Mech System Design Guide

MECHANICAL
SYSTEM DESIGN GUIDE
MECHANICAL SYSTEM PROJECT GUIDE 1

Table of content
I. Introduction ........................................................................................................................................ 5
II. PROCESS MECHANICAL PIPING SYSTEMS DESIGN GUIDE .................................................................. 7
2.0 Phase 0 – Project Definition........................................................................................................ 8
2.0.1 Basic Information – Related to Piping Systems .................................................................. 8
2.0.2 Piping System Alternatives ................................................................................................. 9
2.0.3 Draft and Final Piping System Alternatives Memo ............................................................. 9
2.0.4 Technical Review Committee ............................................................................................ 10
2.1 Phase 1 – Conceptual Design .................................................................................................... 10
2.1.1 Initial Design Coordination Items – Related to Piping Systems ........................................ 10
2.1.2 Initial Piping Selection ....................................................................................................... 10
2.1.3 Additional Design Coordination Items ‐ Related to Piping Systems ................................. 11
2.1.4 Instrumentation and Controls ‐ Related to Piping Systems .............................................. 13
2.1.5 Basis of Design Report ‐ Piping System Aspects................................................................ 13
2.1.6 Conceptual Opinion of Order of Magnitude Probable Construction Costs ...................... 14
2.2 Phase 2 – Preliminary Design .................................................................................................... 14
2.2.2 Valves ................................................................................................................................ 16
2.2.3 Pipe Route and Pipe Specialties ........................................................................................ 16
2.2.4 Pipe and Valve Joints/ End Treatment .............................................................................. 16
2.2.5 Pipe and Valve Interior Linings and Exterior Coatings ...................................................... 16
2.2.6 Heat / Freezing Protection ................................................................................................ 16
2.2.7 Pipe Expansion & Contraction, Restraints, Guides and Anchorage ....................................... 16
2.2.8 Pipe Supports/ Restraints & Anchorage ........................................................................... 16
2.2.9 Design Coordination - Related to Piping Systems ................................................. 17
2.2.10 Drawings ‐ Related to Piping Systems ................................................................................... 18
2.2.11 Draft and Final Preliminary Design Report (PDR) – Piping System Aspects .......................... 18
2.2.12 Preliminary Opinion of Probable Construction Costs and Schedule ..................................... 19
2.2.13 Technical Review Committee ................................................................................................ 19
2.3 Phase 3 – Design Development ................................................................................................ 19
2.3.1 Design – Related to Piping Systems .......................................................................... 19
2.3.2 Drawings ‐ Related to Piping Systems ............................................................................... 20
2.3.3 Specifications – Related to Piping Systems ....................................................................... 20
2.3.4 Interim Opinion of Probable Construction Costs and Constructability ............................. 21
Review .............................................................................................................................................. 21

2.3.5 Technical Review Committee and O&M Review .............................................................. 22
2.4 Phase 4 – Pre‐Final Design ........................................................................................................ 22
2.4.1 Design ‐ Related to Piping Systems ................................................................................... 22
2.4.2 Drawings – additional items ............................................................................................. 22
2.4.3 Specifications – additional items ............................................................................... 22
2.4.4 Final Intra‐Discipline Review‐ within each Function Group .............................................. 22
2.4.5 Pre‐Final Opinion of Probable Construction Costs and Biddability Review ...................... 23
2.5 Phase 5 ‐ Final Design ............................................................................................................... 23
2.5.1 Final Inter ‐ Discipline Review‐ Cross checking between Function Groups ...................... 23
2.5.3 Specifications – additional items ............................................................................... 23
2.5.4 Final Opinion of Probable Construction Costs and Schedule ............................................ 23
2.6 Construction‐Designer Responsibilities .................................................................................... 24
2.6.1 Shop Drawing Review ....................................................................................................... 24
2.6.2 Assistance to Field Staff During Construction ................................................................... 24
III. PUMPING STATION/ SYSTEMS DESIGN GUIDE ............................................................................. 25
3.0 Phase 0 – Project Definition...................................................................................................... 26
3.0.1 Basic Information ‐ Related to Pumping Systems ............................................................. 26
3.0.2 Pumping System Alternatives ........................................................................................... 27
3.0.3 Draft and Final Pumping System Alternatives Memo ....................................................... 28
3.1 Phase 1 ‐ Conceptual Design ..................................................................................................... 29
3.1.1 Initial Design Coordination Items‐ Related to Pumping Systems ...................................... 29
4.1.1.3 ............................................................................................................................................... 29
3.1.2 .................................................................................................................................................. 29
3.1.3 Additional Design Coordination Items ‐ Related to Pumping Systems ............................. 31
3.1.4 Instrumentation and Control ............................................................................................ 31
3.1.5 Basis of Design Report – Pumping System Aspects ........................................................... 32
3.1.6 Conceptual Opinion of Order of Magnitude Probable Construction Costs ............................ 32
3.2 Phase 2 ‐ Preliminary Design .................................................................................................... 33
3.2.1 Refine Piping/ Valve/ Gate Selection‐See also Section 2 of this Guide ............................. 33
3.2.2 Refined System Curves ..................................................................................................... 34
3.2.3 Refine Pump Selection ...................................................................................................... 34
3.2.4 Pumping Station/ Facility Design ...................................................................................... 35
3.2.5 Instrumentation and Control‐ Related to Pumping Systems ............................................ 35

3.2.6 Design Coordination ‐ Related to Pumping Systems ......................................................... 35
3.2.7 Drawings ‐ Related to Pumping Systems ........................................................................ 36
3.2.8 Preliminary Design Report (PDR) – Pumping System Aspects .......................................... 37
3.2.9 Preliminary Opinion of Probable Construction Costs and Schedule ................................. 37
3.3 Phase 3 ‐ Design Development ................................................................................................. 38
3.2.1 Design ‐ Related to Pumping Systems ............................................................................... 38
3.2.2 Drawings ‐ Related to Pumping Systems .......................................................................... 38
3.2.3 Specifications ‐ Related to Pumping Systems ................................................................... 39
3.2.4 Interim Opinion of Probable Construction Costs and Constructability ............ 40
Review ............................................................................................................................................ 40
3.2.5 Technical Review Committee and O&M Review .............................................................. 40
3.4 Phase 4 – Pre‐Final Design ........................................................................................................ 40
3.4.1 Design ‐ Related to Pumping Systems ............................................................................... 40
3.4.3 Specifications– additional items ....................................................................................... 41
3.4.4 Final Intra‐Discipline Review ‐ within each Function Group ............................................. 41
3.4.5 Pre‐Final Opinion of Probable Construction Costs and Biddability Review ...................... 41
3.5 Phase 5 ‐ Final Design ............................................................................................................... 41
3.5.1 Final Inter‐ Discipline Review‐ Cross checking between Function Groups ....................... 41
3.5.2 Drawings– additional items .............................................................................................. 42
3.5.3 Specifications – additional items ...................................................................................... 42
3.5.4 Final Opinion of Probable Construction Costs and Schedule ............................................ 42
3.6 Construction ‐ Designer Responsibilities .................................................................................. 42
3.6.1 Shop Drawing Review ....................................................................................................... 42
3.6.2 Assistance to Field Staff During Construction ................................................................... 42


I. Introduction

This guide presents an approach to process mechanical system designs that are typically
completed on our projects. It is applicable to all types of projects including, but not limited
to: treatment, pumping and related facilities for water, wastewater, stormwater, and
hazardous remediation.

The guide covers the process mechanical design procedures for the following systems:
□ Plant Hydraulics
□ Piping Systems*
□ Pumping Systems*
(* Also includes guidance for the designer during construction)

The pumping and piping portions of this guide do not cover chemical systems.

Design requirements for other disciplines, e.g. HVAC, plumbing, electrical, civil, etc. can be
found on the respective Discipline web sites.

This guide presents a checklist for completing a design, organized by design phase.
Introduction 5

The figure above shows the relationship between Quality Management System (QMP-1),
this check list document, and other more detailed design references for respective process
mechanical systems.

In addition to this document, all requirements of Quality Management System must also be
met. Each individual project will need to be assessed for refinements from these design
methods due to specific project needs.

