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1. GROUPING OF PUMPING STATIONS 2. PUMP WELL 3. SETTING OF PUMPS 4. CHARACTERS OF PUMP SETTING 5. CAPACITY OF THE PUMP STATION 6. CALCULATION OF HEAD 7. PIPE SYSTEM IN THE PUMP HOUSE 8. VALVES 9. PUMPS 10. AUXILIARY FACILITIES
2. PUMP WELL
Obstacles to the operation of the pump should be removed, such as branches, sand, pebbles, etc. The pump well for the inlet pipe should be furnished with a grid of 20 mm mesh in case of smaller pumps, and with a grid of 20-50 mm mesh in case of pumps with capacity higher than 1 000 l/sec. The inlet pipe of smaller pumps can be furnished with an inlet rose head for protection. The size of the pump well should be ten times the water discharge/min. A pump well of bigger size may promote swirling of water. The difference between the lowest possible water level in the pump well and the inlet part of the suction pipe, can be calculated as follows:
(m)
where v = is velocity of water in the suction pipe (m/s) g = 9.81 m/sec2 gravitational acceleration. Generally h = 0.5 dt (m) where dt is the maximum diameter of the bell mouth entry but at least h = 0.3 m. Figure 1. Pump houses
Figure 4. Deep tubewell Pumps or suction pipes with a vertical shaft should not be arranged in series, since swirling of water at the first bell mouth entry may disturb the function of the others, An arrangement, where the water flows perpendicular to the centre line of the bell mouth entry is more
favourable. The centre line of the bell mouth entry should be fairly close to the opposite wall of the inlet chamber (the optimal distance is 0.75 dt). Examples for optimal arrangement of pump wells are shown in Figures 5 and 6. In cases of pumps with large delivery a guide cone should be inserted under the bell mouth entry on the bottom of the pump well so as to control the water stream. Thus the distance between the bell mouth entry and the bottom of the pump well is 0.8 to 1.0 dt (which is 0.35 to 0.5 dt without the guide cone).
3. SETTING OF PUMPS
There are three ways of setting, considering the type of pump and the inlet chamber. (a) Pumps of vertical shaft sunk in the water of the pump well; (b) pumps with vertical or horizontal shafts set in a dry chamber located beside the pump well; (c) pump of generally horizontal shaft located above the water level. Within the arrangement mentioned in (a) three further cases are possible: - Pump is under water and the driving motor is above the water level In this case the electric motor is directly joined to the vertical shaft of the pump and is located in a water-free, dry place. The advantage of this solution is the relatively small space-requirement (there is no suction pipe and foot valve) and the easy start and operation (priming is not needed because air can not penetrate into the suction pipe). Its shortcomings are, especially in case of a large level difference between the motor and the pump, the difficulties in fitting the bearings in the vertical shaft, loss in efficiency (due to the several guide bearings), increased corrosion, and difficulty of checking, maintenance and repair (the pump should be drained first). This setting is illustrated in Figure 1. In cases of small delivery sometimes flexible shaft-driven pumps can be used. - Driving motor and main pump are above the water and the first stage under the water level By applying a first stage submerged part, the pump gets inflow water. No priming is necessary before starting. The level of water delivery is controlled by the upper part, thus the pump in fact, has a double stage made up of a low-pressure (.submerged stage) and a higher-pressure stage. This solution partly eliminates the above-mentioned shortcomings, by having several advantages (power take-off shaft with lower capacity, main part of the pump is easy to maintain). This solution is applied mostly to pumps of high pressure. - Pump and driving motor under the water level To these belong the submerged and deep-well pumps. Characteristic settings of these types of pumps are shown in Figure 4, where a submerged pump is set in a driven well, and in Figure 3, where a lifting submerged pump of high delivery is illustrated. Installing and setting expenses of a pump placed separately in a dry chamber (cf. (b)) are high. Its mechanical construction, operation and maintenance, however, are more economical. The advantage of this arrangement is that no priming or foot valve is necessary. For automatic operation this is the most suitable solution.
