You are on page 1of 84

Pump Station Overview

1

Today’s Objectives
Pump Basics Review pump varieties Review pump applications Understand what’s needed to get a pump quoted Review competitive stations

2

Pump Station Basics
Pressure versus Head Pressure can be measured in pounds per square inch (psi) or in the height of a column of water (feet) One foot of water = .433 pounds per square inch One pound per square inch = 2.31 feet of water

3

Pump Station Basics
Pumps create pressure not flow
– XX gpm in – XX gpm out at an increased pressure of psi – The available flow is a function of the water source not a function of the size of the pump

Pumps create specific pressure at rated flow
– Constant pressure / flow curve – As flow increases – pressure decreases – As flow decreases – pressure increases

Variable Frequency Drives (VFD’s) are used when flow demand varies at constant pressure
– Like an accelerator on a car – varies motor / pump speed – Not needed when flow is constant – Can also vary pressure for zone control

4

Pump Station Basics Inlet pipe size some indication of flow Elevation – impacts how the pumps are rated The discharge of a pump is usually stated in Feet The discharge of a pump station is usually stated in PSI 5 .

7PSI = 33.Pump Station Basics Elevation Affects Pump Performance Atmospheric Pressure at sea level is 14. Motors above 3300FT are de-rated.7PSI – (0. 4% every 1640FT above 3300FT. 14.2PSI Motors are rated at nameplate to 3300FT.96FT Atmospheric pressure above sea level: 14.0005 x 9000FT) = 10.7PSI – (0. 6 .0005 x Altitude above sea level) For Mt Lemmon in Arizona.

What You Need to Know to Quote a Pump Water source Outlet pressure in psi or head in feet Flow in gallons per minute Electrical power for the pump Elevation 7 .

What is the Water Source? Well Lake or Pond River or Ditch Public Source Above Ground Tank Below Ground Tank Potable Water Well Water Reclaim Water Agriculture Water Snowmelt or Storm runoff Chiller or A/C Water Rainwater 8 .

60Hz. 1Φ The largest motor available in 1Φ 230V is 10HP Rest of the World Power: – Canada: 575 V. 3Φ 9 . 3Φ – Asia & Middle East: 380V. – 460 V.S.Electrical Power Most common types of power in U. 60Hz. 60Hz. 60Hz. 50Hz. 3Φ Can power pumps up to 100HP – 230 V. 3Φ Can power pumps up 500HP – 230 V.

city main) – not open to atmosphere Must have minimum inlet head or pressure to operate properly 10 .Boost Application Similar to Flooded Suction with positive head or pressure to pump inlet Water supplied to inlet of pump in enclosed pipe (e.g.

Booster Application Pump that is developing 60 PSI (138.6 Feet of Head) 20 PSIG 80 PSIG Suction Discharge 11 .

Flooded Suction Flooded Suction is where water level is located above the inlet to the pump Positive head or pressure to pump inlet Water source is open to atmosphere Must have minimum inlet head or water level to operate properly 12 .

Flooded Suction Application Pump that is developing 50 PSI (115.5 Feet of Head) 5 PSIG 55 PSIG Tank Suction Discharge 13 .

straw in water glass) Locate the pump as close to the water surface as is practical Rule of thumb – maximum height of station above water level is 15 vertical feet 14 .Suction Lift Suction Lift is where the water level is below the inlet of the pump Atmospheric pressure pushes water up pipe to inlet of pump (e.g.

8’ (14.31) • Elevation of source = -8’ (below pump) • Suction plumbing friction loss = 3’ • NPSHA = 32.000’ elev.Suction Lift Application Atmospheric pressure 14.2 X 2.8’ 15 .) Suction piping friction loss = 3’ 8’ • Atmospheric pressure = 32.8’ – 8’ – 3’ = 21.2 PSIA (1.

Air then replaces water at the inlet to the pump.Suction Lift Problems Loss of Prime The pressure in the suction line is less than atmospheric pressure. A leaking foot valve or suction pipe can allow air to leak into the suction line. so the pump just spins. Ai r 16 . Pumps cannot pump air. This is referred to as a Loss of Prime. performing zero hydraulic work.

