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A common application of control equipment in water and
Current Issue wastewater treatment is the management of pumping
Next Issue stations. Pump stations are found in such varied
applications as the clearwell of gravity filtration systems
Past Issues
in wastewater treatment plants, at the base of water
Submissions storage tanks, as booster stations for feed to distribution .
Contact Staff
grids and even on golf courses for irrigation. In
wastewater treatment, pump stations are found before
Editorial Calendar the influent of the treatment plant (called lift stations),
Review Products and at the outfall of the treatment plant to move the
treated wastewater to the actual discharge point.
Technology Spotlight

Pump stations are available in two forms. Sometimes, an

engineering firm is retained to design and draw plans for
Event Calendar
a custom pumping plant. Other times, the water or
Associations wastewater utility purchases a pre-designed “package”
pump station complete from a vendor, and hires a
contractor to install it and connect it to the system. There
Standards are advantages or disadvantages to both forms.
Bookshelf
Before the design is started, or before the requisition to
Research buy a package pump station is written, there are issues
Links on which the end user must decide, including the overall
control strategy. Selecting an inexpensive control
strategy may result in the installation of equipment that
About Flow
has a lower purchase cost, but a much higher operating
cost that could offset the savings in a short period of
Advertise time.
Media Kit

Contact Us
On/Off Pump Control Strategy
A common control strategy is on/off pump control. This
strategy is often selected when operating a single pump
in a pump station with one pump fed from a sump or
tank. The pump is turned on when the level in the tank
or sump is high, and turned off when the level is low.
This can be implemented using two limit switches --- one
to detect high level and another to detect low level. The
outputs of the level switches are used to operate the
pump motor starter, where appropriate provisions are

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 1 of 6

SEARCH THE SITE

Flow Control Network > PastIssues > jun2002 > Pump search criteria GO
Industry Headlines Station Control
News Alerts
Pump Station Control Current Issue

Free Subscription by Walt Boyes and David W. Spitzer, P.E.

Renew Subscription
A common application of control equipment in water and
Current Issue wastewater treatment is the management of pumping
Next Issue stations. Pump stations are found in such varied
applications as the clearwell of gravity filtration systems
Past Issues
in wastewater treatment plants, at the base of water
Submissions storage tanks, as booster stations for feed to distribution .
Contact Staff
grids and even on golf courses for irrigation. In
wastewater treatment, pump stations are found before
Editorial Calendar the influent of the treatment plant (called lift stations),
Review Products and at the outfall of the treatment plant to move the
treated wastewater to the actual discharge point.
Technology Spotlight

Pump stations are available in two forms. Sometimes, an

engineering firm is retained to design and draw plans for
Event Calendar
a custom pumping plant. Other times, the water or
Associations wastewater utility purchases a pre-designed “package”
pump station complete from a vendor, and hires a
contractor to install it and connect it to the system. There
Standards are advantages or disadvantages to both forms.
Bookshelf
Before the design is started, or before the requisition to
Research buy a package pump station is written, there are issues
Links on which the end user must decide, including the overall
control strategy. Selecting an inexpensive control
strategy may result in the installation of equipment that
About Flow
has a lower purchase cost, but a much higher operating
cost that could offset the savings in a short period of
Advertise time.
Media Kit

Contact Us
On/Off Pump Control Strategy
A common control strategy is on/off pump control. This
strategy is often selected when operating a single pump
in a pump station with one pump fed from a sump or
tank. The pump is turned on when the level in the tank
or sump is high, and turned off when the level is low.
This can be implemented using two limit switches --- one
to detect high level and another to detect low level. The
outputs of the level switches are used to operate the
pump motor starter, where appropriate provisions are

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 2 of 6

made for the installation of a hand-off-auto (HOA) switch

that allows for manual or automatic pump operation.

