S02 - ATTACHMENT A - SALIENT CHARACTERISTICS.pdf

Attachment A 36C24822Q1046

C.W. Bill Young VA Medical Center

Bay Pines, FL 33744

SyncroFlo Triplex IronHeart PR Variable Speed Water Pressure Booster System - Brand Name or Equal

*** Reference manufacturer – SyncroFlo Pumping System Solutions ***

Salient Characteristics

Required for Booster Pump Package for Building 100 Bay Pines VAHCS

Pump Package

SyncroFloTriplex IronHeart PR Variable Speed Water Pressure Booster System (Brand Name or Equal). The system shall be capable of providing a constant system pressure of 80 psig with flow rates from 0 to 1086 GPM when suction pressure is 50 psig minimum using 460 Volt, 3 phase, 60 hertz power. System shall be a factory-assembled and -tested, fluid-handling system for domestic water, with pump, piping, valves, specialties, and controls, all mounted common on a base. Controls and Headers are all mounted on a common skid base for indoor installation in a utility plant. The complete pump station win be NSF, ETC and UL listed, and will be completely tested prior to shipment. SyncroFlo (Brand Name or Equal) has earned certification to manufacture packaged pumping systems to the NSF 61 standard for safe drinking water equipment.

System comprises of the following components:

• (3) pump system capable of providing peek flow of 1086 GPM @ 37psi (85’ TDH). This load should be split evenly across 3 pumps. Must may be any of the following, or equivalent:

o Gould’s Pumps.

o Xylem Bell & Gossett o FloTherm Corporation o Pumps shall be Ebara 3U series NSF certified close coupled end suction centrifugal pumps.

o Pump casings shall be 304L SS and integrally foot mounted with 150 psi flanged suction and 150 psi flanged discharge connections.

o The pump discharge shall be top centerline and self-venting.

o A ¼” tap shall be provided and utilized for a temperature probe to protect the pump from the harmful effects of operation at no flow.

o A casing drain tap shall be provided with stainless steel plug.

o The pump assembly shall incorporate a back pull-out design to allow for pump repair and maintenance without the need to disconnect suction and/or discharge piping.

• 460V, 3 phase, 60 hertz power

• The pump drive motor shall be NEMA standard design JM fame suitable for vertical mounting.

• 304L stainless-steel piping with welded ASME B16.5 flanged connections rated for the system pressure and ASME flanges in accordance with ASME B16.5 and welded to the headers

• Motors when coupled to a VFD shall have a 1.0 service factor per NEMA MG-1. No thrust bearing required

• 10” flanged bolt connections – ANSI Class 150

• 100% flanged construction

• 304 Stainless steel pumps close coupled end suction

• Zinc electro plated base with anchor holes and pipe supports

• Isolation Valves NPS 2-1/2 and Larger: NSF certified, lug-type butterfly valve with lever handle, valve shall be rated for operation at maximum system pressure plus suction pressure. Valves shall be mounted on the suction and discharge of each pump

• Check Valve NPS 2 and Larger: NSF certified stainless steel, silent type in pump discharge piping.

• Thermal-Relief Valve: Mechanical temperature-and-pressure relief type in pump discharge piping.

• High performance check valves for low station losses

• Nema 12 enclosure with air filter and fan for heat dissipation

• Bolt on panel stand. A removable panel stand constructed of metal framing strut bolted to the base plate. A removable panel stand constructed of metal framing strut bolted to the base plate.

• Carbon steel base system with grout holes, anchor holes, and pipe supports

• Mitsubishi PLC and HMI based controls with 5-year warranty standard o Must be non-proprietary o The PLC shall control all pump starts and stops and indicate all alarms.

o Program cartridge or loader which allows program changes to be made by the factory and sent to the field for simple loading by the operator.

o Input and output "on" status lights for ease of monitoring.

Third Party Compliance for Packaged Pumping Systems:

• NSF/ANSI 61, “Drinking Water System Components”

• UL 508, "Industrial Control Equipment."

• UL 508A, "Industrial Control Panels."

• UL 778, "Motor-Operated Water Pumps."

• UL 1995, "Heating and Cooling Equipment."

• UL QCZJ, “Packaged Pumping Systems

Manufacturers Qualifications

• A single supplier shall furnish equipment under this section.

• Manufacturer shall have in place a quality assurance program under ISO 9001-2015.

• Manufacturer shall have a contracted factory authorized service center with a minimum of 10 years experience.

