PUMPING STATION ENGINEERING HANDBOOK

Volume 1 Fundamentals of pumping equipment 1. Introduction to pumps 1.1. Classification of Pumps 1.1.1. Centrifugal pumps 1.1.2. Mixed flow pumps 1.1.3. Axial flow pumps 1.2. Pumping Theory 1.2.1. Theory of centrifugal pumps. 1.2.2. Theory of axial flow pumps 1.2.3. Theory of mixed flow pumps 1.3. Pumps Characteristics 1.3.1. Theoretical characteristics and hydraulic loss 1.3.2. Total pump head characteristic curve (with consideration of leakage loss) 1.3.3. Shaft power and pump efficiency 1.3.4. Pump specific speed and characteristic curve 1.3.5. Complete pump characteristics 1.3.6. Pump starting torque 1.3.7. Similarity law for pumps 1.3.8. Performance change due to decreased impeller diameter 1.3.9. Plotting pump performance curves 1.3.10. Approximate calculation of principal-pump dimensions 1.4. Pump types 1.4.1. Shaft direction 1.4.2. Impeller suction type 1.4.3. Classification by number of impellers 1.4.4. Classification by division of casing 1.4.5. Special type pumps 1.4.6. Impeller types 1.4.7. Other types 1.5. Materials for pump construction 1.5.1. Materials used for pumps 1.5.2. Materials used for ancillary equipment 1.6. Cavitation 1.6.1. Cavitation phenomenon 1.6.2. Decreased pump performance due to cavitation 1.6.3. Categories of cavitation 1.6.4. Noise and vibration due to cavitation 1.6.5. Measure to be taken when cavitation has developed 1.6.6. Net positive suction head 1.6.7. Cavitation prevention 1.7. Pump noise and vibration 1.7.1. Pressure pulsation 1.7.2. Methods for reducing pressure pulsation (low pressure pulsation pumps) 1.7.3. Vibration of pump facilities 2. Drivers and power transmission devices 2.1. Drivers 2.2. Electric Motors 2.2.1. Types of electric motors 2.2.2. Features of electric motors 2.2.3. Principles of induction motors 2.2.4. Motor output power and rotational speed 2.2.5. Motor rated voltage 2.2.6. Motor efficiency and power factor 2.2.7. Motor characteristics 2.2.8. Effects of power source variations on motors 2.2.9. Motor classifications 2.2.10. Motor shaft types 2.2.11. Motor insulation classes and temperature rise limits 2.2.12. Motor start characteristics 2.2.13. Considerations for selecting motor start method 2.2.14. Motor start methods 2.2.15. Motor noise 2.3. Diesel Engines 2.3.1. Diesel engine classification 2.3.2. Diesel engine start methods 2.3.3. Diesel engine heat balance 2.3.4. Diesel engine cooling system 2.3.5. Torsional vibration of diesel engines 2.4. Gas turbine engines 2.5. Power transmission devices 2.5.1. Reduction gears 2.5.2. Couplings 3. Suction sumps and discharge tanks 3.1. Suction Sumps 3.1.1. Flow in suction sump 3.1.2. Basic shape and standard dimensions for a suction sump 3.1.3. Nonstandard shaped suction sumps 3.1.4. Standard sump shapes for small-bore pumps 3.1.5. Suction sump shapes for large-bore pumps 3.1.6. intake channels 3.1.7. Suction sump planning and eddy flow prevention devices. 3.1.8. Model experiments 3.1.9. Other considerations 3.2. Discharge tanks 3.2.1. Considerations for discharge tank design 3.2.2. Location and dimensions of drainage pump discharge tank 3.2.3. Considerations in water distribution tank design 4. Electric equipment 4.1. Electric equipment configuration 4.1.1. Loads 4.1.2. Incoming/distribution facility 4.1.3. Instrumentation 4.1.4. Supervisory and operation equipment.. 