Note that on/off pump operation results in zero flow

when the pump is off, and full flow when the pump is on.
This operation might have significant effects on the
process. For example, using this control strategy in the
wet well of a wastewater treatment plant can cause the
flow through the entire plant to stop. If the control
strategies in the plant do not take this into account,
chemical additives like chlorine could continue to flow
while the pump is off. This can cause concentrations of
additives that not only cause instability, but also waste
chemicals. The additional cost of the chemicals could be
significant, especially as the amount of time at zero flow
increases. If chlorine is being added while there is no
flow, a significant hazard can be created, as well.

This controls strategy can also be used when a spare

pump is installed. In this case, a sequencer may be used
to alternate the pumps to distribute wear between the
two pumps. Should one pump fail to start, the other
pump can automatically be started to handle the load. In
addition, a high-high level switch could be added to
operate both pumps under high flow conditions. It is
useful to take another contact from a current sensor to
make sure that the pump started and is running at load.

The level switch signals can also be generated from a

signal from a level transmitter by using signal trip
modules or software in the sequencer. The significant
advantage of this approach is that it provides level
measurement information instead of the presence or lack
of level. In many cases, the level measurement can
provide information that allows the diagnosis of a
potential problem prior to the problem affecting the
process. In addition, changing the level at which the
pump turns on or off can be performed electronically
instead of mechanically.

The calibration of the level transmitter should be checked

occasionally to ensure proper operation. On the other
hand, a level switch typically requires little maintenance
until it fails. Note that failure of either a level transmitter
or level switch can cause major problems. However, it is
often possible to use the level measurement information
to detect a problem prior to it affecting the process.

In some applications, one operating pump cannot handle

the design load. In this case, additional level switches (or
trips) can be used to sequence the operation additional
pumps and alternate the pumps. For example, a three-
pump station may be sequenced 1-2-3 or 1-3-2, and may
operate based upon:

Level Operating Pumps

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 2 of 6

made for the installation of a hand-off-auto (HOA) switch

that allows for manual or automatic pump operation.

Note that on/off pump operation results in zero flow

when the pump is off, and full flow when the pump is on.
This operation might have significant effects on the
process. For example, using this control strategy in the
wet well of a wastewater treatment plant can cause the
flow through the entire plant to stop. If the control
strategies in the plant do not take this into account,
chemical additives like chlorine could continue to flow
while the pump is off. This can cause concentrations of
additives that not only cause instability, but also waste
chemicals. The additional cost of the chemicals could be
significant, especially as the amount of time at zero flow
increases. If chlorine is being added while there is no
flow, a significant hazard can be created, as well.

This controls strategy can also be used when a spare

pump is installed. In this case, a sequencer may be used
to alternate the pumps to distribute wear between the
two pumps. Should one pump fail to start, the other
pump can automatically be started to handle the load. In
addition, a high-high level switch could be added to
operate both pumps under high flow conditions. It is
useful to take another contact from a current sensor to
make sure that the pump started and is running at load.

The level switch signals can also be generated from a

signal from a level transmitter by using signal trip
modules or software in the sequencer. The significant
advantage of this approach is that it provides level
measurement information instead of the presence or lack
of level. In many cases, the level measurement can
provide information that allows the diagnosis of a
potential problem prior to the problem affecting the
process. In addition, changing the level at which the
pump turns on or off can be performed electronically
instead of mechanically.

The calibration of the level transmitter should be checked

occasionally to ensure proper operation. On the other
hand, a level switch typically requires little maintenance
until it fails. Note that failure of either a level transmitter
or level switch can cause major problems. However, it is
often possible to use the level measurement information
to detect a problem prior to it affecting the process.

In some applications, one operating pump cannot handle

the design load. In this case, additional level switches (or
trips) can be used to sequence the operation additional
pumps and alternate the pumps. For example, a three-
pump station may be sequenced 1-2-3 or 1-3-2, and may
operate based upon:

Level Operating Pumps

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 3 of 6

90% alarm

80% 3 pumps

70% 2 pumps

60% 1 pump

20% off

As the level rises, more pumps are turned on to handle

the load, creating four flowing rates --- zero, one pump,
two pumps and three pumps. Due to pumping and piping
hydraulics, when at least one pump continues to operate,
turning another pump on or off will not affect the flow
rate as much as the single pump operation described
above. Therefore, designing to keep at least one pump
on continuously tends to reduce these abrupt flow rate
changes.

