10-11 PS 25-49-59-85-SUPPLEMENTAL TECHNICAL SPECIFICATION.docx

SUPPLEMENTAL TECHNICAL

SPECIFICATIONS FOR WET-WELL

MOUNTED PUMP STATION

General

10.1.1 Scope of Work- Wet Well Mounted Pump Station (WWMPS)

Contractor shall furnish, deliver and install an automatic wet well mounted sewage pump station WWMPS). The station shall be complete with all needed equipment. The principle items of equipment shall include two vertical, close-coupled, motor driven, vacuum primed, non-clog pumps; valves; internal piping; control panel with circuit breakers; motor starters; automatic pumping level controller; junction box/enclosure to interface with central control panel; ventilating blower; priming pumps with prime detection system; and all on‐site improvements including slab replacement, wet well lining, discharge piping including emergency by‐pass, gravity piping, including plug valve, emergency generator (PS 59), electrical wiring, control panel modifications, control panel shelters, emergency bypass manhole (PS 85 & 59) , stormwater culvert (PS 85), fence and all items shown on the plans which make the station complete and operable.

These specifications are intended to give a general description of what is required, but do not cover all details which will vary in accordance with the requirements of the equipment as offered. It is, however, intended to cover the installation and field testing, of all materials, equipment and appurtenances for the complete pumping units as herein specified, whether specifically mentioned in these specifications or not.

To assure unity of responsibility, the pumps, accessories, and pump control system shall be furnished and coordinated by the pump manufacturer. The contractor shall assume responsibility for the satisfactory installation and operation of the entire pumping system including pumps, accessories and controls as specified.

The WWMPS shall be factory-built, automatic pumping station as manufactured by Smith & Loveless, Inc. The operating conditions are indicated on the construction drawings. The station shall be complete with all needed equipment, factory-installed on a welded steel base with a hinged fiberglass cover. The specifications and drawings detail Smith & Loveless equipment and represent the minimum standard of quality for both equipment and materials of construction. The contractor shall prepare their bid based on the equipment and materials specified for the purpose of determining the low bid. The owner has standardized on the named equipment to optimize their operation, facilitate maintenance and safety programs, provide for interchangeability of costly equipment items, reduce stocking levels required for necessary spare parts and provide increased flexibility in the utilization of their pumping equipment. Equipment substitutions will not be considered.

The furnished pumps shall be designed, constructed and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed. All equipment furnished under this specification shall be new and unused. Pumps shall be manufactured in accordance with the Hydraulic Institute Standards.

10.1.2 Submittals

Copies of all materials required to establish compliance with the specification shall be submitted in accordance with the provisions of the general conditions. Submittals shall include at least the following:

a. Shop erection drawings showing all important details of construction, dimensions and anchor bolt locations.

b. Descriptive literature, bulletins, and/or catalogs of the equipment.

c. Data on the characteristics and performance of each pump. Data shall include guaranteed performance curves, based on actual certified tests of similar units, which show that they meet the specified requirements for head, capacity, efficiency, NPSHR, and horsepower, except where certified witness testing is requested by the City. Curves shall be submitted on 8½ by 11‐inch sheets; at as large a scale as is practical. Curves shall be plotted from no flow at shut off head to pump capacity at minimum specified TDH for one pump running and for two pumps operating in parallel. Catalog sheets showing a family of curves will not be acceptable.

d. Complete wiring diagrams showing in full detail all line voltage wiring and components, and control voltage wiring and components.

e. A drawing showing layouts of the pump control panel for each pumping station shall be furnished.

f. The total weight of the equipment including the weight of the single largest item.

g. A complete bill of materials for all equipment.

h. A list of the manufacturer’s recommended spare parts, with the manufacturer’s current price for each item. Include O-rings, seals, etc. on the list. List bearings by the bearing manufacturer’s name and part number.

i. All submittal data required by the general conditions.

j. Complete motor data.

In the event that it is impossible to conform to certain details of the specifications due to different manufacturing techniques, describe completely all non‐conforming aspects.

10.1.3 Materials and Equipment

The pumping units required under this section shall be complete including pumps and motors with proper alignment and balancing of the individual units. All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness and to be especially adapted for the work to be done.

The factory-built assembly shall be sized to rest on the top of the wet well as detailed in the construction drawings.

Other features of the factory-built assembly shall include:

Corrosion-Resistant Stainless-Steel Baseplate: The baseplate of the pump station structure shall be fabricated of ½” corrosion-resistant lean duplex series 2100 stainless steel alloy, 316L stainless steel or equal. The stainless steel shall have a Pitting Resistance Equivalent Number (PREN) of 24.0 or greater and general corrosion resistance shall be less than or equal to 0.1 mm per year in 15% H2SO4 at 120 degrees F. Due to the corrosion resistance requirements, Grade 304-304L is not acceptable.

