Design recommendations

for pump stations with vertically installed Flygt axial

and mixed flow pumps
Contents
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

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 Flygt PL and LL pump introduction
Our Systems Engineering team offers in-depth ex- Flygt submersible vertically installed axial flow
pertise in the design and execution of comprehen- pumps (PL) and mixed flow pumps (LL) have been
sive solutions for water and wastewater transport used in a wide variety of storm water stations and
and treatment. sewage treatment plants, land drainage and irriga-
tion systems, fish farms and power plants, shipyards,
Our know-how and experience are combined with a amusement parks and many other applications
broad range of suitable products for delivering cus- where large volumes of water have to be pumped.
tomized solutions that ensure trouble-free opera-
tions for customers. Our engineers utilize our own Flygt submersible PL and LL pumps
custom developed computer programs to provide offer important advantages such as:
evaluations for your specific project design. • Compact motor and pump unit
• No separate lubrication system
Flygt not only can provide assistance with the se- • No external cooling system
lection of products and accessories but can pro- • Low operating sound level
vide analysis for complex systems and/or piping • Quick connection and disconnection
networks. for installation and inspection
• Minimal station superstructure
We also provide hydraulic guidance and assistance • Simple pipe work
for flow-related or rheological issues. Assistance
can include but is not limited to hydraulic transient Flygt PL and LL pumps are usually installed in a ver-
calculations, pump starting calculations, and evalua- tical discharge tube on a support flange incorporat-
tion of flow variations. ed in the lower end of the tube. No anchoring is re-
quired because the weight of the pump is sufficient
Additional services to keep it in place. The pumps are equipped with
• Optimization of pump sump design an anti-rotation gusset. This arrangement provides
for our products and specific sites the simplest possible installation – the pump is just
• Assistance with mixing and aeration lowered into the discharge tube by hoist or crane.
specifications and design of Retrieval of the pump is equally simple.
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 axial flow pumps (PL) Flygt mixed flow pumps (LL)

4
General considerations Hydraulically, three zones of the pumping station
for pumping station design are significant: inlet, forebay and pump bay.
The 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 Pump bay
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 Forebay

also augment vortices.

• Vortices with a coherent core cause discontinuities
in the flow and can lead to noise, vibration and Inlet area
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. • Inlet: An inlet conveys water to the pumping
station from a supply source such as a culvert,
Experience with designs already in use provides valu- canal or river. Usually, the inlet has a control
able guidelines for the design of multiple pump sta- structure such as a weir or a gate.
tions. Adaptations of existing and well-proven designs • Forebay: The role of the forebay is to guide the
can often provide solutions to complex problems even flow to the pump bays in such a way that it is
without model tests. We have extensive experience uniform and steady. Because the inflow to each
based on many successful projects, and the services module should be steady and uniform, the design
of our qualified engineers are always available. of the forebay feeding the individual modules
is critical and should follow guidelines in this
For special applications beyond the scope of this brochure. Design of the forebay depends on
brochure, please contact our local system engineer water approach to the pumping station commonly
for assistance. encountered as parallel with the sump centerline,
the preferred layout, or perpendicular to the
Pumping station with multiple pumps sump centreline.
Multiple pump systems provide greater capac- • Pump bay: In practice, only the design of the
ity, operational flexibility and increased reliability, pump bay can be standardized for a given pump
which is why pumping stations are usually equipped type. A properly designed bay is a prerequisite
with two or more pumps. for correct presentation of flow to the pumps, but
it does not guarantee correct flow conditions. A
Transition to the sump, whether diverging, converg- bad approach to the pump bay can disturb the
ing or turning, should result in nearly uniform flow at flow in the pump intake. As a rule of thumb, the
the sump entrance. Obstacles that generate wakes approach velocity to the individual pump bays
should not be allowed to interfere with the approach- should not exceed 0.5m/s (1.64ft/s). The dimensions
ing flow. High velocity gradients, flow separation from of the bay’s individual modules are a function of
the walls and entrainment of air should be avoided. pump size and the flow rate (see Appendix 4).

5
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 High level front inlet
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 side inlet

Low level side inlet

Culvert or canal inlet

6
Pump bay design alternatives Open sump intake design
Enclosed intake design This intake design is the most sensitive to non-uniform ap-
Enclosed intake design are the least sensitive to dis- proaches. If used for more than three pumps, the length
turbances of the approaching flow that can result from of the dividing walls should be at least 2/3 of the total
diverging or turning flow in the forebay, or from single width of the sump. If flow contraction occurs near the
pump operation at partial load. Therefore, enclosed sump entrance because of screens or gates, the sump
intake design are nearly always the preferred choice length should be increased to 6D or more, depending on
and recommended for stations with multiple pumps the degree of contraction.
with various operating conditions.

