How to properly install, start and adjust the pumping station

When it comes to a private residence, having an independent water supply is a crucial engineering system, especially if there is no access to a centralized water supply nearby. In order to guarantee a consistent flow of water to the house, it becomes necessary to install and connect a pumping station. While this equipment may be costly, there is still an opportunity to save a substantial amount of money by undertaking the installation and connection of the station independently.

Options for the location of the pumping station

1. It is important for the unit to be situated in close proximity to the water source. This will ensure that the unit is able to effectively and consistently draw liquid from the source, allowing for smooth operation of the station. If the equipment is placed too far away from the well, it will be unable to properly pump water and may malfunction.
2. When installing the equipment, it is crucial to select a dry, well-ventilated, and warm location.
3. It is essential that the apparatus does not come into contact with any objects or walls.
4. There should be unrestricted access to the equipment for the purpose of conducting preventative inspections and repair work.

Note: It is important to consider the high level of noise generated by a surface pump station during operation.

Based on the information presented above, there are multiple options for installing the unit.

In the house

For optimal performance of the station, the most preferred choice would be a room with heating. It would be advantageous if the private residence is equipped with a well-insulated boiler room.

If necessary, the water supply equipment can be positioned in a hallway, bathroom, corridor, or storeroom. However, it is important that these areas be located at a significant distance from the bedroom and living room. To mitigate any noise concerns, the equipment may be stored in a closet or concealed with a soundproof cover.

Pumping equipment is typically placed in the house’s basement or cellar. Occasionally, the unit is installed beneath the floor, allowing for access via a hatch. Regardless of the location, it is important for the installation site to be adequately soundproofed and waterproofed. Additionally, it should be sufficiently heated to prevent temperatures from dropping below 0°C during the winter months.

In a well

In order to position the station within the well, a small platform is installed within the confines of the well. The platform is securely fastened beneath the freezing point of the surrounding ground.

Hint! It is advisable to insulate the well mainly from the top. However, this arrangement of the equipment can pose challenges when it comes to its accessibility for maintenance and repair work.

To correctly install the pump in this situation, it is necessary to arrange a small room (caisson) around the water source that is wide and deep enough (below the frost boundary).

A cover is placed on top of the caisson, equipped with a hatch for servicing the unit. The cover is properly insulated to withstand the winter.

With the presence of a pit, it becomes feasible to establish an independent water supply system utilizing a surface pump, even if the groundwater level is situated at a depth of 9-11 meters below the surface.

When constructing a station with a submersible pump, there is no need to be concerned about soundproofing, as the unit is situated deep underground, resulting in its operation being nearly silent. All components of the station are installed within a heated room, while the pump itself is placed in a well or borehole. This method of assembling the pumping station is particularly suitable for country houses.

Variants of pump station piping

The term "strapping" of a pumping station typically refers to the process of connecting the pumping equipment to the piping system and other components.

In order to install a pumping station in a caisson or a house, the same procedure is followed. The initial step of this procedure involves laying an underground supply pipe at a depth below freezing. At the end of the pipeline, a coarse filter made up of a fine mesh is installed. Additionally, a check valve is placed after the filter to avoid the occurrence of backflow when the pump is turned off. The diagram below illustrates the technological scheme of the pumping station.

Note! The method for connecting the pumping station involves positioning the supply pipe inside the building’s foundation, and it is crucial to ensure proper insulation at this location.

Furthermore, a coupling is used to connect the supply pipe to the pump. The diagram below depicts a basic illustration of the piping setup for a pump station.

If there is a need to connect multiple water points to the unit, the assembly scheme shown above (refer to the figure below) can be enhanced.

Connection to a well

To establish a connection between the surface pump and a well that has a dynamic water level of less than 8 meters, it will be essential to install the pump inside a caisson with a depth of approximately 2 meters. In the event that a submersible pump is utilized, it will be possible to house additional equipment such as a hydraulic accumulator, voltage stabilizer, automation system, etc. inside the caisson along with the pump.

An automatic water intake system for the pressure tank can be achieved by employing a pressure switch that activates and deactivates the pump based on specific pressure thresholds in the system. Additionally, it is feasible to construct a control unit to automate the pump’s functionality. The diagram presented below illustrates the layout of such a unit.

The control unit operates based on the following principle:

• The unit is turned on and off by relay K₁.
• Switch S₁ controls the operational mode (lift-drain).
• Sensors F1 and F2 monitor the water level in the storage tank.
• If the water level is below the F1 sensor, the unit is turned on through contacts K₁ with the help of switch S₁.
• When the water reaches sensor F1, the transistor VT₁ opens and activates relay K₁.

