Table Of Content

Pumping Station Design Second Edition Editor-in-Chief ROBERT L. SANKS, Ph.D., PE Consulting Engineer and Professor Emeritus Montana State University Bozeman, Montana Co-Editors GEORGE TCHOBANOGLOUS, Ph.D., PE Consulting Engineer and Professor Emeritus University of California at Davis Davis, California BAYARD E. BOSSERMAN II, PE GARR M. JONES, PE Principal Engineer Senior Vice President, Design Boyle Engineering Corporation Brown and Caldwell Consultants Newport Beach, California Walnut Creek, California 1^1 U T T E R W Q R TH |g|E I N E M A NN Boston Oxford Johannesburg Melbourne New Delhi Singapore Disclaimer All ideas, recommendations, methods, techniques, principles, training, or subjects mentioned are for information and educational purposes only. Because of the intangible and external influences that may bear on the use of these ideas and suggestions in any application and the absolute necessity for a totally integrated planning effort, the authors and publisher make no promises and accept no responsibility for the manner in which any of the information provided or contained herein may be applied, nor for the adverse effects that may result therefrom. Copyright © 1998 by Butterworth-Heinemann -^2 A member of the Reed Elsevier group All rights reserved. Except for Chapter 1, no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. © Recognizing the importance of preserving what has been written, Butterworth-Heinemann prints its books on acid-free paper whenever possible. AMER'i^RRESTS Butterworth-Heinemann supports the efforts of American Forests and DMfTAT* me Global ReLeaf program in its campaign for the betterment of trees, ^^%20QO forests, and our environment. Library of Congress Cataloging-in-Publication Data Pumping station design / editor-in-chief, Robert L. Sanks. — 2nd ed. p. cm. Includes bibliographical references and index. ISBN 1-7506-9483-1 (alk. paper) 1. Pumping stations—Design and construction. 2. Water treatment plants. 3. Sewage disposal plants. I. Sanks, Robert L. TD485.P86 1998 628' .29—dc21 97-15436 CIP British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. The publisher offers special discounts on bulk orders of this book. For information, please contact: Manager of Special Sales Butterworth-Heinemann 225 Wildwood Avenue Woburn, MA 01801-2041 Tel: 781-904-2500 Fax:781-904-2620 For information on all Butterworth-Heinemann business books available, contact our World Wide Web home page at: http://www.bh.com 10 9 8 7 6 5 43 Printed in the United States of America To the Memory of Mary Clement Sanks June 11,1920-October 24, 1994 Musician of impressive accomplishments, organizer and director of the Annual Chamber Music Festival (1971-1994) for nearly 200 players from North America and Europe, inspiring teacher, enthusiastic chamber music player, and indefatigable worker. On the piano, she could switch keys or leave out a beat or a phrase to match others' mistakes so smoothly that the audience was unaware of a mishap. Generosity, kindliness, com- passion, and service to others characterized her life. She once taught a university course for two students after hours for no compensation. A gentle, unassuming lady, she was loved by all who knew her. Without her patient typing throughout many revisions for seven years, Pumping Station Design could not have been written at all. She was also our ultimate authority on grammar and clarity. If she, a non-engineer, could not understand something, it was recast until she could. She had much to do with the book's quality and readability. It is altogether fitting that our profession should know how much it owes to this one dynamic, dedi- cated musician. Contents List of Examples .............................................................................................. xv Locator for Equations, Figures, and Tables ................................................. xvii Preface to the Second Edition ........................................................................ xxi Acknowledgments ........................................................................................... xxii Preface to the First Edition ............................................................................xxiii Authors and Contributors .............................................................................. xxv 1. Introduction ................................................................................................. 1 1-1 Authors and Contributors ............................................................................ 1 1-2 Responsibilities of Project Engineers ......................................................... 1 1-3 Units ............................................................................................................ 2 1-4 Standards and Codes ................................................................................... 2 1-5 Manufacturers' Recommendations .............................................................. 2 1-6 Safety .......................................................................................................... 3 1-7 How to Utilize This Book ........................................................................... 3 1-8 How to Select Consulting Engineering Firms ............................................. 4 1-9 Value Engineering ...................................................................................... 5 1-10 Ensuring Quality and Economy .................................................................. 6 1-11 Avoiding Litigation ..................................................................................... 7 1-12 Library ........................................................................................................ 8 1-13 Operator Training ........................................................................................ 8 1-14 References ................................................................................................... 9 vii viii Contents 2. Nomenclature .............................................................................................. 11 2-1 Abbreviations .............................................................................................. 11 2-2 Definitions .................................................................................................. 17 2-3 Symbols ...................................................................................................... 23 2-4 Supplementary Reading .............................................................................. 23 3. Flow in Conduits ......................................................................................... 33 3-1 Fundamentals of Hydraulics ....................................................................... 33 3-2 Friction Losses in Pipe ................................................................................ 35 3-3 Pipe Tables .................................................................................................. 40 3-4 Headlosses in Pipe Fittings ......................................................................... 