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    Design of Wastewater and Stormwater Pumping Stations MOP FD-4, 3rd Edition
    Design of Wastewater and Stormwater Pumping Stations MOP FD-4, 3rd Edition
    Design of Wastewater and Stormwater Pumping Stations MOP FD-4, 3rd Edition
    Ebook608 pages5 hours

    Design of Wastewater and Stormwater Pumping Stations MOP FD-4, 3rd Edition

    By Water Environment Federation

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    About this ebook

    This Manual of Practice presents current design considerations for wastewater and stormwater pumping stations. It covers station capacity requirements and configuration, the selection and design of pumping equipment, piping system layout and hydraulic considerations, electrical and instrumentation systems design, and other station appurtenances. Intended for design professionals, it addresses design of stations of all sizes and highlights the differences between wastewater and stormwater stations.
    LanguageEnglish
    PublisherWater Environment Federation
    Release dateJan 19, 2023
    ISBN9781572784468
    Design of Wastewater and Stormwater Pumping Stations MOP FD-4, 3rd Edition

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      Design of Wastewater and Stormwater Pumping Stations MOP FD-4, 3rd Edition - Water Environment Federation

      Preface

      This manual of practice presents contemporary design considerations for wastewater and stormwater pumping stations. The manual, which updates the previous pumping station design manual published in 1993 by the Water Environment Federation, covers station capacity requirements and configuration, the selection and design of pumping equipment, piping system layout and hydraulic considerations, electrical and instrumentation systems design, and other station appurtenances.

      The manual is intended for the practicing design professional. Accordingly, it focuses on current design practice for those individuals that have a general knowledge of the basic principles of pumping station design. Considerations discussed are intended to cover the design of both small and large pumping stations and highlight the differences between wastewater and stormwater stations.

      The contents of this manual represent the collected background and experience of more than 20 professionals active in the design of wastewater and stormwater pumping stations. Material presented is intended to complement other Water Environment Federation manuals of practice and published design guidelines and textbooks.

      The third edition of this Manual of Practice was edited under the direction of Robert Otey, PE, PACP, and Mazen Kawasmi, PE, CFM, GISP, PACP, IAM.

      Authors’ and reviewers’ efforts were supported by the following organizations:

      Chang Tech International, Inc.

      Drummond Carpenter, PLLC

      Freese and Nichols, Tampa, Florida; New Orleans, Louisiana; Charlotte, North Carolina; Raleigh, North Carolina; Tulsa, Oklahoma; Austin, Texas; Dallas, Texas; Fort Worth, Texas; Houston, Texas; Oklahoma City, Texas; Pearland, Texas; San Marcos, Texas

      Macon Water Authority

      Orange County Sanitation District

      1

      Introduction

      1.0 OVERVIEW

      2.0 GUIDE TO THE MANUAL

      1.0 OVERVIEW

      Wastewater and stormwater collection and conveyance systems are extensive networks of interconnected piping. Because of the expansiveness and topography of these systems, wastewater or stormwater flows cannot always be conveyed by gravity. As a result, pumping stations are needed to lift the flow over high points in the systems or to treatment facilities. Because these stations play a vital role in the collection system, design engineers must produce plans for well-engineered pumping stations that operate reliably and efficiently.

      Wastewater or stormwater pumping stations range from simple facilities of low capacity in remote areas to complex facilities capable of pumping billions of liters (gallons) of wastewater or stormwater each day. Often, especially at the influent end of a treatment facility, the pumping station is combined with other preliminary treatment systems. As a result, the design of these facilities is a complex undertaking that requires an understanding of all of the design engineering disciplines. The design engineer should use all the technical disciplines early in the design process to ensure a well-coordinated and functional pumping station.

      Originally published in 1993 by the Water Environment Federation, this manual has been prepared to assist the practicing engineer in the design of wastewater and storm-water pumping stations; it is for the experienced designer rather than the novice. While there are many similarities between the design of wastewater and stormwater pumping stations, there also are differences. For example, while there is similarity between wastewater and stormwater pumps, pipes, valves, and controls, there are differences in station hydraulics and operational considerations such as the intermittent operation of a stormwater pumping station. This manual has been revised to include updated processes and technological advances in pumping stations. For a detailed description of those changes, refer to the chapter descriptions located within Section 2.0.

