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German Atv-Dvwk Rules and Standards: Standard ATV-DVWK-A 134E Planning and Construction of Wastewater Pumping Stations
German Atv-Dvwk Rules and Standards: Standard ATV-DVWK-A 134E Planning and Construction of Wastewater Pumping Stations
STANDARD
ATV-DVWK-A 134E
June 2000
ISBN 3-937758-45-3
Preparation
This Standard has been elaborated by the ATV-DVWK Specialist Committee ES-3 “Wastewater Pumping
Stations” within the ATV-DVWK Main Committee ES “Drainage Systems”.
Standard.
A 134E. Planning and Construction of Wastewater Pumping Stations/[from the ATV Working Group]. –
2000
ISBN 3-937758-45-3
All rights, in particular those of translation into other languages, are reserved. No part of this Standard may
be reproduced in any form – by photocopy, microfilm or any other process – or transferred into a language
usable in machines, in particular data processing machines – without the written approval of the publisher.
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Contents
Preparation...............................................................................................................................................2
User Notes................................................................................................................................................6
Foreword ..................................................................................................................................................6
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5 Electrical Engineering............................................................................................................ 27
5.1 External and Structural Prerequisites........................................................................................ 27
5.2 Energy Supply ........................................................................................................................... 28
5.2.1 Energy Supply with a Voltage up to 1000 V (Low Voltage) ...................................................... 28
5.2.2 Energy Supply with a Voltage over 1000 V (Medium High Voltage)......................................... 29
5.2.3 Measurement of Consumption .................................................................................................. 30
5.3 Switchboard Plant, Actuators and Appliances .......................................................................... 30
5.3.1 Main Drives................................................................................................................................ 30
5.3.2 Ancillary Drives.......................................................................................................................... 31
5.3.3 Ancillary Facilities...................................................................................................................... 31
5.3.4 Operating and Measuring System............................................................................................. 31
5.4 Emergency Power Supply ......................................................................................................... 31
5.5 Types of Protection and Regulations ........................................................................................ 32
5.5.1 Explosion Protection.................................................................................................................. 32
5.5.2 Protection against Accidental Contact ..................................................................................... 32
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8 Commissioning ........................................................................................................................36
8.1 Pumping Station.........................................................................................................................36
8.2 Pressure Main ............................................................................................................................36
10 Annexes ....................................................................................................................................42
Annex 1: Example of a pumping station with centrifugal pumps in horizontal, dry-well installation ........43
Annex 2: Basic circuit diagram ..................................................................................................................48
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Wastewater pumps, which are mainly installed in 2.1 Type of Structure and Structural
the tank facilities (see ATV-A 166 [Not available in Dimensions of the Pumping Station
English]), are also frequently employed for the sur-
face feeding and, in particular, for the emptying of The type of structure and the structural dimensions
stormwater tanks. The Standard applies analo- are determined by the pumping tasks (see Section
gously for these, however the technical require- 2.4), the type of pump installation (wet- or dry-well)
ments are to be matched to the tank-specific re- and corresponding with the equipping through the
quirements (e. g. impeller shape, completely free associated scope of ancillary facilities (transformer
passage, no continuous operation). room, switchboard plant, tank farm), other ancillary
facilities (fixed crane, heating and ventilation
Pumping stations are also suitable for control of plants, standby plant) as well as, if required, further
flow in larger networks. necessary ancillary rooms (stores, workshops) and
social rooms. The arrangement of the pumps in
It is emphasised, that this Standard is not to be dry-well installation (vertical or horizontal) has ef-
employed where special drainage methods are fects on the dimensions of the building.
used. These cases are dealt with in Standard ATV-
A 116E. As a rule, wastewater pumping stations are
equipped with centrifugal pumps. They are not
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Examples for the different types of construction are presented in Figs. 1 and 2 and in Appendix 1.
Fig. 1: Examples for types of pumping station construction with pumps in dry-well installation
Fig. 2: Examples of types of pumping station construction with pumps in wet-well installation
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- number and type of connected industrial and 2.3 Ordinates and Pumping Heads
commercial concerns.
The ordinate of the invert of the inflow sewer, the
The inflow is presented in a hydrograph, which re- switch-on and switch-off ordinate of the pumps, the
flects the inflow of wastewater in the course of a outlet ordinate of the pumping destination and the
day (see Figs. 3 and 4). gradient of the terrain between pumping station
and the pumping destination are of considerable
significance in order to be able to dimension a
pumping station.
The hydrograph is the basis for the arrangement of With planning it is to be considered whether, in the
the delivery plant (determination of the operating course of time, the required delivery flow has to be
points, selection of the type of pumps, decision on increased. If this is the case, then the possibility of
the employment of drives with one, several or vari- a later expansion must be taken into account. It
able rotational speeds). can, for example, be sufficient, taking into account
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ATV-DVWK-A 134E
the motor output, later to increase the revolutions erator and, if necessary, with the approval authori-
of the centrifugal pump which is driven via belt ties.
drives or to enlarge the impeller of the centrifugal
pump; under certain circumstances, however,
room for a larger or additional machine must also 2.7 Flow Rate and Inside Diameter of
be planned within the structure. Equally the laying the Pressure Main
of an additional pipeline can also be necessary
(see also Section 7.3). The following aspects are to be taken into account
with the determination of the flow rate in the main:
2.6 Minimum Completely Free Passage The lower limit of the flow rate should lie between
0.5 m/s with larger and 1.0 m/s with smaller total
Experience has shown that, with sewer networks, delivery times of the connected pumping stations.
a formation of textile balls cannot be excluded. Depending on the composition of the wastewater
Nevertheless, one can dispense with screens in so higher flow rates must be selected with longer
far as suitable types of pump and sufficient free downtimes.
cross-section are selected in the complete delivery
facility. A too low a flow rate leads to deposits and thus to
reductions of the cross-section so that the danger
In order to guarantee a secure delivery a com- of blockage increases.
pletely free passage of 100 mm both for the deliv-
ery installation as well as for fittings and the pres- The highest speed of the delivery flow is depend-
sure main are recommended. The use of specially ent on the nominal width. For a pipeline length of
developed, blockage-free impellers with a free up to ca. 500 m the following speeds should not be
cross-section of less than 100 mm (see Section 4) undercut:
and appropriate selection of the pipeline diameter
is to be examined. Inside diameter in mm 80 100 150 200
Speed in m/s 2.0 2.0 2.2 2.4
The pumps of smaller wastewater pumping sta- Delivery in l/s 10 16 40 75
tions therefore are not only to be dimensioned ac-
cording to inflows but insensitivity to blockage and Flow rates greater than 2.5 m/s should be avoided.
minimum speed are also relevant parameters. This
can, in relation to the wastewater inflow, lead to With pipelines of more than 500 m length appro-
over-dimensioning of the pumps. priately lower speeds are to be preferred to avoid
unacceptable pressure surges, for example with
An inside diameter of 80 mm for the pressure main pump failure. Investigation of pressure surge
should not be undercut. should be undertaken.