Pumps working above the inlet level (cf. also (c) above) are of mostly horizontal arrangement, with lower building and installation cost. Its disadvantage, beside suction difficulties (e.g. leakage, air - or gas development - caused water break, vacuum, cavitation), is that foot-valve and priming is necessary before starting - and all the extra costs coming from these difficulties, and in automatic starting. There are many pumps of this type working well with a suction head of 5-7 m, nevertheless, suction head higher than 3-4 m should be avoided.
Figure 8. Mobile pump The reserve pump is the so-called operational reserve ready to work. In small pump stations, where there is a proper staff, half of the spares are ready to work and the other half in store. If no significant fluctuation can be expected in consumption, there are generally three pump units of the same delivery, two of them are operating and the third one is the reserve.
6. CALCULATION OF HEAD
6.1 Entrance Loss: 6.2 Resistance of Suction Screen 6.3 Resistance of Foot Valve 6.4 Pressure Loss Coming from Pipe Friction (h3) 6.5 Valves Built in the Pipeline (Gate Valve, Check Valve, etc.) 6.6 Pressure Loss from Inversion (h7)
To determine the total head of a pump, the geodetic level difference between the inlet-side and delivery-side water levels and the pressure affecting them (e.g. in a discharge air chamber) should be known as well as the various hydraulic losses during lifting.
(m)
where H = total head (m) hg = geodetic lifting level (m) h0 = entrance loss (m) h1 = resistance of the filter (m) h2 = resistance of the foot valve (m) h3 = loss by pipe friction (m) h4 = loss from increase in cross section (m) h5 = loss from reduction in cross section (m) h6 = loss from valves (m) h7 = loss from inversion (m) Ps = external pressure on the inlet-side water (Pa) Pd = external pressure on the delivery-side water (Pa) = density of water 1 000 kg/m3 g = 9.81 m/sec2 gravitational acceleration If atmospheric pressure affects the water levels of both inlet and delivery sides the last item is:
where v = velocity of water on entering the inlet of the pump (m/sec) 0 = value in case of not rounded inlet part: 0.8 - 1.0; in case of properly rounded inlet 0.04, i.e. the entrance loss is practically equal to the value which is necessary to accelerate the water.
where 1 = value depends on the suction screen; according to preliminary calculation can be 2-3. In case of a suction screen of proper size and shape with free surface this loss can be markedly reduced.
which is equal to the specific valve-loading, and the loss-factor is gradually decreasing along with the increasing velocity if the valve is automatic
if v = 1 then 2 3 4
If
where = pipe friction constant l = length of the pipe-line (m) v = water velocity in the pipe (m/s) d = inner diameter (m) = kinematic viscosity (m3/sec) as a function of water temperature. It is 1.3 . 106 at 10C and 1 . 106 at 20C Pipe friction constant according to the latest research data should be calculated with consideration of Re and wall roughness of pipe. The International Congress on Water Supply held in Paris in 1952 accepted the formula of Colebrook for calculating the pipe-friction constant. Which is
where k= the absolute roughness of the pipe which can be selected from Table 2. Values of pressure loss by pipe friction are determined with approximate equations, nomograms or tables. Figure 9 shows the resistance values in cases of steel and polyethylene pipes, while in Table 3 different approximate equations are collected. Figure 9. Pipe flow diagrams Table 2 Absolute values of pipe friction
Type of pipe drawn glass-, brass-, lead-, copper-, aluminium-, polyethylene pipes drawn steel pipe welded steel pipe Condition of the pipe new, with smooth wall k absolute roughness (mm) 0 (glazed) - 0.0015 new, with different smoothness new corroded heavily corroded galvanized steel pipe asbestos cement pipe concrete pipe, tube from concrete new new new concrete, with smoothing, prestressed new, without smoothing reinforced concrete mains with smoothing after few years operating 0.01-0.05 0.05-0.1 0.1 -0.2 up to 3.0 0.02-0.12 0 - 0.1 0 - 0.15 0.2-0.3 or 0.2-0.3 or above
where the length of diffusor piece is at least six times the difference in diameters 4 = 0.15 - 0.24 v = the velocity value of the smaller cross-section If the increase in cross-section is very sudden, i.e. Bordas's loss:
(m)
where
4 = 1.2 - 1.3 v1 and v2 are the velocity values belonging to the larger and smaller cross-sections, respectively. In case of a reduction in cross-section (confusor) the pressure loss is:
(m)