• Complete system shall be warranted for a period of three (3) years after shipment or twenty-four (24) months after startup whichever comes first.

• PLC, HMI and VFD’s shall be warranted for 5 years after shipment.

Human Machine Interface (HMI)

An HMI shall be flush mounted on the door of the control panel.

The following data shall be accessible through the HMI:

• System status including current system pressure and setpoint, pump run status, power (kW/Hp), amps (A), speed (Hz) of the pumps (Hz) and the method of speed control.

Display system alarms on all user screens.

• Usage history shall record, along with the date and time, pump starts, and pump run hours. Usage history may be reset.

• A Set Points Menu system for adjusting setpoints. Display and adjust system pressure, VFD speed, power, minimum speed, lead pump shutdown mode, and tank pressurizer set points and time delays. Restore to either factory defaults or the last saved field defaults. Protect adjustable settings with a password.

• Alarm History of the past 200 alarms. Each log shall include individual pump run status, system pressure and run setpoint, alarm type and the date and time. Alarm Type shall be in plain English, not codes requiring a reference list.

• Alarm List of all possible alarms and their current status. Display any current alarms on all user screens.

• Startup instructions and checklist.

The HMI shall include a method for transferring data:

• System information shall automatically copy to a installed SDHC card every minute (Adjustable 10-300 sec), plus an additional entry for each alarm.

• Include fault codes from the PLC and VFD

• Copy usage data to the card every 5 minutes, creating a daily file.

• Data shall be stored in a text file, readable by non-proprietary software.

• HMI software shall allow for program changes to the HMI to be transferred via the SDHC card.

Pump selector switch shall be provided on the HMI with the following positions:

• HAND: Use for manual operation only - to start up, restart and reset or test each pump.

No pump should run in this position without supervision.

• OFF: Pump will not run at all. Use during start up, restart and reset, or when a pump is down for service.

• AUTO: Automatic position for each pump, which allows the controller to have full control over the pump’s operation.

Alarms:

Low Suction Pressure \ Level Alarm: The low suction device (pressure switch, pressure transmitter, or level switch) signals a loss of supply water pressure for 5 seconds (default), all pumps will be locked off.

Low System Pressure Alarm: If system pressure drops to or below the low system pressure set point for 30 seconds (default), this alarm will activate.

Low System Alarm: Via the HMI, the operator can enable or disable this alarm. If enabled and the system pressure drops to or below the low low system pressure set point for 60 seconds (default) with a pump running, this alarm will activate. This alarm will shut down the pumps and prevent operation until the alarm has been manually reset as described below. The pressure set point is differential from the normal set point pressure and can be set as low as equivalent to 5 psig. Enabling or disabling this alarm creates a log in the event history on the HMI. It is also logged to the SDHC card in the HMI (if logging is enabled), which is explained further in the HMI manual

High System Pressure Alarm: If system pressure rises above the high system pressure set point for 5 seconds (default), this alarm will activate and lockout the pumps. This alarm will be disabled in the event of a system pressure transmitter failure.

Pressure Transmitter Out of Range Alarms: The correct output range of the pressure transmitter(s) is 1 - 6 kHz. The pressure transmitter failed low alarm will activate if the controller receives an abnormally low signal for 2 seconds. The pressure transmitter failed high alarm will activate if the controller receives an abnormally high signal for 8 seconds.

Individual Drive Fault Alarms: If a fault occurs in the drive when it is being called to run, the VFD failure alarm will be activated. This alarm will stop the pump with the failed drive and start the next available pump if it is not currently running. The alarm requires manual resetting with the alarm silence / reset push button.

Alarm Combinations: If multiple alarms occur, the controller will indicate all alarm conditions by continually scrolling them on the HMI. The alarm silence/ reset push button can be pressed to stop the scrolling.

Resetting Alarms: Each of the alarms requires manual resetting before returning to normal automatic operation.

Event History: This feature displays the last 200 events that have occurred on the system.

Pressure transmitters

Digital pressure transmitters shall be connected to the system suction and discharge headers.

The transmitter shall have 1.0% accuracy, stainless steel wetted parts and a waterproof enclosure. Transmitter shall be capable of withstanding over pressurization of double its range.

Pump system shall be capable of calibrating the zero setting in the field.

Variable Frequency Drives

• Each pump shall have its own Mitsubishi variable frequency drive (or approved equal) with the following features.

• Voltage source, GTR or IBGT power transistor-based inverter - PWM Type

• Use a high carrier frequency to reduce drive and motor noise

• Shall be capable of operating in an ambient temperature between 15 degrees F and 100 degrees F and a line voltage variation of less than 10 percent.

