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ACKNOWLEDGEMENTS

I wish to express my appreciation to Mr. Lyle
Whitsitt, Highland.Park City Engineer, Mr. George
Golden, Water wOrks Superintendent, Mr. Irving
Dahljelm, Chemist in charge of the Filter’Plant,
and the Pump House Operators for their cooperation
in carrying out the work connected with this thesis.
I also wish to thank Prof. Frank R. Therouz, of the
Michigan State College Civil Engineering Department,

for valuable guidance and assistance.

UP: 5.1mm 5
E‘V’EMTFP ~21."

n ' aw "(30K

TABLE OF CONTENTS

Acknowledgements
Introduction - ----------------- 1
General Layout of Highland.Park Water System - - 3

Pumps in General - -------------- 10
Methods of Testing Pumps ----------- 15
Test Results -------------- a - - 19
Conclusion ------------------ 35

Bibliography

Efficiency Studies
at the

Highland Park Pumping Station

A Thesis Submitted to

The Faculty of
MICHIGAN STATE COLLEGE
of
ACEICULEUEE AND APPLIED SCIENCE

by

William N. Rieger

Candidate for the Degree of

Bachelor of Science

June l9hl

erq:q

It is the aim of every public water department to de-
liver water to the consumer at the lowest possible cost. ’To
accomplish this aim, it is essential that the most efficient
equipment obtainable be used.

Today, more and more public water departments realize
that, under most conditions, motor-driven centrifugal pumps
are able to furnish the necessary water more economicallyifimn
any other type of pumping equipment. Some of the larger cen-
trifugal pumps of modern design are able to attain efficien-
cies as high as ninety per cent.

It seems to be a rather general practice for water
departments using the motor-driven centrifugals to forget all
about the efficiency of the pumps, once they are installed or
to assume that they are going to maintain their efficiency in-
definitely.

When new pumps are installed, acceptance tests are
made to determine whether or not the pumps will accomplish
what the specifications called for. In many cases these are
the only tests ever made on the pumps, or ever intended t1:
be made. To illustrate this point, let me give an example
of what was done at the Highland Park Pumping Station. Be-
fore giving the example, however, I want to say that I am
not making a criticism.of the Highland Park Water Department
specifically, but am.making the criticism of water depart'-

ments in general, because similar things have been done at

other plants.

tr)
CS
f X
'9. I
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pi“:
L1

-2-

The pumps at the above mentioned station are set on
a concrete base about six inches above the floor level. The
intakes for the pumps extend vertically downward below the
center of the pumps. When first installed the concrete
bases were not filled in solid, but there was an open space
allowing access to the discharge line where it extends thro
the floor. When the original tests were made, a hole was
tapped in the flange which is situated just above the floor
level in the intake line, but below the top level of the
concrete base, to which a mercury U-tube gage could be con-
nected for the tests. After the tests were completed the
base was filled in with concrete, completely covering this
flange, thus indicating that no tests in the future were
contemplated.

When you buy a new automobile, the dealer tells you
that you will get 25 miles per gallon of gasoline, so you
try it out and find out for yourself that you do get 25 miles
per gallon. 'Yet, do you assume from this test that after
the automobile is two or more years old, it will still go 25
miles on a gallon of gasoline? The wise motorist will make
an occasional check of his gasoline mileage, and when it
decreases a considerable amount he concludes that something
is wrong, and that he will save money by having it repaired,
or by getting a new automobile. The same reasoning can, and
should be, applied-to pumps.

Certainly, we cannot expect pumps to maintain the il-
itial efficiency year after year. As any other piece of

equipment, they too, become worn and become less efficient.

Every water department should make a practice of
making periodical tests on its pumps and when there is a
considerable drop in efficiency, necessary action should
be taken to correct this condition of inefficiency.

It will be my purpose to make a check on the ef-
ficiency of the pumps at the Highland Park Davison.Ave.

Pump Station, and to suggest improvements where needed.

GENERAL LAYOUT OF HIGHLAND PARK WATER SYSTEM

The Highland Park water supply is taken from Lake
St. Clair at a point about i mile from the shore, near
Seven Mile Road and Lake Shore Drive.

