Online Continuing Education for Professional Engineers

Since 2009

Fundamentals of Pump Station

and Force Main Design

PDH Credits:

4 PDH
Course No.:
PSF101

Publication Source:
Original Courseware
by Donald W. Parnell, PE
“Fundamentals of Pump Station and Force Main Design”

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 Fundamentals of Pump Station and
Force Main Design

1
Fundamentals of Pump Station and Force Main Design
 Introduction

2
Fundamentals of Pump Station and Force Main Design
 Purpose And Scope
This course provides guidance, instructions and criteria for the design of sanitary and
industrial wastewater pumping facilities.

This course is based on a publication which was initially created for Corp of Engineer
based pump station and force main design. It has been modified for presentation as a
more generalized overview of the subject matter.

3
Fundamentals of Pump Station and Force Main Design
 Types of Pump Station Facilities
The types of pump station facilities which are covered in this course include pump and
ejector stations which are used for the following purposes.

• For the removal of sanitary and industrial wastes from remote or low lying which
cannot be served hydraulically by gravity sewers
• Controlled introduction and lifting of raw wastewater into the waste treatment
plant
• Transfer of recycled and bypassed flows throughout the plant
• Discharge of treated effluent

4
Fundamentals of Pump Station and Force Main Design
 Design Aspects of a WW Pumping Station
The design of a wastewater pumping station will typically include:

Civil and Structural aspects - site improvements, structures

Electrical/Mechanical aspects - mechanical and electrical components, system

controls and instrumentation, screening and flow monitoring devices

Piping aspects - pumping units, pump drives, interior piping, underground force
mains, valves and appurtenances

5
Fundamentals of Pump Station and Force Main Design
 Special Waste Conditions
Pumping systems for hazardous and explosive
wastes, corrosive acids or alkalis, high temperature
or other industrial type wastes, generally require the
selection of highly resistant pumps, valves and piping
materials.

Design of these systems should be in accordance

with special criteria developed for each particular
situation.

6
Fundamentals of Pump Station and Force Main Design
 Selection of Materials
The selection of types of materials used for pumps, piping, valves and controls, etc.,
will be based on manufacturers' recommendations, product specifications, and any
other appropriate design manuals or applicable criteria.

7
Fundamentals of Pump Station and Force Main Design
 Pump Station Choices
Pumping stations and pneumatic ejectors – will normally be required to remove
wastes from areas which cannot be served hydraulically by gravity sewers.

Gravity sewer systems - can be used In certain situations, but only at the
expense of deep trench excavation, jacking, boring, tunneling, or construction of
long sewer runs to avoid high terrain.

Combination gravity and pump - In some cases, both wastewater pumping and
gravity flow sewers will be technically feasible and capable of meeting service
requirements. However, they may not be equivalent in economic terms.

8
Fundamentals of Pump Station and Force Main Design
 Using Life Cycle Cost Comparison
When it is not readily apparent which solution would be more economical, the
decision to use one or the other will be based on a life cycle cost analysis.

Initial capital and construction costs - for pumps, ejectors, structures, force mains,
etc., plus operation and maintenance costs, will be compared with the costs of deep
trench excavation, or other special construction methods required for a gravity
system.

Generally, a gravity sewer system is justified until its cost exceeds the cost of a
pumped system by 10 percent.

9
Fundamentals of Pump Station and Force Main Design
 Grinder Pumps And Vacuum Systems
There may be areas so limited by high groundwater,
subsurface rock, unstable soil or steep topography,
that neither gravity sewers nor centralized pumping
stations will be feasible.

In these cases, the use of grinder pumps (see image)

or vacuum systems should be investigated.

10
Fundamentals of Pump Station and Force Main Design
 Siting Considerations for Pumping Stations

11
Fundamentals of Pump Station and Force Main Design
 When are Pump Stations needed
Based on topography - The requirement that an area be served by a wastewater
pumping facility, will in most cases be determined by the topography of the area and
the need to provide for future development.

Building and grade elevations in the area generally will be too low for proper gravity
drainage to an existing or proposed sewer system, or waste treatment facility. Thus,
collection and pumping of wastes from these low lying areas will be necessary.

Other considerations - In addition to topographic considerations, natural boundaries

like waterways, rivers, streams, etc., and property lines of Federal, state and local
jurisdictions, also play a role in determining the size and limits of service areas.

12
Fundamentals of Pump Station and Force Main Design
 Site Considerations
Pump stations will be located so that all points within the intended service area can be
drained adequately by gravity sewers.

Any planned development within the service area, such as construction of new
buildings or modifications to existing ones, or any projected shifts in population
and/or workforce will be considered.

It is a relatively simple matter to design a pumping station with the capacity for future
development, by providing room for additional or larger pumps, motors, impellers,
etc. However, the physical location of the station is more critical since it cannot be
moved to accommodate new buildings or population increases.

13
Fundamentals of Pump Station and Force Main Design
 Guidelines for Siting of Pump Stations
The following general guidelines for site selection and location of pumping stations
should be used:

Guideline 1- Pumping facilities should not be constructed beneath buildings, streets,

roadways, railroads, aircraft aprons or runways, or other major surface structures, to
the maximum extent practical.

Guideline 2 - The location of pumping stations should be made with proper

consideration given to the availability of required utilities such as electric power,
potable water, fire protection, gas, steam and telephone service.

14
Fundamentals of Pump Station and Force Main Design
 Guidelines (continued)
Guideline 3 - Pump stations will not be located closer than 500 feet to
buildings, or other facilities to be occupied by humans, unless adequate
measures are provided for odor and gas control.

Guideline 4 - Pumping stations at wastewater treatment facilities will

normally be located adjacent to, or in connection with, other plant elements
as required for proper functioning of the treatment systems.

15
Fundamentals of Pump Station and Force Main Design
 Building And Site Requirements - Floor And Building Elevations
Invert elevations - the invert elevations of incoming sewers will determine the depths
of underground portions (substructure) of the pumping station.

Maximum liquid level - it is common practice to set the maximum liquid level in the
wet well equal to the 80-90 percent flow depth of the lowest incoming sewer.

16
Fundamentals of Pump Station and Force Main Design
 Elevations
Subsurface and soil conditions - at the site will dictate the structural design,
excavation depths, and top of footing elevations required for the foundation.

Surface conditions - such as adjacent buildings and site grading will determine
the elevations of floors above ground (superstructure), except that the elevation
of the ground floor will be set above the maximum expected flood level.

17
Fundamentals of Pump Station and Force Main Design
 Building Appearance
Populated areas - For pumping stations located in built-up areas, the
architectural exterior of the buildings should be made similar to, or compatible
with, surrounding buildings.

Remote areas - When the station is located in a remote area, building

appearance is not important, but the possibility of future development in the
vicinity will be considered.

18
Fundamentals of Pump Station and Force Main Design
 Surrounding Appearance
Fencing - pump stations and facilities will be provided with fencing where
necessary to prevent vandalism, and to protect people from hazardous
contact with electrical transformers and switching equipment.

Landscaping - should be considered in built-up areas, and will be required

in residential communities.

Where stations must be constructed in close proximity to residences or

other quarters, buffer zones of planted shrubbery should be provided for
noise reduction.

19
Fundamentals of Pump Station and Force Main Design
 Building Access
All pump stations should be readily accessible from an improved road.

Not enclosed - For stations that are not enclosed, access will be provided for direct
maintenance from a truck equipped with hoist attachments.

Enclosed – for these stations, provisions should be included in the structure to

facilitate access for repair, and to provide a means for removal and loading of
equipment onto a truck.

20
Fundamentals of Pump Station and Force Main Design
 Type And Capacity Of Pumping Stations

21
Fundamentals of Pump Station and Force Main Design
 Required Pumping Capacity
Proper selection of the number and capacity of pumping units, depends on the
quantity and variation of wastewater flows to be handled.

Except as indicated for small stations (on the page for “Small Stations”),
pumping units will be selected to handle the normal daily range of wastewater
flows generated in the service area.

The number and capacity of pumps provided will need to be sufficient to

discharge the minimum, average, peak daily and extreme peak flowrates.

Pumping capacity will be adequate to discharge the peak flowrates with the
largest pump out of service.

Specifications for pumps utilized for treatment plant processes, recycling and
bypassing of flows, etc., will be based on criteria specific to those types of
systems.

22
Fundamentals of Pump Station and Force Main Design
 Future Pumping Needs
Consideration should be given to future conditions which may occur during the life of
the station.

Normally, where future development and population increases are projected for the
area, pumps will be designed for initial conditions only, and the station will be
provided with adequate room for expansion of pumping capacity at a later date.

23
Fundamentals of Pump Station and Force Main Design
 Expansion of Pumping Capacity
The expansion of pumping capacity can be accomplished with the installation of
additional pumping units, larger pumps, impellers, drive units, adjustable or variable
speed drives.

However, some situations may warrant the provision of capacity for future increases
initially, for economics or other reasons. Each situation should be analyzed on a case
by case basis.

24
Fundamentals of Pump Station and Force Main Design
 Small Stations
Two identical pumping units will be provided for those pumping stations which are
required for small remote areas generating extreme peak flowrates of less than 700
gpm, and where the possibility of future expansion is unlikely, and grinder pump
installations serve three or more buildings.

Each pumping unit will be of the constant speed type, and will be capable of
discharging the extreme peak wastewater flowrate. The station will be designed to
alternate between zero discharge and peak discharge.

This arrangement will provide 100 percent standby capacity to allow for necessary
maintenance and repairs. Pneumatic ejector stations will be provided with duplex
ejectors each sized for the extreme peak flowrate.

