B09_A0006_Att_33_32_00_Wastewater_Utility_Pumping_Stations_REV_1_0006.pdf

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WASTEWATER UTILITY PUMPING STATIONS

SECTION 33 32 00 – WASTEWATER UTILITY PUMPING STATIONS

PART 1 - GENERAL

1.1 SECTION REQUIREMENTS

A. Contractor shall furnish and install one factory built above ground, automatic pump station. The station shall be complete with all equipment specified herein; factory assembled in a fiberglass reinforced polyester resin enclosure. The lift-station shall be complete with all equipment specified herein, factory assembled on a common steel baseplate. In addition to the station enclosure, principle items of equipment shall include two horizontal, self-priming, centrifugal sewage pumps, V-belt drives, motors, auto-start diesel, water cooled stand-by engine for back-up to one pump, diesel tank and piping, internal piping, valves, motor control panel with thermal-magnetic circuit breakers, magnetic motor starters, automatic liquid level control system, and internal wiring. Work includes, but is not limited to; new wetwell, new above ground pump station, piping, controls, motors, electrical service, alarms and similar work required to provide a complete, operational lift station.

B. Submittals: Items to be submitted include: wetwell layout, pipe, fittings, pumps, motors, controls, Variable Frequency Drives, valves, piping, backflow devices, hatches, enclosure, engines, fuel tank, heaters, fittings and other similar items.

1. New Pump station:

a. Submittal shall include shop drawings, electrical ladder logic drawings, and support data as follows: Catalog cuts sheets reflecting characteristics for major items of equipment, materials of construction, major dimensions, motor and v-belt drive data, pump characteristic curves showing the design duty point capacity (GPM), head (FT), net positive suction head required (NPSHr), and hydraulic brake horsepower (BHP).

Electrical components used in the motor branch and liquid level control shall be fully described.

b. Shop drawings shall provide layout of mechanical equipment and anchor bolt locations for station. Pipe penetrations and station access clearances shall be dimensioned relative to the station centerline. The electrical ladder logic drawings shall illustrate motor branch and liquid level control circuits to extent necessary to validate function and integration of circuits to form a complete working system.

2. New Pump station Operations and Maintenance Manuals

a. Operations and Maintenance Manuals: Operation shall be in accordance with written instructions provided by the pump station manufacturer. Comprehensive instructions supplied at time of shipment shall enable personnel to properly operate and maintain all equipment supplied. Content and instructions shall assume operating personnel are familiar with pumps, motors, piping and valves, but lack experience on exact equipment supplied.

b. Documentation shall be specific to the pump station supplied and collated in functional sections. Each section shall combine to form a complete system manual covering all aspects of equipment supplied by the station manufacturer. Support data for any equipment supplied by others, even if mounted or included in overall station

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design, shall be provided by those supplying the equipment. Instructions shall include the following as a minimum:

1) Functional description of each major component, complete with operating instructions.

2) Instructions for operating pumps and pump controls in all modes of operation.

3) Calibration and adjustment of equipment for initial start-up, replacement of level control components, or as required for routine maintenance.

4) Support data for commercially available components not produced by the station manufacturer, but supplied in accordance with the specifications, shall be supported by literature from the prime manufacturer and incorporated as appendices.

5) Electrical schematic diagram of the pump station circuits shall be in accordance with NFPA 70. Schematics shall illustrate, to the extent of authorized repair, pump motor branch, control and alarm system circuits including interconnections. Wire numbers and legend symbols shall be shown. Schematic diagrams for individual components, not normally repairable by the station operator, need not be included. Details for such parts shall not be substituted for an overall system schematic. Partial schematics, block diagrams, and simplified schematics shall not be provided in lieu of an overall system diagram.

6) Mechanical layout drawing of the pump station and components, prepared in accordance with good commercial practice, shall provide installation dimensions and location of all pumps, motors, valves and piping.

c. Operation and maintenance instructions which rely on vendor cut-sheets and literature which include general configurations, or require operating personnel to selectively read portions of the manual shall not be acceptable. Operation and maintenance instructions must be specific to equipment supplied in accordance with these specifications.