Smaller completely free passages combined with The optimum nominal width is to be determined
shredders and appropriate pipeline diameters through an efficiency calculation and this com-
should only be used in special cases, for example pared with the above guidance values.
for the disposal of waste from individual real estate,
when the connection to a central plant is sought for With the determination of the diameter of the pres-
water management, technical or economic reasons sure main attention is to be paid that the inside dia-
(see ATV-A 116E, ATV-A 200 [Not available in Eng- meter of a pipe can deviate considerably from the
lish]). Shredded materials can lead to increased de- nominal width depending on the material.
posits in sewers and pressure mains. Various prob-
lems can also occur in the wastewater treatment
plant with increased production of shredded mate-
rial. The employment of shredders should therefore
be clarified, already with the planning, with the op-
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2.8 Number of Cycles of the Pumping The type of subsoil and the groundwater conditions
Plant and Dimensioning of the Inlet are decisive contributory factors for determining
Chamber the type of construction work.
Pumping stations, elevators and pumping points With this it can be necessary to carry out verifica-
are structures which consist of an underground tion for the construction state (e.g. safety against
part and, as far as possible, an over ground part. buoyancy) and for the finished state separately.
Prefabricated shafts are also used for the The concrete must be impermeable to water in
construction of smaller wastewater pumping accordance with DIN 1045 and show high resis-
stations. tance against chemical attack through the em-
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ATV-DVWK-A 134E
Only the switch room and the toilets are to be ac- Windows and doors are to be designed as far as
cessible via the pump room. A crane rail or possible secure against break-in and damage.
shackle, dimensioned for the largest assembly Windows can be dispensed with if sufficient aera-
part, is to be provided in the ceiling. With larger tion and ventilation as well as lighting of the rooms
pumping stations a crane system can also be nec- can be provided alternatively.
essary (see Section 4.13).
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The matching of a changed inflow can be under- - efficiency as a rule less than with multi-port
taken through the modification of the revolutions non-clog impellers,
and, in addition, through change of the impeller di- - hydraulic out-of-balance, which can only be
ameter. extensively compensated, and this at great ex-
pense, related to a defined operation point. A
With all pumps the cavitation behaviour should be rate of rotation above 1450 min-1 should be
examined in order to avoid cavitation, noises, er- avoided, with large impellers a rate of rotation
ratic running and material wear. of 1000 min-1 should not be exceeded.
NPSHP
≥1.3
NPSHR
Fig. 6: Single port non-clog impeller
should be sought for security against cavitation The multi-port non-clog impeller (see Fig. 7) is, as
with water pumps. a rule, a two or three port non-clog impeller. In
comparison with the single port non-clog impeller it
Further details can be taken from DIN 24260, Part is characterised by the following features:
1 “Centrifugal pumps and centrifugal pump sys-
- greater delivery heads are achieved.
tems” [Not available in English].
- a static and dynamic balancing is relatively
simple to carry out. Higher rates of rotation,
and due to this, greater delivery heads are also
4.1.2 Impeller Shapes and Completely possible.
Free Passage - variable speed operation is without problem.
- noise- and vibration-free running is easier to
For the conveyance of untreated wastewater with achieve.
coarse and fibrous constituents specially shaped
impellers are employed (see Figs. 6 to 9) which, to
a great extent, prevent blockages and the forma- It is, however, more susceptible to blockage than
tion of clogs. the single port non-clog impeller as, with the same
delivery flow, the completely free passage of the
The non-clog impeller is employed as single and impeller channels are smaller.
multi-port non-clog impeller.
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Fig. 11: Dry-well and horizontally mounted If a submersible motor-driven pump in wet-well in-
centrifugal pump with fitted motor stallation (see Fig. 13) is employed, then attention
is to be given to certain peculiarities. Inlet cham-
To tension the v-belts the motor must be mounted bers are explosion endangered zones. In accor-
so that it is adjustable. Through the compact con- dance with the regulations of the [German] Asso-
struction the unit is substantial insensitive to vibra- ciation for Social Insurance against Occupational
tion. The installation of a pump with motor in Accidents (VBG) pump casings and components,
modular construction is also possible. in contact with water, made from aluminium alloys
in explosion endangered plant components of
wastewater treatment plants of Zones 0 and 1 are
4.1.4.2 Vertically Mounted Pumps (Dry- not permitted. Fundamentally the motor must be
well Installation) protected against explosion in accordance with
VDE 0170/0171, and that is, as a rule, in E Ex dll
BT3. cleaning ports on the casing are ruled out.
Every wet-well installed pump should be capable
of being installed and removed without emptying
the inlet chamber and without tightening or loosen-
ing of bolts on their pressure joints. The mounting
parts required for this are subjected to corrosive at-
tack to a particularly high degree. They should be
made from stainless steel Material No. 1.4571; this
also applies to nuts, bolts and washers.
