Design Guidelines for Pumping Stations

TET/DG/5004
Design Guidelines Date: 04/03/2012

PUMPING STATIONS Issue: 1.0
Electronic Document, only the original archived in Quality Department is signed / Printed copies uncontrolled
Contents
Introduction ......................................................................................................................................................... 2
1. Pump Design .............................................................................................................................................. 2
1.1 Field of use ............................................................................................................................................ 2
1.2 Number of impeller (s) .......................................................................................................................... 2
1.3 Shaft position ......................................................................................................................................... 3
1.3.1 Surface / Immersed / Submersible / Line Shafting ................................................................................ 3
1.4 Type of impeller .................................................................................................................................... 3
1.5 Seals ....................................................................................................................................................... 3
1.6 Coupling ................................................................................................................................................ 4
1.7 Bearings ................................................................................................................................................. 4
1.8 Motors.................................................................................................................................................... 5
1.9 Materials ................................................................................................................................................ 5
2. Hydraulic calculations for pump ................................................................................................................ 5
2.1 Specific speed ........................................................................................................................................ 5
2.2 Pump design parameters ........................................................................................................................ 6
2.3 Operating point ...................................................................................................................................... 7
2.4 NPSH and cavitation............................................................................................................................ 11
2.5 Motor drive .......................................................................................................................................... 12
2.6 Points to note ....................................................................................................................................... 12
3. Design of pumping station ....................................................................................................................... 13
3.1 General Recommendations .................................................................................................................. 13
3.2 Access and maintenance ...................................................................................................................... 14
3.3 Over head hoist .................................................................................................................................... 14
3.4 Access and protection .......................................................................................................................... 14
3.5 Health, Safety and Environmental Requirements ................................................................................ 15
3.5.1 Alarm systems ..................................................................................................................................... 15
3.5.2 Lighting including Emergency lighting ............................................................................................... 15
3.5.3 Emergency exits................................................................................................................................... 15
3.5.4 Health and Safety signage.................................................................................................................... 16
3.5.5 Fire fighting equipment ...................................................................................................................... 17
3.5.6 Confined Spaces .................................................................................................................................. 17
3.5.7 Welfare facilities.................................................................................................................................. 17
3.6 Other facilities ..................................................................................................................................... 18
3.7 Ventilation ........................................................................................................................................... 19
4. Hydraulic equipment ................................................................................................................................ 19
4.1 Schematic layout of a pumping station ................................................................................................ 19
4.2 Pipes .................................................................................................................................................... 20
4.3 Valves .................................................................................................................................................. 20
4.4 Flow meter ........................................................................................................................................... 20
4.5 Disinfection ......................................................................................................................................... 20
4.6 Electrical equipment ............................................................................................................................ 20
4.7 Emergency Power ................................................................................................................................ 21
4.8 Fire Protection ..................................................................................................................................... 21
4.9 Safety Shower and Eye Wash .............................................................................................................. 21
5. SCADA .................................................................................................................................................... 22
Attached to: TET/PRO/5002 1/22

Sultanate of Oman, Public Authority for Electricity and Water
TET/DG/5004
INTRODUCTION
The function of a pumping station is to transmit water at higher flow and/or pressure from that
received. Pumping stations are generally found at the following locations:
 Wells: to transfer water to storage sites, treatment plants or distribution systems;

 Storage: to transfer water from main storage locations to distribution storage reservoirs;
 Network: boosting water to increase the pressure in a pipe line.
The design of the pump station depends on technical, economical and geographical
considerations.
A pumping station that supplies water to the distribution system is ideally located near a water
treatment or water storage facility. Booster pumps to increase the pressure are in the network.
Dimensioning the pump is a key factor, the information on pumps (design, type, size etc...) is
detailed in the document below.
1. PUMP DESIGN
This section provides some information on each component of the pump.

