Usacoe Pump Sta Design em - 1110-2-3105 PDF
Usacoe Pump Sta Design em - 1110-2-3105 PDF
Usacoe Pump Sta Design em - 1110-2-3105 PDF
US Army Corps
of Engineers
ENGINEER MANUAL
DEPARTMENT OF THE ARMY EM 1110-2-3105
U.S. Army Corps of Engineers Change 2
CECW-ET Washington, DC 20314-1000
Manual
No. 1110-2-3105 30 November 1999
Manual
No. 1110-2-3105 31 August 1994
a. Updates Appendix B.
b. Updates Appendix E.
c. Adds Appendix I.
d. Updates the Table of Contents to reflect the changes in Appendix B and the addition of Appendix I.
Colonel, Corps of
Chief of Staff
DEPARTMENT OF THE ARMY EM 1110-2-3105
U.S. Army Corps of Engineers
CECW-EE Washington, DC 20314-1000
Manual
No. 1110-2-3105 30 March 1994
1. Purpose. The purpose of this manual is to provide information and criteria pertinent to the design and
selection of mechanical and electrical systems for flood-control pumping stations. Elements discussed include
equipment requirements, design memorandum, Operation and Maintenance manuals, pumping equipment and
conditions, discharge system, engines and gears, pump drive selection, pump and station hydraulic tests, earth-
quake considerations, power supply, motors, power distribution equipment, control equipment, station wiring,
station and equipment grounding, surge protection, electrical equipment, environmental protection, station
service electrical system, and station service diesel generator.
2. Applicability. This manual applies to all HQUSACE elements, major subordinate commands, districts,
laboratories, and field operating activities having civil works responsibilities.
Manual
No. 1110-2-3105 30 March 1994
Table of Contents
Chapter 2 Chapter 7
Equipment Requirements Discharge System
General . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 General . . . . . . . . . . ....... . . . . . 7-1 7-1
Design Life . . . . . . . . . . . . . . . . . . . 2-2 2-1 Discharge Types . . . ....... . . . . . 7-2 7-1
Materials of Construction . . . . . . . . . 2-3 2-1 Selection Criteria . . . ....... . . . . . 7-3 7-1
Design . . . . . . . . . . ....... . . . . . 7-4 7-1
Chapter 3 Pipe Construction and Material . . . . . 7-5 7-2
Design Memorandum Requirements
General . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 Chapter 8
Design Memoranda and Engines and Gears
Documents . . . . . . . . . . . . . . . . . . 3-2 3-1 General . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1
Engines . . . . . . . . . . . . . . . . . . . . . 8-2 8-1
Chapter 4 Fuel Supply System . . . . . . . . . . . . . 8-3 8-2
Operation and Maintenance Manuals Gear Drives . . . . . . . . . . . . . . . . . . 8-4 8-2
General . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1
Coverage . . . . . . . . . . . . . . . . . . . . 4-2 4-1 Chapter 9
Schedule . . . . . . . . . . . . . . . . . . . . . 4-3 4-2 Miscellaneous Equipment
Testing and Exercise . . . . . . . . . . . . 4-4 4-2 Sump Closure . . . . . . . . . . . . . . . . . 9-1 9-1
Trash Protection . . . . . . . . . . . . . . . 9-2 9-2
Chapter 5 Equipment Handling . . . . . . . . . . . . . 9-3 9-3
Pumping Equipment Ventilation . . . . . . . . . . . . . . . . . . . 9-4 9-3
General . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 Equipment Protection . . . . . . . . . . . . 9-5 9-4
Pump Characteristics and Types . . . . 5-2 5-1
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Chapter 22 Appendix D
Station Service Diesel Generator Closure Gates
Chapter 23 Appendix E
Station Studies Head Loss Methods and Formulas
Voltage Drop Studies . . . . . . . . . . . 23-1 23-1
System Protection and Coordination Appendix F
Studies . . . . . . . . . . . . . . . . . . . . 23-2 23-1 Sample Operation and
Short Circuit Studies . . . . . . . . . . . 23-3 23-2 Maintenance Manual
Chapter 24 Appendix G
List of Plates Electrical Data Request
Appendices Appendix H
Glossary
Appendix A
References * Appendix I
Formed Suction Intake - Geometry
Appendix B Limitations
Pump Selection Method
Appendix C
Trashraking Equipment
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reliability cannot be easily assigned a cost, it should be will be performed by the Hydroelectric Design Center in
evaluated on the basis of what effect an equipment fail- accordance with ER 1110-2-109.
ure would have on the operation of the station. A piece
of equipment whose failure would still permit partial 1-6. Deviations
operation of the station would be more desirable than an
item that would cause the entire station to be out of This manual allows the designer considerable design
operation. The annual costs should include the first flexibility. Some requirements, such as sump design,
costs, operating costs, maintenance costs, and replace- must be followed. When a deviation to stated require-
ment costs based on project life. As certain items of ments is believed necessary, the designer should com-
equipment may affect the layout of the station including pletely document the deviation and request higher
the location and suction bay and discharge arrangement, authority approval.
the structural costs associated with these designs should
be included in the cost analysis. On major equipment 1-7. Safety Provisions
items, this study should be included as part of the Fea-
ture Design Memorandum. For stations over 30 cubic Certain safety provisions will be required by
meters per second (m3/s) (1,060 cubic feet per second EM 385-1-1, Safety and Health Requirements Manual,
(cfs)) capacity, a separate Feature Design Memorandum guide specifications, trade standards, codes, and other
should be prepared for the pumping equipment before the manuals referenced herein. Additionally, the require-
design is started on the station. ments of the Occupation Safety and Health Administra-
tion (generally referred to as OSHA Standards) are to be
c. Other design information. considered minimum requirements in Corps of Engineers
design. Areas of particular concern to mechanical and
(1) Sources. Important design information is avail- electrical design are safety, noise levels, personnel access
able from sources besides the prescribed Corps of provisions, working temperature conditions, air contami-
Engineers manuals and standard handbooks. Design nation, load handling provisions, and sanitary facilities.
memoranda and drawings from other projects, manufac- OSHA Standards are continuously being modified and
turers catalog information, sales engineers, project oper- expanded. Conformance to the latest published require-
ation and maintenance reports, field inspectors, operation ments is essential.
and maintenance personnel, and the pumping station
structural design personnel are all valuable and readily 1-8. Appendices
available sources. Communication with HQUSACE and
other USACE District and Division offices can often Required and related references are provided in Appen-
provide information to solve a particular problem. dix A. Appendix B presents a method to determine the
size of a pump to meet pumping requirements; it also
(2) Evaluation. All existing information should be provides the dimensions for the sump and station layout
carefully examined and evaluated before applying a new once the pump has been selected. Three general cate-
product. Relying on previous satisfactory designs gories of trash-raking equipment are described in
requires that the design conditions and requirements be Appendix C. In Appendix D, the procedures used in
carefully compared for applicability. The design engi- determining the size of gate closure, stem size, and oper-
neer should consult with field engineers and make field ator size, and loads to be carried by the structure at the
trips to pumping stations under construction. Consulta- gate location are explained. The different methods and
tion with pump station operators is also very helpful. formulas used to determine the head losses occurring in a
Obtaining and evaluating information from field sources pumping station are given in Appendix E. Appendix F
is improved by making personal acquaintances and obser- provides the format for an operation and maintenance
vations at stations under construction or operating sta- manual for a typical stormwater pump station, and
tions as well as by making visits to pump manufacturers Appendix G contains an electrical data request. Appen-
plants. Office policies should permit and encourage dix H is a glossary.
these visits.
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Chapter 4 c. Maintenance.
Operation and Maintenance Manuals
(1) General. A pumping station maintenance pro-
gram should consist of inspections, standards, a control
system, and lubrication. The available shop drawings on
4-1. General the equipment should be made a part of the manual so
that they may be used when performing detailed main-
An adequate operation and maintenance manual must be tenance or repair work.
prepared to permit successful operation of the pumping
station. The portion of the manual covering the mechani- (2) Inspections. The success of a maintenance pro-
cal and electrical equipment is generally prepared by the gram is dependent on adequate inspections. The inspec-
designers responsible for specifying this equipment. The tions assure that the equipment receives proper attention
manual should provide a platform for carry-over of infor- and is ready for use. The extent of preventative mainte-
mation from the designer to the operating personnel. The nance inspections includes adjusting, lubricating,
manual should be prepared to aid the operating personnel repairing, and replacing worn out or defective parts. A
in understanding the equipment and to set the guidelines guide for the inspection frequencies and tasks for the
for maintenance procedures. A manual provides a guide various items of equipment is usually obtained from
which can carry on beyond personnel changes and verbal manufacturers recommendations, but may need to be
instructions. adjusted for flood control pumping station operating
conditions. Any changes to manufacturers recommenda-
4-2. Coverage tions should be coordinated with the manufacturer to
avoid the possibility of voiding warranties.
a. General. The operation and maintenance manual
should be complete. In most instances, this manual will (3) Standards. A balanced criteria maintenance
be the only information available to operate and maintain program must be based on defined criteria that establish
the station. The contents are usually divided into three quality, extent, and quantity of maintenance desired. A
sections, operation, maintenance, and reference. Each quality program requires capable personnel, proper tools,
section is described below, and some examples are use of quality materials, and a record of meeting program
included in Appendix F. General guidelines are included performance. The maintenance recommendations of most
in ER 25-345-1, Systems Operation and Maintenance equipment manufacturers are usually for continuous
Documentation. Although ER 25-345-1 is for military operation, which is typically not the case for flood con-
construction, it also contains valuable information that trol pumping stations. Inspection and maintenance
pertains to civil works projects. The electrical fault requirements must be keyed to the expected operation of
protection coordination study, including protective device the station.
settings, should be provided with the operation and main-
tenance manual. (4) Control system. An effective maintenance con-
trol system should include comprehensive and accurate
b. Operation. The operation portion is divided into basic data, such as equipment records, historical inspec-
three parts: criteria, constraints, and procedures. The tion, maintenance, and repair records. Effective schedul-
criteria portion describes the operation of the facility that ing of maintenance work is required to ensure the most
satisfies the project requirements. It deals with the over- effective use of the operating agencies personnel. The
all operation of the station as opposed to operation of record filing system should consist of:
individual pieces of equipment. The constraints section
should indicate all conditions that must be considered (a) An equipment data file. This file should be
external to the station so that it can be successfully oper- indexed by equipment name or title and contain all perti-
ated. These items usually consist of control structures nent data for that specific item of equipment or facility,
away from the station that require certain gate opening such as manufacturers instruction books, operating pres-
and closing operations for the station to perform pro- sure limits, parts catalogs, manufacturers drawings,
perly. The procedures part would include detailed oper- reference field tests, special reports on major repairs,
ating procedures for each piece of equipment. The dates of replacements and retirements, and changes in
detailed equipment operating procedures are provided by operating procedures.
the equipment manufacturers. The operations portion of
the operation and maintenance manual should be coordi-
nated with the hydraulics and hydrology (H&H) engineers.
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(b) A preventative maintenance file. This file should design memoranda should be furnished to the user as an
contain a record of equipment inspections, maintenance appendix to the operation and maintenance manual. The
data, a record of hours of operation, number of opera- design memoranda should be furnished as a separate
tions, or other significant operating data. Consideration package. The contract specifications for the equipment
should be given to furnishing the information on a com- should contain the requirement for the contractor to fur-
puter database program for large and complex stations. nish as-built shop drawings of the equipment. Since this
reference material is usually voluminous, it is recom-
(5) Lubrication. Proper lubrication is an important mended that a file cabinet be furnished as part of the
part of a good maintenance program. Dependable opera- construction of the station so that adequate storage is
tion and the life expectancy of equipment requiring lubri- available at the station.
cation are almost entirely dependent on the use of proper
lubricants at the right time intervals and in the proper 4-3. Schedule
quantities. All equipment requiring lubrication should be
surveyed and appraised for the type of bearings, gears, The construction of a pumping station usually does not
and service conditions under which the equipment must permit a final manual to be prepared before it is turned
operate. After these operating conditions are fully ana- over to the user or operating agency. Because of this, an
lyzed, then it can be determined what characteristics the interim manual should be prepared to benefit the end
proper lubricant should have, such as resistance to mois- user when they receive the station. The interim manual
ture, temperature range, whether an extreme pressure should include complete operating instructions and any
lubricant is required, and the proper viscosity range. maintenance instructions prepared to that time. The
Some manufacturers recommend only the viscosity of the operating instructions should be prepared early enough so
lubricant while others list the lubricants by trade name. that they may be checked during the preliminary and
The number of different types should be kept to a mini- final testing of the station. The final operation and main-
mum. The frequency of lubrication used is recom- tenance manual should be available for the user within
mended by the manufacturer. The frequency of 1 year of the turnover date of the pumping station.
lubrication may have to be adjusted based on special use
or experience. The equipment must be examined in 4-4. Testing and Exercise
detail when preparing lubrication instructions, so that
every grease fitting and oiling location can be indicated Since flood control pumping stations are usually operated
in the maintenance instructions. Manufacturers informa- on an infrequent basis, trial operation is required between
tion does not always show enough detail to permit accu- flood events. All equipment should be operated at least
rate preparation of the lubrication instructions. every 30 days. It is acceptable to operate the pumping
Photographs of the various pieces of equipment showing equipment in the dry providing that equipment is
the locations of all the lubricating points are very useful. designed for dry operation and the water level present is
below the bottom of the pump suction bell or umbrella.
d. Reference. The reference section of the operation Wet testing of pumping equipment should occur only if
and maintenance manual should contain a listing of all the water present is above the minimum pumping level.
data that are necessary to operate and maintain the sta- These test operations should be included in the mainte-
tion. These data should include all of the shop drawings nance schedule. The duration of the exercise period
for the equipment, as-built contract drawings, advertised should be coordinated with the equipment suppliers but
specifications, and design memoranda used in the design should be limited to as short a period as possible.
of the station. Copies of all reference items except the
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satisfy most head requirements. The pump can be con- motor could cost more than the right-angle gear reducer
structed similar to an axial flow pump with water flow- and higher speed horizontal motor combined, the
ing axially from the pumping element, or the impeller decreased reliability and increased operation and mainte-
can be placed in a volute (spiral casing), where the water nance costs due to the additional auxiliary equipment
flows from the pump radially. The volute design would involved may offset the first cost savings. One problem
be used either for large pumps where a volute would associated with a vertical pump layout is that the pump
allow the pump to operate at lower heads or for small dimensions may locate the discharge elbow higher than
pumps where it is desirable to have a dry pit installation the minimum head required by hydraulic conditions. The
with the discharge pipe connected near the pumping higher head will require greater energy. Other type
element. The value of Ns for this type of pump should layouts such as a siphon discharge or volute, horizontal,
be limited to 9,000. and flower pot type pumps will permit lower minimum
heads or in the case of a siphon only the discharge
d. Centrifugal. The impeller of these pumps devel- system losses. Vertical pumps are used with open or
ops head only by centrifugal force on the water. The closed sumps, wet or dry, and are suspended from an
path of flow through the impeller would be at a operating floor or an intermediate floor.
90-degree angle with respect to the pump shaft. A
special design of this pump has a non-clog impeller b. Horizontal. Horizontal type pumps are usually
which makes it very useful for pumping sewage. This limited to applications where the total head is less than
type of pump is used for pumping small flows and in 6 meters (20 feet) and the quantity of water to be
applications where a dry pit sump is desirable. It is pumped is large. Horizontal pumps are seldom less than
generally used in a vertical configuration and can be 2,500 millimeters (100 inches) in diameter. Smaller
constructed to operate in a wet or dry sump. The value horizontal pump installations are generally more expen-
of the Ns is typically less than 4,000. sive than vertical installations. The pumps are not self-
priming, and the design must provide a separate priming
e. Net positive suction head. This term is used to system.
describe the suction condition of a pump; it is commonly
abbreviated with the letters NPSH. Two forms of NPSH c. Formed suction intake. Formed suction intakes
are used. One is used to describe what suction condition are not really a pump type but are suction arrangements
is available to the pump and is called Net Positive Suc- that generally improve flow conditions to the pump.
tion Head Available (NPSHA), and is a function of the They are applied to vertical pumps and are used in place
station layout and suction water levels. NPSHA is of the standard bell arrangement. Typical dimensions of
defined as the total suction head in feet of liquid abso- a formed suction intake are shown in Figure B-12,
lute, determined at the suction nozzle and referred to Appendix B.
datum, less the absolute vapor pressure of the liquid in
feet of liquid pumped. See Appendix B for formula and d. Submersible.
terms used. The other term Net Positive Suction Head
Required (NPSHR) is a property of the pump and indi- (1) General. Submersible pumps are considered for
cates what suction condition is required for the pump to stations that have pumping requirements with each pump
operate without cavitation. NPSHR is determined by the having a capacity less than 6 m3/s (200 cfs). These
pump manufacturer by running cavitation tests on the pumps have the electric motor close coupled to the
pump. pumping element with the entire pumping unit being
submerged in water. The size and selection of these
5-3. Pump Arrangements units are limited by the number of poles in the motor or
the size of the gear unit, if used, and its resultant
a. Vertical. Most pumps used in flood-control encroachment on the water passage. These types of
pumping stations are of the vertical type. This type of pumps should be removable from above the floor without
pump has a vertical shaft with the driver having a verti- any unbolting of the discharge piping. Their use allows
cal or horizontal shaft arrangement. A vertical motor is the superstructure of the station to be greatly reduced.
usually direct connected to the pump, whereas a horizon- Substructure requirements are approximately the same as
tal motor or engine requires the use of a right-angle gear. for vertical pumps. Submersible pumps used for flood
The vertical arrangement usually requires the least floor control pumping stations are of three different types:
space per unit of pumping capacity. While the vertical axial flow, mixed flow, and centrifugal volute.
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(2) Axial or mixed flow. These pumps consist of an b. Capacity. The capacity requirement for the pump
axial- or mixed-flow impeller close coupled to a sub- is determined from the hydrology requirements of the
mersible electric motor. The impeller may be on the station. This information is provided by the H&H
same shaft as the motor or a set of gears may be between engineers. The number of pumps used should be kept to
the motor and the impeller to permit greater variety of a minimum and determined as set forth in
speed. The pump is suspended above the sump floor EM 1110-2-3102. If more than one capacity requirement
inside of a vertical tube that extends to the operating exists, the pump is selected to satisfy all of the condi-
floor. The tube allows placement and removal of the tions. This means that the pump will most likely be over
pump and forms part of the discharge piping. These capacity for some of the requirements. Variable capacity
pumps are used in a wet pit-type sump. Some pumps of pumping units may be economically justifiable. Variable
this design are constructed so that the blades are detach- capacity can be achieved by using variable speed drives
able from the propeller hub and are connected to the hub or pumps that are equipped with variable pitch blades.
in a manner that allows a multitude of blade angle set-
tings. The blade angle adjustment feature also permits c. Head. The head requirements of the pump are
changing the pump performance characteristics very also determined from the hydrology requirements plus
easily. This permits a pump installation to meet a differ- the losses in the pumping circuit which are a function of
ent future hydrology condition with adjustment of the the station layout. The pump head requirement is called
blade angle. total head and is a summation of all heads for a given
capacity. The method of computation of these heads is
(3) Centrifugal. These pumps consist of a volute included in Chapter 6. Selection of pumps should strive
casing close coupled to a submersible electric motor. to achieve the lowest total head requirement to provide
The impeller and motor are on the same shaft. The the smallest size driver and lowest energy cost. The best
pumping unit is guided to its operating position from the pump operation occurs when the pump is operating at or
operating floor level by a system of guide rails or cables. near the head that occurs at the pumps best efficiency
The volute attaches to the discharge piping flange by point. With the wide range of heads that occur for flood-
means of a bracket using the weight of the pump to seal control pumping stations, this is usually not possible.
the connection. These pumps are used for smaller flows The pump must be selected to satisfy all the required
than the axial- or mixed-flow type and when pumping conditions. However, if a choice exists, the pump should
heads are high. These pumps are also suitable for use in be selected so that the best efficiency point is near the
a dry pit sump. These pumps are usually equipped with head where the most pumping operation occurs. Some
a water jacket surrounding the motor to cool the motor pumps, particularly the axial flow type, may have a curve
with pumped fluid. For special applications, these pumps which contains what is called a "dog-leg." This part of
can also be fitted with a different diffuser which allows the curve consists of a dip in head which allows the
them to be tube mounted similar to the axial-flow sub- pump to operate at as many as three different pumping
mersible pumps. rates, all being at the same head. Pump operation and
priming at this head must be avoided due to unstable
5-4. Selection of Pump Type operation.
a. General. Many items must be considered during d. Net positive suction head. The suction conditions
the pump selection process. Alternative station layouts available for the pump should be determined for all
should be developed in sufficient detail so that an annual pumping conditions. A diagram should be prepared
cost of each layout over the life of the project can be showing the NPSHA for the entire range of pumping
determined. The annual cost should include the annual- conditions. The method of computation of the NPSHA is
ized first cost, operating costs which include cost of shown in Appendix B. The NPSHA should meet the
energy, maintenance, and replacement costs. It is usually margins and limits indicated in Appendix B. In all cases
best to consider all of the above types of pumps when the NPSHA should be greater than the NPSHR for the
developing the station layout unless it is obvious that selected pump over the entire range of required pump
certain ones are not applicable. The station layout and operation. Pumps not requiring the cavitation tests
pump selection should be done in sufficient detail to should be specified to meet the suction limits developed
permit the reviewer to follow the process without refer- over the entire range of required pump operation and the
ence to additional catalogs or other such sources. suction limit criteria as indicated in Appendix B.
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e. Efficiency. Higher efficiencies available from the suitable for the conditions. Using each pump type
different types of pumping units are a consideration when selected from the chart, a pump selection is made using
the estimated amount of operation is great enough to the method indicated in Appendix B. A station layout
affect cost considerations. Usually for stations with for each type of pump can be developed. Dimensions for
capacities less than 14 m3/sec (500 cfs) and operating the pumping equipment and sump dimensions can be
less then 500 hours per year, differences in operating obtained from the procedure given in Appendix B. It
efficiencies of various types of pumping equipment need may be necessary to refine the heads and therefore the
not be considered. The highest efficiency that is com- station layout due to changes in head when the equip-
mercially attainable should be specified for whatever type ment is selected and located in the station. The informa-
of pump is selected. This will not only control operating tion from the final pump station layout should be sent to
costs but will normally improve the operation of the a minimum of two pump manufacturers requesting their
pump through less vibration, cavitation, and maintenance selection of recommended pumping equipment for the
requirements. given station layout. It is important that the communica-
tion with the pump manufacturers takes place during the
f. Other considerations. Certain limitations some- design memorandum phase of the project. See Chart B-3
times guide pump selection. in Appendix B for a typical pump manufacturer data
sheet. The information thus obtained should be used to
(1) Incoming electric service. Incoming electric correct, if necessary, the station layout and finalize the
service may limit the horsepower rating of the driver or alternate study layouts and costs. Operation, mainten-
may not permit the use of electric motors. ance, and equipment replacement costs must also be
considered in the selection of the type of station to use.