Corner fillets Enclosed suction intake Corner fillets Dividing wall

Dividing wall

Flow straightening vane (splitter) L-shaped flow straightening vane (splitter)

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

Corner fillets Enclosed suction intake Corner fillets Dividing wall

Dividing wall

Flow straightening vane (splitter) L-shaped flow straightening vane (splitter) with cone

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

Enclosed intake design can be constructed in either Open sump intake design includes devices such as
concrete or steel. The intake reduces disturbances and flow straightening vanes (splitters) that alleviate the ef-
swirl in the approaching flow. The inclined front wall fects of minor asymmetries in the approaching flow.
prevents stagnation of the surface flow. Geometrical The minimum required submergence of the pump inlet
features of the intake provide smooth acceleration and with open sump intake design is a function of the flow
turning as the flow enters the pump. The minimum rate, the pump inlet diameter and the distribution of the
inlet submergence should not be less than nominal flow at the approach to the pump. Minimum submer-
diameter (D). gence diagrams are shown in the Appendix 2. Each

7
diagram has three curves for various conditions of the Model testing can also be employed to seek solu-
approaching flow. Because vortices develop more read- tions to problems in existing installations. If the cause
ily in a swirling flow, more submergence is required to of a problem is unknown, it can be less expensive to
avoid vortices if the inlet arrangement leads to disturbed diagnose and remedy with model studies rather than
flow in the sump. Hence, the upper curve in the sub- by trial and error at full scale. The pump manufactur-
mergence diagrams is for a perpendicular approach, er’s involvement is often required in the evaluation of
the middle one is for the symmetrical approach and the the results of model tests. Experience is required to
lowest curve for duty-limited operation time (about 500 determine whether the achieved results are satisfac-
hours/year). The curve appropriate to the inlet situation tory and will lead to proper overall operation.
should be used to determine the minimum water level in
the sump to preserve reliable operation of the pumps. We can offer guidance regarding the need for
model tests and assist in their planning, arrange-
Pump station model testing ment and evaluation.
Hydraulic models are often essential in the design of
structures that are used to convey or control the flow Computational modeling
distribution. They can provide effective solutions to Computational fluid dynamics (CFD) analysis has the
complex hydraulic problems with unmatched reliabil- potential of providing far more detailed information
ity. Their costs are often recovered through improve- of the flow field at a fraction of cost per time needed
ments in design that are technically better and yet for the model tests. It has been more and more ac-
less costly. Model testing is recommended for pump- cepted as a tool in station design in combination with
ing stations in which the geometry differs from rec- Computed Aided Design (CAD) tools. It is possible to
ommended standards, particularly if no prior experi- obtain a more efficient method for numerical simula-
ence with the application exists. Good engineering tion of station design utilizing CFD. It offers increased
practice calls for model tests for all major pumping sta- qualitative and quantitative understanding of pump-
tions if the flow rate per pump exceeds 2.5 m3/s (40 ,000 ing station hydraulics and can provide good compar-
USgpm) or if multiple pump combinations are used. isons between various design alternatives. However,
the possibilities of CFD should not be overestimated.
Tests are particularly important if: Difficult cases are encountered where free surface
• Sumps have water levels below the effects are important. Also, a phenomenon like air en-
recommended minimum submergence trainment is difficult to capture with CFD analysis.
• Sumps have obstructions close to the pumps
• Sumps are significantly smaller or larger than Both model tests and CFD have advantages and disad-
recommended (+/- 10%) vantages that need to be evaluated in each individual
• Multiple pump sumps require baffles to control case. We can advise on a good combination between
the flow distribution model tests and CFD.
• 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.
8
Corrective measures or from erosion of the propeller blades. They can be elim-
The designs described in this brochure have been inated by disturbing the formation of stagnation points
proven to work well in practice. However, in some ap- in the flow. The flow pattern can be altered, for example,
plications–perhaps due to limitations of space, installa- by the addition of a center cone or a prismatic splitter
tion of new pumps in old stations, or difficult approach under the pump, or by insertion of fillets and bench-
conditions–not all the requirements for a good, simple ing between adjoining walls, as in some of our standard
design can be met. Sometimes, for example, it may be configurations.
impossible to provide adequate submergence so that
some vortexing or swirl may occur. Corrective measures Air-entraining vortices may form either in the wake of the
must then be undertaken to eliminate the undesirable pump tube or upstream from it. They form in the wake
features of the flow, particularly those associated with if the inlet velocity is too high or the depth of flow is
excessive swirl around the pump tube, with air-entrain- too small. Also, they form upstream if the velocity is too
ing surface vortices and with submerged vortices. low. In either case, these vortices can be eliminated by
introducing extra turbulence into the surface flow, i.e. by
Swirl around the pump tube is usually caused by an asym- placing a transverse beam or baffle at the water surface.
metrical velocity distribution in the approach flow. Ways Such a beam should enter the water at a depth equal to
should be sought to improve its symmetry. Subdivision about one quarter of the tube diameter and be placed at
of the inlet flow with dividing walls, and the introduction a point about 1.5–2.0 diameters upstream of the tube. If
of training walls, baffles or varied flow resistance are the water level varies considerably, a floating beam can
some options that may achieve this result. Alternatively, be more effective. In some cases, a floating raft upstream
a reduction of the flow velocity, for example, by increas- of the tube will eliminate air-entraining vortices. This raft
ing the water depth in the sump, can help to minimize may be a plate or a grid. Both forms impede the formation
the negative effects of an asymmetrical approach. of surface vortices. An alternative is the use of an inclined
plate similar to that shown in the draft tube installation.

