Standard for

Transmission Water Pump Stations

DP-14

Ver. 0.1

Date: 22 June 2018

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 1 of 31
 Revision Description Released by Date

0.1 Working draft for comment J de Villiers 22/06/2018

Reviewed by:

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 2 of 31
 Table of contents

GLOSSARY: TERMS AND ABBREVIATIONS ........................................................................................................ 5

PART A – PRELIMINARY AND GENERAL REQUIREMENTS .................................................................................. 6

1. INTRODUCTION ........................................................................................................................................ 7

2. REFERENCED STANDARDS ........................................................................................................................ 7

2.1 WATERCARE STANDARDS............................................................................................................................... 7

2.2 NATIONAL AND INTERNATIONAL STANDARDS ..................................................................................................... 7
2.3 OTHER PUBLICATIONS ................................................................................................................................... 8

3. DESIGN DELIVERABLES ............................................................................................................................. 8

4. CRITICALITY AND INFRASTRUCTURE FLEXIBILITY PRINCIPLES ................................................................... 9

4.1 DESIGN LIFE ................................................................................................................................................ 9

4.2 FUNCTION CLASSES AND CRITICALITY ................................................................................................................ 9
4.3 RESILIENCE AND REDUNDANCY ....................................................................................................................... 9
4.3.1 Resilience measurements {Table based on the IIMM, 2015 example table 3.2.8} .......................... 9
4.3.2 Scoring .......................................................................................................................................... 10

5. RISK ........................................................................................................................................................ 10

6. SAFETY AND HAZARD MITIGATION ........................................................................................................ 11

6.1 SAFETY IN DESIGN GUIDELINES ..................................................................................................................... 11

6.2 SAFETY IN FACILITIES DESIGN GUIDELINES ....................................................................................................... 11

7. DESIGN PROCESS FOR TRANSMISSION PUMPING STATIONS .................................................................. 12

8. PUMP STATION PLANNING CONSIDERATIONS ....................................................................................... 14

9. DESIGN OUTPUT FORMAT ...................................................................................................................... 14

10. PUMPING STATION SITE ..................................................................................................................... 15

10.1 SITE GROUND CONDITIONS........................................................................................................................... 15

11. GENERAL DESIGN CONSIDERATIONS .................................................................................................. 17

12. DESIGN REVIEW.................................................................................................................................. 17

13. CONSTRUCTION .................................................................................................................................. 18

14. PUMPING STATION ASSET DATA ........................................................................................................ 18

15. TESTING AND HANDOVER .................................................................................................................. 18

15.1 COMMISSIONING ....................................................................................................................................... 18

15.2 REJECTION OF MATERIALS OR PRODUCTS ........................................................................................................ 19
15.3 HANDOVER DOCUMENTS ............................................................................................................................. 19

PART B – PUMP STATION LAYOUT AND SPECIFIC DESIGN REQUIREMENTS .................................................... 20

1. GENERAL CONFIGURATION .................................................................................................................... 21

2. MATERIAL SELECTION ............................................................................................................................ 22

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 3 of 31
 2.1 PIPEWORK ................................................................................................................................................ 22
2.2 INLET STRAINERS ........................................................................................................................................ 22
2.3 VALVES .................................................................................................................................................... 22
2.3.1 Isolation valves ............................................................................................................................. 22
2.3.2 Non-return valves ......................................................................................................................... 22
2.3.3 Pump bypass valves ...................................................................................................................... 22
2.3.4 Air release valves .......................................................................................................................... 22

3. PUMPING SYSTEM ................................................................................................................................. 23

3.1 HYDRAULIC DESIGN .................................................................................................................................... 23

3.2 PUMP SELECTION ....................................................................................................................................... 23

4. PUMP STATION OUTLET ......................................................................................................................... 24

5. RISING MAINS ........................................................................................................................................ 24

5.1.1 General ......................................................................................................................................... 24

5.1.2 Hydraulic design............................................................................................................................ 24
5.1.3 Pipe Material ................................................................................................................................ 25
5.1.4 Rising main levels .......................................................................................................................... 25
5.1.5 Combined rising mains .................................................................................................................. 25
5.2 RISING MAIN SCOUR AND ISOLATION POINTS ................................................................................................... 25

PART C – ELECTRICAL, CONTROL AND TELEMETRY ......................................................................................... 26

1. ELECTRICAL, CONTROL AND TELEMETRY ................................................................................................ 27

1.1 ELECTRICAL............................................................................................................................................... 27
1.2 CONTROL SYSTEM AND TELEMETRY ............................................................................................................... 27

PART D – INFRASTRUCTURE AND SUPPORT SYSTEMS .................................................................................... 29

1. WATER SUPPLY ...................................................................................................................................... 30

2. LIGHTING ............................................................................................................................................... 30

3. SITE DRAINAGE ...................................................................................................................................... 30

4. NOISE CONTROL AND VIBRATION .......................................................................................................... 30

5. LIFTING EQUIPMENT .............................................................................................................................. 30

6. VENTILATION ......................................................................................................................................... 31

7. SECURITY AND ACCESS LIDS ................................................................................................................... 31

8. SIGNAGE ................................................................................................................................................ 31

9. SITE ACCESS ROAD ................................................................................................................................. 31

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 4 of 31
Return to Index

Glossary: Terms and abbreviations

Accept(ance) a sign-off by Watercare that it is in general agreement with a
proposal. This sign-off does not transfer the designer’s liability to
Watercare.

BEP Best efficiency point, typically at about 85% of the pump shut-off
head. This is the pump design point.

DN Nominal metric diameter designation conforming to the

International Standards Organization.

ΣDDT Trichloride-2,2-bis(p-chlorophenyl)ethane, synthetic organic

compound used as an insecticide.

FD Functional description completed to Watercare’s template

Head Measure of liquid surface elevation.

