Water pumps and pumping systems

CONTENTS Preface xix Table of Symbols and Terminology xxiii Location of Figures xxv PART 1. The Basic Tools of Design CHAPTER 1. Digital Electronics and Water Pumps and Systems 1.3 Introduction I 1.3 Computer-Aided Calculations of Water Loads and Pipe Friction I 1.3 Hydraulic Gradient Diagrams I 1.4 Speed and Accuracy of Electronic Design of Water Systems I 1.5 Equation Solutions by Computer I 1.5 Databasing I 1.5 Electronic Communication I 1.6 Electronic Design of the Piping and Accessories I 1.6 Electronic Selection of Water Pumping Equipment I 1.6 Electronic Control of Water Pumping Systems I 1.6 Electronics and Water Pumping Systems I 1.7 Electronics and Variable-Speed Pumping Systems I 1.7 Electronic Commissioning I 1.7 Purpose of This Book I 1.8 CHAPTER 2. Physical Data for Water Pumping Systems 2.1 Introduction 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 I 2.4 Viscosity of Water I 2.6 Vapor Pressure and Specific Weight for Water, 32 to 2l2"F I 2.6 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 viii CONTENTS Additional Reading I 2.13 Books for a Personal Library I 2.14 ,. CHAPTER 3. System Friction 3.1 Introduction I 3.1 Total Owning Cost I 3.1 Maximum Capacities and Velocities of Actual Piping I 3.3 Pipe Velocity is Designer's Responsibility I 3.4 Pipe and Fitting Specifications I 3.5 General Pipe Friction Analysis I 3.5 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 Asphalt-Coated Cast Iron and New Steel Pipe Friction Tables I 3.36 Plastic Pipe I 3.36 PVC and CPVC plastic pipe I 3.37 HDPE pipe I 3.37 Copper Pipe and Tubing / 3.42 Pipe Fitting Losses I 3.42 Steel and cast iron pipe fittings / 3.79 Results of Recent Laboratory Testing of Fittings I 3.83 Effect of Fabrication on Steel Fitting Loss / 3.86 Copper Fittings I 3.88 Plastic Pipe Fittings I 3.88 Hydraulic Gradient Diagrams I 3.90 Piping Network Analyses / 3.91 Summary I 3.95 References I 3.98 PART 2. Pumps and Their Performance CHAPTER 4. Basic Design of Centrifugal Pumps 4.3 Introduction I 4.3 General Design of Centrifugal Pumps I 4.4 General Performance of a Centrifugal Pump I 4.7 Centrifugal Pump Impeller Design I 4.10 Specific Speed of a Centrifugal Pump I 4.12 Critical Speed of a Centrifugal Pump I 4.17 Minimum Speed for a Variable-Speed Pump / 4.21 Minimum Flow for Centrifugal Pumps I 4.22 Pump Suction Limitations / 4.22 Net positive suction head I 4.23 Submergence in open tanks, wet wells, and open pits / 4.27 CONTENTS Ix Sizing Centrifugal Pumps I 4.27 General Pump Design Information I 4.28 Books for Further Reading I 4.29 CHAPTER 5. The Physical Design of Centrifugal Pumps for Water 5.1 Introduction I 5.1 Basic Elements of Physical Design 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 Two Basic Types of Centrifugal Pumps I 5.16 Volute Type Pumps I 5.16 Single-suction pumps I 5.17 Double-suction pumps I 5.27 Axial Flow Type Pumps I 5.32 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 5.57 Mechanical Devices for Pumps I 5.58 Additional Reading I 5.59 CHAPTER 6. Centrifugal Pump Performance 6.1 Introduction I 6.1 Pump Head-Flow Curves I 6.1 Affinity Laws I 6.5 Variable-speed performance I 6.5 Variable impeller diameter performance I 6.7 Constant-Speed Head-Flow Curves I 6.10 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 Pump Head-Flow Curves I 6.22 Air Entrainment and Vortexing I 6.26 Pumping Energy in hp I 6.32 Water horsepower I 6.33 Pump brake horsepower I 6.33 Pumping Energy in kW I 6.33 Electric Motor Power in kW I 6.34 Engine-driven pumps I 6.34 • Actual energy consumed by variable-speed pumps / 