DESIGN REPORT

SUGGESTED IMPROVEMENT TO THE ONGOING PROJECT, ST.

SEBASTIAN SOUTH STORMWATER PUMPING STATION

K. D. D. S. Kumarage
AM - 13288
8/6/2020
Executive Summary
A storm water pumping station project of 10 m³/S capacity is under construction to safe guard the people
and properties from floods in the canal catchment area of St. Sebastian South. Similarly, another pumping
station of 30 m³/S capacity, is being constructed at the Northern end of the canal.

Generally, the canal flow in both directions with respect to the intensity of the rainfall throughout the year.
One direction towards the southern end which flows through the Beira Lake which spills at the Galle Face
front at +1.8mMSL. The other end flows to the north which flourishes the Kelani River at +0.5mMSL.
Even though, there is another gravity outlet gate, located in the lake, at “McCallum Gate” which is closed
to avoid sea water contamination of the lake.

Furthermore, the authorities have identified that maintaining the water level at +1.6 ~ +1.8mMSL of the
Beira Lake side is mandatory to avoid collapsing of the existing structures adjacent the canal and lake.
Accordingly, the southern end which is the location of “St. Sebastian South Pumping Station” has become
a dead-end due to the water level differences.

Hence, the present design has create a dam across the canal at the pump discharge bay. It has blocked the
possibility of inland transportation that has been properly functioned in ancient era through the waterways
in the greater Colombo city.

However, I found it is possible to maintain the water levels by improving the design of the pumping station
where the boat navigation can be facilitated.

In addition, the continuous flow though the canal improves the biodiversity of the canal while enhancing
the quality of human life. Apart from all, the boat transportation is one of the most economical and
environment friendly method of transport and surely will attract the tourists at a larger scale.

In view of this, the Design Report itself will only be considered on the design, selection, and sizing of the
equipment for the Flood Control/ Storm water Pumping station with possibility for canal transportation.

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Declaration

I declare that this report was created from the genuine efforts to fulfill the requirements of the mechanical
engineering design for the Professional Review process of the Institution of Engineers of Sri Lanka (IESL).
As per the evaluation guidelines, the report is prepared and presented to elevate the Associate membership
to the Corporate membership category of the Institution. In my understanding, the entire design which is
described in this report has not previously mentioned, remarked, published nor used anywhere in the world.
Nevertheless, it includes ideas or concepts obtained from the previous projects that serve the communities
at a bigger scale all over the world.

……………………. Thursday, August 6, 2020

Desaja Kumarage
AM-13288

ii
Preface

Stormwater or floods creates hazardous situations for the living beings and the properties. These damages
not withstand to a specific area nor for an ethnic group. As per the records of the Ministry of Disaster
management, yearly Sri Lanka losses over five billion Sri Lankan rupees economically while having more
than hundreds of fatalities. So, seeking for a solid solution by addressing all associated concerns is a key
for a sustainable solution.

Generally, the risks do not completely disappear soon after the water levels fallen down. What does most
reports are considered, the physical damages of the disaster while some burning issues continue for a
considerable period. For instance, the viral diseases like, Dengue, Diarrhea or even long lasting life threats
of kidney problems can be spread among the generations of a flood affected areas. And, the psychological
impact on humans by losing their loved ones and belongings are vital matters to be considered. Hence,
having a properly maintained stormwater management system is a must for a country in its long run.

By considering a small scale, the St. Sebastian canal catchment area often faces difficulties by handling
excess water. The area is drained to the canal and it is connected to the Beira Lake and the Kelani River.
With respect to the seasonal water level variations that occurs throughout the year canal discharges water
either the river or the lake. By utilizing the phenomenon, ancient records reveal that a properly functioned
naval system has been established and maintained for the transportation purpose of the city. Some parts
of the old system, including the lock gates can still be witnessed along the canal. Therefore, a solution
should be generated by improving the existence.

However, the recent developments have been forgotten to consider the value of the functioning canal
network until the floods/stormwater becomes a threat. More numbers of people are occupied adjacent the
canal and mega structures were created closer the water bodies without considering the water level
variations or the environment aspects. This way, the problem of the quality of water management has been
fallen drastically.

All in all, the design report is suggested an improvement for the pumping station that can provide
necessary space for the boat transport which can be improved further possibilities as mentioned in the
report.

iii
Acknowledgement

I would like to express my sincere thanks to the Institute of Engineers, Sri Lanka for initiating the
Continuous Professional Development (CPD) Course on Mechanical Engineering Design in order to guide
and assist the Associate members to fulfill the design requirement necessary for acquiring the Corporate
membership of the Institution.
And, I am grateful to the Course Coordinator of the CPD Course, Eng. P. Kalubowila, and the Senior
Engineers who presented during the sessions for devoting their valuable time in preparation of the design
course and improving its quality up to date. Further, their enormous encouragement and the guidance gave
me sufficient energy and the enthusiasm to present the design.
Also, my gratitude goes to all the Lecturers who conducted lectures during the CPD course. Especially, I
am highly grateful to my mentor Eng. T. Jayasekara for allocating his precious time to provide tremendous
guidance to complete this report.
Moreover, I highly appreciate the assistance given by some of the officers of the Sri Lanka Land
Development Reclamation Corporation and Department of Irrigation while preparing the report.
Further, I thank and highly appreciate the engineers of the China Geo Engineering Corporation. Especially
Eng. C. D. Mahagamage and Eng. H. Chathuranga.
Also, I would like to thank one of my senor colleagues who gave novel ideas, Eng. O. U. Pathirathna and
Grundfos Korea Pump manufacturing team namely, Gyung Ho Jung, and Hyun Jo Kim and all others who
helped me to complete the design report.
Last, but not least, I am grateful to my loving wife for encouraging me continuously mostly by providing
ideas from different perspectives when I come across with problems in the conceptual design, and giving
me immense support by allocating enough time required to complete the design, especially during the
Covid-19 quarantine period.

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Table of Contents
1. Problem Statement ...........................................................................................................................1

2. Introduction .................................................................................................................................. 1-4

3. Objectives and Envisaged Outcomes from the Suggested Improvement .................................... 5-7

4. The Design Approach ................................................................................................................ 8-17

5. Selecting the Optimized Solution ............................................................................................ 18-37

6. Detailed Design ........................................................................................................................ 38-53

7. Operation Philosophy............................................................................................................... 54-55

8. Cost Estimation ..............................................................................................................................56

9. Drawings .................................................................................................................................. 57-62

10. Maintenance Schedules ............................................................................................................ 63-67
11. Suggestions for further Improvements...........................................................................................68

12. References and Annexures ....................................................................................................... 69-73

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1. The problem Statement:

How to upgrade the ongoing pumping station design and select the equipment that can help to
activate the waterway transportation and the circulation of water through the canal to improve the
quality of life while maintaining the critical requirements of the ongoing project?

2. Introduction
The initial plan of the project was to facilitate the naval transport and flood control. However,
subsequently, the requirements were reduced forgoing the naval transport and limiting the pumping
station for the flood control. Accordingly, this study is to critically analyze the design of the ongoing
project and enable to include the naval transportation through the canal while preventing the floods in
the catchment area.

The present project is planned to evacuate the flood waters of the canal catchment area which is
approximately 20km² and the land area is mostly low-lying, with the elevations varying between -2.00
to +6.00 mMSL approximately. At present, the Northern end of the canal (North Lock Gate) at the
Nagalagam Street has a gated outlet to the Kelani River, which functions only when the water level of
the Kelani River is low (low Kelani condition). When the river reaches high levels (high Kelani
condition), the gates are closed to prevent river water entering the land side.

At present, a pumping station is under construction at St. Sebastian North Lock Gates to pump 12 m³/S
capacity for reverse pumping. Which will fulfil the requirement of the canal flushing during the dry
season.

Consequently, the Southern end of the canal (South Lock Gate) near the St. Sebastian Hill at Maradana
is presently a dead end. Since the water level of the Beira Lake is higher (+1.60~1.80 mMSL) than the
normal water level of the canal (+0.6~0.40 mMSL). To prevent sea water inflow to the canal a stop log
arrangement is in place. (A stop log structure)This enables to maintain the water level in the lake at
(+1.60~1.80 mMSL).