The stainless steel surfaces shall be glass bead blast cleaned to remove surface contamination and provide a uniform finish, after which the baseplate shall undergo an electrochemical passivation process to remove any free iron contamination from the stainless steel surface. This process shall also add a transparent oxide film to protect the surface from future contamination.

Fiberglass Cover: The pump station shall be enclosed by a hinged fiberglass cover made of molded reinforced orthophthalic polyester resins with a minimum of 30% glass fibers with a minimum average length of 1-1/4”. The outside of the enclosure shall be coated with a polyester protective in-mold coating for superior resistance to weathering, ultraviolet radiation, yellowing and chalking. The completed fiberglass enclosure shall be resistant to mold, mildew, fungus and corrosive liquids and gases normally found in pump station environments. The dimensions of the enclosure shown on the drawings shall be considered a minimum, for internal component clearances and accessibility, and nothing smaller will be acceptable. The cover shall have a suitable drip-lip around the edge and shall be provided with a hasp and staple connection to the floor plate to allow the pump chamber to be locked with a padlock.

The cover shall be attached with a multi segment stainless steel hinge, constructed of 7 gauge (minimum) type 304 stainless steel with a 3/8” diameter stainless steel pin and supporting at least 75% of the width of one end. Stainless steel bolts with tamperproof heads and a full width 3/8” thick anodized aluminum backing plate shall anchor the hinge to the fiberglass cover.

Dual high-pressure gas struts shall be provided to counteract the dead weight of the cover assembly and limit the maximum lifting force required for opening to less than 20 pounds. The cover shall be self-latching upon opening, with a manually operated release for closing. Duplex heavy gauge safety chains shall be provided to prevent over-extension. All hardware and components of the cover assembly that are exposed to the weather shall be constructed of corrosion-resistant materials.

Heavy extruded aluminum, adjustable ventilating louvers shall be provided on each end of the fiberglass cover, which are capable of being closed during cold weather operation.

An aluminum manway cover fabricated of 1/4” treadplate, located exterior to the fiberglass pump chamber shall be provided, complete with padlocking provisions. The manway shall be an integral part of the station floor plate and provide access to the wet well. The minimum open area of the manway access into the wet well shall be at least 4.2 square feet.

The manway cover shall have a three color 7” x 10” (minimum) corrosion-resistant sign permanently affixed to it, reading “DANGER – Before Entering, Test For Explosive Gases. Test For Oxygen Deficiency. Supply Fresh Air To Work Area”.

Enclosures utilized to house the valve train and/or controls, which are defined under OSHA Article 29CFR, Parts 1910 as a Confined Space shall not be acceptable.

The pump casings and discharge piping shall be mounted in relation to the floor plate as detailed in the construction drawings. The suction and discharge connections, where they pass through the floor shall be sealed by gaskets, rather than being welded, to allow adjustment and replacement.

Welding: All steel structural members shall be joined by electric arc welding with welds of adequate section for the joint involved. Structural welding shall be performed in accordance with AWS standards and procedures.

Protection Against Corrosion: All structural steel surfaces shall be factory blasted with steel grit, in an environmentally controlled booth, to remove rust, mill scale, weld slag, etc. All weld spatter and surface roughness shall be removed by grinding. Surface preparation shall comply with SSPC-SP6 specifications. Sandblasting is specifically prohibited.

Immediately following cleaning, a single 6-8 mil dry film thickness coating of VERSAPOX®, a self-priming Cycloaliphatic Amine Epoxy shall be factory applied to the base. After curing, a 2-3 mil DFT top coating of XTRATHANE™, a moisture-cured Aliphatic Polyurethane protective finish, for abrasion resistance and weather protection, shall be applied to the top of the base and as a finish coating for all other structural, pump and piping assemblies. The bottom of the station base, exposed to the wet well, shall be further coated with an additional 6-8 mil coating of XTRAGUARD™ epoxy for chemical and abrasion resistance. These coatings shall be as formulated by Smith & Loveless specifically for this type of application and service.

Stainless steel, aluminum and other corrosion-resistant surfaces shall not be coated. Carbon steel surfaces not otherwise protected shall be coated with a suitable non-hardening rust preventative compound. Auxiliary components such as the electrical enclosure, ventilating blower and vacuum pumps shall be furnished with the original manufacturer’s coating.