In the water supply systems centrifugal pumps are mostly used. A centrifugal force is defined as
the action that causes something to move away from its access of rotation.
A centrifugal pump uses an impeller and volute (or casing) to create the partial vacuum to suck
water in and discharge pressure necessary to move water through the pump casing. The
impeller and volute are the essential parts of the pump and help determine its flow, delivery
pressure and suction capability.
There are four main characteristics to describe a centrifugal pump:

 Field of use;
 Number of impellers or stages;
 Shaft orientation;
 Type of impeller.
1.1 Field of use
It is important to know the type of water (clear water or loaded water). The choice of the pump
also requires knowledge of the pumped water (hardness of the water, conductivity, sand
content etc.).
1.2 Number of impeller (s)
There are two types of pumps:

 Single stage pump: is composed of one volute with a single impeller;
 Multi stages pump: is composed of more than one impeller, each increasing pressure
above its predecessor.

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1.3 Shaft position
 Horizontal pump: The shaft of the pump is horizontal or parallel to the ground. Entire
pump unit would be installed on the ground level;
 Vertical pump: The shaft of the pump is vertical or perpendicular to the ground. Motor is
located above the pump head or at a higher level with an extended shaft.
1.3.1 Surface / Immersed / Submersible / Line Shafting
 Surface pump : The pumping unit (motor + pump) is situated outside of the liquid to be
pumped, both motor and pump are above ground level;
 Immersed pump: Pump unit is in liquid but motor is above the liquid;
 Submersible pump: The pumping unit is immersed in the liquid to be pumped. Both
pump and motor are inside the liquid and they can work only in the liquid medium for the
sake of cooling and cannot work outside;
 Pump with line shafting: The motor is situated outside of the liquid to be pumped and the
pump is immersed and they are connected by a shaft.
1.4 Type of impeller
The type of impeller depends on the type of water to be pumped, the total head and the
discharge.
There are different types of impellers.
 Open;
 Semi open;
 Closed.
Suction can be either single suction or double suction. A single suction impeller allows liquid to
enter the centre of the blades from only one direction. A double suction impeller allows liquid to
enter the centre of the impeller blades from both sides simultaneously.
Pumps can be classified according to the suction and delivery of the liquid with reference to the
position of the access of the impeller.
1. Radial Flow–Normally a centrifugal pump is of radial type in which liquid enters at

access and flows out radially. In radial flow pressure is developed wholly by centrifugal
force;
2. Axial Flow–In axial flow liquid enters along the access and flows out along the access.
In axial flow the pressure is developed by the propelling or lifting action of the vanes of
the impeller on the liquid;
3. Mixed Flow–This is a combination of radial and axial flow in which the pressure is
developed partly by centrifugal force and partly by the lift of the vanes of the impeller on
the liquid.
1.5 Seals
Seals are basically meant to control escape of liquid from the volute along the shaft. The seals
are designed to ensure that the point where shaft passes from the inside to the outside of the
pump does not leak.
They are of two types:

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 Gland packing;
 Mechanical seals.
Packings are made of woven fabrics impregnated with various lubricating substances in order to
lower friction. It is packed within a gland housing that needs manual adjustment to prevent
leakage but still ensure lubrication by the liquid to be pumped.
Mechanical seals are another key component of pumps. They consist of two faces, one
stationary on the outer side and the other rotating inner side and are located on the shaft
between the impeller and the rear casing.
1.6 Coupling
The coupling is a unit which connects the motor shaft and the pump shaft enabling the transfer
of torque energy from water to pump.
The coupling must full fill several functions such as:

 Absorbing and accommodating torque irregularities (shocks);
 Allow some misalignment between the shaft of the motor and the pump;
 Separate the critical systems (avoid the problem of resonance).
The choice of coupling requires knowledge of the following parameters:

 Nominal transmission torque;
 Stiffness, permissible misalignment, offsets;
 Dimensions;
 Atmosphere, temperature;
 Safety coefficient, nominal torque of the coupling.
1.7 Bearings
Bearings are intended to provide smooth friction free rotation of the shaft of motor and pump.
A wide variety of bearings is available.
Bearing must be able to:

 Support the loads between the rotor and the pump casing;
 Ensure a minimum friction with good lubrication;
 Ensure proper alignment.
Bearings consist of:

