GERMAN ATV-DVWK

RULES AND STANDARDS

STANDARD
ATV-DVWK-A 134E

Planning and Construction of Wastewater

Pumping Stations

June 2000
ISBN 3-937758-45-3

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ATV-DVWK-A 134E

Preparation
This Standard has been elaborated by the ATV-DVWK Specialist Committee ES-3 “Wastewater Pumping
Stations” within the ATV-DVWK Main Committee ES “Drainage Systems”.

ATV-DVWK Specialist Committee ES-3 has the following members:

Dr.-Ing. Peter Evers, Essen

Dipl.-Ing. Heinz Haendel, München († 1997)
Dipl.-Ing. Peter H. Hanitsch, Frankfurt am Main (Vice Chairman)
Dipl.-Ing. Günther Koch, Stuttgart
Dipl.-Ing. Lutz Naupold, Bremen
Dipl.-Ing. Wolfgang Tochtermann, Berlin (Chairman)
Dipl.-Ing. Manfred Tornow, Berlin
Dipl.-Ing. Bernd Zander, Braunschweig

In addition the following have collaborated:

Dipl.-Ing. Hansjoachim Mahret, Berlin

Dipl.-Ing. Dietrich Warnow, Berlin

Die Deutsche Bibliothek [The German Library] – CIP-Einheitsaufnahme

Standard.
A 134E. Planning and Construction of Wastewater Pumping Stations/[from the ATV Working Group]. –
2000
ISBN 3-937758-45-3

All rights, in particular those of translation into other languages, are reserved. No part of this Standard may
be reproduced in any form – by photocopy, microfilm or any other process – or transferred into a language
usable in machines, in particular data processing machines – without the written approval of the publisher.

© GFA-Gesellschaft zur Förderung der Abwassertechnik e. V., Hennef 2000

Setting and printing (German original): DCM, Meckenheim

2 June 2000
 ATV-DVWK-A 134E

Contents
Preparation...............................................................................................................................................2

User Notes................................................................................................................................................6

Foreword ..................................................................................................................................................6

1 Area of Application ..................................................................................................................6

2 Planning and Dimensioning..................................................................................................7

2.1 Type of Structure and Structural Dimensions of the Pumping Station ......................................7
2.2 Wastewater Inflow......................................................................................................................8
2.3 Ordinates and Pumping Heads..................................................................................................9
2.4 Pumping Task ............................................................................................................................9
2.5 Expansion Possibilities...............................................................................................................9
2.6 Minimum Completely Free Passage ..........................................................................................10
2.7 Flow Rate and Inside Diameter of the Pressure Main ...............................................................10
2.8 Number of Cycles of the Pumping Plant and Dimensioning of the Inlet Chamber ....................11
2.9 Digestion of the Wastewater ......................................................................................................11

3 Structural Engineering ..........................................................................................................11

3.1 Methods of Laying Foundations.................................................................................................11
3.2 Verification of Stability................................................................................................................11
3.3 Building Protective Measures ....................................................................................................12
3.4 Design of the Structure ..............................................................................................................12
3.4.1 Inlet Chamber.............................................................................................................................12
3.4.2 Machinery Room ........................................................................................................................12
3.4.3 Superstructure, Entrances .........................................................................................................12
3.4.4 Stairs, Ladders, Step Irons, Platforms .......................................................................................13
3.4.5 Heating/Heat Removal ...............................................................................................................13
3.4.6 Windows, Doors .........................................................................................................................13
3.4.7 Earthing ......................................................................................................................................13
3.4.8 Lightning Protection ...................................................................................................................13
3.4.9 External Design and Outside Facilities ......................................................................................14
3.4.10 Connection of Pipelines, Protective Pipes and Similar to the Building ......................................14

4 Mechanical Engineering .........................................................................................................14

4.1 Centrifugal Pumps......................................................................................................................14
4.1.1 Design of the Pumps..................................................................................................................14
4.1.2 Impeller Shapes and Completely Free Passage .......................................................................15
4.1.3 Notes on Design.........................................................................................................................16
4.1.4 Type of Mounting .......................................................................................................................17
4.1.4.1 Horizontally Mounted Pumps (Dry-well Installation) ..................................................................17
4.1.4.2 Vertically Mounted Pumps (Dry-well Installation) ......................................................................18

June 2000 3
ATV-DVWK-A 134E

4.1.4.3 Submerged Pumps (Wet-well Installation) ................................................................................ 18

4.2 Pump Drives .............................................................................................................................. 18
4.2.1 Electric Motors........................................................................................................................... 18
4.2.2 Combustion Engines ................................................................................................................. 20
4.3 Pipelines in the Pumping Station .............................................................................................. 20
4.4 Gate Valves ............................................................................................................................... 21
4.4.1 Gate Valves with Elastomer Coated Obturators ....................................................................... 23
4.4.2 Parallel Slide Gate Valves......................................................................................................... 23
4.4.3 Tapered Gate valves ................................................................................................................. 23
4.5 Non-return Valves ..................................................................................................................... 24
4.6 Pump Air Bleeding..................................................................................................................... 24
4.7 Admission Gate Valves ............................................................................................................. 24
4.8 Water Supply Facilities.............................................................................................................. 25
4.9 Washdown Facilities.................................................................................................................. 25
4.10 Machinery room Drainage ......................................................................................................... 25
4.11 Ventilation Facilities for Machinery Rooms ............................................................................... 26
4.12 Ventilation Facilities for Inlet Chambers................................................................................... 26
4.13 Lifting Gear ................................................................................................................................ 27

5 Electrical Engineering............................................................................................................ 27
5.1 External and Structural Prerequisites........................................................................................ 27
5.2 Energy Supply ........................................................................................................................... 28
5.2.1 Energy Supply with a Voltage up to 1000 V (Low Voltage) ...................................................... 28
5.2.2 Energy Supply with a Voltage over 1000 V (Medium High Voltage)......................................... 29
5.2.3 Measurement of Consumption .................................................................................................. 30
5.3 Switchboard Plant, Actuators and Appliances .......................................................................... 30
5.3.1 Main Drives................................................................................................................................ 30
5.3.2 Ancillary Drives.......................................................................................................................... 31
5.3.3 Ancillary Facilities...................................................................................................................... 31
5.3.4 Operating and Measuring System............................................................................................. 31
5.4 Emergency Power Supply ......................................................................................................... 31
5.5 Types of Protection and Regulations ........................................................................................ 32
5.5.1 Explosion Protection.................................................................................................................. 32
5.5.2 Protection against Accidental Contact ..................................................................................... 32

6 Measurement Engineering ..................................................................................................... 33

6.1 Level Measuring Systems ......................................................................................................... 33
6.2 Delivery Pressure Measuring Systems ..................................................................................... 33
6.3 Flow Measuring Systems .......................................................................................................... 33
6.4 Transmission of Measured Values............................................................................................ 33

7 Wastewater Pressure Pipelines ............................................................................................. 33

7.1 Pressure Pipelines .................................................................................................................... 33
7.2 Pipeline Routes ......................................................................................................................... 34
7.3 Dimensioning............................................................................................................................. 34
7.4 Stresses..................................................................................................................................... 35
7.5 Pipe Materials............................................................................................................................ 35
7.6 Corrosion and Corrosion Protection.......................................................................................... 35

4 June 2000
 ATV-DVWK-A 134E

8 Commissioning ........................................................................................................................36
8.1 Pumping Station.........................................................................................................................36
8.2 Pressure Main ............................................................................................................................36

9 Information on Standard Specifications, Directives, Standards, Advisory Leaflets

(Selection).................................................................................................................................37
9.1 General Terms and Conditions for Engineering Services, (VOB)..............................................37
9.2 Standard Specifications .............................................................................................................37
9.2.1 Building Standards .....................................................................................................................38
9.2.2 Pipes and Fittings.......................................................................................................................38
9.2.3 Mechanical Engineering.............................................................................................................39
9.2.4 Measurement Technology..........................................................................................................39
9.2.5 Electrical Engineering ................................................................................................................40
9.3 Directives, Standards and Advisory Leaflets .............................................................................41
9.3.1 of the ATV ..................................................................................................................................41
9.3.2 of the DVGW ..............................................................................................................................41
9.3.3 des VDI.......................................................................................................................................41
9.3.4 of the VDMA [German Association of Mechanical Engineering Establishments] ......................42

10 Annexes ....................................................................................................................................42
Annex 1: Example of a pumping station with centrifugal pumps in horizontal, dry-well installation ........43
Annex 2: Basic circuit diagram ..................................................................................................................48

June 2000 5
ATV-DVWK-A 134E
User Notes
This Standard is the result of honorary, technical-
scientific/economic collaboration which has been
achieved in accordance with the principles appli-
cable therefor (statutes, rules of procedure of the
ATV-DVWK and the Standard ATV-DVWK-A
400E). For this, according to precedents, there ex-
ists an actual presumption that it is textually and
technically correct and also generally recognised.
The application of this Standard is open to every-
one. However, an obligation for application can
arise from legal or administrative regulations, a
contract or other legal reason.
This Standard is an important, however, not the
sole source of information for correct solutions.
With its application no one avoids responsibility for
his own action or for the correct application in spe-
cific cases; this applies in particular for the correct
handling of the margins described in the Standard.
Foreword
Standard Specification EN 752-6 “Drainage sys-
tems outside buildings”, Part 6 “Pumping stations”,
elaborated by its Technical Committee TC 165
“Wastewater Engineering”, has been issued by the
European Committee for Standardisation (CEN). It
was to be adopted into the German Standards as
DIN EN 752-6. Supplementary to this the earlier
Standard ATV-A 134 “Planning and Construction
of Wastewater Pumping Stations with Small In-
flows” has been revised and expanded by ATV
Specialist Committee 1.3 “Wastewater pumping
stations”, so that it can be applied, like the stan-
dard specification, for small and large wastewater
pumping stations including their pressure mains.
Standard ATV-DVWK-A 134E supplements
Standard Specification EN 752-6 and provides
advanced information and proposals as to how,
taking account of economic aspects, pumping
stations can be planned and built. EN 1671 is to
be applied for pumping stations with pressure
drainage.
It deals exclusively with the employment of cen-
trifugal pumps for the conveyance of wastewater,
for which they are mainly employed. This does not,
6 June 2000
however, exclude other delivery plant (see “Kom-
munale Abwasserpumpwerke” [Municipal waste-
water pumping stations], Vulkan-Verlag,). State-
ments made here also apply equally for such
pumping stations so far as they do not demand
other technical solutions. It would be beyond the
framework of the Standard to go into these in de-
tail.
Conveyor spirals with their completely different de-
livery principle and thus also other structural con-
cept are also dispensed with, although it is just
these which are relatively frequently employed to
raise wastewater before the wastewater treatment
plant.
The special requirements affecting these are laid
down in Standard Specification DIN 1184 Part 4
“Pumping stations; Archimedean screw pumps; di-
rectives for planning”. Taking into account the
wastewater-specific requirements (e.g. explosion
protection) indicated in this Standard, these apply
equally for wastewater pumping stations.
Facilities in the field of wastewater as a rule are
used for a long time. They must, in addition, have
a high availability for the protection of surface wa-
ters against pollution and for the securing of local
hygiene. Great significance is given to ideas on
quality. Cost reductions are possible. They may,
however, not be at the expense of the environ-
ment.
With a comparison both investment costs as well
as operating costs are always to be considered
with the annual costs arising from both compo-
nents.
1 Area of Application
The pumping station, with the discharge of waste-
water, has its particular significance in that,
through the avoidance of too deep a position, it
can improve the economic efficiency of a drainage
system. It is extensively independent of topog-
raphical conditions and makes it possible to feed
effluents into receiving waters and sewers even at
high levels. Furthermore, using pumping stations,
wastewater can be conveyed for widely spread
catchment areas to treatment facilities sited at
suitable locations.

