Pumping Station Desing - Second Edition by Robert L. Sanks, George Tchobahoglous, Garr M. Jones
Подождите немного. Документ загружается.
tenance
costs.
Excessive equipment vibration
can
often
be
traced directly
to an
inadequate foundation.
Often,
equipment
manufacturers
are not
fully
aware
of the
need
for the
care required
to
construct
a
proper machine
foundation
and
thus their
own
recommendations
for
equipment supports
are
found
wanting.
API
standard
610
provides
an
excellent specification
for
baseplate construction details. Although
a
rigid baseplate
or
soleplate
is
important,
it
must
be
installed level
and
with
sufficient
care
to
ensure that
it is
fully
supported
by a
long-lasting
grout base.
Key
elements required
to
achieve this objective include:
•
Anchor bolt sleeves
are
filled
with
wax or
similar compounds
to
prevent grout
from
bonding
to the
anchor
bolts.
The wax filling
assures
that
the
full
clamping force required
to
anchor
the
machine
is
transmitted
to the
struc-
tural
foundation
and not to the
grout.
• The
concrete foundation
pad is
roughened
by
chipping
the
concrete
to a
depth
of 50 to
100
mm (2 to 4
in.)
to
reach solid aggregate.
The
baseplate
or
soleplate
is
roughened
by
abrasive blasting. Both concrete
and
base-
plate
are
primed
with
an
epoxy bonding compound prior
to
grouting.
•
Soleplates
or
baseplates
are
leveled
on
shims
and
steel blocks
or
jackscrews (not leveling nuts) against
the
anchor
bolt
nuts
to a
tolerance
of
0.17
mm/m
(0.002
inches/ft) prior
to
grouting.
•
Epoxy grout, poured under
a
head
of not
less
than
150
mm (6
in.)
is
used rather than cementitious grout. Care
is
taken
to
ensure complete contact with baseplate
or
soleplate.
•
Once
the
grout
has
fully
cured
and
reached
its
design strength,
the
leveling devices
are
removed
and the
anchor bolts
are
torqued sequentially
by
increments
to
develop
the
required clamping force
and
ensure com-
plete contact
with
the
grouted foundation.
•
Pockets
left
for the
removal
of
shimming devices
are
filled
with grout
and
pointed.
Although
the
cost
of the
procedures outlined above
is
somewhat greater than that with commonly accepted
practices,
the
results
can be
startling
in
terms
of
reduced vibration
and
lengthened equipment service
life.
One
company
was
able
to
reduce
the
magnitude
of
equipment vibration
by
more than half
by
using these procedures
[3].
Another company credits
the
major
portion
of an
increase
in
mean time between
failures
of 950
percent
(from
6
months
to 57
months)
in
pumping equipment
in
their plant
to
improved equipment support requirements
[4].
In
addition
to
improved equipment support design, owners have
found
that advanced alignment techniques,
using
laser-
and
computer-based equipment, have resulted
in
improved power train alignment. This equipment
is
also capable
of
detecting support imperfections
on
both driving
and
driven machines.
A
study reported
by the
University
of
Tennessee demonstrated that even small amounts
of
misalignment result
in
significant
increases
in
the
loads applied
to
bearings,
shafts
and
seals
[5].
Machine alignment should
be the
responsibility
of
specialists
using
a
variety
of
tools
to
align
all
elements
of the
power train accurately.
1-5.
References
1.
Maintenance Protection Systems, 43317 Moody Dixon Road,
Prairieville,
LA
70769,
or
Thortex
America,
420
Babylon
Road,
Horsham,
PA
19044,
or
Thortex America West,
600
S.E. Maritime Ave.,
Ste.
250, Vancouver,
WA
98661,
or
Mountain
West
Thortex,
6969
N.
16th.,
Coeur d'Alene,
ID
83814.
2.
International Valve Marketing, Inc., P.O.
Box 56,
Plainfield,
IL
60544.
Phone (815)
439-0588;
Web
www.ventomat.com.
3.
Monroe,
PC.
