Pump Station Design

Session 1 Overview of Checklist for Pump Station Design

By Teow Boo Koh 24 June 2011

Checklist for Pump Station Design

Brief background
High instances of pump station not meeting desired expectations PI Claims

In 2002, David Papps formulated this check list based on

feed back from Beca Engineers past experiences In Auckland Water this check list used to be a mandatory submission for all pump station design calcs verification review.

Some Key Items

1. Client requirements
Design standards /preferences Manufacturers proven pump station design Risk identified and clients buy in

2. Design Flows
Future flows Min, Max flow, peaking factor Guaranteed design flow Acceptance test standards

Some Key Items (cont)

3. Pumped Media
Critical to understand and characterise media Media behaviour duty normal flow, extreme conditions Impact on pump /motor sizing

4. Hydraulic Design
IHI Pump Intake Design 9.8 When do we need model testing IHI guideline for model testing
 pump flow > 2520L/s  Total pump station flow 6310L/s  Critical pump station  Remedial work cost > 10x model cost

Some Key Items (cont)

5. System Hydraulics
 what is the dominant characteristics
Suction static head /discharge static head Dynamic head Minor fitting losses Upper, lower and most likely system characteristics NPSH required and NPSH available

 Friction head loss calculation

Darcy Weisbach formula Colebrook-White equation Swamee-Jain approximation Hazen-Williams equation

Some Key Items (cont)

6. Pump selection/mechanical design
POR/AOR Test standard to AS2417(ISO 9906) Grade 1, 2 or Appendix A Impeller size, media, speed

7. Electrical Design
Power margin VSD harmonics, EDM, Loss Motor cooling Cable routing corridor

Some Key Items (cont)

8. Operation/Controls
Sensitivity of control, response time etc Is your upstream or downstream capacity compatible Rate of rise of inflow

9. Maintenance
Access Provision of gantry crane, mono-rail or mobile crane Lay down area Access for flushing of pipework

10. Safety
Operator safety, confine space accessment

Typical System Curve

S GRAPH OF SYSTEM CURVES - TE AWA AVENUE PUMP STATION
HIGH FLOW PUMPS - SINGLE PIPE FROM INDIVIDUAL PUMP TO END of FORESHORE - Post Tender Hydraulics
16.00

14.00

12.00

10.00

9.97
8.64 3425

HEA

0.0

500.0

1000.0

1500.0

Upper Bound Intake Water Level RL 9.2m Lower Bound Intake Water Level RL 11.6m Duty Point 2 Amacan PB4 1200-870/450-20degrees 580RPM 1P 575 RPM 487 RPM

2000.0 FLOW L/

2500.0

000.0

System Curve For Guaranteed Duty Point at Level RL 10.0m Guaranteed Duty Point Duty Point KSB BEP BEP BEP

8.00 6.40 6.00

8.21 6.34
1

5.60

4.00 4.00

2.00

0.00

500.0

4000.0

Preferred

perating Region
B P at ull Impeller Dia

NSI I Centrifugal Pump: %B P P R % to Vertical Pump % to % SS < = % to R % to % SS> %

P R

Variable Speed Pump

Speed control hen the operation speed is varying the operation data change as well, according to the similarity rules (= affinity rules), as stated below low Q = Q ead = (n (n (n n) n) n)

Power P = P

The affinity rules are not valid for the NPS , for approximative calculations the following equation can be used NPS NPS - value ~ NPS (n n )x

x ~ , for calculation to higher speeds x ~ , for calculation to lower speeds

Acceptance test in accordance with N IS

Measured points

Guarantee design point

Unit Flow Head Pump efficiency Symbol tQ th tL Grade 4,5 3 -3 Grade 8 5 -5 Annex A% 9 7 -7

Acceptance test in accordance with AS ld BS : Part Class B tests :

Part

Guarantee point

Factory Test Curve BS test (IS )

Part

Class C

Cavitation NPS

required

 When the pump manufacturer develops the pumps NPSHr curve, the calculated values are for conditions where the expected head has fallen off by 3 % for that specific flow rate. So if NPSHav = NPSHreq Incipent cavitation will occur  NPSHre is defined NPSHre = H0re - Pvap  where H0re is the measured inlet pressure when the performance curve falls from a non cavitating curve, by > 3%
(ISO 2548 -> 9906)
Head Hdp 0,97*Hdp NPSH NPSHre NPSHinc

Typical Factory Test Curve and NPS Test

Suction nergy evel ( I

NPS margin ratio recommendations (ANSI I )

Pump Reference Plan For Test Measurements

Especially important for NPSH

Datum