Professional Documents
Culture Documents
Chapter 16 Design of Pumping Stations
Chapter 16 Design of Pumping Stations
J. Kepenyes
Fish Culture Research Institute
Szarvas, Hungary
A pressure intensifier device inserted into the water supply system compensates for lack of
pressure, which can be done by:
- discharge air chamber (Figure 7 b)
- revolution control of the pumps (Figure 7 a).
2. PUMP WELL
Obstacles to the operation of the pump should be removed, such as branches, sand, pebbles, etc.
The pump well for the inlet pipe should be furnished with a grid of 20 mm mesh in case of
smaller pumps, and with a grid of 20-50 mm mesh in case of pumps with capacity higher than 1
000 l/sec. The inlet pipe of smaller pumps can be furnished with an inlet rose head for protection.
The size of the pump well should be ten times the water discharge/min. A pump well of bigger
size may promote swirling of water.
The difference between the lowest possible water level in the pump well and the inlet part of the
suction pipe, can be calculated as follows:
(m)
where
v = is velocity of water in the suction pipe (m/s)
g = 9.81 m/sec2 gravitational acceleration.
Generally
h = 0.5 dt (m)
where
dt is the maximum diameter of the bell mouth entry but at least h = 0.3 m.
Figure 1. Pump houses
Pumps or suction pipes with a vertical shaft should not be arranged in series, since swirling of
water at the first bell mouth entry may disturb the function of the others, An arrangement, where
the water flows perpendicular to the centre line of the bell mouth entry is more favourable. The
centre line of the bell mouth entry should be fairly close to the opposite wall of the inlet chamber
(the optimal distance is 0.75 dt). Examples for optimal arrangement of pump wells are shown in
Figures 5 and 6.
In cases of pumps with large delivery a guide cone should be inserted under the bell mouth entry
on the bottom of the pump well so as to control the water stream. Thus the distance between the
bell mouth entry and the bottom of the pump well is 0.8 to 1.0 dt (which is 0.35 to 0.5 dt without
the guide cone).
3. SETTING OF PUMPS
There are three ways of setting, considering the type of pump and the inlet chamber.
(a) Pumps of vertical shaft sunk in the water of the pump well;
(b) pumps with vertical or horizontal shafts set in a dry chamber located beside the pump well;
(c) pump of generally horizontal shaft located above the water level.
Within the arrangement mentioned in (a) three further cases are possible:
- Pump is under water and the driving motor is above the water level
In this case the electric motor is directly joined to the vertical shaft of the pump and is located in
a water-free, dry place. The advantage of this solution is the relatively small space-requirement
(there is no suction pipe and foot valve) and the easy start and operation (priming is not needed
because air can not penetrate into the suction pipe). Its shortcomings are, especially in case of a
large level difference between the motor and the pump, the difficulties in fitting the bearings in
the vertical shaft, loss in efficiency (due to the several guide bearings), increased corrosion, and
difficulty of checking, maintenance and repair (the pump should be drained first). This setting is
illustrated in Figure 1. In cases of small delivery sometimes flexible shaft-driven pumps can be
used.
- Driving motor and main pump are above the water and the first stage under the water level
By applying a first stage submerged part, the pump gets inflow water. No priming is necessary
before starting. The level of water delivery is controlled by the upper part, thus the pump in fact,
has a double stage made up of a low-pressure (.submerged stage) and a higher-pressure stage.
This solution partly eliminates the above-mentioned shortcomings, by having several advantages
(power take-off shaft with lower capacity, main part of the pump is easy to maintain).
This solution is applied mostly to pumps of high pressure.
- Pump and driving motor under the water level
To these belong the submerged and deep-well pumps. Characteristic settings of these types of
pumps are shown in Figure 4, where a submerged pump is set in a driven well, and in Figure 3,
where a lifting submerged pump of high delivery is illustrated.
Installing and setting expenses of a pump placed separately in a dry chamber (cf. (b)) are high.
Its mechanical construction, operation and maintenance, however, are more economical. The
advantage of this arrangement is that no priming or foot valve is necessary. For automatic
operation this is the most suitable solution.
