Chapter 4 - Pumping System PDF

Water Pumping System
Chapter 04
Pump - Technical Presentation
Part -I Part -III

• Introduction to Motors • Drainage
• Introduction to Starters • Sewage Pumps
• Different sewage
Part-II Transportation systems
• Law of Affinity • Dewatering Pumps
• Concept of Hydro-pneumatic
• Parts in Hydro-pneumatic
The First Pumps
Pumping systems are as old as 7000B.C.
7,000 and 5,000 B.C

Evolution of Pumping Systems
Archimedean Screw – 200 B.C
Saqia Water Wheel – 150 B.C – By Egyptians

Classification of Pumps
 Positive displacement pump – Pump Share

force the fluid along with Positive Displacement
Roto Dynamic
volume changes plunger,
squeegee,…)
 Roto Dynamic pump – 27%

acelerates the fluid on a casing 73%
by rotary movement (centrifugal
pump).
Centrifugal action
Centripetal action
Based on direction of flow in ref. to the axis of rotation
 Radial flow - The impeller discharges

Fluid at right angles to shaft axis.
They are used for high head low discharge
 Axial flow - The flow through impeller is parallel

to shaft axis impeller discharges
These are used for Low head but high flow.
 Mixed flow - The flow direction is partially axial

& partially radial hence as a result the flow is diagonal.
These are used for medium head and large discharge.
 Centrifugal pumps - High discharge and Medium Head
 Centripetal pumps - Low discharge and High Head
 Reciprocating pumps - Low discharge and High Head
 Gear / Screw pumps - Handling sludge / Oil
 Air Operated - Corrosive chemicals Diaphragm Pumps

Pump Basics - Technical Presentation
 We will talk on the Centrifugal Pumps, which is one of the type of roto dynamic
pump commonly used.
 The centrifugal Pump has an impeller with radial vanes which rotate, draw water in
to the centre of the pump and discharge it by centrifugal force.
Pump Basics - Technical Presentation
Centrifugal pumps are further classified into ;
Based on Suction Type
 Single-suction: Liquid inlet on one side.

 Double-suction: Liquid inlet to the impeller
symmetrically from both sides.
Based on Mechanical Construction
 Closed: Shrouds or sidewall enclosing the vanes.

 Open: No shrouds or wall to enclose the vanes.
 Semi-open or vortex type.
Types of Pumps – On Mounting
• Depending on the mounting of Motor or prime Mover.
• Vertical
• Horizontal
Types of Pumps - on mounting of Pump/Motor
• Surface Mounted
• Submersible
Types of Pumps – On Coupling
• Depending on the way they are coupled or driven by prime

mover
• Coupled
• Monoblock
Types of Pumps – On Staging
• Single Stage Pumps
• Multistage Pumps
Types of Pumps – On Suction & Discharge
Depending on the orientation of suction and discharge ;
 In Line
 Side Suction Top Discharge

Water Pumps
Application Limitation Advantage Use
Medium capacity Not to be use for Versatile • Water Supply

& Medium Head less flow & High Economical • Fire Fighting
head. Eff low
Low Capacity & Not to be used Economical • Sprinkler Pump

high Head for large flow & Higher Efficiency • Jockey Pump
Low head • Curing Pump
Principle of Centrifugal Pump
The centrifugal Pump has an

impeller with radial vanes which
rotate, draw water in to the
centre of the pump and
discharge it by centrifugal force.
What are the parts in the Centrifugal Pumps?
Casing or Volute
Impeller Shaft
Shaft Sleeve
Bearing bracket
Mechanical Seal or Packing
Prime mover( Motor, Diesel

Engine etc)
Parts of Pumps
 Casing
 Impeller
 Shaft
 Bearing Bracket
 Packing
Pump Casing
• Casing is a receptacle for enclosing the impeller both at

the suction and delivery ends so as to form a pressure
vessel.
• Casings also provides supporting and bearing mediums

for the shaft and impeller assembly.
 Volute Casing Diffuser Casing
 Unsymmetrical Layout Symmetrical Layout
 Simple Construction Complicated Due To In Single Stage Pump
Stationary Vanes In Single
Stage Pum
 Radial Thrust At Part Loads No Appreciable Radial
Thrust And Over Loads
But High Axial Thrusts
 Thrust Sharply Increases As
Qh Characteristic Is Moderate Drooping And Over Loading Type Qh
 Non Overloading Type Unstable Operations At Part Loads Stable
Operation
 Mostly Horizontal And Single Vertical Type And

Multistage Stage Type
Pump Impeller
Based on mechanical construction
 Closed: used where in the transportation of liquid is

clear and does not contain any solids or fibrous material
 Open: used where the liquid to be pumped is with solids.

The height of the vane determines the solid size it can
handle.
 Semi-open or vortex type.- used where some solids are

present in the liquid. The typical use is for handling
muddy water.
SHAFT
 Shaft s a component that carries all the

rotating parts and also provides power to the
impeller.
 The shaft is designed in such a way to

withstand the rotating torque, radial and axial
thrust.
 Depending on the liquid as well as endurance

limit the material of construction is
determined.
Bearings
 Bearings as you all know is device which

keep the shaft or rotor in correct
alignment with its stationary parts under
the action of axial and radial thrust.
 Bearings which are designed to take

radial thrust are called as line bearings
 Those which are designed for axial thrust

are called as thrust bearings.
Couplings
 Coupling are devices used for connecting pump with the prime
mover. This is some times called as mechanical fuse.
Couplings are of two types ;

 Rigid Coupling
 Flexible Coupling.
 A coupling that connect the two shafts solidly for power

transmissions are rigid coupling.
 Flexible coupling allows for easy assembly and dismantling without

disturbing the shafts
Stuffing Box
The purpose of the a stuffing box is to seal off the space around the rotating
shaft where it passes through delivery casing of pump.
Gland packing or mechanical seal are commonly used in pumps