1.2 QUALITY ASSURANCE

C. Electrical Components, Devices and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. Must also meet requirements of the NEC.

D. Manufacturer’s Qualifications: Firm regularly engaged in manufacture and maintenance of sewage pumps and pump stations, of types, materials, and sizes required, whose products have a record of successful in-service performance for not less than five (5) years. Equipment must be completely compatible with existing equipment.

1. The pumps and pump station manufacturer must be ISO 9001:2015 revision certified, with scope of registration including design control and service after sales activities.

2. The pumps and pump station manufacturer must be registered to the ISO 14001

Environmental Management System standard and as such is committed to minimizing the impact of its activities on the environment and promoting environmental sustainability by the use of best management practices, technological advances, promoting environmental awareness and continual improvement.

3. Upon request from the Contracting Officer, the pump station manufacturer shall prove financial stability and ability to produce the station within the specified delivery schedules.

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Evidence of facilities, equipment and expertise shall demonstrate the manufacturer's commitment to long term customer service and product support.

4. Manufacturer must show proof of original product design and testing. Products violating intellectual property regulations shall not be allowed, as they may violate international law and expose the user or Contracting Officer to unintended liabilities. “Reverse-engineered” products fabricated to substantially duplicate the design of original product shall not be allowed, as they may contain substantial differences in tolerances and material applications addressed in the original design, which may contribute to product failure.

5. The term “pump manufacturer” or “pump station manufacturer” shall be defined as the entity which designs, machines, assembles, hydraulically tests and warranties the final product.

Any entity that does not meet this definition will not be considered a “pump manufacturer” or “pump station manufacturer” and is not an acceptable supplier. For quality control reasons and future pump and parts availability, all major castings of the pump shall be sourced and machined in North America

E. Pump Performance Certifications

1. Pump must dry prime 10.5 vertical feet at the specified speed and impeller diameter. Dry prime lift is defined as the static height of the pump suction above the liquid, while operating with a full casing of the liquid remaining in the pump. The pump must prime and deliver full capacity within five minutes after the pump is energized in the dry prime condition.

a. Liquid to be used for dry prime test shall be water

b. A check valve to be installed down stream from the pump discharge flange. The check valve size shall be equal (or greater than) the pump discharge diameter.

c. A length of air release pipe shall be installed between pump and the discharge check valve. This line shall be open to atmosphere at all times duplicating the air displacement rate anticipated at a typical pump station fitted with an air release valve.

d. The pump suction check valve shall be removed. No restrictions in the pump or suction piping will prevent the siphon drop of the suction leg. Suction pipe configuration for reprime test shall incorporate a 2 feet minimum horizontal run, a 90o elbow and vertical run at the specified lift. Pipe size shall be equal to the pump suction diameter.

e. Impeller clearances shall be set as recommended in the pump service manual.

f. Repeatability of performance shall be demonstrated by testing five consecutive reprime cycles. Full pump capacity (flow) shall be achieved within five minutes during each cycle.

2. All internal passages, impeller vanes, and recirculation ports shall pass a 2.5" spherical solid.

Smaller internal passages that create a maintenance nuisance or interfere with priming and pump performance shall not be permitted. Upon request from the Contracting Officer, manufacturer’s certified drawings showing size and location of the recirculation port(s) shall be submitted for approval.

3. Reprime Performance

a. Consideration shall be given to the sanitary sewage service anticipated, in which debris is expected to lodge between the suction check valve and its seat, resulting in the loss of the pump suction leg, and siphoning of liquid from the pump casing to the approximate center line of the impeller. Such occurrence shall be considered normal, and the pump must be capable of automatic, unattended operation with an air release line installed.

b. During unattended operation, the pump shall retain adequate liquid in the casing to insure automatic repriming while operating at its rated speed in a completely open

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system. The need for a suction check valve or external priming device shall not be required.

F. Factory System Test

1. All internal components including the engines, pumps, motors, valves, piping and controls will be tested as a complete working system at the manufacturer's facility. Tests shall be conducted in accordance with Hydraulic Institute Standards at the specified head, capacity, rated speed and horsepower. Factory operational test shall simulate actual performance anticipated for the complete station.

