11 Pump Stations Final Redacted
11 Pump Stations Final Redacted
11 Pump Stations Final Redacted
SPU Design Standards and Guidelines Chapter Owner: Jesse Nofziger November 2020 11-i
Chapter 11 Pump Stations
Appendices
Appendix 11A - Example Pump Station CSI Specifications
Appendix 11B - Pump Station Design Calculator (Constant Speed)
Appendix 11C - Pump Station Design Calculator (Variable Speed)
Appendix 11D - Example Calculations - Wet Well Sizing
Appendix 11E - Equipment Data Sheet Template
Appendix 11F - Operational Checklists
Appendix 11G - Equipment Testing Checklist
Appendix 11H - Operational Acceptance Checklist
Appendix 11I - Systems Acceptance Testing
Appendix 11J - Example Bypass Vault Layout
List of Figures
Figure 11-1 SPU Water Pump Station Map ............................................................................................................ 11-9
Figure 11-2 SPU Wastewater and CSO Pump Station Map ............................................................................. 11-12
Figure 11-3 Basis of Design Plan Sheet Data for Pump Stations...................................................................... 11-20
Figure 11-4 Planning a Pump Station Retrofit ...................................................................................................... 11-24
Figure 11-5 Example Process Flow Schematic: South Park Pump Station and Water Quality Facilities . 11-33
Figure 11-6 Typical Pump Station Identification Signage ................................................................................... 11-35
Figure 11-7 Typical Water Pump Station Layout ................................................................................................ 11-66
Figure 11-8 Typical Dry Well/Wet Well and Wet Well Layout ..................................................................... 11-68
Figure 11-9 Typical Submersible (Wet Well) Layout ......................................................................................... 11-70
Figure 11-10 Typical Inlet and Outlet Configuration ......................................................................................... 11-71
Figure 11-11 Pump Suction Elbow Leading to Pump Body ............................................................................... 11-73
Figure 11-12 Common Pump and Piping System Terms .................................................................................. 11-79
Figure 11-13 Typical HGL and EGL ....................................................................................................................... 11-80
Figure 11-14 Pump Station Schematic ................................................................................................................... 11-82
Figure 11-15 System Curve ..................................................................................................................................... 11-84
Figure 11-16 Net Positive Suction Head............................................................................................................... 11-85
Figure 11-17 Typical Modified Pump Curve ......................................................................................................... 11-86
Figure 11-18 Typical Pump Characteristic Curve ............................................................................................... 11-88
Figure 11-19 Pump Curves for Parallel Pumps and Series Pumps ................................................................... 11-89
Figure 11-20 Typical Modified Pump and System Curve (Parallel Pumping) ................................................. 11-89
Figure 11-21 Typical Modified Pump and System Curve (Series Pumping) ................................................... 11-90
Figure 11-22 Variable Speed Pump Curves .......................................................................................................... 11-92
Figure 11-23 Pump Base Support ........................................................................................................................... 11-97
Figure 11-24 Self-Cleaning Wet Well Configuration ......................................................................................... 11-99
Figure 11-25 Usable Wet Well Storage Volume .............................................................................................. 11-101
List of Tables
Table 11-1 Typical Design Life for SPU Pump Station Elements ....................................................................... 11-5
Table 11-2 SPU Water Pump Stations .................................................................................................................. 11-10
Table 11-3 SPU Wastewater and CSO Pump Stations...................................................................................... 11-13
Table 11-4 SPU Drainage Pump Stations .............................................................................................................. 11-15
Table 11-5 Industry Standards and International and National Codes for Pump Stations......................... 11-17
Table 11-6 City and State Standards and Codes for Pump Stations ............................................................... 11-19
Table 11-7 Design Criteria List for Pump Stations ............................................................................................. 11-21
Table 11-8 Typical Content of a Preliminary Engineering Report for Pump Station Design ..................... 11-25
Table 11-9 Typical Pump Station Design Calculations ....................................................................................... 11-26
Table 11-10 Checklist for Pump Station Design Documents Draft (D) and Final (F) ................................. 11-27
Table 11-11 Equipment Access Recommendations............................................................................................ 11-34
Table 11-12 Air Change Standards – Wastewater Pump Stations.................................................................. 11-39
Table 11-13 Recommended Duct Sizing ............................................................................................................... 11-42
Table 11-14 Pump Station Recommended Paint Coloring Scheme ................................................................ 11-42
Table 11-15 Noise Requirements .......................................................................................................................... 11-45
11-ii SPU Design Standards and Guidelines Chapter Owner: Jesse Nofziger November 2020
Table 11-16 Typical Utilities Required for Pump Station Operation.............................................................. 11-45
Table 11-17 Typical Structural Codes ................................................................................................................... 11-47
Table 11-18 Typical Lateral Loading Parameters ................................................................................................ 11-48
Table 11-19 Harmonic Mitigation Methods for VFDs ....................................................................................... 11-54
Table 11-20 Alternatives for Monitoring Electrical Power Consumption ..................................................... 11-62
Table 11-21 Advantages and Disadvantages of Submersible Layout ............................................................... 11-69
Table 11-22 Velocities for Pump Inlet (Suction) and Discharge Piping for Individual Pumps .................... 11-74
Table 11-23 Valves for SPU Water Pump Stations ........................................................................................... 11-76
Table 11-24 Valves for SPU Drainage or Wastewater Pump Stations ........................................................... 11-77
Table 11-25 Typical C Coefficients for Pipe Types used in SPU Pump Stations .......................................... 11-81
Table 11-26 Typical K Values/ Fittings (Minor) Loss Coefficients ................................................................... 11-83
Table 11-27 Recommended Motor Starts per Hour ......................................................................................... 11-95
Table 11-28 Preferred Manufacturers for Water and Wastewater Pumps .................................................. 11-96
Table 11-29 Wet Well Self-Cleaning Trench vs. Rectangular Style ................................................................ 11-99
SPU Design Standards and Guidelines Chapter Owner: Jesse Nofziger November 2020 11-iii
Chapter 11 PUMP STATIONS
This chapter of the Design Standards and Guidelines (DSG) presents guidance for Seattle Public
Utilities (SPU) pump stations for potable water, stormwater, and wastewater facilities. The
primary audience for this chapter is SPU engineering staff, who both design improvements to
SPU pump stations and advise consulting engineers responsible for pump station design. DSG
Standards are shown as underlined text.
The information in this chapter should be used in conjunction with other DSG standards,
including Chapter 7, DWW System Modeling; Chapter 9, Electrical Design; and Chapter 10,
Instrumentation & Control (I&C) Supervisory Control and Data Acquisition (SCADA).
Note: This chapter of the DSG does not replace the experienced engineering judgment of a
registered professional engineer. All pump station designs for both upgrades and new stations
should be done under the supervision of an experienced, licensed engineer.
11.1.1 Abbreviations
Abbreviation Term
AASHTO formerly American Association of State Highway and Transportation Officials now just
AASHTO
ac alternating current
ASTM formerly American Society of Testing and Materials; now known as ASTM International
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Chapter 11 Pump Stations
Abbreviation Term
BEP best efficiency point
ft feet
HI Hydraulic Institute
HP horsepower
IEEE formerly Institute of Electrical and Electronics Engineers; now known as IEEE
OI Operator Interface
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Abbreviation Term
SBC Seattle Building Code
V volt
11.1.2 Definitions
Term Definition
backflow A device installed in potable water piping to prevent the flow of non-potable water into a
preventer potable system.
best efficiency The discharge rate at which an impeller of a given diameter rotating at a given speed operates
point (BEP) at maximum efficiency.
booster A pump that takes suction from a pressurized piping system and discharges, at a higher
pressure, to a second, isolated piping system.
cavitation Vapor bubbles formed on a solid surface (often an impeller) in contact with a liquid. The
vapor bubbles occur when the pressure in the liquid falls below the vapor pressure.
centrifugal pump A rotodynamic pump in which the fluid is displaced radially by the impeller. Commonly, any
rotodynamic pump in which the fluid is displaced radially, axially, or by a combination of both.
dry well The below-grade structure of a pump station in which the pumped liquid is contained within
piping valves and pumps.
firm pumping Capacity of the pumping station with the largest pump out of service or on standby.
capacity
force main Piping, external to the station and filled with liquid under pressure, through which the station
discharges.
guidelines Advice for preparing an engineering design. Guidelines document suggested minimum
requirements and analysis of design elements to produce a coordinated set of design
drawings, specifications, or lifecycle cost estimates. Guidelines answer what, why, when, and
how to apply design standards and the level of quality assurance required.
impeller A circular casting mounted on a rotating shaft with vanes to accelerate the fluid.
net positive Absolute dynamic head of the pumped liquid at the suction eye of the pump.
suction head
(NPSH)
net positive The NPSH at which the pump in each system operates at a given discharge rate.
suction head
available
(NPSHa)
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Chapter 11 Pump Stations
Term Definition
net positive The minimum NPSH at which a pump can properly operate for a given discharge rate.
suction head
required
(NPSHr)
packing Semi-plastic material installed in a stuffing box to seal the shaft opening in the casing to
restrict the leakage of liquid from the casing along the shaft.
pump A machine that imparts kinetic and potential energy (from an external energy source) to a
liquid to force a discharge from the machine.
pump station A structure housing pumps, piping, valves, and auxiliary equipment.
standard Drawings, technical or material specifications, and minimum requirements needed to design a
particular improvement. A design standard is adopted by the department and generally meets
the functional and operational requirements at the lowest lifecycle cost. It serves as a
reference for evaluating proposals from developers and contractors.
For a standard, the word must refer to a mandatory requirement. The word should is used to
denote a flexible requirement that is mandatory only under certain conditions. Standards are
underlined throughout the DSG.
submersible A pump or pump and motor suitable for fully submerged operation.
pump
total dynamic The total head at which a pump will operate at any given discharge rate.
head
total static head The difference in elevation between the surface of the pond from which the pump draws
water and the surface of the pool into which the outlet discharges.
water hammer Rapid, severe, and often destructive changes in pressure in a piping system caused by a sudden
change of liquid velocity.
wet well The below-grade compartment of a pump station into which liquid flows and from which
pumps draw suction.
11-4 SPU Design Standards and Guidelines Chapter Owner: Jesse Nofziger November 2020
SPU pump stations are structures that house mechanical equipment. The structure itself has an
anticipated design life, as does each piece of mechanical equipment inside it (Table 11-1).
Table 11-1
Typical Design Life for SPU Pump Station Elements
Component
Type Design Life
(years)
Structural Buildings (aboveground) and most structural elements 100
Mechanical Valves 25
Piping (within pump station)
Backflow preventers
HVAC
Pumps
• Water Dry well pumps (horizontal axial split pumps, single or 35+
dual stage)
Notes
1 Electrical elements other than motor windings may last over 35 years. Many electrical elements are replaced sooner
when more efficient systems are developed or when motors are repaired or replaced and require new starters or
control systems. A cost-benefit analysis should be done to determine whether to replace electrical elements.