Gland Packing
 In earlier days or for that matter in water pumps still gland

packing is used to prevent water coming out of gland.
Mechanical Shaft Seal
 Mechanical seals according to DIN 24960 norm

Fixed
 Single bellow seal
 Cartridge seal
 Easy Access
 Elastomer:
 EPDM (-15 up to +120°C) Easy
Access
 : Viton® (-15 up to +120°C*)
(*) depending on type of fluid pumped
 Seal faces:
 p < 10 Bar: carbon / silicon carbide
 p > 10 Bar: silicon carbide / carbon Cartridge
Mechanical seal in Normal
(Fixed) version
Recommendation: Use of
the fixed seal is when a long
service life is expected.
 In case of a seal
replacement the disassembly
of the motor stool is
necessary.
Mechanical seal in normal version

(Fixed)
Easy Access-Seal
 Rec.: use for medium-

expected service life of the seal
 With a special tool the seal can

quickly be replaced
 No disassembly of motor stool

for motors >=5.5kW
EasyAccess-mechanical seal
Cartridge Seal
 Use in case of a short-

expected service life
 Quick seal exchange
 No disassembly of motor
stool for motors >=5.5kW
Cartridge-mechanical seal
Prime Mover
 All pumps require a prime mover which is device that

rotates the impellers mounted on shaft.
 The prime Mover can be either Motor, Diesel Engine,

steam turbine etc.
Electric Motors
Electric Motors
Technical Data ;
 Motors are the prime movers to the pump.

Motor with longer shaft
(VM Version)
 They are classified based on the mounting such as
Horizontal/ Vertical.
 They are further divided in to normal shaft or extended

shaft on how they are used in Pumps.
Design V 1  Depending upon the usage they are classified as S1,S2,S3

etc.
Design V 18
Electric Motor Section
The motors which are normally

used and referred are Squirrel
Cage Induction Motor.
The motors when are referred or

specify has to stipulate following
minimum information.
 Voltage
 Voltage Variation
 Frequency
 Frequency Variation
 Class of Insulation
 Degree of Protection.
Cut View of Motor
Cutaway view through stator of induction motor

Open View of Motor
Electric motor rotor (left) and stator (right

Type & Identification of Motor
Motor – Insulation Class
Duty of Motors
 S1Continuous duty : The motor works at a constant load for enough time to
reach temperature equilibrium.
 S2Short-time duty : The motor works at a constant load, but not long enough
to reach temperature equilibrium. The rest periods are long enough for the
motor to reach ambient temperature.
 S3Intermittent periodic duty : Sequential, identical run and rest cycles with
constant load. Temperature equilibrium is never reached. Starting current
has little effect on temperature rise.
 S4Intermittent periodic duty with starting Sequential, identical start, run and
rest cycles with constant load. Temperature equilibrium is not reached, but
starting current affects temperature rise.
Duty of Motors
 S5 Intermittent periodic duty with electric braking Sequential, identical

cycles of starting, running at constant load and running with no load. No
rest periods.
 S6 Continuous operation with intermittent load Sequential, identical

cycles of running with constant load and running with no load. No rest
periods.
 S7 Continuous operation with electric braking Sequential identical cycles

of starting, running at constant load and electric braking. No rest periods.
 S8 Continuous operation with periodic changes in load and

speedSequential, identical duty cycles run at constant load and given
speed, then run at other constant loads and speeds. No rest periods.
Selection of Motors for Pumps
 Motors to have only 10 – 15% excess power over pump’s requirement to

run on optimum efficiency.
 Motor speeds to match the manufacturer’s choice to have better efficiency

of the pump.
 Choose Energy Efficient Motor in general and it is most preferred when

load is highly fluctuating like Boiler feed, Reverse Osmosis System,
Water Treatment, Cooling Water Systems.
Motor Power depends on the following factors ;
 Run pumps only in designed head and flow rate
 Maintain optimum clearance in pump internals to avoid

efficiency loss
 Avoid excessive Gland packing pressure
 Avoid Air entry through gland when pump runs with negative
suction.
Reason for Excess Power Consumption
 Wrong selection on type of pump
 Over designed / Under designed pump
 Improper layout
 Old inefficient pump
 Multiple smaller size pumps
 Ad-hoc decisions taken during break down.

How Efficiency of Motor is improved ?
 Reduction of Iron losses achieved by low loss magnetic material or

reduced flux density.
 Reduction of Copper losses achieved by increased copper

section and consequently increasing the core length.
 Maintaining uniform low air gap between stator and rotor to

reduce the slip.
 Reducing weight and dimension of the fan to reduce windage loss.

Should I Rewind A Failed Motor ?
 Rewinding reduces efficiency.
 More no of rewinding reduces efficiency drastically

even to the tune of 10% of the original efficiency.
 It is always better to change to new motor to save on loss

of efficiency thereby increasing the energy cost.
 It would be better to replace with high efficiency motor, cost

of which would be paid back by the cost of energy saved
over a period of time.
Starters
 DOL
 Star- Delta
 ATS
 Soft starters
DOL Starter
A small motor can be started by simply plugging it into an

electrical receptacle or by using a switch or circuit breaker.
When energized, a direct on line (DOL) starter immediately
connects the motor terminals directly to the power supply.
 high inrush current of the motor does not cause excessive

voltage drop in the supply circuit.
DOL starter
Star Delta starters
 Star Delta starters are generally used in situations where you want to
reduce the inrush current to the motor when the starting contacts
close.....
 When a relay starter closes on a motor wired delta it can draw as much
as 5 times its running current..... This can cause nuisance trips of
circuit breakers but it can also cause lights in a building to dim and
other low voltage conditions...
 When a motor starter starts in star it draws far less inrush current to the
motor windings of the buildings electrical equipment. Reducing the
above effect.
Star Delta Starter
Soft Starter
 A motor soft starter is a device used with AC electric motors to temporarily reduce the
load and torque in the powertrain and electrical current surge of the motor during startup.
This reduces the mechanical stress on the motor and shaft, as well as
the electrodynamic stresses on the attached power cables and electrical distribution
network, extending the lifespan of the system.
 Motor soft starters can consist of mechanical or electrical devices, or a combination of