The project manager (PM) is responsible for ensuring all aspects of a system design are
completed. This document may be used as a design guide for the project engineer and other
project team members, as well as a review checklist for the PM. It can also be used to assess
the earned value or percent completion of a project with respect to the percent of budget
spent. In addition the PM should coordinate the scope of work in this document with the
contract scope of work.
Introduction 6

II. PROCESS MECHANICAL PIPING SYSTEMS DESIGN GUIDE

Piping is an integral part of most process mechanical projects. This design guide can be used
for any project that involves piping and valves within structures and between structures,
including pipes that are full, weather from pumped flow or from gravity flow. Designs for
gravity sewers (open channel flow) project, and water transmission and distribution
systems should use design manuals specifically developed for those purposes. Force mains
are partially covered in this Section and Section 4 (Pumping).

The following project steps are developed for the majority of process mechanical project. It
is the project manager’s responsibility to ensure that all necessary design steps are
completed.

This design guide applies to any project that creates or modifies conventional water,
wastewater, storm water, hazardous remediation and sludge piping systems. For piping
systems that are nontraditional applications (i.e. outside the typical applications mentioned
above) such as steam, natural gas, or any high pressure/high temperature application, care
should be used to ensure that the proper expertise is utilized to ensure the piping has been
designed correctly.

For chemical piping systems not covered by this document.

The design guides in this document are intended to outline the procedure to complete the
indicated process mechanical portion of a design project. The following references should be
used to complete the tasks included in the Process Mechanical piping design procedures:

 Nayyar, Piping Handbook – 7th Edition, 2000
 Frankel, Facility Piping Handbook – 2nd Edition 2002
 Menon, Piping Calculations Manual – McGraw Hill 2005
 Piping related to pumping systems – see Section 4 of this Guide

The approved quality management system must be followed at all design stages of the
project regardless of any information presented in this document.
PROCESS MECHANICAL PIPING SYSTEMS DESIGN GUIDE 7

2.0 Phase 0 – Project Definition

2.0.1 Basic Information – Related to Piping Systems

2.0.1.1 Obtain Information and Set Design Criteria
□ Identify data sources, data gaps and prepare a memo that shows what
data will be collected and in what format.
□ Document the characteristics of the material to be transmitted through
the piping for each service. For chemicals see Section 6 of this Guide.
□ Determine the present and future flow rate, pressure, and temperature
for each piping system being developed – see also Sections 2, 4 and 5 of
this Guide (including use of the Process Flow Diagram to construct a
Mass Balance).
□ Establish all existing environmental conditions in the area where the
piping is to be run.
□ Check for previous engineering reports on piping at the facility.
□ Summarize all flows and pressures.
□ For upgrades of existing systems:
 Field verify all information
 Obtain information on existing piping and its conditions)
□ Obtain information (as part of the Geotechnical Investigations) on:
 Soils corrosion potential
 Soils types
 Potential settlement of facilities and between facilities and buried
pipes
 Seismic design criteria (also consult codes)
□ Obtain additional survey data (including site limits, location of facilities
and topography)

2.0.1.2 Basic Process Related Regulatory Requirements
□ Identify and evaluate applicable current and potential future process
related regulations.
□ Establish basic regulatory requirements for the overall system and
process component – as related to the piping systems.
 Verify plant’s inlet and discharge requirements (including flow
limitations)
 Determine any unit process connection requirements
 Determine redundancy and similar requirements
□ Use a table showing how our design criteria and items meets or exceeds
the regulations.

2.0.1.3 Client Preferences
□ Determine and document Client preferences in the following areas
(typically this would include interviews with appropriate Client staff):
 Pipe and Valve Material and joint type
 Pipe manufacturers

 Valve type as well as manual or automatic actuation
 Valve manufacturers
 O&M preferences
 Single point of failure
 Redundancy
 Isolation of units and piping for maintenance and operation

2.0.2 Piping System Alternatives

2.0.2.1 Identify Alternatives
□ Review regulations to determine design options which cannot vary in the
alternatives.
 Regulation clarification or variance requests should be developed at
this point to prevent project delay at later phases.
□ Discuss with the Client the identification of viable alternatives.
□ Design team to confirm the technical and functional requirements for the
proposed solution(s) with Client, regulators and experience of Engineer
experts.

2.0.2.2 Develop Alternatives
□ Develop alternatives demonstrating the use of different piping materials
and arrangements.
□ Develop (with the Process Engineer):
 Basic Process Flow Diagram (PFD) of the overall facility incorporating
the individual alternatives
 Conceptual sizing of the individual units
 General foot print layout of the alternative and the overall facility
 Major piping connections
□ Complete preliminary mass balance to establish pipe and channel sizing.
□ Gather preliminary information and pricing on piping and valves.

2.0.2.3 Evaluate Alternatives
□ Work with the Client to:
 Define and prioritize criteria to be used for evaluation of alternatives.
 Include sustainability as an evaluation criteria, see also QMP-1,
Section 4.2
 Define appropriate velocity and pressure parameters
□ Evaluate the alternatives internally with the lead practitioner, project
manager, and Client service manager.
□ Conduct a Client discussion (preferably in a workshop) to present the
design options, results of alternatives evaluation and preferred methods
at this point. Document all Client discussions and decisions, and
reconfirm them with the Client to ensure consistency with Client
expectations throughout the project.

2.0.3 Draft and Final Piping System Alternatives Memo
□ Include the following as a minimum:

 Variables used for alternative evaluation (including flows and other
information in Sections 2.0.1 and 2.0.2) – including development of velocity
and pressure parameters and other design criteria
 General conceptual site layout and major structure layouts with major
interconnecting piping
 Coordinate with Sections 2 (Hydraulics), 4 (Pumping Systems), 5 (Blower
Systems) and 6 (Chemical Systems) of this Guide
□ Identify all items with long delivery times that will need to be designed on an
accelerated schedule.
□ Prepare a draft for TRC review.
□ Incorporate appropriate TRC comments into the draft selection memo and
finalize the memo for delivery to the Client.

2.0.4 Technical Review Committee
□ Prior to submittal to the Client, get client reviews and approval for the selection
memo, including design criteria, alternative evaluation and selection.
□ Design team to send their responses to the TRC members, showing the review
and evaluation of TRC comments.

2.1 Phase 1 – Conceptual Design

2.1.1 Initial Design Coordination Items – Related to Piping Systems

2.1.1.1 Establish, project nomenclature for structures and equipment naming.
□ With Client, O&M Specialists, and Engineers for Process, Electrical,
Instrumentation.

2.1.1.2 Regulatory Requirements
□ Reconfirm Process Related Regulations determined in Phase 0.
□ Identify and research all regulatory requirements for the overall facility
and system components.
□ Include the following disciplines in the review process related to Piping
Systems:
 Process/ Process Mechanical (including NFPA and related codes)
 Architectural
 HVAC
 Plumbing and Fire Protection
 Electrical (including not allowing piping above electrical equipment)
 Health and Safety
□ Use a table showing how the design criteria and items meets or exceeds
the regulations.

2.1.1.3 Process Flow Diagram
□ Update PFDs for any revisions throughout the design.

2.1.2 Initial Piping Selection


2.1.2.1 Design Criteria – Reconfirm and Refine

□ Clearly identify and reconfirm the minimum and maximum flow rate,
pressure, and temperature for each service.
□ Determine all physical characteristics of each fluid in the system.

2.1.2.2 Treatment Process/ Pumping Unit Sizing
□ Update the initial sizing of the units.
□ Determine, with the Process Engineer, redundancy or bypass
requirements for each process.

2.1.2.3 Piping and Valve/Gate Arrangement and Layout
□ Develop conceptual piping layouts with placement of major equipment.
□ Make sure that the arrangement meets all Client and regulatory
requirements.
□ Ensure that an adequate number of valves (and or gates) have been
included for maintenance and operation, including isolation of units.
□ Consider carefully, and add valves (and/ or gates) as required for any
single point of failure in the main treatment/pumping stream.
□ Ensure that the piping arrangement will incorporate other site
requirements in the same area.

2.1.2.4 Pipe Materials/ Joints and Size Selection
□ Select a suitable piping material and joint for each service. Gather vendor
information from multiple sources for each type of piping.
□ Determine if any linings/coatings will be required or may be of benefit
for each service.
□ Establish the range of nominal pipe diameters that will be utilized for
each particular service, based on the velocity parameters established.

2.1.2.5 Pipe Routing/ Layout
□ Establish an initial piping route between the key process equipment and
between the individual facilities.