2 Typically small submersible pumps (<25 hp) are replaced rather than repaired given their low cost versus the repair
cost. Dry well pumps will likely need rebuilding of subcomponents such as bearings, couplings, seals, or impellers.
Acronyms and Abbreviations
hp: horsepower
HVAC: heating, ventilation, and air conditioning
Existing SPU pump stations are generally between 40 and 100 years old. Some pump stations
have been rehabilitated over the years, while others operate using original equipment. In most
cases, past equipment replacement or upgrades are not well documented in the Engineering
Records Center. Therefore, existing conditions should be evaluated thoroughly at each facility
before beginning design work.
Where maintenance information (such as Maximo Records) is available for major equipment,
the design engineer should compare that data with the operations and maintenance (O&M)
Manual for that equipment. If repairs occur more frequently than expected, an evaluation may
be warranted for design life, repair, or replacement. In general, Maximo Records data should be
available for maintenance completed in the past ten years.
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Chapter 11 Pump Stations
11.2.2.1 Water
The water pumping system is robust and sufficient to meet SPU’s water LOB service levels. For
water pump stations, the 2019 Water System Plan identifies these level-of-service objectives:
• Provide agreed-upon pressure and flow in the water transmission system for wholesale
customers.
• Provide adequate pressures for drinking water supplies in the water distribution system.
This includes delivering peak hour demands at a minimum of 30 pounds per square inch
(psi) at utility meters and not drop below 20 psi during normal operations for delivery to
retail customers.
• Meet efficiency goals in the water distribution system. This includes maintaining system
leakage losses of no more than 10% of that supplied to the retail service area, as defined
by Washington State Department of Health (DOH) guidelines.
To confirm these objectives, the designer should determine the actual pressure and flow for the
existing facilities (review SCADA data) and the required pressure and flow at the locations
serviced by the pump station (utilize water system model).
11.2.2.2 Wastewater
For wastewater pump stations, consider the following performance criteria when providing a
recommendation on firm pumping capacity and design scope for a station being overhauled as
part of the combined sewer overflow (CSO) Program or the Pump Station Program:
• Pump stations should have minimal sewer backups with specific guidelines based on
interim drainage and wastewater (DWW) LOB sizing guidance for the Capital
Improvement Program (CIP):
− Pump stations serving non-critical services. No more than one sewer backup in 10
years (10% annual probability) at the wet well (through the wet well hatch or into
an unpermitted point of overflow) or within the affected upstream or downstream
combined or sanitary sewer lines.
− Pump stations serving critical services (e.g., hospitals and fire stations). No more
than one sewer backup in 25 years (4% annual probability) at the wet well (through
the wet well hatch or into an unpermitted point of overflow) or within the affected
upstream or downstream combined or sanitary sewer lines.
• CSOs should be limited to an average of one untreated discharge per permitted outfall
per year. This limit is based on eliminating the basin’s control volume. Control volume is
a highly uncertain, climatic horizon dependent value that should be determined based
on site context, infrastructure context, and financial context. The control volume
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associated with the modeled 50th percentile 2035 climate horizon may be used for initial
planning purposes. Consult the LOB for further guidance.
• The facility should be designed to produce zero dry-weather overflows into permitted
outfalls.
• Zero overflows at unpermitted points of overflow, regardless of weather conditions.
The SPU wastewater system discharges to King County’s regional wastewater collection system.
The design engineer must consider the potential effects on King County’s system when making a
pump capacity and design recommendation. Any effects on King County must be negotiated
with King County by the DWW LOB representative. Increases in firm pumping capacities typically
require compensation for the effects on the regional system. The design engineer should
identify ways to achieve the performance criteria described in the bullets above without
affecting King County’s system. The DWW LOB representative can provide regional and basin
hydraulic and hydrologic models to assist in this analysis. For information on permitting and
environmental review requirements with King County, see DSG Chapter 2, Design for Permitting
and Environmental Review.
11.2.2.3 Drainage
Currently, SPU operates one temporary drainage pump station to manage runoff within the
Alaskan Way Viaduct project area. A permanent drainage pump station in the South Park
neighborhood is planned to begin operations in 2021. For a potential drainage pump station,
refer to the Interim Conveyance Design Criteria for DWW Capital Projects (SPU Policy DWW-
130) for level of service design criteria. Use the following targets for managing stormwater
runoff within City of Seattle (City) right-of-way (ROW):
• Protect public safety and buildings from flooding, up to and including runoff from the
25-year, 24-hour design storm event.
• Allow access to and maintain functionality of critical services such as hospitals, fire
stations, and schools up to and including runoff from the 100-year, 24-hour design storm
event.
• Protect public safety and support mobility on the following:
− Major transportation routes up to and including runoff from the 25-year, 24-hour
design storm event.
− Residential roads up to and including runoff from the 5-year, 24-hour design storm
event.
Developing requirements for drainage pump stations can be challenging because reliable
information is often not available on the amount and duration of flow. SPU does have extensive
rainfall data that can be used to model flow and duration to develop pump station criteria.
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Chapter 11 Pump Stations
determine the full set of specifications necessary for each project and review each
example specification for applicability.
− Section 01 35 05 Sewer Bypass Plan
− Section 08 31 00 Access Hatches
− Section 09 90 00 Painting and Coating
− Section 23 00 00 Ventilation
− Section 23 80 00 Odor Control Equipment
− Section 26 24 19 Motor Control Centers
− Section 26 29 13 Combination Motor Starter
− Section 26 29 23 Variable Frequency Drive Motor Controllers
− Section 40 07 00 Mechanical Identification
− Section 40 23 00 Pipe, Fittings, and Accessories
− Section 40 23 01 Pump Station Valves
− Section 40 90 05 Control Loop Descriptions – Variable Speed
− Section 40 90 05 Control Loop Descriptions – Constant Speed
− Section 40 91 10 Primary Elements and Transmitters
− Section 40 91 16 Magnetic Flow Meters
− Section 40 91 23 Staff Gage
− Section 43 21 13 Variable Speed Vertical Centrifugal Pumps
− Section 43 21 29 Sump Pumps
• Example Calculations. Example calculations are available for sizing pump station
elements and selecting pump equipment (Appendix 11B - Pump Station Design
Calculator [Constant Speed], Appendix 11C - Pump Station Design Calculator [Variable
Speed], and Appendix 11D - Example Calculations - Wet Well Sizing). These calculations
are for reference only and not intended as standards. It is at the discretion of the
engineer to select a calculation methodology. The example calculations provided in
Appendix 11D are for a duplex wet well/dry well wastewater station. Separate examples
are provided for constant speed and variable speed applications.
• Equipment Data Sheet Template. An equipment data sheet template is provided as an
example only (Appendix 11E - Equipment Data Sheet Template). It can also be tailored
for instruments.
• Operational Checklists. Start-up and commissioning checklists are provided as examples
only (Appendix 11F - Operational Checklists, Appendix 11G - Equipment Testing
Checklist, Appendix 11H - Operational Acceptance Checklist, and Appendix 11I -
Systems Acceptance Testing).
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Chapter 11 Pump Stations
operations manager, and SPU project engineer before resolving the issue (see contacts in DSG
section 11.11). In general, the more stringent requirement should govern.
Table 11-5
Industry Standards and International and National Codes for Pump Stations
AWWA Various Disinfection, piping, and other elements of drinking water systems
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Chapter 11 Pump Stations
NFPA 37 Installation and use of stationary combustion engines and gas turbines
Local Codes
11.3.2 Regulations
All pump stations must be built to the currently adopted version of applicable City of Seattle and
Washington State and federal guidelines, including local building, fire, safety, and electrical
codes for pump stations. SDCI and Seattle Department of Transportation (SDOT) maintain
current lists of City construction codes. Table 11-6 shows City and Washington State regulations
that commonly apply to pump stations. This is not an exhaustive list.
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Chapter 11 Pump Stations
Table 11-6
City and State Standards and Codes for Pump Stations
Code Document
City of Seattle
• Right-of-Way Opening SDOT Right-of-Way Opening and Restoration Rules (SDOT DR 01-2017)
and Restoration Rules
• City Standard Plans and City of Seattle Standard Specifications for Road, Bridge, and Municipal
Specifications Construction and Standard Plans for Municipal Construction
• Seattle Land Use Code Seattle Land Use and Zoning Code, SMC 23
• Seattle Plumbing Code Washington State Plumbing Code with Seattle amendments, 2015
• Seattle Mechanical Code International Mechanical Code with Seattle amendments, 2015
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Chapter 11 Pump Stations
The basis of design plan sheet is not intended for construction and should not be included with
the bid set. The sheet is inserted after completion of bidding for the project. See DSG Chapter 1,
Design Process.
Figure 11-3
Basis of Design Plan Sheet Data for Pump Stations
Pump Stations
Number of Pumps (provide information for each pump):
Size of Pump (range of gpm): __________
Design Flow Rate: __________
Total Dynamic Head: __________
NPSHA: __________ ft
Pump Info: Impeller type and size _______________
Maximum Sizing __________
Speed ________________
Power ________ hp
Efficiency _______________
Configuration ___________________
Type of Station: (ejector, submersible, drywell, wet well, booster, well, storage facility, other)
Pump Set Points:
_______________________________________________________________
Primary Power Source:
__________________________________________________________
Backup Power Source:
___________________________________________________________
Utility Power: ______________kW Phase: ______________ Voltage:__________
Drive Type (combination starter, soft start, VFD, other): _______________________
Force main: size _____________; type ____________; length __________
Static Head Elevation: _______________ft Pressure Zone: ______________________
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Chapter 11 Pump Stations
Table 11-7
Design Criteria List for Pump Stations
Description Criteria
Pump Setting Must be a minimum dual pump system on parallel setting
Station must provide required capacity with largest pump out of service.
Maximum Pumping Cycles Motor Size dependent (consult manufacturer for recommended maximum pump
cycles)
Submersible Pump Motor Tandem pump shaft seals w/ moisture sensing of space between seal
Seal
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Chapter 11 Pump Stations
Description Criteria
Pump Shaft Seals Flush-less mechanical seal for wastewater and drainage (stormwater) pump
stations
Bearing Heavy duty. Minimum ANSI B-10 bearing life of 40,000 hours when pump
operates at 25% of BEP capacity for impeller diameter supplied at maximum speed
of operation
Piping Minimum Ductile Iron Pipe CL52 (CL 53 for fabricated and process piping) or
Standard Steel Pipe Schedule 40 with double-thick cement mortar lining
(stations with higher operating pressures may require Schedule 80 or custom-
fabricated steel pipe)
Wastewater Force Main Minimum 2 fps (5 fps where heavy ragging conditions are anticipated)
Velocity and Minimum Size
Pipe Maximum 8 fps
Minimum size 4 inches required
Net Positive Suction Head Minimum twice the manufacturer’s stated Net Positive Suction Head required
available (NPSHa) (NPSHr)
Check Valve Horizontally placed swing check valve with outside lever and spring
Utility Power Minimum 480V, 3-phase (retrofit projects will have unique power requirements)
Drive Type VFD or soft starter required for pumps 15 hp or larger. Recommended for
pumps 10 hp or larger.