This type of check valve is referred to as a foot valve.Suction Lift Kits It is recommended that a check valve be installed at the inlet of the suction piping to ensure water in the suction pipe does not flow back out after pumps stop running. 17 .

Vertical Turbine Used in applications that have a wet-well Utilizes Vertical Turbine Pumps – thus the name Capable of providing high flow and high pressure Easy to service the motor Requires crane to service the pump 18 .

Wet Well– Vertical Turbine Application 19 .

pond or underground tanks The pump and motor are submersed into the water.Submersible Turbine Used in applications for river. reduced pump house ventilation requirements Lower pump profile versus suction lift May plug in dirty water applications Less efficient than vertical turbine pumps Requires a crane to service motors 20 . thus the name (vertically or horizontally) Quiet operation.

Submersible – Horizontal Sled 21 .

What Type of Pump for the Source? Well Lake or Pond River or Ditch Public Source Above Ground Tank Below Ground Tank Vertical Turbine or Submersible Vertical Turbine or Suction Lift Suction Lift or Submersible Boost Flooded Suction or Boost Suction Lift or Submersible 22 .

Pump Types – Horizontal End Suction & Vertical Multi-Stage Horizontal End Suction Vertical Multi-Stage Centrifugal Typically up to 2000GPM per pump but can go higher Typically up to 130PSI Vertical Multi-stage Up to 500GPM per pump Wide range of pressure 23 .

Pump Types – Vertical Turbine & Submersible Vertical Turbine Vertical Turbine Submersible Turbine Typically up to 1000GPM per pump but can go higher Wide range of pressure Submersible Typically up to 600GPM per pump but can go higher Wide range of pressure Pump Motor Location Pump Motor Location 24 .

Identifying Pump Components 25 .

D Series Control Cabinet 26 .

D Series Rear View 27 .

DPX Front View 28 .

DPX Rear View 29 .

DPX Control Cabinet 30 .

Requesting A Quotation 31 .

Requesting a Quotation Fill out Job Information Form (JIF) available on Rain Bird Website Complete as much contact information as possible New Specifier Identification Specify whether indoors or outdoors Specify available power 32 .

wet well.Requesting a Quotation Identify type of Application – boost. flooded suction. or submersible State flow and boost requirements Identify options 33 . suction lift.

Rain Bird Pump Product Overview 34 .

2009 Pump Stations – Product Line Low Profile D Series Intermediate Flow Large Commercial 35 .

Sports Field. Racetracks. Large Parks. boost applications Schools. Roads.000 Up to 100 and greater Application Dependant Large developments.Pump Stations – Product Line Flow (GPM) Low Profile (LP) 0-150 Pumps (HP) Price Range Applications Up to 10 $9K – $15K Large residential turf. Waterfalls. Stadiums D Series 0-300 Up to 30 $10K-$25K Intermediate Flow 0-750 Up to 60 $15K-$35K Large Commercial 0-10. Zoos. Medians Resorts. Parks. Nurseries. drip. Botanic Gardens. Water features 36 .

Low Profile (LP) Aluminum Enclosure – 52”L x 36”W x 35”H Powder Coated Skid & Piping Plumbing thru wall or slab VFD Driven Vertical Multistage or Horizontal End Suction Nema 3R Enclosure w/ Touchscreen Operator Display Relay Start or Optional Pressure Start Thermal & low pressure flow protection Circuit Breaker protection 37 .

Low Profile – Vertical Multistage 38 .

Horizontal End Suction 39 .Low Profile .

Low Profile (LP) Options Bypass w/ isolation valve Pressure tank w/ flow switch (pressure start) Environmental Package – insulation + heater Paddle Wheel flow meter Pressure Relief Valve (PRV) Alarm light and audible horn Suction screen and foot valve Check valve for suction lift Inlet / Outlet Z pipes 40 .

