Suggested Specification Duophase System Variable Speed Constant Pressure (Vertical Turbine

Suggested Specification
DuoPhase System
Variable Speed Constant Pressure
(Vertical Turbine Pumps with Remote Tank)
Water Pressure Booster System

JOB NAME:

LOCATION:

CONSULTING ENGINEER:

DATE:

PARTI. GENERAL

1.01 Summary

Furnish and install a prefabricated DuoPhase model ______water pressure booster system as designed and manufactured by SyncroFlo.

1.02 References

A. American National Standards Institute (ANSI)

B. American Standard for Testing Materials (ASTM)

C. National Electric Code (NEC)

D. Underwriters Laboratory (UL) - Electrical Assemblies - UL 508

E. Occupational Safety and Health Administration (OSHA)

F. Food and Drug Administration (FDA)

G. National Fire Protection Association (NFPA) 70

1.03 System Description

The system shall be capable of automatically providing a controlled system pressure of _____ psig while at a flow rate from 0 to _____ GPM with a suction pressure of _____ psig minimum, _____ psig maximum. Incoming power shall be 3 phase/60 cycle/volts. Major components of this SyncroFlo DuoPhase system shall include vertical turbine pumps, vertical hollowshaft motors, HydroCumulator tank, gauge board, drip-tight shutoff valves, pressure and flow sequencing, and NEMA 1 control panel.

1.04 Submittals

A. Prior to Fabrication

Submit six copies to the Engineer for approval, including the following:

1. Certification that the manufacturer is a UL listed control panel manufacturer
2. Manufacturer's NRTL approval as a manufacturer of factory assembled pumping systems meeting OSHA safety standards
3. Easily readable functional description of the proposed equipment
4. Sequence of operation
5. Electrical schematic showing internal and external wiring connections
6. Test facility location, flow capacity, and all standard measurements taken
7. Pump performance curves plotting flow, head, efficiency, and NPSH required
8. Panel face diagram showing location of components
9. List of job name, city, state, system type, model number, consulting engineer, and contractor of the past 30 projects that used similar components
10. System data sheet listing all mechanical components and overall size
11. Control panel data sheeting listing major components and pressure switch settings
12. System warranty
13. Detail drawings or descriptions of all components listed in section 2.01

B. Prior to Final Acceptance

1. As-built drawings for all components and software listed above
2. Flow test results (X-Y plot)

1.05 Manufacturer's Qualifications

A. Equipment under this section shall be furnished by a single supplier.

B. The supplier shall have the sole responsibility for proper functioning of the system and equipment supplied.

C. Equipment shall be products that the manufacturer regularly produces.

D. Manufacturer shall have in place a quality assurance program.

E. Manufacturer shall have thirty years manufacturing and pump system application experience.

F. Manufacturer shall have a facility capable of testing the specified system at design flow and system pressure. Facility shall be capable of providing suction pressure throughout the specified range.

1.06 Warranty

The SyncroFlo internal multistage pumping assemblies and pressure regulating valves shall be guaranteed for one year from date of shipment against defective material and workmanship. The motors shall also be guaranteed for one year from date of shipment against burnout from any cause when equipped with the pumping system manufacturer's over-temperature protection and maintained according to instructions.

The complete pumping system shall be guaranteed in writing by the manufacturer for a period of one year from date of startup or eighteen months from shipment, whichever comes first, against defects in design, materials, or construction. Warranties and guarantees by the suppliers of various components in lieu of single-source responsibility by the manufacturer will not be accepted.

1.07 Spare Parts

Ship the following spare parts with the system: 1 pint of touchup paint, spare control power fuses, and spare light bulbs.

PART II. PRODUCTS

2.01 System Performance

A. Attributes

1. Normal Operation

The lead pump shall start based on system pressure. Lag pumps shall be sequenced on and off by an insertion-type paddlewheel flow sensor. As backup, lag pumps shall be sequenced on and off by the low system pressure sensor.

