Case Study on the Functional Performance of a large

Wastewater Pumping Station

Stefan Gerlach1*, Rita Ugarelli2, Paul Uwe Thamsen1

Abstract
In this paper a case study on a large wastewater pumping station is conducted. In a Fault Tree
Analysis the critical assets within a wastewater pumping station are identified and the root
causes for critical failures are discussed. The relevant Performance Indicators (PIs) for
centrifugal pumps are presented and the significance for a PI including wastewater properties
and performance under wastewater conditions is discussed. The performance of the critical
wastewater pumps in the observed wastewater pumping station is analyzed. An approach for
ISROMAC 2016 risk assessment for clogging of wastewater pumps is described and a strategy to counter
International clogging problems is addressed.
Symposium on
Transport
Phenomena and
Dynamics of
Rotating Machinery Keywords
Wastewater pump — Clogging — Risk — Functional Efficiency Index — Centrifugal Pump
Hawaii, Honolulu
1
April 10-15, 2016 Department of Fluid System Dynamics, Technische Universitaet Berlin, Berlin, Germany
2
Department of Hydraulic and Environmental Engineering, NTNU, Trondheim, Norway
*Corresponding author: [email protected]

INTRODUCTION
1. CURRENTS STATE THE WASTEWATER
Climate change, demographics and water-sensitive PUMPING STATION
behaviour put a great strain on the urban wastewater The pumping station analysed in this paper is a large
system by changing amounts, composition and behaviour of pumping station in an urban area. With a connected
wastewater. Especially, combined sewer systems face big catchment area of more than 250,000 inhabitants and about
changes of loads between dry-weather runoff as the 750km of sewer system this main pumping station delivers
minimum and stormwater as maximum load. Additionally about 45,000m³/day of dry-weather run-off to the three
operating conditions, the challenging fluid “Wastewater” and connected wastewater treatment plants. The power
the regulatory background [1],[2],[3] create an operational consumption of the 8 installed pumps ranges from 40 kW
frame for the main wastewater pumping station that results up to 455 kW for electrical power and up to 711 kW for
in a high risk of failures. Especially fibres and textile diesel-driven peak-load pumps. These machines are used
structures within the wastewater lead to frequent failures in to pump from 100 l/s during nights up to 1450 l/s during rain
wastewater pumps due to clogging. events.
The pump setup is redundant.
In a structured approach based on the frame of Integrated
Asset Management (IAM) the case study is oriented along
the “Five Core Management Questions” of IAM. The
necessary steps are addressed below:

• Status: What is the current state of the assets?

• Performance: What is the required Level of Service?
• Risk: Which of the assets are critical?
• Costs: What are my best minimum lifecycle cost CIP
and O&M strategies?
• Plan: Given above, what are the best long-term
funding strategies?

Figure 1. Wastewater Pumping station [8]

The most common way wastewater pumping stations are
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 2

operated in is on-off-operation. The volume of the suction in the system.

chamber is used as a buffer. Once a specific water level is
reached fixed speed pump operation is started. Once the The Fault Tree Analysis (FTA) for the wastewater pumping
level falls below a defined minimum pumping is stopped. station results in the main events leading to a critical failure
For high levels parallel operation of multiple pumps can be of the whole pumping station. Figure 3 shows that out of 8
implemented. pumps only 4 pumps contribute to a failure of the whole
The use of Variable Speed Drives (VSD) allows adjusting pumping station under certain conditions.
the pump operation according to the inflow. In the observed
pumping station a so-called level-controlled operation is
used. Figure 2 shows the schematic layout of a level-
controlled pump operation. Each box shows the flow rates
the specific pump delivers according to the respective level
in the pump sump. The left boundary of each box shows the
flow rate at minimum pump speed and the right boundary
the flow rate at maximum pump speed for the pump or
pump combination.
Below a specific minimum level in the suction chamber
pump operation is stopped. Once the level increases above
this minimum the smallest pump is started with minimum
speed. If the level in the suction chamber increases further Figure 3. Fault Tree Analysis for the observed Wastewater Pumping
the pumps speed is also increased. If maximum pump Station showing clogging as a root cause for critical failure
speed is reached, the small pump is stopped and the mid-
Pump 1 to Pump 4 are the large and peak-load pumps of
sized pump starts operation with minimum speed. As long
the pumping station. Two out of these four pumps are
as the level still increases the pump speed is also increased
needed to deliver the required quantities of wastewater
accordingly. The next step is parallel operation of mid-sized
during peak-load or rain operation.
pumps. For peak loads and emergencies parallel operation
While Pump 1 and Pump 2 are driven electrically, Pump 3
of mid-size and peak-load pumps is implemented.
and 4 have diesel engines. The allowed operating hours for
the diesel engine are limited by clean-air regulations.
In this context the FTA identifies Pump 1 and Pump 2 as
the most critical pumps in the pumping station.