6.35 Noise in Pumping Systems I 6.35 Summation of the Performance of Centrifugal Pumps I 6.36 Sources of Pump Information I 6.37 X CONTENTS -CHA-PTER 7. Positive Displacement Pumps 7.1 Introduction I 7.] Types of Positive Displacement Pumps / 7.] Rotary Pumps / 7.] Vane pumps / 7.2 Flexible member pumps / 7.2 Lobe type pumps / 7.3 Gear pumps / 7.5 Screw pumps / 7.5 High volume screw pumps (Archimedes principle) / 7.7 Progressive cavity pumps / 7.8 Definitions for Rotary Pumps / 7.11 Reciprocating Power Pumps / 7.11 Piston pumps / 7.12 Plunger pumps / 7.13 Definitions for Reciprocating Power Pumps / 7.13 Diaphragm Pumps / 7.13 SUmmary / 7.14 -CHAPTER 8. Pump Drivers and Variable-Speed Drives 8.1 Introduction I 8.1 Electric Motors / 8.] Electric motor power characteristics / 8.2 Motor output ratings / 8.3 Motor speed / 8.3 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 Variable-Frequency Drives / 8.10 Early Variable-Frequency Drives / 8.12 PWM Drives / 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 Drives / 8.32 Sizing of Variable-Frequency Drives / 8.32 Efficiency of Variable-Frequency Drives / 8.33 Application of Variable-Speed Drives / 8.35 Variable Frequency-Drive Accessories and Requirements / 8.37 Engine-Driven Pumps / 8.39 SUIT1lnary / 8.42 Sources of Technical Information / 8.42 CONTENTS xl PART 3. The Pumping World CHAPTER 9. The Movement of Water 9.3 Introduction / 9.3 Determination of Useful Energy / 9.3 Useful consumption of pumping energy / 9.3 Inefficient use of energy / 9.4 Calculation of System Efficiency / 9.4 kW/MGD / 9.6 Energy Lost to Mechanical Flow Control Devices / 9.7 Evaluation of Piping Design / 9.8 Load Range for a Water System / 9.8 Energy Consumption and Water Use / 9. /0 Categorization of Water Systems / 9./0 Suggested Design Rules / 9.10 CHAPTER 10. Configuring a Pumped Water System 10.1 Introduction / /0.1 Modeling a Water System / 10.2 System Head Curve Components / 10.3 Pumping System Losses / 10.5 System Head Areas / 10.9 Static Pressure / 10.13 Configuration of Typical Water Systems / /0.13 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 Piping Network Analysis / 10.24 Summary / 10.25 CHAPTER 11. Basics of Centrifugal Pump Application to Water Systems 11.1 Introduction / 11.1 Point of Selection / 11.2 Selecting constant-speed pumps / 11.2 • Selecting variable-speed pumps / 11.4 Increased Pump Speed for Variable-Speed Pumps / 11.5 Decreased Pump Speed for Variable-Speed Pumps / 11.9 Selecting a Larger Impeller at Maximum Motor Horsepower / 11.11 Proper Use of Affinity Laws with Constant -Speed Pumps / 11.13 Number of Pumps Operating in Parallel / 11.15 Mixing Constant- and Variable-Speed Pumps / 1].]8 xii CONTENTS Jockey Pumps / 11.21 Efficiency of a Pumping System / 11.21 Wire-to-Water Efficiency / 11.23 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 / 11.35 Pump Control / 11.35 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 / 11.39 Pump Speed Control / 11.40 Sensors for pump speed control / 11.43 Communication from Remote Transmitters / 11.44 Effects of Water Systems on Pump Performance / 11.45 Using Centrifugal Pumps as Turbines / 11.47 Priming Systems / 11.49 Summary / 11.52 Additional Reading / 11.53 CHAPTER 12. Centrifugal Pump Intake Design 12.1 Introduction / 12.1 Wet well volume / 12.1 Inlet Bell Design Diameter / 12.2 Submergence / 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 / 12.12 Strainers, Screens, and Trashracks / /2.12 Strainers / 12.13 Screens and trashracks / 12.14 Summary / 12.15 CONTENTS xIII PART 4. Clear Water Pumping CHAPTER 13. Pumps for Central Water