      2.0 GUIDE TO THE MANUAL

      The content and organization of the manual is intended to assist in the planning and design of both wastewater and stormwater pumping stations. The manual is divided into eight chapters and should be used in conjunction with other Water Environment Federation manuals that deal with the design of collection and treatment facilities.

      Chapter 2, Station Capacity, covers the methods of determining the need for a pumping station and the station’s capacity. Determining the peak hourly wastewater flowrate and developing an inflow hydrograph for determining stormwater flowrate also are discussed. Updates to this chapter include computational fluid dynamics descriptions, inclusion of Ten States Standards, inflow/infiltration modeling, volume sizing determinations, effects of inflow hydrographs on the system, analysis of more scenarios, and evaluating parameters such as peak stage, peak discharge, drain time, and pump cycling.

      Chapter 3, Station Configuration and Design, presents information on facility location, types, aesthetic and safety considerations, and architectural and structural design. Wet well configuration and storage considerations also are addressed. Updates to this chapter include identifying the distinction between wastewater and stormwater stations and describing larger stormwater pumping stations and the unique challenges faced on the coast and/or during major storm events.

      Chapter 4, Pumping Systems, reviews pumping system definitions and describes the types of pumps and drives that are typically used. The chapter also presents pumping system design concerns such as pump curve preparation and pump selection criteria. Updates to this chapter include a more in-depth discussion of allowable operating range and preferred operating range designations.

      Chapter 5, Piping Systems, reviews fluid flow fundamentals, water hammer and surge considerations, and the design of station piping systems, including piping arrangements, piping materials, valves, and flow-metering considerations. Updates to this chapter include a more in-depth discussion of piping requirements for stormwater pumping stations; expansions on flow meters, fusible pipe, and C factors; and hydraulics such as evaluating minor losses.

      Chapter 6, Electrical Design, describes the layout of a pumping station’s electrical system, including reliability and redundancy, voltage considerations, substations, transformers, switchgears, conduit and wire, lightning protection, standby power considerations, and adjustable-speed drives. Updates to this chapter include revised references to National Fire Protection Association and IEEE standards such as National Electrical Code, National Electrical Safety Code, IEEE Color Books, evaluating arc flash hazards, and discussion of the several types of variable frequency drive technologies.

      Chapter 7, Instrumentation and Control Systems, presents information about process and instrumentation diagrams, flow gauges, flow metering elements, system alarms, controls, and telemetry systems. Updates to this chapter include revised instrumentation options such as radar for level measurement, fiber optics for supervisory control and data acquisition systems, and evaluating options for communication between different electrical, control, and instrumentation equipment via Ethernet.

      Chapter 8, Appurtenances, discusses design considerations for typical appurtenances found in pumping stations, including screening, odor control and treatment, noise control, and building services such as heating, ventilation and cooling, lighting, water supply, drainage, utilities, hoists, and safety features. Updates to this chapter include incorporating the latest technology in screening equipment, addressing non-dispersibles, and evaluating the pros and cons of odor control options.

