LECTURE SIX

PUMPING STATIONS DESIGN

6. 0 Introduction
The design of a pumping station depends on several specialties, including planning and
water resources management, Surveying, Foundation and soils engineering, Hydraulic
engineering, Analysis for transients, Structural engineering, Civil and mechanical
engineering, Electrical engineering, Instrumentation engineering, Architecture,
Specifications and contract administration, Construction engineering, Start-up,
operations, and checkout

Although each discipline is important to the success of the design, several specialties do
not require a detailed knowledge of hydraulics or pumps. To direct the design of a plant,
it is not necessary to be a structural, soils, mechanical, or electrical engineer. But the
project leader should be familiar with these disciplines and must be able to coordinate the
work of the specialists.

Pumping station is associated with pipes, fittings, valves which are normally used in
pressurized flow of water, wastewater and sludge. Therefore it is important to understand,
materials, piping, fittings, joints and valves.

Objective of the lecture

The objective of this lecture is to equip you with knowledge of the proper pipes, fittings
and valves used in the pumping stations. At the end of this lecture you will able to
1. Describe types of joints used in the pumping station.
2. Describe types of fittings which most applicable in the pumping station.
3. Explain the function, classification and types of valves

6.1 Joints
The most practical connections in exposed piping are flanged, bolted joints because they
are rigid, cannot be deflected, and can resist a considerable amount of bending moment.
There must, however, be enough couplings to make assembly and disassembly easy and
to allow for inaccuracies in spool lengths and position. For example the connection in
Figure 6.1 allows for considerable deflection.

Figure 6.1 Common flanged Joints for exposed and buried pipes

The common joint connection used in the pumping station is the flanges. These joints can
be applied both in plastic pipes and for steel pipes, however in the steel pipes, are always
welded (6.1).

6.1.1 Flanges

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The flange is a ring-shaped device that is used as an alternative to welding or threading
various piping system. Flanged connections which require bolting are preferred
alternative to welding because they can be easily assembled, disassembled then
reassembled when needed for shipping, inspection and maintenance or replacement.
Flange connection are favoured over threaded connection because threading large-bore
pipes is note economical or reliable operation as a leakage in large pipes in difficult to
prevent. For these reasons the flange is an important component of any piping system.

Flanges are primarily used where a connecting or dismantling joints is needed. This joint
may include attaching pipe to fittings, valves, mechanical equipment or any other integral
component within a piping configuration.

6.1.1.1 Flange facings

The mating surface of flange or valve is called face. The face is usually machine to create
smooth surface. This smooth surface will help to assure a leak-proof seal when two
flanges are bolted together with gasket sandwiched between.

6.1.1.2 Flange types

Flange have been designed and developed to be used in myriad of applications. Each one
has its own special characteristics and should be carefully selected to meet specific
function requirements.

The following are flange which is commonly used.

(i) Weld neck (ii) Threaded (iii) Socket weld (iv) Slip-on (v) Lap-joint (vi) Reducing (vii)
Blind (viii) Orife

(i) Weld Neck: The weld neck as shown in figure 6.2. is

occasionally referred as the high-hub flange. It is designed to
reduce high-stress concentration at the base of the flanges
transferring stress to the adjoint pipes.

Weld neck flange are normally used in severe services

application involving high pressure and high temperature.

Welding Neck Flanges are easy to recognize at the long tapered hub, that goes gradually
over to the wall thickness from a pipe or fitting. The long tapered hub provides an
important reinforcement for use in several applications involving high pressure, sub-zero
and / or elevated temperatures. The smooth transition from flange thickness to pipe or
fitting wall thickness affected by the taper is extremely beneficial, under conditions of
repeated bending, caused by line expansion or other variable forces.

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(ii) Threaded flange: These are flanges which the bore is threaded. Its principal value is
that it can be assembled without welding. This features makes the threaded flange well
suited to extremely pressure services that operates at normal atmospheric temperature and
is highly explosive areas where welding may create a hazard. Threaded flanges are not
suited, however for conditions involving temperatures or bending stresses of any
significance, particularly when cyclic condition exist, which may cause leakage through
the threads. After just relatively few cycles of expansion and contraction or movement
caused by stress, the threaded flange no longer performs adequately.

(iii) Reducing Flange: The reducing flange is most frequently used in installations with
limited space. Crowded situations may necessitate the use of reducing flange because it
has a shorter overall length when compared to weld neck flange and reducer fitting
configuration. Be advised however the flow should travel from the smaller size to the
larger. If the flow were reversed, severe turbulence could develop.

