CONTENTS

Preface xixTable of Symbols and Terminology xxiiiLocation of Figures xxv

PART 1. The Basic Tools of Design

CHAPTER 1. Digital Electronics and Water Pumps and Systems 1.3

Introduction I 1.3Computer-Aided Calculations of Water Loads and Pipe Friction I 1.3Hydraulic Gradient Diagrams I 1.4Speed and Accuracy of Electronic Design of Water Systems I 1.5Equation Solutions by Computer I 1.5Databasing I 1.5Electronic Communication I 1.6Electronic Design of the Piping and Accessories I 1.6Electronic Selection ofWater Pumping Equipment I 1.6Electronic Control of Water Pumping Systems I 1.6Electronics and Water Pumping Systems I 1.7Electronics and Variable-Speed Pumping Systems I 1.7Electronic Cornrnissioning I 1.7Purpose ofThis Book I 1.8

CHAPTER 2. Physical Data for Water Pumping Systems 2.1

Introduction I 2.1Standard Operating Conditions I 2.1

Standard Air Conditions I 2.2Operating Pressures I 2.2

Thermal Equivalents I 2.4Water Data I 2.4

Viscosity ofWater I 2.6Vapor Pressure and Specific Weight for Water, 32 to 212°F I 2.6Solubility of Air in Water I 2.7Velocity of Sound in Water I 2.10

Areas and Volumes of Steel Pipe and Tanks I 2.10Electrical Data I 2.10Efficiency Evaluation ofWater Systems I 2.13

-viii CONTENTS

Additional Reading I 2.13Books for a Personal Library I 2.14

CHAPTER 3. System Friction 3.1

lntroduction I 3.1Total Owning Cost I 3.1Maximum Capacities and Velocities of Actual Piping I 3.3Pipe Velocity is Designer's Responsibility I 3.4Pipe and Fitting Specifications I 3.5General Pipe Friction Analysis I 3.5

Pipe friction formulas I 3.7Reynolds number and Moody diagrams I 3.8Use ofthe Darcy-Weisbach equation I 3.11Use of the Hazen- Williams formula I 3.35

Pipe Friction Tables I 3.35Asphalt-Coated Cast lron and New Steel Pipe Friction Tables I 3.36Plastic Pipe I 3.36

PVC and CPVC plastic pipe I 3.37HDPE pipe I 3.37

Copper Pipe and Tubing I 3.42Pipe Fitting Losses I 3.42

Steel and cast iron pipe fittings I 3.79Results of Recent Laboratory Testing of Fittings I 3.83Effect of Fabrication on Steel Fitting Loss I 3.86Copper Fittings I 3.88Plastic Pipe Fittings I 3.88Hydraulic Gradient Diagrams I 3.90Piping Network Analyses I 3.91Summary I 3.95References I 3.98

PART 2. Pumps and Their Performance

CHAPTER 4. Basic Design of Centrífugal Pumps 4.3

lntroduction I 4.3General Design of Centrifugal Pumps I 4.4General Performance of a Centrifugal Pump I 4.7Centrifugal Pump lmpeller Design I 4.10Specific Speed of a Centrifugal Pump I 4.12Critical Speed of a Centrifugal Pump I 4.17Minimum Speed for a Variable-Speed Pump I 4.21Minimum FIow for Centrifugal Pumps I 4.22Pump Suction Limitations I 4.22

Net positive suction head I 4.23Submergence in open tanks, wet wells, and open pits I 4.27

x CONTENTS

CHAPTER 7. Positive Displacement Pumps 7.1

Introduction I 7.1Types of Positive Displacement Pumps I 7.1Rotary Pumps I 7.1

Vane pumps I 7.2F1exible member pumps I 7.2Lobe type pumps I 7.3Gear pumps I 7.5Screw pumps I 7.5High volume screw pumps(Archimedes principIe) I 7.7Progressive cavity pumps I 7.8

