Tài liệu Water pumps and pumping systems.

WATER PUMPS AND PUMPING SYSTEMS James B. (Burt) Rishel, P.E. McGRAW-HILL Madrid New York Chicago San Francisco Lisbon London Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto Cataloging-in-Publication Data is on file with the Library McGraw-Hill A Division of The McGraw-HiU Companies of Congress ZZ Copyright © 2002 by The McGraw-Hili Companies, Inc. All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. I 2 3 4 5 6 7 890 AGM/AGM o 9 8 7 6 5 4 3 2 ISBN 0-07-137491-4 The sponsoring editor for this book was Larry Hager, the editing supervisor was Steven Melvin, and the production supervisor was Sherri Souffrance. It was set in the HBI design in Times Roman by Kim Sheran and Wayne Palmer of McGrawHill's Professional's Hightstown, N. J., composition unit. Printed and bound by QuebecorlMartinsburg. * This book was printed on recycled, acid-free paper containing a minimum of 50% recycled, de-inked fiber. McGraw-Hili books are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. For more information, please write to the Director of Special Sales, Professional Publishing, McGraw-Hili, Two Penn Plaza, New York, NY 10121-2298. Or contact your local bookstore. Information contained in this work has been obtained by The McGraw-Hili Companies, Inc. ("McGraw-Hili") from sources believed to be reliable. However, neither McGraw-Hili nor its authors guarantee the accuracy or completeness of any information published herein, and neither McGraw-Hili nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that McGraw-Hili and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. This book is dedicated to my wife Alice for her patience during the time required for its completion. CONTENTS Preface xix Table of Symbols and Terminology Location of Figures xxv xxiii PART 1. The Basic Tools of Design CHAPTER 1. Digital Electronics and Water Pumps and Systems Introduction I 1.3 Computer-Aided Calculations of Water Loads and Pipe Friction I 1.3 I 1.4 Hydraulic Gradient Diagrams Speed and Accuracy of Electronic Design of Water Systems Equation Solutions by Computer Databasing I 1.5 I 1.5 I 1.5 Electronic Communication I 1.6 I 1.6 Electronic Design of the Piping and Accessories Electronic Selection of Water Pumping Equipment Electronic Control of Water Pumping Systems Electronics and Water Pumping Systems Electronics and Variable-Speed Electronic Commissioning Purpose of This Book I 1.6 I 1.6 I 1.7 Pumping Systems I 1.7 I 1.7 I 1.8 CHAPTER 2. Physical Data for Water Pumping Systems Introduction 2.1 I 2.1 Standard Operating Conditions I 2.1 Standard Air Conditions I 2.2 Operating Pressures I 2.2 Thermal Equivalents I 2.4 Water Data 1.3 I 2.4 Viscosity of Water I 2.6 Vapor Pressure and Specific Weight for Water, 32 to 2l2"F Solubility of Air in Water I 2.7 Velocity of Sound in Water I 2.10 Areas and Volumes of Steel Pipe and Tanks I 2.10 Electrical Data I 2.10 Efficiency Evaluation of Water Systems I 2.13 I 2.6 • viii CONTENTS Additional Reading I 2.13 Books for a Personal Library Sizing Centrifugal Pumps I 2.14 I 4.27 I 4.29 Books for Further Reading CHAPTER 3. System Friction Introduction 3.1 CHAPTER 5. The Physical Design of Centrifugal I 3.1 Pipe Velocity is Designer's Responsibility Pipe and Fitting Specifications I 3.5 General Pipe Friction Analysis I 3.5 Introduction I 3.3 Two Basic Types of Centrifugal Pumps Volute Type Pumps I 3.36 Axial flow pump heads I 5.37 Column assemblies for axial flow pumps I 5.43 Axial flow type bowls and impellers I 5.47 Regenerative Turbine Pumps I 5.57 Materials of Construction I 3.42 Effect of Fabrication on Steel Fitting Loss Plastic Pipe Fittings Additional Reading I 3.83 I 5.58 I 5.59 / 3.86 I 3.88 Piping Network Analyses CHAPTER 6. Centrifugal Pump Performance Introduction / 3.91 I 6.1 Pump Head-Flow Curves I 3.95 Affinity Laws I 3.98 CHAPTER 4. Basic Design of Centrifugal Pumps 4.3 Typical constant-speed pump head-flow curves I 6.12 Brake horsepower required curves I 6.17 "Steep" versus "flat" head-flow curves I 6.17 Series and Parallel Operation of Centrifugal Pumps I 6.19 Variable-Speed I 4.4 of a Centrifugal Pump Centrifugal Pump Impeller Design Air Entrainment I 4.17 Minimum Speed for a Variable-Speed Pump Minimum Flow for Centrifugal Pumps Pump Suction Limitations Electric Motor Power in kW / 4.21 I 6.34 Engine-driven pumps I 6.34 Actual energy consumed by variable-speed Noise in Pumping Systems I 6.35 I 4.22 / 4.22 Net positive suction head I 4.23 Submergence in open tanks, wet wells, and open pits I 6.22 I 6.26 and Vortexing Water horsepower I 6.33 Pump brake horsepower I 6.33 Pumping Energy in kW I 6.33 I 4.12 Critical Speed of a Centrifugal Pump Pump Head-Flow Curves Pumping Energy in hp I 6.32 I 4.7 I 4.10 Specific Speed of a Centrifugal Pump I 6.1 I 6.5 Variable-speed performance I 6.5 Variable impeller diameter performance I 6.7 Constant-Speed Head-Flow Curves I 6.10 I 4.3 General Design of Centrifugal Pumps General Performance 6.1 I 3.90 PART 2. Pumps and Their Performance Introduction I 5.57 Mechanical Devices for Pumps I 3.88 Hydraulic Gradient Diagrams References I 5.16 I 5.16 Single-suction pumps I 5.17 Double-suction pumps I 5.27 Axial Flow Type Pumps I 5.32 PVC and CPVC plastic pipe I 3.37 HDPE pipe I 3.37 Copper Pipe and Tubing / 3.42 Steel and cast iron pipe fittings / 3.79 Results of Recent Laboratory Testing of Fittings I 5.1 Forces on centrifugal pumps I 5.2 Leakage control in centrifugal pumps I 5.7 Physical Description of Centrifugal Pumps I 5.11 Asphalt-Coated Cast Iron and New Steel Pipe Friction Tables Plastic Pipe I 3.36 Summary 5.1 I 5.1 Basic Elements of Physical Design I 3.4 Pipe friction formulas I 3.7 Reynolds number and Moody diagrams / 3.8 Use of the Darcy-Weisbach equation I 3.11 Use of the Hazen-Williams formula I 3.35 Pipe Friction Tables / 3.35 Copper Fittings Pumps for Water I 3.1 Maximum Capacities and Velocities of Actual Piping Pipe Fitting Losses I 4.28 General Pump Design Information ,. Total Owning Cost Ix CONTENTS / 4.27 • pumps Summation of the Performance of Centrifugal Pumps Sources of Pump Information I 6.37 / 6.35 I 6.36 X CONTENTS -- CHAPTER 7. Positive Displacement xl CONTENTS Pumps 7.1 PART 3. The Pumping World Introduction I 7.] Types of Positive Displacement Rotary Pumps / 7.] Vane pumps / 7.2 Flexible member pumps / Lobe type pumps / 7.3 Gear pumps / 7.5 Screw pumps / 7.5 Pumps / Introduction 7.2 / principle) / 9.3 / 9.3 kW/MGD / 9.6 Energy Lost to Mechanical Flow Control Devices Evaluation of Piping Design 7.11 Energy Consumption / 7.13 Categorization / 9.8 and Water Use of Water Systems