(iv)Blind flange: Serves as a function similar to that of a plug cap. It is used to terminate
the end of piping system. The blind flange is basically a flange that does not have a hub
or a bored centre. Blind flanges have the face thickness of flange a matching face type
and similar bolting pattern. Blind flange provides easy access to the entire of a vessel or
pipe unlike a cap that welded.

Figure 6.2: Blind flange

(v) Orifice flange: Of flanges discussed, the orifice flange is the only one that actually
performs functions. The function of orifice flange is to measure the rate flow of the
commodity through piping system. Orifice flanges are easy to recognise because they
have a hole drilled through the face perpendicular to the pipe. They also have addition set
of bolts, called jack screws. These screws are used to help separate the flanges so
inspection and/or replacement of the orifice plate can be performed.

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Figure 6.3: section of Orifice section

(vi) Socket Weld Flanges

Socket Weld flanges were initially developed for use on small-size high pressure piping.
Their static strength is equal to Slip On flanges, but their fatigue strength 50% greater
than double-welded Slip On flanges.

The purpose for the bottoming clearance in a socket weld is usually to reduce the residual
stress at the root of the weld that could occur during solidification of the weld metal. The
image shows you the X measure for the expansion gap.

The disadvantage of this flange is right the gap, that must be made. By corrosive
products, and mainly in stainless steel pipe systems, the crack between pipe and flange
can give corrosion problems. In some processes this flange is also not allowed. I am not
an expert in this matter, but on the internet, you will find a lot of information about forms
of corrosion.

6.1.2 Gasket
Gaskets are used for sealing of flange joints. In general gaskets should not be reused.
Various types of gasket are available depending upon their construction, materials and
features. The following are types of gaskets commonly used
 Non metallic Gasket
 Spiral-wound Gasket
 Ring joint Gasket

6.2 Common fittings

6.2.1 Elbow:
An elbow is a pipe fitting installed between two lengths of pipe to allow a change of
direction, usually a 90 or 45 angle. The end must be machined or threaded. When the two
ends differ in size, the fitting is called a reducing elbow or reducer.

Elbow are categorised based on various design features

- Long radius Elbows
- Short radius Elbows

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 - 90 degree Elbow
- 45 degree Elbow

Figure 6.4: Elbow (a) 90 o bend and (b) 45o bend

6.2.2 Coupling
A coupling connects two pipes to each other. If the size of the pipe is not the same, the
fitting may be called a reducing coupling or reducer or an adapter.

6.2.3 Union
A union is similar to a coupling, except it is designed to allow quick and convenient
connection and disconnection of pipes for maintenance or fixture replacement. A
standard union pipe is made in three parts consisting of a nut, a female end and a male
end.

NOTE: The joint in piping station should almost universally be bolted flanges
augmented with a few strategically placed grooved-end couplings or sleeve pipe coupling
to permit disassembly and allow misalignment connections to equipment (such as pumps)
should be flexible to prevent the transmission of undue forces including shear.

6.2.4 Valves
A valve is the device that regulates, direct or controls the flow of the fluid by opening
closing or partially obstructing various passage ways. Valve varies widely in term of
application. But most valves in pumping station are for isolation service such as open
and closed. Most valves consist of a body containing a flow element (discs, plug, gates,
etc) attached to and operated by rotation of a stem. (There are expectations that e.g swing
check and pinch valves has no stem). The stem together with stem seal is enclosed within
a bonnet. The top stem is fitted with a hand wheel (or lever) for rotation of the stem
(Figure 6.5)

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Figure 6.5: Parts of Valves

With threaded stems (giving a screw-down, screw-up motion) the threaded portion may
be fully enclosed by the bonnet, known as inside screw or exposed beyond the bonnet,
known as outside screw. The former obviously provides maximum protection for the
screw threaded. Outside screws have the advantage of being easier to lubricate.

With rising stem valves the hand wheel and steam move together giving a visual
indication of the degree of valve opening. With a non-rising stem the hand wheel does
not rise (or fall) with the turning movement. The advantage of this type is that it can be
installed in situations providing only minimum headroom above the hand wheel.