 Two rings: outer one linked to a fix element (body of the pump) and inner element
related to a rotating part (shaft);
 A cage: to position and maintain the rotating balls in the bearing rings;
 Rolling body: Balls or rollers ensure proper contacts between the rotating and the
stationary rings.
The lubricant must full fill the following functions:

 Reduction of friction torque;
 Reduction of the wear;
 Transfer of heat (oil lubrication);
 Reduction of operating noise;
 Protection of the bearing against corrosion;

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 Quench of the bearing (grease lubrication) to prevent penetration of solid or liquid

bodies;
 Compatibility with the seals;
 Tolerance or repellence to moisture.
There are two types of lubrication:

1. Oil lubrication: when speed and temperature are high;
2. Grease lubrication: when speed is restricted (the maximum speed permitted for grease
lubricated bearings is 20% less than the maximum speed permitted in oil lubrication).
When protection against corrosion is important and to provide life-lasting lubrication.
1.8 Motors
The selection of the motor is done according to the capacity of the pump.
For the selection of a motor the following factors should be considered:

 Selection of the speed of rotation: depends on number of poles;
 Selection of the motor power: nominal power of the motor is the power delivered by the
motor to the shaft. The efficiency of the motor is at its maximum at a point between 75%
and 100 % of its maximum load.
Different types of motors:

 Fixed speed;
 multi-speed (generally two);
 variable speed.
 Protection index: provides the correct security level;

 Insulation class: determined by motor overheating capacity and room temperature;
 Selection of type of cooling: cooling by pumped liquid, cooling by circulation of oil and
cooling by oil filled jacket.
When determining a motors size, safety margins should be considered. Safety margins
normally vary between 10 and 15 %.
For large motors, soft-starters should be used in order to reduce the electrical current intake.
Variable frequency drivers (VFD) may be used to adapt the pumping regime to output
parameters (pressure, flow rate…). VFD should be limited to the range of 50% to 120% of the
nominal frequency of the motor.
1.9 Materials
There is a choice of materials depending on the environment the pump will be working in. The
principal materials are ductile iron, stainless steel, bronze and plastics.
2. HYDRAULIC CALCULATIONS FOR PUMP
2.1 Specific speed

The specific speed of a pump is the speed at which the pump will rotate when discharging
1m3/s under a head of 1 m at its highest efficiency.

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Specific speed is a number characterizing the type of impeller in a unique and coherent manner
and is determined independent of pump size. This factor can be useful when comparing
different pump designs.
Specific speed can be expressed as:

Ns = N .
N = Actual speed (RPM),
Q = discharge (m3/s),
H = Total head (m of water column.)
The variation of Q, H and power P, with N are given by the following expressions:
2 3
Q' = Q; H' = .H; P' = .P
A wide variety of impeller types are available. Depending on the quality of the fluid and the Q/H
desired a choice must be made.
2.2 Pump design parameters
For the selection of the pump size the flow rate or capacity Q (m3/h) and pump head H (m.w.c)
are needed at the required duty point.
These variables are determined for the pumping regime that occurs the most frequently. The
correct pump size and speed can then be selected from pumping group (pump + motor)
performance curves. Other parameters such as efficiency η, input power P and N.P.S.H. of the
selected pump can be found from its individual curves.
The main pump curve of a pump gives the relationship between the two variables Q and H. A
typical pump curve of a constant speed centrifugal pump is given below.
Fig 1. Pump Characteristic Curves
A characteristic feature of the curve of a centrifugal pump is the increase of the flow rate Q while
decreasing head H.
The pump has a self-regulating capacity for varying heads.
The selection of the appropriate pump curve depends on the specific duty point requirements.

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For the same value of (ΔH) the value of (ΔQ) changes considerably between flat and steep
curves of the pump.
To assess the necessary pump head H, the system head, Hs, must be determined.
Hs = hsta + Ʃ hf
Where
hsta = static head: height difference between the suction and the discharge fluid levels.
Ʃ hf = The sum of all pressure head losses caused by friction in pump and pipeline systems, for
a given flow rate.
2.3 Operating point
Pump characteristics are known from the pump curve.
The system characteristics, i.e. the Q – H relationship of the pipe system have a form as can be
seen below (fig 2).
Fig 2: System Curve
The point of intersection between system curve and the pump curve is the operating point.

