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Water Supply Pumping System O&M Manual Version 1March??, 2015

Water Supply Pumping System Operation & Maintenance (O&M)

ManualLas Delicias, El Salvador

(DRAFT)By,

Engineers Without Borders (EWB) - USA, Philadelphia Professional Chapter (Contact info should be included)

in cooperation with,

<<insert key local contact names and contact info>>

Version No.

Purpose of Update By Date

1? Initial? EWB and ? ? March 2015


Contents1.0 Water System Overview..............................................................................................................9

1.1. Background..............................................................................................................................9

1.2. Supply Side..............................................................................................................................9

1.2.1. Storage Tanks....................................................................................................................9

1.2.2. Pumps..............................................................................................................................10

1.3. Distribution Side.....................................................................................................................10

1.4. Increased Efficiency and Reduced Cost.................................................................................11

2.0 Pumping System Operation.......................................................................................................14

2.1. Manual Operation of the Pumping System.............................................................................21

2.2. Continuous Automatic Operation of the Pumping System......................................................23

2.3. Timed Automatic Operation of the Pumping System..............................................................25

3.0 Distribution Piping Operations - To be added later....................................................................29

4.0 Water Quality – To be added later.............................................................................................29

App. A. Preventative Maintenance Requirements...........................................................................30

App. B. Troubleshooting Guide........................................................................................................30

App. C. Booster Pump Backup Configuration..................................................................................30

App. D. Manufacturer’s Instructions (for the equipment we have purchased?)................................41


1.0 Water System Overview

1.1.Background

The Las Delicias water system services the approximately 500 homes in the community plus the school, community center, daycare center and church. Improvements were made to the system in 2013–2015 to increase its engineering efficiency and take advantage of reduced electricity rates. These improvements consisted of the construction of a new water storage tank and the installation of new pump control components. The overall objective of these improvements was to allow more water to be pumped and distributed for the same cost of electricity. These improvements are discussed in the subsections below.

1.2.Supply Side

A diagram of the supply side of the water system is shown in Figure 1. The water source is a well at a relatively low elevation.

1.2.1.Storage Tanks

The water is pumped from the well to the following four storage tanks:

Tanks 1 and 3, which are at relatively high elevations. They have a capacity of approximately 34,900 gal and 25,400 gal, respectively. They are referred to as the alta (upper) tanks.

Tanks 4 and 5, which are at an intermediate elevation. They have a capacity of approximately 17,400 gal and 11,200 gal, respectively. They are referred to as the bajar (lower) tanks

o Tank 4 is the tank that was added as part of the improvement project. It was built adjacent to Tank 5.

o Prior to the improvement project, Tank 5 was fed by water from the higher elevation tanks (so it was essentially on the distribution side of the system). As part of the improvement project, Tanks 4 and 5 were connected by an overflow line from Tank 4 so that Tank 5 is now on the supply side. The combined capacity of these two tanks is approximately 28,600 gal.

Note: Tank 2 is fed from a spring and is not part of this system.


1.2.2.Pumps

There are two pumps in the system:

A 15 hp submersible pump that draws water from the well into a cistern.

A 60 hp booster pump that pumps the water from the cistern to either Tanks 1 and 3 or to Tank 4 (which then overflows into Tank 5).

Control of the submersible pump is by an across-the-line motor starter. It operates at a single speed and pumps approximately 200 to 260 gpm. This range in the flowrate is speculated to depend on the level of the water table feeding into the well.

Control of the booster pump is by a variable frequency drive (VFD). The VFD was added as part of the improvement project to allow the pump to operate at different speeds: a faster speed for pumping to Tanks 1 and 3 (at the high elevations) and a slower speed for pumping to Tank 4 (at the intermediate elevation). At the faster speed and pumping to the higher elevations, the booster pump has a flowrate of approximately 200 gpm. At the slower speed but pumping to the intermediate elevation, the booster pump has a flowrate of approximately 260 gpm.

The VFD gets hot as it operates. To prevent it from overheating, a heat exchanger was also added. [We need to add how to turn on the heat exchanger, what to do if it fails, etc. in later sections of this manual.]

Heat exchanger section.

[??? How do we want to address throttling of the booster pump based on the recent observations that it was pumping around 260 gpm?]

1.3.Distribution Side

The water is distributed to the community from Tanks 1, 3, 4 and 5 by manual operation of a system of valves. Generally, the upper portion of the community receives water that was pumped to Tanks 1 and 3, and the lower portion of the community receives water that was pumped to Tanks 4 and 5. A drawing of the distribution side of the water system is shown in Figure 2. [We need to add Figure 2.]