Emergency Generator Plug Required for all wastewater and drainage pump stations without onsite
generators
Water Service Minimum 1-inch water service required for all stations. For wastewater stations,
backflow prevention is required. See DSG section 11.6.1.10 of this chapter.
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Chapter 11 Pump Stations
11.5.1 Planning
SPU routinely monitors pump station performance. When a problem is identified and an O&M
solution cannot fix it, the facility is further assessed within a standard decision-making
framework. LOB representatives use a four-step framework to develop CIP projects (Figure
11-4):
• Identify the project drivers. Examples are exceeding design life and risk of failure,
backups if a component failed, and risks of damage to other infrastructure.
• Frame the problem. Functionality and performance of the component are evaluated
and weighed against expected criteria.
• Analyze the data. Cost/benefit analysis is conducted to estimate lifecycle cost and net
present value.
• Make recommendations. A final decision is made following asset management process
and presented in a business case.
Each time the evaluation occurs, the LOB looks at sole replacement-in-kind of the pump station
element, reconsiders the service levels and functionality of the pump station, and considers
opportunities for fixing other known problems with the pump station.
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Chapter 11 Pump Stations
Figure 11-4
Planning a Pump Station Retrofit
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Chapter 11 Pump Stations
Table 11-8
Typical Content of a Preliminary Engineering Report for Pump Station Design
Section Description
Section 1: Introduction Project background info and objective: desired level of service, need for project, and
facilities to be constructed.
Section 2: Business Case Standalone document (summary) submitted to Asset Management Committee (AMC)
Documentation for business case 2 approval, which includes background, objective, options,
benefit/cost analysis, and recommendations.
Section 3: Facility Selection Alternatives (if any) for site locations, facility configurations and layouts. Must discuss
geotechnical characteristics. Should include alternative analysis and risk/value modeling
and site plans of most viable alternatives.
Section 4: Pump Selection Discussion of number of pumps and their capacities, design discharge pressures, and
motor sizing. Includes a process flow diagram.
Section 5: Facility Operation Discussion of upstream and downstream system elements (e.g., tanks, other stations,
& Control and plants), process mechanical for pump station piping and valves, and pumping unit
controls and instrumentation.
Section 6: Electrical Description of potential service supply, proposed electrical loads, voltages, motor
starting, and lighting.
Section 7: Structural and Description of structural and building codes and assumptions for pump station design.
Architectural Presents criteria facilities are expected to comply with (e.g., exterior building shell
types). For above-grade, includes an architectural rendering.
Section 8: Building Description of the building mechanical codes and assumptions for pump station design.
Mechanical Presents criteria that the facilities are expected to comply with (e.g., required air
changes per hour).
Section 9: Project Controls Planning level cost estimate and detailed project schedule.
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Chapter 11 Pump Stations
Section Description
equipment layout, key building sections, electrical one-line diagram, prelim P&ID,
control architecture, sheet &spec list finished design
• Preliminary design calculations
• State Environmental Policy Act (SEPA) Checklist
Table 11-9
Typical Pump Station Design Calculations
System curves and Reinforcement Generator, Soil classification Potable water and
pump selection sizing and schedule transformer, and MCC and friction gas demands
sizing angles
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Chapter 11 Pump Stations
Table 11-10
Checklist for Pump Station Design Documents Draft (D) and Final (F)
Title Sheet D F F
Drawing Index D F F
Abbreviations D F F
Design Data and Criteria (process flow diagrams, safety considerations, utility needs) D F F
Hydraulic Profile D F F
Key Map D F F
Civil Details D F
Landscaping Drawings
Architectural Drawings
Structural Drawings
Mechanical Drawings
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Chapter 11 Pump Stations
Electrical Drawings
One-Line Diagrams D D F
Major Equipment (MCCs, substations, and transfer switches) Layout and Electrical Room Plans D D F
Instrumentation Drawings
Riser Diagrams D F
Table of Contents D D F
General Requirements (e.g., sequence, constraints, work scope, and asbestos determination) D F
Physical Security
Equipment List D D F
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Chapter 11 Pump Stations
Calculations D D F
Cost Estimate D D F
A. 30-Percent Design
At 30% design, a pump station submittal should include all the applicable items
described in DSG Chapter 1, Design Process. The following list provides additional
guidance specific to pump station design:
• Basis of design plan sheet established and depicted in an acceptable format.
• A final design criteria list that includes all major equipment sizing information,
and general design assumptions. Pump type, size, head and flow, and
assumptions for redundancy should be clearly stated. The list should include all
project utility needs (including power, communications, fire flow, and potable
water). It should also list major safety considerations (whether an area is
classified, occupancy ratings, and fire rated walls).
• Hydraulic profile sheet showing the current design and any future requirements.
• Plans and profiles of pipelines that locate major utilities and piping corridors
(horizontal and vertical). Property acquisition and easements necessary for
permitting and construction should be identified.
• Preliminary mechanical plans and sections that show location of major
equipment and major piping alignments to verify clearances and general
configurations. Plans should indicate proposed equipment maintenance
features (e.g., overhead crane and monorails, hatches, and pads). Plan should
identify areas requiring noise abasement. HVAC/plumbing plans that depict
location of major equipment and major piping alignments.
• Preliminary electrical one-line diagrams and site electrical plans. Preliminary
layout of electrical rooms in adequate detail to determine size requirements
and clearances. The following should be identified: National Electrical
Manufacturers Association (NEMA) ratings for all rooms, available corridors for
routing electrical raceways and cable trays, and area classifications per
NEC/National Fire Protection Association (NFPA).
• Process and instrumentation diagrams (P&IDs) that depict the mechanical
equipment, piping, and I&C equipment interlocking. P&IDs should be at a more
advanced level than other documents in the submittal (at least 60% complete).
• Level I Environmental Assessment and work plan for Level II Environmental
Assessment.
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Chapter 11 Pump Stations
B. 60-Percent Design
At 60% design, a pump station submittal should include all the items described in DSG
Chapter 1, Design Process. The following list provides additional guidance specific to
pump station design:
• Hydraulic profile complete.
• Site plan with proposed final location of structures, roadways, and major site
elements (e.g., hatches, vents, fencing and gates). Include proposed contractor
staging, storage, access, and offsite corridors (traffic routing plans).
• Site plan with horizontal control and proposed grading.
• Plans and profiles of pipelines with final proposed alignments (horizontal and
vertical). Easement limits identified and included on drawings.
• Details of maintenance holes, pavement, and trench sections, as well as other
civil details.
• Proposed landscaping plan and schedules.
• Architectural plans, sections, and elevations that depict the proposed final
exterior architectural theme, materials of construction, and floorplan of
structures.
• Structural plans, sections, and details—this should be coordinated with other
design disciplines. Large structural penetrations should be identified and
potential conflicts with mechanical and electrical features should be resolved.
Foundation plans, floorplans, and roof plans should include dimensional
information and structural member sizes with reinforcement detailing partially
complete.
• Mechanical plans, sections, and details with proposed final location of major
equipment, piping, and appurtenances. Minor piping partially complete
(adequate corridors should be identified). Location of equipment maintenance
features finalized.
• HVAC/plumbing plans and sections adequately complete to verify SPU standards
and building code compliance. Equipment schedules and system schematics
should be sufficient to allow review of system configuration and design intent.
Fire protection system design (if required) should be included.
• Proposed final electrical one-line diagrams, control room layouts, and panel
layouts.
• Power plans, control diagrams, and schedules adequately complete to review
layout and design intent.
• Proposed final lighting plan and reflective ceiling plan.
• P&IDs developed to detail including revisions based on proposed final
equipment selection and configuration. P&IDs and control architecture should
be 90% complete.
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C. 90-Percent Design
At 90% design, a pump station submittal should include all the items described in DSG
Chapter 1, Design Process. The following list provides additional guidance specific to
pump station design:
• Hydraulic profile complete.
• Final electrical one-line diagrams, control room layouts, and panel layouts.
• Power plans, control diagrams, and schedules complete and coordinated with
process/mechanical design.
• Final lighting plan and reflective ceiling plan coordinated with other disciplines.
• Final P&IDs developed to greater detail and including revisions from previous
comments and coordinated with final operational control strategies.
• Physical security construction site plan submitted.
• Arc flash hazard analysis.
A. Technical Specifications
SPU technical specifications for pump stations are general design specifications
presented in CSI format. Unless the pump station is part of a large project formatted in
APWA style, it must use CSI format. APWA specifications are generally written for
roadway projects and do not work well for electrical and mechanical projects. Pump
stations contain a great deal of electrical and mechanical equipment. Specialized
subcontractors are needed on large electrical/mechanical projects. For each specialty,
specifications are generally presented in more detail than is typical in APWA format.
The most recent edition of the CSI standards is the MasterFormat, 2018 edition. SPU has
adopted CSI as its standard for construction specifications on pump station and
electrical projects.
B. Master Specifications
SPU Master Specifications govern many specific work items for construction contracts.
However, not all SPU Master Specifications have been converted to CSI.
For a list of example specifications for pump station installations, see Appendix 11A -
Example Pump Station CSI Specifications.
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Figure 11-5
Example Process Flow Schematic: South Park Pump Station and Water Quality Facilities
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11.6.1 Civil
Additional civil engineering design considerations for pump stations include access, parking,
electrical vehicle charging stations, pipeline corridors, bypass pumping, flood protection, water
supply backflow prevention, future expansion, physical security elements, hydrants, and influent
screening.
11.6.1.1 Access
Pump stations must be arranged to allow a boom truck to lift major equipment, such as pumps,
motors, and valves, completely out of the pump station. Verify that adequate flat, firm ground is
available for boom trucks. If site constraints prohibit equipment lifting by boom truck, fixed
equipment lifting hoists and conveyance systems must be provided. Both wet and dry wells
should be equipped with a large hatch located over all major equipment for equipment
installation and removal (Table 11-11).
Wastewater stations must allow for vacuum truck access to the wet well. This includes a clear
path from the wet well access hatch to the bottom of the well. Working platforms located
directly below the hatch must include hinged or removable grating panels.
Coordinate access hatch locations, sizes, and features with SPU Operations. Hatches for
personnel access must provide enough space for a retrieval tripod to be set up over the opening
or for the hatch to be equipped with a removable davit arm. Hatches must include a padlock
hasp that can accommodate SPU’s standard padlocks.
Table 11-11
Equipment Access Recommendations
Access to Pump not at Internal stairwell Ladder, one per 10-ft vertical drop if
Grade total vertical distance is greater than
15 ft
Large Access Hatch Equipment dimension plus 10-inch Equipment dimension plus 6-inch
for Lifting Equipment minimum on all sides; overall minimum of minimum on all sides, overall minimum
and Cleaning 36 inches x 42 inches of 36 inches x 36 inches
Hatch 6-ft wide and greater must be a
double door
Lifting Mechanism Boom truck preferred, then crane hoist. Crane hoist or overhead traveling
crane. Lifting points must be centered
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Clearance 8-ft minimum under lifting hoist, subject to Largest equipment dimension in
overall equipment size hoisting orientation, plus 2 ft between
bottom of equipment and any other
equipment in the station that must be
crossed over, plus rigging height
11.6.1.2 Parking
Refer to section 4.3.1.1 of DSG Chapter 4, General Design Considerations for general parking
requirements. A minimum of two parking spaces must be provided for all pump stations.