Wastewater pumps, which are mainly installed in
the tank facilities (see ATV-A 166 [Not available in
English]), are also frequently employed for the sur-
face feeding and, in particular, for the emptying of
stormwater tanks. The Standard applies analo-
gously for these, however the technical require-
ments are to be matched to the tank-specific re-
quirements (e. g. impeller shape, completely free
passage, no continuous operation).
Pumping stations are also suitable for control of
flow in larger networks.
It is emphasised, that this Standard is not to be
employed where special drainage methods are
used. These cases are dealt with in Standard ATV-
A 116E.
2 Planning and
Dimensioning
The pumping station has to be so dimensioned
that, with the taking into account of sufficient
reserves the same disposal security as with
discharge under gravity is achieved.
The basic requirements to be placed on a
wastewater pump are an automatic, fault-free
operation with which the unhygienic and haz-
ardous maintenance tasks remain limited to a
minimum.
The initial considerations to be made for planning
and dimensioning, the relevant factors for the se-
lection of terrain or location as well as the decisive
criteria for the dimensioning and equipping of the
pumping station are presented in detail in EN 752.
The following notes serve as supplement.
The layouts of the routes for the supply and
disposal pipelines and the method of their lay-
ing are to be agreed with the authorities repre-
senting public interests. Rights of way for pe-
destrians, vehicles and pipelines are, if
necessary, to be agreed.
ATV-DVWK-A 134E
2.1 Type of Structure and Structural
Dimensions of the Pumping Station
The type of structure and the structural dimensions
are determined by the pumping tasks (see Section
2.4), the type of pump installation (wet- or dry-well)
and corresponding with the equipping through the
associated scope of ancillary facilities (transformer
room, switchboard plant, tank farm), other ancillary
facilities (fixed crane, heating and ventilation
plants, standby plant) as well as, if required, further
necessary ancillary rooms (stores, workshops) and
social rooms. The arrangement of the pumps in
dry-well installation (vertical or horizontal) has ef-
fects on the dimensions of the building.
As a rule, wastewater pumping stations are
equipped with centrifugal pumps. They are not
self-priming and therefore should be installed
sufficiently low so that the water flows in under
gravity in order to avoid being subject to ab-
normal occurrences. Fundamentally at least
two pumps should be installed.
Before the decision as to whether the pumps
should be installed with wet- or dry-wells, the plan-
ner should clarify with later operation the differ-
ences in construction, equipping and, in particular,
operation of the pumping station.
With wet-well installation safety against flooding
and lower investment costs are up against in-
creased unhygienic and in part hazardous mainte-
nance work with greater expense with personnel.
In addition, the decision has to be made whether
the pumping station should be provided with a su-
perstructure (see Section 3.4.3).
In flood areas the superstructure must be so
designed that, with flooding, an endangering of
the pumping station is excluded.
For smaller pumping stations there are also pre-
fabricated stations as a complete design. They
must meet the requirements placed here.
June 2000 7
ATV-DVWK-A 134E

Examples for the different types of construction are presented in Figs. 1 and 2 and in Appendix 1.

Fig. 1: Examples for types of pumping station construction with pumps in dry-well installation

Fig. 2: Examples of types of pumping station construction with pumps in wet-well installation

Before the decision is made on a solution, in 2.2 Wastewater Inflow

addition to the technical, environmentally rele-
vant, operational, personnel, social, energetic The daily inflow of wastewater has to be ascer-
and other criteria, the financial and economic tained for the determination of the size of the
effects of the possible variants must also be pumping station. It is influenced by:
taken into consideration. In addition to invest-
- the type of drainage method (combined or
ment costs it is essential that the operating and
separate),
capital costs are included in the consideration
- size and structure of the catchment area,
of economic efficiency.
- number of inhabitants,

8 June 2000

- number and type of connected industrial and
commercial concerns.
The inflow is presented in a hydrograph, which re-
flects the inflow of wastewater in the course of a
day (see Figs. 3 and 4).
Fig. 3: Examples of inflow hydrographs with
dry weather, mainly residential area
Fig. 4: Examples of inflow hydrographs with
dry weather, strong industrial influ-
ence
There can be considerable differences both in the
characteristics and in the daily quantities between
working and non-working days. With rainfall one
has to reckon with an increased yield of wastewa-
ter (see ATV-A 118E).
The hydrograph is the basis for the arrangement of
the delivery plant (determination of the operating
points, selection of the type of pumps, decision on
the employment of drives with one, several or vari-
able rotational speeds).
ATV-DVWK-A 134E
2.3 Ordinates and Pumping Heads
The ordinate of the invert of the inflow sewer, the
switch-on and switch-off ordinate of the pumps, the
outlet ordinate of the pumping destination and the
gradient of the terrain between pumping station
and the pumping destination are of considerable
significance in order to be able to dimension a
pumping station.
The pumping head, in addition to the pure static
heights, also includes the friction losses which are
determined depending on the speed of the medium
being pumped as well as the inside diameter and
length of the pressure main. In addition, with the
delivery by several pumping stations into a com-
mon pressure main, depending on the current op-
eration of the individual stations different pumping
heads arise which influence the arrangement of
the pumps (see Section 4.1.1).
2.4 Pumping Task
As pumping task can be, for example, the function
as pump-over station (delivery of the wastewater
into another catchment area), connecting pump
station (delivery into a pressure main network to-
gether with other pumping stations), pumping sta-
tion ahead of a wastewater treatment plant, empty-
ing of stormwater tanks etc.
The effects of the delivery flows on the down-
stream drainage system (gravity or pressure main
system) with possible further connected systems
and the wastewater treatment systems, are to be
taken into account with the employment of waste-
water pumping stations. Here, not only hydraulic
aspects such as, for example, discharge capacity
(overloading due to unfavourable layout of the
pipeline, height and/or dimension) play a role but
also the actual status of the drains concerned, i.e.
renovations are possibly to be undertaken.
2.5 Expansion Possibilities
With planning it is to be considered whether, in the
course of time, the required delivery flow has to be
increased. If this is the case, then the possibility of
a later expansion must be taken into account. It
can, for example, be sufficient, taking into account
June 2000 9
ATV-DVWK-A 134E
the motor output, later to increase the revolutions
of the centrifugal pump which is driven via belt
drives or to enlarge the impeller of the centrifugal
pump; under certain circumstances, however,
room for a larger or additional machine must also
be planned within the structure. Equally the laying
of an additional pipeline can also be necessary
(see also Section 7.3).
2.6 Minimum Completely Free Passage
Experience has shown that, with sewer networks,
a formation of textile balls cannot be excluded.
Nevertheless, one can dispense with screens in so
far as suitable types of pump and sufficient free
cross-section are selected in the complete delivery
facility.
In order to guarantee a secure delivery a com-
pletely free passage of 100 mm both for the deliv-
ery installation as well as for fittings and the pres-
sure main are recommended. The use of specially
developed, blockage-free impellers with a free
cross-section of less than 100 mm (see Section 4)
and appropriate selection of the pipeline diameter
is to be examined.
The pumps of smaller wastewater pumping sta-
tions therefore are not only to be dimensioned ac-
cording to inflows but insensitivity to blockage and
minimum speed are also relevant parameters. This
can, in relation to the wastewater inflow, lead to
over-dimensioning of the pumps.
An inside diameter of 80 mm for the pressure main
should not be undercut.
Smaller completely free passages combined with
shredders and appropriate pipeline diameters
should only be used in special cases, for example
for the disposal of waste from individual real estate,
when the connection to a central plant is sought for
water management, technical or economic reasons
(see ATV-A 116E, ATV-A 200 [Not available in Eng-
lish]). Shredded materials can lead to increased de-
posits in sewers and pressure mains. Various prob-
lems can also occur in the wastewater treatment
plant with increased production of shredded mate-
rial. The employment of shredders should therefore
be clarified, already with the planning, with the op-
10 June 2000
erator and, if necessary, with the approval authori-
ties.
2.7 Flow Rate and Inside Diameter of
the Pressure Main
The following aspects are to be taken into account
with the determination of the flow rate in the main:
The lower limit of the flow rate should lie between
0.5 m/s with larger and 1.0 m/s with smaller total
delivery times of the connected pumping stations.
Depending on the composition of the wastewater
higher flow rates must be selected with longer
downtimes.
A too low a flow rate leads to deposits and thus to
reductions of the cross-section so that the danger
of blockage increases.
The highest speed of the delivery flow is depend-
ent on the nominal width. For a pipeline length of
up to ca. 500 m the following speeds should not be
undercut:
Inside diameter in mm 80 100 150 200
Speed in m/s 2.0 2.0 2.2 2.4
Delivery in l/s 10 16 40 75
Flow rates greater than 2.5 m/s should be avoided.
With pipelines of more than 500 m length appro-
priately lower speeds are to be preferred to avoid
unacceptable pressure surges, for example with
pump failure. Investigation of pressure surge
should be undertaken.
The optimum nominal width is to be determined
through an efficiency calculation and this com-
pared with the above guidance values.
With the determination of the diameter of the pres-
sure main attention is to be paid that the inside dia-
meter of a pipe can deviate considerably from the
nominal width depending on the material.

2.8 Number of Cycles of the Pumping
Plant and Dimensioning of the Inlet
Chamber
The available volume of the inlet chamber for the
employment of centrifugal pumps with fixed revolu-
tions results as follows between switch-on and
switch-off levels:
Q pm
V = 0.9
Z
V = volume in m3
Qpm = mean pump delivery flow in l/s
Z = number of cycles per hour
A number of cycles of 15 per hour should not be
exceeded.
The number of cycles is dependent on the stability
of the mechanical and electrical plant components,
in particular the electric motors (see Section 5.3).
2.9 Digestion of the Wastewater
With comparatively small daily delivery quantities
and long pressure mains the retention time of the
wastewater in the pressure main is very large and
therefore the danger of digestion of the wastewater
is present. There is strong odour development and
the aggressiveness of the wastewater increases.
The possible biogenic hydrogen sulphide corrosion
has to be taken into account with the selection of
pipe material.
Detailed information for countermeasures is given
in Advisory Leaflet ATV-M 168 [Not available in
English].
3 Structural
Engineering
Pumping stations, elevators and pumping points
are structures which consist of an underground
part and, as far as possible, an over ground part.
Prefabricated shafts are also used for the
construction of smaller wastewater pumping
stations.
ATV-DVWK-A 134E
The type of subsoil and the groundwater conditions
are decisive contributory factors for determining
the type of construction work.
3.1 Methods of Laying Foundations
Before start of construction, investigations of
the subsoil and existing underground buildings
are to be carried out. Firmly planned construc-
tion projects of other parties in the vicinity
must also be taken into consideration.
As essential assessment criteria the following are
to be determined:
- type of soil (cohesive, non-cohesive, non-
plastic and similar in accordance with DIN
18196 and DIN 18300),
- soil structure (inclusions of all types),
- bearing capacity,
- settlement behaviour,
- groundwater (rush, variations in level, utilisa-
tion or non-utilisation),
- surrounding buildings,
- load carrying traffic areas,
- aggressiveness of soil and groundwater,
- contaminated sites.
According to the thus determined conditions vari-
ous methods for the construction of the under-
ground part are possible:
- sloped excavation,
- revetted excavation (e. g. Berlin lining),
- excavation with pile sheeting,
- well-foundation (caisson),
- compressed air foundation work.
3.2 Verification of Stability
Stability is to be verified for
the excavation and
-
- the structure itself.
With this it can be necessary to carry out verifica-
tion for the construction state (e.g. safety against
buoyancy) and for the finished state separately.
The concrete must be impermeable to water in
accordance with DIN 1045 and show high resis-
tance against chemical attack through the em-
June 2000 11
ATV-DVWK-A 134E
ployment of cements with high resistance to
sulphate in accordance with DIN 1164, Part 1.
Assumptions about loads are to be made in ac-
cordance with DIN 1055. To limit the width of
cracks and for improved crack distribution a
method of conservation of crack limitation is to be
planned. The concrete covering in the under-
ground part should be at least 4 cm.
For safety against buoyancy, calculations must
be carried out with the factor µ = 1.1, whereby
the highest possible level of the groundwater
or the high water level is to be taken into ac-
count. Here the soil friction or the weight of the
demountable assemblies my not be taken into ac-
count. Verification of water pressure is to be car-
ried out for both internal and external water pres-
sure.
The highest possible water level in the inlet
chamber must be assumed to be the upper sur-
face of the ground.
As one has to reckon with wastewater with ag-
gressive substances the values in DIN 4030 are
to be observed for the evaluation of the level of
attack.
As a rule the upper limiting values are to be taken
into account in order to make allowance for a pos-
sible unfavourable change of the composition of
the wastewater (for some considerable time one
has ascertained damage to existing buildings
which can be traced back to a change in composi-
tion of the wastewater). Therefore, in accordance
with the provisions of DIN 1045 on concrete cov-
ers, the water-cement ratio, concrete texture and
similar are to be taken into account.
3.3 Building Protective Measures
The best protective effect is achieved through the
quality of the material itself. With very aggressive
water or soil characteristics or the danger of bio-
genic hydrogen sulphide corrosion additional pro-
tective measures in the form of coats of paint,
coatings or sheathing can be necessary.
12 June 2000
3.4 Design of the Structure
(For this see Annex 1)
Fundamentally attention is to be paid to suffi-
cient entrances secure against flooding and
free space around the operational installations
which have to be served, maintained and/or re-
paired.
3.4.1 Inlet Chamber
Inlets in the inlet chamber are to be so designed
that the following are avoided:
- entry of air into the pumps,
- stripping of gases,
- accumulations of solids on installations and
- unfavourable streaming of the pumps.
The inlet chamber is to be so designed that no
dead space results and depositing is avoided
(slope ≥ 60°). With the employment of concrete
this is to be compacted carefully and covered with
a compound screed using cement with a high re-
sistance to sulphide and is to be smoothed. In
special cases an additional acid resistant coating
or a ceramic sheeting can be sensible. Enclosed
inlet chambers must be equipped with an effec-
tive ventilation (see Section 4.12). With regard to
inlet chamber space see Section 2.8.
3.4.2 Machinery Room
The dimensions of the room result from the dimen-
sions of the machines, the free space around the
machines and the space requirement for stairs. For
the pumps, assembly holes are to be arranged in
the roof above them. The floor is to be made as far
as possible anti-skid. A pump well (see Section
4.10) for draining the pump room is to be planned.
See Section 4.11 with regard to ventilation.
3.4.3 Superstructure, Entrances
The superstructure with entrances must be se-
cure against flooding. It enables the accom-
modation of:

