for pump stations with vertically installed flygt … · the flygt standard pump station design can...

Design recommendationsFOR PUMP STATIONS WITH VERTICALLY INSTALLED FLYGT AXIAL AND MIXED FLOW PUMPS

Contents

This document is intended to assist application engineers, designers, planners and users of sewage and storm water systems incorporating Flygt axial and mixed flow pumps installed in a column.

A proper design of the pump sump is crucial in order to achieve an optimal inflow to the pumps. Important design requirements to be met are: uniform flow approach to the pumps, preventing pre-rotation under the pumps, preventing significant quantities of air from reaching the impeller and transport of settled and float-ing solids. The Flygt standard pump station design can be used as is, or with appropriate variations upon review by Flygt engineers.

Pump and sump are integral to an overall system that includes a variety of structures and other elements such as ventilation systems and solids handling equipment. Operating costs can be reduced with the help of effective planning and suitable operation schedules. Our personnel and publications are available to offer guidance in these areas. Transient analysis of pump system behaviour, such as air chamber dimension-ing, valve selection, etc., should also be considered in wastewater pump station design. These matters are not addressed in this brochure, but we can offer guidance.

Please consult our engineers to achieve optimum pump performance, maximum pump life, and a guaran-tee that product warranties are met. The design recommendations are only valid for Flygt equipment. We assume no liability for non-Flygt equipment.

Systems Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Flygt PL and LL pump introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General considerations for pumping station design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pumping station with multiple pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump bay design alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pump station model testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Computational modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Corrective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cable protection and suspension for tube installed pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Flygt cable seal units for pressurized tube (column). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Appendix 1: Head losses diagrams for Flygt designed discharge arrangements . . . . 14

Appendix 2: Submergence diagram for open sump intake design . . . . . . . . . . . . . . . . . . . . . . . 20

Appendix 3: Sump layout alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Appendix 4: Pump bay alternatives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Systems Engineering Our Systems Engineering team offers in-depth ex-pertise in the design and execution of comprehen-sive solutions for water and wastewater transport and treatment.

Our know-how and experience are combined with a broad range of suitable products for delivering cus-tomized solutions that ensure trouble-free opera-tions for customers. Our engineers utilize our own custom developed computer programs to provide evaluations for your specific project design.

Flygt not only can provide assistance with the se-lection of products and accessories but can pro-vide analysis for complex systems and/or piping networks.

We also provide hydraulic guidance and assistance for flow-related or rheological issues. Assistance can include but is not limited to hydraulic transient calculations, pump starting calculations, and evalua-tion of flow variations.

Additional services • Optimization of pump sump design

for our products and specific sites • Assistance with mixing and aeration

specifications and design of appropriate systems

• System simulation utilizing computa-tional fluid dynamics (CFD)

• Guidance for model testing – and organizing it

• Guidance for achieving the lowest costs in operations, service and installation

• Specially developed engineering software to facilitate designing

The range of services is comprehensive, but our philosophy is very simple: There is no substitute for excellence.

Flygt PL and LL pump introductionFlygt submersible vertically installed axial flow pumps (PL) and mixed flow pumps (LL) have been used in a wide variety of storm water stations and sewage treatment plants, land drainage and irriga-tion systems, fish farms and power plants, shipyards, amusement parks and many other applications where large volumes of water have to be pumped.

Flygt submersible PL and LL pumps offer important advantages such as:• Compact motor and pump unit• No separate lubrication system• No external cooling system• Low operating sound level• Quick connection and disconnection

for installation and inspection• Minimal station superstructure• Simple pipe work

Flygt PL and LL pumps are usually installed in a ver-tical discharge tube on a support flange incorporat-ed in the lower end of the tube. No anchoring is re-quired because the weight of the pump is sufficient to keep it in place. The pumps are equipped with an anti-rotation gusset. This arrangement provides the simplest possible installation – the pump is just lowered into the discharge tube by hoist or crane. Retrieval of the pump is equally simple.

Flygt axial flow pumps (PL) Flygt mixed flow pumps (LL)

4

General considerations for pumping station designThe proper design of the pump sump is crucial in order to achieve an optimal inflow to the pumps. Ideally, the flow at the pump inlet should be uniform and steady, without swirl, vortices or entrained air.

• Non-uniform flow at the pump intake can reduce efficiency and cause pulsating loads on the propeller blades, resulting in noise and vibrations.

• Unsteady flow can also cause fluctuating loads, noise and vibrations.

• Swirl in the intake can change the head, flow, efficiency and power in undesirable ways. It can also augment vortices.

• Vortices with a coherent core cause discontinuities in the flow and can lead to noise, vibration and local cavitation. Vortices emanating from the free surface can become sufficiently powerful to draw air and floating debris into the pump.

• Entrained air can reduce the flow and efficiency, causing noise, vibration, fluctuations of load and physical damage.

