11310_-_Submersible_Pumps.pdf

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SECTION 11300

SUBMERSIBLE WASTEWATER PUMPS

PART 1 - GENERAL

1.01 DESCRIPTION

A. Furnish all labor, materials, equipment and incidentals required to install, complete, and ready for operation, submersible wastewater pumps as shown in the drawings and specified herein.

B. These Specifications are intended to give a general description of what is required, but do not cover all details that will vary in accordance with the requirements of the equipment as offered. All materials, equipment, and appurtenances for the complete pumping units, whether specifically mentioned in these Specifications or not, shall be included.

C. The pump station shall be comprised of a concrete wet well, concrete valve vault, concrete meter vault, two submersible wastewater pumps with controls, discharge piping and all appurtenances as specified herein and shown on the drawings. The pump station will pump raw, unscreened, domestic wastewater.

D. It is expected that the equipment as offered incorporate the highest standards for this type of service.

1.02 RELATED SECTIONS

A. Concrete work and installation of anchor bolts is included in Division 3, but anchor bolts shall be furnished under this Section.

B. Piping and Valves are included in Division 15.

C. All Instrumentation and Controls are specified in Division 13 – Special Construction, in Section 13300 – Instrumentation and Controls, Section 13315 – Control Panels, Section 13320 Control System, and Section 13330 - Telemetry.

D. Other Sections as applicable.

1.03 REFERENCES

A. ANSI/Hydraulic Institute (HI) Standards;

1. ANSI/HI 11.6-2012. Rotodynamic Submersible Pumps: for Hydraulic Performance, Hydrostatic Pressure, Mechanical and Electrical Acceptance Tests

B. ANSI/HI 14.6-2011.Rotodynamic Pumps: for Hydraulic Performance Acceptance Tests

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C. ANSI/National Electrical Manufacturers Association (NEMA) American National Standard Motors and Generators MG-1

D. International Organization for Standardization (ISO).

E. Applicable sections of the NEC, IEEE, ANSI and NEMA.

1.04 QUALIFICATIONS

A. To assure unity of responsibility, the pumps, motors, automatic discharge connection system, hatches, control system and all appurtenances shall be furnished by the pump manufacturer and coordinated by the local pump manufacturer’s representative. The Contractor and pump manufacturer shall assume responsibility for the satisfactory installation and operation of the entire pumping system.

B. The pumps covered by these Specifications are intended to be standard pumping equipment of proven ability as manufactured by a reputable manufacturer having a minimum of ten years’ experience in the production of such pumps. The pumps furnished shall be new and unused and be designed, constructed, and installed in accordance with the best practice and methods of the industry.

Pumps shall be manufactured in accordance with the Hydraulic Institute Standards.

C. The pumps, motors, control system, and appurtenances shall be furnished by Sulzer-ABS, Xylem-Flygt, or Wilo-EMU. No substitution is permitted.

1.05 WARRANTY

A. The pump manufacturer shall provide a full, non-prorated, 5-year warranty covering all parts, service, and labor for 5 years from date of start-up.

B. The pump manufacturer shall provide a full, non-prorated, lifetime warranty covering the pump seals for all parts, service, and labor required to replace failed seals and all consequential pump damage.

1.06 SUBMITTALS

A. Copies of all materials required to establish compliance with the Specifications shall be submitted in accordance with the provisions of the General Conditions.

Submittal shall include at least the following:

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

2. Descriptive literature, bulletins, and catalogs of the equipment.

3. Data on the characteristics and performance of each pump. Data shall include a certified performance test, based on actual shop tests of the sale units, which show that they meet the specified requirements for head, capacity, efficiency, submergence, and horsepower. Curves shall

11311-3 be submitted on 8½ x 11 sheets, at as large a scale as is practical, including grid-lines. Curves shall be plotted from no flow at shut off head to the maximum flow at the minimum pressure recommended for the proposed pump. Curves also shall include NPSHR, Horsepower, and hydraulic efficiency. Catalog sheets showing a family of curves will not be acceptable. All tests shall be in accordance with ANSI/HI 11.6-2012.

