Pumping Station Desing - Second Edition by Robert L. Sanks, George Tchobahoglous, Garr M. Jones
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Pumping
Station
Design
Second
Edition
Editor-in-Chief
ROBERT
L.
SANKS,
Ph.D.,
PE
Consulting
Engineer
and
Professor
Emeritus
Montana
State
University
Bozeman,
Montana
Co-Editors
GEORGE
TCHOBANOGLOUS,
Ph.D.,
PE
Consulting
Engineer
and
Professor
Emeritus
University
of
California
at
Davis
Davis,
California
BAYARD
E.
BOSSERMAN
II, PE
GARR
M.
JONES,
PE
Principal
Engineer Senior
Vice
President,
Design
Boyle
Engineering Corporation Brown
and
Caldwell
Consultants
Newport
Beach,
California
Walnut
Creek,
California
1^1
U
TTERWQRTH
|g|E
INEMANN
Boston
Oxford Johannesburg Melbourne
New
Delhi Singapore
Disclaimer
All
ideas, recommendations, methods, techniques, principles, training,
or
subjects mentioned
are for
information
and
educational purposes only. Because
of the
intangible
and
external influences that
may
bear
on the use of
these
ideas
and
suggestions
in any
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and the
absolute necessity
for a
totally integrated planning
effort,
the
authors
and
publisher make
no
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and
accept
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responsibility
for the
manner
in
which
any of the
informa-
tion
provided
or
contained herein
may be
applied,
nor for the
adverse
effects
that
may
result therefrom.
Copyright
©
1998
by
Butterworth-Heinemann
-^2
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Library
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Cataloging-in-Publication
Data
Pumping
station design
/
editor-in-chief, Robert
L.
Sanks.
— 2nd ed.
p. cm.
Includes
bibliographical references
and
index.
ISBN
1-7506-9483-1
(alk.
paper)
1.
Pumping
stations—Design
and
construction.
2.
Water treatment
plants.
3.
Sewage disposal plants.
I.
Sanks, Robert
L.
TD485.P86
1998
628'
.29—dc21
97-15436
CIP
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10
9876543
Printed
in the
United
States
of
America
To
the
Memory
of
Mary Clement
Sanks
June
11,1920-October
24,
1994
Musician
of
impressive accomplishments, organizer
and
director
of the
Annual Chamber Music Festival
(1971-1994)
for
nearly
200
players
from
North America
and
Europe, inspiring teacher, enthusiastic chamber
music
player,
and
indefatigable worker.
On
the
piano,
she
could switch keys
or
leave
out a
beat
or a
phrase
to
match others' mistakes
so
smoothly that
the
audience
was
unaware
of a
mishap. Generosity, kindliness,
com-
passion,
and
service
to
others characterized
her
life.
She
once taught
a
university course
for two
students
after
hours
for no
compensation.
A
gentle, unassuming lady,
she was
loved
by all who
knew
her.
Without
her
patient typing throughout many revisions
for
seven years, Pumping Station Design could
not
have
been written
at
all.
She was
also
our
ultimate authority
on
grammar
and
clarity.
If
she,
a
non-engineer,
could
not
understand something,
it was
recast until
she
could.
She had
much
to do
with
the
book's
quality
and
readability.
It is
altogether
fitting
that
our
profession should know
how
much
it
owes
to
this
one
dynamic, dedi-
cated musician.
