F-BIC-1000
“At A Glance”
Backflow Irrigation Control Station
BIC-1000
www.wattsreg.com
Table of Contents
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Existing & Current Irrigation Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Backflow Irrigation Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Backflow Irrigation Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Irrigation Component Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Common Field Situation #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Common Field Situation #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Common Field Situation #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Annual Maintenance Cost Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2
Purpose
Popular belief implies that system failure occurs more frequently
after the master valve and flow meter. It suggests that the system’s only defense and safety mechanism is the flow meter.
Without the flow meter, the system will continue to flow until the
irrigation cycle has completed the run schedule.
There can be no compromise for what is known in advance to
cause damage from system failure. To allow damage is questionable by all parties and ultimately more expensive over the life
of the system.
The common system design suggests that a master valve and
a flow meter be installed to prevent possible flooding due to
broken pipes, missing sprinkler heads, vandalism, etc. These
occurrences would ultimately result in additional costs and
potential liability to the Owner or the City.
What if there was a more accurate way to analyze the cause of
break? From the break-to the flow meter-to the master valve-to
the cause – PRESSURE. We take great pleasure to introduce a
concept that was developed with a simple, clear, basic analysis
of the entire system and its pressure response profile. A backflow irrigation control station built with the best practice design
principles.
The focus remains on the master valve and flow meter; lending
little or no consideration to the piping system from the meter-to
the backflow-to the master valve. This part of the system (before
the master valve) is subjected to the highest of all pressure available and is on 24 hours a day, seven days a week, 52 weeks of
the year. The system after the master valve is only pressurized
during the irrigation cycle that may last 2-4 hours day.
The purpose of this system is to maximize operating performance and to further eliminate causes of damage to the system.
The Existing & Current Irrigation Design
• Allows piping system after the master valve to be subjected to
damage when the master valve is turned on/off and piping
system is loaded into a 0psi system.
• All or most components of operation and safety to the system
are buried and are not easily accessible. This often requires
cutting or breaking the line for replacement. The parts are
often spread out and can be difficult to locate.
• The existing irrigation design does not allow a quick visual of
the current pressure reading at all times.
• The backflow assembly is sometimes installed incorrectly;
upside down, wrong strainer, no unions, double checks have
been installed where RP type is required, incorrect model, etc.
• High-pressure fatigue on piping system results in excessive
failure and maintenance (where applicable). Further, unaccounted or non-billable water losses may occur.
• Master valve repairs are time consuming due to additional
steps needed for accessibility. Same for flow meter repairs
(where applicable).
• Allows backflow assembly to have in excess of 175psi or
greater taking it out of warranty (where applicable) on the
existing irrigation design.
• The existing irrigation design does not allow automatic monitoring for control of excessive high pressure on piping when
the irrigation system regulator should fail or creep to unacceptable pressure levels beyond the set point.
• Every line break can be a major source of water loss to the
system especially if it is before the master valve. The existing
and current design with a flow meter only shuts off the irrigation system down stream of the master valve. In some installations, this allows the long run of piping from the water meter
to be subject to breakage as it is not controlled by the master
valve shutoff.
• The existing design allows irrigation system to work with
severe high pressure. Most commonly, repairs are made and
system is re-pressured to repeat the same breaks. These
repairs are often of an urgent nature and may require costly
overtime to complete and inconvenience to the customer.
3
The Backflow Irrigation Control Station
• The BIC Station’s ACV regulator component shifts the pilot
and it preloads all pressure lines to a lower sustainable pressure of 20psi. This eliminates the need for high pressure on
the system when the sprinkler irrigation is shut off. The BIC
Station’s operating design pressure is only activated when the
master valve turns on.
• The Backflow Irrigation Control Station (BIC Station) takes into
consideration by design with integrity and assurance to the
system and the customer that the system is protected.
• Components of the BIC Station are above ground level on a
stainless steel station. Repairs can be done without the conventional digging up of components buried underground.
• The BIC Stations uses a Diaphragm Actuated, Pilot
Controlled, Automatic Control Valve (ACV) to set the pressure
rather than using a Direct Acting (DA) regulator. The ACV
pressure regulator fall off is significantly lower than a DA regulator and holds set pressure over a wide range of flow rates.