"Pump baseplate installation
and
grouting." Proceedings
of the
Fifth
International Pump Users Symposium,
Turbomachinery
Laboratory, Texas
A & M
University, College Station,
TX, pp
117-128
(1988).
4.
Hrivnak,
SJ.
"In-plant
perspective: Eastman Kodak Company." Pumps
and
Systems (January
2000).
5.
Piotrowski,
J.
"Understanding
and
using
shaft-to-shaft
alignment measurement systems." Pumps
and
Systems (April
1999).
Index terms Links
965
A
Abbreviations 11
for hydraulic transients 140
for instrumentation and controls 629
for piping material 103
of publishers' names 931
for pump hydraulics 242
of standard specifications 69
for structural design 792
for vibration 659
See also Symbols
Accelerometer 652 662
Access
blunders, avoiding 827 828 837
for maintenance 742 757
operators' preferences 745
for safety 742 768
to site 739 804
ACI 350 code 794
Acoustic resonance 679
Acoustic velocity 680
Actuators
blunders 834
symbols 28
valves 107 130
Adapters 74 83
Added mass 657
Adjustable frequency (AF) converters 472 473
Adjustable frequency drives (AFDs)
advantages and disadvantages of 469
compared with C/S drives 444 864
efficiency 473
emergency generators 477
function of 472
harmonics 473 477
966
Index terms Links
Adjustable frequency drives (AFDs) (Continued)
maintenance 477
motors 475
operating costs 474
operational problems 475
pulse excitation control 649
specifications 476
vibration and noise problems 642
Admittance probes 607
Admixtures for concrete 796
Adsorption 713
Advertisements for bids 843
Aerobic conditioning 712
Aesthetics
architectural design 765
and noise 708 765
and odor control 708 765
and wastewater pumping station site selection 497
AF. See Adjustable frequency converter
AFD. See Adjustable frequency drives
Affinity laws 17 250 446
Air, piping for 104
Air and vacuum valves
description 132
precautions 133 154 834 962
for wastewater 133 834 962
for water 133
Air binding 132 341 904
Air bubblers
for fuel level measurement 622
function of 609
operators' preferences 744
and pumping unit control 635
reliability of 604 609
rodding of 610
967
Index terms Links
Air bubblers (Continued)
start-up of 954
Air chambers
blunders, avoiding 830
and column separation 156
and flow reversal 122
operation of 161
in sludge pumping 582
as transient control device 165
with turbine pumps 169
and wastewater service 155
Air compressors
design considerations 790
noise problems 694
operators' preferences 748
Air conditioning
and refrigerated cooling system 735
symbols 27
See also Cooling
Air in piping 42 154 834 904
Air lift pumps 282 313 582 783
Air pressure alarm systems 621
Air release valves
blunders, avoiding 834
and deep well pump start-up 164
description of 133
and empty pipe start-up 159
on sewage force mains 758
as transient control device 162 165
and turbine pump 169
in wastewater systems 133 154 155
in water systems 133 156
Alarms
for booster pumping station 632
design considerations 790
968
Index terms Links
Alarms (Continued)
for high-service pumping stations 633
for large wastewater lift station 639
for moderately sized wastewater lift station 636
operators' preferences 745
for well pump with hydropneumatic tank 631
Albany Combined Sewer Overflow Pumping Station
(CSO PS 88) 819
Alignment, pump 644
Alternating current (ac) 180 183
Altitude
control valves 129 625 632
derating engines for 429
derating gen-sets for 204
derating motors for 961
American Consulting Engineers Council (ACEC) 842
American Institute of Architecture (AIA) 842
American Society of Civil Engineers (ASCE) 842
Amplification factor 657
Anchors 94 799 837
Angle valves 128
Annunciators 626
Anti-rotation baffle 361
Application-engineered equipment 961
Approach pipe 370
active volume in 389
allowable flowrates 372
transition manhole 371 391
Aqueducts 544
Archimedes screw pumps 281 778
Architecture
aesthetics 765 766 767
basic contract forms 842
blunders, avoiding 837
design checklist 938
969
Index terms Links
