Project_Specifications.pdf

VFD Main Pump System Specifications

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ENGINEERING SPECIFICATIONS FOR

MESA-2SUB-2VFD

VARIABLE SPEED PUMPING SYSTEMS

1.0 GENERAL:

1.01 Description

The pumping system shall automatically supply water to the turf irrigation system. The manufacturer shall be solely responsible for providing manufacturing, warranty and service of a prefabricated, skid mounted, fully automatic variable speed pumping system for the irrigation system. The pumping system shall automatically maintain a pre-set discharge pressure at varying flow demands within the flow rating of the station. The pumping system shall conform to all specification documents. The complete pumping station shall be built in accordance with applicable standards for usage and safety and electrical control panel shall display the U.L. label for safety.

The manufacturer shall provide a complete set of general arrangement drawings, electrical diagrams, and control panel schematics with the operation and service manual.

1.02 Scope

Include all components necessary to construct a complete pumping system capable of delivering water to the irrigation system at the designed pressure and flow rate. The pump station shall be a completely skid mounted Submersible pump station built by a single manufacturer. All equipment including, but not limited to pumps, motors, valves, instrumentation and controls shall be mounted on common structural steel base to form a complete operating pumping system. Pumps and motors shall be removable for shipping and servicing purposes.

1.03 General Specifications

A. The Submersible turbine pumping station shall include the pumps, motors, valves, discharge manifold, Outdoor control panel, and all accessories.

B. The prefabricated pumping system shall be a factory fabricated and tested system with all components completely piped, wired and assembled on a structural steel skid before shipment.

C. All pumping station components shall be supplied by, and be the responsibility of one pumping system manufacturer

D. The pumping system shall be completely assembled and tested at the manufacturer’s facility prior to shipping to assure operation and performance. Job site start up shall be limited to minor adjustments for site conditions.

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2.0 MATERIALS:

2.01 Submersible Turbine Pumps

A. The pump shall be of the vertical multi-stage design with the motor mounted directly on the bottom of the pump. The pump shall be installed in accordance with the recommendations of the manufacturer including the installation of a flow inducing shroud around the entire pump and motor unit to insure proper cooling of motor.

2.02 Discharge Head

A. The Submersible turbine pump discharge head shall be fabricated from carbon steel with a minimum of 60,000-psi tensile strength.

B. The discharge flange shall be a 150# ANSI raised face flange. The column connection under the discharge head shall be a butt flange with a raised centering ridge. The discharge head will be machined and taped for attachment of the butt flange. Welded column connections are not acceptable.

C. The discharge head shall abrasive blasted to a near white metal condition and shall immediately thereafter be coated with an industrial epoxy primer and a final coat of industrial powder coat

2.04 Submersible Pump Motors

A. The submersible electric motor, which powers the submersible pump, shall be three phase submersible motor as manufactured by Franklin.

B. The motor shall have a horsepower rating so that the motor will carry the maximum pump load without overloading the nominal horsepower value.

C. The submersible motor shall be 25 HP, operate at 460 volts, three phase power, and have a

1.15 service factor.

D. The submersible motor shall be U.L. and C.S.A. approved.

2.05 Pump Station Skid

A. The pump station base shall provide proper structural support for all attached equipment and shall provide sufficient rigidity to withstand the stresses from reasonable transportation to site, off-loading, installation, and operation.

B. The pump station skid shall incorporate into its structure provisions for off-loading and handling at the site of installation. These lifting points shall be an integral part of the structure.

C. The base shall include a 3/16’" steel deck plate, and a 5/8" steel pump plate.

D. The pump station shall not completely cover the wet well to shall allow access to the wet well through a side mounted hinged access cover.

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2.06 Piping, Manifold, Valves:

A. All piping shall be ASTM A53 Schedule 40 pipe.

B. Manifold piping shall be of a sufficient size for the designed flows.

C. Each pump discharge assembly shall be equipped with a silent check valve and a grooved end butterfly valve installed with (2) Victaulic couplings to provide easy field assembly.

D. The structural steel base, piping and supports shall be abrasive-blasted to a near white metal condition. The cleaned steel surface shall immediately thereafter be powder coated inside and out.

2.07 Pump Check Valve

A. Each main pump shall have a check valve bolted directly to the pumps discharge head sized so that pressure drop does not exceed 2.0 psi.

B. Check valves shall be of the silent operating type. Swing checks are not permitted.

C. Valve bodies shall be cast from grade 35 cast iron or better and shall be free of blowholes, sand holes, and other impurities.

D. The valve design shall incorporate a center guided, spring loaded popped, guided at opposite ends and having a short linear stroke that generates a flow area equal to the pipe diameter.

E. Internals shall include machined bronze disc, seat, and stem guide. The valve seat shall be

Buna-N to provide resilient sealing.