6.5 Valves Built in the Pipeline (Gate Valve, Check Valve, etc.)
(m)
the value of 6, for a gate valve depends on A/A0 where A is the whole, and A0 is the gatevalve reduced cross section of the pipe.
If A/A0 = 1.05 1.1 1.4 1.8 2.5 3.0 5.0 7.0 10.0 then 0.1 0.21 1.15 4.0 9.7 15.0 42.0 72.0 121.0 6=
If a flap valve or regulating flap is used, 6, values depending on the construction o installation of the flap valve or regulating flap are 1.0-10.0, where the higher values correspond to pipe diameter of 80-300 mm and the lower ones to the diameter of 400 mm or more. As an average, a value of 2-3 can be approximated, but the exact number can be give experimentally only. For the 6 value of a butterfly valve, denoting the angle between the plate of the valve and the axis of the pipe
If CT = 0 10 20 30 40 45 50 60 65 70 then 18.7 32.6 118 256 750 6 = 0.1 0.52 1.54 3.91 10.8
where 7 depends on the relation of pipe diameter and radius r of the pipe bend midline, and on the central angle of the bent pipe, that is the degree of inversion. Using a standard bend of 90 (r = d mm + 100 mm) 7 = 0.2 if the angle of bending is
= 22 then 45 60 90
where 7 = 0.7 - 1 s = the vectoral difference between the velocity values before (v1) and after (v2) the breaking point. Practically speaking v1 = v2 = v, that is the cross-section of the pipe is constant, thus there is no change in the velocity.
If = 22 30 45 60 90 then s = 0.37 v 0.5 v 0.75 v 1.41 v
With T-profile - the pressure loss corresponds to a 90 direction-break with Y-profile - the pressure loss is of the 90 direction-break. Values given for pressure loss are related to clean water. With sandy or muddy water these values have to be increased according to the extent of pollution. Table 3 Approximate calculation of pipe friction factor for different types of pipes A . da . Reb where d = inner diameter of the pipe (m)
Type of pipe Steel New cast-iron Concrete Fault 10% 10...13 % A 0.094 0.053 0.0156 ha k = 0.4 0.0180 ha k = 0.7 a - 0.2 - 0.2 b - 0.08 0 Limit of application Re < 106 e - 0.055 - 0.14
0.218 ha k = 1.5 0.29 ha k = 4.0 Asbestos-cement 0.22 0 - 0.21 104 < Re <10 k = 0.05
Due to the incidental cavitation, the total suction head (H) is very important, and can be calculated with the following formula:
(m)
where hsman = pressure measured in the suction piece of the pump with manometer (m) P0 = atmospheric pressure (Pa) v = velocity in the suction pipe (m/sec) The static pressure (head) of the delivered water significantly changes while passing through the pump from the inlet to the outlet. The minimum overpressure is around the entrance of the impeller. Steam bubbles arise here, if the pressure of the delivered water decreases below the pressure value of saturated steam with the same temperature (cf. Table 4). In the course of energy conversion in the pump, the pressure increases again along the stream when the water is passing through the pump and when it exceeds the pressure of the steam the bubbles are crushed (cavitation) thus starting to destruct the impeller mechanically. To prevent cavitation at the inlet of the pump the minimum inflow pressure should be maintained. Each pump has a minimum suction head value, at which it can still work. This value is always smaller than the atmospheric pressure value expressed in pressure head of the liquid to be delivered. This value is known in the Anglo-American literature as the necessary "net positive suction head" - that is the NPSH of a pump. This value can be considered as a loss factor and must be always subtracted from the theoretical suction head. Manufacturing companies always indicate these values for different deliveries and revolutions, since along with the increase of delivery these values increase as well. To apply properly these values, the NPSHa value of the pump under the actual conditions should be calculated with the following formula:
(m)
where hs geod = geodetic suction head (m) hs = head loss on the inlet side (m) Pd = steam pressure of the liquid (Pa) Checking of NPSH of a working system should be performed as follows:
(NPSH)a = Hs - Pd (m)
NPSHa NPSH is necessary for cavitation prevention and vibrationless operation. The actual value of (NPSH)a necessary depends on the characteristics of the liquid, the total height of delivery, the rpm, the delivery and on the shape of the impeller.