A Pumping station equipped with three 8 MGD and
three 10 MGD centrifugal pumps takes the water from the
lake through a 30” cast iron pipe line and delivers it
to the Filter Plant, located at Davison and Dequindre
Awenues - a distance of fourteen miles.

In front of the filter plant the 50" lake line di-
vides into two 30' lines, one of which leads to the open
storage reservoir, and the other of which enters the pump
house. (see print No. l) The system is so arranged that
the amount of water being used at the time goes into the
pump house line, while the excess goes into the storage
reservoir thro the other 30" line.

The water which enters the pump house is disposed
of in two ways. Part of it is pumped directly from the
30" line to the Ford motor Plant by pumps No. 7 and No. 8.
The remainder goes through the filtration process and

thence into the city mains.

The water which.goes thro the filter plant flows
under the influence of the head furnished by the Grosse
Pointe pumps. Just before leaving the pump house chlorine
and alum.are added - about 1.5 to 2.0 ppm of chlorine be-
ing used to give more efficient operation of the filter
beds.

After the chlorine and alum are added, the water
passes thro a baffled mixing chamber and then into the
coagulating basin, where sedimentation takes place. From
the coagulating basin the water goes into the filters. Be-
fore entering the filters powdered activated carbon is
added for removing odors and tastes.

The filter plant consists of sixteen units, each
having an area of 0.00785} acres, with a gravel bed of
about 18 to 2h inches, and sand layer of about 30 inches.
The filters are operated at a rate of l MGD per unit,
which is equivalent to about 125 MED per acre of filter
area.

From the filters the water goes into the clear
well, which has a capacity of 3 M.G., and is located di-
rectly beneath the filter plant. After final chlorina-
tion, to insure a residual of 0.2 ppm, the water is led
by a h2" pipe line to the pump house whence it is pumped
into the distribution system.

The pump house is equipped with nine centrifugal

pumps, arranged as shown on.Print No.2. Pumps No. 3, h,
5, 6, and 9 are ordinarily used to pump the filtered

water.

-5-

 

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Starting Switch

-8-

All pumps are single stage, double suction pumps
equipped with the volt, 5 phase, 60 cycle, General Electric
Motors. With the exception of pump No. 9, all are the Rees
Roturbo type, manufactured by the Manistee Iron Works 00.,
Manistee, Michigan. Pump No. 9 is a Worthington pump, man-
ufactured by the Worthington Pump and Machinery Corporation
of Harrison, New Jersey. Details of the various pumps are
given in Table 1.

Two 2h? feeder lines lead from the pump station to
the distribution system. One of these enters the system at
Davison and Oakland Avenues, and the other at Oakland and
McLean.

A 250,000 gallon elevated storage tank, with a 50"
riser pipe, maintaining a 125' head is connected into the
system.just outside the pump station. The purpose of this
tank is to prevent surging and to maintain a more or less
constant pressure in the distribution system.

The aforementioned open storage reservoir is of re-
inforced concrete construction with dimensions of
1380' x 250' x lh'-6" and a capacity of hB MbG. It is di-
vided into two parts, so that half of it may be cleaned
without disrupting service. As stated before, if more
water is pumped from the lake than is being used at present
the excess goes into the reservoir. If, however, an in-
sufficient amount is being pumped from the lake, the differ-
ence can be made up from the reservoir supply. With the
reservoir full, water will flow by gravity thro the filter
plant, unless the filters are operating at a rate greater
than 8 MGD. In such a case, the water is pumped by pumps

PUMP NO.

\Om-NimU'I-P'WNH

RATED
CAPACITY
MGD

5

\nmmmm

11

O\

-9-

Table 1

RATED
HEAD

FT

100
100
120
120
125
125

155

HP

100
100
150
150
150
150
60
he
85

MOTOR

RPM

1150
1150
1200
1200
1200
1200
680-720
680-720
1800

-10-

7 and 8, through a 5h" concrete conduit leading from the
reservoir. The piping is so arranged that these pumps can
pump to the Ford Motor Co. and to the filter plant at the

same time.