Various types of bonnet may be used e.g screw-in, screw-on, union-style and bolted or
flanged bonnet. Screw-in or screw-on bonnets are simplest and cheapest but largely
limited to smaller valve used on low-pressure services. Union bonnets generally provide
tighter sealing and particularly suitable for valves which are dismantled frequently for
servicing. Plain (flat) Flange and male-female flanged bonnet are generally preferred for
high-temperature or high-pressure valves and also larger sizes of valves. An alternative
type high-pressure and/or high-temperature services is the breech-lock bonnet.

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Figure 6.6 : Screwed bonnet, Union bonnet and Bolted flanged Bonnet

6.2.4.1 Valve Trim

Trim is the term used to describe the parts of a valve which are replaceable, i.e. normally
those parts likely to be subjected to wear or degradation. The following parts are
considered as trim
 Gate valves-stem, seat ring, wedge, back-seat bushing
 Globe and angle valves-stem, seat ring, disc, disc nut, back-seat bushing
 Disc valve-disc, disc nut, back seat bushing
 Swing-check valves-disc, disc holder, disc nut, side plug, carrier pin
 Lift-check valves-disc, disc guide, seat rings

6.2.4.2 Classification of valves

Valve may be classified in a number of ways e.g by category (general type) specific type,
purpose or name or by flow characteristics (e.g. straight-through, full-flow or throttled-
flow). Descriptions can also differ slightly in different countries although the main type
names are established internationally (with some exceptions). Classification of valves by
category is given in Table 1. This follows British Standards and general practice adopted
by British manufactures but is is also generally applicable to American practice.

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Classification of valves by function yields the following general list where any individual
type valves may be capable of performing one or more of these functions.
 On-Off services
 Throttling or flow control
 Preventing of reverse flow
 Pressure control

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  Directional flow control
 Sampling.
 Flow limiting

6.2.4.3 Valve connection

Valves are normally designed to either threaded pipes ends, or with flanges for flanged
connection. Threaded connections are simpler and cheaper to produce and more easily
installed. However it can prove difficult to remove valves so mounted without
dismantling a considerable portion of the piping unless a number of extra fittings such as
unions are incorporated.

Flanged ends make a stronger, tighter and more leak-proof connection. Where heavy
viscous media are to be controlled, as in refineries, process and chemical plants etc.
flanged-end valves are normally used. The initial cost is higher, not only because of the
extra metal but because the flanges must be carefully and accurately flanges, to which the
valve-end flanges are bolted as well as gaskets, bolts and nuts must be provided.

6.2.4.4 Types of Valves

There are several types of valves which have been used in piping system. The most
common valves are: plug valves, ball valves, ball floats valves, butterfly valve, rotary
disc valve/ rotor valves Globe valves, gate valves, needle valves, pinch valves,
Diaphragm valves, slide valves, screw-down valve spool valves, solenoid valves, swing
check valve and Penstocks.

6.2.4.5 Plug Valves

The description plug valve or cock valve is given to the simplest form of valve form of
valve comprising a body with a tapered or less frequently a parallel seating into which a
plug fits. The plug is formed with a through-port, the relative position of the port
controlling the amount of opening through the valve. A 90o rotation of the plug fully
opens or closes the fluid flow.

Figure 6.7 : Example Simple Plug Valves

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The simple plug valve is generally suitable for low-pressure, low-temperature
applications, and can be made in quite large sizes: 250 to 300 mm bore is quite common
in some applications. Its main limitation is that if wide variation in fluid temperature is
involved, differential expansion is inevitable, leading either to undue stiffness of
operation or loss of pressure- tightness.

Plug valves may be categorized by pattern

(i) Round opening-with full-bore round ports in both plug and body.
(ii) Rectangular (rectangular opening) with rectangular or similar shaped ports of
substantially full-bore section.
(iii) Standard opening-where the area through the valve is less than the area of
standard pipes
(iv) Diamond port- where the opening through the valve is diamond-shaped. Such
valves are normally of venturi design.
(v) Multi-port-with three or more pipe connections, used mainly for transfer or
diverting services.
(vi) Venturi design-with reduces area porting (down to 40%) and featuring venturi
flow through the body.
(vii) Short-with reduced area ports and /or reduced face to face dimensions.
(viii) Vertical with reduced-area seating ports and the plug passages reduced in
section to form a throat

Ball Valves
Ball valves are amoung the least expensive but most widely used of all valve type as well
as being available in an extremely wide range of sizes. Basic geometry involves a
spherical ball located by resilient sealing rings in a simple body form.

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