Finish coating shall be accomplished prior to shipment of the station from the factory and shall comply fully with the intent of these specifications. Touch-up kits for both the XTRAGUARD™ epoxy and XTRATHANE™ Polyurethane coating systems shall be provided by the pump station manufacturer for repair of any mars or scratches occurring during shipping and installation. The kits shall contain detailed instructions for use.

10.1.4 Product Handling

All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation.

Factory assembled parts and components shall not be dismantled for shipment or installation unless permission is received in writing from the City.

Finished surfaces of all exposed pump openings shall be protected by wooden blanks strongly built and securely bolted thereto.

Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.

Use padded straps when handling pipe and fittings so not to damage finished metal and/or coated surfaces. Any damaged surfaces shall be repaired or replaced by the Contractor at the City’s discretion.

After hydrostatic or other tests, all entrapped water shall be drained prior to shipment, and proper care shall be taken to protect parts from the entrance of water during shipment, storage and handling.

Each box or package shall be properly marked to show its net weight in addition to its contents.

Products

10.1.5 Pumps

The pumps shall be vertical, centrifugal non-clog type of heavy cast-iron construction, especially designed for the use of mechanical seals and vacuum priming. In order to minimize seal wear caused by linear movement of the shaft, the shaft bearing nearest the pump impeller shall be locked in place so that endplay is limited to the clearance within the bearing. To minimize seal wear resulting from shaft deflection caused by the radial thrust of the pump, the shaft from the top of the impeller to the lower bearing supporting the impeller shall have a minimum diameter of 1-7/8” for motor frame sizes 213 through 286; 2-1/8” for motor frame sizes 324 and 326; and 3” for frame 364 and larger. The dimension from the lowest bearing to the top of the impeller shall not exceed 6”. The motor shaft shall be directly connected to the impeller without the use of drive belts or couplings, which require alignment and maintenance, and which increase power consumption due to their inherent energy losses.

Pumps with less than a standard 4” suction or 4” discharge connection, or with less than a 3” spherical solids handling capacity will be rejected for this application.

The oversized shaft incorporating oversized bearings and heavier bearing frame construction provides for extended mechanical seal, bearing and overall pump/motor life. Since the larger shaft with the specified minimum overhang is the key to heavier, more rigid construction throughout, no deviation from the specified shaft diameter or tolerances will be allowed.

The bearing nearest the impeller shall be designed for the combined thrust and radial load. The upper bearing shall be free to move in a linear direction with the thermal expansion of the shaft and shall carry only radial loads.

The shaft shall be solid stainless steel through the mechanical seal to eliminate corrosion and abrasive rust particles. Removable shaft sleeves will not be acceptable if the shaft under the sleeve does not meet the specified minimum diameter.

The pump shall have an integral adapter providing a large water reservoir above the impeller to provide for positive exclusion of air from the impeller. The seal shall be inside this area to assure lubrication. Pumps which do not use hollow priming adapters for positive lubrication of the seal will not be acceptable. Self-priming pumps are specifically unacceptable due to the need for suction check valves, air vent piping and the possibility of overheating and damaging the pump or producing steam or high temperatures in the pump, which may be a hazard to the operator, when the pump is run dry.

The pump controls must be set so that the main pumps cannot be turned on unless they are filled with liquid, and the pump is completely primed.

The pump shall be constructed so as to permit priming from the lower pressure area behind the impeller. Priming from high- pressure connections, which tends to cause solids to enter and clog the priming system, will not be acceptable. The priming bowl shall be transparent, enabling the operator to monitor the priming level.

The pump shall be arranged so that the rotating element can easily be removed from the casing without disconnecting the electrical wiring or disassembling the motor, impeller, backhead or seal, so that any foreign object may be removed from the pump or suction line. Enclosed impellers must be used to avoid the necessity of wear plates and the associated costs of replacement and maintenance of wear plate clearances with semi-open impellers.

The pump shaft shall be sealed against leakage by a single mechanical seal constructed so as to be automatically drained and primed each time the pump is drained and primed. Water, which lubricates the mechanical seal, shall be automatically drained from around the seal if the pump loses prime in order to allow both the pump and the seal to be drained, thereby preventing freezing and breakage of the seal during power outages in sub-freezing temperatures.

The seal shall be of carbon and ceramic materials with the mating surfaces lapped to a flatness tolerance of one light band. The rotating ceramic shall be held in mating position with the stationary carbon by a stainless steel spring. The entire seal assembly shall be held in place by a bronze seal housing to prevent excessive heat buildup. Use of cast-iron or other ferrous material for the seal housing which will rust and damage the seal, shortening its life, will not be acceptable.