(2) Foundation conditions. Foundation conditions Operation costs should consider the cost of energy and
may increase the cost of excavation to the point where it operating labor when the station is in operation. In some
may not be feasible to lower the sump to that required cases, these costs are very small due to limited operation
for some types of pumps. and the detail in those cases can be limited. When the
estimated operating costs for a station exceed
(3) Available space. The available space at the $10,000 per year, it could be necessary to use a detailed
proposed station site may limit the size of the station. energy cost analysis based on pump head, cycling effect,
and any special considerations the supplier of the energy
(4) Low discharge capacity. Axial- and mixed-flow may require. Maintenance cost should be carefully con-
pumps may have too small flow passages and would sidered since it goes on whether the station is in opera-
therefore be subject to clogging. A centrifugal pump tion or not. The tendency is to underestimate this
would then be used because of its greater solid passing expense. Discussion with the eventual user could aid the
capability. designer in determining the maintenance methods that
will be used. Replacement costs should be based on both
g. Selection procedure. The first step in developing wear out and obsolescence of the equipment. Equipment
a pump selection is to determine the approximate pump replacements are also made when the cost of mainte-
operating conditions. Total heads used for these approxi- nance becomes excessive and the reliability of the equip-
mate operating conditions can be determined from adding ment is in doubt. Equipment manufacturers usually
the static heads (discharge pool level or pump discharge provide the expected life of their equipment while operat-
elevation minus the lowest pump suction level) to an ing under normal conditions. When equipment operation
approximation of the system losses plus the velocity will occur beyond the normal conditions, as defined by
head. Use the capacities from the hydrology require- the manufacturer, the expected life should be adjusted
ments, the approximate total heads, and Chart B-1 in accordingly. Selection is then based on annual costs and
Appendix B to determine the types of pump that may be reliability factors.
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Chapter 6 elbow) are considered internal pump losses and are not
Pumping Conditions included in any head loss determination included with the
pumping equipment specification. In those cases where
the suction and discharge systems are complicated and
form an integral part of the pump, a model test to deter-
6-1. General mine the total head should be conducted by the Water-
ways Experiment Station (WES), Vicksburg, MS.
This chapter includes the procedures used for determin-
ing the pumping conditions. Several different pumping b. Static head. In most flood-control pumping sta-
conditions can occur for the same station layout due to tion applications, the static head can be considered the
multiple hydrology requirements. The determination of difference between the pool elevation on the inside of the
pumping conditions for the final station layout should be protective works and the pool elevation at the discharge
included as part of the design documents. point. Usually there are several different static head
requirements for a given station layout or set of hydrol-
6-2. Capacity Determination ogy conditions. Consideration should be given to the
differences in static head caused by the variation in
The capacity for the pumping conditions is determined pumping levels on the intake side between the project
from the hydrology requirements. Generally, the storm- authorized level of protection and the minimum pumping
water pumps in a station should have equal capacity; level. The static head for satisfying the hydrology
however, certain other conditions such as foundation, requirements is determined from many different sump
submergence, inflow requirements, and pump-drive elevations. These include the minimum pumping eleva-
match may dictate the need for pumps of different capac- tion, the pump starting elevation, and the average sump
ity ratings. Varying the size of the pumps may also be elevation. These elevations should be determined during
required to minimize pump cycling where ponding stor- the hydraulic/hydrologic studies. The lowest stopping
age is small compared with the base flows that must be elevation along with the highest elevation to be pumped
pumped. Generally, there is a different capacity require- against (this elevation is determined according to the type
ment for low and high river conditions. Intermediate of discharge system being used or the maximum eleva-
conditions are possible, and also special requirements tion of the discharge pool) is used to determine the maxi-
such as siphon priming may occur. The capacity mum static head that will be used to select the pumping
required for a self-priming siphon discharge is that unit. A reduction in capacity for this maximum head
capacity that provides a velocity of 2.2 meters per second condition is permitted and should be coordinated with the
(7 feet per second) in the discharge pipe at the crest of H&H engineers. If the discharge is to operate as a self-
the protection. This value is conservative, and for large priming siphon, the static head is the difference between
stations, a model test of the siphon discharge should be the top of the discharge pipe at its highest point and the
considered to determine the minimum priming velocity. pumps lowest starting level. For the priming phase of a
A decrease in this velocity could affect the pump selec- siphon system and for a vented nonsiphon system, it is
tion. Also, a siphon system that is long or contains assumed that discharge flows by gravity past the highest
many dips should be model tested as the 2.2-meters-per- point in the discharge line, except as noted hereafter.
second (7-feet-per-second) velocity criterion may not Discharge systems having long lengths of pipe beyond
prime the siphon. For stations that have a baseflow the crest of the levee may have a head profile greater
pumping condition, a separate smaller pumping unit or than the top of the pipe at the top of the levee. Typical
units are provided to handle the baseflow. The source static head conditions for various types of stations is
for the capacity determination should be indicated in the illustrated on Plates 2-8.
design memorandum.
c. Losses.
6-3. Head Determination
(1) General. The losses consist of friction and other
a. General. The term used to specify the amount of head losses in the conveying works, before the pump
lift that a pump must overcome when pumping is called (intake losses), and after the pump discharge (discharge
total head. Total head is composed of static head, losses losses). Intake losses include trashrack, entrance gates,
in that pumping circuit, and the velocity head developed. entrance piping losses, and any losses in intake channels.
All the losses in the portion of the pump that is supplied Discharge losses include discharge pipes, discharge
by the pump manufacturer (generally between the suction chamber losses, and backflow preventer valves. These
bell or flange and the discharge flange or the end of the
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losses should be considered for different numbers of e. Total system head curves. A total system head
pumps operating. Generally, the losses will be lowest curve is a curve that includes all the losses plus the static
with one pump operating and highest with all of the head in the pumping circuit plotted against the pumped
pumps in operation. For the majority of pumping sta- capacity. The losses would include both the external and
tions, the entrance losses, except the loss across the pump piping losses plus the velocity head. A different
trashrack, will be minor, and in most cases can be total system head curve occurs for each static head con-
neglected. dition. In determining the total system head curves, the
worst-case condition should be considered when multiple
(2) External losses. These losses start at the station pumps of equal rating are used. In a multi-pump station,
forebay or sump entrance. This is usually the sewer or the piping system that has the greatest losses would be
ditch adjacent to the station. The losses would be from used to determine the total system curve for the highest
this point to the sump where pump suction occurs. The head condition, while the piping system with the least
losses are calculated by applying K factors to the vari- losses would be used for the lowest total system head.
ous elements of flow and then multiplying them by the For pumps discharging into a common manifold, the
velocity head occurring at that location. Based on obser- highest head occurs with the maximum discharge level
vations at operating stations, the losses through the trash- and all pumps operating. The total system head curves
rack are usually assumed to be 150 millimeters for the final station layout shall be submitted in whatever
(6 inches). The other losses are those occurring on the design document preceeds the P&S.
exit side of the pump piping and could include the losses
occurring in the discharge chamber and its piping system 6-4. Suction Requirements
to the point of termination as identified in the hydrology
report. The losses in the discharge chamber and piping a. General. The two factors to be considered are the
entrances, exits, and bends are calculated with K fac- NPSHA, resulting from pump submergence, and the flow
tors similar to those on the entrance side. A special case conditions in the sump. Successful pump operation is
occurs in narrow discharge chambers where a critical not possible without satisfying the effects of these two
depth of flow may occur causing the water level in the influences. NPSH is defined in Chapter 5.
chamber to be higher than that occurring downstream of
the chamber. This usually occurs only for the low head b. Submergence. Submergence is defined as the
condition. Appendix E provides design information for setting of the impeller eye of the pump with respect to
handling this case. the water surface in the suction sump area. Principal
factors involved in the determination of submergence
(3) Pump piping losses. These losses will include requirements are cavitation limits and the prevention of
all losses in the connecting pipes to the pump including vortexes in the suction sump. Minimum submergence
both the entrance and exit losses of this piping. The requirements, based on estimated annual operating hours,
Darcy-Weisbach formula should be used for determina- are provided in Appendix B. Submergence requirements,
tion of piping friction losses. An explanation of the with respect to the inlet of the pump, to prevent the
formula and terms used is shown in Appendix E. formation of vortexes in the sump are presented in ETL
Methods and factors to be used in determining losses in 1110-2-313 and Appendix B, Chart B-2. The informa-
fittings, bends, entrance, and exits are shown in tion provided above could yield more than one submer-
Appendix E. gence requirement. However, the most conservative
(largest) value of pump submergence should be selected.
d. Velocity head. The velocity head represents the It must also be remembered that the impeller must be
kinetic energy of a unit weight of liquid moving with submerged at the start of pumping if the pump is to be
velocity V and is normally represented as the difference self-priming.
of the kinetic energy of the suction and discharge piping.
However, when the pump does not have any suction pip- c. Flow conditions. The layout of the station, the
ing and is fitted with a suction bell, the velocity head is sump water levels, and the shape of the pump intake
that calculated for the discharge pipe. The velocity head determine what flow paths occur in the sump. These
is considered a loss for free discharges and partially or flow paths can cause uneven distribution into the pump,
totally recovered for submerged discharges. For the which affects pump performance. The most observable
purposes of determination of system losses, and as a detriments of these are vortexes. Certain dimensions that
safety margin, the entire velocity head will be considered have been found by model testing should be used for
unrecoverable and thereby added to the other losses.
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/2 feet) above the highest discharge water level. Flap gates 7-5. Pipe Construction and Material
shall be of the type suitable for pump discharges. This type
of gate is of heavier construction, and the arms that support a. Constrnction. Discharge piping to pump connections
the flap are double hinged so that fhe flap will fully close. is generally made hy means of a flexible coupling with
Flap gates with a buill-in hydraulic cushion effect are not harness. bolts across the connection. Rigid or flanged
required \vhere the head on the gate is below 7.6 meters {25 connections could he u,;ed for pullout design pumps and
feet). All non-cushion type flap gates used on pump for those pmnps that may be cast into the structure. All
discharves should h<'lVC a mbber seat which aids in sealing bUiied piping needs to he cmmected with flexible
and eh~ating some of the dosing shock. A station having couplings with harness bolts wh~never the pipe runs ~nto
fhis type of discharge arrangement is shown on Plate 5. or out of a concrete structure, at bends, and at other pomts
where differential settlement or nom1a1 expansion or
c. Over the le1ee. Pipes oYer the levee require an air contraction of the pipe is anticipated. Where piping leaves
release and a siphon breakt:r at the crest. If the pipe a structure and goes underground, the tlrst flexible
system docs not operate as a siphon, a permanent vent coupling should he placed within !.5 meters (5 feet) of the
opening can he used. Discharge pipes 1500 millimeters wall with an additional 11exihle coupling placed l .5 meters
(60 inches) and less can usnally he opcmted as a self- (5 feel) farther downstream. An emhedded wall !lange
priming siphon if the flow velocity at the crest is 2.2 ~hould .he provided for all piping passing fhrough concrete
meters per second (7 feet per second) or greater when walls. Pipe selected should be of the minimum wall
priming is initiated. Model te~!s should he considered for thickness that will satisfy the requirements of the
discharge pipes of greater dian1eter and those pipes having installation and, if possihle, should be of a standard stock
an arrangement different from the standard type discharge wall thickness. Where corrosion may he a problem, an
sho\\11 on Plate 4. For pipes operating as a siphon, the use increase in thickness of 25 percent may be considered for
of a remotely operated valve to break the siphon should be steel pipe. In addition to the tensile circumferential
used. This valve is air-operated except for small sizes in s.trcsscs resulting from the normal internal \\'ater pressure,
which electric operation is possible. The valve is operated stresses due to lbe follmving may be a consideration in the
from a signal initiated by the starting of the pmnping unit. design of some pump discharge lines.
A timer is placed in the cin:uitry to provide a time delay
of valve closing after start -np to vent the discharge pipe (I) Excess stress due to water hammer.
system. There are flow-operated siphon breakers
available, but care should be taken that they are designed (2) Longitudinal stresses due to beam action of the
for heavy duty operation and arc adjusted correctly after pipe, when the pipe is exposed and supported hy piers or
instaUation to prevent air leakage into the pipe. The siphon suspendL-d supports.
valve is sized according to the fonnula provided at the end
of this paragraph. When the calculated result indicates a (3) Stresses caused by extcmalloading.
non-standard size valve or piping. the next larger standard
sized valve and piping should be used. A manual valve of (4) Stresses cansed by collapsing pressures due to
the same size sha!l be used in addition to the siphon valve formation of vacuum in the pipe.
for emergency breaking of the siphon. All of the siphon
breaker piping and valves should be located near the (5) Stresses due to temperature changes.
descending leg in an enclosure_ Problems in priming the
siphon can occur when the changes in discharge line (6) Stresses due to differential settlement.
gradient occur on the discharge side of the protection. The
section of pipe aller the down leg should be as flat as The discharge pipe and its support system including
possible to prevent these problems. Manufacturers of air anchors. thrust blocks, and tie rods sbould be designed in
and vacuum valves should bt: consulted for proper valve sufficient detail so that the above considerations can be
sizing. Vent size can be calculated using the following checked. American Water Works Association (A W\VA)
fonnula. Manna! M-Il should he referenced for recommended
design and installation practices for steel pipe. Preparation
D, ~ 0.25 D, X (21h)0 L' of detailed pipe shop fabrication dmwings should be made
the responsibility of the Contractor suhject to the approval
where of the Contracting Offxcer.
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used for piping of 300 millimeter ( 12-inch) diameter and
undeL Exposed steel piping inside of stations may be
flanged or flexible coupling connected. whereas ductile iron
pipe should be fitted with mechanical joints or flanged.
Steel and ductile iron pipe should conform to the applicable
AWWA staudard specifications. All discharge line pipe
should be protected on the inside with a smooth coating.
The designer should consult with the paint laboratory at the
Construction Engineering Research Laboratory.
C'l1ampaign. IL Buried pipe should also be provided wjth
an outer protective coa1-tar coating and a felt wrapping.
Shop coatings should be used to the maximwn extent
possible due to the better quality control. Flanges should
conform to A WWA specifications for the pressure rating
required. The applicable AWW A standards arc listed in
Appendix A. Valves should be selected that will be easily
maintained. Unless larger than 1.200 millimeters (48
inches). gate and butterfly rype valves are preferred. Gate
valves '"ith cast iron bodies should be brmv..c fitted.
Butterlly Yalves should be rubber seated~ The type of valve
operator. either electric or manual. is the designer's choice
based on site-specific requirements, e.g., accessibility,
frequency of use. and anticipated loads.
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c. Engine equipment and auxiliaries. supply of fuel oil is required to ensure station operation
without the need for emergency replenishment. The
(1) Clutches. Engines less than 450 kW (600 HP) volume of the storage tank system should provide for a
may be equipped with a manual clutch mechanism, minimum of 2 days of continuous operation of all units
which allows the engine to be started and operated with- operating at maximum horsepower. The volume pro-
out running the pump. This permits testing of the engine vided may be increased for those stations that are remote
without regard to water levels that may not allow pump or of such a size that quantities required would not per-
operation. mit ready replenishment. The location and type of fuel
storage should be determined after review of the applica-
(2) Flexible drive shafts. Flexible drive shafts elimi- ble local, state, and national Environmental Protection
nate the need for critical alignment of the engine to the Agency (EPA) regulations.
gear reducer. The drive shaft consists of a center section
with a flexible joint on each end. One of the flexible b. Natural gas. Stations equipped with engines
joints incorporates a splined slip joint that permits operating on natural gas supplied from a utility system
longitudinal movement to occur. The drive shaft manu- need to be provided with a stored gas backup system if
facturers published rating at the maximum engine speed reliability of the source could cause the station to be out
should be at least 1- times the maximum torque of the of operation for more than 24 hours. The volume of the
pump that usually occurs at its maximum head condition. gas storage system should provide for a minimum of
A drive shaft minimum length of 900 millimeters 2 days of continuous operation of all units operating at
(36 inches) is desirable to allow for intentional or acci- maximum load. The storage usually consists of one or
dental misalignment. A vertical difference of approxi- more pressure tanks above ground. All gas tanks should
mately 15 millimeters (0.5 inch) (for 900 millimeters be installed with foundations attached to the tanks, which
(36-inch) shaft length) should be provided between the preclude floating of the tank in case of flooding. A
engine output shaft and the gear input shaft to provide station with natural gas-operated engines must be pro-
continuous exercise for the flexible joints. There are vided with devices capable of measuring air content for
other types of engine-to-gear connections, such as direct explosive conditions and indicating this condition with
through flexible couplings. This can be investigated if alarms both inside and outside the station. The venti-
site conditions prevent the use of the drive shaft lating system must be suitable for operating in an explo-
described above. sive atmosphere and capable of being turned on from
outside the station. The sump should be ventilated in a
(3) Starting system. The engine starting system similar manner. All installations need to be designed and
should be pneumatic except for small engines. The air installed in accordance with the National Fire Protection
system should contain a reservoir of sufficient size to Association (NFPA).
permit two starts of each unit without recharge by the air
compressor. The time for the air compressor to recharge 8-4. Gear Drives
the reservoir should not exceed 2 hours. Two air com-
pressors should be provided for reliability. Unless a Most applications for pumping stations will use a vertical
standby generating unit is provided for the station, one of pump with a right-angle gear to transmit power from the
the air compressors should be engine driven so that the horizontal engine shaft to the vertical pump shaft. Gear
air pressure can be built up during electric power drives may also be used with horizontal electric motors
outages. driving vertical pumps. This permits the use of less
expensive high-speed horizontal drive electric motors.
(4) Prelubrication. Engine manufacturers should be Horizontal pump installations may use chain drive or
consulted as to any requirements for a prelubrication parallel shaft gear reducers. The gear units should have
pump. Factors that are normally used to determine the a service factor of 1.25 when driven by an electric motor
need for prelubrication requirements are engine size and and 1.5 when driven by an engine. The service factor
the expected period of time between operations. should be based on the maximum horsepower require-
ment of the pump. Right-angle drives should be of the
8-3. Fuel Supply System hollow shaft type to permit vertical adjustment of the
pump propeller at the top of the gear. All right-angle
a. Fuel oil. The type of fuel oil used should be gear drives should be designed to carry the full vertical
recommended by the engine manufacturer for the type of thrust from the pump. The gear unit should be equipped
environment the engine will operate in. An adequate with an oil pump directly driven from one of the reducer
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difficult to obtain a water tight seal; therefore, they are to with manually raked methods. Hand raking should not
be used only when standard-size slide gates are not be used when the rake handle has to be longer than
available. 20 feet to reach the bottom of the rack with the operator
standing on the trashrack platform. Trashrack sizing and
(c) Operators. Slide and roller gates are usually bar spacing are furnished in EM 1110-2-3102. Pump
raised and lowered by means of a manual or electric manufacturers should also be consulted concerning their
motor-operated geared hoist. In special cases, hydraulic recommended bar spacing. Any hand rake to be fur-
cylinders can also be used for raising and lowering oper- nished that is of a length greater than 2.74 meters (9 feet)
ations. For manual operation, portable electric power should be constructed of a non-electrically conductive
wrenches may be used when the gates are small, easily material as the operator may inadvertently touch ener-
accessible, gate operation is infrequent, and the time gized overhead electrical lines while cleaning the
required to open or close the gates is short. For larger trashrack. Handrailing should be provided for safe hand-
gates, when electric service is available (less than raking operations.
1.49 square meters (16 square feet)), the gate operator
should be motor operated. Where the size and weight of b. Power rake types. There are three general types
a gate, or the quantity of gates, are such that manual of power-raking equipment: cable hoist, mechanical, and
operation would require two persons for more than catenary. These types were classified based on operating
30 minutes, provision for power operation should be characteristics or drive mechanisms used to remove trash.
considered. Fixed power operators should be provided Each of the types has several sub-categories. All the
when portable units must be manhandled to inconvenient types are described and shown in Appendix C. In gen-
and difficult to reach places. These hoists should be eral, only one raking unit will be provided for a station if
equipped with torque and position-limiting devices. All it is of the type that can be moved from trashrack to
power hoists should also be equipped for manual opera- trashrack. On large stations with four or more pumps or
tion. Tandem-operated hoists using two stems but one those stations where extreme amounts of trash are possi-
motor are required for any gate whose width is equal to ble, multiple trashrakes should be used. Most types of
or greater than twice its vertical height, or for a roller rakes will not handle all types of trash. They should be
gate whose width is greater than 3.66 meters (12 feet). selected to handle the trash that will be in greatest quan-
The hoist is usually mounted on a steel beam system tity and is most likely to cause clogging problems.
which must be designed to take both the up thrust devel- Power-raking units should not be remotely operated
oped during seating and the down thrust developed dur- unless specifically designed to protect the mechanism
ing unseating. A computation method used to determine from breakage should a lock up occur due to trash.
thrust loads and stem diameters is shown in Appendix D. Consideration should be given to the method of handling
The surface finish on the threads should not be greater the trash after it is raised to the forebay platform.
than 63 rms, a radius of 0.76 millimeters (0.030 inch)
should be provided on the thread corners, and the lift nut c. Selection. Selection of the type of trashraking
and stem should be manufactured at the same location so equipment is based on the anticipated types of trash and
that their fit may be confirmed. Hydraulic cylinder oper- its quantity. Field surveys may be performed to deter-
ation of the gate stems is usually considered only for mine the type of trash and possible amounts. Similar
large stations with eight or more gates where the costs drainage basins can also be used for comparison as can
required for multiple hydraulic units are justified. Opera- other pumping stations in the same general area. An
tor motors should be rated for continuous duty. attempt should be made to estimate the amount of trash
to be removed and the time period during which this
9-2. Trash Protection trash would accumulate at the station. In general when
comparing two different drainage basins, the amount of
a. General. Trashracks are required to protect the trash per unit of area diminishes as the total contribution
pumps from debris which could clog or damage the area increases. The greatest quantity of trash usually
pumps. Accumulated debris in front of the racks should occurs during the first peak inflow to the station during
be removed to prevent structural damage to the rising water conditions. Consideration should be given to
trashracks or damage to the pumps due to restricted flow the installed equipment costs, operating costs, and
into the pump sump. Hand raking and power raking are maintenance costs in addition to the rakes efficiency.
two methods used for removing trash from the rack. Because of its raking capabilities, it is sometimes neces-
Hand raking should be used only for the smallest stations sary to select the raking system that might have the
and then only when the amount of trash can be handled
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highest costs. Additional information on selection proce- raised overhead with the station crane. This is usually
dures used is indicated in Appendix C. required only for those pumps that have part of the pump
bowl embedded in the sump ceiling.