25
Fundamentals of Pump Station and Force Main Design
 Large Stations
Pumping stations serving large areas of the installation, and especially stations where
the entire wastewater flow or major portions thereof must be pumped to the
treatment facility, will be designed to operate on a continuous basis.

The pump rate must change in increments as the inflow to the station varies.

This mode of operation will normally require two or more wastewater pumps of the
constant or variable speed type, operating in single or multiple pump combinations, as
required to match the incoming flowrates.

26
Fundamentals of Pump Station and Force Main Design
 Type Of Construction
A classification of pumping stations
by capacity and the method of
construction normally utilized for
that capacity is provided in Table 3-1.

27
Fundamentals of Pump Station and Force Main Design
 Package type stations
Factory assembled pumping stations, commonly referred to as package type stations,
are manufactured in standard sizes and are shipped from the factory in modules with
all equipment and components mounted, installed, and ready for connection.

This type of station is suitable for low flows, and where the need to protect pumps
from clogging is minimal.

28
Fundamentals of Pump Station and Force Main Design
 Field-constructed Pumping Stations
Conventional field erected pumping stations are designed for a particular location and
to meet specific requirements.

Field constructed stations will be used where the quantity of flow or its variation, or
both, exceeds the capacity of available factory assembled stations, or where site
conditions require the use of special designs or construction methods.

29
Fundamentals of Pump Station and Force Main Design
 Wastewater Pumping Equipment

30
Fundamentals of Pump Station and Force Main Design
 Wastewater Pumps - Centrifugal Pumps
The centrifugal pump is the predominate type of
wastewater pump used.

These pumps are available in three variations:

• Radial flow
• Mixed flow
• Axial flow

Centrifugal pumps will not be used in capacities of less than 100 gallons per minute.

31
Fundamentals of Pump Station and Force Main Design
 Radial Flow Pumps
The radial flow centrifugal pump is the major type used for pumping raw wastes. In a
radial flow pump, the fluid enters the impeller axially and is discharged at right angles
to the shaft.

Two types of radial flow pumps are available, single suction and double suction:

Single-end suction pump - fluid enters the impeller from one side. The shaft does not
extend into the suction passage, and because of this, rags and trash do not clog the
pump. The single-end suction pump will be suitable for handling untreated
wastewater.

Double suction pump - fluid enters the impeller from both sides, however the shaft
extends into the suction passage, thereby limiting its use to handling only clear water.

32
Fundamentals of Pump Station and Force Main Design
 Sizes of Radial Flow Centrifugal Pumps
Radial flow centrifugal pumps are available in discharge sizes of 2 to 20 inches.
However, pumps with a capacity to pass 3-inch minimum solids will be required.

The recommended capacity range for these pumps is 100 to 20,000 gpm. Pumps are
available in discharge heads of 25 to 200 feet total dynamic head (TDH).

Peak design efficiency ranges from 60 percent for smaller pumps to 85 percent for
larger pumps. Radial flow pumps are suitable for either wet well or dry well
applications. They can be installed with horizontal or vertical shafting, however,
vertical shaft pumps require considerably less space.

33
Fundamentals of Pump Station and Force Main Design
 Mixed Flow Pumps
The mixed flow centrifugal pump is an intermediate design between the radial flow
type and the axial flow type, and has operating characteristics of both. The mixed
flow pump is designed with wide unobstructed passages, and is therefore suitable for
handling wastewater or clear water.

Mixed flow centrifugal pumps are available in 8 inch through 84 inch discharge sizes.
The recommended capacity range for these pumps is 1,000 to 80,000 gpm. Pumps are
available to operate at 10 to 60 feet TDH.

Peak design efficiency - depends on the size and characteristics of the individual
pump, but generally ranges from 80 to 90 percent. The mixed flow centrifugal pump is
normally used only in dry well applications, with either horizontal or vertical shafting
configuration.

34
Fundamentals of Pump Station and Force Main Design
 Axial Flow Pumps
Axial flow centrifugal pumps appropriate for
pumping raw untreated wastewater. This pump
is designed primarily for clear water service and
for wet well installations. The pump is furnished with vertical shaft having a bottom
suction, with the propeller mounted near the bottom of the shaft and enclosed in a
bowl.

The propeller is totally submerged and can be easily clogged by large solids, rags or
trash. Therefore, this pump will only be used for clear well applications.

Axial flow centrifugal pumps are available in 8-inch through 72-inch discharge sizes.
The recommended capacity range for these pumps is 500 to 100,000 gpm. Pumps are
available to operate from 1 to 40 feet TDH.

35
Fundamentals of Pump Station and Force Main Design
 Pump Construction
Centrifugal wastewater pumps will normally be constructed of cast iron with bronze or
stainless steel trim, and with either cast iron or bronze impellers.

When wastewater contains substantial quantities of grit, impellers made of bronze,

cast steel or stainless steel will be required.

36
Fundamentals of Pump Station and Force Main Design
 Enclosed Impellers
Enclosed impellers will be specified for wastewater pumps required to pass solids.
Pump casings of the volute type will be used for pumping raw untreated wastes and
wastewaters containing solids.

Diffusion of turbine type casings may be utilized for effluent or clear water service at
waste treatment facilities.

37
Fundamentals of Pump Station and Force Main Design
 Pump Shafts
Pump shafts will be high grade forged steel, and will be protected by renewable
bronze or stainless steel sleeves where the shaft passes through the stuffing box.

Stuffing boxes will utilize either packing glands or mechanical type seals.

38
Fundamentals of Pump Station and Force Main Design
 Stuffing Box
The stuffing box will be lubricated and sealed against leakage of wastewater (into the
box) by grease, potable water, or another clear fluid.

The lubricating and sealing medium will be supplied to the stuffing box at a pressure
of 5 to 10 psi greater than the pump shutoff head.

39
Fundamentals of Pump Station and Force Main Design
 Grease Seals
Grease seals are usually provided by cartridges which are either spring loaded or
pressurized by connections off the pump discharge. These arrangements generally do
not maintain sufficient seal pressure on the stuffing box.

However, they will be acceptable for low head pumps and where the wastewater
contains little grit, as when pumping treated effluent.

40
Fundamentals of Pump Station and Force Main Design
 Potable Water Seal System
When pumping raw untreated wastes containing the usual quantities of grit, a potable
water seal system with seal pump will be required if a potable water line is assessable
within a reasonable distance.

The later seal system should be capable of supplying 3 gpm per pump minimum.

The principal advantage of a water seal over a grease seal is the positive pressure
maintained on the stuffing box by the seal pump, and small amount of water which
flows from the stuffing box into the pump casing.

Grit and other abrasive materials that may be in the wastewater are thereby
prevented from entering the stuffing box, thus reducing wear on the shaft and
packing.

41
Fundamentals of Pump Station and Force Main Design
 Potable Water Seal System (continued)
The advantage of less frequent repairs to the shaft and less frequent repacking should
be considered in relationship to the cost of providing the water line and other
necessary facilities for the water seal.

Where freezing of seal water is likely to occur, protective measures will be taken.
There must not be, under any circumstances, a direct connection between wastewater
pumps and the potable water system, nor any possibility of backflow of wastes into
the potable water system.

42
Fundamentals of Pump Station and Force Main Design
 Screw Pumps
The screw pump is classified as a positive displacement pump, and as such, maintains
two distinct advantages over centrifugal pumps.

It can pass large solids without clogging, and can operate over a wide range of flows
with relatively good efficiencies.

Screw pumps are normally available in capacities ranging from 150 to 50,000 gpm with
a maximum lift of 30 feet.

43
Fundamentals of Pump Station and Force Main Design
 Screw Pumps (continued)
Because of its non-clog capabilities and wide pumping range, the screw pump is best
suited for lifting raw untreated wastewater into the treatment facility, and for the
pumping of treated effluent.

Also, when treatment plants are upgraded, screw pumps may be installed to
overcome the additional head losses created by new treatment units, so that existing
discharge facilities can be retained.

Screw pumps are usually driven by a constant speed motor with gear reducer, and are
inclined at angles of 30 to 38 degrees from the horizontal.

In most instances, screw pumps will be installed outdoors with only the drive unit
enclosed.

44
Fundamentals of Pump Station and Force Main Design
 Pneumatic Ejector
Pneumatic ejector stations will generally be used
only in remote areas where quantities of wastes are
small, and where future increases in waste flows are
projected to be minimal.

A pneumatic ejector (see image) consists of a

receiving tank, inlet and outlet check valves, air
supply, and liquid level sensors.

45
Fundamentals of Pump Station and Force Main Design
 Pneumatic Ejector (continued)
When the wastewater reaches a preset level in the receiver, air is forced in
ejecting the wastewater.

When the discharge cycle is complete, the air is shut off and wastewater flows
through the inlet into the receiver.

Generally, duplex ejectors operate on a 1-minute cycle, filling for 30 seconds

and discharging for 30 seconds.

Thus, each receiver tank will be equal in volume to 30 seconds of the extreme
peak flowrate. Pneumatic ejector stations are available in capacities ranging
from 30 to 200 gpm with recommended operating heads up to 60 feet TDH.

A typical ejector installation will include duplex units with two compressors,
receivers, level sensors, etc.

46
Fundamentals of Pump Station and Force Main Design
 Grinder Pumps
Grinder pumps shred solids normally found in domestic wastewater, including
rags, paper and plastic, into a slurry.

The slurry can be pumped under low head through pressure sewers as small as
1¼ inches in diameter.

Grinder pumps are for submersible installation, with a recommended operating

range of 10 to 100 gpm.

These pumps are available in discharge heads of 10 to 150 feet TDH.

The peak design efficiency is generally very low.