11.6.1.5 Signage
Refer to section 4.14 of DSG Chapter 4, General Design Considerations for signage requirements
at SPU facilities. Pump station facility identification signage must be 18 inches by 24 inches and
retroreflective following the standard design shown in Figure 11-6 below.
Figure 11-6
Typical Pump Station Identification Signage
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A. All Grades
To reduce flooding risk and facilitate easy cleanup, the floors of buildings and outdoor
equipment pads at all grades must be built at least 6 inches above the surrounding
finished grade. Sites must be graded to ensure that surface waters drain away from
hatches, doors, and other openings.
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• Provide an earthen embankment around the site to a height above the 100-year
flood elevation, with a small pump station for removal of stormwater collected
within the earthen embankment; this method may result in higher operating
cost.
Protection of water supply pump stations from 100-year flood waters is critical to
protecting public health during a flood. Extra care should be taken during design and
construction to prevent contamination of the water supply by flood water.
In all facility types, the electrical equipment including motor control centers (MCCs),
variable frequency drives (VFDs), main panels, and backup power supplies must be
protected from 100-year flood waters.
For waterfront pump stations potentially exposed to future rises in sea level, coordinate
flood-proofing requirements with the LOB representative.
Clearly identify planned future improvements on the design drawings so that design intent can
be documented. When possible, install provisions for future equipment to ensure installation
can be completed with minimal disruption to ongoing facility operations. This can include
routing empty conduits and ducts to future equipment locations and providing empty pump
bays and empty MCC sections or buckets. Where future pumps are planned, provide piping
connection points with isolation valves.
11.6.2 Mechanical
Additional mechanical engineering design considerations include HVAC, painting, plumbing,
insect screening and temperature, odor, noise control, and sump pumps.
11.6.2.1 HVAC
Typically, HVAC systems are designed according to the American Society of Heating,
Refrigerating and Air-Conditioning Engineers (ASHRAE) standards.
The number of air changes required is dependent on the location and area (Table 11-12).
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Table 11-12
Air Change Standards – Wastewater Pump Stations
Underground Vaults 12
Air change standards determine, in part, the electrical classification, and thus design
requirements, for each space in a wastewater pump station. Table 11-5 lists applicable codes
and regulations that must be met for construction of all existing and new wastewater and
drainage pump stations.
For water pump stations, including below-grade spaces, follow applicable building and
mechanical codes and standard practices for industrial buildings when determining the required
number of air exchanges. For facilities with water chemical addition (e.g., chlorine), the design
engineer must research applicable codes and requirements.
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− Motor enclosure and voltage: totally enclosed fan cooled (TEFC) or open drip proof
(ODP), minimum 120-volt (V) single phase.
• Wet well exhaust fans:
− Type: In-line centrifugal.
− Material: FRP, where available, aluminum with corrosion-resistant coating
elsewhere.
− Motor enclosure and voltage: Air Movement and Control Association (AMCA) Type
A or Type B, minimum 120-V single phase. Explosion-proof rated motors are
required for fans located within classified spaces.
• Physical separation of wet wells and dry wells:
− Any existing leaking piping/conduit penetrations must be sealed with non-shrink
epoxy grout or similar type material.
− All conduits going to and from wet wells must have code-approved seal-offs if not
already installed. Seal-offs must be installed if not included on an existing conduit.
All existing seal-off fittings should be inspected for adequate sealing compound.
− Existing access doors between dry wells and wet wells should be removed and the
openings sealed. Alternate means of access to wet wells may need to be
constructed.
− Existing ventilation openings between wet wells and dry wells must be permanently
sealed with non-shrink epoxy grout or a similar material. Separate ventilation
systems for wet and dry wells must be provided.
• Dry well ventilation monitoring and alarm requirements for unclassified space:
− Operation of the ventilation equipment is required to be continuously monitored
per NFPA 820. A flow detection device that is connected to the SCADA building data
monitoring system must be provided for each fan. Thermal dispersion flow switches
are SPU’s preferred flow detection device.
− As required by code, non-audible signals consisting of a dual light (go/no-go or
green light/red light) alarm system must be provided at the entrance of the dry well.
This device should be located just inside each dry well access hatch or door, such
that it is easily visible from outside.
− Fire extinguishers must be provided in dry wells per NFPA 820.
• Filtration: For waterfront stations with exposure to salt-bearing marine air, moisture
removal filters must be installed on the suction side of supply air intakes (dry well and
wet well). Filters generally use a combination of stainless-steel mesh and other filtration
media to remove salty and corrosive moisture from the air stream before it enters the
pump station. Filters such as the American Metal Filter Company’s HM series are
suitable for this application.
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Table 11-13
Recommended Duct Sizing
Table 11-14
Pump Station Recommended Paint Coloring Scheme
Piping System or Equipment Solid Color Color Band Letter Code Letter Color
Buildings
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Piping System or Equipment Solid Color Color Band Letter Code Letter Color
• Drain – Suction or Pressure (Process) White Drain Black
Equipment – General
• Water – Non Potable, Non Chlorinated Lt Blue Brown Sec Effluent White
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Piping System or Equipment Solid Color Color Band Letter Code Letter Color
• Water – Service, Return Lt Blue Red SW Ret White
Floor coatings for areas subject to water and washdown should include a non-skid aggregate
treatment unless otherwise requested by SPU Operations.
11.6.2.7 Plumbing
Most pump stations require little plumbing. Detailed plumbing design is beyond the scope of the
DSG. For additional guidance on plumbing, consult the Seattle-King County Department of
Health.
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Table 11-15
Noise Requirements
Residential 55 57 60
Commercial 57 60 65
Industrial 60 65 70
11.6.2.10 Utilities
All pumping facilities require one or more utility services (e.g., electrical, water, sewer, natural
gas, and communications). The availability and capacity of existing utilities should be
investigated and compared with the estimated demands of a new facility. Power lines at or near
the site do not guarantee that ample electrical capacity or the appropriate type of service will be
available. New services or additional capacity may be required.
One common example of additional capacity need is a small pump station for a residential area.
While the residential power lines may have excess capacity, they may only provide 240V, 1-
phase service. Most pumps require 480V, 3-phase. In such cases, new power lines must be
brought to the site from a 480V transformer, which the local utility must design and install.
Typical utilities required for water supply and wastewater pump stations should be verified
(Table 11-16).
Table 11-16
Typical Utilities Required for Pump Station Operation
Potable Water Restrooms, Backflow prevention provisions required. See DSG Chapter 17, Water
Supply drinking fountains Service Connections
and fire protection
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Storm Drain External Service 4 inch if required 6 inch or larger per site 6 inch or larger per
Drain requirements site requirements
Flushing Water2 Pump seal flushing 3/4 inch to 1 inch if required Recommended
Notes
1 Washdown water system connected to a potable water supply or a reclaimed water source must have step-down
pressure valve and backflow protection as required by the DOH and the Uniform Plumbing Code.
2 Flushing water systems, if supplied by a potable water source, must have an air-gap separation from the potable
supply system. In-line pressure reduction and backflow preventions are not allowed for this application.
Acronyms and Abbreviations
DOH: Washington State Department of Health
SCADA: supervisory control and data acquisition
V: volt
Larger mechanical equipment, including pumps and combination air valves located in wet wells
or vaults, must be specifically designed to operate in corrosive environments. The manufacturer
of each piece of equipment should be consulted to verify the equipment is suited for operation
in the intended location.
Wet well linings should be considered when designing new pump stations. Typical linings for wet
wells at SPU stations are high-build epoxy coatings on all concrete surfaces. For retrofit projects,
wet well coatings should be evaluated on a case-by-case basis in coordination with SPU
Operations. Wet well linings must be installed at existing pump stations that show visible
evidence of concrete deterioration.
Epoxy coatings should also be considered for force main discharge structures, which typically
have high H2S exposure due to flow turbulence. Where epoxy coatings are used in areas that
may have foot traffic during maintenance (e.g., wet well floors), a non-skid aggregate surface
treatment should be included.
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11.6.3 Structural
DSG Chapter 8, Drainage and Wastewater Infrastructure provides general structural engineering
requirements for SPU facilities. This section provides additional guidance specific to pump
stations.
Table 11-17
Typical Structural Codes
Code Name
ASCE 7 Minimum Design Loads for Buildings and Other
Structures
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If modifications are made to the primary structure or new loads are applied to the structure, the
capacity of the existing structure must be considered. The design engineer can use available
design plans for the existing structure to determine the existing load capacity. If no plans are
available, the design engineer must use best judgement based on experience.
Common modifications that affect the capacity of the existing structure are new openings in the
walls or top slab or demolition of portions of walls or beams that support the wall or top slab.
When such modifications to the existing structure occur, the structure typically must be
strengthened.
A. Exterior Walls
Structural loads sustained by exterior walls of SPU pump stations generally include soil,
surcharge, seismic, and hydrostatic lateral loads. Because of the rigid nature of the
pump station walls being supported laterally at the base and top slab, typical lateral soil
loads for most pump stations are from at-rest soil. Surcharge loads are due to vehicles,
equipment, or piled soils adjacent to the walls. Numerous design manuals provide
methods for estimating lateral soil loads created by distributed, line, or point loads. SPU
projects commonly refer to the Naval Facilities Engineering Command (NAVFAC) Design
Manual (DM) 7.1. Surcharge loads need only be applied to 10 ft below ground surface.
Lateral seismic loads are calculated based on expected ground accelerations and soil
types and are determined through geotechnical exploration and analysis. Hydrostatic
loads result from groundwater. Groundwater elevation, and thus hydrostatic loads from
groundwater, is determined geotechnical exploration and analysis. Table 11-18 below
shows typical lateral loading parameters, which can be used if no geotechnical analysis
is available.
Table 11-18
Typical Lateral Loading Parameters
Parameter Value
At-rest lateral load, 60 pcf equivalent fluid pressure
above groundwater
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B. Interior Walls
Interior walls in SPU pump stations are generally located between the wet well and dry
well. Interior walls are typically required to handle hydrostatic and seismic lateral loads.
Hydrostatic loads are calculated based on water surface elevations in the wet well. The
maximum possible water surface elevation should be considered. Seismic loads are
calculated based on lateral accelerations generally determined through geotechnical
analysis. If no analysis is available, acceleration coefficients can be obtained using the
online U.S. Geological Survey (USGS) ground motion calculator. If using the USGS
calculator and the soil type is unknown, input soil type based on a conservative
assessment. After determining an acceleration coefficient, the structural engineer can
determine the seismic loads applied to the interior wall using guidance provided by
ASCE 7, Chapter 12. Because of the typical wet well size in SPU pump stations, sloshing
waves need not be considered. If the wet well size requires that sloshing waves be
considered, American Concrete Institute (ACI) 350.3 can serve as a design guide.