9-3. Equipment Handling
9-4. Ventilation
a. General. A station crane should be provided, for
all but the smallest stations, for handling the major items a. General. Ventilation is provided for both safety
of equipment. Small stations may be built with remov- and heat removal purposes. Ventilation facilities should
able ceiling hatches so that a mobile crane may be used be segregated between pump sump and operating areas.
when work is required. Except for those stations in urban areas where explosive
conditions are known to occur in the sewer adjacent to
b. Station cranes. Since the service expected of the the station or in the sump area, gravity ventilation will be
crane is standby, a Class 1-A in accordance with the adequate for all zones during inoperative periods. For
Crane Manufacturers Association of America can be those cases where the hazard of an explosion exists, the
used. Bridge-type cranes are usually used, but a mono- station should be designed so that it may be completely
rail type over the pumping units may be used if that is ventilated. All equipment used in connection with the
the only requirement for the crane and it is capable of ventilating system should be electrically rated for use in
doing the job. Cranes of less than 2,722-kilogram the explosive condition expected. The operating period,
(3-ton) lifting capacity should be of the manual type. equipment ratings, duct arrangements, locations of outlets
Cranes with capacities from 2,722- to 9,072-kilogram and fresh air inlets, and all other details should be based
(3- to 10-ton) lifting capacity may be equipped with a on accepted principles outlined in publications of the
motorized hoist while still retaining manual travel American Society of Heating, Refrigerating and Air-
arrangements. Cranes over 9,072-kilogram (10-ton) Conditioning Engineers.
capacity should be of the three-motor type, where all
functions of the crane are motorized. Hoist and travel b. Sump ventilation. Mechanically forced ventilation
speeds can be kept to a minimum since the crane will be should be provided for all wet and dry sumps during
used only for major maintenance. Cranes over 10-ton operating periods to prevent accumulation of gases.
capacity should be equipped with multi-speed type con- Gravity ventilation of the sump will be adequate if the
trols with speeds such that "inching" is possible to permit trashrack is not enclosed, operation is not required from a
close positioning of the loads. The high position of the lower platform, and the sump is not exposed to sewer
crane hook should be at such an elevation to permit gases. The mechanical ventilation of sumps should be
removal of the pump in pieces; however, allowance accomplished using motor-driven blowers removing air
should be made for use of slings and lifting beams plus from the sump while fresh air is ducted into the sump.
some free space. If a hatch is provided in the operating The blower should be located outside the sump and
floor, the crane hook should have sufficient travel to should be connected to ductwork from the sump and to
reach the sump floor to permit removal of items from the ductwork which discharges to the atmosphere outside the
sump. The crane should have a capacity large enough to station. The discharge from the blower should be located
lift either the completely assembled motor or pump, but such that recirculation of fumes into the operating area is
not both at the same time except for submersible pump- minimum. The suction ducts from the blower should run
ing units, in which case the entire unit is lifted. Consid- to a point near the sump floor and shall be equipped with
eration should be given to removal of equipment from louvers that allow suction from either the floor or ceiling
the station when determining the crane travel require- area of the sump. The louvers should be operable from
ments. It may be necessary to run the crane rails to the outside the sump. If the sumps are separated in such a
outside of the station in order to load the equipment onto way that openings are not located at both the top and
hauling equipment rather than provide space inside the bottom of the sumps, individual ventilation will be
station for this equipment. Because most stations are required for each sump. It is a requirement that all sump
usually located some distance from rail facilities, trucks areas must be ventilated before any personnel enter. The
should be considered for movement of the equipment to ventilation rate should provide a minimum of 15 air
or from the station. Station design may permit the use of changes per hour based on the total volume of an empty
chain blocks from I-beams or from arrangements of sump. The fresh air inlet areas should be a minimum of
hooks in the operating room ceiling where the loads are twice the outlet area to prevent high losses. For stations
small. Permanently embedded eyes or hooks in the sump pumping sanitary flows or a mixture thereof, the
may be required for those pump parts that cannot be
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(3) Dehumidification of the operating-room area, (1) General. The sump pump should be of the sub-
which includes sealing of the motor room and the appli- mersible motor, nonclog sewage type suitable for passing
cation of vapor barrier material to the interior surfaces. maximum-sized trash. The pump should be rated to pass
a minimum of 64-millimeter- (2.5-inch-) diameter solids.
(4) Heating the interior of the motors and switchgear The pump/motor should be capable of pumping down
by means of a central heating plant. until it breaks suction and rated to run with its motor
above the water surface for a minimum of 1 hour without
(5) Dehumidification of the interior of the motors damage.
and switchgear by means of individual dehumidifiers.
(2) Semipermanent. This type of sump pump is
Operating experience indicates that method (1) above is mounted on a discharge shoe that allows the pump to be
the most practical and economical for small- and removed using a system of rails or cable guides without
medium-size stations. For the larger stations, using unbolting from the discharge piping. Unless the station
motors rated 1,500 kW (2,000 HP) and above, methods crane can be centered over the pump, a separate hoist
(4) and (5) may be feasible. Dehumidification methods should be provided for pump removal. This is usually
are usually less costly to operate; however, maintenance accomplished by using a wall-mounted jib with a hoist.
and replacement costs are such that local users seldom Head room limitations may require multiple lifts to be
keep the units running after initial failure. The sizing of made. This is accomplished by fitting the lifting chain
electric heating elements in system (1) is done by the connected to the pump with evenly spaced eyes on short
equipment supplier; however, the ambient conditions lengths of chain that allow the pump to be hung from a
should be specified for this equipment.
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beam or embedded hook while releasing the load from Specification CW15160, Vertical Pumps, Axial and
the lifting hoist for a lower attachment. Mixed Flow Impeller Type, has a section that covers the
grease lubrication system for stormwater pumps. Each
(3) Portable. The pumps used for this type would be bearing should have a separate grease line and a feed
similar to the semipermanent type except that it would indicator. All lubrication lines below the maximum
discharge through a hose. When this type of pump is water level should be protected against damage or break-
used, a means of placing and removing must be furnished age from floating debris. The lubrication system should
if the pumping unit weighs more than 27 kilograms be automatic with a control system that provides a pre-
(60 pounds). Usually the station crane provided for lube cycle before the pumps are allowed to start and an
equipment removal can be used if a lifting chain similar adjustable period between greasing cycles. Manual
to that described in the previous paragraph is provided greasing systems should be considered for use only on
along with an access opening in the operating floor. pumps such as sump pumps and for flood control pumps
Usually two different-sized pumps are provided, since it whose capacity is less than 600 liters per second ( /s)
may not be possible to use a depressed sump. In this (20 cfs) and where the time of operation is such that
case, a larger pump would be used to unwater down to daily greasing would not be required. The frequency of
approximately 0.5 meter (1.5 feet) (shutoff point of pump greasing is based both on the manufacturers recommen-
provided) of water remain. A small pump would then be dations and how the equipment will be operated.
used to remove the remainder of the water and handle
leakage. This method usually does not permit complete 9-8. Pump Bearing Temperature System
removal of water from the sump floor.
Pumping units with discharges greater than 600 millime-
(4) Control. Operation of the semipermanent sump ters (24 inches) should be fitted with detectors to deter-
pumps is by means of a bubbler system or electrodes. mine the temperature of each pump bowl bearing. If the
Portable sump pumps are usually operated by manual pump will operate less than 100 hours per year, a tem-
means; some pumping units are equipped with current perature detector should be installed only at the impeller
sensors that control the on-off cycling of the pump by bearing. The system should consist of resistance temper-
sensing the change in motor current which occurs when ature detectors (RTD) mounted so that they are in contact
the pump breaks suction. with the bearing, and a monitoring system that allows
display of individual bearing temperatures and alarms
9-7. Pump Bearing Seal and Lubrication when preset high temperatures are exceeded. It is rec-
Systems ommended that the monitoring and alarm system be
designed as part of the electronic control system of the
Grease lubrication of all mixed-flow/axial-flow vertical station and not part a separate system. A detail of a
lineshaft pump bearings is the standard lubrication uti- pump bearing RTD mounting is shown on Plate 9.
lized because of the type of bearing system used and the
usual infrequent periods of operation. Rubber pump 9-9. Pump Reverse Rotation Protection
bearings are not used since a dependable water supply is
usually not available and the use of pumped liquid for Pumping units are subject to reverse rotation when the
lubrication is not always available when periodic test unit is shut down. Depending on the available head and
operation is necessary. Bearings exposed to water pres- the design of the unit, reverse rotation may reach
sure should be provided with seals. Usual pump con- 165 percent of the forward running speed of the unit.
struction provides for a shaft seal immediately above the This can occur as a planned operation such as occurs for
impeller. This seal is usually a lip-type seal installed so pumping units when the water runs out of piping between
the water pressure seats the lip against the shaft. In time the top of the protection or the discharge flap gate and
these seals will leak, letting pumped water at discharge the pump or possibly on an extended basis during failure
bowl pressure enter the shaft enclosing tube. To pre- of a siphon breaker valve or discharge flap gate. All
clude this water from traveling up the tube and leaking pumping units should be designed to withstand this
onto the operating floor, the pump should be equipped reverse rotation. Two means are used for this protection.
with an overflow pipe connected to the enclosing tube The first is to prevent reverse rotation by the use of a
and leading to the sump or a built-in catch basin where reverse ratchet or overrunning clutch mounted on the
the shaft leaves the baseplate with a drain to the sump. motor or gear reducer. The second is to design the
Individual seals for each bearing are not used except for pumping unit, including the drive motor, to withstand the
the bearing below the impeller, if used. Guide maximum speed possible during reverse rotation. Units
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that cavitation starts when the pump performance starts the blade speed at the tip of the vortimeter blade to the
to decrease as the effective sump level is reduced. The average velocity for the cross section of the pump
inception of cavitation definition has not been agreed column. There should not be any vortex formations
upon by all the pump suppliers and users. A typical allowing entrance of air into the pump. In order to accu-
pump test consists of operating the pump at a fixed rately simulate the field conditions, the model should
capacity while reducing the pressure on the suction side include sufficient distance upstream of the station to a
of the pump. As the suction pressure is reduced, a point location where changes in geometry will not affect flow
is reached where a plot of the head-capacity curves devi- conditions in the sump. The prototype-to-model ratio is
ates from a straight line. The Corps specifies the start of usually determined by the testing agency, but it should
cavitation at a point where the curve starts to deviate not be so large that adverse conditions cannot be readily
from the straight line. Others use as the start of cavita- observed. Normally the model should be sized to ensure
tion, a point where a 1- or 3-percent deviation in perfor- that the Reynolds number in the model pump column is
mance from the straight line occurs. Submergence equal to or exceeds a value of 1 105. Reynolds
requirements, as used in this manual, are based on the number is defined by the following equation:
Corps criterion of zero deviations from the straight line
portion. In most cases, some cavitation has already
R dV/r (11-1)
started at either point; therefore, a design allowance of
extra submergence should be provided in addition to that
indicated by the tests results. The submergence allow- where
ance is based on the estimated number of operating hours
expected annually. The amounts of allowance are indi- R = Reynolds number
cated in Appendix B. In all cases, the cavitation tests d = column diameter
should be performed in a test setup that uses a variation V = velocity
of water levels on the suction side of the pump. r = viscosity of water
a. General. Hydraulic model tests of pumping sta- (1) General. These tests are performed to evaluate
tion sumps and discharge systems should be performed the performance of a discharge system. Usually two
by WES for stations with unique or unusual layouts. types of systems are investigated, discharges which form
The procedure in ER 1110-2-1403 should be followed a siphon and/or through the protection discharges for
when requesting model tests. A decision should be made large stations where the friction head loss would be a
on the requirement for model testing during the General substantial portion of the total head of the pump.
Design Memorandum stage so that the results of any
testing are available during the design of the station. (2) Siphon tests. The siphon tests are run to deter-
Test results are usually not available until 6 to 9 months mine that a siphon will prime the system in the required
after forwarding a work order to the test agency. time. This test is recommended when the down leg of
the siphon system is long or it contains irregular flow
b. Sump model tests. The primary purpose for per- lines and for pumps of 20 m3/s (750 cfs) or greater
forming a model test of a pumping station sump is to having a siphon built into the station structure.
develop a sump design that is free of adverse flow distri-
bution to the pump. Optimal flow into a pump impeller (3) Discharge tests. A head loss test should be
should be uniform without any swirl and have a steady, considered only for pump discharges with capacities of
evenly distributed flow across the impeller entrance. 20 m3/s (750 cfs) or greater and where the accuracy
However, it is usually not possible to obtain the optimal deviation for estimating the total head exceeds 20 percent
flow conditions without considerable added expense. of the total head. Other considerations would be the
Acceptable pump operation will occur when a deviation sizing of the pump and its driver. In some cases, a
in the ratio of the average measured velocity to the aver- safety factor of 10 to 20 percent of the total head may
age computed velocity is 10 percent or less and when the not change the pump unit selection, and therefore the
swirl angle is 3 degrees or less. Swirl in the pump expense of a discharge test may not be warranted. For
column is indicated by a vortimeter (free wheeling pro- those stations where the size of the driver is close to its
peller with zero pitch blade) located inside the column. rating, a test may be in order to ensure that the driver
Swirl angle is defined as the arc tangent of the ratio of would not be overloaded due to error in head determination.
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Chapter 12
Earthquake Considerations
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indicates some of the more commonly used distribution single-phase transformers connected either wye-delta or
system configurations. Beginning at the top left of the delta-delta so that, in the event of a transformer failure,
drawing with the network primary feeder, the systems they can remain in operation when connected in an open-
reliability increases as one moves clockwise around the delta configuration. However, this configuration should
loop. In general, the usage of a radial feed should be be used with caution since it prohibits the application of
limited to projects where either the economics or charac- ground fault relaying as well as producing inherent
teristics of the protected property do not justify or require unbalanced voltages which could result in the overload-
a more expensive network. Not all of the network ing of motors. Another, more attractive, option would be
schemes shown will be available from every utility. the furnishing of a fourth single-phase transformer or a
Consultation with each utility will be necessary to pro- second three-phase transformer as a spare.
vide the appropriate system for the particular application.
13-5. Supply System Characteristics
13-4. Pumping Station Distribution Substation
An interchange of information between the designer and
a. Layout and design. Normally the Government the utility is necessary if the pumping station electrical
contracts with the local utility to design, construct, oper- system is to be compatible with the power supply fur-
ate, and maintain the power supply to the pump station. nished. The designer should obtain the data requested in
In some cases, the electric utility will ask the Govern- Appendix G from the local utility supplying power to the
ment to provide the transformer pad as part of the pump- proposed pump station. To prepare the short-circuit
ing station contract. In such cases, close coordination studies indicated in Paragraph 23-3, the designer will
between the utility, the Government, and the contractor need to obtain the maximum fault current available from
will be necessary to ensure pad sizes, and mounting bolt the utility as well as information concerning the distribu-
locations are as required by the utilitys transformers or tion substation transformer impedance. The designer
other substation equipment. The substation should be should transmit station loads and motor starting require-
located as close to the pumping station as possible. ments to the local utility as soon as they become avail-
Further guidance on rights-of-way, ownership, operation, able so that the utility can prepare an analysis of the
etc., of the transmission line and substation may be found impact upon their system. The utility can then advise the
in TM 5-811-1, Electric Power Supply and Distribution. designer of power factor and motor inrush current limita-
tions. After details of the electrical system have been
b. Transformers. The type of transformer used, i.e., coordinated, the designer should request time-current
whether single-phase or three-phase, should generally be curves of the substation primary side protective devices
determined by the availability of replacements from the so that a coordination study as described in Para-
local power company stock. Most utilities keep an graph 23-2 can be prepared.
inventory of replacement transformers of the various
sizes necessary to provide quick replacement. The 13-6. Pumping Station Main Disconnecting
designer should inquire as to the location of transformer Equipment
storage and the length of time required to transport and
install it in an emergency. All transformers used must be For guidance on selection of the pumping station main
non-PCB to comply with all Federal, State, and local disconnecting equipment, see Paragraph 15-2.
laws. It is common in rural areas to employ three
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for providing the additional torque necessary to "pull" the 14-4. Submersible Motors
rotor into synchronism with the revolving magnetic field
established by the stator windings. The time at which Submersible motors have been used very effectively in
direct current is applied to the field coil windings is smaller stations where economy of design is paramount.
critical and usually takes place when the rotor is revolv- Where the possibility exists that combustible gases or
ing at approximately 95 to 97 percent of synchronous flammable liquids may be present, the motor should be
speed. rated for explosion-proof duty. Thermal sensors should
be provided to monitor the winding temperature for each
b. Field coil winding excitation. There are several stator phase winding. A leakage sensor should be pro-
methods commonly employed to achieve field coil wind- vided to detect the presence of water in the stator cham-
ing excitation. Generally, brushless field control is the ber. If the possibility exists that rodents may enter the
preferred method of field application. In a brushless sump, special protection should be provided to protect
motor, solid state technology permits the field control the pump cable(s).
and field excitation systems to be mounted on the rotor.
The motor, its exciter, and field control system are a self- 14-5. Common Features
contained package. Application and removal of field
excitation are automatic and without moving parts. The Guide Specifications CW 15170 and CW 15171 give
brushes, commutator collector rings, electromagnetic detailed requirements for common motor features such as
relay, and field contactor are eliminated. Thus, the extra enclosures, winding insulation, overspeed design, or anti-
maintenance and reliability problems usually associated reversing device and core construction.
with older brush-type synchronous motors are greatly
reduced. 14-6. Shaft Type
c. Load commutated inverter. A recent development Motors can be furnished with either a hollow or solid
that may have limited application in pumping station shaft. Commonly, however, hollow shaft motors are
design is the load commutated inverter (LCI). It is a available only up to about 750 kW (1,000 HP). The hol-
promising adjustable-frequency drive for variable-speed low shaft motor provides a convenient means to adjust
high-voltage, high-power applications utilizing synchro- the impeller height. Other factors such as station ceiling
nous motors. Because of the internal counter electromo- height and the ability of the crane to remove the longer
tive force generated in a synchronous motor, the design pump column must be considered in the decision of the
of inverter circuits is greatly simplified. This device type of shaft to employ.
provides continuously variable speed regulation of from
10 to 100 percent of synchronous speed. It also limits 14-7. Starting Current Limitations
inrush currents to approximately rated full-load current.
Being a solid state device, however, the LCI may cause Guide Specifications CW 15170 and CW 15171 limit the
harmonic currents in the neutral conductors. Neutrals locked rotor current to 600 percent of rated (full-load)
should be sized to 1.732 times the phase current. Further current. However, when utility requirements necessitate,
guidance can be found in CEGS 16415, Electric Work lower inrush current induction motors may be specified
Interior. not to exceed 500 percent of the rated full-load current.
(Note: Starting inrush varies with efficiency; therefore,
d. Flow- or propeller-type pumps. Synchronous specifying reduced inrush will result in a somewhat
motors find their application as pump drives in the large lower efficiency.) The motor manufacturer should be
capacity, low rpm mixed flow- or propeller-type pumps. contacted before specifying a reduction of inrush current
In general, their usage should be limited to pumps of at for a synchronous motor. If 500 percent is not accept-
least 375 kW (500 HP) and above, and at speeds of able, reduced-voltage starting of the closed-transition
500 rpm and below. Careful attention must be given to autotransformer type should generally be used. Auto-
available pull-in torque to "pull" the rotor into synchro- transformer starters provide three taps giving 50, 65, and
nism with the revolving magnetic field. At this point, 80 percent of full-line voltage. Caution must be exer-
the motor must momentarily overspeed the pump past the cised in the application of reduced voltage starting, how-
moving column of water. Knowledge of the pump speed ever, since the motor torque is reduced as the square of
torque curve, voltage drop at the motor terminals, and the the impressed voltage, i.e., the 50-percent tap will pro-
ability of the motor field application control to provide vide 25-percent starting torque. Connections should be
the best electrical angle for synchronism must all be considered. made at the lowest tap that will give the required starting
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torque. Reactor-type starters should also be given con- The load torques and WK3, so called "normal" values, on
sideration for medium voltage motors. Solid state motor which NEMA MG-1 requirements are based are gener-
starters employing phase-controlled thyristors are an ally for unloaded starts and are therefore relatively low.
option to reduce inrush currents for 460-volt motor appli- Starting and accelerating torque shall be sufficient to start
cations. However, the reliability, price, availability of the pump and accelerate it against all torque experienced
qualified maintenance personnel, and space consider- in passing to the pull-in speed under maximum head
ations should all be studied carefully before electing to conditions and with a terminal voltage equal to 90 per-
use solid state starters. cent of rated. The minimum design for a loaded pump
starting cycle should be: 60-percent starting torque,
14-8. Duty Cycle 100-percent pull-in torque, and 150-percent pull-out
torque for 1 minute minimum with a terminal voltage
Care should be taken in the selection of the number and equal to 90 percent of rated. This would produce inrush
size of pumps to avoid excessive duty cycles. Mechani- currents of 550 to 600 percent of full load.
cal stresses to the motor bracing and rotor configuration
as well as rotor heating are problems with frequently d. Amortisseur windings. Double-cage amortisseur
started motors. The number of starts permissible for an windings may be required to generate the uniformly high
induction motor should conform to the limitations given torque from starting to pull-in that is required by loaded
in MG-1-20.43 and MG-1-12.50 of NEMA MG-1, as pump starting. They consist of one set of shallow high-
applicable. Synchronous motors should conform to MG- resistance bars and one set of deeper low-resistance bars.
1-21.43 of NEMA MG-1. The motor manufacturer
should be consulted concerning the frequency of starting 14-10. Selection
requirements if other than those prescribed above. Eco-
nomic comparisons of different pumping configurations a. General. The choice between a squirrel-cage
should include the reduction in motor life as a function induction and synchronous motor is usually determined
of increased motor starting frequency. by first cost, including controls, and wiring. In general,
the seasonal operation of flood-control pump stations
14-9. Starting Torque results in a fairly low annual load factor, which, in turn,
diminishes the advantage of the increased efficiency of
a. General. Most stations use medium or high spe- synchronous motors. A life-cycle cost analysis should be
cific speed propeller-type pumps with starting torques in performed that includes first costs, energy costs, and
the range of 20 to 40 percent of full-load torque. The maintenance costs. Another factor that should be consid-
motor must be designed with sufficient torque to start the ered is the quality of maintenance available since the
pump to which it is connected under the maximum con- synchronous motor and controls are more complex than
ditions specified, but in no case should the starting torque the induction motor. The additional cost of providing
of the motor be less than 60 percent of full load. For a power factor correction capacitors to squirrel-cage induc-
more detailed discussion of torque values, see the partic- tion motors, when required, should be included in cost
ular motor type below. comparisons with synchronous motors. Also, the extra
cost to provide torque and load WK2 values higher than
b. Squirrel-cage induction motors. Normally, motors normal for a synchronous motor because of loaded pump
specified in CW 15170 will have normal or low starting starting characteristics must be taken into account.
torque, low starting current. Each application should be
checked to ensure that the motor has sufficient starting b. Annual Load Factor (ALF): The ALF can be
torque to accelerate the load over the complete starting estimated from data obtained from a period-of-record
cycle. CW 15170 requires a minimum starting torque of routing (PORR) study or from the electric billing history
60 percent of full load. Breakdown torque should not be of a similar pumping station. If a PORR or billing his-
less than 200 percent of full load unless inrush is reduced tory is used, ALF would be defined as
to 500 percent of full load. If 500 percent is specified,
the breakdown torque must be reduced to 150 percent of ALF = We/(Pd 8,760) (14-1)
full load.
where
c. Synchronous motors. Synchronous motors must
usually be specially designed for pumping applications.
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Advantages Disadvantages
15-1. General
Simple and foolproof Requires spares
The power distribution equipment for motors used in Constant characteristics Self-destructive
flood-protection pumping stations must be as simple as Initial economy (3:1 or Nonadjustable
possible, compact, and reliable, and since the equipment 4:1 versus medium-
will stand idle for long periods and be subject to wide voltage breakers)
temperature variations, provisions must be made to pre- No maintenance No remote control
vent condensation within control enclosures
(Plates 12-19). See Chapter 20, "Electrical Equipment d. Circuit breaker. Some general advantages and
Environmental Protection," for recommended protective disadvantages of a circuit breaker:
requirements.
Advantages Disadvantages
15-2. Main Disconnection Device
Remote control Periodic maintenance
a. General. The main pumping station disconnecting Multipole Higher initial cost
device should be located within the station as part of the Smaller, convenient (at Complex construction
motor control center (for low-voltage stations) or the low voltage) (at medium voltage)
motor controller line-up (for medium-voltage stations). Resettable
The main for the motor control center could be a molded Adjustable
case circuit breaker, power air or vacuum circuit breaker,
or a quick-make, quick-break fusible interrupter switch. 15-3. Low-Voltage Stations
Similarly, the medium-voltage motor controller line-ups
can utilize high-voltage load interrupter switches or a. General. In general, motor control centers are
power circuit breakers of the air or vacuum type. preferred over "metal enclosed low-voltage power circuit
breaker switchgear" for control of motors 480 volts and
b. Design decision. The design decision between a below in pumping station design. While metal-enclosed
fusible interrupter switch and a circuit breaker ultimately switchgear is a high quality product, its application is
depends upon the specific application. In some cases, found more in feeder protection and starting and stopping
continuous current requirements or interrupting capacities of infrequently cycled motors and generators.
will dictate. Below 600 volts, circuit breakers and fuses
are generally available in all continuous current ratings b. Maintenance. Experience has shown that frequent
and interrupter ratings likely to be encountered. At the operation of power circuit breakers requires additional
medium-voltage level, however, fuses are usually limited maintenance of the various mechanical linkages that
to 720 amperes continuous with 270 mVA maximum comprise the operating mechanisms. Since maintenance
interrupting capacity. Additionally, at this continuous of pumping station equipment is usually a local levee or
current level, the slow interrupting characteristics of the sewer district responsibility, every effort should be made
fuse often presents coordination problems with the util- to reduce system maintenance and optimize station reli-
itys overcurrent protective relaying. A new product, ability. Magnetic starters provide a simple, reliable, and
current limiting electronic fuses, improves the fuse reac- less expensive alternative to the usage of power circuit
tion time by electronic sensing of the rate of change of breakers. Combination magnetic starters are available in
current. It should be considered when coordination is a either the circuit breaker or fusible type.
problem. In any event, the utility should be advised of
the choice of main disconnect in order to ensure compli- c. Motor protection. Protection of the motor is pro-
ance with their standards and to prevent coordination vided by thermal overload relays, which are normally
problems. If a fusible interrupter switch is selected, built into the starter itself. The relays contain
protection from single phasing should also be provided.