Treatment Plants 13.3 Introduction / 13.3 Types of Water Plants Utilizing Rainwater / 13.3 Surface-water treatment plants / 13.4 Underground water treatment plants / 13.6 Desalinization / 13.11 Water Reuse / 13.11 Recharge / 13.12 Summary / 13.12 CHAPTER 14. Water Pumps for Municipal Water Distribution 14.1 Introduction / 14.1 Primary Pumping Stations / 14.1 System head curves for primary pumping / 14.2 Variable- or constant-speed primary pumps / 14.3 Secondary Pumping Systems / 14.4 Multiple pumping stations / 14.7 Calculation of Friction Loss in Municipal Water Systems / 14.9 Hydraulic Shock from Long Discharge Lines / 14.9 Summary / 14.13 CHAPTER 15. Pumps for Plumbing Systems 15.1 Introduction / 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 / 15.6 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 Sewage Ejectors / 15.20 Storm Water / 15.21 Graywater / 15.21 Additional Reading / 15.22 CHAPTER 16. Fire Pumps . 16.1 Introduction / 16.1 Types of Fire Pump Installations / 16.1 Location of fire pump installations / 16.4 Source of Waterfor Fire Pumps / 16.4 xiv CONTENTS Types of Fire Pumps I 16.4 Rate of Flow of Stationary Fire Pumps for Water I 16.7 Fire pump performance I 16.8 Fire Pump Accessories I 16.8 Fire Pump Fittings I 16.9 Fire Pump Drivers I 16.14 Electric motors I 16.14 Electrical power supply I 16.15 Diesel engines I 16.16 Testing Fire Pumps and Their Installation I 16.16 Shop tests of fire pumps I 16.16 Field testing for approval of the entire installation I 16.17 Summary I 16.18 CHAPTER 17. Pumps for Agriculture 17.1 Introduction I 17.1 Irrigation I 17.1 Open-channel (ditch) irrigation I 17.1 Closed-pipe irrigation I 17.2 Golf course irrigation I 17.4 Waterfrom Wells I 17.7 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 Pumps for Animal Waste Disposal Systems I 17.15 Agricultural Use of Sewage Plant Sludge and Effluent I 17.16 PART 5. Solids Handling Pumping CHAPTER 18. Performance of Positive Displacement Pumps 18.3 Introduction I 18.3 Basic Performance of Positive Displacement Pumps I 18.3 Performance of Rotary Pumps I 18.4 Rotary screw pumps I 18.4 Large screw pumps (Archimedes principle) I 18.5 Progressive cavity pumps I 18.8 Flexible element pumps I 18.11 Reciprocating Pumps I 18.12 Diaphragm pumps I 18.12 Summary I 18.14 CHAPTER 19. Pumps for Sewage Collection Systems 19.1 Introduction I 19.1 Basic Configurations of Sewage Lift Stations I 19.1 Constant-Speed Sewage Lift Station I 19.1 Wet-well size for constant-speed pump station I 19.4 CONTENTS XV Variable-Speed 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 Friction Loss in Sewage Lift Stations I 19.20 Types of Pumps for Lift Stations I 19.22 Grinder Pump Systems I 19.23 Hydraulic Shock from Long Force Mains I 19.24 Special Control Procedures for Sewage Wet Wells I 19.26 Resume I 19.28 CHAPTER 20. Pumps for Sewage Treatment Plants 20.1 Introduction I 20.1 Types of Sewage Treatment Plants I 20.1 Main Flow Pumps I 20.3 Sludge and Grit Pumps I 20.4 Use of Variable-Speed Drives in Sewage Plants I 20.5 Water Reuse I 20.5 Recharge I 20.11 Summary I 20.11 CHAPTER 21. Storm Water Pumps 21.1 Introduction I 21.1 Design Parameters I 21.1 Maximum Flow I 21.1 Rational method I 21.2 Soil Conservation Service method I 21.2 Computerized runoff models I 21.2 Source of Water I 21.2 Storm Water Pumps I 21.3 "Contractor" pumps I 21.4 Pump Head I 21.4 Above Ground Flood Plain Stations I 21.4 Below Ground Stations I 21.5 Summary I 21.10 PART 6. Installing, Testing, and Operating Pumps CHAPTER 22. Installation of Water Pumps and Pumping Systems 22.3 Introduction I 22.3 Preinstallation