H&S Health and Safety.

kPa Kilo-Pascal.

LIM Land Information Memorandum.

l/s Litres per second.

NES National Environmental Standard.

PS Pumping Station.

CS1, CS2, CS3, CS4 Watercare engineering compliance statements for design and
construction.

PN Nominal internal pressure that a component can safely withstand.

P&ID Piping and instrumentation diagram.

Rising main Pressurised water pipe through which water is elevated to a point
of supply.

SCS Soil contaminant standard.

VOC Volatile organic compound.

WGS84 World geodetic system. WGS84 is the latest reference coordinate

system used by global positioning systems (GPS).

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 5 of 31
Return to Index

Part A – Preliminary and general

requirements

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 6 of 31
Return to Index

1. Introduction

Design and construction of pumping stations need to be completed by competent persons to the minimum
requirements as set out in this standard.

This standard covers the planning, design and construction requirements for water pump stations to transfer
water from storage to another storage location or to boost system pressure.

The electrical standards and control templates are available separately and shall be read in conjunction with this
standard. Watercare’s telemetry requirements are location based and require input from Watercare to identify
the applicable standards and/or site requirement at the pump station site.

2. Referenced standards
This standard must be read in conjunction with the Watercare, national and international standards listed
below. Where conflict or ambiguity exists this standard shall take precedence. Where there is conflict between
referenced standards, the higher level of standard shall take precedence.

2.1 Watercare standards

 DP-07 Design principles for transmission water and wastewater pipeline design
 DP–10 Safety in Design guide
 DP-11 Watercare, 2017. Health and Safety in Facility Design
 DP-12 Architectural design guidelines
 7363 – Watercare CAD manual
 AI - Data and Asset Information standard1
 MS – Material supply standard
 DP-09 Electrical design standard
 DW18 - Pump station electrical drawing set
 DW04 – Water pump station drawings for networks
 DW06 – Access structure drawings for water infrastructure
 CG – General civil construction standard
 ME – General mechanical construction standard
 EC - General electrical construction standards
 COP-03 Code of Practice for commissioning

2.2 National and international standards

NZS 1170 Structural design actions

Part 5 Earthquake actions – New Zealand

Part 5 Supp 1 earthquake actions – New Zealand - Commentary

NZS 3101 Concrete structures

AS 3996 access covers and grates

1
At the time of publication, the referenced standard is still under review and will take affect once published.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 7 of 31
Return to Index

AS/NZS1657 Fixed platforms, walkways, stairways and ladders. Design, construction and installation AS 1418

AS 1418 Cranes, hoists and winches

AS 4991 Lifting devices

AS/NZS 3000 Wiring rules

2.3 Other publications

Roberts, R, New Zealand Geotechnical Society, 2017, New Zealand Ground investigation specification, Volume
0, 1, 2 and 3

Worksafe NZ, Approved Code of Practice for cranes

3. Design deliverables
Design work shall be completed by Chartered Professional Engineers or a suitably qualified engineer who have
their work reviewed by a Chartered Professional Engineer in accordance with the Watercare compliance
statement policy. Any design produced may be subjected to review by a Chartered Professional Engineer.

The designer must consider the design under the full operational requirements and apply good engineering
practice that reflects:

 Compliance with New Zealand legislation, the most recent national standards, regulations and local
conditions
 Watercare standards as included and referenced in this standard
 Historical information that may impact on the design
 Community and customer expectations
 Other information or specific conditions as provided by Watercare

The design shall not imitate or amend a current approved Watercare standardised design. Specific design
drawings shall cross-reference the standard Watercare design and constructions standards.

The following comprehensive documents shall be provided to Watercare for evaluation of the design:

a) Geotechnical reporting on the suitability of the land for the life of the asset
b) Basis of design report describing options and selection of design
c) Risk analysis
d) Design report
e) Material schedules
f) Project execution plan
g) Site specific specification for construction
h) Nominated minimum levels of construction supervision
i) Drawings showing location, detailed long sections, pipe grades and sectional details
j) Functional descriptions (FD) of the transmission system function in network
k) O&M manual draft
l) Standard operating procedure (SoP) draft
m) New assets register in accordance with Watercare’s data and asset information standards
n) Design compliance statement – See Watercare compliance statement policy

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 8 of 31
Return to Index

4. Criticality and infrastructure flexibility principles

4.1 Design life

The design life for pumping stations system and associated structures is to provide 100 years’ service life
within an acceptable level of service (quality and capacity of service) offset against an acceptable cost of
maintenance of the service at this level. Some components may require maintenance or intervention before
the 100 year service life, such as instrumentation or pump replacements, and must be included in the overall
lifecycle cost of the pump station.

Note: Further information on life cycle cost and optimal point of replacement can be found in the International
Infrastructure Maintenance Manual (IIMM, 2015)

4.2 Function classes and criticality

Transmission pump stations and the associated infrastructure within the pumping station site shall have a
minimum function class of 3.

Note: Refer to the New Zealand Ground investigation specification for the level of geotechnical information to
be applied

Design Safety Factors Seismic

return
Function class Description Peak ground Liquefaction Landslide/ Surface period
acceleration /subsidence lateral loading factor
movement (NZS1170) Ru
3 Critical Pump stations servicing
large numbers of
customers (>10,000
people) failure could
cause significant
1.8 1.35 1.6 1.5 1.8
economic impact or
substantial hazard to
human life, the natural
environment and
properties.
4 Essential Pump stations that are
lifeline essential to maintain
service post natural
2.3 1.5 2.6 2 1.8
disaster or man-made
mishap and are intended
to remain in service.

4.3 Resilience and redundancy

Resilience of pumping stations include site specific flexibility as well as the wider system that the pumping
station is functioning within to sustain a level of service and absorb or adapt to changing conditions when
there is a failure at the pumping station.