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high-wattage electric heaters, in each phase, which are (1) Circuit breaker benefits. The benefit of circuit
heated by the passage of motor current. The heat gener- breakers is that although the contact mechanism is not
ated either bends a bi-metallic strip or melts a low tem- designed for a large number of operations, it is designed
perature (eutectic) fusible alloy. The bent bi-metallic to interrupt short-circuit currents of high magnitude and
strip opens contacts that interrupt the current to the con- be returned to service immediately. While vacuum bottle
tactor-operating coil. The melted alloy frees a spring- technology increases the number of operations possible,
loaded shaft that rotates and breaks contacts in the contactors are still the preferred mechanism for fre-
operating coil circuit. The bi-metallic relay has two quently started motors.
advantages not found in the fusible-alloy type: it can
reset itself automatically and can compensate for varying (2) Cost. Another consideration in the choice
ambient-temperature conditions if the motor is located in between the two is the relative cost. Metal-clad
a constant temperature and the starter is not. The heaters switchgear is approximately three times as expensive as
must be sized to accept the starting current of the motor an equivalent line-up of motor controllers. Where
for the expected starting time without causing the con- required, air or vacuum circuit breakers can be used as
tactor to open. To achieve this with a variety of con- mains with transition sections to accommodate the motor
nected loads, conventional starters are available with a controller line-up.
range of standard heaters, which can be selected accord-
ing to the application. b. Medium-voltage motor controllers. The medium-
voltage controllers should comply with NEMA ICS
d. Undervoltage protection. Undervoltage protection 2-324, "A-C General-Purpose High-Voltage Class E
is supplied inherently by the action of the operating coil. Controllers" and UL Standard 347 (Underwriters Lab-
An abnormally low supply voltage causes the motor to oratories, Inc. 1985). They may be described as
run well below synchronous speed, drawing a current metal-enclosed high-interrupting capacity, drawout, mag-
which, even though not as high as the starting current, netic-contactor type starter equipments with manual
quickly overheats the motor. A low supply voltage, isolation. Medium-voltage motor controllers are avail-
however, also means a low current to the holding coil able for reduced-voltage and full-voltage starting of non-
and causes the contactor to drop out and isolate the reversing squirrel-cage and full-voltage starting of
motor. If more protection from undervoltage is required, synchronous motors typically used in pumping stations.
an undervoltage relay can be added for increased
protection. (1) High- and low-voltage sections. Each motor
controller enclosure is divided into a high- and low-
e. Combination motor controllers. Combination voltage section. The high-voltage section contains the
duplex or triplex motor controllers are sometimes pro- magnetic contactor and its protective fuses. The low-
vided by the pump manufacturer as part of a pump, voltage section contains the controls and protective
motor, controller package. This is often the case for relaying. Contingent upon motor size and relaying
smaller stations employing submersible motors. This is a requirements, one, two, or three starters can be located in
viable option, where applicable, and assures one manu- one vertical section. Power for control relays is usually
facturer responsibility should problems arise. 115 volts but may be 230-volt AC or 48-, 125-, or
250-volt DC.
15-4. Medium-Voltage Stations
(2) Fuses. The contactor itself is not capable of
a. General. The designer must choose between a interrupting a short circuit and must be protected by
medium-voltage motor controller (incorporating a mag- silver-sand type current limiting fuses. Fuses are gener-
netic contactor) and an air-magnetic or vacuum circuit ally mounted on the contactor itself and can be drawn out
breaker. While "metal-clad" switchgear is the highest of the cabinet for replacement by withdrawing the con-
quality equipment produced by the industry, motor con- tactor. One limitation of such fuses is that, should a
trollers are still preferred. Circuit breakers in metal-clad short-circuit occur on one phase only, only that fuse will
switchgear are used as motor starters primarily by utili- blow, and the motor will continue to operate on the
ties, where a motor, once started, may run a week or single phase between the remaining two lines. Current
more without stopping. In industry, circuit breakers find drawn in that phase is twice full-load current and will
their application as main or feeder breakers that are not rapidly overheat the motor. This can be avoided by the
frequently opened or closed. addition of suitable relaying, as described later, but, in
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some cases, the contactor may also incorporate a trip immediately to fast changes in the stator conductor tem-
mechanism that is actuated by the blown fuse itself. The perature as would be the case under stalled conditions.
trip mechanism causes the contactor to open immediately The Device 49S relay includes a special high-drop-out
when the fuse is blown, isolating the motor. Either pro- instantaneous-overcurrent unit which is arranged to pre-
tective relaying or a mechanical trip mechanism should vent its time-overcurrent unit from tripping except when
be provided. the magnitude of stator current is approximately equal to
that occurring during stalled conditions. Device 48, the
c. Motor protection. incomplete sequence timer, would be included where the
control package is of the reduced-voltage type. It pro-
(1) General. The following gives general guidance vides protection for the motor and control package
for protection of medium-voltage motors. For further against continued operation at reduced voltage which
information on motor protection, refer to ANSI/IEEE could result from a control sequence failure. For wound-
242, "Recommended Practices for Protection and Coordi- rotor motors where the starting inrush current is limited,
nation of Industrial and Commercial Power Systems." more sensitive short-circuit protection can be provided
For motor protection against lightning and switching with the addition of the Device 51 time over-current
surges, refer to Chapter 19. relays. With the motor inrush current limited, these
relays can generally be set to operate at full-voltage
(2) Induction motor protection. It is logical that locked-rotor current with all secondary resistance shorted.
more extensive protection be considered for larger motors
than for smaller motors, since they represent a larger (b) Motors rated 375 kW (500 HP) or above. For
capital investment. Therefore, minimum recommended the larger motors rated 375 kW (500 HP) and above, a
protective relaying is divided into two groups: one for current-balance relay, Device 46, is included to provide
motors rated below 375 kW (500 HP), and the other for protection against single-phase operation. Differential
those rated 375 kW (500 HP) and above. protection for larger motors is provided by Device 87.
This device provides sensitive and fast protection for
(a) Motors below 375 kW (500 HP). Referring to phase-to-phase and phase-to-ground faults.
Figure 15-1, for motors rated below 375 kW (500 HP),
protection against loss of voltage or low voltage is gener- (3) Medium-voltage brushless synchronous motor
ally provided by the single-phase time-delay undervoltage protection. Figure 15-2 covers the recommended mini-
relay, Device 27. Where it is desired to secure three- mum protection for brushless synchronous motors.
phase undervoltage protection, such as when the motor is Device 26 has been included to provide stalled-rotor
fed through fuses or from an overhead open line wire, protection. It is a stator-current operated device. The
Device 47 would be used in place of Device 27. In characteristic and rating of this device is provided by the
addition, Device 47 would provide protection against equipment manufacturer and must be closely coordinated
phase sequence reversal should it occur between the with the starting and operating characteristics of the
source and the motors associated switchgear. The individual motor being protected. The power factor relay
Device 49/50 provides short-circuit, stalled-rotor, and Device 55 has also been included to protect the motor
running overload protection; this relay has a thermally from operating at sub-synchronous speed with its field
operated time-overcurrent characteristic. It is therefore applied. This commonly called out-of-step operation will
generally to be preferred for this application over an produce oscillations in the motor stator current, causing
inverse time-overcurrent relay such as the Device 51 them to pass through the "lagging" quadrature. The
relay. The instantaneous device on the Device 49/50 power factor relay is connected to sense this current and
relay is normally set at 1.6 to 2 times locked-rotor will operate when it becomes abnormally lagging. Upon
current. Sensitive and fast ground-fault protection is operation, excitation is immediately removed from the
provided by the instantaneous ground-sensor equipment, motor, allowing it to run as an induction machine. After
Device 50GS. Device 49 operates from a resistance- excitation has been removed, the control is arranged to
temperature detector embedded in the machine stator shut down the motor.
winding. This type of running overload protection is to
be preferred over the stator-current-operated device, since (4) Microprocessor-based motor protection systems.
it responds to actual motor temperature. The Device 40S Microprocessor-controlled motor protective systems are a
provides protection against stalled rotor conditions. This relatively recent development that combines control,
device is necessary since the resistance-temperature monitoring, and protection functions in one assembly.
detector used with Device 49 will not respond
15-3
EM 1110-2-3105
30 Mar 94
BUS
* 1
---- CONTROL
PACKAGE
r:--1
MOTOR
u RTD
DEV.
27AUNDERVOLTAGE
46-CURRENT BALANCE (375 KW (500 HP)
THRU 2200 KW (3000 HP))
49-THERMAL
49S-THERMAL (STALLED)
50-INST. SHORT CIRCUIT
50GS..INSTANTANEOUS GROUND SENSOR
87-0IFFERENTIAL (375 KW {500 HPl THRU
2200 KW (3000 HP))
47~UNDERVOLTAGE & REVERSE PHASE
ROTATION
48-INCOMPLETE SEQUENCE-TIMER FOR WOUND
ROTOR MOTORS ADD 2-0EV. 51
IF 871S SELF-BALANCING PRIMARY CURRENT
ADD20EV.51
tNCLUOE IF CONTROL PACKAGE IS REDUCED
VOLT. START
&oMIT DEV. 27 WHEN DEV. 4715 INCLUDED.
Figure 15-1. Recommended minimum protection for medium-voltage induction motors (all horsepowers
except as noted)
15-4
EM 1110-2-3105
30 Mar 94
BUS
* 1
CONTROL
---- PACKAGE
.r:--1
EXC.~
FLO.~
u
RTD
MOTOR
DEV.
~APPAAATUSTHERMALD~CE
27~NDERVOI..TAGE
46-CURRENT BALANCE (375 KW (500 HP) THRU 2200 KW (SOOO HP))
47.aa-UNDERVOLTAGE & REVERSE PHASE
ROTATION
48-INCOMPLETE SEQUENCE-TIMER
49-THERMAL
50-INST. SHORT CIRCUIT
50GS-INSTANTANEOUS GROUND SENSOR
55-POWER FACTOR RELAY
87-DIFFERENTIAL (375 KW (500 HP) THRU 2200 KW 3000 HP))
IF 871S SELF-BALANCING PRIMARY CURRENT
AOD2DEV.51
*INCLUDE IF CONTROL PACKAGE IS REDUCED
VOLT. START
.60MIT DEV. 27 WHEN DEV. 471S INCLUDED.
Figure 15-2. Recommended minimum protection for medium-voltage brushless synchronous motors (all
horsepowers except as noted)
15-5
EM 1110-2-3105
30 Mar 94
15-6
EM 1110-2-3105
30 Mar 94
16-1
EM 1110-2-3105
30 Mar 94
concerns. A comparison should be made of the particu- the correct output should immediately be restored upon
lar pumping station requirements in relation to the vari- restoration of power. Units are available in single or
ous level sensor capabilities before deciding upon the multiturn construction.
system to be employed. In more sophisticated stations, it
may be desirable to utilize an angle encoder. With its 16-4. Elapsed Time Meters and Alternators
associated electronic packages, very accurate level com-
parisons and alarm functions are possible. Also, its To ensure even wear on pumping units as well as reduc-
output may be convenient for inputting to programmable ing the frequency of motor starting, it is recommended
controllers or computers. The selection of a sophisticated that elapsed time meters and alternators (where pumps
water level sensing system, however, must always be are started automatically) be installed to provide a record
made with consideration of the quality of maintenance of pump usage.
and repair services available to the station after
construction. 16-5. Timing Relays
b. Bubbler systems. Bubbler systems when used are Several timing relays are commonly employed in pump
usually of the air-purged type. The nitrogen gas purged control circuits. If siphon breakers are required, an on-
type is usually employed at remote sensing areas where delay timer delays closing of the siphon breaker sole-
power to run the air compressor of an air-purged system noids until the siphon system is fully primed. This
is difficult to obtain. The air-purged system operates by feature reduces motor horsepower requirements to estab-
purging air into a channel, sump, etc., through a tube and lish prime. The other is an off-delay timer which pre-
measuring the back pressure which varies in proportion vents the motor from being restarted until any reverse
to the variation in liquid level. A linear variable differ- spinning of the pump has stopped.
ential transformer is usually used to convert pressure
readings to low voltage or current signals. When used in 16-6. Miscellaneous Circuits
sufficient number, this system may be cheaper than an
equivalent float-actuated system. However, it is more The miscellaneous small power circuits commonly
complex and is subject to clogging in highly siltatious required in installations for the control transformers,
waters. potential transformers, lighting transformers, and control
power should either be protected by standard circuit
c. Angle encoders. The transducer should be of the breakers or fuses of adequate rating.
electromagnetic resolver type and nonvolatile. Each shaft
position should be a unique output that varies as a func-
tion of the angular rotation of the shaft. If power is lost,
16-2
EM 1110-2-3105
30 Mar 94
17-1
EM 1110-2-3105
30 Mar 94
18-1
EM 1110-2-3105
30 Mar 94
18-2
EM 1110-2-3105
30 Mar 94
19-1
EM 1110-2-3105
30 Mar 94
20-1
EM 1110-2-3105
30 Mar 94
Chapter 21
Station Service Electrical System
21-1
EM 1110-2-3105
30 Mar 94
Chapter 22
Station Service Diesel Generator
22-1
EM 1110-2-3105
30 Mar 94
c. Motor running. Undervoltage during the motor (2) Additional information. For further information
running condition may produce excessive heating in the on protection and coordination studies refer to:
motor windings, nuisance tripping of undervoltage relays
and motor-overload devices, dim lighting, and reduced (a) ANSI/IEEE 141, Recommended Practice for
output of electric space heating equipment. Approxi- Electric Power Distribution for Industrial Plants.
mately 5-percent voltage drop from the transformer sec-
ondary terminals to the load terminals is acceptable. (b) ANSI/IEEE 242, Recommended Practices for
Protection and Coordination of Industrial and Commer-
23-2. System Protection and Coordination cial Power Systems.
Studies
c. Main disconnecting device. The utility supplying
a. General. When a short circuit occurs in the elec- the power to the facility should be consulted regarding
trical system, overcurrent protective devices such as the type of protective device it recommends on the load
circuit breakers, fuses, and relays must operate in a pre- side of the supply line which best coordinates with the
determined, coordinated manner to protect the faulted source side protective device furnished by the utility.
portion of the circuit while not affecting the power flow
to the rest of the system. d. Motors. Protective device characteristics must be
coordinated with motor start-up characteristics. The
(1) Isolation of faulted section. Isolation of the devices must be insensitive enough to allow motors to
faulted section protects the electrical system from severe start up without nuisance tripping caused by the relatively
damage. It also results in efficient trouble shooting since
23-1
EM 1110-2-3105
30 Mar 94
high magnitude of motor start-up current. The devices percent IX, percent IZ with X/R ratio, or percent IZ with
must be sensitive enough, however, to operate during no load and total watt losses.
overload or short-circuit conditions.
(5) Cable insulation smolder temperature.
e. Transformers. Transformer protection is similar
to that of motor protection as discussed above. The (6) Completed time-current coordination curves
protective device must be insensitive to the transformer indicating equipment damage curves and device protec-
magnetizing in-rush current, but sensitive enough to oper- tion characteristics.
ate for a short circuit condition. Note, the new ANSI
standard on transformer protection (ANSI/IEEE C57.109) (7) A marked-up one-line diagram indicating ratings
could be used as an alternative to the classic method of and trip sizing of all equipment.
transformer protection. Transformer magnetizing inrush
should be specified as 8 X full-load current for trans- 23-3. Short-Circuit Studies
formers rated less than 3 MVA, and 12 X full-load cur-
rent, otherwise. a. General. Short-circuit calculations are necessary
in order to specify equipment withstand ratings and for
f. Cables. Cable protection requires coordinating use in conjunction with the protective device coordination
the protective device characteristics with the insulation study. Switchgear, motor control centers, safety
smolder characteristics of the power cable. The insula- switches, panelboards, motor starters, and bus bar must
tion smolder characteristics of the cable are the same as be capable of withstanding available fault currents. After
the "short-circuit withstand" and "short-circuit heating the available fault current has been calculated at each bus
limits" of the cable. in the electrical network, the available fault current with-
stand ratings are specified.
g. Specification requirements. The pump station
construction specifications should require the contractor (1) Circuit breakers. Circuit breakers must be capa-
to furnish the completed protection and coordination ble of withstanding the mechanical and thermal stresses
study during the shop drawing approval process. The caused by the available fault currents. They must be able
study should then be reviewed by the designer and to remain closed even though tremendous forces are
returned to the contractor with any appropriate com- present in such a direction as to try to force the breaker
ments. It should be clearly stated in the specifications contacts open. The ability of circuit breakers to remain
that it is the contractors responsibility to coordinate with closed is indicated by their momentary ratings. The
his various equipment suppliers to produce a complete momentary rating is a function of the circuit breakers
and accurate protection and coordination study. The interrupting rating, which is the ability to interrupt a fault
actual preparation of the study should be performed by current without incurring excessive damage to the
the equipment manufacturer or an independent consultant. breaker.
The construction specifications should require the con-
tractor to submit the following items as one complete (2) Fuses. Fuses must also be capable of safely
submittal: interrupting fault current and are rated in terms of inter-
rupting capacity.
(1) Full-size reproducibles of protective device char-
acteristic curves. (3) Motor starters. Motor starters furnished with
motor circuit protectors are available with short-circuit
(2) The motor-starting characteristics in the form of withstand ratings up to 100,000 amperes. Starters fur-
time versus current curves or data points. nished with fusible switches are available with withstand
ratings up to 200,000 amperes.
(3) Data indicating the short-circuit withstand capa-
bility of motor control centers, panelboards, switchgear, b. Procedures. The basic elements of a short-circuit
safety switches, motor starters, and bus bar and interrupt- study are the short-circuit calculations and the one-line
ing capacities of circuit breakers and fuses. diagram of the electrical system. For pumping stations
the three-phase bolted fault is usually the only fault con-
(4) Transformer impedance data. These data should dition that is studied. Utility systems line-to-ground
be submitted in one of three forms: percent IR and faults can possibly range to 125 percent of the
23-2
EM 1110-2-3105
30 Mar 94
23-3
EM 1110-2-3105
30 Mar 94
23-4
EM 1110-2-3105
30 Mar 94
24-1
EM 1110-2-3105
30 Mar 94
I HYDRAULIC DATA I
I CHOOSE DISCH. TYPE
I EM PUMP SELECTIONS I
I
I ALTERNATE DISCH. I
l PRELIM. STATION LAYOUT f
I COST ALT. STATION LAYOUTS I
I SELECT ALT. FOR FINAL DESIGN I
I MILESTONE CONF. W/HIGHER AUTH. I FOR LARGE STATIONS
DESIGN PROCEDURES
Plate 1
EM 1110-2-3105
30 Mar 94
DISCHARGE ARRANGEMENTS
CONVENTIONAL STATIONS
OVER PROTECTION
VENTED PIPE
WITH SIPHON
-
-
I
'
I I
I
-\
'
I
I
'
I
I=+=
I \..
l
'--'--
DISCHARGE CHAMBER
Plate 2
EM 1110-2-3105
30 Mar 94
DISCHARGE ARRANGEMENTS
LARGE STATIONS
.. ". . .
" ." A A ' 'A A
PARTIAL SIPHON
WITH MAX. WATER LEVEL
ABOVE SIPHON INVERT
,.
" .
J>,. '
" .
' ""' ' ,.. ',/), .0.
"A
A
FLOWER POT
Plate 3
EM 1110-2-3105
30 Mar 94
F&.EM!l.E
""""'"""'
~TYP.)
STOH PROTECTtON
.....
Plate 4
EM 1110-2-3105
30 Mar 94
ROOF VENTILATOR
---------------------------
VENT P I P E - - - - - - - ...
OLUNG DOO
PARAPET WALL
t.IOTORIZED GUARDRAIL
GATE STEM
OPERATOR
.. .. ... ...
"
.. .
.
Plate 5
EM 1110-2-3105
30 Mar 94
I Of LEVEE
COLLAR
OUTLET STRUCTURE
Plate 6
EM 1110-2-3105
30 Mar 94
,, . .
' '
" 'p~
';' ' '
''
)> ' ' ' '
'>'
"
I I
. I
.'
~'
---------'----:-- -~-- ~.------
,' '
I' DISCHARGE
''
I Tl.eE
..--@
''
_.,
,,
''
' '
'' ' " "' ~ . ,.,..:.'"'---'----'..:, "
' \
~
'
'
.
-......,
I I
' '
I
. .
'
'
~ DISCHARGE lUBE
-
PLAN VIEWS: COMBINED GATEWELL/PUMP STATIONS
Plate 7
EM 1110-2-3105
30 Mar 94
I LYE .
''
~ ... ~
' <
'
'.
'
-~';
10
..+.t
' '
:~,..~; :..;
~
:
.;
. .. ~
"FREE-FALL" DISCHARGE "FLAP GATE" DISCHARGE SECTION 8-8 FROM PLATE G-7
Plate 8
EM 1110-2-3105
30 Mar 94
BEARING--.
BEARING
COVER PI E
ifl'' GALVANIZED
PIPE COUPLING
CONNECTION HEAD
SHAFT
Plate 9
EM 1110-2-3105
30 Mar 94
NOMENCLATURE: SYMBOLS
X" SUB TRN'lSIENT REACTANCE
34.5 kV SYSTEM
350 MVA SYM. AVAILABLE
( FIRST CYC~E 1 @ MOTOR
X' TRANSIENT REACTANCE
X/R 20 < IV~ TO 4 CYCLES ) I..JJ..A.)
POWER TRANSrORMER
X SYNCHRONOUS REACTANCE fYYY'\
! 200 A.
( > 4 CYC~ES )
SYM. SYMMETRICAL
-H- MOTOR STARTER CONTACTOR
l
b, 10 KA I.C.
-l>~ ISOLATING FUSE SWITCH, ~OHJ BREAK
-~
30 FT. 3 POLE CIRCUIT BREAKER WITH THERMAL
3 - 1/C 250 MCM AND MAGNETIC OVERCURRENT DEVICES
OPEN WIRE UN AIRI
30 A.
200 A. 200 A. 5 KA I.C.
5 KA I.C. 5 KA I.C.
90 FT.
65 FT. - - - - - - - 1 - 3/C 6 COPPER
1 3/C 4 COPPER IN MAGNETIC CONDUIT
60FT.
1 - 3/C 2/0 COPPER IN MAGNETIC CONDUIT 300 kVA
IN MAGNETIC CONDUIT X 4.71.
X/R 6
200 F"T.
2000 kVA
X 5.757. - - - - - - 3 - 1/C 500 MCM
X/R 11 IN MAGNETIC CONDUIT
TO SUBSTATION 4.,__ v. _.__
480_ 8 _ .___SYM. AVAILABLE
KA RMS
4160 V. 5 KA RMS SYM. AVAILABLE
~~--~~~-------- 225 A.
35 KA I.C.
225 A.
35 KA I,C,
l
~ 5
200 A.
KA I.C.
~ 200 A.