2.08 Pump Isolation Valves

A. Each pump shall be equipped with a grooved end butterfly isolation valve.

B. Isolation valve shall be sized as shown on the technical data sheets.

C. The valve handle shall be removable to prevent vandalism or unauthorized operation.

2.10 Pressure Gauges

A. Pressure gauges shall be mounted on the discharge header on top of an isolation ball valve.

B. Gauges shall be silicon filled, accurate within 2% and 2 1/4” in diameter.

C. Range shall be at least 30% higher than the highest pressure attainable from the pumps at shutoff head conditions.

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2.11 Pump Station Isolation Valve

A. An isolation valve of the same line size as the discharge spool, shall be installed on the outlet flange of the pump station to allow for complete isolation of the pumping system from the irrigation system.

B. The valve shall be of the lug style butterfly type with a one-piece body cast from ASTM A126 cast iron.

C. The valve shall have a lever operator and shall be rated at 200 psi.

D. The valve handle shall be removable to prevent vandalism or unauthorized operation.

2.13 Discharge “Z” Pipe

A. The pump manufacturer shall include flanged x Plain End schedule 40 steel discharge Z- pipe.

B. The Contractor shall be responsible for pouring a thrust block behind the bottom of the elbow of sufficient size to prevent strain being transfer from the irrigation system back onto the pump station.

C. The Contractor shall be responsible for connection of the “Z” pipe to the discharge outlet of the pumping station and connecting to the irrigation system.

3.0 ELECTRIC EQUIPMENT (OUTDOOR RATED CONTROL PANEL):

3.01 Circuitry

A. The control panel shall include all logic circuitry to provide for the time sequence, start-up and shutdown of all pumps.

B. All relays, terminal strips, and other necessary equipment shall be enclosed in a NEMA 3R, U.L. approved enclosure.

C. The following features shall be included as standard:

1. Minimum 7” Color Touch screen operator interface

2. Low water level safety circuit

3. Low discharge pressure safety circuit

4. High discharge pressure safety circuit

5. Lighting arrestor

6. Manual or auto selection of lead irrigation pump

7. Phase unbalance, phase reversal, loss of phase protection and low voltage safety protection

8. Include remote access and full control via manufacture application

9. Include alert and notification of alarm events

10.Detailed flow monitoring and reporting

D. The control panel shall include all magnetic starters, relays, transformers, pressure sensors and various safety devices for the operation and protection of the pumping station.

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E. A programmable logic controller shall be provided to perform the sequence of operation.

F. The programmable logic controller shall be as manufactured by AutomationDirect.

3.02 Control Enclosure

A. All control equipment shall be housed in a lockable NEMA 3R type enclosure.

B. HMI and power disconnect shall be mounted to an inner door only accessed by approved personnel with provided key.

C. The operator interface device and service disconnect switch shall be mounted on the enclosure inner door.

D. All internal components shall be mounted on the removable back plate assembly.

E. A closed type industrial air conditioning cooling system shall be included to cool the enclosure and reject heat from the VFD. No water line connections shall be permitted inside of the control panel enclosure.

3.03 Lightning and Surge Arrester

A. All electrical equipment shall be protected by a U.L. approved surge arrester to suppress voltage surges on incoming power.

3.04 Main Disconnect

A. Provisions shall be to completely isolate all control and motor starting equipment from incoming power by supply a non-fusible main disconnect.

B. A thru-the-door operator shall be provided for the main disconnect.

3.05 Control Power

A. A power transformer providing 120 volt, single-phase power shall be provided to supply power for the control equipment.

B. No other external load shall be connected to the Control Power transformer.

C. The control power transformer shall be protected on the primary side by circuit breakers. Fuses are not permitted.

D. All control components on the secondary side of the Control Power transformer shall be protected by circuit breakers of adequate sizes. Fuses are not permitted.

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3.07 Variable Frequency Drive PER Motor

The variable speed drive(s) shall be a digital, pulse width modulation (PWM) variable frequency drive (VFD) with IGBT transistors. The VFD shall have a minimum wire-to-wire efficiency of

98%, and shall be rated up to 504 volt operation in order to eliminate nuisance tripping at marginally high voltage conditions. Fast acting semiconductor fuses shall protect front end. Any VFD error messages shall be displayed on 40-character LCD readout in English or any one of 8 other languages. The following fault protection circuits shall be included: Over Current (200%), Over

Voltage (130%), Under Voltage (60%), Over Temperature 158ºF (70ºC), Ground Fault, and Motor

Overload. The VFD shall be capable of starting into a rotating load and accelerate or decelerate to set point without safety tripping. The VFD shall have an automatic extended power loss ride through circuit, which will utilize the inertia of the pump to keep the drive powered.