4.1.5. Emergency power source 4.1.6. DC power source 4.2. Notes for planning electric equipment 4.3. Planning Procedure for Electric Equipment 4.3.1. Classifying and totaling pumping facility loads 4.3.2. Incoming service voltage and power receiving system 4.3.3. Determining distribution voltage 4.3.4. Determining the type of disconnect switch 4.3.5. Determining capacity and type of main transformer 4.3.6. Improving power factor (determining condenser size) 4.3.7. Single-line diagram (skeleton) 4.3.8. Single-line diagram of distribution panel (block diagram) 4.3.9. Breaking capacity 4.3.10. Circuit breaker 4.3.11. Calculating breaking capacity 4.3.12. Electromagnetic contactors and current limiting fuses 4.3.13. Selecting the distribution panel 4.3.14. Non-utility power generation facility 4.3.15. DC power source 4.4. Supervisory and operation equipment 4.4.1. Operation and operating position 4.4.2. Concept of supervisory and operating equipment 4.4.3. Supervisory and operating equipment systems 4.4.4. Programmable controller and CRT display unit 4.4.5. Remote supervisory and operation equipment (tm/tc equipment) 4.4.6. Basic shape of supervisory operation panels 4.4.7. Role of each supervisory operation panel 4.4.8. Layout of supervisory control panel 4.5. Instrumentation 5. Valves for pumps 5.1. Valve types 5.2. Valve standards 5.3. Structural features of valves 5.3.1. Gate valves 5.3.2. Butterfly valves 5.3.3. Check valves 5.3.4. Flap valves 5.3.5. Rotary valves 5.3.6. Foot valves 5.4. Valve Flow Control Characteristics 5.4.1. Valve cavitation characteristics 5.4.2. Flow coefficient value Cv 5.5. Selection of valve type according to application 5.5.1. Flow control valves 5.5.2. Valves for stopping water 5.5.3. Valves for reverse flow prevention 5.5.4. Valves for water hammer prevention 5.6. Valve size selection 5.6.1. Gate valves, butterfly valves, and check valves 5.6.2. Rotary valves 5.6.3. Flap valves 5.7. Calculating motor capacity for motor operated gate valves and Butterfly valves 5.7.1. Calculating motor capacity for motor operated gate valves 5.7.2. Calculating motor capacity for motor operated butterfly valves 5.7.3 Standard values of motor capacity for different valve sizes 6. Main pipes and pipe fittings 6.1. Introduction 6.2. Cast iron pipes and steel pipes for main pipes 6.2.1. Comparisons between ductile cast iron pipe and steel pipe 6.3. Selection of main pipe materials 6.3.1. Main pipe materials in lifting pump room 6.3.2. Main pipe materials for general drainage pumps (2000 mm or less) 6.3.3. Main pipe materials for large bore drainage pumps (2500 mm or more) 6.3.4. Main pipe materials for large-bore drainage pumps (2100 to 2500 mm) 6.4. Standards for ductile cast iron pipes and steel pipes 6.4.1. Types and standards for main pipe materials 6.4.2. Application of standards to main pipes 6.4.3. Main pipe wall thickness 6.5. Pipe fittings 6.5.1. Pipe fittings in stations 6.5.2. Types and features of flange joints. 6.5.3. Flanges and their application standards 6.5.4. Types and features of expansion joints 6.6. Selection of main pipe bore size 6.6.1. Storage pumps 6.6.2. Drainage pumps 6.7. Planning main pipe installation 6.7.1. Suction pipes 6.7.2. Discharge pipes 6.7.3. Pipe supports 7. Auxiliary equipment 7.1. Auxiliary equipment outline 7.2. Auxiliary equipment types and applications 7.2.1. Priming system 7.2.2. Water supply system 7.2.3. Fuel system 7.2.4. Air start system 7.2.5. Hydraulic system 7.2.6. Lubrication oil system 7.2.7. Other auxiliary equipment 7.2.8. Instrument systems 7.3. Summary of auxiliary equipment.... 7.4. Pump accessories 8. Ancillary equipment 8.1. Gates 8.1.1. Gate types installed in a pumping station 8.1.2. Gate configuration. 8.1.3. Gate construction 8.1.4. Opening/closing devices 8.1.5. Example of gate arrangement 8.2. Overhead travelling cranes 8.2.1. Crane types 8.2.2. Components and terms used for overhead traveling cranes 8.2.3. Capacity selection for overhead traveling crane 8.2.4. Lifting height of overhead travelling cranes 8.2.5. Qualifications for overhead traveling crane operation 8.3. Trash removal equipment 8.3.1. Pumping station trash removal equipment 8.3.2. Trash removal equipment configuration 8.3.3. Screens 8.3.4. Trash rake 8.3.5. Trash rake types 8.3.6. Conveying equipment 8.4. Fuel oil storage tank 8.4.1. Related laws 8.4.2. Volume of fuel oil storage tanks and related laws 8.4.3. Classification of fuel oil storage tanks (fire service law: storage of dangerous substances) 8.4.4. Laws related to each type of fuel oil storage tank (fire service law: storage of dangerous substances) 8.4.5. Fuel oil storage tank construction 8.5. Ventilating equipment 8.5.1. Purpose of ventilation 8.5.2. Ventilation methods 8.5.3. Ventilating fan types 8.5.4. Ducts 8.5.5. Ventilation air quantity.. 