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ATV-DVWK-A 134E
production is to be expected it is, however, sensi- requirement for this is additionally to be taken into
ble possibly to design the motor and the coupling account.
more robustly, in any case, however, the associ-
ated electrical parts of the plant, in accordance Power requirement of Reserve capacity of the
with the expansion capacity of the pump. the pump in kW driving motor
up to 7.5 ca. 50%
The following reserve capacities should be pro-
vided as a minimum with regard to a sufficient en- 7.5 – 20 ca. 25%
gine power to avoid blocking of the impeller: 20 -50 ca. 15%
over 50 ca. 10%
With pressure mains with elevator effect and such
which, with every start-up, have to be completely
or in part primed, the increased necessary power
Fig. 13: Section of a wet-well and vertically installed submerged motor pump
It is to be examined whether special measures If, in addition to a smooth start and coast down,
are necessary for the protection of the pressure the revolutions are also variable then the em-
mains against possible pressure surges (see ployment of a static frequency converter is rec-
Section 2.7) or in order to avoid inadmissibly high ommend. Using this, submersible motors and ex-
currents at make of the pump motors. plosion protected motors can be operated with
variable revolutions. The possible change of
To these belongs the so-called smooth starter for revolutions is to be clarified with the pump manu-
cage rotor motors. It prevents undesired load facturer. Here the flow rate in the impeller channels
peaks for pumps and motors. is to be noted (see Section 4.1.2).
It should be equipped with the reverse function, With the employment of a static frequency con-
i.e. a smooth coast down. verter, due to the increased heat loss, the motor
should have a reserve capacity of 10 to 15 %.
With low revolutions an external ventilation of the
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ATV-DVWK-A 134E
motor can be necessary. In order to protect it on the position of the installation room and the
from inadmissible heating the windings should be usage identification of the area in the land devel-
monitored using thermofeelers, i.e. so-called opment plan in which the pumping station lies
positors. The measures to be taken include:
- structure-borne damping machine mountings,
- structure-borne and airborne noise damping
4.2.2 Combustion Engines designs in the exhaust discharge system,
- airborne noise inhibiting structures in the inlet
As a rule, diesel motors with a nominal speed of
and outlet air lines,
1500 min-1 are employed as combustion engines.
- airborne noise damping outfitting of walls,
Their speed is adjustable but, for economic run-
ceilings and doors.
ning the adjustable speed range used should not
go below 75 % of the nominal speed, this means
The exhaust lines are to be insulated using an
that, under certain circumstances, a mechanical
appropriate material which guarantees a surface
intermediate gear becomes necessary.
temperature of the finished insulation of ≤ 70°C.
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ATV-DVWK-A 134E
be at least the diameter of the intake mouth of the Using steel as the pipe material for pressure
pump and be not less than 100 mm. A check mains within the pumping station, for reasons of
valve and, following this, a gate valve are to corrosion, this should be thick-walled. Then an in-
be provided, looking in the direction of flow, ternal wall corrosion protection can be dispensed
on the pressure side of the pump. with. With wet-well installation of pumps and
where later renovations are possible under diffi-
Similarly, with a dry-well installed pump, a cult conditions only, the employment of Material
gate valve should always be inserted in the No. 1.4571 is recommended.
suction line. Only in this way is it ensured that,
with the removal of a blockage or repair of a Pipeline fixtures should be arranged with short
pump or of a check valve, that pumping operation separation and be made particularly stable. With
does not have to be interrupted. longer pipelines they should be displaceable axi-
ally (heat expansion). The pipelines must, in addi-
The integration of the pump pressure mains tion, always be so anchored that they transfer no
must always be horizontally into the main forces to the pump.
pipeline (see Fig. 14), as otherwise the vertical
pipeline becomes clogged. For perfect assembly, i.e. for stress-free connec-
tion, for the balancing of length tolerances and to
avoid damage to seals, depending on the re-
quirements, loose or fixed detachable fittings or
compensators should be incorporated in the pipe-
lines. Detachable fittings can, however, also be
avoided through suitable arrangement of the
pipeline, so that pipe elbows with flanges can
take over their task.
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Fig. 15: Tapered gate valves with respectively internal ad external spindle threads
Preferred is the model with external spindle Spindle: Stainless steel Mat. No. 1.4571
threads as, through removal of the spindle nut and
the spindle thread from the area of the wastewater, Spindle nut: Zinc-free cast Mat. No. 2.1060
heavy wear is avoided and the spindle is easy to bronze
grease. Nevertheless the greater installation height
is to be noted. Ductile cast iron (DCI) is to be pre- Seating ring: Zinc-free cast Mat. No. 2.1060
ferred to grey cast iron (GCI) as casing material bronze
due to the essentially greater security against frac-
ture. Due to their design tapered and parallel slide gate
valves are especially suited for a controlled closure
Attention is to be paid, with gate valves with me- and opening (see EN 752-6, Section 9.3)
chanical drive, that the maximum possible actuat-
ing power cannot damage the gate valve. Clack valves are not suited for wastewater as tex-
tiles can wrap around spindle and swing valve and
To avoid corrosion on components of the gate can prevent the closure procedure.
valve the following materials are recommended for
use in wastewater:
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4.4.1 Gate Valves with Elastomer - spindle and spindle nut are located outside the
Coated Obturators wastewater stream even with non-rising
spindles,
These gate valves have a straight valve opening - the parallel slide gate valve can also be
without valve pocket and an elastic seal (see supplied as throttle valve,
Fig. 16). - cutting effect with solid matter in the
wastewater,
They are particularly suitable as gate valve every- - cost efficient.
where where they are almost exclusively open.
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4.5 Non-return Valves bility of assessing the output of the pump. With
small nominal widths (< 150 mm) with low static
The non-return valve, when fully opened, may not head of water a backwashing can also be intro-
hinder the passage of solid matter. For this the duced by raising the flap by means of the lever.
check valve with a casing made of grey cast iron or Where a check valve fails due to too small a de-
ductile cast iron is particularly suitable (see Fig. gree of opening as a result of small flow rates, a
18). The later is to be preferred. It should be fitted ball check valve should be employed.
with lever and weight. With this it offers the possi-
24 June 2000
ATV-DVWK-A 134E
- for cleaning tasks in the inlet chamber or for cerns, DIN 1988 as well as the DVGW [German
the removal of bulky items and solid matter Technical and Scientific Association for Gas
from the inlet chamber, and Water] Standard W 345 must also be ob-
- for visual checks in the inlet chamber as well served.
as examination of the level switch and other
measuring equipment in the inlet chamber as
well as measuring runs for the determination of 4.9 Washdown Facilities
the pump conveyance flow,
- to dry out the inlet chamber for necessary A supply of water should be provided in order to be
maintenance tasks. able to clean the pump room of a pumping station
with dry-well installed pumps.