1.5–2.0D D

Back wall and floor

splitter plates.
Surface baffle for
vortex suppression
D/4

Back wall vortex caused

by floor splitter only.

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.
Floating raft or
vortex breaker grid
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

9
Installation alternatives
The following examples show possible alternatives using Flygt designed installation components.

Installation type 1 Installation type 3

Suitable for pumping liquid

to a receiving body of water
with small level variations or This arrangement may be
where a short running time used with either a free
can be expected, so non-re- discharge, when liquid is
turn valves are not required. pumped to a receiving body
of water with small water
This arrangement is simple. level variations, or with a flap
It involves the least possible number of steel com- valve, when the water level on
ponents. The pump is set in a circular concrete shaft the outlet side varies
with a relatively short tube grouted in place, instal- considerably so that the
lation component D3, which is used as the support outlet is occasionally submerged. The flow is discharg-
structure for the pump. Alternatively, the shaft can ing into a closed culvert through the component E1.
have a rectangular cross-section above the dis-
charge column. The shaft extends above the maximum Installation type 4
water level in the outlet channel to prevent water from
running back to the sump when the pump is shut off.

Installation type 2

This arrangement is suitable

An alternative to the con- whenever the liquid is
crete shaft is to place the pumped to a receiving body
pump in a steel column of water with a varying water
with a collar that rests on level. The outlet is equipped
a supporting frame (instal- with a flap valve to prevent
lation component D1). The back-flow. When the pump is
top of the pipe must extend not in operation, the valve
sufficiently above the maxi- closes automatically, prevent-
mum water level to prevent ing water from running back
back-flow from the outlet into the sump. The static
channel. 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
Installation type 5

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.

11
Installation components Vertical discharge column (D)
The objective in the design and development of in- in which the pump is set Depending upon the depth
stallation components is to devise simple systems, of the station, the installation may consist of one
which offer a wide variety of options to deal with most part (D1) or several parts joined together by flanges
situations. These components have been developed (D2), or it may consist of a short tube prepared for
to facilitate design work and estimation of costs. grouting in concrete (D3).
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 D1 D2 D3
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. Discharge elbows (E)
with rectangular exit flange (E1) and discharge elbows
with circular exit flanges (E2, E3, E4).

Flygt FSI

E1 E2 E3

Cover (C) Column bracket (B) Supporting frame (F)

for discharge elbows (E1 and E2 for anchoring the tube for suspending the tube
from ceiling.

C B F

12
Cable protection and suspension Installation of pumps
for tube installed pumps Pump installation can be
For tube-installed submersible pumps, proper cable facilitated with the aid of
protection and suspension is essential for trouble the Dock-Lock™ device
free operation. Cable suspension and protection for easy and safe retriev-
requirements become more stringent with longer al of pumps in a wet well.
cable lengths and higher discharge velocities. 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.