Figure 5. Arrangements of pump wells
Pumps working above the inlet level (cf. also (c) above) are of mostly horizontal arrangement,
with lower building and installation cost. Its disadvantage, beside suction difficulties (e.g.
leakage, air - or gas development - caused water break, vacuum, cavitation), is that foot-valve
and priming is necessary before starting - and all the extra costs coming from these difficulties,
and in automatic starting. There are many pumps of this type working well with a suction head of
5-7 m, nevertheless, suction head higher than 3-4 m should be avoided.
There is an in-between solution, a temporary set pump station, where the structural parts (tubes,
mountings) are built, and the driving motor and pump are mobile.
Pump units
Total
number
for
reserve
50
33
25
33
29
25
22.5
10
20
6. CALCULATION OF HEAD
6.1 Entrance Loss:
6.2 Resistance of Suction Screen
6.3 Resistance of Foot Valve
6.4 Pressure Loss Coming from Pipe Friction (h3)
6.5 Valves Built in the Pipeline (Gate Valve, Check Valve, etc.)
6.6 Pressure Loss from Inversion (h7)
To determine the total head of a pump, the geodetic level difference between the inlet-side and
delivery-side water levels and the pressure affecting them (e.g. in a discharge air chamber)
should be known as well as the various hydraulic losses during lifting.
(m)
where
H = total head (m)
hg = geodetic lifting level (m)
h0 = entrance loss (m)
h1 = resistance of the filter (m)
h2 = resistance of the foot valve (m)
where
v = velocity of water on entering the inlet of the pump (m/sec)
0 = value in case of not rounded inlet part: 0.8 - 1.0; in case of properly rounded inlet 0.04, i.e.
the entrance loss is practically equal to the value which is necessary to accelerate the water.
where
1 = value depends on the suction screen; according to preliminary calculation can be 2-3.
In case of a suction screen of proper size and shape with free surface this loss can be markedly
reduced.
(m)
which is equal to the specific valve-loading, and the loss-factor is gradually decreasing along
with the increasing velocity if the valve is automatic
if v = 1
1.7
0.77
0.43
then
2 = 6.9
If
where
= pipe friction constant
l = length of the pipe-line (m)
v = water velocity in the pipe (m/s)
d = inner diameter (m)
= kinematic viscosity (m3/sec) as a function of water temperature.
It is 1.3 . 106 at 10C and 1 . 106 at 20C
Pipe friction constant according to the latest research data should be calculated with
consideration of Re and wall roughness of pipe. The International Congress on Water Supply held
in Paris in 1952 accepted the formula of Colebrook for calculating the pipe-friction constant.
Which is
where
k= the absolute roughness of the pipe which can be selected from Table 2.
Values of pressure loss by pipe friction are determined with approximate equations, nomograms
or tables. Figure 9 shows the resistance values in cases of steel and polyethylene pipes, while in
Table 3 different approximate equations are collected.
Figure 9. Pipe flow diagrams
Table 2 Absolute values of pipe friction
Type of pipe
k absolute
roughness (mm)
0 (glazed)
- 0.0015
0.01-0.05
new
0.05-0.1
corroded
0.1 -0.2
heavily corroded
up to 3.0
new
0.02-0.12
new
0 - 0.1
0 - 0.15
0.2-0.3 or
0.2-0.3 or above
where the length of diffusor piece is at least six times the difference in diameters
4 = 0.15 - 0.24
v = the velocity value of the smaller cross-section
If the increase in cross-section is very sudden, i.e. Bordas's loss:
(m)
where
4 = 1.2 - 1.3
v1 and v2 are the velocity values belonging to the larger and smaller cross-sections, respectively.
In case of a reduction in cross-section (confusor) the pressure loss is:
(m)
where
5 = 0.02 - 0.05
v = the velocity measured at the narrowest section.
6.5 Valves Built in the Pipeline (Gate Valve, Check Valve, etc.)
(m)
the value of 6, for a gate valve depends on A/A0 where A is the whole, and A0 is the gate-valve
reduced cross section of the pipe.