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Fig 3: Pump Performance individual and combined
The operating point changes based on the arrangement of the pumps (individually or
combinedly).
There are several ways to change this operating point.
One way is to change the pump curve. This can be achieved by:
 Parallel operation of more pumps (max. discharge );
 Serial operation of more pumps (max. head).

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Fig 4: Changing operating point by pumps in parallel / pumps in series
Another way is to change the system characteristics by:
 Altering pump speed;

 Controlling valves;
 Changing pipe diameters;
 Altering impeller diameter.

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Fig 5: Changing operating point by changing pump speed / valve position

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2.4 NPSH and cavitation
Centrifugal pumps will only operate satisfactorily if there is no build-up of vapour within the
pump.
Cavitation on the impeller blades should always be avoided. This phenomen is caused by
carried air or water vapour being released from the water. The developed bubbles (of a very
small size) move inside the pump and collapse when entering a higher pressure zone. The
continuous collapsing of bubbles on the tip of an impeller blade causes the metal to be eroded.
The lifting of water by suction should be avoided as far as possible. The pump parameter
N.P.S.H. (Net Positive Suction Head) must be evaluated. The N.P.S.H. can be roughly defined
as the static head above vapour pressure.
It is important to accurately differentiate the required N.P.S.H. indicated on the characteristic

curve of the pump and the available N.P.S.H. that is determined from the characteristic of the
network.
To avoid the phenomen of cavitation, it is necessary to comply with the rule:

 Available N.P.S.H. > required N.P.S.H;
 For safety, the available N.P.S.H. must always be greater than the required N.P.S.H. of at
least 0,5 m to 1 m.
NPSH available from the system
NPSH required by the pump
The intersection of two N.P.S.H. curves reveals the point of cavitation.
NPSH could be calculated as below:

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Where
p0 = pressure at the water surface;
pv = vapour pressure for the fluid at the temperature T1 at 1;
∆z = difference in height (z1-z0) from the water surface to the location;
ρ = fluid density;
g = gravitational acceleration
2.5 Motor drive
There are three different types of motors. These are:

 Fixed speed: one speed, used in most cases;
 Multi-speed: generally two choices of speed, rarely used in pumping;
 Variable speed: constantly adapting to the pumping need (direct delivery system with
variable flow and constant pressure). These motors are coupled to a Variable
Frequency Drive (VFD).
The speed of rotation depends on the number of pairs of poles

Rotation frequency =
Where
n = number of pole par phase
F = Frequency (50 or 60 Hz)
The Common values for a frequency of 50 Hz are:
 2900 rpm with 2 poles

 1450 rpm with 4 poles
 960 rpm with 6 poles.
The motor performance is at its maximum for a point between 3/4 and 4/4 of his charge.
The pump power input P of the pump is the mechanical energy at the pump coupling or pump
shaft absorbed from the drive. P can be calculated using the following formula:
P=
Where
P = power (kW),
= density of the fluid (kg/m3)
= gravitational constant (m/s2)
Q = pump capacity (m3/s),
H = pump head (m)
= pump efficiency
When determining the required power of the motor drive an overall efficiency must be used:
= pump + motor + cable + transformer +( VFD if any)
2.6 Points to note
 Never oversize a pump but select with the required duty point;