2. PERFORMANCE OF THE WASTEWATER

PUMPING STATION

2.1 PERFORMANCE INDICATORS

The evaluation of performance of pumps in pumping
systems is generally based on hydraulic characteristics and
energy considerations such as energy-efficiency or
specific energy Es.[1]
Figure 2. Scheme for level-controlled operation based on
The evaluation of the performance of wastewater pumps
actual operating schemes provided by Berliner
Wasserbetriebe however is more difficult. At this moment, the European
Commission is implementing energy-efficiency regulation
In many cases urban wastewater systems are set up for wastewater pumps in the frame of the European
hierarchically with a number of wastewater pumping Ecodesign Directive[11]. In a preliminary study it was shown
stations spread over the catchment area that transport the that no standard exists to link the pump performance to
wastewater to one or more main pumping stations. These anything other than energy-efficiency [1]. However, the
main pumping stations pump the wastewater through performance of wastewater pumps is evaluated through the
pressure lines to the wastewater treatment facilities. The following parameters:
first step to identify the crucial pumping station is a criticality
analysis of the wastewater network. The observed • Hydraulic performance
catchment area includes only one main pumping station • Efficiency
that is fed by a gravity sewer system. Naturally this main • Reliability
pumping station is identified as most critical pumping station
Pumps are designed for a specific hydraulic task, i.e. a
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 3

