In Rural Water Alliance Pump Stations

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In Rural Water Alliance Pump Stations

  1. 1. ALLIANCE OF INDIANA RURAL WATER Spring 2007 - Bloomington Wastewater Pumping System Design Considerations and Troubleshooting
  2. 2. Seminar Overview <ul><li>Site Selection </li></ul><ul><li>Basis of Design Considerations </li></ul><ul><li>Key Design Issues </li></ul><ul><li>Operational Troubleshooting </li></ul><ul><li>Wrap-up and Final Questions </li></ul>
  3. 3. Intro to F&V/Speaker <ul><li>F&V Summary </li></ul><ul><ul><li>IN presence since late 1970s as Gove Associates </li></ul></ul><ul><ul><li>120+ Staff with Indianapolis/Ft Wayne Offices </li></ul></ul><ul><ul><li>70% of our clients are small-mid size communities </li></ul></ul><ul><li>Ed’s Background </li></ul><ul><ul><li>21 yrs experience (over 10 in IN) </li></ul></ul><ul><ul><li>WWTP/CSO/Collection/PSs/IPP/System Rehab. </li></ul></ul><ul><ul><li>Civil/Env Eng with Hydraulics/Hydrology Conc. </li></ul></ul>
  4. 4. Site Selection (new locations) <ul><li>Location-Location-Location </li></ul><ul><ul><li>Facility Depth </li></ul></ul><ul><ul><li>Property Size </li></ul></ul><ul><ul><li>Growth Provisions </li></ul></ul><ul><li>Environmental Issues </li></ul><ul><ul><li>Wetlands </li></ul></ul><ul><ul><li>Floodplains </li></ul></ul><ul><ul><li>Aesthetic Surroundings </li></ul></ul>
  5. 5. Site Selection (cont) <ul><li>Access Issues </li></ul><ul><ul><li>Maintenance Vehicles </li></ul></ul><ul><ul><li>Chemical Feed </li></ul></ul><ul><ul><li>Adverse Weather </li></ul></ul><ul><ul><li>Drainage/Floodplains </li></ul></ul><ul><li>Utility Infrastructure </li></ul><ul><ul><li>Electrical service </li></ul></ul><ul><ul><li>Telemetry signal / system issues </li></ul></ul>
  6. 6. Basis of Design (exist PS) <ul><li>Why is it important to understand this? </li></ul><ul><ul><li>Know the facility limitations (flow, area etc) </li></ul></ul><ul><ul><li>Be aware of design constraints / limitations </li></ul></ul><ul><ul><ul><li>Discharge Conditions </li></ul></ul></ul><ul><ul><ul><li>Low Flow Conditions </li></ul></ul></ul><ul><ul><ul><li>Peak Flow Conditions </li></ul></ul></ul><ul><ul><ul><li>Expansion Constraints </li></ul></ul></ul>
  7. 7. Basis of Design (cont) <ul><ul><li>Pump Station Design </li></ul></ul><ul><ul><ul><li>Know “factory” original capacity </li></ul></ul></ul><ul><ul><ul><li>Original wetwell cycle times </li></ul></ul></ul><ul><ul><ul><li>Understand O&M schedules/issues </li></ul></ul></ul><ul><ul><ul><li>Equipment Life Cycles (anticipate future costs) </li></ul></ul></ul><ul><ul><ul><li>Odor control </li></ul></ul></ul><ul><ul><ul><li>Floatable Solids </li></ul></ul></ul><ul><ul><ul><li>Grease/Oils </li></ul></ul></ul>
  8. 8. Basis of Design (new) <ul><li>Important Components to Have Input On </li></ul><ul><ul><li>Location – Location – Location </li></ul></ul><ul><ul><li>Service Area – Existing and Future </li></ul></ul><ul><ul><li>Access – Maintenance & Chemical Delivery </li></ul></ul><ul><ul><li>Hydraulic Design </li></ul></ul><ul><ul><ul><li>Wet well capacity / cycle times </li></ul></ul></ul><ul><ul><ul><li>Peak Flow Capacity </li></ul></ul></ul><ul><ul><ul><li>Number and Size of Pumps </li></ul></ul></ul><ul><ul><ul><li>Pump Control Approach (VFD/Constant) </li></ul></ul></ul><ul><ul><ul><li>Low Flow Conditions </li></ul></ul></ul><ul><ul><ul><li>Impeller Selection </li></ul></ul></ul>
  9. 9. Basis of Design (cont) <ul><ul><li>Type of pump station (submersible etc) </li></ul></ul><ul><ul><li>Electrical Service </li></ul></ul><ul><ul><ul><li>Phase </li></ul></ul></ul><ul><ul><ul><li>Voltage </li></ul></ul></ul><ul><ul><li>Pump Control Issues </li></ul></ul><ul><ul><ul><li>VFD vs Constant Speed </li></ul></ul></ul><ul><ul><ul><li>Start/Stop Level Control Type </li></ul></ul></ul><ul><ul><li>Provisions for future capacity </li></ul></ul><ul><ul><ul><li>Impeller changes </li></ul></ul></ul><ul><ul><ul><li>Pump changes </li></ul></ul></ul><ul><ul><ul><li>Wetwell Changes </li></ul></ul></ul>
  10. 10. Key Design Issues - Summary <ul><li>Site Design Considerations </li></ul><ul><li>Pump Station Type / Pump Selection </li></ul><ul><li>Hydraulic Pump Design </li></ul><ul><li>Wetwell Design </li></ul><ul><li>Controls/Telemetry </li></ul><ul><li>Odor Control </li></ul>