      2

      Station Capacity

      1.0 SANITARY WASTEWATER FLOW

      1.1 Engineering Report

      1.2 Design Life

      1.3 Population Growth Projection

      1.4 Land Development

      1.5 Quantity of Available Water

      1.6 Quantity of Wastewater Flow

      1.7 Additional Contributors

      1.7.1 Commercial

      1.7.2 Industrial

      1.7.3 Institutional

      1.7.4 Infiltration and Inflow

      1.8 Peak Hourly Wastewater Flowrate

      2.0 STORMWATER FLOWS

      2.1 Inflow Hydrograph

      2.2 Methods of Developing Inflow Hydrographs

      2.2.1 Rational Method

      2.2.2 Curve Number Method (Natural Resources Conservation Service Method)

      2.2.2.1 Rainfall

      2.2.2.2 Runoff Volume Parameters

      2.2.2.3 Time Parameters

      2.2.2.4 Determination of Runoff Volume

      2.2.2.5 Time of Concentration, Travel Time, and Lag

      2.2.2.6 Peak Discharge

      2.2.3 Computerized Runoff Models

      2.2.3.1 Planning Models

      2.2.3.2 Design Models

      2.2.3.3 Operational Models

      2.2.3.4 Sensitivity Analysis

      3.0 COMBINED FLOW SYSTEMS

      4.0 FLOW REGULATION

      5.0 QUALITY OF INFLUENT

      6.0 REFERENCES

      7.0 SUGGESTED READING

      1.0 SANITARY WASTEWATER FLOW

      Sanitary wastewater primarily consists of used portions of public or private potable water supplies that are discharged to sewers through the plumbing systems of residential buildings. It may also include portions of a public or private water supply discharged through the plumbing systems of industrial and commercial establishments. Sanitary wastewater also contains an infiltration and inflow (I/I) component. The ratio between residential, industrial, and commercial and I/I components will vary from one sanitary waste collection system to another. Before final discharge, these flows typically are collected and carried to a treatment facility where various pollutants are reduced or removed.

      To provide economical and effective treatment for sanitary wastewaters, their volume should be kept to a minimum and not combined and diluted with larger volume stormwater flows, infiltration, or inflow. Inflow, such as storm runoff from roof, yard, and foundation drains, typically is collected separately from sanitary wastewater and conveyed to a disposal point by a separate sewer or drainage system designed for this purpose.

      1.1 Engineering Report

      Before the design and construction of a sanitary wastewater collection and pumping station, an engineering report detailing the basis of design should be prepared. This report should analyze associated planning studies, drainage areas, population growth projections, land development, quantity of available water, projected quantity of wastewater flows—including all significant wastewater contributors—I/I, and the quality of influent water. The engineering report often includes the design schedule for the project and estimated costs of alternatives.

      Based on the results of these preliminary studies, the engineering report should be expanded, if applicable, to include the pumping station basis of design. The basis of design should include the range of expected flows for which the facility will be designed, the number and capacity of pumps, the design life, and the design criteria for each engineering discipline (that is, civil, structural, architectural, mechanical, electrical, and instrumentation and control) involved. The basis of design should include an estimate of the construction cost, a preliminary assessment of the type of equipment, need for screening or other pretreatment, reliability standards (standby pumps and backup power supplies), need for station amenities (such as restrooms and offices), general facility layout, equipment access, control system, monitoring needs, overall pumping station aesthetics, and odor control considerations (Jones & Sanks, 2008).

      This chapter addresses development of the facility design life and determination of facility capacity. Subsequent chapters address the facility basis of design.

      1.2 Design Life

      There is a maximum hydraulic or functional capacity beyond which a waste-water system will not operate satisfactorily. The time span, a period ranging from 10 to 30 years from the date of the original design to an estimated future date when the capacity of the system will be reached, is referred to as the design life. The system’s design life should be determined before the start of any engineering design. An analysis of the design life should consider the following:

      Anticipated obsolescence and wear and tear on the mechanical equipment,

      The possibility of needing to expand the system in the future,

      The ease or difficulty of implementing such an expansion, and

      The efficiency of the system’s performance during its initial years when it may not yet be operating to full capacity.

      In choosing a design life, undue financial burden on the system’s present users should be avoided. A longer design life will require that larger facilities be constructed, resulting in higher construction and operations and maintenance (O&M) costs. Selecting too short a design life could result in additional facility expansion costs sooner than desired. Careful selection of the design life is important to ensure that the system’s cost be shared equitably by existing and future users.

      In summary, selecting a reasonable design life should reflect the ability of the design to accommodate the flexibility to meet future conditions through planned modification options (impeller and motor changes) or expansion of standard elements (pumps).