Experience with designs already in use provides valu-able guidelines for the design of multiple pump sta-tions. Adaptations of existing and well-proven designs can often provide solutions to complex problems even without model tests. We have extensive experience based on many successful projects, and the services of our qualified engineers are always available.

For special applications beyond the scope of this brochure, please contact our local system engineer for assistance.

Pumping station with multiple pumpsMultiple pump systems provide greater capac-ity, operational flexibility and increased reliability, which is why pumping stations are usually equipped with two or more pumps.

Transition to the sump, whether diverging, converg-ing or turning, should result in nearly uniform flow at the sump entrance. Obstacles that generate wakes should not be allowed to interfere with the approach-ing flow. High velocity gradients, flow separation from the walls and entrainment of air should be avoided.

• Inlet: An inlet conveys water to the pumping station from a supply source such as a culvert, canal or river. Usually, the inlet has a control structure such as a weir or a gate.

• Forebay: The role of the forebay is to guide the flow to the pump bays in such a way that it is uniform and steady. Because the inflow to each module should be steady and uniform, the design of the forebay feeding the individual modules is critical and should follow guidelines in this brochure. Design of the forebay depends on water approach to the pumping station commonly encountered as parallel with the sump centerline, the preferred layout, or perpendicular to the sump centreline.

• Pump bay: In practice, only the design of the pump bay can be standardized for a given pump type. A properly designed bay is a prerequisite for correct presentation of flow to the pumps, but it does not guarantee correct flow conditions. A bad approach to the pump bay can disturb the flow in the pump intake. As a rule of thumb, the approach velocity to the individual pump bays should not exceed 0.5m/s (1.64ft/s). The dimensions of the bay’s individual modules are a function of pump size and the flow rate (see Appendix 4).

Hydraulically, three zones of the pumping station are significant: inlet, forebay and pump bay.

Pump bay

Forebay

Inlet area

5

Culvert or canal inlet

High level side inlet

Low level side inlet

Front wide inlet to the station When water approaches the station from a wide supply source such as a culvert or canal, the pumps should be placed symmetrically to the inlet cen-treline without changing direction of the approach-ing flow. If the width of the inlet is less than the total width of the pump bays, the forebay should diverge symmetrically. The total angle of divergence should not exceed 20° for the Open Sump Intake Design or 40° for the Formed Intake Design. The bottom slope in the forebay should not be larger than 10° (See Appendix 3). If these parameters cannot be met, flow direction devices should be used to im-prove the flow distribution. Such arrangements and more complex layouts should be investigated using model tests in order to arrive at suitable designs.

High front inlet or side inlet to the station When the inlet to the station is located at higher level or perpendicular to the axis of the pump bays, an inlet chamber or overflow-underflow weir can help to redis-tribute the flow. A substantial head loss at the inlet area is required to dissipate much of the kinetic energy from the incoming flow. Alternatively, baffle systems can be used to redirect the flow, but model tests are then re-quired to determine their correct shape, position and orientation. The distance between the weir or baffles and the pump bays must be sufficient to allow eddies to dissipate, and entrained air to escape, before the water reaches the pump inlet (See Appendix 3).

High level front inlet

6

Pump bay design alternatives Enclosed intake design Enclosed intake design are the least sensitive to dis-turbances of the approaching flow that can result from diverging or turning flow in the forebay, or from single pump operation at partial load. Therefore, enclosed intake design are nearly always the preferred choice and recommended for stations with multiple pumps with various operating conditions.

Enclosed intake design can be constructed in either concrete or steel. The intake reduces disturbances and swirl in the approaching flow. The inclined front wall prevents stagnation of the surface flow. Geometrical features of the intake provide smooth acceleration and turning as the flow enters the pump. The minimum inlet submergence should not be less than nominal diameter (D).

Open sump intake design This intake design is the most sensitive to non-uniform ap-proaches. If used for more than three pumps, the length of the dividing walls should be at least 2/3 of the total width of the sump. If flow contraction occurs near the sump entrance because of screens or gates, the sump length should be increased to 6D or more, depending on the degree of contraction.

Open sump intake design includes devices such as flow straightening vanes (splitters) that alleviate the ef-fects of minor asymmetries in the approaching flow.The minimum required submergence of the pump inlet with open sump intake design is a function of the flow rate, the pump inlet diameter and the distribution of the flow at the approach to the pump. Minimum submer-gence diagrams are shown in the Appendix 2. Each

Enclosed suction intake

Enclosed suction intake

Corner fillets Corner fillets

Corner fillets

Dividing wall

Dividing wall

Flow straightening vane (splitter)

Flow straightening vane (splitter)

L-shaped flow straightening vane (splitter)

Dividing wall

Corner fillets

L-shaped flow straightening vane (splitter) with cone

Dividing wall

Enclosed intake design in concrete Open sump intake design for Flygt LL pumps

Enclosed intake design in steel Open sump intake design for Flygt PL pumps

7

diagram has three curves for various conditions of the approaching flow. Because vortices develop more read-ily in a swirling flow, more submergence is required to avoid vortices if the inlet arrangement leads to disturbed flow in the sump. Hence, the upper curve in the sub-mergence diagrams is for a perpendicular approach, the middle one is for the symmetrical approach and the lowest curve for duty-limited operation time (about 500 hours/year). The curve appropriate to the inlet situation should be used to determine the minimum water level in the sump to preserve reliable operation of the pumps.