By the present design, the LWL and the HWL of the canal are maintained at +0.3mMSL and
+1.3mMSL. However, the water level of the Beira Lake is maintained at +1.8mMSL by the spillover

1
at the Galle face front. The maximum allowed water level is +2.6mMSL. The topography of the
Colombo canal network and the water level variations are depicted in figures 01 & 02.

Figure 2.01

Figure 2.02
The new pumping station will create a barrier to the gravity flow. The plan and the section are as
below.

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 Figure 2.03

Figure 2.04

*(Clearer drawings are attached in the 9. Drawings section)

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The shortcomings of the present project design are as follows:

1. Boat navigation through the canal up to the lake is not possible in future.
2. Stagnant water throughout the year will create a health hazard and bad smell due to growth
of algae. The aquatic life will also subjected to danger.
3. The present design require a higher discharge pressure (5.5m) resulting a higher power
consumption consequently high cost for the ancillaries (Generators and panels).
4. The pump operation is by two pumps without any standby facility. Therefore a failure of
any pump will lower the install capacity by 50%.

With the suggested improvements, it is expected to create necessary facilities for the canal
transportation by a canal boat which has a length of 57ft (17.37m), beam of less than 06ft (2.08m)
and draught of less than 04ft (1.06m), which can carry twelve people, as shown in the figure below.

And, the expected outcomes are mentioned in the section 3.

Figure 2.04

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3. Objectives and Envisaged outcomes from the suggested improvement

3.1. Objectives of the Project.

3.1.1. Functional Requirements

1. Total pumping capacity shall be at least 10m3/S.

2. +1.6 ~ +1.80 mMSL were taken as the water level of the Beira Lake at normal
condition.

3.1.2. Physical Needs

1. The all facilities of the pumping station shall be planned in the determined land
area. Hence, the determined boundary line of the Pumping Station is shown in the
Site Layout drawing (Annexure
(Section 9). – 03).

Therefore, the Designer shall not request any additional land acquisition from the
Project Owner/ Employer for the installation or the construction of all facilities of
pumping station.

(*Length about 75m and width 11m approximately, yet it not an exact rectangular
canal.)

3.1.3. Performance Needs

1. Selection of equipment during the design shall be carried out considering the energy
efficient and the environmentally friendly manner.

2. The efficiency of the pump shall be 75% and performance test criteria shall be
according to the ISO 9906: Grade 2B.

3. Pump motors shall be rated a minimum of 10% higher than the maximum power
required by the pump across the whole of its operating duty.

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 3.1.4. Desired Objectives

1. 10m³/S of the flood waters shall be removed from the St. Sebastian South canal.
The pumping operation shall be restricted not exceed the High-Water Level (HWL)
of the downstream of the canal.

2. Low Water Level (LWL) is defined to ensure the required submergence for the
pumps.

3. The construction of the pumping station shall not obstruct the naval transport
system. Instead, shall be able provide suitable space for the operation with the
support of naval lock gate system.

3.1.5. Constrains of the Project

1. -3.40 mMSL which is the sump bottom shall be maintained as shown in the drawing
(Annexure
(Section 9). – 04).

3.2 The Benefits of the Improvement

The St. Sebastian canal will become a navigable path for the narrowboats with a proper
functioning lock gate mechanism. (The design of the lock gate mechanism will not be part
of this report.)

The following benefits are directly associated with the country’s economical and
sociological developments while enhancing the environmental friendly operation.

1. Transportation system can be improved to avoid traffic congestion and to attract both
local and international tourists.

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2. The circulation of water inside the lake will improve its quality while improving the
aquatic life.
3. The quality of human life of the surrounding area of the canal and lake will improve.
4. Electrical Power consumption of the pumping station will be reduced nearly by a half
compared to the ongoing project.
5. Mechanical and Electrical cost of the pumping station will be reduced comparatively
by its low head immerse operation.
6. With more numbers of pumps the operation is more flexible.
7. Only 20% of pumping capacity will be reduced when a single pump is out of order.

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4. The Design Approach

4.1 The Approach

The pumping station layout will be enhanced to an arrangement where passenger boats (a
Narrowboat) can pass through the pumping station. These changes are done without violating the
project restrictions like, maximum allowable width of the canal and maximum allowable depth of
the canal for the sump bottom. The general requirements of the Stormwater Pumping Station which
3 under the objectives of the project shall be maintained.
are mentioned in the chapter 4.IV

Initially, the advantages and disadvantages of more number of pumps, pump arrangement and flow
discharge pattern shall be studied.

Then, the conceptual design is evaluated by changing the numbers of pumps and the arrangement
of the pumps.

Finally, an evaluation of though a solution matrix shall be done to select the optimized design.

The optimization will be achieved based on the following parameters.

I. Numbers of Pumps (two, three or more)

II. Pumps Arrangement (Gate mounted/ Horizontal configuration or Conventional/
Vertical configuration)
III. Flow Discharge Pattern (Open Discharge, Pipe Discharge or Immerse into the water)
IV. Objectives of the Project

***Figures 3.01 and 3.02 illustrate the Pumping arrangement and the Flow discharge pattern.

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 Vertical Pump Configuration Horizontal Pump Configuration

Figure 3.01

Figure 3.02

4.2 Selection of Pumps and pumping systems.

4.2.1. Numbers of Pumps

The number of pumps shall be decided based on the pumping capacity given in the
hydrological study. The discharge head (the duty head) is same for each pump since the
water level variation is expected to be similar to all pump in the approach canal. Then,
separate pump approach canals are conceptualized as per the ANSI-HI 9.8_2012 guideline
to minimize the effect of the flow turbulences.

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For the particular application, it is considered to handle higher volume (above 500 liters
per second) of water carrying solid particles against a low head, typically, less than ten
meters of total head.

Instead of most common centrifugal, radial flow pumps it is advisable to use centrifugal
axial flow pumps by considering the flow rate, pressure and the ability of handling solid
particles. (Please see the 05. Solution)

However, availability of centrifugal axial flow pumps are limited with horizontal
configuration where the pump and motor are combined to serve as one unit. (Submersible
pump)

Advantages:

The discharge head is constant and equal for any numbers of pumps. (Please see the section
05. Solution)
The flow rate can be varied by selecting the combination of pumps.

Option 01
For example, 10 numbers of pumps can be selected with each pump having discharge
capacity of 01 m³/S and discharge head of 5.5m. The pump characteristic curve of the
proposed pump is given below.

According to the curves, duty point lies between 19 degree and 21 degree propeller angles.
As the pumps are customized versions the manufacture will be produced the matching
curve at about 19.5 or 20 degree angles. And, below are the plus points.

1. The pumping system can pump 01 m³/S, 02 m³/S, 03 m³/S... up to 10 m³/S by

operating the relative number of pumps. (System runs with flexible discharge
flow requirements)
2. By using variable speed drive operation more flexibility can be obtained.

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3. In the event of maintenance or breakdown of one pump, the system will not lose
the operation of the considerable amount of flow during the floods.
4. Since, minimum submergence is low the sump bottom level will be
comparatively less than the present selection.

Figure 4.01
5. Electrical power demand can be optimized since the motors will be working at
optimum efficiency.
6. Electrical equipment appliances cost can be lowered. E.g. Switch gears, cables,
generators, etc

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Disadvantages:

1. More building footprint will be required.

2. The cost of the equipment is expected to be high. (E.g. Pumps, pipes, etc)
But can be compared, it is the effect of minimum number of pump selection.

Option 02
However, at present, pumps of capacity 10 required for the present design is not any of the
established, reputed manufactures. Therefore, the next available option is two pumps which
has 05 m³/S of each at the head of 5.5m

Figure 4.02
According to the curves, the duty point is on 23 degree propeller angle. And, following
points should be noted on the selection.