both.
 Electrical soft starters can use solid state devices to control the current flow and therefore
the voltage applied to the motor. They can be connected in series with the line voltage
applied to the motor, or can be connected inside the delta (Δ) loop of a delta-connected
motor, controlling the voltage applied to each winding. Solid state soft starters can control
one or more phases of the voltage applied to the induction motor with the best results
achieved by three-phase control. Typically, the voltage is controlled by reverse-parallel-
connected silicon-controlled rectifiers (thyristors), but in some circumstances with three-
phase control, the control elements can be a reverse-parallel-connected SCR and diode.
Schematic of Soft starter
Part - II
 Pump and System curves
 Laws of affinity
 Hydro pneumatic System
 Parts of HPN
 VFD system
Review of Pumps, Motors, Starters
 Parts
 Types
 Motors
 Insulation
 Degree of protection
 Starters
 DOL
 Star- Delta etc
Principle of Centrifugal Pump
 The head and capacity are the main factors, which affect
the horsepower of the motor to be used.
 Head- Depends on impeller diameter, number of

impellers, size of impeller eye & shaft speed.
 Capacity- Is determined by exit width of the impeller.

Pump Performance Curves
 The Head – flow curve.
 The Efficiency curve
 The Energy curve
 NPSH Curve
The Head-Flow Curve
The pump companies develop their curves using head in meters ( H ).

They specify the pumps only in height ( H ) and not in pressure ( Bar)
The reason
 When the companies make pump they do not know the liquid that the pump
will be pumping,
 But they know the elevation to which pump can raise liquid.
 By knowing the Head, Pressure could be calculated using following formula.

The Head-Flow Curve
The matrix of the pump curve graph is the same as the mathematical
‘x-y’ graph.
 On the horizontal line –

 The flow is shown normally
 in m3/hr or lpm or lps
 The vertical line -

 The head in feet or meters.
The Head-Flow Curve
The pump can elevate a liquid in a vertical tube up to a point where the weight of the liquid
and gravity will permit no more elevation. This point on the pump curve would be the
‘shut-off head’.
Once again, imagine starting a pump and raising the fluid in a vertical tube to the point of
maximum elevation. On the curve this would be maximum head at zero flow. Now, rotate the
running pump on its centerline 90°, until the vertical tube is now in a horizontal position.
The Energy - BHp Curve
The energy (BHp) curve

The brake horsepower (BHp) is the
energy required by the pump.
Consider the following:

The pump consumes a certain
quantity of energy just to maintain
shut-off head.
Then, as flow begins and

increases, the horsepower
consumption normally increases.
(On certain specific duty pumps,

the BHp may remain mostly flat or
even fall with an increase in flow.)
The Pump Efficiency Curve
Imagine a small pump connected

to a garden hose squirting a stream
of water across the lawn.
• Direct the flow from the hose up

into the air at about a 45-deg angle
• The stream of water would attain

a specific height into the air and a
specific distance.
• The elevation that attains the best

distance, when plotted onto the
pump curve, is called (BEP)
• The efficiency curve of a pump is

seen as the trajectory or arc of a
stream of water.
Basic Parameters Required for Choosing
Centrifugal Pumps
 Liquid to be handled
 Flow rate in Cu.m/hr / LPM / LPH
 The total head in Mtrs
 Specific gravity
 Viscosity
 Temperature
TOTAL HEAD OF PUMP
Total Head = Hsuction + Hdischarge + Hlosses
Brake KW Calculation
Typical Pump Characteristic Curves
NPSH m
Pump System Resistance Curve
Pump Operating Point
Selection of Point
At point ‘A’ – Best efficiency point
1. Optimum efficiency point best

efficiency
2. Optimum energy curve.
3. Optimum NPSHr ,where it

begins its sharp rise.
Selection of Point
At point ‘B’ – Head (Pr) is

High & Flow is low
The pump is operating to the left
of BEZone.
1. Low Efficiency at this point.
2. Reduced NPSHr,
3. The BHP consumption is also
reduced,
Pump behavior
1.The pump will vibrate and

heat the pumped liquid.
2.The shaft is under deflection,
causing stress to the bearings
3. Causing stress to mechanical
seal or shaft packing rings).
Selection of Point
At point ‘C’
- Flow is high & head (Pr) is low.
The pump is operating to the right
of BE Zone.
1. Efficiency is low at this point.
2. The NPSHr is very high, and
3. The BHP consumption is also rising,
The NPSHr has risen to the point that

1.The pump is being strangled;
2.Liquid exit is faster than its entry
into pump.
3. Pumped liquid is prone to vaporize
or boil.
4.This is where vaporization
cavitations occurs.
The Pump Curve Landmarks
Allowable Operating Range – (AOR)

Recommended by the pump manufacturer
service life of the pump is not seriously

compromised.
Preferred Operating Range - (POR)

flows specified around the pumps BEP
Continued operation within the POR
extends the pump life further.
A recommend value for POR is between