The pump volute shall be furnished with mounting lugs and bolted to the station floor plate, forming a gas-tight seal.

Pump Motors: The pump motors shall be vertical, solid shaft, NEMA P-base, squirrel-cage induction type, suitable for 3 phase, 60 cycle, 240 volt electric current. They shall have Class F insulation. Insulation temperature shall, however, be limited to Class B. The motors shall have normal starting torque and low-starting current, as specified by NEMA Design B characteristics. They shall be open drip-proof design with forced air circulation by integral fan. Openings for ventilation shall be uniformly spaced around the motor frame. Leads shall be terminated in a cast connection box and shall be clearly identified. The motors shall have 1.15 service factor. The service factor shall be reserved for the owner’s protection. The motors shall not be overloaded beyond their nameplate rating, at the design conditions, nor at any head in the operating range as specified under Operating Conditions. The motor-pump shaft shall be centered, in relation to the motor base, within .005” (0.127 mm). The shaft runout shall not exceed .003” (0.076 mm). The motor shaft shall equal or exceed the diameter specified under Main Pumps at all points from immediately below the top bearing to the top of the impeller hub.

A bearing cap shall be provided to hold the bottom motor bearing in a fixed position. Bearing housings shall be provided with fittings for lubrication as well as purging old lubricant.

The motor shall be fitted with heavy lifting eyes or lugs, each capable of supporting the entire weight of the pump and motor. The pump motors shall be Premium Efficiency type, per NEMA MG-1 table 12-12, Inverter Ready per NEMA Part 31.4.4.2, with cast-iron frames, and be UL Recognize or CSA Approved. The motor windings shall be 200 C Inverter Spike-Resistant magnet wire and the rotors shall have an epoxy coating for corrosion protection.

Impellor: The pump impeller shall be of the enclosed two-port type made of close-grained cast-iron and shall be balanced. The eye of the impeller as well as the ports shall be large enough to permit the passage of a sphere 3” (76 mm) in diameter in accordance with nationally recognized codes. The impeller shall be keyed with a stainless steel key and secured to the motor shaft by a stainless steel capscrew equipped with a Nylock or other suitable self-locking device. The impeller shall not be screwed or pinned to the motor pump shaft and shall be readily removable without the use of special tools. To prevent the buildup of stringy materials, grit and other foreign particles around the pump shaft, all impellers less than full diameter shall be trimmed inside the impeller shrouds. The shrouds shall remain full diameter so that close minimum clearance from shrouds to volute is maintained. Both the end of the shaft and the bore of the impeller shall be tapered to permit easy removal of the impeller from the shaft.

10.1.6 Stainless Steel Pump Discharge Piping and Fittings

Stainless steel pipe is the approved material for 4” – 12” wet well discharge piping and above ground pipe and fittings at pump stations. Stainless steel pipe shall be Schedule 40S T304L austenitic stainless steel in accordance with the latest revision of ASME B36.19/ASTM A312. Stainless steel pipe and fittings shall have flanged connections. Flanges shall be slip‐on welded type, 150#, raised‐faced, T304L stainless steel in accordance with ASTM A182. All welds shall be made by an American Welding Society (AWS) Certified Welder according to the AWS D10 (and other applicable standards) for welding stainless steel pipe and fittings.

All stainless steel pipe and fittings shall be fabricated in the USA from only high‐quality stainless steel materials, free from defects, and from sources that maintain certification to ISO9001:2015 quality management system requirements.

10.1.7 Ductile Iron Pump Discharge Piping and Fittings

With approval from the Engineering Manager or designee, ductile iron pipe can be used for pump station discharge piping and fittings (except inside the wet well). All ductile iron pipe and fittings shall be as specified in the City of Tallahassee Technical Specification for Distribution and Transmission System Piping (Section 7).

10.1.8 Electromagnetic Flow Meter

An electromagnetic flow meter shall be furnished and installed. The flow meter shall be McCrometer Ultra‐Mag® UM‐06, with 150‐lb AWWA Class‐D flanges. The flow meter shall operate within a range of 0.2 – 32.0 FPS and be accurate within 0.5% of the actual flow.

The flow meter shall be installed per manufacturer’s recommendations. The flow meter signal shall be wired as shown in the electrical plans. (The electromagnetic flow meter is not supplied by Smith & Loveless Inc. and shall be provided by the contractor.)