Suggested Design Rules / 9.7 / 9.8 Load Range for a Water System Piston pumps / 7.12 Plunger pumps / 7.13 Definitions for Reciprocating Power Pumps Diaphragm Pumps / 7.13 SUmmary / 7.14 - of Useful Energy Useful consumption of pumping energy Inefficient use of energy / 9.4 Calculation of System Efficiency / 9.4 / 7.7 9.3 of Water / 9.3 Determination High volume screw pumps (Archimedes Progressive cavity pumps / 7.8 Definitions for Rotary Pumps / 7.11 Reciprocating Power Pumps CHAPTER 9. The Movement 7.] / 9. /0 / 9./0 / 9.10 CHAPTER 10. Configuring a Pumped Water System CHAPTER 8. Pump Drivers and Variable-Speed Introduction Drives 8.1 I 8.1 Pumping System Losses / 8.2 System Head Areas Static Pressure Types of polyphase motors and code letters / 8.3 Electric motor torque and horsepower / 8.4 Motor currents / 8.6 Electric motor output horsepower / 8.7 Electric motor power factor / 8.7 Electric motor efficiency / 8.7 Electric motor construction / 8.8 Motor siZing for pumps / 8.9 ~llowable motor starts per hour / 8. /0 Vanable-Speed Drives for Pumps / 8.10 Configuration . Drives Drives Efficiency of Variable-Frequency of Typical Water Systems Piping Network Analysis / /0.13 / 10.24 / 10.25 CHAPTER 11. Basics of Centrifugal Water Systems 11.1 / 11.2 Selecting constant-speed pumps / 11.2 Selecting variable-speed pumps / 11.4 Increased Pump Speed for Variable-Speed Pumps / 8.33 / 8.35 / 8.42 Pump Application to / 11.1 Point of Selection / 8.32 Drives Drives Introduction / 8.32 Variable Frequency-Drive Accessories and Requirements Engine-Driven Pumps / 8.39 SUIT1lnary / 8.42 Sources of Technical Information / 10.9 / 10.13 / 8.12 Drives with multipulse input circuits / 8.15 Clean POWervariable-speed drives / 8.15 Medium Voltage drives / 8.]5 Harrnonics and Variable-Frequency Drives / 8.29 Advantages of Variable-Frequency / 10.3 / 10.5 All friction system / 10.13 High static system / 10.14 System with two subsystems / 10.15 High static system with variable supply pressure / 10.15 System with high supply pressure and no static pressure / 10.17 System with variable supply pressure and no static pressure / 10.18 Hydraulic Gradients / 10.20 Summary / 8.10 Early Variable-Frequency Drives PWM Drives / 8.12 Application of Variable-Speed / 10.2 System Head Curve Components Electric motor power characteristics Motor output ratings / 8.3 Motor speed / 8.3 Sizing of Variable-Frequency / /0.1 Modeling a Water System Electric Motors / 8.] Variable-Frequency Drives Introduction 10.1 / 8.37 Decreased Pump Speed for Variable-Speed Pumps • / 11.5 / 11.9 Selecting a Larger Impeller at Maximum Motor Horsepower Proper Use of Affinity Laws with Constant -Speed Pumps Number of Pumps Operating in Parallel Mixing Constant- and Variable-Speed / 11.15 Pumps / 1].]8 / 11.11 / 11.13 xii CONTENTS Jockey Pumps / 11.21 Efficiency of a Pumping System Wire-to-Water Efficiency PART 4. Clear Water Pumping / 11.21 / 11.23 CHAPTER 13. Pumps for Central Water Treatment Calculated wire-to-water efficiency of single constant-speed pumps / 11.25 Calculated wire-to-water efficiency of a single variable-speed pump / 11.27 Calculated wire-to-water efficiencies of multiple-pump systems / 11.27 Total kW Input for a Pumping System / 11.28 Conclusions / 11.31 Total kW input indication and pump programming / 11.32 Use of Adaptive Control / 11.34 Total kW input for variable-speed pumping systems with a small lead pump Pump Control / 11.35 Introduction Pump Speed Control Water Reuse / 11.35 Summary / 13.12 Summary / 13.12 CHAPTER 14. Water Pumps for Municipal Water Distribution / 11.40 / 14.1 System head curves for primary pumping / 14.2 Variable- or constant-speed primary pumps / 14.3 Secondary Pumping Systems / 14.4 / 11.45 Multiple pumping stations / 14.7 Calculation of Friction Loss in Municipal Water Systems / 11.47 Hydraulic Shock from Long Discharge Lines / 11.52 Summary / 14.9 / 14.9 / 14.13 / 11.53 CHAPTER 15. Pumps for Plumbing Systems CHAPTER 12. Centrifugal Pump Intake Design Introduction / 12.1 / 12.2 Clear Service Pumps / 12.3 Rectangular structures / 12.6 Formed suction intakes / 12.6 Circular structures / 12.6 Trench-type intakes / /2.9 Intake Structures for Solids Bearing Liquids / 12.10 Trench-type wet wells for solids handling liquids / 12.10 Circular wet pits for solids handling pumps / 12.12 Testing Intake Structures / 12./2 Remedial Measures for Intake Structures Strainers, Screens, and Trashracks Strainers / 12.13 Screens and trashracks Summary / 12.15 / 12.14 / 12.1 Introduction Sewage Ejectors Storm Water Graywater 15.1 / 15.1 Cold Water Systems / 15.1 Water flow / 15.1 Pressure losses in cold water systems / 15.3 Calculation of pump head for cold water plumbing systems Materials for cold water pumping systems / 15.6 Pumps for domestic water / 15.7 Cold water system configuration / 15.8 Sizing the hydro-pneumatic tank / 15.10 Cold water system head curves and areas / 15.14 Location of pressure switches and transmitters / 15.17 Hot Water Systems / 15.19 Wet well volume / 12.1 Inlet Bell Design Diameter / 12.2 Submergence 14.1 / 14.1 Primary Pumping Stations Sensors for pump speed control / 11.43 Communication from Remote Transmitters / 11.44 Additional Reading / 13.3 / 13.11 Recharge Introduction Effects of Water Systems on Pump Performance 13.3 Surface-water treatment plants / 13.4 Underground water treatment plants / 13.6 Desalinization / 13.11 / 11.39 Using Centrifugal Pumps as Turbines Priming Systems / 11.49 Plants / 13.3 Types of Water Plants Utilizing Rainwater Pump Start-Stop Procedures in Response to Physical Events / 11.36 System activation or shut-down / 11.36 System demands such as level, flow, or pressure / 11.36 Emergency backup on pump failure / 11.37 Sequencing of Pumps / 11.37 Alternation of Operating Pumps xIII CONTENTS / 15.6 / 15.20 / 15.21 / 15.21 Additional Reading / 15.22 / 12.12 /2.12 . CHAPTER 16. Fire Pumps Introduction / 16.1 Types of Fire Pump Installations / 16.1 Location of fire pump installations / 16.4 Source of Waterfor Fire Pumps / 16.4 16.1 xiv CONTENTS I 16.4 Types of Fire Pumps Variable-Speed Rate of Flow of Stationary Fire Pumps for Water I 16.7 I 16.9 Fire Pump Drivers I 16.14 Electric motors Electrical power Diesel engines Testing Fire Pumps I 16.14 supply I 16.15 I 16.16 and Their Installation Sewage Lift Station I 19.6 Control for a variable-speed sewage pumping station I 19.6 Energy savings from constant wet-well control I 19.7 Pump addition and subtraction points I 19.11 Adaptive control for pump transition points I 19.14 Programming with flow meters I 19.16 Multiple Sewage Lift Stations I 19.17 Fire pump