C. Top Slabs
SPU pump station top slabs are generally buried or at grade. Top slabs are typically
required to resist the following types of loads:
• Concrete roof, with a typical dead load of 150 pounds per cubic ft (pcf)
• Soil, with a typical dead load of 120 pcf.
• Pavement, either concrete or HMA 145 pcf.
• Aggregate base under pavement 130 pcf.
• Snow load up to 25 pounds per square ft (psf).
• Vehicle loading when vehicle access is possible over top slab, with loads
consisting of 32-kip axle load at 14-ft spacing or tandem 25-kip axle loads at 4-ft
spacing. American Association of State Highway and Transportation Officials
[AASHTO] HL 93 can serve as a design guide. For top slabs with 2 ft or less soil
cover, a 1.3 impact factor should be added to this vehicle live load. Where top
slab is inaccessible to vehicle traffic, SPU recommends a minimum 300 psf live
load.
• Construction loads should be determined on a project specific basis. Wall
backfill prior to top slab construction is one possible example.
D. Bottom Slabs
SPU pump station bottom slabs are typically required to handle bearing loads and uplift
from hydrostatic water pressure. Bearing loads generally consist of dead and live loads
on the top slab, weight of the walls, and weight of the bottom slab distributed over the
area of the bottom slab. Structural engineers may also need to consider stability-related
foundation reactions when evaluating bearing loads on a bottom slab.
E. Suspended Platforms
Suspended platforms and associated framing at SPU pump stations should be designed
to handle the following live loads:
• 100 psf over entire surface area.
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• 350 pounds (lbs) pedestrian point load (at controlling location) plus 40 psf
distributed load.
• Equipment loads, if equipment maintenance could result in placing heavy loads
(such as pumps or motors) on the platform. Combine any equipment loads with
20 psf distributed load.
• Dynamic loads do not need to be considered if all of the above loads are
considered.
F. Grating
Many of the suspended platforms at SPU pump stations are constructed with grating
supported by beams. The grating should be designed to handle the same loads as the
associated suspended floor design. At minimum, the grating should be designed for a load
of 100 psf with a maximum deflection of ¼ inch. The NAAMA Metal Bar Grating Manual
provides grating design guidance. Hot-dip galvanized grating, which allows for future field
modifications, should be used in most cases. Grating design and support systems must
consider and allow for future penetrations for piping and conduit. Often framing is required
to support the grating edges around such penetrations. Grating should be fully banded
along all edges and openings. SPU generally does not allow use of FRP gratings at this time.
G. Guardrail
Per ASCE 7, chapter 4, pedestrian guardrail design load must be 200 lbs at any point and
in any direction along the top rail, or a uniform load of 50 lb/ft along the top rail.
Pedestrian guardrails are required to meet Occupational Safety and Health
Administration (OSHA) requirements for fall protection open spacing, which requires a
two-rail system. If the public has access to the pump station, as defined in SBC, the
pedestrian guardrail must not allow a 4-inch ball to pass through the guardrail.
H. Ladders
Ladders at SPU pump stations should be designed to handle the following loads:
• Ladder supports (standoffs) should handle two 250-lb loads located between
two consecutive ladder supports.
• Ladder rungs must be capable of handling a 250-lb load at the center of the
rung.
• Minimum ladder rung length between side rails is preferred to be a minimum of
16 inches.
• A minimum of 15-inch clearance between wall and the center of the ladder is
required.
The above ladder load requirements are based on OSHA 1926.1053.
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B. Durability
The structural engineer can ensure durability for concrete construction using the following
methods:
• Concrete mix, a minimum 28-day compressive strength of 4,000 psi and a
maximum water/cementitious ratio of 0.42. This guideline generally follows the
requirements of ACI 318.
• Use of the appropriate cement type in the concrete based on possible soil
conditions. Concrete using type II cement (moderate sulfate resistance) is
typically adequate. If a soil investigation indicates more severe sulfate attack,
type V cement may be appropriate. Generally, type III cement (high-early
strength) should be avoided because of its higher heat of hydration, which can
result in additional cracking.
• Concrete cover over reinforcement for both interior and exterior walls should
be 2 inches.
• Minimum reinforcement requirements (for crack control) should follow ACI
350’s guidance for higher reinforcement requirements based on distance
between control joints.
• Concrete mix requirements regarding alkali/silica reactivity should be included
in the project structural concrete specifications. Such requirements are included
in the City of Seattle Standard Specifications but may not be included by default
in a CSI type specification.
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C. Anchors
Anchor bolts are designed in accordance with ACI 318, chapter 17. This includes cast-in-
place, adhesive type (epoxy), and mechanical type (expansion) anchors. Anchors should
be constructed of the same type of material as the member being anchored. However,
aluminum or fiberglass members should use stainless-steel anchors. When anchoring
machinery, use cast-in-place or adhesive type anchors. For wall-mounted anchors such
as pipe supports or ladders, either adhesive or mechanical type is acceptable. For ceiling
mounting, mechanical anchors are recommended.
11.6.4 Electrical
DSG Chapter 9, Electrical Design, provides overall code compliance and general guidelines. This
section describes electrical items specific to pump station operation and control. There are no
pump station-specific requirements for conduits and receptacles, grounding, and lighting. For
requirements on these electrical considerations, refer to DSG Chapter 9, Electrical Design.
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the SCADA equipment and all instruments for a minimum four hours of utility power outage.
The UPS must not power environmental controls (HVAC), including those in the SCADA control
panel, due to the large power needs required by such devices.
A. Requirements
The following are design guidelines for VFDs:
• Manufacturer. If possible, VFDs should be designed and specified to be the
product of a single manufacturer. Drives up to 200 hp may be mounted in an
MCC. Larger drives should be furnished by the pump or equipment supplier.
• Power Factor Correction. SPU does not recommend using individual power
factor correction capacitors or banks of capacitors on distribution systems with
VFDs or other non-linear loads. Capacitors with tuned filters may be required to
eliminate the potential of a resonant frequency developing on the distribution
bus. On large distribution system capacitor banks with automatic controls,
tuning filters may be considered. Unfiltered power factor correction capacitors
should never be added to any bus directly connected to VFDs.
• VFDs for Existing Motors. Restrictions on motor lead length and winding
insulation class due to reflected voltages can be a problem when applying VFDs
to existing motors. The VFD manufacturer should be consulted to determine if a
problem potentially exists. Output reactors or cable terminators may be
necessary. SPU recommends replacing the motor with a new inverter duty
motor if possible.
• 6-Pulse Systems. When 6-pulse systems with line reactors do not meet the
harmonic limitations imposed by the Institute of Electrical and Electronic
Engineers (IEEE 519), or where standby generators are used as a power source,
specify low harmonic multi-pulse or “clean power” VFDs.
• Location/Enclosure. Investigate all potential VFD manufacturers and provide
adequate space inside the pump station for a worst-case scenario.
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B. Harmonics
VFDs are non-linear devices that develop harmonics. Harmonics are integer multiples of the
fundamental frequency (Table 11-19). When summed to the fundamental frequency, the
result is a distorted waveform that can create adverse conditions in a distribution system.
IEEE has set the only recognized standard addressing harmonic limits: IEEE 519-2014,
the Recommended Practice and Requirements for Harmonic Control in Electrical Power
Systems. This standard stipulates specific limits for current and voltage distortion at a
point of common coupling; traditionally for pump stations, this is the point where the
utility connects to multiple customers (i.e. line side of the utility transformer).
Table 11-19
Harmonic Mitigation Methods for VFDs
Method Description
6-Pulse Drive • Common, cost-effective.
• Typically, reactor per unit impedance is 3% to 5%.
• Providing drive with a line reactor can eliminate the most severe effects.
• Increasing impedance of line reactor does not reduce harmonics linearly. A practical
minimum can be reached simply by adding inductance.
• Cost and size vs. the theoretical minimum comparison and optimization lead typically
to 3% to 5% line reactors.
Multiple Pulse Rectifiers • In 12-, 18- or 24-pulse drives the two, three, or four rectifiers are parallel-connected
and fed by a phase shifting transformer.
• Harmonic compensation is effective at the primary side of the transformer.
• 18- and 24-pulse systems are not economical for floor space, losses, and power factor
when compared with other low harmonic solutions. In an 18-pulse drive, the efficiency
is typically 96%.
• Multi-pulsed systems always require a dedicated transformer for the drives because the
cancellation is reached on the primary side.
• Power factor in 18-pulse systems is poor (typically 0.95). Current distortion when
these phase shifting transformers are used is total harmonic distortion (THD) = 3% to
15% depending on parameters such as pulse number, line imbalance, and balancing of
windings.
Passive Filter Designs • Trap or shunt filters are tuned to a certain frequency component. For example,
connecting several traps (multiple arm filters) can be effective for filtering out the fifth
and seventh harmonic component.
• This type of solution may be sensitive to resonance phenomena with other network
components and may introduce a high leading power factor.
• Can cause voltage drop and thus reduce the drive capacity.
Active Filters • Compensate actively harmonic components in a network by generating the same
harmonic components in an opposite phase. This technology is realized with modern
power electronic devices.
• Cost is relatively high, compared to passive filter.
Insulated Gate Bipolar • Typically used when regenerating is required.
Transistor (IGBT) • Generates low harmonic voltage and current distortion levels.
• Cost is higher than a passive filter.
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Removable units should connect to the vertical bus in each section with tin-plated, self-aligning,
pressure type copper plug connectors. Removable units should be aligned in the structure on
guide rails or shelves and secured with a cam latch mechanism or racking screw.
A. Combination Starters
Constant speed motors sized from ½ to 15 hp must be a combination starter with a
motor circuit protector (MCP) and across-the-line full voltage starter sized according to
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NEMA. The MCP is a means of short circuit protection. Motor starters are magnetic line
voltage type with individual control power transformer, 120V secondary fuses and 3-
phase bimetallic overload protection. Primary side fuse overcurrent protection should
be provided on all control power transformers.
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• An illuminated indicator per channel and limit to light after the time delay when
any set point is exceeded
• A trip light to illuminate immediately when any set point is exceeded and before
alarm or shutdown is initiated
• A circuit checker with illuminated indicator to continuously light when the
pickup circuit is working properly
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when the pump LOR switch is in the Remote position and the operator inputs a
command in the Human Machine Interface (HMI).
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I. Pump Running
Pump running status is monitored by a run contact in each pump motor starter. The run
status signal is sent to the PLC, then to the SCADA operator workstation.
P. Intrusion or Security
Intrusion switches and vault security alarms should be added as basic data for water
quality security and site security purposes at pump station sites.
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Table 11-20
Alternatives for Monitoring Electrical Power Consumption
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separate room from the pumps. It is, however, desirable if space allows. Electrical equipment
separated from the rest of the process is more cost effectively temperature controlled and can
require less stringent NEMA classifications.