4. Complete master wiring diagrams, elementary or control schematics, including coordination with other electrical control devices operating in conjunction with the pump control system and suitable outline drawings shall be furnished for approval before proceeding with manufacture.

Standard pre-printed sheets or drawings simply marked to indicate applicability to this contract will not be acceptable.

5. A scale drawing showing the layout of the pump control panel shall be furnished. The layout shall indicate every device mounted on the door with complete identification.

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

7. A complete, total Bill of Materials for all equipment.

8. A list of the manufacturer’s recommended spare parts to be supplied in addition to those specified in paragraph 1.08, with the manufacturer’s current price for each item. Include gaskets, seals, etc. on the list. List bearings by the bearing manufacturer’s numbers only.

9. All submittal data required by the General Conditions.

10. Complete motor data.

B. 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.

C. Upon receipt of approval of submitted material, provide the number of prints specified in the General Conditions. Provide electronic drawings in AutoCAD format upon request of engineer.

1.07 OPERATING AND MAINTENANCE MANUALS

A. Operating and maintenance manuals 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 operating and maintenance personnel unfamiliar with such equipment. The number and special requirements shall be as specified in the Contract Documents.

B. A factory representative who has complete knowledge of proper operation and maintenance shall be provided for one day, to instruct representatives of the Owner and the Engineer on proper operation and maintenance. If there are

11311-4 difficulties in operation of the equipment due to the manufacturer’s equipment or fabrication, additional service shall be provided at no cost to the Owner.

1.08 TOOLS AND SPARE PARTS

A. One 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.

B. The manufacturer shall furnish a complete set of recommended spare parts necessary for the first five years operation of the pumping system, which shall include at least the following for each pump supplied:

1. 1 set of upper bearings

2. 1 set of lower bearings

3. 1 set of upper and lower tandem shaft seals

4. 1 set of “O-Rings” or gaskets required for replacement of bearings and seals

5. 1 impeller wear ring or plate

6. 1 cable cap, if applicable

C. Spare parts shall be properly packaged and labeled for identification without opening the packaging and suitably protected for long term storage.

1.09 PRODUCT HANDLING

A. 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.

B. All equipment and parts must be properly protected against any damage and weather during a prolonged period at the site.

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

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

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

F. 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.

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

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PART 2 - PRODUCTS

2.01 MATERIALS AND EQUIPMENT

A. 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. Ample room shall be provided for inspection, repairs, and adjustments.

B. All necessary fasteners, chain, bolts, plates, nuts, and washers shall be AISI class 316 or greater Stainless Steel.

C. Stainless steel or brass nameplates giving the name of the manufacturer, the rated capacity, head, speed, and all other pertinent data shall be attached to each pump and motor. Nameplates shall include Underwriters Laboratories (UL) or Factory Mutual (FM) approval.

D. The nameplate ratings for the motors shall not be exceeded, nor the design service factor be reduced, when operating at any point on the characteristic curve.

2.02 PUMPS

A. Certification

The pump manufacturer must have a Quality Management System certified to ISO 9001.

B. General

Provide submersible non clog sewage pumps suitable for continuous duty submerged operation in liquids with a maximum temperature of 104°F without loss of watertight integrity. Pump system design shall include a guide rail system such that the pump will be automatically connected to the discharge piping when lowered into place on the discharge connection. The pump shall be easily removable for inspection or service requiring no bolts, nuts, or other fasteners to be disconnected, or the need for personnel to enter the wet well. The motor and pump shall be designed, manufactured, and assembled by the same manufacturer.

C. Pump and Motor shall conform to the following Specifications

Pump Pump Type Centrifugal, Submersible, Non-clog Pump Mounting Stainless Steel Guide Rail(s) Number of Pumps 2 Pump Speed 1190 RPM Pump Discharge Size 8 inches minimum Minimum Solids Passage 3 inch diameter

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Operating Points Min Design Max Flow, gpm 2400 3600 4000 Pressure, ft H2O 131 110 80

Motor

HP (Non-overloading) 139 (103 kW)

RPM 1190

Voltage 460V Phase 3 Frequency 60 Hz Refer to motor construction below.