70% and 120% of the BEP flow.
Net Positive Suction Head Required
NPSHr
It is the energy in the liquid required to overcome the
friction losses from the suction nozzle to the eye of the
impeller without causing vaporization.
Remember :
It is a characteristic of the pump and is indicated on
the pump's curve. It varies by design, size, and the
operating conditions.
An easy way to understand NPSHr is to call it the
minimum suction pressure necessary to keep the pumped
fluid in a liquid state.
According to the Standards of the Hydraulic Institute, a suction lift test is

performed on the pump and the pressure in the suction vessel is lowered to the
point where the pump suffers a 3% loss in total head. This point is called the
NPSHr of the pump.
Net Positive Suction Head Available
NPSHa
This is the energy in the fluid at the
suction connection of the pump over
and above the liquid’s vapor pressure.
It is a characteristic of the system.
Remember :
NPSHa only deals with the suction
side of the pump.
NPSHa and NPSHr
During pump operation,

NPSHa should be always greater than the NPSHr
NPSHa > NPSHr

As a general guide the NPSHa should be a minimum 10% or 1 meter above the
NPSHr, whichever is greater.
NPSHa is in system which user want pump for.
Therefore you have to calculate it
HOW ?
Formula of NPSHa is….
NPSHa = Ha +/- Hs - Hvp - Hf

Before we proceed keep in mind following:
Pressure can be converted into head with the following

equation:
10,2 x Pressure ( bar )
H (mtr) =
Specific gr
Head can be converted into pressure with the following

equation:
H ( mtr ) x Specific gr
P (bar) = 10,2
Affinity Law
• If pump speed is reduced from 2900 to 1450

• Head becomes 1/4th and Capacity is reduced to 1/2
• Power consumption to 1/8th.of the rated parameters.
Effect of Speed Variation
Effects of Variable Speed
n1 = 2900
H
n1 x (Q2/Q1) = n2
2900 x (12.5/25) = 1450 10
n2 = 1450
H1 x (Q2/Q1) 2 = H2 2.5
2
10 x (12.5/25) = 2.5
1.2
3
P1 x (Q2/Q1) = P2
1.2 x (12.5/25) 3 = 0.15 0.15
12.5 25 Q
Impeller Diameter Reduction on
Centrifugal Pump Performance
Changing Impeller Diameter
d1  216
Q2 H
d 2  d1  d 2  193
Q1
40
d 2  216
50
d 2  193 0
0 Q2 Q1 Q
Pumps in Parallel With System Curve
Pumps should be identical

Parallel Operation of Pumps
Q
Theoretic:
Double flow [2 x Q]
Same head [1 x H]
Benefits of pumps in parallel
• Improved operating economy
– Only the required number of pumps in operation
• High efficiency
– Each pump runs at high point of efficiency
– Low power consumption
• Reliability
– Redundancy
– Service
– Pump failure
• Wide performance range
• Improved adaptation of duty point
– Parallel operation improves adaptation to varying
demands
Series operation of Pumps
Theoretic:
Double head [2 x H]
Same flow [1 x Q]
Q
Water Pumps-Vertical Inline
Application Limitation Advantage
Most suited for • Clear water • High Efficiency

low flow and high
head • Dry run very
dangerous • Complete SS304
/ SS316
• Jockey pump •Costlier
• Sprinkler Pump • Pay back of

investment in
• Hydro pneumatic one year
System
Vertical multistage in-line Stainless Steel Pumps
Vertical Multistage in-line Stainless Steel Pumps
Affinity Laws
nx  Qx 
   Speed n is proportional to
flow Q
n Q
2
H x  Qx  Head H is proportional to flow
  
H Q in second power.
3
Px  Qx  Input power is proportional to
 
P  Q  flow Q in third power
Hydropneumatic Boosters
Methods of Boosting, Methods of
Distributon
Main Purpose of a Booster Set
 Boosting a sufficient amount of water against minimum required

pressure, keeping the water quality at the highest level
Hydro Vs Overhead Tank……General issues
 Maintenance could be a problem...

 No water in case of power failure…
 Systems are costly compared to overhead tanks…
 Too advanced systems and it could be difficult to run these systems…
 These systems are useful for only Hotels…
 Why should builder pay money unnecessarily on these systems when
they do not get any returns…
Hydro Vs Overhead Tank……A Study
A Residential building having peak demand of 50 M3/Hr…….
Total capacity of overhead tanks: 1,60,000 Litres

Number of Tanks: 4 nos. of 40,000 Litres each
Approx cost of each Tank: Rs. 4,00,000=00

Total Cost: Rs 16,00,000=00
(This itself is very conservative figure)
Approx cost of Variable Speed Hydro Pneumatic system for this

capacity
Rs 6,00,000=00 Lacs
Net saving in direct cost
Rs 10,00,000=00
Other Savings/Advantages of
Hydro over Overhead Tanks
 Saving in labour cost…
 Lower weight on structure columns…
 Removal of overhead tank…….good for seismic areas/regions as dead load is

removed from rooftop of buildings…
 Smaller pipe size due to Hydro boosters…so less cost of piping…
 No hassle of maintenance of overhead tanks…
 No leakage problem from overhead tanks…
 Most of the buildings are with DG back up supply so no issue of water problem
in case of power failure…
Other savings/Advantages of Hydro over
Overhead Tanks
 No scale formation in pipe lines due to increased velocity of water due to

boosters…
 Improved building elevation and aesthetics…
 Far better comfort level compared to gravity feed (overhead tank) systems…
 Recognition for builder for providing comfort and better water supply system…
What are the options if overhead tank is still there
 Small booster for top floors
 Pressure reducing valves for other floors
 Control the roof tank level with control

Piping layout ( Booster with O/H Tank)
• Roof tank
• Booster system: 106% p=0
p min
p max
Piping layout (Direct Booster)
 1 x unit + PRV (Pressure Reducing Valve)

 Booster system: 100%
p min
p max
p min
p max
Piping layout Stage Pumping
2 x units, high and low pressure - Booster system
p min
p max
p min
p max
Piping layout
 2 x units, Stair step

 Booster system: 54%
Continued…
 In the system the most important thing is to size the tank.
 The two types of the systems available in the market are :