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1. The pumping system can only provide 05 m³/S and 10 m³/S which are the 100%
capacity requirement during the flood and the 50%.
2. With the variable speed/frequency drives, the theoretical system variability can
achieve a lower of 2.5 m³/S.
3. In the event of maintenance or breakdown of one pump, the system will be lowered
by 50%.
4. Minimum submergence, which is the decision factor of sump bottom level will be
higher than that of a small pump. (Please see: Pump Manufacturer's design
guidelines. Nominal column diameter represents the pump size and the comparison
was done between KPL700 vs KPL1500)

Figure 4.03

5. Electrical demand is high with the higher motor rating.

6. Electrical ancillaries cost is high. E.g. Switch gears, cables, generators, etc

Therefore more numbers of pumps will be beneficial to obtain small flow rates upon
the same discharge head. However, it will increase the cost of the maintenance and the
building footprint.
For this project, there is a limitation on building footprint based on the existing canal
size. (Please see the 05. Solution) Therefore, the number of pumps can go only up
to FIVE.

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 4.2.2 Pumps Arrangement

Vertical Pump Configuration Horizontal Pump Configuration

Figure 4.04

To facilitate the water flow during normal condition, it is required to construct a bypass
canal (Figure 4.04), in vertical configuration. In other words, pumping station itself is
an obstacle to the normal flow with the construction constrains and only will operate
when forced flow is required.

14
In horizontal concept, the facility is covered by lifting the gate where the pump is
mounted on the Gate (Figure 4.04).

Advantages: (Horizontal Configuration)

a) Less building footprint is required.
b) Reverse flow can be easily facilitated.
c) Aquatic life friendly design as it does not affect the natural flow.
d) Water quality can be improved by circulating the water.

Disadvantages: (Horizontal Configuration)

a) Mechanical and Electrical equipment cost will be high.
b) For the particular location, presently a dead-end. So that, the gate mounted
pumping station will be lowered throughout the year to prevent excessive back-
flow due to the considerable water level difference.

Advantages: (Vertical Configuration)

a) By creating a bypass arrangement, it helps to the gravity flow.
b) Beira lake side is a dead-end. Hence, it can be closed.
c) Less maintenance occurs compared to the horizontal setup.

Disadvantages: (Vertical Configuration)

a) Construction cost will be high with the bypass arrangements and the backflow
prevention techniques.
b) There will not be any reverse flow if there is no any bypass arrangement.
c) Reverse flow operation will be an extra cost.

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4.2.3. Flow Discharge Pattern

Figure 4.05

The discharge arrangement is a key factor to influence the discharge head (power
consumption), numbers of ancillaries like valves and expansion joints (cost), safety, and
the ease of control.

Advantages: (Open Discharge)

a) It helps to generate lesser discharge head. As a result, the power consumption

will be low.
b) Valves, expansion joints and the discharge pipes are not included. (low
equipment cost)
c) Less erosion issues at the downstream since it occurs a lower flow velocity.
d) Lower down the construction cost with the simple setup.

Disadvantages: (Open Discharge)

a) Operation safety will be low as objects or living things are subjected to fallen
inside.
b) There is no method to backflow prevention.

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Advantages: (Pipe Discharge)
a) A controlled discharge can be obtained through the pipe and fittings.
b) Compared to the open discharge safety of falling objects or living things are
improved.
c) Backflow prevention is facilitated.

Disadvantages: (Pipe Discharge)

a) Higher head will give the high-power consumption.
b) High equipment cost with the pipes and fittings.
c) Higher erosion issues with the extra generated discharge head.
d) Higher construction cost with the complex structure compared to the open
channel and immerse into the water design.

Advantages: (Immerse into the water)

a) Less occurrence of the dynamic imbalance in the thrust bearing of the pumps.
b) Lower discharge head occurs comparatively.
c) Less erosion issues will be occurred.
d) Construction cost is low.

Disadvantages:
a) Mechanical and Electrical equipment cost will be high.
b) Maintenance cost will be high.

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5. Selecting the Optimized Solution

Work Flow:

1. Selecting the suitable pump type

2. Selecting the numbers of pumps
3. Selecting the discharge flow arrangement
4. Conceptualization the pumping station layout
5. Defining the solution matrix

5.1 Selecting the suitable pump type

As mentioned in section 4. 01, the pump selection can be started by qualifying

centrifugal radial discharge flow pump.

Availability of Pumps for above 500 liters per second will be;

a.) Centrifugal radial flow, double suction volute shape, split casing single stage pumps.
There are pump manufacturers who have high-power pumps as below specified.
Flow rate: up to 40,000 m³/h
Head: up to 250 m
Power: up to 7,000 KW
Max: particle size: 70mm

b.) Centrifugal radial flow, submersible motor pumps.

There are pump manufacturers who have high-power pumps as below specified.
Flow rate: up to 10,000 m³/h
Head: up to 120 m
Power: up to 1,000 KW
Max: particle size: 120mm

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However, the volute casing design is suitable for the higher head requirements with respect to
the best efficiency point of the pump curves. And, the maximum particle size that can be handle
is also a limitation.

c.) Positive displacement, Screw pumps.

There are pump manufacturers who have high-power pumps as below specified.
Flow rate: up to 40,000 m³/h
Head: up to 15 m
Power: up to 5,000 KW
Max: particle size: 200mm

There are no openly and widely available design guidelines for the screw pumps and
availability of pump manufacturers are fairly low compared to the axial flow pumps. Also, the
equipment cost high and history of reference projects still new.

d.) Centrifugal axial flow pumps.

There are pump manufacturers who have high-power pumps as below specified.
Flow rate: up to 40,000 m³/h
Head: up to 15 m
Power: up to 5,000 KW
Max: particle size: 300mm

Axial flow pumps are available with the submersible motor facility and long-shaft models
whereas motor driven or engine driven.
By considering below factors it was decided to proceed further with the centrifugal axial
flow submersible motor pumps.

 Equipment cost
 Effect on the construction cost
 Maintenance cost and time
 Ease of operation.
 Widely available in numbers of reference projects (success records)

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  Openly available design guidelines from the pump manufacturers which complies to the
ANSI HI intake structure designs.

5.2 Selecting the numbers of pumps

Functional requirements of the project:

 Total Required flow rate to be pumped = 10 m³/S

 Intake side:
LWL: +0.30mMSL
HWL: +1.30mMSL
 Canal bed level: -1.0mMSL
 Maximum allowed sump bottom level: -3.4mMSL
 Discharge side:
LWL: +1.8mMSL (Beira lake nominal water level)
HWL: +2.6mMSL (Beira lake flood level)

Accordingly, below discharge heads are required to be fulfilled by the pump.

Case 01: Canal water level is at LWL and Beira lake water level is at HWL (usually considered
as pump switched off level where the flood situation seems to be controlled, which provides the
maximum static head)
Hs.max = 2.6 – 0.3 = 2.3m

Case 02: Canal water level is at HWL and Beira water level is at HWL (pumping operation will
have to be stopped at this level since the flood situation has reached the maximum
operational level of the pumping operation and the surrounding. Unless, the excess water will
return to the canal by directly or indirectly. Nevertheless, for the specific project location there
is a considerable advantage of the Beira lake spillover which is maintained at +1.8mMSL.
Therefore, at the HWL of both canal and lake side will not significantly effect to the switch off
level unless a flash flood occurs.)

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Hs.op1 = 2.6 – 1.3 = 1.3m

Case 03: Canal water level is at HWL and Beira water level is at LWL (All pumps are in
operation)
Hs.op2 = 1.8 – 1.3 = 0.5m
Case 04: Duty point where the maximum efficiency occurs, a theoretical point to determine the
best efficiency points at each service points.
Hs. duty = [discharge side (LWL+HWL)/2 - intake side (LWL+HWL)/2] = 1.4m

5.3 Selecting the discharge flow arrangement

To determine the dynamic head requirements it is required to conceptualize the pumping station
design with the necessary piping setups.
Hence, it is required to decide the numbers of pumps and the discharge flow pattern which is the
driving factor of discharge pressure/head at the same time to proceed the pump selections.

