case study 9 - golf course
When Caldwell golf course near Glasgow wanted to stop pipe bursts and cut energy costs (as well as protecting their course) they turned to EDC.
Project: Caldwell Golf Course
Challenge: Pressure fluctuation and high energy consumption, problems with old pipes bursting and valves leaking.
Solution: Retrofit with ACQ580-based control panel including full inlet/outlet protection.
Results:
- 25–30% reduction in energy usage
- Pressure stability within system
- Zero pipe work bursts recorded over 6 months
Technical Specifications:
• Supply: 230–690V AC, 3-Phase
• Motor Range: Custom sized per pump requirement
• Protection Rating: IP54 / IP55 options
• Communications: Modbus TCP, BACnet, Profinet (optional)
• HMI: Integrated touchscreen interface (optional)
Overview:
Our engineered control panels are purpose-built for golf course irrigation systems. Designed around ABB ACQ580 variable speed drives, the system delivers stable pressure control, reduced energy consumption, and comprehensive pump and pipework protection. Adjustable set point, timed functions available, provides duty assist or duty standby ability for up to 8 pumps using a drive to link cable cutting out the need for expensive PLC control. Can be customized for your courses with all sizes of pumps covered.
Proven technology used by Scottish Water for direct feeding pressure controlled pumping stations for public water supply.
Key Features
• ABB ACQ580 Variable Speed Drive (VSD) technology optimized for pump applications.
• Precision PID pressure control
• Inlet protection to prevent dry-run and low suction pressure damage.
• Outlet over-pressure protection to safeguard pipework and sprinklers
• Soft-fill pipe protection to eliminate water hammer protecting pipework and fittings.
• Remote monitoring and SCADA integration options
• Fully assembled, factory tested and commissioned.
• 230V single phase input models available for sites without 3-phase supply (subject to motor rating) allowing higher output pumps.
• VSDs can also be retrofitted to existing control panel setups.
• Extended Warranty available – Up to 5 Years.
• Future proof with OEM Support for up to 20 years.
Integrated Protection Functions. Inlet protection can be done in several ways.
1. Monitors suction pressure to prevent cavitation and dry-run conditions.
2. Automatic shutdown and restart logic protects pump integrity using inlet pressure switch or inlet pressure transducer.
3. If fed from tank can be controlled from level controller or float switch in tank
4. Can be done from conductive liquid switch installed in pipework.
5. Any of these features can be set to inhibit the pumps meaning they will auto restart on event water level returns to healthy, or by making a fault if the operator wants to investigate why water issue is occurring.
6. Outlet Protection: Continuous discharge pressure monitoring prevents over-pressurization and system damage can be done with pressure transducer or independent. Pressure switch for double protection.
7. Soft-Fill Pipe Protection: Controlled acceleration ramps eliminate pressure spikes and reduce mechanical stress across long irrigation pipe runs.
Filling empty pipes should be done with care to avoid water hammer and unintended stress on pipes, sensors, and valves. The result of this could be severe and cause failure in the installation. By using the ACQ580 'soft pipe fill' function, the risk can be eliminated. The pipes will gradually be filled in a controlled way and unintended stress will be avoided. The soft pipe fill function is linked to closed loop control, typically a constant pressure control. The following sections will explain the behavior of the system without using the pipe fill function and with the function activated. The system looks like this:
A pressure sensor (P) at the pump outlet is closing the feedback loop for the closed loop control and the PID is controlling the speed based on the provided set point the second figure shows how constant outlet pressure will look using the pump’s HQ curve.
System behavior without soft pipe fill function.
The pipe is empty, and the set point active waiting for the start signal to be given. Since the pipe is empty, there is currently no feedback from the pressure sensor, which means that the PID controller will ask for higher speed and the motor will accelerate until it reaches the maximum speed. Thus, the pipe is being filled at full speed/flow, and the pressure sensor will not detect the desired pressure until the pipe is full. In the case where the pipe is closed at the end, water hammer will occur and a pressure spike will travel back through the pipe stressing all junctions, bends, sensors, and valves. It is at this time the PID will start decreasing speed, but the damage to the system has already been done. Additionally, it will take time before the system settles.
System behavior with soft pipe fill function activated.
The pipe is empty, the set point is active and the start signal is given. Rather than using the desired running pressure set point directly upon start, the ACQ580 gradually increases the internal set point from zero to the running set point. Since the set point is gradually changed over time, the speed will change with the changing set point, the feedback from the sensor will be increasing as the pipe is filled with water (at least for ascending pipes) and the system will not see the water hammer or the pressure spikes. The PID control will keep the system in control after the predefined filling time, running at the predefined set point.
Operational Benefits for Golf Courses
• Consistent pressure across tees, greens, and fairways
• Reduced sprinkler wear and valve stress
• Lower energy consumption through demand-based pump speed control
• Extended pump and infrastructure lifespan
• Reduced maintenance call outs
• Less stress on existing and sometimes antiquated piping infrastructure in golf course (less time fixing bursts in pipework)
• Ability to turn sprinkler system on at night using easy to set in built time clock function of ACQ580 and to turn on remotely via app if a smart switch is installed. (WIFI, GSM dependent)
Graph of pressure spikes with direct on-line start and stops.
(These upwards and downwards spikes are the causes of water hammer which causes pipe bursts).
Graph of pressure spikes with VSD starts and stops.
(No spikes showing, so control is much smoother).