43 3-5 Friction Losses in Open Channel Flow ....................................................... 43 3-6 Energy in Pressurized Pipe Flow ................................................................ 45 3-7 Energy in Open Channel Flow .................................................................... 47 3-8 Unbalanced Hydraulic Forces ..................................................................... 51 3-9 Field Measurement of Friction Coefficient ................................................. 53 3-10 Flow of Sludges .......................................................................................... 62 3-11 Unsteady Flow ............................................................................................ 62 3-12 Model Studies ............................................................................................. 63 3-13 Computational Fluid Dynamics (CFD) ....................................................... 66 3-14 References ................................................................................................... 66 4. Piping ........................................................................................................... 69 4-1 Selection of Exposed Pipe .......................................................................... 70 4-2 Selection of Buried Piping .......................................................................... 78 4-3 Ductile Iron Pipe (DIP) ............................................................................... 84 4-4 Steel Pipe .................................................................................................... 85 4-5 Plastic Pipe .................................................................................................. 88 4-6 Asbestos Cement Pipe (ACP) ..................................................................... 90 4-7 Reinforced Concrete Pressure Pipe (RCPP) ............................................... 90 4-8 Design of Piping ......................................................................................... 91 4-9 Special Piping and Plumbing ...................................................................... 102 4-10 References ................................................................................................... 105 4-11 Supplementary Reading .............................................................................. 106 5. Valves ........................................................................................................... 107 5-1 Designing for Quality ................................................................................. 107 Contents ix 5-2 Isolation Valves .......................................................................................... 110 5-3 Sluice Gates, Shear Gates, Flap Valves, and Stop Plates ........................... 119 5-4 Check Valves .............................................................................................. 121 5-5 Control Valves ............................................................................................ 126 5-6 Valve Actuators .......................................................................................... 130 5-7 Air and Vacuum Valves .............................................................................. 132 5-8 Materials of Construction ........................................................................... 134 5-9 Installation of Valves .................................................................................. 135 5-10 Corrosion Protection ................................................................................... 136 5-11 References ................................................................................................... 136 6. Fundamentals of Hydraulic Transients .................................................... 139 6-1 Introduction ................................................................................................. 139 6-2 Nomenclature .............................................................................................. 140 6-3 Methods of Analysis ................................................................................... 140 6-4 Surge Concepts in Frictionless Flow .......................................................... 141 6-5 Slow Closure of Valves .............................................................................. 145 6-6 Surge Concepts in Flow with Friction ........................................................ 148 6-7 Column Separation ...................................................................................... 149 6-8 Criteria for Conducting Transient Analysis ................................................ 150 6-9 References ................................................................................................... 151 7. Control of Hydraulic Transients ............................................................... 153 7-1 Overview of Hydraulic Transient Control Strategies .................................. 153 7-2 Control of Pumps ........................................................................................ 160 7-3 Control Tanks ............................................................................................. 161 7-4 Valves for Transient Control ...................................................................... 162 7-5 Containment of Transients .......................................................................... 164 7-6 Surge Control for Water Pumping Stations ................................................ 164 7-7 Surge Control for Raw Sewage Pumping Stations ..................................... 169 7-8 Pipeline Design ........................................................................................... 170 7-9 Computer Analysis ...................................................................................... 172 7-10 Transients in Distribution Systems ............................................................. 176 7-11 References ................................................................................................... 177 8. Electrical Fundamentals and Power System Principles .......................... 179 8-1 Definitions and Code References ................................................................ 179 x Contents 8-2 Electrical Fundamentals .............................................................................. 180 8-3 Power and Control System Elements .......................................................... 187 8-4 Standby Generators and Auxiliaries ........................................................... 203 8-5 Grounding ................................................................................................... 205 8-6 Lighting and Power Outlets ........................................................................ 208 8-7 Electrical Circuit Diagrams ......................................................................... 211 8-8 Power and Control System Practices .......................................................... 214 8-9 Reference .................................................................................................... 