8.6. Lighting Facilities 8.6.1. Required illumination 8.6.2. Source for room lighting 8.6.3. Lighting facilities planning 9. Pump operation control and monitoring 9.1. Water management control system and pumps 9.1.1. Water feed systems for irrigation 9.1.2. Water feed systems for drainage 9.1.3.

Water control for irrigation 9.1.4. Water control system for drainage 9.2. Water feed systems for irrigation and drainage versus control systems 9.2.1. Open water feed systems and control systems 9.2.2. Semi-closed water feed systems and control systems 9.2.3. Closed water feed systems and control systems 9.3. Controlling functions for automatic control 9.3.1. Types of controlling functions 9.3.2. Types of controllers 9.4. Composite characteristics with more than one pump 9.4.1. When pumps with the same characteristics are operated in parallel 9.4.2. When pumps with different characteristics are operated in parallel 9.4.3. When pumps with the same characteristics are operated in series 9.5. Pump characteristics and water feed pipe characteristics 9.5.1. Water feed pipe characteristics 9.5.2. When water is fed to one point 9.5.3. When water is fed to more than one point 9.6. Pump characteristics and drainage pipe characteristics 9.7. Pump control methods 9.7.1. Unit number control 9.7.2. Valve opening degree control 9.7.3. Revolution control 9.7.4. Vane angle control 9.7.5. Operation by impeller replacement 9.7.6. Pump type and control method 9.8. Revolution control method 9.8.1. Classifications of revolution control methods 9.8.2. Features of revolution control methods 9.8.3. Reference data on revolution control methods 9.8.4. Economic comparison of revolution control equipment 9.9. Pump operation and its location 9.9.1. Location of pump operation 9.9.2. Operation modes 9.9.3. Operation modes and locations of operations 9.10. Sequential pump operation 9.11. Monitoring and measurement in a pump facility 9.11.1. Monitored items and measurements 9.11.2. Location of operation and monitored items 9.11.3. Examples of monitored/control items 9.11.4. Examples of fault indications 9.12. Example of pumping station control (storage pump) 9.12.1. Equipment 9.12.2. Water feed methods in three pumping stations 9.12.3. Operation of main pump 9.12.4. Automatic control 9.12.5. Interlock of the three pumping stations 9.12.6. System configuration 9.13. Example of pumping station control (drainage pump) 9.13.1. Equipment 9.13.2. Operation 9.13.3. Automatic control 9.13.4. Monitoring and control instruments 10. Water hammer in pumping facilities 10.1. Features of water hammer in pumping facilities 10.2. Propagation speed of pressure wave 10.3. Changes in flow velocity and pressure 10.4. Basic equation for water hammer 10.4.1. Basic equation for change in pressure. 10.4.2. Pump characteristic equation 10.4.3. Water feed line characteristics and valve characteristics 10.4.4. Pump torque and rotation speed 10.5. Water hammer analysis procedure 10.5.1. Analysis procedure 10.5.2. Without reverse flow check valve 10.5.3. With check valve 10.6. Change in quantities of state just behind pumping 10.6.1. Without check valve 10.6.2. With check valve 10.7. Necessity for water hammer study.... 