 1. Booster System With Pressure Switches
 2. Booster System With VFD.
Schematic Diagram of Hydro-pneumatic Systems
Hydro-Unit Design
 Main components – key features

Hydro-Unit Main Components
 Pumps
 Non-return valves
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device
high efficiency
stainless steel
 Pumps
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device
min. press. loss, no water

hammering
 Pumps
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device
free passage viton ball sealing
 Pumps
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device high accuracy class 1.6
 Pumps
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device
first class components failure safe

design
 Pumps
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device pressure reference small pressure tank
 Pumps
 Shut-off valves
 Pressure gauge
 Control panel
 Headers
 Pressure tank
 Control device
Hydro-Unit Controllers
The two types of the systems available in the market are:

– 1. Booster sets with constant speed
– 2. Booster sets with variable speed
Constant Speed Booster Sets
Typical performance curve
Fixed Speed:
 Flow leading (opening taps)
 Pressure as a result of the
performance curve
Q/H
P/St.
Eff [%]
NPSHreq.
-- No demand
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Demand of water
-- Pressurisation
-- Pressurisation
-- Pressurisation
-- Pressurisation
-- Pressurisation
-- Pressurisation
-- Pressurisation
-- Pressurisation
Variable Speed Booster Sets
Typical performance curve
Frequency controlled:
 Keeping a constant pressure
Q/H
P/St.
Eff [%]
NPSHreq.
Frequency controlled booster sets
 Single frequency converter

 Multiple frequency converters
 Integrated frequency converters
Basic Calculation of Booster Sets
 Required head
 Required capacity
 The relationship is the pump curve!
Required Head H [m]
h min
h stat.
h fl
h city/tank h max
Required Head H [m]
h min (10 – 30 m)
h stat.
h fl (1 m / 10 m stat.)
- h city/tank
h req.
Zones 1 – 4 bar
120 m / 40 floors
 Min head = 10 m
 Max head = 40 m
 Zone range = 30 m
 Floors 30/3 = 10 floors per zone
Zones 1 – 4 bar
90 m 4
1
60 m 4
1
30 m 4
1
13 bar 10 bar 7 bar 4 bar 0m 4

Required Capacity Q req. [l/s]
Each tap point = n x Tap Unit's

1 Tap Unit = 0.083 l/s
Toilet = 0.25 TU
Washbasin = 1 TU
Shower = 1 TU
Bath = 4 TU
Kitchen tap = 4 TU
Dishwasher = 4 TU
Q req = 0.083 x √TUtotal

Q req Curve
Capacity [lpm]
450
400
350
300
Apartment:
250
2 toilets
200 1 wash basin
1 wash basin mixture
150
1 shower
100 1 kitchen sink mixture
1 dishwasher
50
1 washer
0
nr 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380
apartments
Pump Selection
• H req. [m]
• Q req. [l/s] Typ. program
Nr of pumps?
2 pumps
• Duty / standby  Qreq = 100%
• 2 duty  Qreq = 50% per pump
3 pumps
• 2 duty / 1 standby  Qreq = 50% per pump
• 3 duty  Qreq = 33% per pump
Type selection booster systems
looking @ energy
Installation
Booster control: with running time 100%
HU Standard
Installation
Booster control: Each pump a VFD - Energy 83%
HU FR
Installation
Booster control: one VFD - Energy 69%
HU MCF
Installation
Booster control: without running time - Energy 39%
HU HR
Installation
With running on time 100 %
Each pump a VFD 83 %
1 VFD 69 %
Without running on time 39 %

Piping layout
Rooftank 106 %
1 x unit + PRV 100 %
2 x unit, High and Low pressure 54 %
2 x unit, Stair step 54 %

Storm and Drainage Pumps
Storm water and Drainage Pumps
 Radial flow or mixed type are divided in to 3 type

depending on the type of impellers
Open Impeller
Semi Open Impeller

 Open Impellers
 The pumps with open impeller are, used where the

liquid to be pumped is with solids. The height of
the vane determines the solid size it can handle.
 Semi Open Impellers
 As the name suggests, these are used where some

solids are present in the liquid. The typical use is ,
for handling muddy water.
 Closed Impellers
 The Pumps with closed impellers are used where in the

transportation of liquid is clear and does not contain any
solids or fibrous material
 After seeing the type of the impellers , now it is clear that for handling
muddy water, we have to use pumps with either semi open or open type
impellers.
 Next step after, selecting the type of impeller to be used in pump, is to

select type of the pit (Collection Chamber).
 However it’s better that we know the standard terms which are used in the
storm water or sewage pumping.
Sullage: The waste water which comes from bath

rooms, Kitchens, Wash basins etc is known as Sullage
waste water.
Sewage: The waste water coming from latrines,

Urinals, Stable industrial waste, ground water and
surface water including Sullage water is known as
sewage water.
• Domestic Sewage: As the name suggest, the waste water originating from
urinals, latrines, bathroom kitchen sinks etc of the residential, commercial or
institutional buildings.
• Industrial sewage: It consists of liquid wastes, generating from industrial

processes of various industries, urinals, Latrines etc .
• Sanitary sewage: This is the sum of total domestic and Industrial sewage.
• Storm Sewage: The run off resulting from the rain storms is called
storm sewage or drainage.
• Sewers: It is an underground conduit through which sewage is carried

to a point of disposal.
• This storm water or the sewage system is divided further based on the
way it is carried to the destination and the type of waste water it carries.
Types of Waste water carriage systems.
Separate sewers: These type of sewers carries domestic and Industrial

wastes only.
Storm water sewers: These type carries rain water.
Combined sewers: As name suggests they carry both rain water as well as
domestic and Industrial wastes.
 Separate systems: When the drainage or storm water and sewage are taken
independently of each other through 2 different sets of conduit they are called
separate systems
 Combined Systems: When drainage and sewage are taken through one
conduit they are called combined systems.
 Partially separate: As the name says sometimes drainage

water or storm water is allowed to admit in to the sewers, this
is known as partially separate system.
 In the modern days separate system is generally preferred.