1.4.Increased Efficiency and Reduced Cost

As noted above, the overall objective of the 2013-2015 improvement project was to allow more water to be pumped and distributed to the community for the same cost of electricity. The primary means of achieving this objective was increasing the engineering efficiency of the system. This was accomplished by the combination of adding storage capacity at the intermediate elevation (Tanks 4 and 5) and adding the VFD to allow the booster pump to run at a slower speed when it is pumping to the intermediate elevation. The booster pump uses less electricity at the slower speed, leading to a reduction in the amount of electricity required to provide water to lower portion of the community.


Figure 1. Supply side of the water system.TO DO ON FIGURE: Correct spelling of field, label the cistern, take out word new by Tank 4.Note: The new features added as part of the improvement project are shown in dashed boxes.


Figure 2. Water distribution system.[Insert the plan view that shows which tanks serve which homes and buildings, if we decide to do this.]


2.0 Pumping System Operation

There are three modes of operation available with this system:

Manual: operator attends system. Continuous Automatic: operation using level control switches located in the cistern. Timed Automatic: operation using level control switches located in the cistern plus a timer.

Figure 3 is a photograph of the fronts of the booster pump, submersible pump and VFD control panels. Figures 4a and 4b are close-up photographs of the submersible pump panel and the booster pump panel, respectively. Note that the instructive markings drawn on the booster pump panel and visible in Figure 4b were drawn after the photograph in Figure 3 was taken.

The following sub-sections reference these figures and provide step-by-step procedures to run the pumps in either the Manual or one of the two Automatic modes.

Appendix A contains a list of preventative maintenance guidelines. Appendix B contains a list of troubleshooting suggestions. In the event that there is a failure of the VFD, the booster pump can be controlled using the original soft start controller after wiring in the booster panel is modified. This reconfiguration is referred to as Booster Pump Backup. Figures and procedures to adjust the wiring are provided in Appendix C.

Add heat exchanger section.

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Figure 3: Pump and VFD control panelsFrom left to right: 60 hp booster pump panel (photo taken prior to markings shown in Figure 4a) 15 hp submersible pump panel VFD panel (installed in 2014)

[Take new photo with current system. Show translation of front of panel in English.]

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Figure 4a: Submersible pump panel showing the three position selector switch indicating light and the Start (green) / Stop (red) push buttons.

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Figure 4b: Booster pump panel.Note: In the photograph the system is set for manual operation to fill Tanks 1 and Tank 3, the alta

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tanks. There is also a note explaining that if the panel is to be opened, the breaker beside the panel needs to be opened. The note tells the operator to “look” (with eyes) and ensure the breaker is open (panel is de-energized.) prior to opening the panel door.

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2.1.Manual Operation of the Pumping System

The following steps are used to start and stop the pumping system in Manual mode. Note: during manual operation, the water level control switches in the cistern are not active.

Start the pumping system in Manual mode:

1. On the front of the booster pump panel (see Figure 4b) there is a “TANQUE SELECT” switch. Select either “ALTA” for the upper elevation tanks (Tanks 1 and 3) or “BAJAR” for the lower elevation tanks (Tanks 4 and 5).

2. Locate the three position switch on the submersible pump panel (see Figure 4a MANUAL-OFF-AUTO). Select “MANUAL”. Note: when the submersible pump mode selector switch is in the “OFF” position the pump will not run.

3. Locate the three position switch on the booster pump panel (See Figure 4b MANUAL-OFF-AUTO). Select “MANUAL”. Note, when the booster pump mode switch is in the “OFF” position the pump will not run.

4. Press the green button located beneath the three position switch on the submersible pump panel to start the submersible pump. (The green indicating light will turn on.)

5. Press the green “START” button on the booster pump panel (marked as Encender (manual)). It is located beneath the three position switch on the booster pump panel. (The green indicating light “MARCHA” will turn on.)

Stop the pumping system in Manual mode:

1. To stop operation of the booster pump press the red “STOP” button located directly beneath the green “START” button. The three-position switch may be moved to “OFF” (recommended).

2. To stop operation of the submersible pump, press the red button located directly beneath the green start. The three-position switch may be moved to “OFF” (recommended).

Note: during operation a red indicating light will illuminate to show when the booster pump drive is faulted (“FALLA”?).

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2.2.Continuous Automatic Operation of the Pumping System

The Continuous Automatic mode allows the system to run continuously until manually halted. There are two level control switches located in the cistern beside the booster pump which are active when in automatic mode.

The high level control switch will stop the submersible pump when the water level in the cistern reaches the high setpoint to prevent overfilling of the cistern.

The low level control switch will stop the booster pump when the water level in the cistern water falls below the low setpoint to prevent the booster pump from running the cistern empty (this would damage the pump). If the low level control switch stops the booster pump, a yellow indicating light “BAJO NIVEL” (low level) on the booster panel will illuminate. The low level switch also controls the submersible pump; it allows the pump to run once the water level falls below the low level.

The following steps are used to start and stop the pumping system in Continuous Automatic mode.