Grinder pumps will be used only to handle domestic type wastes from one or
more individual buildings, and only in remote areas or areas where gravity
sewers and centralized pumping facilities are not feasible.

47
Fundamentals of Pump Station and Force Main Design
 Types of Pump Drives

48
Fundamentals of Pump Station and Force Main Design
 Electric Motors
As a general rule, electric motors will be provided as the primary drive unit in
sanitary and industrial wastewater pumping stations.

Small pump stations serving remote areas where electric power is not available, will
usually require engine drives.

The three types of electric motors most commonly used in wastewater pumping are:
1) squirrel cage induction
2) wound-rotor induction
3) synchronous

49
Fundamentals of Pump Station and Force Main Design
 Squirrel-cage Induction Motors
Squirrel-cage induction motors (see image) will
normally be selected for constant speed pump
applications because of their simplicity, reliability
and economy.

They can also be used for variable speed operation

when provided with the proper speed control.

Synchronous motors - may be more economical

for large capacity, low rpm, constant speed
pumps.

50
Fundamentals of Pump Station and Force Main Design
 Wound-rotor Induction Motors
Wound-rotor induction motors are most commonly used for pumps requiring variable
speed operation.

For a 60 cycle, alternating current power supply, the maximum synchronous motor
speed allowed for wastewater pumps will be 1800 rpm (approximately 1770 rpm
induction speed).

The normal range of speeds is from 600 to 1200 rpm, with speeds below 450 rpm
unusual at military installations.

Lower speed pumps and motors are larger and more expensive, but generally are
more reliable.

51
Fundamentals of Pump Station and Force Main Design
 Selection of Electric Motors
The selection of electric motors will depend upon the type, size and location of the
pumps, type of speed control used, and the power available at the site. Pump
location will determine the type of motor enclosure.

For Dry pit pump installs - motor enclosures will normally be the open, drip proof
type.

Outdoor dirty or corrosive environments - will require totally enclosed motors.

Submersible pumps will have motor enclosures which are watertight.

Motors installed outdoors will have temperature ratings adjusted to suit ambient
operating conditions.

For pumps designed to operate on an intermittent basis, space heaters will be

provided in motor housings to prevent condensation. Motors installed in wet wells
will be explosion proof.

52
Fundamentals of Pump Station and Force Main Design
 Motor Starting Equipment
Motor starting equipment will be suitable for the type of motor required voltage.
Motor starters will be designed for limiting the inrush current where shocks or
disruptions to the electrical supply are likely to occur as a result of pump start-up.

Where low starting inrush current is required for constant speed pumps, such as when
using engine driven generator sets, wound-rotor motors will be considered as an
alternative to squirrel-cage motors.

53
Fundamentals of Pump Station and Force Main Design
 Pump Drives - Internal Combustion Engines
(IC) Internal combustion engines will be used primarily at large pumping stations
where electric motors are the primary drive units, and where emergency standby
facilities are required.

Internal combustion engines are required for small pump stations in remote locations
where no electric power source exists.

54
Fundamentals of Pump Station and Force Main Design
 At large wastewater treatment plants
At large wastewater treatment plants where abundant digester gas is produced, it will
generally be more feasible to use IC engines which are fueled by the waste gas.

IC engines may be arranged to drive horizontal pumps by direct or belt connections, or

they may drive vertical pumps through a right angle gear drive with an electric motor
as the primary drive unit (dual drive).

It is more common however, and will be the general rule at large pump stations, to
provide fixed emergency generator sets powered by IC engines.

55
Fundamentals of Pump Station and Force Main Design
 IC Powered Generators
Generators produce electric power not only for pumps, but also for auxiliary
equipment such as heaters, lights, alarms, etc., and for critical pump control systems.

The types of internal combustion engines normally used include:

1) diesel
2) gasoline
3) natural gas, primarily digester gas
4) dual-fuel diesel

56
Fundamentals of Pump Station and Force Main Design
 Fuel Types
Gasoline engines - for anything except small, remotely located pumping stations is not
recommended due to the hazards associated with fuel handling and storage.

Dual-fuel diesel engines - fire a mixture of diesel oil and natural gas, with a minimum
of 10 percent diesel fuel required to ignite the mixture.

Propane - is usually provided as a backup fuel for gas and dual-fuel diesel units.

57
Fundamentals of Pump Station and Force Main Design
 Drive Mechanisms

58
Fundamentals of Pump Station and Force Main Design
 Direct Drive
Direct drive, with the shaft of the drive unit directly connected to the pump
shaft, is the most common configuration. This connection can be either close-
coupled or flexible-coupled.

When using a close-coupled connection, the pump is mounted directly on the

drive shaft. This is the normal arrangement for a vertical pump driven by an
electric motor.

A horizontal pump will usually have a flexible connection, with the engine
mounted adjacent to the pump.

A vertical motor mounted above, and at a distance from a vertical pump, will
be connected to the pump with one or more lengths of flexible shafting.

Direct drive offers the most efficient operation because no power is lost
between the drive unit and the pump.

59
Fundamentals of Pump Station and Force Main Design
 Belt Drives
Belt drives may be utilized if the pump speed is different from those available
with standard drive units, or if speed adjustment is required.

Speed adjustment is accomplished by changing pulley or sheave ratios.

Belt drives used with horizontal pumps require more floor space than a direct
drive unit.

There is power loss through the belt, which results in lower efficiency, and belt
wear increases maintenance requirements.

Belt drives will be used only when it is not

possible to choose single speed equipment
to cover service conditions, or where pump
speed adjustments may be required, but
variable speed operation is not.

60
Fundamentals of Pump Station and Force Main Design
 Right Angle Drives
Right angle drives (see image) will be used on vertical pumps
being driven by horizontal engines.

If the engine serves as emergency standby, a combination

gear box will be installed on the angle drive to allow operation
of the pump by the primary drive unit, which is normally an
electric motor.

A clutch or disconnect coupling disengages the right angle

gear when the motor drives the pump.

When the engine drives the pump, the clutch is engaged and
the motor rotates freely.

In case of a power failure the engine is automatically started,

and after reaching partial operating speed is engaged to drive
the pump.

61
Fundamentals of Pump Station and Force Main Design
 Pump Speed Controls

62
Fundamentals of Pump Station and Force Main Design
 Mode of Operation
Wastewater pumps will be designed to operate in one of the
following modes:
1) constant speed
2) adjustable speed
3) variable speed

The type of speed control system will be selected accordingly, and the type
of speed control required will influence the type of electric motor to be
used.

63
Fundamentals of Pump Station and Force Main Design
 Constant Speed
Constant speed drive is the simplest, most reliable, and most
economical mode of operation, and will be suitable for the majority of
wastewater pumping applications at military installations.

However, where there is a need to match pumping rates with the

incoming wastewater flowrates, a variable speed drive will usually be
more appropriate.

64
Fundamentals of Pump Station and Force Main Design
 Adjustable Speed
By changing pulley or sprocket ratios on a belt driven pump, the speeds
can be adjusted to accommodate several constant speed pumping rates.

This type of system will be used mainly in sludge pumping, but can be a
good alternative to variable speed control in wastewater pumping when
speed adjustment is not required too often.

Where automatic operation is needed pulleys or sheaves can be

positioned through the use of pneumatic, hydraulic or electric devices.

65
Fundamentals of Pump Station and Force Main Design
 Variable Speed
Variable speed operation will usually be required at large pumping
stations where the entire wastewater flow, or major portions thereof,
must be pumped to the treatment facility, and where it is desired to
match the incoming flowrates in order to maintain a smooth,
continuous flow into the plant.

66
Fundamentals of Pump Station and Force Main Design
 Constant vs Variable
Pumping stations will normally require more pumps under a constant speed
system than one utilizing variable speeds.

Also, the size of the wet well can be reduced greatly when pumps operate on a
continuous basis.

Variable speed operation is less efficient than constant speed when pumping at
reduced rates, however friction losses and thus power costs are generally less for
the smaller flows.

67
Fundamentals of Pump Station and Force Main Design
 Selection and Design of the Speed Control System
The selection and design of the speed control system will be coordinated
closely with the selection of the pump and drive units.

The simplest system which allows pumps to accomplish the required

hydraulic effects will be chosen for design.

Factors to be considered in selecting a system include cost, efficiency,

reliability, structural requirements, ease of operation and degree of
maintenance necessary.

Pumping stations will normally be designed for automatic on/off

operation of the pumping units, with manual override by pushbutton or
selector switch.

68
Fundamentals of Pump Station and Force Main Design
 Automatic Speed Control Systems
Most automatic constant speed and adjustable speed systems will
operate from level signals.

Pumps are turned on as the liquid level in the wet well rises, and are
turned off when it falls.

69
Fundamentals of Pump Station and Force Main Design
 Sensor Systems

70
Fundamentals of Pump Station and Force Main Design
 Sensor Types
Pumping systems utilized in treatment plant processes are sometimes
controlled by flow or pressure sensors.

Level detection systems in standard use include the following:

1) Float Switches
2) Mercury Switches
3) Bubbler Tube
4) Electrodes
5) Sonic Meters

The capacitances tube and pressure diaphragm sensor types of

controls will not normally be used due to fouling by the wastes.

71
Fundamentals of Pump Station and Force Main Design
 Float Switches
The simplest type of switch consists of a float
attached to a rod or tape, and suspended in the
wet well.

The float rod opens or closes a switch, depending

on the rise or fall of the float riding on the liquid
level.

The float may also be suspended in a tube or cage.

These units usually require frequent maintenance

as grease, scum and debris in the wastewater build
up on the equipment.

72
Fundamentals of Pump Station and Force Main Design
 Mercury Switch
Another type of float control incorporates a mercury
switch encapsulated in a corrosion resistant ball, and
suspended by cable in the wet well.