DP.D Series Powder Coated Enclosure (PCE) – 72”L x 36”W x 52”H PCE available in Green or Tan Powder Coated Piping and Enclosure Plumbing thru wall or slab Front & Rear Doors for Easy Access Forced Air Ventilation w/ optional heater D. DPX Versions 41 .

Sized for the Application D – Basic suction or boosting application up to 300 GPM / 150 PSIG – Limited features or controls – Single pump application only DP – Requires more controls such as lake level. – Pump station monitoring and control from the site control computer desired (full optional touch screen required) 42 . remote monitoring. or flow adjustments – Required if application needs a “Self-Cleaning” suction screen – Multi-pump applications DPX – High temperature climates requiring a fully enclosed. liquid cooled electrical panel (heat exchanger).

Control Panel Nema 4 Controls Enclosure w/ optional water cooled heat exchanger Variable Frequency Drive (VFD) on all models for maximum energy efficiency Optional Programmable Logic Controller allows advanced functionality beyond pressure and flow control 43 .

Control Panel Emergency Shutdown w/ manual bypass Circuit Breakers instead of fuses Auto Restart on power loss ensures seamless operation Thermal protection – motor shutdown Low pressure discharge .run dry protection Full Alarms and safety features to protect equipment and irrigation piping 44 .

User Display GT1020 Monochrome Touch Screen (standard) E1071 Full Color Touch Screen (optional) Optional remote monitoring software 45 .

D Series Options Enclosure – Green or Tan or Marine Exhaust Fan for Enclosure Enclosure Heater Paddle Wheel flowmeter or upgrade to Magmeter Lake Level Control Pump Bypass piping Pressure Relief Valve (PRV) Power Zone Transformer for 115 or 230 VAC auxiliary power 46 .

D Series Options
Cable or Radio Modems for remote communications Filtration (Rain Bird, Amiad, VAF, Tekleen, Orival, wye strainer or other) Self Cleaning or Stainless Steel box intake screen Discharge Z-Pipe w/ FNPT ports Foot Check Valve for Suction Lift Applications Power Conditioner for poor quality power

47

Testing Facility – State-of-the-Art
Every station is fully water tested before shipment System check is the same completed at start-up in the field Hydraulics, electronics, & software is verified under full speed operation
Full Flow Hydraulic and Electrical Testing

48

Intermediate Station

49

Intermediate Flow Pump Station

50

Intermediate Enclosures Marine Enclosure – Custom sized for skid – Front and rear access doors – Can be unbolted and lifted off Wooden Building – – – – Sizes range from 6’x 6’ to 16’x 24’ Doors sizes range from 3’ to 8’ wide Multiple color choices 10 year warranty Powder coated piping for durability Plumbing connection thru wall or slab Forced Air Ventilation w/ optional heater 51 .

Submersibles 52 .

Floating Submersibles 53 .

Engineered Stations 54 .

55 .

Unique Features / Differentiators 56 .

Pump Station Leadership Superior Electronics Design – Circuit Breakers instead of old fashioned fuses – Labeled wires. clean wire runs and documentation Variable Frequency Drives (VFD) – Greater efficiency and unmatched energy savings – VFD per motor Powder Coating Technology & Protection – Polyester Powder Coated components both inside and outside for extra protection 57 .

Pump Station Leadership Pump Controller and Software – An intuitive multi-lingual Color Touch Screen operator interface instead of a text display – Available remote monitoring software Fully Engineered System – CAD and 3-D Drawings Full Factory Testing prior to shipment – Actual full speed water testing Phone Support & Problem Escalation thru GSP 58 .

Superior Electronics Design 59 .

Superior Electronic Design An Industrial Circuit Breaker is good for thousands of trips and has three visible positions: 1) Open. 60 . and offers zero visible indication of its status. 2) Shut. or 3) Tripped A fuse is good for one over current transient.

Superior Electronics Design Circuit Breakers instead of Fuses (a station can be down because of a single fuse) 61 .

