Ok I got a little farther today.
I started actually designing how the sumps will flow into each other etc. The first design I came up with allows me to really easily control different rates of flow, disconnect one section, etc. So it is super super flexible.
They are on casters so I can move them around if I need. The drains will be ~60" high so that should be adequate to gravity feed the tallest sump. The problem I came up with here is the skimmer placement. I would have to build a really tall skimmer stand to get it even with the first sump. And with the skimmer itself being ~60 inches tall it would be almost to the ceiling. I would have to build some steps to get up there, etc. Major pain.
So I rethought and went much simpler. This takes away most of my flow control (even though I could build bypass loops around the refugium) but makes it much easier from the skimmer standpoint. I could still easily disconnect with unions and either run tubing or put a new sump in if I ever have a problem it just won't be quite as versatile. Do you see any potential issues with it?
I think I will end up going with something like this. The simplicity it brings is worth the control sacrifice I think.
Also the return sump is off the picture and the drains will have a bypass to there for sure so if nothing else I can take these three sumps totally out of the loop and still run the system with just the return sump if necessary. It's also about 6" lower then the other sumps so when the return pump is turned off all the excess will drain into the return section. Maybe I should make them all level so if the water goes above the bulkheads (when the return pump turns off. I would have to overflow a lot more before a flood happens? Thoughts?
The other issue I'm contemplating is pipe size. I will have 3 1.5" drains on the tank. The run from the tank to the sumps will be ~20ft with a roughly 2ft drop. I'm thinking of consolidating the 3 drains into one 2 inch pipe to run the 20ft and have the 2" pipe drain into the skimmer sump. I'm only going to use an Iwaki 55 for the return pump so only ~1500GPH. Would it be significantly better just to go ahead and run three seperate 1.5" down the wall and have all three dump?
The other issue is from sump to sump. If I choose option B should I just go ahead and have 3 1.5" bulkheads on each side so I don't have to worry about bottlenecking or will 2 be sufficient?
Off to research fans and FRP