Flygt cable seal units

for pressurized tube (column)

Flygt cable suspension system

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 The Flygt cable seal
as other cables. units with Roxtec seal-
• Cables should be bundled together, using ing technology are
components which will not cut or abrade the used to make a water
cables. tight cable entry into a
• Proper strain relief and support at prescribed discharge column with
intervals (depending on length) should be water tight cover.
provided Spring-controlled tensioning and an
integrated “guide wire” are recommended for The cable seal units are
long cable lengths . complete with frame,
Roxtec cable seal mod-
We offer a variety of cable protection and suspen- ules, tightening wedge,
sion accessories with recommendations to suit lubricant and installa-
all types of installations and running conditions. tion manual.
Contact your local Application engineer for infor-
mation on the best system to meet your needs.

13
Appendix 1: Head losses diagrams for Flygt designed discharge arrangements

Appendix 1: Head losses diagrams for

Flygt designed discharge arrangements

Head losses are comparatively small for systems 16” Installation pipe inner diameter (D)
using propeller pumps. Even so, an accurate predic- Flygt PL7020
tion of losses, and hence the total required head,
is crucial when selecting the best pump. Propeller H (in)
E1, E5
pumps have relatively steep head and power char- E1
E1 W=16 K=0.45
acteristics, and an error in predicting the total head E5 W=24 K=0.37 HS=Static head
H=Head loss
25 E5 W=31 K=0.35
can result in a significant change in the power re- E5 W=39 K=0.34
H

HS

quired. A potentially vulnerable situation can arise E5 W=47 K=0.33

20 D
if head loss is significantly underestimated, which H=
Q
2
3

can mean that a pump operates against a higher K W 2g

15
head, delivers less flow and uses more power.
Conservative assumptions should thus be made in
10 E5 Side E5 Top
determining head loss calculations. For all installa- 16 19

tions described herein, the head losses that must H

W
5 HS

be accounted for occur in the components of the D

discharge arrangement (friction losses in short pipes 0

HS=Static head H=Head loss

0 2000 4000 6000

are usually negligible). The loss coefficients and the Q(USgpm)
head loss as a function of the flow rate for the system
components designed by Flygt are shown in the dia- H (in)
E2
grams. For system components not covered by this E2
E2 Dout=14 K1=1.41
document, loss coefficients can be obtained from 40 E2 Dout=16 K1=1.13
E2 Dout=14 K2=0.85
their manufacturers or from appropriate literature.
Do
35 E2 Dout=16 K2=0.77 r

D
30
r
K1: Sharp bend =0
25 Do
r
K2: Smooth bend > 0.1
Do
20

15

10

0
0 2000 4000 6000
Q(USgpm)

H (in)
E3, E4
E3 E4
E4 Dout=14 K3=0.60
18 E3 Dout=14 K3=0.55 Do Do
E4 Dout=16 K3=0.35
16 E3 Dout=16 K3=0.32
14 D D

12

10

0
0 2000 4000 6000
Q(USgpm)

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

20” Installation pipe inner diameter (D) 22” Installation pipe inner diameter (D)
Flygt PL7030 Flygt PL7035

H (in)
E1, E5 H (in)
E1, E5
E1 E1
E1 W=20 K=0.45 E1 W=22 K=0.45
E5 W=30 K=0.37 HS=Static head E5 W=32 K=0.37 HS=Static head
30 H=Head loss 30 H=Head loss
E5 W=39 K=0.35 H E5 W=43 K=0.35 H
E5 W=49 K=0.34 HS
E5 W=54 K=0.34 HS

25 E5 W=59 K=0.33 25 E5 W=65 K=0.33

D D
2 2
Q 3 Q 3
H= H=
20 K W 2g 20 K W 2g

15 15

E5 Side E5 Top E5 Side E5 Top

10 20 24 10 22 26

H H
W

W
HS HS
5 5
D D

HS=Static head H=Head loss HS=Static head H=Head loss

0 0
0 2000 4000 6000 8000 10000 12000 0 2000 4000 6000 8000 10000 12000
Q(USgpm) Q(USgpm)

H (in)
E2 H (in)
E2
E2 E2
E2 Dout=18 K1=1.35 E2 Dout=20 K1=1.33
40 E2 Dout=20 K1=1.13 35 E2 Dout=22 K1=1.13
E2 Dout=18 K1=0.83 Do E2 Dout=20 K2=0.82 Do

35 E2 Dout=20 K2=0.77 r
E2 Dout=22 K2=0.77 r
30
D D
30
r 25 r
K1: Sharp bend =0 K1: Sharp bend =0
Do Do
25
r r
K2: Smooth bend > 0.1 20 K2: Smooth bend > 0.1
Do Do
20
15
15
10
10