2. Upon request from the Contracting Officer, the operational test may be witnessed by the

Contracting Officer, and/or representatives of his choice, at the manufacturer's facility.

G. Manufacturer’s Start-up service

1. The manufacturer's technical representative shall inspect the completed installation, correct or supervise the correction of any defect or malfunction, and instruct operating personnel in the proper operation and maintenance of the equipment as described in Part 3 of this section.

2. Testing shall be performed at a time approved by the Contracting Officer. Contractor shall provide all labor, pumps, pipe, connections, plugs, gauges and necessary equipment to conduct tests.

1.3 MANUFACTURER’S WARRANTY

A. The pump station manufacturer shall warrant all equipment to be of quality construction, free of defects in material and workmanship. A written warranty shall include specific details described below.

1. In addition to defects in material and workmanship, fiberglass reinforced polyester station enclosures are warranted for sixty (60) months to be resistant to rust, corrosion, corrosive soils, effects of airborne contamination or physical failures occurring in normal service for the period of the pump station warranty.

2. All other equipment, apparatus, and parts furnished shall be warranted for sixty (60) months, excepting only those items that are normally consumed in service, such as light bulbs, oils, grease, packing, gaskets, O-rings, etc. The pump station manufacturer shall be solely responsible for warranty of the station and all components.

B. Components failing to perform as specified by the Contracting Officer, or as represented by the manufacturer, or as proven defective in service during the warranty period, shall be replaced, repaired, or satisfactorily modified by the manufacturer.

1.4 NEW PUMP STATION DESCRIPTION

A. Design requirements consist of factory-built pump station design, including materials of construction, pump features, valves and piping, and motor controls shall be in accordance with requirements listed in this specification.

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B. Contractor shall furnish and install one factory built above ground, automatic pump station. The station shall be complete with all equipment specified herein, factory assembled in a fiberglass reinforced polyester resin enclosure.

C. In addition to the station enclosure, principle items of equipment shall include two horizontal, self priming, centrifugal sewage pumps, V-belt drives, motors, internal piping, valves, motor control panel, Variable Frequency Drives (VFD), auto-start diesel engine for pump back-up, diesel fuel tank, piping of fuel, automatic liquid level control system, and internal wiring.

D. Pumps must be designed to handle domestic sanitary effluent. Pumps shall have 4" NPT suction connection, and 4" NPT discharge connection. Each pump shall be selected to perform under following operating conditions:

E. Utility Power Requirements

1. Site power furnished to pump station shall be three phase, 60 hertz, 480 volts (verify with

Government prior to start of submittal process) maintained within industry standards.

Voltage tolerance shall be plus or minus 10 percent. Phase-to-phase unbalance shall not exceed 1% average voltage as set forth in NEMA Standard MG-1.

F. The following publications referenced in this specification are made part of this specification.

Latest edition shall apply.

1. American National Std. Institute (ANSI) / American Water Works Assoc. (AWWA)

a. ANSI B16.1 Cast iron pipe flanges and flanged fittings.

b. ANSI/AWWA C115/A21.51 Cast/ductile iron pipe with threaded flanges.

c. ANSI 253.1 Safety Color Code for Marking Physical Hazards.

d. ANSI B40.1 Gages, Pressure and Vacuum.

e. AWWA C508 Single Swing Check Valves.

2. American Society for Testing and Materials (ASTM)

a. ASTM A48 Gray Iron Castings.

b. ASTM A126 Valves, Flanges, and Pipe Fittings.

c. ASTM A307 Carbon Steel Bolts and Studs.

d. ASTM A36 Structural Steel.

3. Institute of Electrical and Electronics Engineers (IEEE)

a. IEEE Std 100 Standard Dictionary of Electrical Terms.

b. IEEE Std 112 Test Procedure for Polyphase Induction Motors.

c. IEEE Std 242 Protection of Industrial and Control Power Systems.

