Packaged pumping systems are gaining in popularity due to benefits including ease of installation, single source responsibility and streamlined manufacturing.

 

Packaged systems simplify the installation process. Installation of a system typically involves lifting it off the delivery truck, setting it into place and connecting the piping and power to prepare it for operation.

Single source responsibility means only calling one company if a service issue exists. Issues are solved quickly and end users do not need to consult with multiple vendors to determine which company to call. This ultimately reduces service downtime.

Packaged systems are manufactured in a controlled environment that allows for testing of a system prior to jobsite delivery and reducing fabrication timelines. This controlled approach minimizes start-up problems in the field and allows for system testing.

Packaged pump systems satisfy the demands of many pump industry applications including municipal distribution systems, industrial process systems, non-potable and water reuse systems and domestic water booster systems in high-rise buildings.

 Pictured is a packaged domestic water pressure booster system for Chicago's McCo

Pictured is a packaged domestic water pressure booster system for Chicago's McCormick Convention Center that increases the pressure provided by the City's water system and satisfies the potential peak flow demands of the facility. Photo courtesy of Metropolitan Industries, Inc.

 

Municipal Water Distribution Systems

For years, municipalities have relied on water mains to bring treated, disinfected water from the source to our homes through a distribution network. This network may be comprised of reservoirs, pump stations, water towers and storage facilities. To ensure clean, drinkable water is supplied at an adequate pressure to keep the supply system working properly, water districts employ pump stations that pressurize water to run our household plumbing devices (toilets, sinks, showers, etc.) as well as provide water for cooling, industrial needs and fire protection.

These pump stations can be packaged and delivered as a complete unit. Typical designs include a large steel base with pump and control components pre-installed. Base and components are eventually housed in any material of the customer's choosing. Organizations like the American Water Works Association help create standards used when designing the various components in such a system.

When sizing a packaged pump station for a distribution network, flow and pressure are the two main elements, but many other variables factor into how a pump system is designed and ultimately operated. The size required varies directly with the number of users or volume of water required. Designers will engineer systems for the total "peak demand" for that segment of the community. For instance, factors such as usage (flow) will affect pump and piping sizing; topography will affect the pressure required; a water tower will affect pressures and how much water is stored to fight a fire. Monitoring requirements may vary, but the dynamic nature of the system will make it important to monitor changing conditions and react appropriately to prevent these changes from causing water hammer and wide pressure swings that often result in water main breaks.

Whether the system is pumping from a reservoir or directly boosting the pressure "in-line" within the piping network, pressure and flow monitoring instrumentation is needed locally and remotely. Motor and valve controls needed at the pump station and level monitoring of towers and reservoirs also directly interface with the pump system. SCADA systems are often used to collect data and automatically make system adjustments to keep the water pressure constant. They also serve as a means to allow operators to be more proactive in the regular maintenance of system equipment.

Whether the system is 50 gpm or 25,000 gpm, it is possible to pre-fabricate or package these elements to provide the end user with a product designed with "complete system responsibility" in mind.

Processed Industrial Systems

Factory prefabricated pumping packages can be applied in many different industrial process water applications. Water transfer, level control, recirculation and pressure boosting are just a few examples. Typical skid-mounted packages include pumps, motors, valves, package piping and a factory pre-wired and integrated control system. Specifiers may also consider systems with complete factory prefabricated buildings to protect the equipment and provide a controlled environment in which to perform maintenance and service.

Note that many important variables should be considered when selecting equipment best suited for these applications. Reliability and efficient operation are keys to making the right choices. The properties of the source water and demands of the process must be considered when selecting the construction materials for the pumps, valves and piping. It is imperative that all wetted parts be researched for compatibility to ensure safe, reliable operation. In addition, these types of centrifugal pump applications can often use variable speed control strategies. Simplicity, precise process control and maximum efficiency will be realized when variable speed control is specified.

Non-Potable, Water Reuse Systems

Wastewater treatment plants often need a non-potable water service to satisfy demands throughout the treatment process. For example, wash down water at bar screens, belt filter presses, yard hydrants and clarifier spray water can all be served with a non-potable source. Reuse water reclaimed from the final effluent of the plant can serve as the source for these non-potable demands as well. Potable water mains can also supply water for these applications but it is important that the potable water source be protected from cross contamination. When back flow protectors are not allowable, protected water systems frequently employ an air gap break tank to effectively decouple the non-potable loads from potable water mains.

Seal water systems requiring a source of clean water to pressurize stuffing boxes on large sewage pumps are another example where an air gap protected potable water source can be used. Many different pump types are suitable for these applications. End suction, vertical multistage, vertical turbine and split case pumps are all sound choices. Selecting the best suited pump involves finding a unit that is a good hydraulic fit, simple to maintain and efficient to operate.

Factory prefabricated pumping packages are available for both water reuse systems and protected water systems. Typical packages include pumps, motors, tanks, package piping and controls. Recirculation circuits, valve subsystems and safeties make for a complete integrated package.

Domestic Water Pressure Booster Systems

When the water pressure provided by any given municipal water system is not sufficient to satisfy the demands of end users at higher elevations such as mid-rise or high-rise buildings, these facilities often need equipment designed to increase the pressure provided by horizontal municipal water systems.

These types of prefabricated systems are engineered to satisfy the potential peak flow demands of the facility and are often provided with multiple pumps on a single structural steel fabrication with electronic controls, wiring, piping, valves and multiple safety-devices. These packaged systems are typically designed based on the calculated increase in pressure required to deliver pressurized water to the highest or furthest point-of-use in the facility.

Multiple electronic sensors are often installed at remote locations within the facility. These sensors allow the controls to optimize system operation, and enhance the equipment's energy efficiency. In certain regions of the country, the design requirements of these types of systems are regulated by local, national or international code requirements.