5 5

0 0
0 2000 4000 6000 8000 10000 12000 0 2000 4000 6000 8000 10000 12000
Q(USgpm) Q(USgpm)

H (in)
E3, E4 H (in)
E3, E4
E3 E4 14 E3 E4
E4 Dout=18 K3=0.53 E4 Dout=20 K3=0.51
16 E3 Dout=18 K3=0.49 E3 Dout=20 K3=0.47
Do Do Do Do
E4 Dout=20 K3=0.35 12 E4 Dout=22 K3=0.35
14 E3 Dout=20 K3=0.32 E3 Dout=22 K3=0.32

12
D D 10 D D

10 8

8
6
6
4
4
2
2

0 0
0 2000 4000 6000 8000 10000 12000 0 2000 4000 6000 8000 10000 12000
Q(USgpm) Q(USgpm)

15
Appendix 1: Head losses diagrams for Flygt designed discharge arrangements

24” Installation pipe inner diameter (D) 28” Installation pipe inner diameter (D)
Flygt PL7040 Flygt PL7045, PL7050

H (in)
E1, E5 H (in)
E1, E5
E1 E1
E1 W=28 K=0.45 E1 W=28 K=0.45
35 E5 W=35 K=0.37 HS=Static head 35 E5 W=41 K=0.37 HS=Static head
H=Head loss H=Head loss
E5 W=47 K=0.35 H E5 W=55 K=0.35 H
E5 W=59 K=0.34 HS
E5 W=69 K=0.34 HS
30 E5 W=71 K=0.33 30 E5 W=83 K=0.33
D D
2 2
25 Q 3 25 Q 3
H= H=
K W 2g K W 2g

20 20

15 15
E5 Side E5 Top E5 Side E5 Top
24 28 28 33
10 10
H H
W

W
HS HS

5 D
5 D

HS=Static head H=Head loss HS=Static head H=Head loss

0 0
0 2000 4000 6000 8000 10000 12000 14000 16000 0 2000 4000 6000 8000 10000 12000 14000 16000
Q (USgpm) Q(USgpm)

H (in)
E2 H (in)
E2
E2 E2
E2 Dout=20 K1=1.55 E2 Dout=20 K1=2.55
E2 Dout=24 K1=1.13 45 E2 Dout=20 K2=2
70
E2 Dout=20 K2=0.99 Do E2 Dout=24 K1=1.45 Do
E2 Dout=24 K2=0.77 40 E2 Dout=28 K1=1.13
r r
60 E2 Dout=24 K2=0.9
D 35 E2 Dout=28 K2=0.77 D

50 r r
K1: Sharp bend =0 30 K1: Sharp bend =0
Do Do
r r
40 K2: Smooth bend > 0.1 25 K2: Smooth bend > 0.1
Do Do
20
30
15
20
10
10
5

0 0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 0 2000 4000 6000 8000 10000 12000 14000 16000 18000
Q (USgpm) Q(USgpm)

H (in)
E3, E4 H (in)
E3, E4
E3 E4 E3 E4
24 E4 Dout=20 K3=0.73 E4 Dout=20 K=1.34
E3 Dout=20 K3=0.66 Do 28 E3 Dout=20 K=1.23 Do
Do Do
E4 Dout=24 K3=0.35 E4 Dout=24 K=0.65
E3 Dout=24 K3=0.32 E3 Dout=24 K=0.60
20 24 E4 Dout=28 K=0.35
D D D D
E3 Dout=28 K=0.32
16 20

16
12
12
8
8

4
4

0 0
0 2000 4000 6000 8000 10000 12000 14000 16000 0 1500 3000 4500 6000 7500 9000 10500 12000 13500 15000 16500 18000
Q (USgpm) Q(USgpm)

16
 Appendix 1: Head losses diagrams for Flygt designed discharge arrangements

32” Installation pipe inner diameter (D) 36” Installation pipe inner diameter (D)
Flygt PL 7055, PL 7061, PL 7065, LL 3356 Flygt LL 3400

H (in)
E1, E5 H (in)
E1, E5
E1 E1
E1 W=31 K=0.45 E1 W=35 K=0.45
45 E5 W=47 K=0.37 HS=Static head E5 W=53 K=0.37 HS=Static head
H=Head loss 30 H=Head loss
E5 W=63 K=0.35 H E5 W=71 K=0.35 H
40 E5 W=79 K=0.34 HS
E5 W=89 K=0.34 HS
E5 W=94 K=0.33 25 E5 W=106 K=0.33
30 2
D
2
D
Q 3 Q 3
H= H=
25 K W 2g 20 K W 2g