specific flow rate at a specific head. Any deviation between extended by wastewater characteristics. It contains
this design point and the actual operating point results in wastewater classes based on the degree of contamination
loss of energy-efficiency. DC and the pumps degree of functional performance D F for
The operating point itself is predefined by system conditions the specific wastewater class and the degree of long-term
and characteristic pump curve. Any change of system functional performance DLTF.Pump testing is done using
conditions, i.e. system pressure, or flow conditions within artificial wastewater represented by clear water with added
the pump, i.e. clogging, result in a shift of the operating dusters. The artificial wastewater simulates textiles and
point. fibers that are found in real wastewater and result in pump
clogging.
The efficiency of pumps is evaluated in accordance to ISO
The degree of contamination DC describes the actual
9906 [12]. This standard defines the testing setup, the contamination of the artificial wastewater used for the
testing conditions and the measurement setup to obtain specific pump test compared to a defined maximal
data on hydraulic performance and energy demand. It contamination. Clear water results in D C=0 and testing with
describes solely the hydraulic performance for clear water highest contamination results in D C=1. The mechanical
operation. A market-study [4] for the most-common impeller properties of the artificial wastewater used for testing are not
types already shows that different impeller types for only defined by amount of textiles used for simulating the
wastewater pumps result in different expected energy- behavior of rags and fibers in real wastewater (DC), but also
efficiencies for clear water operation. A direct comparison of their size and their material.
existing wastewater pumps can only be conducted under The pumps actual capability of handling the specific degree
the consideration of the real operating conditions, including of contamination is evaluated during the actual experimental
equal compositions of wastewater. pump test and results in DF and DLTF. Where DF is the dry-
weight of material that passed the pump during the test
compared to the total dry-weight of textiles in the artificial
wastewater and DLTF assesses the resistance against
accumulative clogging by observing changes of the pumps
efficiency.
and are scaling factors. The tasks of on-going research
are the clear definition of different wastewater classes that
allow pump testing using artificial wastewater with the same
mechanical properties and actual pump testing to describe
pump performance for contaminated fluids.
The FEI therefore represents the total efficiency ratio for the
Figure 4. Mean efficiencies of wastewater pumps for different pump extended by wastewater performance. This new
impeller types according to power consumption [4] Performance Indicator can support the decision process of
pump selection for specific tasks in wastewater transport.
On-going research in cooperation with the pump
manufacturers associations EUROPUMP is showing the The most crucial Performance Indicator for wastewater
different performance of different impeller technologies
pumps is Reliability. Pump failures, especially for the large
under real wastewater conditions. It is already known that
pumps, are a high risk for the failure of the pumping station
vortex impellers operate with the low energy-efficiencies but
also with high reliability for difficult wastewater compositions as a whole. As shown in the Fault Tree Analysis [Figure 3]
especially for high textile or fibre load. Other impeller different failure types contribute to pump failures.
designs however show higher efficiencies but operate with Mechanical and electrical failures are assessed using
lower reliability. To define a scientific foundation for the MTBF (Mean Time between Failures), failures per 1000
comparison of reliability for different impeller types is focus operating hours or similar markers. Additionally condition
of present research at the TU Berlin. monitoring is commonly used to monitor critical assets to
To increase the significance of wastewater pump testing predict failures and plan predictive maintenance.
a new Performance Indicator has to be defined. Within a
research project with the pump manufacturers The reliability against clogging of wastewater pumps is
associations the Function-Efficiency-Index FEI is influenced by [2], [3]:
proposed[5]:
𝜌∙𝑔∙𝐻∙𝑄 (1) • Wastewater composition
𝐹𝐸𝐼 = (𝛼 ∙ 𝐷𝐶 + 𝛽 ∙ 𝐷𝐹 + 𝛾 ∙ 𝐷𝐿𝑇𝐹 ) ∙
𝑃 • Operational conditions
where ρ is the water density, g is gravitational constant, H is • Impeller geometry
lifting height (pressure increase) and Q is the flow delivered • (Maintenance)
by the pump, altogether representing the pump output P Q.
The required power is P. The ration of P Q and P is the pump
In opposition to pumps in clear water operation, where
efficiency for clear water operation. The energy-efficiency is
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 4

failure occurs mainly because of ageing or wear of 100

components, wastewater pumps fail due to clogging.

Total number of clogging events

78 78
Obviously the wastewater composition contributes greatly to 80
this type of failure. Large solids result in clogging if the 60
pumps ball passage is exceeded. More commonly pumps
are clogged by accumulations of fibres. Here geometric 40
dimensions, material and surface conditions, but also 4 5 13 11 6 1
20
existence of other substances, such as fat, contribute to
0
clogging. P1 P2 P3 P4 P5 P6 P7 P8
It was also shown that operating conditions, i.e. operating
point, pumps speed, influence the clogging behavior of Figure 6. Distribution of clogging events for the installed
wastewater pumps. [3] pumps in a period of 12 month

These number exceeded mechanical or other failures by

far. In most cases, the clogging material could be removed
through a service opening at the pump. In some cases the
pumps had to be disassembled resulting in costs exceeding
1000€ per assignment. The common clogging mechanism
is ragging in front of the impeller. Actual observation shows
slow accumulations of fibrous material in front of the
impellers that subsequently lead to failure of the pumps.
It shows that the most critical pumps in the pumping station
are also the pumps with the highest rate of failures due to
clogging.

Figure 5. Different impeller types for wastewater application

[9,10]

Finally, manufactures have developed many different

impeller types and shapes with different behaviors in
wastewater operation (Figure 5).

These parameters evidently show that the performance of

wastewater pumps is not only defined by the pump type, but
additionally by the conditions they are operated in. To this
date, there are no existing standards or testing procedures
that consider their impact on the actual pump performance.