Calculation of the flow:
 Residential: For all small residential areas, waste water flows are commonly
determined on the basis of average per capita contribution of waste water and
density of people.
 For large residential areas waste water flows are determined by considering 75 to
80%of the accounted water supplied from the water works.
 Commercial: These flow are generally calculated based on existing or

anticipated future development data. Commercial sources of waste water are
airports, Hotels, Laundries, Shopping centers etc.
• Industrial: Industrial waste water flows are

dependant on the type of industry in consideration
e.g. Textile industry requires more water than
automobile industry.
• Once we know what is the type of flow for which

we are designing pumping station next step is to
calculate detailed flow. This total qty of waste water
or sewage water is further divided in two
components.
Dry weather Flow
Storm water flow.
• As the name indicates, Dry weather flow or in short DWF is

the qty of waste water that flows through sewer in dry weather
when no storm water is in the sewer.
Factors affecting the DWF
Population Growth
Type of Area served
(Residential, Commercial, Industrial)
Infiltration of ground water
Rate of water supply (Rural, Urban etc)

 The designer should consider both maximum and minimum flow while designing
the sewer.
 The designed sewer should take maximum load and at the same time they should be
laid on such longitudinal gradient that there are no deposits in the sewer at minimum
flow.
 There can be variation in the sewage ,which may be due to following ;

 Type of industries
Habits of the people
Climatic conditions
Timing of water supply

 Theoretically speaking, the quantity of waste water likely to enter in the

municipal sewer should be equal to quantity of water supplied to the
contributing area, from the water works.
 The record of water supplied to the public through the public distribution
systems are easily available from the water works office. The other sources
such as private wells, tube wells may be used by public for domestic needs
and similarly certain industries may utilize their own source of water. This
quantity however can be calculated by actual field observation.
In short
 Net quantity of waste water produced =

Accounted qty of water supplied from water works + addition due to
the above factors.
In practice based on the data collected , following table is used to

determine the estimated design flow.
Serial Number Population Per capita Per capita
water demand sewage or
lit/per/day waste water.
Lit/person/day
1 Less than 110 90
20,000
2 20,000- 110-150 90-120
50,000
3 50,000- 150-180 120-150
2lakhs
4 2lakhs-5 lakhs 180-210 150-170
5 5lakhs-10 210-240 170-190

lakhs
6 Over 10 lakhs 240-270 190-200
 Variation of waste water flow with respect to time is shown in the

below graph.
 While designing sewer we have to consider both peak flow and
the minimum flow
 This slide will show the variation of the flow with respect to
climatic conditions. This aspect has to be taken care while
designing the peak flow.
 As explained earlier , for designing the sewer size the maximum flow,
minimum flow and average daily flow are calculated.
 Minimum flow is important in designing sewer because ,if the flow is

less it’s velocity will be less through the pipe. This may cause silting. As
can be seen from the graph The flow is minimum at night when people
are at sleep.
 Sustained flow which are the flows that persist for various time(2 hrs or
larger) are also important while design of the sewer.
 We have seen about the Dry weather flow and factors considered
while calculating this flow.
 Storm Water Flow
 In the separate sewage system the sewers and drains should be

designed for maximum sewage discharge and maximum rain run
off separately.
 When rain fall takes place, a part of it infiltrates into the ground surface
and the remaining water flows over land. This storm water ultimately
drained through sewers.
 The amount of peak storm water flow is generally very high say 20-25
times that of sewerage discharge.
 In a combined system , consideration is given to the fact that normally

sewers are not designed to pass this combined flow only, but they
should be capable of passing the low sewage discharge during non
monsoon period with minimum permissible velocities.
The peak rate of run off depends on the following factors.
 Intensity of rain fall.

 Duration of Rainfall.
 The rainfall distribution.
 The soil moisture deficiency.
 Ground slope.
 Permeability of the ground.
 Shape and type of catchments basin.
 Extent of vegetation growth.
 The direction of prevailing storm etc.
 There are various methods by which you can calculate the storm
water flow. We are not covering this aspect.
 We have now seen the basic points considered to calculate the capacity
or the flow from the sewers. We have also seen some aspects which are
considered for designing the sewers.
 We should now understand the necessity of the pumping these waste

water. The necessity of lifting the sewage arises under the following
conditions.
 The sewage of low –lying area of town has to be pumped in to branch or

main sewer of town.
 Due to this low lying , the laying of sewers at their designed gradient
requires deeper and deeper excavation. To avoid this it may be advisable to
lift sewage at suitable intervals
 In case if the basement of the large commercial buildings ,sewage may
have to be pumped because, the sewer at the street may be at higher level
than of basement floor.
 When the sewer has to go across a high ridge it will be more economical to
pump it in to sewer laid across the slope of the ridge at reasonable depth
instead of driving through a tunnel.
 After knowing the importance of pumping we have to select a proper

location of pumping station. Normally these pumping stations are near a
disposal unit such as river or a lake so that the accumulated sewage can
overflow in such disposal units in case break down of pumping plant etc.
 In the European countries all efforts are put in so that the effluent water is
treated further and can be used for gardening purpose. In India also such
type of plants have been designed , but because of lack preventive
maintenance most of the plants are not treating the sewage effectively.
The Pump station design presents the designer , a
challenge to provide a cost-effective drainage
system that meets the needs of the project.
There are many considerations involved in their

design. Below is a listing of some of them.
• Wet pit vs. dry pit
• Type of pumps
• Number and capacity of pumps
• Peak flow vs. storage
• Force main vs. gravity
• Monitoring systems
• Backup power systems
 Many of the decisions regarding the above factors are currently based on
engineering judgment and experience.
 To assure cost-effectiveness, the designer should assess each choice and

develop economic comparisons of alternatives on the basis of annual
cost. However, some general recommendations, as discussed can be
made which will help to minimize the design effort and the cost of these
expensive drainage facilities.
Before going in to detail about the pumping station we should

know the terminology of the components which are part of the
pumping station.
 Grit Channel
 Coarse and Fine screen
 Rising mains
 Sump well
 Pump room
 Other accessories such as valves, flow recorders, starters
etc.
Grit channel: To minimize the wear and tear of the impeller and of rising
main from the indestructible solid matters, sand, gravel etc this chamber
is provided at the inlet of sewage station. In this chamber the velocity of
sewage is reduce which allows the grit to settle down and then is removed
by a chain or buckets etc. Typical lay out is as shown below.
 Storage Requirements and Design of Sump