20 15

15 E5 Side E5 Top E5 Side E5 Top

32 37 10 35 43

10 H
W
H

W
HS HS
5
5 D D

HS=Static head H=Head loss HS=Static head H=Head loss

0 0
0 5000 10000 15000 20000 25000 0 2000 4000 6000 8000 10000 12000 14000 16000
Q(USgpm) Q(USgpm)

H (in)
E2 H (in)
E2
E2 E2
55 E2 Dout=24 K1=2.15 E2 Dout=28 K1=1.9
E2 Dout=24 K2=1.62 E2 Dout=31 K1=1.38
50 E2 Dout=28 K1=1.41 Do 12.5 E2 Dout=28 K2=1.37 Do
E2 Dout=31 K1=1.13 r
E2 Dout=35 K1=1.13 r
45 E2 Dout=28 K2=0.85 E2 Dout=31 K2=0.84
40 E2 Dout=31 K2=0.77 D
10 E2 Dout=35 K2=0.77 D

r r
35 K1: Sharp bend =0 K1: Sharp bend =0
Do Do
r r
30 K2: Smooth bend > 0.1 7.5 K2: Smooth bend > 0.1
Do Do
25
20 5
15
10 2.5
5
0 0
0 5000 10000 15000 20000 25000 0 2000 4000 6000 8000 10000 12000 14000 16000
Q(USgpm) Q(USgpm)

H (in)
E3, E4 H (in)
E3, E4
E3 E4 E3 E4
E4 Dout=24 K=1.11 E4 Dout=28 K4=0.96
E3 Dout=24 K=1.01 Do 7 E3 Dout=28 K3=0.87 Do
Do Do
25 E4 Dout=28 K=0.60 E4 Dout=31 K4=0.56
E3 Dout=28 K=0.54 E3 Dout=31 K3=0.51
E4 Dout=31 K=0.35 6 E4 Dout=35 K4=0.35
D D D D
20 E3 Dout=31 K=0.32 E3 Dout=35 K3=0.32
5

15 4

3
10
2
5
1

0 0
0 5000 10000 15000 20000 25000 0 2000 4000 6000 8000 10000 12000 14000 16000
Q(USgpm) Q(USgpm)

17
Appendix 1: Head losses diagrams for Flygt designed discharge arrangements

40” Installation pipe inner diameter (D) 48” Installation pipe inner diameter (D)
Flygt PL 7076, PL 7081 Flygt PL 7101, PL7105, LL 3531, LL 3602

H (in)
E1, E5 H (in)
E1, E5
E1 E1
E1 W=39 K=0.45 55 E1 W=47 K=0.45
40 E5 W=59 K=0.37 HS=Static head E5 W=71 K=0.37 HS=Static head
H=Head loss H=Head loss
E5 W=79 K=0.35 H 50 E5 W=94 K=0.35 H
35 E5 W=98 K=0.34 HS
E5 W=118 K=0.34 HS
E5 W=118 K=0.33 45 E5 W=142 K=0.33
30 2
D 40 2
D
Q 3 Q 3
H= H=
35
25 K W 2g K W 2g

30
20
25
15 E5 Side E5 Top 20 E5 Side E5 Top
39 47 47 57
15
10 H H
W

W
HS
10 HS

5 D D
5
HS=Static head H=Head loss HS=Static head H=Head loss

0 0
0 5000 10000 15000 20000 25000 30000 35000 0 10000 20000 30000 40000 50000 60000
Q (USgpm) Q(USgpm)

H (in)
E2 H (in)
E2
E2 E2
E2 Dout=31 K1=1.75 E2 Dout=39 K1=1.51
E2 Dout=35 K1=1.35 45 E2 Dout=47 K1=1.13
30
E2 Dout=31 K2=1.2 Do E2 Dout=39 K2=0.99 Do
E2 Dout=39 K1=1.13 40 E2 Dout=47 K2=0.77
r r

25 E2 Dout=35 K2=0.83 r
E2 Dout=39 K2=0.77 D 35 K1: Sharp bend =0 D
Do
r r
K1: Sharp bend =0 30 K2: Smooth bend > 0.1
20 Do Do
r
K2: Smooth bend > 0.1 25
Do
15
20

10 15

10
5
5

0 0
0 5000 10000 15000 20000 25000 30000 35000 0 10000 20000 30000 40000 50000 60000
Q (USgpm) Q(USgpm)

