Pumping Station Desing - Second Edition by Robert L. Sanks, George Tchobahoglous, Garr M. Jones
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xiv Contents
16-14 Electric Motors ........................................................................................... 493
16-15 Optimum Efficiency .................................................................................... 493
16-16 References ................................................................................................... 494
17. System Design for Wastewater Pumping ................................................ 495
17-1 Organization and Control of the Process .................................................... 495
17-2 Preliminary Engineering ............................................................................. 496
17-3 Detailed Layout ........................................................................................... 499
17-4 Detailed Design ........................................................................................... 503
17-5 Examples of Large Lift Stations ................................................................. 504
17-6 Examples of Medium-Size Lift Stations ..................................................... 514
17-7 Examples of Small Lift Stations ................................................................. 522
17-8 References ................................................................................................... 528
18. System Design for Water Pumping ......................................................... 529
18-1 Types of Water Pumping Stations .............................................................. 529
18-2 Pumping Station Flow and Pressure Requirements .................................... 529
18-3 Raw Water Pumping from Rivers and Lakes .............................................. 533
18-4 Raw Water Pumping from Aqueducts ........................................................ 544
18-5 Well Pumps with Elevated Tanks ............................................................... 551
18-6 Booster Pumping Stations ........................................................................... 560
18-7 References ................................................................................................... 571
18-8 Suggested Reading ...................................................................................... 571
19. System Design for Sludge Pumping ........................................................ 573
19-1 Hydraulic Design ........................................................................................ 574
19-2 Types of Pumps .......................................................................................... 581
19-3 Pumping System Design ............................................................................. 585
19-4 Piping System Design ................................................................................. 595
19-5 Long-Distance Pumping ............................................................................. 599
19-6 References ................................................................................................... 599
20. Instrumentation and Control Devices ..................................................... 601
20-1 Reliability .................................................................................................... 601
20-2 Instrument Selection ................................................................................... 602
20-3 Level Measurements ................................................................................... 605
20-4 Pressure Measurements ............................................................................... 610
20-5 Flow Measurements in Pipes ...................................................................... 612
Contents xv
20-6 Open Channel Flow Measurement .............................................................. 618
20-7 Chlorine Residual Measurement ................................................................. 619
20-8 Utility and Environmental Measurements .................................................. 620
20-9 Pumping Unit Monitors .............................................................................. 622
20-10 Control Equipment ...................................................................................... 623
20-11 Control Logic .............................................................................................. 624
20-12 Altitude Valves ........................................................................................... 625
20-13 Monitoring and Data Acquisition ............................................................... 626
20-14 Design Considerations ................................................................................ 627
20-15 References ................................................................................................... 628
20-16 Supplementary Reading .............................................................................. 628
21. Instrumentation and Control Applications ............................................ 629
21-1 Process and Instrumentation Diagrams ....................................................... 629
21-2 Well Pump with Hydropneumatic Tank ..................................................... 630
21-3 Booster Stations .......................................................................................... 631
21-4 High-Service Pumping Station ................................................................... 632
21-5 Small Wastewater Lift Station .................................................................... 633
21-6 Moderately Sized Lift Station ..................................................................... 635
21-7 Large Wastewater Pumping Station ............................................................ 636
22. Vibration and Noise .................................................................................. 641
22-1 Problems of Vibration and Noise ................................................................ 641
22-2 Avoiding Vibration Problems ..................................................................... 643
22-3 Troubleshooting Excessive Vibration ......................................................... 650
22-4 Introduction to Vibration and Noise Calculations ...................................... 659
22-5 Vibration and Noise Characteristics ........................................................... 662
22-6 Applicable Codes ........................................................................................ 665
22-7 Equipment Vibration ................................................................................... 669