2.1.2.6 Valves and Gates‐types, locations and arrangement
□ Determine the type of valves that will be used for isolation, back flow
prevention, control, pressure relief, surge and other functions, for each
service. Determine types of gates to be used for isolation or flow control.
□ Establish the size and location of all major valves and gates in the system,
first on an annotated process flow diagram, then transferred to the P&ID.

2.1.3 Additional Design Coordination Items ‐ Related to Piping Systems

2.1.2.1 Identify all Motorized Valves and Gates
□ Obtain estimates of all motor sizes and voltage requirements for
motorized valve and gate actuators.


2.1.2.2 Equipment Data Sheets and Process Pipe Schedules

□ Process Pipe Schedules – for all major lines (12” diameter or larger) on the
PFD and the initial P&ID, include as a minimum the initial selection for::

 Pipe name/designation
 Pipe materials/standards and ends/joints
 Design, surge and test pressures
 Linings and coatings
□ Equipment Data Sheets – created under the equipment sections of this
guide.
□ Initial coordination:
 Process Mechanical ( basic pipe and valve size, types and materials )
 Structural (especially for sizes and weights)
 Instrumentation (for controls) also with the P&IDs
 Hydraulics

2.1.4 Instrumentation and Controls ‐ Related to Piping Systems
□ The instrumentation design should be completed by both the process and
the instrumentation engineer.

2.1.4.1 P&IDs
□ Start initial P&ID once the Alternatives Memo approved.
□ P&ID to be developed by expanding the information on the PFD.
□ P&IDs at this level to contain, as a minimum:
 Key equipment
 Pipe diameters (and materials if know)and interconnections
 Basic instrumentation elements
□ For design/build projects, P&IDs should include pipe material, size, and
service.

2.1.4.2 Control Descriptions
□ Start initial Control Descriptions once the Alternatives Memo is
approved.
□ Develop for all key equipment/ components under all modes of
operation, including emergency operations.

2.1.4.3 Instrumentation
□ Based on the control descriptions make sure adequate instrumentation is
provided to ensure satisfactory system operation.

2.1.5 Basis of Design Report ‐ Piping System Aspects

2.1.5.1 Design Criteria/ Schedules/ Layouts
□ Include an updated version of the Pipe/Valves/Gate Selection Memo.
□ Include process piping memo. (Preferably put these on the drawings –
but as a minimum put into the appropriate specs)
□ Include Regulatory requirements.
□ Include basic layout of individual components and overall facilities and
major pipe interconnections and routing.
□ Include sustainability aspects.
□ Include all other items developed under this Conceptual Phase.

2.1.5.2 Pre‐Final Process Flow Diagram and Initial P&IDs
□ The process flow diagram will be included as the general flow path for
the overall piping arrangement.

2.1.5.3 System Description
□ Include the design approach, equipment selection and basic control
strategy for any instrumentation in normal or emergency operation.

2.1.5.4 Draft & Final
□ Incorporate appropriate TRC comments into the draft Basis of Design
Report and finalize the report for delivery to the Client and/or
regulators.

2.1.6 Conceptual Opinion of Order of Magnitude Probable Construction Costs
(PM to check if included in Contract’s scope of work)
□ This may be included in the Basis of Design Report
□ At the end of 10% design, provide all drawings and specifications to Client
to perform a complete order of magnitude construction
cost estimate.
□ Based on the project the design team should provide:
 Previous cost estimates
 Pricing from major vendors
□ PM to Review the completed cost estimate to ensure all design elements were
included.
{Note: For All Phases: PM to make sure communicates to Client the difference
between Construction Costs and Total Project Costs)

□ Get review and approval for the design criteria and design approach for the
pump station.

2.2 Phase 2 – Preliminary Design

2.2.1 Pipe Size

2.2.1.1 Inside Diameter
□ Determine the inside diameter required for each leg of piping in the
system.
□ Document the nearest nominal pipe size available for each type of pipe as
the final pipe size used in each leg of piping.

2.2.1.2 Wall Thickness
□ Determine the required wall thickness required for the internal and

external pressure as well as handling thickness of each piping system.

□ All other inline components of the piping system should be selected from
a pressure class that has a higher pressure-temperature rating than the
design pressure and temperature of the piping system.

2.2.1.3 Lay Lengths
□ Verify the availability of piping lay lengths for each type of piping used
in the project.
□ Document that each type of pipe is available in a lay length that can be
used in construction of the project.

2.2.2 Valves

2.2.2.1 Valve Selection and Location
□ Determine the diameter and joints required for each valve application.
□ Select materials for valve parts suitable for withstanding all conditions
and loadings for the service.
□ Confirm that each valve location has enough space for the valve body,
stem, and operator.
□ Locate and size all valves required for operation and maintenance.
□ Provide isolation and bypass capabilities for any control equipment and
motorized valve.
□ Provide downstream gating or valving so that motorized/ control valves
and all gates can be removed for repair.
□ Request manufacturer information to confirm size, availability, and cost
of each valve with its actuator.

2.2.2.2 Valve and/or gate Control
□ Determine the type of actuator used for each manual valve and gate in
the system and ensure enough space is available for the operator to fit
and be accessible in the layout.
□ Confirm the operating range for each system control valve and/or gate.
□ Confirm valve/gate actuating is electric and the available voltage rating
(if actuator force is other than electric confirm quantity and pressure of
operating fluid).
□ Request the confirmation of motor size and voltage for all electric
actuated valves/gates from vendors.
□ Identify open/close or modulating operation for all valves/gates.

2.2.3 Pipe Route and Pipe Specialties
□ Develop detailed piping routes for all systems locating all fittings, flexible
connectors, expansion joints, valves and required piping specialties.
□ Locate all drains, vents, and sample ports required in the piping system.
□ All piping below slabs or building shall be concrete encased, with suitable
expansion joints in the concrete and pipe at building expansion joints.

2.2.4 Pipe and Valve Joints/ End Treatment
□ Confirm types of joints for each service (especially for pressure and locations).

□ Confirm types of joints based on pressure class that has a higher pressure -
temperature rating than the design pressure and temperature of the piping
system.
□ Confirm restraint and anchorage of all pipes – typically all exposed piping has
restrained joints; as does all piping with pumped flows and/ or where pipe is
full from “gravity” induced pressure.

2.2.5 Pipe and Valve Interior Linings and Exterior Coatings
□ Determine linings and coatings for each type of pipe and each service and
installation environment.
□ Make sure to confirm Client preference and successful industry practice in the
area of the facility, as well as regulatory requirements.
□ Investigate and confirm where linings and/or coatings are not required (i.e. most
stainless steel installations).

2.2.6 Heat / Freezing Protection
□ Determine where insulation is needed for heat loss or gain, freeze protection, and
noise control. Evaluate the use of insulation or if heat tracing is required (always
use insulation when heat tracing is required).
□ Document the type of insulation required for each service.

2.2.7 Pipe Expansion & Contraction, Restraints, Guides and Anchorage
□ Special attention shall be directed towards the need to provide for expansion and
contraction for all pipes because of internal pressures, water hammer, changes in
temperatures or seismic.
□ In all cases (especially for air piping) in the proper expertise shall be sought for
addressing these situations. See also other subsections of this Guide.

2.2.8 Pipe Supports/ Restraints & Anchorage
□ Pipe supports, restraints and anchorage includes all devices to support, hang, tie
together, guide, resist movement and similar functions for all pipes and valves.
□ Pipe support design shall be a careful coordination between the Process Engineer
(who provides loads and locations and types of premanufactured supports) and
the Structural Engineer (who does the actual pipe support and related structural
design).
□ Detailed considerations of pipe supports are to be started during the preliminary
design and completed by the end of the Pre-Final Design.
□ Review all piping layouts for the use of pipe supports, restraints and anchorage
(see also the subsection above concerning Joints and end treatment).
□ Locate pipe supports, guides, anchorage, expansion provisions (coordinate
especially with structural)
□ Document any space that is required to be open where pipe supports cannot be
placed.
□ Special pipe supports (including anchorage) is required for all piping (especially
exposed piping) in seismic areas – experienced personnel in this design areas
should be consulted.
□ Normally for piping in and around facilities (site piping) restrained joins should
be used for all piping; thrust blocks are strongly discouraged due to previous or
future adjacent construction.