Selection A: Ten numbers of 01 m³/S capacity pumps with Vertical Pipe discharge pattern.
Points to concern:

Figure 5.01 (ANSI/HI 9.8-2012 Figure 9.8.2.1.4a - Rectangular intake structure layout, page 05)
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 Since the Beira lake (discharge side) flood level is +2.60mMSL, the flat form level of the pumping
station to be defined above that to avoid any damages due to the flooding for the electrical
appliances.
- Flat form level +3.00 is selected.

 And, back-flow prevention method also to be considered.

- Flap valve is introduced.
 Also, erosion due to the pump discharge to be minimized.
- Water retaining dam about 60 to 75 degree angle is to be constructed.

 Column pipe diameter of the pump which is the key point to determine the total length and width
of the pumping bay area.
- Grundfos KPL700 pump model is selected based on the discharge flow 01m³/S and
assuming the total discharge head is 5.5m.

Justification to the above assumption:

Figure 5.02

Minimum submergence requirement of the pump from the manufacture's design guidelines.

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 KPL 700
PUMP

Figure 5.03

Sump bottom level = LWL(0.3mMSL) – Minimum submergence requirement of the pump.(1.95m)

= - 1.65mMSL

Discharge Pipe Center level

= Flat form level + Maintenance space (0.5m) + half a diameter of pipe (0.35m)
= 3.85mMSL

Therefore, new maximum static head

= Discharge pipe center – LWL
= 3.85 – 0.3
= 3.55m

and, new minimum static head

= Discharge pipe center – HWL
= 3.85 – 1.3
= 2.55m

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Dynamic head calculations:

1. Head-loss through the pipes (HL pipe )

In some practices it has been used reduced diameter pipes than the vertical pipe for the discharge
horizontal pipe. But, I selected a same size horizontal and vertical pipes.(700mm)

Velocity through the pipe (V) = Flow rate/ Area

= 1/ ( π·r2 ), where 'r' is 350mm
= 2.63m/s
By using Darcy-Weisbach equation;
Head-loss through the pipes (HL pipe ) = f (l/D)(V2/2g)

where,
f - friction factor
l – length of the pipe(m)
D – Diameter of the pipe(m)
V – flow velocity through pipe(m/s)
g – acceleration of gravity(m/s2)

To find 'f' the Reynold's number (Re ) to be found. = DVρ / μ

where,
ρ – density of water assumed as 998 kgm-3 at room temperature, (250C)
μ - viscosity of water 0.001Nsm-2 at room temperature, (250C)

Hence, the Reynold's number (Re ) = ( 0.7 x 2.63 x 998 ) / 0.001

= 1.83 x 106
The Roughness factor, ('ε') of the pipe (new pipe) = 0.1mm
Hence, the Roughness ratio = ε/D
= 0.00014

Therefore, from below Moody's diagram, 'f'' = 0.016

24
 Figure 4.04

Accordingly,
Head-loss through the pipes (HL pipe ) = 0.016 (10.5/ 0.7) (2.632/ 2x 9.81)
= 0.068m

Local Losses as below (HL LOCAL ) = (HL Tee )+(HL Flap v/v )+(HL EXP.J )+(HL DISCH );

1. Head loss due to the 'Tee' – Joint. (HL Tee )

By using Darcy-Weisbach equation for all the necessary pipe fittings as below;

Head loss of the 'Tee' – Joint. (HL Tee ) = K(V2/2g)

= 0.35m, where K=1 for 900 directional

2. Head loss of the Swing check valve. (HL Flap v/v ) = K(V2/2g)
= 0.70m, where K=2 from table Appendix
25
3. Head loss through Expansion joint. (HL EXP.J ) = K(V2/2g)
= 0.35m, where K=1 from table Appendix
4. Discharge Head loss. (HL DISCH ) = K(V2/2g)
= 0.35m, where K=1 from table Appendix

Accordingly, total dynamic head loss, (HL TOTAL ) = (HL pipe ) + (HL LOCAL )
= 1.818m

Therefore, new maximum Total head = Maximum Static Head + (HL TOTAL )
= 5.368m ~ 5.5m

and, new minimum Total head = Minimum Static Head + (HL TOTAL )
= 4.368m

Correspondingly, to meet the design requirements, the pump shall operation on above both points.
In short, the assumption is satisfied for the selections. At this point, it can be considered Grundfos
KPL700 model as the selection 01 for the preliminary design, as mentioned in chapter 4.

5.4 Conceptualization the pumping station layout

As per the ANSI HI 9.8_2002 guidelines and the pump manufacture's design guidelines;

Figure 4.05
26
Width of the pumping station = 2 x Pump Diameter x Numbers of pumps + Separation wall widths
= 2 x 700mm x 10 + 250mm x 9
= 16.25m

However, maximum allowed width for any type of construction on the canal is 11m. And, there
is no support for reduction of the total width even the pump placed horizontal.

Selection B: five numbers of 02 m³/S pumps with Vertical Pipe discharge pattern

The next option is to check the feasibility of five numbers of 02 m³/S pumps to fulfill the
requirement(10m³/S). Similar to the above procedure it is to be selected a pump from the
manufacture's data.

Assumptions: (And this can be justified as above calculations if the selection can fulfill the design
constrains, which is the total width of the pumping station.)

Total Discharge Head = 5.5m

Though, there are pump models with the diameter of 800mm and 900mm, those do not fulfill the
best efficiency points as above defined. So, the next available pump model is KPL1000.

27
 Figure 4.06
Now,
Width of the pumping station = 2 x Pump Diameter x Numbers of pumps + Separation wall widths
= 2 x 1000mm x 5 + 250 x 4
= 11m
Finally, it is satisfied the maximum allowable width for the construction.

Selection C: five numbers of 02 m³/S pumps with Horizontal and Immerse into water(Gate Pump)
Here, the width of the pumping station is same as above, Selection B. But, the discharge head
will be changed as below.

Total discharge head(Max) = Hs.max (from case 01) + (HL DISCHARGE = as per 02 m³/S)
Hence, HL DISCHARGE = K(V2/2g), where K=1 and V= (2.55 m/S)/ ( π·r2 ), r = 0.5m
= 0.33m

28
Therefore,
Total discharge head(Max) = 2.3 + 0.33
= 2.63m
And,
Total discharge head(Min) = 0.5 + 0.33
= 0.83m

Figure 4.07

Figure 4.08
29
As mentioned in the Chapter 4, this setup reduces the total discharge head compared to the same
pump model with the previous selection. Whereas to reduce the power consumption. And, the
selected pump curve is as shown above.

Selection D: Four numbers of 2.5 m³/S pumps with Vertical Pipe discharge pattern

The next option is to check the feasibility of four numbers of 2.5 m³/S pumps to fulfill the
requirement(10m³/S). Similar to the above procedures it is to be selected a pump from the
manufacture's data.

Assumptions: (And this can be justified as above calculations if the selection can fulfill the design
constrains, which is the total width of the pumping station.)

Total Discharge Head = 5.5m

Figure 4.09

30
Though, the pump manufacture has a pump model which can cater the demand, the pump cure
itself produces less flow sensitivity against flow changes. That defines an older term called “steep
pump curve”. For the specific requirement, flood control it is advisable to maintain higher flow
changes at a low pressure (head) difference. On the other hand, it consumes high-power at the
same operational point.
Correspondingly, below pump model (Figure 4.10) was selected.

Figure 4.10

Then,
Width of the pumping station = 2 x Pump Diameter x Numbers of pumps + Separation wall widths
= 2 x 1200mm x 4 + 250 x 3
= 10.35m
It is also satisfied the maximum allowable width for the construction.