10.8. Water hammer prevention measures 10.8.1. Examples of water hammer prevention equipment 10.8.2. Water hammer preventive measures 10.9. Simplified calculation method 10.9.1. Basic data 10.9.2. Calculation procedure 10.9.3. Water hammer analysis charts 10.9.4. Notes for using water hammer analysis charts Volume 2. Plans, designs, and applications Part 1. Basics of plan and design of pumping stations 1. Basics of plan and design 1.1. Introduction 1.2. Basic investigation procedure 1.2.1. Details of investigation procedure 1.2.2. Understanding of project outline 1.2.3. Understanding characteristics of the objective area 1.2.4. Hydrological analysis 1.2.5. Water delivery and drainage networks 1.2.6. Planning and design of pumping equipment 1.2.7. Water channels and civil engineering work 1.2.8. Architectural structures 1.3. Investigation for preparing basic policies 1.3.1. Procedure for studying basic policies 1.3.2. Water intake at pumping station 1.3.3. Location of drainage station 1.3.4. Survey of existing facilities 1.3.5. Investigation of water quality, inclusions and sand 1.3.6. Survey of geology and underground water 1.3.7. Environmental surveys 1.3.8. Surveys of conditions for on site construction and future maintenance.... 1.3.9. Surveys of intakes, intake -conduits and suction sumps 1.3.10. Survey of discharge tank site 1.3.11. Outline study of water delivery networks and control 1.3.12. Control of water delivery and operation system 1.3.13. Overall system layout 1.4. Establishing pumping station design requirements 1.4.1. Study items for design criteria 1.4.2. Giving importance to energy-saving operation 1.4.3. Ability of drainage capacity to follow flow rate and head variations 1.4.4. Minimizing pumping station costs 1.4.5. Reliability, durability, safety and flexibility for emergencies 1.4.6. Simple structure, ease of operation and maintenance 1.4.7. Level of operational control 1.4.8. Environmental considerations, noise, and vibration 1.4.9. Pumping station as a total system 2. Basic planning of pumping facilities 2.1 Basic planning study items 2.2. Pump types selection 2.2.1. Pump type and applicable diagrams 2.2.2. High-head centrifugal pumps 2.2.3. High-head vertical shaft mixed flow pumps 2.2.4. Low-head mixed flow pumps 2.2.5. Axial flow pumps 2.2.6. Pump types and bores 2;2.7 Selection of pump floor types 2.3. Pump number determination 2.3.1. Capacity for water demand 2.3.2. With No. of pumps under control.... 2.3.3. Equipment and operating costs 2.3.4. Other items 2.4. Selection of prime movers and power transmission 2.4.1. Selection of prime mover types 2.4.2. Selection of power transmission 2.5. Selection of operation control system 2.5.1. Operation control level 2.6. Basic layout planning for a pump station 2.6.1. Intake channels, suction sump and discharge tank 2.6.2. Pumping station layout 2.6.3. Basic pump layouts 2.6.4. Auxiliary equipment layout 2.6.5. Electric room and field control room layouts 2.6.6. Fuel storage tank 2.6.7. Other facilities 3. Design requirements for pumping stations 3.1. General 3.2. Design specifications 3.2.1. Specific design specifications 3.2.2. Design standards, guidelines and applicable standards 3.2.3. For overseas projects 3.2.4. Examples of design specifications and conditions 3.2.5. Application of planning and design standards for land improvement projects 3.3. Site situations 3.4. Operating conditions 3.4.1. Irrigation pumping stations 3.4.2. Drainage pumping stations 3.5. Total pump head 3.5.1. Total pump head 3.5.2. Total head of plus back pump 3.5.3. Total head of vertical pump 3.5.4. Relation between total pump head and pressure gages 3.6. Protectors, location of operation, details of control, instruments 3.6.1. Protectors 3.6.2. Locations of operations 3.6.3. Details of control 3.6.4. Instruments 3.7. Management and maintenance conditions 3.7.1. Entire operation and control facilities 3.7.2. Scope of facilities under control 3.7.3. Control targets 3.7.4. Operation control methods 3.7.5. Control organization and operators 3.7.6. Determination of control levels 3.7.7. Acquisition -of control personnel 3.8. General specifications for civil engineering work Part 2. Design examples for irrigation pumping station 1. Determination of conditions in design example 1.1. Purposes of design example 