8. VALVES
To cut off the pipeline as well as to control the amount of water passing through different valves such as gate valves, ring valves or flap/butterfly valves are applied. They are manually operated. If the gate valve is bigger than 800 mm and fast and frequent operation is expected, or automatic or distant-control is needed, the device can be run by hydraulic or electric control. In case of distant operation, a jam proof wedge gate valve should be applied or a parallel slide valve, cup valve or flap valve. If the space is limited, a butterfly valve or flap valve can be used with manual, electric or hydraulic operation. To ensure smooth operation and safety shut off of pipelines with high pressure and cross-section of 400 mm or more ring or cup valves can be inserted. If the pump stops, efflux can be prevented with a flap valve, or regulating flap. Automatic butterfly valves or a ring valve cause less pressure loss or resistance than flap valve does. With intake pipes of pools and wells, with a pressure of 0-2 m water column, a catch mounted on the end of the tube should be applied, with automatic cut off. To take unilateral pressure or to cut off intake pipes of wells, sluices moving between the walls of the well or sliding sluice-valves are used. They are operated with spindle-drive up to 3-4 m water pressure. At higher water pressure, diameter rack-drive or sliding sluices, or sluice valves provide the best solution. The sluices are generally controlled manually. Electric or hydraulic drive is only occasionally used (e.g. at very quick cut off, or open, in case of automatic operation).
9. PUMPS
9.1 Choice of the Proper Type of Pump 9.2 Control of Delivering Capacity
ensure the inflow prescribed by the manufacturer. To pump water of a driven well, a submerged pump should be used.
10.1 Priming
For centrifugal pumps, where the suction level is under the pump, i.e. there is no inflow, and a foot valve cannot be used because of the high delivering capacity or other reasons, priming is necessary before starting. For priming, electric motor driven watering vacuum pumps are the most suitable. With the pumps of smaller stations, starter tanks, or extraresistance forming, self-priming pumps are applied.