Architecture (Continued)
superstructure 503
Arredi diagram 50
Asbestos cement (AC) pipe 79 83 90 924
Atmospheric pressure 883
Auxiliary power
checklist 940
operators' preferences 745
Axial-flow pumps 301 303 308
Axial split-case pumps 283 300
Axial thrust 307
B
Backflow prevention 830
Baffle channel in pump intake basin 379
Balancing 643 647
Ball lift check valves 124 596
Ball valves
actuators for 131
closure of 145
description of 111
and water hammer 123
for water service 119
Barrel (can) pumps 306 308
Baseplates 644
Batteries 205 441
Battery charger operation 622
Bearings,
bowl 302
design and function of 289
L-10 life 493 916 962
pump shaft 493
replacing 832
seals 290
support of steady 686
970
Index terms Links
Bearings, (Continued)
temperature monitors 622
for VTSH pump 297
Bellows 612
Bending vibration 675 676 686
Bernoulli equation 34
energy grade line (EGL) 34 141 391 394
specific energy 34 371
Bids
advertisement for 843
bidders 841
bond 843
contract agreement 843
evaluation of 919
form 843
information for bidders 843 913
selection 4 838
standard documents 842
submittal requirements 848 913
Billings raw water intake, see River intakes
Bingham plastic and sludge behavior 575 576 578
Biofilters 712
Biogas 427
Black Diamond Pumping Station 527
Blunders, avoiding
access, inadequate 827 837
common, examples of 921
design review 838 840
economic 838
electrical 836
environmental 828
examples of 838 839
and front-end engineering 761
future expansion 838
hydraulics 829
971
Index terms Links
Blunders, avoiding (Continued)
mechanical 835
O&M manual 840
operations 840
pumps 830
safety 828
site 828
specifications 837
structural 837
valves 833
ventilation 828
written records, failure to keep 827
Booster pumping station design examples 328 819
Booster pumping stations
application 631
comparative advantages 782
construction costs of 856 859
design considerations 328 563 781
design of 328 563
diagram of 633
distribution 561
head-capacity curves 566
hydraulic schematic 569
in-line 560
packaged 571
plan 334 570
pump performance curves 331 333
selecting pumps for 328
V/S operation 465
Bourdon gauges 602 611
Bowl assembly of vertical pumps 302
Budget cost estimates 862
Building materials, STC ratings for 696
Buried pipe
cleanouts 100
972
Index terms Links
Buried pipe (Continued)
design of 98
selection of 78
See Asbestos cement, Ductile iron, Plastic,
Reinforced concrete pressure, or Steel pipe
Butane 426
Butterfly valves
actuator for 131
blunders, avoiding 834
description of 114
headloss coefficient 146
materials 134
as transient control device 166
for water service 110 111
Bypass, and minimum discharge rates in V/S systems 462 464 465
C
Cables
electric 200
for submersible pumps 772 831
Calculations and documentation 496
Can pumps. See Barrel pumps
Capacitance 182 184 607 612
Capacitors 234
Capsule anchors 94
Catalytic detectors 620
Cathodic protection 82
Caustic 712
Cavitation
as cause of vibration 656
constant 260
effects of 255 835
at the operating point 262
prevention and control of 260
and pump operating range 266
973
Index terms Links
Cavitation (Continued)
See also Net positive suction head (NPSH)
Cement 795
Cement-mortar linings 41 75 896
thicknesses 75
Center-post guided check valves 124
Centrifugal pumps
categories of 282
characteristic curves 263 264 326 333
classification of 241
construction of 283
energy transfer in 248
flow, head, and power coefficients 249 250
Lomakin effect in 648
multistage 312 313
pipe vibration with 678
radial thrust 265
selection of 646
See Pump selection
for sludge pumping 581 582 585
specifications for, typical 907
submersible 282 285
See also Submersible pumps
vibration isolation 672 673
vibration problems with 656 662
volute 279
Cerami-Tech and Cerami-Flex 962
Change orders 7 844
Checklist
for civil design 937
for cross connections 939
design, for ease of maintenance 741
for electrical design 938
for future expansion 769
for instrumentation and control 939