PUMPS IN GENERAL

In any water supply pumping station, two items are
of primary importance, namely, quantity and variability.
Pumping units must be provided to satisfy the maximum
demand and the units must be of such size that the pumping
rates can be varied to conform.with the rates of consump-
tion.

It is a well known fact that pumps operate most
efficiently under the conditions for which they were de-
signed. Operating pumps at rates greater or less than
that for which they were designed, results in a consider-
able decrease in efficiency, as will be seen in the test
results which will be given later. Therefore, it will be
seen that maximum efficiency results if units of such size
are provided that they can operate at rated capacity and
supply the demand under the various conditions.

Consumption rates vary from hour to hour, from day
to day, and from month to month. The reasons for these
variations will not be discussed here but typical values
will be given to show that such variations do exist and
that they are of considerable amount. Figure 1 shows the
hourly pumping rates for a typical day, while Tables 2

and 5 show the daily and monthly variations, respectively.

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DAILY PUMPING RECORDS
FOR THE MONTH
OF
JANUARY, 1959

 

 

 

 

GROSSE PTE. HIGHLAND PK. FILHHHHD FORD
PUMP HOUSE PUMP HOUSE
6,827,000 5,180,000 h.h70.000 710,000
- 5, 887, 000 5, 280, 000 2,550,000 750, 000
7,112, 000 7,100, 000 ,100,000 1, 000, 000
7, 298, 000 7,150,000 6,090,000 1, 060, 000
7, 271, 000 7,090,000 6,150,000 960, 000
7, 2gu,000 2,1 0,000 6,190,000 980, 000
7,2 000 ,2 0,000 5,550,000 890, 000
7,255,000 g, ,150, 000 .h00.000 750,000
7, 205, 000 ,7 0, 000 6,020,000 250, ,000
7,10 ,000 6,7 0, 000 M180 000 20 000
7, lb, 000 z, ,100, 000 6, 210, 000 890, 000
72 $6 000,850,000 5, Do, 000 910, 000
7,858, 000 6,520,000 5, 10, 000 910, 000
7,712, 000 5, 920, 000 “080 000 880, 000
5,152, 000 2,0 0,000 u,guo, ,000 00,000
7,85 h,000 ,6 0,000 2, 50, 000 50,000
7,0§u,000 7, 90,000 70, 000 920,000
7,0 2 000 7, 00,000 6, 90, 000 1,110,000
7,055, 000 2,060,000 6, 010, 000 1,050,000
7,092,000 ,620,000 5, 910, 000 710,000
7,079,000 6,050,000 5,280, 000 750,000
6,666,000 ,520,000 8,650, 000 670,000
,511,000 ,790,000 2, ,890, 000 900, 000
,09 ,000 7,100,000 060, 000 1 ,OhO, 000
5,15 ,000 7,1 0,000 6,150, 000 1, 000, 000
7,7 1,000 . z,1 0,000 6,150,000 1, 010, 000
13,0 ,000 ,920,000 5,990,000 50,000
01h,000 6,550,000 5,510,000 20,000
g, 638, ,000 5,?80,000 2.,750,000 750, 000
, 2 000 7, 60 000 570, 000 1,090,000
8,197,000 9,000 000 7,720,000 1, 280, 000
22u,999,000 205,550,000 178,010,000 27,520,000
G.P.P.H. H.P.P.H.
Daily Average 7, 2 8,000 6 ,630, 000
max. Daily 1 ,000 9, 000, 000
Min. Daily 3? 511, 000 5.0h0. 000

Electric Cost
Electric Cost per M.G.

3 1,571.68 3 1 ,219. 09

509

GPPH.

January 22h,999
February 205,55u
March 2153708
April 205,0h5
May 225:1hl

JUne 218,2h6
July 2789511
August 2523961
September228,l65

October 21 ,122
November 18 .109
December 199,092

January 209,516
February 19 ,975
March 20 ’79

April‘ 1999064
May 215!h08
June 2299581
July 22192 3
August 2 5,9 2
September227,529

October 253,285
November 2 6,855
December 2 6,600

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-14..