Start the pumping system in Continuous Automatic mode:

1. On the front of the booster pump panel (see Figure 4b) is a “TANQUE SELECT” switch. Select either “ALTA” for the upper elevation tanks (Tanks 1 and 3) or “BAJAR” for the lower elevation tanks (Tanks 4 and 5).

2. Locate the three position switch on the submersible pump panel (see Figure 4a MANUAL-OFF-AUTO). Select “AUTO”.

3. Locate the three position switch on the booster pump panel (see Figure 4b MANUAL-OFF-AUTO). Select “AUTO”.

4. Locate the “AUTO SELECT” switch located on the right hand side of the booster pump panel. Select “NORMAL.”

5. Press the green button located beneath the three position switch on the submersible pump panel to start pump. (A green indicating light will turn on.)

6. Press the green “BAJA DEMAND INCIAR” button located on the right hand side of the booster pump panel to start the booster pump in automatic mode. (A green indicating light “BAJA DEMANDA MARCHA” will turn on.)

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Note: the system will operate continuously in this Continuous Automatic mode. The cistern will not overflow, but the storage tanks (Tanks 1, 3, 4 or 5) could overflow if they are not monitored by the operator when operating in this mode.

Stop the pumping system in Continuous Automatic mode:

1. To stop operation of the booster pump press the red “BAJA DEMANDA DETENER” located on the right hand side of the booster pump panel. The three-position switch may be moved to “OFF” (recommended).

2. To stop operation of the submersible pump, press the red button located directly beneath the green start. The three-position switch may be moved to “OFF” (recommended).


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2.3.Timed Automatic Operation of the Pumping System

The Timed Automatic mode allows the system to run for a preset amount of time. The option to operate in this mode was added as part of the 2013-2015 improvements so that the system can be operated at night to take advantage of “off-peak” electricity rates.

The following steps are used to start the pumping system in Timed Automatic mode. Also included are steps to force the system to stop before the timer stops the system.

Start the pumping system in Timed Automatic mode:

1. On the front of the booster pump panel (see Figure 4b) is a “TANQUE SELECT” switch. Select either “ALTA” for the upper elevation tanks (Tanks 1 and 3) or “BAJAR” for the lower elevation tanks (Tanks 4 and 5).

2. Locate the three position switch on submersible pump panel (see Figure 4a MANUAL-OFF-AUTO). Select “AUTO”.

3. Locate the three position switch on the booster pump panel (see Figure 4b MANUAL-OFF-AUTO). Select “AUTO”.

4. Locate the “AUTO SELECT” switch located on the right hand side of the booster pump panel. Select “BAJO” (marked RELOJ/TIMER.)

5. Press the green button located beneath the three position switch on the submersible pump panel to start pump. (A green indicating light will turn on.)

6. Press the green “BAJA DEMAND INCIAR” button located on the right hand side of the booster pump panel to start the pump in automatic mode. (A green indicating light “BAJA DEMANDA MARCHA” will turn on.)

Operation will halt at preset time.

Note: the system will operate continuously in this Timer Automatic mode for the preset amount of time. The cistern will not overflow, but the storage tanks (Tanks 1, 3, 4 or 5) could overflow if the timer is set for too long of a period. Also, they may not be filled to the desired levels if the timer is not set for a long enough period.

IS RESET BUTTON UNUSED.

Force the pumping system to stop in Timed Automatic mode:

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1. Force the booster pump to stop by pressing the red “BAJA DEMANDA DETENER” located on the right hand side of the booster pump panel.

2. Force the submersible pump to stop by pressing the red button located directly beneath the green start button.


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3.0 Distribution Piping Operations - To be added later

4.0 Water Quality – To be added later

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App. A. Preventative Maintenance Requirements

To be filled in.

App. B. Troubleshooting Guide

To be filled in.

App. C. Booster Pump Backup Configuration

[Perhaps mesh this as a subsection under troubleshooting.]

Control of the booster pump is by the variable frequency drive (VFD). If the VFD fails the booster pump can be run by the original soft start controller. In order to run in this Backup configuration, several wires in the control enclosure, shown in Figure 5, must be moved as shown in Figures 6 and 7. An electrician should be used for this change.

The steps for moving the wires are as follows:

1. The following 24 volt wires must be moved to the adjacent terminal: 24C, 24+, 221

2. The following 120 volt wires must be moved to the adjacent terminal: 120V, 201, 251, 281 (

3. The following 480 volt wires must be moved to the adjacent terminal: (Inputs) 2L1, 2L2, 2L3, (Outputs) T1, T2, T3 (see Figure 7).

For control wires, simply shift wires down to transition from VFD to across the line starter. See attached electrical schematic.

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Figure 5: Booster pump panel wiring

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Figure 6: Control wiring for VFD.

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Figure 7: Control wiring for old soft starter controller.

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Figure 8: 480V Power Re-wiring, please refer to full electrical schematic.

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App. D. Manufacturer’s Instructions (for the equipment we have purchased?)

To be filled in and referred to in the main body of the manual.

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