1.2. Determination of conditions in design example 1.3. Basic design flow sheets 1.4. Basic and detailed designs 2. Basic design for pumping stations 2.1. Basic conditions 2.2. Rough determination of total head 2.3. Comparison and determination of pump types 2.3.1. Rough determination of pump types from water feed and total head 2.3.2. Study on pump installation 2.3.3. Comparison of pump speeds 2.3.4. Comparison of pump types 2.4. Rough determination of pump bores and motor outputs 2.5. Comparison of plans for number of pumps 2.5.1. Comparison of approximate layouts and spaces 2.5.2. Comparison of estimated civil engineering and architectural expenses 2.5.3. Comparison of estimates on equipment costs 2.5.4. Comparison of operating costs 2.5.5. Comparison of economy 2.6. Study on pump installation 2.6.1. -Comparison between minus back suction and plus back systems 2.6.2. Cost comparison between installation systems 2.6.3. Use of plus back system 2.7 Layout planning 2.7.1. Layout of 2 pumps 2.7.2. Determination of basic layout 2.8. Determination of total pump head 2.8.1. Calculation of main piping losses (suction and discharge pipes) 2.8.2. Determination of total head 2.8.3. Final determination of pump type 2.9.

Determination of pump installation level and speed 2.9.1. Determination of pump speed 2.10. Determination of prime mover output 2.10.1. Formula for prime mover output 2.10.2. Output calculations at design point and maximum pump input 2.11. Selection of main equipment 2.11.1. Main pumps 2.11.2. Valve selection 2.12. Selection of auxiliary equipment 2.12.1. Sealing pumps 2.12.2. Auto-strainer 2.12.3. Overhead crane 2.12.4. Vacuum pump 2.13. Water hammer study 2.13.1. Design conditions 2.13.2. Basic data 2.13.3. Calculations of parameters 2.13.4. Preparation of minimum pressure gradient chart 2.13.5. Preparation of maximum pressure gradient chart 2.13.6. Flywheel installed as a preventive measure for negative pressures 2.13.7. Air chamber installed as a preventive measure for negative pressures 2.13.8. One-way surge tank installed as a preventive measure for negative pressure 2.13.9. Selection of preventive measures for negative pressures 2.14. Study on pressure pulsation 2.14.1. Pumps design specifications 2.14.2. Operating conditions and pipeline layout 2.14.3. Calculation results. 2.15. Selection of ventilating system 2.15.1. Ventilation system layout 2.15.2. Design conditions and heat sources 2.15.3. Heat radiation from building 2.15.4. Necessary air rate for quantity of heat generated 2.15.5. Necessary air rate for ventilation frequency 2.15.6. Determining type and capacity of ventilator fan 2.16. Flow meter installation 2.17. Pipeline filling 2.18. Sludge discharge line installation 2.19. Air valves installation 2.20. Loads on floor slabs 2.20.1. Location of loads on floor slabs 2.20.2. Foundation loads 3. Basic design of electrical facilities 3.1. Operation modes 3.1.1. Content of operation modes 3.1.2. Planned operation modes 3.2. Load list and power assumption receiving contract type 3.2.1. Load list. 3.2.2. Assumption of power receiving contract type 3.3. Studies on main motor protection, rotor structure, start system and rated voltage 3.3.1. Protection system 3.3.2. Rotor structure, start system and rated voltage 3.4. Study on interrupting capacity 3.4.1. Calculation of short-circuit current 3.5. Calculation of condenser capacity 3.6. Calculation of battery capacity 3.7. Calculation of transformer capacity for low-voltage power 3.8. Contents of distribution board 3.8.1. Operation, control system and classification 3.8.2. Contents of distribution board 3.8.3. Types and dimensions of distribution load 3.9. Electrical drawings 3.9.1. Single line connection diagram 3.9.2. Instrument flow diagram 3.10. Sequence diagrams 4 Layout drawings of pumping stations 4.1. Layout drawings 5. Pumping station noise control 5.1. General... 