      1.3 Population Growth Projection

      The quantity of sanitary wastewater generated by a community depends largely on the population and the per capita wastewater contribution. Therefore, an accurate population projection is essential to implementing a well-planned collection and treatment system. A community’s population growth and distribution may be affected by local economics, employment opportunities, commuting distances for workers, socioeconomic factors, zoning, availability of community facilities and services, and other community amenities. Factors not evident at the time of the study may emerge to cause a major shift in population growth, for example, the discovery of new natural resources in the vicinity, availability of new or expanded water supplies, or an industry’s decision to move to or from the community.

      Historical population information can be obtained from various sources. The U.S. government decennially has conducted a census since 1790. The census provides valuable demographic information on population, such as socioeconomic characteristics, housing facts, and population per household.

      Additional data for the interim period may be obtained from local surveys for schools, building permit records, tax records, chamber of commerce studies, local public utility records, and local and regional planning commissions. Careful analysis of census data may reveal past population trends.

      There are various methods of projecting population trends, depending on the amount and types of historic data available. These are determined by the following factors:

      Arithmetic (changes population by a fixed constant quantity);

      Geometric (changes population in proportion to population size, by a fixed ratio);

      Cohort survival (determines population by age groups and sex);

      Graphical (comparison with the growth of a similar but larger community);

      Apportionment (establishes population based on projections for larger dimensions, such as county or state); and

      A combination of the above.

      Because some of these methods may be complicated, especially when used in combination with one another, the desired degree of accuracy should be considered when projection techniques are selected. The engineer should check with the local planning agency first, because in many cases population projections may already have been developed in sufficient detail. Population projections should be reviewed with the local planning agency and the project owner before proceeding with the study.

      Details of population projection methods are discussed in many textbooks and references (McJunkin, 1964; McLean, 1952; United Nations, n.d.). Most graphical or mathematical projections are based on extending past growth trends. These methods are more applicable to communities with historically stable growth. For young and fast-growing communities, or communities with high growth potential, a meaningful projection requires good engineering judgment based on past information coupled with consideration of all related environmental determinants. Similarly, consideration should be given to the possibility of reduced growth rates in older or more mature communities at or near growth saturation.

      Population projections can also be obtained from previous studies prepared for the community. Previous U.S. Environmental Protection Agency (U.S. EPA)–funded construction grant studies contain population projections for the community or for larger basin areas. These projections may require further breakdown for meaningful use on a single project covering a smaller area.

      1.4 Land Development

      Local and regional land use planning, development, urban renewal projects, and zoning regulations will influence future population growth and distribution, which, in turn, will affect the quantity of wastewater generated by a community. In many urban areas, burgeoning construction of multi-dwelling apartments, condominiums, and town homes had led to increased population densities and wastewater quantities.

      Many housing units are equipped with appliances (such as a dishwasher, garbage disposal unit, or clothes washer) that increase water consumption and the amount of sanitary wastewater generated. However, rising costs of water in some communities have tended to suppress water use, hence reducing wastewater flow.

      1.5 Quantity of Available Water

      The quantity of wastewater flow generated is closely related to the quantity of available water and its consumption rate. In addition, the public’s general tendency to use water will vary depending on weather conditions, metered or unmetered water supplies, water rates, local conservation efforts, availability of public sewers, and the economic condition of the community.

      Because wastewater consists primarily of used water, which is often metered, per capita water consumption can be established. From this information, it is possible to estimate the per capita quantity of wastewater reaching the sewer. Records of water usage (daily, monthly, and seasonally) typically are available from the water utility that provides water service to the study area. National and regional water usage rates may also be available. Annual fluctuations in water demands and, subsequently, wastewater flows also play an important role in the design of sewerage systems, hence in the required capacity of pumping stations.

      1.6 Quantity of Wastewater Flow

      The quantity of wastewater flow varies continuously in a wastewater collection system. There will be a wide fluctuation of flow throughout the day in any system in which sanitary wastewater is a significant contributor to the total flow. If wastewater facilities are not designed to accommodate these fluctuations, they can and will cause operational problems in collection and pumping systems and in treatment facilities.

