Pump Station Overview
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Today’s Objectives
Pump Basics
Review pump varieties
Review pump applications
Understand what’s needed to get a pump quoted
Review competitive stations
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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
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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
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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
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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.
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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
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What is the Water Source?
Well
Potable Water
Lake or Pond
Well Water
River or Ditch
Reclaim Water
Public Source
Agriculture Water
Above Ground Tank
Snowmelt or Storm
runoff
Below Ground Tank
Chiller or A/C Water
Rainwater
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Electrical Power
Most common types of power in U.S.
– 460 V, 60Hz, 3Φ
Can power pumps up 500HP
– 230 V, 60Hz, 3Φ
Can power pumps up to 100HP
– 230 V, 60Hz, 1Φ
The largest motor available in 1Φ 230V is 10HP
Rest of the World Power:
– Canada: 575 V, 60Hz, 3Φ
– Asia & Middle East: 380V, 50Hz, 3Φ
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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
Suction
80 PSIG
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’
8’
• 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.
Ai
r
Pumps cannot pump air, so
the pump just spins,
performing zero hydraulic
work.
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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
Vertical Turbine or Submersible
Lake or Pond
Vertical Turbine or Suction Lift
River or Ditch
Suction Lift or Submersible
Public Source
Boost
Above Ground Tank
Flooded Suction or Boost
Below Ground Tank
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
Submersible
Turbine
Vertical 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)
Pumps
(HP)
Price Range
Applications
Low Profile (LP)
0-150
Up to 10
$9K – $15K
Large residential turf,
drip, boost applications
D Series
0-300
Up to 30
$10K-$25K
Schools, Parks, Sports
Field, Roads, Medians
Intermediate Flow
0-750
Up to 60
$15K-$35K
Resorts, Large Parks,
Nurseries, Zoos, Botanic
Gardens, Racetracks,
Stadiums
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
– 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
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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)
– 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, 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 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
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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 it’s 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 Bird’s powder coat paint scored a 10 on an
ASTM corrosion test. The competition’s 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
customer’s 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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