Century Village East - Masuen Consulting LLC





Century Village East

Deerfield Beach, Florida


Water Conservation and Long Term Value

Focused Project


CVE Map

Figure 1: Century Village East project boundaries

Project Overview

Century Village East (CVE) in Deerfield Beach, FL is an active adult community composed of 254 low and hi-rise buildings (with 253 separate condominium associations) and associated common areas. The project sits on approximately five hundred (560) total acres, not including the golf course, about half of which is irrigated.

The entire community was built in the 1970’s with no significant investment in infrastructure since this time.

In the late 1990’s the community’s consumptive water use permit was up for renewal. Due the magnitude of the water use, the condition of the existing irrigation systems and the concern for dwindling water supplies in the region, the local water use permitting agency (South Florida Water Management District - SFWMD) required that a water conservation plan be created and implemented by the community for permit renewal. Among other things, the water conservation plan required irrigation water to be applied efficiently, which could not be done with the existing completely manual system. The idea of replacing the entire system, and the significant investment required, caused considerable unrest and difference of opinions within the community, and except for applications for temporary variances no concrete direction was taken for many years.

Over a couple year period, many consulting and construction firms were interviewed to assist the community with devising potential solutions to these issues. Ultimately Masuen Consulting, LLC was selected and hired based on our reputation, unique skills, success history with such projects, and the specialized approach we recommended for completing the project.

This approach consisted of hiring Masuen Consulting as the lead designer to guide the ultimate design and installation of a water conserving and long term value focused irrigation system. The other six parts of this recommended approach consisted of the following:

First, Masuen Consulting recommended purchasing high resolution aerials, and adding a limited amount of vector line work, to create an adequate base plan to create the irrigation design. This recommendation was made because there were no ‘engineered’ base plans available and the expense to produce them was determined to be cost prohibitive.

Second, Masuen Consulting recommended CVE hire a reputable irrigation contractor, from the project area, to be a part of the design team. This contractor was retained to review design concepts proposed by Masuen Consulting to ensure all three perspectives (Designer, Contractor, and Owner) were given a ‘seat at the design table’.

Third, Masuen Consulting recommended the irrigation design include detailed specifics on the points of connection (POC’s “ pump stations and water sources), mainline system (mainline, sleeving, remote control valves (RCV’s)), and the control system (wiring, controllers, sensors, etc.).

CVE Construction Document

Figure 2: Typical sheet from construction documents


All components downstream of the RCV’s would be guided by ‘building type’ typical designs, a very tight design specification, and Masuen Consulting's in-field guidance and approval.


CVE Building Layout

Figure 3: Typical building type layouts

CVE Detail Sheet

Figure 4: CVE Detail Sheet




Fourth, at the completion of the design, Masuen Consulting assisted the owner through the bidding process with bid administration services. The project was traditionally bid out to a select group of pre-qualified contractors who had previously demonstrated success with the unique requirements/equipment included in the project (the contractor list was provided by Masuen Consulting and approved by CVE). In addition to developing the bid package and conducting a pre-bid meeting, Masuen Consulting assisted the owner in reviewing the bids and providing comments and insight; CVE ultimately selected which contractor to hire.

The fifth step required Masuen Consulting to apply for and obtain a new consumptive use permit for the project. To ensure this would be a seamless and effective process, Masuen Consulting remained in touch with SFWMD through the design process. Masuen Consulting’s previous experience with the District as well as this communication and cooperation allowed Masuen Consulting to use the completed design as the basis of the water conservation plan.

CVE Workers

Figure 5: Construction underway

The sixth and final part of this approach required the system be installed in strict accordance with the original design and thereby be in total compliance with the water conservation plan. Since quality control would be critical to the success of this effort, Masuen Consulting was hired to provide construction observation and consulting services. Masuen Consulting would work with the contractor in the field during installation to answer questions and help guide the overall effort for the entire three year project duration. These observation services provide the owner valuable insurance that what was in the plans and specifications is what actually gets installed, creating a seamless progression from design through construction. This avoids the all too common issue of a significant shift between the design concept (focused on long term value) and the installed system (focused on lowest install cost).

Construction started in late 2011 and is currently on going (2012) with an estimated completion date of later 2014.







System Overview

Please see the following for more specific information on the system itself. Each major element and product was selected to play a role in water conservation.


CVE Construction Document

Figure 6: Construction Document

Statistics:

  • Over 23 miles of high density polyethylene (HDPE) mainline ranging in size from 4 to 12 inches
  • Over 26 miles of two wire control wire
  • 900 irrigation zones
  • 3 independent pump systems with variable frequency drives capable of 1900 gpm each
  • 9 satalite field controllers with associated tipping rain buckets
  • 18 soil moisture sensors
  • 1 Campbell Scientific weather station

The Control System:

During the design, the concept of an evapotranspiration (ET) based central control system was presented to the owner and agreed to in concept. A user-friendly central control product that included soil moisture sensing (SMS) inputs as well as ET was not commonly available. Masuen Consulting coordinated with Baseline to develop a system truly capable of doing just that - using both ET and SMS to control irrigation scheduling.