2.2 Actual performance of critical pumps at the

observed pumping station
2.2.1 Reliability
Figure 7. Fibre accumulation in front of the impeller and
The task of the observed pumping station is the safe
transport of wastewater from the sewer system to the pump cleaning at the observed pumping station [8]
connected wastewater treatment plants. Apart from energy-
considerations, the hydraulic performance and the reliability 2.2.2 Hydraulic performance and Energy-
of the pumping station are of main concern. efficiency
Figure 8 shows the theoretical Characteristic Pump Curve
The observed pumping station shows a clear distribution of
for Pump 2 at 780 rpm and the specific System Curve for
failure events for the last years. While most of the pumps
the connected wastewater pressure line to the connected
show a low number of clogging events, Pump 1 and Pump
Wastewater Treatment. Also included are actual operating
2 show equally high numbers of failures. In the observed
points for pump speeds between 580rpm and 630rpm in
period of 12 month, both pumps clogged 78 times, resulting
comparison to the scaled pump curves for these speeds.
in a high demand for manual cleaning(Figure 6).
All data was gathered from the operators’ data-
management system over the course of one year. The flow
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 5

rate Q is measured at the pressure main exit of the This behaviour is supported by level-controlled operation of
wastewater pumping station using a Magnetic Flow Meter. the pumping station. Once the level in the suction chamber
This setup allows direct flow measurement only for single reaches the starting level for Pump 1 or Pump 2, one of the
pump operation, since multiple pumps are feeding the pumps is started at the lowest pump speed of 580rpm. As
pressure main. The pump head H is calculated from long as the level in the suction chamber is increasing, the
pressure sensors at suction side and discharge directly at pump speed is gradually increased. In case of beginning
the pump and the flow rate at the pressure main. Only accumulation of fibres in the impeller, the actual delivered
single operation is considered for the data analysis. All flow rate decreases resulting in increasing water levels in
sensors are installed according to their specification and are the suction chamber thus increasing the pump speed. While
routinely calibrated. the accumulation of fibres grows pump speed increases
Theoretically all operating points should fall between the while the actual operating point shift further away from the
scaled pump curves close to the theoretical System Curve. theoretical Performance Curve.
Operating points that fall below the scaled pump curve for
580rpm are affected by clogging.

Figure 10. Pump 2: Actual attained flow rates for all pump
speeds
Figure 8. Pump 2: Theoretical Characteristic Pump Curve
for Pump 2 and actual operating points for pump speeds Figure 10 shows that the actual hydraulic capacity of the
580rpm – 630rpm pumping station is limited. Increased accumulation of fibres
affect flow rates to an extent where increasing pump
While for low pump speeds most operating points are not speeds cannot deliver higher flow rates, but flow rates
affected by clogging the picture changes for higher pumps actually decrease.
speeds. Especially for the highest speeds it is shown that This behaviour is shown for all pump speeds using
the actual pump performance is affected by clogging to high dimensionless coefficients in Figure 11.
extend and the observed pump never actually works under
design conditions when operated with full pump speed.
[Figure 9]

Figure 11: Pump 2: Pressure coefficient over flow coefficient

Pump 2 actual operating points in comparison to the
theoretical pump performance curve for all pump speeds
Figure 9. Pump 2: Theoretical Characteristic Pump Curve
for Pump 2 and actual operating points for pump speeds Head and flow rate are presented through pressure
730rpm – 780rpm coefficient and flow coefficient. These are dimensionless
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 6