If A/A0 =
1.05
1.1
1.4
1.8
2.5
3.0
5.0
7.0
10.0
0.1
0.21
1.15
4.0
9.7
15.0
42.0
72.0
121.0
then
6=
If a flap valve or regulating flap is used, 6, values depending on the construction o installation of
the flap valve or regulating flap are 1.0-10.0, where the higher values correspond to pipe
diameter of 80-300 mm and the lower ones to the diameter of 400 mm or more. As an average, a
value of 2-3 can be approximated, but the exact number can be give experimentally only.
For the 6 value of a butterfly valve, denoting the angle between the plate of the valve and the
axis of the pipe
If CT =
then
10
20
30
40
45
50
60
65
70
6=
0.1
0.52
1.54
3.91
10.8
18.7
32.6
118
256
750
where
7 depends on the relation of pipe diameter and radius r of the pipe bend midline, and on the
central angle of the bent pipe, that is the degree of inversion.
Using a standard bend of 90 (r = d mm + 100 mm) 7 = 0.2 if the angle of bending is
= 22
45
60
90
0.075
0.09
0.10
then
7 = 0.045
where
7 = 0.7 - 1
s = the vectoral difference between the velocity values before (v1) and after (v2) the breaking
point.
Practically speaking v1 = v2 = v, that is the cross-section of the pipe is constant, thus there is no
change in the velocity.
If = 22
30
45
60
90
0.5 v
0.75 v
1.41 v
then
s = 0.37 v
Steel
New cast-iron
Concrete
Fault
10%
0.094
10...13 %
0.053
- 0.2
- 0.08
0.0156 ha k = 0.4
- 0.2
Limit of application
- 0.055 - 0.14
Re < 106 e
0.0180 ha k = 0.7
0.218 ha k = 1.5
0.29 ha k = 4.0
Asbestos-cement
0.22
- 0.21
Due to the incidental cavitation, the total suction head (H) is very important, and can be
calculated with the following formula:
(m)
where
hsman = pressure measured in the suction piece of the pump with manometer (m)
P0 = atmospheric pressure (Pa)
v = velocity in the suction pipe (m/sec)
The static pressure (head) of the delivered water significantly changes while passing through the
pump from the inlet to the outlet. The minimum overpressure is around the entrance of the
impeller. Steam bubbles arise here, if the pressure of the delivered water decreases below the
pressure value of saturated steam with the same temperature (cf. Table 4). In the course of energy
conversion in the pump, the pressure increases again along the stream when the water is passing
through the pump and when it exceeds the pressure of the steam the bubbles are crushed
(cavitation) thus starting to destruct the impeller mechanically. To prevent cavitation at the inlet
of the pump the minimum inflow pressure should be maintained.
Each pump has a minimum suction head value, at which it can still work. This value is always
smaller than the atmospheric pressure value expressed in pressure head of the liquid to be
delivered. This value is known in the Anglo-American literature as the necessary "net positive
suction head" - that is the NPSH of a pump.
This value can be considered as a loss factor and must be always subtracted from the theoretical
suction head. Manufacturing companies always indicate these values for different deliveries and
revolutions, since along with the increase of delivery these values increase as well. To apply
properly these values, the NPSHa value of the pump under the actual conditions should be
calculated with the following formula:
(m)
where
hs geod = geodetic suction head (m)
hs = head loss on the inlet side (m)
Pd = steam pressure of the liquid (Pa)
Checking of NPSH of a working system should be performed as follows:
(NPSH)a = Hs - Pd
(m)
In the case of delivery pipes in the pump house, a velocity of 2 m/sec is the most economic.
Connection to an external pipeline of bigger cross-section should be done outside of the pump
house. Velocity higher than 2 m/sec is admissible for temporary fluctuations of water amount
only, and for as short time as possible.
In ease of marked fluctuation of the water amount, two delivery pipes should be applied, which
besides ensuring an even velocity, results in a safer operation. In this case all the pumps should
be attached to a common collecting main to both ends of which delivery pipes are connected.
With the help of a gate valve in the middle of the collecting main, the two delivery pipes and the
pump units can be operated separately.