Procedures I 22.3 Pump and Pumping System Bases I 22.4 Pump bases with seismic restraints I 22.7 xvi CONTENTS Connecting Piping to Pumps I 22.8 Pump fitting sizing I 22.8 Pump fitting ap-angement I 22.10 Expansion Provisions at Pumps I 22.10 Electrical Provisions for Pumps 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 I 22.12 Summary I 22.12 CHAPTER 23. Instrumentation for Water Pumping Systems 23.1 Introduction I 23.1 Definitions and Terms I 23.1 Transmitters I 23.3 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 Controllers I 23.13 Simple controllers I 23.13 Electronic controllers I 23.13 Quality of controllers I 23.14 Control Wiring I 23.14 Control Valves I 23.14 Summary I 23.15 Reference I 23.15 CHAPTER 24. Testing Water Pumps 24.1 Introduction I 24.1 Objective I 24.1 Types of Tests I 24.2 Hydrostatic Tests I 24.2 Centrifugal pumps: Volute and axial flow types (includes vertical pumps) I 24.2 Positive displacement pumps I 24.2 Performance Tests I 24.3 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 I 24.5 Priming Time for Self-Priming Centrifugal Pumps I 24.5 Testing Procedures I 24.5 Field Testing of Pumps I 24.6 CONTENTS xvII Test Instrumentation I 24.6 Instrument accuracy I 24.6 Simultaneous recording I 24.7 Interval for calibration of instrumentation I 24.7 Installation of instrumentation I 24.7 Test Reports and Records I 24.7 Accuracy of Pump Head-Capacity Curves I 24.8 Understanding Factory Tests of Pumps I 24.8 Summary I 24.8 CHAPTER 25. Operating and Maintaining Water Pumps 25.1 Introduction I 25.1 Checking for Efficient Selection of Water Pumps I 25.1 Constant- or Variable-Speed Pumps I 25.2 Proper Selection and Operation of Variable-Speed Pumps I 25.3 Selection of variable-speed pumps I 25.3 Operation of variable-speed pumps I 25.3 Checking Pump Performance I 25.4 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 Sequencing and Alternation I 25.9 Sequencing I 25.9 Alternation I 25.9 Maintaining Pumping Equipment at High Efficiency I 25.10 Maintenance Schedules I 25.11 Summary I 25.11 Reference I 25.11 CHAPTER 26. Factory-Assembled Pumping Systems 26.1 Introduction I 26.1 Applications of Factory-Assembled Pumping Systems I 26.1 Typical Factory-Assembled Pumping Stations I 26.2 Factory-Assembled Control Centers for Existing Pumps I 26.2 Complete Pump Houses I 26.6 Advantages of Factory-Assembled Pumping Systems I 26.8 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 I 26.17 Pumps I 26.17 Pumping system accessories I 26.17 xviii CONTENTS Electrical equipment I 26.18 Testing of Factory-Assembled Pumping Systems I 26.19 Summary I 26.19 CHAPTER 27 . Retrofitting Existing Water Pumping Systems 27.1 Introduction I 27.1 System Evaluation I 27.1 Graphical Description of Flow in an Existing System I 27.2 Evaluation of Existing Procedures I 27.4 Trimming the Pump Impeller I 27.4 Changing to a Variable-Speed Pump I 27.6 Evaluation of Existing Pumps and Motors I 27.7 Evaluation of the Number of Pumps I 27.7 Control of Existing Pumps I 27.8 Variable-Speed Control and Drives for Modified Systems I 27.8 Actual Generation of a System Head Area for an Existing System I 27.9 Synopsis I 27.10 CHAPTER 28. Summary of Water System Energy Evaluations 28.1 Introduction I 28.1 Pumping System Efficiencies I 28.1 Water System Efficiencies I 28.2 Purpose of Efficiency Equations I 28.2 Sustained System and Equipment Efficiencies I 28.3 Summary I 28.3 APPENDIX A. Abbreviations and Symbols A.3 APPENDIX B. Terms and Nomenclature B.1 APPENDIX C. Glossary of Equations C.1 APPENDIX D. Conversion of English Units to SI Units Index 1.1 D.1