Selection E: Four numbers of 2.5 m³/S pumps with Horizontal and Immerse into water(Gate
Pump)
31
In this selection, the width of the pumping station is same as above, Selection D. But, the
discharge head will be changed as below.
Total discharge head(Max) = Hs.max (from case 01) + (HL DISCHARGE = as per 2.5 m³/S)

Hence, HL DISCHARGE = K(V2/2g), where K=1 and V= (2.21 m/S)/ ( π·r2 ), r = 0.6m
= 0.25m
Therefore, (similar to Figure 4.07)
Total discharge head(Max) = 2.3 + 0.25
= 2.55m
And,
Total discharge head(Min) = 0.5 + 0.25
= 0.75m

Figure 4.11
32
Similar to the Selection C, the power consumption is low and the selected pump curve is as above
shown, Figure 4.11.

Selection F: Three numbers of 3.3 m³/S pumps with Vertical Pipe discharge pattern
It will be another option to check the feasibility of three numbers of 3.3 m³/S pumps to fulfill the
requirement(10m³/S). Similar to the above procedures it is to be selected a pump from the
manufacture's data.
Assumptions: (And this can be justified as above calculations if the selection can fulfill the design
constrains, which is the total width of the pumping station.)

Total Discharge Head = 5.5m

Figure 4.12

33
Then,
Width of the pumping station = 2 x Pump Diameter x Numbers of pumps + Separation wall widths
= 2 x 1200 x 03 + 250 x 2
= 7.7m < 11m
Accordingly, the width of the pumping station is to be reduced with a convergent section.
However, it will be a negative point if the structure is to be built by supporting the naval functions.
Even the horizontal configuration will cost the same width as above. Therefore, it is not required
to include a selection for the report.

Selection G: Two numbers of 05 m³/S pumps with Vertical Pipe discharge pattern
The pump selection is exactly similar with the ongoing project.
Assumptions: (And this can be justified as above calculations if the selection can fulfill the design
constrains, which is the total width of the pumping station.)
Total Discharge Head = 5.5m

Figure 4.12
34
Furthermore, the selection of two pumps as per the ongoing project does not facilitate the naval
function as the building footprint itsef cost more than 7m of space as the Pumbay area. The pumps
are used in the project, KPL1500 which has the nominal diameter of 1500mm. And, there is no
space for the bypass arrangement for the specific project location.

5.5 Defining the solution matrix

According to the pros & cons and the work flow of selections, the evaluation of concepts will be
as stated below.

Selection A: Ten numbers of 01 m³/S capacity pumps with Vertical Pipe discharge pattern.
Selection B: five numbers of 02 m³/S pumps with Vertical Pipe discharge pattern
Selection C: five numbers of 02 m³/S pumps with Horizontal and Immerse into water(Gate Pump)
Selection D: Four numbers of 2.5 m³/S pumps with Vertical Pipe discharge pattern
Selection E: Four numbers of 2.5 m³/S pumps with Horizontal and Immerse into water(Gate
Pump)
Selection F: Three numbers of 3.3 m³/S pumps with Vertical Pipe discharge pattern
Selection G: Two numbers of 05 m³/S pumps with Vertical Pipe discharge pattern

The selections will be evaluated as below:

 Numbers of Pumps – Higher the numbers of pumps, more the flexibility in operation.
 Pump Arrangement – Horizontal: More suitable for the project.
 Flow discharge pattern – Immerse into water will reduce power consumption and allows
sufficient space
 Objectives of the Project –
1. Functional Requirement[FR] – Need to be complied
2. Pysical needs[PN] – Need to be complied
3. Performance needs[PFN] – More is better
4. Desired Objectives[DO] – More outcomes will increase the value of the project.
*Passenger boat transportation – Only will get marks.

35
 5. Constrains of the project[COP] – Need to be complied

Above bulletins are a summary of the chapter 4. Advantages and disadvantages. (Please refer for
more details.)

Comparison with the below given marks:

a.) Excellent = 10 b.) Very Good = 8
c.) Good = 6 d.) Adequate = 4
e.) Poor = 0

SELECTION CRITERIA
Numbers
of Flow Discharge
pumps Pump Arrangement Pattern Objectives of the Project
SELECTION Horizontal Vertical Pipe Immerese FR PN PFN DO COP
A          
B          
C          
D          
E          
F          
G         

Table 01

SELECTION CRITERIA WITH MARKS

Numbers
of Flow Discharge
pumps Pump Arrangement Pattern Objectives of the Project
SELECTION Horizontal Vertical Pipe Immerese FR PN PFN DO COP TOTAL
A 10 6 6 10 0 10 0 10 52
B 8 6 6 10 10 6 0 10 56
C 8 10 10 10 10 10 6 10 74
D 6 6 6 10 10 8 0 10 56
E 6 10 10 10 10 8 10 10 74
F 4 6 6 10 10 10 0 10 56
G 0 6 6 10 10 10 0 10 52
Table 02

Then, the weights have been given for Two Key Factors.
Function as a Stormwater Pumping station 0.5 and Posibility for the Boat transportation
0.5

36
 SELECTION CRITERIA WITH WEIGHTS (PAIRWISE COMPARISON)
Numbers
of Pump Flow Discharge
pumps Arrangement Pattern Objectives of the Project
SELECTION Horizontal Vertical Pipe Immerese FR PN PFN DO COP TOTAL WEIGHT*MARKS
A 0.5 0.5 0.5 0.5 0 0.5 0 0.5 3 156
B 0.5 0.5 0.5 0.5 0.5 0.5 0 0.5 3.5 196
C 1 1 1 1 1 1 1 1 8 592
D 0.5 0.5 0.5 0.5 0.5 0.5 0 0.5 3.5 196
E 1 1 1 1 1 0.5 1 1 7.5 555
F 0.5 0.5 0.5 0.5 0.5 0.5 0 0.5 3.5 196
G 0.5 0.5 0.5 0.5 0.5 0.5 0 0.5 3.5 182

Table 03

Accordingly, the Selection C has been selected to proceed as the optimized design.

Hence, the identified problems are clearly addressed whereas the circulation of water, and navigable
operation at a minimum power requirement of having 75kW five identical pumps for the operation.
Accordingly, the detailed design in the next section is elaborated the design with the suitable major
equipment selection with the specific specifications for the operation of the stormwater pumping station.

37
6. Detailed Design
Correspondingly, the Selection C, the Detailed Design process is as follows;

1. Optimizing the Pump Selection

2. Preparing the conceptual design and drawings
3. Selecting the major mechanical equipment for the operation

6.1 Optimizing the Pump Selection

At this stage, it is required to smoothen the pump performance and match the specific
specifications with the collaboration of the Pump Manufacturer. Which is included of the
operational performances, such as catering of duty point, efficiency, and NPSH (Minimum
Submergence requirement) and the long-lasting of the pump by selecting suitable materials
against the operational conditions.

Input details for the selection of the pump are as follows.

PUMP

a.) Head (Static + Dynamic);

From the 5.4, Selection C the Total discharge head (Max) = 2.63m and the Total
discharge head (Min) = 0.83m
And above should be modified with the head-loss of the Flap valve.

HL FLAP VALVE = K (V2/2g), where K=1 and V= (2.55 m/S)/ (π·r2) and r = 0.5m

= 0.33m

Therefore, total discharge head (Max) = 2.63 + 0.33

= 2.96 ~ 3m

And, total discharge head (Min) = 0.83 + 0.33

= 1.16 ~ 1.2m

So, the head of the duty point = (3 + 1.2)/ 2

= 2.1m

38
 b.) Flow - 2 m³/S (Total capacity 10 m³/S is to be covered with five pumps)
c.) Expected Pump efficiency – above 75%
d.) Factory acceptance test standard – ISO 9906:2012 Grade B
e.) Installation method – Horizontal Gate Mounted
f.) NPSH available (For the axial flow pumps, minimum submergence available)
= (LWL – Sump bottom level)
= 3700mm
g.) Fluid flow type/ Application – Stormwater/flood
h.) Fluid temperature - 25°C
i.) Density - 998.2 kg/m³
j.) PH level – 5.5 to 8

MATERIAL OF CONSTRUCTION

Normally, the submersible pumps are manufactured within the certain standard materials
that allows to operate them for variety of applications. However, it is a responsibility of
the specifier let manufacturer know the exact quality of fluid that pump is handling through
its life and what kind of environment it is exposed. Hence, below specific materials were
specified to the some components of the pump.