Therefore, from the very beginning, an admis-
sion gate valve should be planned with the To clean the inlet chamber an output of from 4 to
construction of a wastewater pumping station. 6 m3/h is required. A fire hydrant is ideal as water
With a small wastewater pumping station manual source to which a DN 25 hose with D-spout in ac-
operation as far as possible using an above cordance with DIN 14365 can be connected.
ground column should be sufficient. With a larger
works the gate valve should have an electric Due to the danger of corrosion the washdown
actuator, explosion protected in the Class E Ex dII pipeline in the inlet chamber should be made from
BT3. The most suitable gate valve is one without PE Hard plastic in accordance with DIN 19533 or
casing with external threaded spindle, which can stainless steel Material No. 1.4571, PN 10.
be installed in a sewer manhole. Due to water-
tightness it is to be so installed in the manhole Attachment of the pipeline should take place also
shaft that the slider plate is pressed against the using plastic, or better, stainless steel (Material No.
frame by the water, i.e. from the inflow side. 1.4571 or equivalent) clips. The bolts/screws used
for this must also be made implicitly from stainless
Threaded spindle, rods as well as all bolts and all steel of the same quality.
anchor bolts, should be manufactured from Mate-
rial No. 1.4571 or equivalent. The seals and guides The washdown pipeline in the inlet chamber
should be made from a zinc-free bronze, for ex- may be connected with a potable water pipeline
ample Material No. Nr. 2.1060. in accordance with DIN 1988, Part 4, only indi-
rectly via a water tank and a downstream
booster system. Only a pipe disconnector ap-
4.8 Water Supply Facilities proved by the DVGW which automatically and visi-
bly establishes a 20 mm long break in the pipe as
In accordance with VBG 54 [Regulations of the soon as the water pressure falls below a certain
Trade Association] (UVV 25) [Accident Preven- safety value may also be employed in short-term
tion Ordinance] washing facilities with running operation. DIN 1988, Part 5, gives further informa-
water must be available in pumping stations. tion.
Further details are to be found in the Implementa-
tion Instructions to the VBG 54 (ZH 1/177). In addi- With several plants of the same type a transport-
tion, water for cleaning purposes in the machinery able washdown facility, if required equipped with
room and inlet chamber is, in particular required water tank, can also be employed.
(see also Section 4.9).
With the installation of water supply facilities 4.10 Machinery room Drainage
potable and non-potable water connections
must be differentiated. For the discharge of leaking water and/or
washdown water and for the draining of pumps
If a potable water connection is intended then, a pump well is to be provided at the deepest
in addition to the respective regulations of the point of the machinery room and a light sub-
Federal German States and water supply con- mersible motor-driven pump with the greatest pos-
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ATV-DVWK-A 134E
sible free impeller passage and automatic level equipped in accordance with VBG 54 with ef-
switch is to be so connected to a fixed pipe that, fective ventilation (see Section 4.11).
with blockage, it can be removed easily and
cleaned at any time by hand. The pipeline must For the inlet chamber of small wastewater pumping
be so laid that a siphoning over to the machin- stations a stationary or transportable mechanical
ery room is prevented, i.e. as a rule using a aerator is, as a rule, sufficient. The displaced air
gooseneck via the highest possible ordinate of the must be able to flow via a sufficiently dimensioned
backwater of the wastewater inflow. free cross-section. With larger pumping stations
both a mechanical aerator as well as an air extrac-
The drainage pump should have a return valve tor should be installed.
immediately behind the pressure hose. The instal-
lation of a gate valve in the fixed pipeline is useful. Fundamentally with ventilation plants attention is to
be paid that no short circuits form between inflow
The size of the pump well depends on the pump and outflow air areas.
selected. It should not undercut the dimensions
500 x 500 mm and a depth of 300 mm. Both the external inflow as well as the outflow
openings are to be so arranged that the
neighbourhood is neither hazarded nor incon-
4.11 Ventilation Facilities for Machinery venienced by exiting gases. With pumping sta-
Rooms tions with superstructure they should be as high as
possible, whereby the outlet of the outgoing air
In accordance with VBG 54 (UVV 25) rooms of channel should be located above the ridge of the
wastewater treatment systems as well as roof (as far as available), that is outside a possible
stormwater tanks and pump pits (inlet cham- lee of the wind.
bers) must be equipped with an effective venti-
lation. Details on the type of ventilation are to be For practical purposes the ventilators should be
found in the Implementation Instruction of the permanently installed in separate above-ground
VBG 54. rooms. These rooms are, as is also the inlet
chamber, to be considered as explosion endan-
With an above-ground structure usually the win- gered and therefore must receive a natural diago-
dows and, additionally, shaft ventilation suffices for nal ventilation.
small machinery rooms. All air inlet and outlet
openings to the outside are to be provided with All horizontal air channels are to be laid with a
protective screens for birds and weather, whereby slight gradient so that any condensed water that
the protective screen for weather must be seated forms can run off to the ventilator or inlet chamber
outside of the protective screen for birds. Further respectively. Every ventilator itself is to be pro-
information is contained in VDI [Association of vided with an outlet pipe at the lowest point of its
German Engineers] Standard 3803. casing, which exits into the ventilation channel to
the inlet chamber. Thus it is avoided that water
If a machinery room lies well below ground level which, under certain circumstances, can even
then a five times the hourly forced air exchange freeze, can collect in the ventilator and lead to its
should be sought. This is most usefully achieved destruction.
using an exhaust fan and appropriate air resupply
openings. All channel sections and naturally also the
connection to the ventilator must be joined,
sealed, with each other. Firms involved in as-
4.12 Ventilation Facilities for Inlet sembly are to be informed urgently on this point.
Chambers
Air distribution must be so designed that the
Enclosed rooms of wastewater discharge facili- air can exit both ca. 1 m above the floor of the
ties and pump wells (inlet chambers) must be empty inlet chamber and also above the maxi-
mum water level of the inlet chamber.
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ATV-DVWK-A 134E
Before first commissioning, following building Allowance should be made for the protection of
modifications and with lifting gear for loads structures from oil, acids, overpressure as well as
greater than 1 t, the complete crane system for fire protection.
must be tested once a year by a specialist.