4. National Electric Code (NEC) / National Electrical Manufacturers’ Assoc. (NEMA)

a. NEC National Electrical Code.

b. NEMA Std MG1 Motors and Generators

5. Miscellaneous References

a. Ten-State Standards Recommended Standards for Sewage Works.

b. Hydraulic Institute Std for Centrifugal, Rotary and Reciprocating Pumps.

c. ISO 9001 International Organization for Standardization.

d. ISO 14001 International Organization for Standardization.

PART 2 - PRODUCTS

2.01 MANUFACTURERS

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A. The pump station system integrator must be ISO 9001:2015 revision certified, with scope of registration including design control and service after sales activities.

B. In order to unify responsibility for proper operation of the complete pumping station, it is the intent of these Specifications that all system components be furnished by a single supplier (unitary source). The pumping station must be of standard catalog design, totally warranted by the manufacturer. Under no circumstances will a system consisting of parts compiled and assembled by a manufacturer's representative or distributor be accepted.

C. All salient features noted in this specification shall be met as decided by the Government.

D. The decision as to an acceptable manufacturer and/or supplier rests solely on the Government.

E. Basis of Design for new lift station: Reliasource (Gorman Rupp) Above-Ground Lift Station

2.02 STATION ENCLOSURE

A. The station enclosure shall contain and protect all pumps, interior piping, valves and associated controls. Enclosure shall incorporate the following design and service features:

1. Enclosure shall be 12’x16’x 8-9’(H) to accommodate all equipment including flow meters, auto-start diesel engine, exhaust fans, heaters and other related equipment. It shall be weatherproof and all openings sealed to prevent weather, insects or animals from entering.

2. Lift station shall be NFPA 820 compliant

3. Two side access panels, a double-man and a removable roof shall be provided for easy access. Doors shall be installed as an integral part of the statin enclosure and include locks and keys. Enclosure shall be vandal-resistant design for security.

4. Exhaust vents, fans, intake vents, exhaust silencer, heater, thermostats and other necessary equipment to provide a complete, operational, safe and comfortable working environment for the equipment and personnel shall be provided and installed with the enclosure.

5. Station Enclosure Low Temperature Alarm

a. Pump station shall be supplied with a thermostat which shall monitor interior station temperature. The control shall incorporate an unpowered dry contact wired to terminal blocks for field connection to a remote alarm device. The contact will close in the event that the temperature within the enclosure falls below approximately 35 degrees F.

6. Enclosure shall be manufactured with a sheet of closed-cell foam, covered with reinforcing fiber layer on each side and linked together by fiberglass bridging strands that form a triangular truss network.

7. The enclosure shall be supplied by the pump station manufacturer and be a standard enclosure as described in their normal brochures, with the features noted in these specifications. An alternate enclosure, not supplied by the pump station supplier shall not be acceptable.

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B. Station shall include, but not be limited to the following:

1. Exhaust Vent assembly

2. Exhaust Fan Assembly

3. Interior LED light fixture

4. Exterior Security light fixture

5. LED emergency light

6. Load center

7. Transformer

8. Fan Thermostat

9. Seal around OPW adapter

10. Heater (Electric and back-up propane heater)

11. Insulation (R-20)

2.03 UNIT BASE

A. Station base shall be comprised of structural steel with a perimeter flange and reinforcements.

Perimeter flange and reinforcements shall be designed to prevent flexing or warping under operating conditions. Perimeter flange shall be drilled for hardware used to secure unit base to concrete pad by the Contractor. Unit base shall contain provisions for lifting the complete pump unit during shipping and installation.

2.04 PUMP DESIGN

A. Pumps shall be a horizontal, self-priming centrifugal type, designed specifically for handling raw, unscreened, domestic sanitary sewage. Pump solids handling capability and performance criteria shall be in accordance with requirements listed below and elsewhere in this specification.