The submersible well pump is assembled with the station following the scheme provided below.

Connecting the station to the water supply system

In some cases, it may be necessary to utilize a pumping station, even when a centralized water supply system is already connected to the residence. The installation of a station with a storage tank is typically carried out when the water supply system experiences low pressure. Additionally, this equipment becomes invaluable when water supply through the primary pipeline is restricted to specific hours.

The pumping station is linked to the centralized water supply system in the following manner:

• Connect the pipe from the centralized mains to the storage tank;
• attach the intake pipe of the pump to the tank;
• connect the outlet pipe from the pump to the house’s water supply system;
• install and connect the electrical wiring to the unit;
• perform a test run of the unit and subsequently adjust the equipment to meet the necessary capacity.

Prior to initiating the initial operation of the pumping apparatus, it is vital to undertake the necessary preparations for the accumulator, as the overall stability of the water supply system is contingent upon maintaining the appropriate pressure within the accumulator. Elevated pressure within the tank will incite frequent cycling of the unit, which will ultimately have a detrimental impact on its longevity. Conversely, if there is insufficient pressure within the air chamber of the tank, it will result in excessive expansion of the rubber bladder with water, ultimately leading to malfunction.

To prepare the hydraulic tank, first ensure that the bulb inside the tank is completely empty before proceeding to pump air into it. After that, use a car pressure gauge to check the pressure in the tank. Generally, new tanks come pre-pumped with air from the factory. For hydro tanks with a capacity of up to 25 liters, the ideal pressure range is between 1.4 and 1.7 bar. For tanks with a capacity of 50 to 100 liters, the recommended air pressure should be between 1.7 and 1.9 bar.

Hint! In case the gauge reading is below the recommended level, it is advisable to inflate the tank with a car pump and make adjustments based on the gauge reading.

To ensure a proper initial start-up of the pumping station, follow these steps sequentially:

1. Unscrew the plug that seals the water hole on the unit’s body. Some units may have a valve instead of a plug. Make sure to open it.
2. Then, fill the suction pipe and pump with water. Stop pouring liquid once it starts overflowing from the fill hole.
3. Once the suction pipe is filled, seal the opening (close the valve).
4. Connect the station to the power source and turn it on.
5. To eliminate any remaining air from the equipment, open the faucet closest to the pump’s water intake point.
6. Allow the machine to operate for 2-3 minutes. During this time, water should flow from the faucet. If this doesn’t occur, switch off the pump, refill the water, and then start the pumping station.

Adjusting the automation

Once the startup process is completed successfully, it is important to conduct an inspection and fine-tune the automation system. The newly installed pressure switch comes from the factory with preset upper and lower pressure thresholds, which trigger the pump to either turn on or off when reached. However, there may be situations where it is necessary to modify these values to achieve the desired on/off pressure.

To make adjustments to the automation system, follow the steps below:

1. Turn off the unit and drain the water from the accumulator.
2. Remove the cover from the pressure switch.
3. Start the pump to allow water to accumulate in the hydraulic tank.
4. When shutting down the unit, take note of the pressure gauge reading. This recorded value will serve as the upper threshold for shutting down the system.
5. To determine the lower switch-on threshold, first, open the faucet located at the highest or farthest point of the water intake. As water begins to flow out, the system pressure will gradually decrease, causing the relay to trigger the pump.
6. At this point, observe the pressure gauge reading, as it will indicate the lower switch-on threshold. Make a note of this value, as it will be important for further calculations.
7. To calculate the difference between the upper and lower thresholds, subtract the lower threshold value from the upper threshold value.

Typically, the ideal switch-on pressure is 2.7 bar, while the switch-off pressure should be 1.3 bar. Therefore, the difference in pressure should ideally be 1.4 bar.

It is important to note that if the resulting difference is indeed 1.4 bar, no further adjustments are necessary. However, if the pressure is too low, the pump will be activated frequently, leading to premature wear of its components. Conversely, if the pressure is too high, the pump will operate less frequently, but the fluctuation in water pressure will be noticeable and unstable.

Hint: If you want to increase the pressure difference, you should tighten the nut on the small spring. If you want to decrease the difference, you should loosen the nut on the small spring.

When checking the relay’s operation, pay attention to the pressure at which the water flows out of the faucet. If the pressure is low, you will need to adjust it. In this case, the system’s pressure should be higher. To achieve this, turn off the unit and slightly tighten the nut that holds the large spring of the pressure switch. To lower the pressure, loosen the nut.