Automatic sequencing shall include the following features:

1. Successive and 24-hour alternation of equal capacity pumps
2. Pump overlap during 24-hour alternation
3. Lag pump exerciser function
4. Sequential pumps starts and stops
5. Minimum run and stop delay timer for each pump
6. Field adjustable time delay for low system pressure start signals

2. Low Flow Operation

Provide pressure sensor and a flow sensor to automatically control lead pump operation. These controls shall prevent lead pump short-cycling while maximizing the stored water available from the HydroCumulator tank.

3. Emergency Alarms and Control

Automatic alarm sequencing shall include the following features:

1. Sequence shifting that adjusts the pump sequence when any pump is disabled
2. Each pump shall have a temperature relief valve
3. Sequencing to reduce hydraulic or electric surges after power restoration or alarm reset
4. All pumps shall stop and require manual reset in the event of low system pressure, high system pressure, or low suction pressure alarm conditions.

B. Code Compliance

All packaged equipment shall be Nationally Recognized Testing Laboratory (NRTL) certified as a packaged pumping system suitable for the intended use in accordance with OSHA Federal Regulations and National Electric Code (NEC) Article 90-7. Safety certification label shall be permanently attached to pump system.

C. Factory Prefabrication

The entire booster system shall be factory prefabricated on a structural channel or I-beam steel stand with all interconnecting piping and wiring completed and operationally tested prior to shipment. The assembled package shall also include lug type butterfly or full port ball valves for isolating pumps. Suction and discharge headers shall be stainless steel. Header piping connections shall be flanged. All discharge-side piping shall be rated for the specified maximum suction pressure plus pump shutoff pressure. Tubing for pressure switches and gauges shall be copper with brass isolation valves. The only field connections required will be to the suction and discharge headers, and the power connections at the control panel.

D. Factory Test and Certification

The factory shall certify in writing that the water pressure booster system and its component parts have undergone a complete operational electric and hydraulic flow test prior to shipment. The test shall include a SYSTEM operating test from zero to 100% design flow and suction and system pressure conditions. The certification shall include copies of the flow and pressure test data as recorded on 11" x 17" X-Y plot. The system test may be witnessed by the owner, architect, consulting engineer, or contractor by reporting intent to do so to the factory no later than 2 weeks before expected system shipment. After flow test, manufacturer shall conduct hi-pot voltage test of system.

2.02 Components

A. Pumps

The pumps shall be of the vertical multi-stage design with the motor mounted directly to the top of the pump.The pumps shall be capable of operating at continuous temperatures up to 230 degrees F and working pressures of 175 psig. The pump motor stool, base plate, and shaft coupling shall be constructed of cast iron. The pump suction and discharge chambers, pump shaft, and diffuser chambers; shall be constructed of 304 stainless steel. The pump impellers and impeller seal rings; shall be constructed of 316 stainless steel The impellers shall be secured directly to the pump shaft by means of a stainless steel tapered split cone and locking nut or by a splined shaft arrangement. Intermediate and lower shaft bearings shall be bronze or tungsten carbide and ceramic. Pumps shall be equipped with a high temperature reversible mechanical seal constructed of tungsten carbide mounted in a stainless steel housing.

B. Motors

Electric motors shall be NEMA design B, constant speed, squirrel cage induction motors, having normal starting torque or breakdown torque not less than the value specified in NEMA Standard MG-1.Motors shall be rated for 15 HP, 460 Volts, 3-phase, 60 Hertz, TEFC, and a 1.15 service factor. The minimum Nema nominal motor efficiency must be 90%.Motors shall not be overloaded beyond their nameplate rating at any design condition or at any point within the operating range.

C. Check Valves

Provide non-slam check valves on the discharge branch of each pump.

D. HydroCumulator Tank

Provide a factory precharged, ASME code and NB stamped, HydroCumulator tank rated for 120 psig. Tank shall include a replaceable FDA approved flexible membrane to separate air and water. No water shall come in contact with the walls of the tank. The HydroCumulator tank shall be shipped precharged to the proper design conditions.

The tank shall be located near the top of the building, as indicated on the plans. Contractor shall install the tank and provide floor drain as required by the manufacturer for adequate serviceability.