- electrical plant,
- standby equipment,
- stationary ventilation plant,
- spare parts,
- non-stationary operational equipment,
- social facilities
and guarantees at all times a weather-independent
and secure access to the pumps and inlet cham-
ber.
Requirement for space for the energy supply plant
(see Section 5.2) is to be taken into account.
The inlet chamber and the associated ventilator
room must be accessible from outside and
their doors must be capable of being opened
outwards only. Access from the pump room is
not permitted.
Only the switch room and the toilets are to be ac-
cessible via the pump room. A crane rail or
shackle, dimensioned for the largest assembly
part, is to be provided in the ceiling. With larger
pumping stations a crane system can also be nec-
essary (see Section 4.13).
All rooms are to be so equipped that they require
little maintenance and servicing.
3.4.4 Stairs, Ladders, Step Irons,
Platforms
Pump rooms which are not at ground level should
be provided with stairs. Steep and spiral stairways
should be avoided, i.e. they are an alternative only
with tight space conditions.
The stairs are to be designed according to the re-
commendations of the agency responsible for ac-
cident insurance. Climbing ladders and climbing
irons are to be installed in exceptional cases only.
Above 5 m total length they are basically to be
provided with a system to prevent falling. Above
the entrance points with ladders are to be provided
with insertible or extendable stay bars of at least
1 m in length or handholds.
Vertical ladders in the inlet chamber should not be
permanently mounted below the water level, but
should be foldable or removable. They may not be
made of aluminium. In the place of a back protec-
ATV-DVWK-A 134E
tion, vertical ladders are to be equipped with a pro-
tective rail or other safety device. With particularly
deep inlet chambers it is recommended that an in-
termediate platform be installed. As for handrails,
corrosion resistant steel Material No. 1.4571 is
equally suitable.
3.4.5 Heating/Heat Removal
All rooms are to be maintained frost-free. The
heat emitted by the electrical plant and equipment
is to be included with the calculation of the heat
requirement. In special cases a heat removal can
be necessary (see also Section 5.3.1).
3.4.6 Windows, Doors
Windows and doors are to be designed as far as
possible secure against break-in and damage.
Windows can be dispensed with if sufficient aera-
tion and ventilation as well as lighting of the rooms
can be provided alternatively.
3.4.7 Earthing
The earthing device is to be so dimensioned
that, in the case of a fault, the currents to earth
do not exceed the earth potential of 50 V with
alternating current and 120 V with direct cur-
rent. In order to achieve the necessary resis-
tance, foundation earth connectors are to be
laid in buildings and, if required, additionally
lattice networks are to be laid in open ground.
VDE [Association of German Electrical Engi-
neers] regulations are to be observed (see Sec-
tion 5.5).
3.4.8 Lightning Protection
For the protection of people and plant pumping
station buildings must be provided with a
lightning protection system. Here, in accordance
with the ABB [German Committee for Lightning
Conductor Construction], the metallic construction
components of roofs and facades can be included
in the lightning protection system both for collector
devices and for conducting, if these are reliably
connected to this. The conductors of the lightning
June 2000 13
ATV-DVWK-A 134E

protection system are to be connected with the

earthing system via “spacers” (see Section 5.5). 4 Mechanical
For further prevention of damage through the ef-
Engineering
fects of a lightning strike the lightning protection
system should be installed in accordance with the
Standard Specification DIN IEC 61024-1-2, VDE 4.1 Centrifugal Pumps
0185 Part 102 (see Annex 2).

4.1.1 Design of the Pumps

3.4.9 External Design and Outside Fa-
cilities Section 2 “Planning and Dimensioning” is relevant
for the design of the pumps. The delivery head is
The route to the pumping station is to be matched made up of:
suitably in width and surfacing to the local re-
- the difference in height (Hgeo) between the
quirements.
highest point in the pressure side of the system
and the water level in the inlet chamber,
The superstructure is to be matched in size and
- the admission pressure (Hadm), e. g. through
form and in the materials employed, for example
conveyance in an already otherwise streamed
for the outer façade, with the surroundings.
pressure pipeline, and
Planted strips several metres wide have proved
- the pressure loss (Hloss) in the pipes and fit-
their usefulness as visual and emission protection
tings.
(see Annex 1). With a view to later maintenance of
the outside facilities, attention is to be paid in the
Due to changes in level in the outlet and in the inlet
planning that these cause the lowest possible ex-
chamber as well as a varying admission pressure
pense.
there results a range of the pipeline characteristic
curves in accordance with Fig. 5.
With sensitive locations it is recommended that ar-
chitects and landscape gardeners are already in-
The operating range of the pump lies between the
volved with the planning.
intersection point of the throttle curve with the
highest and lowest pipe characteristic curve. In the
case of a compound or parallel operation, attention
3.4.10 Connection of Pipelines, Protective is to be paid for an as steep as possible throttle
Pipes and Similar to the Building curve with the selection of the pump.

Every rigid pipeline laid underground, which is

fixed between two points with different subsi-
dence characteristics must be connected flexi-
bly. This applies, for example, for inflow sewers
which run from the inlet structure to the pumping
station.

Pipe fairleads through walls and roofs are to be

suitably sealed.

Fig. 5: Pumping diagram centrifugal pump

14 June 2000
 ATV-DVWK-A 134E

The matching of a changed inflow can be under-
taken through the modification of the revolutions
and, in addition, through change of the impeller di-
ameter.
With all pumps the cavitation behaviour should be
examined in order to avoid cavitation, noises, er-
ratic running and material wear.
- efficiency as a rule less than with multi-port
non-clog impellers,
- hydraulic out-of-balance, which can only be
extensively compensated, and this at great ex-
pense, related to a defined operation point. A
rate of rotation above 1450 min-1 should be
avoided, with large impellers a rate of rotation
of 1000 min-1 should not be exceeded.

A measure for the cavitation behaviour is the

NPSH value (net positive suction head), i.e. the net
energy head (= absolute energy head less the va-
porisation pressure head) in the entry cross-
section of the pump impeller. The NPSH value of
the plant (NPSHP) is compared with the NPSH
value of the pump (NPSHR). In every case the
drop must be NPSHP > NPSHR.

The NPSHR value must be given by the pump

manufacturer. The ratio

NPSHP
≥1.3
NPSHR
Fig. 6: Single port non-clog impeller

should be sought for security against cavitation
with water pumps.
Further details can be taken from DIN 24260, Part
1 “Centrifugal pumps and centrifugal pump sys-
tems” [Not available in English].
4.1.2 Impeller Shapes and Completely
Free Passage
For the conveyance of untreated wastewater with
coarse and fibrous constituents specially shaped
impellers are employed (see Figs. 6 to 9) which, to
a great extent, prevent blockages and the forma-
tion of clogs.
The non-clog impeller is employed as single and
multi-port non-clog impeller.
The multi-port non-clog impeller (see Fig. 7) is, as
a rule, a two or three port non-clog impeller. In
comparison with the single port non-clog impeller it
is characterised by the following features:
- greater delivery heads are achieved.
- a static and dynamic balancing is relatively
simple to carry out. Higher rates of rotation,
and due to this, greater delivery heads are also
possible.
- variable speed operation is without problem.
- noise- and vibration-free running is easier to
achieve.
It is, however, more susceptible to blockage than
the single port non-clog impeller as, with the same
delivery flow, the completely free passage of the
impeller channels are smaller.

The single port non-clog impeller (see Fig. 6) has

the following characteristics:
- constant completely free passage from the en-
trance to the intake to the exit to the pressure
pipe corresponding to the completely free pas-
sage of the impeller,

June 2000 15
ATV-DVWK-A 134E
Fig. 7: Multi-port non-clog impeller
The spiral non-clog impeller (see Fig. 8) is a semi-
axial single-vane impeller with helicoidal or screw
formed inlet component. It runs very quietly and
therefore is employed with rotational speeds of
3000 min-1.
Fig. 8: Spiral non-clog impeller
The non-chokable impeller (see Fig. 9) effects the
transport medium indirectly only. With the convey-
ance of wastewater it can be employed with rota-
tional speeds up to 3000 min-1. The characteristic
curve is usually flatter and the efficiency lower than
with the other impellers.
16 June 2000
Fig. 9: Non-chokable impeller
All given impeller shapes are, in principle, suitable
for employment in screenless pumping stations,
under the assumption that the requirements of
Section 2.6 are met. They are employed normally
up to the following pressure values in the point of
operation:
- single-port non-clog impeller up to 4 bar,
- spiral non-clog impeller up to 6 bar,
- multi-port non-clog impeller up to 10 bar,
- non-chokable impeller up to 10 bar.
The rate of flow in the impeller channels should, as
far as possible, not undercut 2 m/s as otherwise
the danger of pump blockage is very great.
4.1.3 Notes on Design
With a dry-well wastewater pump (see Fig. 10) suf-
ficiently large cleaning ports are provided on the in-
take and outlet to the pressure pipe so that block-
ages can be removed from inside the pumps
manually. With smaller pumps the size of the
cleaning ports should approach the nominal width
of the pumps. With larger pumps they should be
180 to 200 mm.