Pump station model testing Hydraulic models are often essential in the design of structures that are used to convey or control the flow distribution. They can provide effective solutions to complex hydraulic problems with unmatched reliabil-ity. Their costs are often recovered through improve-ments in design that are technically better and yet less costly. Model testing is recommended for pump-ing stations in which the geometry differs from rec-ommended standards, particularly if no prior experi-ence with the application exists. Good engineering practice calls for model tests for all major pumping sta-tions if the flow rate per pump exceeds 2.5 m3/s (40 ,000 USgpm) or if multiple pump combinations are used.

Tests are particularly important if: • Sumps have water levels below the

recommended minimum submergence• Sumps have obstructions close to the pumps • Sumps are significantly smaller or larger than

recommended (+/- 10%) • Multiple pump sumps require baffles to control

the flow distribution • Existing sumps are to be upgraded with

significantly greater discharges.

A model of a pumping station usually encompasses a representative portion of the headrace, the inlet structure, the forebay and the pump bays. The discharge portion of the flow is seldom included. Testing may encompass the following flow features and design characteristics:

• Inlet structure: flow distribution, vortex formation, air entrainment, intrusion of sediment and debris.

• Forebay and pump bays: flow distribution, mass swirl, surface and bottom vortices, sediment transport.

• Operating conditions: pump duty modes, start and stop levels, pump down procedures.

Model testing can also be employed to seek solu-tions to problems in existing installations. If the cause of a problem is unknown, it can be less expensive to diagnose and remedy with model studies rather than by trial and error at full scale. The pump manufactur-er’s involvement is often required in the evaluation of the results of model tests. Experience is required to determine whether the achieved results are satisfac-tory and will lead to proper overall operation.

We can offer guidance regarding the need for model tests and assist in their planning, arrange-ment and evaluation.

Computational modeling Computational fluid dynamics (CFD) analysis has the potential of providing far more detailed information of the flow field at a fraction of cost per time needed for the model tests. It has been more and more ac-cepted as a tool in station design in combination with Computed Aided Design (CAD) tools. It is possible to obtain a more efficient method for numerical simula-tion of station design utilizing CFD. It offers increased qualitative and quantitative understanding of pump-ing station hydraulics and can provide good compar-isons between various design alternatives. However, the possibilities of CFD should not be overestimated. Difficult cases are encountered where free surface effects are important. Also, a phenomenon like air en-trainment is difficult to capture with CFD analysis.

Both model tests and CFD have advantages and disad-vantages that need to be evaluated in each individual case. We can advise on a good combination between model tests and CFD.

8

Back wall and floor splitter plates.

Back wall vortex caused by floor splitter only.

Corrective measures The designs described in this brochure have been proven to work well in practice. However, in some ap-plications–perhaps due to limitations of space, installa-tion of new pumps in old stations, or difficult approach conditions–not all the requirements for a good, simple design can be met. Sometimes, for example, it may be impossible to provide adequate submergence so that some vortexing or swirl may occur. Corrective measures must then be undertaken to eliminate the undesirable features of the flow, particularly those associated with excessive swirl around the pump tube, with air-entrain-ing surface vortices and with submerged vortices.

Swirl around the pump tube is usually caused by an asym-metrical velocity distribution in the approach flow. Ways should be sought to improve its symmetry. Subdivision of the inlet flow with dividing walls, and the introduction of training walls, baffles or varied flow resistance are some options that may achieve this result. Alternatively, a reduction of the flow velocity, for example, by increas-ing the water depth in the sump, can help to minimize the negative effects of an asymmetrical approach.

or from erosion of the propeller blades. They can be elim-inated by disturbing the formation of stagnation points in the flow. The flow pattern can be altered, for example, by the addition of a center cone or a prismatic splitter under the pump, or by insertion of fillets and bench-ing between adjoining walls, as in some of our standard configurations.

Air-entraining vortices may form either in the wake of the pump tube or upstream from it. They form in the wake if the inlet velocity is too high or the depth of flow is too small. Also, they form upstream if the velocity is too low. In either case, these vortices can be eliminated by introducing extra turbulence into the surface flow, i.e. by placing a transverse beam or baffle at the water surface. Such a beam should enter the water at a depth equal to about one quarter of the tube diameter and be placed at a point about 1.5–2.0 diameters upstream of the tube. If the water level varies considerably, a floating beam can be more effective. In some cases, a floating raft upstream of the tube will eliminate air-entraining vortices. This raft may be a plate or a grid. Both forms impede the formation of surface vortices. An alternative is the use of an inclined plate similar to that shown in the draft tube installation.