2.2.9 Design Coordination - Related to Piping Systems

2.2.9.1 Equipment Data Sheets and Pipe &Gate/Valve Schedules
□ Process Engineer to provide pre-final equipment data sheets and lists for
all motorized and major pieces of equipment including motorized valves
and gates.
□ Update Equipment Data Sheets – produced under the equipment
portions of this guide.
□ Process Pipe Schedules – update with the information determined in the
previous sub-sections of this Phase.
□ Process Valves and Gate Schedules (for units of 12 inch diameter and
larger and/or motorized) valve/gate types, size, flow rates, pressures,
service/function (on/ off, modulating, etc.) actuators (motor size, voltage
and enclosure classification) & also for gates: seating/unseating heads.
□ Coordination:
 Process Mechanical ( confirmed size and connecting pipe/ valves and
access)
 Structural (confirmed sizes, locations and weights)
 Electrical (confirmed connected loads)
 Instrumentation (for controls)
 Plumbing (utility requirements)
 HVAC (utility and environment requirements & heat/ cooling loads)

2.2.9.2 Instrumentation and Controls
□ Pre-final (90%) P&IDs building on the previously created P&IDs
 All Key equipment and all valves
 Pipe diameters and materials)and interconnections + valves
 Complete instrumentation (tag numbers may not have been assigned)
 Initial links for the P&IDs to electrical data.

2.2.9.3 Civil
□ Locate all piping leaving a building and coordinate with the civil yard
piping; provide profiles of major buried process piping.
□ Determine flexibility required at all locations where pipe leaves building
(including buried pipe and pipe between buildings).
□ Consult geotechnical report for specific information (see also Phase
above).

2.2.9.4 Architectural
□ Confirm all code requirements are being addressed.
□ Locate all architectural wall and roof penetrations.
□ Coordinate window location with pipe routing.


2.2.9.5 Structural
□ Locate all structural wall and floor penetrations.
□ Coordinate floor drainage needs with the structural and plumbing
disciplines.
□ Consider loads due to the support, anchorage and expansion/
contraction of piping.

2.2.9.6 HVAC
□ Locate all ducting, louvers, vents, and fans relative to process piping.
□ Locate all ducting, louvers, vents, and fans relative to process piping,
adjust process piping as required.

2.2.9.7 Plumbing and Fire Protection
□ Locate the routing of all exposed plumbing piping relative to process
piping.

2.2.9.8 Electrical
□ Establish all power requirements including future and backup needs.
□ Locate all elements requiring power.
□ Determine area classifications (so valves and other actuators can be
properly selected).
□ Coordinate electrical equipment so no piping runs above it.

2.2.10 Drawings ‐ Related to Piping Systems
□ Develop and/or coordinate the following drawings. All discipline drawings
should be developed to the preliminary (30%) level by the end of this phase
unless otherwise noted.

2.2.10.1 Process Mechanical
□ Finalize Process Flow Diagrams for each service.
□ Interim (60%) Piping/Gate/Valve Schedules
□ Pipe Layout Plans and Sections/Profiles
□ Other process mechanical drawings to the Interim (60%) level

□ Overall P&ID and major facility systems P&IDs – completion level as
noted above.

2.2.10.3 Other Preliminary Design Drawings – as noted above.

2.2.11 Draft and Final Preliminary Design Report (PDR) – Piping System Aspects
□ Update information included in the Basis of Design Report.
□ Include all drawings and schedules generated during this phase.
□ Re-Check regulatory submittal requirements.
□ Develop preliminary plan of normal operations for facility.
□ Develop a table of contents for the specifications for the design.

□ For existing facilities: include an initial discussion on Maintenance of Existing
Operations during construction (MOEODC). This may include: needed bypasses,
temporary pumping, limitations, etc.
□ Include all other information developed during this phase.
□ Incorporate appropriate TRC comments into the draft PDR and finalize the
report for delivery to the Client and/or regulators.

2.2.12 Preliminary Opinion of Probable Construction Costs and Schedule
□ Typically included in the Preliminary Design Report
□ Based on the project size the design team should also provide:
 Quantity take-offs
 Vendor pricing and delivery times
□ Identification of items with long lead (delivery) times.
□ PM to Review the completed cost estimate and schedule to ensure all design
elements were included.

□ Get review and approval for and changes to the design criteria as well as the
layout for the piping system.

2.3 Phase 3 – Design Development
□ Further develop the size and character of the entire project.
□ Many times items under this phase are submitted as an Interim Design submittal
– check regulatory and scope of work requirements.

2.3.1 Design – Related to Piping Systems
□ Evaluate the constructability of the piping and valve systems.
□ Develop a construction-sequencing plan, with refinement of the MOEODC.
□ If the Client requests a Process Safety Review it should be completed at this
stage.
□ as required, have final force main surge and air valve analysis performed. The
need for surge analysis should be determined during the proposal stage of any
pump station project, and preliminary surge evaluation may also show that this
is required (which may require and addition to the scope if not previously
identified).
□ Where appropriate for key items: Submit draft drawings and specifications for
manufacturer review.
□ Pre-Final (90%) all equipment data sheets.
□ Pre-final all pipe/gate/valve schedules (preferably those are on the Drawings
but may be put in the specs).

2.3.2 Drawings ‐ Related to Piping Systems
□ Develop and/or coordinate the following drawings for the piping systems. All
discipline drawings should be developed to the interim (60%) level by the end of
this phase unless otherwise noted.

□ Final Process Flow Diagrams
□ Piping/Gate/Valve Schedules - as noted above
□ Piping Plans and Sections
□ Details
□ Pre-final Operations Plan
□ Pre-final Construction Sequencing Plans
□ Other Process Mechanical Drawings brought to the 75+% completion
level

□ Updated P&IDs (see also requirements above)

2.3.2.3 Civil
□ Updated Yard Piping Plans and Profiles of major and other pipes
□ See also requirements above

□ Floor Plan and Elevations

2.3.2.5 Structural
□ Plan and Sections

2.3.2.6 HVAC

□ Below Slab Plan and Sections
□ Above Slab Plan and Sections

2.3.2.8 Electrical
□ One Line Diagrams
□ Wiring Plans
□ Pre-final Electrical Site Plans

2.3.3 Specifications – Related to Piping Systems
□ Using a specification listing/control matrix, gather master specs on the
various components of the piping systems.
 Piping

 Valves
 Gates
 Actuators
 Insulation
 Piping Supports, restraints, guides, expansion provisions, etc
 Piping Specialties
 Construction Sequencing/ MOEODC
□ Evaluate each individual piping system to determine if there are any specialty
pieces of equipment, for example piping systems, which need to be included in
the specifications.
□ Coordinate pipe and valve schedules with pipe and valve specs (including
testing)
□ Verify the Client’s name is used properly and there are no references to past
projects.
□ Determine if the Client has specific requirements.
□ Ensure each specification includes all areas included in master specification
format.
□ Complete specifications for any items that have long delivery times (and
potential early bidding/ purchase to not delay the overall project)
□ A vetting process among the purchasing manager and the engineer of record is
generally required to reach consensus on the minimum level of quality that will
be accepted.

2.3.4 Interim Opinion of Probable Construction Costs and Constructability
Review
□ At the end of 60% design, provide all drawings and specifications to perform a
complete construction cost estimate and scheduling.
□ Based on the size of the project the project engineer may also be asked to
provide:
 Vendors’ pricing and delivery times
□ Also perform a constructability review as the complete the Interim cost estimate
□ PM to review the completed cost estimate to ensure all design elements were
included.

2.3.5 Technical Review Committee and O&M Review
□ Get review and approval for any changes to the piping layouts as well as the
construction sequencing.
□ Have an O&M person perform an O&M review.
□ Incorporate appropriate comments for TRC, constructability and O&M reviews
into the submittal for delivery to the Client and/or regulators.

2.4 Phase 4 – Pre‐Final Design
□ Complete the requirements and details of construction and implementation (for
design-bid-construct) of the entire project – ready for formal cross checking.

2.4.1 Design ‐ Related to Piping Systems
□ Verify all required documentation is completed and filed appropriately.
□ Verify that all required calculations have been properly completed, reviewed,
checked and filed appropriately.
□ Verify that all Equipment Data sheets have been properly finalized, reviewed,
□ Ensure that all review comments have been addressed and the responses have
been included in the documentation.
□ Review the initial Client preferences and regulatory review documents to ensure
that these design concepts have remained intact.
□ Confirm that all documents are at the 90% level, including having been properly
checked within each discipline – see below.

2.4.2 Drawings – additional items
□ Ensure that all title block information is complete and corresponds with the
information on the drawings index.
□ Spell check all drawings.
□ Check all section, detail, and match line references.