This control system will be a state of the art two-wire computerized central control system allowing realtime 2 way communication between the central computer and field devices. The integration of Et/SMS inputs combined with effective management provides an unsurpassed ability to use only the water needed. In order to secure this ability the system uses a site specific database containing zone specific data collected from on-site for each and every zone (slope, aspect, sun/shade, soil type, plant type, root depth, etc). This data is used in the system’s logarithmic engine to determine whether to irrigate, and how much water to apply. The central computer connects and coordinates the 9 satellite field controllers and 3 pump systems, allowing the water demand to closely match the pump system ‘sweet spot’ as well as reduce the watering window. The control system is remotely accessible from anywhere in the world.


6000 System PC

Figure 7: Central Control Computer

CVE 3200 Controller

Figure 8: Sateltite Field Controller



CVE Weather Station

Figure 9: Weather Station



Ultimately, this system will be the first of its kind and will provide very important ongoing information on the correlation between the ET and SMS concepts in a real world, practical, commercial landscape irrigation system.


The Pumping Stations:

There are three hydraulically independent irrigation systems on the site. Each irrigation system has a 1,900 gpm pump station equipped with a magnetic flow meter and master valve to allow remote and automatic flow monitoring and shutdown capabilities. These features allow the system to conserve water by preventing continued pumping during a mainline break, and when more water is being demanded than should be required. A variable frequency drive (VFD) on each motor reduces energy consumption and maximizes motor life. Additionally VFDs minimize pressure fluctuations and water hammer in the mainline system which minimizes mainline maintenance repairs and extends the life of the mainline.


Pump Station

Figure 10: Pump Station

Flow Meter

Figure 11: Magnetic Flow Meter



The Mainline:

All mainlines are high density polyethylene (HDPE). HDPE is an extremely tough, flexible pipe product used in Europe and the gas industry for decades. Through a fusion welding process done on site during installation, the resulting mainline system is truly seamless. This accordingly minimizes leaks. Additionally, due to the inherent toughness/flexibility of the product, mainline breaks are minimized, thereby reducing water losses required by the mainline draining, refilling and flushing process normally required when a break occurs.


HDPE Pipe

Figure 12: HDPE

HDPE Butt Fusion Process

Figure 13: HDPE Butt Fusion Process




The Water Application Equipment

Approximately 80% of the site is irrigated with turf rotary heads with the remaining 20% served by geared rotor heads. Turf rotary heads are considered to be the most efficient overhead application method, providing up to an 80% efficiency rate. Geared rotors provide up to a 75% efficiency rate. By comparison, the industry standard and ubiquitous spray head provides up to a 65% efficiency rate. The use of these products maximizes the efficiency of the system, providing improved distribution uniformity and therefore fewer wet/dry spots. Additionally, all zones irrigate areas/plants with similar needs (turf is separated from shrubs, etc.) which allows proper management and minimized water use tailored to each zone.


Turf Rotary Head

Figure 14: Turf Rotary Head

Geared Rotor Head

Figure 15: Geared Rotor Head




The Summary

Masuen Consulting guided Century Village East to future success through the long‐term‐value oriented thinking that it used throughout the decision making process. This ranged from the initial concepts through the actual construction, quality control, and ultimately management and maintenance. The community will be prepared for the future difficulties associated with reduced water availability.


In the words of our client:


CVE Director Al Smith

Al Smith: Executive Director of CVEMM

“We couldn’t have put this together without Masuen. The design and construction of the new irrigation system is the largest and most expensive construction project the village has undertaken since its construction in the 1970’s. Since the management of the infrastructure operation and maintenance is mainly directed by a fifteen (15) member Board of Directors who are all volunteers, we had to have a competent consultant whose design ability and decision making could be trusted implicitly. Masuen proved to be that consultant. They have been extremely easy to work with and very patient with the committee of senior citizens appointed to direct the implementation of the design. Through the design process there were numerous presentations, and hours of questions, yet Masuen employees were always available, professional, responsive, and polite. Masuen diligently worked with CVE through the design process providing detailed feedback on a weekly basis. During the construction Masuen is proving to be more than a consultant; they are a partner.”






In the words of the contractor:


CVE Contractor Tom Balling

Tom Balling: President of Treasure Coast Irrigation

““Masuen Consulting offers an incredible value to the irrigation contractor in a large scale job, such as the Century Village East project. Their third party perspective helps to ensure clear communication between the contractor and the owner from the start to the finish of a project, and their presence on the jobsite gives us the confidence to know that the customer’s expectations will be exceeded, and quality and safety will remain a top priority.”