E. Power and Control Panel

Furnish a single compartment SyncroFlo power and control panel. Enclosure and base pan shall be steel and coated with an industrial grade enamel. It shall house all control components and include control power transformer with control power light, pulsating audiovisual alarm system, and other necessary controls. Include fused disconnect switches with external operating handles, magnetic starters with 3-leg overload protection, pump run lights, and hand-off-auto selector switches for each pump. All of the electrical components shall be factory wired and tested by the pump system manufacturer in accordance with the provisions of the National Electrical Code. All control wires shall be individually numbered and each component shall be labeled accordingly. All internal wiring shall be copper stranded, A.W.G. with a minimum insulation of 90o C. Pump manufacturer shall certify the complete power and control assembly with the UL mark for Industrial Control panels.

F. Programmable Controller

Provide a UL listed programmable controller to control all pump starts and stops and indicate alarm conditions. The controller shall have the following features:

1. Nonvolatile EEPROM memory to prevent program loss due to power failure
2. 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
3. Input and output "on" status lights for ease of monitoring
4. Controller shall be designed for use in locations where electromagnetic noise, voltage spikes, 32 - 130o temperature, 35 - 85% humidity, and mechanical shock within the range certified by JIS 0912 exist.

G. Flow Sensor

FlowSensor shall be accurate within 1.0% of full scale and repeatable within .3%. Flow sensor shall detect flow to ½ FPS when flow rate is decreasing.

H. Operator Interface (Data Access Console)

The data access console shall be flush mounted in the door of the control panel. The console shall include an alphanumeric keypad with audible feedback. The following data shall be accessible through the operator interface:

1. One-touch access to display system status including flow rate (GPM), current pressure, any existing system alarm (or "NO ALARMS"), the current speed of the pumps (%), and the date and time.

2. One-touch access to Usage History, which may be reset. Usage History shall record the maximum instantaneous flow, along with the date and time.

3. A Setup Menu system for adjusting setpoints. Display and adjust flow and pressure set points and time delays. Set pump alternation to manual or automatic. Set the hour of the day for automatic alternation. Restore all factory defaults. Protect adjustable settings with a password.

4. One-touch access to an Alarm History of the past 10 alarms. Each log shall include individual pump run status, VFD mode, flow, and alarm type.

5. One-touch access to an Alarm List of all possible alarms and their current status.

J. Variable Frequency Drives

Each pump shall have its own variable frequency drive with the following features:

The drive shall be a voltage source, GTR or IBGT power transistor based inverter - PWM Type. The inverter shall use a high carrier frequency to reduce drive and motor noise.

Drive 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.

Self protection features shall include: under voltage and over voltage protection, current overload protection, short circuit protection, power failure protection, ground fault protection, and over-temperature protection.

A four digit LED readout shall be provided to indicate the following: drive enabled, output frequency, and all VFD fault conditions.

The drive shall be capable of automatically restarting 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.

K. PRESSURE TRANSMITTER

A digital pressure transmitter shall be connected to the system header. 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.

L. Instrumentation and Emergency Controls

1. Temperature relief valve shall be mounted in the pump casing or seal bypass line for fast, accurate response.
2. Individual 4½" ASA grade A pressure gauges for each pump, system, and suction pressures.
3. All pressure sensors shall be control panel mounted.
4. Pressure gauges shall be mounted on a gauge board with 5 sides enclosed, located adjacent to the control panel.
5. Provide pressure sensors for high system pressure, low system pressure, and low suction pressure conditions.

PART III EXECUTION

3.01 Installation

The contractor shall install the system in accordance with the manufacturer's recommendations.

1. Include a floor drain sized according to local code. Drain shall provide emergency drainage to prevent building damage in the event of seal failure, over- temperature, or tank discharge.
2. Install pump system on a concrete pad at least _____" tall.
3. Anchor pump system in accordance with system manufacturer's recommendations.
4. Pipe temperature relief valve discharge to drain
5. Install isolation valves on each header.
6. Pipe pumping system bypass line with isolation valve
7. All field anchoring, piping, and wiring shall comply with local codes.

3.02 Startup Service

The service of a factory-trained representative shall be made available on the jobsite to check installation, supervise startup, and instruct the operator.