performance I 16.8 Fire Pump Accessories I 16.8 Fire Pump Fittings XV CONTENTS I 19.20 Friction Loss in Sewage Lift Stations I 19.22 Types of Pumps for Lift Stations I 16.16 I 19.23 Grinder Pump Systems Shop tests of fire pumps I 16.16 Field testing for approval of the entire installation Summary I 16.18 I 19.24 Hydraulic Shock from Long Force Mains I 16.17 Special Control Procedures for Sewage Wet Wells Resume CHAPTER 17. Pumps for Agriculture I 19.26 I 19.28 17.1 CHAPTER 20. Pumps for Sewage Treatment Irrigation Plants 20.1 I 17.1 Introduction I 17.1 I 20.1 Introduction Open-channel (ditch) irrigation I 17.1 Closed-pipe irrigation I 17.2 Golf course irrigation I 17.4 Waterfrom Wells I 17.7 Types of Sewage Treatment Plants Creating a well for irrigation I 17.7 Location of a well I 17.11 Well design criteria I 17.11 Drilling the well I 17.11 Well development I 17.12 Selection of the production pump I 17.13 Finalized design flow rate I 17.15 Well Pumps for Farm Domestic Water I 17.15 Use of Variable-Speed Recharge I 20.11 Summary I 20.11 I 17.15 of Positive Displacement Pumps Constant-Speed Rational method I 21.2 Soil Conservation Service method I 21.2 Computerized runoff models I 21.2 Source of Water I 21.2 I 18.5 Summary I 21.4 I 21.5 I 21.10 PART 6. Installing, Testing, and Operating Pumps I 19.1 19.1 CHAPTER 22. Installation Introduction of Sewage Lift Stations Wet-well size for constant-speed I 21.4 Above Ground Flood Plain Stations Below Ground Stations I 18.12 Sewage Lift Station I 21.3 "Contractor" pumps Pump Head I 21.4 I 18.3 CHAPTER 19. Pumps for Sewage Collection Systems Basic Configurations I 21.1 Storm Water Pumps Rotary screw pumps I 18.4 Large screw pumps (Archimedes principle) Progressive cavity pumps I 18.8 Flexible element pumps I 18.11 Reciprocating Pumps I 18.12 Introduction 18.3 I 18.3 Diaphragm pumps Summary I 18.14 I 21.1 Design Parameters Pumps 21.1 I 21.1 Introduction I 17.16 PART 5. Solids Handling Pumping Basic Performance of Positive Displacement Performance of Rotary Pumps I 18.4 I 20.5 CHAPTER 21. Storm Water Pumps Maximum Flow Introduction Drives in Sewage Plants I 20.5 Water Reuse Agricultural Use of Sewage Plant Sludge and Effluent CHAPTER 18. Performance I 20.4 Sludge and Grit Pumps Pumps for Animal Waste Disposal Systems I 20.1 I 20.3 Main Flow Pumps I 19.1 I 19.1 pump station Preinstallation of Water Pumps and Pumping Systems I 22.3 Procedures I 22.3 Pump and Pumping System Bases I 19.4 I 22.4 Pump bases with seismic restraints I 22.7 22.3 xvi CONTENTS xvII CONTENTS I 22.8 Connecting Piping to Pumps Electrical Provisions for Pumps Instrument accuracy I 24.6 Simultaneous recording I 24.7 Interval for calibration of instrumentation Installation of instrumentation I 24.7 Test Reports and Records I 24.7 I 22.11 Electrical connections for pump motors I 22.11 Safety controls for pumps I 22.11 Alignment of Pumps, Motors, and Engines I 22.12 Initial Operation of Pumps I 22.12 Direction of Rotation of Pumps Summary I 22.12 I 24.6 Test Instrumentation Pump fitting sizing I 22.8 Pump fitting ap-angement I 22.10 Expansion Provisions at Pumps I 22.10 Accuracy of Pump Head-Capacity Understanding Summary I 22.12 I 24.8 Curves Factory Tests of Pumps I 24.7 I 24.8 I 24.8 CHAPTER 25. Operating and Maintaining CHAPTER 23. Instrumentation for Water Pumping Systems 23.1 I 23.1 Introduction Definitions and Terms I 23.1 Constant- or Variable-Speed Sequencing and Alternation I 23.15 Reference I 23.15 Maintenance CHAPTER 24. Testing Water Pumps Objective Schedules Summary I 25.11 Reference I 25.11 I 25.10 I 25.11 24.1 I 24.1 Introduction I 25.9 Sequencing I 25.9 Alternation I 25.9 Maintaining Pumping Equipment at High Efficiency I 23.14 Control Valves I 25.3 Checking a pump at design flow I 25.4 Pump operation at the shutoff or no-flow condition I 25.6 Graphical observation of pump performance I 25.6 Vibration I 25.6 Control Signals for Speed Control I 25.8 Simple controllers I 23.13 Electronic controllers I 23.13 Quality of controllers I 23.14 Control Wiring I 23.14 Summary Pumps Selection of variable-speed pumps I 25.3 Operation of variable-speed pumps I 25.3 Checking Pump Performance I 25.4 I 23.13 Controllers I 25.1 I 25.2 Pumps Proper Selection and Operation of Variable-Speed Flow meters I 23.3 Pressure and differential pressure transmitters I 23.9 Temperature indicators and transmitters I 23.9 Level transmitters I 23.10 Watt transmitters I 23.10 Indicators I 23.12 CHAPTER 26. Factory-Assembled Pumping Systems 26.1 I 24.1 Types of Tests Introduction I 24.2 Hydrostatic Tests Centrifugal pumps: Volute and axial flow types (includes vertical pumps) Positive displacement pumps I 24.2 Performance Tests I 24.3 Priming Time for Self-Priming Testing Procedures I 24.5 Field Testing of Pumps I 26.1 Applications of Factory-Assembled I 24.2 Centrifugal pumps-Volute type I 24.3 Vertical pump tests I 24.4 Submersible pump tests I 24.4 Positive displacement pump tests I 24.4 Net Positive Suction Head Required (NPSHR) Test Centrifugal Pumps I 24.6 25.1 I 25.1 Checking for Efficient Selection of Water Pumps I 23.3 Transmitters Introduction Water Pumps I 24.2 Typical Factory-Assembled Factory-Assembled I 24.5 I 26.2 Control Centers for Existing Pumps Complete Pump Houses I 26.2 I 26.6 Advantages of Factory-Assembled I 24.5 I 26.1 Pumping Systems Pumping Stations Pumping Systems First cost I 26.9 Time saving I 26.11 Unit responsibility I 26.15 Less pump maintenance and repair I 26.16 Code compliance I 26.17 Components of Factory-Assembled Pumping Systems Pumps I 26.17 Pumping system accessories I 26.17 I 26.8 • I 26.17 xviii CONTENTS Electrical equipment I 26.18 Testing of Factory-Assembled Pumping Systems Summary I 26.19 CHAPTER 27 . Retrofitting Introduction I 26.19 PREFACE Existing Water Pumping Systems I 27.1 System Evaluation I 27.1 Graphical Description of Flow in an Existing System Evaluation of Existing Procedures I 27.4 Trimming the Pump Impeller I 27.4 Changing to a Variable-Speed Pump Evaluation of the Number of Pumps Control of Existing Pumps Variable-Speed I 27.2 I 27.6 Evaluation of Existing Pumps and Motors I 27.7 I 27.7 I 27.8 Control and Drives for Modified Systems I 27.8 Actual Generation of a System Head Area for an Existing System Synopsis I 27.10 CHAPTER 28. Summary Introduction 27.1 I 27.9 of Water System Energy Evaluations I 28.1 I 28.1 Pumping System Efficiencies Water System Efficiencies I 28.2 Purpose of Efficiency Equations I 28.2 Sustained System and Equipment Efficiencies Summary I 28.3 APPENDIX A. APPENDIX B. APPENDIX C. APPENDIX D. Index 1.1 I 28.3 Abbreviations and Symbols A.3 Terms