10.1.9 Wet Well and Manhole Liners

Inside the wet wells that lining is specified (PS 49 & 85), liner type and installation shall adhere to City of Tallahassee Technical Specifications for Water and Sewer Construction (latest edition) section 9.2.7.9. Newly installed emergency bypass manholes shall be coated according to City of Tallahassee Technical Specifications for Water and Sewer Construction (latest edition) section 9.2.7.8.

10.1.10 Access Frames

The pumping station wet‐well shall be furnished with the necessary aluminum access frames, complete with hinged and hasp‐equipped covers, fall protection grating, stainless steel upper guide holder and level sensor cable holder. Doors shall have safety‐locking handle in open position. Doors shall have a 300 psf load rated (H20, if traffic bearing) aluminum checkered plate and shall be similar to Model “JD‐AL” with stainless steel hardware manufactured by the Bilco Company, model “S2R” by Halliday Products, Electric Specialty, or model ”APD 300” manufactured by US Foundry.

When the existing wet‐well has a diameter greater than 6 feet (PS 85), the installation of a concrete cap with a 6’-0” opening may be necessary if not already in place. The S&L pump stations are designed to cover a 6’-0” diameter opening.

10.1.11 Pump Control System

See also Section 11 of City of Tallahassee Technical Specifications for Water and Sewer Construction, latest edition and Electrical Construction Drawings. Contractor to note that some items listed in Section 11 are already in place and do not need to be replaced such as the batteries and boxes specified in Section 11.2.4, SCADA equipment, and control panels. Only items that are shown on the plans to be replaced or renovated will need to be provided.

Control Panel: See Section 11, Electrical and Field Wiring of City of Tallahassee Technical Specifications for Water and Sewer Construction, latest edition and Electrical Construction Drawings. The panel in the afore-mentioned specifications and drawings shall be the central panel with all controls located in this panel except for the pump controls. The provider of the wet well mounted pump station pumps shall provide a NEMA-Type 4A stainless steel enclosure with lockable doors that serves as a junction box for motor connections and instrument terminations and serves as interface to the central control panel.

Pressure Transmitter: Pressure transmitter and S.S. ball valve required for all pump stations. Transmitter must be mounted at the 3 or 9 o'clock position downstream of the check valve in the tapping boss of the tee or using a tapping saddle in the pipe that goes into the ground after the Air Release Valve. Pressure transmitter shall be as follows (electromagnetic flow meter is not supplied by Smith & Loveless Inc.):

Brand: Rosemount 2051 Transmitter Model: 2051TG3A2B21AS1M5T1 Remote Seal Model: 1299N2DD00AP1SSSG2F2FBB2

Pump Failure to Prime or Failure to Pump Alarm (check valve switch type):

The pump failure circuit for each pump shall consist of a proximity switch mounted on the pump discharge check-valve such that when the check-valve is open the contacts on the switch open providing an input to the RTU. The RTU shall be configured such that if the pump is running (auxiliary contact from SMC) and the proximity switch is not opened within a specific amount of time, then the pump is stopped and a fault alarm is generated in the RTU.

Vacuum-Priming System A vacuum priming system shall be furnished to prime the main pumps. The system shall be as shown on the vacuum priming schematic and shall include two vacuum pumps, providing 100 percent standby. Vacuum pumps shall have corrosion-resistant internal components. The vacuum priming system shall be complete with large port vacuum control solenoid valves, WaveStart™ prime level sensor, float-operated check valves to protect the vacuum pumps, and all necessary shut-off valves as shown on the piping schematic. The float-operated check valves shall have a transparent body for visual inspection. All hoses and tubing used in the priming system shall be at least 3/8” (9.5 mm) nominal diameter.

The solenoid valves used in the vacuum priming system shall be of the high flow, direct acting brass body type, with threaded ports, NBR seals and 300 Series stainless steel plunger, rod, plate and springs.

The minimum orifice diameter shall be 5/16” (8 mm). The solenoid valves shall be UL Listed, with Class F coil rating and of suitable voltage and thermal capacity for the application.

Liquid level in the pump priming chamber shall be monitored by a WaveStart™ liquid level sensing probe incorporating frequency spectrum technology to evaluate the media with which it is in contact at several measurement points. At each measurement point the sensor shall take readings. Using a multi-variable sensing technology, collected over a spectrum sweep, the sensor shall create an outline of the medium, its residue and absence of medium. From these reference points the sensor shall be able to accurately determine the presence or absence of liquid, unaffected by foam, residue or deposits. The liquid level sensor algorithm shall provide prime status in less than 100 milliseconds.