22-8 Vibration Isolation Theory .......................................................................... 669
22-9 Vibration Isolators ...................................................................................... 672
22-10 Piping Vibration .......................................................................................... 675
22-11 Vibration of Drive Shafts ............................................................................ 685
22-12 Vibration of Structures ................................................................................ 689
22-13 Noise ........................................................................................................... 691
22-14 Reducing Exterior Noise ............................................................................. 701
xvi Contents
22-15 References ................................................................................................... 703
23. Heating, Ventilating, and Cooling ........................................................... 705
23-1 Need for Heating, Ventilating, and Air Conditioning ................................. 705
23-2 HVAC Design Criteria ................................................................................ 708
23-3 Odor Control ............................................................................................... 710
23-4 Dry Well Design Guidelines ....................................................................... 714
23-5 Energy Use and Conservation ..................................................................... 716
23-6 Corrosion Protection ................................................................................... 718
23-7 Sequence of Design Steps ........................................................................... 718
23-8 Ventilating System Design ......................................................................... 720
23-9 Design of Heating Systems ......................................................................... 728
23-10 Design of Building Cooling Systems .......................................................... 732
23-11 Design of Refrigerated Cooling Systems .................................................... 734
23-12 References ................................................................................................... 737
23-13 Supplementary Reading .............................................................................. 737
24. Designing for Easy Operation and Maintenance ................................... 739
24-1 Site Selection .............................................................................................. 739
24-2 Landscaping ................................................................................................ 739
24-3 Hydraulics ................................................................................................... 740
24-4 Mechanical Considerations ......................................................................... 741
24-5 Electrical Considerations ............................................................................ 742
24-6 Architectural Considerations ...................................................................... 743
24-7 Standby Facilities ........................................................................................ 743
24-8 Specifications .............................................................................................. 743
24-9 Operators' Preferences ................................................................................ 744
24-10 Survey of Two Thousand Wastewater Pumping Stations ........................... 752
24-11 References ................................................................................................... 760
25. Summary of Design Considerations ........................................................ 761
25-1 Need for Pumping Stations ......................................................................... 762
25-2 Site Selection .............................................................................................. 763
25-3 Architectural and Environmental Considerations ....................................... 765
25-4 Future Expansion ........................................................................................ 769
25-5 Hydraulic Constraints ................................................................................. 770
25-6 Types of Pumping Stations ......................................................................... 771
Contents xvii
25-7 Power, Drivers, and Standby ...................................................................... 782
25-8 Station Auxiliaries ...................................................................................... 788
25-9 Instruments and Control .............................................................................. 791
25-10 Structural Design ........................................................................................ 792
25-11 Concrete Protection: Coatings and Linings ................................................ 800
25-12 Force Main Design ...................................................................................... 801
25-13 References ................................................................................................... 802
26. Pumping Station Design Examples ......................................................... 803
26-1 Redesigned Clyde Wastewater Pumping Station ........................................ 804
26-2 Redesigned Kirkland Wastewater Pumping Station ................................... 810
26-3 Jameson Canyon Raw Water Pumping Station ........................................... 816
26-4 Albany Combined Sewer Overflow Pumping Station (CSO PS 88) .......... 819
26-5 References ................................................................................................... 823
27. Avoiding Blunders .................................................................................... 827
27-1 General ........................................................................................................ 827
27-2 Site .............................................................................................................. 828
27-3 Environmental ............................................................................................. 828
27-4 Safety .......................................................................................................... 828
27-5 Hydraulics ................................................................................................... 829
27-6 Pumps .......................................................................................................... 830