and Nomenclature B.1 Glossary of Equations C.1 Conversion of English Units to SI Units D.1 28.1 The purpose of this book is to provide information on water pumps and their application to water systems. This book is organized to be a sourcebook on pumps for water system designers, owners, and operators. It is not intended to be a reference book for designers of pumps. Excellent books are available already on the detailed design of pumps. This book will include a number of descriptions of pumping installations for municipal water and sewage, storm water, plumbing, fire protection, and agricultural applications. General information about design, construction, and operation of centrifugal and positive displacement pumps will be provided. Disclaimer: This book offers no final answers on how to design a specific water system or to apply pumps to it. It has brought together technical data and, it is hoped. has provided answers to particular pumping applications in these industries. There are so many excellent books on every aspect of pumps and their application. This book is, in many ways, a synopsis of these books. References are included throughout this book that provide extensive, continued reading. Many of them should be in the library of any serious designer or user of pumps. The format for this book has been developed to provide a working handbook. There may appear to be an excessive amount of cross referencing and many variations of the same formula. The reason for these inclusions is to provide rapid access to the desired subject. The water system designer, owner, or operator who uses this book should be able to reach a pumping subject quickly without having to hunt through several chapters. A section called "Location of Figures" has been included following the Contents to make it easier to find a specific figure. Many of the figures, although located in one chapter, apply to the pumps and water systems in other chapters. Much of the technical data required for applying pumps to these systems is included in this book. It is hoped that it can become a source of pump information for the water system designer. With the advent of electronic, on-line data services for these industries, much additional information will continue to be made available to the designer or user of water pumps. This book is being written at a time of great changes in our methods of communicating technical information. This technological revolution is probably the greatest since the invention of the printing press. Also, digital electronics is just now bringing its tremendous potential to the way we design these water syr;tems, select equipment for them, and control the flow of water in them. Recognizing the electronic revolution that we are in the midst of, an effort has been made to point the reader toward new methods of information transmission that will become commonplace in the near future. Another significant event in the water pumping field is the realization of the great capability of the variable-speed pump in saving energy and improving the performance of water systems. So far, most variable-speed pumps in these industries have PREFACE PREFACE been applied to larger water systems. Now they are being installed on smaller systems. The ongoing increase in cost and unavailability of electrical energy, along with the continued reduction in cost of variable-speed drives, will result in a great many water pumps being variable speed during the twenty-first century. Two great facts thrust themselves forward as this book was prepared. They are: 1. There is so much inexactness in the data used to design water systems and their pumps. For example: a. What do we mean when we use the word "water"? Do we mean distilled or pure water? Or do we mean water furnished by the local water company? All of the data furnished in this book makes no reference as to what the water is when properties such as its specific gravity or viscosity are defined. It is presumed that the scientific data included pertains to pure water, but that is not what is coursing through most of these water systems. b. Pipe and fitting friction is at best an inexact science. The Hydraulic Institute estimates that the variation in the roughness factor, E, can be as much as - 5 to + 10 percent for steel pipe, and the listed losses for steel and cast iron fittings can vary from -10 to +35 percent. We, at this writing, have very little information on the friction loss for water flowing through reducing tees or other reducers such as 12" X 10" fittings. Work is now being done to advance our knowledge of such pipe fitting losses. c. Pump manufacturing must have acceptable tolerances to achieve any reasonable production. These tolerances are basically -0 to +8 percent variation in pump head at rated flow and efficiency. Recognizing also that pumps are tested at specific suction pressures and temperatures and operated at other pressures and temperatures, it is obvious that tested pump performance is quite different from that achieved with the pump in operation on one of these water systems. 2. Realizing the above inexactness, in the past, the water system designer resorted to pressure-regulating or relief valves, and complicated piping systems to destroy design overpressure and to make the systems function properly. The variable-speed pump now can eliminate many overflow and overpressure factors included in the design condition. Also, variable-speed drives can eliminate many of the mechanical devices that were used in the past. With the development of digital electronics and the variable-speed pump, we now have the tools to allow for the above inexactness during design and eliminate it in operation. We can remove much of the old mechanical complexity that was used to destroy excess pump pressure. One of the most significant control procedures in this book, "Total kW Input for a Pumping System" in Chapter 11, uses total kW input as a control procedure for pumps operating in parallel or series. This is a relatively new concept for programming pumps on and off. Not only is it applicable to pumps of all kinds, it is a useful method of staging any set of devices that are operating together. This can include fans, blowers, filters, presses, mixers, or any energy-consuming equipment where more than one device is operating on a fluid stream. The kW input to variable-speed drives and motors is so easy to attain and evaluate with various numbers of equipment in operation. If the equipment is maintaining the process variable, adding a device should reveal a reduction in total kW input; if it does