Systems utilizing an electrode, mechanical means such as a float or protrusions into the pump, which may become fouled due to bridging or wrapping, or that require any type of electrical or moving parts inside the priming chamber, which may accumulate debris, short out, bind or fail will not be acceptable. Single or double medium sensing probes will be unacceptable.

The WaveStart™ probe shall be provided with light emitting diodes. This diagnostic tool shall indicate connectivity, prime status or a fault condition. The probe shall be complete sealed and have a 316L stainless steel housing for corrosion resistance. It shall be provided with a wiring connector of molded thermoplastic for impact and chemical resistance. The probe shall have a threaded electrical connector to facilitate easy removal.

The priming system shall automatically provide positive lubrication of the mechanical seal each time a main pump is primed. To prevent excessive stoppage due to grease accumulation, no passageway in the priming system through which the pumped liquid must pass shall be smaller than the equivalent of a 2-1/2” (64 mm) opening.

The vacuum priming system shall have two field selectable modes of operation. In the “On-Demand” mode, the priming system will operate only after a pump is called on to run, and if it is not primed. Once primed, the pump will be allowed to run. In the “Constant Prime” mode, both pumps are kept primed continuously, and ready to start immediately when called for.

10.1.12 Wiring

The control panel provided by Smith & Loveless shall be completely wired at the factory, except for the power feeder lines, in accordance with National Electric Code. All wiring outside the Smith & Loveless enclosure shall be in accordance with City of Tallahassee Technical Specifications for Water and Sewer Construction Section 11.2.2.

10.1.13 Environmental Equipment

A ventilating blower capable of delivering 250 CFM at 0.1” (118 l/s at 2.5 mm) static water pressure shall be provided in order to remove the heat generated by continuous motor operation. The ventilating blower shall be turned on and off automatically by a preset thermostat. A heavy extruded aluminum louvered grille with adjustable openings shall cover the discharge of the blower. A similar grille shall be provided in the other end of the station enclosure for air intake.

Insulated Hood: The fiberglass cover shall have a minimum of 1” thick urethane insulation, protected by fiberglass, with an “R” value of 7 or more.

10.1.14 Main Piping

The pump suction connections shall be drilled and tapped for a 125-pound American Standard flange for easy attachment of the suction risers. The discharge line from each pump shall be fitted with a clapper-type check valve and eccentric plug valve. Size, location and quantity of check valves and plug valves shall be as shown on the construction drawing.

Protrusions through the station floor shall be sealed where necessary to effect sealing between the equipment chamber and the wet well. The suction and discharge connections, where they pass through the floor, shall be sealed by gaskets in order to prevent corrosive, noxious fumes from entering the station. Welded joints that do not allow adjustment or replacement will not be considered for this application. The pump station manufacturer shall extend the suction and discharge connections below the floor at the factory so that field connections can be made without disturbing the gas-tight seals. Once the station is installed, however, it shall be possible to remove the entire 4” or 6” suction pipes through the station floor without having to enter the wet well to unbolt them.

The manufacturer of the pump station shall provide a compression-type sleeve coupling for installation on the common discharge pipe. A minimum of two anchoring points shall be provided on the bottom of the station baseplate for attachment of coupling joint restraints, which shall be provided by the installing contractor.

An operating wrench shall be provided for the plug valves. All station piping and fittings shall be capable of passing a 3” spherical solid.

10.1.15 Check Valves

The Rapid-Jack™ check valve shall be provided. The cast iron check valve body shall be designed so that the upper portion may be easily removed, without disturbing the end flange seals to adjacent piping, to service the shaft, arm and clapper or to remove any material which may be causing clogging. Provide one spare body gasket for each valve.

10.1.16 Pressure Gauges

A four-inch (4”) Bourdon tube-type compound vacuum/pressure gauge with 3-1/2” dial, fitted with a brass stop valve and a manual air relief valve shall be provided for each pump. The gauges shall be mounted apart from the pumps, on a bracket attached to the control panel support structure and connected to the pump discharge taps by flexible tubing to minimize vibration. The range of each gauge shall be selected to place the normal operating discharge pressure reading in the middle one-third of the scale and the gauge shall also be capable of measuring up to 30” HG of vacuum. The dial shall be white with black markings and the gauge itself shall have an accuracy of 1% of scale. The gauge shall be American made, with a Zytel Nylon case with 1/2” blow-out plug, stainless steel bezel, acrylic lens and phosphorus bronze tube with brass socket. Temperature compensation shall be provided by an internal compensating diaphragm. Gauges shall be protected from the service fluid by a Buna-N elastomer “boot” diaphragm within the stem, and the Bourdon tube and the space between the Bourdon tube and the internal isolating diaphragm shall be filled with low temperature instrument oil, completely isolating the gauge components from the fluid being measured.