4.3.1 Resilience measurements {Table based on the IIMM, 2015 example table 3.2.8}
Dimension Principle Indicators Assessment
method
Robustness Maintenance regime i.e. preventative or run-to-failure Audit against
vulnerab
Technica

best practice
ility
l

Asset renewal strategy is up to date Audit against

standards

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 9 of 31
Return to Index

Dimension Principle Indicators Assessment

method
Design standards are followed and reviewed Audit against
best practice
Spare capacity in the network system Audit / system
modelling
Condition rating of exiting asset/system Audit
Redundancy Supply of backup equipment/components are identified Supplier audit
and suppliers hold stock
System diversion plans are in place, kept up to date with System
new assets/system changes modelling and
audit of plan
Capacity from alternative source System
modelling
Modularity / Modular systems, interchangeability Standard design
flexibility / best practice
Future allowance for upgrade, improvements and Audit against
strengthening best practice
Variation Qualifications of staff are appropriate to roles and Audit
readiness responsibilities
Staff quantity and resources are adequate to deal with Audit
reactive changes
Continual development of staff Survey / audit
Communication is clear with protocols in place Survey
Organisational vulnerability

Information on systems and assets such as drawings and Survey / audit

operational manuals are readily availability
Readiness/response planning are in place and practiced Audit
Funding availability to effect operational variance Audit
Insurance are up to date and with appropriate risk cover Audit
Leadership / Decisive decision making Survey
culture Situational awareness Survey
System knowledge Survey
Innovative thinking Survey
External Ability to leverage on external knowledge Survey
partners Partnerships, design and service delivery arrangements Audit
Behavioural/communication barriers that could restrict Survey
productive solutions

4.3.2 Scoring
Scores are assigned based on the assessment outcome for the individual fields listed under section 5.3.1 and
collated up under the principle categories and rolled up as averages for technical and organisational averages.

Score Description
1 Poor, not adaptive, complete loss of level of service
2 Marginal, adaptive but with system constraints or reduced level of service
3 Good, adaptive
4 Excellent, very adaptive/diverse with multiple redundancy options

5. Risk
Risk shall be assessed in accordance with the current Watercare Risk Management Framework.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 10 of 31
Return to Index

6. Safety and hazard mitigation

6.1 Safety in Design guidelines

Refer to the Watercare Safety in Design standard for output requirements and to complete HAZOP analysis.

6.2 Safety in Facilities Design guidelines

Refer to Watercare Health and Safety in Facilities guidelines, 2017 for the functional safety outputs required at
pumping stations.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 11 of 31
Return to Index

7. Design process for transmission pumping stations

The following flow chart is a guideline on the expected stages for developing the pump station design:

Watercare process Designer Key documents

Strategy / Planning / Service

Delivery  Business case
 Size of catchment  Project brief
 Location

Electrical and telemetry desk study

on location serviceability

 Resource consent
 Develop concept design  Concept design report
 Architectural design concept  Report demonstrating NDC compliance
 AEE  Land transfer plan

Strategic consent
Complete analysis
Finalised project brief

Preliminary design
Safety in design
Finalise Architectural design

Review design

 Final design report (covering

Detailed design requirements in this standard, i.e.
Serviceability and operational  Plans and technical calculations, surge analysis, FD, P&ID's,
review drawings schedule of materials, etc.)
(Design to be finalised)  Design drawings  Project execution plan
 Finalise calculations;  Design compliance statement (CS1 or
 Discharge plan; etc. CS2)
 Serviceability limit state (confirmed with
Watercare Planning)

Design accepted
Y/N

Auckland Council
Resource consent application
Building consent application  Auckland Council consents

Construction contract
specifications

Contract tender and

award

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 12 of 31
Return to Index

Watercare process Designer Key documents

 Prelim as-built drawings

Construction phase  Electrical certificate of compliance (CoC)
-  Signed-off pre-commissioning test
Construction results of structures and pipework.
monitoring  Draft Operations and Maintenance
Manual.
 Factory acceptance testing (FAT).
 Commissioning plan
 Construction QA/QC sign-off (CS3 and
CS4 with supporting documentation)

Final commissioning and takeover

All pre-commissioning documents finalised and approval received  Commissioning plan
 Approval to connect

Watercare acceptance of final Final documentation

documents  Post-construction residual risks register
 Operations and Maintenance Manual
 Final Functional Description (FD)
supplied separately to the O&M manual.
 Electrical Certificate of Compliance
 Design drawing sets, as-built drawings
Watercare handover and survey data
Final documentation
 Asset certificate
 Engineering compliance statements
 Agreed to transfer of liability

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 13 of 31
Return to Index

8. Pump station planning considerations

The feasibility study shall have considered technical, environmental and financial criteria over the entire design
life of the system.

When planning and designing for a pumping station; consideration shall be given to pumping station placement
including:

 Future expansion / upgrades that will allow the existing infrastructure to accommodate overall increase
in the capacity of the pumping station and other staged infrastructure
 Running costs, life-cycle and ongoing maintenance costs
 Impact on existing pumping stations will require a full system integrated design
 Environmental and health and safety risks
 Dry-weather storage capacity
 Pumping station structures shall allow for the following minimum design life:
i. Storage tanks 100 years
ii. Pipework 100 years
iii. Valves and meters 30 years
iv. Electrical equipment 25 years
v. SCADA and control 15 years

9. Design output format

The design considerations for review by Watercare shall follow the following output format:

Pumping station site location

considerations

Inlet system Pumping system Power system Control and Output system Infrastructure
telemetry and support
systems systems

 Storage tank  Pump sets  Power  Pumping Discharge  Access

/ upstream  Connections supply control pipework  Drainage
pipe  Pump  Standby  Alarms Valves  Services
 Access pedestal/dis power  Telemetry Pressure  Lighting
 Strainers charge  Cabling & system, mains  Material
 Foot valve connection connection PLC/RTU Discharge handling
 Engineered  Starters &  Standard  Level / point and storage
overflow VSD template pressure  Buildings
details by sensors  Site security
Watercare  Equipment  Signage
and devices  Water
 Instruments supply
 Standard
details by
Watercare

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 14 of 31
Return to Index

10. Pumping station site

Pump stations shall be sited on public land or a dedicated lot for the exclusive purpose of housing the station
and all related structures and equipment. The site must provide adequate space for service vehicle movements
and future expansion as may be predicted.