a.) Impeller – Stainless Steel 316

For the axial flow pumps, the impeller often calls the propeller which has a freedom to
fabricate almost all the impeller materials that are used in municipal wastewater
applications. Namely, Cast Iron, Bronze, and Stainless Steel are major of them. But, for
the flood control/ stormwater it is a must to consider the corrosiveness of the water which
decreases the lifetime of the pump.
Even though, the economical solution of having the Cast Irion provides better resistance
against the abrasiveness that is poor in withstanding against the corrosion.
By considering the water quality of the St. Sebastian canal it is clear that the chloride
content is high and the exposed environment is C4 will increase the risk of corrosion at a
considerable rate. And, the damage due to the abrasiveness has been diminished by the

39
pump vane design such that, it allows stormwater to pass through without clogging or
imparting with its considerable free passage of 120mm and the pump approach canal
design. Therefore, it is suitable to select Stainless Steel 316 for the propeller of the pump.

b.) Casing – Cast Iron

Similar to the above propeller selection, the Stainless Steel 316 seems to be the suitable
solution, except the cost consideration. To minimize the cost while improving the life it is
recommended to use Cast Irion with a proper anodic protection as specified in ISO 12944.
On the other hand, the Pump Casing is a stationary part and which can be fabricated with
a freedom of applying protective coatings more effectively rather than spending
unnecessary cost by producing the pump casing in Stainless Steel 316. Finally, the total
coating thickness shall not less than 150microns.

c.) Shaft – Stainless Steel

As the Shaft and the propeller are connected and contacted with the water during the
operation it is to be fabricated with the similar material configuration of the propeller.
Besides, different connected materials without an insulation layer will increase risk of
diffusion and creating cathodic reaction which results corrosion. The required strength of
the shaft is to be achieved by the case hardening and increasing the cross section area.

d.) Shaft Seal – SIC/SIC (Silicon Carbide)

Silicon carbide is very hard and has excellent abrasion and wear resistance. It has a low
coefficient of friction, high hardness, and high modulus of elasticity. It also retains its
strength at elevated temperatures, has a low coefficient of thermal expansion, a high
thermal conductivity, and excellent corrosion resistance.
On the other hand, silicon carbide is quite brittle and its mechanical strength is less than
that of other hard metal carbide faces such as tungsten carbide. It is susceptible to chipping
and/or fracture when placed under mechanical stress or shock. To overcome the drawback,
silicon carbide placed into a metal holder. So, a metal shroud will be mounted on the

40
outside diameter of a rotating silicon carbide face to give it more mechanical strength and
prevent catastrophic failure.
e.) Bearing life – higher than 20,000hrs
The pumps shall be fitted with bearings greased for life. As, there are two positioned
bearings for rotating the pump shaft. The upper bearing shall be a cylindrical roller or single
ball type bearing to handle radial loads. The lower bearing shall be a double row angular
contact ball bearing to compensate for axial thrust and radial forces. The bearings shall be
lubricated by grease for open type or closed type. The minimum L10 bearing life shall be
60,000 hours at the most efficient operating point.

MOTOR
a.) Rated Voltage – 400V
b.) Rated Power – shall be less than 75kW
Sizing of the motor:

Hydraulic power of the pump = Qρgh/3.6 x 106

Where, Q= Flow, ρ = density of water, g – gravitational acceleration and h= head

= (7200 x 1000 x 9.81 x 2.1)/3.6 x 106

= 42.20 kW

Pump efficiency = 75% (Expected)

So, pump efficiency = Hydraulic power / shaft power

Shaft power = Hydraulic power/pump efficiency

= 42.02/0.75

Shaft power = 56.03 kW

Safety factor for motor = 10%

So Motor Size = 56.03/0.9

= 62.26 kW

So, available motor size for this pump = 75kW

41
 c.) Main Frequency – 50Hz
d.) Number of Phases – Three Phase
e.) Starting Method – VFD
f.) Minimum allowable numbers of starts per hour – 10
g.) Enclosure class (IEC 34-5) – IP 68
h.) Insulation class (IEC 85) – Insulation Class F and Temperature rise Class B
i.) Cable type – PNCT (EPR/Rubber insulated, 0.6/1kV rated cable)

As per the above inputs, the selected pump model is GRUNDFOS KPG.1000.10.T.50.E
and selected pump engineering data sheets are attached as an annexure.

Figure 6.01

42
 Figure 6.02

6.2 Preparing the conceptual design and drawings

Further to the chapter 5, Solution details, the conceptual design is developed as follows;

Figure 6.02

43
 Figure 6.03

As per the guidelines of the pump manufacturer, Grundfos which are complying with the
ANSI-HI 9.8_2012 intake structure is conceptualized.

The width of the pumping station = 10.8m

Justification for the above selection.

1. As mentioned in the chapter 5. (Solution 5.3), the width of the pumping station;

= Numbers of Pumps x Two times Diameter of a pump + Separation Wall

widths

= 05 x 02 x 1000mm + 02 x 400mm

= 10,800mm

2. Minimum Submergence requirement of the pump from the Figure 4.03/ 5.03

= 2700mm

44
However, it is to be noted that above submerge requirement is for the vertical
installation and for the horizontal (Gate mounted Pump) installation it should be
modified with the pump manufacturer installation data.

Table 6.01

Figure 6.03

45
 According to the table 6.01 and the figure 6.03 the minimum submergence requirement for
a Gate mounted pump is 1750mm, which should be below the low water level (+
0.3mMSL) of the St. Sebastian canal side. Hence, the available submergence is 3750mm
with the maximum allowable sump bottom level of -3.4mMSL.

3. For the Length of the pumping station, it has the freedom to move up to 60m. So, the
placing of major equipment like Automatic Trash Removal System, Stop logs, Penstock,
Naval Lock Gate System have the sufficient space along the canal.

Pump Gate
The pump gate should be a combination of a pump and flood gate and to be used for
purposes to discharge canal into the lake. The condition of design should be which the
pump gate is installed in the waterway.

Figure 6.04

46
 Table 6.02
However, I found using a steel structure (a gate) to mount a pump creates additional problems
for the space of the boat transfer. Further, it generate extra costs for the equipment and
maintenance. Also, there is no such requirement of lifting the pumps unless an event of repair
or maintenance. For that emptying the pump pit is the ideal solution.

Figure 6.05

47
 Hence, I decided to install the pumps on a concrete bed with the support of the column pipe
which usually use for the vertical installation. In addition, a simple pipe clamp will be used to
increase the holding strength of the system. And that can be fasten the concrete by using the
chemical anchoring.

However, the spacing between pumps, minimum submergence and all the necessary
geographical constraints as advised by the pump manufacturer will remain unchanged.

Accordingly, the pumping stations conceptual drawings are updated and include in section 9.
Drawings.

Boat Navigation

The present allocation for the boat transport is only for a channel as marked in the drawings.
The suggested operation is mentioned in the Section 7.

6.3 Selecting the major mechanical equipment for the operation

6.3.1 Stop Logs

Figure 6.06

48
  Width of the stop log = 4000mm and 6000mm
 Height of the stop log = HWL – Canal bed level
= 2.6mMSL – (-1.0mMSL)
= 3.6 ~ 4m

Size Water tight

Name Quantity Remark
(“W”x”H”) method
For one channel 08
sets.
Stop log 6.0m x 1.0m 08 4 Side sealing
Approach side 04 and
discharge side 04 sets.
Approach side 04 and
discharge side 04 sets.
Stop log 4.0m x 1.0m 14 4 Side sealing Close the discharge
side during a flood
06sets.
Close the discharge
Stop log 2.0m x 1.0m 03 4 Side sealing
side during a flood

Table 6.03

1. ALLOWABLE STRESSES

For Thickness < 40mm vertical lift gate type stop logs.

