arm83,
Artisi, JJPellin, et al, have given you the best suggestions that I can imagine. The essence of engineering is recognizing that there is seldom, if ever, a single right solution to a problem. The important issue is to arrive at the most reasonable set of compromises that serve the needs of the particular application.
Your statement, "I ... have to justify ..." is very familiar to me, and it is associated with numerous disasters or potential disasters, and always associated with misapplication of pieces of major equipment (not just pumps). I will not go into an "old geezer rant" about this, but do take caution.
The pump type, size, drive, controls, ... are always best determined by the needs of the specific application and never by a "need to justify."
Since your application has a three decade history of difficulties, it would be wise to reconsider the pumps and piping for your application in light of current pump application knowledge and practices that may highlight the source(s) of your pump's problems. Don't be surprised to find that cleaning up piping issues solves your pump problems. Also, you may find that adding adjustable speed drives may help to permit the existing pumps to function more suitably.
From my experience and observations, pump problems almost always arise from their associated systems, mis-application, or mis-operation rather than from an inherent flaw in the pump itself.
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One of the first steps in pump-station design is to determine what type of pump station best suits the system's needs.
The type of pump station sets the stage for the design of the entire facility. Some specific design items the designer will need to consider when selecting a type of pump station include: system curve, initial demand and expansion requirements, pump availability, storage requirements, NPSH available, maintenance and cost.
Vertical turbine and horizontal split case centrifugal pumps are the most common types of pumps utilized in water applications.
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Typical system curves for horizontal and vertical pumps lend themselves to certain applications based on system coverage. Vertical Turbine pump curves are typically rather steep and can cover a wide range of heads while horizontal pump curves are typically flatter and can cover a wide range of flows. Certain criteria are also critical for an Owner to consider when selecting a type of pump station: capital and life cycle cost, potential failure modes, and maintenance activities.
Here are how horizontal split case pumps and vertical turbine pumps stack up.
Frequently an Owner may have a very strong opinion about the type of pump station design preference, but it is incumbent on the designer to bring other ideas that will be well-suited to the application.
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