Pump Station Overview

Todays Objectives
Pump Basics Review pump varieties Review pump applications Understand whats needed to get a pump quoted Review competitive stations

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

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 (VFDs) 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

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

Pump Station Basics

Elevation Affects Pump Performance Atmospheric Pressure at sea level is 14.7PSI = 33.96FT Atmospheric pressure above sea level: 14.7PSI (0.0005 x Altitude above sea level) For Mt Lemmon in Arizona, 14.7PSI (0.0005 x 9000FT) = 10.2PSI Motors are rated at nameplate to 3300FT. Motors above 3300FT are de-rated. 4% every 1640FT above 3300FT.

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

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

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

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. city main) not open to atmosphere Must have minimum inlet head or pressure to operate properly

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Booster Application
Pump that is developing 60 PSI (138.6 Feet of Head)

20 PSIG

80 PSIG

Suction

Discharge

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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

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Flooded Suction Application

Pump that is developing 50 PSI (115.5 Feet of Head)

5 PSIG

55 PSIG

Tank Suction Discharge

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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. 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

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Suction Lift Application

Atmospheric pressure 14.2 PSIA (1,000 elev.)

Suction piping friction loss = 3

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Atmospheric pressure = 32.8 (14.2 X 2.31)

Elevation of source = -8 (below pump) Suction plumbing friction loss = 3 NPSHA = 32.8 8 3 = 21.8

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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. Air then replaces water at the inlet to the pump. This is referred to as a Loss of Prime. Pumps cannot pump air, so the pump just spins, performing zero hydraulic work.
Ai r

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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. This type of check valve is referred to as a foot valve.

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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

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Wet Well Vertical Turbine Application

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Submersible Turbine
Used in applications for river, pond or underground tanks The pump and motor are submersed into the water, thus the name (vertically or horizontally) Quiet operation, 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

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Submersible Horizontal Sled

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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

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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

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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

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Identifying Pump Components

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D Series Control Cabinet

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D Series Rear View

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DPX Front View

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DPX Rear View

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DPX Control Cabinet

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Requesting A Quotation

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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

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

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Rain Bird Pump Product Overview

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2009 Pump Stations Product Line

Low Profile D Series

Intermediate Flow

Large Commercial

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Pump Stations Product Line

Flow (GPM)
Low Profile (LP) 0-150

Pumps (HP)

Price Range

Applications

Up to 10

$9K $15K

Large residential turf, drip, boost applications Schools, Parks, Sports Field, Roads, Medians Resorts, Large Parks, Nurseries, Zoos, Botanic Gardens, Racetracks, Stadiums

D Series

0-300

Up to 30

$10K-$25K

Intermediate Flow

0-750

Up to 60

$15K-$35K

Large Commercial

0-10,000

Up to 100 and greater

Application Dependant

Large developments, Waterfalls, Water features

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Low Profile (LP)

Aluminum Enclosure
52L x 36W x 35H

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

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Low Profile Vertical Multistage

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Low Profile - Horizontal End Suction

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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

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D Series
Powder Coated Enclosure (PCE)
72L x 36W x 52H

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, DP, DPX Versions

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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, 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). Pump station monitoring and control from the site control computer desired (full optional touch screen required)

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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

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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

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User Display
GT1020 Monochrome Touch Screen (standard)

E1071 Full Color Touch Screen (optional) Optional remote monitoring software

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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

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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

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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

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Intermediate Station

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Intermediate Flow Pump Station

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Intermediate Enclosures
Marine Enclosure
Custom sized for skid Front and rear access doors Can be unbolted and lifted off

Wooden Building
Sizes range from 6x 6 to 16x 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

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Submersibles

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Floating Submersibles

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Engineered Stations

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Unique Features / Differentiators

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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

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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

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Superior Electronics Design

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Superior Electronic Design

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

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Superior Electronics Design

Circuit Breakers instead of Fuses (a station can be down because of a single fuse)

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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

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Solid Pump Station Control Panels

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

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Powder Coating Technology & Protection

Polyester Powder Coating Applied Top, Bottom, Inside and Out. 2 -3 times as thick as typical industrial paint coatings Polyester powder does not easily flake or chip Testing proves its the best coating in the industry Internal powder coating

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Powder Coating Technology

Rain Bird Test Sample following 1,400 hours of salt-spray.

Rain Birds powder coat paint scored a 10 on an ASTM corrosion test. The competitions paint scored a 4 on the very same test.

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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).

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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 .DWG and .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

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And enclosed horizontal end-suction systems as well

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Fully Engineered System

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Fully Engineered System

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Fully Engineered System

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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.

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Display Options
E1071 Full Color Touch Screen (Optional)

GT1020 Monochrome Touch Screen (Standard)

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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

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Lake Level Settings

NEW Requires Analog Sensor

Original - Digital

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Flow Graph

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Site Control/Smart Pump

Pump Manager provides remote computer access for monitoring and control of the pump station. 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

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Smart Pump Video

Key Advantages 1. Operate at Full Capacity reduce the water window 2. Identifies Pipe Breaks avoid major washout damage 3. Identifies a Pump Loss Continue irrigation 4. Customer Notification Stay connected

www.Rainbird.com

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Set / Start
Rain Bird Services Corporation

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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

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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 customers complete satisfaction RBSC follows up within 30-60 days to ensure customers continued satisfaction (Customer Acceptance)

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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)

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Contacts
Sr. Product Manager Gordon Van Dyke
1-520-468-9743 or gvandyke@rainbird.com

Quotes pumps@rainbird.com

Questions locally Check with your Rain Bird Sales Manager

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