vii
Contents
List of Examples .............................................................................................. xv
Locator for Equations, Figures, and Tables ................................................. xvii
Preface to the Second Edition ........................................................................ xxi
Acknowledgments ........................................................................................... xxii
Preface to the First Edition ............................................................................xxiii
Authors and Contributors .............................................................................. xxv
1. Introduction ................................................................................................. 1
1-1 Authors and Contributors ............................................................................ 1
1-2 Responsibilities of Project Engineers ......................................................... 1
1-3 Units ............................................................................................................ 2
1-4 Standards and Codes ................................................................................... 2
1-5 Manufacturers' Recommendations .............................................................. 2
1-6 Safety .......................................................................................................... 3
1-7 How to Utilize This Book ........................................................................... 3
1-8 How to Select Consulting Engineering Firms ............................................. 4
1-9 Value Engineering ...................................................................................... 5
1-10 Ensuring Quality and Economy .................................................................. 6
1-11 Avoiding Litigation ..................................................................................... 7
1-12 Library ........................................................................................................ 8
1-13 Operator Training ........................................................................................ 8
1-14 References ................................................................................................... 9
viii Contents
2. Nomenclature .............................................................................................. 11
2-1 Abbreviations .............................................................................................. 11
2-2 Definitions .................................................................................................. 17
2-3 Symbols ...................................................................................................... 23
2-4 Supplementary Reading .............................................................................. 23
3. Flow in Conduits ......................................................................................... 33
3-1 Fundamentals of Hydraulics ....................................................................... 33
3-2 Friction Losses in Pipe ................................................................................ 35
3-3 Pipe Tables .................................................................................................. 40
3-4 Headlosses in Pipe Fittings ......................................................................... 43
3-5 Friction Losses in Open Channel Flow ....................................................... 43
3-6 Energy in Pressurized Pipe Flow ................................................................ 45
3-7 Energy in Open Channel Flow .................................................................... 47
3-8 Unbalanced Hydraulic Forces ..................................................................... 51
3-9 Field Measurement of Friction Coefficient ................................................. 53
3-10 Flow of Sludges .......................................................................................... 62
3-11 Unsteady Flow ............................................................................................ 62
3-12 Model Studies ............................................................................................. 63
3-13 Computational Fluid Dynamics (CFD) ....................................................... 66
3-14 References ................................................................................................... 66
4. Piping ........................................................................................................... 69
4-1 Selection of Exposed Pipe .......................................................................... 70
4-2 Selection of Buried Piping .......................................................................... 78
4-3 Ductile Iron Pipe (DIP) ............................................................................... 84
4-4 Steel Pipe .................................................................................................... 85
4-5 Plastic Pipe .................................................................................................. 88
4-6 Asbestos Cement Pipe (ACP) ..................................................................... 90
4-7 Reinforced Concrete Pressure Pipe (RCPP) ............................................... 90
4-8 Design of Piping ......................................................................................... 91
4-9 Special Piping and Plumbing ...................................................................... 102
4-10 References ................................................................................................... 105
4-11 Supplementary Reading .............................................................................. 106
5. Valves ........................................................................................................... 107
5-1 Designing for Quality ................................................................................. 107
Contents ix
5-2 Isolation Valves .......................................................................................... 110
5-3 Sluice Gates, Shear Gates, Flap Valves, and Stop Plates ........................... 119
5-4 Check Valves .............................................................................................. 121
5-5 Control Valves ............................................................................................ 126
5-6 Valve Actuators .......................................................................................... 130
5-7 Air and Vacuum Valves .............................................................................. 132
5-8 Materials of Construction ........................................................................... 134
5-9 Installation of Valves .................................................................................. 135
5-10 Corrosion Protection ................................................................................... 136
5-11 References ................................................................................................... 136
6. Fundamentals of Hydraulic Transients .................................................... 139
6-1 Introduction ................................................................................................. 139
6-2 Nomenclature .............................................................................................. 140
6-3 Methods of Analysis ................................................................................... 140
6-4 Surge Concepts in Frictionless Flow .......................................................... 141
6-5 Slow Closure of Valves .............................................................................. 145
6-6 Surge Concepts in Flow with Friction ........................................................ 148
6-7 Column Separation ...................................................................................... 149
6-8 Criteria for Conducting Transient Analysis ................................................ 150
6-9 References ................................................................................................... 151