2.4.3 Specifications – additional items
□ Ensure that all of the author’s comments (bold statements from Master Specs)
have been addressed and removed.
□ Cross check the specification title with the table of contents.
□ Submit specs for powered valve to electrical and instrumentation for review

2.4.4 Final Intra‐Discipline Review‐ within each Function Group
(Calcs, Equipment Data Sheets, Drawings, Specs)
□ Request TRC comments/responses from all disciplines to confirm all issues have
been resolved.
□ Ensure all documents are in their final form before review.
□ Complete final red/yellow/green markups within the individual function
groups.
□ Documents should be ready for detailed cross checking.

2.4.5 Pre‐Final Opinion of Probable Construction Costs and Biddability Review
□ Obtain updated quotes from vendors.
□ Send 90% drawings and specs along with updated equipment quotes and
delivery times to update to the construction cost estimate and schedule.
□ Should be tasked to perform a biddability review with appropriate
comments incorporated before the final bidding sets are put together.

2.5 Phase 5 ‐ Final Design
□ Produce a completely checked and ready for bidding set of construction
documents.

2.5.1 Final Inter ‐ Discipline Review‐ Cross checking between Function Groups
(Equipment Data Sheets, Drawings, and Specs.)
□ Ensure all documents are in their final form (i.e. checking completed within each
discipline) before starting cross checking review.
□ Complete final red/yellow/green markups between the individual function
groups, and correction of any discrepancies, and information in any specific
cross checking memo.
□ Cross Check:
 Drawings with Drawings
 Drawings with Specs
 Specs with Drawings
 Equipment Data Sheets with both Drawings and Specs

□ Complete the final inter-discipline cross check per quality management system:
 Ensure all drawing background references are accurate
 Check all cross discipline page references
 Check all cross discipline detail numbers
□ Each drawing should be signed and sealed by the appropriate P.E. (reasonable
Senior Design Engineer)
□ Cross check the drawing titles with the Drawing Index.

□ Ensure all related specifications have been referenced.
□ Check final spec formatting.
□ Each Specification set should be signed and sealed by the appropriate P.E.

2.5.4 Final Opinion of Probable Construction Costs and Schedule
□ Obtain updated quotes and delivery times from vendors.
delivery times to the construction cost estimate.

2.6 Construction‐Designer Responsibilities

2.6.1 Shop Drawing Review
□ Determine if the submittal may be accepted or should be returned for further
clarification.
 Ensure that all specification and drawing requirements have been met
 Confirm that all required materials of construction are clearly identified
 Review any major dimensions with information shown on the Contract
drawings
 Perform all reviews in a timely manner
□ Ensure that cross discipline information is reviewed by each discipline involved.
□ Submit all completed shop drawings and review forms to the technical manager
or task leader for them to return to the Contractor.

2.6.2 Assistance to Field Staff During Construction
□ Promptly address, research and answer (with proper documentation) any
inquiries from field staff, (including those passed on from the Contractor), since
time is normally of the essence in any ordering, construction and startup
situation.
□ All Contractor enquires, such as Requests for Information (RFIs), shall be
properly documented, and promptly returned to the field staff.

III. PUMPING STATION/ SYSTEMS DESIGN GUIDE

Pump stations can be designed as a project of their own or as part of an overall facility
design project. This guide can be used to complete any type of project that incorporates a
pump station.

The following project steps are developed for the majority of process mechanical projects.
Every project with pumping shall include each of the items indicated in phases 0 to 5 unless
determined otherwise by the project scope of work.

This design guide applies to conventional water, wastewater, hazardous remediation and
sludge pumping systems. For nontraditional pumping applications (i.e. those outside the
typical applications mentioned above) care should be used to ensure that the proper
expertise is utilized to ensure the pumping system/station has been designed correctly.
Chemical pumping systems are not covered by this section.

The pumping station design guide should be used in conjunction with the piping system
design guide for the piping and valves associated with the pump station. Many of the steps
listed for the phases for the piping and the pump station design may be similar because of
the close relationship of the pump and piping systems.

The design guides in this document are intended to outline the procedure to complete the
indicated process mechanical portions of a design project. The following references should
be used to complete the tasks included in the Pumping system design procedures (in all
cases the latest version of any documents shall be used):
 Local Design Guidelines (i.e. State or local regulations, 10 State Standards or
New England Interstate Water Pollution Control Commission TR-16 Guides
for the Design of Wastewater Treatment Works, etc.)
 Garr Jones, et al, Pumping Station Design – 3rd Edition, 2006 (note: this is
normally referred to as the Sanks Pumping Book)- This should be considered
the primary reference for design of Pumping systems, especially the
checklist.
 Karassik, Pump Handbook – 3rd Edition, 2001
 Nayyar, Piping Handbook – 7th Edition, 2000
 Frankel, Facility Piping Handbook – 2nd Edition 2002
 Hydraulic Institute Standards – Most Current Version

The quality Management System must be followed at all design stages of the project
regardless of any information presented in this document.
PUMPING STATION/ SYSTEMS DESIGN GUIDE 25

3.0 Phase 0 – Project Definition
(% represents overall level of design completion)

3.0.1 Basic Information ‐ Related to Pumping Systems
3.0.1.1 Obtain Information and Set Design Criteria
□ Identify data sources, data gaps and prepare a memo that shows what
data will be collected and in what format.
□ Gather information and document the characteristics of the material to be
pumped.
□ Check for previous engineering reports on pumping at the facility.
□ For upgrades of existing systems: Obtain information on existing
pumping units, their location, equipment, piping, elevations of floors and
wet wells, and field verify
□ Gather information of the available area and other constraints for the
facility.
□ Collect the flow into the pump station and out of the pump station for
minimum and maximum flows over the life of the pump station.
□ Establish the general location of the pump facility (including elevation
above sea level), area available for the pumping, and any constraints on
its size. This is needed to estimate elevation differences as well as space
constraints for the system.
□ Establish the location of the discharge point for the fluid being pumped to
estimate the length of the force main as well as assist with determining
the height the station must lift the fluid.
□ Decide with the LP the friction formulas to be used and friction criteria/
factors (to be refined with the type of pipe materials selected) as well as
velocity parameters (maximum and minimum); for pumping of sludge
consult Ernie Sturtz.
□ After making an initial selection of piping material and pipe diameter
(based on velocity parameters), make an initial calculation of friction
losses and static head to estimate the range of discharge pressures of the
pumping facility.
□ Summarize all flows and heads.
□ Obtain additional survey data (including site limits, location of facilities
and topography).

3.0.1.2 Basic Process Related Regulatory Requirements
□ Identify and evaluate applicable current and potential future process
related regulations.
□ Establish basic regulatory requirements for the overall system and
process component – as related to the pumping systems.
 Verify required capacities (including flow limitations)
 Determine any unit process connection requirements
 Determine redundancy and similar requirements
the regulations.

3.0.1.3 Client Preferences
□ Determine Client preferences in the following areas (preferably done in
interviews):
 Type of pump
 Manufacturers
 Level of instrumentation and control
 Single point of failure
 Redundancy
 Specific maintenance and operation considerations

3.0.2 Pumping System Alternatives

3.0.2.1 Identify Alternatives
□ Review regulations to determine design options which cannot vary in the
alternatives.
 Regulation clarification or variance requests should be developed at
this point to prevent project delay at later phases.
□ Use existing pump stations to evaluate positive and negative elements for
the pump station alternatives. Several sources for station experience are:
 Client Facilities
 Local Installations
□ Discuss with the Client the identification of viable alternatives.
□ Confirm the technical and functional requirements for the proposed
solution(s) with Client, regulators .

3.0.2.2 Develop Alternatives
□ Develop alternatives demonstrating the use of different types of pumps
and delivery methods (constant speed, varying speed, etc.).
□ Develop, with the Process Engineer:
 Basic Process Flow Diagram (PFD) of the overall facility incorporating
the individual alternatives.
 Conceptual sizing of the individual units
 General foot print layout of the alternative and the overall facility
 Major piping connections.
□ Complete preliminary mass balance to establish pipe and channel sizing.
□ Gather preliminary vendor input on equipment size, limitations, and
pricing.