A suitable gate valve or other cut off device should be inserted in the delivery pipe of each pump
possibly close to the outlet of the pump or in case of an inflow system before the inlet of the
pump as well, in order to cut off the pump. To prevent reflux of water in the delivery pipe, in
case of a sudden stop of the pump, especially if several pumps are operated on a common
delivery pipe, a flap valve or regulating flap should be inserted between the pump and the gate
valve on the delivery side.
Pipes in the pump house should be made of flange joint cast iron or welded steel. Use of flanges
meaning extra cost and source of operational faults should be restricted to connections to pumps
and pipe fitting.
To render dewatering of the common delivery pipe possible, a gate valve regulated branch pipe
should be inserted at the deepest part of the common delivery pipe depending upon its size and
the quantity of the water to be drained.
8. VALVES
To cut off the pipeline as well as to control the amount of water passing through different valves
such as gate valves, ring valves or flap/butterfly valves are applied. They are manually operated.
If the gate valve is bigger than 800 mm and fast and frequent operation is expected, or automatic
or distant-control is needed, the device can be run by hydraulic or electric control.
In case of distant operation, a jam proof wedge gate valve should be applied or a parallel slide
valve, cup valve or flap valve. If the space is limited, a butterfly valve or flap valve can be used
with manual, electric or hydraulic operation. To ensure smooth operation and safety shut off of
pipelines with high pressure and cross-section of 400 mm or more ring or cup valves can be
inserted.
If the pump stops, efflux can be prevented with a flap valve, or regulating flap. Automatic
butterfly valves or a ring valve cause less pressure loss or resistance than flap valve does.
With intake pipes of pools and wells, with a pressure of 0-2 m water column, a catch mounted on
the end of the tube should be applied, with automatic cut off.
To take unilateral pressure or to cut off intake pipes of wells, sluices moving between the walls
of the well or sliding sluice-valves are used. They are operated with spindle-drive up to 3-4 m
water pressure. At higher water pressure, diameter rack-drive or sliding sluices, or sluice valves
provide the best solution. The sluices are generally controlled manually. Electric or hydraulic
drive is only occasionally used (e.g. at very quick cut off, or open, in case of automatic
operation).
9. PUMPS
9.1 Choice of the Proper Type of Pump
9.2 Control of Delivering Capacity
10.1 Priming
For centrifugal pumps, where the suction level is under the pump, i.e. there is no inflow, and a
foot valve cannot be used because of the high delivering capacity or other reasons, priming is
necessary before starting. For priming, electric motor driven watering vacuum pumps are the
most suitable. With the pumps of smaller stations, starter tanks, or extra-resistance forming, selfpriming pumps are applied.
10.2 Cranes
To make installation and mounting easier, above the machines in the pump house of smaller
stations a crane with suspended pulley block should be mounted above the pumps. In pump
stations of several pumps of high capacity an overhead electric traveller should be installed.