As more flow or demand is called for, the ACV will open more
while holding pressure at the system design setting. The existing conventional DA regulator drops off pressure when more
flow is needed. Thus requiring a much higher DA regulator
pressure initial set-point to start with to account for the loss or
drop off.
• The BIC Station combines the master valve, regulator valve,
preload valve, and high-pressure lockout switch and backflow
preventer all in one easily located component.
• Unlike the current and existing irrigation design, repairs will
not be subjected to mud, dirt, or debris going into the valve
component body during removal and repair.
• The BIC Station’s system components for electrical connections are also above ground. Moisture at the wire nut connection is highly unlikely. In the current system design, a high
electrical resistance at this connection from moisture would
cause a drop in voltage and possibly be a cause for failure.
Sometimes, the entire component of the current system is
replaced due to misdiagnosis.
• The entire irrigation pressure piping system after the master
valve is never allowed to drain off to 0psi. In some cases, this
drain off occurrence subjects the piping system to excessive
damage when the master valve is turned on.
• All of the BIC Station’s components are flanged type, nut and
bolt modular design for easy replacement.
• The entire irrigation pressure piping system is preloaded with
a field adjustable, low flow, low pressure control valve. This in
combination with a higher set point on the regulator and master valve creates a buffer when turned on. This eliminates
water hammer due to excessive velocities, pressure spikes,
and excessive pressure buildup.
• Proper selection and installation of the backflow preventer,
strainer, unions / maintenance disconnects is ensured by certified factory assembly and test.
• This is a 24-hour monitoring system of the outlet pressure for
excessive buildup above set operating pressure.
• The backflow assembly warranty is not exceeded.
• The BIC Station’s system monitoring of pressure will lockout
the 24-volt circuit with a field adjustable excessive pressure
switch; making it inoperable. This lockout will not let the irrigation pressure piping system be subjected to high-pressure
shock or water hammer when remote control valves (RCV)
open and close for days and months unnoticed like on conventional irrigation systems now being used.
• The backflow assembly is not severely damaged or worn out
in a shorter period of time.
• Water is conserved by reducing or eliminating the line breaks
caused by high pressure – water hammer, and by providing a
shut-off at the beginning of the system rather than in the middle of the system.
4
Backflow Irrigation Control Station
24V Master Valve
Watts ACV Regulator
Pressure Switch
2" 009 PCQT
1 4
/ " Preload Pilot
1 2
/ " 5300A
Adj Relief
1 8
(20 / )
2" SS Wye-Strainer
2" Butterfly Shutoffs (2)
(35)
(465/8)
Irrigation Component Control Station
Automatic Control Valve
High Pressure Regulator
Pressure Auto Shifting
Control Valve
Backflow
Preventer
Automatic Control Valve
Manual Override On ACV
24 Volt Master Valve
High Pressure Regulator
Low Pressure Preload Regulator
High Pressure Lockout
High Pressure
Relief Valve
High Pressure
Relief Valve
SS Strainer
90psi System On
25psi System Off
Shutoff
Valve (2)
Water
Meter
Main
Highway
90psi System On
25psi System Off
Flow Meter
Shutoff Valve (2)
80psi System On
25psi System Off
25psi System Off
Typical Remote Control
Irrigation Valves
Below Ground
Typical 110-150psi
When the master valve opens at cycle start of 25psi
When master valve closes at the end of the water cycle of 80psi
All system pressures shift up to operating pressures of 80-90psi
All system pressures drop to a stand by pressure of 25psi
From the operation of the ACV pressure auto shifting valve
From the operation of the ACV pressure auto shifting valve
5
Maintenance Costs
The following information is for comparison purposes only. The scenarios, method of solution, and costs are based on our
experience in collaboration with landscape professionals.
Common Field Situation #1
Water flow has decreased and the system has shut down. It is determined that the regulator is damaged and needs immediate
attention. The regulator’s location is known and identified as a 2”.
Current and Existing Irrigation Design
Backflow Irrigation Control Station
Action Taken:
Action Taken:
1. Dig up ground to retrieve regulator.
1. Perform diagnostic test on the BIC Station that will identify
the component on the regulator that is damaged.