3.0.2.3 Evaluate Alternatives
□ Work with the Client to:
 Define and prioritize criteria to be used for evaluation of alternatives.
□ Evaluate the alternatives internally with the lead practitioner, process
engineer, project manager, and Client service manager.
□ Conduct a Client discussion (preferably in a workshop) to present the
design options, results of the alternatives’ evaluation, and preferred
methods at this point. Document all Client discussions and decisions to
ensure consistency with Client expectations throughout project.

3.0.3 Draft and Final Pumping System Alternatives Memo
□ Include the following:
 Variables used for alternative evaluation (including design criteria, such as
flows, pressures and other information in Sections 4..0.1 and 4.0.2) – and
development of velocity and pressure parameters and other design criteria.
 Initial PFD for selected alternative
 Initial general control philosophy
 Coordinate with Section 2 (Hydraulics), 3 (Piping) and 6 (Chemical Systems)
of this Guide.
 General conceptual layouts of the selected pumping facility(s) and its location
on the site and the pumping discharge pipe routing.
□ Identify all equipment with long delivery times that will need to be designed on
an accelerated schedule.
□ Incorporate appropriate TRC comments into the draft selection memo and
finalize the memo for delivery to the Client.

□ Prior to submittal to the Client, get Client reviews and approval for the selection
memo, including design criteria, alternative evaluation and selection.

3.1 Phase 1 ‐ Conceptual Design

3.1.1 Initial Design Coordination Items‐ Related to Pumping Systems

3.1.1.1 Project Nomenclature for Structures and Equipment
□ Develop nomenclature with Client, O&M Specialists, and Engineers
for Process, Electrical, Instrumentation.

3.1.1.2 Regulatory Requirements
□ Reconfirm Process Related Regulations determined in Phase 0.
□ Identify and research all regulatory requirements for the overall facility
and all system components.
□ Include the following disciplines in the review process related to
Pumping Systems:
 Process/ Process Mechanical
 Architectural
 Structural
 Electrical
 HVAC
 Plumbing and Fire Protection
 Health and Safety
the regulations.

4.1.1.3 Process Flow Diagram
□ Update the PFDs for any revisions throughout the design.

3.1.2 Initial Pump Selection
□ The initial pump selection is based on the material being pumped, the flow
design criteria and the pressure that the pumps must overcome to move the fluid
to the discharge point.

3.1.2.1 Design Criteria‐Reconfirm and Refine
□ Clearly identify the minimum and maximum flows based on information
and constraints determined in Phase 0.
□ Verify and refine pump type selection and space and location available
for pumping facility.
□ Determine the suction elevation based on the chosen pump type and
general station layout.
□ Verify the location of the pump station discharge point.

3.1.2.2 Main Discharge Pipe/ Force Main
□ Verify the previously selected initial force main size based on selected
velocity and pressure constraints.
□ Refine the previously selected route for the pump main discharge piping
between the pump facility and the discharge point.
□ Confirm the appropriate pipe material and corresponding roughness
coefficient.

□ Re-calculate the preliminary total head loss in the main discharge piping
with the friction and fitting head loss.

3.1.2.3 Initial System Curve
□ Construct preliminary pumping system curves based on the following:
 Maximum System Curve:
Max Static Head + Max (Friction & Fitting Losses)
 Minimum System Curve:
Min Static Head + Min (Friction & Fittings Losses)

3.1.2.4 Refined Pump Selection and pump room piping sizing
□ Based on the calculated total system minimum and maximum fluid flow
and minimum and maximum pressures (head):
 Confirm the types of pumps initially selected
 Estimate the number of pumps required to meet the minimum and
maximum flows. Consider the maximum available capacity of any
individual unit of the pump types with operating flexibility and
turndown.
 Consideration should be given to the use of variable speed pump
units, including required operating conditions, wet well sizing and
overall costs of pump units.
 Select specific pump units (make and models) from several
manufacturers. Consult the listed pumping references to determine
the specific considerations for selecting specific pumps.
 Obtain from vendors the Net Positive Suction Head (NPSH) required
by the selected units and compare that to the NPSH available (don’t
forget elevation, temperature and fluid specific gravity).
□ Document the preliminary selection and size of the pump, motor, and
suction and discharge piping diameters.
□ Establish the total number of pumps in the station including the number
required to meet the flow range and the required back-up pumps.
□ Obtain from the initially selected vendors the weight, electrical
characteristics (hp, voltage, etc); normal rpm, dimensions (including
motor) and confirm the detailed pump characteristic curves (including
NPSHR) and proposed method of operation.
□ Provide a minimum of 3 feet horizontally in all directions from units,
with additional distance for larger size motors.
□ Consider overhead clearances for a crane, monorail or lifting tripod for
Maintenance.

3.1.2.5 General piping and valve arrangement
□ Ensure that an adequate number of valves (and/or in some cases gates)
have been included for maintenance and operation.
□ Carefully consider the types of valves for shutoff and check valves (and
consider for any required surge control valves).
□ Analyze valve and piping arrangement to ensure an adequate amount of
redundancy if pumps or control valves or other types of valves are taken
out of service.

3.1.2.6 Wet Well
□ Determine the wet well volume required for the pumping application,
including the evaluation of variable speed pumping to optimize wet well
volume.
□ Develop a preliminary wet well layout locating the influent and pump
suction as well as the operating water levels.

3.1.3 Additional Design Coordination Items ‐ Related to Pumping Systems

3.1.2.1 Auxiliary Water and Air
□ Include any flushing water or wash down water piping and valves on the
process flow diagrams.
□ Consider maintenance and instrumentation air needs.

3.1.2.2 Initial Layout
□ Determine required floor space, showing major equipment, major piping
and valves.
□ Develop conceptual room and building layouts.
□ Make sure that the arrangement meets all Client and regulatory
requirements.

3.1.2.3 Identify all motorized components
□ Obtain estimates of all motor sizes and voltage requirements for
motorized components.
□ Consider the impacts on maintenance requirements and area
classification when locating all motorized components.

3.1.2.4 Equipment Data Sheets and Process Pipe Schedules
□ Equipment data sheets for all large and/or key motorized and process
equipment. These will include all of the information as noted for
pumping unit selection and shown on the Equipment Data Sheet basic
form .
□ Using the Equipment Data Sheets tabulate the number, flow, pressure,
motor criteria, control methods, orientation, and type of each pump. This
table will be used as the pump schedule (part of the equipment schedule).
□ Process Pipe schedule – see section 3 of this Guide.
□ Initial coordination:
 Process Mechanical ( basic size and connecting pipe/ access)
 Structural (especially for sizes, weights and thrusts)
 Electrical ( for initial connected loads)
 Instrumentation (for controls) and with P&IDs

3.1.4 Instrumentation and Control
□ The instrumentation design should be completed by both the process and the
instrumentation engineer.

31.4.1 P&IDs

□ Start initial P&ID once the Alternatives Memo is approved.
□ Develop P&ID by expanding the information on the PFD.
□ P&IDs at this level to contain, as a minimum:
 Key equipment
 Pipe diameters (and materials if know)and interconnections
 Basic instrumentation elements

3.1.4.2 Control Descriptions
□ Start initial Control Descriptions once the Alternatives Memo is
approved.
□ Develop for all key equipment/components under all modes of
operation, including emergency operations.

□ Make sure adequate instrumentation is provided to ensure satisfactory
system operation based on the control descriptions.

3.1.5 Basis of Design Report – Pumping System Aspects
□ Include an updated version of the Pump System Alternatives Memo.

3.1.5.1 Design Criteria/Schedules/Layouts
□ Compile similar information into Schedules for all piping and valves (and
gates) included in the process flow diagram and P&ID as described in the
Piping Systems section.
□ Include Regulatory requirements.
□ See also Sections 2 Piping requirements.
□ Include basic layout of individual pump facility/stations and force mains
and overall site.
□ Include sustainability aspects.
□ Include all other items developed under this conceptual phase.

3.1.5.2 Pre‐Final Process Flow Diagram
□ Include the general flow path for the system.

3.1.5.3 System Description
□ Include the design approach, equipment selection and control strategy for
any instrumentation in normal or emergency operation.

3.1.5.4 Draft and Final
□ Incorporate appropriate TRC comments into the draft Basis of Design
Report and finalize the report for delivery to the Client.

3.1.6 Conceptual Opinion of Order of Magnitude Probable Construction Costs
(PM to check if included in Contract’s scope of work)
□ This may be included in the Basis of Design Report.

