- Sumps, Pumps, and Plumbing -
Hello to all the staff at WWM!
<Hello.>
First off, MAD PROPS and HUGE THANK-YOUs to the entire crew! I wouldn't want to think what the hobby and industry would be like without you folks!  Late in 2003, and early 2004 I spent some time building a very nice custom stand, canopy and sump for a planned 90 Gallon rig. In 2004, I was laid-off and my expensive project was put on hold and I settled myself by enjoying my then current 40gal tank.
Recently, I moved from one state to another and destroyed the old 40 gallon tank before moving. However, all the life, rocks and some sand from that tank are currently living in my new home office in a Rubbermaid container awaiting their newer, nicer, roomier home.  I figured it is only fair since I got one.
At this point, I have 200 pd.s of very fine sand, have re-poly'd my tank and canopy, looked at integrating the 440W VHO light system into the canopy, have the custom sump leak-tested, have 88lbs of Tonga Kaelini LR curing in the garage (Thanks Walt and ReeferMadness.us!), and am currently in the ordering process for the tank (90 Gallon Acrylic). I posted some pictures in my user profile here of the rock on receipt. I also plan on adding pictures through-out the whole project.
Anyways, I can't seem to get a solid opinion on the boards and I am at the scary part (for me) which is the plumbing and pump selection. This seems to be the hardest area to research in tank construction due to the overwhelming number of configurations. I was hoping someone might answer a few questions and tell me If I am on the right track. Ok, here goes!
<Ok, I'm wearing my seat belt.>
I have already purchased 2 -- 2.0" diameter bulkhead fittings for the tank output to the sump and 2 -- 1.5" return bulkhead fittings. In your opinion is this a little bit overkill for a 90 Gallon or is my planning sound in that I wanted to run 1000gph (quietly/ish) to the sump through the outputs and that I thought that the larger the size the better in terms of clogging, noise levels, etc? <It is a bit of overkill, but not something that will cause you trouble - just takes up real estate.>
Due to the stand and sump design I created, I have now figured out that I will have to mount those fittings high up on the back pane of the aquarium as my sump does not allow much in terms of extra holding capacity (the internal walls are high relative to the total height of the exterior sump walls) and I don't want to take a chance of flooding. 
I won't make that mistake in design again but I still want to utilize the existing sump, darn it! It is, relative to the tank, at least, a high capacity sump (45 gallons filled) and I custom built it to the stand so that when the main door is open you will be looking at the refugium area of the sump. Considering this do you have any recommendations or suggestions for placement of the bulkheads on the back pane? 
<Evenly spaced along the back wall.> 
How close to the top can I safely go in the standard 1/2 Acrylic they use in 90 Gallons? 
<On acrylic, you'll be fine fairly close to the top - you do realize that with the two inch bulkheads, you'll have a noticeably low water level in the tank - the outer diameter of that bulkhead will determine its placement on the back wall, meaning the lowest part of the inner diameter will be almost three inches from the top... you may want to reconsider the use of these bulkheads.>
Since I will have to use the back pane I planned on using a weir built around the strained bulkheads to control the maximum amount of water that can evacuate the tank. 
<Ahh yes... this would help, but how would this work with the returns?> 
Also, I plan on using an anti-siphon run in my return line in conjunction with check valves to avoid flooding! Does that sound pretty bullet-proof? 
<I'm not familiar with "an anti-siphon run"... but the check valves should help with this issue.> 
Did I mention I have a fear of flooding? 
<Think I noticed this theme, yes.>
Besides the sump I also plan on building a closed loop incorporating a SCWD or similar on the system for circulation, so as to avoid powerheads and provide a higher turnover rate and a healthier environment for future denizens. Do you have any favorite devices in that arena? 
<SCQD is a fine device. SeaSwirls are also widely used but much more expensive.>
Since I am at the point that I need to look at ordering the pumps, I had hoped for some further input. What 2 pumps (matched if possible) would you use to drive the 90 gallon system while achieving a 10x turnover in the sump (900+gph) and a 10x in the closed loop (900+) given that:
A. The sump return would be pushing 2 1.5" diameter lines to the tank with each having at least 3 90's in them and the runs would be at least 4-5 feet.
--Would that roughly equate to 11 to 12 feet of head pressure?-- 
<I think much less... 6-7 I think.>
B. The closed loop would feature 3-4 1" lines with approximately the same number of 90's and length in runs.
-17 to 18 feet of head?- 
<Think you're giving too much credit to those 90's - I won't deny that they are an impediment to direct flow, but I don't think they knock off even a foot for each bend.>
Would 2 Iwaki 30RXLT or 2 Dolphin Ampmaster 3000's be appropriate? 
<The AmpMaster would be a significantly larger pump than the Iwakis. Depending on where this tank is placed in the house, you may prefer the AmpMaster for its quiet operation, but you could likely do fine with the 2100.> 
Would you use two different spec pumps? Do you have a favorite between those two or any other favorites with the newer manufacturers that might be a little less hefty in price? 
<Both are excellent, I use Iwaki pumps, but they run outside in the garage where I don't have to hear them. Have many friend who use the AmpMaster and am impressed by its silent operation... is supposed to be kind to your electric bill too.>
Also, for pump output plumbing, where is the appropriate place to go up in size in pipe diameter to match the return bulkhead size if the outputs on the pump is smaller?
(for example, say if 1.5" bulkheads and 1"output on pump)? 
<Right after the pump.>
For the plumbing itself, should I use a ball or gate valve directly connected to the bulkheads or should I have a slip union between each plumbing device in the system? 
<Ball valves only - and slip unions everywhere there is a device you might want to remove from the chain for replacement or maintenance.> 
From what I have been able to research on my own (assuming a union between each) does the following sound ok? 
Tank Output side: strainer/tank bulkhead/union/ball or gate valve/union/pipe-run/sump
Sump Output: strainer/sump bulkhead/union/pump/union/manifold or tee/return pipe-runs/union/check valve/union/ball or gate valve/union/tank return bulkhead
<Unions around things like pumps, check valves... not so important directly after bulkheads unless you think the connected item might have to come out at some point in the future.>
In closing, I want to thank you so very, very much for all the help and at the same time apologize for having so many questions on specifics. Having someone trusted, and willing to answer some questions is so very appreciated. I promise to continue to buy at least one of each book!
Thanks so much!
The Drunken Monkey
<Cheers, J -- >