• Include a four-digit LED readout to indicate the following: drive enabled, output frequency, and all VFD fault conditions.

• The drive shall automatically restart after any of the following: overload over-voltage, converter over-current, inverter over-current, or power failure.

• The following drive parameters shall be user adjustable: acceleration speed (1 to 300 seconds), deceleration speed (1 to 300 seconds), minimum speed, and maximum speed.

• The drive shall have a front mounted "HAND-OFF-AUTO" selector switch and a potentiometer for adjusting drive speed in the "HAND" position.

• Minimum 100,000 SCCR

The VFD shall communicate with the PLC with a DIGITAL connection.

PUMP SEQUENCING AND OPERATION

The lead pump will start on a low system pressure condition. The lead pump shall run continuously if selected by the operator. The lag pump(s) will sequence based on a combination of system pressure, high lead pump speed, and power usage. This combination of parameters will ensure the starting of the lag pumps as the running pump(s) come to full capacity. System pressure is continuously maintained by adjusting the speed of the pump(s).

Automatic sequencing shall include the following features:

• Power sequencing, programmable in horsepower not Watts.

• Pressure sequencing.

• End-of-curve protection, based on pump differential, with 2% accuracy

• VFD speed sequencing

• Lead pump shutdown feature that can be enabled or disabled by the operator

• Low-flow test feature testing pressure, power, VFD speed, and flow (if equipped with flow sensor), to reduce pump short-cycling, pressure swings, power surges, and motor wear.

• Time clock to disable lead-pump shutdown during building occupancy.

• Sequence shifting that adjusts the pump sequence when any pump is disabled

• Successive and 24-hour alternation of equal capacity pumps

• Pump overlap during 24-hour alternation

• Lag pump exerciser function

• Special sequencing to reduce surges during power restoration

• Sequential sequencing of lag pumps

• Minimum run and stop delay timer for each pump

• Field adjustable time delay for lag pump pressure start signals

• Field adjustable low suction pressure alarm Field adjustable selection to enable / disable limited auto reset of low suction, high system pressure alarms, and VFD fault.

Manual speed control:

• If the system pressure transmitter fails or the operator chooses, the controller will output a constant speed value to the drive, which can be adjusted by the operator using the

HMI.

Instrumentation and Emergency Controls:

• Provide pressure sensors for high system pressure, low system pressure, and low suction pressure conditions. All pressure sensors shall be control panel mounted.

• Digital pressure transmitters shall be connected to the system suction and discharge headers. The transmitter shall have 1.0% accuracy, stainless steel wetted parts and a waterproof enclosure. Transmitter shall be capable of withstanding over pressurization of double its range. Pump system shall be capable of calibrating the zero setting in the field.

• Provide individual NSF certified 2½" ASA grade A, glycerin-filled pressure gauges for each pump, system, and suction pressures.

• A temperature relief valve shall be mounted in the discharge head or seal bypass line for fast, accurate response.

Set-Up

• Install will be done by VA personal with the assistance of pump suppliers assistance on start up.

• After installation is completed provide an operational test of the completed system including flow rates, pressure compliance, alarms and all control functions.

• Pump supplier to provide (1) one annually maintenance and inspection for (2) two years from start up.

Deliverables

• Complete operating and maintenance manuals including wiring diagrams, technical data sheets, information for ordering replacement parts, and troubleshooting guide:

1. Include complete list indicating all components of the systems.

2. Include complete diagrams of the internal wiring for each item of equipment.

3. Diagrams shall have their terminals identified to facilitate installation, operation and maintenance.

• Provide onsite training to VA staff as to the set-up, maintenance and operation of unit and its components.

• Submit manufacturer’s literature and data updated to include submittal review comments and any equipment substitutions.

• Submit operation and maintenance data updated to include submittal review comments, substitutions and construction revisions shall be inserted into a three-ring binder. All aspects of system operation and maintenance procedures, including piping isometrics, wiring diagrams of all circuits, a written description of system design, control logic, and sequence of operation shall be included in the operation and maintenance manual. The operations and maintenance manual shall include troubleshooting techniques and procedures for emergency situations. Notes on all special systems or devices such as door closure interlocks shall be included. A List of recommended spare parts (manufacturer, model number, and quantity) shall be furnished. Information explaining any special knowledge or tools the owner will be required to employ shall be inserted into the As-Built documentation.