Development of a technical manual for pumping istallations in the water industry with emphasis on water supply systems

Abstract

Pumping stations must be highly reliable. energy saving and economical. while at the same time their capital costs, operational and maintenance costs should be minimized. A technical manual for the multi disciplinary set of expertise who design, construct, operate and maintain pumping installations will help to achieve better performances. The objective of the manual is to impart knowledge on main plant and equipment, infrastructure and associated practical behaviour in pumping installations to those who design, construct, operate and maintain pumping installations. This manual covers planning, design, operation and maintenance aspects, main and ancillary equipment, and also practical behaviours. Chapter 1 has been devoted to discuss the important aspects of pumps needed for designers, operation and maintenance staff. Starting with the classification of pumps, the basics have been covered. Use of system head curves in different situations and affinity laws have been dealt with giving examples. NPSH has been dealt with critically. Pumps in series and parallel, effects of cavitation and recirculation causes of noise and vibration have also been covered. The importance of taking precautions to ensure proper design of sumps have been highlighted in Chapter 2. The adverse effects on pumps and its facilities that can result due to poor shapes and dimensions of sumps have been discussed. Basic dimensions. shapes. undesirable suction layouts and their improvements are provided to avoid mistakes. Chapter 3 summarises the guarantees and the acceptance tests for centrifugal pumps. This chapter will be useful mainly to those who are engaged in pump and other equipment testing and the approval of their performances. Chapter 4 is about pressure surges in pipe lines. The causes for pressure surges and different surge prevention measures have been discussed so that the most appropriate method for a given situation can be selected. A sample calculation has been included. Chapter 5 is on electrical equipment. Power supply and power factor, drivers, different starting methods, motor enclosures. motor protection, ratings and selection of motors, effect of temperature on life of motors, protection of electrical equipment etc. have been dealt with. Chapter 6 on pipe work valves and fittings will assist the Design Engineer to design and size the pipes and valves in pumping stations properly and the erection engineer ..to install them. Recommended flow velocities and a comprehensive list of head losses in valves and fittings have been included. Chapter 7 is about basic planning and design 'aspects of pumping, stations. Importance of minimisation of capital, operation and maintenance costs have been highlighted. Investigation procedures. Selection of pump types, number of pumps, pump speed, layout of equipment, electrical facilities. Positive and negative suction conditions have been discussed. Planning of electrical facilities and energy conservation have also been covered. Chapter 8 is about the civil engineering aspects of pumping stations. Importance of looking into civil as well as mechanical and electrical aspects have been highlighted. Chapter 9 deals on seven practical applications related to pumping stations. Vertical vs Horizontal pumps. performance of submersible pumps and methods of reducing energy costs. decision on whether to repair or replace the pumps. wear caused by sand in-intakes. choice of pump to suit system head. gland packing or mechan-ical seal are the areas covered. Chapter 10 covers the important points and how to size the ancillary equipment such as lime and alum pumps. blowers, chlorinators and overhead cranes. Ditferent types of now meters too have been discussed. Finally Chapter 11 summaries the aspects of operation and maintenance activities in a pumping station.