values of the head and the flow rate. The pressure failures due to the difficult fluid to be pumped. Failures that
coefficient 𝜓 is defined by: are connected to the service life are countered by detailed
2∙𝑔∙𝐻 (2) maintenance of the pump units. Condition Monitoring is
𝜓= 2 2 2
𝜋 ∙𝑛 ∙𝐷 used for predictive maintenance. These procedures are
where g the gravitational acceleration in m/s², H the head defined by the operator and are not connected to clogging.
in m, n the rotational speed in 1/s and D the impeller Failures through externalities for wastewater pumps are
diameter in m. hard to predict. The main parameter leading to failures is
The flow coefficient 𝜑 is described by: the wastewater itself in connection to the used pump. At this
4∙𝑄 (3) moment, there are no known deterministic or statistic
𝜑=
𝜋² ∙ 𝑛 ∙ 𝐷³ models that link wastewater composition and pump type to
where Q the flow rate in m³/s, n the rotational speed in 1/s failure probabilities. On the one hand, it is impossible to
and D the impeller diameter in m. predict the wastewater composition for any given time; on
the other hand, there are no existing performance indicators
It is shown that the actual pump operation is strongly for wastewater pumps that describe the ability of handling
influenced by clogging for all pump speeds. textiles or solids during operation. The proposed FEI will
support the decision process for choosing the right
The consumed electrical power for the pumps is only wastewater pump for a specific task. In-depth knowledge of
measured at the electric feed of the Variable Speed Drives. wastewater compositions for the planned application are to
Since the efficiency of the motors and the variable speed be provided by the operator. At this time research on
drives are not constant but functions of different operational mechanical properties of wastewater components is only
parameters such as speed, current and torque, a precise starting.
determination of the pumps power consumption is not Anyhow, it is already seen that certain parameters have a
performed at the pumping station. A calculation of energy- negative effect on wastewater pump performance:
efficiency for the pumps is not done. The decreased • Single events: Wastewater transports all sizes of
hydraulic power transferred by the pumps due to clogging solids that can enter the system at any place up-
results in an overall drop of energy-efficiency. stream the pumping station. This ranges from small
debris, to dead animals and bricks from canals, up
3. Risks and costs to car tires or truck tarpaulins. Failure events
The risks analysis for the pumping station is done according connected to large fibre accumulations or solids are
to an adapted scheme provided by Eiswirth et al. [6] for the impossible to predict.
condition assessment for pipes in 2001. Figure 12 was • Ragging: Ragging is a gradual accumulation of
adapted to fit the conditions of the observed pumping textiles, tissues and fibres in the wastewater pump.
station. This process can be supported by starts and stops
The risk of failure is a combination of the probability of of the pump. Gradual ragging of impellers can be
failures and the consequences connected to the occurring the objective of clogging detection and counter-
failures. measures at the pump.
• Wastewater composition and impeller type: At
the moment, pump manufacturers describe the
capabilities of their pumps for handling different
wastewater “classes” very vaguely. Wastewater
classes are only described by their origin, e.g.
municipal, industrial, and not by their actual load
with fibres or textiles. The capability of handling
those classes is described by good, neutral or bad.
• Weather influence: Rain events lead to first-flush
effects the lead to increased loads of solids and
fibres in the wastewater. The missing link between
wastewater composition and actual pump
performance does not allow any calculation.
Figure 12. Risk Assessment for wastewater pumping • Critical operating points and VSD operation:
stations Certain operating conditions aggravate the
occurrence of clogging in wastewater pumps. It was
The probability of pump failure is determined by failures observed that low pump speeds and part-load
connected to the service life of the pump and external operation increase the risk of clogging [3]. Low
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 7