1) Tensile stress in axis direction : (for net sectional area) 1,200 kg/cm²

2) Bending stress : 1,200 kg/cm² for beam (for net sectional area)

3) Shearing stress : (for total sectional area) 700 kg/cm²

2. MATERIAL

The material to be used in this construction shall be same as below material or higher.

a. Skin plate : Stainless Steel, SS 304

49
 b. Rubber

Material : NEOPRENE
Specific gravity : 1.1-1.4

c. Rubber contact area : Stainless steel, SS 304

d. Bolt/nut & washer : Stainless steel, SS 304

e. Bracket : Stainless steel, SS 304

6.3.3 Automatic Trash Removal System

6.3.3.1 Screen
Specifications:
Details
Description
Multi rake bar screen
1 Type
6000 mm and 4000mm
2 Channel Width
4000 mm
3 Channel Depth
2600 mm
4 Max. water Level
1800 mm (Above FFL)
5 Discharge Height
10 x 50 mm
6 Bar Size
50 mm
7 Screen Opening
75°
8 Installation Angle
3 m/min
9 Racking Speed

Materials
AISI 316
1 Screen Frame :
AISI 316
2 Screen Bar:

50
 AISI 316+ PE
3 Wiper :
AISI 316
4 Dead Plate
AISI 316
5 Rake:
AISI 316
6 Discharge Chute
AISI 316
7 Cover
AISI 316
8 Chain

Motor
Squirrel cage
1 Type :
F
2 Class of insulation :
380 V, 3 phases, 50 Hz
3 Power Supply :
5.5 kW
4 Motor Power :
IP 55
5 Enclosure Protection :
Table 6.04

6.3.3.2 Conveyor
Specifications:
Details
Description
Horizontal trough type belt
1 Type
conveyor
12m
2 Length
18.6 m3/hr
3 Maximum Capacity
Non inclined (0⁰)
4 Installation Angle
Stainless steel 304
5 Inlet

51
 Materials
Stainless steel 304
1 Trough :
Stainless steel 304
2 Screw:
Stainless steel 304
3 Wearing Shoe :
Stainless steel 304
1 Legs

Drive/ motor
Synchronous motor
1 Type :
F
2 Class of insulation :
AC 3phase
3 Power Supply :
3.7 kW
4 Motor Power :
IP 55
5 Enclosure Protection :
Table 6.05

6.3.4 Gantry crane for handling pumps and stop logs

Specifications:
Details
Description

Single Girder Electric Overhead

1 Type
Travelling Crane

5 tons
2 Carrying Capacity

15 m maximum
3 Lift Height

9.5m
4 Crane Beam Length

12m
5 Gantry Beam length

18 / 6 m/min
6 Traversing Speed

52
 30 / 10 m/min
7 Traveling Speed

8 / 1.3 m/min
8 Hoist Speed

Materials

Mild Steel SS400

1 Crane Beam :

Mild Steel SS400

2 Gantry Beam:

Plough steel galvanized

3 Hoist Chain/ Wire Rope :

Epoxy / 250 micron minimum

4 Paint

Drive /Motor

Conical Rotor Squirrel Cage

1 Type :

F
2 Class of insulation :

400V 3 Phase 50 Hz
3 Power Supply :

IP55
4 Enclosure Protection :

53
7. Control Philosophy
7.1. Pumping station
The pump station has five pump systems utilizing a local pump control panel to manage the
speed of the pumps based on level settings using float switches or other means. Pump speeds are
controlled by the VFD.

Five levels will be defined as follows:

1. LS-0 (Redundant-OFF) = -2.3mMSL

2. LS-1 (All Pumps OFF) = +0.3mMSL

3. LS-2 (Lead Pumps ON) = +0.5mMSL

4. LS-3 (Lag Pumps ON) = +0.8mMSL

5. LS-4 (All Pumps ON) = +1.0mMSL

When the water level in the well reaches LS-2, the lead pumps turns ON with minimum speed. If
the water level continues to rise, motor speed increases proportional to water level until pump
reaches to its rated speed.
When the water level reaches LS-3, the lag pump turns ON. The lead and/or lag pumps shall
continue to run until the water level falls to the LS-1 (All Pumps– Off) level setting.
LS-0 is a Redundant Off level setting, which will turn off the lead and lag pumps in the event of
failure of the LS-1 level device. The LS-0 level shall be set at the pump minimum submergence
as required by the pump manufacturer.
LS-4 level will be defined as the high level alarm to the station’s telemetry system. The LS-4
level is typically set at the same level or slightly higher level as the LS-3 (Lag Pump –
ON/Alarm) level setting.
The LS-1 (All – Pumps OFF) level will be set at a location meeting the pump manufacturer’s
recommended pump off-elevation but no lower than the minimum submergence requirement of
the pump.
Also, the Pump-ON and Pump-OFF elevations will be based on the calculations to limit the
pump cycle time to less than the specified 10 starts per hour and Limit the well fill times under
design average flow conditions to 30 minutes or less.

54
7.2. Suggested Procedure for the Boat operation.
The channel with the Removable Screen and Conveyor belt is to be used for the boat navigation.
The stop logs, on top of the pumps, at the lake side and the canal side will be removed further the
trash removal system.

7.3. During a flood

During the rainy season, stop logs, on top of the pumps will be installed. And, the trash removal
system will be put in order. Then, the pumping station will start its operation.

7.4. Repair or maintenance of the pumping station

For the repair or maintenance of the pumps, flap valves or for the cleaning of the pump pit, a grit
removal pump/ pit emptying pump is to be used. And, during the maintenance the stop logs on
the lake side and the canal side will also be installed.
Minimize the amount of pumping capacity for the sludge pump, the provided gate valves can be
used.

55
8. Cost Estimation

ST. SEBASTIAN SOUTH NAVIGABLE STORMWATER PUMPING STATION

BILL OF QUANTITIES
Summary of the BOQ
Lump sum value
Foreign Local
Currency Currency Taxations
Item Description USD LKR LKR
1 Design, drawing & documentation 2,700,000.00

2 Mechanical Equipment 2,50,832 7,168,140.00 13,544,928.00

Stormwater Pumps
Flap v/v
Automatic Trash Removal System
Stop logs
Gantry crane
Spare parts

3 Electrical Equipment 65,578 2,804,040.00 2,951,010

Generator
Control panels
Spare parts

Training, Installation supervision &

4 commissioning 22,270 4,008,600.00

Sub
5 total 338,680 16,680,780.00 16,495,938.00

6 Add contingencies 10% 33,868 1,668,078.00 1,649,593.80

7 Grand Total 372,548 18,348,858.00 18,145,531.80

Table 8.01
*Above cost is displayed without VAT
* 01 USD = 180.00LKR, exchange rate.

56
9. Drawings
No Drawing Number TITLE
1 SSPS/DWG/D/G/001 P & I DIAGRAM – NAVIGABLE STORMWATER
PUMPING STATION
2 SSPS/DWG/D/G/002 GENERAL ARRANGEMENT – LAYOUT PLAN
3 SSPS/DWG/D/M/003 GENERAL ARRANGEMENT – PUMPING STATION
SECTION VIEW
4 NA GENERAL ARRANGEMENT – OVERALL LAYOUT
PLAN OF THE ONGING PROJECT
5 NA GENERAL ARRANGEMENT – PUMPING STATION
SECTION VIEW OF THE ONGOING PROJECT

Table 9.1

57
 PIT EMPTYING
PUMPS

ST. SEBASTIAN STOP LOGS TO AUTOMATIC STORMWATE STOP LOGS

ISOLATE THE REMOVABLE R TO PREVENT
PUMPING STATION TRASH BACK FLOW
PUMPS
DURING REMOVAL DURING A
CANAL MAINTENANCE OR SYSTEM 2CMC X 05 FLOOD
REPAIR
APPROACH SIDE

MOVABLE
GANTRY CRANE

GARBAGE
CONTAINER UPSTREAM

BEIRA LAKE

(STORMWATER DISCHARGE)

