Pumping Systems and Day Tanks Presented By Ken Still, CB Kramer 1

Agenda Introduction Basic System Generator Pump Selection Boiler Pump Selection Pump Types and Limits Day Tanks Day Tank Accessories Pump and Day Tank Control Conclusion 2

Introduction Pump sets and day tanks typically operate as a single system with a common controller. 3

Basic System 4 Monitoring and Control

Generator Pump Selection 7 gph per 100KW = GPH GPH x # gensets = GPH Total GPH total x 4 = transfer pump size 5

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Boiler Pump Selection 30gph per 100 BHP = GPH GPH x # boilers = GPH total GPH total x 2.5 – 3 to accommodate boiler mounted pump total flow 7 Typical boiler system selection

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Typical System w Boiler Pumps Boiler Mounted pump limitations Tight pump suction limits; 15hg – 3psi Boiler pump single point of failure Boiler pumps requires times flow rate (sometimes 10-15x more) from transfer pump 9

10 Typical System w Boiler Pumps

Alternative Boiler System

Pump Types Match the pump to the application Suction or pressure type 12 SUCTION PUMP SETPRESSURE (submersible) PUMPS

Pump Sets Submersible Pumps 13 Pro Submerged suction Simple single tank systems Simple installation Con Pressurized in-ground piping Limited sizes Difficult maintenance Unmanned Piping Monitoring Complicated multi-tank redundant systems

14 Submersible Pump Installation

Pressure Pump System 15 Redundancy Each tank must have redundant pumps

Pump Sets Suction Pumps 16 Pro Buried piping under suction Ease of maintenance Simpler multi tank systems Simple installation Con Limited suction ability Additional floor space

Suction Pump System 17 Redundancy A single duplex pump set satisfies redundancy requirement

Suction Pump Set Options High Pressure 100psi Low Pressure <50 psi 18 mechanical pump set pump set with motor starter panel Pump set with motor starter and logic control panels

Suction Pump Set Construction 19 Pump/motor sets Control panel(s) Gauges Priming funnel Relief valves Flow switch Suction strainer(s) Reservoir base w/leak switch

Suction Pump Set Construction Recommend welding of fuel piping over 1. A threaded pipe retains less than ½ of wall thickness

Piping and Valves Vibration Isolation WRONG 21 Flexible Connectors Fixed to Building Fixed to Equipment

Piping and Valves Vibration Isolation CORRECT 22 Flexible Connector Fix to BuildingIsolation Pads or Springs Fix to Equipment

Basic System 23 Monitoring and Control Day Tanks

Built and certified to UL142 Pressure tested to 5 psi Almost always used on generators Stand Alone Belly Tank Sometimes used on boilers 24

Day Tanks Stand Alone Generator Belly Tank 25

Belly Tanks Completely isolate tank from generator 26 Flexible fuel hose Spring isolation

Independent Day Tanks Double Wall Return Pump Option 27

Independent Day Tanks Single Wall Single Wall w/Tub Type Rupture Basin Available w/o rupture basin 28

Day Tank Accessories Automatic fill manifold Multi-tank applications Sized to precisely match required flow 29

Day Tank Accessories Return Pumps Manipulate tank level to test controls Refresh fuel if it overheats Empty day tank in emergency 30

Day Tank Accessories Accessories Vent Caps Level Indication Level Monitoring Temperature Monitoring 31

Day Tank Sizing No rules or regulations requiring minimum sizes. Some regulations limiting maximum sizes IFC limit to 660 gallons in certain installations Generator KW x.07 x hours desired = tank size Often space dependent 32

Day Tank Construction Fittings in top of tank (except drain) Easy access to all fittings Drop tubes on all supply and returns Keep the inflow away from generator suction Inspection and Extra Ports 33

Primary functions Monitor day tank level Start/stop pumps Open/close fill manifolds Secondary functions Leak detection Communications and alarms Auxiliary controls 34 Pump and Day Tank Controls

Safe Design High voltage separate from low voltage Easy serviceability and compliance to NFPA and OSHAE standards 35 High voltage motor control panel Low voltage logic control not to exceed 49 volts

Pump and Day Tank Controls NFPA 70e 36

Conclusion Sizing – 70GPH per MW or 30GPH per 100BHP Oversizing / Hot Oil Return / BLR Requirements Suction or Submersible (Pressure) Pumps Day Tank (Stand Alone – Base Tank) Construction (Double Wall – Rupture Basin – Connections) Flow Control Manifolds Return Pumps We can help with installation and sizing issues! 37

Conclusion 38 Basic System Generator Pump Selection Boiler Pump Selection Pump Types and Limits Day Tanks Day Tank Accessories Pump and Day Tank Control