Professional Documents
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1. Introduction
Water pumping system design involves the process of pumping water from a source which can either be Rivers and streams, springs,
boreholes and wells, subway dams, artificial discharge or from rain harvesting to a particular destination for a specific purpose. This
depends on the quality of water, the demand – quantity, protection from pollution, the geographical aspects, the available resources
and the feasibility of the project.
Water pumping system design is best done through a step by step process for clarity and ease of understanding. Water pumping
system design is a ten step process which starts with basic data collection about location and elevation, water source characteristics,
type of water demanded, community served and ends with sizing the power source and power conditioning equipment.
Pumps work for many heads by changing the flow inversely. Inefficiencies arising from over designing (i.e., choosing a pump that
will, for a given head, deliver more water than is needed) are common. Such systems are wasteful in terms of both initial investment
and continuing operating cost. To avoid this pitfall, the design must consider pump characteristics and system head curves carefully.
In this regard the efficiency of both the pump and the driver should be considered. Pumps with fairly steep characteristic curves are
usually preferred since their capacity to deliver water is relatively unaffected by changes in head. As pumps, water lines, valves, etc.,
age, head losses will tend to increase. This can significantly affect flow rates if both the pump characteristic and system head curves
are fairly flat. Hence selecting the duty point of the pump is necessary. The pump works efficiently at this point in addition
minimizing the pumping costs is central to the long term viability of the system. Recurrent electric expenditure is a significant element
of the system operating costs and hence consideration is to be given to the following:
Accurately calculating the system operation point and specifying Limits for the deviation of pump duty points from the system
operation point.
The design should ensure that pumps will operate under a negative suction head. Each pump should have a gate valve upstream and
downstream for maintenance purposes together with a non-return valve, air relief valve and a pressure gauge downstream. Pump
protection devices will be specified to prevent damages to pumps caused by no water or closed delivery valves. Motors have to be
protected against phase failure as well as too low or high voltage.
Where multiple pumps are used, it is preferable to use its own intake, or the multiple intakes should be carefully designed to ensure
that all pumps have essentially the same inlet conditions. Care must be exercised to make sure that the pumps always draw water, not
an air/water mixture, or air alone. The specific locations of check valves and other appurtenances will depend on the inlet conditions,
type of storage and piping layout.
Pumps: It is a machine which is used to give a certain head to the water which passes through it.
Flow: The quantity of water that is moved through the pump in a unit of time. This can be measured in liters per minute (l/min), liters
per second (l/s), cubic meter per hour (m3/h) etc.
Head: The height through which the pump is capable of heading/lifting the water.
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The total vertical lift for a well is the elevation between the surface of the water extraction source, the static (not changing)
water level and the drawdown (which varies with volume pumped from the well and the well recharge rate). The schematic
diagram above illustrates these variables for a pump installed in a well.
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Additional Equipment
o 3 vulcanized electrodes for water level monitoring system to prevent pump from running dry.
o with 3x1.5 mm2 control cable for electrodes equal length with power cable
o Cable clamp per 3 meter length for total power cable length (total head) two pairs of pipe clamp at bore hole mouth with bolts and
nuts for the specified pipe diameters on the BOQ
o Pressure gauge as specified in the boq.
o One or two, according to a number of cable core, jointing kit with quick drying epoxy resin compound.
2.1.5 Technical Information
o The technical information should include but not limited to
o Pump discharge and total head.
o Complete pump performance at duty point and at different heads and discharge.
o Pump HP or KW
o Pump efficiency at 0.8 power factor (lagging) ,for centrifugal surface pumps efficiency>=0.65
o Number of stages and total length of pump and motor
o Pump over cable and motor diameter
o Pump out let connection diameter
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o Type of impeller
o Impeller pump shaft, motor and pump casing material
o Size of submersible cable
o Make and type of starter
o Control panel box full details (wiring diagram and spare list)
o Impeller vane thickness, number of vane, vane angle at inlet and outlet of typical stage.
o Other relevant information.