10.2 Cranes
To make installation and mounting easier, above the machines in the pump house of smaller stations a crane with suspended pulley block should be mounted above the pumps. In pump stations of several pumps of high capacity an overhead electric traveller should be installed. Table 4
Temperature of water Steam pressure Density of water t C 0 1 2 3 T K 273.15 274.15 275.15 276.15 Pd bar 0.006107 0.006566 0.007056 0.007577 kg/dm3 0.9998 0.9999 0.9999 1.0000
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
277.15 278.15 279.15 280.15 281.15 282.15 283.15 284.15 285.15 286.15 287.15 288.15 289.15 290.15 291.15 292.15 293.15 294.15 295.15 296.15 297.15 298.15 299.15 300.15 301.15 302.15 303.15 304.15 305.15 306.15 307.15 308.15 309.15 310.15 311.15 312.15 313.15 314.15 315.15 316.15 317.15 318.15
0.008131 0.008722 0.009349 0.010016 0.010725 0.011477 0.012275 0.013122 0.014020 0.014971 0.015979 0.017045 0.018174 0.019367 0.02063 0.02196 0.02337 0.02486 0.02643 0.02808 0.02982 0.03166 0.03360 0.03564 0.03778 0.04004 0.04241 0.04491 0.04753 0.05028 0.05318 0.05621 0.05939 0.06273 0.06623 0.06990 0.07374 0.07776 0.08197 0.08638 0.09099 0.09581
1.0000 1.0000 0.9999 0.9999 0.9998 0.9997 0.9996 0.9995 0.9994 0.9993 0.9992 0.9990 0.9988 0.9987 0.9985 0.9984 0.9982 0.9979 0.9977 0.9975 0.9972 0.9970 0.9967 0.9964 0.9961 0.9958 0.9956 0.9952 0.9949 0.9946 0.9942 0.9939 0.9935 0.9932 0.9929 0.9926 0.9922 0.9918 0.9914 0.9910 0.9906 0.9902
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87
319.15 320.15 321.15 322.15 323.15 324.15 325.15 326.15 327.15 328.15 329.15 330.15 331.15 332.15 333.15 334.15 335.15 336.15 337.15 338.15 339.15 340.15 341.15 342.15 343.15 344.15 345.15 346.15 347.15 348.15 349.15 350.15 351.15 352.15 353.15 354.15 355.15 356.15 357.15 358.15 359.15 360.15
0.10084 0.10611 0.11161 0.11735 0.12334 0.12959 0.13611 0.14292 0.15001 0.15740 0.16509 0.17311 0.18146 0.19015 0.1992 0.2086 0.2184 0.2285 0.2391 0.2501 0.2615 0.2733 0.2856 0.2984 0.3116 0.3253 0.3396 0.3543 0.3696 0.3855 0.4019 0.4189 0.4365 0.4547 0.4736 0.4931 0.5133 0.5342 0.5557 0.5780 0.6011 0.6249
0.9898 0.9893 0.9889 0.9885 0.9880 0.9877 0.9872 0.9867 0.9862 0.9857 0.9852 0.9847 0.9843 0.9837 0.9832 0.9826 0.9821 0.9816 0.9811 0.9805 0.9800 0.9794 0.9788 0.9783 0.9777 0.9771 0.9766 0.9760 0.9754 0.9748 0.9743 0.9737 0.9730 0.9725 0.9718 0.9713 0.9706 0.9699 0.9694 0.9687 0.9681 0.9674
88 89 90 91 92 93 94 95 96 97 98 99 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 145 150 155 160 165 170 175 180 185
361.15 362.15 363.15 364.15 365.15 366.15 367.15 368.15 369.15 370.15 371.15 372.15 373.15 375.15 377.15 379.15 381.15 383.15 385.15 387.15 389.15 391.15 393.15 395.15 397.15 399.15 401.15 403.15 405.15 407.15 409.15 411.15 413.15 418.15 423.15 428.15 433.15 438.15 443.15 448.15 453.15 458.15
0.6495 0.6749 0.7011 0.7282 0.7561 0.7849 0.8146 0.8453 0.8769 0.9094 0.9430 0.9776 1.0132 1.0878 1.1667 1.2504 1.3390 1.4326 1.5316 1.6361 1.7464 1.8627 1.9853 2.1144 2.2503 2.3932 2.5434 2.7011 2.8667 3.041 3.223 3.414 3.614 4.155 4.760 5.433 6.180 7.008 7.920 8.925 10.027 11.234
0.9667 0.9660 0.9653 0.9647 0.9640 0.9633 0.9626 0.9619 0.9612 0.9604 0.9598 0.9590 0.9583 0.9568 0.9555 0.9540 0.9526 0.9510 0.9496 0.9480 0.9464 0.9448 0.9431 0.9415 0.9398 0.9382 0.9365 0.9348 0.9332 0.9314 0.9296 0.9279 0.9261 0.9217 0.9169 0.9122 0.9074 0.9024 0.8973 0.8921 0.8869 0.8814