Floor coverings must be insulated and secure
against electrical breakdown for the corre-
sponding operational voltages. The coverings
may not lead to a build-up of static electricity.
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The switchboard plants for voltage levels above All switching plant is to be installed safe from
1000 V should, for the protection of personnel, be flooding.
employed only as plants secured against
accidental arcing in accordance with Pehla
Directive No. 2, Criterion 1 to 6, with firmly installed 5.3.1 Main Drives
switchgear or on a rail mounted platform
(retractable). As far as possible, three phase squirrel-cage
motors with small current at make should be
In order that the switchgear still remains operable provided as drive motors for the wastewater
even with failure of the mains and the appropriate pumps (see Section 4.2.1).
information is retained, it is recommended that
both the drive of the switchgear and the control Winding sensing devices can be planned to protect
and reporting systems are designed independent the motor against overload. For drives with
of the mains supply (battery). operationally conditioned long down-times, and
with high air humidity, a down-time heater can be
practical.
5.2.3 Measurement of Consumption
The IP 54 system of protection is to be preferred.
As a rule this is provided and installed by the ESC.
The build-up of the metering facility depends on Every drive has a control selection switch with the
the voltage levels used and thus has an influence positions MANUAL – OFF – AUTOMATIC.
on the room programme. It is to be clarified with
the ESC where the electricity consumption meter is The switching ON and OFF of the pumps is
to be installed. dependent on water level, in special cases the
delivery flow can be over or underlaid. Operating
conditions must be recognisable on the electrical
5.3 Switchboard Plant, Actuators and control panel. Pump exchange switch, current
Appliances meter and operating hours counter should be
integrated. In addition each drive has one (or
Low voltage switchboard plants are normally more) EMERGENCY OFF switches in situ, which
produced in the shape of standardised sheet steel engage directly in the control system.
cabinet systems which are secure against
accidental arcing to increase the protection of Faults always lead to the immediate shutdown of
personnel. the plant. With this the control system, goes into
locked status, an automatic restart following a fault
As a rule a modular method, otherwise an insertion may not occur.
method, is employed for the power items.
Modification of the number of pump revolutions is
To control and monitor the machines motor control possible through pole changing motors (2 or 3
cards (electronic) can be used for the realisation of rpm) or using frequency converter drives (infinitely
the basic circuitry and basic locking mechanism. variable, simultaneous starter in the lower rpm
range).
Higher voltage switches are realised through the
employment of stored-programmable control Frequency converter drives create heat and
systems (SPS). noise which possibly has respectively to be
dissipated or restrained. In addition, converters
Unavoidable blind current components should be create harmonic waves in the power supply. The
compensated using fixed or regulatable blind power supply reactions of these harmonic waves
current compensation. For later expansion a space must be compensated.
and capacity reserve of from 15 – 20 % should be
planned.
30 June 2000
ATV-DVWK-A 134E
Attention is to be paid that the adjustment of the - Plug connections for three phase 400 V to
rpm modifies all characteristic curves of the 63 A, 230 V/16 A AC and extra-low voltage
pumps. 25 V/10 A,
- Water heaters for sanitary objects,
There are the following possibilities for the - Connections for measuring technology, fused
automatic operation of the pumps: outlets 230 V,
- Reserve outlets; for each voltage level 1 to 3
- Pumping control
reserve outlets.
Conveyance of the pump is monitored.
- Protection against dry running
It is prevented that the pump lowers the water
level in the inlet chamber below a permitted
5.3.4 Operating and Measuring System
level and thus runs dry.
Recording of operating and fault messages:
- Simultaneous start
Simultaneous start of large consumers is
Operating messages should be displayed
prevented to avoid expensive peak loads.
individually optically, fault messages shown
- Reserve pump with malfunction
individually optically and collectively acoustically.
With malfunction of the service pump the
The fault messages can, if required, be combined
reserve pump takes over operation
together as a group fault message.
automatically.
- Conveyed quantity- or pressure control
A test key for all illuminated displays is
- Parallel operation of several pumps
recommended.
- Reclosure preventing device
The immediate reclosure following switching off
The remote transmission of operating and fault
for operational reasons is prevented depending
messages as well as status signals can, for
on time in order to avoid the inadmissible
example take place via a cable or leased lines.
heating of electrical components and/or heavy
start.
Remote transmission is, however, only sensible if
- Monitoring of oil and cooling water
there are possibilities of acceptance or of calling
- Alternating closure
up this information in rotation as well as for its
With every new closure impulse another drive
operational processing.
is switched on in preselected sequence.
June 2000 31
ATV-DVWK-A 134E
whereby, at the same time, the separation from Zones 0, 1 and 2 are differentiated according to
the power supply and locking must take place. the timely and local probability of the presence of
- Automatic plant dangerous atmospheres capable of explosion.
Automatic emergency power supply systems
switch in immediately following voltage Valid as “explosion endangered rooms” are all
breakdown and, with a time delay, switch off rooms or areas in which, according to local or
following reestablishment of the power supply. operational conditions, atmospheres capable of
For rotational maintenance their must be a explosion can collect. In the area of the pumping
possibility of running the emergency power station they are, in general, to be assigned to Zone
system under load over several hours. 1, so that the Explosive Ordinance is to be
- Special cases applied.
The energy supply of the complete works or
parts of this can take place with the aid of a
stationary, automatic generator (see Section 5.5.2 Protection against Accidental
4.2.2). Contact
32 June 2000
ATV-DVWK-A 134E
June 2000 33
ATV-DVWK-A 134E
one hand, by the pump characteristic curve (throt- trained air or the gas cushions resulting from the
tle curve) and the pipeline characteristic curve on formation of gas. Gas cushions can lead to higher
the other (see Section 4.1.1). energy losses as a result of a narrowing of the flow
cross-section.
The pressure pipeline must be able to accept
the internal and external pressure on the If, in the case of repair with pumps at standstill, the
system continuously and without damage. To pipeline does not empty itself due to geodetic
this belong the pressure transient processes (e.g. gradient, emptying pipelines with connection to the
water hammer), if no other safety measures are wastewater and combined wastewater sewer
taken. system or for suction vehicles are to be planned for
suitable low points.
