The Systems Approach To Lift Station Design, Operation,
The Systems Approach to LiftStation Design, Operation,Installation and Maintenance
Xylem is a world leader in water handling andtreatment. With global direct sales and servicecapabilities, we work closely with our customers todeliver energy-efficient and reliable solutions in morethan 150 countries. Intelligent pumps and controls totransport water and wastewater Advanced treatment systems to cleanand disinfect water Full-service dewatering capabilities – including pumpsales, rental and onsite services – toremove unwanted water Advanced TotalCare service capabilitiesIntegrated solutions combining world-class productsand systems design expertiseFlygt invented the world’s first submersible sewagepump and continues to innovate with self-cleaning FlygtN technology ensuring efficient non-cloggingperformance.
HydroScrewImmersibleSolids HandlingVortexVTSHSubmersibleChopper
SpeakersBarry JongsmaManager of Product EngineeringPentairErnest C. Sturtz, P.E., BCEEAssociateCDM SmithJim VukichApplication EngineerXylem – Flygt Products
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What is the Systems Approach?Charlotte, N.C.200 MGDSugar Creek WRFInfluent PS (2009)Images Used withPermission of CMU
Available Data for Creation of aComputer Model (Existing Systems)GISPump Station DBPipesNodesElevationParcelsLand useNewComputerModelCustomer Billing DatabaseWater DemandsCustomer TypePumpsWet WellsControls
Design of a SinglePump StationGravity CollectionSystem BoundaryPopulation - 1,000ADF- 60 gpmPeak factor - ?Design flow - ?
Examples of ADF andPopulation Based Peak FactorsPeak Factor5.0ADF BasedPeak FactorPopulation BasedPeak Factor4.54.03.53.02.52.0050,0001,000,000Flow (gpm)1,500,0002,000,000
Design of a SinglePump StationGravity CollectionSystem BoundaryPopulation - 1,000ADF- 60 gpmPeak factor - 3.80Design flow - 230 gpm
Small Systems Are“Easy” to DesignPumpStation#1PumpStation#2Capacity of pump station #2must be equal to capacity ofpump station #1
Large Manifolded SystemsAre Another Matter
What is the Appropriate Sizeof the Re-Pump Station ?Re-pumpStation
Modeling Practice –Limit Pumps in OperationRe-pumpStation
Modeling Practice –Discount FlowsRe-pumpStation
Preliminary Evaluationof Manifolded SystemsRelative Size of PumpStation- Small- Medium- LargeRe-pumpStation- Less than MAF- Flow exceeds MAF- Flow exceedsdesign flow rate
Over Sizing Facilities can Causeas Much Trouble as Under Sizing2000 PHF2010 PHF2020 PHF160140 800 gpm120TDH (feet)10018’806040Existing Low Head - HWL20Existing High Head - 2/3DPump Performance Curve001,0002,0003,000Pump Flow (gpm)4,0005,0006,000
Step by Step Design of aTypical Pump Station
Municipal Design CodeRequirementsHow many pumps are needed?A typical design should include permanentlyinstalled redundant pumping capacity equaling thelargest single pump in a stationFirm capacity with one largest pump out ofservice
Understand Your ProjectNew, upgrade or retrofit?New or existing forcemain?Present and futureconditions?
Understand Your Project Ownerexpectations? Present and futureconditions? Demographics? Zoning? Land usage?
What do We do First?Establish relevant design information Location of station Go visit the site! Location of discharge point Electrical requirements Find out actual line voltages Back-up power needs Utility supply limitations
What do We do First?Establish relevant design information, cont. Condition of existinginstallation and equipment Verify static head Find flow duration data Daily peak flows Daily min. flows 10, 25, 50 or 100 year flows Research existing force maindata
Quick and rough design take-offSystem head loss calcs Use 6fps (based on daily peakflow) to rough out a force mainsize Calculate FM head loss Add 5ft for station pipinglosses Don’t add unnecessarysafety factors!
Quick and rough design take-offEstablish station design flowbased on one of the year dailypeak flows Duplex station 2 equal pumps, each sizedfor daily peak flow Standard concept Triplex station 3 equal pumps, each sizedfor ½ daily peak flow May yield better energyefficiency, moreredundancy, and a lowerLCC
Quick and rough design take-off Select pumps for both the duplexand triplex scenarios Establish the minimum station insidediameter based on: HI 9.8 intake design formula(section 9.8.2.3) I.D. based on the requiredminimum active wet pit volume Pump manufacturer’srecommendations Decide on preliminary start-stoplevels
HI 9.8 intakedesign formulafor minimumstation IDWarning: This formulamay give a sump diameterthat is too small – verifypump start/hour and activesump volumeDS min 2 Db 2 Cw CbDS min 2.5 Db 2 Cw Cb
Station Diameter &Minimum Active Volume Active volume is thevolume between pump“on” and pump “off” (in aduplex station)Min. volume is dictatedby allowed motorstarts/hourPump OnPump Off
How To DetermineMinimum Active VolumeVmin. (Tmin. x Q) 4Where:Vmin minimum active sump volumeTmin minimum cycle time for fill-up and draw-downQ pump flow rateTo keep the size of the sump at a reasonable minimum,the pump capacity should be two times the inflow atcritical or peak flow times
Quick and rough design take-offMake a decision Analyze the two station designs based on: Excavation volume ( /c.y.)Pump, valve, piping, accessory, and control cost ( )Energy usage (kW-hr)Redundancy (subjective value?)Complexity and general attractiveness (subjective value?)Calculate station LCC (total for life of station)Initial CostEnergy CostMaintenanceCost
Final Design Process Use the “Quick & Rough” design as a basis to layout final station and FM piping Make adjustments based on findings during thepreliminary pump selections Be flexible with head loss and flow rates so that you canselect pumps that operate close to BEP Use station piping that gives an average liquid velocity of3-6 fps through fittings Use a FM diameter that satisfies your LCC analysis (often4-7 fps)
Pump Selection– Full SumpFull SumpMin Static HeadNew PipeMinimum FrictionOperating range
Pump Selection – Head loss increaseFull SumpMin Static HeadOld PipeMaximum FrictionOperating range
Pump Selection– Empty SumpEmpty SumpMin Static HeadNew PipeOld PipeOperating range
Pump Selection – All TogetherOperating rangeEmpty sump5’ draw-downFull sump
Pump Operating Range
SummaryDry Well Pumping StationWet Well Pumping Station
Don’t miss SWPA’s two-day PumpingSystems and Controls Training Seminar –all based on the systems approach.April 9-10 – Baltimore, MDRegister by calling 847.681.1868or visiting swpa.org.Today’s webinar attendees may receive½ off their registration.
Q&ATo contact today’s presenters, email:Barry Jongsma - Barry.Jongsma@pentair.comErnest C. Sturtz - sturtzec@cdmsmith.comJim Vukich – jim.vukich@xyleminc.comVisit pump-zone.com to: view the answers to all of the questions asked during the Q&A sessionaccess the recording of the webinar or download the presentationThe next webinar in the SWPA series will be onJune 19, 2014. More details coming soon.
Design of a Single Pump Station Gravity Collection System Boundary Peak factor - 3.80 Design flow - 230 gpm Population - 1,000 ADF - 60 gpm . Capacity of pump station #2 must be equal to capacity of pump station #1
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