STOP LOGS TO
ISOLATE THE
PUMPING
STATION
DURING
MAINTENANCE
OR REPAIR

PROCESS AND INDICATION DIAGRAM

58
SSPS/DWG/D/P/002
59
SSPS/DWG/D/S/003
60
LAYOUT PLAN
4:1
61
62
10. Maintenance Schedules
10.1. Stormwater Pumps

ST. SEBASTIAN SOUTH STORMWATER PUMPING STATION

HEALTH CHECK LIST OF THE STORMWATER PUMPS

EQUIPMENT FREQUENCY
NO NAME NATURE OF WORK D W 2W M 3M 6M A

1 PUMP 1 CHECK ANY ABNORMAL NOISES X

2 PUMP2 CHECK ANY ABNORMAL VIBRATIONS X

3 PUMP 3 CHECK PUMP WEARING AND PROPELLER X

4 PUMP 4 CHECK LIQUID IN STATOR HOUSING X

5 PUMP 5 CHECK WATER IN LIQUID CHAMBER X

CHECK POWER CABLE CONNECTION X

CHECK ANY WATER LEAK IN CABLE ENTRY X

CHECK INSULATION RESISTANCE OF

STATOR X

CHECK OIL LEVEL X

VISUAL CHECK ON ENTIRE PUMP X

CHECK CONTROL PANEL INDICATIONS X

CHECK/ CLEAN CONTROL PANELS X

TEST RUN FOR OBSERVATIONS X

63
1. MAKE SURE ALL THE ELECTRICAL SWITCHES ARE IN "OFF" POSITION BEFORE CAARYING INSPECTIONS ON
ROTATING PARTS.
2. FOLLOW INSPECTIONS FOR ALL THE PUMPS*
3. WAER A PROPER PPE FOR THE SAFETY PURPOSES.

REMARKS/ OBSERVATIONS:

D : DAILY 3M: QUARTERLY

6M: SIX
W: WEEKLY MONTHLY
2W: FORTNIGHTLY A: ANNUALY
M: MONTHLY

10.2. Automatic Trash Removal System

ST. SEBASTIAN SOUTH STORMWATER PUMPING STATION

HEALTH CHECK LIST OF THE AUTOMATIC TRASH REMOVAL SYSTEM

EQUIPMENT FREQUENCY
NO NAME NATURE OF WORK D W 2W M 3M 6M A

CLEAN THE TRASH RACK IF ANY DEBRIS

1 SET 1 REMAIN X

2 SET 2 CHECK DEBRIS THROUGH CLEAN AREAS X

CHECK THE GREASE LEVEL OF THE DRIVE

CHAIN X
CHECK ANY DEBRIS ON SPROCKET WHEELS X

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 VISUAL INSPECTION OF RAKES AND CHAINS X

OPERATE THE SYSTEM FOR INSPECTION X

CHECK ANY ABNORMAL NOISES X

CHECK ANY ABNORMAL VIBRATIONS X

CLEAN AND CHECK CONTROL PANEL X

CHECK THE CONVEYOR BELT OPERATION

FOR ANY TENSIONS OR SAGGING X

1. MAKE SURE ALL THE ELECTRICAL SWITCHES ARE IN "OFF" POSITION BEFORE CAARYING INSPECTIONS ON
ROTATING PARTS.
2. FOLLOW INSPECTIONS FOR THE TWO SETS.
3. WAER A PROPER PPE FOR THE SAFETY PURPOSES.
4. REMOVE/LIFT RAKE AND CONVEYOR BELT WHEN NOT IN USE.
REMARKS/ OBSERVATIONS:

65
D : DAILY 3M: QUARTERLY
6M: SIX
W: WEEKLY MONTHLY
2W: FORTNIGHTLY A: ANNUALY
M: MONTHLY

10.3. Gantry crane

ST. SEBASTIAN SOUTH STORMWATER PUMPING STATION

HEALTH CHECK LIST OF THE GANTRY CRANE 05 TON

EQUIPMENT FREQUENCY
NO NAME NATURE OF WORK D W 2W M 3M 6M A

OVERHEAD
1 GANTRY DAILY HEALTH CHECKS

2 VISUAL INSPECTION X

CHECK THE OPERATION OF LIMIT

SWITCHES X

CHECK THE OPERATION OF BRAKES X

CHECK THE PENDANT FUNCTION X

CHECK THE WIRE ROPE/CHAIN CONDITION X

CHECK THE HOOK CONDITION X

WEEKLY CHECKS

VISUAL CHECKS ON OPERATION AND

LUBRICATION LEVELS X

APPLY LUBRICANTS FOR LEVERS AND

MOVING PARTS IF NECESSARY X
MONTHLY INSPECTIONS

66
 CHECK ANY WEAR MARKS OF PULLEYS OR
WHEELS X

CHECK AND CLEAN POWER SUPPLY AND

CONNECTIONS X

CHECK AND CLEAN CONTROL PANEL IF

NECESSARY X

QUATERLY HEALTH CHECKS

TEST RUN AND INSPECT ALL THE MOVING

PARTS FOR THE GOOD HEALTH. X

CHECK FOUNDATION, STRUCTURE AND

MOVING WHEELS FOR ANY DAMAGES OR
LOSEN PARTS. TIGHT THEM, IF NECESSARY X

CHECK MOTOR FOR ANY ABNORMAL

VIBRATIONS OR NOISES X

06 MONTHS

LUBRICATE ALL MOVING MARTS WITH

GREASE IF NECESSARY X

1. MAKE SURE ALL THE ELECTRICAL SWITCHES ARE IN "OFF" POSITION BEFORE CAARYING INSPECTIONS ON
ROTATING PARTS.
2. WEAR A PROPER PPE FOR THE SAFETY PURPOSES.

REMARKS/ OBSERVATIONS:

D : DAILY 3M: QUARTERLY

6M: SIX
W: WEEKLY MONTHLY
2W: FORTNIGHTLY A: ANNUALY
M: MONTHLY

67
11. Suggestions for further improvements.
 A properly design screening mechanism that is capable of lifting or removing while not in
operation will improve the ease of operation and risk of falling objects or debris.
 By improving the ability of lifting or removing when not in operation of the trash removal
system, can increase the usage of other 4m width channel for the boat navigation.
 Having two sets of sludge pumps will improve the time taken to empty the pump pit in
case of maintenance or repair.
 A properly designed bracket for holding the stormwater pumps can help to eliminate the
use of steel, column pipes and flanges.
 By improving the water quality (with a treatment process) of the lake and canal the water
can be used for gardening or farming purposes with the modern concepts of vertical
farming.

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12. References and Annexures

12.1 Reference codes, standards and guidelines

The following standards are used for the design of pump intake and the selection of the
pump.

 ANSI-HI 9.8_2012 - American National Standard for pump intake design

 ISO 9906 - International Standard for Pump performance tests

 ISO 12906 - International Standard for coating specifications and

Procedures

 Flood control design guideline from the pump manufacturer Grundfos.

 Data booklet of the pump manufacturer Grundfos

12.2 Internet Resources

Absolute Roughness of material

https://www.enggcyclopedia.com/2011/09/absolute-roughness/

K factors for fitting

www.neutrium.net/fluid_flow/pressure-loss-from-fittings-excess-head-k-method/

Boat Handling

1. https://www.gov.uk/guidance/inland-waterways-and-categorisation-of-waters#safety-
requirements-for-boats-to-operate-on-inland-waters
2. www.black-prince.com
3. https://en.wikipedia.org/wiki/Canals_of_the_United_Kingdom
4. https://en.wikipedia.org/wiki/Narrowboat

69
Automatic Bar Screens and trash removal systems

5. https://www.huber.de/products/screens-and-fine-screens/perforated-plate-and-bar-
screens/huber-multi-rake-bar-screen-rakemaxr.html
6. https://www.chinaboeep.com/Bar-Screen-pl6446456.html

Gate Pumps

7. http://en.eastpump.com/792b9977-f23d-718a-6a81-dbade5bfbe3b/47c4ff47-f08a-d4fe-
1fa8-3eae14a8a24c.shtml
8. http://www.hasuh.co.kr/new2/eng/main/main.php

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