217 8-10 Supplementary Reading .............................................................................. 217 9. Electrical Design ......................................................................................... 219 9-1 Final Construction Drawings ...................................................................... 219 9-2 Specifications .............................................................................................. 221 9-3 Contacting Utilities ..................................................................................... 222 9-4 Construction Information to Utilities .......................................................... 223 9-5 Load Estimation .......................................................................................... 223 9-6 Overcurrent Protection and Conductor Sizing ............................................ 226 9-7 Lighting ....................................................................................................... 232 9-8 Power Factor ............................................................................................... 234 9-9 Engine-Generator Sizing ............................................................................. 235 9-10 Short Circuit Current Calculations .............................................................. 237 9-11 Harmonics ................................................................................................... 239 9-12 Construction Service ................................................................................... 239 9-13 References ................................................................................................... 240 10. Performance of Centrifugal Pumps ........................................................ 241 10-1 Classification of Centrifugal Pumps ........................................................... 241 10-2 Pump Application Terminology, Equations, and Performance Curves ......................................................................................................... 241 10-3 Pump Operating Characteristics ................................................................. 248 10-4 Cavitation .................................................................................................... 255 10-5 Pump Characteristic Curves ........................................................................ 262 10-6 Pump Operating Ranges ............................................................................. 265 10-7 Elementary Pump System Analysis ............................................................ 266 10-8 Practical Pumping System H-Q Curve Analysis ......................................... 271 10-9 Complex Pumping System H-Q Curves ..................................................... 276 10-10 References ................................................................................................... 276 Contents xi 11. Types of Pumps ......................................................................................... 277 11-1 General Classifications of Pumps ............................................................... 277 11-2 Classification of Centrifugal Pumps ........................................................... 282 11-3 Construction of Centrifugal Pumps ............................................................. 283 11-4 Overhung-Impeller Pumps .......................................................................... 292 11-5 Impeller-between-Bearings Pumps ............................................................. 300 11-6 Classification of Vertical Pumps ................................................................. 301 11-7 Construction of Vertical Pumps .................................................................. 302 11-8 Types of Vertical Pumps ............................................................................. 307 11-9 Positive-Displacement Pumps .................................................................... 309 11-10 Special Pumps ............................................................................................. 312 11-11 Summary of Typical Pump Applications .................................................... 314 11-12 References ................................................................................................... 315 11-13 Supplementary Reading .............................................................................. 315 12. Pumps: Selection, Installation, and Intakes ........................................... 317 12-1 Initial Screening .......................................................................................... 317 12-2 Final Selection ............................................................................................ 320 12-3 Illustrative Examples .................................................................................. 321 12-4 Summary and General Considerations in Pump Selection ......................... 337 12-5 Installation .................................................................................................. 340 12-6 Pump Intake Basins: an Appraisal .............................................................. 350 12-7 Pump Intake Basin Design .......................................................................... 356 Caveat ............................................................................................................. 360 Trench-Type Sumps for Solids-Bearing Waters ............................................ 360 Controls for V/S Pumping .............................................................................. 363 Cleaning Trench-Type Sumps ........................................................................ 364 Rectangular Sumps for Clean Waters ............................................................. 369 Active Storage Volume for C/S Pumping ...................................................... 370 Approach Pipe ................................................................................................ 370 Examples of the Design of Pump Sumps ....................................................... 374 Critique of Example 12-3 ............................................................................... 379 Critique of Example 12-4 ............................................................................... 387 Critique of Example 12-5 ............................................................................... 396 Round Sumps for Small Lift Stations ............................................................. 397 Sumps for Large Pumps ................................................................................. 399 xii Contents 12-8 References ................................................................................................... 399 13. Electric Motors .......................................................................................... 401 13-1 General ........................................................................................................ 401 13-2 Applications of Motors ............................................................................... 