Execution

10.1.17 Inspection and Testing

10.3.1.1 General

The engineer shall have the right to inspect, test, or witness tests of all materials or equipment to be furnished under these specifications, prior to their shipment to the job site. The engineer shall be notified in writing prior to initial shipment, in ample time so that the Engineer can make arrangements for inspection.

The services of a factory representative shall be furnished for 1 day and he shall have complete knowledge of proper operation and maintenance to inspect the final installations and supervise the test run of the equipment. This must be done on a Monday, Tuesday, Wednesday or Thursday; not on a Friday, Saturday or Sunday nor on a holiday or the day before a holiday. This must be closely coordinated with the City, providing a minimum of two weeks advance notice.

10.3.1.2 Pumps

After all pumps have been completely installed, and working under the direction of the manufacturer, conduct in the presence of the Engineer, such tests as are necessary to indicate that pumps conform to the specifications. Field tests shall include all pumps included under this section. The Contractor shall supply all electric power, water or wastewater, labor, equipment and incidentals required to complete the field tests.

If the pump performance does not meet the specification, corrective measure shall be taken or pumps shall be removed and replaced with pumps, which satisfy the conditions, specified. A 24‐hour operating period of the pumps will be required before acceptance. During this 24‐hour operating period, the contractor shall supply all power necessary.

10.3.1.3 Field Testing

Upon completion of all the mechanical work, the contractor shall conduct testing as specified herein to demonstrate that the equipment performs in accordance with all specifications.

The contractor shall perform initial testing of the equipment to ensure that the tests listed below can be satisfactorily completed.

The initial start‐up shall demonstrate that all items of these specifications have been met by the equipment as installed and shall include, but not limited to, the following tests:

a. That all units have been properly installed and are in correct alignment.

b. That the units operate without overheating or overloading and without objectionable vibration.

c. That there are no mechanical defects in any of the parts.

d. That the pumps can deliver the specified pressure and flow rate.

e. That the pumps are capable of pumping raw unscreened sewage.

f. That the pump sensors and controls perform satisfactorily, and the pumps start(s), stop and high alarm levels are correct.

10.3.2 Guarantee

The contractor shall guarantee the station for 24 months from the date of acceptance that the structure and all equipment will be free from defects in design, materials and workmanship. The lift station manufacturer shall furnish replacement parts FOB factory, for any component proven defective, whether of theirs or of other manufacturer during the guarantee period, except for those items which are normally consumed in service such as light bulbs, oil, grease, pump seals, etc.

10.3.3 Warranty

The manufacturer of the station shall warrant for one (1) year from date of start-up, not to exceed eighteen (18) months from date of shipment, that the structure and all equipment he provides will be free from defects in material and workmanship. Warranties and guarantees of the suppliers of various components in lieu of a single-source responsibility by the Manufacturer will not be accepted. The Manufacturer shall assume prime responsibility for the warranty of the station and all components provided by them. Equipment supplied by others and incorporated into the station is not covered by this warranty.

In the event a component fails to perform as specified or is proven defective in service during the warranty period, the Manufacturer shall repair or replace, at his discretion, such defective part.

He shall further provide, without cost, such labor as may be required to replace, repair or modify the steel structure. After start-up service has been performed, the labor to replace accessory items, such as the blower, priming pumps, alternator, etc., shall be the responsibility of others.

It is not intended that the Manufacturer assume responsibility for contingent liabilities or consequential damages of any nature resulting from defects in design, material, workmanship or delays in delivery, replacement or otherwise.

The motor adapter, volute, impeller, fiberglass enclosure and steel base shall be covered by a 10-year pro-rated warranty. The fiberglass enclosure shall be warranted against failure of the fiberglass components. The steel base shall be warranted against structural failure and perforation due to corrosion. If applicable, the microprocessor controller, panel display unit and submersible level transducer shall be covered by a 5-year pro-rated warranty.

The pro-rated warranties shall be computed on a monthly basis starting at shipment and shall cover replacement parts only.

The repair or replacement of those items normally consumed in service, such as pump seals, grease, light bulbs, etc., shall be considered as part of routine maintenance and upkeep.

This warranty is valid only when installation, operation and maintenance has been done in accordance with the manufacturer’s recommendations. A start-up report filed by an authorized representative of the manufacturer must be received by the manufacturer after the unit is placed in service.

The manufacturer shall provide a warranty certificate covering specific details.

The manufacturer’s warranty period shall run concurrently with the Contractor’s warranty period. No exception to this provision shall be allowed.