 The sump storage volume, shape and position are important ,
because together with pump capacity, they determine the intermittent
operating characteristics of the pump.
 The sump must be large enough so the pump doesn’t start/stop

excessively. Storage below the minimum water level serves as
sediment storage and should be as minimum as possible.
 There should be a bottom clearance of 1/3 the diameter of the

suction pipe.
 First we will see what are the types of pits
 Wet Well type Motor on the top)

 In a pumping station shown , the pumps are located at ground

level above the wet well.
 The water rises up from the wet well to the pump through a
vertical suction pipe.
 The pumps can be self-priming or primed with a small vacuum

pump. The pumps, valves, and control panel are located above
ground. The equipment is usually housed in a enclosure. This
is a relatively economical installation. This installation is used
for temporary purpose or at the sites.
Dry Pit
 In this type of Pumping station the pumps are installed in a

dry area adjacent to and taking its suction from a wet well.
In this type of station, both the wet well and dry well are
constructed of reinforced concrete.
 The above ground structure is often brick and block. The

pumps, piping, valves, and control panel are installed in the
dry pit.
 This type of station is more appropriate for the larger capacity

installations.
 An engine-driven generator can be installed for use in case of

a power failure.
 Dry Pit extended motor type Pump
 If you see in the earlier slide the motor was coupled to the
pump directly where as in second type motor shaft is extended
till the floor level and then coupled to the motor.
 Wet Pit Submersible type Pump

 A submersible non-clog pump operates underwater. The motor

is sealed water-tight and designed to operate in submerged
conditions.
 The pumps are removable for maintenance without a person

entering in the wet well.
 A pump can be easily hoisted out on guide rails by a person

standing on the ground surface. The electrical control panel is
mounted on posts above ground. This type of station normally
includes a separate valve chamber. It is considered the lowest
cost sewage pump station for many reasons.
 Submersible Grinder
A submersible grinder pump is similar to a non-clog pump
except that it grinds up the solid matter in sewage rather than
pumping it. A grinder pump can have smaller discharge piping
than a non-clog pump.
 At least two pump units should be provided, each capable of handling
the expected maximum flow.
 Where three or more units are provided, they shall be designed to fit
actual flow conditions and must be of such capacity that, with any one
unit out of service, the remaining units will have capacity to handle the
maximum sewage flow.
 When the incoming flow rate in the station is less than ½ of the
average design flow ,the design of the sump should take care septic
nature of the sewage and reduce the holding time in the wet well.
Normally detention time of 15 to 30 minutes of peak flow is considered.
 Some times the use of variable-speed pumps are

considered, particularly when the pump station delivers
flow directly to a treatment plant, so that sewage will be
delivered at approximately the same rate as it is received
at the pump station. This system has it’s own advantages
and disadvantages.
 Wet well ventilation may be either continuous or intermittent.
 Ventilation, if continuous, should provide at least 12 complete air changes

per hour; if intermittent, at least 30 complete air changes per hour. The fresh
air should be forced to go in wet well by mechanical means.
 In case of dry pit installation access to the wet well should not
be through the dry well.
 The dry well should have a gastight seal when mounted

directly above the wet well.
 Submersible pumps if used ,should be readily removable and

replaceable without dewatering the wet well or requiring
personnel to enter the wet well.
 A hoist and accessories for removing the pumps from the wet
well should be provided.
• Sewage Pump Stations
How Sewage Pump Stations Operate

Most sewage pump stations operate on a float-type
system.
• As the wastewater flows into the wet well by gravity,

the water level in the wet well rises until the maximum
operating level is reached. At the high level, a float
switch is actuated to turn on a pump. With the pump
running, the water level falls. The pump keeps running
until the water level reaches the low level. At the low
level, another float switch is actuated to turn off the
pump.
• The cycle is repeated several times during the

day. The station can include a high water
alarm that alerts you when the pump has
failed or isn't pumping out fast enough to
keep up with the flow.
•
Pump Control Level.
high level alarm / float set at 300mm above
standby cut-in level
• emergency level alarm set at 500mm above
standby cut-in level
• Pump control is to be set for not greater than
6 hours detention period or 30 min of peak
flow
 The pump controller is to switch off pump under the following

conditions:
 Low water level.
 Thermostatic overload is tripped;
 Any pump failure.
 Dry pit stations are more expensive than wet pit

stations. (Construction Cost)
 Dry pit stations are more appropriate where pump and

motor size increases. Over all maintenance cost of these
are less than the submersible.
 Ease of access for personnel to perform routine and