not, the device should not have been started. Similarly, if stopping a device does not xxi reveal a reduction in total kW input, it should not have been stopped. This procedure of "kW input" should provide an energy-saving program on the operation of many pumping systems. When writing a technical book, the symbols, abbreviations, and names used are so important. The symbols and nomenclature used herein are basically those used in the water industries. Included is a table that describes these symbols and abbreviations. A number of distinctions have been made, namely that pump head is always define as h while water system head is labeled H. This distinction between pump head and water system head must be maintained, as they are not always the same. Likewise, pump horsepower is indicated as Pp, and the work required by the water system or the work done on it is the water horsepower, Pw. Throughout the book, every effort was made to distinguish pump characteristics from those of the water system. This may seem trite, but in all water system analysis, we must always remember whether we are evaluating a water system or a pump for that system. In view of the great amount of detailed information that had to be gathered to produce this handbook, a number of people who are recognized as authorities in their field of endeavor have been called on and have responded to offer advice in its development and writing. Most of the information acquired for this book came through long associations with manufacturers, consulting engineers, contractors, salesmen, and service technicians. Their practical experience is the foundation of this book. Following is a list of some of these knowledgeable people: Russell Fediuk of General Electric Supply Division, Cincinnati, OH; Ronald E. Kastner, President of Corporate Equipment Company, Cincinnati, OH; George Ries, Vice-President (retired), Peerless Pumps, Yorba Linda, CA; Richard H. Osman, Vice President of Robicon, Pittsburgh, PA; Keith H. Sueker, P.E., Pittsburgh, PA; Lawrence Tillack, tekWorx, L.L.c., Cincinnati, OH; William F. Reeves, P.E., of Cincinnati, OH; and David Castelleni, P.E., of Cincinnati, OH. Grateful acknowledgment is made to these engineers and authorities. This handbook would have been impossible without their assistance. In particular, recognition must be given to the careful review made of the manuscript by John H. Doolin of the Hydraulic Institute. This effort revealed many needed changes to eliminate typographical errors, incorrect calculations, and wrong symbols. The author wishes to acknowledge also his appreciation of the great profession of engineering. It has provided a field of work so rewarding in knowledge and personal relationships. TABLE OF SYMBOLS AND TERMINOLOGY Following are the symbols When using being applied these tenns, and tenninology distinction to a water system Symbol should or the pump nonnally always used in the pumping be made industry. as to whether Description Unit Area square inches in2 13 Meter or orifice ratio - d Brake horsepower Diameter Dimensionless hp feet ft D Diameter inches in (epsilon) Absolute Friction factor Dimensionless (delta) - 1] (eta) Difference Efficiency kW kWH Kilowatts Kilowatt-hours 1]0 Variable-speed 1]E 1]p Motor efficiency E f ~ roughness hp Dimensionless or differential - percent % kilowatts kilowatt -hour kW kWH percent % percent % Pump efficiency percent % 1]s System efficiency percent 1]T Water turbine efficiency percent % % 1]ws 1]ww Wire-to-shaft Wire-to-water g -y (gamma) h Hs Hep Hp Hf Hp Hp Gravitational acceleration Specific weight percent percent feetlsecond2 drive efficiency efficiency efficiency % % ftlsec2 pounds/foot3 Ib/ft3 Pump head feet ft Total system head at design flow A control pressure in a water system feet ft ft Water system friction head feet feet Friction loss in equations System pressure feet feet System friction loss or component feet ft • ft ft ft of a system Hpp K Pump fitting loss feet ft Pipe fitting coefficient - L Pipe length in hundreds Dimensionless feet of feet are Abbreviation A (Beta) BHP they itself. ft xxiv TABLE OF SYMBOLS Symbol n NPSHA NPSHR NS IL (mu) v (nu) P psia psig PA P. Pp Pv Pc Ps Pw Pp PkW q Q RE SDR S s t T (tau) v V WHP Z AND TERMINOLOGY Description Speed Net positive suction head available Net positive suction head required Specific speed Absolute viscosity Kinematic viscosity Pressure Absolute pressure Gauge pressure Atmospheric pressure Atmospheric pressure Plastic pipe pressure rating Vapor pressure of water System energy consumed System useful energy Water horsepower Brake horsepower Electric power Rate of flow Rate of flow Reynolds number Standard dimension ration Hydraulic design stress-pipe Specific gravity Temperature Torque Velocity Volume Water horsepower Elevation or static head * for plasticpipe ** U. S. gallons Unit revolutions/minute feet feet Dimensionless lb-sec/square foot square feet per second pounds/square inch pounds/square inch pounds/square inch pounds/square inch feet of water pounds/square inch feet of water kilowatts kilowatts horsepower horsepower kilowatt-hour cubic feet/second gallons per minute Dimensionless Dimensionless pounds/square inch Dimensionless degrees Fahrenheit pound-feet feet per second cubic feet or gallons hp feet Abbreviation rpm ft ft LOCATION OF FIGURES - Ib-sec/ft2 ft2/sec psi psia psig psi ft psi ft kW kW hp hp kWH cfs gpm psi* - This listing has been provided because many figures in one chapter of the book are applicable to pump installations described in other chapters. An effort has been made to include in the titles of the figures the key words that should provide guidelines for the use of the figures. CHAPTER 1. DIGITAL ELECTRONICS PUMPS 1.1 Energy and hydraulic AND gradients CHAPTER 2. PHYSICAL DATA FOR WATER PUMPING SYSTEMS of lb-ft ft/sec or fps fe or gal** hp ft 2.1 Solubility of air in water 2.2 Velocity of sound in water CHAPTER 3. SYSTEM 3.1 Economic 3.2 Description FRICTION pipe sizing of the Bernoulli theorem 3.3 Moody diagram for steel or wrought iron pipe 3.4 Moody diagram for asphalt-dipped 3.5 Chart for kinematic viscosity and Reynolds 3.6 Loss coefficients for ells 3.7 Loss coefficients for reducing ells 3.8 Summary cast iron pipe plot of the effect of close-coupled 3.9 Fabrication of fittings 3.10 Comparison ofPVC elbows with steel 3.11 Shapes of plastic pipe reducers number 4" ells • xxvi LOCATION LOCATION OF FIGURES 3.12 System configuration for calculating maximum system pressure 3.13 Maximum system pressures xxvII 5.3 Axial thrust in volute-type pumps 5.4 Axial thrust versus rate of flow