5.2. Basis of noise 5.2.1. Sound pressure level 5.2.2. Noise level 5.3. Regulated noise levels 5.4. Pumping station noise control 5.4.1. Noise sources in pumping stations 5.4.2. Estimation of noise level 5.4.3. Study on propagation routes 5.5. Noise control methods 5.5.1. General 5.5.2. Noise control through solid structures 5.6. Example of noise control at water supply pumping station 5.6.1. Main noise sources 5.6.2. Calculation method 5.6.3. Results of calculations 5.6.4. Noise after control 5.7. Example of noise control at a drainage pumping station 5.7.1. Noise limits under regulations 5.7.2. Noise sources 5.7.3. Building materials (before specification changes) 5.7.4. Sound pressure contour map before improvements 5.7.5. Noise level at sound receiving points (before improvements) 5.7.6. Review after improvements 5.7.7. Building materials (after specification changes) 5.7.8. Sound pressure contour map after improvements 5.7.9. Noise levels at sound receiving points (after improvements) 6. Supplementary explanations for design example 6.1. Line losses for straight pipeline runs 6.2. Pipeline diameter determination 6.3. No. of pumps and spares 6.4. Pump types 6.5. Pump numbers 6.6. No. of pumps and adaptability 6.7. Conditions for operating cost calculations 6.8. Optimal no. of pumps for direct water delivery 6.9. Comparison of installation methods and pump types 6.10. Interval between pump start and stop 6.11. Pumping station layout 6.12. Shapes and sizes of pump room piping 6.13. Screen 6.14. Suction Bellmouths 6.15. Max discharge points 6.16. Pump efficiencies 6.17. Pump bores 6.18. Pressure pulsation in pipeline 6.19. Pressure pulsation prevention in pumping facilities 6.20. Valve locations 6.21. Determining capacity of vacuum pumps and priming time 6.22. Simplified water hammer analysis charts 6.23. Ventilating system 6.24. Filling pipeline with water 6.25. Motor pulsation torque occurrence 6.26. Standard sized reducers (JIS G3541) 6.27. Pipeline flow velocity 6.28. Trash in pumped water 6.29. Selection and locations of air valves 6.30. Air hammer calculation example Part 3. Design examples for drainage pumping stations 1. Determination of conditions in design example 1.1. Purposes of design example 1.2. Determination of conditions in design example 1.3. Basic design flow sheets 1.4. Basic and detailed designs 2. Basic design of pumping equipment 2.1. Basic conditions 2.2. Rough determination of designed station drainage capacity 2.2.1. Cumulative inflow curve 2.2.2. Rough determination of pump capacity 2.3. Ponding Analysis ... 2.3.1. Temporary determination of total pump head 2.3.2. Temporary determination of pump type 2.3.-3. Ponding analysis using computer 2.4. Determination of pump numbers 2.4.1. Comparison of approximate layout and spaces 2.4.2. Estimated equipment cost 2.4.3. Cost comparison 2.4.4. Study on adaptability to flood run-off variation 2.5. Determination of pump types and bores 2.5.1. Selection using applicable diagrams for pumps 2.5.2. Selection in relation with total pump bead 2.5.3. Study -on suction performance and installation level 2.6. Piping plans 2.6.1. Selection of valves 2.6.2. Pump room piping 2.6.3. Outdoor piping 2.7. Determination of total pump head 2.7.1. Calculation of piping losses 2.7.2. Total pump head determination 2.7.3. Pump type determination 2.8. Check of suction performance and installation level 2.9. Selection of prime mover and power transmission 2.9.1. Prime mover output determination 2.9.2. Determination of diesel engine speed and selection of reduction gear 2.9.3. Analysis of diesel engine torsional vibration 2.10. Determination of specifications for main pump facilities 2.10.1. Main pumps 2.10.2. Prime mover 2.10.3. Power transmission 2.11. Design of building and suction sump 2.11.1. Pump room floor length = pump room beam span (floor length in water flow direction) 2.11.2. Pump room floor width = pump room girder (length normal to water