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 Choose a motor with sufficient power reserve but not too oversized;
 Respect the maximum number of starts per hour depending on motor power:
P < 4 kW 15 starts / hour maximum
P from 5 to 11 kW 12 starts / hour maximum
P from 15 to 30 kW 10 starts / hour maximum
P > 30 kW 6 starts / hour maximum
 Prefer a motor running 1500 rpm rather than 3000 rpm to maximise longevity and
reliability;
 Power on the motor plate is the nominal power delivered by this motor;
 Minimize head loss at the suction side, prevent the possibility of air intake;
 Never control the pump from the suction side;
 The discharge flow should be a straight as possible (avoid Tee and 900 elbow);
 For the installation of pressure gauges and flow meters comply with manufacturers
recommendations.
3. DESIGN OF PUMPING STATION
The required capacity of pumping station and its location is determined from hydraulic network
analysis.
A pumping station should have at least:
 Pump hall;
 Control room (optional);
 Electrical room;
 Automation room;
 Office;
 Maintenance and workshop facilities;
 Storage for parts and equipment;
 Storage for chemical and substances;
 Welfare facilities (including PPE changing area).
All equipment must be protected from climatic conditions.
3.1 General Recommendations
The architectural design should harmonize with the surrounding environment and respect the
natural landscape as far as reasonably practicable.
The foundations of structures depend on the results of a soil analysis. Usually, the structure is
of reinforced concrete, steel and masonry construction.
The building should be designed considering both the initial requirement and the potential need
for space to accommodate future equipment for expansion.
The impact of noise on houses or other buildings near the station must be considered.
Windows should not be included in unattended locations or chemical storage including chlorine
gas.
All equipment must be installed or built in such a way that flooding or other spillages cannot
jeopardise the operation or running of such equipment. All electrical panels must also meet
these requirements so as to prevent failure or electrocution.

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Floors should slope to a sump fitted with a pump. The floor should be non-slippery to avoid
accidents.
Welfare needs of operators, operations / maintenance, cleaning and security of employees

should be considered in the design.
In line with MD 286 the Design team must carry out an assessment of all potential Hazards
during construction and operation phases. This must include a risk assessment detailing the
future requirements for fire fighting, manual handling, electrics, lone working, confined spaces,
chemical control etc. PAEW HSE is to be consulted at all stages of the design.
3.2 Access and maintenance
A paved road access for maintenance vehicles should be provided. All equipment should have
horizontal and vertical clearances to allow for repairs and maintenance to be carried out
efficiently and safely. Pumps, motors and equipment should be installed after finishing civil
works.
Stepped platforms should be installed if necessary to access equipment.
If the pumping station has different floor levels, stairs and safety railings should be installed.
To avoid the need to climb over pumps, motors or pipes, stairway shall be provided to provide
access to all sides of pump and motor. Where required lifting equipment specific to fitting new
parts i.e. A frames or block and tackle must meet all HSE requirements
3.3 Over head hoist
If temporary or portable hoisting is not practical, crane rails and electrical hoists should be
installed for maintenance or repair works. These should cover all heavy equipment and allow for
offloading of Trucks etc.
Hoists should be designed so that the equipment located inside can easily be taken outside for
heavy maintenance or replacement. Hoists must be marked and included in routine inspections
by the relevant competent authority at least annually for the hoist and every 6 months for hoist
equipment i.e. chains, straps, strop, hooks, shackles and D rings.
3.4 Access and protection
The protection of access to water facilities is important. Metal fences must be provided to
prevent trespassing, theft and from act of domestic and non-domestic aggression.
The following elements could be installed:

 Secured hatch, doors or covers to direct access points;
 Direct access door to the pumping station or technical room (s);
 Ventilation grills;
 Access ladders.
Pumping stations are normally completely enclosed by high fences. These could be of the
chain-link or iron railings type, depending on architectural requirements and risk level.
Alternatively a masonry wall could be constructed to meet architectural requirements.

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The security fence is generally adjacent to the property line. Each site should have a boundary/
perimeter fence which should comply with regulations and PAEW’s security and HSE Policy.
3.5 Health, Safety and Environmental Requirements
Emergency equipment must be set on the risk of the hazards on the site. The following are
some mandatory emergency equipment:
 Alarms;
 Signage;
 Lighting;
 Exits;
 Fire extinguishers;
 Confined spaces;
 Welfare facilities.
3.5.1 Alarm systems
Emergency alarms must meet the requirements governing the hazards and the risk. As a
minimum all sites including pumping station must have a fire alarm system capable of
evacuating the site safely in a minimum of time, be it electrical or mechanical.
Other alarms to consider in pumps room and treatment works would be:
 Pump alarm normally blue flashing;
 Telephone alarm normally white flashing;
 Chlorine alarm normally orange flashing;
 Fire alarm normally red flashing.
All alarms are normally backed up with audible high pitched sound. Staff must be trained and
aware of what to do in the event of any alarm.
3.5.2 Lighting including Emergency lighting
Interior and exterior lighting facilities must be provided where necessary and automatically
operate emergency lighting system must be installed as part of the normal lighting and must last
for a minimum of 30 minutes on automatic action during an emergency. It must also illuminate
the safe route to a final exit from any part of the building structure.
Where exterior lighting is requited it shall be equipped with an automatic presence detector
lasting not less than 5 minutes.
3.5.3 Emergency exits
Emergency exists must be provided so that staff can evacuate the building during an
emergency by the fastest safe route and all final exits must have push/paddle bar release.
Where required, dependent on volume of staff these may need to be double doors.