Fig. 10: Cross-section of a horizontally mounted centrifugal pump
Longer downtimes and possibilities of repair are
achieved through an exchangeable obturator in the
area of the suction mouth of the pump casing and
a locking ring on the reverse side of the impeller. In
principle, with large pumps, they should be pro-
vided. With these an exchangeable obturator is
recommended also on the pressure side, i.e. on
the bearing side of the pump casing.
Attention is to be paid that every impeller is pro-
vided with vanes on the back or pressure side of
the impeller disk.
The sealing of the pump in the area of the shaft
can be achieved using gland or axial face seals. If
a gland seal is used then attention is to be paid
that the shaft protective covering is highly wear re-
sistant and packings are easy to exchange without
greater dismantling.
Assessment criteria with the employment of axial
face seals, also with pumps with submersible mo-
tor, are a short separation between impeller and
first bearing and the employment of specially
formed axial face seals which, in particular, do not
allow wastewater to penetrate to the contact pres-
sure rings of the seals (danger of contamination).
A transmitter which signals a possible entry of wa-
ter into the sealing oil which lubricates and cools
the axial face seal as well as preventing immediate
entry of water into the machinery room, should be
installed.
ATV-DVWK-A 134E
4.1.4 Type of Mounting
With the installation of the pumps a differentiation
must be made between horizontal and vertical
pumps. Submersible motor-driven pumps can also
be employed in dry-well installation and thus, with
suitable arrangement of the electrical connections,
ensure the pumping of wastewater even with flood-
ing of the pump room. With its employment in dry-
well installation the question of heatremoval from
the motor is to be clarified with the pump manufac-
turer.
4.1.4.1 Horizontally Mounted Pumps
(Dry-well Installation)
In the horizontal layout (see Fig. 11) there is the
space saving design of the pump with saddle
mounted motorist which, moreover, offers even
more advantages.
In this way, with the drive of the pump via v-belts,
an easy matching to a possibly changed inflow is
possible by changing the transmission ratio; moni-
toring and certain repairs on the pump are signifi-
cantly more simple.
The pump should have a base frame. The bracket
for the mounting of the electric motor is to secured
with bolts so that it is removable.
June 2000 17
ATV-DVWK-A 134E
Fig. 11: Dry-well and horizontally mounted
centrifugal pump with fitted motor
To tension the v-belts the motor must be mounted
so that it is adjustable. Through the compact con-
struction the unit is substantial insensitive to vibra-
tion. The installation of a pump with motor in
modular construction is also possible.
4.1.4.2 Vertically Mounted Pumps (Dry-
well Installation)
Fig. 12: Dry-well and vertically installed cen-
trifugal pump
18 June 2000
The vertical type of installation (see Fig. 12) offers
a greater security against flooding through the high
mounting of the electrical motor.
The connection between pump and motor is
always to be elastic for the acceptance of ad-
justment tolerances and for the damping of vi-
bration and impact.
4.1.4.3 Submerged Pumps (Wet-well
Installation)
If a submersible motor-driven pump in wet-well in-
stallation (see Fig. 13) is employed, then attention
is to be given to certain peculiarities. Inlet cham-
bers are explosion endangered zones. In accor-
dance with the regulations of the [German] Asso-
ciation for Social Insurance against Occupational
Accidents (VBG) pump casings and components,
in contact with water, made from aluminium alloys
in explosion endangered plant components of
wastewater treatment plants of Zones 0 and 1 are
not permitted. Fundamentally the motor must be
protected against explosion in accordance with
VDE 0170/0171, and that is, as a rule, in E Ex dll
BT3. cleaning ports on the casing are ruled out.
Every wet-well installed pump should be capable
of being installed and removed without emptying
the inlet chamber and without tightening or loosen-
ing of bolts on their pressure joints. The mounting
parts required for this are subjected to corrosive at-
tack to a particularly high degree. They should be
made from stainless steel Material No. 1.4571; this
also applies to nuts, bolts and washers.
4.2 Pump Drives
Electric motors are almost exclusively employed
for driving the pumps. However, for reasons of dis-
posal security, an uncertain energy supply or to
cover peaks it can be necessary to employ another
type of drive, for example, combustion engines.
4.2.1 Electric Motors
For centrifugal pumps the electric motors should
be designed (see Section 5.3.1) for the limiting
power requirement of the specified operating
range. The same applies for the coupling between
pump and motor. Where an increasing wastewater
 ATV-DVWK-A 134E

production is to be expected it is, however, sensi- requirement for this is additionally to be taken into
ble possibly to design the motor and the coupling account.
more robustly, in any case, however, the associ-
ated electrical parts of the plant, in accordance Power requirement of Reserve capacity of the
with the expansion capacity of the pump. the pump in kW driving motor
up to 7.5 ca. 50%
The following reserve capacities should be pro-
vided as a minimum with regard to a sufficient en- 7.5 – 20 ca. 25%
gine power to avoid blocking of the impeller: 20 -50 ca. 15%
over 50 ca. 10%
With pressure mains with elevator effect and such
which, with every start-up, have to be completely
or in part primed, the increased necessary power

Fig. 13: Section of a wet-well and vertically installed submerged motor pump

It is to be examined whether special measures
are necessary for the protection of the pressure
mains against possible pressure surges (see
Section 2.7) or in order to avoid inadmissibly high
currents at make of the pump motors.
To these belongs the so-called smooth starter for
cage rotor motors. It prevents undesired load
peaks for pumps and motors.
If, in addition to a smooth start and coast down,
the revolutions are also variable then the em-
ployment of a static frequency converter is rec-
ommend. Using this, submersible motors and ex-
plosion protected motors can be operated with
variable revolutions. The possible change of
revolutions is to be clarified with the pump manu-
facturer. Here the flow rate in the impeller channels
is to be noted (see Section 4.1.2).

It should be equipped with the reverse function, With the employment of a static frequency con-
i.e. a smooth coast down. verter, due to the increased heat loss, the motor
should have a reserve capacity of 10 to 15 %.
With low revolutions an external ventilation of the

June 2000 19
ATV-DVWK-A 134E

motor can be necessary. In order to protect it
from inadmissible heating the windings should be
monitored using thermofeelers, i.e. so-called
positors.
4.2.2 Combustion Engines
As a rule, diesel motors with a nominal speed of
1500 min-1 are employed as combustion engines.
Their speed is adjustable but, for economic run-
ning the adjustable speed range used should not
go below 75 % of the nominal speed, this means
that, under certain circumstances, a mechanical
intermediate gear becomes necessary.
on the position of the installation room and the
usage identification of the area in the land devel-
opment plan in which the pumping station lies
The measures to be taken include:
- structure-borne damping machine mountings,
- structure-borne and airborne noise damping
designs in the exhaust discharge system,
- airborne noise inhibiting structures in the inlet
and outlet air lines,
- airborne noise damping outfitting of walls,
ceilings and doors.
The exhaust lines are to be insulated using an
appropriate material which guarantees a surface
temperature of the finished insulation of ≤ 70°C.

For low capacities motor and gearbox often form

It is to be clarified with the approval authorities
one unit which is connected with the pump by
which limiting values of atmospheric pollution in
means of an elastic coupling.
the diesel exhaust gas must be met. It is possible
that soot filters or catalytic exhaust gas cleaners
With diesel engines of higher performance, gear-
could be required.
box and pump are to be connected using an elas-
tic coupling. The connection between diesel en-
The diesel engine plant must satisfy the pro-
gine and gearbox should be via a universal joint
visions of the valid ordinances of the [Ger-
shaft. It can counterbalance axle variations
man] Technical Instructions Air (TA Luft) and
which, after longer periods of time, cannot be ex-
Noise (TA Lärm) of the Federal German Im-
cluded with respectively separate foundations.
mission Protection Law.

A reverse rotation of the diesel engine is to be

Fuel storage is also to be planned for energy sup-
prevented under all circumstances!
ply of the diesel motor. It should consist of
storage tanks and a service tank. The service
Mainly water-cooled diesel engines with internal
tank should be arranged at a sufficient height so
and external cooling water circuits are employed.
that the fuel flows to the diesel engine.
Oil coolers for gearboxes of higher performance
are to be included in the cooling system.
For a secure operation of diesel engine plants a
certain number of operational monitoring mes-
To remove the radiated heat of the diesel engines
sages are unavoidable. To these belong:
and to introduce sufficient combustion air the
rooms in which they are installed are to be pro- - fuel tank overfilled,
vided with air inlet and outlet openings for outside - lack of fuel,
air. With diesel engines of higher performance - cooling water temperature too high,
and/or smaller rooms inlet and outlet air blowers - lack of cooling water,
can additionally be necessary. - lubricating oil pressure too low or lack of lu-
bricating oil (emergency shutdown!).
Precautionary measures for winter operation are
to be taken
4.3 Pipelines in the Pumping Station
Diesel plants create high noise levels; this
means that structural measures are to be
For the proper operation of dry-well installed
taken in the interest of the operating staff and
pumps the suction (inlet) pipeline must al-
the environment. The approval authorities will,
ways be laid inclined upwards to the pump.
under certain circumstances, issue requirements.
The nominal width of the suction pipeline should
The scope of the measures to be taken depends

20 June 2000

be at least the diameter of the intake mouth of the
pump and be not less than 100 mm. A check
valve and, following this, a gate valve are to
be provided, looking in the direction of flow,
on the pressure side of the pump.
Similarly, with a dry-well installed pump, a
gate valve should always be inserted in the
suction line. Only in this way is it ensured that,
with the removal of a blockage or repair of a
pump or of a check valve, that pumping operation
does not have to be interrupted.
The integration of the pump pressure mains
must always be horizontally into the main
pipeline (see Fig. 14), as otherwise the vertical
pipeline becomes clogged.
Fig. 14: Integration of the pump pressure
main
A pressure pipe emergency connection should be
provided for a transportable pump for the case of
pump room flooding or of total pump failure. The
emergency connection should be provided flood-
ing- and frost-free in at least DN 100 and as
short, vertically upwards, easily accessible con-
nection piece with gate valve and blind flange.
ATV-DVWK-A 134E
Using steel as the pipe material for pressure
mains within the pumping station, for reasons of
corrosion, this should be thick-walled. Then an in-
ternal wall corrosion protection can be dispensed
with. With wet-well installation of pumps and
where later renovations are possible under diffi-
cult conditions only, the employment of Material
No. 1.4571 is recommended.
Pipeline fixtures should be arranged with short
separation and be made particularly stable. With
longer pipelines they should be displaceable axi-
ally (heat expansion). The pipelines must, in addi-
tion, always be so anchored that they transfer no
forces to the pump.
For perfect assembly, i.e. for stress-free connec-
tion, for the balancing of length tolerances and to
avoid damage to seals, depending on the re-
quirements, loose or fixed detachable fittings or
compensators should be incorporated in the pipe-
lines. Detachable fittings can, however, also be
avoided through suitable arrangement of the
pipeline, so that pipe elbows with flanges can
take over their task.
All painting is to be carried out with the observa-
tion of Advisory Leaflet ATV-M 263 (Not available
in English).
Larger wall fairleads are, if absolute sealing is re-
quired (e.g. against groundwater), to be carried
out as wall flanged pipes with one or more wall
flanges. In principle these are to be built-in from
the start as, with later installation sealing problems
can occur.
4.4 Gate Valves
With gate valves it is differentiated between mod-
els with internal and external spindle threads (see
Fig. 15).
June 2000 21
ATV-DVWK-A 134E

Internal spindle threads External spindle threads

Fig. 15: Tapered gate valves with respectively internal ad external spindle threads

Preferred is the model with external spindle
threads as, through removal of the spindle nut and
the spindle thread from the area of the wastewater,
heavy wear is avoided and the spindle is easy to
grease. Nevertheless the greater installation height
is to be noted. Ductile cast iron (DCI) is to be pre-
ferred to grey cast iron (GCI) as casing material
due to the essentially greater security against frac-
ture.
Attention is to be paid, with gate valves with me-
chanical drive, that the maximum possible actuat-
ing power cannot damage the gate valve.
To avoid corrosion on components of the gate
valve the following materials are recommended for
use in wastewater:
Spindle: Stainless steel Mat. No. 1.4571
Spindle nut: Zinc-free cast Mat. No. 2.1060
bronze
Seating ring: Zinc-free cast Mat. No. 2.1060
bronze
Due to their design tapered and parallel slide gate
valves are especially suited for a controlled closure
and opening (see EN 752-6, Section 9.3)
Clack valves are not suited for wastewater as tex-
tiles can wrap around spindle and swing valve and
can prevent the closure procedure.

22 June 2000
 ATV-DVWK-A 134E

4.4.1 Gate Valves with Elastomer
Coated Obturators
These gate valves have a straight valve opening
without valve pocket and an elastic seal (see
Fig. 16).
They are particularly suitable as gate valve every-
where where they are almost exclusively open.
- spindle and spindle nut are located outside the
wastewater stream even with non-rising
spindles,
- the parallel slide gate valve can also be
supplied as throttle valve,
- cutting effect with solid matter in the
wastewater,
- cost efficient.

Deposits which have settled and hardened in the

valve pocket with tapered gate valves (applies only
with horizontal mounting) are thus avoided. Gate
valves with elastomer coated obturators, however,
are not suitable as throttles.

Fig. 16: Gate valves with elastomer coated

obturators

The dimensions of the gate valve with elastomer

coated obturator, depending on the nominal pres-
sure, correspond with the tapered gate valves. Ma-
terials for spindle and spindle nut here also should Fig. 17: Parallel slide gate valve
be the above given.