Since the pumping station is equipped with four 5 max)
pumps and a 3 MGD pump, ‘79 may conclude by referring to
Figure 1 that the 81268 Of the pumping units are satisfactcry
with respect to variability.

Maximum pumping rates to be provided are dependent
upon two things, first, the maximum ordinary consumption,
and second, fire demand.

I am going to assume a maximum ordinary demand of
10,000 6PM. The fire demand for a city of 50,000 popula-
tion, which is approximately the Population of Highland

Park, is 6,500 GPM, based on a table compiled by the National

Board of Fire Underwriters.1 This gives a total maximum de-

mand of 16,500 GPM. The plant is equipped with four _
3,1;20 GPM and one 1.8110 GPM pumps, having a total output of
15,520 GPM, and two 3,1190 GPM pumps (1 8c 2) which can also
be put on the line, thus giving a maximum output of

22,520 GPM, which is certainly an ample amount to take care
of any conditions which might arise.

Bulletin No. 116, National Board of
Fire Underwriters, "Water Supply for

Municipal Fire Fighting", Jan. 15,
191.1.

-15-

METHODS OF TESTING PUMPS

The acceptance tests on pumps are usually made to a
considerable degree of accuracy in order to be sure that the
pumps come up to the guarranteed standards. Subsequent
tests are usually run merely as a check to see Whether or
not there has been any considerable loss in performance.

In making pump tests three things must be measured:
the head pumped against, the power input into the motor,
and the amount of water pumped.

The head pumped against consists of the pressure
on the discharge side of the pump, the suction lift, and
the frictional loss in the intake line. The discharge
head is measured by means of a pressure gage placed on the
discharge side of the pump. The suction head is usually
determined by attaching a mercury U-tube on the intake
side of the pump, in.vhich case the frictional loss in the
line is included in the U-tube reading. In this case the
total head is equal to the discharge head plus the suction
head measured by the U-tube and.the difference in elevaticn
6f the pressure gage and the point where the U-tube is
connected into the intake line. 4

Under certain conditions it is possible to‘connect
one side of the Ubtube to the pressure side of the pump
and the other side to the intake side of the pump, in

thich case the total head pumped against is registered
by the U-tube.

-15-

Often it is inconvenient to connect a U-tube to the:
intake side of the pump. In such a case, the discharge
pressure is measured in the usual way and the suctidn head
is determined by measuring from the water surface from
which the water is being pumped to the center of the pump
and arbitrarily adding a foot or two for frictional losses
in the intake line. The frictional losses can be estimated
quite accurately by taking into consideration the amount
of pipe and the number of fittings through which the water
flows and the velocity of the water through them. In this
case the total head pumped against is the sum of the
discharge head, the difference in elevation of the water
surface and the center of the pump, and the estimated
frictional loss. This latter method is the one which
was used in making the present tests.

The power input into the motor is measured by one
of two methods. The first method, commonly called the
disc constant method, involves the use of a kilowatt-hour
meter. In this method it is necessary to count the
number of revolutions of the meter disc during a period

of time. The horsepower is then computed from the formula,

R x K x M_“

H.P. =
.2072 x t

 

where, R is the number of revolutions of the disc, t is
the time in seconds for this number of revolutions, K is
the disc constant, and M is a multiplying factor obtained
by multiplying the current transformer ratio by the

potential transformer ratio. The factors K and‘M are

-17-

usually given on the name plate of the meter but if they are
not given they can be obtained from the manufacturer.

The second method of measuring power input involves
the use of a kilowatt, or watt meter. In this case the rate
of kilowatt consumption is given by the meter. To obtain
the horsepower input it is necessary only to divide the
kilowatt input by 0.7%. since 1 H.P. = 0.7% KW. In
equation form,

H.P. = KW

This second method is the one which was used in making our
tests.

The amount of water pumped can also be measured in
one of several ways. Perhaps the simplest, and the one used
in our tests, is the use of Venturi meters. In important
tests Venturi meters should first be checked before relying
on their results.