This unit is not dependent upon the smooth, vertical

movement of a rod, and thus is not subject to the
maintenance problems described on the previous
page.

73
Fundamentals of Pump Station and Force Main Design
 Bubbler Tube
One of the most commonly used systems employs a bubbler tube
which is suspended in the wet well and is fed by compressed air.

The backpressure on the open end of the tube is sensed by pressure

switches, and then transduced to a voltage or current signal.

These signals are transmitted to a controller which operates the pumps.

This system has no moving parts in contact with the wastewater, and
requires very little maintenance.

The constant flow of compressed air keeps the tube free of solids
accumulations.

74
Fundamentals of Pump Station and Force Main Design
 Electrodes
A series of electrodes are mounted at different elevations so that when the liquid level
rises and contacts an electrode, an electric circuit is energized.

Electrodes are used primarily in pneumatic ejectors where the compressed air serves
to keep the electrodes clean.

They will not normally be used in wet wells due to frequent fouling by grease and
waste debris.

75
Fundamentals of Pump Station and Force Main Design
 Sonic Meters
A sonic meter measures the distance from the liquid level to the meter. They are
difficult to install free of obstructions, and must be isolated from stray electrical or
acoustic signals.

76
Fundamentals of Pump Station and Force Main Design
 Speed Control Devices

77
Fundamentals of Pump Station and Force Main Design
 Bubbler System
A bubbler system will in most cases be employed to control the operation of
automatic variable speed pumps.

In these systems, the backpressure from the bubbler tube is transduced to a

pneumatic or electronic signal for use in on/off and variable speed control of the
pumps.

On/ off controls are usually provided by pressure or electronic switches.

78
Fundamentals of Pump Station and Force Main Design
 Variable Speed Control Devices
Variable speed control devices consist of:
1) magnetic (eddy current) clutches
2) liquid clutches
3) variable voltage controls
4) variable frequency controls
5) wound-rotor motor controls

In general, variable speed control devices are more expensive, less efficient,
and require a higher degree of maintenance than constant speed controls.

79
Fundamentals of Pump Station and Force Main Design
 Magnetic and Liquid Clutches
Magnetic and liquid clutches have been available for many years as
controllers for variable speed pumps.

These older methods are inefficient in that the slip losses which
developed are lost as heat.

The recent development of solid state electronics has led to the

introduction of newer methods of variable speed control suitable for both
squirrel-cage and wound-rotor induction motors.

80
Fundamentals of Pump Station and Force Main Design
 Variable Voltage and Variable Frequency Controls
The variable voltage and variable frequency controls are suitable for use with
squirrel-cage motors.

Variable frequency drives are possible in efficiencies up to 95 percent, and are

available in sizes up to 250 hp. However, variable voltage units are inefficient and
are not recommended.

81
Fundamentals of Pump Station and Force Main Design
 Wound-rotor motor controls
Wound-rotor motor controls come in five categories:
1) fixed step resistors
2) liquid rheostats
3) reactance/resistance controllers
4) electronic rheostats
5) regenerative secondary controls

Of these, the regenerative secondary control offers the best efficiency, while the
other units are considerably less efficient and require more maintenance.

82
Fundamentals of Pump Station and Force Main Design
 Force Mains

83
Fundamentals of Pump Station and Force Main Design
 Force Mains
The pipeline which receives wastewater from a
pumping station, and conveys it to the point of
discharge, is called a force main.

Force mains are designed as pressure pipe, and

must be adequate in strength to withstand an
internal operating pressure equal to the pump
discharge head, plus an allowance for transient
pressures caused by water hammer.

84
Fundamentals of Pump Station and Force Main Design
 Pipe Selection
The internal operating pressure is maximum at the pumping station, and is
reduced by friction to atmospheric, or near atmospheric, at the point of force
main discharge.

The primary consideration in the hydraulic design of force mains is to select a

pipe size which will provide the required minimum velocities without creating
excessive energy losses due to pipe friction.

85
Fundamentals of Pump Station and Force Main Design
 Pipe Size
The most economical size of force main should be determined on the basis of
power costs required for pumping, and capital investment costs of piping and
equipment.

In practice however, the size is usually governed by the need to maintain

minimum velocities at low flows to prevent deposition of solids, and to
develop sufficient velocity at least once a day to resuspend any solids which
may have settled in the line.

However, regardless of pipe sizes required for minimum velocities, the

minimum diameters to be used are 1Y4-inch for pressure sewers at grinder
pump installations, 4-inch for force mains serving small pump stations and
pneumatic ejectors, and 6-inch for all other force mains.

86
Fundamentals of Pump Station and Force Main Design
 Force Main Hydraulics - Design Formula
Force mains will be designed hydraulically with the use of the Hazen-
Williams following formula (shown above.)

87
Fundamentals of Pump Station and Force Main Design
 Hazen-Williams Chart
Force mains may also be
designed hydraulically with
the use of the Hazen-
Williams chart to the right.

88
Fundamentals of Pump Station and Force Main Design
 Roughness Coefficient
Values of C to be used in the formula range from 100 for older
force mains which have been in service a number of years (usually
over 10), to 140 for force mains which are newly constructed.

Some manufacturers of plastic and asbestos-cement pipe report C

values as high as 150.

However, due to uncertainties in design and construction, plus a

desire to provide a margin of safety, C values greater than 140 will
not normally be permitted.

89
Fundamentals of Pump Station and Force Main Design
 C Value for Force Mains in Poor Condition
At some installations, force mains may be very old (40 to 50 years)
and in extremely bad condition, with offset joints broken pipe, or
materials encrusted on pipe walls.

For these cases, lower C values may be justified.

However, values lower than 80 will not be allowed unless verified

by flow and pressure tests.

90
Fundamentals of Pump Station and Force Main Design
 Velocity Criteria
Velocity criteria for force mains are based on the fact that suspended
organic solids do not settle out at a velocity of 2.0 foot per second or
greater.

Solids will settle at velocities less than 1.0 fps and when wastewater
pumps are idle.

However, a velocity of 2.5 to 3.5 fps is generally adequate to resuspend

and flush the solids from the line.

91
Fundamentals of Pump Station and Force Main Design
 Small Station - Force Main Velocities
Force mains serving small pump stations, which are designed to operate on
an intermittent basis, will be sized to provide a minimum velocity of 3.5 fps
at the peak discharge rate.

For small stations having flows too low to warrant a minimum velocity of
3.5 fps with one pump operating, the design may call for both pumps to be
operated manually once a week for a sufficient period of time to flush out
the line.

92
Fundamentals of Pump Station and Force Main Design
 Large Station - Force Main Velocities
Larger stations having three or more pumping units - which operate a
major portion of the time, will require minimum force main velocities
ranging from 2.0 fps with one pump operating, to 5.0 fps with several
pumps operating.

In these cases, it is only required that a minimum velocity of 2.5 to 3.5 fps
be provided once or twice daily.

Large pumping stations which serve the entire installation - or major

portions thereof, and which are designed to pump continuously, will usually
have a greater number of pumps operating over a wider range of flowrates.

Since the pumping range may vary from 7 or 8 to 1, it will generally be

sufficient to design for velocities of 0.5 up to 7.0 or 8.0 fps. Maximum
velocity is set at 10.0 fps.

93
Fundamentals of Pump Station and Force Main Design
 Value of S (Slope)
The value of S in the formula is equivalent to the kinetic energy loss due
to pipe friction divided by the length of conduit, or:

Minor energy losses from fittings and valves will be converted to

equivalent lengths of conduit for use in the formula.

94
Fundamentals of Pump Station and Force Main Design
 Total Kinetic Energy Loss
Conversion tables for fittings and valves can be found in standard hydraulics
textbooks.

The total kinetic energy loss in a force main will be computed by multiplying the
slope of the energy grade line by the total length of conduit including equivalent
lengths, or:

95
Fundamentals of Pump Station and Force Main Design
 Pump Analysis And Selection –Total Dynamic Head
The head in feet against which a pump must work when wastewater is being
discharged is termed the total dynamic head (TDH).

The two primary components of TDH in wastewater applications are the static
discharge head and the kinetic losses due to pipe friction.

96
Fundamentals of Pump Station and Force Main Design
 TDH - Bernoulli energy equation
Velocity and pressure heads are also
present, but are usually insignificant.

The TDH will be calculated with the use of

the Bernoulli energy equation which can be
written as follows (image to the right)

All head terms are in feet. Subscripts d and

8 represent force main discharge and pump
suction, respectively.

In order to determine hydraulic conditions

at the pump suction, it will be necessary to
write an energy equation from the liquid
level in the wet well to the pump suction
nozzle.

97
Fundamentals of Pump Station and Force Main Design
 Pump Analysis And Selection

98
Fundamentals of Pump Station and Force Main Design
 System Head - Capacity Curve
To determine the head required of a pump, or group of pumps, that would discharge
at various flowrates into a force main system, a head-capacity curve must be
prepared.

This curve is a graphic representation of the total dynamic head, and will be
constructed by plotting the TDH over a range of flowrates from zero to the maximum
expected value.

99
Fundamentals of Pump Station and Force Main Design
 Friction Losses
Friction losses can be expected to increase with time, thus affecting the capacity of
the pumping units and their operation.

Therefore, system curves well reflect the maximum and minimum friction losses to be
expected during the lifetime of the pumping units, as well as high and low wet well
levels.

100
Fundamentals of Pump Station and Force Main Design
 System Curves
The typical set of system curves will generally consist of two curves using a Hazen-
Williams coefficient of C = 100 (one for maximum and one for minimum static head),
and two curves using a Hazen-Williams co-efficient of C = 140 (for maximum and
minimum static head).