4.4.3 Tapered Gate valves

4.4.2 Parallel Slide Gate Valves
Parallel slide gate valves (see Fig. 17) are charac-
terised by the following advantages:
- very short construction length,
- all installation positions are permitted,
- easy adjustment of the parallel slide seal,
The tapered gate valve (see Fig. 15) is very robust
and has proved itself in rough wastewater opera-
tion. The exception here is, however, the gate
valve with two-part (elastic) wedge with which the
slider can become clogged with textiles.
Gate valves are standardised up to DN 600 in
DIN 3352, Parts 1 – 8.

June 2000 23
ATV-DVWK-A 134E
4.5 Non-return Valves
The non-return valve, when fully opened, may not
hinder the passage of solid matter. For this the
check valve with a casing made of grey cast iron or
ductile cast iron is particularly suitable (see Fig.
18). The later is to be preferred. It should be fitted
with lever and weight. With this it offers the possi-
Fig. 18: Check valve
4.6 Pump Air Bleeding
Through conveyance of the centrifugal pump up to
the inlet side breakdown of the pumping flow or
through leaking glands a dry-well installed cen-
trifugal pump empties itself into the inlet chamber
after shutting down. Should the return valve be lo-
cated immediately or just slightly above the pump
pressure connection piece the pump casing re-
mains filled with air.
As centrifugal pumps in such a state cannot nor-
mally pump they must be bled of air beforehand.
For this the bleed line with horizontally mounted
pumps must run from the highest point of the pump
casing or, with vertically mounted pumps, as short
as possible in front of the return valve.
The bleed line should end in the inlet chamber.
With this it is to be led so high in the pump room
that even with maximum water level in the inlet
chamber a perfect bleeding of the air is possible
(see Annex 1).
24 June 2000
bility of assessing the output of the pump. With
small nominal widths (< 150 mm) with low static
head of water a backwashing can also be intro-
duced by raising the flap by means of the lever.
Where a check valve fails due to too small a de-
gree of opening as a result of small flow rates, a
ball check valve should be employed.
To avoid pumping into the bypass through the
bleed line and its blocking, that will certainly
occur within the shortest time, the line within
the machinery room must have a shut-off de-
vice, which automatically closes with the start-
up of the pump and, with the shutdown of the
pump, opens with a time delay (time until the
impeller of the pump has stopped turning). So-
lenoid or pinch valves are suitable as shut-off
devices.
Where a return valve is located so high that the air
from the pump can be forced into the pressure
main through the rising water level no bleed line is
necessary. With wet-well installed submersible mo-
tor-driven pumps this is often the case.
4.7 Admission Gate Valves
For the following reasons it is necessary to sepa-
rate the inlet chamber of a pumping station from
the inflow:

- for cleaning tasks in the inlet chamber or for
the removal of bulky items and solid matter
from the inlet chamber,
- for visual checks in the inlet chamber as well
as examination of the level switch and other
measuring equipment in the inlet chamber as
well as measuring runs for the determination of
the pump conveyance flow,
- to dry out the inlet chamber for necessary
maintenance tasks.
Therefore, from the very beginning, an admis-
sion gate valve should be planned with the
construction of a wastewater pumping station.
With a small wastewater pumping station manual
operation as far as possible using an above
ground column should be sufficient. With a larger
works the gate valve should have an electric
actuator, explosion protected in the Class E Ex dII
BT3. The most suitable gate valve is one without
casing with external threaded spindle, which can
be installed in a sewer manhole. Due to water-
tightness it is to be so installed in the manhole
shaft that the slider plate is pressed against the
frame by the water, i.e. from the inflow side.
Threaded spindle, rods as well as all bolts and all
anchor bolts, should be manufactured from Mate-
rial No. 1.4571 or equivalent. The seals and guides
should be made from a zinc-free bronze, for ex-
ample Material No. Nr. 2.1060.
4.8 Water Supply Facilities
In accordance with VBG 54 [Regulations of the
Trade Association] (UVV 25) [Accident Preven-
tion Ordinance] washing facilities with running
water must be available in pumping stations.
Further details are to be found in the Implementa-
tion Instructions to the VBG 54 (ZH 1/177). In addi-
tion, water for cleaning purposes in the machinery
room and inlet chamber is, in particular required
(see also Section 4.9).
With the installation of water supply facilities
potable and non-potable water connections
must be differentiated.
If a potable water connection is intended then,
in addition to the respective regulations of the
Federal German States and water supply con-
ATV-DVWK-A 134E
cerns, DIN 1988 as well as the DVGW [German
Technical and Scientific Association for Gas
and Water] Standard W 345 must also be ob-
served.
4.9 Washdown Facilities
A supply of water should be provided in order to be
able to clean the pump room of a pumping station
with dry-well installed pumps.
To clean the inlet chamber an output of from 4 to
6 m3/h is required. A fire hydrant is ideal as water
source to which a DN 25 hose with D-spout in ac-
cordance with DIN 14365 can be connected.
Due to the danger of corrosion the washdown
pipeline in the inlet chamber should be made from
PE Hard plastic in accordance with DIN 19533 or
stainless steel Material No. 1.4571, PN 10.
Attachment of the pipeline should take place also
using plastic, or better, stainless steel (Material No.
1.4571 or equivalent) clips. The bolts/screws used
for this must also be made implicitly from stainless
steel of the same quality.
The washdown pipeline in the inlet chamber
may be connected with a potable water pipeline
in accordance with DIN 1988, Part 4, only indi-
rectly via a water tank and a downstream
booster system. Only a pipe disconnector ap-
proved by the DVGW which automatically and visi-
bly establishes a 20 mm long break in the pipe as
soon as the water pressure falls below a certain
safety value may also be employed in short-term
operation. DIN 1988, Part 5, gives further informa-
tion.
With several plants of the same type a transport-
able washdown facility, if required equipped with
water tank, can also be employed.
4.10 Machinery room Drainage
For the discharge of leaking water and/or
washdown water and for the draining of pumps
a pump well is to be provided at the deepest
point of the machinery room and a light sub-
mersible motor-driven pump with the greatest pos-
June 2000 25
ATV-DVWK-A 134E
sible free impeller passage and automatic level
switch is to be so connected to a fixed pipe that,
with blockage, it can be removed easily and
cleaned at any time by hand. The pipeline must
be so laid that a siphoning over to the machin-
ery room is prevented, i.e. as a rule using a
gooseneck via the highest possible ordinate of the
backwater of the wastewater inflow.
The drainage pump should have a return valve
immediately behind the pressure hose. The instal-
lation of a gate valve in the fixed pipeline is useful.
The size of the pump well depends on the pump
selected. It should not undercut the dimensions
500 x 500 mm and a depth of 300 mm.
4.11 Ventilation Facilities for Machinery
Rooms
In accordance with VBG 54 (UVV 25) rooms of
wastewater treatment systems as well as
stormwater tanks and pump pits (inlet cham-
bers) must be equipped with an effective venti-
lation. Details on the type of ventilation are to be
found in the Implementation Instruction of the
VBG 54.
With an above-ground structure usually the win-
dows and, additionally, shaft ventilation suffices for
small machinery rooms. All air inlet and outlet
openings to the outside are to be provided with
protective screens for birds and weather, whereby
the protective screen for weather must be seated
outside of the protective screen for birds. Further
information is contained in VDI [Association of
German Engineers] Standard 3803.
If a machinery room lies well below ground level
then a five times the hourly forced air exchange
should be sought. This is most usefully achieved
using an exhaust fan and appropriate air resupply
openings.
4.12 Ventilation Facilities for Inlet
Chambers
Enclosed rooms of wastewater discharge facili-
ties and pump wells (inlet chambers) must be
26 June 2000
equipped in accordance with VBG 54 with ef-
fective ventilation (see Section 4.11).
For the inlet chamber of small wastewater pumping
stations a stationary or transportable mechanical
aerator is, as a rule, sufficient. The displaced air
must be able to flow via a sufficiently dimensioned
free cross-section. With larger pumping stations
both a mechanical aerator as well as an air extrac-
tor should be installed.
Fundamentally with ventilation plants attention is to
be paid that no short circuits form between inflow
and outflow air areas.
Both the external inflow as well as the outflow
openings are to be so arranged that the
neighbourhood is neither hazarded nor incon-
venienced by exiting gases. With pumping sta-
tions with superstructure they should be as high as
possible, whereby the outlet of the outgoing air
channel should be located above the ridge of the
roof (as far as available), that is outside a possible
lee of the wind.
For practical purposes the ventilators should be
permanently installed in separate above-ground
rooms. These rooms are, as is also the inlet
chamber, to be considered as explosion endan-
gered and therefore must receive a natural diago-
nal ventilation.
All horizontal air channels are to be laid with a
slight gradient so that any condensed water that
forms can run off to the ventilator or inlet chamber
respectively. Every ventilator itself is to be pro-
vided with an outlet pipe at the lowest point of its
casing, which exits into the ventilation channel to
the inlet chamber. Thus it is avoided that water
which, under certain circumstances, can even
freeze, can collect in the ventilator and lead to its
destruction.
All channel sections and naturally also the
connection to the ventilator must be joined,
sealed, with each other. Firms involved in as-
sembly are to be informed urgently on this point.
Air distribution must be so designed that the
air can exit both ca. 1 m above the floor of the
empty inlet chamber and also above the maxi-
mum water level of the inlet chamber.

Ventilators and air channels are to be manufac-
tured from corrosion resistant material.
4.13 Lifting Gear
Crane systems are required for the installation and
removal of machinery. With smaller pumping sta-
tions without superstructure it is to be examined
whether mobile lifting gear can be employed, oth-
erwise a slewing pillar crane should be provided. In
smaller pumping stations with superstructure the
lifting device can be designed as single-beam
crane trolley with suspended pulley block. With
this, the crane girder is to be so directed that the
heaviest plant component can be placed directly
on to the assembly point. With larger pumping sta-
tions a double-beam travelling crane with crane
trolley should be installed in the machinery room.
With this a picking up and setting down of a load is
possible in the complete area of the room. While
longitudinal and transverse movement is entirely
possible by hand an electrical drive for lifting is a
particular advantage when pumps are installed
very deep. To be noted is, that for crane sys-
tems > 1 t which are permanently installed, a
crane maintenance platform, which can be in-
stalled transportable or fixed, is essential for
maintenance, repair and the legally prescribed
tests.
The height and weight of the machine parts includ-
ing securing and overall height of the lifting gear,
the crane trolley and the crane carrier are to be
checked for the dimensioning of the crane system
and clear height of the superstructure. Here
thought is to be given to possible expansion of the
machine plant.
Statics must take into account all working and con-
stant loads.
Before first commissioning, following building
modifications and with lifting gear for loads
greater than 1 t, the complete crane system
must be tested once a year by a specialist.
ATV-DVWK-A 134E
5 Electrical
Engineering
(for this see also Annex 2)
5.1 External and Structural Prerequi-
sites
Electro-technical installations, in particular
switchboard plant, must be housed dry, free of
dust and pollutants.
If electro-technical devices are installed as switch
boxes in the open, attention must be additionally
paid to their maintenance-friendly accessibility as
well as to protection against damage through road
traffic or vandalism. Switchboard plant and trans-
formers may not be installed in areas endangered
by flooding.
Rooms with electro-technical installations are
to be aerated and ventilated as well as heated
so that their function remains assured.
Electro-technical plant may be accessible for a
very limited circle of trained or specially instructed
technical personnel only. The electrical opera-
tional rooms and also the switching plant, so
far as it is not installed in electrical operational
rooms, must be kept under lock and key.
All doors to electrical operational rooms must be
equipped with a panic lock (escape lock), which
can be opened from inside, even when locked,
without aids.
Information for the design and dimensioning of
electrical operational rooms can be found in the
VDE Regulations.
Allowance should be made for the protection of
structures from oil, acids, overpressure as well as
for fire protection.
Floor coverings must be insulated and secure
against electrical breakdown for the corre-
sponding operational voltages. The coverings
may not lead to a build-up of static electricity.
June 2000 27
ATV-DVWK-A 134E
5.2 Energy Supply
The energy supply as a rule is from the low voltage
network (400/230 V, 50 Hz) of the responsible
ESC (= energy supply company). It can, however,
be also required from the medium high voltage
network 20, 10 or 6 kV, in exceptional cases 30 kV
and more. If a particularly high operational or sup-
ply security respectively is necessary, one should
provide two independent feeders, laid on two sepa-
rate cable routes and secured against simultane-
ous connection (considerable additional costs!).
For the securing of the electrical energy supply of
a wastewater pumping station the connected load
must be determined and contact made with the re-
sponsible ESC as early as possible.
The clarification of the supply conditions must
take place with the responsible ESC immedi-
ately after establishment of the essential con-
sumers, that is at a very stage, as they have a
28 June 2000
considerable influence on the room programme,
the costs and the design of the pumping station.
Every ESC has available application forms for the
establishment of the connected load, in which the
required data such as the number and capacity of
the individual consumers is entered.
5.2.1 Energy Supply with a Voltage up to
1000 V (Low Voltage)
Depending on local conditions there is a maximum
possible connected load (standard value ca. 10 to
50 kVA) for the low voltage supply (LV supply)
which depends on the respective ESC. Already for
cost reasons an attempt should be made, as far as
possible, to manage with a LV supply (in general
400/230 V AC), without limiting oneself operation-
ally.