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2.1.9 Bearings
All bearings shall be rated to ensure cool running and meet the load factors specified. For vertically mounted pumps the bearings
shall be a combined thrust and journal type, designed to prevent any thrust loads being imposed upon the drive motor. Where
grease points are necessary they shall be fitted with removable screwed plugs which shall be accessible without removing guards.
2.1.10 Pumps Miscellaneous
Pumping equipment shall be constructed as in drawings (and Contract drawings) with all necessary, equipment for installation and
operating.
Pump capacities are given in this specification. The contractor shall calculate the head of the pumps required, taking into
consideration all head losses in pumps, pipes and fittings and shall guarantee the performance of each combined pump and motor
unit after the information given in this specification.
The arrangement of the pumping units and other equipment is tentatively indicated in the Contract Drawings. The weight of each
pump unit shall be indicated in the Tender. The pump suppliers shall supply all necessary spare parts as required. The tender shall
include all, necessary drawings and pamphlets of value for the complete evaluation of the tender.
2.1.11 Performance
The guarantees given in respect of output, overall efficiency and N.P.S.H shall be verified with Class C tests in accordance with
BS 5316 at the manufacturer's works. No negative tolerance shall be applicable to the guaranteed values for Flow, Head or
Efficiency. The tests shall be performed by pumps driven by their own motors.
2.1.12. Flanges
All flanged connections of pumps, pipe work, valves and other relevant equipment shall have flanges in accordance with BS4504
Table 16, unless otherwise specified in the Particular Specification Sections.
All flanged joints shall be made with 3 mm thick full face canvas reinforced rubber insertion gaskets to BS 4865 Part 1. During
Installation all pipes shall be hung on their respective supports and lined up so that their joint faces are parallel before flanges are
bolted together.
2.1.13 Butterfly Valves
Valves shall be provided as specified on the Drawings and in the Particular Specifications and shall be specifically designed for use
in raw and treated water and in chemical solutions used in water treatment.
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Valves shall unless otherwise specified be double flanged and flanges shall be as specified in Section All valves and penstocks
shall be of the sizes shown on the Drawings or stated in the Documents and shall be obtained from manufacturers approved by the
Engineer.
Where specified valves shall be fitted with easing screws and a clean-out box in the base.
All valve bodies shall give the following information:-
Manufacturer's name
Hydraulic test pressure
Size of valve
Direction of flow 'Arrow'
2.1.14 Valve Access
All valves, hand wheels, spindles and headstocks shall be positioned to give good access for operational personnel.
Extension spindles shall be supplied wherever necessary to achieve the specified operating requirements.
Valves buried or installed in underground chambers where access to a hand wheel would be impractical shall be key operated.
It shall be possible either to remove and replace or to recondition seats and gates. Gland packing shall be accessible without
removal of the valve from the pipe work.
2.1.15 Operation
The operating gear of all valves and penstocks shall be such that they can be opened and closed by one man against an unbalanced
head 15 per cent in excess of the maximum service value and any gearing shall be such as to permit manual operation in a
reasonable time and not exceed a required operating torque of 100 Nm.
All hand wheels shall be arranged to turn in a clockwise direction to close the valve or penstock and the direction of rotation for
opening and closing shall be indicated on the hand wheels.
Unless otherwise stated the hand wheels shall be coated with black plastic and incorporate facilitates for padlocking in either the
open or closed position.
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Headstocks and valves of 50 mm or greater nominal bore shall be fitted with mechanical position indicators to show the amount
which the valve is open or closed in relation to its full travel, i.e. 0.25, 0.50, 0.75, 1.
2.1.16. Materials
Valve bodies, discs and wedges shall be of cast iron, with facing rings, seating rings, wedge nuts and other trim of corrosion
resistant bronze, all as specified.
The valve stem, thrust washers, screws, nuts and other components exposed to the water shall be of a corrosion resistant grade of
bronze or stainless steel.
Valve bodies and other components of plastic or other non-metallic materials shall be compatible with the medium and of robust
industrial design.
Rubber seated butterfly valves shall be airtight when shut-off. Valves shall be suitable for the application/pressures and for
mounting in any position and shall comply with BS 5155, for double flanged valves, except where otherwise specified. All bolts,
nuts and other fixings which will be in contact with the contents of the pipelines or, in the case of buried valves within the ground,
shall be stainless steel.