Modulating Pump Control Strategy

The pump station can also be controlled such that flow is
modulated. When operating a single pump in a pump
station with one pump fed from a sump or tank, the
modulation could be based upon a signal from a liquid
level transmitter. This modulation can be achieved using
a control valve on the discharge of the pump, but issues
associated with operating high on the pump curve (dead-
heading) should be considered. In part for this reason, it
is more common to vary the speed of the motor driving
the pump. In addition, varying pump speed is more
energy efficient than using a control valve and can
reduce pump wear and reduce pump maintenance.

Modulating control allows flow to be varied continuously

from near zero to maximum flow. When the incoming
flow into the sump or tank is relatively steady, the
pumped flow can be manipulated to match the incoming
flow. When this occurs, the level can be controlled to
remain relatively stable. If the level is relatively steady,
the incoming flow is approximately equal to the pumped
flow, and therefore the pumped flow will be relatively
steady.

In contrast, the on/off control might cause the pumped

flow to jump from zero to one pump flow several times
each hour, as the level is allowed to rise and fall
significantly (from 20 to 60 percent in the example).
These flow changes can have significant adverse effects
on the process, as outlined above, when appropriate
compensation is not included in the control strategy.
Using a modulating strategy to stabilize the pumped flow
can make the process operate better with less complex
control strategies.

As previously stated, modulating flow using a variable

speed drive to vary pump speed is more energy efficient

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 3 of 6

90% alarm

80% 3 pumps

70% 2 pumps

60% 1 pump

20% off

As the level rises, more pumps are turned on to handle

the load, creating four flowing rates --- zero, one pump,
two pumps and three pumps. Due to pumping and piping
hydraulics, when at least one pump continues to operate,
turning another pump on or off will not affect the flow
rate as much as the single pump operation described
above. Therefore, designing to keep at least one pump
on continuously tends to reduce these abrupt flow rate
changes.

Modulating Pump Control Strategy

The pump station can also be controlled such that flow is
modulated. When operating a single pump in a pump
station with one pump fed from a sump or tank, the
modulation could be based upon a signal from a liquid
level transmitter. This modulation can be achieved using
a control valve on the discharge of the pump, but issues
associated with operating high on the pump curve (dead-
heading) should be considered. In part for this reason, it
is more common to vary the speed of the motor driving
the pump. In addition, varying pump speed is more
energy efficient than using a control valve and can
reduce pump wear and reduce pump maintenance.

Modulating control allows flow to be varied continuously

from near zero to maximum flow. When the incoming
flow into the sump or tank is relatively steady, the
pumped flow can be manipulated to match the incoming
flow. When this occurs, the level can be controlled to
remain relatively stable. If the level is relatively steady,
the incoming flow is approximately equal to the pumped
flow, and therefore the pumped flow will be relatively
steady.

In contrast, the on/off control might cause the pumped

flow to jump from zero to one pump flow several times
each hour, as the level is allowed to rise and fall
significantly (from 20 to 60 percent in the example).
These flow changes can have significant adverse effects
on the process, as outlined above, when appropriate
compensation is not included in the control strategy.
Using a modulating strategy to stabilize the pumped flow
can make the process operate better with less complex
control strategies.

As previously stated, modulating flow using a variable

speed drive to vary pump speed is more energy efficient

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 4 of 6

than installing a control valve on the pump discharge. In

a control valve installation, the pump generates hydraulic
pressure, some of which is dissipated across a restriction
(the control valve) to manipulate flow. In a variable
speed drive installation, pump speed is manipulated to
generate only the hydraulic energy needed to pump the
desired flow without any restriction.

