Beginning in the late ’80s and early ’90s, notable “packaged pump station” companies broke out with this product, and it grew from being hard to find to being available everywhere by the 2010s.
Packaged pumping systems have changed the way small pumping systems are done, but they also have the potential to change the way all water and wastewater pumping and infrastructure are handled. Additionally, just as there are unlimited pumping requirements, there are now packages that range from very small to very large and from very simple to very complex.
When someone refers to a pumping system as a “package,” the first question should be, “Does it cover the basics?” All pumping systems have structural, mechanical, electrical (power) and control and communication (data) aspects. The structural basics include things like how to overcome uplift and a long list of structural issues that exist in various sites, soil types, water levels, etc. Structural issues exist in systems for all water types, such as wastewater, stormwater, industrial process water and clean (potable) water pumping systems. Structural issues should be carefully considered for any aspects that will be buried in the ground, such as the sump, the valve box/vault, the flow meter, etc. In most cases, with water types like sewer and/or storm, it is very likely that the best choice in design types will lead to several major aspects of the packaged pump station being in ground.
In many cases, the packaged pump station is also going to have to fit in, work with or be a part of existing pumping systems and their related piping. This requirement is common when pumping sewage. The circumstances vary from shared force mains with now and future flow to both the new and existing pumping systems. It is important to understand that, in many cases, these shared utilities are part of some sewer, storm or water district’s plan, and the packaged pumping system must fit into that district’s current and long-term plans.
Thirty years ago, what was allowed in terms of pumping system configurations, site layouts, materials, control and communication, etc., was very flexible. Today, those same districts are much stricter, and what they allow is much more defined and scrutinized.
Small (less than 10-20 gallons per minute [gpm]) packaged pump systems have been accepted by some sewer districts. These packaged systems have become increasingly reliable, and they essentially own the market in low-flow scenarios (less than 10-20 gpm) with sump depths at less than 10 feet below grade. In many applications, these small packaged systems are the best choice relative to price, reliability and lifespan. They may last only half as long as a more site-specific design, but at their price and their availability, they are a compelling option.
The next step up involves more flow—for example, 20-50 gpm with the overall depth in the 10-20 feet range. This step up is not just depth related; it might also have to fit into an existing supervisory control and data acquisition (SCADA) system that will involve some custom code writing or specific types and/or brands of backup power, odor control, chemical feeds or specifications that involve various custom materials, coatings, site layouts and more.
What is important to understand is that packaged systems are available for a long list of custom conditions, materials and specifications. Some of the most sophisticated and complex pumping systems being designed and built today are custom packaged pumping systems for all water types and all physical, mechanical, electrical and control and communication requirements.
Some companies design, engineer, supply and construct complete custom packaged pumping systems for various water types and pumping conditions. From preliminary designs and budgeting to the prefabrication, delivery and construction management of all structural, mechanical, electrical, control and communications, this too is the world of packaged pumping systems.
It takes experience to understand how to do what a jurisdiction, an industry or an engineering firm does. Experience in pumping system design, engineering, manufacturing, construction, startup and operation comes from designing hundreds and thousands of different systems for different water types and different duty points (flow and total dynamic head [TDH]).
This level of design and site-specific layout and construction is not any less of a package approach than several small packaged pump stations for each home in a new housing development. In both cases, the design, supply, construction, startup, documentation, testing and troubleshooting is being done by the package supplier. This approach is in every way different than a “design, bid, build” approach, which is configured as follows:
- Structural and mechanical is designed by engineering firm #1.
- Electrical is designed by the engineer from firm #2.
- Control and communications is designed by engineering firm #3.
This is all done with virtually no construction oversight and with startup, testing, training and other tasks being performed by others.
The real story is that the package engineers and suppliers—who also prefabricate and oversee delivery, construction, startup, testing and training—are what makes packaged pump systems so popular today.
Pumping systems for all water types are inherently more complex today than they were 30 years ago. The pumping systems of today, whether they are simple or complex, are being designed and built by companies whose only job is designing, prefabricating, delivering, constructing, starting, testing, training and documenting pumping systems.
Packaged pump systems, whether small or large, simple or sophisticated, are pumping all types of water. On the smaller end, they are often identical systems, and that in and of itself is an advantage. On the larger end, they are more sophisticated and not in any way identical, but they are designed and engineered with a common set of hands.
In other words, all structural, mechanical, electrical, control and communication is done by one company that also does the work of prefabricating, quality control, shipping, overseeing the construction, starting, testing, documenting, training and warrantying.
Pumping system packages have come a long way, and as in other industries, it is no longer necessary to buy the parts and hope they all fit together. Users no longer need to rely on a contractor to understand the full intention of the engineer. They no longer must settle for less or more than they want or need. Instead, they can buy a package that will do what they need and do it in a manner that is both efficient and affordable.
For more on packaged pumping systems, visit pumpsandsystems.com/tags/packaged-pumping-systems.