5 KA I.C.
M~
225 A.
1800 A.
150 A.
1800 A.
25 FT.
3 1/C 110 COPPER
I
-1 IL !r~ ~Jc AVpjLABLE
110 cOPPER
100FT.
3 1/C 4/0 COPPER
IN MAGNTIC CONDUIT
75 FT.
3 - 1/C 110 COPPER
IN MAGNETIC CONDUIT
PUMPING STATION
01 Lt DIAGR""'
fOR ELECT~CAL SYSTEM STUD$
Plate 10
EM 1110-2-3105
30 Mar 94
GENERATING PLANT
STEP - UP TRANSFORMER
TRANSMISSION SYSTEM
SUBTRANSMISSION SYSTEM
DISmiBUTION
SUBSTATION
DISmiBUTIDN
mANSFOAWER
PUMPING LOAD
STATION
COMPONENTS OF AN ELECTRIC
POWER SYSTEM
PUMPING STATION
POWER SUPPLY SYSTEI.t CONFIGURATIONS
Plate 11A
EM 1110-2-3105
30 Mar 94
T I I
DISTRIBUTION
TRANSFORMER
I
~::::r::~
( ~ I
I
i T
I
T
r-----------------~ r-----------------1
I
I
I
I
I
I
I
irt
~]
:[________ --.-------
1 -......__/ I I -......__/ I I
~-.T--~-:- - - l -.....T~- ~
----I
1:l 1 1
I ~--- ~---
I 1
1
I I I
1
I
i
~~
DISTRIBUTION
SUBS! ATION DISTRIBUTION
SUBSTATION I
PUMPING
i
nr: T T
STATION
I I
I I DISTRIBUTION _ / :
J RADIAL I I
TRANSFORMER 1
' (t (l [
I I I
FEED I r r '"Y"'' I I
I I I
I ____ ---~ I __ _
: ( ( :
L __
PUMPING PUMPING
L--~----------l--J STATION STATION
r--~----------t--l ---1
I I I SINGLE TRN'lSFORMER DUPLEX SUBSTATION
I I I
I I SUBSTATION W/SINGLE PRIMARY W/SINGLE PRIMARY
I
I DISTRIBUTION 1 I
DISTRIBUTION
TRANSFORWER 1 TRANSfORWER I
I I I
I I I
I I I
I I I
II __ I I
PUMPING
STATION
Plate 11B
EM 1110-2-3105
30 Mar 94
USUH.L Y 4801201208
3 PHASE, 4 WIRE
n " \Wl5~1E l6'J~~~r~9s
~
l
LIGHTING
PANEL
INDICATE MOTOR
HORSEPOWER RATIN INDICATE STARTER SIZE
INDICATE MOTOR SIZE AND CB RATING
3 PHASE VALVE TYPE AND PURPOSE
ALL 40 HP AND LARGER---.../ REQUIRED WHEN OUT OF
SITE OF MOTOR CONTROLLER
INDICATE SWITCH SIZE
PUMPING STATION
TYPICAL LOW VOLT AGE STATION ONELINE
Plate 12
EM 1110-2-3105
30 Mar 94
LEGEND
_J-A.o--~1 LIGHTNING ARRESTER @ VOLTt.IETER
........ TRANSFORMER _L
'"""' I CAPACITOR
8 VOLTMETER SWITCH
F CURRENT TRANSFORMER
@ AMMETER
IDl FUSE
-'-- DISCONNECT SWITCH
@] AMMETER SWITCH 42 MOTOR CONTACTOR
~--
\..!::...--
.,_._-rrl~ E-----G.>
~
1ST t.IOTR TYPE.
HORSEPOWER ANO
VOLTAGE RATING
IJ-o
I
+': 138 KV/4160 V 138 KV/4160
'
6. I
Ji-o L.A.
LIST TRANSFORMER PRit.IARY AND SECONDARY
VOLTAGE RATING, KVA RATING, TYPE OF CON
NECTION, r. II,IPEOENCE, AV AlLABLE SHORT 'til !
CIRCUIT CURRENT
SOOSTATION BY UTIL!lY---1,.. ( (
! ~ 138 KV INCOr.IING LINE !
i_ __ ------------------------------------------- __ j PUMPING STATION
TYPIC!>L t.IEOIUM VOLT AGE
STATION ONE LINE
Plate 13
EM 1110-2-3105
30 Mar 94
MOTOR ST Ml'ER
toO HP
P\1,11' N0.3
PGIVE:R
42~TS
480 V, SWITCHGEAR NOTOR CONTROL CENTER 4160 VOLT NOTOR CONTROLLER LINEUP
3
:I:-}
~-
20A.-
oPERATttfG ROOM LIGHTS
....- DEWATER~
l-}
7
12
SUloP PU).P
SUMP WAlKWAY UGKlS
"
13 ,. 20A.- 5\M" fLOODLIGHTS
SLUCE GATE HOIST
CGRAVIlY OR~IO :I:-}
.. .. _........
RESTROOM tATCR WATER HEATER
10 20A.-
20A.-
S(j;,'_
,--...
20A.-
UCC STRIP tATRS
STORAGE IM.A liGHTS
TRASH RN<E MOTOR HEATERS
ROOF' VENTLATOR:
" " I-} ROOF' VENTI..ATOR
GATE: OPE!tATOR HEATERS
"23 22
24
,--...
20A.-
:I:-}
OE:WATEAHG MNolttOL UGHT
ll
"'
20A.-
.. ....- SUMP YNTLATOR f JN
SPAR l}lilA.-
SPME
SPAR
SPAR
27
2&
~
..........
lOA.-
} SPNlE
SPM
Plate 14
EM 1110-2-3105
30 Mar 94
SYMBOLS1
+ SOLENOID
'180120 VOLT
-o...L.a- NORIIALLY CLOSED IIOUENTARY PUSH8UITON
-::::"" GRO
o-
-o
......J_ HORIIALLY OPEN IIOIIENTARY PUSIIIUTTON
-o- RELAY
2TR
-+1- NOIIIof&LLY CLOSED CONTACTS
CR 10.1 FUSE
NOMENCLATURE
CR AT AUTOTRANSFORIIER
t-~1-----------'-----------i G r--_. 1525
GRO,GNO
STARTING CONTACTORS
GROUND
R RUN CONTACTOR
MOT MOTOR
TI,T2,T3 OUTGOING TERIIINALS ON STARTER OR IAOTOR
FULL VOLTAGE NON-REVERSING S8 SIPHON BREAKER
ETM ELAPSED TillE IIETER
CIRCUIT BREAKER TYPE ~ CONTROL RELAY
TR TIMING RELAY
IU TillE DELAY RELAY I PREVENTS REENEI.lCIZATION
DURING BACitSPINNING I
2TR TillE DELAY RELAY I DElAYS CLOSING OF SIPHON
BREAKER UNTIL SIPHON IS 1AA0E I
NO TEl
I. CONTROL SCHEMATIC SHOWN IS FOR OVER THE LEVEE
TYPE DISCHARGE PIPING THAT REQUIRE SIPHON BREAKERS
IN DISCHARGE LINES, TOR DISCHARGE CHAMBER TYPE
STATIONS, DELETE RELAY TD2 AND SIPHON BREAKER RELAY
so. PUMPING STATION
TYPICAL LOW VOLTAGE
MOTOR CONTROL SCHEMATIC
Plate 15A
EM 1110-2-3105
30 Mar 94
SYMBOLS
fillY LISTED FU SW
MOTOR STARTER WITH I..)..J.J...J
CONTRO~ CIRCUIT TRANSfORMER
U/L LISTED CLASS Blt.tET AlLIC
K OR L FUSES fYYY'I
OVERLOADS
T1 _........__ SWITCH
[[]) fUSE
-o- RELAY
sa SIPHON BREAKER
ETM ELAPSED TIME METER
FULL VOLT AGE NON-REVERSING CR CONTROL RELAY
TR TNING RELAY
FUSIBLE SWITCH TYPE 1TR ~tf/Nj'~,l~lik:~~ PfEVENTS REENERGIZATION
2TR TNE DELAY RELAY ( DELAYS ClOS~G Of SIPHON
BREAKER UNTl. SIPHON IS N.OOE I
NOTE
1. CONTROL SCHEMATIC SHOWN IS FOR OVER THE LEVEE
TYPE DISCHARGE PIPING THAT REQUIRE SIPHON BREAKERS
IN DISCHARGE LINES, FOR DISCHARGE CHAMBER TYPE
STATIONS, DELETE RELAY TD2 NlD SIPHON BREAKER RELAY
PUMPING STATION
SB. TYPICAL LOW VOLTAGE
MOTOR CONTROl SCHEMATIC
Plate 15B
EM 1110-2-3105
30 Mar 94
AUTOTRANSFORMER
AT lRNtSFORUER
BHAET.<i.LIC
OVERLO..OS
ClOSED $WITCH WITH T~ DELAY OFIE:NHG F'E:A1UA
FUSE
lCD
NQIWIUY Q.OS0 UCICN'fllfY PIJSteJrTCN
IS TOII:RNA OVERLO.O
t - - - 1 1 - - -..
R -n- NORNIU Y OPEN COHT ACTS
NOIAENCLATUII1
AT NJTOTRIHSFORWER
orr DELAY
15.2$ STARTING COHT ACTORS
GIIO GROIJNO
ON DELAY R RUN COHT ACTOQ
MOT MOTOR
Tl.f2,13 OUTGOING TERt.llfillS
SBI SIPHON PAEN<tR
TM ELAPSED TINE METER
CR CONTROL RELAY
TR TUNG RELAY
ITA Tt.E DELAY RELAY CPRVENTS REEHERCI2ATION
DURING BACKSPNtNG I
2TR TU:: DELAY RELAY CDELAYS (I.OSIHG Of' SlPHON
lmEAKER UHTl. SIPHON IS MADE: l
CR
t-~------------------------~c~-4
NOTE
1. CONTROL SCHEMATIC SHOWN IS FOR OVER TilE LEVEE
REDUCED-VOLTAGE NON-REVERS~G TYPE DISCHIRCE PPING THAT REOIJIRE SIPHON BRt:AKERS
01 OISCHAAGE LINES. FOR OISCHAAGE CH ...BER TYPE
~~liONS, DELETE RELAY 102 AND SPHON 8RAKER RELAY PUMPING STATION
AUTOTRNI!Sf'ORMER TYPE (CLOSED TRANSITION> TYPICAL LOW VOL TOG!:
MOTOR CONTROL SCHEMATIC
Plate 15C
EM 1110-2-3105
30 Mar 94
SYIISO~S
{
LJ--(~Mt---1~---j SEE CONT~OL CIRCUIT T~ANSFORIAI;;~
CURRENT TRANSFORWER
CPT
CPI lPI CPI 4160260V. TPI LOW WATER CUTOFF
u rrYY'
3FU
II
I
I
I
T
PURCHASER'S
TEST POWER
TPI
H
1
GRO":'"
II
I
I
I
~AWOUT CONTACTOR
SlOP
START
f'ULL -VOLT AGE NON-REVERSING INDUCTION UOTOR
--12b AH!:OSTAT
_L_ 11R
....---1-f---Q...Wl-.--i> M O>---<o;j;>-r-1:1"n--r---<
1-1-----'- NOIIIENCLATURE
0 RECTIF~R
PUMPING STATION
TYPICAL MEDIUM VOLT AGE FULL VOLT AGE
INDUCTION NON REVERSING CONTROL SCHEMATIC
RELAY LOGIC
Plate 16
EM 1110-2-3105
30 Mar 94
SYIIIIOtS
SEE
3 PHASE fll.tE O!VY TO CLOSE OH OEEHERCIZATION
60 HERTZ NCTC~
AC SOURCC RElAYING
ONE-LIN NOTC~()- TIME OELAY TO CLOSE OH ENERCIZATION
POTENTI/4. fft~ORIIER
CIJRR1111 TR~SfORIIER
RHEOSTAT
RECllf'IR
TYPICAL ONELINE PROTECTIVE RELAYING
REOUCEOVOL TAGE NON-REVERSING INDUCTION MOTOR
TDAE 10 SEC
CR
r-----------------------~TR:r----+ NONENCLATURE
CPI CONTROL POWER IITERLOCK TD1 TillE OELAY RELAY CPRVENTS REENERCIZAfiON
1,2,3, CT CURRENT TRN<SFORNER DilliNG BACI<SPINNIHC I
1,2,3, FU FI)SE T02 TllotE OELAY RELAY C DELAYS CLOSING OF SI'HON
BREAKER UIITII. SIPHON IS MAO I
<lRO GROUNO
LINE CONT ACT;JR ETN Lif'SEO TINE NETER
TR N
CONTROL RELAY
NOT MOTOR CR
STARTING CONTACTOR
CPT CONTROL POWER TRANSFORNER ~
T.O.
TPI
L1,L2,LJ
TEST POW[R IITERLOCI<
1NCOMNG TE-14-S
..
TR
RUN CONT ACTOR
HEUTRoll
TIWIIfO RELAY FOR REDUCED VQ.TME
2TR T1,T2,TJ OUTGOING TERWNALS
TIIAHSITION TIMER
o;rcT.C.
SB
AMIAETER
SIPHON BREH<ER
2TR
DEVICE NUIIBERS
~
26 N'PARATUS THERMAL DEVICE
27 Ul'llERVQ. TIQE 1. CONTROL SCHEMATIC SHOWN IS FOR OVER THE lEVEE
TYPE DISCHARGE PIPING THAT REOUIRE SIPHON BREAKERS
4& CURRENT BAL~ IN DISCHARGE LINES, FOR lllSCHARGE CHAMBER TYPE
48 IHCONPI.ETE SCM:NCE T"'ER REOUCEO VOLTME STARTING STATIONS. DELETE RELAY T02 AND SIPHON BREAKER RELAY
49 THERIAAL sa.
49S THERIAAL. CST ALLEOJ
50 IHSTN;T-01.1S SHORT CIRCUIT
CR SOGS INSTN;T-01.1S CROUNO SENSOR
+--H------~--------------------~Gr----+ ~~
86
POWEll FACTOR PU.LOUT
NOTOR TRIP AND LOCKOUT
8711 NOTOR CIFFERENTIAL
TYPICAL 1NOUCTION - MOTOR CONTROL PUMPING STATION
TYPICAL IIAEDIUM VOLT AGE REDUCED - VOLT ACE
INDUCTION NON - REVERSING CONTROL SCHEIIAATIC
AUTOTRANSFORMER REOUCEOVOL TAGE NON-REVERSING RELAY LOGIC RELAY LOGIC
Plate 17
EM 1110-2-3105
30 Mar 94
Tl
SEE
2FU
TIUE OELAY TO CLOSE ON ENERGIZATION
===
POTENTIA. TRANSFOIM:R
CPT ~ 1601260V.
ORAWOUT COHTACTOR
-o- RELAY
~ RHEOSTAT
CR
FULLVOLTAGE NON-REVERSING SYNCHRONOUS MOTOR 0 RECTifi(R
1--------------------------~
o-------------------------------,sar---~
NOt.tENCLATUREa
CPI CONTROL POWER INTERLOCK TOI Tll,l DELAY RELAY < PREYNTS REENERGIZATIOH
1,2,3, CT CURRENT TRANSFORNER DUliNG &ACKSPINNIItC l
1,2,3. ru FUSE T02 TillE DELAY RELAY < DELAYS CLOSING Of SPHON
BREAKER UNTIL SIPHON 1$ "'.oDE l
..
GRO
MOT
GROUND
LINE CONT ACTOR
MOT Oft
ETU
CR
ELI'PSEO TIN!: METER
CONTROL RELAY
2AM Oc: N.NETER
CPT CONTROL POWER TRANSFORMER
EXC rtD EXCITER FIELD
TPI TEST POWER INTERLOO<
TR FIELD ~ JPPL YING TINER
L1,L2,LJ INCOMING TERUINII.S
RH EXCITER fiLO RHEOSTAT
CR Tt,T2,T3 OUTGOING Hftt.INII.S
TR1 PU.LOUT PROTECTION APPLYING TIWER
G A AMMETER
SB Sll'llON BREH<ER
OEYIC IIUIBRS
t!Qll.!
26 A"PARATUS THERNAL 0 \liCE
27 UNDRVOL TAG 1, CONTROL SCHEt.tATIC SHOWN IS FOR OVER 11 LEVEE
TYPE OISCHoiRGE PIPING THAT REQUIRE SIPHON BREN<ERS
45 CURRENT BloLifit IN DISCHARGE LINES. fOR DISCHARGE CHANBE:R TYPE
<48 INCOMPLETE SEQUENCE lNER REDUCED VOLTAGE ST~TING ST AllONS. OELETE RELAY TD2 AND SIPHON BREN<ER RELAY
49 TI-ERMAL sa.
41l'l TIRt.tll. ISTALLEOI
50 IHST..,.TAI0US SHORT CIRCIMT
!lOGS ..sT ANT mEOUS GROUND SENSOR
55 POWER FACTOR PULLOUT
86 NOTOR lRIP 00 LOCKOUT
t17U NOTOR OlffEA:ENTIAL PUMPING STATION
TYPIC.6L. BRUSHLESS SYNCHRONOUS MOTOR CONTROL TYPICAL NEOIUt.t VOLTAGE rULL - VOL TAC
BRUSHLESS SYNCffiONOUS NON - REVERSING
F'ULL VOLT AGE NON-REVERSING RELAY LOGIC CONTROL SCHEt.tATIC RELAY LOGIC
Plate 18
EM 1110-2-3105
30 Mar 94
SYNBOI.S<
IPRIHJ
FUSE
Ht H2 HI H2
MX NJXILLIARY RELAY
IOl FUSE
Gl"l Gr2
...L
cusr. 12ov
TEST POWER
POTEtmAL TRNfSFORMA
X1 "X2
I -=. I
cusr 1.-i''
RCPT 1 r
ORAWOUT CONTACTOR
'---11-+-' Gi<J
-o- NORM AU. Y OPEN CONTACTS
._______~r~----~~~r--~~~---------------------e
I
NOIWf.Lt.Y Q..OS0 C!ONT ACTS
TYPICAL REVERSING MOTOR CONTROL FULL VOLT AGE NON-REVERSING PUMPING STATION
TYP!CAI. IA;OIUOI VOL TAG[ FIA.L VOLT Jl;E tiDtJCTI()N
NON-REVERSING CONTROL SCHNAT1C ~ICROPROCSS(M
MICROPROCESSOR PROTECTION PACKAGE BAS0 PROTECTIVE LOOIC
Plate 19
EM 1110-2-3105
30 Mar 94
b!J~EI
SECTION NO. I SECTION NO. 2 SECTION NO. 3 SECTION NO. 4 SECTION NO. S SECTION NO. 6
20"
PANEL B PANEL B ITYPICIU
10"- o
......
__ ,
, ,___ ,
.__I-I-~4..:....!!-o -_-------~~-
~
........
CONTROL CONSOLE
::
I
IA1111 LMI. -s--3
I n.Oir IMIUIDII
PANEL A PANEL A
PUMPING STATION
TYPICIII. REMOTE CONTROL CONSOLE
Plate 20
EM 1110-2-3105
30 Mar 94
I
\
\
I
l
+-
1
I
l SUMP GROUND[NG PLAN
I
I
I
t- TYPICAL tlTESo
1. "'IDITIIlNAI.. LEIIlHTS OR f'tlio49ER5 (1F OROIHI AOOS SHIII..l 1 ADDED AS FIEOUIFIEO TO
A MIIXIKJM RESJSTNICE TO GRCUIO (IF 25 OHMS.
2, OAOIHI BUS SHIII.L BE EXCITMEAtUCIILLY VELDED TO Tf !DIP FLOOR FIEilORSoNif NET"l.
FIWEWORK (1F Tf BUILDING AMI METALLIC UtlERGAOUtll V..TER PIPE IF PRESENT.
3. liE FRAH5 IF ALL STAtllll'WIY OR PE,_NTLY LOCATEO 140TORSo STIITIC EOUIPMENT OR
~&W~14E~T~t;mN~Mrc:'=0 1~yS~~T f~ l~~T~~::r I=YT~ LINE
I CONNECTED TO Tf EOUIPNENl IIUT NOT LESSTIIIIN NO. S AWO.
I
j
COY~
TRASH FIEM0'/111.. IIANH1.E
PI.IITFORH
OROIHI ~
PUMPING STATION
TYPICAL GROI.Nll NG PI.AA
UTILIZING DRIVEN ELECTRODES
Plate 21
EM 1110-2-3105
30 Mar 94
FENCE
1
L_yL~.
~I
I
I
I
:
I
I Q I
:MOTCANO.r
I
1Nhrt:A
I I
N0
I
1 1:1
I-
1"brOR N0
I
1~ I
I 11 I
I I
I
I I
I
I I I I I I I I I
__I I --~
UP TO LAND SIDEOFOFPUMPING
RIVERSIDE PLANTGROUNDING
PUMPINGPLANT LOOP
UP TO RIVER SIDE CORNERS OF StBSTATION GROIHIING LOOP
::?:5,z
GROUNDINGL~~l!~~;::==~~~==========::
~
~ J"~;>
2
/..;:; ~......
h :/'( h~/
L.
/-" , - - ::=::::%""
/
/
GENERAL NOTES
~
! I. LOC~T GRtliHJ GRID IN MEA OF PE-NENTLY NOIST SOIL. P~S
SIGA.D HAVE A MINIMUM OF 12 INCHES OF CON!liTE COVER. THE
GROUHO GRID BCAJNOARY SHOLl.O liE INDICATED IIY IIBOVE GROUND
~ - R S IINII PROTECTED AGAtNST II~SHOUT$ CA OISTURilNICES
RESU. TlNG FR!J4 FUTURE CDNSTRU:TION.
!
!IIIII 101 BARE STRANDED ~
..~.. 2. ALL EQUIPMENT FRAOIES AND HOUSINGS, METAL CABINETS INCLOSING
ELECTRICAL EOUIPNENT AND HETAL CONDUITS 5HOLLO liE CONNECTED
TO GAOUNIIING SYSTEM
CCJ'PER GROUND WIRE ! J. THE CONTACT MEA OF ALL .JDINTS IN GROIHIING CIRCUIT SHOULD PROVIDE
A CURRENT CARRY lNG CAP.-c I TV "'T LEAST EQUAL TO TIUil OF THE CONM:CTING
WIRE OR CABLE. ALL TERMINAL LUJS SHOULD BE OF THE SOLMRI.ESS 1lPE
~ ANG
SECURELY CI:HCTEO 10 THE EQUIPMENT.
-
__! ,__ 4. IN ADDITION TO SOLDERLESS CONNECTORS, GROUND CONIECTIONS 1oN11
SPLICES, WHICH VIU BE CONCEALED uPON CONPLET!DN OF WORK, SHOULD
BE EXOTHERMICALLY WELDED.
5. QROUNJ CABLE WHERE EHBECil0 IH CONCRETE SHOUl.D liE COWERED WITH
WATERPROOF CORRUGATED P*!R OR SIMILAR MATERIAL TO PROTECT THE CABLE
llLRING PLACEMENT "'NN VIBRATING OF THE CONCRETE.
6. HAXlHUH RESISTANcE TO OIIOUICl NOT TO EXCEED 25 OHMS.
Plate 22
Em 1110-2-3105
30 Mar 94
---------
.
-------~-
1
I DISCHARGE ELBOW
I
COLUMN PIPE
DIFFUSER
DISCHARGE BOWL
Plate 23
EM 1110-2-3105
30 Mar 94
Plate 24
Em 1110-2-3105
30 Mar 94
. . .
~
J
.