10.3.4 Operating Instructions

Four (4) operating and maintenance manuals complete with spare parts lists for all equipment shall be furnished. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operation and maintenance personnel unfamiliar with such equipment.

A factory representative of all major component manufacturers, who has complete knowledge of their proper operation and maintenance, shall be provided one day to instruct representatives of the City on proper operation and maintenance. With the permission of the City, this work may be conducted in conjunction with the inspection of the installation and test run as provided under Section 9.3.1.3. If there are difficulties in operation of the equipment due to the manufacturer’s design or fabrication, additional service shall be provided at no cost to the City.

10.3.5 Tools and Spare Parts

One (1) set of all special tools required for normal operation and maintenance shall be provided. All such tools shall be furnished in a suitable steel tool chest complete with lock and duplicate keys. A complete replacement pump shaft seal assembly shall be furnished with each pump station. The spare seal shall be packed in a suitable container and shall include complete installation instructions. A spare volute gasket and seal gasket shall be provided.

An instructional video presentation on the pump mechanical seal system in DVD format shall be included. The DVD shall contain a presentation on the following subjects: purpose and location of the mechanical seal, signs of a defective mechanical seal, how to remove the mechanical seal, troubleshooting seal failure causes, seal components, required tools, how to reinstall the seal and how to place the pump back into service. The video shall include footage of an actual seal replacement.

Check out ‐ The manufacturer shall have his representative place the station in initial operation after all construction has been completed. This shall be done on a Monday, Tuesday, Wednesday or Thursday (not on a Friday, Saturday, Sunday or holiday or day before a holiday). The manufacturer shall furnish the City with four (4) copies of the “crank up” report. A formal inspection of the pumping station shall be scheduled on a day following the station start up but not concurrently (again not a Friday, Saturday, Sunday, Holiday or day before a Holiday). This must be closely coordinated with the City, providing a minimum of two weeks advance notice.

10.3.6 Miscellaneous

Any materials not listed in the Contract Documents (specification, construction drawings, special provisions, bid solicitation) will be per latest FDOT specifications.

All 90° and 45° flanged bends on the entire project will be long radius bends. There is to be no 90° or 45° bend on the job site that is not long radius bends except for 90° and 45° MJ bends and bends used in the in the manufacturing of Smith & Loveless provided pump station components.

Pump motors Pump supplier will certify the date of manufacture.

All stainless steel will be 316 series unless noted otherwise.

The pump station includes everything to make the station fully operational which includes, but is not limited to, pumps, piping, valves, control panel (which must be furnished by the pump supplier), 2 glycerin filled gauges.

10.3.6.1 Fencing

The fence and gate bolts shall be pinned to make disassembly difficult. Fencing shall be vinyl coated (green or black) with top rail. All slabs, equipment, and utilities shall be located within the fenced area at least 4 feet from the fence. A 6‐foot high perimeter chain link fence shall be installed with a walk in and drive through sixteen (16) foot cantilever slide gate. This metal fencing shall conform to the current FDOT standard specification for Type “B” fencing or as detailed on the construction documents. Barbed wire attachments are not to be included, unless specifically noted otherwise in the construction documents.

10.3.6.2 Driveway and Parking Areas

Concrete driveway and parking areas shall meet the current FDOT specification. Where approved by the engineer, asphalt driveway & parking area are permitted given the following requirements. Drive and parking area shall include subgrade base and wearing surface in accordance with current City Standards. Pavement grade shall be determined in relation to the drainage installations. The station’s paved access road shall be 16‐feet wide and have a slope between 2% and 12%. The road width may be reduced to a minimum of 12‐feet wide with the permission of the Engineering Manager or designee. A paved vehicle turnaround area with a 20‐foot inside turning radius to allow a two‐ton truck to turn around is required. Four (4) inches of FDOT No. 57 gravel over 20 mil geotextile, or equivalent topsoil and sod, will be placed in the unpaved areas surrounding the station. Should the plans show a concrete drive and parking area, the drive and parking area will be per the plans.

10.3.6.3 Exceptions

No exceptions from these specifications will be allowed unless specifically approved in writing by the Water Resources Engineering Manager or designee.

The City will review submittal data of the pump station manufacturer to facilitate inadvertent exceptions, however, inclusion of exceptions in the submittal shall not satisfy the requirement that it be specifically approved.

END OF SUPPLEMENTAL SPECFICATION SECTION

Supplemental Technical Specifications - Wet Well Mounted Pump Stations

REVISION DATE: JUNE 2018 2016