Definitions for Rotary Pumps I 7.11Reciprocating Power Pumps I 7.11

Piston pumps I 7.12Plunger pumps I 7.13

Definitions for Reciprocating Power Pumps I 7.13Diaphragm Pumps I 7.13Summary I 7.14

CHAPTER 8. Pump Drivers and Variable-Speed Drives 8.1

Introduction I 8.1Electric Motors I 8.1

Electric motor power characteristics I 8.2Motor output ratings I 8.3Motor speed I 8.3Types of polyphase motors and code letters I 8.3Electric motor torque and horsepower I 8.4Motor currents I 8.6Electric motor output horsepower I 8.7Electric motor power factor I 8.7Electric motor efficiency I 8.7Electric-motor construction I 8.8Motor sizing for pumps I 8.9Allowable motor starts per hour I 8.10

Variable-Speed Drives for Pumps I 8.10Variable-Frequency Drives I 8.10Early Variable-Frequency Drives I 8.12PWM Drives I 8.12

Drives with multipulse input circuits I 8.15Clean power variable-speed drives I 8.15Medium voltage drives I 8.15

Harmonics and Variable-Frequency Drives I 8.29Advantages of Variable-Frequency Drives I 8.32Sizing ofVariable-Frequency Drives I 8.32Efficiency of Variable-Frequency Drives I 8.33Application ofVariable-Speed Drives I 8.35Variable Frequency-Drive Accessories and Requirements I 8.37Engine-Driven Pumps I 8.39Summary I 8.42Sources of Technical Inforrnation I 8.42

CONTENTS xi

PART 3. The Pumping World

CHAPTER 9. The Movement of Water 9.3

Introduction I 9.3Determination of Useful Energy I 9.3

Useful consumption of pumping energy I 9.3Inefficient use of energy I 9.4

Calculation of System Efficiency I 9.4kWIMGD I 9.6

Energy Lost to Mechanical Flow Control Devices I 9.7Evaluation of Piping Design I 9.8Load Range for a Water System I 9.8Energy Consumption and Water Use I 9.10Categorization of Water Systems I 9.10Suggested Design Rules I 9. lO

CHAPTER 10. Configuring a Pumped Water System 10.1

Introduction I 10.1Modeling a Water System I 10.2System Head Curve Components I 10.3Pumping System Losses I 10.5System Head Areas I 10.9Static Pressure I 10.13Configuration of Typical Water Systems I 10.13

Ali friction system I 10.13High static system I 10.14System with two subsystems I 10.15High static system with variable supply pressure I 10.15System with high supply pressure and no static pressure I 10.17System with variable supply pressure and no static pressure I 10.18

Hydraulic Gradients I 10.20Piping Network Analysis I 10.24Summary I 10.25

CHAPTER 11. Basics of Centrifugal Pump Application toWater Systems 11.1

Introduction I 11.1Point of Selection I 11.2

Selecting constant-speed pumps I 11.2Selecting variable-speed pumps I 11.4

Increased Pump Speed for Variable-Speed Pumps I 11.5Decreased Pump Speed for Variable-Speed Pumps I 11.9Selecting a Larger Impeller at Maximum Motor Horsepower I J 1.J 1Proper Use of Affinity Laws with Constant-Speed Pumps I 1/.13Number of Pumps Operating in Parallel I //./5Mixing Constant- and Variable-Speed Pumps I //.18

xii CONTENTS

Jockey Pumps I 11.21Efficiency of a Pumping System I 11.21Wire-to-Water Efficiency I 11.23

Calculated wire-to-water efficiency of single constant-speed pumps I 11.25Calculated wire-to-water efficiency of a single variable-speed pump I 11.27Calculated wire-to-water efficiencies of multiple-pump systems I 11.27

Total kW Input for a Pumping System I 11.28Conclusions I 11.31Total kW input indication and pump programming I 11.32Use of Adaptive Control I 11.34Total kW input for variable-speed pumping systems with a smalllead pump I 11.35