The pumping station general site layout shall have:

a) A level aspect within the boundaries of the pumping station.

b) 24hr all-weather vehicle access, adequate parking and adequate manoeuvrability and hard stand areas
to access all components for maintenance and replacement.
c) Dedicated underground mains power supply.
d) A dedicated control room / cabinet to house electrical equipment as specified in the Watercare
electrical and control standards.
e) Building doors, switchboards, control cabinets and chamber cover-plates are to be provided with
adequate clearances for maintenance access.
f) Electrical connection facilities for the provision of a temporary generator.
g) Dedicated utility service ducting.
h) Associated valves and metering.
i) Landscaping and planting as required by consent conditions or as otherwise specified by Watercare
during the design review. Refer to Watercare architectural design guidelines.

10.1 Site ground conditions

Ground investigations shall be completed in accordance with the New Zealand Ground investigation
specification, 2017 (http://www.nzgs.org/library/nz-ground-investigation-specification).

All data collected shall be uploaded to the Auckland Geotechnical Database in AGS4 format at:
https://agd.projectorbit.com

Contaminated sites should be avoided. Where a contaminated site has been confirmed, written approval to
proceed shall be obtained from the Auckland Council and Watercare. The following issues shall be addressed
in the request for approval:

 The nature of the contamination;

 Compliance with statutory requirements;
 Options to de-contaminate the area;
 Selection of pipeline materials to achieve the required life expectancy of the wastewater main;
 Safety of construction and maintenance personnel; and

Any contaminants in the soil, including topsoil on the site, shall be at the lesser levels of the health-based or
environmental related protection values as described below:

 Health based protection values:

NES Soil contaminant standards (SCS) for residential land use (no produce, if applicable) as derived
in accordance with Ministry for the Environment Methodology for Deriving Standards for
Contaminants in Soil to Protect Human Health (Chapter 7). In the absence of a derived NES Soil SCS,
then a standard following the hierarchy outlined in the Ministry for the Environment, Contaminated
Land Management Guidelines No 2 shall be adopted.

 Environmental related protection values:

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 15 of 31
Return to Index

Auckland Council Air Land and Water (ALW) Plan criteria for discharges as described in Rules 5.5.41.

 No asbestos containing material or volatile organic compounds in site soils.

No free (or separate) phase liquid contaminants and groundwater contaminant concentrations, with the
exception of volatile organic compounds, which must be below the Australian and New Zealand Guidelines for
Fresh and Marine Water Quality at the level of protection for 80% of freshwater species. Concentrations of
volatile organic compounds shall be below typical laboratory screening detection limits (0.5 mg/L or lower).

The following table sets out the acceptance criteria for contaminant free sites:

Contaminant Acceptance level (mg/kg)

Arsenic <24
Cadmium <7.5
Chromium <400
Copper <325
Lead <250
Mercury <0.75
Nickel <105 1
Zinc <200 1
Benzo(a)pyrene equivalent <2.15
Pyrene <1
ΣDDT <0.7
VOCs Below laboratory detection
limit
1 Can use upper limit background concentration in Auckland region (i.e. 320 for Nickel and 1160 for Zinc) if the soil is
volcanic source

A site investigation including soil sampling and testing must be undertaken and a report submitted to
Watercare in accordance with the requirements of the Ministry for the Environment, 2011, Contaminated
Land Management Guidelines No. 1 - Reporting on Contaminated Sites in New Zealand. Testing shall be
conducted by a NATA/IANZ accredited laboratory.

Soil testing data is required at the position for the proposed pumping station. Depending on the size of the
proposed site additional soil testing at more than one location may be required if a single sample is not
considered representative of the site.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 16 of 31
Return to Index

11. General design considerations

The design shall be carried out in conjunction with the standard drawings, showing the typical layout that is
expected for a pumping station. It is expected that the core requirements shall remain unchanged with design
outcomes establishing the pipe sizes, fall/grade changes, pump and discharge sizes and any other dimensions.

The general design considerations include:

a) The general principles for pipe layout and structural design shall be reflected in accordance with the
requirements of DP-07 Design principles for transmission water and wastewater pipeline design, Part
C and D.
b) A designation schedule of essential infrastructure for post-disaster operational continuity shall be
determined in consultation with Watercare and to determine the appropriate serviceability limit state.
c) Determine the station lifting height requirements, flow losses through pipework and fittings to calculate
the total head.
d) Determine the operating philosophy and associated SCADA and telemetry requirements.
e) Develop the system curve that considers:
 The flow velocity initial flow and ultimate state and any staging.
 Static and friction losses.
 Total lifting head.
f) Complete geotechnical investigation for the purpose of structural design, construction considerations
and land contamination report.
g) Structural design of infrastructure.

12. Design review

Once the design has been completed the designer shall undertake a review to ensure compliance with the
requirements set out in this standard. The design shall be signed-off by a suitably qualified Chartered
Professional Engineer. Compliance checks shall cover the following minimum criteria before submittal for
evaluation by Watercare:

 Health and safety considerations identified during the design that includes for construction, normal
operation, maintenance and emergency operation
 Community and environmental impact assessment
 System components, layout and configuration meet this standard and are in accordance with the typical
pumping station standard details in the standard drawings
 Pump selection
 Plans indicating layout covering pipe size, grade, material types, transfer points and long sections
 Details of air release/vacuum and scour points
 Route selection meets concept/planning design
 Easements as appropriate
 Geotechnical data and considerations are taken into account during design
 Provisions made for future extension as appropriate, including upgrade staging and triggers
 Life cycle cost
 Compliance with referenced standards

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 17 of 31
Return to Index

13. Construction
Each section of the pump system shall be constructed but not connected until individually tested, unless suitable
isolation is available to complete individual tests before testing and commissioning the system as a whole (refer
to section 15 on commissioning).