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3.5.4 Health and Safety signage
All emergency exits, walkways, staircases, hall ways must have emergency signage dictating
the direction of travel to the emergency exits including pictograms on what actions to carry out
on route or at the exit i.e. push bar release.
Other signage required on the site should follow best international practice and the following
categories must be observed:
 Mandatory;
 Prohibition;
 Emergency and warning;
 Danger;
 Information.
All signage will be worked out on the hazard identified risk assessment and may change with
further building design or alteration. For example see followings chart.

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3.5.5 Fire fighting equipment
Fire fighting equipment can only be decided on the recommendations from a fire risk
assessment in line with the completed design from the designer and further improved during the
course of construction. Only with this information and in line with Oman HSE regulations and
guidance by external authorities i.e. ROP, municipality can the right equipment per location be
decided upon. This may include but not be limited to fire extinguishers, suppression systems,
fire blankets etc.
3.5.6 Confined Spaces
In a pumping station confined spaces are normally found where chemicals are stored or dosing
i.e. chlorine or in an area with limited access and egress, or where there is a risk from flooding,
free flowing solids or the design of the building or structure dictates.
Mandatory equipment requirements should be used in these areas and the following list should
be included but is not exhaustive:
 Gas monitors;
 Tripod and Winch;
 Harness;
 Breathing apparatus;
 PPE.
This would be decided on a thorough and comprehensive confined space risk assessment.
3.5.7 Welfare facilities
Welfare facilities must be included in all pumping stations for the benefit of staff and operational
requirements. They should include the following as a minimum but this may change on the use
of the site or risks that develop:
 Toilets and washing facilities;
 Changing areas;
 Canteen facilities (depending on size of site);
 First aid facilities including a minimum of a 10 man first aid kit with 2 eye wash bottles;

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 On all sites where chemicals or substances are to be used a safety shower (s) must be
fitted (see requirements in Other facilities).
3.6 Other facilities
Doors giving access to the facilities and equipment must be equipped with anti-intrusion system
providing access only through use of a code or badge. The doors must opened in an outward
direction.
A chain must be installed across access ladders as a means of preventing further entry and as
a visible sign unless authorised not to go beyond. In this instance, the chain must be replaced
after the entry and exit.
Sump covers should be installed and be of the gridded type each grid not exceeding 30 x 30
mm.
The sump shall be equipped with float level controllers '' Pear shape type '' and a drainage
pump that initiates automatically when the sump is full.
For the security of the pumping station an independent flood alarm system shall also be
installed. This system shall consist of a level controller '' Pear shape type '' positioned 1or 2 cm
above the floor which will inform the Control room.
A telephone booth shall be provided inside the building adjacent to the pump room with a vision
panel in to the pump room. A flashing white light shall be installed to indicate the phone is
ringing in the pump room. The operator must go into the telephone booth to operate the phone.

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3.7 Ventilation
Ventilation will be provided to protect against over heating equipment, and will be either air
conditioning, heat extraction or a mixture of both and shall be designed for internal (motor,
lighting etc...) and external loads (structure, climatic conditions). A specific ventilation study is
required for each installation.
4. HYDRAULIC EQUIPMENT
4.1 Schematic layout of a pumping station
Manometer
Pressure
sonde
Anti-ram
PI Sondes
temperature & Meter
Suction vibration Discharge
WM
Sonde
temperature &
vibration
A typical pumping station has at least the following equipment:

 Suction pipe;
 Discharge pipe;
 Valves (gate valves, non-return valves and butterfly valves);
 2 pumps (minimum or 33 % standby) with temperature and vibration sensors (for pumps
above 20kW);
 Pressure gauges;
 Surge vessels;
 Anti ram / Surge Tank;
 Air compressor;
 Secondary or post chlorination (optional);
 Online water quality monitoring (optional);
 Sampling points (on inlet and outlet);
 Flow meter;
 Pressure transmitters;
By-pass for booster stations only.