Pump Control I 11.35Pump Start-Stop Procedures in Response to Physical Events I 11.36

System activation or shut-down I 11.36System demands such as levei, flow, or pressure I 11.36Emergency backup on pump failure I 11.37

Sequencing of Pumps I 11.37Altemation of Operating Pumps I 11.39Pump Speed Control I 11.40

Sensors for pump speed control I 11.43Communication from Remote Transmitters I 11.44Effects of Water Systems on Pump Perforrnance I 11.45Using Centrífugal Pumps as Turbines I 11.47Priming Systems I 11.49Summary I 11.52Additional Reading I 11.53

CHAPTER 12. Centrifugal Pump Intake Design 12.1

Introduction I 12.1Wet well volume I 12.1

Inlet Bell Design Diameter I 12.2Submergence I 12.2Clear Service Pumps I 12.3

Rectangular structures I 12.6Forrned suction intakes I 12.6Circular structures I 12.6Trench-type intakes I 12.9

Intake Structures for Solids Bearing Liquids I 12.10Trench-type wet wells for solids handling liquids I 12.10Circular wet pits for solids handling pumps I 12.12

Testing Intake Structures I 12.12Remedial Measures forIntake Structures I 12.12Strainers, Screens, and Trashracks I 12.12

Strainers I 12.13Screens and trashracks I 12.14

Summary I 12.15

CONTENTS xiii

PART 4. elear Water Pumping

CHAPTER 13. Pumps for Central Water Treatment Plants 13.3

lntroduction I 13.3Types of Water Plants Utilizing Rainwater I 13.3

Surface-water treatment plants I 13.4Underground water treatment plants I 13.6

Desalinization I 13.]]Water Reuse I 13.]]Recharge I 13.12Summary I 13.12

CHAPTER 14. Water Pumps for Municipal Water Distribution 14.1

lntroduction I 14.1Primary Pumping Stations I 14.1

System head curves for primary pumping I 14.2Variable- or constant-speed primary pumps I 14.3

Secondary Pumping Systems I 14.4Multiple pumping stations I 14.7

Calculation of Friction Loss in Municipal Water Systems I 14.9Hydraulic Shock from Long Discharge Lines I 14.9Summary I 14.13

CHAPTER 15. Pumps for Plumbing Systems 15.1

lntroduction I 15.1Cold Water Systems I 15.1

Waterflow I 15.1Pressure losses in cold water systems / 15.3Calculation of pump head for cold water plumbing systems I 15.6MateriaIs for cold water pumping systems I 15.6Pumps for domestic water / 15.7Cold water system configuration I 15.8Sizing the hydro-pneumatic tank I 15.10Cold water system head curves and areas I 15.14Location of pressure switches and transmitters / 15.17

Hot Water Systems I 15.19Sewage Ejectors I 15.20Storm Water / 15.21Graywater I 15.21Additional Reading I 15.22

CHAPTER 16. Fire Pumps 16.1

lntroduction I 16.1Types of Fire Pump lnstallations I 16.1

Location of fire pump installations I 16.4Source of Water for Fire Pumps I 16.4

xiv CONTENTS

Types ofFire Pumps I 16.4Rate of F10w of Stationary Fire Pumps for Water I 16.7

Fire pump performance I 16.8Fire Pump Accessories I 16.8Fire Pump Fittings I 16.9Fire Pump Drivers I 16.14

Electric motors I 16. 14Electrical power supply I 16. 15Diesel engines I 16.16

Testing Fire Pumps and Their Installation I 16.16Shop tests of fire pumps I 16.16Field testing for approval of lhe entire installation I 16. I 7

Summary I 16.18

CHAPTER17. Pumpsfor Agriculture 17.1

Introduction I /7./Irrigation I 17.1

Open-channel (ditch) irrigation I /7./Closed-pipe irrigation I 17.2Golf course irrigation I 17.4