These coefficients represent the extremes normally found in wastewater applications.

101
Fundamentals of Pump Station and Force Main Design
 Pump Head - Capacity Curve
The head that a particular pump can produce at various flowrates is established in
pump tests conducted by the pump manufacturer.

The results of these tests are plotted on a graph to form the pump characteristic
curve.

Along with the discharge head developed, the pumps operating efficiency, required
power input, and net positive suction head are generally included on the same
diagram.

102
Fundamentals of Pump Station and Force Main Design
 Efficiency And Power Input
Pump efficiency is the ratio of the useful
power output to the input, or brake
horsepower, and is given by:

103
Fundamentals of Pump Station and Force Main Design
 Pump Efficiency
Pump efficiencies usually range from 60 to 85 percent. Most
characteristic curves will indicate a best efficiency point (BEP)
at which pump operation is most efficient.

Where possible, pumps will be selected to operate within a

range of 60 to 120 percent of the BEP.

104
Fundamentals of Pump Station and Force Main Design
 Net Positive Suction Head
When pumps operate at high speeds and at
capacities greater than the BEP, the potential
exists for pump cavitation.

Cavitation can reduce pumping capacity and may

in time damage the pump impeller.

105
Fundamentals of Pump Station and Force Main Design
 Cavitation
Cavitation occurs when the absolute pressure at the pump inlet
drops below the vapor pressure of the fluid being pumped.

To determine if cavitation will be a problem, the net positive

suction head (NPSH) available will be computed, and compared
with the NPSH required by the pump.

106
Fundamentals of Pump Station and Force Main Design
 NPSH Formula
The NPSH is not normally a problem when
discharge heads are less than 60 feet.

However, when heads are greater than 60

feet, or when the pump operates under a
suction lift, or far out on its curve, the
NPSH will be checked.

The NPSH available at the eye of the

impeller in feet will be calculated with the
following formula (image to the right.)

Note: All head terms are in feet.

107
Fundamentals of Pump Station and Force Main Design
 Affinity Laws
A set of relationships derived from flow, head and power coefficients for
centrifugal pumps, can be used to determine the effect of speed changes
on a particular pump.

These relationships are known as affinity laws and are as follows:

108
Fundamentals of Pump Station and Force Main Design
 Variables from the Affinity Laws
Q, H and P terms represent pump capacity, discharge head, and power
output respectively, at speeds N1 and N2.

These relationships will be used in analyzing variable speed pump

operation in the absence of manufacturer's characteristic curves, or where
characteristic curves do not show performance at the desired speeds.

109
Fundamentals of Pump Station and Force Main Design
 Pump Selection
System analysis for a pumping station will be conducted to select the most
suitable pumping units which will meet service requirements, and to
determine their operating points, efficiencies, and required horsepower.

110
Fundamentals of Pump Station and Force Main Design
 Single Pump Operation
A system head capacity curve will be prepared showing all
conditions under which the pump is required to operate.

The system curve will then be superimposed onto a pump head-

capacity curve, or characteristic curve, to define the pump
operating point.

111
Fundamentals of Pump Station and Force Main Design
 Typical Pump System Curve
The point where the two curves
intersect represents the head and
capacity at which the pump will
operate in the given piping system.

A typical set of system curves with

pump characteristic curves is
shown in the diagram to the right.

112
Fundamentals of Pump Station and Force Main Design
 Multiple Pump Operation
Where two or more pumps discharge into a common header, the head losses in
individual suction and discharge lines will be omitted from the system head-
capacity curve.

This is because the pumping capacity of each unit will vary depending upon which
units are in operation.

In order to obtain a true picture of the output from a multiple pump installation,
the individual suction and discharge losses are deducted from the pump
characteristic curves.

This provides a modified curve which represents pump performance at the point
of connection to the discharge header.

113
Fundamentals of Pump Station and Force Main Design
 Multiple Pump Performance
Multiple pump performance will be determined by adding the capacity for
points of equal head from the modified curve.

The intersection of the modified individual and combined pump curves with
the system curves shows total discharge capacity for each of the several
possible combinations.

Pumps should be selected so that the total required capacity of the pump
installation can be delivered with the minimum level in the wet well and
maximum friction in the discharge line.

Pump efficiency will be a maximum at average operating conditions.

114
Fundamentals of Pump Station and Force Main Design
 Design of Wet Wells for the
Storage of Pumpage

115
Fundamentals of Pump Station and Force Main Design
 Wet Well Design
Wet wells will be constructed at pumping stations for the purpose of storing
wastewater flows prior to pump operation. The storage volume required depends
upon the method of pump operation, i.e., whether pumps are constant, adjustable or
variable speed.

In addition to providing adequate storage volume, wet wells will be designed to:
1) allow for proper pump and level controls
2) maintain sufficient submergence of the pump suction inlet
3) prevent excessive deposition of solids
4) provide ventilation of incoming sewer gases

In smaller stations, bar racks or comminuting devices may be installed within the wet
well in order to reduce costs. Overflows from wet wells are prohibited in all cases.

116
Fundamentals of Pump Station and Force Main Design
 Storage Volume
If pumps are of constant or adjustable speed type, the wet well volume must be large
enough to prevent short cycling of pump motors.

For pumps driven by variable speed drives, the storage volume may be small provided
pumping rates closely match the incoming flowrates.

The volume (V) required for the wet well will be computed with the above formula:

117
Fundamentals of Pump Station and Force Main Design
 Minimum Pump Cycle Times (Pumps driven by Squirrel Cage Motors)
Constant or adjustable speed pumps driven by squirrel cage induction motors will be
designed for minimum cycle times as shown in the following table:

118
Fundamentals of Pump Station and Force Main Design
 Control Circuit for Alternating Pumps
The storage volume calculated for small stations (capacities less than 700 gpm) which
utilize two identical constant speed pumps, may be reduced one half by providing a
control circuit to automatically alternate the pumps.

The storage volume required for variable speed pumps will be based on providing
sufficient time for a change in capacity when a pump is started or stopped.

119
Fundamentals of Pump Station and Force Main Design
 Wet Well Storage Retention Time
When a pump is started, the motor must be ramped to the desired speed, and the
pumps already in operation must be reduced in speed. The time required for this is
usually less than 1 minute.

A considerable amount of storage is normally available in large sewers which serve

stations utilizing variable speed pumps. This volume may be considered in design by
calculating backwater curves for the various operating levels.

The maximum retention time in the wet well will not exceed 30 minutes to prevent
septicity.

120
Fundamentals of Pump Station and Force Main Design
 Suction Pipe Connections
Pump suction piping will be selected to provide a velocity of 4 to 6 feet per second.
Pipe should be one or two sizes larger than the pump suction nozzle.

Vertical pumps installed in a dry well which is adjacent to the wet well, will be fitted
with a 90 degree suction elbow, followed by an eccentric reducer and a gate valve.

121
Fundamentals of Pump Station and Force Main Design
 Common Piping Arrangements
The suction line will be extended through the wall into the wet well, and terminated
with either a 90 or 45 degree flared elbow, or an elbow with a flared fitting. The most
commonly used piping arrangements are illustrated in the images above, where D is
the diameter of the flared inlet, and S is the submergence depth.

122
Fundamentals of Pump Station and Force Main Design
 Adequate depth of Submergence to avoid Vortexing
Adequate submergence of the suction inlet is critical to prevent air from being
drawn in by vortexing.

Minimum required submergence depths are given in the table above as a

function of velocity.

The net positive suction head (NPSH) will also be considered when
determining S.

123
Fundamentals of Pump Station and Force Main Design
 Dividing Wet Wells into Two or More Compartments
Larger, conventional type pump stations will normally be constructed with wet wells
divided into two or more sections, or compartments, so that a portion of the station
can be taken out of service for inspection or maintenance.

Each compartment will have individual suction pipes, and will be interconnected with
slide or sluice gates.

124
Fundamentals of Pump Station and Force Main Design
 Slope on Floor of Wet Well
The floor of the wet well will be level from the wall to a point 12 to 18 inches beyond
the outer edge of the suction bell, and then will be sloped upward at a minimum 1:1
slope.

125
Fundamentals of Pump Station and Force Main Design
 Pump Controls And Instrumentation

126
Fundamentals of Pump Station and Force Main Design
 Instrumentation at a Pumping Station
Instrumentation at a pumping station includes
automatic and manual controls used to sequence
the operation of pumps, and alarms for indicating
malfunctions in the pumping system.

Automatic control of pumps will usually be based

on the liquid level in the wet well.

127
Fundamentals of Pump Station and Force Main Design
 Manual Control and System overrides during Emergencies
Manual control of pumps is always required in order to operate the pumps during
emergencies, for maintenance purposes, or when automatic systems fail.

Manual overrides will be set to bypass the low level cut-off, but not the low level
alarm.

128
Fundamentals of Pump Station and Force Main Design
 Selection Of Control Points
A control range of at least 3.0 feet is required between maximum and
minimum liquid levels in the wet well.

A minimum of 6 inches will be required between pump control points used to

start and stop successive pumps, or to change pump speeds.

For small stations, the control range may be less, however control points will
not be set closer than 3 inches.

129
Fundamentals of Pump Station and Force Main Design
 Pump Speed
Constant or adjustable speed pumps - require simple on-off switches to start or stop
pumps, or to change from one speed step to the next.

Variable speed pumps - require a more complex control arrangement.

The two basic types of level control for variable speed operation are:
• variable level
• constant level

130
Fundamentals of Pump Station and Force Main Design
 Variable Level Control for Pump Speed
For variable level control, a narrow band of control points is established in the wet
well.

Pump speed is then adjusted in steps by the level detection system (usually a bubbler
tube) as the level varies.