Fig. 19: Basic forms for ready-built stations
5.2.2 Energy Supply with a Voltage over
1000 V (Medium High Voltage)
If the supply conditions do not allow a low voltage
supply a medium high voltage supply is necessary.
Medium high voltage switchboard plants are, in
ATV-DVWK-A 134E
any case, to be installed in locked operating
rooms. For medium high voltage systems one or
more transformers are required. Ready-made as-
sembled small switchboard plants (compact plants)
are available for smaller transformer capacities
(see Fig. 19).
June 2000 29
ATV-DVWK-A 134E
The switchboard plants for voltage levels above
1000 V should, for the protection of personnel, be
employed only as plants secured against
accidental arcing in accordance with Pehla
Directive No. 2, Criterion 1 to 6, with firmly installed
switchgear or on a rail mounted platform
(retractable).
In order that the switchgear still remains operable
even with failure of the mains and the appropriate
information is retained, it is recommended that
both the drive of the switchgear and the control
and reporting systems are designed independent
of the mains supply (battery).
5.2.3 Measurement of Consumption
As a rule this is provided and installed by the ESC.
The build-up of the metering facility depends on
the voltage levels used and thus has an influence
on the room programme. It is to be clarified with
the ESC where the electricity consumption meter is
to be installed.
5.3 Switchboard Plant, Actuators and
Appliances
Low voltage switchboard plants are normally
produced in the shape of standardised sheet steel
cabinet systems which are secure against
accidental arcing to increase the protection of
personnel.
As a rule a modular method, otherwise an insertion
method, is employed for the power items.
To control and monitor the machines motor control
cards (electronic) can be used for the realisation of
the basic circuitry and basic locking mechanism.
Higher voltage switches are realised through the
employment of stored-programmable control
systems (SPS).
Unavoidable blind current components should be
compensated using fixed or regulatable blind
current compensation. For later expansion a space
and capacity reserve of from 15 – 20 % should be
planned.
30 June 2000
All switching plant is to be installed safe from
flooding.
5.3.1 Main Drives
As far as possible, three phase squirrel-cage
motors with small current at make should be
provided as drive motors for the wastewater
pumps (see Section 4.2.1).
Winding sensing devices can be planned to protect
the motor against overload. For drives with
operationally conditioned long down-times, and
with high air humidity, a down-time heater can be
practical.
The IP 54 system of protection is to be preferred.
Every drive has a control selection switch with the
positions MANUAL – OFF – AUTOMATIC.
The switching ON and OFF of the pumps is
dependent on water level, in special cases the
delivery flow can be over or underlaid. Operating
conditions must be recognisable on the electrical
control panel. Pump exchange switch, current
meter and operating hours counter should be
integrated. In addition each drive has one (or
more) EMERGENCY OFF switches in situ, which
engage directly in the control system.
Faults always lead to the immediate shutdown of
the plant. With this the control system, goes into
locked status, an automatic restart following a fault
may not occur.
Modification of the number of pump revolutions is
possible through pole changing motors (2 or 3
rpm) or using frequency converter drives (infinitely
variable, simultaneous starter in the lower rpm
range).
Frequency converter drives create heat and
noise which possibly has respectively to be
dissipated or restrained. In addition, converters
create harmonic waves in the power supply. The
power supply reactions of these harmonic waves
must be compensated.
 ATV-DVWK-A 134E

Attention is to be paid that the adjustment of the - Plug connections for three phase 400 V to
rpm modifies all characteristic curves of the 63 A, 230 V/16 A AC and extra-low voltage
pumps. 25 V/10 A,
- Water heaters for sanitary objects,
There are the following possibilities for the - Connections for measuring technology, fused
automatic operation of the pumps: outlets 230 V,
- Reserve outlets; for each voltage level 1 to 3
- Pumping control
reserve outlets.
Conveyance of the pump is monitored.
- Protection against dry running
It is prevented that the pump lowers the water
level in the inlet chamber below a permitted
5.3.4 Operating and Measuring System
level and thus runs dry.
Recording of operating and fault messages:
- Simultaneous start
Simultaneous start of large consumers is
Operating messages should be displayed
prevented to avoid expensive peak loads.
individually optically, fault messages shown
- Reserve pump with malfunction
individually optically and collectively acoustically.
With malfunction of the service pump the
The fault messages can, if required, be combined
reserve pump takes over operation
together as a group fault message.
automatically.
- Conveyed quantity- or pressure control
A test key for all illuminated displays is
- Parallel operation of several pumps
recommended.
- Reclosure preventing device
The immediate reclosure following switching off
The remote transmission of operating and fault
for operational reasons is prevented depending
messages as well as status signals can, for
on time in order to avoid the inadmissible
example take place via a cable or leased lines.
heating of electrical components and/or heavy
start.
Remote transmission is, however, only sensible if
- Monitoring of oil and cooling water
there are possibilities of acceptance or of calling
- Alternating closure
up this information in rotation as well as for its
With every new closure impulse another drive
operational processing.
is switched on in preselected sequence.

A telephone connection is necessary,

5.3.2 Ancillary Drives
alternatively paging or service radio. In any
case personnel working in the pumping station
Ancillary drives are, inter alia:
must be available or must be capable of
- Actuators for fittings, making contact with the control centre.
- Inlet chamber ventilators, if required pump
room ventilators,
- Drainage pumps for pump rooms, 5.4 Emergency Power Supply
- Booster pumps for wash down facilities,
- Grease or oil pumps for bearing lubrication, Depending on the security of the energy supply,
- Lifting gear, possibilities of retaining the wastewater in cases of
- Compressors. failure and the operational significance of the
pumping station in the drainage system, a mobile
or a stationary, automated emergency power
5.3.3 Ancillary Facilities equipment is required.
- Mobile plant
These cover:
This requires a signal of the fault at the central
- Electrical heating for frost protection, point, a possibility that the plant can be trans-
- Lighting plant, additional emergency lighting, ported in and connected to the switchboard
- Battery systems, plant rapidly and without complications, where-

June 2000 31
ATV-DVWK-A 134E
whereby, at the same time, the separation from
the power supply and locking must take place.
- Automatic plant
Automatic emergency power supply systems
switch in immediately following voltage
breakdown and, with a time delay, switch off
following reestablishment of the power supply.
For rotational maintenance their must be a
possibility of running the emergency power
system under load over several hours.
- Special cases
The energy supply of the complete works or
parts of this can take place with the aid of a
stationary, automatic generator (see Section
4.2.2).
5.5 Types of Protection and
Regulations
All equipment and installations must
correspond with the relevant VDE and VBG
regulations as well as the technical connection
conditions (TAB) of the responsible ESC.
An earthing of the complete plant, incl. the
conductive plant components which do not
belong to the operating power circuit, in
accordance with the VDE is to be carried out
with the aid of the foundation earth planned by
the customer and, if required, additional
earthing (see Section 3.4.7).
Equipotential bonding between all conductive
components must be carried out whereby
protection against lightning strike is included
in the bonding.
Lightning protection in accordance with ABB is
required for superstructures (see Section 3.4.8).
5.5.1 Explosion Protection
With the pumping station, as a rule, the inlet
chamber, inlet shaft and, possibly, the ventilator
room are explosion endangered areas.
The operating equipment therein must be so
installed and the plant so mounted and
operated that no explosion can be caused.
32 June 2000
Zones 0, 1 and 2 are differentiated according to
the timely and local probability of the presence of
dangerous atmospheres capable of explosion.
Valid as “explosion endangered rooms” are all
rooms or areas in which, according to local or
operational conditions, atmospheres capable of
explosion can collect. In the area of the pumping
station they are, in general, to be assigned to Zone
1, so that the Explosive Ordinance is to be
applied.
5.5.2 Protection against Accidental
Contact
In order to protect personnel working in a pumping
station from the results of an electrical accident
such as
- three-phase power accident,
- arcing accident or
- three-phase power accident with an intrinsically
non-hazardous current,
the following protection against accidental contact
is necessary:
- protection with direct contact,
- protection against direct contact,
- partial protection against accidental contact,
- protection with indirect contact.
Protective measures with indirect contact are
fundamentally required with all electrical plant
or equipment (see Section 3.4.7).
Protective measures without earth conductor:
- double insulation,
- protective low voltage,
- fuse.
Protective measures with earth conductor:
- protective earth,
- earthing,
- earthed conductor system,
- fault-voltage [German = FU] protective circuit,
- residual current [German = FI] operated
device.

6 Measurement
Engineering
The external prerequisites are practically identical
with those of electrical engineering. The
transmitters must, however, as a rule be install in
situ. Therefore, with these devices there is the
involvement of large expense for protection against
moisture, cold, dust, corrosion through pollutants,
mechanical damage as well as possibly for
explosion protection.
With the employment of electronic components
conditions are to be created which allow the
electrical equipping of various type and design to
exist alongside each other.
6.1 Level Measuring Systems
Level measuring systems are required for the
determination of the respective water level on the
inlet side and, in special cases, also on the outlet
side and for the automatic control of the pumping
plant.
The following measuring methods are employed:
- electrical pressure sensor,
- depth sounder.
6.2 Delivery Pressure Measuring
Systems
Delivery pressure measuring systems are required
for the determination of the pressure head at the
pump and the pressure in the pressure pipeline.
Electric pressure sensors, which are flanged directly
to the pressure pipeline, are suitable for suction and
pressure measurement. A further possibility lies in
the employment of spring-tube manometers in
overpressure secure design in accordance with
DIN 16005 with a damping device and reinforced
dial train as well as pure water seal.
ATV-DVWK-A 134E
6.3 Flow Measuring Systems
Permanently installed flow measuring systems are
to be employed when a continuous measuring of
the delivery flow is necessary for an accurate
determination of the delivery efficiency of the
pumping station. The manufacturer-specific
installation conditions (e.g. calming stretches) are
to be observed.
Magnetic-inductive flow measurement (MID)
The measuring method functions without contact,
therefore is reliable and easily maintained. The
measuring system in addition is the only one
capable of calibration.
Ultrasonic flow measurement
Flow measurements with the aid of the Doppler
effect are available. These systems are, however,
significantly less accurate than the MID and not
capable of calibration.
Flow monitoring
In the area of wastewater flow monitoring is
possible using the signals of the MID or from the
position of the flap of the non-return valve.
6.4 Transmission of Measured Values
The electrical transmission of the measured values
takes place via electronic measuring transducers
which convert the measured value into a
proportionally formed direct current of 0...20 mA or
4...20 mA and/or of 0...10 V.
7 Wastewater Pressure
Pipelines
7.1 Pressure Pipelines
Pressure pipelines serve for the transport of the
wastewater from the pumping station to the desti-
nation. Pump and pressure pipeline are to be dealt
with as hydraulic unit. The relationship is given, on
June 2000 33
ATV-DVWK-A 134E
one hand, by the pump characteristic curve (throt-
tle curve) and the pipeline characteristic curve on
the other (see Section 4.1.1).
The pressure pipeline must be able to accept
the internal and external pressure on the
system continuously and without damage. To
this belong the pressure transient processes (e.g.
water hammer), if no other safety measures are
taken.
7.2 Pipeline Routes
Basically the pressure pipeline should represent
the shortest possible connection between the
pumping station and the discharge point.
The pipeline should as far as possible be laid
straight constant with the run of the vertical
position in order to keep the hydraulic losses low
through small changes of direction. If the ground
permits the pipeline should be designed with a
steady incline in order to transport the air also
conveyed to the end of the pipeline.
Digested matter in the wastewater can lead to the
formation of H2S and thus to an endangering of the
pipe inner walls. In particular the employment of
cement-bonded materials (concrete pipes, cement-
fibre and cement-mortar lining) is problematic here
(see Advisory Leaflet ATV-M 168).
Pipelines must be laid at depths safe from frost
or be appropriately protected. The required
crown covering in Germany lies between 0.8 m
and 1.5 m.
For static reasons (see ATV-A 127E) a greater
minimum covering can be necessary in view of
extreme traffic loading. Further security measures
in the form of protective pipes or concrete cladding
can be considered for use.
At significant high points pressure mains must
equipped with venting and ventilation fittings.
Venting is necessary in order that the pipeline can
be completely emptied and a return flow due to si-
phoning effect is prevented. Ventilation is required
for the controlled filling of the pipeline. With filled
pipelines it is necessary to be able to remove en-
34 June 2000
trained air or the gas cushions resulting from the
formation of gas. Gas cushions can lead to higher
energy losses as a result of a narrowing of the flow
cross-section.
If, in the case of repair with pumps at standstill, the
pipeline does not empty itself due to geodetic
gradient, emptying pipelines with connection to the
wastewater and combined wastewater sewer
system or for suction vehicles are to be planned for
suitable low points.
Monitoring ports, for example for pipe inspection
using cameras, venting and ventilation as well as
emptying fittings, are, from a practical point, to be
accommodated in shafts which should be
equipped with a pump well at the bottom.
7.3 Dimensioning
The required pipe diameter is determined based
on the delivery flow determined through the
hydraulic calculation (see Sections 2.6 and 2.7).
The pressure rating of the pipeline to be used is
determined according to the static and dynamic
effective internal pressure. Both the nominal width
(DN) of the pipes and the pressure rating (PN)
must correspond with DIN 2401 and DIN 2402
respectively.
The minimum and maximum speeds of the delivery
flow are to be observed. Furthermore the
statements in Section 2.7 apply.
As the delivery flow conditioned by the wastewater
yield is subjected to considerable variations it can
be practical, if required, to lay instead of one
pressure pipeline a second (or more), which can,
at the same time, serve as reserve pipeline. The
pipe material is determined through the hydraulic,
mechanical and chemical stresses which can have
an effect both internal and external.
Pipe wall thickness is dependent on the required
pressure rating, the external loads and the type of
material.
The hydrostatic pressure is determined from the
geodetic height difference. The dynamic loading
results from the pressure loss and the unsteady