Water from Wells I 17.7Creating a well for irrigation I 17.7Location of a well I 17.11Well design cri teria I /7.JlDrilling lhe well I 17.11Well development I 17.12Selection of lhe production pump I 17.13Finalized design flow rate I /7.15

Well Pumps for Farm Domestic Water I /7.15Pumps for Animal Waste Disposal Systems I 17.15Agricultural Use of Sewage Plant Sludge and Effluent I /7.16

PART 5. Solids Handling Pumping

CHAPTER18. Performance of Positive Displacement Pumps 18.3

Introduction I 18.3Basic Performance of Positive Displacement Pumps I 1B.3Performance of Rotary Pumps I lB.4

Rotary screw pumps I 18.4Large screw pumps (Archimedes principIe) I lB.5Progressive cavity pumps I 1B.BFlexible element pumps I lB.ll

Reciprocating Pumps I 1B.12Diaphragm pumps I 1B.12

Summary I 1B.14

CHAPTER19. Pumps for Sewage Collection Systems 19.1

Introduction I 19.1Basic Configurations of Sewage Lift Stations I 19.1Constant-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 19.6Control for a variable-speed sewage pumping station I 19.6Energy savings from constant wet-well control I 19.7Pump addition and subtraction points I 19.11Adaptive control for pump transition points I 19.14Programming with flow meters I 19.16

Multiple Sewage Lift Stations I 19.17Friction Loss in Sewage Lift Stations I 19.20Types of Pumps for Lift Stations I 19.22Grinder Pump Systems I 19.23Hydraulic Shock from Long Force Mains I 19.24Special Control Procedures for Sewage Wet Wells 19.26Resume I 19.28

CHAPTER 20. Pumps for Sewage Treatment Plants 20.1

Introduction I 20.1Types of Sewage Treatrnent Plants I 20.1Main Flow Pumps I 20.3Sludge and Grit Pumps I 20.4Use ofVariable-Speed Drives in Sewage Plants I 20.5Water Reuse I 20.5Recharge I 20.11Summary I 20.11

CHAPTER 21. Storm Water Pumps 21.1

Introduction I 21.1Design Parameters I 21.1Maximum Flow I 21.1

Rational method I 21.2Soil Conservation Service method I 21.2Computerized runoffmodels I 21.2

Source ofWater I 21.2Storm Water Pumps I 21.3

"Contractor" pumps I 21.4Pump Head I 21.4Above Ground Aood Plain Stations I 21.4Below Ground Stations I 21.5Summary I 21.10

PART 6. Installing, Testing, and Operating Pumps

CHAPTER 22. Installation of Water Pumps and Pumping Systems 22.3

Introduction I 22.3Preinstallation Procedures I 22.3Pump and Pumping System Bases I 22.4

Pump bases with seismic restraints I 22.7

xvi CONTENTS

Connecting Piping to Pumps I 22.8Pump fitting sizing I 22.8Pump fitting arrangement I 22.10

Expansion Provisions at Pumps I 22.10Electrícal Provisions for Pumps I 22.11

Electrícal connections for pump motors I 22.11Safety controls for pumps I 22.11

Alignment of Pumps, Motors, and Engines I 22.12Initial Operation of Pumps I 22.12Direction of Rotation of Pumps I 22.12Summary I 22.12

CHAPTER 23. Instrumentation for Water Pumping Systems 23.1

Introduction I 23.1Definitions and Terms 23.1Transmitters I 23.3

F10w meters I 23.3Pressure and differential pressure transmitters I 23.9Temperature indicators and transmitters I 23.9levei transmitters I 23.10Watt transmitters I 23.10

Indicators I 23.12Controllers I 23.13

Simple controllers I 23.13Electronic controllers I 23.13Quality of controllers I 23.14