Figure 11-7 shows a typical layout of an SPU water pump station.
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Figure 11-7
Typical Water Pump Station Layout
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Disadvantages:
• Greater cost due to excavation and build below-grade. Expensive if ground
water is high, if soils are poor, or if blasting is required.
• Greater risk of outage from flooding. Dry well must be kept dry.
• Flood-protected motors (in the dry well) are expensive.
• Long leads to motor (in dry well) from control panel if motors are frame
mounted to pumps.
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Figure 11-8
Typical Dry Well/Wet Well and Wet Well Layout
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Table 11-21
Advantages and Disadvantages of Submersible Layout
Advantages Disadvantages
• No dry well; excavation and concrete reduced. • Pumps are larger.
• No superstructure required except for engine- • Wet well will probably need to be wider than with non-
generator or cabinet for motor controls. clog, dry well pumps, thus requiring more wet well air
• Functionally best suited for on/off operation with flow and odor scrubbing capacity.
relatively narrow band of head requirements. • Pumps can get extremely heavy in larger sizes.
• Good when equipment is centrally located for • Unit must be removed and disassembled for routine
servicing. servicing. Cannot be inspected during operation.
• Excess heat from pumps is dissipated into liquid • Limited manufacturer’s ability to custom engineer for
(not load added to building cooling requirements). heavy-duty service.
• No seal water system, no long shafts with steady • Pumps and motors not as well suited for variable speed
bearings required. operation.
• No flood hazard to motors. • Difficult to diagnose vibration or leaks.
• Reduces the land area needed. • Tandem seals on larger units are expensive, $5,000 or
• Quick removal and replacement in emergencies. more. These are routine replacement items.
• Well adapted for increasing the capacity of a pump • Generally non-adjustable (e.g., not possible to adjust
station using existing wet and dry wells. impeller-wear ring clearance to prolong component life).
• No daily or weekly maintenance. • Valves and headers must be accessible in one of these:
1) adjacent vault; 2) small above-grade superstructure;
• Units removable for shop servicing, minimizes field
or 3) by exposing the header above-grade.
work.
• Not possible to adjust impeller-wear ring clearance to
• Quiet operation.
prolong component life. Needs overhaul every few years
• Safety from flooding. based on motor size.
• Can balance lower first cost of submersible • Valves and headers must be accessible in either: 1) in
pumping station w/ its lack of regular, frequent adjacent vault; 2) in small above-grade superstructure;
maintenance against cost of complete overhauls by or 3) by exposing header above-grade.
specially trained mechanics or service center.
• Pump must be removed and disassembled for inspection
and maintenance. Heavier pumps require hoist or crane
and specially trained mechanics. Often more difficult to
remove pumps than manufacturers admit.
• Hazard of pumps jamming on guide rails or not seating.
• Larger units tend to break down more often than
smaller units and require higher maintenance cost.
• Special motors, seals, and moisture monitoring required.
Moisture probes are useless for leaks via power cable.
• Performance and quality of pump/driver unit may differ
greatly. High impact on maintenance and lifecycle cost.
• Warranty valid when repairs are made by pump
manufacturer’s authorized service center.
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Figure 11-9
Typical Submersible (Wet Well) Layout
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Figure 11-10
Typical Inlet and Outlet Configuration
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separation and unnecessary head loss, it is beneficial to provide a flared inlet (turned-
down elbow with a flared inlet or a horizontal flared inlet) that can create smooth
acceleration of flow as it enters the inlet pipe.
1) Turned-down Inlet
Generally, a turned-down elbow is more effective than a horizontal inlet when there is
low velocity in the wet well.
2) Horizontal Inlet
SPU recommends a horizontal inlet. It is less prone to generation of pre-swirl in the
suction piping than is a turned-down elbow. Pre-swirl is flow rotation approaching the
pump inlet, which is a common source of impeller cavitation damage and vibration. SPU
recommends horizontal inlets for turbulent wet wells that have higher velocity flows
and circulation patterns. Horizontal inlets do, however, require greater submergence
than turned-down elbows to prevent surface vortex formation. Flared inlets should be
flush with the partition wall.
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represents the pump suction elbow of a submersible pump mounted in a wet well. For large
pumps with case-in-place bases, the elbow resides between concrete walls on either side.
Figure 11-11
Pump Suction Elbow Leading to Pump Body
In some circumstances, the pump suction elbow has been cited as a major concern associated
with pump vibration and increased maintenance. Physical modeling shows that pump suction
elbow geometry affects hydraulics at the pump inlet. It is critical to use a reducing elbow
because a standard (non-reducing) elbow will deliver a severely skewed velocity profile to the
pump inlet.
To deliver a flow that meets HI velocity distribution criteria, the ratio between the inlet and
outlet sides of the elbow must be a ratio of 1:1.5. The inside diameter of the pump throat is
typically a smaller diameter than the pump inlet flange and can be used for this calculation in
lieu of the downstream diameter of the pump suction elbow. Use of long radius elbow is
preferred in this configuration. However, short radius reducing elbows can also be effective.
For most submersible pumps, the fitting immediately downstream of the pump discharge is
typically a 90-degree elbow required to orient the pumped discharge flow vertically and route it
through the balance of the downstream mechanical equipment. These fittings can experience
significant and highly variable thrust forces, especially at startup. SPU recommends that the
pump manufacturer be closely consulted to determine what, if any, additional reinforcement
may be required for fittings attached to the pump nozzle. Such provisions may affect the final
dimensions and should be considered when designing concrete bases and supports to
accommodate this equipment.
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Table 11-22
Velocities for Pump Inlet (Suction) and Discharge Piping for Individual Pumps
Discharge Piping 2 8
A. Minimum Velocities
Certain technical constraints affect pipe size selection. For force mains conveying
sewage, minimum velocity must be 2 ft per second (fps) for wastewater and 2 fps for
drainage pump stations during initial operation. For stations subject to ragging or above-
average solids in the influent, higher minimum velocities (at least 5 fps) are
recommended.
B. Maximum Velocities
To maintain head losses at reasonable values, the maximum velocity in wastewater
force mains must be 8 fps. For short (< 100 ft) force mains, SPU allows higher velocities
(up to 10 fps) on a case-by-case basis. Pipe wall erosion from grit is a concern when
velocities exceed 10 fps.
B. Materials
The following are SPU standards for pump station pipe materials. Other materials may
be acceptable if approved by SPU:
• All piping within the pump station structure must be either ductile iron or
carbon steel and must be designed with restrained joints.
• At a minimum, ductile iron piping must be service Class 52. Flanged, grooved, or
otherwise fabricated ductile iron pipe must be service Class 53 minimum. All
ductile iron piping must follow Standard Specification 9-30.1(1).
• Steel piping design must follow AWWA M11. All steel piping must follow
Standard Specification 9-30.1(4).
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• Wastewater force mains beyond the pump station structure may be constructed
of restrained joint ductile iron pipe service Class 52 or thicker, or of high-density
polyethylene (HDPE) (thickness as required, not to exceed a dimension ratio
(DR) of 17).
C. Jointing
Typically, ductile iron piping uses flanged connections, and carbon steel piping uses
either flanged or welded connections for piping inside a pump station. Flanged pipe
should not be used in buried applications.
Where in-line equipment (e.g., pumps, valves, or flow meters) is installed, jointing must
be provided on either side of the equipment, to allow for disassembly and removal. For
this application, SPU generally recommends dismantling joint fittings, grooved
couplings, or other fittings that allow length adjustment and disassembly clearance. In
most cases, flanged joints are not appropriate for equipment removal. Flexible,
rubberized couplings should not be used to connect equipment to the piping system.
Force mains, ventilation ducts, and other pipe penetrations must include a flexible joint
at the entrance to, or exit from, a structure. Joints must be located a distance from the
outside wall of the structure of 12-inches or one pipe diameter, whichever is greater.
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For most small pump stations, pressure surges caused by water hammer are not severe and no
water hammer control equipment is needed. All pumping and pressure pipeline systems should
be investigated for water hammer where flow can be rapidly accelerated and/or decelerated.
A comprehensive computer modeling study must be completed to fully understand the
potential effects of pressure surges on force main operation. For wastewater pump stations,
SPU recommends considering a comprehensive modeling study when the force main meets at
least one of the following criteria:
• Crosses under a river or other water body
• Has local high and low points along the alignment that require air/vacuum valves
• Is longer than 500 ft and larger than 6 inches in diameter
• Has other unusual or unique operating conditions prone to abrupt changes in flow
velocity, siphoning effects, or air pockets
A completed modeling study will inform the need for, and location of, any required surge
mitigation devices. Required devices based on modeling could include air/vacuum relief valves,
surge tanks, and pump flywheels. Force mains should be designed to avoid the need for surge
mitigation devices wherever possible. When air/vacuum relief valves are required for
wastewater service, SPU recommends the Vent-O-Mat RGX B valve with piped outlet (that is, an
outlet routed to nearby gravity sewer main). Modelling studies should be started at the 30%
design milestone and finalized by the 90% design milestone.
11.7.2.7 Valving
Valve selection is critical to properly control flow and pressure through a pipe system. SPU
generally provides a check valve immediately downstream of the pump. Isolation valves should
be included on either side of any piece of equipment that will be routinely isolated and removed
from service. At a minimum, isolation valves should be incorporated on both the suction and
discharge side of each installed pump or major piece of equipment.
Table 11-23
Valves for SPU Water Pump Stations
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Other valves associated with ancillary systems for pump stations include those for a
potable water source for hose bibs, fire protection, or drain and flushing valves for the
system. Smaller valves for these connections should be ball valves for isolation and
globe valves for draining.
Table 11-24
Valves for SPU Drainage or Wastewater Pump Stations
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Notes
1 Air release valves (or some other device by which air can be released from a discharge pipe) should be
placed at all significant high points along the discharge pipe. If these locations are not vented, air that comes
out of solution will accumulate in high points of the pipe and create additional head in the system and can
accelerate corrosion due to the accumulation of hydrogen sulfide.
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Figure 11-12
Common Pump and Piping System Terms
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Figure 11-13
Typical HGL and EGL
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1) Friction Losses
Friction losses in closed conduit flow are commonly estimated by one of the following
equations:
• Hazen-Williams Equation
• Darcy-Weisbach Equation
The Hazen-Williams equation must be used to calculate friction losses for pumped flow
for all pipes less than 2,000 ft in length or less than 18 inches in diameter:
1.85
𝑉𝑉
ℎ𝐿𝐿 = � � × 𝐿𝐿
1.318 × 𝐶𝐶 × 𝑅𝑅0.63
Where:
hL = head loss (ft)
V = pipe velocity (ft/sec)
C = Hazen-Williams C coefficient of friction
R = hydraulic radius (ft)
L = pipe length (ft)
Ensure that the above units are consistent with project information. Ranges of Hazen-
Williams C coefficients for various pipe materials, diameters, and ages are available from
manufacturers and various sources in technical literature. Such information should be
obtained for the specific pipes being considered in addition to the anticipated design life
of the pipes. When existing pipe is reused for upgrading or rehabilitating a pump
station, the actual C coefficient must be calculated through field testing. For water
stations, use a minimum of two hydrant flow tests for each size and material of piping.