Relatively small asymmetries of flow can be corrected by the insertion of splitter plates between the pump tube and the back wall of the sump and underneath the pump on the floor. These plates block the swirl around the tube and prevent formation of wall vortices. These measures are integral features in most of our standard configurations.

Submerged vortices can form almost anywhere on the solid boundary of the sump and they are often difficult to detect on the site. However, they can be detected much more readily in model tests. Submerged vortices exis-tence may be revealed by the rough running of the pump

Surface baffle for vortex suppression

Floating raft or vortex breaker grid

D/4

1.5–2.0D D

9

Installation alternativesThe following examples show possible alternatives using Flygt designed installation components.

Suitable for pumping liquid to a receiving body of water with small level variations or where a short running time can be expected, so non-re-turn valves are not required.

This arrangement is simple.

An alternative to the con-crete shaft is to place the pump in a steel column with a collar that rests on a supporting frame (instal-lation component D1). The top of the pipe must extend sufficiently above the maxi-mum water level to prevent back-flow from the outlet channel.

Installation type 2

Installation type 1

This arrangement may be used with either a free discharge, when liquid is pumped to a receiving body of water with small water level variations, or with a flap valve, when the water level on the outlet side varies considerably so that the

Installation type 3

This arrangement is suitable whenever the liquid is pumped to a receiving body of water with a varying water level. The outlet is equipped with a flap valve to prevent back-flow. When the pump is not in operation, the valve closes automatically, prevent-ing water from running back into the sump. The static

Installation type 4

It involves the least possible number of steel com-ponents. The pump is set in a circular concrete shaft with a relatively short tube grouted in place, instal-lation component D3, which is used as the support structure for the pump. Alternatively, the shaft can have a rectangular cross-section above the dis-charge column. The shaft extends above the maximum water level in the outlet channel to prevent water from running back to the sump when the pump is shut off.

outlet is occasionally submerged. The flow is discharg-ing into a closed culvert through the component E1.

head is the difference between water level in the sump and water level at the outlet, and it will be kept to a minimum in this type of installation. Elbow type E2–E4 can be used for discharging.

10

This easy-to-install elbow construction allows pumps to work in combination with a siphon or discharge line. When outlet is sub-merged a siphon breaking valve is required to prevent back-flow and allow venting at start. This installation keeps the static head to a minimum, since the static head will be the difference between the water level in the sump and the water level at the outlet. Two types of elbows can be used with this station E2–E4 As in previous cases, the steel tube rests on a support frame (installation component D1).

Note: Support bracket (B1) should be used if the free unsupported length of the column pipe exceeds 5 times pipe diameter.

Installation type 5

11

Installation components The objective in the design and development of in-stallation components is to devise simple systems, which offer a wide variety of options to deal with most situations. These components have been developed to facilitate design work and estimation of costs. Normally, the installation components will be manu-factured locally based on Flygt drawings. The draw-ings can also serve as a basis for the development of new or modified components which better match the local requirements and/or manufacturing facilities.

Drawings are available for the following installation components:

Flygt Formed Suction Intake (Flygt FSI) is prefer-able for very adverse inflow conditions or when the pump bay dimensions are less than recommended. The main function of the intake device is to preserve an optimal inflow to the pump by gradual acceleration and redirection of the flow toward the pump inlet.

Vertical discharge column (D) in which the pump is set Depending upon the depth of the station, the installation may consist of one part (D1) or several parts joined together by flanges (D2), or it may consist of a short tube prepared for grouting in concrete (D3).

Discharge elbows (E) with rectangular exit flange (E1) and discharge elbows with circular exit flanges (E2, E3, E4).

D1 D2 D3

E1 E2 E3

Flygt FSI

Cover (C) for discharge elbows (E1 and E2

C

Column bracket (B) for anchoring the tube

Supporting frame (F) for suspending the tube from ceiling.

B F

12

A few basic principles govern good cable protec-tion and suspension practices: • Cables must be suspended in such a way that if

they should move, they will not come in contact with any surfaces which could abrade the jacket – these include pump and tube components, as well as other cables.

• Cables should be bundled together, using components which will not cut or abrade the cables.

• Proper strain relief and support at prescribed intervals (depending on length) should be provided Spring-controlled tensioning and an integrated “guide wire” are recommended for long cable lengths .

We offer a variety of cable protection and suspen-sion accessories with recommendations to suit all types of installations and running conditions. Contact your local Application engineer for infor-mation on the best system to meet your needs.

Cable protection and suspension for tube installed pumps For tube-installed submersible pumps, proper cable protection and suspension is essential for trouble free operation. Cable suspension and protection requirements become more stringent with longer cable lengths and higher discharge velocities.

Flygt cable seal units for pressurized tube (column)

Installation of pumpsPump installation can be facilitated with the aid of the Dock-Lock™ device for easy and safe retriev-al of pumps in a wet well. The Dock-Lock con-sists of a spring-loaded hooking device, a guide line and a tension drum. Because the line guides the hook, there’s no time wasted trying to find the pump shackle. The device ensures that the hook actually locks into the shackle. Pumps are retrieved safely, easily and quickly, with mini-mal maintenance costs.