Minimum power loss ride-through shall be one cycle based on full load and no inertia. The VFD shall be optimized for a 3KHz carrier frequency to reduce motor noise. The VFD shall employ three current limit circuits to provide “tripless” operation. The following operating information shall be displayed on the VFD LCD: KWH, elapsed time, output frequency (Hz), motor speed

(RPM), motor current (amps), and voltage. Line reactor will be installed on input of VFD to protect against voltage transients. VFD shall be as manufactured by Danfoss and have a 6 year warranty.

3.08 Pressure Transducer

A. A pressure transducer shall be installed to transmit all pressure signals to the programmable logic controller.

B. The pressure transducer shall be a solid-state bonded strain gage type with accuracy of plus/minus 0.2%.

C. All wetted parts of the pressure transducer shall be constructed of stainless steel. Plastic is not permitted.

D. The pressure transducer shall be installed downstream of an isolation ball valve for easy service.

E. The pressure transducer shall be rated for the station discharge pressure and be manufactured by Turk.

3.09 Flow Meter Signal Conditioner

A. The pump station control panel shall be equipped with a Data Industrial model 310 or

Approved Equal flow meter signal conditioner totally programmable with a PC based computer.

3.10 Controls

A. All execution of control logic shall be performed by an industrial grade programmable logic controller (PLC).

B. A touch-screen operator interface providing data entry and read-out-capabilities shall handle all operational interfacing.

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C. The PLC shall have LED indicators signaling input and output ON/OFF status as well as LED indicators showing PC Run Mode and CPU Fault.

D. The PLC shall be provided with a built in flash memory and battery for memory backup.

E. All logic for system control and control of the VFD speed shall be handled by the PLC.

F. The PLC shall have a built in clock/calendar.

G. The PLC shall be model DO-MORE as manufactured by AutomationDirect.

H. The minimum standard control features and equipment to be included are as follows:

1. Alarms and Shutdowns:

Low discharge pressure

Over-demand (flow) alarm

High discharge pressure

Low water level

Phase loss

Low voltage

Phase unbalance

VFD fault

Remote monitoring and control if internet is available via ethernet or Cell Modem.

2. Touch screen Operator Interface:

Individual pump run indication

VFD selector switch (in manual mode, a speed pot will be available to manually select VFD speed)

Alarm indication with reset

Current alarm and Alarm History indication

Low discharge pressure override (override will default off after preset time).

PID trending

Access to PI adjustment of VFD

Set point access with ten-key keypad for set point entry

Status screen indication of current pressure and flow

Automatic alternation or manual selection of lead pump

3.11 Sequence of Operation

A. During non-irrigation times, the pressure maintenance pump (PM) will cycle ON and OFF as required to maintain the irrigation system pressure. The PM pump start and stop pressures can be user selected and can be set substantially below normal set point pressure, if desired.

B. If the PM pump cannot maintain the desired pressure, then the VFD will start the first pump and will gradually ramp the pressure up to the desired irrigation pressure. The pump speed will be modulated to hold a constant discharge pressure regardless of flow.

C. As the flow rate increases and the VFD pump can no longer maintain pressure while at maximum speed, the next sequential pump controlled by VFD with start.

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D. As the flow continues to increase, pumps will be started sequentially until all pumps are ON.

E. As the flow begins to decrease, pumps will sequentially be turned OFF until only a single VFD driven pump is operating.

F. When a no flow condition occurs, the VFD pump will be turned OFF.

4.0 WIRING:

A. The main control panel disconnect shall be feed by a sufficient Amperage, 460/60hz/3 service line from the pump house electrical entrance.

B. A main disconnect with fuses shall be installed to protect and feed the motor control panel

C. Motors shall be connected via non-metallic liquid-tight flexible.

D. Fittings to be used with the non-metallic liquid-tight flexible conduit shall be liquid-tight strain relief fittings.

5.0 POWDER COAT AND RUST PROTECTION:

A. All structural steel, piping, and supports shall be abrasive blasted to a near white metal condition, and promptly coated with a Fusion Bond Epoxy inside and out.

B. The top surface of the skid platform, after blasting, will then receive a coating of high strength polyurethane surface protection. This surface treatment will contain a Kevlar additive for added strength and slip resistance.

6.0 STATION START-UP AND ADJUSTMENT:

Once the manufacturer has received written verification that the station has been connected both electrically and hydraulically (by others), the manufacturer shall send a field service technician to start up and calibrate the station to the specified performance levels.

7.0 WARRANTY:

The pumping station manufacturer shall warranty all items of their manufacture to be free of defects in workmanship for a period of 24 months from the date of delivery or 2 year from the date of start-up, provided that authorized start-up and recommended service has been performed.

This warranty excludes any defects caused by misuse, neglect, improper maintenance, acts of

God or war or any cause beyond the manufacturers control. This expression of warranty is limited to the repair or replacement of the defective part and does not assume liability for any consequential costs or damages. Any defective material should be returned to the factory for a warranty determination.