In some applications, the difference in electrical energy

consumption between the two installations can be
sufficiently large to justify replacing a control valve
installation with a variable speed drive installation.
Potential energy savings are especially large when the
pump is relatively large as compared to the operating
load. For example, this can occur when a pumping
system is sized for the maximum possible flow (such as
during start-up), but normal operating flow is much
smaller.

In some applications, one operating pump cannot handle

the design load. In this case, variable speed drives
should be installed on all of the operating pumps to vary
their speeds in unison. When the pumps are identical,
operating the pumps at the same speed will distribute the
flow equally between the pumps. This strategy should
avoid potential backflow situations that can occur when
the pressure produced by one pump operating at high
speed overcomes the pressure produced by another
pump operating at a lower speed. As in on/off
applications, the pumps can be sequenced to distribute
wear and change the number of operating pumps as the
load changes. Control strategies used to determine the
number of operating pumps include the use of pump
speed and/or pumping flow rate information.

Modulating control as described above can be

implemented using a single control loop consisting of a
level transmitter, level controller, and variable speed
drive(s). In most applications, superior control can be
achieved by using a cascade control strategy that
includes information from a flow transmitter that
measures the pumped flow. In some applications, further
improvement can be obtained using feedforward control
techniques that use other process measurements.

Package and Custom Installations

Pumping stations can be purchased as a package system
or designed as a custom installation. Some packaged
systems can be provided with either on/off or variable
speed drive control strategies. Custom pump stations can
be designed using any of the control strategies discussed.
The choice of package versus custom pump station
controls is often a matter of their economic impact on the
process and the ability of the designer to recognize and
mitigate these effects.

Package pumping station systems generally do not offer

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 4 of 6

than installing a control valve on the pump discharge. In

a control valve installation, the pump generates hydraulic
pressure, some of which is dissipated across a restriction
(the control valve) to manipulate flow. In a variable
speed drive installation, pump speed is manipulated to
generate only the hydraulic energy needed to pump the
desired flow without any restriction.

In some applications, the difference in electrical energy

consumption between the two installations can be
sufficiently large to justify replacing a control valve
installation with a variable speed drive installation.
Potential energy savings are especially large when the
pump is relatively large as compared to the operating
load. For example, this can occur when a pumping
system is sized for the maximum possible flow (such as
during start-up), but normal operating flow is much
smaller.

In some applications, one operating pump cannot handle

the design load. In this case, variable speed drives
should be installed on all of the operating pumps to vary
their speeds in unison. When the pumps are identical,
operating the pumps at the same speed will distribute the
flow equally between the pumps. This strategy should
avoid potential backflow situations that can occur when
the pressure produced by one pump operating at high
speed overcomes the pressure produced by another
pump operating at a lower speed. As in on/off
applications, the pumps can be sequenced to distribute
wear and change the number of operating pumps as the
load changes. Control strategies used to determine the
number of operating pumps include the use of pump
speed and/or pumping flow rate information.

Modulating control as described above can be

implemented using a single control loop consisting of a
level transmitter, level controller, and variable speed
drive(s). In most applications, superior control can be
achieved by using a cascade control strategy that
includes information from a flow transmitter that
measures the pumped flow. In some applications, further
improvement can be obtained using feedforward control
techniques that use other process measurements.

Package and Custom Installations

Pumping stations can be purchased as a package system
or designed as a custom installation. Some packaged
systems can be provided with either on/off or variable
speed drive control strategies. Custom pump stations can
be designed using any of the control strategies discussed.
The choice of package versus custom pump station
controls is often a matter of their economic impact on the
process and the ability of the designer to recognize and
mitigate these effects.

Package pumping station systems generally do not offer

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 5 of 6

the flexibility of custom designed stations. In addition,

many package pumping stations have limited areas for
maintenance and limited headroom, making maintenance
more problematic. Custom pumping stations are
generally built to suit, and the designer often allows the
operator more room to work in doing the required
maintenance on the station after it has been installed and
operational.

