>
Pr ot ecl ed agamsr
dr oos of wz e r
fal l ~ng venlcally.
I
Prot ect ed agal nst
s oi ~d ool ect s l arger
rhan 1 2 rnm ( e g
I ft nger of The ha nd)
L
Pmt e c r e c v n s r
dr oos of w a r e
falling ar uo to 1.5'
from t he vmtcal.
Pr or ect ea agnlnst
soraylng warer a1
UP to 60 f r m me
ve n~c a l .
Prot ecred against
sol ashmg water
from all d~r e c l l ons
Protecred agacnst
solid o b l e a s l arger
than 1 rnm ( e . g.
fine tools arld
w~r e s ) .
f'ro[X-Ied aga~nsi
dust. Prevent enrry
In suff l aen:
ouanr ~r y ro
~ n l e d e r e wtfh
s a t ~s t a a or y
omr at t on
Prorecl ed aqarnsi
lets of wat er rrorn
all dlreclrons
Camolerely
prot ecred agal nst
dust.
Prot ect ed a ga ns t
iers of wat er d
s t m~l zr f or m to
h e a w s eas .
Prot ect ed agatnn
drlvmg r a m
Pr ot e a e d awmg
t he e t i m of
I r nr ner sm.
Exercise On Pump Starfion 8 Sump Design
Given:
Pumpset: Type = M a l flow
Capadty = 1180 W c each
Nos.
-
- 3
Water level : Max. = + 55' [Floor level]
Normal = + 49' [efficiency]
Lowest = + 46' [submergence]
Delieryliie : FS-L = + 57'
Propose:
Pump sump dimensions
intake channel dimensions
Layout for pumpsets
Floor Level
Pumpset dimensions