H (in)
E3, E4 H (in)
E3, E4
E3 E4 E3 E4
E4 Dout=31 K=0.85 E4 Dout=39 K=0.73
E3 Dout=31 K=0.78 22.5 E3 Dout=39 K=0.66
18 Do Do Do Do
E4 Dout=35 K=0.53 E4 Dout=47 K=0.35
E3 Dout=35 K=0.49 20 E3 Dout=47 K=0.32
12 E4 Dout=39 K=0.35
E3 Dout=39 K=0.32 D D 17.5 D D

10
15

8 12.5

10
6
7.5
4
5
2
2.5

0 0
0 5000 10000 15000 20000 25000 30000 35000 0 10000 20000 30000 40000 50000 60000
Q (USgpm) Q(USgpm)

18
 Appendix 1: Head losses diagrams for Flygt designed discharge arrangements

56” Installation pipe inner diameter (D)

Flygt PL 7115, PL 7121, PL 7125

H (in)
E1, E5
E1
75 E1 W=55 K=0.45
70 E5 W=83 K=0.37 HS=Static head
H=Head loss
65 E5 W=110 K=0.35 H
E5 W=138 K=0.34 HS
60 E5 W=165 K=0.33
55 D
2
50 Q 3
H=
45 K W 2g

40
35
30
E5 Side E5 Top
25 55 67
20
H
15 HS
W

10 D
5 HS=Static head H=Head loss

0
0 20000 40000 60000 80000 100000 120000
Q(USgpm)

H (in)
E2
E2
75 E2 Dout=47 K1=1.45
70 E2 Dout=55 K1=1.13
65 E2 Dout=47 K1=0.9 Do
E2 Dout=55 K2=0.77 r
60
r
55 K1: Sharp bend =0 D
Do
50 r
K2: Smooth bend > 0.1
45 Do
40
35
30
25
20
15
10
5
0
0 20000 40000 60000 80000 100000 120000
Q(USgpm)

H (in)
E3, E4
E3 E4
E4 Dout=47 K=0.65
E3 Dout=47 K=0.59
30 Do Do
E4 Dout=55 K=0.35
E3 Dout=55 K=0.32
25 D D

20

15

10

0
0 20000 40000 60000 80000 100000 120000
Q(USgpm)

19
Appendix 2: Submergence diagram for open sump intake design

Appendix 2: Submergence diagram

for open sump intake design

The minimum required submergence of the pump S (in)

Flygt PL 7020
inlet with open sump intake design is a function of
the flow rate, the pump inlet diameter and the dis-
80
tribution of the flow at the approach to the pump.
Each diagram has three curves for various conditions 60
of the approaching flow. Because vortices develop
more readily in a swirling flow, more submergence 40

is required to avoid vortices if the inlet arrange-

20
ment leads to disturbed flow in the sump. Hence,
the upper curve in the submergence diagrams is 0
0 1000 2000 3000 4000 5000 6000 7000
for a perpendicular approach, the middle one is for Q(USgpm)
the symmetrical approach and the lowest curve for
duty-limited operation time (about 500 hours/year). S (in)
Flygt PL 7030
The curve appropriate to the inlet situation should
be used to determine the minimum water level in the
80
sump to preserve reliable operation of the pumps.
60
Note: NPSH required for specific duty point may
supersede submergence requirements. 40

20
Lateral approach
Symmetrical approach
0
Limit of operation (500 hours/year) 0 2000 4000 6000 8000 10000
Q(USgpm)

S (in)
Flygt PL 7035

100

80

60

40

20

0
0 2000 4000 6000 8000 10000 12000
Q(USgpm)

S (in)
Flygt PL 7040
120

100

80

60

40

20

0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000
Q(USgpm)

20
 Appendix 2: Submergence diagram for open sump intake design

S (in)
Flygt LL 3356 S (in)
Flygt PL 7055, PL 7061, PL 7065
140

75 120

60 100

80
45
60
30
40

15 20
0 2000 4000 6000 8000 10000 0 5000 10000 15000 20000 25000
Q(USgpm) Q(USgpm)

S (in)
Flygt LL 3400 S (in)
Flygt PL 7076, PL 7081

80
90

60

60
40

20 30
0 4000 8000 12000 16000 20000 0 5000 10000 15000 20000 25000 30000 35000
Q(USgpm) Q(USgpm)

S (in)
Flygt LL 3602 S (in)
Flygt PL 7101, PL 7105

150
100

120
80

60 90

40 60

20 30
0 1000 2000 3000 4000 0 10000 20000 30000 40000 50000 60000
Q(USgpm) Q(USgpm)

