Portable Water System
Criteria and Constraints
When programming and testing a client's water-based project, Terrasimco would gather available pumps, VFDs, and piping ad hoc in order to simulate water and chemical flow. To streamline testing, saving time and money, we created a modular portable water system (PWS) for internal testing and verification.
The PWS needed to be easily adaptable for a wide variety of testing, so had to meet a flexible set of criteria and constraints:
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Configurable flow from 0 to 300 LPM, 0 to 80 GPM
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Configurable pressure from 0 to 120 PSIG
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Proper filtration to use rain water during testing
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Lightweight and mobile inside the shop and warehouse
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Automatic recirculation line to avoid deadheading the pump
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Automatic fluid transfer between tanks
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Ability to test flow meters of varying sizes (½’’, 1’’, 2’’)
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Reuse existing components wherever possible
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Features
​​The final PWS met all the specified criteria. Given the constraint to use as many existing components as possible, the system has some noteworthy design decisions.​
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The electrical is a multi-voltage system, dual 120/240V, allowing the PWS to be used either inside or outside the shop. Outside the shop, water can easily be transferred between tanks utilizing standard 120V outlets. Inside, where 240V is available, the 5 HP pump can be utilized in conjunction with the 1 HP pump in order to hit the upper limits of the 0-300 l/min range. Neither pump alone is capable of hitting the upper limits of this range.
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We utilize hydrostatic submersible pressure transmitters to monitor tank level. These sensors are tank agnostic, as they merely measure the depth at which they are submerged. Thus, by dropping a transmitter into a tank, we can verify the presence of water for the pumps to pull, preventing dry running. When filling or emptying a tank, this sensor is used to automate the completion of this task.
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In order to make the PWS adaptable for a wide variety of testing, we selected an ifm CR1140 PLC/HMI, with fully programmable screens and 11 input buttons. This allows for more complex programming and more complex user input. The programming allows the user to set an optimal PSI or flow output, and then utilizes a PID to reach the desired value. We also created custom functions for tank filling, tank to tank transfer, and flow meter testing.
If the system being testing no longer pulls water, the PWS recognizes building pressure and opens the recirculation line so neither pump is at risk of deadheading.
If the system being testing no longer pulls water, the PWS recognizes building pressure and opens the recirculation line so neither pump is at risk of deadheading.
This electrical box can run off of 240V or 120V. By selecting power supplies and components that are compatible with either voltage, we treat the additional hot wire in 240V as a neutral wire for 120V wiring.
This electrical box can run off of 240V or 120V. By selecting power supplies and components that are compatible with either voltage, we treat the additional hot wire in 240V as a neutral wire for 120V wiring.
Clients return broken flow meters to Terrasimco for diagnostics and refurbishment. This outlet allows for any flow meter to be compared to a working in-line flow meter for accuracy.
Clients return broken flow meters to Terrasimco for diagnostics and refurbishment. This outlet allows for any flow meter to be compared to a working in-line flow meter for accuracy.
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