4 4 4
I I ' I f t 1
Plate 25
EM 1110-2-3105
Change 1
31 Aug 94
Appendix A CW 15160
Guide Specifications for Vertical Pumps, Axial and
References Mixed Flow Impeller Type
CW 15170
A-l. Required Publications Guide Specifications for Electric Motors 3-Phase Vertical
Induction Type (for Floor-Control Pumping Stations)
Code of Federal Regulations, 29 Part 1900-1910, July
1992 CW 15171
Occupational Safety and Health Administration Guides Guide Specifications for Electric Motors 3-Phase Vertical
Synchronous Type 1500 Horsepower and Above (for
TM 5-809-10 Flood-Control Pumping Stations)
Seismic Design for Buildings
CW 16120
TM 5-811-l Guide Specifications for Insulated Wire and Cable (for
Electric Power Supply and Distribution Hydraulic Structures)
ER 25-345-l NFPA-70
Systems Operation and Maintenance Documentation National Electric Code
ER 37-2-10 American Water Works Association 1989
Accounting and Reporting Civil Works Activities American Water Works Association. 1989. Steel Pipe
and Installation Manual, M-11, 3rd ed., Denver, CO.
ER 1110-2-109
Hydroelectric Design Center * Fletcher 1990
Fletcher, R. P. 1990. Formed Suction Intake Approach
ER 1110-2-1150 Appurtenance Geometry, Technical Report HL-90-1,
Engineering After Feasibility Studies U.S. Army Engineer Waterways Experiment Station,
Vicksburg, MS. *
ER 1110-2-1403
Hydraulic and Hydrologic Studies by Corps Separate King and Brater 1963
Field Operating Activities and Others King, H. W., and Brater, E. 1963. Handbook of Hydrau-
lics, 5th ed. McGraw-Hill, New York.
EM 385-l-l
Safety and Health Requirements Manual A-2. Related Publications
EM 1110-2-3102 Section 1
General Principles of Pumping Station Design and General
Layout
EM 1110-2-3101
EM 1110-2-3104 Pumping Stations - Local Cooperation and General
Structural and Architectural Design of Pumping Stations Considerations
ETL 1110-2-313 CW 16120
Hydraulic Design Guidance for Rectangular Sumps of Guide Specifications for Insulated Wire and Cable (for
Small Pumping Stations with Vertical Pumps and Ponded Hydraulic Structures)
Approaches
ANSI/ASME Y1.l 1972
ETL 1110-2-327 American Society of Mechanical Engineers. 1972.
Geometry Limitations for the Formed Suction Intake Abbreviations for Use on Drawing and in Text, United
Engineering Center, New York.
CEGS 16415
Guide Specifications for Electric Work Interior
A-l
EM 1110-2-3105
30 Mar 94 *
*
EM 1110-2-3105
* 30 Mar 94
A-3
EM 1110-2-3105
3O Mar 94 *
Technical Report HL-82-21, U.S. Army Engineer Water- County, IL, Technical Report HL-88-13, U.S. Army
ways Experiment Station, Vicksburg, MS. Engineer Waterways Experiment Station, Vicksburg, MS.
A-5
EM 1110-2-3105
30 Mar 94
c. Selection process.
B-1. General (1) Vertical wet pit pumps. The selection process
uses the model and affinity laws to obtain the perfor-
a. Purpose. This appendix provides a method to mance of a prototype pump from the various supplied
determine the size of a pump to meet certain pumping model pump performance data. Model performance data
requirements. It also provides dimensions for the sump can be obtained from pump manufacturers, existing
and station layout once the pump is selected. Certain pumping stations, or from other Districts. The following
information must be available before the pump selection general steps are used in the selection process:
can be started. This information includes the pumping
requirements as determined from hydrology data, number (a) Determine pump operating conditions using the
of pumping units, and discharge/station arrangement as furnished hydrology and station/discharge arrangement.
determined by EM 1110-2-3101.
(b) Determine prototype pump performance from
b. Procedure. This appendix is divided into two model performance.
major sections, selection of vertical wet pit pumps and
selection of vertical submersible propeller pumps (2) Submersible pumps. The selection process makes
(Plates 23-25). Sample calculations are used to aid in use of typical catalog curves of head-capacity and Net
understanding the selection procedures. Chart B-1 indi- Positive Suction Head Required (NPSHR). The
cates the operating range of the various type pumps used
B-1
EM 1110-2-3105
30 Mar 94
various curves allow direct selection of pumps after the = 29,000 gpm @ river elevation (el) 339.0 and
system design conditions are known. sump el 317.0
d. Information sources. The following is a list of QL = Flow rate at minimum differential head (low
information needed to perform the selection process and head)
where it may be found:
= 34,000 gpm @ river el 314.0 and sump
Number of Pumps EM 1110-2-3102
el 314.0
Pump Discharge EM 1110-2-3102
Configuration (2) Station arrangement. Station general arrangement
and discharge system are determined as presented in EM
Hydrology Data Project Hydrology
1110-2-3102. For this example, a discharge over the
Report
protection with siphon assist was assumed (Figure B-1).
e. Appendix results. The application of the methods A static head diagram (Figure B-2) should now be con-
illustrated in this appendix will allow the user to deter- structed. The top of the discharge pipe is obtained by
mine the following pump and station parameters. sizing the pipe diameter based on an approximate maxi-
mum velocity in the pipe of 12 feet per second (fps)
(1) Maximum design head. (using the greatest Q requirement) and adding the diame-
ter to the invert elevation. The invert elevation is usually
(2) Design heads at rated pumping station capacity. set equal to the top of the protection on either side of the
station so that backflow will not occur with any river
(3) Capacity requirements other than those required level to the top of the protection.
by the hydrology requirements, such as capacity required
for siphon priming. (3) Size discharge pipe.
(6) Power required at the design points. Pipe Area = {[(Pipe Dia.)2] / 4} 3.14
(8) Station Net Positive Suction Head Available Pipe Area = Qmax / Vpipe
(NPSHA) and pump NPSHR.
Pipe Diam. = [(Qmax 4) / (Vpipe 3.14)]1/2
(9) Sump dimensions.
= 2.83 feet or 34 inches
B-2. Vertical Wet Pit Pump Selection Sample
Problem Use standard sized pipe, the next larger standard size
pipe = 36 inches nominal (35.25 inches inside diameter
a. Design data and requirements. (ID))
(1) Pump conditions. The starting point for all For this first calculation, use the following wall
pump selection is the hydrology requirements for the thickness:
station site. The following is assumed given conditions
for each pump: 1/4 inch, 12- to 20-inch diameter of pipe
3/8 inch, 24- to 42- inch diameter of pipe
Required from hydrology report: 1/2 inch, 48 inch and over *
QH = Flow rate at maximum differential head * (larger pipe sizes may require thickness greater than
(design flood) 1/2 inch for support considerations)
B-2
EM 1110-2-3105
30 Mar 94
HYDRAULIC GRADIENT
PRIMING HEAD
HYDRAULIC GRADIENT
HYDRAULIC GRADIENT
LOW HEAD
B-3
EM 1110-2-3105
30 Mar 94
0
c(
w
:I:
u
~
en
0
8
[[
z
S2
en
w
0
SUMP FLOOR
B-4
EM 1110-2-3105
30 Mar 94
A diagram of the typical over the levee discharge pipe Siphon recovery = top of pipe elevation - lowest river
system is shown in Figure B-1. elevation for pumping
Highest point in discharge pipe at top of protection = for pumps with suction head:
elevation of protection + diameter of pipe = 341.0 + 3.0
= 344.0. NPSHA = hp + hse - hf - hvpa
(5) Siphon condition. With a siphon assist system, hsa = total suction head in absolute feet
it is required that the siphon recovery is not greater than
28 feet. The value of 28 feet is used to prevent possible hvpa = vapor pressure of water at given temperature
water vaporization and siphon priming problems. An
up-turned saxophone discharge pipe or a weir is used to hp = absolute pressure on water surface, for open
limit the recovery to 28 feet and seal the end of the pipe. sump = atmospheric pressure in feet
When one of these means is used, the low head must be
checked based on the saxophone or weir elevations. If, hse = static water level above (+) or below (-)
at the pumping mode, the lowest water level on the dis- impeller eye datum
charge side provides for a recovery less than 28 feet,
then a saxophone discharge or weir is not required. The hf = friction and entrance (0 for pumps with
discharge end of the pipe should be submerged when a bellmouths in wet sumps)
separate vacuum priming system is provided to prime the
pump. The computation is as follows:
B-5
EM 1110-2-3105
30 Mar 94
(8) Total system head. The next step is to compute BHPp = BHPm(dp/dm)5(Np/Nm)3
the total system head curves for each condition. The
total system curves will include all the losses plus the
static head for that condition. For the purposes of pump
B-6
EM 1110-2-3105
30 Mar 94
Table B-1
Total System Head
Design4
Other Losses Bends Low3 Flood
V2 Pump K = 1.2 Total1 Total Total
Q 2g HF/100 HF/250 K = 0.4 ft Loss Head Head
gpm ft ft ft ft ft ft ft
dp = Impeller exit diameter of prototype pump Hsm = Required suction head of model pump
dm = Impeller exit diameter of model pump BHPp = Brake horsepower of prototype pump
B-7
EM 1110-2-3105
30 Mar 94
shown on each model pump curve. For mixed-flow type is usually best to start with a model pump that has a
pumps, the maximum impeller diameter is indicated on head range near that of the required condition points. As
the curves. On mixed flow pumps, it is possible to a first try, use model curve MF-1 (Figure B-4) and calcu-
reduce the impeller diameter by up to 5 percent, thereby late prototype performance. A mixed-flow impeller was
changing the performance of the pump from that shown tried because highest head requirement was over 20 feet.
on the curves for full diameter performance. Blade The selected prototype impeller is usually smaller than
pitches are taken into account and shown as different the discharge pipe diameter. The maximum prototype
model pump curves. pump speed can be estimated by applying the following
formula based on suction specific speed (S).
(3) Calculation method. The actual calculations of
the prototype pump performance is best done by trial and S = Np ( Qp )1/2 / NPSHAp3/4
error. A personal computer using a spreadsheet type
program simplifies and speeds these calculations and the (a) For this sample problem, use a value of S =
pump selection. CECW-EE can furnish information of 8,000.
various Districts where different programs are available
to perform these computations. Np = ( 8,000 ) ( NPSHA )3/4 / ( Q 1/2
)
B-8
EM 1110-2-3105
30 Mar 94
NPSHAp = calculated for the lowest head pumping (b) The pump speed should not in general exceed
condition, ft this calculated rotative speed. The speed used must also
meet the restrictions of the pump driver. If using an
Qp = flow rate for lowest head pumping electric motor that is directly connected to the pump,
condition, gpm then the synchronous speed of the motor must be
considered.
therefore
B-9
EM 1110-2-3105
30 Mar 94
When using an induction motor, the full-load speed can Np/Nm = 582/1,090.4 = 0.534
be estimated to be 97 percent of the synchronous speed.
The synchronous speed can be calculated using the fol- BHPp = BHPm (1.81)5 (0.534)3 = BHPm (2.96)
lowing formula for electricity with a frequency of
60 cycles.
From curve MF-1 Calculated prototype
Np = 7,200/number of motor poles (such as model pump performance pump performance
10,12,14...) Qm Hm BHPm Qp Hp BHPp
7,000 38.8 75 22,200 38.8 222
Motor speed = 7,200/12 or 7,200/10
8,000 33.2 73 25,400 33.2 216
= 600 rpm or 720 rpm 9,000 26.9 70 28,530 26.9 207
(c) Since 720 rpm is over the calculated maximum of 10,000 19.0 60 31,700 19.0 178
634 rpm, the lower synchronous speed of 600 rpm is 11,000 7.2 45 34,900 7.2 133
used. Assuming an induction motor is to be used, the
running speed when operating at full load is estimated to
be 97 percent of 600 rpm or 582 rpm. (f) The results of the first prototype pump computa-
tion are plotted on the system head loss curves. Results
(d) Try Model MF-1. Based on the Pump Model show that a pump with a 27.7-inch impeller rotating at
Curve MF-1 (Figure B-4), calculate the diameter of the 582 rpm will satisfy the design requirements. Next,
prototype impeller using the model law (constant specific other model pumps and different prototype speeds would
speed and equal heads. have been tried to find other prototype pumps that will
meet the requirements. An average prototype pump size
dp = dm (Qp/Qm)0.5 could then be calculated. All station layout dimensions
would be based on the corresponding standard size pump.
where The NPSH required by the prototype or model is then
checked against the NPSH available. Cavitation curve
dp = 15.33 (29,000/8,900)0.5 = 27.7 inches MF-1 (Figure B-6) confirms that there is adequate
submergence.
dm (from model curve MF-1) = 15.33 inches
(5) Pump dimensions.
Qp = QH (design flood) = 29,000 gpm at 27 feet
TDH (a) General. Determine the dimensions for all the
model pumps selected. Since the sump dimensions and
Qm (from model curve MF-1) = 8,900 gpm at 27 feet elevations used depend on the pump dimensions, some
TDH means must be used to determine the dimensions to use
for the station layout from the range of pumps selected.
(e) Develop prototype performance curve based on The selection of dimensions to allow the maximum num-
model curve MF-1 and verify that design conditions have ber of pumps to meet the guidelines is given below.
been met (Figure B-5).
(b) Bell diameter.
Qp = Qm (dp/dm)3 (Np/Nm)
The bell diameter = D
BHPp = BHPm (dp/dm)5 (Np/Nm)3
Average D, (DA) = sum of bell diameter for all selected
where pumps divided by number of selected pumps.
Qp = Qm (1.81)3 (0.534) = Qm (3.17) Largest bell diameter (DLARGE), but not larger than
1.2 times DA
dp/dm = 27.7/15.33 = 1.81
B-10
EM 1110-2-3105
30 Mar 94
Figure B-5. Prototype performance curve superimposed on the system head curves (pump bowl)
pump MF-1
Smallest bell diameter (DSMALL), but not less than Bottom of pump bell = impeller eye elevation minus
0.9 times DA 1/2 D
Sump width1 = 2 times DLARGE Floor of sump = bottom of bell elevation minus 1/2 D
Sump width2 = 2.5 times DSMALL (d) Minimum pump height. The minimum distance
from the floor of the sump to the centerline of the pump
Sump width is the larger of sump width1 or width2 discharge must be determined to establish a minimum
floor elevation. The dimension form the floor of the
D = 1/2 of the sump width from the above step. sump to the bell inlet is determined above. The distance
between the centerline of the discharge to the suction bell
(c) Impeller elevation. The impeller eye (entrance) is inlet should be provided by pump manufacturers offering
set to provide the submergence indicated above in the the type and size of pump indicated by the prototype.
paragraph on pump conditions. In this example, the This pump dimension will vary from one manufacturer to
impeller was set at el 311.0. The bottom of the bell and another. The maximum distance found should be used to
sump floor elevation are set as follows: determine the minimum operating floor. Other
B-11
EM 1110-2-3105
30 Mar 94
considerations such as local flooding due to power outage Waterways Experiment Station Hydraulic Laboratory to
and surrounding ground elevations may require a higher determine alternative layouts to correct or compensate for
operating floor elevation. the problems.
(1) Pump dimensions. For stations with up to three (a) Space inside of the station is provided to set one
equal sized pumps having capacities not greater than pump driver and disassemble one pump using the over-
5.66 m3/s (200 cfs), and with straight inflow, in front of head crane.
the station, the dimensions indicated on Chart B-2 may
be used. The flow to the station should occur in a (b) Space in front, side and back of electrical equip-
straight symmetrical channel with a length equal to or ment is provided as required by the electrical code
greater than five times the station width (W on Chart requirements.
B-2). The invert of the channel in front of the station
should not contain any slopes greater than 10o. The (c) Space is provided to remove any pumping unit
submergence indicated on Chart B-2 is the depth of without disassembly of another unit or electrical gear.
water suggested to prevent harmful vortexes. In most
cases the water depth will be greater due to the cavitation (d) Space is provided for an office and sanitary
allowance listed above. If there are any unique inflow facilities for any station that will be manned.
conditions or problems the designer should contact the
B-12
EM 1110-2-3105
30 Mar 94
t 1.00 0
~
0
0
0
20 fiS
en
R20
::1
135" ~
a:
w
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i5
S = SUBMERGENCE PLAN
0= PUMP BELL
DIAMETER
1.50 A
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~ I
"" I
I ....- 0.50
MINIMUM
WATER
I
f--
I
I
I
H~ 0
en
--
LEY,_EL
I 0
-
ID
~ "!
j
i
0 .250 1.00 0.50-
SECTION A-A
B-13
EM 1110-2-3105
30 Mar 94
(e) Space is provided for spare parts and mainte- QL = The flow rate at minimum differential head
nance equipment to be stored at the station.
= 33,000 gpm @ river el 322.0 and sump
(f) Location of electrical gear is coordinated with el 319.0
service entrance.
= 2,095 L/S
(g) Exit and equipment door are provided and
properly located. Pump stop elevation - 315.0
Pump start elevation - 318.0
(h) Straight approach to pump sump is provided. Normal pumping elevation - 316.0
(Level at which the majority of pump operation will
(i) Any sump closure gate is neck down at least 4D occur)
from the pumps.
(b) Submersible propeller pumps (Plate 24) typically
(j) Access is provided to trashrack platform for trash are constructed in such a manner that the pitch angle of
removal by truck. the propeller blades can be changed; therefore, the selec-
tion method used is different from that used with fixed
(k) Sufficient room is provided to position a truck blade pumps. The selection procedure used for submers-
for equipment removal. ible pumps will be to compute the system requirements,
and then select a pump from available performance
(l) Minimum slope is provided in ditch flow line curves. After the initial selection is made, then the sys-
beyond the front of the trashrack. tem requirements can be corrected if necessary due to a
more accurate discharge tube sizing and the pump selec-
(m) Incoming overhead power lines do not present a tion confirmed or changed. In addition to the selection
hazard to operation and maintenance of the station. based on pump head and capacity requirements, the
pump selected must also be checked to ensure that its
d. Pump manufactures selection. Using the prelim- suction requirements are satisfied by those provided by
inary layout, correct any system head curves such as the station layout.
change in low head due to different elbow elevation.
Check the pump selections using the new system require- (c) The pumping system is composed of a
ments and refine layout as necessary. It is also best at discharge/support tube in which the submersible pumping
this time to request pump selections from the pump man- unit is located. In this example, the tube would be fitted
ufacturers using the requirements and sump layout above. with an elbow section and a horizontal pipe terminating
This will confirm the pump selections. Chart B-3 is an with a flap gate. For submersible pump installations of
example of the information to be furnished and requested this type, the discharge line invert should be well above
from the pump manufacturer. the motor to hold the elbow losses to a minimum but low
enough to keep reasonable the static head reasonable.
B-3. Vertical Submersible Pump Selection
(d) The first estimate of the tube diameter can be
a. Design data and requirements. based on the size required using a 6.5-fps velocity and
the greatest required capacity. After calculating a diam-
(1) Pump conditions. The sample calculations are eter based on these conditions, the nearest size tube
based on a pumping station with a through-the-protection diameter as shown on Table B-2 shall be used for the
discharge, pumping into a discharge chamber. The fol- preliminary calculations. For the example problem, the
lowing is the assumed conditions for each pump. calculated discharge is 45.4 inches. The nearest standard
tube diameter of 48 inches is used. The bottom of the
(a) Required from hydrology report: tube can be set using the minimum tube submergence
required. These submergence requirements are provided
QH = The flow rate at maximum differential head by the submersible pump manufacturer and are based on
annual operating hours and pump tube design. For this
= 27,000 gpm @ river el 339.0 and sump el 321.0 example, 3.0-ft minimum submergence is required.
B-14
EM 1110-2-3105
30 Mar 94
Information furnished:
Name of station
Type of driver and operating voltage if electric
Type of pump
System head curves, using losses external to the pump, showing required condition points
Pump setting elevation
Sump layout
Number of pumping units to be installed
For large pumps over 54-inch size, additional information such as the WR2 of both the pump and
motor along with starting torque curves would also be requested.
B-15
EM 1110-2-3105
30 Mar 94
Table B-2
curves include all of the losses plus the static head for
Submersible Pump Dimensions that condition (Figure B-9). The system loss curves
include all the losses beyond the pump motor, since
Discharge
Tube Pump Height of Max. Wt.
losses below this point are included in the given pump
Pump Diameter Speed Pump/Mot. Pump.Mot. Motor kW curves. A loss of K = 0.7 is used for the losses in the
No. inches rpm inches pounds rating pump column and elbow. The other losses in this exam-
AF-S-1 40 705 97 7,350 236 ple are considered to be equal to the velocity head.
Next, calculate the net positive suction head available
AF-S-2 48 590 135 12,200 355 (NPSHA) for the various pumping conditions. Refer
back to the previous example problem for the definition
of terms.
(e) The bottom of the tube elevation may need to be
lowered later to satisfy the sump velocity criteria as indi-
cated in Figure B-7; however, this will not affect the Pumping Low High
pump selection. Condition Hd. Cond. Hd. Cond.
B-16
EM 1110-2-3105
30 Mar 94
For the example pump conditions the selected pump would have the
following sump dimensions:
4
- <~> k-aj
I
I
- JJ
.
FLOW
b
-------EB- ~ . - .i
4
A
i /:-1
A
TUBE
DIA.
DIM.
a 0.750
l
b 2.00
IE D sl c 0.50
--<=::;
ABOVE MAX. SUMP LEVEL
r---~~~~~~~~~~----+-------.,-
I
--- e 0.50
1
I
I l 40 Min.
I
I
I
. .:..
B-17
EM 1110-2-3105
30 Mar 94
B-18
EM 1110-2-3105
30 Mar 94
Table B-3
Low and High Head Conditions
Pump & Total Total
V2 Elbow Total Head Head Max.
Q 2g K = 0.7 Losses Low Hd/ High Hd. Head
gpm ft ft ft ft m ft m ft
B-19
EM 1110-2-3105
30 Mar 94
12~~--~~--~~--,
10~~.-~~==~~~
PUMP NO. AF-S-1
TUBE DIA. 40 IN.
RATED SPEED 705 RPM
4r-~--r-~--~~~
21--t--
o~~--~~~~~~
0 400 800 1200 1600 2000 2400
Us
12
2o
36 11 ..... 15 '\:\
~ ~
34
10' ~41 \ "' .~ ~ :~.\
\) ~ \ \\ ,~
32
30
10
9
- ,....__ 7~
\,' "\
'\~'lit~., "'r ~ -~ ~' \ \.78
-.\
,, ,., \: ~'
.3, \' ~
., \
'
78\ ;( 'f' ~1 \ \r\
28
26 8 so\ 8~ '\ ~... \ :,~ .\ ~ \
\ \ r"' Xi\
'
t:22
24
E
7 '
A."' \
-\'\ \ \ )t' ~~ \ 1~74
so"'~ ~ "\ \ tlr~ \ \ \
..
~' \ ~69
.'tr ~,
'
o20
~ 18
16
cis
;5
::z:
5
t\ :S.."" \
~a'! \ \ ~ l.l. ~ ' \ 1\
\
"
\ ~ f~ i\ \' .~ ~) \ 1\.\
'.,
.J
74..,. \ \ \.. .\ )68
14
4 1\ \ !).. .. ...~ \ \ ,'\...
