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Pump Station Design
Session 1 Overview of Checklist for PumpStation Design
By Teow Boo Koh
24 June 2011
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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
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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
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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
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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
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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
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Typical System Curve
S GRAPH OF SYSTEM CURVES - TE AWA AVENUE PUMP STATIONHIGH FLOW PUMPS - SINGLE PIPE FROM INDIVIDUAL PUMP TO END of FORESHORE - Post Tender Hydraulics
9.97
6.346.40
8.64
5.60
4.00
8.21
3425
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
0.0 500.0 1000.0 1500.0 2000.0 2500.0
000.0
500.0 4000.0
FLOW L/
HEA
Upper Bound Intake Water Level RL 9.2m System Curve For Guaranteed Duty Point at Level RL 10.0m
Lower Bound Intake Water Level RL 11.6m Guaranteed Duty Point
Duty Point 2 Duty Point
Amacan PB4 1200-870/450-20degrees 580RPM 1P KSB BEP
575 RPM BEP
487 RPM BEP
1
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Preferred perating Region
NSI I
Centrifugal Pump:
P R % to % B P
Vertical Pump
P R % to % SS < =
% to % SS>
R % to %
B P at ullImpeller
Dia
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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 (n n )
ead = (n n )
Power P = P (n n )
The affinity rules are not valid for the
NPS , for approximative calculations the
following equation can be used
NPS - value
NPS ~ NPS (n n ) x
x ~ , for calculation to higher speeds
x ~ , for calculation to lower speeds
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Acceptance test in accordance with N IS
Unit Symbol Grade Grade Annex
A %
Flow tQ 4,5 8 9
Head th 3 5 7
Pumpefficiency
tL -3 -5 -7
Guarantee design
point
Measured points
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Acceptance test in accordance with AS Part
ld BS : Part Class B tests :
Guarantee point
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Factory Test Curve BS Part Class C
test (IS )
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Cavitation NPS required
When the pump manufacturer develops the pumps NPSHrcurve, 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)
NPSH
Head
NPSHincNPSHre
0,97*Hdp
Hdp
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Typical Factory Test Curve and
NPS Test
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Suction nergy evel ( I - )
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NPS margin ratio recommendations
(ANSI I - )
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Pump Reference Plan ForTest Measurements
Especially important for NPSH
Datum
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