27-7 Valves ......................................................................................................... 833
27-8 Mechanical .................................................................................................. 835
27-9 Electrical ..................................................................................................... 836
27-10 Structural-Architectural .............................................................................. 837
27-11 Specifications .............................................................................................. 837
27-12 Economics ................................................................................................... 838
27-13 The Future and Remodeling ........................................................................ 838
27-14 Illustrative Examples .................................................................................. 838
27-15 Design Reviews .......................................................................................... 838
27-16 Operations ................................................................................................... 840
27-17 References ................................................................................................... 840
28. Contract Documents ................................................................................. 841
28-1 General ........................................................................................................ 841
28-2 Contractual or Legal Documents ................................................................ 842
xviii Contents
28-3 Technical Specifications ............................................................................. 844
28-4 Source Material ........................................................................................... 845
28-5 Specifying Quality ...................................................................................... 847
28-6 Submittal Requirements .............................................................................. 848
28-7 References ................................................................................................... 848
29. Costs ........................................................................................................... 851
29-1 Cost Indexes ................................................................................................ 851
29-2 Cost Curves ................................................................................................. 853
29-3 Maintenance and Energy ............................................................................. 857
29-4 Interest Formulas ........................................................................................ 860
29-5 Cost Estimates ............................................................................................. 862
29-6 References ................................................................................................... 877
Appendix A. Physical Data ............................................................................ 879
Table A-1 Base SI Units ..................................................................................... 879
Table A-2 Derived SI Units and Physical Quantities .......................................... 880
Table A-3 Physical Constants ............................................................................. 881
Table A-4 SI Prefixes .......................................................................................... 881
Table A-5 Conversion Factors ............................................................................ 881
Table A-6 Atmospheric Pressure (SI Units) ....................................................... 883
Table A-7 Atmospheric Pressure (U.S. Customary Units) ................................. 883
Table A-8 Physical Properties of Water (SI Units) ............................................. 884
Table A-9 Physical Properties of Water (U.S. Customary Units) ....................... 884
Table A-10 Physical Properties of Pipe Materials ................................................ 885
Table A-11 Equivalent Weights and Measures ..................................................... 885
A-1 References ......................................................................................... 887
Appendix B. Data for Flow in Pipes, Fittings, and Valves .......................... 889
Table B-1 Mortar-lined Class 53 Ductile Iron Pipe (SI Units) ........................... 890
Table B-2 Mortar-lined Class 53 Ductile Iron Pipe (U.S. Customary
Units) ................................................................................................. 890
Table B-3 Standard Weight Steel Pipe (SI Units) .............................................. 892
Table B-4 Standard Weight Steel Pipe (U.S. Customary Units) ........................ 894
Table B-5 Probable Coefficients of Pipe Friction for Design ............................. 896
Fig. B-1 Moody Diagram for Determining ѓ in the Darcy-Weisbach
Formula .............................................................................................. 897
Contents xix
Table B-6 Recommended Energy Loss Coefficients, K, for Flanged Pipe
Fittings ............................................................................................... 898
Table B-7 Recommended Energy Loss Coefficients, K, for Valves Fully
Open ................................................................................................... 899
Fig. B-2 Headlosses for Mueller Swing Check Valves with Spring-
loaded Levers ..................................................................................... 900
Fig. B-3 Headlosses for Mueller Swing Check Valves with
Counterweighted Levers .................................................................... 900
Fig. B-4 Geometric Properties of Partly Full Pipes ......................................... 901
Fig. B-5 Hydraulic Elements of Circular Pipes as Open Channels .................. 902
Table B-8 Comparison of Computed Values of Velocity, Depth, Area, and
Flow in Open Channels ..................................................................... 903
Table B-9 Velocities Required to Scour Air Pockets from Pipelines ................. 904
B-1 References ......................................................................................... 905
B-2 Supplementary Reading ..................................................................... 905
Appendix C. Typical Specifications for Pumps and Drivers ...................... 907
Appendix D. Common Blunders .................................................................... 921