\c' ~ 1\168 KW-
0
2
0
10 ' 15
-, I I
800 1000 1200 1400 1600 1800 2000 2200
FLOW, Us
B-20
EM 1110-2-3105
30 Mar 94
4000
~.,~l~ ~~ 120
'5\ ry~--ill~ ~~
~~
~ ~79
~"~\ ~~ ~l'a~ f( .4,1\l ~' ~
~~ ~ ~
~'
\ J I ~ .\~ ~, 1\' ~ ~300KW
74~-\
~' ~~ fi.~w
r... 0 :\ \~
~ts)
~' ~ 60
200KW
el 1\"1
6o\ I-I ~i '. ~1 1\~ ~l~
~,
~
50
t'
1
~
11 ""\
~'
1'o
,- 15
\
160KW
I
5
0
800 1200 1600
I
2000 2400 2800 3200 3600
FLOW, Us
B-21
EM 1110-2-3105
30 Mar 94
shown in kilowatts, which is the input power to the pump The sump layout is now complete, and the remainder of
shaft. The dashed lines running diagonally from upper the station layout can now be done. It is also best at this
left to the lower right show the motor sizes available. time to request pump selections from the pump manufac-
Any design condition below these dashed lines may use turers using the requirements and sump layout above.
the motor rating indicated for that line. The information This will confirm the pump selections and permits ade-
furnished in this manual can be used for the preliminary quate bidding competition. The following are consider-
layout of submersible type pumping stations; however, ations for station layout:
information should be requested from all manufacturers
for the design memorandum. (a) Sump velocities. The average velocity in each
pump sump in front of the pump for continuous opera-
(2) Selection procedure. Review of the pump curves tion should not be greater than 0.37 meter per second
indicates that an AF-S-1 size pump operating at a speed (1.2 feet per second). For intermittent operation (less
of 705 rpm and set at a blade angle of 20 degrees will than 200 hours per year), the average velocity may be
satisfy the head-capacity design conditions. increased to 0.49 meter per second (1.6 feet per second).
To obtain these velocities, the sump depth is varied while
(a) The next step is to check the suction requirements the sump width is kept equal to two tube diameters.
of the pump. This is done by plotting the head-capacity These maximum velocities are maintained to diminish the
curve for the blade angle chosen above on the NPSHR formation of vortices in the sump. The water levels
curve for that pump. The plotted head-capacity curve obtained by application of these velocities may not be
crosses the various NPSHR curves for that pump indicat- high enough to satisfy the pumps NPSHR. The NPSHR
ing the required suction head for different pumping takes precedent, and the resultant submergence will be
requirements. The curve shown below indicates that the greater than that necessary to prevent vortices.
preliminary AF-S-1 pump selection requires a greater
submergence than is available; therefore, another pump (b) Superstructure. A structure should be provided
must be tried or greater submergence provided. Unless to house the motor starters, switchgear, and engine gener-
the additional submergence required is less then 1 or ator, if provided, and office space for operating per-
2 feet, it is usually less expensive to provide a larger, sonnel. Unless dictated by climatic conditions or needed
slower speed pump than provide a deeper station. A cost to satisfy some other specific purpose, the structure need
comparison can be made to more accurately compare a not cover the pump locations.
deeper sump station with that station requiring a larger
area because of increased pump size. (c) Hoist. A method for removing the pumping
units should be provided. Any inspection or repair work
(b) The next choice would then be the next larger to the pumping unit is done with the unit removed from
size pump operating at its the highest available speed and the tube. Inspection which requires the removal of the
meeting all the required design conditions. This would pumping unit are required at least annually to check the
be the AF-S-2 size pumping unit operating at 590 rpm. integrity of the pump/motor seal system. A monorail
The 10-degree blade angle satisfies the design conditions hoist capable of lifting the entire pumping unit should be
and the suction requirements. provided. If the maintenance organization has a truck
crane of sufficient capacity to raise the pumping unit or
(c) Since the selected size pump of AF-S-2 has the such a crane would be readily available on an emergency
same size tube as that first selected, the static head dia- basis, then a permanent hoist would not be required.
gram and system head curves are correct.
B-4. Formed Suction Intakes
(d) The net positive suction head requirements for
the pump are determined by plotting the selected blade a. General. The formed suction intake (FSI) is used
angle head-capacity curve on the cavitation curve. on pumps to improve flow to the impeller of vertical
Where this head-capacity curve crosses the NPSHR lines pumps. The FSI can be used on almost any pumping
indicates the NPSHR values for the pump. application. It is, however, recommended when adverse
flow conditions occur upstream. Figure B-12 shows a
(3) Station layout. Using the listed discharge tube typical FSI. ETL 1110-2-327, Geometry Limitations for
diameter (Table B-2), the sump can be sized according to the Forced Suction Intake, provides additional informa-
Figure B-7. Check the pump selections using the new tion. The FSI can be used on small pumps; however, the
system requirements and refine the layout as necessary.
B-22
EM 1110-2-3105
30 Mar 94
B-23
EM 1110-2-3105
30 Mar 94
B-24
EM 1110-2-3105
30 Mar 94
(3) Unguided cable hoist trash guides. Unguided (3) Elbow arm-type trashrakes. The elbow-type unit
cable hoist trashrakes are similar to the guided types consists of a rake on the end of a two-piece arm similar
except that the rake is not restrained by guides on the to that used on a backhoe. The arm is moved by means
sides (Figure C-3). The rake moves up and down the of a hydraulic cylinder. In addition to the up and down
trashrack on wheels. Except for the guided provisions, movement of the rake, it also can be made to pivot
the unguided mechanism is very similar to the guided
C-1
C-2
30 Mar 94
EM 1110-2-3105
CABLE HOIST MECHANICAL CATENARY
I I
I I I I I
GUIDED UNGUIDED CLIMBER SLIDING ARM GUIDED FREE
I I
FnONT BACK ELBOW
CLEANING CLEANING ARM
c. Catenary trashrakes.
Table C-1
Trash Material Classification
(1) General. Two types of catenary trashrakes are
Class Description unguided (free hanging) and guided. Both types consist
of a chain on each side, supported by two sprockets that
1 Very light weight debris or no debris
hang down the front of the trashrack. Several beams
2 Light weight floating debris - small limbs or sticks, with teeth attached (rakes) have each end connected to
agricultural waste, orchard prunings, corn stalks, each chain. The continuous movement of the chain drags
hay and leaves. the beams across the rack. The beams are held into the
rack by gravity. This type of rake can be used for racks
3 Medium weight floating debris - limbs or large sticks
and small logs (up to 76.2-millimeter (3-inch) diameter) up to 12.2 meters (40 feet) wide with depths up to
12.2 meters (40 feet). The chains are motor driven uti-
4 Flowing debris - water grass, water-logged debris lizing gearing and drive shafts similar to dam tainter gate
and refuse such as tires, rugs, and mattresses machinery. Since the beams rub along the trashrack,
5 Heavy weight floating debris - large logs or trees
care must be given to the alignment of the racks so that
it provides a smooth surface without any projections for
the rake beams to catch on.
where attached to the operating platform, thus allowing it
to sweep a greater width and provide unloading capabil- (2) Unguided catenary trashrakes. The unguided
ity adjacent to the rake unit. For a station with multiple catenary trashrake consists of a free-hanging chain with
pumps, the rake unit is mounted on a traveling platform rake beams spaced approximately every 3.0 to 4.6 meters
allowing its operation in front of any pump. The rake is (10 to 15 feet) along the chain. The chains are supported
limited to a width of 3.0 meters (10 feet), and the raking by an idler sprocket at the top of the trashrack and a
depth can vary to 8.7 meters (25 feet). Manual control driven sprocket located at the same elevation as the idler
of the rake is performed by an operator from a cab sprocket and a sufficient distance from the trashrack so
located on the platform. This rake also has the advan- that the free hanging chain makes contact with the
tage of power down movement rather then depending on bottom of the rack. A typical unguided catenary trash-
gravity forces to lower the rake. A typical arrangement rake is shown on Figure C-7. The trash removal capabil-
of the elbow type trashrake is shown on Figure C-5. The ity of the unguided catenary trashrake would include
trash removal capability of the elbow-type rake would material classes 1 and 2 with some limited capability of
include material classes 1, 2, 3, 4, and 5. classes 3 and 4. Items of size greater than the depth of
the rake beams are usually not removed by the rakes.
(4) Sliding arm trashrakes. Sliding arm or telescop-
(3) Guided catenary trashrakes. The guided catenary
ing arm rakes consist of a pivoting boom assembly sup-
trashrake is the same as the unguided catenary trashrake
ported from a frame. The boom assembly supports a
except that the down leg of the chain from the driven
sliding rake arm that allows the rake to be lowered and
sprocket is guided to ensure that the chain reaches the
raised. Pivoting of the boom assembly also allows the
bottom of the rack. A typical guided catenary trashrake
rake arm to be moved away from or to the trashrack.
is shown on Figure C-8. The trash removal capability of
The frame supporting the rake can be permanently fixed
the guided trashrake would include material classes 1
at one location for raking only one trashrack or can be
and 2. As with the unguided type, this rake can on a
mounted on a rail-supported platform which would per-
limited basis handle some class 3 and 4 material depend-
mit one unit to rake multiple trashracks. The rake can
ing on its size.
empty into a cart onto the operating platform. This rake
can be obtained in widths up to 4.6 meters (15 feet) and
rake racks to 8.7 meters (25 feet) deep. The controls can C-2. Selection Criteria
permit a complete operation cycle of the rake with one
a. General. Table C-2 indicates some of the com-
activation. A typical arrangement of the sliding arm
parison factors that can be used to judge the trashrakes
trashrake is shown on Figure C-6. The trash removal
and their application. Intangible factors may also need to
capability of the sliding arm trashrake would include
be considered such as local operating agencies requests.
material classes 1, 2, 3, and 4. The ability to handle
In most cases it will be necessary to make a comparison
classes 3 and 4 depends on the rake arm being able to
for a minimum of two different type rakes and obtain
clear the trash on the downward movement of the rake
arm.
C-3
C-4
30 Mar 94
EM 1110-2-3105
HOIST
~
-.. "'""
TRASH RACK
-1 1 1 1
11
FLOW--- TRASH RACK
TRASH RAKE
I I I I I
TRA SHRAKE-
vlllll l1
I
f
I
DEAD PLATE
TRASHRACK
TRASH RAKE
I
SIDE ELEVATION FRONT ELEVATION
EM 1110-2-3105
Figure c-3. Unguided cable holst trashrake arrangement
30 Mar 94
C-5
EM 1110-2-3105
30 Mar 94
C-6
EM 1110-2-3105
30 Mar 94
C-7
C-8
30 Mar 94
EM 1110-2-3105
h
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
TRANSPORTER TRACK
TRACK
SLIDING ARM
TRASH RAKE
- TRASHRACK
\---~~--L-------~=--.J_.....:..DR~I.:_::VE CHAIN
1
~AA~ I
\~~----~ BOTTOM OF INTAKE _ . /
BOTTOM OF INTAKE _ . /
EM 1110-2-3105
30 Mar 94
C-9
C-10
30 Mar 94
EM 1110-2-3105
BRIDGE FLOOR
DRIVE MECHANISM
DRIVE MECHANISM
WATER LEVEL
DRIVE
CHAIN
DRIVE CHAIN--~
GUIDE
BOTTOM OF INTAKE
Table C-2
Selection Factors
Type Guided Unguided Mech. Mech. Mech. Catenary Catenary
of Rake Cable Cable Climber Elbow Arm Sliding Arm Guided Unguided
estimated costs from the manufacturers. The results of designed to remove this first flush quickly in order to
this study and reasons for selection should be presented prevent a buildup that may damage the trashrack.
in the design memorandum.
(c) It is usually best to plan for a greater amount of
b. Design considerations. Many items must be trash than current conditions may indicate since it is very
considered in the selection of the type of trashrake and costly to make changes to the raking system after the
whether the rake should be manually or power operated. pumping station has been constructed.
Some of these items are the type of trash expected, the
quantity of trash and how quickly it occurs, the number (2) Other considerations. The rated lifting capacity
and size of the pump bays to be raked, the hazard created of the rake should be large enough to lift the majority of
with a trashrake failure, and the first costs and operating the trash expected. In most cases, a capacity of 454 kilo-
and maintenance costs. grams (1,000 pounds) is sufficient. The speed of opera-
tion is also a consideration. Some rakes, due to their
(1) Type and quantity of trash. A physical survey of design, do not permit fast raking of the entire trashrack.
the contributory area and consultation with the local The maximum time for the rake system to be able to
interests and operators at nearby pumping stations should rake the entire pumping station trashrack should be less
be conducted to determine the type and quantity of trash than 1 hour. The hazards that may be created with a
expected. If information concerning the quantity of trash trashrake failure should be considered when deciding on
is not available, the following can be assumed. the number and type of rake to use. Where the entire
pumping station capacity is expected to be used on a
(a) Pumping stations located on open ditches will regular basis and trash may occur which would clog the
have the trash arrive at an even rate, and the trash can be trashrack limiting pump operation, multiple units or units
handled with a minimum number of raking units. with good raking capability should be used. If trash is
larger than capable of being handled by normal raking,
(b) Pumping stations located on sewers in urban such as large parts of trees, an auxiliary crane in front of
areas will have most of the trash arrive during the first the raking area should be considered.
flush of the runoff, and the raking system should be
C-11
EM 1110-2-3105
30 Mar 94
Appendix D not be higher than the elevation at which all pumps are
Closure Gates operating. For this example use:
40 = H W => H = 5 ft and W = 8 ft
The purpose of this appendix is to explain the procedure Slide gates can be used for seating and unseating operat-
used in determining the size of gate closure, the stem ing head conditions. Seating head occurs when the level
size, the operator size, and loads to be carried by the of the water is greater on the gate side of the wall. This
structure at the gate location (Figures D-1, D-2, and type of head condition results in the best seal against
D-3). leakage. Unseating head occurs when the level of the
water inside the gate is greater than the water outside the
D-2. Gate Size gate. This type of head condition results in a lesser seal
when compared with that achieved with the seating head
The size of gate required is determined using the maxi- condition.
mum pumping capacity of the station and the number of
pumps. The velocity through the gates at the maximum D-4. Gate Operator Size
capacity should be limited to 2.0 feet per second (fps) to
achieve the best flow conditions to the pump when used a. Required force. The size of the gate operator is
for sump closure. The maximum capacity of the station determined by first calculating the force needed to open
can be estimated at 33 percent above the design capacity. the gate with the maximum differential head acting on
the gate. This will normally occur when the sump is dry
Example: Station Capacity = 180 cfs and the maximum expected forebay water elevation is
No. of Pumps = 3 present.
V = Q/A (1) There are three terms used during the selection
of a motorized gate operator: run torque, pullout torque,
where and stall torque. The definition of each of these terms is
as follows:
V = Velocity through gate = 2.0 fps
(a) Pullout torque. This is the torque the operator
Q = Flow through a gate = Max. Cap./3 develops to initially break the seal caused by the wedges
Max. Cap. = 180 1.33 = 240 cfs on the sluice gate; operators are designed to develop this
therefore Q = 240/3 = 80 cfs torque for only a short period of time.
A = Gate area in ft2 (b) Run torque. This is the torque the operator
develops to move the gate after the wedge seal is broken;
2.0 = 80/A => A = 40 ft2 operators should be designed to develop this torque
continuously.
A= W H
(c) Stall torque. This is the torque that is developed
where by the operator just as the motor stalls out; this is the
maximum torque which will be exerted on the gate stem.
W = Gate opening width in feet.
(2) Example: See Figure D-1:
H = Gate opening height in feet.
Gate centerline - el 50.0
Note: The gate opening height and width are then deter-
mined using the area calculated, the sump floor elevation, Maximum expected forebay water elev. - el 54.0
sump width, and the minimum pumping elevation. The
top of the gate opening should not be higher than the Gate height - 5.0 ft. Gate width - 8.0 ft.
minimum pumping elevation. If this is not possible at a
particular site, then the top of the gate opening should Operating floor elevation - el. 65.0
D-1
EM 1110-2-3105
30 Mar 94
El. 65.0
~
.. A
. ' .A
. ~ . .. . ~
I> l>
.. I I> I
~.
STEM GUID
~L.....-.,1 A
EL. 60 . .._5- ""
..
EXTERIOR INTERIOR
A
EL.54.0
EL. 50. 0
~--- ------------ H
EL. 4 7. 5
D-2
EM 1110-2-3105
30 Mar 94
fu = Friction factor for unseating (bronze seals) (2) The electric data for this operator are then
obtained from either the catalog or directly from the
WG = Weight of the movable disk, lb manufacturers. These data are used for preparing the
(standard sluice gate catalog information) electrical design of the station.
WS = Weight of stem, lb. Assume a 3-inch diameter D-5. Maximum Loads on Stem
stem that extends from the top of the disc to
4 feet above the operating platform elevation a. Calculation of maximum loads. The maximum
(standard sluice gate catalog information) loads which can be transferred to the stem and the struc-
ture are calculated. The design shall be such that the
For this example: stem would fail before any supporting structural failure
would occur. The maximum loads are based on 125 per-
S = el 54.0 - el 50.0 = 4 ft cent of the stall torque (taken from published catalog
information) of the operator selected.
A = 5 8 = 40 ft2
(1) For this example, the stall torque of the selected
fu = 0.6 operator is 481 ft-lb (this figure should always be veri-
fied by the gate operator manufacturer).
WG = 4900 lb
Max. Thrust = (Stall Torque 1.25)/Stem Factor
WS => Stem length - (el 65.0 + 4.0) -
(el 50.0 + 5.0/2) = 16.5 ft = (481 1.25)/0.0204 = 29,473 lbf
Weight = 16.5 ft 24.03 lb/ft = 396.5 lb (2) The maximum thrust is an upward thrust of
30 kips and a downward thrust of 35 kips (this includes
Therefore, the dead weight of the gate itself).
Fu = 62.4 4.0 40.0 0.6 + 4,900 + 396.5 (3) The required spacing of the stem guides is then
= 11,287 lbf determined. The Euler Column Formula is used:
(b) Preliminary hoist and stem size. This force or FCR = C 2EA/(L/r)2 (D-2)
thrust to unseat the gate is then compared with manufac-
turers of motorized gate operators catalog information to where
determine a preliminary hoist and stem size.
FCR = Maximum thrust, lbf
b. Required torque. The required torque (ft-lb) is
determined by multiplying the calculated thrust with the C = End condition factor
stem factor (provided by manufacturer). For this exam-
ple the stem factor is 0.0204 with 3 threads per inch. E = Modulus of elasticity, psi
The resultant torque = 11,287 0.0204 = 230.3 ft-lb A = Cross-sectional area of the stem, in2
D-3
EM 1110-2-3105
30 Mar 94
L = Maximum unsupported length of stem, in. the previously calculated 100-in. maximum length is
applied). The other stem guide would be located at the
r = Radius of gyration, in. bottom of the gate operator base. This location would
result in a length between guides of 54 inches, which is
(4) The L/r ratio shall not exceed 200. less than the minimum for threaded stem (82 in.).
(5) For this example: b. Position limit switches. All motorized gate opera-
tors shall be equipped with position limit switches in the
C = 2 (for all slide gate computations) open and closed positions. In addition, mechanical
torque limit switches should be provided. These would
E = 28,000,000 psi (for stainless steel) provide backup in case the position limit switches fail or
if debris jams the gate while opening or closing.
A = for threaded portion = 2.14 in2
for plain portion = 3.14 in2 c. Roller gates. The same computations are done
for roller gates to size the operators and structural design
r = for threaded portion = 0.41 in. loads. The force required to open this type of gate is the
for plain portion = 0.50 in. sum of gate weight, stem weight, seal friction, and roller
friction. The seal friction is a result of the deflection of
(6) Using these numbers, the maximum unsupported the rubber J-seal attached to the top and sides of the gate.
lengths of the stems can be calculated: The roller friction is a result of the bearing friction in the
roller and the roller-to-rail friction. The amount of seal
L = r [(C E A)/FCR]1/2 (D-3) and roller friction will vary depending on the types of
materials used for the roller wheels, roller bearings, rails
Maximum length of threaded stem (LMT) = 82.2 in. and seal plates.
Maximum length of plain stem (LMS) = 121.5 in. (1) If the roller gate is extra wide or if the ratio of
the width to the height is equal to or greater than 2:1, the
(7) However, at an L/r ratio of 200 gates are normally raised and lowered through the use of
two stems placed near each side of the gate. Each stem
LMT = 200 0.41 = 82 in. passes through a geared operator. The geared operators
are both connected to an electric or hydraulic operator
LMS = 200 0.50 = 100 in. located between the two stems. The loads incurred by
raising the gate are equally distributed between the two
(8) Since both the L/r ratio < 200 and the Eulers stems.
Column Formula criteria have to be met, the criterion
resulting in the shortest lengths is used. For this exam- (2) During the early design phases of a pump sta-
ple, the L/r ratio < 200 criterion has resulted in the short- tion, a roller gate manufacturer should be consulted to
est lengths. Two stem guides are located to meet these assist in determining the design loads, forces, and lifting
calculated lengths. Figure D-1 shows that one stem arrangement.
guide was placed at el 60.5 or 96 inches (8.0 feet) above
the top of the gate (this length of stem is solid; therefore
D-4
EM 1110-2-3105
30 Mar 94
~~--------: 4E
I
TO TOP
OF DISC
IN "OPEN II
POSITION
D - I -
i
I c
llo I
I
'dJ'
I
I
I
I
I
I oil
I
I
I F
.
I
- -----------1---------- -- ,_..
I
.
I
I
I
lllo I
I
I I oil B
I
I
I
D-5
EM 1110-2-3105
30 Mar 94
36 18 88 40 46 14 20 33 6 8-1/2
36 24 88 30 46 17 26 42 6-1/4 8-1/2
36 30 60 36 46 20 32 51 6-1/2 9-1/2
36 36 60 30 46 23 38 60 6-1/4 9-1/2
36 42 76 43 47-1/2 26 44 69 6-1/4 9-1/2
36 48 65 30 47-1/2 29 50 78 6-1/2 10
42 24 90 21 53-1/2 17 26 42 6 8-1/2
42 30 88 25 53-1/2 20 32 51 6-1/4 9-1/4
42 36 88 24 53-1/2 23 38 60 6-1/4 9-1/2
42 42 87 23 53-1/2 26 44 69 6-1/4 9-1/2
42 48 80 23 53-1/2 29 50 78 6-1/4 10
D-6
EM 1110-2-3105
30 Mar 94
D-7
EM 1110-2-3105
Change 1
31 Aug 94
E-l
EM 1110-2-3105
l
3O Mar 94
the discharge flap gates. For purposes of head determi- rack should be in accordance with EM 1110-2-3104. In
nation, it is assumed that the greatest water level unusual cases where the design of the rack is such that
occurring in the discharge chamber will be effective for for a clean rack the losses would be greater than
all the pump discharges. 6 inches, the calculated loss plus a 6-inch margin should
be used for the head loss.
c. Trashrack losses. Head loss through the trash-
racks should be less then 6 inches for a properly d. Gate opening losses. The head loss through gate
designed rack that is raked regularly. A head loss value openings is assumed to be equal to the velocity head that
of 6 inches will be used when determining the trashrack occurs for the gate opening. If multiple gate openings
portion of the total external losses. It is possible to occur in the water path to the pumps, then a loss would
exceed this value when the rack becomes partially occur at each gate opening and be additive.
clogged with debris; therefore the structure design of the
E-2
EM 1110-2-3105
30 Mar 94
E-3
EM 1110-2-3105
30 Mar 94
II
PLAN VIEW - DISCHARGE CHAMBER
WATeR PROFILE WICONSTRICI'ION
ATER PROFILE W/0 CRITICAL~
AND CRITICAL DEPTH CONDITION
SEWER
E-4
EM 1110-2-3105
30 Mar 94
Given Conditions:
E-5
EM 1110-2-3105
30 Mar 94
STEP 7. Water elevation in drop shaft with low river elevation and
flow rate of 177 cfs is 417.0.
418.8
STEP 9. This elevation (418.8) is greater than the water level in the
drop shaft (417.0), therefore it is used to determine head loss if it
is higher than the centerline of the flap gate.
STEP 10. When the elevation of water in the drop shaft is greater
then the water elevation as result of a critical depth condition at
the constriction, the water level in the discharge chamber is only
dependent on the drop shaft water elevation and the resultant velocity
head.
The discharge chaml1er water elevation would equal the drop shaft water
elevation + the velocity head.