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4.2 Pipes
The type of pipe depends on the fluid being transported and the environment in which it is
installed. Usually, suction and discharge pipes are made of steel (cast or carbon steel).
4.3 Valves
 Isolation valves are installed on suction and discharge pipes, pump inlets and discharge
pipes and, by-pass pipelines.
 The discharge valve(s) should be modulating type and motorized.
 Pump controls must have an emergency shutdown power check feature for surge
protection when power fails.
 Air release, air vacuum release or combination of air release and vacuum valves are to
be provided at critical locations in the pumping station piping.
Unless otherwise required, the discharge side of all pumps is to be provided with pump control
valves as well as check valves
Drain valves should be also installed on the suction and discharge pipes of each pump.
Tapping points for pressure monitoring should be installed at the suction and delivery sides of
each pump as well as on the main header of suction and discharge.
4.4 Flow meter
In order to measure the flow at the outlet of the pumping station, an electromagnetic or
ultrasonic flow meter should be provided.
4.5 Disinfection
Water quality studies are necessary to choose the type of disinfection (for example gas or
hypochlorite), its installation, control, storage, handling and transport requirements. For example
chlorine in bottles, must be installed inside the station in a separate closed, secure and alarmed
room. The alarm must warn at the extremities and main entrance to the site.
Injection of chlorine in a closed chamber shall be avoided.
4.6 Electrical equipment
For the fixed speed pump soft starter should be installed.
For the variable speed VFD should be installed.
All electrical panels, switchgear and electrical control equipment should be located in the
electrical room. Good visibility of panels is necessary as is proper warning and danger signage
on the equipment. The electrical panels should have at least 30% extra capacity for extension.
Every electrical panel shall be equipped with command buttons with three positions (Manual,
Automatic and stop).
The main parameters (power, power totalizer, voltage, currant, temperature, hour running meter
etc.) should be displayed.

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The electrical equipment room is to be separate from the pump room. It could be either in a
separate building or physically separated from the pump room by a structurally sound dividing
wall with a viewing window. Normally the second internal door to the room should have no
windows. This room should be air conditioned.
Emergency push isolation button or dead man’s switch should be provided.
The general electric supply must be dual and able to take a permanent or temporary stand by
generator. Switch over arrangements, automatic or manual, need to be decided.
The medium/high voltage electrical cells should be equipped with an automatic restart system.
The power supplied to the Pumping station should have the capacity to run all the pumps
including stand-by pump if needed.
4.7 Emergency Power
Pumping stations should be equipped with an emergency un-interrupted power supply with
sufficient capacity to provide electric output in case of main power failure.
4.8 Fire Protection
After checking the fire protection regulations, the following systems should be installed: Heat/
smoke detection in all rooms. Fire extinguishing / suppression appropriate to the installed
equipment and size of the site. For example CO2 for all electrical equipment, dry powder for
generators and foam for fires on liquid fuels and oils. This will be established by a risk
assessment of the blue print by HSE Department PAEW. Alarm should be both, audible on site
and relay back to the operations centre.
4.9 Safety Shower and Eye Wash
Safety showers must be available in all areas where there is a high concentration of chemicals
or substances with the potential to harm. This could be one or more on larger sites. The shower
must be constructed of steel and rise from the floor at least 2,5 metres with a shower arm at
right angle to the main body “length of 0,5 metres” and a shower head 20 cm wide. It must
have a pull handle activation that will release copious amounts of water from a free flowing main
or tank that is at normal body temperature between 16 and 26 degrees. The water must run for
a minimum of 30 minutes. Around the base of the shower must be an interceptor that can take
the residue chemical or substance away to safe storage (Remember that this storage must be
emptied after emergency use). The shower must be green with white striping and must be
signed above and from any substance source it must be a maximum of 10 meters from any
substance.
Attached to the safety shower fitted to the main stem at about 1,2 metres should be an eye
wash which is activated on opening allowing the injured person to places eyes in the flow of
water which must be controlled a reasonable speed so as not to cause further damage. This
should also empty to the interceptor.