Key design criteria for pumping stations include the

ability to handle a wide variation in diurnal flows from
minimum through average to peak flow without causing
plant upset or flooding the wet well. In addition,
designers need to provide a means for equalizing the
operating hours, and therefore, the wear on multiple
pumps. Designers need to be mindful of both operational
issues and maintenance requirements when designing
the physical layout of a pump station.

Summary
Designing pump station controls correctly can result in
years of excellent operation with minimal maintenance.
Designing pump controls incorrectly, or purchasing a
package pump station that does not meet your criteria
can swell the cost of operation, increase downtime and
maintenance, and result in premature replacement of
equipment.

References
1. Flow Measurement (2nd Edition), David W. Spitzer,
ISA, 2001 (838 pages).
2. Industrial Flow Measurement, David W. Spitzer, ISA,
1990 (441 pages).
3. Variable Speed Drives: Principles and Applications for
Energy Cost Savings, (2nd Edition, Revised), David W.
Spitzer, ISA, 1990 (201 pages).

About the Authors

David W. Spitzer, P.E., and Walt Boyes have more than
50 years combined experience in instrumentation and
process control, and are the principals of Spitzer and
Boyes, offering product development, marketing,
specifying, installing, start-up and troubleshooting
services for manufacturing and automation companies.
Both Mr. Spitzer and Mr. Boyes have written numerous
books and articles, have taught seminars, and are
members of standardization committees. Mr. Spitzer can
be reached at 845 623-1830; dwspitzer@aol.com.Mr.
Boyes can be reached at 425 432-8262;
walt@waltboyes.com.

Subscribe | Site Map | Advertise

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03
Pump Station Control Page 5 of 6

the flexibility of custom designed stations. In addition,

many package pumping stations have limited areas for
maintenance and limited headroom, making maintenance
more problematic. Custom pumping stations are
generally built to suit, and the designer often allows the
operator more room to work in doing the required
maintenance on the station after it has been installed and
operational.

Key design criteria for pumping stations include the

ability to handle a wide variation in diurnal flows from
minimum through average to peak flow without causing
plant upset or flooding the wet well. In addition,
designers need to provide a means for equalizing the
operating hours, and therefore, the wear on multiple
pumps. Designers need to be mindful of both operational
issues and maintenance requirements when designing
the physical layout of a pump station.

Summary
Designing pump station controls correctly can result in
years of excellent operation with minimal maintenance.
Designing pump controls incorrectly, or purchasing a
package pump station that does not meet your criteria
can swell the cost of operation, increase downtime and
maintenance, and result in premature replacement of
equipment.

References
1. Flow Measurement (2nd Edition), David W. Spitzer,
ISA, 2001 (838 pages).
2. Industrial Flow Measurement, David W. Spitzer, ISA,
1990 (441 pages).
3. Variable Speed Drives: Principles and Applications for
Energy Cost Savings, (2nd Edition, Revised), David W.
Spitzer, ISA, 1990 (201 pages).

About the Authors

David W. Spitzer, P.E., and Walt Boyes have more than
50 years combined experience in instrumentation and
process control, and are the principals of Spitzer and
Boyes, offering product development, marketing,
specifying, installing, start-up and troubleshooting
services for manufacturing and automation companies.
Both Mr. Spitzer and Mr. Boyes have written numerous
books and articles, have taught seminars, and are
members of standardization committees. Mr. Spitzer can
be reached at 845 623-1830; dwspitzer@aol.com.Mr.
Boyes can be reached at 425 432-8262;
walt@waltboyes.com.

Subscribe | Site Map | Advertise

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Pump Station Control Page 6 of 6

©2003 Witter Publishing, Inc. All rights reserved. Unauthorized use prohibited
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Pump Station Control Page 6 of 6

©2003 Witter Publishing, Inc. All rights reserved. Unauthorized use prohibited
Privacy Policy Terms of Use
webmaster@WitterPublishing.com

http://www.flowcontrolnetwork.com/PastIssues/jun2002/3.cfm 7/8/03