flow) 2.11.3. Pump room height 2.12. Discharge tank design 2.12.1. Discharge tank dimensions 2.12.2. Discharge tank surging analysis 2.13. Slab loads 2.14. Auxiliary machine selection 2.14.1. Water feed system 2.14.2. Fuel system 2.14.3. Air start system 2.14.4. Oil feed system 2.14.5. Other auxiliaries 2.15. Selection of additional equipment 2.15.1. Overhead crane 2.15.2. Trash rake selection 2.15.3. Ventilating system selection 2.16. Layout of entire facility 3. Basic designing of electrical facilities 3.1. Design of operation control facilities 3.1.1. Selecting operating system 3.1.2. Selection of operation monitoring facilities 3.2. Design of electric facilities 3.2.1. Power reception systems 3.2.2. Receiving voltage and contract power.. 3.2.3. Formation of electric panels 3.2.4. Calculating of transformer capacity... 3.2.5. Calculating battery capacity 3.2.6. Calculating capacity of private generator 3.2.7. Lighting fixtures 3.3. Operation block diagrams 3.4. List of loads 3.5. List of contacts 3.6. One-line connection diagram 4 Design drawings 4.1. Layouts and small pipeline drawings 5. Supplementary explanations of design example 5.1. Basic conditions 5.1.1. Suction water level 5.1.2. Screen losses 5.1.3. Lowest suction water level 5.1.4. Highest suction water level 5.1.5. Discharge water level 5.1.6. Lowest discharge water level 5.1.7. Designed maximum actual head.. 5.1.8. Design point actual head 5.1.9. Maximum actual head 5.1.10. Minimum actual head 5.1.11. Design flood drainage capacity and designed external water curves 5.1.12. Relation between internal water level and ponding capacity 5.1.13. Other assumptions in design example 5.2. Rough determination of designed pumping station drainage capacity 5.2.1. Rough determination of drainage capacity 5.3. Ponding Analysis 5.3.1.

Provisional determination of pump types 5.3.2. Analysis results 5.3.3. Procedure for ponding analysis and calculation 5.4. Pump Number determination 5.4.1. Study on determination of number of pumps 5.4.2. Adaptability to variations in flood run-off 5.5. Pump types 5.5.1. Tubular pumps 5.5.2. Floor level for horizontal pumps 5.5.3. Extra suction head (0.5 m) 5.5.4. Atmospheric pressure values (10.33 m) and vapor pressure (0.33 m) 5.5.5. Vertical pump impeller reference plane 5.5.6. Ttpes of pump installation floor 5.6. Pipeline planning 5.6.1. Distance between pumping station and discharge tank 5.6.2. Flap valve depth of submergence 5.6.3. Necessity of discharge valves for drainage pumps 5.7. Prime mover selection and power transmission 5.7.1. Prime mover selection 5.7.2. Clutch necessity 5.7.3. Extra factor for prime mover output.. 5.7.4. Diesel engine speed 5.7.5. Diesel engine torsional vibration 5.7.6. Power transmissions capacities 5.7.7. Allowable bearing thrust loads and pump thrust loads of reduction gears 5.8. Discharge tank design 5.8.1. Important points for planning discharge tank 5.9. Selection of auxiliaries 5.9.1. Water lubrication of pumps 5.9.2. Comparison of cooling systems 5.9.3. Trash rakes 5.10. Electric facility design 5.10.1. Power receiving system and private power generating facility 5.11. Layout of entire facility 5.11.1. Overall layout Volume 3. Manufacture, installation, and maintenance management 1. Manufacture of pumps and related equipment 1.1. Outline 1.2. Outline of detailed design by pump manufacturer 1.3. Design of pumping equipment 1.3.1. Scope of design by contractor 1.3.2. Design of pumping equipment and collection of manufacturing specifications 1.4. Main pump design 1.4.1. Confirmation of pump design 1.4.2. Selection and design of hydro. model... 1.4.3. Structural design 1.4.4. Electric motor pedestal design 1.4.5. Shaft joint selection 1.4.6. Selection of component parts of . pump and materials 1.5 The manufacturing process in the pump factory 1.5.1. Steps in manufacture 1.5.2. Casting, forging and pipe. processing..., 1.5.3. Machining 1.5.4. Assembly of products 1.6. Production control in the pump factory 1.6.1. Purpose of production control and system characteristics 1.6.2. Role of production control department 1.7. Quality control in the pump factory... 