TET/DG/5004
5. SCADA
The Supervisory Control and Data Acquisition (SCADA) and Programmable Logic Controller
(PLC) shall supervise, monitor and control the pumping station.
All the data shall be collected from the different units and transferred to the Regional Control
Room.
The following represents the basic minimum which should be monitored in the SCADA system.
 Electrical valves: Open, intermediate, Closed, % opening;
 Pump: Start, Stop, running, trip….;
 Pressure alarm: low , high, normal;
 Pump Temperature control;
 Pump discharge control;
 Vibration sensors;
 Pressure control;
 Level: Low , high, normal;
 Water quality parameters;
 Energy consumption for each pump;
 Number of hours in operation (for maintenance );
 Flood alarm;
 Doors access control;
 Situation of electrical power;
 Historic.
The following indicators shall be present in fault inquiry status:

 MCC/Local;
 Auto Stop;
 Auto Running;
 Auto Trip;
 Fault/ Out of service;
 Manual Stop;
 Manual Running;
 Manual Trip.


Design Guidelines for Pumping Stations

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Design Guidelines for Pumping Stations

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TET/DG/5004

Design Guidelines Date: 04/03/2012

Attached to: TET/PRO/5002 1/22

 Wells: to transfer water to storage sites, treatment plants or distribution systems;

This section provides some information on each component of the pump.

There are four main characteristics to describe a centrifugal pump:

1.1 Field of use

1.2 Number of impeller (s)

There are two types of pumps:

Attached to: TET/PRO/5002 2/22

1.3 Shaft position

1.3.1 Surface / Immersed / Submersible / Line Shafting

1.4 Type of impeller

1. Radial Flow–Normally a centrifugal pump is of radial type in which liquid enters at

They are of two types:

Attached to: TET/PRO/5002 3/22

The coupling must full fill several functions such as:

The choice of coupling requires knowledge of the following parameters:

Bearing must be able to:

Bearings consist of:

The lubricant must full fill the following functions:

Attached to: TET/PRO/5002 4/22

 Quench of the bearing (grease lubrication) to prevent penetration of solid or liquid

There are two types of lubrication:

For the selection of a motor the following factors should be considered:

Different types of motors:

 Protection index: provides the correct security level;

2. HYDRAULIC CALCULATIONS FOR PUMP

2.1 Specific speed

Attached to: TET/PRO/5002 5/22

Specific speed can be expressed as:

2.2 Pump design parameters

Fig 1. Pump Characteristic Curves

The pump has a self-regulating capacity for varying heads.

Attached to: TET/PRO/5002 6/22

2.3 Operating point

Pump characteristics are known from the pump curve.

Fig 2: System Curve

Attached to: TET/PRO/5002 7/22

Fig 3: Pump Performance individual and combined

There are several ways to change this operating point.

Attached to: TET/PRO/5002 8/22

Fig 4: Changing operating point by pumps in parallel / pumps in series

Another way is to change the system characteristics by:

 Altering pump speed;

Attached to: TET/PRO/5002 9/22

Fig 5: Changing operating point by changing pump speed / valve position

Attached to: TET/PRO/5002 10/22

2.4 NPSH and cavitation

It is important to accurately differentiate the required N.P.S.H. indicated on the characteristic

To avoid the phenomen of cavitation, it is necessary to comply with the rule:

NPSH available from the system

NPSH required by the pump

The intersection of two N.P.S.H. curves reveals the point of cavitation.

NPSH could be calculated as below:

Attached to: TET/PRO/5002 11/22

2.5 Motor drive

There are three different types of motors. These are:

The speed of rotation depends on the number of pairs of poles

The Common values for a frequency of 50 Hz are:

 2900 rpm with 2 poles

2.6 Points to note

Attached to: TET/PRO/5002 12/22