For wastewater pump stations, use a minimum of two closely agreed (preferably more)
pressure and drawdown tests at the station. Table 11-25 lists the typical Hazen-Williams
coefficient values.
The Hazen-Williams equation should be cautiously used for pipes of either significant
length (>2,000 ft) or large diameter (>18 inches). In these cases, the Darcy-Weisbach
equation is a more accurate estimation of friction loss. It should be used to verify the
results obtained using the Hazen-Williams equation.
For most SPU installations, the Hazen-Williams Equation can be readily used because
the piping is typically less than 18 inches in diameter and less than 2,000 ft in length.
Table 11-25
Typical C Coefficients for Pipe Types used in SPU Pump Stations
Material Hazen-Williams C
New Pipe
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Material Hazen-Williams C
PVC 150
Figure 11-14
Pump Station Schematic
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Typical K (minor loss coefficient) values for a limited number of common fittings are
listed in Table 11-26. Use coefficients provided by the valve or fitting manufacturer
where available. Otherwise, K values for pump station design must follow HI Engineering
Data Book Tables 32(a) and 32(b).
Table 11-26
Typical K Values/ Fittings (Minor) Loss Coefficients
Reducers/increasers:
Smooth bends:
45° 0.1
22.5° 0.05
a. Angle 2
b. Butterfly 0.3 to 1
c. Swing check (if spring-loaded, head loss may increase by 2 psi or 2 to 2.5*
more)
d. Rubber flapper check 1 to 2
f. Foot 0.8
g. Gate 0.1
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Notes
1 K values for check valves will vary widely with the brand of valve and flow velocity. Consult with valve
manufacturers for actual K values for use in design calculations. K values for fittings are typical reference
values only and may scale with size.
Acronyms and Abbreviations
psi: pounds per square inch
G. System Curves
The system curve is a graphical representation of total dynamic head versus discharge
flow. The total head equals the system static head plus the dynamic head losses.
Minimum and maximum system curves should be plotted. Other critical points of
operationsuch as common operating conditionsshould also be identified.
The boundary defined by the minimum and maximum system curves provides the range
of operation for system head requirements. One curve should show the maximum static
head with loss. The other should show the minimum static head with loss (Figure 11-15).
Except for systems where flow is to be externally controlled, system curves of the range
of conditions the pump will encounter should be provided to the manufacturer.
Tip: Provide pump manufacturers with a reasonable estimate of what station losses are
likely to be. Pump selection should always strive for highest efficiency at the most
frequent pumping rate(s).
Figure 11-15
System Curve
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Figure 11-16
Net Positive Suction Head
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Figure 11-17
Typical Modified Pump Curve
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B. Shut-Off Head
The head produced by a pump at zero discharge is called the shut-off head. SPU does
not recommend operating pumps continuously at or near the shut-off head. For large
pumps, even operation for a few minutes at shut-off head may damage the pump.
Adverse effects of operation at shut-off head are heat build-up and excessive vibrations.
C. Pump Runout
The last or maximum discharge point shown on the manufacturer's pump curve is
referred to as the pump runout point. Runout implies “close to running away,” which
refers to operating against little head and pushing enough flow that the pump operating
on the extreme right of, or beyond, the end of the manufacturer’s published
performance curve. Operation on this part of the curve is outside the manufacturer’s
recommended operating region and is a region of low efficiency and high-power
consumption and causes vibration and cavitation damage. This condition is often made
worse by the fact that conservative engineering can overestimate pipe friction. Pumps
should primarily be selected for where and how they will operate most frequently. To
help avoid this condition, the design engineer should evaluate proposed pumps across
the entire range of possible pipe friction losses.
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Figure 11-18
Typical Pump Characteristic Curve
B. Multiple-Pump Operation
When pumps are operating in parallel, pump head stays the same but the amount of
flow increases (Figure 11-19). When pumps are operating in series, the TH increases but
the flow remains the same. SPU currently only operates systems in parallel.
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Figure 11-19
Pump Curves for Parallel Pumps and Series Pumps
Figure 11-20
Typical Modified Pump and System Curve (Parallel Pumping)
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Figure 11-21
Typical Modified Pump and System Curve (Series Pumping)
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• Unless approved by all acceptable manufacturers for a particular project, pumps must
operate within the AOR, even for less frequent operating conditions such as minimum
and maximum pumping rates.
Exceptions for efficiency requirements may be considered for pump stations that require
specialized pumping equipment for rag handling. If impeller sizing requirements cannot be met,
contact the SPU project engineer. For more detail on pump design criteria, see DSG section
11.4.2.
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Figure 11-22
Variable Speed Pump Curves
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• Variable Speed Operation at or left of BEP at Full Speed. For pumps intended
to operate at multiple speeds, this approach can severely limit the range of
speeds over which system performance will fall within the POR or AOR. As pump
speed is decreased, the POR and AOR effectively move to the left relative to the
system curve. That means less of the total POR or AOR will overlap with the
system curve(s) at all other speeds.
C. Cutter Impellers
Cutter impellers feature a fixed blade on the pump suction plate that acts against
rotating blades on the bottom of the impeller. This design generates a scissoring effect
that reduces the size of rags and directs rags through the pump. These impellers offer
excellent performance in stations with moderate ragging, with minimal loss of
efficiency. In many cases, cutter impellers can be retrofitted into existing modern
pumps.
D. Chopper Impellers
Chopper impellers are unique to specific types of pumps. They generally provide very
poor hydraulic efficiency but operate under the most severe ragging conditions.
E. Screw-Centrifugal
Screw-centrifugal impellers are a unique hybrid type that offer excellent hydraulic
efficiency and excellent rag-handling capabilities. Pumps with screw-centrifugal
impellers typically require more vertical space and are generally only serviceable by
specialized machinists. SPU operates screw-centrifugal pumps at only a small number of
stations that are subject to extreme ragging conditions.
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The following are the most important factors for multiple pump operation:
• For pumps operating in series, pump discharge pressures are additive while total flow
remains constant. The discharge of Pump 1 is connected to the suction of Pump 2 with
no other (normally open) process connections.
• For pumps in parallel, pump discharge flows are additive while pressures remain
constant. The discharges of Pumps 1 and 2 are normally open and connected to a
common discharge header and both pumps are in operation.
Table 11-27
Recommended Motor Starts per Hour
20 to 50 4
60 to 200 2
> 200 1
20 to 50 4
60 to 200 2
> 200 1
> 100 6
> 100 4
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The following is the formula for the required wet well volume based on pump cycle time:
𝑡𝑡 × 𝑄𝑄
𝑉𝑉 = � �
30
Where:
V = wet well volume (ft3)
t = motor cycle time (minutes)
Q = pump flow rate (gpm)
The pump station wet well sizing example (Appendix 11D - Example Calculations - Wet Well
Sizing) shows how to calculate wet well volume. One method for reducing the required wet well
volume is incorporating control strategies that stagger pump operation in multiple pump
installations. In a two-pump installation, alternating the pumps will result in an effective overall
motor cycle time for each pump. That time will be only half as long as it would have been if one
pump served as the sole duty pump and the other as standby. As motor cycle time decreases, so
does required wet well volume.
Table 11-28
Preferred Manufacturers for Water and Wastewater Pumps
Pump Company
Water Aurora
Fairbanks & Morse
Worthington
Drainage/Wastewater Cornell
Fairbanks & Morse
Aurora
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potential pump base problems, SPU recommends using concrete bases over steel frames for
larger pumps.
Concrete pump pedestals should be used for pump supports and designed for easy maintenance
access (Figure 11-23). The pedestals can be designed with vertical sides to maximize the amount
of concrete mass beneath the pumps. Tapered sides can be used to improve access between
pumps. Incorporation of a sole plate on top of the pump pedestal allows the pump to be
accurately leveled and eases pump removal and maintenance. It is critical that the sole plate be
properly grouted into place to provide firm contact between the pump and the pedestal. Cast-
in-place J or headed anchor bolts should be provided to affix the sole plate to the pump
pedestal. The pump pedestal should be anchored to the pump station floor using cast-in rebar
curtains wherever possible, although epoxy grouted connections are acceptable for retrofits.
Pump bases are unique for submersible pumps installed in a wet well. Their geometry can
significantly affect the pump intake hydraulics. Sufficient exposure is required to the wet well
volume or pump suction appurtenances.
Figure 11-23
Pump Base Support
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breaking of pump nozzles or feet. Another piping problem is natural frequencies of the piping
system causing the pump to operate out of range. A properly designed pipe support system
holds the weight of the pipe rather than imparting such loads on the pump nozzles, while
restraints and guides are used to redirect the forces generated by thermal effects and thrust
away from the pump nozzle. Pipe supports must be designed to handle vertical, horizontal, axial,
thermal, and seismic forces. See DSG Chapter 4, General Design Considerations. Do not connect
piping to pump nozzles with flexible rubberized couplings, as these may result in piping
misalignment when they are improperly installed.
Wet well sizing is nearly always a function of required storage rather than pump hydraulic
performance. Wastewater pump station wet wells require storage capacity to avoid excess
cycling of pump motors and for storage. This storage is required to accommodate pump start
failure and to provide time for maintenance crews to respond to power failures or other
problems. The storage required for managing pump cycling differs from that required for
adequate storage. Each should be considered and the larger value used whenever possible. Cost
and space limitations may limit size. At a minimum, the impacts to motor cycling and emergency
response time (a function of adequate storage volume) should be noted for the wet well size
(volume) chosen.
Improperly designed wet wells can result in excessive capital and O&M cost and can
compromise pumping equipment reliability. Adverse hydraulic conditions at the pump intake
are among the most common source of pump station problems. These problems include
vibration, cavitation, pump failure, unnecessary pump maintenance, and excessive wet well
cleaning and maintenance.
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Table 11-29
Wet Well Self-Cleaning Trench vs. Rectangular Style
Figure 11-24
Self-Cleaning Wet Well Configuration
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The following are design criteria for a self-cleaning, trench-style wet well:
• These wells are sensitive to the uniformity of wet well approach flow. To ensure proper
influent hydraulics, a minimum of eight equivalent diameters of straight influent conduit
are recommended upstream of the wet well.
• A smooth and uniform transition between the influent pipe and the ogee ramp is
required to clean the wet well. To facilitate this transition, the narrow portion of the
trench should extend above the invert of the transition section by a distance greater
than the critical depth of the maximum influent flow during the cleaning cycle. The
narrow portion of the trench should be the same width as the transition section unless a
sluice gate is installed at the wet well entrance. For installations with sluice gates, space
should be provided to allow the gate frame to fit within the narrow portion of the
trench.
• The top radius of the ogee ramp must be designed so that flow does not separate during
the cleaning cycle.
