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Pumping Systems and

Day Tanks

PresentedBy

Ken Still, CB Kramer

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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

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Introduction• Pump sets and day tanks typically operate as a

single system with a common controller.

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Basic SystemMonitoring and Control

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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

• 30gph per 100 BHP = GPH• GPH x # boilers = GPH total• GPH total x 2.5 – 3 to

accommodate boiler mounted pump total flow

Typical boiler system selection

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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

• Match the pump to the application• Suction or pressure type

SUCTION PUMP SET PRESSURE (submersible) PUMPS

Pump Sets

• Submersible Pumps

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• 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

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Submersible Pump Installation

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Pressure Pump System

• Redundancy• Each tank must have

redundant pumps

Pump Sets

• Suction Pumps

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• Pro• Buried piping under

suction• Ease of maintenance• Simpler multi tank

systems• Simple installation

• Con• Limited suction ability• Additional floor space

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Suction Pump System

• Redundancy• A single duplex pump

set satisfies redundancy requirement

Suction Pump Set Options• High Pressure 100psi • Low Pressure <50 psi

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mechanical pump set

pump set with motor starter panel

Pump set with motor starter and logic control panels

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Suction Pump Set Construction

Pump/motor sets

Control panel(s)

Gauges

Priming funnel

Relief valvesFlow 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

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Piping and Valves

• Vibration Isolation WRONG

Flexible Connectors

Fixed to Building

Fixed to Equipment

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Piping and Valves

• Vibration Isolation CORRECT

Flexible Connector

Fix to Building Isolation Pads or Springs

Fix to Equipment

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Basic SystemMonitoring 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• Vent Caps• Level Indication• Level Monitoring• Temperature Monitoring

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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• 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

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• Primary functions• Monitor day tank level• Start/stop pumps• Open/close fill manifolds

• Secondary functions• Leak detection• Communications and alarms• Auxiliary controls

Pump and Day Tank 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

High voltage motor control panel

Low voltage logic control not to exceed 49 volts

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Pump and Day Tank Controls

• NFPA 70e

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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!

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