7. Control of Hydraulic Transients ............................................................... 153
7-1 Overview of Hydraulic Transient Control Strategies .................................. 153
7-2 Control of Pumps ........................................................................................ 160
7-3 Control Tanks ............................................................................................. 161
7-4 Valves for Transient Control ...................................................................... 162
7-5 Containment of Transients .......................................................................... 164
7-6 Surge Control for Water Pumping Stations ................................................ 164
7-7 Surge Control for Raw Sewage Pumping Stations ..................................... 169
7-8 Pipeline Design ........................................................................................... 170
7-9 Computer Analysis ...................................................................................... 172
7-10 Transients in Distribution Systems ............................................................. 176
7-11 References ................................................................................................... 177
8. Electrical Fundamentals and Power System Principles .......................... 179
8-1 Definitions and Code References ................................................................ 179
x Contents
8-2 Electrical Fundamentals .............................................................................. 180
8-3 Power and Control System Elements .......................................................... 187
8-4 Standby Generators and Auxiliaries ........................................................... 203
8-5 Grounding ................................................................................................... 205
8-6 Lighting and Power Outlets ........................................................................ 208
8-7 Electrical Circuit Diagrams ......................................................................... 211
8-8 Power and Control System Practices .......................................................... 214
8-9 Reference .................................................................................................... 217
8-10 Supplementary Reading .............................................................................. 217
9. Electrical Design ......................................................................................... 219
9-1 Final Construction Drawings ...................................................................... 219
9-2 Specifications .............................................................................................. 221
9-3 Contacting Utilities ..................................................................................... 222
9-4 Construction Information to Utilities .......................................................... 223
9-5 Load Estimation .......................................................................................... 223
9-6 Overcurrent Protection and Conductor Sizing ............................................ 226
9-7 Lighting ....................................................................................................... 232
9-8 Power Factor ............................................................................................... 234
9-9 Engine-Generator Sizing ............................................................................. 235
9-10 Short Circuit Current Calculations .............................................................. 237
9-11 Harmonics ................................................................................................... 239
9-12 Construction Service ................................................................................... 239
9-13 References ................................................................................................... 240
10. Performance of Centrifugal Pumps ........................................................ 241
10-1 Classification of Centrifugal Pumps ........................................................... 241
10-2 Pump Application Terminology, Equations, and Performance
Curves ......................................................................................................... 241
10-3 Pump Operating Characteristics ................................................................. 248
10-4 Cavitation .................................................................................................... 255
10-5 Pump Characteristic Curves ........................................................................ 262
10-6 Pump Operating Ranges ............................................................................. 265
10-7 Elementary Pump System Analysis ............................................................ 266
10-8 Practical Pumping System H-Q Curve Analysis ......................................... 271
10-9 Complex Pumping System H-Q Curves ..................................................... 276
10-10 References ................................................................................................... 276
Contents xi
11. Types of Pumps ......................................................................................... 277
11-1 General Classifications of Pumps ............................................................... 277
11-2 Classification of Centrifugal Pumps ........................................................... 282
11-3 Construction of Centrifugal Pumps ............................................................. 283
11-4 Overhung-Impeller Pumps .......................................................................... 292
11-5 Impeller-between-Bearings Pumps ............................................................. 300
11-6 Classification of Vertical Pumps ................................................................. 301
11-7 Construction of Vertical Pumps .................................................................. 302
11-8 Types of Vertical Pumps ............................................................................. 307
11-9 Positive-Displacement Pumps .................................................................... 309
11-10 Special Pumps ............................................................................................. 312
11-11 Summary of Typical Pump Applications .................................................... 314
11-12 References ................................................................................................... 315
11-13 Supplementary Reading .............................................................................. 315
12. Pumps: Selection, Installation, and Intakes ........................................... 317
12-1 Initial Screening .......................................................................................... 317
12-2 Final Selection ............................................................................................ 320
12-3 Illustrative Examples .................................................................................. 321
12-4 Summary and General Considerations in Pump Selection ......................... 337
12-5 Installation .................................................................................................. 340
12-6 Pump Intake Basins: an Appraisal .............................................................. 350
12-7 Pump Intake Basin Design .......................................................................... 356
Caveat ............................................................................................................. 360
Trench-Type Sumps for Solids-Bearing Waters ............................................ 360
Controls for V/S Pumping .............................................................................. 363
Cleaning Trench-Type Sumps ........................................................................ 364
Rectangular Sumps for Clean Waters ............................................................. 369
Active Storage Volume for C/S Pumping ...................................................... 370