7.2 Pipeline Routes Monitoring ports, for example for pipe inspection
using cameras, venting and ventilation as well as
Basically the pressure pipeline should represent emptying fittings, are, from a practical point, to be
the shortest possible connection between the accommodated in shafts which should be
pumping station and the discharge point. equipped with a pump well at the bottom.
34 June 2000
ATV-DVWK-A 134E
pressure changes (pressure surges) combined through minimum cover and/or insulation, with
through the individual pipe losses. varying or even continuous high temperatures of
the pumped medium, an additional stress of the
The overall dynamic pressure loss is made up from pipeline can occur. The pipe material here is to be
the pressure loss through pipe friction and the selected with particular care.
individual losses due to mountings, fittings such
as, for example, elbows cross-section chambers Abrasion occurs with pressure mains if increased
and branches as well as through losses at inlets mineral substances occur in the wastewater.
and outlets. For details see The ATV Handbook Effects are to be expected particularly in the area
„Bau und Betrieb der Kanalisation“ [“Construction of changes of direction and throttle points. It can
and operation of sewer systems]”. be necessary to counter these through increasing
wall thickness, for example through the selection of
a higher nominal pressure rating, in the critical
7.4 Stresses area.
June 2000 35
ATV-DVWK-A 134E
Pipe materials susceptible to corrosion must lation, possibly regulation/control, displays) under
be protected through internal and external the local installed conditions.
insulation. Thus steel pipes receive externally a
polyethylene jacket or coating with polyurethane In detail the following are recommended as
tar and, internally, an epoxy-resin or cement controls:
mortar lining. With pressure pipes made from
- tension-free assembly,
ductile cast irons external spray galvanisation,
- adjustment of end bearings and torque,
bitumen paint or epoxy-resin coating and internally
- direction of pump rotation,
cement mortar lining are used. Reinforced
- pump sequential switching,
concrete and fibre-cement pipes in many cases
- setting of rpm,
receive an additional coating on a bitumen basis or
- venting of the pump casing,
of epoxy-resin (see DIN 4030), for example with
- sealing,
the danger of sulphide formation in the wastewater
- noises,
and with high sulphate content.
- vibrations,
- temperatures,
8 Commissioning - pressure surges,
- non-return valve clapper knock,
- measurement and control technology,
The documentation of all plant components - remote monitoring and control,
must be available for commissioning (see ATV- - emergency energy supply.
A 148E).
The pumps should be tested under full load for at
least two hours. If there is not enough water
8.1 Pumping Station available for a test run it has proved advantageous
if the existing water can be pumped via a diversion
Acceptance with functional testing and trial in a circle.
runs of the individual component parts must
precede commissioning of the pumping For the commissioning and later operation it is
station. Those responsible for planning and necessary that the operating personnel receive
construction work, from the undertaking and, for precise knowledge of the plant engineering
reasons of warranty, also representatives of the already with assembly and that they have
manufacturer and/or supply companies are to take already received instruction.
part in this.
The pumping station can be taken into operation
Before commissioning the electrical plant all after the functional testing.
short circuit and overcurrent protective
systems are to be checked for correct setting With this the requirements of the pressure main
and are to be secure. All switching and control commissioning are to be observed.
procedures are to be carried out first without
loading (cold testing). Only then can the facility be In the run-in phase (ca. 4 weeks) it is
released for operation. recommended that the complete operating cycle
has increased monitoring as, from experience, an
In general the pumps have been subjected to a increased number of faults occur on the plant
test bench trial at the manufacturer’s works. This components during this period.
factory acceptance serves for the examination of
whether the guaranteed delivery data are
achieved. In contrast to that the test run in the 8.2 Pressure Main
pumping station is to provide information on its
mechanical and hydraulic behaviour, freedom from An internal pressure test in accordance with
vibration, heating of bearings and correct function- DIN 4279 is to be undertaken before commis-
ing of ancillary facilities (lubrication, cooling, venti- sioning. For commissioning the ventilation fittings
36 June 2000
ATV-DVWK-A 134E
to be operated manually are to be opened and 9.1 General Terms and Conditions for
controlled during the filling procedure. Engineering Services, (VOB)
With the connection of the pressure main to the Part C, General Technical Regulations for
existing network with different pressure potentials, Engineering Services:
it should be noted that pressure surges result
through too rapid opening or closing of the gate DIN 18 017 Lüftung von Bädern und Spül-
valves, which can lead to damage to the pressure Part 1 aborten ohne Außenfenster durch
main. Once a flow is no longer detectable the gate Schächte und Kanäle, ohne
valve can be opened very slowly. Closure is Motorkraft; Einzelschachtanlagen
carried out analogously. [Ventilation of baths and flush
toilets without outer widows