D. Pump Construction

All major pump components shall be cast iron per ASTM A48 Grade 35. Castings shall have smooth surfaces devoid of blow holes and other casting irregularities. All fasteners shall be AISI class 316 stainless steel. All surfaces shall be primed with factory applied zinc phosphate primer and top-coated with either high solids two-part epoxy or polyester resin. The final top coat shall be 7 mils minimum thickness.

1. Impellers

The impeller shall be of non-clog (capable of passing a 3 inch diameter sphere), single-suction, semi-open (single-shrouded), radial flow design, incorporating one or two long sweeping vanes with wide flow channel(s) and be constructed of cast iron per ASTM A48 Grade 35. Vortex-type design is not acceptable. Alternative impeller designs may be submitted for consideration given the following conditions:

a) The proposed alternative impeller design has been in-use for this application and horsepower for a minimum of five years.

b) The manufacturer can provide a minimum of five references of utility operators for interview by the Engineer.

c) The manufacturer provides an additive or deductive alternate price for the acceptance of the alternate impeller. Such alternate price must not be included in the bid but offered to the Owner after award.

The impeller shall be dynamic balancing and be capable of handling solids, fibrous materials, heavy sludge, and all other matter normally expected in raw domestic sewage. All fasteners shall be AISI class 316 stainless steel. The pumps shall be furnished with a removable impeller wear ring or plate. The impeller shall be primed with factory applied zinc phosphate primer and top-coated with either high solids two-part epoxy or polyester resin.

2. Shaft Seals

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Two separate mechanical shaft seals shall be provided and arranged in an upper and lower configuration. Seals shall be UL or FM approved for explosion proof motors and may be a Crane Type 21, Sealol Type 42, or a proprietary design. All seals must be silicon carbide. All metal components shall be AISI Class 316 stainless steel. All elastomers shall be Viton or Nitrile (Buna-N).

Seal systems shall be separated by an oil-filled reservoir. The reservoir shall have separate oil fill and drain plugs to insure accuracy when measuring lubricant level and for ease of maintenance. The outer seal shall be protected from exposure to solids and foreign matter.

Seal shall require no special maintenance or routine adjustment;

however, shall be easily inspected or replaced. No seal damage shall result from operating the pump for short periods of time without liquid.

E. Electric Motor Construction

1. Design

a) All motors shall confirm to the latest HI, NEMA, IEEE, ANSI, and NEC standards and shall have UL and CSA approval on the name plate. The motor shall be continuous duty with the following characteristics:

(1) Submersible motor integrity testing to 15 psi minimum for 5 min duration per HI 11.6.

(2) Housing Materials: ASTM A-48, Grade 35 or greater

(3) Motor Classification: NEMA Design B with torque and starting current in accordance with NEMA MG-1-12.2

(4) Minimum efficiency – In accordance with NEMA MG-1

Table 51.

(5) Service Factor: 1.15 minimum

(6) Explosion class: NFPA 70 (NEC) Class 1 Division 1 Group

C or D

(7) Insulation Class: NEMA class F or H moisture resistant insulation

(8) Starting frequency: Minimum of 10 starts per hour

(9) Voltage tolerance: In accordance with NEMA MG-1-14.30

b) The motor shall be designed to continuously operate while in a wholly, partially, or non-submerged condition. If a cooling jacket is proposed to accomplish this, it shall be a non-clogging design.

c) The motor horsepower shall be adequate as to be non-overloading throughout the entire pump performance curve.

2. Rotor

Rotor shall be cast solid and dynamically balanced for vibration free operation. The pump and motor shaft shall be the same unit. The shaft shall be constructed from AISI class 420 or greater stainless steel. The shaft shall be machined for positive placement of bearings. The upper

11311-8 and lower bearing shall be of heavy duty design, capable supporting the shaft and rotor while under maximum radial and thrust loads. The bearings shall be permanently grease lubricated and sealed at the time of installation.