Pumps operate at maximum speeds near the HWL, and at minimum speeds near the
LWL. However, pumps are started and stopped by level switches.

131
Fundamentals of Pump Station and Force Main Design
 Constant Level Control for Pump Speed
Constant level control is seldom used, but may be required where a very narrow band
of operation is necessary.

In a constant level system, one level is set as the control point, and pump speed is
adjusted in a stepless fashion as the liquid level rises above, or falls below this point.

132
Fundamentals of Pump Station and Force Main Design
 Level Alarms
Alarms will be provided to signal high and low liquid levels in the wet well, pump
failure, or a malfunctioning speed control system.

The high level alarm will be set above the start point of the last pump in the
operational sequence, but below the start point of the standby pump, if used.

The low level alarm will be set below the shutoff point of the lead pump. An
emergency, low level pump cutoff will be set below the low level alarm.

133
Fundamentals of Pump Station and Force Main Design
 Surge Phenomena (Water Hammer)

134
Fundamentals of Pump Station and Force Main Design
 Surge Phenomena - Water Hammer in Force Mains
Sudden changes in flow and velocity in force mains can occur as a result of pump
startup, pump shutdown, power failure, or rapid closing of a valve.

These velocity changes can produce large pressure increases or surge phenomena
known as water hammer, which can cause extensive damage to force mains (see
image).

Most severe water hammer conditions - are usually caused by a pump shutdown or
power failure. An analysis of water hammer will include calculating the critical time,
determining the maximum pressure increase, and selecting a method of control.

135
Fundamentals of Pump Station and Force Main Design
 Surge Phenomena - Critical Time
When flow is suddenly changed in a force main, a pressure wave is generated which
rapidly travels the entire length of conduit, and back to the point of change. The time
required for this roundtrip is given by:

136
Fundamentals of Pump Station and Force Main Design
 When the Time Interval is more than/less than Tc
When flow is completely stopped (Q = O) in a time interval greater than Tc, the
maximum theoretical pressure increase is not fully developed.

When flow is stopped in a time interval less than or equal to Tc, the change is said to
be instantaneous, and the maximum pressure increase is developed (see next page).

137
Fundamentals of Pump Station and Force Main Design
 Surge Phenomena-Maximum Pressure Increase
The maximum theoretical pressure increase or surge caused by water hammer is
calculated from the following:

138
Fundamentals of Pump Station and Force Main Design
 Surge Phenomena-Methods Of Control
Whenever a pump is shut down, or power to the station fails, the pump motor is
suddenly cut off.

Pump speed along with flow and velocity in the force main are quickly decelerated by
pressure waves, which travel up the pipeline and back in accordance with Newton's
second law of motion.

139
Fundamentals of Pump Station and Force Main Design
 Reversed Flow through Pump
When the velocity is reduced to zero, reverse flow through the pump would
occur if a gravity operated check valve or an automatic control valve were not
installed on the pump discharge line, and did not close properly.

Reverse flow fully accelerated through the pump could cause transient flows
and pressures well above maximum design conditions.

140
Fundamentals of Pump Station and Force Main Design
 Pressure Surges due to Valve Conditions
A swing check valve which stuck open temporarily, and then slammed shut
under these conditions, would result in a large pressure surge as mentioned
previously.

In order to control and limit surge phenomena - the following valve applications
may be used:

141
Fundamentals of Pump Station and Force Main Design
 Gravity-operated Check Valves
For simple cases involving small to medium sized pump stations with gradually
rising force mains (no intermediate high points) of less than 1000 feet in length,
and with static discharge heads of less than 50 feet, a gravity operated check
valve will usually be sufficient.

Gravity type check valves may be either swing checks utilizing outside lever and
weight (or spring) set to assist closure, or then may be ball checks.

Swing check valves are usually installed horizontally, while ball check valves may
be either vertical or horizontal.

142
Fundamentals of Pump Station and Force Main Design
 Pressure Relief Valves
For additional protection, a pressure relief valve may be installed in conjunction with
check valves to allow reversing flow to reenter the wet wall.

Pressure relief valves must be specially designed for sewage applications. As an

alternative to relief valves, a hydro-pneumatic tank may be utilized.

143
Fundamentals of Pump Station and Force Main Design
 Automatic Control Valves
In situations where long force mains are required, pipe profiles must
conform to existing ground elevations for economic reasons.

This normally will result in high points in the force main, with the
possibility of water column separation at the high points during pump
shutdown or power failure.

The pressures generated when these separated columns come to rest

against closed valves or against stagnant columns may be large, and are
again determined by the conditions previously mentioned.

144
Fundamentals of Pump Station and Force Main Design
 Automatically Operated Valves
In general, where force mains are greater than 1000 feet in length or contain
intermediate high points, and where pumping stations are large in capacity, or static
discharge heads are greater than 50 feet, control valves will be automatically operated
cone, plug, ball, or butterfly valves.

145
Fundamentals of Pump Station and Force Main Design
 Valve Closure during Pump Shutdown
Normal operation of these valves upon pump shutdown, is to slowly close the valve
while the pump continues to run. When the valve is closed, a limit switch then stops
the pump motor. On power failure, an emergency hydraulic or other type operator
closes the valve slowly.

The time of valve closure is of utmost

importance. Valves should be half
closed when the velocity in the force
main has dropped to zero.

The time required to reach zero velocity

can be calculated with this formula:

146
Fundamentals of Pump Station and Force Main Design
 Valve Closure Times
The types of valve operators most often utilized are hydraulic, electric and
pneumatic. Valves and operators specified for use will be fully adjustable for
closure times ranging from t to 4t minimum. In some large pumping stations,
the use of automatically controlled valves alone will not be sufficient

Extremely long force mains (over 1 mile) may require very long valve closing
times, and thus result in excessive backflow to the wet well and reverse rotation
of the pump and motor. To solve these problems, a pump bypass with surge
relief valve will generally be required.

147
Fundamentals of Pump Station and Force Main Design
 Valves used for Surge Relief
Valves used for surge relief will be automatically controlled cone or
butterfly valves, similar to the pump discharge valves.

Normal operation upon pump shutdown now will require the pump
discharge valve to be fully closed when the velocity has dropped to zero.

The surge relief valve will be fully open allowing backflow to enter the wet
well at a reduced rate. As before, the relief valve must close slowly to
avoid water hammer.

148
Fundamentals of Pump Station and Force Main Design
 Use of Software for Water Hammer Analysis
Most cases involving large pump stations with long force mains, which contain several
intermediate high points, will be too complex to solve by hand using conventional
methods such as graphical solutions, arithmetic integration, or water hammer charts.

Many computer programs are now available for water hammer analysis, and are
recommended for use in those instances.

149
Fundamentals of Pump Station and Force Main Design
 Screening And Comminuting Devices

150
Fundamentals of Pump Station and Force Main Design
 Screening And Comminuting Devices
Centrifugal pumps are susceptible to clogging by rags, trash, and other debris normally
found in wastewater. To protect pumps from clogging, equipment will be installed to
screen or cut up these materials prior to pumping.

Small pump stations with capacities of less than 200 gpm, including grinder pumps
and pneumatic ejectors, are exempt from this requirement.

151
Fundamentals of Pump Station and Force Main Design
 Bar Racks and Screens
The types of equipment to be used include bar
racks, screens, and comminutors (see image)
which are installed in the wet well, or in a
separate influent channel.

152
Fundamentals of Pump Station and Force Main Design
 Use of Manually-cleaned Racks at Smaller Stations
At most medium to large sized pump stations, the use of mechanically cleaned bar
screens or comminutors will be required. However, at smaller stations in remote
areas, manually cleaned racks may be more feasible.

The smallest clear opening between bars is normally 1 inch, and spacing of less than
3/4 inch will not be permitted. All electrically operated equipment in wet wells will
have explosion proof motors.

153
Fundamentals of Pump Station and Force Main Design
 Force Mains: Types of Piping

154
Fundamentals of Pump Station and Force Main Design
 Factors for Selection of Pipe Materials, Fittings And Joints
Factors to be considered in the selection of pipe materials and piping systems for
force mains are:
• Flow characteristics or friction coefficient
• Life expectancy and history of use
• Resistance to scour and abrasion
• Resistance to acids, alkalis,
• Resistance to high temperature, or corrosive wastes and soils
• Ease of handling and installation
• Physical strength and pressure rating
• Joint water-tightness and ease of installation
• Availability of pipe in required sizes, strengths, etc.
• Availability of fittings, connections and adapters

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Fundamentals of Pump Station and Force Main Design
 One Size doesn’t Fit All
No pipe manufactured is suitable for all installation requirements and conditions. The
pipe materials covered here, are the ones most often used for force mains carrying
sanitary and industrial wastes.

Each type of pipe will be evaluated to determine its suitability for the particular
design. Where iron or concrete pipe are to be considered, special attention should be
paid to subsurface and soil conditions.

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Fundamentals of Pump Station and Force Main Design
 Soil Characteristics and Corrosion
The characteristics of the soil in which a pipe is placed affect the rate of corrosion,
with the most corrosive soils being those having poor aeration and high values of
acidity, electrical conductivity, dissolved salts, and moisture content.

The relative potential for corrosion may be estimated by evaluating the degree of
corrosion of existing metallic or concrete pipelines previously buried in the soil.

When this information is not available, or is non-conclusive, resistivity tests of the soil
should be conducted and results evaluated. Pipe materials found inappropriate for
use should be removed from the project specifications.

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Fundamentals of Pump Station and Force Main Design
 Ductile Iron Pipe for Force Mains
Ductile iron (D.I.) pipe is suitable for force mains used at pumping stations and
wastewater treatment facilities.