The Flygt cable seal units with Roxtec seal-ing technology are used to make a water tight cable entry into a discharge column with water tight cover.

The cable seal units are complete with frame, Roxtec cable seal mod-ules, tightening wedge, lubricant and installa-tion manual.

Flygt cable suspension system

13

Appendix 1: Head losses diagrams for Flygt designed discharge arrangements

Head losses are comparatively small for systems using propeller pumps. Even so, an accurate predic-tion of losses, and hence the total required head, is crucial when selecting the best pump. Propeller pumps have relatively steep head and power char-acteristics, and an error in predicting the total head can result in a significant change in the power re-quired. A potentially vulnerable situation can arise if head loss is significantly underestimated, which can mean that a pump operates against a higher head, delivers less flow and uses more power. Conservative assumptions should thus be made in determining head loss calculations. For all installa-tions described herein, the head losses that must be accounted for occur in the components of the discharge arrangement (friction losses in short pipes are usually negligible). The loss coefficients and the head loss as a function of the flow rate for the system components designed by Flygt are shown in the dia-grams. For system components not covered by this document, loss coefficients can be obtained from their manufacturers or from appropriate literature.


16” Installation pipe inner diameter (D)Flygt PL7020

E1 W=16 K=0.45E5 W=24 K=0.37E5 W=31 K=0.35E5 W=39 K=0.34E5 W=47 K=0.33

E1, E5H (in)

Q (USgpm)0 4000 60002000

0

20

10

5

15

25

E2H (in)

Q (USgpm)0 2000 60004000

0

30

20

10

5

15

25

35

40

E3, E4H (in)

Q (USgpm)0 2000 4000 6000

0

18

12

10

2

4

8

6

16

14

E2 Dout=14 K1=1.41E2 Dout=16 K1=1.13E2 Dout=14 K2=0.85E2 Dout=16 K2=0.77


16E5 Side E5 Top

D

W

19

HS

HS=Static head H=Head loss

H

E1

D

HS

HS=Static headH=Head loss

H

H=

K W 2g

Q23

E2

D

r

Do

E3 E4

D D

Do Do

K2: Smooth bend > 0.1rDo

K1: Sharp bend = 0rDo

14





E1, E5 E1, E5

E2 E2

E3, E4 E3, E4

H (in)

H (in)

H (in)

Q (USgpm)

0

10

6

2

4

8

12

14

16

H (in)

H (in)

H (in)

Q (USgpm)

Q (USgpm)

0 4000 6000 8000 1200020000

30

20

10

5

15

25

Q (USgpm)

Q (USgpm)

Q (USgpm)

0

0

0

2000 6000 8000 10000 120004000

2000 6000 8000 10000 120004000

2000 6000 8000 10000 120004000

0

0

12

10

20

6

10

5

2

15

4

25

8

30

14

0

25

30

15

10

5

20

35


10000

0 4000 6000 8000 120002000 100000

30

20

10

5

15

25

35

40

0 4000 6000 8000 120002000 10000





20E5 Side E5 Top

D

W

24

HS


H

E1

D

HS


H

H=

K W 2g

Q23

E2

D

r

Do

E3 E4

D D

Do Do

22E5 Side E5 Top

D

W

26

HS


H

E1

D

HS


H

H=

K W 2g

Q23

E2

D

r

Do

E3 E4

D D

Do Do





15


28” Installation pipe inner diameter (D)Flygt PL7045, PL7050


H=

K W 2g

Q23


E1

D

HS


H

E1, E5E1, E5H (in)H (in)

Q (USgpm)Q (USgpm)00 20002000 60006000 80008000 1000010000 1200012000 1400014000 1600016000 40004000

00

3030

2020

1010

55

1515

2525

3535

28E5 Side E5 Top

D

W

33

HS


H

E2E2H (in)H (in)

Q (USgpm)Q (USgpm)00 20002000 60006000 80008000 1000010000 1200012000 1400014000 1600016000 1800018000 40004000

00

30

40

20

2010

5

15

10

25

30

35

50

4060

4570

E3, E4E3, E4H (in)H (in)

Q (USgpm)Q (USgpm)00 15002000 45004000 60006000 75008000 9000 1050010000 1200012000 1500014000 13500 180001650016000 3000

00

24

24

20

20

12

12

44

88

16

16

28

E2 Dout=20 K1=2.55E2 Dout=20 K2=2E2 Dout=24 K1=1.45E2 Dout=28 K1=1.13E2 Dout=24 K2=0.9E2 Dout=28 K2=0.77

E4 Dout=20 K=1.34 E3 Dout=20 K=1.23E4 Dout=24 K=0.65E3 Dout=24 K=0.60E4 Dout=28 K=0.35E3 Dout=28 K=0.32