E-6
EM 1110-2-3105
30 Mar 94
Velocity at constriction, Vc
= 1.15 ft/sec
Velocity Head = {Vc) 2 /2g
E-7
EM 1110-2-3105
30 Mar 94
Appendix F
Sample Operation and Maintenance
Manual
F-1. General
F-1
EM 1110-2-3105
30 Mar 94
Table of Contents
Section 1 - Pumps
2.01 General
2.02 Operation
2.04 Maintenance
2.05 Lubrication
3.01 General
F-2
EM 1110-2-3105
30 Mar 94
3.07 Operation
3.08 Maintenance
Section 4 - Gates
4.02 Operation
4.03 Maintenance
5.06 Maintenance
Section 6 - Cranes
F-3
EM 1110-2-3105
30 Mar 94
7.04 Ventilators
Section 8 - Switchgear
8.02 Maintenance
9.01 General
9.04 Grounding
9.13 Maintenance
F-4
EM 1110-2-3105
30 Mar 94
10.01 General
11.01 General
APPENDICES
Maintenance Responsibilities
F-5
EM 1110-2-3105
30 Mar 94
Annual Report
Maintenance Chart
Operation
Operating Instructions
Staff Gages
Motor Data
Arrangement Drawings
F-6
EM 1110-2-3105
30 Mar 94
Storm Water
Pump Unit No. No.1 No.2 No.3 Remarks
Time of Reading
Air Receiver
Pressure
Discharge Staff
Gage Reading
Motor Readings
Volta_g_e
Amps
Elapsed Hours
F-7
EM 1110-2-3105
30 Mar 94
ELECTRICAL:
1. Motors
2. Motor Bearings
3. Switchgear Controls
4. Control Panels
GENERAL:
1. Water Levels Elevation Remarks
Forebay
Sumps
F-8
EM 1110-2-3105
30 Mar 94
1. Sump
2. Forebay
3. Discharge Chamber
4. Gatewell to River Outlet
5. Structure
6. Fire Extinguishers
7. Tools and Cabinets
8. Painting
9. Caulking
10. Grating, Rails and Ladders
11. Water System and Plumbing
12. Louvers and Ventilators
13. Windows
14. Doors
Remarks:
STORM WATER
PUMPS SUMP
Mechanical Vibration REMARKS
PUMF
Levels: No.1 No.2 No.3
Upr
North-South
Lwr
Upr
East-West
Lwr
Axial:
Motor
Floor
Coast Down Time
Electrical Insulation ROLLER
REMARKS
Resistance Readings: GATES
T1
T2
T3
Temp. in Degrees C
SIGNATURE:
F-9
F-10
30 Mar 94
EM 1110-2-3105
BLUE WATERS DITCH PUMPING STATION MAINTENANCE CHART BLUE WATERS DITCH PUMPING STATION MAINTENANCE CHART (CONTINUED)
STARTUP MONTHLY 3MO 6MO 1 VR SYR OPRHRS STARTUP MONTHLY 3MO 6-MO 18-MO 1YR OPRHRS
FARVAL SYSTEM Gl COMPRESSED AIR GI,O
RESERVOIR GI,AL COMPRESSOR CRANKCASE Gl CH(S)
PUMP OIL A0(2) CH(2) COMPRESSOR INTAKE FILTER CL
CLEAN SCREEN CL BELT TENSION Gl
AIRLINE FILTERJORVER CL
MOTOR 0 Gl MOTOR BEARINGS PG
HEATERS Gl Gl RECEIVERS RC Gl
THRUST BEARING Gl TO CH(3)
GUIDE BEARING PG(-4}(1) PG-3000 BRIDGE CRANE 0 Gl(6)
INSULATION MR PILLOW BLOCKS, WHEELS PG
INTERIOR & VENTS CL AND WHEEL BEARINGS Gl
STEM Gl Cl,SG
THRUST NUT Gl Cl,SG
MANUAL OPERATORS PG
MOTOR OPERATORS GI,CL
NOTE: FOR LEGEND AND NOTES SEE SHEET Al2 Blua Walera llltc:h Pumping SUlton
AW-ndiXA
STARTUP MONTHLY 3MO 8MO 1VR SVR OPRHRS ~
1. TIME PERIOD OR HOURS, WHICHEVER COMES FIRST
2. S TO 10%. ACIDLESS TALLOW WITH VISCOSITY OF
TRASH RAKE GI,O,CL Gl(8) 150 SSU @210 F
MOTORS AL(8) PG(9) CL 3. TURBINE OIL ISO VGea (APPRO X. 30 GAL.)
4. SCRAPE OUT OLD GREASE AND ADD 19.5 OZ.
HEATERS Gl LITHIUM BASE GREASE (NLGI '2)
GEAR REDUCER Gl CH(10) 5. 150 SSU NON-DETERGENT NAPHTHENICBASE OIL
WITH RUST AND OXIDATION INHIBITORS
DRIVE CHAIN PG8 PG8 6. ANSI 830.18
7. SEE HOIST O&M MANUAL FOR LU8RCATION TYPE
PILLOW BLOCKS PG(9)
8. SAE 10
TORQUE LIMIT COUPLING PG (9) 9. NLGIII2
10. AMGAN4
SHEAR PIN & SPROCKET Gl
TRIP CAM Gl
CONTROL PANEL GI.CL
SUBSTATION DRAINAGE Gl
BUILDING STRUCTURE Gl
TRASHRACK Gl LEGEND:
TOILET FACILITY Gl 0 - - .- OPERATE
CH --CHANGE
DOMESTIC WATER Gl CL --CLEAN
HOLDING TANK Gl PO MR - MEGGER AND RECORD
PG - - PRESSURE GREASE
SIPHON BREAKERS Gl SG - - SURFACE GREASE
RC - - REMOVE CONDENSATE
UNIT HEATERS Gl
Gl - - GENERAL INSPECTION
FIRE EXTINGUISHERS Gl Gl GRT - - GROUND RESISTANCE TEST
TO - - TEST OIL
AL --ADD LUBRICANT
SWITCHGEAR Gl PO - - PUMP OUT
TS - - TEST (SEE A13 FOR PROCEDURE)
BUS AND CONNECTIONS GI,CL RS - - REMOVE SILT
INSTRUMENTS AND LAMPS Gl GI,CL
HEATERS Gl
LIGHTING PANEL Gl Gl
CONTROL PANELS Gl Gl
GROUNDING GRT
FLOAT CONTROL Gl Gl
MAIN PUMP MOTOR STARTS TS
EM 1110-2-3105
30 Mar 94
F-11
F-12
30 Mar 94
EM 1110-2-3105
BLUE WATERS DITCH PUMPING STATION
GENERAL
The Pump Station shall be made ready for operation by performing the
preliminary and trial operations described by a competent operator when
there is a rising sump and an interior water level of 396.0 The pump
station shall be put into flood stage operation at a water elevation of
398.0 on the interior water level gage.
15.5 (400.5)
MANUAL START
OF 3rd PUMP NOTES:
-
BLI.E VATERS DITCH Pf.M'IND ST"liCIN
INIERIM SJiiA!\TIIG INSIRlJCT!(Jrl
THE Pl.M' STATION SHALL BE MACE READY FOR OPERATION BY PERFORMING THE PRELIMINARY
AND TRIAL OPERATIONS Sf.CIIIN BELOW VITH A COMPETENT OPERATe:!: 'WHEN 11 INTERIOR WATER
LEVEL REACHES 3'16.11!1 FEET OR 11.1 FEET ON THE FLOAT DUlL,
151
161
PRESS THE 'RESET' PUSH-BUTTON.
PLACE SELECTOR SWITCH TO 'FIItl" POSITION.
PRESS THE 'FOJn!ARD START"
REIlVE DEBRIS,
PRESS Tl-IE 'STOP"
PIJSHBUTTON.
PUSH-BUTTOl.
NOTE ABOVE PflOCEOURE SHAU. BE REPEATEO FOR ALL THREE TRASH RACKS,
1. OPENING STATJON 41, OPEN ALL OF TI-E SUMP ROLLR GATES.
A, TURN ON LIGHT INSIDE THE STAlJON, A, SET DISCCI>INECT SWITCH TO "ON' POSITION,
B. TURN HAJN CIRCUJT BREAKER CONlROL TO 'CLOSE' POSITION, IRED 'BREAKER B. USE ELECTRIC OPERATCJ:t TO FUUY OPEN THE GATE BY PRESSING THE 'OPEN'
CLOSED' INDICATING LIGHT ON) BUTTON !GREEN INDICATOR LIGHTS ON AT FULL OPEN PCSITIOHI
C. MAKE CHECK OF THE PHASETO PHASE USINCi THE 'VOLT~TER' SWITCH TO C, IF GillE DOES NOT OPEN ENGAOE MANUAL LEVER AN) CPERATE HANDWHEEL IN
SELECT PAIRS OF PHASE, THE 'OPEN' DIRECTION.
NOTE THE VOL.TAGE HI.JST BE BETWEEN 371111!1 ANO 4590 VOLTS FOR EACH PHASE WITH NOT NOTE ABOVE PROCEDURE SHALL BE REPEATED FOR AU THREE ROLLER GATES.
GREATER THAN 21110V DIFFERENCE PHASE TO PHASE, IF THE 5, PUMP LUBRICATION
VOLTAGE IS OUTSIDE THIS RANGE. THE UNION ELEClRIC COMPANY MUST BE HOTJF"IED A, CHECK THAT THE LEVL OF GREASE IN THE FARVAL LU3RICATOR RESERVOIR IS AOEOUAT
IMMEDIATELY, NO PUMP !PERATJON WILL SE ALLOWED WITH THE VOLTAGE OUTSIDE THIS RANGE 8, TUfiN LUBRICATOR CONTROL SWITCH (LOCATED ON THE OUTSJ[E OF THE
D. TURN ON ALL POWER P.etL BOMD CJRC\JJTS, I NO. l-17 ON SW[TCH GEARJ FARYAL CCIIITFl.. ENCLOSIHI TO 'MANUAL' POSITION AND PRESS THE 'MANlJAI...' PUSHBUTTON
E. REHDYE Tl THREE INTAkE UJUVER COVERS. TWO TIMES, FOR PRE-GREASING CYCLE,
F. START THE l'WQ POWER ROOF VENliLATORS BY TURNJNG Tl- SWITCHES TO THE C. TlfflN FARVAL LlBRlCATOR CONTROL SWITCH TO THE 'AUTO' POSITION.
'HAND' POSITION, 6. ELECTRIC IIJTOR LUBRICATION
Q, CHECK THAT THE THREE MOTOR OPERATED INTAt:E LOUVERS ARE OPEN. A. CHECK THAT TI-E LUBRJCAT[NG OIL IN THE UPPER CHAMBER IS AT THE PROPe;R
2, AIR SYSTEM LEVEL. BY CHECKING THE SIGHT GLASS TO SEE THAT THE Oll LEVEL IS BETWEEN THE MINI..._,H
C1 I SET DISCONNECT SWITCH TO 'ON" POSITION. 8. CHECK THAT LUBRICANT IS PRESENT IN THE LOWER HOTOR BEARING BY OPENING THE
12 I PRESS 'RESET' PUSHBUTTON. 'GREASE WTLET' PLATE ON 11 SIDE OF Tl HOTCA.
131 TURN SEl.ECTM SIIITCH TO 'AUTO', IRED INDICATING LIGHT ON. I 7. ROTATE PlJtPS HAtf.JAI..LY CINE FULl. REVOL.UTICIII TO ASSl.RE FREE ROTATION.
9, CHECk THAT n .AIR COMPRESSOR STARTS IF THE AIR RECEIVER PRESSURE 8. CHECK FLOAT SWITCH SETTINGS ACCORDING TO OPERATI~ SEQUENCE DIAGRAM.
IS LESS THAN 1211 PSI AN:! THAT IT STOPS WHEN THE AAES$URE READ-ES 151 PSI, q, SIPJ.O.I BREAKER VAULT ILOCATED AT TDF" OF LEvl!:El,
C, OPEN AND CLOSE THE ORAJN VALVES ON THE BOTTOM OF THE AIR RECEIVER, A, CHECK THAT WIRE CLOTH PIPE COVER IS UNBROI<EN.
STRAIPER, A,t.ll FILTER: TO DRAIN ANY CONDENSATION. 8. CHECK THAT AIR-OPERATED BUTTEAR.Y VALVE IS IN 'OPEN" POSITION,
3, CCJ,IOJTION OF DITCH APPROACH AND TRASHRAC!<, C. CHECK THAT EACH OF THE TtftE MANUAL ACTUATED BUTTERFLY VALVES IS IN
A, CHECK FOR ICE OR 0TlR DEBRIS, THE 'CLOSED" POSITJ(Jol.
B. LU~ICATE T~ THE LINKS OF TRASH RAKE DRIVE CHAIN USINO TI-E AIR OPERATED
PORTABLE GREASE PUP.P,
C, REMOVE TRASH FROM THE TRASH RACk. THE PUMP STATION SHALL BE MADE READY FOR OPERATION BY PERFORHINJ THE PRELIMINARY
I 1l SET DISCOt-N!CT SWITCH TO 'ON' POSJTION,
F-13
EM 1110-2-3105
30 Mar 94
TRJf'IL. OPERATION
l. PU1P START CVATER LEVEL IN SUMP MUST 8 ELEV. )qS,IIJ ~ Hl0tR ll.fl ON THE FLOAT DIAl.l
A, L..lGHTINO PAtEL.
131 AFTER WAITINO FIVE HINUTES PLACE THE "SJPHI:> MODE' SWITCH IN THE
~ll TURN 'OfF' YASKAIIA MOTCIR WINDING HEATERS Cl7o lCio 21l
'OFF' POSITION,
CIRCUn BREAKERS BEFORE STARTING HOT~S.
141 TL.RN TI-lE START SELECTOR S'IIITCH TO Tt "ON' POSITION.
B. ELECTRIC 1\QTOOS
C5l OfPRESS AND HJLD DOWN TJ-E: 'TEST" PUSHBUTTON ANl TI-EN PRESS Tl
C1 ~ TO TEST ~~ STARTER IUTHCliT ENEROIZING HOTORSt
"START' PUSHBUTTON C'RI.tl' LIGHT ONI,
AI BE SI.R T~T THE Pl.f!P HOT~ CONTACTOR BEING TESTED IS
C6l AF1ER: IGTDA HAS CPEAATED F"OR APPROXIMATELY IIJ SECONJS RELEASE THE
DAA'IIN OUT B'Y' OiECKING THAT THE HOTOR LOAD BREAK SIIITCH llPERATING
THE "TEST" PUSHIlJTTON I'OFF' LIOHT Oil. IF THE Ft.OAT DtAL IS BELDV Tl CUTOFF
HAHI)LE IS IN THE FULLY 1XNN POSITION. T~ THE "TEST NORMAL'
ELEVATION F(fl THE PUHP THE li\IIt WILL SHUTOOIIN. IF" n UNIT DOES NOT STCP TtN
TWQPOSJTIQN SELECTOR SWITCH TO THE 'TEST' POSITlON. THE GREEN [EPRESS Tl 'STOP" PUSH6UTTON,
'a:'F' PILOT LlOHT WILL. ILLU1INATEo HOI CATINO THAT CQHTROL POWER OJ T~N FMYAL LUBRICATOO SWlTDI TO "CFF" POSITION.
IS ON. NJTE REPEAT ABO\IE PROCEDUFE FOR PI..JWS !C) 2 AND 3.
HEARD TO BANG SHUTo SIMULTANEOUSLY ILLliUNATJttJ Tl RED "RUN' 3. REPEAT 'TRIAL OPERATION NO lB.
Pl.M"IND OPERATION.
PILOT LIGHT AftiJ EXTINGUISHING .THE GREEN 'IFF' PIL.OT LIGHT.
A, OPEN SIPHOH BREAKER AIR SIPPLY VALVE LOCATEJ;I IN 11 SOUTHWEST CCRNER
01 IF THIS DCES l'fOT HAPPEN CALL A CERTIFIED EL.CTRICIAN TO OF BUILDING.
CHECK Tt SW ITCHOEM. B. PL.IICE THE FMVAL L.UiiiRICATOR CONTROL S\IJT05 IN Tl 'AUTO' POSITION.
C. FCI..l.O'II T) CPERATII'O SEOUE1CE DIAGRAM.
El IF TtE TEST IS SUCCESSFULo DEPRESS THE RED "STOP"
0. MANJAU.Y START PUMPS AT SPECIFIED LEVELS.
PUSHBUTlUI. THE CONTACTOR SHOULD 8Nil CPEN. SJMJLTANEOUSl.Y TJ-E: CII START PUfoP FIJL.LOWING THE SAME PROCEOI..I USED IN VET TEST EXCEPT
QREN "o:F'' PilOT LIGHT SHOULD IL.L.I.Jtt.NAle AMJ THE RED 'Fillol" PILOT PLACE THE "SIPHJN HalE' SELECTOR SWITCH IN THE 'AUTO' POSITION AIIJ PflfSS Tt
liGHT SHOU.D EXTlrGJISH "STMT' PUSHBUTJOol ONLY CRED "FIUN' JtlliCATINO LIOHT CIU TO STAAT EACH PIJIFIMG
lllliT.
Fl RETtft<( floE 'TEST NJAHAL.' nroPOSITION SELECTOR SlfiTCH
NOTE A. TIHER IN n SVITCHQEM Vll.L PREVENT 1HS RESTART OF ANY UN.JT l.loiTIL 5
TO THE 'NORHAL.' POSITION.
MINJTES AFTER StiJTIXl'IIN CTO PREVENT RESTART CF HOTtfil IIJTH THE PIJtll 8ACIC SPINoiiNOI.
C2l RAISE MOTOR: LOAD MEAl< SWITCH TO 'ON' PQSITJQH Fm P1W fll. I E. DUliNG PlH'ING OPERATIONS AT 1!5 Mlt<MIE MAXJK.It INTERWIL.S OBSERVE
~D ltfiEAD THE CAPTIVE lHUHB SCAEV INTO PLACE USINCI FINGER PAESSUAE ON.Y TO THe RL.tWHil tXNUTIO.. 0: Tt EOUIPMENT.
TIGHTEN. I GREEN 'OFF INDICA.TINO L.IGHT 01\11 NOTE THE. C I) 00< THE VOLTMETER ON THE SVlTCtKiEAR AND TIE AMMETERS ON THE
tai!TRCl.. PAIIELS OF EPCH MOTOI SlART!FI.
C2l IF nE CU'IAENT EXCEEDS 1!5S AMPS THE MOTOR SHALL BE STOPPED
WARNING DO NOT OPERATE PUMPS WHEN WATER LEVEL
IN SUMP IS BETWEEN ELEV, 3q6,0 AND ONE FOOT Nil THE CAUSE 0: ll EXCESS I YE CURRENT COMECTED.
BELOW THE PUMP SUCTION. (3) RECOFID llF'RATtHO MTA AT 38 MINUTE INTEIWAL.S.
CCEJIITINI.ED Cf4 84 I
F-15
EM 1110-2-3105
30 Mar 94
CRed lndieaUna light on through sreeee oyolef. 6. Turn orr power roof ventilaton end check that all motor operated dampera
?. Keep 101; of AU OperaLiona. 8. Jnaure t.hat allatrtp heater oirculta In the UshUng panel are turned on.
e. Record at.art end :lll1.op Umea. Leave the thrH lubricator oircui\lt oo.
b. Record all ebaorm.al noil!le, vlbrii.L1on and o'l'erheaUna. 7. Dewater Sump..
8. Aa noa.t. control automeUeally abuts clown pumplnc unita, check that aipbon a. Ctoue e.H the eump roller ge.tae.
breaker .,.ahe baa opened. If It does not. open, the operator muat open it. by llJ Pra11 the "CLOSJ:" puab~butt.on and wait until ge.'-e 11 complet..ely
manually operaUns the vah.. In the compresaecl alr control panel ae ahown In cloaad.
appendiz .:.f t.ba 01<11 manual or muet. manually operate tbe laver actuated butterfly (21 Se'- disoonn~ct awltch to tbe "OI"F" position. Padlock the awltchea.
valve located in siphon llreaker vanlt muat be opened. b, Turn 011. the sump pump and wait until the tlaat switch In Lhe d.ewaterlns
NO'J'E: Ear proLect.ion muat be uaed when openins this valve. man hole abl:lt.a orr Lbe pump. Clean tbe aump aa required.
8. Set tbe dlseoD.nact switcbal on each trash rake Lo the "01'1'" poaltloo.
CLOSING DOWN STATION Padlock tbe wlLohes.
1. Looeen tbe oapUve thumb rrorew and lower motor loa4 breaker nritoh to the 9. Turn Ye.in Circuit breaker to "TRIP"' poaltlon. CGreen "'BREAKER OPEN" li&ht on I
"OFF" politlon. Padlock the awltchee. 10. Turn off all power panel board. circuits exoept. u;.
a. Lqbricatlon. 11. Transfer to Z40Y 3 Phue auxiliary power clrculL from Unioo Electric.
a. Fill Parve.t lubricator"' reservoir wnh greue. 12. Turn orr alllilhh.
b. Turn beater ewttoh on l'arval lubrieator control panel to 50wat\. poa!Uon. 13. Clcae station and lock doors.
c. Check that tbe lubrlcaUn& oil in the electrle motora Ia at the REFER TO SHEET Bl FOR OPBRATJNG SEQUUCB DIAGRAM.
:prc.per level by checking the el&ht class to aae Lhe.t the oil level Ia between NOTE: ln cue ol a loa In tb 840 volt urvice the followinl procedure
the minimum and th111 maximum. 'Will allow continued operation. of the station.
a. Depl'fiU the "CLOSE" puah~button on the "Transformer FlliDBR... fRed
e. For cold weather;
CU Turn off water Indicating 111bt. onJ.
b. Transfer ll'Wit4h muat be moved from the down position to the up
~2~ Drain all pipea by openlna drain valves in the sump
poaiUon
13J Add anUAtree:e to elnk trap, LotllfiLtrep end toilet fluah tank and bowl.
d. Cheok that lubricant 1111 preeent in the lower mot.ar beartna by opentna
tb "GRRASB DUTLST.. plate on the aide of the motor.
3. Cheek Suppu .. and Clean Station.
a. Inspect end clean all equipment.
b. Restore tools to tool ebeata.
e, lhplenlab euppllaa Coil, lh!UIIfl, ie...)
cl. Rf:move all fire hazara (oily raga, le...J
F-17
EM 1110-2-3105
30 Mar 94
Appendix G
Electrical Data Request
PROJECT: _______________________________________________________
LOCATION: _______________________________________________________
ATTN: _______________________________________________________
TITLE: _______________________________________________________
PHONE: _______________________________________________________
or
G-1
EM 1110-2-3105
30 Mar 94
G-2
EM 1110-2-3105
30 Mar 94
lNOENTlFY
POWER CO.
PERFORM
LOAOCALCS.
WRITE LETTER
TO POWER CO.
OBTAIN FINAL
FOLLOW UP
APPROVAL LTR.
NO DESIGN
CHANGE
APPROVED
.---
PREPARE MTG. LETTER FROM
~ FINAL DESIGN
MINUTES POWER CO. ~
~
MEET UPDATE PREL. _..,. SEND LETTER
FOLLOW UP
WITH OWNER SERVICE SYSTEM TO POWER CO.
G-3
EM 1110-2-3105
30 Mar 94
H-1
EM 1110-2-3105
Change 1
31 Aug 94
I-1
EM 1110-2-3105
Change 1
31 Aug 94
*
BREAST WALL -
ELEVATION
T.C. = TRUNCATED CONE
S = MINIMUM SUBMERGENCE
R0.08d
SECTION A-A
l-2
EM 1110-2-3105
Change 1
31 Aug 94
BREAST WALL
ELEVATION
RO.O8d
l-3
I
EM 1110-2-3105
Change 1
31 Aug 94
*
ISOMETRIC VIEW
FRONT VIEW
REAR VIEW
*
Figure l-3. Typical FSI
l-4
EM 1110-2-3105
30 Mar 94
H-2