curves for axial flow pumps 5.5 Actual thrust curve for a vertical turbine pump with enclosed impeller 3.14 System arrangement for networking 5.6 Comparison of the effect of casing designs on radial forces 3.15 Node pressures in psig for simulation No.1 3.16 Supply from tanks, pumps stopped, simulation No.2 3.17 Simulation No.3, fire condition-pump(s) OF FIGURES stopped CHAPTER 4. BASIC DESIGN OF CENTRIFUGAL PUMPS 5.7 Double volute pump 5.8 Common packing arrangement 5.9A Cyclone separator 5.9B Pump discharge water for seal flushing 5.10 Basic parts of a mechanical seal 5.11 Single flat-casing-ring construction 4.1 Basic centrifugal pump configurations 5.12 Double flat-casing-ring construction 4.2 Radial and mixed flow impellers 5.13 Hook or L type casing ring 4.3 Typical pump head-flow curve 5.14 Efficiency decrease due to casing ring clearance 4.4A Power balance at constant speed 5.15 Relative position of head shaft adjustment on axial flow pumps 4.4B Power losses in double-suction pumps 5.16 Basic configuration of volute impellers 4.5 Family of head-flow curves 5.17 Horizontal, close-coupled volute pump for clear service 4.6 Centrifugal pump impeller vector diagram 5.18 Submersible, close-coupled volute pumps for solids handling 4.7 Inlet and discharge vector diagrams 5.19 Horizontal, flexible-coupled volute pump for clear service 4.8A Quality pump suction design 4.8B Average pump suction design 4.9 Impeller shapes with variations in specific speed 5.20 Horizontal, flexible-coupled volute pump for solids handling 5.21 Vertical, in-line, close-coupled volute pump for clear service 5.22 Vertical-mounted, flexible-coupled volute pump for clear service 4.10 Relation of impeller types to specific speed 5.23 Vertical-mounted volute pump with suction elbow for clear service 4.11 Variation of pump curves with specific speed 5.24 Vertical-mounted volute pump, close coupled for solids handling 4.12 Open and semitype impellers 5.25 Vertical-mounted volute pump, flexible coupled, for solids handling 4.13 Open mixed-flow impeller 5.26 Horizontal, multistage volute pump, flexible coupled for clear service 4.14 Diagrams of most centrifugal pump impellers 5.27 Horizontal, self-priming volute pump, flexible coupled for clear service 4.15 Extended line shafting for centrifugal pumps 5.28 Horizontal, self-priming volute pump, flexible coupled for solids handling 4.16 Typical natural frequency band of a propeller type pump 5.29 Horizontal vortex pump, flexible coupled 4.17 Types of NPSHR curves 5.30 Horizontal, single-stage, double-suction volute pump 4.18 Pressure gradient along liquid path in pump 5.31 Vertical, single-stage, double-suction volute pump 4.19 Net positive suction head available 5.32 Horizontal, two-stage, double-suction volute pump 4.20 Inducer for reducing NPSH required 5.33 Vertical, single-stage, double-suction volute pump with column and discharge head 5.34 Cross-sections of an axial flow bowl • CHAPTER 5. THE PHYSICAL DESIGN OF CENTRIFUGAL PUMPS FOR WATER 5.1 Forces and leakages in a volute-type pump 5.2 Forces and leakages in an axial flow (turbine) pump 5.35 Four subassemblies for an axial flow pump 5.36 Horizontal, axial flow pump with propeller type impeller and integral discharge head 5.37 Horizontal, axial flow pump with mixed flow impeller and integral discharge head xxvIII LOCATION LOCATION OF FIGURES 5.38A Horizontal, multistage axial flow pump, flexible coupled 6.10B Operating range for a high specific speed pump 5.38B Vertical, multistage axial flow pump. flexible coupled 6.11 Certified efficiency curve 5.39A Cast iron head for axial flow pump, nonpressurized base 6.12 Properly developed head-flow curves 5.39B Cast iron head for axial flow pump, pressurized base 6.13 Separate brake horsepower curves 5.40A Steel fabricated head for axial flow pump, nonpressurized base 6.14 Flat-curved and steep-curved pumps 5.40B Steel fabricated head for axial flow pump, pressurized base 5.41 Below-base discharge for axial flow pumps 5.42 Two-piece top shaft for axial flow pumps 5.43 Flange-type top-shaft couplings for axial flow pumps xxix OF FIGURES 6.15A Series-parallel pumping 6.16B Two-stage pumps operating in parallel 6.16 Parallel operation of pumps with unequal head-flow curves 6.17 Variable-speed curves for one pump diameter 5.44 Open line shaft assemblies for axial flow pumps 6.18 Best efficiency curves for small single-suction volute pumps 5.45 Enclosed line shaft assemblies for axial flow pumps 6.19 Head-flow curves for three equal pumps operating in parallel 5.46 Standard type oiler for enclosed line shaft assemblies 6.20 Single pump performance under variable speed 5.47 Enclosed impellers for vertical turbine pumps 6.21 Two-pump performance under variable speed 5.48 Deep well turbine pump with open line shaft and enclosed impellers 6.22 Three-pump performance under variable speed 5.49 Vertical, multistage turbine pump with submersible motor 6.23 Centrifugal pumps and entrained-air problems 5.50 Vertical, multistage turbine pumps in barrels or cans 6.24 Effect of air in pump suctions 5.51 Vertical, multistage, close-coupled turbine pump 6.25 Vortexing in open tanks 5.52 Vertical, mixed-flow pump with open line shafting for clear service 6.26 Surface vortex suppression 5.53 Vertical, mixed-flow pump with enclosed line shafting for solids handling service 5.54 Vertical propeller pump with enclosed line shafting for clear service 6.27 Special vortex suppressors 5.55 Horizontal, regenerative turbine, flexible coupled CHAPTER 6. CENTRIFUGAL PERFORMANCE PUMP 6.1 Typical head-flow curve for centrifugal pumps 6.2 Efficiency as a function of specific speed and capacity 6.3 Efficiency increase due to improved surface finish of mixed flow impeller 6.4 Turbine performance with three levels of impeller finish 6.5 Classical affinity law curves 6.6 Affinity laws for a pump operating with static head 6.7 Aberration in affinity laws pertaining to pump impeller diameter 6.8 Head-flow and horsepower curves compared to specific speed and impeller profiles 6.9 Drooping head-flow curve 6.1OA Head-flow curve for a high specific speed pump CHAPTER 7. POSITIVE DISPLACEMENT PUMPS 7.1 Types of rotary pumps 7.2 Sliding vane pump 7.3 Flexible member pumps 7.4 Exploded view of a flexible hose pump 7.5 Lobe-type pumps 7.6 Gear pumps 7.7 Screw pumps 7.8 Open screw pump (Archimedes principle) 7.9 Enclosed screw pump (Archimedes principle) 7.10 Terms and definitions for an open type screw pump' (Archimedes principle) 7.11 Flights for an open type screw pump 7.12 Progressive cavity pump 7.13 Piston pumps 7.14 Diaphragm pump with ball