Table 4
Temperature of water
Steam pressure
Density of water
t
C
T
K
Pd
bar
kg/dm3
273.15
0.006107
0.9998
274.15
0.006566
0.9999
275.15
0.007056
0.9999
276.15
0.007577
1.0000
277.15
0.008131
1.0000
278.15
0.008722
1.0000
279.15
0.009349
0.9999
280.15
0.010016
0.9999
281.15
0.010725
0.9998
282.15
0.011477
0.9997
10
283.15
0.012275
0.9996
11
284.15
0.013122
0.9995
12
285.15
0.014020
0.9994
13
286.15
0.014971
0.9993
14
287.15
0.015979
0.9992
15
288.15
0.017045
0.9990
16
289.15
0.018174
0.9988
17
290.15
0.019367
0.9987
18
291.15
0.02063
0.9985
19
292.15
0.02196
0.9984
20
293.15
0.02337
0.9982
21
294.15
0.02486
0.9979
22
295.15
0.02643
0.9977
23
296.15
0.02808
0.9975
24
297.15
0.02982
0.9972
25
298.15
0.03166
0.9970
26
299.15
0.03360
0.9967
27
300.15
0.03564
0.9964
28
301.15
0.03778
0.9961
29
302.15
0.04004
0.9958
30
303.15
0.04241
0.9956
31
304.15
0.04491
0.9952
32
305.15
0.04753
0.9949
33
306.15
0.05028
0.9946
34
307.15
0.05318
0.9942
35
308.15
0.05621
0.9939
36
309.15
0.05939
0.9935
37
310.15
0.06273
0.9932
38
311.15
0.06623
0.9929
39
312.15
0.06990
0.9926
40
313.15
0.07374
0.9922
41
314.15
0.07776
0.9918
42
315.15
0.08197
0.9914
43
316.15
0.08638
0.9910
44
317.15
0.09099
0.9906
45
318.15
0.09581
0.9902
46
319.15
0.10084
0.9898
47
320.15
0.10611
0.9893
48
321.15
0.11161
0.9889
49
322.15
0.11735
0.9885
50
323.15
0.12334
0.9880
51
324.15
0.12959
0.9877
52
325.15
0.13611
0.9872
53
326.15
0.14292
0.9867
54
327.15
0.15001
0.9862
55
328.15
0.15740
0.9857
56
329.15
0.16509
0.9852
57
330.15
0.17311
0.9847
58
331.15
0.18146
0.9843
59
332.15
0.19015
0.9837
60
333.15
0.1992
0.9832
61
334.15
0.2086
0.9826
62
335.15
0.2184
0.9821
63
336.15
0.2285
0.9816
64
337.15
0.2391
0.9811
65
338.15
0.2501
0.9805
66
339.15
0.2615
0.9800
67
340.15
0.2733
0.9794
68
341.15
0.2856
0.9788
69
342.15
0.2984
0.9783
70
343.15
0.3116
0.9777
71
344.15
0.3253
0.9771
72
345.15
0.3396
0.9766
73
346.15
0.3543
0.9760
74
347.15
0.3696
0.9754
75
348.15
0.3855
0.9748
76
349.15
0.4019
0.9743
77
350.15
0.4189
0.9737
78
351.15
0.4365
0.9730
79
352.15
0.4547
0.9725
80
353.15
0.4736
0.9718
81
354.15
0.4931
0.9713
82
355.15
0.5133
0.9706
83
356.15
0.5342
0.9699
84
357.15
0.5557
0.9694
85
358.15
0.5780
0.9687
86
359.15
0.6011
0.9681
87
360.15
0.6249
0.9674
88
361.15
0.6495
0.9667
89
362.15
0.6749
0.9660
90
363.15
0.7011
0.9653
91
364.15
0.7282
0.9647
92
365.15
0.7561
0.9640
93
366.15
0.7849
0.9633
94
367.15
0.8146
0.9626
95
368.15
0.8453
0.9619
96
369.15
0.8769
0.9612
97
370.15
0.9094
0.9604
98
371.15
0.9430
0.9598
99
372.15
0.9776
0.9590
100
373.15
1.0132
0.9583
102
375.15
1.0878
0.9568
104
377.15
1.1667
0.9555
106
379.15
1.2504
0.9540
108
381.15
1.3390
0.9526
110
383.15
1.4326
0.9510
112
385.15
1.5316
0.9496
114
387.15
1.6361
0.9480
116
389.15
1.7464
0.9464
118
391.15
1.8627
0.9448
120
393.15
1.9853
0.9431
122
395.15
2.1144
0.9415
124
397.15
2.2503
0.9398
126
399.15
2.3932
0.9382
128
401.15
2.5434
0.9365
130
403.15
2.7011
0.9348
132
405.15
2.8667
0.9332
134
407.15
3.041
0.9314
136
409.15
3.223
0.9296
138
411.15
3.414
0.9279
140
413.15
3.614
0.9261
145
418.15
4.155
0.9217
150
423.15
4.760
0.9169
155
428.15
5.433
0.9122
160
433.15
6.180
0.9074
165
438.15
7.008
0.9024
170
443.15
7.920
0.8973
175
448.15
8.925
0.8921
180
453.15
10.027
0.8869
185
458.15
11.234
0.8814
190
463.15
12.552
0.8760
195
468.15
13.989
0.8703
200
473.15
15.551
0.8647