Construction practices for components shall comply with the following Watercare standards:

a) General civil construction standard

b) General mechanical construction standard
c) General electrical construction standard
d) Material supply standard

14. Pumping station asset data

Pumping station data shall be captured in accordance with Watercare’s Data and Asset Information standard.

Note: As a minimum, redline mark-ups will be accepted for commissioning in anticipation of the final CAD
versions being provided at handover.

15. Testing and Handover

15.1 Commissioning
This section shall be read with Watercare’s Code of Practice for Commissioning.

All pre-testing and quality assurance checks shall be completed before commencing with commissioning.

Once the individual sections have been tested, the final connections are made ready for commissioning of the
pumps. A suitably qualified Watercare representative for the respective engineering disciplines shall witness the
commissioning in conjunction with the third party professional(s) that is responsible for the commissioning
works.

Commissioning work shall not progress unless the following documentation has been provided and has been
accepted to proceed:

 Preliminary as-built drawings

 Electrical certificate of compliance (CoC)
 Signed-off pre-commissioning test results of structures and pipework
 Draft Functional Description
 Process and instrumentation diagrams (P&ID)
 Draft Operations and Maintenance (O&M) Manual
 Factory acceptance testing (FAT) completed, see Watercare Code of Practice for Commissioning (COP-
03)
 Redline mark-up drawings
 Commissioning plan
 Applicable construction quality control signed off

The commissioning plan shall include, but is not limited to:

 HAZOP study

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 18 of 31
Return to Index

 Testing of all control system inputs and outputs (I/O’s), see Watercare Code of Practice for
Commissioning (COP-03)
 Pressure and level sensor adjustment
 Alarm status
 Pump control units
 Remote control and data transmission (RTU and PLC checks)
 Data logging and analysis
 Pump flow rates and rising/pressure main performance
 Noise and vibration level conforming during operation
Any non-conformance with this standard shall be corrected and re-tested.

15.2 Rejection of materials or products

All materials specified shall be accepted or standardised equipment as appropriate. Where products are required
to be sourced that is not listed on any of these materials lists, prior approval by Watercare is required.

Materials supplied shall comply with the nominated standards and the minimum certification criteria provided
as part of the handover process. Where substitutions of any materials or products are deemed necessary during
the construction of the pumping station, approval in writing from both Watercare and the pump station designer
is required.

Materials not accepted by Watercare shall be replaced at no additional cost to Watercare.

15.3 Handover documents

Watercare shall take over the pumping station when all of the below documentation are finalised and supplied:

a) Post-construction residual risks register.

b) Signed construction quality control sheets.
c) Operations and Maintenance Manual, see Watercare’s Data and Asset Information standard.
d) Final Functional Description (FD) (supplied electronically and separate to the O&M manual), see
Watercare’s Data and Asset Information standard.
e) Electrical Certificate of Compliance.
f) Design drawing sets, as-built drawings and survey data.
g) New assets register including for associated linear assets in accordance with Watercare’s Data and
Asset Information standard.
h) Engineering compliance statements for design, construction and construction monitoring.
Where materials have not been supplied by Waterdcare, all product and material warranties and guarantees
shall be transferred to Watercare.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 19 of 31
Return to Index

Part B – Pump station layout and specific

design requirements

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 20 of 31
Return to Index

1. General configuration
a) Two methods are used for providing water to the pump; positive suction head such as with an elevated
tank or pressure main (see part C for booster pumps), and suction lift conditions where the pump must
draw water from a lower level, requiring the inlet pipeline to be filled for priming the pump.
b) The pump station shall be installed at a minimum of 500mm above the 100 year flood level.
c) Isolation valves shall be accessible for operation without the need for confined space access.
d) The inlet shall be configured to minimise incoming flow turbulence.
e) The pump intake pipe from a reservoir or tank shall be formed with a long radius bend and facing
downwards. The suction pipe must always be on a rise to permit air movement.
f) The inlet pipework shall be the same size as the pump inlet. The diameter may be slightly increased to
reduce friction losses in which case an eccentric taper must be used. Concentric tapers should not be
used.
g) The centre-to-centre clearance between pump intakes shall be a minimum of 1.5 times the external
pipe diameter, or as otherwise required by the pump supplier to prevent vortices, air entrapment and
pre-swirl.
h) The side clearance from the centre of the pump intakes to the walls of the pump station shall be
minimum 750mm, or 0.8 times the external pipe diameter, whichever is greater.
i) Where the pump manufacturer requires minimum clearances for maintenance access an additional
250mm shall be provided.
j) Booster pump stations shall be installed above ground in an architectural designed building housing all
the associated equipment.
k) The building or enclosure shall have a minimum internal operator standing height clearance of 2150mm
l) Structural design shall be to the selected function class.
m) Suitable drainage must be included to maintain the pump house in a dry condition from any seepage
or surface flooding. The floor must be graded to a sump location with sump pump that discharges above
the flood level.
n) Clearances around equipment shall be as specified in Watercare Design principles for transmission
water and wastewater pipelines and:
 Pipework and pumps shall be at a height of minimum 400mm from the base of the building.
 Minimum (1.5 x diameter) lateral spacing between valves and pumps.
 Minimum 600 mm spacing between the wall and piping.
 600mm clear space from the end of control and electrical cabinet doors when opened.
 Control cabinets shall be mounted at operator standing height.
 Valves and pumps must all be installed on a horizontal plane – equipment shall not be required
to be removed on a lateral plane for replacement or servicing.
 Pipe protrusions through walls shall have a minimum clearance of 500mm before the first
flange
 Adequate space for future replacement with larger diameter pipework and components.
o) Footings or supports shall be provided underneath larger valves, pumps and manifolds that are in
excess of 35kg for the individual component.
p) Pipe support shall be provided to withstand structural and dynamic forces, and to provide the required
height from the base of the building.
q) The pump station building shall be isolated against noise, refer Part D, section 4.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 21 of 31
Return to Index