      For design purposes, it is necessary to estimate future wastewater flows based on existing conditions. State and municipal regulatory agencies often provide average per capita domestic wastewater design flows or curves of flow versus population to evaluate required pumping station capacity. If no such guidance is available and the system has no flow records, or if a complex sewer network makes actual measurement of flows impractical, design flows may be determined by either estimating and totaling the flows from the various contributors or by calculating total flow as a percentage of the total available water supply. In either case, careful study and judgment are needed to project wastewater flow because average flows have been shown to vary between 190 and 1000 L/cap·d (50 and 265 gpd/cap) (American Society of Civil Engineers [ASCE], Environmental and Water Resources Institute [EWRI], & Water Environment Federation [WEF], 2007).

      Engineers typically are interested in the average daily flow, maximum and minimum daily flows, and peak hourly flow in a sanitary sewer collection system for a variety of different design purposes. For pumping stations, the capacity of required pumping equipment and the pumping station wet well volume will depend on either the peak hourly or maximum daily flow, or a combination of the two (i.e., the peak hour of the maximum day), whichever is greater. Peak hourly flow will determine the maximum required pumping capacity of the station. However, minimum daily flows also are important in pumping station design, not only to assess maximum residence time in wet wells, but also to determine required turndown capacity of the pumping equipment. Turndown capacity is the ratio of maximum to minimum pumping capacity of the pumping station (e.g., a required turndown capacity of 2:1 would indicate that the minimum pumping capacity at which the pumping station will have to operate effectively is 50% that of the maximum capacity).

      1.7 Additional Contributors

      In addition to domestic wastewater flows, contributions may come from commercial, industrial, institutional, and I/I sources.

      1.7.1 Commercial

      Wastewater flows from commercial districts often are estimated in m³/ha·d (gpd/ac), based on information from existing similar establishments, water consumption, and comparative data from other cities. Flow allowances for sewer design can vary from 42 000 to more than 1 500 000 L/ha·d (4500 to 160 000 gpd/ac) in different cities and depend on the type of commercial activity (ASCE, EWRI, & WEF, 2007). Generous allowances for many commercial establishments may be justified because of the possibilities of future expansions and improvements.

      1.7.2 Industrial

      Two basic types of wastewater typically are generated by industries in addition to the sanitary flow originating from employees: process wastewater and spent cooling water. For existing industries, the quantity of process wastewater may be obtained through a field survey and flow monitoring or by analysis of water consumption records. For future industrial facilities, wastewater flow may be projected by studying the processes to be included in the new facility, the water consumption rate for each process, time of day and duration of process operation, types and numbers of industrial buildings, estimated number of employees, and comparative data from similar industries.

      Spent cooling water to be handled by sanitary systems typically comes from water-cooled air-conditioning chiller units. The average water demand for once-through, water-cooled air-conditioning equipment ranges from 0.10 to 0.14 × 10-3 L/kg·s (1.5 to 2 gpm/ton) of refrigeration. Water for multiple-pass cooling systems and for major industrial processes generally is treated and handled by separate systems. A small amount of water generally is wasted or blown down to the sewer to maintain system stability. Consideration must be given to this water because, while it may be small in volume, it may contain a high proportion of certain pollutants such as water-conditioning additives and total dissolved solids.

      1.7.3 Institutional

      The quantity of institutional wastewater may be established based on such items as the population served, the number of buildings, the number of units of equipment, hygiene controls, and individual habits. The design flow can be determined by field survey of the existing facilities or by analyzing comparative data from similar institutions.

      1.7.4 Infiltration and Inflow

      When calculating design flows for pumping stations, consideration must be given to I/I. Inflow is water entering a sewer system and service connections from roof drain leaders, cellar drains, cooling water discharges, manhole covers, cross connections, and surface runoff (WEF & ASCE, 2018; WEF et al., 2009). Infiltration is groundwater that enters a sewer through defective and cracked pipes, open or loose pipe joint connections, and leaking manhole walls. The actual amount of I/I will depend on the material and integrity of the sewer system, the number and type of building connections, the elevation of the groundwater compared to that of the sewers, the integrity of manholes, and the degree of manhole submergence during a rainfall event. Infiltration and inflow to sanitary sewers most often is estimated in terms of the amount of water entering a sewer based on the diameter and length of pipe (mL/m·d)/m (gpd/in. dia/mi). Infiltration may range from 9260 to 926 000 (mL/m·d)/m (100 to more than 10 000 gpd/in. dia/mi) (ASCE, EWRI, & WEF, 2007).