Variable Frequency Drive (VFD) Every main motor on a Rain Bird Pump Station is started on the VFD VFD saves energy by only powering the pumps that are needed based upon demand VFD starting of every motor provides motor longevity Helps minimize pressure surge on irrigation piping 62 .

relays Provides best motor life w/ power conditioning & motor Protection Quick repair time: less wiring and VFD error codes reveal problems quickly. 63 . surge protection.Solid Pump Station Control Panels Each motor is controlled by its own VFD Eliminate moving parts – contactors.

– 2 -3 times as thick as typical industrial paint coatings – Polyester powder does not easily flake or chip – Testing proves it’s the best coating in the industry – Internal powder coating 64 .Powder Coating Technology & Protection Polyester Powder Coating – Applied Top. Inside and Out. Bottom.

The competition’s paint scored a 4 on the very same test. Rain Bird’s powder coat paint scored a 10 on an ASTM corrosion test.400 hours of salt-spray. 65 .Powder Coating Technology Rain Bird Test Sample following 1.

Powder Coated Flat Steel Deck Vs Liquid Coated Diamond Deck Both stations are located near the east coast and are of the same vintage (~8 years). 66 .

Fully Engineered Pump Station All pump stations are custom engineered using our 3-D CAD design system 3-D CAD saves time and money – no preassembly Shop drawings can be generated within 2 hours of design completion .PDF typical drawings available with quotation E drawing is available for customer presentation Customization can save money in renovation of existing stations New Specifier CD and Thumb drives 67 .DWG and .

And enclosed horizontal end-suction systems as well 68 .

Fully Engineered System 69 .

Fully Engineered System 70 .

Fully Engineered System 71 .

Custom Application One Size Does Not Fit All Custom engineering allowed Arthur Pack Golf Course to use its existing well cap. saving the golf course $10k in construction costs. 72 .

Display Options E1071 Full Color Touch Screen (Optional) GT1020 Monochrome Touch Screen (Standard) 73 .

Color Touch Screen – Enhanced Colors • Increased clarity • Increased readability in brighter lights Pumps Off = Grey Pumps Enabled (Ready to Run) = Yellow Pump On VFD = Blue Pumps On (Running at 100%) = Green 74 .

Digital 75 .Lake Level Settings NEW – Requires Analog Sensor Original .

Flow Graph 76 .

• Smart Pump™ provides direct and real time communication between the pump station and the central control system (Site Control) • Adjusts flow demand based on actual field conditions to maximize pump efficiency 77 .Site Control/Smart Pump Pump Manager™ provides remote computer access for monitoring and control of the pump station.

Customer Notification – Stay connected www. Identifies Pipe Breaks – avoid major washout damage 3.Rainbird. Identifies a Pump Loss – Continue irrigation 4.com 78 .Smart Pump™ Video Key Advantages 1. Operate at Full Capacity – reduce the water window 2.

Set / Start Rain Bird Services Corporation 79 .

Start-up Facts Start-up is the first service event Most service issues can be traced back to start-up There are generally three tiers of customers involved in every start-up A successful start-up is crucial for future sales RBSC manages all start-ups 80 .

Pump Station Start-up Process The start-up process begins when the pump station is in early production RBSC monitors the pump station during production and keeps the customer informed RBSC acts as liaison between the Plant and the Customer RBSC manages the delivery communication of all domestic pump stations RBSC manages communication until a pump station is ready for start-up RBSC coordinates the start-up service event RBSC follows up within 24 hours of a successful start-up to ensure the customer’s complete satisfaction RBSC follows up within 30-60 days to ensure customers’ continued satisfaction (Customer Acceptance) 81 .

Total “Customer” Satisfaction Model RBSC has identified (in general) three tiers of customers Distributors Contractors End-Users RBSC engages all three tiers of customers during the start-up process Distributors: Engaged during production through delivery (and in some cases through start-up) Contractors: Engaged during production through 24-hour start-up completion follow-up End-users: Engaged at Customer Acceptance (30-60 post start-up) 82 .

83 .

Product Manager – Gordon Van Dyke 1-520-468-9743 or gvandyke@rainbird.Contacts Sr.com Questions locally – Check with your Rain Bird Sales Manager 84 .com Quotes – pumps@rainbird.