Immediately after commissioning of a new pres- through shafts and channels,
sure main the first pressure pipe characteristic without motor drive, single shaft
curve should be adopted. It serves for the estab- facilities]
lishment of a practical and economic dimensioning DIN 18 300 Erdarbeiten [Excavation works]
and for the evaluation of the delivery pumps in this DIN 18 303 Verbauarbeiten [Revetting]
pressure main. DIN 18 304 Rammarbeiten [Pile driving]
DIN 18 305 Wasserhaltungsarbeiten
[Dewatering works]
DIN 18 306 Entwässerungskanalarbeiten
June 2000 37
ATV-DVWK-A 134E
EN 752 Drainage systems outside buil- DIN 2614 Cement mortar linings for ductile
Parts 1-7 dings iron and steel pipes and fittings;
EN 1671 Pressure sewerage systems application requirements and
outside buildings testing
DIN 3352 Gate valves [Available in English
9.2.1 Building Standards Parts 1-8 Parts 1-4 only]
DIN 4032 Concrete pipes and fittings
DIN 1045 Structural use of concrete; design DIN 4035 Stahlbetonrohre und zugehörige
and construction Formstücke aus Stahlbeton
DIN 1055 Design loads for buildings [Reinforced concrete pipes and
Parts 1- 6 associated fittings made from
DIN 1084 Control (Quality control) of reinforced concrete]
Parts 1-3 concrete structures and reinforced DIN 4279 Testing of pressure pipelines for
concrete structures Parts 1-10 water by internal pressure [Parts
DIN 1164 Portland-, Eisenportland-, Hoch- 1,7,8 not available in English]
Parts 1,2,8, ofen- und Trasszement; Begriffe, DIN 8061 Unplasticised polyvinyl chloride
Bestandteile, Anforderungen, pipes (PVC-U); general quality
Lieferung [Portland, iron Portland, requirements and testing
blast furnace slag and trass DIN 8062 Unplasticised polyvinyl chloride
cement; Terms, requirements, pipes (PVC-U, PVC-HI);
delivery] dimensions
DIN 1986 Site drainage systems DIN 8063 Pipe joints and fittings for pipes
DIN 1988 Drinking water supply systems Parts 1-12 under pressure made of
DIN 2000 Zentrale Trinkwasserversorgung; unplasticised polyvinyl chloride
Leitsätze für Anforderungen an (PVC-U) [Parts 5,7,9,10 not
Trinkwasser, Planung, Bau und available in English]
Betrieb der Anlagen [Central DIN 8074 Polyethylene (PE) pipes –
drinking water supply; Guidelines dimensions
for requirements on drinking water, DIN 8075 Polyethylene (PE) pipes –
planning construction and dimensions – General quality
operation of plants] requirements and testing
DIN 2001 Private and individual drinking DIN 8077 Polypropylene (PP) pipes –
water supply; governing principles dimensions
DIN 4030 Assessment of water, soil and DIN 8078 Types 1, 2 and 3 Polypropylene
gases for their aggressiveness to (PP) pipes – General requirements
concrete and testing
DIN 4124 Building pits and trenches – slopes, DIN 14 365 Multi-purpose branch pipes for
working place widths, sheeting Parts 1-2 nominal pressure 16; dimensions
DIN 18 196 Soil classification for civil materials, construction, marking
engineering purposes DIN 19 532 Rohrleitungen aus weichmacher-
freiem Polyvinylchlorid (PVC hart,
9.2.2 Pipes and Fittings PVC-U) für die
Trinkwasserversorgung [Pipelines
DIN 1333 Zahlenangaben [Numerical data] made from unplasticised polyvinyl
DIN 2440 Steel tubes; medium-weight chloride [PVC-H, PVC-U for
suitable for screwing drinking water supply]
DIN 2448 Seamless steel pipes and tubes DIN 19 533 Pipelines of high density PE and
DIN 2458 Welded steel pipes and tubes low density PE for drinking water
DIN 2605 Steel butt-welded pipe fittings supply; pipes, pipe connections
Parts 1-2 and fittings for pipelines
38 June 2000
ATV-DVWK-A 134E
DIN 19 534 Rohre und Formstücke aus EN 1299 Vibration isolation of machinery –
weichmacherfreiem information fort he application of
Polyvinylchlorid (PVC-U) mit source isolation
Steckmuffe, für Abwasserkanäle EN 1610 Construction and testing of drains
und –leitungen [Pipelines and and sewers
fittings made from unplasticised
polyvinyl chloride (PVC-U) with 9.2.3 Mechanical Engineering
sleeves, for drains and sewers]
DIN 19 537 High density polyethylene (HDPE) DIN 1184 Pumping stations; Archimedean
pipes and fittings for drains and Part 4 screw pumps; Directives for
sewers; technical delivery planning
conditions DIN 1944 Acceptance tests on centrifugal
DIN 19630 Richtlinien für den Bau von pumps (VDI rules for centrifugal
Rohrleitungen [Directives for the pumps)
construction of pipelines] DIN 24 260 Kreiselpumpen und
DIN 19 800 Asbestos-cement pipes and fittings Part 1 Kreiselpumpenanlagen; Begriffe,
Part 1 for pressure pipelines; pipes, Formelzeichen, Einheiten
dimensions [Centrifugal pumps and centrifugal
DIN 19 850 Fibre-cement pipes and fittings for pump systems; Terms, symbols,
Parts 1-2 drains and sewers; Part 1: units]
dimensions of pipes, branches and DIN 24 293 Kreiselpumpen – Technische
bends; Part 2: Dimensions of joint Unterlagen – Begriffe,
assemblies Lieferumfang, Ausführung
DIN 30 675 External corrosion protection of [Centrifugal pumps – technical
Parts 1-2 buried pipes, corrosion protection documents, scope of delivery,
systems for steel and ductile iron design]
pipes DIN 45 635 Measurement of noise emitted by
EN 295 Vitrified clay pipes and fittings and Part 1 machinery
pipe joints for drains and sewers
EN 545 Ductile iron pipes, fittings,
accessories and their joints for
water pipelines; Requirements and
test methods
EN 639 Requirements for concrete 9.2.4 Measurement Technology
pressure pipes including joints and
fittings DIN 1319 Basic concepts in metrology
EN 640 Reinforced concrete pressure DIN 16005 Überdruckmessgeräte mit
pipes and distributed reinforce- elastischem Messglied für die allg.