D-1 Figure 27-1 .................................................................................................. 921
D-2 Figure 27-2 .................................................................................................. 921
D-3 References ................................................................................................... 922
Appendix E. Codes, Specifications, and Standards ..................................... 923
Appendix F. Publishers .................................................................................. 931
F-1 Abbreviations .............................................................................................. 931
F-2 Addresses of Publishers .............................................................................. 932
F-3 Reference .................................................................................................... 936
Appendix G. Checklist for Project Reviews ................................................. 937
G-1 Civil Design Checklist ................................................................................ 937
G-2 Structural/Geotechnical/Architectural Design Checklist ............................ 938
G-3 Electrical Design Checklist ......................................................................... 938
G-4 Instrumentation and Control Checklist ....................................................... 939
G-5 Cross-Connection Control .......................................................................... 939
G-6 Mechanical Design Checklist ..................................................................... 940
G-7 References ................................................................................................... 942
Appendix H. Start-Up ..................................................................................... 943
H-1 Pre-Visit Check ........................................................................................... 944
xx Contents
H-2 Pre-Start-Up Check ..................................................................................... 944
H-3 Electrical Systems ....................................................................................... 946
H-4 Simplified Operational Checks for Small Stations ..................................... 950
H-5 Well Pumps ................................................................................................. 951
H-6 Chlorination ................................................................................................ 953
H-7 Complex Drives .......................................................................................... 953
H-8 Control Panel and Electrical Systems ......................................................... 953
H-9 Bubbler Systems ......................................................................................... 954
H-10 Vacuum Priming Systems ........................................................................... 954
H-11 Compressed Air Systems ............................................................................ 956
H-12 Hydropneumatic Tank Systems .................................................................. 957
H-13 Main Pumps, Final Pre-Start-Up Checks .................................................... 958
H-14 Wet Well and Testing of Main Pumps ........................................................ 958
H-15 Cleaning Wet Wells .................................................................................... 959
H-16 References ................................................................................................... 960
Appendix I. Addenda ...................................................................................... 961
I-1 Fire Safety in Pumping Stations ................................................................. 961
I-2 Application-Engineered Equipment ............................................................ 961
I-3 Air-Vacuum Valves for Wastewater Service .............................................. 962
I-4 Machine Foundations and Installation ........................................................ 962
I-5 References ................................................................................................... 963
Index ................................................................................................................. 965
xv
List of Examples
3-1 Designing Pipe with the Pipe Tables ................................................................... 41
3-2 Design of a Sewer Pipe ........................................................................................ 44
3-3 Venturi Meter in a Pipe ....................................................................................... 46
3-4 Venturi Flume in a Channel ................................................................................. 49
3-5 Unbalanced Forces on a Wye .............................................................................. 51
4-1 Design of Tie Rods for a Sleeve Pipe Coupling .................................................. 92
4-2 Hanger Rod Sizing and Spacing .......................................................................... 97
5-1 Energy Penalties for Three Valves ...................................................................... 109
6-1 Effect of Pipe on Wave Speed and Pressure ........................................................ 144
6-2 Seating a Valve .................................................................................................... 147
7-1 Determination of Minimum Pipe Wall Thickness ............................................... 171
9-1 Electrical Load Estimation .................................................................................. 224
9-2 Branch Circuit Calculations for Pump Motors .................................................... 227
9-3 Branch Circuit Calculations for Sump Pump ...................................................... 228
9-4 Lighting and Small Power Transformers ............................................................. 230
9-5 Heating and Ventilating Electrical Equipment .................................................... 230
9-6 Service Circuit Transformer, Protection, and Conductors ................................... 231
9-7 Lighting a Small Pumping Station ....................................................................... 233
9-8 Power Factor Relationship ................................................................................... 234
9-9 Capacitor Sizing .................................................................................................. 234
9-10 Size of the Engine-Generator Set ........................................................................ 236