1.7.1. Role of quality control department 1.7.2. Securing quality in each production process 1.7.3. Inspection 1.8. Manufacture of fittings, auxiliary equipment and electrical equipment 1.8.1. Types of related equipment 1.8.2. Manufacturing instructions 1.8.3. Valve manufacture 1.8.4. Reduction gear manufacture 1.8.5. Fluid coupling manufacture 1.8.6. Main pipe manufacture 1.8.7. Diesel engine manufacture 1.8.8. Automatic trash rake manufacture 1.8.9. Overhead crane manufacture 1.8.10. Electric motor manufacture 1.8.11. Electrical equipment manufacture 1.8.12. Auxiliary equipment manufacture 1.9. Painting 1.9.1. Purpose of painting 1.9.2. Outline of painting 1.10. Packing and transportation.. 1.10.1. Packing 1.10.2. Transportation 2. Materials for pumps and related equipment 2.1. Outline 2.2. Manufacture of iron and steel 2.2.1. Iron manufacture 2.2.2. Steel making 2.2.3. Transformation and texture of steel material 2.2.4. Change of characteristics by heat treatment 2:2.5 Kinds of steel 2.3. Cast parts 2.3.1. Casting 2.3.2. Representative casting alloys 2.4. Plate-work and formed steel parts 2.4.1. Welding methods 2.4.2. Steel fabrication 2.4.3. Steel directly shipped to machining division 2.5. Forged parts 3. Factory witness inspections for pump equipment 3.1. Outline 3.2. Witness inspection manual for main equipment 3.2.1. Main pump 3.2:2 Valves 3.2:3 Reduction gear 3.2.4. Hydraulic coupling 3.2.5. Main piping 3.2.6. Diesel engine 3.2.7. Trash removal equipment 3.2.8. Overhead crane 3.2.9. Motor 3.2.10. Electrical equipment 4. Installation and trial operation adjustment 4.1. Outline 4.2. Construction planning form 4.2.1. Outline of work .4.2.2. Extent of work 4.2.3. Progress chart 4.2.4. Work organization 4.2.5. Safety controls 4.2.6. Work control 4.2.7. Labor plan 4.2.8. Temporary construction plan 4.2.9. Use plan for construction machines 4.2.10. Carrying-in plan of major equipment and materials 4.2.11. Installation methods 4.2.12. Painting 4.2.13. Adjustment, trial operation of equipment 4.3. Installation centering 4.3.1. Purpose of installation centering 4.3.2. Installation centering accuracy .4.3.3. Instruments for measurement and auxiliary tools 4.3.4. Centering items and sequence 4.3.5. Place and method of measurement 4.4. Installation work 4.4.1. Study of drawings 4.4.2. Product control before installation 4.4.3. Transportation and handling of heavy materials 4.4.4. Installation preparation 4.4.5. Installation of two floor type vertical pump 4.4.6. Single floor type vertical pump installation 4.4.7. Horizontal double suction volute pump installation 4.4.8. Horizontal mixed flow pump and axial flow pump installation 4.4.9. Auxiliary machines installation 4.4.10. Main piping installation 4.4.11. Small piping work 4.4.12. Switchboard installation and electrical wiring work 4.5. Trial operation adjustment 4.5.1. Site adjustment 4.5.2. Operation preparation 4.5.3. Completion inspection 4.6. Control of finished form by direct measurement 4.7. Finished part inspection and completion inspection 5. Operation and maintenance 5.1. Main contents of operation and maintenance 5.2. Management work 5.2.1. Equipment for management 5.2.2. Management system 5.2.3. Relevant laws and standards 5.3. Type of maintenance management 5.3.1. Inspection cycles and inspection items 5.3.2. Maintenance management during operation periods 5.3.3. Maintenance management during suspended periods 5.3.4. Periodic maintenance 5.3.5. Check and maintenance records 5.4. Failure response 5.4.1. Response to failures 5.4.2. Causes of failures and preventive measures 5.4.3. Equipment diagnosis 5.5. Purpose of installation management..

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