  11. 11. Site Design Considerations <ul><li>Site Access Issues – Daily </li></ul><ul><li>Site Access Issues – Chemical Feed Deliveries </li></ul><ul><li>Electrical Power Facilities (OH/Transformers) </li></ul><ul><li>Configuration of PS Structures </li></ul><ul><li>Drainage Considerations </li></ul><ul><li>Telemetry Considerations </li></ul><ul><li>Future Capacity Considerations </li></ul>
  12. 12. Pump Station & Pump Selection <ul><li>Submersible </li></ul><ul><li>Self-Priming </li></ul><ul><li>Dry Pit </li></ul><ul><li>Alternative Configurations </li></ul><ul><li>High Flow </li></ul><ul><li>CSO/Storm </li></ul>
  13. 13. Pump Basics Pump Types / Characteristics
  14. 14. Pump Basics (cont) <ul><li>Pump Selection Factors </li></ul><ul><ul><li>Fluid Type </li></ul></ul><ul><ul><li>Flow </li></ul></ul><ul><ul><li>Solids Handling Requirements </li></ul></ul><ul><ul><li>Site and Facility Constraints </li></ul></ul><ul><ul><li>Existing Equipment/Owner Preference </li></ul></ul>
  15. 15. Pump Basics (cont) Specific Gravity of Pumped Fluid has large affect on Total Dynamic Head
  16. 16. Submersible
  17. 17. Self-Priming <ul><li>Cost-Effective </li></ul><ul><li>Equipment at Ground Level – maintenance </li></ul><ul><li>Needs site fencing for security </li></ul>
  18. 19. Dry Pit Installations
  19. 20. Centrifugal Pump Curve
  20. 21. Alternative Installations Submersible pumps can be installed in dry-pit applications
  21. 22. Alternative (cont) <ul><li>Heavy solids issues require special pumps </li></ul>
  22. 23. High Flow Pumping <ul><li>Turbine, Mixed and Axial Flow Pumps </li></ul>
  23. 24. High Flow (cont)
  24. 25. CSO / Stormwater
  25. 26. CSO / Storm (cont)
  26. 27. CSO / Storm (cont)
  27. 28. Hydraulic Pump Design
  28. 29. Hydraulic (cont)
  29. 30. Hydraulic (cont)
  30. 31. Hydraulic (cont) Net Positive Suction Head (function of alt/fluid/lift/suction friction losses
  31. 32. Hydraulic (cont) <ul><li>Suction Side Cavitation </li></ul><ul><ul><li>Air Entrainment </li></ul></ul><ul><ul><li>Improper Suction Piping </li></ul></ul><ul><li>Discharge Side Cavitation </li></ul><ul><ul><li>Runout beyond pump curve </li></ul></ul>
  32. 33. Wetwell Design <ul><li>Sizing is a function of the following: </li></ul><ul><ul><li>Flow </li></ul></ul><ul><ul><li>Horsepower </li></ul></ul><ul><ul><li>Cycle Times (starts per hour) </li></ul></ul><ul><li>Try to avoid air entrainment </li></ul><ul><li>Try to provide uniform approach velocities </li></ul>
  33. 34. Wetwell (cont)
  34. 35. Wetwell (cont)
  35. 36. Controls / Telemetry <ul><li>Pump Controls (on/off) </li></ul><ul><ul><li>Floats </li></ul></ul><ul><ul><li>Air Pressure Bells </li></ul></ul><ul><ul><li>Pressure Transducer </li></ul></ul><ul><li>Pump Speed Controls </li></ul><ul><ul><li>Constant Speed </li></ul></ul><ul><ul><li>VFD </li></ul></ul><ul><ul><li>Belt Drives (shive adjustable) </li></ul></ul>
  36. 37. Odor Control <ul><li>Key Elements to Fight Odor Problems </li></ul><ul><ul><li>Correct hydraulic and pump station design </li></ul></ul><ul><ul><li>Treat the wastewater (chemicals/aeration etc) </li></ul></ul><ul><ul><li>Treat the off gases (activated carbon) </li></ul></ul>
  37. 38. Operational Troubleshooting <ul><li>Many future operational problems can be prevented by a thorough checkout at startup. </li></ul><ul><ul><li>Do not rely just on the standard manufacturer’s forms </li></ul></ul><ul><ul><li>Remember the pump station basis of design and other key pump design information after the PS is placed into service. </li></ul></ul>
  38. 39. Troubleshooting (cont) <ul><li>Potential Operational Problems </li></ul><ul><ul><li>Pump clogged </li></ul></ul><ul><ul><li>Reduced actual pumping rate </li></ul></ul><ul><ul><li>Overheating/Breaker Issues </li></ul></ul><ul><ul><li>Control malfunctions </li></ul></ul><ul><ul><li>Excessive flows </li></ul></ul><ul><ul><li>Grease/Oil/Floatable Solids </li></ul></ul><ul><ul><li>Odor Issues/Corrosion Issues </li></ul></ul><ul><ul><li>Pump Vibration </li></ul></ul>
  39. 40. Troubleshooting (cont) <ul><li>Many Different Factors can lead to similar problems. </li></ul>
  40. 41. Troubleshooting (cont)
  41. 42. Conclusions

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