      In a properly designed, installed, and well-operated and maintained collection system, the I/I rate should not exceed 18 520 (mL/m·d)/m (200 gpd/in. dia/mi) for any section of the collection system (Commonwealth of Pennsylvania Department of Environmental Protection, 1997). Newer collection systems, constructed after 1970, should achieve I/I rates between 13 900 and 18 520 (mL/m·d)/m (150 and 200 gpd/in. dia/mi), whereas older systems with less efficient joint construction may experience leakage in excess of 27 780 (mL/m·d)/m (300 gpd/in. dia/mi).

      Since the implementation of the Federal Water Pollution Control Act Amendments of 1972, which required grant recipients to demonstrate their sewer systems were not subject to excessive I/I, emphasis has continued to be placed on assessing and limiting I/I to sanitary sewer collection systems. Detailed pumping station design should rely on a more complete sewer system I/I evaluation that establishes accurate I/I flowrates through actual field measurement. While a cost-benefit analysis ultimately will determine whether the owner of a system should rehabilitate a sewer with excessive I/I, the designer of a pumping station needs to be able to assess the effect these additional flows will have on the design of the pumping facilities and, ultimately, treatment facilities.

      Table 2.1 summarizes typical wastewater flows generated from both residential and nonresidential (commercial and industrial), institutional, and recreational (seasonal) establishments. Flows from these establishments can be added to determine the required pumping station capacity needed to serve an existing or new community.

      1.8 Peak Hourly Wastewater Flowrate

      The peak hourly wastewater flowrate is a function of the service area as well as the associated wastewater generation patterns and population being served and will determine the maximum required pumping station capacity. In the absence of actual flow date, the flowrate peaking factor, which is the ratio of peak hourly flowrate to average daily flowrate, can be determined using historical flowrate records or estimated using the following equation (Fair & Geyer, 1954):

      Where

      PF = peaking factor and

      P = population in thousands.

      TABLE 2.1 Typical Wastewater Flows From Establishments Served by a Community Wastewater System (Pennsylvania DEP, 1983).

      Note. Actual flow data for any establishment indicating peak daily flows over a 1-year period may be accepted for use in sizing the on-lot disposal system.

      agpd × 3.785 × 10-3 = m³/d

      The resulting peaking factor includes normal I/I for newer collection systems built with modern construction materials and methods. Higher peaking factors should be considered for collection systems that were built with older materials and construction methods or that are in areas susceptible to higher I/I rates, such as areas with high groundwater tables and areas with combined sewer systems. Pumping stations should be designed such that the peak hourly wastewater flow can be conveyed with the largest pump out of service.

      2.0 STORMWATER FLOWS

      The quantity of flow reaching a stormwater pumping station is determined by hydrologic analysis of regional rainfall events; the characteristics of the watershed; and the hydraulics of the collection, treatment, and discharge system (Chow, 1964; Chow et al., 1988; Linsley et al., 1958; Williams, 1950). In many instances, storm drainage systems are designed solely based on peak runoff values, thus neglecting flow variations with time and routing of the flow through the watershed, the collection and treatment systems, and any storage facilities along the flow route. This method is an adequate but conservative means of sizing gravity stormwater pipelines. The same simplified technique of using only peak flow values, however, cannot be applied to the design of stormwater pumping stations.

      The design of stormwater pumping stations requires not only ascertaining the peak flow, but also defining the variation of flow with time to determine the design inflow to the pumping station. This curve of flow versus time is known as the inflow hydrograph. Methods for its development will be discussed later in this chapter. A distinction needs to be made that the stormwater hydrograph may not necessarily be the same as the pumping station inflow hydrograph. This is because the point of measurement

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