emergency pump maintenance of pumps, valves, and
other equipments compare to submersible wet pit.
 The storm water or sewage water pumping stations with wet well are
provided with extended or long shaft pumps where in space and depth is
constrain. The maximum shaft height can be of 2mts.
 Now a days where the space has become constrain, the use of dry pit
stations are not recommended.
 Submersible type pumps can also be used in a dry pit configuration, thus
eliminating the long shafts. In this type of pumps the provision for cooling
motor is made. All other advantages of dry well pit explained earlier also are
applicable here.
 Material for the pumps.
 When the sewage and storm are carried together in short if the system is
combined type it is better to have all rotating parts in Alloy Cast Iron
instead of only CI.
 When the pumps are selected for handling industrial sewage it is
advisable to go for stainless steel impeller.
 There is present trend to specify all parts in stainless steel. This is really
not necessary.
 The best possible combination for pumps parts are as under.
 Casing: CI, Impeller: Alloy CI, Shaft AISI410 , Fasteners SS, Motor
body for submersible pump in CI for domestic and SS for Industry.
 In a nut shell we will revise what ever we have learnt in this session.
 We have seen the types of pumps and material suitability for sewage
and storm water.
 The importance of shape of the impeller in deciding the application .
 We have seen various types of flow and understood the important

definition used in storm water and drainage applications.
 We have seen the difference between the Sullage and sewage.

 We have learnt the way the Sullage and sewage is transported.
 We have seen by thumb rule as how to calculate the flow.
 We have seen the types of pit or the pumping stations.
 We have also seen how the various types of pumps can be used depending
upon the type of the sumps.
 We have seen the storm water flow and the factors which influence the
same.
 So when you want to design any of this pumping station please check the
following check list.
 PUMP STATION Location @ ?
 Sump type??
 Pump self-priming? Submersible?
 Pump Type Constant-speed non-clog? VS?
 Capacity ?? gpm @ ?? ft Total Dynamic Head
 Overflow Point Overflow elevation and location
 Overflow Discharge Trout Creek? Playground? Sinkhole?
 Avg. Time to Overflow ?? hours
 Auxiliary Power Type Portable diesel generator?
 Length, Type of pipes ?" PVC?

 Profile of land ,Continuously Ascending??
 Discharge Manhole location??
 Average Detention ? min @ start-up,
 Pump HP (each) ?? HP
 Level Control Type
 Telemetry or the controls
SUMMARY AND CONCLUSIONS
 Install all measuring instruments like pressure gauge and

flow meters
 Choose the required duty parameters
 Choose the correct size of pump and motor
 Do not oversize the pump or motor and waste power
 Do not throttle the valve for continuous operation instead
change the impeller dia or change the pump
 Choose high efficiency motors to save on power
 Use VFD only when there is requirement for longer variable
outputs.
 Last but not the least create routine maintenance schedule to
avoid break down.
Sewage Pumps
Medium flow Surface Mounted Economical
Medium head low particle Efficient

handling capacity
• Effluent Easy to Maintain
• Sewage
• Raw / Storm water

Submersible Pumps
Medium flow High particle

Expensive
Medium head
Tough Sump Installed
Maintenance
• Effluent Good aesthetic
• Sewage
• Raw / Storm water

Thank you
Any Questions?
Authors : Rajendra Heda, IPA
Disclaimer : The topics/information included in this presentation and seminar is for informational purpose and plumbing education only. The materials and the oral presentation
accompanying them are for educational purpose and do not constitute legal advice. IPA and individual authors assumes no responsibility for errors or omission in this document, except if
such damages were caused by Indian Plumbing Association (IPA) intentional or gross negligence.

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Water Pumping System

Part -I Part -III

Pumping systems are as old as 7000B.C.

7,000 and 5,000 B.C

Archimedean Screw – 200 B.C

Saqia Water Wheel – 150 B.C – By Egyptians

 Positive displacement pump – Pump Share

 Roto Dynamic pump – 27%

 Radial flow - The impeller discharges

 Axial flow - The flow through impeller is parallel

 Mixed flow - The flow direction is partially axial

 Centrifugal pumps - High discharge and Medium Head

 Centripetal pumps - Low discharge and High Head

 Reciprocating pumps - Low discharge and High Head

 Gear / Screw pumps - Handling sludge / Oil

 Air Operated - Corrosive chemicals Diaphragm Pumps

Centrifugal pumps are further classified into ;

Based on Suction Type

 Single-suction: Liquid inlet on one side.

Based on Mechanical Construction

 Closed: Shrouds or sidewall enclosing the vanes.

• Depending on the mounting of Motor or prime Mover.

• Depending on the way they are coupled or driven by prime

• Single Stage Pumps

Depending on the orientation of suction and discharge ;

 Side Suction Top Discharge

Application Limitation Advantage Use

Medium capacity Not to be use for Versatile • Water Supply

Low Capacity & Not to be used Economical • Sprinkler Pump

The centrifugal Pump has an

Prime mover( Motor, Diesel

• Casing is a receptacle for enclosing the impeller both at

• Casings also provides supporting and bearing mediums

 Mostly Horizontal And Single Vertical Type And

 Closed: used where in the transportation of liquid is

 Open: used where the liquid to be pumped is with solids.

 Semi-open or vortex type.- used where some solids are

 Shaft s a component that carries all the

 The shaft is designed in such a way to

 Depending on the liquid as well as endurance

 Bearings as you all know is device which

 Bearings which are designed to take

 Those which are designed for axial thrust

Couplings are of two types ;

 A coupling that connect the two shafts solidly for power

 Flexible coupling allows for easy assembly and dismantling without

Gland packing or mechanical seal are commonly used in pumps

 In earlier days or for that matter in water pumps still gland

 Mechanical seals according to DIN 24960 norm

Mechanical seal in normal version

 Rec.: use for medium-

 With a special tool the seal can

 No disassembly of motor stool

 Use in case of a short-

 Quick seal exchange

 All pumps require a prime mover which is device that

 The prime Mover can be either Motor, Diesel Engine,

 Motors are the prime movers to the pump.

 They are further divided in to normal shaft or extended

Design V 1  Depending upon the usage they are classified as S1,S2,S3

The motors which are normally

The motors when are referred or

Cutaway view through stator of induction motor