ment concrete pressure pipes Anwendung [Overpressure
(non-cylinder type), including joints measurement equipment with
and fittings elastic measuring unit for general
EN 642 Prestressed concrete pressure applications]
pipes, cylinder and non-cylinder EN 837-1 Pressure gauges - Part 1: Bourdon
types, including joints, fittings and tube pressure gauges -
specific requirements for dimensions, metrology,
prestressing steel for pipes requirements and testing
EN 764 Pressure equipment; Terminology EN 837-3 Pressure gauges – Part 3:
and symbols relating to tempe- Diaphragm and capsule pressure
rature, pressure and volume gauges; dimensions, metrology,
EN 1032 Testing of mobile machinery in requirements and testing
order to determine the whole body
vibration emission value - General
June 2000 39
ATV-DVWK-A 134E
VDE 0410 VDE-Bestimmung für elektrische DIN EN 50 015 Elektrische Betriebsmittel für ex-
Messgeräte; plosionsgefährdete Bereiche;
Sicherheitsbestimmung für Ölkapselung [Electrical equipment
anzeigende und schreibende for explosion endangered areas;
Messgeräte und Zubehör [VDE Oil immersion]
regulations for electrical metering DIN EN 50 016 Elektrische Betriebsmittel für
equipment; safety regulations for explosionsgefährdete Bereiche;
indicating and recording measuring Überdruck-kapselung [Electrical
equipment and accessories] equipment for explosion
endangered areas; Pressurising]
9.2.5 Electrical Engineering DIN EN 50 017 Elektrische Betriebsmittel für
explosions-gefährdete Bereiche;
VDE 0100 Bestimmungen für das Errichten Sandkapselung [Electrical
von Starkstromanlagen mit equipment for explosion
Nennspannungen bis 1000 V endangered areas; Powder filling]
[Regulations for the erection of DIN EN 50 018 Elektrische Betriebsmittel für
high tension facilities with nominal explosionsgefährdete Bereiche;
voltages up to 1000 V Druckfeste Kapselung [Electrical
VDE 0105 Betrieb von Starkstromanlagen equipment for explosion
[Operation of high tension facilities] endangered areas; Flame-proof
as well as i.a.: Operation of power installations enclosure]
EN 50110 DIN EN 50 019 Elektrische Betriebsmittel für ex-
Part 1 plosionsgefährdete Bereiche;
VDE 0160 Ausrüstung von erhöhte Sicherheit [Electrical
Starkstromanlagen mit equipment for explosion
elektronischen Betriebsmitteln endangered
[Equipping of high tension facilities areas; Increased safety]
with electronic equipment] DIN EN 50 020 Elektrische Betriebsmittel für ex-
as well as i.a.: Adjustable speed electrical power plosionsgefährdete Bereiche;
EN 61 800 drive systems Eigensicherheit [Electrical
Part 3 equipment for explosion
endangered areas; Own safety]
VDE 0165 Errichten elektrischer Anlagen in DIN EN 50 021 Elektrische Betriebsmittel für ex-
explosionsgefährdeten Bereichen plosionsgefährdete Bereiche;
[Installation of electrical plant in Betriebsmittel der Zündschutzart
explosion-endangered areas] [Electrical equipment for explosion
as well as i.a.: Elektrische Betriebsmittel für endangered areas; Equipment with
EN 60 079 gasexplosionsgefährdete Bereiche “e”-type protection ]
Part 10 [Electrical equipment for gas DIN EN 50 039 Elektrische Betriebsmittel für ex-
explosion endangered areas] plosionsgefährdete Bereiche;
VDE Elektrische Betriebsmittel für Eigensichere elektrische Systeme
0170/0171 explosionsgefährdete Bereiche [Electrical equipment for explosion
[Electrical equipment for explosion endangered areas; Intrinsically
endangered areas] safe electrical systems]
As well as i.a.: DIN IEC Blitzschutz baulicher Anlagen
DIN EN 50 014 Elektrische Betriebsmittel für 61024-1-2; [Lightning protection of structural
explosionsgefährdete Bereiche; works]
Allgemeine Bestimmungen VDE 0185
[Electrical equipment for explosion Part 102
endangered areas; General
conditions]
40 June 2000
ATV-DVWK-A 134E
VDE 0266 Halogenfreie Kabel mit ATV-A 166 Bauwerke der zentralen
verbessertem Verhalten im Regenwasserbehandlung und -
Brandfall [Halogen-free cables with rückhaltung - Konstruktive
improved behaviour in case of fire] Gestaltung und Ausrüstung
VDE 0660 Niederspannungs-Schaltgeräte [Structures for Centralised
[Low voltage switch gear] Treatment, Retention, Design and
as well as i.a.: Low voltage switchgear and Equipping of Stormwater Facilities]
EN 60 439 control gear - combinations ATV-M 168E Corrosion of Wastewater Systems
Parts 1-5 – Wastewater Discharge –
EN 60 947 Low voltage switchgear and ATV-M 176 Hinweise und Beispiele zur
Parts 1-7 control gear konstruktiven Gestaltung und
VDE 0670 Wechselstromschaltgeräte für Ausrüstung von Bauwerke der
Spannungen über 1 kV [AC zentralen
equipment for voltages above Regenwasserbehandlung und -
1 kV] rückhaltung - [Notes and Examples
VDE 0800 Fernmeldetechnik for the Design and Equipping of
[Telecommunications engineering] Structures for Centralised
Wastewater Treatment and
Retention]
9.3 Directives, Standards and Advisory ATV-M 263E Recommendations for Corrosion
Leaflets Protection of Steel Components in
Wastewater Treatment Plants
Using Coating and Cladding
9.3.1 of the ATV
9.3.2 of the DVGW
ATV-A 105E Selection of the Drainage System
ATV-A 110E Hydraulic Dimensioning and DVGW W 302 Hydraulische Berechnung von
Performance Verification of Rohrleitungen und Rohrnetzen
Sewers and Drains [Hydraulic calculation of pipelines
ATV-A 116E Special Sewer Systems - Vacuum and pipe networks]
Drainage Service – Pressure DVGW W 303 Dynamische Druckänderungen in
Drainage Service Wasserversorgungsanlagen
ATV-A 118E Hydraulic Dimensioning and [Dynamic pressure changes in
Verification of Drainage Systems water supply facilities]
ATV-A 127E Static Calculation of Drains and DVGW W 342 Werkseitig hergestellte
Sewers Zementmörtelauskleidungen für
ATV-A 128E Standards for the Dimensioning Guss- und Stahlrohre [Factory
and Design of Stormwater produced cement mortar cladding
Structures in Combined Sewers for cast and steel pipes]
ATV-A 142E Sewers and Drains in Water DVGW W 345 Schutz des Trinkwassers in
Catchment Areas Wasserrohrnetzen vor
ATV-A 148E Service and Operating Instructions Verunreinigung [Protection of
for Personnel of Wastewater drinking water from pollution]
Pumping Stations, Wastewater
Pressure Pipelines and 9.3.3 des VDI
Stormwater Tanks
ATV-A 200E Principles for the Disposal of VDI 2058 Beurteilung von Arbeitslärm in der
Wastewater in Rurally Structured Nachbarschaft [Assessment of
Areas work noise in the neighbourhood]
ATV-A 241 Bauwerke der Kanalisation
[Structures in Sewer Systems]
June 2000 41
ATV-DVWK-A 134E
42 June 2000