□ at the end of 10% design, provide all drawings and specifications to Perform a
complete order of magnitude construction cost estimate.
□ Based on the project the design team should provide:
 Pricing from major vendors
□ PM to Review the completed cost estimate to ensure all design elements were
included.
{Note: For All Phases: PM to make sure communicates to Client the difference
between Construction Costs and Total Project Costs)

□ Get reviews and approval for the design criteria and design approach for the
pump station.
□ Design team to send their responses to the TRC members showing the review

3.2 Phase 2 ‐ Preliminary Design

3.2.1 Refine Piping/ Valve/ Gate Selection‐See also Section 2 of this Guide

3.2.1.1 Station Piping
□ Determine the final piping characteristics as described in the Piping
System Section.
□ Develop a complete layout of the suction and discharge piping in the
station including the following elements:
 Valves (including check valves normally only in the horizontal for
WW, sludge, grit or scum pipes)
 Fittings (including proper straight length of suction piping, and not
coming into the bottom of sludge, wastewater, grit or scum pipes)
 Connectors and restrained flexible connections at pump suction and
discharge – normally of the solid sleeve type)
 Instrumentation

3.2.1.2 Main Discharge Pipe/ Force Main
□ Confirm the final piping characteristics as described in the Piping System
Section.
□ Complete a cost evaluation to determine the most efficient piping
diameter versus present worth cost of pumping, but with consideration
for minimizing energy use where appropriate (this may include larger
pipe diameters to minimize pump energy consumption).
□ Establish the entire force main route with stationing and basic profile
information.
□ Evaluate and adjust the overall force main profile to determine the
highest point in the pumping system, and minimize multiple high points
and abrupt changes in profile.

□ Perform a preliminary force main surge analysis and air valve analysis.
The need for surge analysis should be determined during the proposal
stage of any pump station project.
□ Locate all air valves and line drainage points (with considerations for
regulatory restrictions on drainage).

3.2.2 Refined System Curves
3.2.2.1 Head Loss
□ Develop detailed head loss calculations, including station losses,
accounting for characteristics of the selected piping material and all
elements in the piping system.
□ Confirm NPSHA and compare to selected unit’s NPSHR.

3.2.2.2 Minimum and Maximum System Curves
□ Finalize system curves based on detailed station design.

3.2.3 Refine Pump Selection
□ For use of individual pump curves and pump system curves on the same graph
and integrating the station head losses with the overall system head losses
□ Select the best model from each of the preferred pump manufacturers, in
discussion with the vendors (preferably with factory technical experts).
□ Refine the pre-final horsepower, voltage, control methods, dimensions, weights,
vibration, and range of speed of the selected pumps.
□ Select the desired materials of construction for each of the pump components
based on the intended service for the selected pumps.
□ Review the standard drive arrangement, seal type, and bearing life for each
application.
□ Request a vendor review of the pump selection and layout.
□ Further evaluate each listed manufacturer in the specification to ensure they can
meet the specified equipment design criteria.
□ Confirm with the vendor the cost, dimensions, power characteristics, control
methods, materials, NPSHR, and weight of each pump selection.

3.2.4 Pumping Station/ Facility Design

3.2.4.1 Wet Side
□ Finalize the volume and operating band of the wet well.
□ Refine the layout of the intake structure locating all piping and
instrumentation locations.
□ Complete detailed calculations or perform intake modeling to ensure
adequate suction side design. The use of intake modeling should be
determined during the proposal stage of any pump station project.

3.2.4.2 Dry Side
□ Refine the complete layout of the pump station including:
 Location of all equipment and instrumentation
 Location of all auxiliary systems
 Space reserved for operation/maintenance

3.2.5 Instrumentation and Control‐ Related to Pumping Systems
□ Process Engineer to complete the control descriptions including all set points,
alarms and timers for all modes of operation.

3.2.6 Design Coordination ‐ Related to Pumping Systems

3.2.6.1 Equipment Data Sheets and Process Pipe/ Valve/Gate Schedules
□ Provide pre-final equipment data sheets and lists for all motorized and
major pieces of equipment including motorized valves and gates.
□ For the Equipment Data Sheets – update those under Phase 1 and add the
information determined in the previous sub-sections of this Phase.
□ For Process Pipe/Valve/Gate Schedules – see section 3 of this Guide,
update those under Phase 1 and add the information determined in the
previous sub-sections of this Phase.

3.2.6.2 Instrumentation and Controls
□ Pre-final (90%) P&IDs shall include:
 All Key equipment
 Pipe diameters and materials)and interconnections + valves
 Complete instrumentation (tag numbers may not have been assigned)
 Initial links for the P&IDs to electrical data

3.2.6.3 Civil
□ Locate all piping leaving the pump station and coordinate with the civil
yard piping.
□ Allocate adequate site access to the pump station

□ Determine adequate egress from all pump station rooms.
□ Establish requirements for removing pumping equipment from buildings

for future replacement or repair.

□ Locate all architectural wall and roof penetrations.
□ Coordinate window location with pipe routing and equipment placement
in the room.

3.2.6.5 Structural
□ Identify all equipment locations.
□ Locate all structural wall penetrations.
□ Coordinate floor drainage needs with the structural and plumbing
disciplines.
□ Consider loads due to the support of piping.

3.2.6.6 HVAC
□ Establish all ventilation and temperature requirements for the space.
□ Locate all ducting, louvers, vents, and fans relative to process equipment.
□ Define any space needed for additional mechanical equipment in the
pump station area.

□ Locate the routing of all floor and roof drainage piping.
□ Define all potable and non-potable water quantity and quality needs and
drainage requirements for each pump station.

3.2.6.8 Electrical
□ Pre-finalize all power requirements including future and backup needs.
□ Locate all elements requiring power.
□ Establish future and backup.
□ Provide 1 line drawing and major MCCs.
3.2.7 Drawings ‐ Related to Pumping Systems
□ Develop and/or coordinate the following drawings. All discipline drawings
should be developed to the preliminary (30%) level by the end of this phase
unless otherwise noted.

□ Final Process Flow Diagram
□ Updated Hydraulic Profile-(per Section 2 of this Guide)
□ Interim (60%) & Updated Equipment Schedules
□ Updated Process Piping/Gate/Valve Schedules-per Section 3
□ Pump Facility Plans and Sections including main pipe/valves/gates
□ Interim Force Main Plans and Profiles ( process/civil cross over)
□ Other process mechanical drawings to the Interim (60%) level

□ Overall P&ID and pump system P&ID with completion level as notedabove
3.2.7.3 Civil Drawings – preliminary as noted above

3.2.7.4 Architectural Drawings ‐ preliminary as noted above

34.2.7.5 Structural Drawings – preliminary as noted above

3.2.7.6 HVAC Drawings – conceptual (basic unit and duct layout)

3.2.7.7 Plumbing Drawings – not always include in PDR

3.2.7.8 Electrical Drawings ‐ conceptual as noted above

3.2.8 Preliminary Design Report (PDR) – Pumping System Aspects
□ Update information included in the Basis of Design Report.
□ Include all drawings generated during this phase.
□ Re-Check regulatory submittal requirements.
□ Develop a table of contents for the design specifications for the project.
□ Develop preliminary plan of normal operations for facility.
□ For existing facilities: include an initial discussion on Maintenance of Existing
Operations during construction (MOEODC). This may include: needed bypasses,
temporary pumping, limitations, etc.
□ Prepare a draft for TRC review
□ Incorporate appropriate TRC comments into the draft PDR and finalize the
report for delivery to the Client and/or regulators.

3.2.9 Preliminary Opinion of Probable Construction Costs and Schedule
□ Typically included in the Preliminary Design Report
□ At the end of 30% design, provide all drawings and specifications to Client
to perform a complete construction cost estimate and
work with the PM to develop a construction schedule.
□ Based on the project size the design team should also provide:
 Vendor pricing and delivery times
□ Identification of items with long lead (delivery) times.
□ PM to Review the completed cost estimate and schedule to ensure all design
elements were included.

□ Get reviews and approval for and changes to the design criteria as well as the
layout for the pump station and force main.