r) Service doors shall be sized to accommodate handling and removal of the pump station components to
the largest removable component as a whole. Doors shall be sliding type or hinge open outwards.
s) Access to the pump station building shall be unhindered with adequate clearance for service trucks and
any equipment required to maintain components.

2. Material selection

2.1 Pipework
a) Above ground pipework, or pipe transitioning from below ground to the surface shall be selected from
Stainless steel, epoxy lined mild steel, or ductile iron.
b) Pipe fitting connections shall be flanged. Threaded, socketed, vitaulic or compression couplings are not
acceptable.
c) Strategically located restrained dismantling joints are acceptable. Un-restrained joints are not
acceptable.
d) Welded pipe connections shall be fabricated in removable sections, and shall be flange jointed as per
above.
e) The minimum pipe pressure rating shall be PN16 (unless otherwise stated), and any other component,
valve, or fitting shall have a minimum pressure rating of PN16.

2.2 Inlet strainers

a) In areas where screening or strainers are required, the device shall be incorporation into the inlet
pipework, upstream of the pump.
b) Resilient seated valves shall be installed upstream of screens to enable individual isolation for cleaning.

2.3 Valves

2.3.1 Isolation valves

a) Main inlet and outlet isolation of the pump system shall be by resilient seated gate valve. Geared
butterfly valves may be approved on a case-by-case application.
b) Individual pump train isolation may with ball valve type up to 50mm diameter or butterfly valves over
50mm diameter.

2.3.2 Non-return valves

a) Non-return valves shall be swing check type with a rubberised steel disc and as accepted by Watercare.

2.3.3 Pump bypass valves

a) Pump bypass valves used for pump performance control shall either be a controlled needle valve type
a diaphragm release valve type. Modulated butterfly valves shall not be used for this purpose.

2.3.4 Air release valves

a) Air release valves where installed on the rising main shall be double acting and as accepted by
Watercare.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 22 of 31
Return to Index

3. Pumping system

3.1 Hydraulic design

a) Demand estimation shall be based on the requirements of the Watercare Design principles for
transmission water and wastewater pipelines.
b) Pump performance control shall be by speed control. Outlet valve throttle control is not acceptable.
c) The maximum flow velocity shall not exceed 3m/s.
d) The maximum discharge pressure at the top of the hydraulic line shall not exceed 800kPa. The
maximum operating pressure shall be less than the maximum cyclic pressure range (MCPR) for the
selected outlet pipework. Refer to section 4.
The hydraulic design shall also consider:

e) Surge pressure shall be anticipated at minimum 200kPa regardless if calculated to be less.

f) Suction head. Net positive suction head (NPSH) shall have a minimum safety factor of 500mm.
g) Pumping station capacity (initial and ultimate capacity).
h) Internal diameter, length, route and materials of the rising main, including surge and fatigue analysis.
i) Levels and profile of the rising main and discharge point.
j) High points - to account for possible characteristics controlled by intermediate highpoints along the
rising main.

3.2 Pump selection

a) Booster pump stations are designed as open systems with variable demand that depends on customer
usage with a potential zero night-time flow. To meet this demand variability the pumping system is
designed for constant pressure control. Pumps are arranged in parallel for demand fluctuation, raising
pressure and redundancy purposes; and arranged in series for high pressure applications.
a) The minimum overall pump efficiency shall not be less than 80%. Lower efficiency may be considered
in the following exceptional circumstances:
i. The pump curve is very flat thereby consuming less power at intermediate flows, or
ii. The anticipation of excessive impeller clogging and the associated maintenance outweighs the
energy saving costs of selecting a more efficient impeller type.
b) Pump head curves with very flat head flow characteristics can make the pump difficult to control. Small
changes in system resistance can create large changes in flow rate or cause ‘hunting'. The use of variable
speed drives (VSD) in these scenarios shall require prior approval from Watercare.
c) Consideration to pump wear over the pump maintenance cycle to achieve flow design criteria.
d) The number of pumps depends on the pump station flow range, volume and power rating. Standby
capacity shall be sufficient to maintain the pump station operation in the event of a pump failure or
maintenance. Where a single pump provides duty an equal capacity pump shall be provided for
standby. Where three pumps of equal capacity is provided, a fourth of the same capacity shall be
provided as standby. For large or critical pump stations two or more standby pumps shall be used.
e) For wide varying flow ranges different pump sizes should be considered to minimize power costs. The
number and size of standby pumps should be assessed base on the ultimate flow.
f) Phased pump installations should be considered for growth projections by selecting impeller size,
variable speed drives and adequate space for additional pumps or larger replacements.
g) Pump stop/start shall not to exceed more than 6 cycles per hour (design flow). Pump duty standby to
rotate on each successive pumping cycle.
h) The pump shall comply with the standards as listed in Watercare’s material supply standard.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 23 of 31
Return to Index

4. Pump station outlet

a) All pump stations shall have a meter installed on the pump station discharge pipework.
b) The inlet and outlet pipework shall be interconnected with a non-return valve and an isolation valve
installed (normally closed), regardless of whether bypass control is used for pump control inside the
pump station pipework. This bypass is to allow the pump station to be bypassed under emergency.
c) For booster pump stations requiring firefighting capability a firefighting booster connection point shall
be installed on the outlet.
d) The pump discharge pipe material design shall consider pipe and fittings to be pressure de-rated based
on the material maximum cyclic pressure range (MCPR). The maximum operating pressure shall be less
than the MCPR.