S (in)
Flygt PL 7045, PL 7050 S (in)
Flygt PL 7121, PL 7125

210
100
180
80
150
60
120

40
90

20 60

0 30
0 5000 10000 15000 20000 0 2000 4000 6000 8000 10000 12000
Q(USgpm) Q(USgpm)

21
22
 Appendix 3: Sump layout alternatives

Appendix 3: Sump layout alternatives

Stations with low level front inlet Stations with high level side inlet (max 4 pumps)

A–A D A–A
D
W.L.
B D

0.75D 0.75P
0.75D
B B
max 10°

B
B–B B–B P
Vmax=0.1m/s
(2ft/s)
D

to avoid sedimentation
Vmax=1.0m/s Vmax=0.3m/s Vmax=1.7m/s
(3ft/s) (1ft/s) (5ft/s)
A A
B

B
10° (max 20°)

max D max(2/3B or L)

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

Stations with low level side inlet (max 4 pumps) Stations with high level front inlet (max 4 pumps)

A–A D A–A D

W.L.
B 0.75D

B
~ 0.5P

B
0.75D
0.75P

B–B B–B
P 1.25P
P

Vmax=0.5m/s D
Vmax= (2ft/s)
1.2m/s Vmax=
(4ft/s) 1.7m/s
(5ft/s)

A A
B

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

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

23
Appendix 4: Pump bay alternatives

Appendix 4: Pump bay alternatives

Enclosed intake in steel for Flygt PL pumps Enclosed intake in concrete for Flygt PL pumps
C C
A–A C–C A–A C–C
H G H H G
°

D
60

D
max W.L.
max W.L.
B B B
min W.L. B
min W.L.

˚C
N

60
S
S

C C

M
P
C
M
P

B B
J J
K B–B K
L min Splitter
A–A F
L min Splitter
F E

E
W 2
A A
W
E
W 2

W 2
A A

E
W

W 2
E

B–B
C

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

PL7045
28 14 14 28 11 22 31 14 28 42 114 22 11 28 56
PL7050
PL7055
31 16 16 32 13 26 35 16 32 48 126 26 12 32 64
PL7061
PL7065 31 16 16 32 13 26 35 16 32 48 126 26 12 43 64
PL7076
39 20 20 40 16 32 44 20 40 60 162 32 15 40 80
PL7081
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

24
 Appendix 4: Pump bay alternatives

Flygt FSI
C
A AA
–A D C–C

max W.L.

B min W.L. B
S

M
C

B–B L
W 2

A A
W

Recommended dimensions
Nom. dia
Pump type (in) B C D E F G H J K L M N P S W
PL7045
28 14 16 28 - - - - - - 58 21 - - 28 44
PL7050
PL7055
32 16 19 31 - - - - - - 69 25 - - 31 52
PL7061
PL7065 32 16 25 31 - - - - - - 69 25 - - 43 52
Flygt FSI

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

25
 Appendix 4: Pump bay alternatives

Open sump design for Flygt PL pumps Open sump design for Flygt LL pumps
C C
A–A C–C
A AA– A D C–C D

D
min W.L. max W.L.

B B B B
S

S
C
P

C
P
N

M E
B B
J P J
K
2xD
BB– BB
L Splitter B–B E Splitter
E with cone

E
E

W 2
W 2

A A A A
W
W

W 2
W 2

E
E

C
C

Recommended dimensions
Nom. dia
Pump type (in) B C D E F G H J K L M N P S W
PL7020 16 12 8 16 8 - - - 20 28 63 8 4 6 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
submergence diagram

PL7045
28 21 14 28 14 - - - 34 48 114 14 7 11 56
See minimum
intake design
Open sump

PL7050
PL7055
PL7061 32 24 16 32 16 - - - 40 56 126 16 8 12 64
PL7065
PL7076
40 30 20 40 20 - - - 50 70 162 20 10 15 80
PL7081
PL7101
48 36 24 48 24 - - - 60 84 192 24 12 18 96
PL7105
PL7121
56 42 28 56 28 - - - 70 98 222 28 14 21 112
PL7125
submergence diagram

LL3356 32 24 16 32 16 - - - 40 56 64 16 8 12 64
See minimum
intake design
Open sump

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

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

26
 440 . Design recommendations . 1 . US . 2 . 20121024
1) The tissue in plants that brings water upward from the roots
2) 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.

Flygt is a brand of Xylem. For the latest

version of this document and more
information about Flygt products visit
www.flygt.com