10-1 Evaluation of Pump Performance ........................................................................ 246
10-2 Application of Affinity Laws .............................................................................. 250
10-3 Effect of Changes in Impeller Diameter and Speed ............................................ 253
10-4 Use of Specific Speed in Pump Selection ............................................................ 255
10-5 Calculation of Net Positive Suction Head Available (NPSH
A
) ........................... 259
10-6 Determination of NPSH
i
and NPSH
A
.................................................................. 261
10-7 Estimating the Size of the Pump Required .......................................................... 263
10-8 Application of a Variable-Speed Pump ............................................................... 269
12-1 Sump Pumping System ........................................................................................ 322
12-2 Selecting Pumps for a Water Booster Pumping Station ...................................... 328
12-3 Design of Typical Pumping Station Wet Well for C/S Wastewater Pumps ........ 375
xvi List of Examples
12-4 Design of a Trench-Type Wet Well for V/S Wastewater Pumps ........................ 381
12-5 Design of a Trench-Type Wet Well for C/S Wastewater Pumps ........................ 387
13-1 Motors for a Sewage Lift Station ........................................................................ 415
17-1 Duwamish Pumping Station ................................................................................ 505
17-2 Interbay Pumping Station .................................................................................... 508
17-3 West Point Influent Pumping Station .................................................................. 510
17-4 Kirkland Pumping Station ................................................................................... 514
17-5 North Mercer Island Pumping Station ................................................................. 517
17-6 Sunset Pumping Station ....................................................................................... 520
17-7 Vallby Pumping Station ....................................................................................... 523
17-8 Clyde Pumping Station ........................................................................................ 525
17-9 Black Diamond Pumping Station ........................................................................ 527
18-1 Flow Requirements in a Small Town .................................................................. 530
18-2 Raw Water River Intakes and Pumping Stations ................................................. 538
18-3 Raw Water Pumping from an Aqueduct .............................................................. 544
18-4 Design of a Deep Well Pumping Station ............................................................. 553
18-5 Small Distribution System Booster without Reservoir ........................................ 563
19-1 Design of a Vortex Pump System for Sludge ...................................................... 587
19-2 Design of a Plunger Pump Installation ................................................................ 594
22-1 Vibration Isolation of a Centrifugal Pump .......................................................... 673
22-2 Pipe Vibration with a Variable-Speed Centrifugal Pump .................................... 678
22-3 Dynamic Pressure from a Plunger Pump ............................................................. 684
22-4 Torsional Vibration in a Shaft ............................................................................. 688
22-5 Vibration of a Floor ............................................................................................. 690
22-6 Reducing the Sound Level at a Pumping Station ................................................ 698
22-7 Reducing Exterior Noise from a Pumping Station .............................................. 702
23-1 Design of a Ventilating System ........................................................................... 722
23-2 Design of a Heating System ................................................................................ 729
23-3 Design of an Evaporative Cooling System .......................................................... 733
23-4 Design of a Refrigerated Cooling System ........................................................... 736
26-1 Redesigned Clyde Wastewater Pumping Station ................................................ 804
26-2 Redesigned Kirkland Wastewater Pumping Station ............................................ 810
26-3 Jameson Canyon Raw Water Pumping Station ................................................... 816
26-4 Albany Combined Sewer Overflow Pumping Station (CSO PS 88) ................... 819
29-1 Life-Cycle Cost Comparison of Three Alternative Wastewater Pumping
Stations ................................................................................................................ 864
xvii
Locator for Equations, Figures, and Tables
Equations
No. Page No. Page No. Page No. Page No. Page No. Page
3-1 33 3-32 64 9-3 234 12-5 374 22-4 664 22-35 696
3-2 34 4-1 93 10-1 244 12-6 374 22-5 666 22-36 696
3-3 34 4-2 94 10-2 244 12-7 374 22-6 670 22-37 697
3-4 34 4-3 94 10-3 244 12-8 374 22-7 670 22-38 697
3-5 35 4-4 97 10-4 244 12-9 374 22-8 670 23-1 715
3-6 35 4-5 97 10-5 245 12-10 374 22-9 670 23-2 719
3-7 35 4-6 97 10-6 245 12-11 374 22-10 671 23-3 720
3-8 36 5-1 112 10-7 245 12-12 374 22-11 676 23-4 721
3-9 36 5-2 112 10-8 248 12-13 374 22-12 677 23-5 726
3-10 37 6-1 143 10-9 248 13-1 410 22-13 677 23-6 730
3-11 37 6-2 143 10-10 249 14-1 429 22-14 680 23-7 730
3-12 37 6-3 143 10-11 249 14-2 429 22-15 680 23-8 730
3-13 37 6-4 144 10-12 249 14-3 430 22-16 680 23-9 731
3-14 38 6-5 145 10-13 249 15-1 448 22-17 680 25-1 792
3-15 43 7-1 162 10-14 249 15-2 457 22-18 681 29-1 853
3-16 43 7-2 170 10-15 250 15-3 457 22-19 683 29-2 860
3-17 44 7-3 171 10-16 250 15-4 478 22-20 683 29-3 860
3-18 44 7-4 171 10-17 250 15-5 478 22-21 683 29-4 860
3-19 44 8-1 181 10-18 252 15-6 482 22-22 685 29-5 861
3-20 45 8-2 181 10-19 253 18-1 530 22-23 687 29-6 861
3-21 48 8-3 184 10-20 253 18-2 567 22-24 687 29-7 861
3-22 48 8-4 185 10-21 253 19-1 575 22-25 688 29-8 861
3-23 54 8-5 185 10-22 254 19-2 576 22-26 688 29-9 861
3-24 54 8-6 185 10-23 258 19-3 577 22-27 689 29-10 862
3-25 54 8-7 186 10-24 260 19-4 578 22-28 690 29-11 862
3-26 58 8-8 186 10-25 261 19-5 578 22-29 691 B-1 901
3-27 60 8-9 187 10-26 262 19-6 579 22-30 692 H-1 957
3-28 61 8-10 187 12-1 352 20-1 616 22-31 692
3-29 61 8-11 187 12-2 363 22-1 662 22-32 695
3-30 61 9-1 232 12-3 370 22-2 663 22-33 695
3-31 62 9-2 232 12-4 372 22-3 664 22-34 695