pump speeds with low flow rates result in described parameters, additional knowledge to use for
sedimentation of material in the suction chamber. future planning cannot be derived. For mechanical failures,
Sediments are remobilised when flow rates increase low MTBF values create a high pressure of action, resulting
and can result in higher failure rates. in exchange of equipment, change of suppliers or improved
maintenance strategies. For wastewater pumping stations
The consequences of failure at the observed pumping the pressure is equally high, while above strategies will
station are divided into external cost driven by service most likely not improve the situation.
disruption, community disruption and environmental costs
and cost directly connected to the clearance of failures. The 4. Plan
redundant setup-up of the observed pumping station High failure risk for the critical pumps at the observed
reduces the risk for external disruption and damage to a pumping station and a high number of complaints call for
minimum. Residents of adjacent buildings however file action. An exchange of equipment is no option. On the one
complaints about vibrations that are connected to operation hand different pumping technology for this specific task is
of clogged pumps. More detailed information was not not available on the market and on the other hand a
available to the author. prediction of the actual performance of other impeller
technologies for example is at this time not possible.
The costs that are connected to the clearance of failures at A strategy to reduce the impact of clogging on the actual
the observed pumping station were calculated to an pump performance should be based on counter-measures.
average 310,00€ per assignment in the observed 12 month. Especially detection of beginning fibre accumulations in
Number of failures and connected clearance cost allow a front of the impeller connected to automated cleaning
brief calculation of Failure Rates, MTBF, Risk per day and procedures show a high potential of reducing complaints
actual Costs per year. due to vibration and reducing cost by decreasing the
amount of manual work for cleaning clogged pumps.
𝐹𝑎𝑖𝑙𝑢𝑟𝑒𝑠 (4) In the IMEBA Project several active and passive counter-
𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑅𝑎𝑡𝑒 =
365𝑑 measures were proposed [7].
At this point it is planned to implement the Measure
1 (5) Cleaning Sequence at the pumping station. In a two stage
𝑀𝑇𝐵𝐹 =
𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑅𝑎𝑡𝑒 approach data is collected to support the set-up of a
clogging detection tool, while simultaneously the technical
preconditions for implementing VSD-driven “Cleaning
𝑅𝑖𝑠𝑘 𝑝𝑒𝑟 𝑑𝑎𝑦 = 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐶𝑜𝑠𝑡 ∙ 𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑅𝑎𝑡𝑒 (6) Sequence” based on variations of pump speeds are worked
out.

𝐶𝑜𝑠𝑡𝑠 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 = R𝑖𝑠𝑘 𝑝𝑒𝑟 𝑑𝑎𝑦 ∙ 365𝑑 (7) 5. Conclusion

A Fault Tree Analysis was used to identify critical pumps for
the safe operation of the observed pumping station. The
Table 1. Cost calculation for the observed pumping station root causes for failures were identified and it was shown
Number of Failure MTF Average Risk per that the most critical pumps show the highest rate of
failures Rate [days] cost day Cost [year]
Pump 1 78 0,21 5 310,00 € 66,25 € 24.180,00 € failures. An analysis of the hydraulic performance of the
Pump 2 78 0,21 5 310,00 € 66,25 € 24.180,00 € wastewater pumping station discovered that clogging not
Pump 3 4 0,01 91 310,00 € 3,40 € 1.240,00 € only leads to pump failures but also reduces the attainable
Pump 4 5 0,01 73 310,00 € 4,25 € 1.550,00 €
Pump 5 13 0,04 28 310,00 € 11,04 € 4.030,00 € flow rates greatly. Additionally clogging results in a loss of
Pump 6 11 0,03 33 310,00 € 9,34 € 3.410,00 € energy-efficiency.
Pump 7 6 0,02 61 310,00 € 5,10 € 1.860,00 €
Pump 8 1 0,00 365 310,00 € 0,85 € 310,00 €
A risk assessment scheme is proposed that shows the
60.760,00 € different influential parameters on pump clogging and the
lack of deterministic or statistical models was discussed.
Table 1 shows that two pump units at the observed A possible approach to counter pump clogging by
pumping station account for two thirds of the overall failure implementation of early-detection and an automated
clearance costs during the observed 12 month. In this case, cleaning sequence was presented.
this simplified approach already allows identifying the main
objectives for the implementation of risk reduction ACKNOWLEDGMENTS
measures to increase the reliability of the pumping station.
The overall significance of the calculated MTBFs is missing. This paper is based on work within the KURAS project. The
Due to the high influence on the clogging behaviour of the joint research project “KURAS – Concepts for urban
 Case Study on the Functional Performance of a large Wastewater Pumping Station — 8

stormwater management and wastewater systems” is [11] EUR-Lex. Directive 2009/125/EC of the European
funded by the German Federal Ministry of Education and Parliament and of the Council of 21 October 2009
Research and is a research consortium of fourteen establishing a framework for the setting of ecodesign
cooperation partners. Their contributions to the project’s requirements for energy-related products. Brussels. 2005
progress and various inputs to the paper are highly
appreciated. [12] ISO 9906. Rotodynamic pumps -- Hydraulic performance
acceptance tests -- Grades 1, 2 and 3. Geneva. 2012

NOMENCLATURE
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