• Trenches can develop air-entraining surface vortices that can enter the pump inlet. For
this reason, these trench designs require more pump inlet submergence than other wet
well designs. The minimum submergence for this trench-style wet well should be 2.5
times the diameter of the inlet bell. It is generally good practice to provide a vertical
distance of 2.5 inlet bell diameters between the invert of the influent sewer and the
bottom of the turned-down flared inlet. For flared horizontal inlets (not unflared
horizontal pipes), 2.5 inlet diameters are required between the invert of the influent
sewer and the centerline of the intake. Additional submergence may be required based
on the NPSH requirements of the selected pump. Close coordination with the pump
manufacturer is required.
• Fillets and a center splitter are required to suppress subsurface vortex formation for the
turned-down type inlet. Fillets and the center splitter should terminate into the ogee
ramp, providing a smooth transition of the high velocity flow from the ogee ramp to the
wet well floor during the cleaning cycle. The height of the fillets and center splitter
should be equal to about 2/3 the bell to floor clearance.
• Because it has a small working volume, this trench-style wet well is most useful in
variable speed pumping applications where influent flow can be matched by the
pumping rate, thereby minimizing pump cycling and required storage.
• Where the influent sewer is used to increase either wet well working volume or storage
volume, the slope of the surcharged portion of the influent sewer should be increased to
facilitate scouring velocities during wet well cleaning. The influent configuration must be
designed to prevent high-velocity influent flow from separating from the ogee ramp.
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Figure 11-25
Usable Wet Well Storage Volume
Wet well storage volume can consist of any combination of the following:
• Pump station usable wet well storage volume (lag pump elevation to overflow
elevation).
• Capacity in gravity pipelines upstream of the pump station (up to a pre-determined
water surface elevation that corresponds in some fashion to a system overflow condition
before flooded basements).
• Separate detention basin that is normally dry but connected to the pump station
specifically to provide additional storage volume (drainage only).
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Choosing the condition at which wet well storage is evaluated has a significant effect on the
required wet well storage volume. SPU evaluates response time based on analysis of historical
inflow data under four different conditions:
• Average spring-summer inflow (April to September)
• Average winter inflow (October to March)
• Average wet weather inflow (SCADA wet weather tag for the active facility based on
nearby rain gauge data)
• 95th percentile inflow
As available, at least two years of data should be used in calculating storage time. Storage time
for all four conditions must be reported in the Basis of Design regardless of which value is used
for calculating response time. This information is used to plan and guide future maintenance
work at the facility. When estimating the available storage time, the design engineer should
select the condition based on the nature of the inflow at a facility. Spring-summer inflow may
not be used for this calculation. For new facilities, the anticipated maximum daily inflow
indicated by hydraulic modeling should be used for calculating required storage volumes if flow
monitoring data are not available.
Exercise judgment when determining how much, if any, capacity in the collection system can be
used for wet well storage volume. Typically, a water surface elevation in the upstream gravity
pipelines will correspond to an overflow or similar condition (e.g., the invert of a connected
pipeline). The available volume of a collection system that can be used for emergency storage
should be determined case by case depending on system geometry, pipe routing(s), backwater
effects, and criticality of operation. The balance of the emergency storage volume must be met
by either increasing the pump station wet well volume or incorporating a separate, dedicated
detention basin that is normally dry, as noted above.
If permanent standby power system is not provided, all pump stations, regardless of storage
capacity, should be equipped with space dedicated to and provisions for a portable standby
generator.
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11.9 CONSTRUCTION
This section describes construction design elements for pump stations. See also DSG Chapter 3,
Design for Construction.
11.9.1 Submittals
Submittals are required for all equipment and materials provided by the Contractor as defined
in the technical specifications. For pump stations, the following items should be carefully
reviewed and approved:
• Materials verifying that proposed equipment meets all requirements of the
specifications, paying particular attention to pumps, motors, motor starters and MCCs,
SCADA equipment, and HVAC equipment
• Layout shop drawings for process piping
• Layout shop drawings for electrical equipment and conduit routing
• Manner and methods to performing activities such as installation and testing
• O&M instructions and requirements
• Certifications of compliance and completion of testing
• Testing and startup plan
Submittals are then reviewed in detail against the Project Manual. Pumps should be reviewed
against the equipment data sheets developed in design and included in the specifications.
Particularly careful review is required when a manufacturer and or model number other than
the first named product is submitted.
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The following are typical SPU requirements for factory pump performance tests:
• Pump manufacturer should guarantee pump performance at the flow, head, brake hp,
and efficiency specified.
• Testing setup should conform to the requirements and (HI standards (ANSI/HI 1.6 –
latest edition). Testing must have a performance tolerance consistent with acceptance
level 1U, as defined in the HI standards.
• Factory performance test should include at least five data points evenly spaced from
minimum to maximum flow to define the shape of the pump curve.
• For variable speed pumps, testing should be conducted at full speed. Affinity laws can be
used to establish reduced speed operating conditions.
• Pump curves developed during the factory test should be certified to guarantee
performance.
• It is acceptable to test performance with a factory calibrated motor as opposed to the
job motor. However, for large equipment that will have witnessed factory tests, SPU may
decide it is more appropriate to use the job motor for the testing. Submersible pumps
should be tested with the job motors.
Factory performance testing is also required for motors. See typical testing requirements in the
example specifications (Appendix 11A – Example Pump Station CSI Specifications, within the
pumping equipment specifications).
If the equipment does not meet the specified operating conditions during the factory
performance test, the pump manufacturer should make the necessary modifications to the
pumps until the specified operating conditions are met.
In general, it is not recommended that motors or VFDs be transported to the pump
manufacturer’s factory for performance testing. Although testing the motor and VFD at the
factory with the pump could turn up operational problems, this testing approach is costly. It also
presents unnecessary risk that the equipment could be damaged in transport.
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Because the level of environmental controls is lower in field testing as opposed to factory
testing, care must be taken to obtain a reasonable level of accuracy during field testing. Field
data should be compared to factory testing data to confirm pump performance. Minor changes
from factory performance should not cause alarm. Many factors affect performance, including
data collection inconsistencies and differences in pump intake hydraulics. Significant differences
between field tests and factory tests would be a more than 5% change in head and should be
evaluated further. Field testing results should be used as a baseline condition to determine
change in performance during future testing.
On large installations, specifications may require an independent company to do vibration
testing. These tests document that equipment vibration does not exceed limits outlined in the
equipment specifications. Many factors can cause excessive vibration: misalignment or
imbalance of rotating equipment, improper pump support, or natural frequency of the pump
and piping that is coincident with the pump rotating speed or a multiple of the rotating speed. If
vibration levels exceed specified values, the root cause of the vibration should be identified and
corrected promptly before it can cause long-term damage to the equipment.
11.9.2.3 Training
Project specifications should require the pump manufacturer to provide training for proper
O&M of the pumping equipment. The trainer should have complete knowledge of this subject
and should train for a minimum of two 8-hour sessions for small equipment and up to five 8-
hour sessions for larger, more complex equipment. Training should be provided to
representatives of the owner’s O&M and engineering staff. The content of the training should
include proper O&M of the equipment with both classroom and hands-on experience.
11.9.2.4 Checklists
Many items are confirmed during startup of a pumping system and each system varies.
Whenever possible, particularly on large installations, a startup expert should be provided with
a copy of the mechanical layout, specification information, and control write-up. The startup
expert should develop a site-specific checklist for installation. For an example startup checklist,
see Appendix 11F - Operational Checklists, Appendix 11G - Equipment Testing Checklist,
Appendix 11H - Operational Acceptance Checklist, and Appendix 11I - Systems Acceptance
Testing.
A. Pre-Operational Checklist
A pre-operational checklist is a tool for all parties to ensure that the pumping system
has been correctly installed, checked by the Contractor, vendor, and owner’s
representative, and is ready for operation. It should be completed by the construction
manager for the owner.
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Information collected during the test should be used as baseline pump performance
data for maintenance purposes.
Periodic service and calibration of all instrumentation such as level sensors, alarms, flow meters,
and SCADA equipment should also be conducted as a part of routine maintenance activities.
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are associated with the asset in terms of safety and environmental integrity, customer service
and so on. RCM identifies a suitable failure management policy for each failure mode in the light
of its consequences and technical characteristics. Failure management policies may include
predictive or preventive maintenance, training, or redesign of existing systems. RCM offers the
following:
• Greater safety and environmental integrity
• Improved operating performance (output, product quality, and customer service)
• Greater maintenance cost-effectiveness
• Longer useful life of expensive assets
• Comprehensive database of maintenance requirements
• Greater motivation of individuals from improved knowledge of equipment
• Better teamwork through common language and understanding of what must be done
SPU has developed a program to evaluate existing systems including pump stations. All new
pump station facilities must have an RCM analysis done before startup and testing. The analysis
will include a detailed operating context for the station, failure modes and effects analysis, and
preventive maintenance tasks. Results of the analysis must be implemented through MAXIMO.
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11.11 RESOURCES
Documents
1. ANSI:
a. ANSI/AWWA D100, Welded Steel Tanks for Water Storage, and NACE Standard PRO
178
b. ANSI/AWS D1.1, Structural Welding Code
c. 73.1, Horizontal end-suction centrifugal pumps
d. E101, Vertical turbine and submersible pumps
2. American Society of Civil Engineers (ASCE): Seismic Design (ASCE 7-02)
3. American Society of Mechanical Engineers (ASME): Boiler and Pressure Vessel Code,
Section VIII, Pressure Vessels and 7.1, 8.2, Displacement and centrifugal pumps
4. ASTM International
5. American Water Works Association (AWWA): ANSI/AWWA D100, Welded Steel Tanks
for Water Storage, and NACE Standard PRO 178, Item No. 53041 and E101, Vertical
turbine and submersible pumps
6. City of Seattle (most current versions):
a. Seattle Plumbing Code
b. SDOT Streets Illustrated
c. Seattle Energy Code
d. Seattle Municipal Code
e. Seattle Parking Requirement Code
f. Sign Code (Seattle Land Use Code Ch. 23.55)
g. Stormwater, Grading and Drainage Control Code (SMC 22.800-22.808)
h. Environmentally Critical Areas (ECA) Ordinance (SMC 25.09)
i. SBC
j. SDOT
k. SPU: Interim CIP Guidance
7. HI:
a. Pump Intake Design (ANSI/HI 9.8)
b. Rotodynamic Pumps for Pump Piping (ANSI/HI 9.6.6)
c. Pump Intake Design Standard
d. Standards (ANSI/HI 1.6 – latest edition)
e. ANSI/HI 9.6.3
8. National Highway Institute: “Highway Stormwater Pump Station Design” Hydraulic
Engineering Circular No. 24, USDOT Federal Highway Administration, Publication No.
FHWA-NHI-01-007, February 2001
9. NEC: Section 501-8
10. NFPA 820, Recommended Practices for Wastewater and transmission facilities
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Websites
http://www.pumps.org/
Removed for Security
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