Pump Station Specification

This specification will describe an automatic pumping station. The system must produce the maximum gallons per minute needed at the required pressure, as well as adjust itself automatically and efficiently with the pump or pumps supplied to any flow rate below the maximum down to and including 0 GPM. This shall be accomplished with complete absence of water hammer or surge during start up or shut down of any pump on the system. Each pump on the system shall be controlled by a separate pump panel and pressure switch and, except for the incoming power supply, shall be completely electrically independent of all other pumps on the system.

No pump on the system shall be connected to any other control system such as, pump start relays, limit or flow switches. Each pump on the system shall have its own pressure actuated flow control valve. The control valve shall have no electrical components. It shall be fully self operating, fast acting and non-closing to prevent water hammer or surge. Any pump on the system shall be capable of automatic operation by itself or in combination with any or all other pumps on the system. No pump on the system, whether working alone or in combination with other pumps shall be allowed to "jockey" or " short cycle" regardless of the flow rate. All requirements of the pump station shall be met without the use of any microprocessor controls. No technical assistance shall be needed.

The pump station will include the following:

1. Pressure actuated pump control valve per pump
2. Pressure switch sequencing of pumps
3. Full voltage across the line pump panel per pump
4. Vertical turbine, centrifugal, or submersible pumps
5. Check valve and foot valve per pump
6. 125 PSI working pressure captive air tank
7. Modulating pressure relief valve
8. Station isolation valve
9. Heavy gage diamond plate skid
10. Heavy wall pipe manifold
11. Stranded copper wiring
12. Industrial powder coating
13. Enclosure Construction
14. Factory testing
15. Warranty and manuals

(1) PUMP CONTROL VALVES

Each pump shall be regulated by its own pressure actuated pump control valve. Flow range must vary from maximum pump out-put to 5 GPM flow required for adequate cooling of the pump and or motor. To prevent water hammer each valve must be in the closed position on start up as well as shut down of the pump it controls. This will be accomplished by setting each valve to hold steady pressure at low flow, and that pressure being the same pressure at which the corresponding pump is set to start up. In the closed position each valve must still allow 5 GPM flow required for cooling, through the main body of the valve and across the valve seat. This prevents pump "dead heading", and water hammer as well as limits pressure tank fill rate to 5 GPM regardless of pump capacity. Each valve shall be fully self operating having no limit switch or electrical connection of any kind. The control valves shall be a Cycle Stop Valve model CSV3B or an approved equal.


(2) PRESSURE SWITCH CONTROLS

All pressure switches shall be mounted in a NEMA 4X enclosure separate from all other electrical controls. Each pump motor shall be turned on and off by its own mechanically operated pressure switch. Each switch shall be capable of turning on and off the pump motor it controls within a band width of 5 PSI. The smallest pump shall have the highest pressure setting and the largest pump the lowest by increments of 5 PSI. This insures that pump sequencing will always be from smallest to largest, with the largest pump starting up at the lowest system pressure required. Each pump motor requires a low pressure cut off switch and must have its own normally open mechanically operated switch with a band width of 2 PSI. The low pressure switch shall be set to shut down the pump if system pressure drops 10 PSI to 30 PSI below the starting point of the largest pump. On\Off and low pressure switches shall be an Allen Bradley model 836 C7A or an approved equal.


(3) PUMP MOTOR CONTROLS

Each pump motor shall have its own full voltage across the line Nema 3R pump panel. The 480V 3 phase pump panel shall be fusible or circuit breaker type with Hand\Auto switch and main power disconnect handle on the side of the enclosure. Fuses, breakers, and over load relays shall be sized in accordance with the manufacture of the motor it controls. All components shall be UL listed. Soft start is available if required by the power company.


(4) PUMPS AND MOTORS

The pumps shall be all, or a combination of, Vertical turbine, Centrifugal, or Submersible.


(5) CHECK VALVES AND FOOT VALVES

Each vertical turbine and centrifugal pump shall be fitted with a foot valve or a check valve or both as needed. Foot valves shall be screened and sized to fit the pump intake or larger. Check valves shall be sized to fit the control valve intake.


(6) PRESSURE TANK

The pressure tank shall have a 125 PSI working pressure, 119 gallons maximum capacity. The tank shall not be used for surge or dampening.


(7) PRESSURE RELIEF VALVE

The modulating pressure relief valve shall be attached to a discharge line common to all pumps on the system. The discharge of the pressure relief valve shall not be plumbed back into the wet well, but rather piped away from the pump station by the contractor on location, and placed in such a way that fluid discharging can be seen by the operator at a distance. Fluid should not be allowed to discharge from the pressure relief valve unless there is a system failure. The pressure relief valve shall be a Bermad model 400 or an approved equal.


(8) STATION ISOLATION VALVE

The pump station shall have a ball type isolation valve sized to fit the intake and discharge manifold. This valve shall be placed on the edge of the skid. The valve shall be a Watts full port ball valve type.


(9) SKID ASSEMBLY

The skid assembly shall be of I-beam or channel construction with 3\16 diamond plate flooring. The skid shall structurally support all pump station equipment and shall cover wet wells entirely to help prevent foreign material from entering the well. No anchors to the concrete slab are needed as water hammer is eliminated by the control valves.


(10) PIPING

All piping shall be prefabricated to manifold all pumps on the skid assembly together with the pressure tank and then on to the station isolation valve. All piping shall be threaded schedule 40 galvanized, threaded brass, poly, or heavy wall steel pipe welded to ANSI flanges. Stuffing box drains shall be plumbed back into the wet well with tubing.


(11) WIRING

The system shall be fully wired and grounded using UL listed, stranded copper wire with 600 volt rating. All wiring shall be sized large enough to adequately supply power to the pump motors. Seal tight conduit and fittings shall cover all exposed wiring. The contractor on location is responsible for connecting incoming power supply to each pump, and for reconnecting pump motor wires to each individual pump panel. Vertical turbines and submersibles require disconnecting from pump panels for shipment. The contractor on location is also responsible for setting pump motor rotation and pump station start up.


(12) PAINTING

All major components and piping not already painted by the manufacturer shall be sand blasted to white metal, powder coated, and oven baked.


(13) ENCLOSURE CONSTRUCTION

Each is custom built to the layout of the pump station.  The base is built out of 3/16 steel floor plate with a frame of 6.2 # 6" channel iron.  The tops are 10 ga steel, doors are 10ga with lips bent on edges, also they are cross broke for added strength.  The end panels are built out of 12 ga material.  Most of the enclosures have double doors on two of the sides, giving full access to the equipment inside.These are equipped with a fan on a thermostat for ventilation, also a heater with thermostat for freeze protection in the winter. Each enclosure built as of the beginning of 2011 is insulated with Verso-Foam. This is sprayed in with a range of .75-1" foam.  This adds to the freeze protection in the winter, also it aids in the build up of heat in the summer months.There are different coatings used on the enclosures depending on the climate where the pump station is used.  In dryer climates a epoxy of 1.5 ml is used with a polyester coat of 1.5 ml on top of the epoxy.In humid climates a liquid epoxy system is used of 4-5 mls.  On top of this a urethane of 2 mls is applied.  








(14) TESTING

The completed pump station shall be fully tested by the manufacturer prior to shipment. Full range test as well as a pressure hold test shall comply with requirements.


(15) WARRANTY AND MANUALS

The pump station and all components shall be warranted against defects in material and workmanship for a period of one year from date of shipment. An installation sheet and operator manual shall be provided by the manufacturer.