pressure changes (pressure surges) combined
through the individual pipe losses.
The overall dynamic pressure loss is made up from
the pressure loss through pipe friction and the
individual losses due to mountings, fittings such
as, for example, elbows cross-section chambers
and branches as well as through losses at inlets
and outlets. For details see The ATV Handbook
„Bau und Betrieb der Kanalisation“ [“Construction
and operation of sewer systems]”.
7.4 Stresses
Pressure mains are subject to different stresses.
They are caused by:
- transport and storage,
- installation,
- external forces,
- internal forces,
- temperature,
- abrasion,
- corrosion.
With the stresses through transport and storage,
installation as well as through external forces a
wastewater pressure main does not differ from
drinking water pipelines. Important information can
be found in EN 1610, DIN 4124 and DIN 19630.
With the internal forces attention is drawn
particularly to stresses due to pressure surges.
Pressure surges result following unsteady flow
processes with the switching on and off of pumps,
changes to the pump rpm or adjustment of gate
valves and failure of pump drives. Physical bases
and calculation procedures for pressure surges are
contained in DVGW Advisory Leaflet W 303.
With wastewater pressure mains the pressure
(water hammer) problem is reinforced in that the
wastewater can form gases which combine in the
high points into gas cushions. Pressure surges
which occur in the presence of gas cushions are
not predictable. Therefore the high points of
wastewater pressure mains are to be inspected by
rotation, even during operation, and if necessary
vented.
With the exception of external temperature
stresses against which a pipeline is to be protected
ATV-DVWK-A 134E
through minimum cover and/or insulation, with
varying or even continuous high temperatures of
the pumped medium, an additional stress of the
pipeline can occur. The pipe material here is to be
selected with particular care.
Abrasion occurs with pressure mains if increased
mineral substances occur in the wastewater.
Effects are to be expected particularly in the area
of changes of direction and throttle points. It can
be necessary to counter these through increasing
wall thickness, for example through the selection of
a higher nominal pressure rating, in the critical
area.
7.5 Pipe Materials
The medium to be transported in wastewater
pressure mains, as opposed to drinking water,
cannot be described precisely. Wastewater can
contain many putrefactive substances so that fresh
and older wastewater in their behaviour with
regard to some materials is different. Therefore,
the selection of material is to be made taking into
account local conditions. If required, appropriate
pre-treatment and pipe protective measures are to
be planned.
As materials there are available:
- metallic materials,
- cement bonded materials,
- ceramic materials and
- plastic.
7.6 Corrosion and Corrosion Protection
Significant wastewater-specific attacks with
wastewater pressure mains are, above all to be
expected on the inner wall. With this the
composition of the wastewater and its time-
dependent possible change are of significance as
well as the possible aggressiveness with partial
(with gas formation in the crown areas) or
complete filling of the pipeline.
Here it should be noted that wastewater pressure
mains made from certain materials also have
components such as fittings, seals and mountings
made from other materials.
June 2000 35
ATV-DVWK-A 134E
Pipe materials susceptible to corrosion must
be protected through internal and external
insulation. Thus steel pipes receive externally a
polyethylene jacket or coating with polyurethane
tar and, internally, an epoxy-resin or cement
mortar lining. With pressure pipes made from
ductile cast irons external spray galvanisation,
bitumen paint or epoxy-resin coating and internally
cement mortar lining are used. Reinforced
concrete and fibre-cement pipes in many cases
receive an additional coating on a bitumen basis or
of epoxy-resin (see DIN 4030), for example with
the danger of sulphide formation in the wastewater
and with high sulphate content.
8 Commissioning
The documentation of all plant components
must be available for commissioning (see ATV-
A 148E).
8.1 Pumping Station
Acceptance with functional testing and trial
runs of the individual component parts must
precede commissioning of the pumping
station. Those responsible for planning and
construction work, from the undertaking and, for
reasons of warranty, also representatives of the
manufacturer and/or supply companies are to take
part in this.
Before commissioning the electrical plant all
short circuit and overcurrent protective
systems are to be checked for correct setting
and are to be secure. All switching and control
procedures are to be carried out first without
loading (cold testing). Only then can the facility be
released for operation.
In general the pumps have been subjected to a
test bench trial at the manufacturer’s works. This
factory acceptance serves for the examination of
whether the guaranteed delivery data are
achieved. In contrast to that the test run in the
pumping station is to provide information on its
mechanical and hydraulic behaviour, freedom from
vibration, heating of bearings and correct function-
ing of ancillary facilities (lubrication, cooling, venti-
36 June 2000
lation, possibly regulation/control, displays) under
the local installed conditions.
In detail the following are recommended as
controls:
- tension-free assembly,
- adjustment of end bearings and torque,
- direction of pump rotation,
- pump sequential switching,
- setting of rpm,
- venting of the pump casing,
- sealing,
- noises,
- vibrations,
- temperatures,
- pressure surges,
- non-return valve clapper knock,
- measurement and control technology,
- remote monitoring and control,
- emergency energy supply.
The pumps should be tested under full load for at
least two hours. If there is not enough water
available for a test run it has proved advantageous
if the existing water can be pumped via a diversion
in a circle.
For the commissioning and later operation it is
necessary that the operating personnel receive
precise knowledge of the plant engineering
already with assembly and that they have
already received instruction.
The pumping station can be taken into operation
after the functional testing.
With this the requirements of the pressure main
commissioning are to be observed.
In the run-in phase (ca. 4 weeks) it is
recommended that the complete operating cycle
has increased monitoring as, from experience, an
increased number of faults occur on the plant
components during this period.
8.2 Pressure Main
An internal pressure test in accordance with
DIN 4279 is to be undertaken before commis-
sioning. For commissioning the ventilation fittings
 ATV-DVWK-A 134E

to be operated manually are to be opened and 9.1 General Terms and Conditions for
controlled during the filling procedure. Engineering Services, (VOB)

With the connection of the pressure main to the Part C, General Technical Regulations for
existing network with different pressure potentials, Engineering Services:
it should be noted that pressure surges result
through too rapid opening or closing of the gate DIN 18 017 Lüftung von Bädern und Spül-
valves, which can lead to damage to the pressure Part 1 aborten ohne Außenfenster durch
main. Once a flow is no longer detectable the gate Schächte und Kanäle, ohne
valve can be opened very slowly. Closure is Motorkraft; Einzelschachtanlagen
carried out analogously. [Ventilation of baths and flush
toilets without outer widows
Immediately after commissioning of a new pres- through shafts and channels,
sure main the first pressure pipe characteristic without motor drive, single shaft
curve should be adopted. It serves for the estab- facilities]
lishment of a practical and economic dimensioning DIN 18 300 Erdarbeiten [Excavation works]
and for the evaluation of the delivery pumps in this DIN 18 303 Verbauarbeiten [Revetting]
pressure main. DIN 18 304 Rammarbeiten [Pile driving]
DIN 18 305 Wasserhaltungsarbeiten
[Dewatering works]
DIN 18 306 Entwässerungskanalarbeiten

9 Information on Stan- DIN 18 331

[Drainage sewer works]
Beton und Stahlbetonarbeiten
dard Specifications, [Concrete and reinforced concrete
works]
Directives, Standards, DIN 18 335 Stahlbauarbeiten [Steel
construction works]
Advisory Leaflets (Se- DIN 18 336 Abdichtung gegen drückendes
lection) Wasser [Sealing against water
under pressure]
DIN 18 363 Anstricharbeiten [Painting works]
The documents listed below have been mentioned DIN 18 364 Korrosionsschutzarbeiten an Stahl-
in this Standard and must be taken into account in und Aluminiumbauten [Corrosion
the respectively valid version inter alia with the protection works on steel and
design and construction of a wastewater pumping aluminium structures]
station. [Translators note: Where there is a known DIN 18 379 Lüftungstechnische Anlagen
official translation the title is given in English only. [Ventilation plants]
Otherwise a courtesy translation is given in square DIN 18 381 Gas-, Wasser- und
brackets after the German title.] Abwasserinstallationsarbeiten
innerhalb von Gebäuden [Gas,
water and wastewater installation
works within buildings]
DIN 18 382 Elektrische Kabel- und
Leitungsarbeiten in Gebäuden
[Electrical cable and line works
inside buildings]

9.2 Standard Specifications

DIN 4045 Wastewater engineering -

Vocabulary

June 2000 37
ATV-DVWK-A 134E

EN 752 Drainage systems outside buil- DIN 2614 Cement mortar linings for ductile
Parts 1-7 dings iron and steel pipes and fittings;
EN 1671 Pressure sewerage systems application requirements and
outside buildings testing
DIN 3352 Gate valves [Available in English
9.2.1 Building Standards Parts 1-8 Parts 1-4 only]
DIN 4032 Concrete pipes and fittings
DIN 1045 Structural use of concrete; design DIN 4035 Stahlbetonrohre und zugehörige
and construction Formstücke aus Stahlbeton
DIN 1055 Design loads for buildings [Reinforced concrete pipes and
Parts 1- 6 associated fittings made from
DIN 1084 Control (Quality control) of reinforced concrete]
Parts 1-3 concrete structures and reinforced DIN 4279 Testing of pressure pipelines for
concrete structures Parts 1-10 water by internal pressure [Parts
DIN 1164 Portland-, Eisenportland-, Hoch- 1,7,8 not available in English]
Parts 1,2,8, ofen- und Trasszement; Begriffe, DIN 8061 Unplasticised polyvinyl chloride
Bestandteile, Anforderungen, pipes (PVC-U); general quality
Lieferung [Portland, iron Portland, requirements and testing
blast furnace slag and trass DIN 8062 Unplasticised polyvinyl chloride
cement; Terms, requirements, pipes (PVC-U, PVC-HI);
delivery] dimensions
DIN 1986 Site drainage systems DIN 8063 Pipe joints and fittings for pipes
DIN 1988 Drinking water supply systems Parts 1-12 under pressure made of
DIN 2000 Zentrale Trinkwasserversorgung; unplasticised polyvinyl chloride
Leitsätze für Anforderungen an (PVC-U) [Parts 5,7,9,10 not
Trinkwasser, Planung, Bau und available in English]
Betrieb der Anlagen [Central DIN 8074 Polyethylene (PE) pipes –
drinking water supply; Guidelines dimensions
for requirements on drinking water, DIN 8075 Polyethylene (PE) pipes –
planning construction and dimensions – General quality
operation of plants] requirements and testing
DIN 2001 Private and individual drinking DIN 8077 Polypropylene (PP) pipes –
water supply; governing principles dimensions
DIN 4030 Assessment of water, soil and DIN 8078 Types 1, 2 and 3 Polypropylene
gases for their aggressiveness to (PP) pipes – General requirements
concrete and testing
DIN 4124 Building pits and trenches – slopes, DIN 14 365 Multi-purpose branch pipes for
working place widths, sheeting Parts 1-2 nominal pressure 16; dimensions
DIN 18 196 Soil classification for civil materials, construction, marking
engineering purposes DIN 19 532 Rohrleitungen aus weichmacher-
freiem Polyvinylchlorid (PVC hart,
9.2.2 Pipes and Fittings PVC-U) für die
Trinkwasserversorgung [Pipelines
DIN 1333 Zahlenangaben [Numerical data] made from unplasticised polyvinyl
DIN 2440 Steel tubes; medium-weight chloride [PVC-H, PVC-U for
suitable for screwing drinking water supply]
DIN 2448 Seamless steel pipes and tubes DIN 19 533 Pipelines of high density PE and
DIN 2458 Welded steel pipes and tubes low density PE for drinking water
DIN 2605 Steel butt-welded pipe fittings supply; pipes, pipe connections
Parts 1-2 and fittings for pipelines