Butterfly valves shall be suitable for frequent operation as well as for operation after long periods of idleness in either the open or
closed position.
Unless otherwise specified valves shall be hand operated with hand wheels driving through 900 gearboxes.The valve body shall be
cast gray iron, the flanges and hubs for the shaft bearing housing being integrally cast with the valve body.
The disc shall be ductile iron having edges machined with rounded corners and polished to a smooth finish. The valve disc shall
rotate through an angle of 90 degrees from the valve opened to the fully closed position where the seating shall be at an angle
normal to the axis of the pipe. Adjustable mechanical stops shall be provided to prevent over-travel of the valve disc in both the
open and closed positions.
Particular attention shall be given to the pipe work both upstream of all butterfly valves to ensure that the disc cannot foul the
adjacent pipe.
The shaft shall be fabricated of stainless steel. The shaft, disc and mechanical stops shall be capable of absorbing the full operating
torque with a minimum design safety factor of five. Shaft seals, when used, shall be rubber O-ring type. Packing shall be either
rubber O-ring or self-adjusting chevron type.
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The valve seat shall be replaceable and formed of nitride rubber 70/75 IRHD securely clamped into a machined groove in the valve
body or to the edge of the disc by seat retention members or equivalent so as to prevent leakage and to hold the seat surely during
operation. The seat retention members shall be to offer the least resistance possible to the flow through the valve.
Valve seats which extend over the face of the flanges to secure the seat in place, or which require surface grinding and/or hand
fittings of the disc or designs which require the adjoining pipe flange to retain the seat in place and resist the line pressure are not
acceptable.
Each valve shall be tested in accordance with the requirements of BS 5155 for body, seat and disc strength tests. Seat and disc
strength tests shall be carried out in each direction and the valve shall be drop tight.
Metal faced butterfly valves shall generally be as above except:-
a. The valves shall have metal to metal seating
b. The valves shall be designed for operation in the partly closed, throttled position for long periods
c. The valves shall not be of tight shut-off type and the leakage rate shall not be greater than the following
figures: 300 mm - 0.075 l/s; 500 mm - 0.150 l/s: 1200 mm - 0.225 l/s.
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Cable tray, cable tie, cable support and cable lags etc. as required with
Set 1
in of the borehole compound.
1.4
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Pcs 1
1.7 Manual Change over switch with cable lag (rating --A)
Earthling material, including 10sqmm earthling copper cable,
1.8 10sqmm 12m length copper rods, tap bonding straps etc. as necessary Set 1
for the earthling requirements.
1.9 Anchor Nuts and Bolts No 8
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pcs 1
1.7 Manual Change over switch with cable lag (rating 400A)
Earthling material, including 10sqmm earthling copper cable,
1.8 10sqmm 12m length copper rods, tap bonding straps etc. as set 1
necessary for the earthling requirements.
1.9 Anchor Nuts and Bolts No 8
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Cable tray, cable tie, cable support and cable lags etc. as required
set 1
1.4 with in of the borehole compound.
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pcs 1
1.7 Manual Change over switch with cable lag (rating 400A)
Earthling material, including 10sqmm earthling copper cable,
1.8 10sqmm 12m length copper rods, tap bonding straps etc. as set 1
necessary for the earthling requirements.
1.9 Anchor Nuts and Bolts No 8
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Copper Power cable from control panel board to motor, size 3x 50mm2 Mtr 120
1.3
Copper Power cable from changeover switch EEPCO Power meter
Mtr 5
1.4 generator to control panel board, size 4x 120mm2
Cable tray, cable tie, cable support and cable lags etc. as required with in
Set 1
1.5 of the spearing compound
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Copper Power cable from control panel board to motor, size 3x 50mm2 Mtr 60
1.3
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Copper Power cable from changeover switch EEPCO Power meter generator to
Mtr 5
1.4 control panel board, size 4x 95mm2
Cable tray, cable tie, cable support and cable lags etc. as required with in of the
Set 1
1.5 spearing compound
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