3. Entry Cable Seals

All static seals at water tight mating surfaces shall be of Nitrile O-ring type. Use of auxiliary sealing compounds shall not be required. The power and control cables shall enter the motor through a terminal housing and comply with standard Factory Mutual (FM) design requirements. The entrance shall be sealed with a rubber grommet and clamp set which when compressed longitudinally causes a radial water tight seal. The clamp set shall prevent all slippage and rotation of cables while engaged, yet may be easily removed and reused during routine maintenance.

4. Cables

The pump and electrical cables shall be capable of continuous submergence without the loss of waterproof integrity and comply with standard Factory Mutual (FM) design requirements. Cables shall be of adequate length to accommodate installation for this project.

5. Water Tightness Integrity

Water-tight integrity of the motor housing and shaft seal shall be tested during manufacture by pressurizing the motor cavity and submerging in water with motor operating in accordance with ANSI/HI 11.6-2012.

6. Thermal Protection

The motor shall be protected from thermal and moisture damage.

Thermal protection shall consist of three separate thermostatic switches embedded into the stator windings. Each switch shall open independently and terminate motor operation if temperature of the protected winding reaches the high temperature set point of 125 degrees F. The thermal sensing devices shall annunciate in the pump control panel per the control specifications.

7. Moisture Protection

Any moisture in the motor housing shall be detected by a mechanically activated moisture sensing micro-switch. The switch shall be sensitive enough to detect airborne moisture and terminate motor operation before liquid enters the cavity. Use of probes or floats that rely on the presence of liquids to initiate signal shall not be considered acceptable. The moisture sensing devices shall annunciate in the pump control panel per the control specifications.

F. Automatic Discharge Connection System

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1. General

Each pump shall be furnished with an automatic discharge connection system to permit removal and installation of the pump without the necessity of an operator entering the wetwell. The design must insure an automatic, water tight connection of the pump to the discharge piping when lowered into place. The discharge connection system shall consist of a guide rail assembly, a seating flange, a base elbow, and a hoisting system.

Proper installation and alignment of the automatic discharge connection system shall be as directed by the pump manufacturer including all required dimensions and clearances. Any specific work necessary to install these components is to be included whether specifically shown in the contract documents or not. No portion of the pumps shall be supported directly on the bottom of the wetwell, guide rails, or lifting cable.

2. Guide Rail Assembly

The guide rail assembly shall consist of one or two rails or pipes per pump as determined by the manufacturer and shall be sized in diameter and wall thickness appropriate for the specified pumping equipment or schedule 40, minimum. Support brackets shall be provided to fasten the guide rails to the wetwell wall at the frequency of one set of brackets per 20 linear feet of rails, minimum. The guide rail assembly shall be supplied with an upper support bracket and shall be mounted to the base elbow at the bottom. The guide rail(s), all support brackets, fasteners, and appurtenances shall be AISI class 316 stainless steel.

3. Seating Flange

The seating flange (slide bracket or guide shoe) is to be provided as part of the discharge flange of the pump. The seating flange shall direct the pump down the vertical guide rails and onto the discharge connection in a simple linear movement. The seating flange shall be designed with integral hooks at the top to transmit full weight of the pump to the discharge base elbow creating a tight seal. When lowered into place, no rotary motion of the pump shall be required for sealing with the base elbow.

4. Base Elbow

A base elbow shall be provided for each pump designed to mate with the pump discharge as stated above and provide a 90 degree bend to an ANSI class 125 flange consistent with the pump size and discharge diameter. The base elbow diameter shall match the pump flange diameter with no reducers necessary.

The base elbow shall be cast iron per ASTM A48 Grade 35. Castings shall have smooth surfaces devoid of blow holes and other casting

11311-10 irregularities. All fasteners shall be AISI class 316 stainless steel. All surfaces shall be primed with factory applied zinc phosphate primer and top-coated with either high solids two-part epoxy or polyester resin. The final top coat shall be 7 mils minimum thickness. Floor fasteners shall be 3/4” minimum diameter.

5. Hoisting System

The pumps shall be supplied with a lifting bail, for proper balance of pump and release from the discharge connection while using a single lift cable.