5. Rising mains

5.1.1 General
a) The rising main structural design and location shall be to Watercare’s Design principles for transmission
water and wastewater pipeline design. Rising mains shall not be situated in private properties.

5.1.2 Hydraulic design

The rising main pipe shall be designed in combination with the pumping system (see section 3 above) and
include:

a) Length of the main, static and dynamic head losses.

b) Head loss shall be calculated using the Darcy-Weisbach equation with frictional coefficients determined
using the Colebrook-White equation. A Colebrook-White friction coefficient of 0.3 shall be used.
c) Head losses through fittings shall be determined using the component manufacturer’s value with a 10%
inaccuracy factor. Where no data is available refer to Watercare’s design principles for transmission
pipeline systems on manufactured fitting friction losses.
d) Maximum allowed number of pump starts and the impact of cyclic fatigue on the selected rising main
material.
e) Withstand surge pressures not less than 200kPa. Pressure surges shall be within the amplitude of the
acceptable limits throughout the system. The surge analysis shall take into account the material fatigue
of the selected pipe material and the derived maximum allowable operating pressure. The design shall
identify solutions for Watercare’s approval to mitigate the surge effects.
Pressure surge solutions may include:
 VSD drives for even start-up.
 Slow-closing non-return valves.
 Pressure relief valve and quick-closing non-return valve.
 Automatic stepped main shut-off. Initial quick closing, thereafter slow-closing simultaneously
with the pump shutdown.
f) Withstand a transient pressure of at least 80kPa below atmospheric pressure. Negative pressures can
be prevented by:
 Pump inertia/flywheel to continue pump rotation for a short period after power failure.
 Surge tank.
 Double acting air relief valves.
 Air vessel.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 24 of 31
Return to Index

g) A minimum flow velocity is 0.9m/s. The minimum flow velocity shall be calculated at the expected start
of the service life. The design shall be carried out on the basis of full bore flow
h) The maximum rising main flow velocity shall not be more than 3m/s at ultimate service.

5.1.3 Pipe Material

a) Pipe material shall be supplied as complying with the applicable Watercare material standard.
b) The minimum pipe pressure rating shall be PN16 and any other component valve or fitting shall have a
minimum pressure rating of PN16.
c) The maximum pressure design shall consider pipe and fittings to be pressure de-rated based on the
material maximum cyclic pressure range (MCPR).
d) The maximum operating pressure shall be less than the MCPR.

5.1.4 Rising main levels

a) The main shall, wherever possible, rise continuously from the pumping station and terminate at its
upper end into the receiving structure or system.
b) The minimum rising or falling grade shall be 0.5%.
Where a continuously rising main is not achievable the following shall be provided for:

c) Peaks and low points shall be minimised.

d) Peaks shall be constructed with a double acting air release valve structure.
e) Scour valve and air release valve chamber access shall where practicable be located in the back berm
of the road corridor (the first 1m width of the road berm adjacent to the road carriageway is defined
as the front berm).

5.1.5 Combined rising mains

a) Under exceptional circumstances, parallel pumping may be considered. For existing systems where the
design basis is for a completely new parallel system or where the existing systems are redesigned and
replaced specific approval and design philosophy must be developed.
b) The parallel system shall be both as duty mains. Standby mains is not typically acceptable due to water
quality with stagnating water, corrosion and operational challenges with mains standing empty.
c) The operating points for parallel pumping stations shall be considered for the full system to set
individual pumping points based on the pumping head for each pumping station or pump set on the
common rising main. The combined output shall be graphically determined using the individual
geodetic heads; head loss components for each pumping station to the discharge point and then
combined onto a single graph.
d) Where the common rising main is a complex rising main the graphical determination shall be supported
by modelling software. Watercare prefers that the modelling information is provided in InfoWorks.

5.2 Rising main scour and isolation points

a) The number of scour locations and isolation points shall be decided based on the length of the rising
main at adequate intervals to reduce drain down time for repair and maintenance.
b) The scour shall be located with a hard-stand area that is accessible by truck.
c) Scours and mains isolation shall be in accordance with the Watercare Design principles for transmission
water and wastewater pipelines.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 25 of 31
Return to Index

Part C – Electrical, Control and telemetry

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 26 of 31
Return to Index

1. Electrical, Control and Telemetry

a) Electrical, control and telemetry design and installation shall comply with the Watercare electrical and
control standards and template drawing set DW18 for pumping stations.
b) Electrical and control equipment shall be 500mm above the 100 year flood level.

1.1 Electrical
Additional to the electrical standards the following requirements for establishing electrical power on site shall
also be completed:

 Sites owned by Watercare shall be coordinated for connection through Watercare. Early engagement
with the electrical mains provider is required.
 Where mains electricity is not available at the site a new installation point (ICP) will be provided.
 Mains electricity shall be of sufficient capacity taking into account future expansion.
 Unless otherwise approved, substations on a consumer’s premises shall be for the sole supply of the
Watercare facility.
 Information required for the ICP include: supply phase; maximum demand load in amps; physical
address of connection; name and contact of the electrical contractor undertaking the works.
 Any easement requirements for electrical mains and transformers must be referred to Watercare.