38 June 2000
 ATV-DVWK-A 134E

DIN 19 534 Rohre und Formstücke aus EN 1299 Vibration isolation of machinery –
weichmacherfreiem information fort he application of
Polyvinylchlorid (PVC-U) mit source isolation
Steckmuffe, für Abwasserkanäle EN 1610 Construction and testing of drains
und –leitungen [Pipelines and and sewers
fittings made from unplasticised
polyvinyl chloride (PVC-U) with 9.2.3 Mechanical Engineering
sleeves, for drains and sewers]
DIN 19 537 High density polyethylene (HDPE) DIN 1184 Pumping stations; Archimedean
pipes and fittings for drains and Part 4 screw pumps; Directives for
sewers; technical delivery planning
conditions DIN 1944 Acceptance tests on centrifugal
DIN 19630 Richtlinien für den Bau von pumps (VDI rules for centrifugal
Rohrleitungen [Directives for the pumps)
construction of pipelines] DIN 24 260 Kreiselpumpen und
DIN 19 800 Asbestos-cement pipes and fittings Part 1 Kreiselpumpenanlagen; Begriffe,
Part 1 for pressure pipelines; pipes, Formelzeichen, Einheiten
dimensions [Centrifugal pumps and centrifugal
DIN 19 850 Fibre-cement pipes and fittings for pump systems; Terms, symbols,
Parts 1-2 drains and sewers; Part 1: units]
dimensions of pipes, branches and DIN 24 293 Kreiselpumpen – Technische
bends; Part 2: Dimensions of joint Unterlagen – Begriffe,
assemblies Lieferumfang, Ausführung
DIN 30 675 External corrosion protection of [Centrifugal pumps – technical
Parts 1-2 buried pipes, corrosion protection documents, scope of delivery,
systems for steel and ductile iron design]
pipes DIN 45 635 Measurement of noise emitted by
EN 295 Vitrified clay pipes and fittings and Part 1 machinery
pipe joints for drains and sewers
EN 545 Ductile iron pipes, fittings,
accessories and their joints for
water pipelines; Requirements and
test methods
EN 639 Requirements for concrete 9.2.4 Measurement Technology
pressure pipes including joints and
fittings DIN 1319 Basic concepts in metrology
EN 640 Reinforced concrete pressure DIN 16005 Überdruckmessgeräte mit
pipes and distributed reinforce- elastischem Messglied für die allg.
ment concrete pressure pipes Anwendung [Overpressure
(non-cylinder type), including joints measurement equipment with
and fittings elastic measuring unit for general
EN 642 Prestressed concrete pressure applications]
pipes, cylinder and non-cylinder EN 837-1 Pressure gauges - Part 1: Bourdon
types, including joints, fittings and tube pressure gauges -
specific requirements for dimensions, metrology,
prestressing steel for pipes requirements and testing
EN 764 Pressure equipment; Terminology EN 837-3 Pressure gauges – Part 3:
and symbols relating to tempe- Diaphragm and capsule pressure
rature, pressure and volume gauges; dimensions, metrology,
EN 1032 Testing of mobile machinery in requirements and testing
order to determine the whole body
vibration emission value - General

June 2000 39
ATV-DVWK-A 134E

VDE 0410 VDE-Bestimmung für elektrische DIN EN 50 015 Elektrische Betriebsmittel für ex-
Messgeräte; plosionsgefährdete Bereiche;
Sicherheitsbestimmung für Ölkapselung [Electrical equipment
anzeigende und schreibende for explosion endangered areas;
Messgeräte und Zubehör [VDE Oil immersion]
regulations for electrical metering DIN EN 50 016 Elektrische Betriebsmittel für
equipment; safety regulations for explosionsgefährdete Bereiche;
indicating and recording measuring Überdruck-kapselung [Electrical
equipment and accessories] equipment for explosion
endangered areas; Pressurising]
9.2.5 Electrical Engineering DIN EN 50 017 Elektrische Betriebsmittel für
explosions-gefährdete Bereiche;
VDE 0100 Bestimmungen für das Errichten Sandkapselung [Electrical
von Starkstromanlagen mit equipment for explosion
Nennspannungen bis 1000 V endangered areas; Powder filling]
[Regulations for the erection of DIN EN 50 018 Elektrische Betriebsmittel für
high tension facilities with nominal explosionsgefährdete Bereiche;
voltages up to 1000 V Druckfeste Kapselung [Electrical
VDE 0105 Betrieb von Starkstromanlagen equipment for explosion
[Operation of high tension facilities] endangered areas; Flame-proof
as well as i.a.: Operation of power installations enclosure]
EN 50110 DIN EN 50 019 Elektrische Betriebsmittel für ex-
Part 1 plosionsgefährdete Bereiche;
VDE 0160 Ausrüstung von erhöhte Sicherheit [Electrical
Starkstromanlagen mit equipment for explosion
elektronischen Betriebsmitteln endangered
[Equipping of high tension facilities areas; Increased safety]
with electronic equipment] DIN EN 50 020 Elektrische Betriebsmittel für ex-
as well as i.a.: Adjustable speed electrical power plosionsgefährdete Bereiche;
EN 61 800 drive systems Eigensicherheit [Electrical
Part 3 equipment for explosion
endangered areas; Own safety]
VDE 0165 Errichten elektrischer Anlagen in DIN EN 50 021 Elektrische Betriebsmittel für ex-
explosionsgefährdeten Bereichen plosionsgefährdete Bereiche;
[Installation of electrical plant in Betriebsmittel der Zündschutzart
explosion-endangered areas] [Electrical equipment for explosion
as well as i.a.: Elektrische Betriebsmittel für endangered areas; Equipment with
EN 60 079 gasexplosionsgefährdete Bereiche “e”-type protection ]
Part 10 [Electrical equipment for gas DIN EN 50 039 Elektrische Betriebsmittel für ex-
explosion endangered areas] plosionsgefährdete Bereiche;
VDE Elektrische Betriebsmittel für Eigensichere elektrische Systeme
0170/0171 explosionsgefährdete Bereiche [Electrical equipment for explosion
[Electrical equipment for explosion endangered areas; Intrinsically
endangered areas] safe electrical systems]
As well as i.a.: DIN IEC Blitzschutz baulicher Anlagen
DIN EN 50 014 Elektrische Betriebsmittel für 61024-1-2; [Lightning protection of structural
explosionsgefährdete Bereiche; works]
Allgemeine Bestimmungen VDE 0185
[Electrical equipment for explosion Part 102
endangered areas; General
conditions]

40 June 2000
 ATV-DVWK-A 134E

VDE 0266 Halogenfreie Kabel mit ATV-A 166 Bauwerke der zentralen
verbessertem Verhalten im Regenwasserbehandlung und -
Brandfall [Halogen-free cables with rückhaltung - Konstruktive
improved behaviour in case of fire] Gestaltung und Ausrüstung
VDE 0660 Niederspannungs-Schaltgeräte [Structures for Centralised
[Low voltage switch gear] Treatment, Retention, Design and
as well as i.a.: Low voltage switchgear and Equipping of Stormwater Facilities]
EN 60 439 control gear - combinations ATV-M 168E Corrosion of Wastewater Systems
Parts 1-5 – Wastewater Discharge –
EN 60 947 Low voltage switchgear and ATV-M 176 Hinweise und Beispiele zur
Parts 1-7 control gear konstruktiven Gestaltung und
VDE 0670 Wechselstromschaltgeräte für Ausrüstung von Bauwerke der
Spannungen über 1 kV [AC zentralen
equipment for voltages above Regenwasserbehandlung und -
1 kV] rückhaltung - [Notes and Examples
VDE 0800 Fernmeldetechnik for the Design and Equipping of
[Telecommunications engineering] Structures for Centralised
Wastewater Treatment and
Retention]
9.3 Directives, Standards and Advisory ATV-M 263E Recommendations for Corrosion
Leaflets Protection of Steel Components in
Wastewater Treatment Plants
Using Coating and Cladding
9.3.1 of the ATV
9.3.2 of the DVGW
ATV-A 105E Selection of the Drainage System
ATV-A 110E Hydraulic Dimensioning and DVGW W 302 Hydraulische Berechnung von
Performance Verification of Rohrleitungen und Rohrnetzen
Sewers and Drains [Hydraulic calculation of pipelines
ATV-A 116E Special Sewer Systems - Vacuum and pipe networks]
Drainage Service – Pressure DVGW W 303 Dynamische Druckänderungen in
Drainage Service Wasserversorgungsanlagen
ATV-A 118E Hydraulic Dimensioning and [Dynamic pressure changes in
Verification of Drainage Systems water supply facilities]
ATV-A 127E Static Calculation of Drains and DVGW W 342 Werkseitig hergestellte
Sewers Zementmörtelauskleidungen für
ATV-A 128E Standards for the Dimensioning Guss- und Stahlrohre [Factory
and Design of Stormwater produced cement mortar cladding
Structures in Combined Sewers for cast and steel pipes]
ATV-A 142E Sewers and Drains in Water DVGW W 345 Schutz des Trinkwassers in
Catchment Areas Wasserrohrnetzen vor
ATV-A 148E Service and Operating Instructions Verunreinigung [Protection of
for Personnel of Wastewater drinking water from pollution]
Pumping Stations, Wastewater
Pressure Pipelines and 9.3.3 des VDI
Stormwater Tanks
ATV-A 200E Principles for the Disposal of VDI 2058 Beurteilung von Arbeitslärm in der
Wastewater in Rurally Structured Nachbarschaft [Assessment of
Areas work noise in the neighbourhood]
ATV-A 241 Bauwerke der Kanalisation
[Structures in Sewer Systems]

June 2000 41
ATV-DVWK-A 134E

VDI 3743 Emissionskennwerte technischer VDMA 24 297 Kreiselpumpen, Technische

Bl. 1 Sheet 1] Schallquellen – Pumpen – Kreisel- Anforderungen, Richtlinien
pumpen [Characteristic values of [Centrifugal pumps, Technical
emissions from technical noise requirements, directives]
sources – pumps - centrifugal
pumps]
VDI 3803 Raumlufttechnische Anlagen
Bauliche und technische Anforde-
rungen [Ventilation and air 10 Annexes
conditioning facilities; structural
and technical requirements]
Annex 1: Example of a pumping
9.3.4 of the VDMA [German Association station with centrifugal
of Mechanical Engineering pumps in horizontal,
Establishments] dry-well installation
VDMA 24 261 Pumpen – Benennung nach Wir-
Part 1 kungsweise und konstruktiven Annex 2: Basic circuit diagram
Merkmalen – Kreiselpumpen
[Pumps – designation according to
functional and design
characteristics – centrifugal
pumps]

42 June 2000