Pumps and Day Tanks - Critical Fuel Systems

Report
Pumping Systems
and
Day Tanks
Presented
By
Ken Still, CB Kramer
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Agenda
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Introduction
Basic System
Generator Pump Selection
Boiler Pump Selection
Pump Types and Limits
Day Tanks
Day Tank Accessories
Pump and Day Tank Control
Conclusion
Introduction
• Pump sets and day tanks typically operate as a
single system with a common controller.
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Basic System
Monitoring
and Control
4
Generator Pump Selection
• 7 gph per 100KW = GPH
• GPH x # gensets = GPH Total
• GPH total x 4 = transfer
pump size
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Boiler Pump Selection
Typical boiler system selection
• 30gph per 100 BHP = GPH
• GPH x # boilers = GPH total
• GPH total x 2.5 – 3 to
accommodate boiler mounted
pump total flow
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Typical System w Boiler Pumps
• Boiler Mounted pump limitations
• Tight pump suction limits; 15”hg – 3psi
• Boiler pump single point of failure
• Boiler pumps requires 2.5-3 times flow rate
(sometimes 10-15x more) from transfer pump
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Typical System w Boiler Pumps
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Alternative Boiler System
80 - 90
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Pump Types
SUCTION PUMP SET
PRESSURE (submersible) PUMPS
• Match the pump to the application
• Suction or pressure type
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Pump Sets
• Submersible Pumps
• Pro
• Submerged suction
• Simple single tank
systems
• Simple installation
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• Con
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Pressurized in-ground piping
Limited sizes
Difficult maintenance
Unmanned
Piping Monitoring
Complicated multi-tank
redundant systems
Submersible Pump Installation
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Pressure Pump System
• Redundancy
• Each tank must have
redundant pumps
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Pump Sets
• Suction Pumps
• Pro
• Buried piping under
suction
• Ease of maintenance
• Simpler multi tank
systems
• Simple installation
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• Con
• Limited suction ability
• Additional floor space
Suction Pump System
• Redundancy
• A single duplex pump
set satisfies
redundancy
requirement
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Suction Pump Set Options
• High Pressure 100psi
• Low Pressure <50 psi
mechanical
pump set
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pump set with
motor starter panel
Pump set with motor starter
and logic control panels
Suction Pump Set Construction
Control panel(s)
Relief valves
Flow switch
Priming funnel
Suction strainer(s)
Gauges
Pump/motor sets
Reservoir base w/leak switch
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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
Fixed to Equipment
Flexible Connectors
Fixed to Building
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Piping and Valves
• Vibration Isolation CORRECT
Fix to Equipment
Flexible Connector
Fix to Building
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Isolation Pads
or Springs
Basic System
Monitoring
and Control
Day Tanks
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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
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Day Tanks
• Stand Alone
• Generator Belly Tank
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Belly Tanks
• Completely isolate tank
from generator
Flexible fuel hose
Spring isolation
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Independent Day Tanks
• Double Wall
• Return Pump Option
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Independent Day Tanks
• Single Wall
• Single Wall w/Tub Type Rupture Basin
• Available w/o rupture basin
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Day Tank Accessories
• Automatic fill manifold
• Multi-tank applications
• Sized to precisely match required flow
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Day Tank Accessories
• Return Pumps
• Manipulate tank level
to test controls
• Refresh fuel if it
overheats
• Empty day tank in
emergency
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Day Tank Accessories
• Accessories
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Vent Caps
Level Indication
Level Monitoring
Temperature Monitoring
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
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Day Tank Construction
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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
Pump and Day Tank Controls
• Primary functions
• Monitor day tank level
• Start/stop pumps
• Open/close fill manifolds
• Secondary functions
• Leak detection
• Communications and alarms
• Auxiliary controls
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Pump and Day Tank Controls
• Safe Design
• High voltage separate
from low voltage
• Easy serviceability and
compliance to NFPA
and OSHAE standards
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Low voltage logic control
not to exceed 49 volts
High voltage motor
control panel
Pump and Day Tank Controls
• NFPA 70e
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Conclusion
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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!
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Conclusion
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Basic System
Generator Pump Selection
Boiler Pump Selection
Pump Types and Limits
Day Tanks
Day Tank Accessories
Pump and Day Tank Control

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