1.2 Control system and Telemetry

a) Watercare will complete a connection suitability study for the location, to establish the telemetry
requirements for the proposed pumping station site. A desk study will determine if there is an available
connection for the location.
b) If a connection is possible, the desktop study is followed by a site check to establish the signal to noise
level ratio to ensure a good quality signal is available.
c) Should there be no communications available or the signal strength is less than -90dB a specific design
will be required.
d) The telemetry and radio system shall be from a Watercare standardised supplier, refer to Watercare’s
material supply standard. The installation shall be carried out by a Watercare approved contractor.
e) The designer shall obtain a facility code from Watercare that is used to provide the tag information
used to configure the control system. The information required to obtain the facility code is:
 GIS location of the site
 The physical address associated with the site
 Lot number or Land Registry identification
f) The SCADA software shall be developed and implemented by a Watercare approved developer.
g) Watercare has five different control systems that operate in various areas, they are:
 Emerson DCS
 In Touch SCADA
 IFIX LNT SCADA
 Citect SCADA
 Abbey Systems Powerlink
In order for Watercare to complete the SCADA the following will be developed and supplied by the
designer:

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 27 of 31
Return to Index

i. A level 1 Functional Description (FD), to be reviewed and accepted by Watercare Service Delivery
before software programming commences.
ii. Liaise with Watercare point of contact in the production of the Electrical/ Control system design.
iii. Process and instrumentation diagrams (P&IDs).
iv. Bill of materials.
v. Confirmed Input and Output lists (I/O).

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 28 of 31
Return to Index

Part D – Infrastructure and support systems

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 29 of 31
Return to Index

1. Water supply
a) A site water connection shall be installed for cleaning purposes when specified. The connection shall
be a typical domestic connection fitted with a tap connection with ¾” BSP thread to allow fitting of a
hose. See G12/AS1 of the Building Code, for the methods and devices required to comply with
Watercare’s requirements.
b) Where firefighting supply is not within reach as per the New Zealand code of practice for firefighting
water supplies, then a suitable firefighting supply shall be installed in accordance with the Watercare
Code of Practice for Land Development and Subdivision, Chapter 6.

2. Lighting
a) Where considered an operational requirement or for safety reasons, site lighting must be specified. The
designer must confirm the requirement and location such as to provide adequate lighting not have
obstructive and obtrusive effects. The lighting shall be adequately controlled to prevent annoyance to
the neighbouring properties.
b) Lighting shall be provided at the pump station control and machinery rooms
c) Fluorescent lights shall be phase shifted to stop strobe effects on machine rotating shafts.
d) Positioning of lights shall be such as not to cast shadows or unlighted areas in the drywell and control
room.
e) The design shall take into account the types of activities to ensure the safety of people for the task
types in the pumping station environment so that any hazards are visible and well lit.

3. Site drainage
a) The site shall have adequate drainage and fall to prevent standing or ponding water and prevent inflow
into dry areas.
b) Overland drainage shall not affect neighbouring properties and may require a storm water system to
be installed for discharge to a suitable location.

4. Noise control and vibration

a) Noise generated by the pumping station shall not exceed the Council permitted levels. The design shall
include measures to reduce noise appropriately. Where the maximum noise level has not been
specified in the resource consent the maximum shall level be 45 dB LAeq (15min) measured at the pumping
station boundaries.
b) Strong and long term vibrations can cause soil settlement in certain soil types as well as long-term
structural problems. Apart from the effects on physical structures vibration may also cause discomfort
to adjacent property occupiers. The vibration velocity level shall not exceed 1mm/s measured at the
pumping station wet well.

5. Lifting equipment
a) Lifting devices shall comply with AS1418, AS4991 and the Worksafe NZ Approved Code of Practice for
Cranes.
b) Adequate access shall be provided for mobile lifting plant around the pumping station installation and
suitable hard stand areas.
c) Overhead gantry cranes shall be provided for handling large pumps, motors and valves. If the
equipment requires low maintenance and can be removed by mobile plant through suitable access
arrangements in the building design, then dedicated lifting equipment is not required.
The design of lifting equipment shall reflect:

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 30 of 31
Return to Index

d) The design safe working load (SWL shall be suitable for the heaviest component in the plant.
e) Equipment may need to be lifted in part or assembled.
f) Positioning of equipment and the lifting cover area. In some instances the layout may require more
than one gantry. The positioning shall provide for lifting equipment or parts onto and off trucks.
g) Structural design required where the crane girders and runways form part of the building design. It
should be considered that cranes may be used as part of the temporary works when the pump station
is constructed to lift materials and component into the build.
h) Permanent access needs to be provided for overhead cranes. Isolators must be provided adjacent to
the crane access.

6. Ventilation
a) The ventilation characteristics must be documented.
b) The pump room shall have 4-6 air changes per hour.
c) Where the control panel is situated inside the pump room, the room shall have a minimum of 10-15 air
changes per hour within the limitations of AS/NZS61439 and be fitted with replaceable filters.

7. Security and access lids

a) All cabinets and other access points to the main pump station building shall be lockable.
b) Traversable access lids shall comply with the appropriate loading class under AS3996.
c) All entry points shall be fitted with an alarm that will signal unauthorised access through the Watercare
security system. Security systems are fitted with a dual communications option that provides alarm to
Watercare’s security supplier and the Watercare central control room.
d) Pump stations shall be fitted with fire detection equipment to meet building act requirements.
e) Fire alarms shall be monitored for high priority pumping stations. Fire alarm systems are fitted with a
dual communications option that provides alarm to Watercare’s service supplier and the Watercare
central control room. Lower priority pumping stations may only be fitted with a smoke alarm at the
control panel that provides a fire alarm to the Watercare central control room.

8. Signage
a) Signage shall be provided that identifies the pumping station as the property of Watercare
b) Informative operational, health and safety signage that shall be required at the pumping station
perimeter.

9. Site access road

a) The site access road shall comply with Watercare’s general civil construction standard.
b) Adequate vehicle turning area shall be provided within the site.
c) The access road shall be sealed have a minimum laden load bearing capacity of 25tons (unless
otherwise stated) and a minimum width of 3.5m.

Ver.0.1 This is an electronic ESF document that

DP-14 is uncontrolled when copied or printed Page 31 of 31