A frequently used method of measuring the amount of
water pumped involves the use of weirs. In this case the
water pumped is run over a weir, and by measuring the depth
over the weir and the size of the notch the flow can‘be
calcuated by using one of the weir formulae. One of the

most used is King's formula,

Q: 3&th (155632)
-. B?
in.which Q 3 flow in c.f.s. (cubic feet per second)

L = length of the weir, in feet corrected for
end contractions

-18-

H head on the weir, in feet

D area of channel divided by L

This method of measuring the flow was used in making the ac-
ceptance tests on several of the present pumps.

Still another method of measuring the rate of pump-
ing is to pump the water into a tank of known dimension and
measuring the depth of water pumped in a specific time.

After the total head pumped against, the power input
and the pump discharge have been determined the “wire to
water" efficiency of the unit can be computed. "Wire to
waterf efficiency means the combined efficiency of the pump
and the motor.

By definition, efficiency is the ratio of the work
gotten out of a machine to the amount of work put into it.
Or, in our case, it would be the ratio of the horsepower

output to horsepower input. In equation form,

E - Egg'x 100
where, E ' efficiency in per cent
WHP I water horsepower I horsepower output
BHP = brake horsepower I horsepower input.

Water horsepower can be computed from the formula,

where, GPM I gallons pumped per minute

and, head = total head pumped against expressed in feet
Of Water 0

By taking a series of readings on each pump at dif-
ferent rates of discharge enough data is obtained to plot
the characteristic curves of the pump. This has been done

-19-

in our case and the present curves have been compared with
the original curves, where these curves have been available,
in order to show the difference between the pump perform-
anoe when the pump was installed and the present performance.

In comparing the efficiencies of old and new pumps,
the difference in efficiency of the two pumps is often re-
ferred to as the improvement. This, however, is incorrect.
The improvement is the difference in efficiencies divided by
the efficiency of the new pump. For example, if a pump
whose efficiency is 60% is replaced by one whose efficiency
is 80%, the improvement, or power saving, is s§3§6é2 or
25%.

Figure 2 gives an easy way of obtaining the power
saving without doing any computing. Run a straightedge
through.the efficiency of the new pump in Column A and of
the old pump in Column B, and read the improvement in

Column 0.

TEST RESULTS

Pumps No. l a. No. 2 Tested: May 13, 191.1

The present tests on these pumps were made under
very unfavorable conditions. They were pumping raw water
from the lake line and discharging through a six inch line
with four Openings which is much too small to handle the
required amount of water.

The results obtained show a very low efficiency, but
it must be remembered that the pumps were not opened up to

full capacity.

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-21-

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Since these pumps are very seldom used - usually a-
bout once a year - their low efficiency is not of much con-
sequence. However, should conditions become such that the
pumps would be needed more often, I would suggest that an-
other set of test be made under more favorable conditions,
if possible. Referring to Figure 2, it can be seen that by
replacing these pumps with pumps whose efficiencies would
be 80%’wou1d result in a power saving of approximately.h5%.

Pump No. 3 Tested: May 17, 19111

Referring to Figure 11, we see that the present
curves correspond quite closely to the test curves of
January 12, 1917. There is a slight drop in efficiency whidl
is to be expected, since the pump has been in operation fer
over 2h.years.

Let us, however, examine the savings in power cost
which could be expected if a pump of modern design.were in-
stalled. A modern pump of this size may be expected to give
a "wire to water” efficiency of 8011. .gt this rate pump
No. 3 has an efficiency of about 6h%. If a pump of 80%
efficiency were installed the savings in power cost would be
20%. Referring to the column in Table 3 which gives the
electric cost per M.G., we will assume a value of $6.00 per

M.G. The saving in cost per M.G. would be 20% of $6.00, or

1Beckwith, H. E. "Simple Method for Checking Pump

Effifiiencies', Water Works & Seweragg, Vol. 86,
D. So

 

-24-

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-26.-

$l.20. The question now arises as to whether a saving of
$1.20 in power costs per M.G. pumped would justify the pur-
chase of a modern pump. That is a question for the water
department officials to answer. my purpose is merely to

point out the possibilities.