3.3 Phase 3 ‐ Design Development
□ Further develop the size and character of the entire project.
□ Many times items under this phase are submitted as an Interim Design submittal
– check regulatory and scope of work requirements.
3.2.1 Design ‐ Related to Pumping Systems
□ Evaluate the constructability of the pump station and associated piping and
valve systems.
□ Develop a construction sequencing plan, with refinement of the MOEODC.
□ If a Client requests a Process Safety Review it should be completed at this stage.
□ As required, have final force main surge and air valve analysis performed. The
need for surge analysis should be determined during the proposal stage of any
pump station project, and preliminary surge evaluation may also show that this
is required (which may require and addition to the scope if not previously
identified).
□ Complete the calculations, reviews and checks as required in QMP-1 and the
noted references.
□ Finalize system control methods
□ Finalize all system flows, pressures, pump selection, pipe and valves and
equipment data sheets.
□ For major equipment submit draft drawings and specifications for reviews by
manufacturers (at a minimum by those named in the specification and any others
who could produce the units )
□ Pre-Final (90%) all equipment data sheets.
□ Pre-final all pipe/gate/valve schedules.

3.2.2 Drawings ‐ Related to Pumping Systems
□ Develop and/or coordinate the following drawings for the pump station. All
discipline drawings should be developed to the interim (60%) level by the end of
this phase unless otherwise noted.
□ Process Flow Diagram (updated if required)
□ Updated Hydraulic Profile- as noted in Section 2 of this guide
□ Updated Equipment Listing/Schedules – as noted above
□ Updated Process Pipe/Valve/Gate schedules - as noted above
(preferably those are on the Drawings but may be put in the specs)
□ Updated Pre-final (90%) Pump Facility/Station Plans and Sections
□ Pre-final main discharge Pipe/Force Main Plans and Sections
□ Details
□ Pre-final Operations Plan
□ Construction Sequencing Plans
□ Other Process Mechanical Drawings brought to the 75% completion level.

□ Updated P&IDs as noted above

3.2.2.3 Civil
□ Updated Yard Piping Plans and Profiles
□ Site Access Plans showing access to Pumping Facilities

□ Floor Plan and Elevations

3.2.2.5 Structural

3.2.2.6 HVAC

3.2.2.7 Plumbing and Fire protection
□ Below Slab Plan and Sections
□ Above Slab Plan and Sections

3.2.2.8 Electrical
□ One-Line Diagrams
□ Pre-final electrical site plans
□ Wiring Plans
□ Lighting Plans
□ Initial MCC layout

3.2.3 Specifications ‐ Related to Pumping Systems
□ Using a specification listing/ control matrix: Gather master specs on the
various components of the pumping system.
□ The standard pump facility/station will include, as a minimum, the following
specifications from the process mechanical engineer:
 Pumps
 Piping
 Valves/ Gates
 Actuators
 Piping Supports and restraints
 Piping Specialties
 Construction Sequencing/MOEODC
□ Evaluate each individual pump facility/ station to determine if there are any
specialty pieces of equipment, which need to be included in the pump
specifications; for example grinder or strainers, or special pump control valves
are sometimes specified to be supplied by the pump manufacturer.
 Note: Normally the pump, motor and any variable speed units are supplied
as a package by the pump manufacture to provide a single source of
responsibility.
□ Verify the Client’s name is used properly and there are no references to past
projects.

□ Determine if the Client has specific requirements.
□ Ensure each specification includes all areas included in master specification
format.
□ Complete specifications for any items that have long delivery times (and
potential early bidding/ purchase to not delay the overall project)
3.2.4 Interim Opinion of Probable Construction Costs and Constructability

Review
□ At the end of 60% design, provide all drawings and specifications to perform a
complete construction cost estimate and scheduling.
□ Based on the size of the project the project engineer may also be asked to
provide:
 Quotes for major pieces of equipment, including delivery times
□ Also perform a constructability review as the complete the Interim cost estimate
□ PM to review the completed cost estimate and schedule to ensure all design and
construction elements were included.

3.2.5 Technical Review Committee and O&M Review
□ Get approval for any changes to the pump station and force main layout as well
as the construction sequence plan.
□ Have an O&M person perform an O&M review.
□ Incorporate appropriate comments from the TRC, constructability and O&M
reviews into the submittal for delivery to the Client and/or regulators.

3.4 Phase 4 – Pre‐Final Design
□ Complete the requirements and details of construction and implementation (for
design-bid-construct) of the entire project – ready for formal cross checking.

3.4.1 Design ‐ Related to Pumping Systems
□ Verify all required documentation is completed and filed appropriately.
□ Verify that all required calculations have been properly completed, reviewed,
□ Verify that all Equipment Data sheets have been properly finalized, reviewed,
□ Ensure that all review comments have been addressed and the responses have
been included in the documentation.
□ Review the initial Client preferences and regulatory review documents to ensure
that these design concepts have remained intact.
□ Confirm that all documents are at the 90% level, including having been properly
checked within each discipline – see below.

□ Ensure that all title block information is complete and corresponds with the
information on the drawings index.
□ Spell check all drawings.
□ Check all section, detail, and match line references.

3.4.3 Specifications– additional items
□ Ensure that all of the author’s comments (bold statements from Master Specs)
have been addressed and removed.
□ Submit equipment specs to electrical and instrumentation for review.

3.4.4 Final Intra‐Discipline Review ‐ within each Function Group
(Calcs, Equipment Data Sheets, Drawings, Specs)
□ Request TRC comments/responses from all disciplines to confirm all issues have
been resolved.
□ Ensure all documents are in their final form before review.
□ Complete final red/yellow/green markups within the individual function
groups.
□ Documents should be ready for detailed cross checking.

3.4.5 Pre‐Final Opinion of Probable Construction Costs and Biddability Review
□ Obtain updated quotes and delivery times from vendors.
delivery times to construction contractor for an update to the construction cost
estimate and
schedule.
□ construction contractor should be tasked to perform a biddability
review with appropriate comments incorporated before the final
bidding sets are put together.

3.5 Phase 5 ‐ Final Design
□ For Design-bid-Construction Projects: Produce a completely checked and ready
for bidding set of construction documents.

3.5.1 Final Inter‐ Discipline Review‐ Cross checking between Function Groups
(Equipment Data Sheets, Drawings, and Specs)
□ Ensure all documents are in their final form (i.e. checking completed within each
discipline) before starting cross checking review.
□ Complete final red/yellow/green markups between the individual function
groups, and correction of any discrepancies, as required in QMP-1, and
information in any specific cross checking memo.
□ Cross Check:
 Drawings with Drawings
 Drawings with Specs
 Specs with Drawings


3.5.2 Drawings– additional items

□ Complete the final discipline cross check:
 Ensure all drawing background references are accurate
 Check all cross discipline page references
 Check all cross discipline detail numbers
□ Each drawing should be signed and sealed by the P.E.

□ Ensure all related specifications have been referenced.
□ Check final spec formatting.

3.5.4 Final Opinion of Probable Construction Costs and Schedule
□ Obtain updated quotes from vendors.
□ Send 100% drawings and specs along with updated equipment quotes for an
update to the construction cost estimate.

3.6 Construction ‐ Designer Responsibilities

3.6.1 Shop Drawing Review
□ Determine if the submittal may be accepted or should be returned for further
clarification.
 Ensure that all specification and drawing requirements have been met
 Confirm that all required materials of construction are clearly identified
 Review any major dimensions with information shown on the Contract
drawings
 Perform all reviews in a timely manner
□ Ensure that cross discipline information is reviewed by each discipline involved.
□ Submit all completed shop drawings and review forms to the technical manager
or task leader for them to return the submittals to the Contractor.

3.6.2 Assistance to Field Staff During Construction
□ Promptly address, research and answer (with proper documentation) any
inquiries from field staff (including those passed on from the Contractor), since
time is normally of the essence in any ordering, construction and startup
situation.
□ All Contractor enquires, such as Requests for Information (RFIs), shall be
properly documented, and promptly returned to the filed staff.

- - END OF DOCUMENT - -

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MECHANICAL

SYSTEM DESIGN GUIDE

MECHANICAL SYSTEM PROJECT GUIDE 1

MECHANICAL SYSTEM PROJECT GUIDE 6

II. PROCESS MECHANICAL PIPING SYSTEMS DESIGN GUIDE

2.1.2.1 Design Criteria – Reconfirm and Refine

2.1.2.2 Equipment Data Sheets and Process Pipe Schedules

2.2.1 Pipe Size

external pressure as well as handling thickness of each piping system.

III. PUMPING STATION/ SYSTEMS DESIGN GUIDE

for future replacement or repair.

3.2.7.3 Civil Drawings – preliminary as noted above

and evaluation of TRC comments.

3.2.4 Interim Opinion of Probable Construction Costs and Constructability

3.5.2 Drawings– additional items

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