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Pump Tank Stations: Design, Operation, Automation, and Energy Efficiency

Applications for Municipal and Industrial Use

Water tanker pumping stations are widely used by both municipal and industrial entities. Municipal water authorities use them to pump water from sources to treatment plants and on to consumers, as well as to convey wastewater to treatment facilities. Another critical application is managing stormwater by pumping and discharging it into water bodies. From a municipal perspective, the uninterrupted operation of these pumping stations directly affects the quality of life and environmental safety for millions of people.

Industrial enterprises use equipment such as pump tank station within their technological processes to transfer raw materials, semi-finished products, and finished goods between equipment, workshops, and storage facilities. They are implemented in industries such as oil and gas, food and beverage, chemical, pharmaceutical, and metallurgy. Other key applications include cooling water systems, handling industrial wastewater, and serving as part of factory fire protection systems. In essence, these stations are integral to any process requiring the transfer of a liquid from one point to another.

Pump Tank Station by Torch-Air

Station Structure

A pumping station consists of the following key components:

a pump station tank;
a pumping unit, which may consist of one or more individual pumps;
an electric motor;
piping network;
an automated control system (SCADA/PLC-based);
instrumentation (pressure, level, and flow sensors);
safety and protective equipment.

The apparatus controls are typically housed in a dedicated control cabinet, designed to protect against dust and moisture. Depending on its specific application, the station will incorporate equipment with distinct performance characteristics and operational features. For instance, vertical multistage centrifugal pumps constructed from stainless steel or bronze are standard for potable water supply. In contrast, wastewater applications utilize grinder or vortex mechanisms, which are specifically designed to handle solids and fibrous materials.

Depending on its function, a pumping station may require several additional components for normal operation. These include filter elements to protect the pump from solid particles; shut-off valves such as gate valves, taps, and control valves to isolate sections of the system; and lifting equipment like cranes, hoists, or winches for installing and maintaining the machinery.

Pump Tank Stations

Reservoir Sizes 200 to 3000 gallons

Industrial Polypropylene Tanks

Reservoir Sizes
20 — 10,000 gallons

Polyethylene Storage Tanks

Reservoir Sizes:
20 — 14,000 gallons

Plating Tanks

Reservoir Sizes:
20 — 6,000 gallons

Operating Principle

A pumping station operates in a cyclical manner, though the cycle differs between water supply and wastewater disposal.

In a water supply configuration, the pump operates until a preset maximum pressure is reached in the pipeline. Once that pressure is achieved, operation ceases. The system remains idle until pressure drops to a minimum set point, at which point the motor restarts to begin pumping again.

In a wastewater configuration, liquid flows by gravity into a receiving tank (or wet well). When the liquid reaches a high-level sensor, the motor starts, activating the pump to begin discharge. The system moves liquid out of the tank until the level falls to a low-level sensor, triggering the motor to shut off. A check valve in the discharge line prevents liquid from flowing back into the tank.

Pump Tank Station by Torch-Air

Automated Solutions

The entire process is fully automated. To maintain a uniform fluid flow, the system uses pressure sensors that activate at preset high and low setpoints. For efficient drainage, level sensors trigger operation when the fluid reaches predefined upper and lower limits. In addition, systems utilize flow meters, motor and bearing temperature sensors, and vibration sensors for component diagnostics. Fluid quality analyzers can also be integrated as needed.

Integrated frequency converters protect the system from water hammer by ensuring smooth motor start-up and shutdown. If multiple pumps are used, the automation system sequences their activation to distribute wear evenly. All are managed through an intuitive operator interface.

Energy Efficiency and Power Consumption

Pumping stations can consume up to 15% of the energy used in industrial facilities. Therefore, improving their efficiency by even a few percent yields significant cost savings.

Savings are achieved through the following methods:

implementing variable speed drives (VSDs) using frequency converters, which allow pumps to operate at an optimal speed rather than cycling on and off constantly;
using high-efficiency motors, such as IE3 (Premium Efficiency) and IE4 (Super Premium Efficiency) classes per the IEC standard;
installing high-efficiency pumps (e.g., those compliant with the ENERGY STAR standard in the U.S. or meeting the European MEI ≥ 0.7 threshold);

Wastewater Pumping Station

utilizing intelligent control systems (e.g., SCADA) with advanced algorithms that optimize multi-pump operation, dynamically adjust pressure setpoints based on time of day, and prevent operation in inefficient or emergency modes;
properly calculating and selecting pipeline diameters to minimize friction losses.
selecting a pump whose performance curve best matches the required operating point and system load profile;
regularly measuring actual flow, pressure, and power consumption to identify inefficiencies;
integrating renewable energy sources, such as solar power or energy recovery turbines.

System optimization for pumping stations can cut energy use by 30-50%, offering a strong return on investment with payback typically achieved in 1-3 years. Overall, achieving energy efficiency requires a systems approach encompassing competent design, optimal equipment selection, and the implementation of adaptive control systems.

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Head of Engineering,
Vladimir Nikulin

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