Pump No. 1; Tested: May 16, 1911
A study of the test curves shows the tendancy of the
present curves to follow the slopes of the curves determined
by the tests of January 12, 1917. It will be noted, how-
ever, that the present efficiency curve runs higher than the
original, and the BHP curve runs lower. This indicates that
there is an error in measuring the amount of water delivered.
Judging from these curves, I w ould say that the Venturi
meter (meter No. 2) through.which this f10'"I88 measured was
in error. It registers high.- and considerably so. my re-
commendation is that this meter be checked and corrected im-

mediately. An erroneous meter is little better than no meter

at 3.110

Pump No. 5 Tested: may 10, 19h1

The original tests on this pump were made on July 27,
1920. It will be noted on.Figure 6 that the maximum effi-
ciency attained by pump No. 5 was 68%. This comparison is
indicative of the improvement of pump design.between 1917
and 1920.

The present efficiency is comparatively low with.re-
spect to the original. my recommendation is that another

test be run on this pump, and if the results are similar to

-27-

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those of the present test, then an investigation should be
made as to the cause of this decrease in efficiency. There
is a possibility that the impeller may be badly worn, or

that the motor needs repairing. In any case, the possibility
of increasing the efficiency 10% to 15% is certainly worth

an investigation.

Pump No. 6 Tested: May 10, 191:1

No comparison has been made between the present test
results and the original tests. I was unable to get the
curves for this particular pump because I could not find its
serial number. If the department wishes to make the compar-
ison, the original curve may be obtained by writing to the
manufacturer, and giving the serial number of the pump, if
it can be located.

Pumps No. 7 & No. 8

No tests were run on these pumps because of the dif-
ficulty which would be encountered in obtaining a constant
flow.

Pump No. 9

we went through the procedure of running a test on
this pump, but when it came to making the computations I
discovered that I had‘been reading an ammeter instead of a
kilowatt meter. Upon further investigation I found that
these are no means for measuring the power input to this
pump. If the power factor of the motor were known, the

power input could be computed from the voltage and

-52-

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-55-

amperage. However, the power factor would also vary with
the load, so at best, this method would be very crude.

I have included the general efficiency curves for
this particular type of pump so that if the department wishes
to make a test, the results may be compared with the design
efficiency.

If the department feels that it is not necessary to
have a kilowatt meter installed on this pump, a meter can.be
borrowed from any electric company so that tests can be

made.

CONCDUSION

It is my hope that the test results here given will
bring about the realization that occasional check-ups on
equipment are essential to economy of operation.

I believe that pumps should be tested at least once
a year. Some one man in the department should be put in
charge of this work, and it should be his duty to supervise
the tests, draw up the conclusions, and make recommendations
for improvements. This work would take up but several days
time each year, and I am convinced that the benefits derived
therefrom would more than pay for this time.

BIBLIOGRAPHY

Babbit & Doland, ”Water Supply Engineering", McGraw-Hill
Book 00., 1939.

Schoder & Dawson, "Hydraulics", Chapter XVIII, McGrawbfiill
Book Co., 1934. '

Pickels, George W,, "Drainage and Flood-Control Engineering",
Chapter X, McGraw-Hill Book Co., 1925.

Peerless Pump Division, "Catalog P-126", PP. 38-40.

National Board of Fire Underwriters, Bulletin 116, "Water
Supply For Municapal Fire Fighting", Jan. 15, 1941.

Schaphorst, W. F., "How To Compare Pump Efficiencies",
m 37335.3. 333 Sewerage, Jan., 1941, p. 43.

Beckwith, H. E., ”Simple Method For Checking'Pump Efficien-
cies", Egtgg'flggkg g Sewerage, Vol. 86, p. 445.

Angus, R. W., “An Improved Technique for CentrifugaléPump

Efficiency Measurements", Transactions 23 the

 

ASME, Vol. 63, No.1, p,13.

 

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