E2

D

r

Do



E3E3 E4E4

DD DD

DoDo DoDo




24E5 Side E5 Top

D

W

28

HS


H

E1

D

HS


H

H=

K W 2g

Q23

E2

D

r

Do



16

E4 Dout=28 K4=0.96 E3 Dout=28 K3=0.87E4 Dout=31 K4=0.56E3 Dout=31 K3=0.51E4 Dout=35 K4=0.35E3 Dout=35 K3=0.32

32” Installation pipe inner diameter (D)Flygt PL 7055, PL 7061, PL 7065, LL 3356

36” Installation pipe inner diameter (D)Flygt LL 3400

E1, E5 E1, E5

E2 E2

E3, E4 E3, E4

H (in)

H (in)

H (in)

Q (USgpm)0

0

20

10

5

15

25

H (in)

H (in)

H (in)

Q (USgpm)

Q (USgpm)

0

0

10000

10000 15000

15000

20000

20000 25000

25000

5000

5000

10000 15000 20000 250005000

0

0

30

30

20

20

10

10

45

5

5

15

15

25

25

45

40

35

40

55

50

Q (USgpm)

Q (USgpm)

Q (USgpm)

0

0

0

2000

2000

6000

6000

8000

8000

10000

10000

12000

12000

14000

14000

16000

16000

4000

4000

2000 6000 8000 10000 12000 14000 160004000

0

0

6

5

20

3

10

5

1

15

2

25

4

30

7

0

10

5

2.5

7.5

12.5


E2 Dout=28 K1=1.9E2 Dout=31 K1=1.38E2 Dout=28 K2=1.37E2 Dout=35 K1=1.13E2 Dout=31 K2=0.84E2 Dout=35 K2=0.77




E4 Dout=24 K=1.11E3 Dout=24 K=1.01E4 Dout=28 K=0.60E3 Dout=28 K=0.54E4 Dout=31 K=0.35E3 Dout=31 K=0.32




32E5 Side E5 Top

D

W

37

HS


H

E1

D

HS


H

H=

K W 2g

Q23

E2

D

r

Do

E3 E4

D D

Do Do

35E5 Side E5 Top

D

W

43

HS


H

E1

D

HS


H

H=

K W 2g

Q23

E2

D

r

Do

E3 E4

D D

Do Do


17


48” Installation pipe inner diameter (D)Flygt PL 7101, PL7105, LL 3531, LL 3602

40” Installation pipe inner diameter (D)Flygt PL 7076, PL 7081

E1, E5E1, E5

E2E2

E3, E4E3, E4

H (in)

H (in)

H (in)

Q (USgpm)

Q (USgpm)

Q (USgpm)

0

0

0

10000

10000

30000

20000

30000

30000 40000

40000

40000

50000

50000

60000

60000

50000 60000

20000

20000

10000

0

0

0

40

50

30

20

17.5

12.5

20

20

7.5

10

10

5

5

2.5

15

15

5

25

30

25

10

45

55

35

40

45

22.5

H (in)

H (in)

H (in)

Q (USgpm)

Q (USgpm)

Q (USgpm)

0

0

0

5000

10000

15000

10000

15000

20000

15000

20000

20000

25000

25000

30000

30000

35000

35000

25000 30000 35000

5000

10000

5000

0

0

0

30

35

25

12

10

20

15

6

10

10

5

5

2

15

4

25

20

8

40

30

18

35

15

47E5 Side E5 Top

D

W

57

HS


H

E1

D

HS


H

H=

K W 2g

Q23

39E5 Side E5 Top

D

W

47

HS


H

E1

D

HS


H

H=

K W 2g

Q23



E4 Dout=39 K=0.73E3 Dout=39 K=0.66E4 Dout=47 K=0.35E3 Dout=47 K=0.32


E4 Dout=31 K=0.85E3 Dout=31 K=0.78E4 Dout=35 K=0.53E3 Dout=35 K=0.49E4 Dout=39 K=0.35E3 Dout=39 K=0.32


E2

D

r

Do

E2

D

r

Do





E3 E4

D D

Do Do

E3 E4

D D

Do Do

18


56” Installation pipe inner diameter (D)Flygt PL 7115, PL 7121, PL 7125

E2

E3, E4

H (in)

H (in)

H (in)

Q (USgpm)

Q (USgpm)

Q (USgpm)

0

0

0 40000

40000

40000

60000

60000

60000

80000

80000

80000

120000

120000

120000

100000

100000

100000

20000

20000

200000

0

0

6055

30

25

20

4035

20

15

2015

10

105

5

5

3025

15

10

5045

25

7075

65

354045

30

505560657075

E1, E5

55E5 Side E5 Top

D

W

67

HS


H



E4 Dout=47 K=0.65E3 Dout=47 K=0.59E4 Dout=55 K=0.35E3 Dout=55 K=0.32




E1

D

HS

H

H=

K W 2g

Q23

E2

D

r

Do

E3 E4

D D

Do Do

19

8000 10000

Flygt PL 7020

Flygt PL 7035

Flygt PL 7030

Flygt PL 7040

Appendix 2: Submergence diagram for open sump intake design

S (in)