2. Cut the mainline to remove the regulator component and
replace.
2. Repair the identified component parts only.
3. Install the new regulator and retrofit using schedule 40 piping.
4. Backfill area with dirt and return ground to original state
(groundcover, shrubs, etc.)
Labor:
$125
Occurrence Rate:
$170
Generally, the pressure regulator is not repaired inline due to the
difficulty of the repair. The mainline will have to be cut and retrofitted back.
Materials:
Labor:
$500
Materials:
$200
Average Occurrence P/Yr:
Annual Costs:
Annual Costs:
$300
Occurrence Rate:
$45
Average Occurrence P/Yr:
10
$1,700
10
$5,000
Common Field Situation #2
Low water coverage and continual leaking. It is determined that the master valve is damaged and needs immediate attention.
Current and Existing Irrigation Design
Backflow Irrigation Control Station
Action Taken:
Action Taken:
1. Dig up ground to inspect and retrieve master valve.
1. Perform diagnostic test on the BIC Station that will identify
the component on the valve that is damaged.
2. Replace internal components if master valve is worth saving.
2. Repair the identified component parts only.
3. If not worth saving, the entire master valve is replaced from
mainline.
The internal wetted parts of the master valve are stainless steel.
Repair and/or replacement of the master valve itself due to corrosion are less likely to occur.
4. Retrofit new master valve from mainline.
5. Backfill area with dirt and return ground to original state
(groundcover, shrubs, etc.)
Labor:
$125
$170
Labor:
$300
Occurrence Rate:
Occurrence Rate:
$475
Materials:
$175
Average Occurrence P/Yr:
Materials:
Average Occurrence P/Yr:
10
10
Annual Costs:
Annual Costs:
$45
$4,750
6
$1,700
Common Field Situation #3
There is a break in the mainline and the sprinkler system is down. Other than the fact that the break is in a turf area, the exact location
is unknown. The size of piping is also unknown.
Current and Existing Irrigation Design
Backflow Irrigation Control Station
Action Taken:
Action Taken:
1. Attempt to locate leak by excessive digging. Potential wire
damage may occur during this process.
1. The same actions as taken on the current design would still
need to be taken.
2. Leak is found; parts are ordered.
However, the percentage of a mainline break occurring due to
high-pressure buildup is extremely low with the BIC Station. The
design of the system would activate a “high-pressure lockout”
and would be inoperable until the issue is addressed. Therefore,
the occurrence rate would drop to 1 instead of 10.
3. Cut and remove damaged pipe.
4. Repair as needed.
5. Backfill area with dirt and return ground to original state
(groundcover, shrubs, etc.)
Labor:
$500
Labor:
$500
Occurrence Rate:
$540
Occurrence Rate:
$540
Materials:
Materials:
$40
Average Occurrence P/Yr:
$40
Average Occurrence P/Yr:
1
10
Annual Costs:
Annual Costs:
$540
$5,400
Annual Maintenance Cost Summary
Based On 10 Occurrences Only
Field Situation #
1
2
3
TOTALS
Existing
$5,000
$4,750
$5,400
$15,150
BIC Station
$1,700
$1,700
*$540
$3,940
BIC Station
Total Savings
$3,300
$3,050
$4,860
$11,210
*1 occurrence, see explanation on previous page
Conclusion
Numerous common field situations such as the ones previously described create a significant cost burden and customer dissatisfaction levels. Our state-of-the art design will reduce and/or eliminate these costs by early detection and preventative methods.
Available Models:
Backflow Irrigation Station: BIC-1000
Satellite Station: IC-1000
ACV Only: 115-4-74
7
For Technical Assistance Call Your Authorized Watts Agent.
HEADQUARTERS: Watts Regulator Company
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978 688-1811
978 794-1848
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EXPORT Hdqtrs.: Watts Regulator Co.
815 Chestnut St., North Andover, MA 01845-6098 U.S.A.
978 688-1811
978 794-1848
0426
Watts USA website: www.wattsreg.com
Watts Canada website: www.wattscanada.ca
F-BIC-1000 0438
© Watts Regulator Co., 2004
Printed in U.S.A.