Pumping Station Design

1067 Pages·1998·28.757 MB·English

by  Sanks R.L.

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 informa-
tion 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
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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
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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