Special uses include river crossings, pipe located in unstable soil, highway and rail
crossings, and piping installed above ground. D.I. pipe is susceptible to corrosion from
acid wastes and aggressive soils.

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Fundamentals of Pump Station and Force Main Design
 Ductile Iron Pipe (continued)
Cement linings, bituminous coatings or polyethelene linings are usually provided for
interior protections. For extremely corrosive soils, a polyethelene encasement is
recommended for external protection.

Pipe is available in 3-inch through 54-inch diameters, and with mechanical, push-on or
flanged joints. Flanged joints are restricted to interior piping.

The Handbook of Ductile Iron Pipe, Cast Iron Pipe published by the Cast Iron Pipe
Research Association (CIPRA) will be used for guidance in designing ductile iron force
mains.

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Fundamentals of Pump Station and Force Main Design
 Steel Pipe for Force Mains
Steel pipe may be used for force mains when lined with cement mortar or
bituminous materials to provide internal protection. A bituminous coating
must be applied for external protection also. Lined and coated steel pipe is
available in diameters 6-inch through 144-inch.

Galvanized steel pipe will be used for small diameter force mains and
pressure sewers from 1/4-inch to 4-inch in size. Joints for steel pipe less
than 6-inch will be threaded. Pipe 6-inch in diameter and larger will have
mechanical, push-on, or flanged joints. Threaded and flanged joints will be
used only for interior piping.

Steel pipe will be installed in accordance with the manufacturer's

recommendations, and Manual No. M11-Steel Pipe Design and Installation
published by the American Water Works Association (AWWA).

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Fundamentals of Pump Station and Force Main Design
 Concrete Pressure Pipe for Force Mains
Concrete pressure pipe will generally be used where high strength or large diameter
force mains are required.

Pre-tensioned reinforced concrete pressure pipe is available in diameters 10-inch

through 42-inch, pre-stressed concrete pressure pipe in diameters 16-inch through
144-inch, and reinforced concrete pressure pipe in diameters 24inch through 144-
inch. Each type utilizes bell and spigot joints with rubber gaskets.

The Concrete Pressure Pipe Manual, Manual No. M9 published by the American Water
Works Association (AWWA) will be used for design of force mains.

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Fundamentals of Pump Station and Force Main Design
 Asbestos-Cement Pipe for Force Mains
Force mains constructed of asbestos-cement (A.C.) pressure pipe are durable
and light in weight. However, A.C. pipe is affected by corrosive wastes and
aggressive soils, and must be provided with plastic linings for protection.

The type of material required for A.C. pipe will be type II in accordance with
ASTM C 500. Pipe is available in diameters 4-inch through 42-inch, and will be
joined by means of couplings utilizing rubber gaskets.

Design of A.C. force mains will conform to the manufacturer's recommendations.

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Fundamentals of Pump Station and Force Main Design
 Plastic Pipe for Force Mains
Characteristics which make plastic pipe highly desirable for force main use include high
corrosion resistance, light weight, and low coefficient of friction.

Disadvantages - include the possibility of excessive pipe wall deflections when installed
improperly or subjected to high temperature wastes, and chemical breakdown caused by
prolonged exposure to sunlight.

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Fundamentals of Pump Station and Force Main Design
 Plastic Pipe (continued)
The following types of plastic pipe are suitable for use:
Polyvinyl chloride (PVC) - PVC pipe is available in diameters 4-inch through
12-inch, and with screw, push-on, or solvent weld joints.

Polyethylene (PE) - PE pipe may be used in diameters 11/2-inch through

48-inch. Pipe joints consist of mechanical, flanged, or heat fusion type.
(3)Polypropylene (PP).

Pipe diameters available with polypropylene pipe are 1/2-inch through 4-

inch.

All pipe will be joined by heat fusion methods. Screwed and flanged joint
pipe will not be used underground.

Manufacturer's recommendations will be used in design of plastic pipe, in

addition to the Handbook of PVC Pipe-Design and Construction published
by the Uni-Bell Plastic Pipe Association.

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Fundamentals of Pump Station and Force Main Design
 Fiberglass Pipe for Force Mains
Fiberglass pipe provides a good alternative for use in large diameter force mains.
High structural integrity, low pipe friction coefficient, and a high resistance to
internal/external corrosion and to high temperature wastes, are important
properties of fiberglass pipe.

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Fundamentals of Pump Station and Force Main Design
 Fiberglass Pipe (continued)
The following types of fiberglass pipe may be used:
Reinforced thermosetting resin pipe (RTRP) - may be installed in diameters of
6inch through 144-inch. Jointing systems for RTRP pipe include bell and spigot,
flanged, or special mechanical type couplings. Elastomeric gaskets are used to
provide flexible joints

Reinforced plastic mortar pipe (RPMP) - Pipe diameters available for RPMP
pipe range from 8inch to 144-inch. Pipe joints are made with grooved couplings
or bell and spigot joints utilizing rubber gaskets.

Design of fiberglass force mains will follow the manufacturer's

recommendations.

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Fundamentals of Pump Station and Force Main Design
 Other Piping Specs
Pump suction and discharge piping inside the station - will normally be ductile iron or
steel. However, other pipe materials covered in this chapter are not precluded from
use.

Pipe, fittings and joints serving as force mains - will be selected to withstand the
maximum internal operating pressures, including transient surges. The project
specifications should indicate the appropriate pressure class and rating for each pipe
application.

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Fundamentals of Pump Station and Force Main Design
 Force Mains: Valves And Appurtenances

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Fundamentals of Pump Station and Force Main Design
 Valves And Appurtenances
All valves will be installed in a manhole or valve structure with adequate drainage and
protection against freezing.

The use of valves in wastewater pumping can be divided into the following categories:

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Fundamentals of Pump Station and Force Main Design
 Isolation Or Shutoff Valves
Where the need to isolate pumps or part of the piping system occurs, manually
operated shutoff valves will be used.

Gate valves or butterfly valves generally serve as shutoff valves, however ball valves or
plug valves may also be used.

Shutoff valves are required on the suction and discharge sides of all pumps.

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Fundamentals of Pump Station and Force Main Design
 Surge Control Valves
To protect pumps and piping from surges caused by pump shutdown or power failure,
gravity operated swing check or ball check valves, or automatically operated cone,
plug, ball or butterfly valves will be installed in the pump discharge line.

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Fundamentals of Pump Station and Force Main Design
 Blowoff Valves
A valve outlet installed at the low point in a force main, and arranged to drain
or flush the pipeline, is termed a blowoff.

Normally, blowoffs will be required only on long depressed sections of force

main, or where an accumulation of solids is likely to occur.

Blowoff connections will be installed in manholes or valve structures, and will

be protected against freezing. A means of discharging to a suitable location
materials flushed from the system will be provided.

The pipe size of the outlet connection should coincide with the size of the
force main.

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Fundamentals of Pump Station and Force Main Design
 Air Valves
Air valves will be installed at high points in force mains for the purpose of admitting
and releasing air. When the pipeline is taken out of service for draining, flushing and
filling operations, a manually operated valve will be adequate.

However, where air pockets or pressures less than atmospheric are likely to occur with
the pipeline in service and under pressure, automatic air release and/or air vacuum
valves will be used.

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Fundamentals of Pump Station and Force Main Design
 Manual vs Automatic Valves
Manual valves - can also be used with the pipeline under pressure by leaving the valve
partially open.

Automatic valves - are not recommended due to maintenance problems, and should
be used only where absolutely required.

Automatic valves will be of a type specially designed for sewage, and will be provided
with back-flushing connections.

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Fundamentals of Pump Station and Force Main Design
 Force Mains: Protection Measures

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Fundamentals of Pump Station and Force Main Design
 Thrust Protection using Restraints
(Thrust Blocks)
Force mains will be restrained to resist thrusts that
develop at bends, tees, wye connections and plugs
in the pipe.

The magnitude of such forces can be calculated with

the use of formulas found in standard hydraulics
textbooks. Required methods of restraint will
consist of tie rods and clamps, or concrete thrust
blocks.

Restraints should be designed in accordance with

Section VI of the CIPRA Handbook of Ductile Iron
Pipe, Cast Iron Pipe.

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Fundamentals of Pump Station and Force Main Design
 Freeze Protection
Force mains will be installed with sufficient depth to
prevent freezing, and to protect the pipe from
structural damage.

A minimum cover depth of 3 feet will ordinarily be

required for freeze protection. However, in unusually
cold climates, a greater depth may be required.

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Fundamentals of Pump Station and Force Main Design
 Protection of Potable Water Lines
Force mains and pressure sewers will not be installed closer than 10 feet
horizontally to potable water lines. If conditions prevent a 10-foot clearance, a
minimum distance of 6 feet will be allowed provided the bottom of the water
pipe is at least 12 inches above the top of the pressure pipe.

Where a pressure pipe must cross a potable water line, the pressure line will
always be installed below the water line with a minimum vertical clearance of 2
feet.

Pressure pipe joints will not be closer than 3 feet to the crossing unless fully
encased in concrete.

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Fundamentals of Pump Station and Force Main Design
 Pump Station: Construction Requirements

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Fundamentals of Pump Station and Force Main Design
 Station Configuration
The space requirements of pumps, piping and equipment, along with the
storage volume required in the wet well, will be carefully determined so that
the proper size, shape and configuration of the pumping station can be
selected.

The size and shape of the station will often be dictated by equipment other
than pumps, such as bar screens, comminutors, grit collectors, etc.

Rectangular or square structures normally have more usable interior space

than circular ones, and will be employed whenever possible in the design of
medium to large sized pumping facilities.