Stainless steel chain (2 feet) plus lifting braided wire lift cable shall be provided for each pump. The chain, braided wire, and fasteners shall be sized by the manufacturer for the total weight of the pump and motor plus a minimum safety factor of two (2.0). A crimped ball end shall be provided at the upper end of this cable for attaching to the wetwell access frame. All chain, cable, and fasteners shall be AISI Class 316 stainless steel.

6. Unit Responsibility

To assure unity of responsibility, the Automatic Discharge Connection System shall be considered appurtenant to the pump installation and shall be furnished by the pump manufacturer and coordinated by the local pump manufacturer’s representative. The Contractor and pump manufacturer shall assume responsibility for the satisfactory installation and operation of the entire pumping system.

2.03 ACCESS FRAMES AND GUIDES

A. The pumping station shall be furnished with the necessary aluminum access frames, complete with hinged and hasp-equipped covers, stainless steel upper guide holder, and level sensor cable holder. The frames shall be securely mounted above the pumps. Access doors shall have safety locking handle in the open position. Doors shall be of aluminum checkered plate with stainless steel hardware as manufactured by the Bilco Company, Babcock-Davis, Halliday, U.S.

Fabrication or U.S. Foundry Co. No substitution is permitted.

2.04 PUMP CONTROL SYSTEM

Refer to paragraph 1.02C.

PART 3 - EXECUTION

3.01 INSTALLATION

A. Installation shall be in strict accordance with the manufacturer’s instructions and recommendations in the locations shown on the drawings. Installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations.

Anchor bolts shall be set in accordance with the manufacturer’s recommendations.

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B. The Contractor shall submit a certificate from the equipment manufacturer stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and care of each unit.

3.02 SHOP PAINTING

A. Before exposure to weather and prior to shop painting, all surfaces shall be thoroughly cleaned, dried, and free from all mill-scale, rust, grease, dirt, and other foreign matter.

B. All pumps and motors shall be shop coated. All surfaces shall be primed with factory applied zinc phosphate primer and top-coated with either high solids two-part epoxy or polyester resin. The final top coat shall be 8 mils minimum thickness. Alternative coating systems may be submitted for Engineers consideration.

C. All nameplates shall be properly protected during painting.

D. Gears, bearing surfaces, and other similar surfaces obviously not to be painted shall be given a heavy shop coat of grease or other suitable rust-resistant coating. This coating shall be maintained as necessary to prevent corrosion during periods of storage and erection and shall be satisfactory to the Engineer up to the time of the final acceptance test.

3.03 INSPECTION AND TESTING

A. General Description

1. 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 from the point of manufacture.

2. The Engineer shall be notified in writing prior to initial shipment, in ample time so that arrangements can be made for inspection by the Engineer.

3. The Engineer or his representative shall be furnished all facilities, including labor, and shall be allowed proper time inspection and testing of material and equipment.

4. Materials and equipment shall be tested or inspected as required by the Engineer, and the cost of such work shall be included in the cost of the equipment. The Contractor shall anticipate that delays may be caused because of the necessity of inspection, testing and accepting materials and equipment before their use is approved.

5. The services of a factory representative shall be furnished for one day, for each station, and shall have complete knowledge of proper operation and maintenance to inspect the final installation and supervise the test run of the equipment. With the permission of the Owner, these services may be combined with those provided under paragraph 1.07, OPERATING AND

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MAINTENANCE MANUALS.

6. Field tests shall not be conducted until such time that the entire installation is complete and ready for testing.

B. Pumps Inspection

1. 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. Supply all electrical power, water or wastewater, labor, equipment and incidentals required to complete the field tests.

2. If the pump performance does not meet the Specifications, corrective measures shall be taken or pumps shall be removed and replaced with pumps that 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.

C. Motor Inspection

1. The Contractor shall check all motors for correct clearance and alignment and for correct lubrication in accordance with manufacturer’s instructions.

The Contractor shall check direction of rotation of all motors and reverse connections if necessary.

END OF SECTION

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