S (in)

Q (USgpm)

Q (USgpm)

S (in)

S (in)

Q (USgpm)

Q (USgpm)

0

0

2000

2000 4000 6000 8000 12000

6000 12000

10000 14000 16000 18000

40000

20

0

80

60

80

60

20

40

40

100

100

120

The minimum required submergence of the pump inlet with open sump intake design is a function of the flow rate, the pump inlet diameter and the dis-tribution of the flow at the approach to the pump. Each diagram has three curves for various conditions of the approaching flow. Because vortices develop more readily in a swirling flow, more submergence is required to avoid vortices if the inlet arrange-ment leads to disturbed flow in the sump. Hence, the upper curve in the submergence diagrams is for a perpendicular approach, the middle one is for the symmetrical approach and the lowest curve for duty-limited operation time (about 500 hours/year). The curve appropriate to the inlet situation should be used to determine the minimum water level in the sump to preserve reliable operation of the pumps.

Note: NPSH required for specific duty point may supersede submergence requirements.


Lateral approachSymmetrical approachLimit of operation (500 hours/year) 0 2000 4000 80006000 10000

0

60

40

80

20

0 1000 2000 3000 4000 6000 700050000

60

40

80

20

20


Flygt LL 3356 Flygt PL 7055, PL 7061, PL 7065

Flygt LL 3602 Flygt PL 7101, PL 7105

Flygt LL 3400 Flygt PL 7076, PL 7081

Flygt PL 7045, PL 7050 Flygt PL 7121, PL 7125

S (in) S (in)

S (in) S (in)

S (in)

Q (USgpm) Q (USgpm)

Q (USgpm) Q (USgpm)

Q (USgpm)

0 0

0 0

0

2000 5000

4000 5000

20000 40000 60000 100000

6000 15000

12000 15000

80000

8000 20000

16000 20000 25000 30000

120000

4000 10000

8000 10000

10000 25000

20000 35000

15 20

20 30

30

60

80

60

120

150

180

45

60

4060

60

90

3040

75

140

120

100

8090

210

S (in)

0 10000 30000 40000 50000 600002000030

120

90

60

150

S (in)

S (in)

Q (USgpm)

Q (USgpm)

0

0

10000

5000

30000 40000

10000 15000 20000

2000020

0

80

60

80

60

20

40

40

100

100

Q (USgpm)

21

Vmax=0.1m/s(2ft/s)

Stations with low level front inlet

Stations with low level side inlet (max 4 pumps)

Stations with high level side inlet (max 4 pumps)

Stations with high level front inlet (max 4 pumps)

Appendix 3: Sump layout alternatives

W.L.

D

B

AB

B

BB

D

P

A A

AVmax=1.0m/s

(3ft/s)

max 10°

max D max(2/3B or L)

10° (max 20°)

A – A

A – A

B – B

B – B

to avoid sedimentationVmax=0.3m/s

(1ft/s)

Vmax=1.2m/s(4ft/s)

Vmax=0.5m/s(2ft/s)

min 1.25P min 3D max (2/3B or L)

Vmax=1.7m/s(5ft/s)

A – A

A – A

B – B

B

B

B

B

D

D

0.75D0.75

P0.

75D

0.75

P 0.5P

B

D

B – B

Vmax=1.7m/s(5ft/s)

1.5D

1.25P

0.75D

0.75

D

P

3D max (2/3B or L)

~ ~

D

P

P

1.5D 3D max(2/3B or L)

W.L.B

B

D

Appendix 3: Sump layout alternatives

23

Recommended dimensions

Pump type Nom. dia (in) B C D E F G H J K L M P S W

Encl

ose

d In

take

Des

ign

PL7020 16 8 8 16 7 13 18 8 16 24 64 13 7 16 32

PL7030 20 10 10 20 8 16 22 10 20 30 80 16 8 20 40

PL7035 22 11 11 22 9 18 25 11 22 33 88 18 9 22 44

PL7040 24 12 12 24 10 20 27 12 24 36 96 20 10 24 48

PL7045 PL7050 28 14 14 28 11 22 31 14 28 42 114 22 11 28 56

PL7055 PL7061 31 16 16 32 13 26 35 16 32 48 126 26 12 32 64

PL7065 31 16 16 32 13 26 35 16 32 48 126 26 12 43 64

PL7076 PL7081 39 20 20 40 16 32 44 20 40 60 162 32 15 40 80

PL7101 47 24 24 48 19 38 53 24 48 72 192 38 18 48 96

PL7105 47 24 24 48 19 38 53 24 48 72 192 38 18 59 96

PL7121 55 28 28 56 22 45 62 28 56 84 222 45 21 56 112

PL7125 55 28 28 56 22 45 62 28 56 84 222 45 21 69 112

Appendix 4: Pump bay alternatives

Enclosed intake in steel for Flygt PL pumps Enclosed intake in concrete for Flygt PL pumps

B – B

B – B

max W.L.max W.L.

min W.L.min W.L.

