In larger commercial, industrial and infrastructure developments, gravity drainage is not always possible. In these situations a pump station is required to collect and transfer water or wastewater from a low point to a higher discharge location.

Effective pump station design ensures reliable operation, minimises maintenance and reduces the risk of flooding, environmental harm, or system failure. Whether you are considering the design of a pumping station for wastewater, stormwater or other applications, understanding the core principles is critical.

In this guide, we outline the fundamental considerations involved in the design of wastewater and stormwater pumping stations.

How Does a Pump Station Work?

A pump station operates by collecting liquid in a below-ground chamber (often referred to as a wet well) until a predetermined level is reached. Once this level is detected, one or more pumps activate to transfer the liquid through a discharge pipeline to the required destination.

Most modern stations use submersible pumps, meaning the pumps are installed directly within the wet well. This approach simplifies installation, reduces noise, and improves reliability compared to surface mounted alternatives.

A simplified overview of the pump station process includes:

1. Liquid enters the pump station via gravity pipework
2. The liquid level rises within the chamber
3. Level sensors signal the controller to start the pump
4. The pump transfers liquid through a rising main
5. The pump stops once the low-level set point is reached

While the core operating process remains consistent across water, wastewater and stormwater pump stations, system configuration and controls are tailored to suit the specific application.

Where are pump stations used?

Pump stations are used across a wide range of applications, including:

• Commercial and residential developments
• Industrial facilities
• Mining and infrastructure projects
• Municipal wastewater and stormwater networks.

Systems range from compact, prefabricated units to large-scale installations capable of transferring hundreds of litres per second over long distances. The approach to designing a pump station must be tailored to suit the application, site constraints and operational requirements.

Common Types of Pump Stations

While pump stations serve many purposes, they are most commonly designed for:

• Wastewater and sewage transfer
• Stormwater and surface water management
• Process water and trade waste applications

Although these systems share common components, the pump station design and performance requirements vary depending on the liquid type, flow rates and regulatory environment. If the pump station was for a municipality or council, additional modifications can be added to increase operational reliability, safety and regulatory compliance.

Key considerations in Pump Station Design

The Application

Understanding the application is the first step in any successful pump station design. Key factors include:

• Type of liquid being pumped
• Inflow characteristics and variability
• Location of the pump station
• Discharge destination and elevation
• Regulatory or authority requirements

These factors influence pump selection, chamber sizing, materials of construction and control strategies.

Pump Station Design Calculations

Accurate pump station design calculations are essential to ensure the system operates efficiently and reliably.

Typical calculations include:

• Required flow rate
• Total dynamic head (static lift + friction losses)
• Wet well volume and pump cycling rates
• Emergency storage capacity

Errors at this stage can result in excessive energy consumption, frequent maintenance, or premature equipment failure.

Chamber Size and Configuration

The size of the pump station chamber must accommodate expected inflows while limiting excessive pump starts. Depending on the application, stations may be designed with:

• Single pump configurations
• Dual pump arrangements running either (duty/standby or duty/assist)

Material selection such as polyethylene, concrete or fibreglass is influenced by site access, loading conditions and installation requirements. Chamber selection plays a key role in the overall construction of a pumping station.

Pump Selection and Power supply

Pump selection is another key component which is critical to an effective water pumping station design. Submersible pumps are commonly used due to their compact footprint and ease of installation.

Considerations include:

• Flow and head requirements
• Solids handling capability (where applicable)
• Single-phase or three-phase power availability
• Energy efficiency and duty cycle

In high-risk applications, backup power or SMS auto-dialling alarm systems should be considered to reduce operational risk.

Pump Station Components

A typical pump station consists of several core components:

• Wet well or chamber
• Submersible pump/s
• Discharge pipework and valves
• Level float controls
• Control methodology
• Access covers and safety features

Each component is selected to work as part of an integrated system.

Pump Station Controller and Controls

The pump station controller is responsible for managing pump operation, monitoring system performance and protecting the pump station from fault conditions. Well-designed control systems improve reliability, extend equipment life and reduce the risk of flooding or environmental incidents.

Controllers typically use level sensors or floats within the wet well to automatically start and stop pumps based on liquid levels. In multi-pump installations, control logic may alternate pump duty to balance wear and provide redundancy in the event of a failure.

Modern pump station control systems commonly incorporate alarm and monitoring functionality to alert operators to abnormal conditions such as high liquid levels, pump failure, blockages or power outages. Alarms may be audible or visual on site, or connected to remote monitoring systems that notify personnel off-site, allowing issues to be addressed promptly.

Control and alarm requirements can vary depending on the application, site risk and local authority guidelines. These requirements should be considered early in the design of a pumping station, along with maintenance responsibilities and operational access, to ensure the system can be safely and efficiently managed throughout its service life.

Pump Station Installation and Construction

Proper pump station installation is essential to long-term performance. Installation considerations include:

• Excavation and ground conditions
• Structural support and anchoring
• Pipe alignment and backfilling
• Electrical and control integration

The overall construction of a pumping station should comply with relevant standards, authority requirements and manufacturer recommendations based on the site location.

Learn more about Pump Station Design

Designing a reliable pump station requires careful planning, accurate calculations and the right equipment selection. Whether your project involves wastewater, stormwater or process water applications, engaging experienced specialists early can reduce risk and improve outcomes. If you have an upcoming project and would like advice on designing your pump station, installation or equipment selection, get in touch with Global water for expert guidance.