Pressure to conserve precious freshwater is driving demand for sustainable, water-efficient irrigation systems. A recently completed elite sports facility in Victoria shows how Class A recycled water can reliably maintain elite natural sports turf when paired with the right pumping, storage and control system. Constructed by Pitchcraft, the two side-by-side playing and training surfaces will be used for elite-level training and competition.

Although the site holds approval to use Class A recycled water, the incoming supply arrived at low pressure and low flow, making it insufficient to operate the irrigation system directly. Installation constraints for the lateral sprinkler pipework added further challenges, making consistent pressure and intelligent control essential to achieve uniform turf performance.

A modern and efficient solution

The project called for a reliable and efficient setup capable of delivering a total system duty of 17 L/s at 700 kPa, despite the site’s limited supply pressure and spatial restrictions. Working to SPORTENG’s technical specification, ULS Group engaged Brown Brothers Engineers Australia to supply a pump and control package meeting this duty.

At the heart of the system is a triplex Lowara e-SV pump set, configured Duty/Duty/Standby, each unit coupled to a 7.5 kW three-phase IE3 2-pole motor. Each pump is equipped with a Hydrovar Gen 5 variable speed drive (VSD) and pressure transducer for closed-loop control. The Hydrovar drives, in tandem with the transducers, regulate speed to maintain the target pressure and sequence additional pumps as demand increases. The Hydrovar units’ built-in protection functions safeguard both pumps and motors during start-up, ramping and fault conditions.

To manage the variable water supply, a 280 kL above-ground break tank acts as a buffer and is replenished primarily by the recycled water source. “Rather than draw directly from the recycled water mains, the pump set takes suction from this tank, boosting flow and pressure to meet the irrigation needs reliably,” explains Damian Cullen, Principal Consultant at CADSULT. This arrangement overcomes supply limitations and ensures consistent performance despite the constrained site layout.

Electrical and system protection are provided by an INCA BBHYD surge protection panel with an integrated isolation switch, safeguarding the drives and controls from power fluctuations. “The tank has two inlets: a primary Class A recycled water feed and a secondary potable feed,” says Damian. “A hydrostatic level transducer manages both, prioritising recycled water and only admitting potable top-up when required”.

If the tank nears overflow, a visual beacon on the pump shed roof activates and a 24 V solenoid control valve closes the recycled water inlet to prevent wastage. At low level, a separate beacon triggers and a secondary 24V solenoid valve opens to admits potable water to protect the pumps and maintain irrigation capability. The irrigation controls also include a rain sensor to suspend watering during rainfall, and a flow sensor to monitor and record water flow through the irrigation system; both supporting the project’s water sustainability goals.

Tackling unique field design challenges

Beyond the pumping and control system, the irrigation network itself presented unique design challenges. The sprinkler lateral layout was anything but a typical irrigation design, requiring precise planning to achieve uniform turf coverage without conflicts with the subsurface drainage. “The drainage network dictated where laterals could go, Damian explained. “With only four one-metre access points to cross the drainage lines, each lateral had to be laid parallel to the drains at a controlled invert”.

“The result is a uniform sprinkler system that does not impede or intersect any drainage pipe, with nine sprinklers on the main oval and eight on the adjacent community oval,” Damian said.

From generator to mains power

During early installation, the system initially operated on a temporary generator before transferring to mains power in the past week. Initial operation on mains has been excellent, with the pump set running smoothly and achieving the required duty.

This project highlights how thoughtful system design, combining quality pumps, smart controls and well planned field layout, can overcome recycled water limitations to deliver reliable, high-performance irrigation for elite sports turf.