Control Wiring I 23.14Control Valves I 23.14Summary I 23.15Reference I 23.15

CHAPTER 24. Testing Water Pumps 24.1

Introduction I 24.1Objective I 24.1Types of Tests I 24.2Hydrostatic Tests I 24.2

Centrífugal pumps: Volute and axial flow types (includes vertical pumps) I 24.2Positive displacement pumps I 24.2

Performance Tests I 24.3Centrífugal pumps-Volute type I 24.3Vertical pump tests I 24.4Submersible pump tests I 24.4Positive displacement pump tests I 24.4

Net Positive Suction Head Required (NPSHR) Test I 24.5Priming Time for Self-Priming Centrífugal Pumps I 24.5Testing Procedures I 24.5Field Testing of Pumps I 24.6

CONTENTS xvii

Test Instrumentation I 24.6Instrument accuracy I 24.6Simultaneous recording I 24.7Interval for calibration of instrumentation I 24.7Installation of instrumentation I 24.7

Test Reports and Records I 24.7Accuracy of Pump Head-Capacity Curves I 24.8Understanding Factory Tests of Pumps I 24.8Summary I 24.8

CHAPTER 25. Operating and Maintaining Water Pumps 25.1

Introduction I 25.1Checking for Efficient Selection of Water Pumps I 25.1Constant- or Variable-Speed Pumps I 25.2Proper Selection and Operation of Variable-Speed Pumps I 25.3

Selection of variable-speed pumps I 25.3Operation of variable-speed pumps I 25.3

Check.ing Pump Performance I 25.4Checkinga pump at design flow I 25.4Pump operation at the shutoff or no-flow condition I 25.6Graphical observation of pump performance I 25.6Vibration I 25.6

Control Signals for Speed Control I 25.8Sequencing and Altemation I 25.9

Sequencing I 25.9Altemation I 25.9

Maintaining Pumping Equipment at High Efficiency I 25.10Maintenance Schedules I 25.11Summary I 25.11Reference I 25.11

CHAPTER 26. Factory-Assembled Pumping Systems 26.1

Introduction I 26.1Applications of Factory-Assembled Pumping Systems I 26.1Typical Factory-Assembled Pumping Stations I 26.2Factory-Assembled Control Centers for Existing Pumps I 26.2Complete Pump Houses I 26.6Advantages of Factory-Assembled Pumping Systems 26.8

First cost I 26.9Time saving I 26.11Unit responsibility I 26.15Less pump maintenance and repair I 26.16Code compliance I 26.17

Components of Factory-Assembled Pumping Systems I 26.17Pumps I 26.17Pumping system accessories I 26.17

xviii CONTENTS

Electrical equipment I 26.18Testing ofFactory-Assembled Pumping Systems I 26.19Summary I 26.19

CHAPTER 27. Retrofrtting Existing Water Pumping Systems 27.1

Introduction I 27.1System Evaluation I 27.1Graphical Description of Flow in an Existing System I 27.2Evaluation of Existing Procedures I 27.4Trimming the Pump Impeller I 27.4Changing to a Variable-Speed Pump I 27.6Evaluation of Existing Pumps and Motors I 27.7Evaluation of the Number of Pumps I 27.7Control of Existing Pumps I 27.8Variable-Speed Control and Drives for Modified Systems I 27.8Actual Generation of a System Head Area for an Existing System I 27.9Synopsis I 27.10

CHAPTER 28. Summary of Water System Energy Evaluations 28.1

Introduction I 28.1Pumping System Efficiencies I 28.1Water System Efficiencies I 28.2Purpose of Efficiency Equations I 28.2Sustained System and Equipment Efficiencies I 28.3Summary I 28.3

APPENDIX A. Abbreviations and Symbols A.3APPENDIX B. Terms and Nomenclature B.1APPENDIX C. Glossary of Equations C.1APPENDIX D. Conversion of English Units to SI Units D.1Index 1.1