However, where the below ground portion of the station must be made deep
to accommodate incoming sewers, and where foundation conditions are poor,
circular caisson type structures will be required if lateral earth pressures are
excessively high.

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Fundamentals of Pump Station and Force Main Design
 Package Type Stations
Factory assembled or package type stations will generally be circular in design, and
will be anchored to base slabs where warranted by subsurface conditions. Pump
stations located in cold regions or in seismic zones will require special design
considerations.

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Fundamentals of Pump Station and Force Main Design
 Designing For Operation And Maintenance
The design of medium to large sized, conventional type pumping facilities will include
adequate floor openings, doorways, or access hatches for the installation, removal,
and replacement of the largest items of equipment.

Interior dimensions in the dry well will provide a minimum clearance of 4 feet
between adjacent pump casings, and a minimum of 3 feet from each outboard pump
to the closest wall.

Other major items of equipment will be provided similar spacing. A 7-foot minimum
clearance between floor and overhead piping will be maintained where practicable.

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Fundamentals of Pump Station and Force Main Design
 Ingress and Egress
Smaller package type stations will be furnished with necessary access openings for
removal of pumps and equipment, however interior dimensions and clearances will
generally be less than for field erected stations.

Wet wells for medium to large sized stations will be divided into two or more
compartments to facilitate cleaning and repairs.

Wet wells for all stations will have no length, width or diameter smaller than 4 feet.
Eye bolts or trolley beams will be provided in smaller stations, and overhead bridge
cranes in large stations, for hoisting and removing equipment from mountings.

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Fundamentals of Pump Station and Force Main Design
 Access (Vertical)
A suitable means of access will be provided, to service and maintain all equipment.

Stairs will be provided in medium to large sized stations so that personnel may inspect
and maintain equipment.

Smaller stations, except those utilizing submersible pumps, will require the use of
vertical safety ladders.

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Fundamentals of Pump Station and Force Main Design
 Drainage
A floor drainage system will be provided in the dry well, and throughout the
superstructure, for collection of wash down, seepage, and stuffing box leakage.

These wastes will be piped or conveyed to the wet well, either by gravity or by
sump pump. Openings to the wet well and dry well through the main floor of the
station will be above the maximum flood level, or will otherwise be protected
from flooding.

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Fundamentals of Pump Station and Force Main Design
 Materials Of Construction
Large to medium sized, conventional type stations will ordinarily be constructed
of reinforced concrete. The above ground portion of the building may be of
masonry, wood or metal panel construction.

Small package type stations will generally be manufactured of steel or

fiberglass, with separate wet wells constructed of precast concrete or fiberglass
manhole sections.

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Fundamentals of Pump Station and Force Main Design
 Cathodic/Corrosion Protection
Where steel structures are used, cathodic
protection or appropriate corrosion control
measures will be provided for the underground
steel shell.

Alternatively, steel structures may be protected by

a concrete or gunite coating where proof can be
furnished by the manufacturer of satisfactory
design life.

All structures will be designed to withstand

flotation.

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Fundamentals of Pump Station and Force Main Design
 Personnel Safety
Guards will be placed on and around all equipment where operators may come in
contact with moving parts.

Railings will be required around all floor openings, and along platforms or
walkways, where there is a danger that personnel may fall. Warning signs will be
placed at all hazardous locations.

Rubber mats will be provided in front of all electrical equipment where the
potential exists for electrical shock.

Adequate lighting and ventilation will be provided as required.

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Fundamentals of Pump Station and Force Main Design
 Personnel Safety (continued)
In attended stations where the possibility exists for toxic, explosive, or otherwise
hazardous atmospheres, proper design for personnel safety will be in conformance
with the appropriate standards outlined by OSHA.

Design for fire protection will be in accordance with NFPA or other appropriate fire
safety standards. Wastewater pumping stations will be classified as light hazard,
industrial type occupancies.

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Fundamentals of Pump Station and Force Main Design
 Interior Climate Control
All pumping stations subject to possible freezing will be supplied with
automatically controlled heaters in the equipment areas.

Unattended stations - temperatures will be maintained at 40 degrees F.

Attended stations - will be heated to 65 degrees F.

Although wet wells are generally unheated, thermostatically controlled heaters

may be used to prevent condensation on walls and floors during cool weather,
provided the ventilation system is shut off.

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Fundamentals of Pump Station and Force Main Design
 Ventilation
Wet wells - will be provided with a positive ventilation capacity of 30 air
changes per hour during occupancy, based on the wet well volume below grade
and above the minimum wastewater level.

Unattended dry wells - will be provided with a positive ventilation capacity of

30 air changes per hour.

Attended dry wells - will be provided with a continuously-operated ventilation

capacity of 6 air changes per hour, supplemented with additional ventilation in
warm climates to remove pump motor heat to within 5 degrees F. of the
outside air temperature.

Supply intakes and exhaust outlets must be located properly to introduce fresh
air and remove hazardous gases or fumes. The wet and dry well sides of the
station will be provided with separate ventilation systems.

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Fundamentals of Pump Station and Force Main Design
 Electrical Equipment
Pump station equipment will be suitable for operation at either 208V, 230V, or 480V,
60 Hz, three phase power supplies.

However, equipment with motors smaller than 0.5 horsepower, including meters,
switches, timers, clocks, and similar equipment, will be suitable for operation at a
125V, 60 Hz, single phase power source.

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Fundamentals of Pump Station and Force Main Design
 Electrical Equipment (continued)
Motor starters and controls - will be provided and housed in a factory assembled,
free-standing control center located on the ground floor. The center will include
motor starters, switches or circuit breakers, instrumentation and controls.

A pump station requiring a few small sized starters is an exception, and will employ
wall mounted or stand mounted equipment. Enclosures for submersible pump
controls will be installed above grade.

Local trouble alarms - will be provided at all pump stations. Alarms will be
annunciated remotely from unattended stations. Alarm systems will be provided with
manual silencing.

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Fundamentals of Pump Station and Force Main Design
 Standby Power
The requirement for fixed, standby power at wastewater pumping stations will depend
upon the type, location, and critical nature of each pumping facility.

For stations situated in low lying areas, or in areas remote from a treatment plant,
standby capability should be provided if a power outage would result in flooding of
the station, overflows at sewer manholes, backup of wastes into buildings, or any
unlawful pollution of the environment, or health hazard to personnel.

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Fundamentals of Pump Station and Force Main Design
 Standby Power (continued)
Pumping stations located at or in conjunction with treatment facilities, such as those
required for influent pumping, recycling or bypassing of flows, and pumping of
effluent, will require standby power capability if the pumping is essential to critical
treatment processes, plant flow control, or is necessary to maintain compliance with
the discharge permit.

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Fundamentals of Pump Station and Force Main Design
 Potable Water Supply
A potable water supply is required at all large pump stations to supply washroom and
toilet facilities, hydrants, hose bibs and pump seal systems.

A wash basin and toilet facilities will be provided at pump stations which are attended
regularly. Hose bibs will be provided in wet wells, dry wells and bar screen rooms.

The positive separation will be accomplished either by providing a break with an air
gap, or by installing backflow prevention devices.

196
Fundamentals of Pump Station and Force Main Design
 Potable Water Supply (continued)
Freeze proof wall hydrants will be required for outdoor use.

A positive separation will be maintained between the potable water system and any
piping or appurtenances subject to contamination. Warning signs will be posted at all
water taps not directly connected to the potable water supply.

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Fundamentals of Pump Station and Force Main Design
 Flow Measurement
Flow meters installed to indicate and record the discharge from the pump station, and
from individual pumps, will be provided at all medium to large sized stations.

A meter installed in the discharge header provides valuable information on the

operation of the station, and will be required where pumping capacity is expected to
increase significantly in the future.

Pressure gages are required on individual pump discharge lines, and on the station
discharge header. Elapsed time clocks will be mounted on all pump motor starters.

198
Fundamentals of Pump Station and Force Main Design
 Flow Measurement (continued)
For smaller stations utilizing constant speed pumps, an elapsed time clock may be
used in lieu of a pipe mounted flow meter to measure pump discharge. This will also
aid in scheduling routine maintenance on the motor since most small stations are
unattended.

A non-corrodible depth gage installed in the wet well will generally suffice for very
small pumps; flows can be estimated from depth measurements taken manually.

The types of flow measuring devices to be used for large wastewater pumps of the
constant, adjustable or variable speed type, include flow tubes, venturi meters,
magnetic and ultrasonic flow meters.

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Fundamentals of Pump Station and Force Main Design
 Protective Coating Systems
The use of paints and protective coatings at wastewater pumping stations will be in
accordance with Water Pollution Control Federation (WPCF) Manual of Practice No.
17.

A thorough investigation will be made in the design of protective coating systems.

Paint materials selected will be appropriate for the types of surfaces being protected,
both submerged and non-submerged.

Coating systems will be designed to resist corrosion from the wastes being handled,
and from gases and vapors present, taking into consideration the expected
temperature and humidity variations within the station.

200
Fundamentals of Pump Station and Force Main Design
 Protective Coating Systems (continued)
Coating systems will consist of adequate surface preparation, and the
application of prime and finish coats using compatible materials as
recommended by the coatings manufacturer.

All pumps and equipment will receive protective coatings in conformance with
the manufacturer's recommendations. All ferrous materials including
galvanized surfaces will be protected.

Particular care should be taken to protect welds and threads at connections.

Package type stations should be shipped to the construction site with factory
applied paints and coatings sufficient for the required service.

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Fundamentals of Pump Station and Force Main Design
 This concludes our course on “Fundamentals of Pump Station and Force Main Design”.
You may now proceed to the final exam.

Thank you for taking this Flashcard course!

202
Fundamentals of Pump Station and Force Main Design