CC

BB

60°

C

BB

C

SS

CC MMN

PP

GG

DD

H HH

A

A

A

A

EF

BB

F

D

C

JJKK

Splitter

Splitter

L min

W

W E

E

E

E

W

W

W

W

2

2

2

2A – A C – CA – A

A – A

C – C

L min60

˚C


24


Flygt FSI

A A

B – B

max W.L.

min W.L.

C

B B

SC M

D


Pump type Nom. dia (in) B C D E F G H J K L M N P S W

Flyg

t FSI

PL7020 16 12 10 16 - - - - - - 42 13 - - 20 27

PL7030 20 14 13 20 - - - - - - 51 16 - - 24 34

PL7035 22 15 14 22 - - - - - - 55 18 - - 24 37

PL040 24 16 15 24 - - - - - - 60 20 - - 28 41

PL7045 PL7050 28 14 16 28 - - - - - - 58 21 - - 28 44

PL7055 PL7061 32 16 19 31 - - - - - - 69 25 - - 31 52

PL7065 32 16 25 31 - - - - - - 69 25 - - 43 52

PL7076 PL7081 40 20 25 39 - - - - - 90 33 - - 39 68

PL7101 48 24 30 47 - - - - - - 108 39 - - 47 82

PL7105 48 24 30 47 - - - - - - 108 39 - - 59 82

PL7121 56 28 35 55 - - - - - - 129 47 - - 55 98

PL7125 56 28 35 55 - - - - - - 129 47 - - 69 98

A A

B

C

L

WW

2

A – A C – C

25

Open sump design for Flygt PL pumps

A A

B B

min W.L.

C

B B

SC P N

D

Open sump design for Flygt LL pumps


Pump type Nom. dia (in) B C D E F G H J K L M N P S W

Op

en s

ump

in

take

des

ign

PL7020 16 12 8 16 8 - - - 20 28 63 8 4 6

See

min

imum

su

bm

erg

ence

dia

gra

m

32

PL7030 20 15 10 20 10 - - - 25 35 79 10 5 8 40

PL7035 22 17 11 22 11 - - - 28 38 87 11 6 9 44

PL7040 24 18 12 24 12 - - - 30 42 95 12 6 9 48

PL7045PL7050 28 21 14 28 14 - - - 34 48 114 14 7 11 56

PL7055PL7061PL7065

32 24 16 32 16 - - - 40 56 126 16 8 12 64

PL7076PL7081 40 30 20 40 20 - - - 50 70 162 20 10 15 80

PL7101 PL7105 48 36 24 48 24 - - - 60 84 192 24 12 18 96

PL7121 PL7125 56 42 28 56 28 - - - 70 98 222 28 14 21 112

Op

en s

ump

in

take

des

ign

LL3356 32 24 16 32 16 - - - 40 56 64 16 8 12

See

min

imum

su

bm

erg

ence

dia

gra

m

64

LL3400 36 28 18 36 18 - - - 46 62 72 18 9 13 72

LL 3531LL3602 48 36 24 48 24 - - - 60 84 96 24 12 18 96

A A

E

MB

J

K

Splitter with cone

C

L

W

EE

WW

22

A – A

B – B

C – C

max W.L.

C

B

A

B

SPC

D

D

A

E

E

C

BJP

Splitter

W

EE

WW

22

A – A

B – B

C – C

2xD


26

1) The tissue in plants that brings water upward from the roots2) A leading global water technology company

Xylem (XYL) is a leading global water technology provider, enabling customers to transport, treat, test and efficiently use water in public utility, residential and commercial building services, industrial and agricultural settings. The company does business in more than 150 countries through a number of market-leading product brands, and its people bring broad applications expertise with a strong focus on finding local solutions to the world’s most challenging water and wastewater problems. Launched in 2011 from the spinoff of the water-related businesses of ITT Corporation, Xylem is headquartered in White Plains, N.Y., with 2011 revenues of $3.8 billion and 12,500 employees worldwide. In 2012, Xylem was named to the Dow Jones Sustainability World Index for advancing sustainable business practices and solutions worldwide. The name Xylem is derived from classical Greek and is the tissue that transports water in plants, highlighting the engineering efficiency of our water-centric business by linking it with the best water transportation of all -- that which occurs in nature. For more information, please visit us at www.xyleminc.com.

Xylem, Inc.14125 South Bridge CircleCharlotte, NC 28273Tel 704.409.9700Fax 704.295.9080855-XYL-H2O1 (855-995-4261)www.xyleminc.com

Flygt is a trademark of Xylem Inc. or one of its subsidiaries. © 2016 Xylem, Inc. MARCH 2016

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for pump stations with vertically installed flygt … · the flygt standard pump station design can...

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