Approach Pipe ................................................................................................ 370
Examples of the Design of Pump Sumps ....................................................... 374
Critique of Example 12-3 ............................................................................... 379
Critique of Example 12-4 ............................................................................... 387
Critique of Example 12-5 ............................................................................... 396
Round Sumps for Small Lift Stations ............................................................. 397
Sumps for Large Pumps ................................................................................. 399
xii Contents
12-8 References ................................................................................................... 399
13. Electric Motors .......................................................................................... 401
13-1 General ........................................................................................................ 401
13-2 Applications of Motors ............................................................................... 403
13-3 Fundamentals .............................................................................................. 405
13-4 Types of Motors for Pump Drivers ............................................................. 407
13-5 Characteristics of Squirrel-Cage Induction Motors .................................... 410
13-6 Motor Speed ................................................................................................ 410
13-7 Motor Voltage ............................................................................................. 411
13-8 Enclosures ................................................................................................... 412
13-9 Insulation .................................................................................................... 413
13-10 Service Factors for Squirrel-Cage Motors .................................................. 414
13-11 Motor Starting Frequency ........................................................................... 417
13-12 Miscellaneous Motor Features .................................................................... 418
13-13 Specifying Pumping Unit Drivers ............................................................... 420
13-14 Need for Engine-Generators ....................................................................... 421
13-15 Design Checklist ......................................................................................... 421
13-16 References ................................................................................................... 422
14. Engines ....................................................................................................... 423
14-1 Selecting an Engine Drive .......................................................................... 423
14-2 Duty Cycle .................................................................................................. 424
14-3 Fuel for Engines .......................................................................................... 425
14-4 Aspiration .................................................................................................... 428
14-5 Types of Engines ......................................................................................... 428
14-6 Application Criteria .................................................................................... 428
14-7 Starting Methods ......................................................................................... 430
14-8 Cooling Methods ......................................................................................... 430
14-9 Controls ....................................................................................................... 430
14-10 Governors for Engine Control .................................................................... 431
14-11 Accessories for Engines .............................................................................. 431
14-12 Combustion Air ........................................................................................... 432
14-13 Exhaust Silencing ........................................................................................ 435
14-14 Pollution Control ......................................................................................... 435
14-15 Vibration Isolation ...................................................................................... 436
Contents xiii
14-16 Lubrication Oil Storage and Supply ............................................................ 437
14-17 Fuel Oil Storage and Supply ....................................................................... 437
14-18 Gaseous Fuel Storage and Supply ............................................................... 437
14-19 Service Piping ............................................................................................. 437
14-20 Building Envelope ...................................................................................... 438
14-21 Ventilation .................................................................................................. 439
14-22 Maintenance ................................................................................................ 439
15. Variable-Speed Pumping ......................................................................... 443
15-1 Variable Speed versus Constant Speed ....................................................... 444
15-2 Design Considerations ................................................................................ 445
15-3 Theory of Variable-Speed Pumping ........................................................... 446
15-4 Pump Selection ........................................................................................... 450
15-5 Variable- and Constant-Speed Pumps in Simultaneous Operation ............. 454
15-6 Special Design Considerations ................................................................... 457
15-7 Analysis of Variable-Speed Booster Pumping ............................................ 458
15-8 Minimum Discharge Rate ........................................................................... 462
15-9 Operations in Booster Pumping .................................................................. 465
15-10 Simultaneous Operation of V/S and C/S Booster Pumps ........................... 466
15-11 Adjustable-and Variable-Speed Drives ....................................................... 467
15-12 References ................................................................................................... 483
16. Pump-Driver Specifications ..................................................................... 485
16-1 Comparison of Two Approaches to Writing Specifications ....................... 485
16-2 Methods for Specifying Quality of Equipment ........................................... 486
16-3 Nonrestrictive Specifications ...................................................................... 486
16-4 Operating Conditions .................................................................................. 487
16-5 Mass Elastic Systems and Critical Speeds .................................................. 488
16-6 Pump Testing .............................................................................................. 488
16-7 Shipping Major Pumping Units .................................................................. 492
16-8 Submittals ................................................................................................... 492
16-9 Information to Be Provided ........................................................................ 492
16-10 Seals ............................................................................................................ 492
16-11 Pump Shafts ................................................................................................ 493
16-12 Pump Shaft Bearings ................................................................................... 493
16-13 Vertical Drive Shafts ................................................................................... 493