type valves xxx LOCAnON OF FIGURES CHAPTER 8. PUMP DRIVERS AND VARIABLESPEED DRIVES 8.1 Electric motor performance curves 8.2 Typical wire-to-shaft efficiencies for variable-speed drives for centrifugal pumps 8.3 Six-pulse variable-frequency drives 8.4 Pulse width modulated (PWM) variable-frequency drives 8.5 Multipulse rectifiers xxxi LOCAnON OF FIGURES 10.7 Typical water system with 10 loads at 40-percent capacity 10.8 Typical water system with four loads near pumps at full capacity 10.9 Typical water system with four loads far from pumps at full capacity 10.10 System head area for a theoretical water system and actual system head area 10.11 All-friction system and system head curve 10.12 High static system and system head curve 10.13 Combination water system and system head area. 10.14 High static system with variable supply pressure with system head area 10.15 System with high supply pressure and system head curve 8.6 Load-commutated inverter 8.7 MV filter-commutated thyristor drive 8.8 MV current-fed GTO inverter 10.16 System with variable supply pressure and no static head 10.17 Hydraulic gradients for multiload system 10.18 Hydraulic gradient for high static water system with variable supply pressure 8.9 Neutral-point-clamped inverter 8.10 Multilevel series-cell inverter 8.11 Conversion cell of multilevel VFD 8.12 Cycloconverter induction motor drive CHAPTER 11. BASICS OF CENTRIFUGAL APPLICATION TO WATER SYSTEMS PUMP 8.13 Form for computing harmonic distortion 8.14 Running limit for variable-frequency drives 8.15 Variation of wire-to-shaft efficiency with system static head 8.16 Enclosures for variable-frequency drives 8.17 Gasoline engine performance curves 11.1 Correct and incorrect points of pump selection 11.2 Pump operating point 11.3 Typical operation of two 50-percent pumps 11.4 Point pump selection for variable-speed pumps 11.5 Increased pump speed selection 11.6 Increasing impeller diameter CHAPTER 9. THE MOVEMENT OF WATER 11.7 Efficiency curves for pump of Fig. 11.6 11.8 Uniform system head curve and calculation of pump operating point 9.1 Pump suction and discharge fittings 9.2 Pump check valves 11.9 Uniform system head curve and percent horsepower curve 11.10 Percent head-flow and system head curves 11.11 Low-head, high-flow system with six pumps CHAPTER 10. CONFIGURING WATER SYSTEM A PUMPED 11.12 Comparison of one constant- and one variable-speed pump with two variablespeed pumps 11.13 Selection of jockey pumps 11.14 Typical wire-to-water efficiencies of constant-speed pumps 10.1 Components of system head 11.15 Instrumentation for wire-to-water efficiency indication 11.16 Instrumentation for measuring total kW input 10.2 System head curve for a water system with one pump and 20 ft of static head 10.3 Friction losses for a pumping system with five pumps 11.17A kW Input for Tables 11.4, 11.5, and 11.6 10.4 Head-flow curve for each of five pumps 11.17B Use of adaptive control to change automatically the pump transition point 11.18 Specific flow control of pumps 10.5 System head curve adjusted for pump fitting losses 10.6 Typical water system with 10 loads of 60 gpm each 11.19 Single-pump operation area 11.20 Two-pump operation area • xxxii LOCATION OF FIGURES 11.21 Three-pump operation area LOCATION OF FIGURES xxxIII 13.3 Subsurface conditions for development of a groundwater aquifer 11.22 Basic speed control for variable-speed pump 13.4 Underground well field and treatment plant 11.23 Piping and wiring for multiple-pressure transmitters 11.24 Pump relief valve connections 13.5 Production well section 11.25 Turbine/generator installation for energy recovery 13.7 Well water treatment process 13.6 Pitless adapter for a well pump in a flood plain 11.26 System head and turbine curves 11.27 Typical turbine/generator assembly 11.28 Turbine/generator performance 11.29 Turbine generator on irrigation system or water supply CHAPTER 14. WATER PUMPS FOR MUNICIPAL WATER DISTRIBUTION 11.30 Turbine/pump for potable water 11.31 Vacuum pump and tank for priming 14.1 Vertical turbine pump in a clear well 11.32 Vacuum-controlled central automatic priming 14.2 Elevated tank near water plant clear well 11.33 Float valve and switch for priming control 14.3 System head curve for Fig. 14.2 system 11.34 Schematic diagram of priming system using makeup water 11.35 Location of control valves on pumps 14.5 Variation in system head curve due to intermediate draw-off 14.4 Water system with intermediate draw-off 14.6 Use of radio telemetry with variable-speed pump 14.7 Cincinnati Water Works distribution of water CHAPTER 12. PUMP INTAKE DESIGN 14.8 Simulation of pressure waves with and without anticipatory relief valves 14.9 Location of relief valve 12.1 Vortex classification 14.10 Relief valve with surge anticipation 12.2 Open-bottom installations for axial flow pumps 12.3 Suction can classifications 12.4 Rectangular sump arrangement 12.5 Rectangular sump dimensions CHAPTER 15. PUMPS FOR PLUMBING SYSTEMS 12.6 Formed intake structures 12.7 Trench-type intakes for clear service installations 15.1 Conversion offixture units to gpm demand 12.8 Trench-type intakes for solids handling liquids 15.2 Typical plumbing system for cold water 12.9 Pumps sensitive to loss of prime 15.3 Small pumping system for cold water 12.10 Circular wet well for solids handling with constant wet well control 12.11 Mechanically cleaned bar screen 12.12 Travelling screen with trashrack and fish escape 15.4 High-head plumbing system using vertical can pumps 15.5 High-rise plumbing system with bladder tank at top of building and jockey pump 15.6 Plumbing system with suction and roof tanks 15.7 Plumbing system with roof tank CHAPTER 13. PUMPS FOR CENTRAL WATER TREATMENT PLANTS 15.8 Closed plumbing system with little storage 15.9 Volumes of a hydropneumatic tank 15.10 High-rise system with suction tank 13.1 Treatment process for 120-million-gallon river plant 13.2 Post filtration treatment process 15.11 Low-rise development with elevated storage tank 15.12 Low-rise development with little storage • xxxiv LOCATION OF FIGURES 15.13 Low-rise development with supply tank 15.14 Low-rise development with supply tank and elevated tank LOCATION XXXV OF FIGURES 17.10 Pressure tank in use with a submersible pump 17.11 Lagoon aerator 15.15 System head curve for a small system with constant supply pressure 15.16 System head area for small system with variable supply pressure 15.17 System head area for multiple load, plumbing system 15.18 Effect of pipe aging on system head CHAPTER 18. PERFORMANCE DISPLACEMENT PUMPS OF POSITIVE 15.19 System head area with no constant (static) head 15.20 System head area where supply pressure can maintain system pressure at light and medium loads 18.1 Comparison of head-flow curves for rotary and centrifugal pumps 15.21 Sewage ejector installation 18.3 Comparison of efficiencies for rotary and centrifugal pumps with variations in viscosity of the liquid 15.22 Packaged sewage ejector 18.2 Rotary pump performance with respect to differential pressure and viscosity 18.4 Flow and brake horsepower curves for a lobe pump CHAPTER 16. FIRE PUMPS 18.5 Operating range of a screw pump 18.6 Comparison of pump heads-screw pump versus dry-pit pump 18.7 Typical performance curves for an open screw pump 16.1 Typical foam pump piping and fittings 16.2 Typical water mist pump piping and fittings 16.3 Double-suction, volute type fore pump 16.4 Vertical turbine fire pump 16.5 Single-suction volute pump for fire service 16.6 Vertical, multistage jockey pump 18.8 Progressive cavity pump 18.9 Actual capacity of progressive cavity pump at various viscosities 18.10 Performance of a hose pump 18.11 Typical power pump performance 18.12 Discharge rate for power pumps 18.13 Head-flow curves for a ball type diaphragm pump 16.7 Fittings for single- or double-volute fire pumps, motor driven 16.8 Fittings for single- or double-volute fire pumps, engine driven 16.9 Fittings for vertical turbine fire pump, motor driven 16.10 Fittings for vertical turbine fire pump, engine driven CHAPTER 19. PUMPS FOR SEWAGE COLLECTION SYSTEMS 16.11 Fuel system for diesel engine-driven fire pump 19.1 Basic types of sewage lift stations CHAPTER 17. PUMPS FOR AGRICULTURE 17.1 Large portable pump 17.2 Portable pumping system for dust control on roads 17.3 Photograph of center pivot irrigation assembly 17.4 Center pivot irrigation system 17.5 Typical application rates at a radius of 1000 ft from the pivot 17.6 Horizontal pumping systems for golf course irrigation 17.7 Vertical turbine installation for golf course irrigation 17.8 Vertical turbine assemblies for golf course irrigation 17.9 Jet pumps for domestic water 19.2 Sewage lift station 19.3 "Pump-down" control 19.4 Sewage lift station with high friction head 19.5 Performance curves for two-pump sewage lift station with constant speed 19.6 Relation of pump flow, system flow, and sump volume 19.7 Vs• pumping volume for sewage wet-well 19.8 Constant wet well-level control 19.9 Pump kW curves for three variable-speed sewage pumps 19.10 Single pump performance for pumps of Fig. 19.11 • 19.11 Multiple pump and system curves for sewage lift station with four variablespeed pumps 19.12 Pump kW versus system flow for sewage pumps of Fig. 19.11 xxxvi LOCATION OF FIGURES LOCATION xxxvII OF FIGURES 19.13 NPSHR control for pumps of Fig. 19.11 21.8 System head area for system of Fig. 21.6 19.14 Multiple sewage lift stations with common force main 21.9 kW input for three-pump storm water station 19.15 System head area for three sewage lift stations of Fig. 19.14 19.16 Head-flow curves and area for a sewage lift station with two 100-percent flow, constant-speed pumps 19.17 Pump head-flow curves for 50 and 67 percent pumps for the stations of Fig. 19.14 CHAPTER 22. INSTALLATION OF WATER PUMPS AND PUMPING SYSTEMS 19.18 Multiple sewage lift stations at different elevations and connections 19.19 Comparison of mixed-flow pump with underground station 22.1 Pump bases 19.20 Centrifugal type grinder pump 22.2 Installation of pumping system base 19.21 Progressive cavity type grinder pump 22.3 Typical base installation for pumps with flat base plate 19.22 Grinder pump performance, centrifugal type 22.4 Typical base installation for pumps with formed metal bases 19.23 Grinder pump performance, progressive cavity type 22.5 Seismic installation of floor bolts 19.24 Typical grinder pump installation 22.6 Seismic installation of pump bases 19.25 Typical grinder pump installation at a residence 19.26 Rate of rise control for sewage lift station CHAPTER 20. PUMPS FOR SEWAGE TREATMENT PLANTS CHAPTER 23. INSTRUMENTATION PUMPING SYSTEMS FOR WATER 23.1 Full-throated magnetic flow meter with bonding and grounding procedures 23.2 Insertion type magnetic flow meter 20.1 Ideal hydraulic gradient for a sewage treatment plant 23.3 Speed variation in pump head-flow curves 20.2 Hydraulic gradient for a sewage treatment plant with effluent pumping 23.4 Submersible diaphragm level transmitter 20.3 Hydraulic gradient for a sewage treatment plant with influent pumping 23.5 Bubbler type, level transmitter 20.4 Hydraulic gradient for a sewage treatment plant with influent pumping and effluent pumping during flooding of receiving stream 20.5 Typical system head curves for sludge 20.6 Sludge diagram for the Mill Creek Sewage Plant, Cincinnati, OH CHAPTER 25. OPERATION AND MAINTENANCE OF WATER PUMPS 20.7 Control of the flow of activated sludge 20.8 Schematic for recharge 25.1 Single pressure gauge for checking pump performance 25.2 Graphical representation of pump operating point for one pump 25.3 Graphical representation of pump operating point for two pumps CHAPTER 21. STORM WATER PUMPS 21.1 Contractor pump for dewatering 21.2 Storm water station elevation drawing 21.3 Storm water station discharge piping 21.4 Strom water pump installation 21.5 Storm water intake structure 21.6 Float switch assembly 21.7 Storm water station for underground water CHAPTER 26. FACTORY-ASSEMBLED PUMPING SYSTEMS • 26.1 A multiple-pump system with single-suction volute pumps with pressureregulating valves for a building plumbing system. 26.2 Pumping system with small, vertical axial flow pumps 26.3 Typical multiple-pump system with double-suction pumps. 26.4 High-head plumbing system with can pumps and a smaller pump for medium loads xxxvIII LOCA nON OF FIGURES 26.5 Fire pump system with vertical, in-line fire pump 26.6 Engine-driven fire pump package for a large warehouse. 26.7 Sewage pumping system with two self-priming pumps and standby enginedriven generator 26.8 Variable-speed pumping control center for existing pumps 26.9 Engine-driven fire pump with the house and all utilities. 26.10 Fire pump house with engine-driven and electric motor-driven fire pumps 26.11 Municipal booster station with house, engine-driven generator, and calibration room 26.12 Underground municipal water booster station 26.13 Municipal water pump house CHAPTER 27. RETROFITTING EXISTING WATER PUMPING SYSTEMS 27.1 Evaluation of an existing pump installation 27.2 Calculation of trimmed impeller diameter 27.3 Instrumentation for generating an actual system head area 27.4 Comparison of design and actual system head areas THE BASIC TOOLS OF DESIGN