403 13-3 Fundamentals .............................................................................................. 405 13-4 Types of Motors for Pump Drivers ............................................................. 407 13-5 Characteristics of Squirrel-Cage Induction Motors .................................... 410 13-6 Motor Speed ................................................................................................ 410 13-7 Motor Voltage ............................................................................................. 411 13-8 Enclosures ................................................................................................... 412 13-9 Insulation .................................................................................................... 413 13-10 Service Factors for Squirrel-Cage Motors .................................................. 414 13-11 Motor Starting Frequency ........................................................................... 417 13-12 Miscellaneous Motor Features .................................................................... 418 13-13 Specifying Pumping Unit Drivers ............................................................... 420 13-14 Need for Engine-Generators ....................................................................... 421 13-15 Design Checklist ......................................................................................... 421 13-16 References ................................................................................................... 422 14. Engines ....................................................................................................... 423 14-1 Selecting an Engine Drive .......................................................................... 423 14-2 Duty Cycle .................................................................................................. 424 14-3 Fuel for Engines .......................................................................................... 425 14-4 Aspiration .................................................................................................... 428 14-5 Types of Engines ......................................................................................... 428 14-6 Application Criteria .................................................................................... 428 14-7 Starting Methods ......................................................................................... 430 14-8 Cooling Methods ......................................................................................... 430 14-9 Controls ....................................................................................................... 430 14-10 Governors for Engine Control .................................................................... 431 14-11 Accessories for Engines .............................................................................. 431 14-12 Combustion Air ........................................................................................... 432 14-13 Exhaust Silencing ........................................................................................ 435 14-14 Pollution Control ......................................................................................... 435 14-15 Vibration Isolation ...................................................................................... 436 Contents xiii 14-16 Lubrication Oil Storage and Supply ............................................................ 437 14-17 Fuel Oil Storage and Supply ....................................................................... 437 14-18 Gaseous Fuel Storage and Supply ............................................................... 437 14-19 Service Piping ............................................................................................. 437 14-20 Building Envelope ...................................................................................... 438 14-21 Ventilation .................................................................................................. 439 14-22 Maintenance ................................................................................................ 439 15. Variable-Speed Pumping ......................................................................... 443 15-1 Variable Speed versus Constant Speed ....................................................... 444 15-2 Design Considerations ................................................................................ 445 15-3 Theory of Variable-Speed Pumping ........................................................... 446 15-4 Pump Selection ........................................................................................... 450 15-5 Variable- and Constant-Speed Pumps in Simultaneous Operation ............. 454 15-6 Special Design Considerations ................................................................... 457 15-7 Analysis of Variable-Speed Booster Pumping ............................................ 458 15-8 Minimum Discharge Rate ........................................................................... 462 15-9 Operations in Booster Pumping .................................................................. 465 15-10 Simultaneous Operation of V/S and C/S Booster Pumps ........................... 466 15-11 Adjustable-and Variable-Speed Drives ....................................................... 467 15-12 References ................................................................................................... 483 16. Pump-Driver Specifications ..................................................................... 485 16-1 Comparison of Two Approaches to Writing Specifications ....................... 485 16-2 Methods for Specifying Quality of Equipment ........................................... 486 16-3 Nonrestrictive Specifications ...................................................................... 486 16-4 Operating Conditions .................................................................................. 487 16-5 Mass Elastic Systems and Critical Speeds .................................................. 488 16-6 Pump Testing .............................................................................................. 488 16-7 Shipping Major Pumping Units .................................................................. 492 16-8 Submittals ................................................................................................... 492 16-9 Information to Be Provided ........................................................................ 492 16-10 Seals ............................................................................................................ 492 16-11 Pump Shafts ................................................................................................ 493 16-12 Pump Shaft Bearings ................................................................................... 493 16-13 Vertical Drive Shafts ................................................................................... 493