1. Design point: 145 US gpm at 102’ TDH

2. Total Dynamic Suction lift: 19’

3. Maximum Static Suction lift: 18.8

4. Total Discharge Static Head: 6.5’

5. Capable of handling 2.5” diameter solids

6. Basis of Design: Gorman Rupp Model T3A-B-4

B. Materials and Constrution Features:

1. Pump casing: Casing shall be cast iron Class 30 with integral volute scroll. Casing shall incorporate following features:

a. Mounting feet sized to prevent tipping or binding when pump is completely disassembled for maintenance.

b. Fill port coverplate, 3 1/2" diameter, shall be opened after loosening a hand nut/clamp bar assembly. In consideration for safety, hand nut threads must provide slow release of pressure, and the clamp bar shall be retained by detent lugs. A Teflon gasket shall prevent adhesion of the fill port cover to the casing.

c. Casing drain plug shall be at least 1 1/4" NPT to insure complete and rapid draining.

d. Liquid volume and recirculation port design shall be consistent with performance criteria listed under PART 1 - GENERAL of this section.

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2. Cover plate: Cover plate shall be cast iron Class 30. Design must incorporate following maintenance features:

a. Retained by hand nuts for complete access to pump interior. Coverplate removal must provide ample clearance for removal of stoppages, and allow service to the impeller, seal, wearplate or check valve without removing suction or discharge piping.

b. A replaceable wearplate secured to the coverplate by weld studs and nuts shall be AISI 1015

HRS.

c. In consideration for safety, a pressure relief valve shall be supplied in the coverplate. Relief valve shall open at 75-200 PSI.

d. Two O-rings of Buna-N material shall seal coverplate to pump casing.

e. Pusher bolt capability to assist in removal of coverplate. Pusher bolt threaded holes shall be sized to accept same retaining capscrews as used in rotating assembly.

f. Easy-grip handle shall be mounted to face of coverplate.

3. Rotating Assembly: A rotating assembly, which includes impeller, shaft, mechanical shaft seal, lip seals, bearings, sealplate and bearing housing, must be removable as a single unit without disturbing the pump casing or piping. Design shall incorporate following features:

a. Sealplate and bearing housing shall be cast iron Class 30. Separate oil filled cavities, vented to atmosphere, shall be provided for shaft seal and bearings. Cavities must be cooled by the liquid pumped. Three lip seals will prevent leakage of oil.

1) The bearing cavity shall have an oil level sight gauge and fill plug check valve. The clear sight gauge shall provide easy monitoring of the bearing cavity oil level and condition of oil without removal of the fill plug check valve. The check valve shall vent the cavity but prevent introduction of moist air to the bearings.

2) The seal cavity shall have an oil level sight gauge and fill/vent plug. The clear sight gauge shall provide easy monitoring of the seal cavity oil level and condition of oil without removal of the fill/vent plug.

3) Double lip seal shall provide an atmospheric path providing positive protection of bearings, with capability for external drainage monitoring.

b. Impeller shall be ductile iron, two-vane, semi-open, non-clog, with integral pump out vanes on the back shroud. Impeller shall thread onto the pump shaft and be secured with a lockscrew and conical washer.

c. Shaft shall be AISI 4140 alloy steel unless otherwise specified by the Contracting Officer, in which case AISI 17-4 pH stainless steel shall be supplied.

d. Bearings shall be anti-friction ball type of proper size and design to withstand all radial and thrust loads expected during normal operation. Bearings shall be oil lubricated from a

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dedicated reservoir. Pump designs which use the same oil to lubricate the bearings and shaft seal shall not be acceptable.

e. Shaft seal shall be oil lubricated mechanical type. The stationary and rotating seal faces shall be tungsten titanium carbide alloy. Each mating surface shall be lapped to within three light bands flatness (35 millionths of an inch), as measured by an optical flat under monochromatic light. The stationary seal seat shall be double floating by virtue of a dual O-ring design; an external O-ring secures the stationary seat to the sealplate, and an internal O-ring holds the faces in alignment during periods of mechanical or hydraulic shock (loads which cause shaft deflection, vibration, and axial/radial movement). Elastomers shall be viton. Cage and spring to be stainless steel. Seal shall be oil lubricated from a dedicated reservoir. The same oil shall not lubricate both shaft seal and shaft bearings. Seal shall be warranted in accordance with requirements listed under PART 1 - GENERAL of this section.

f. Pusher bolt capability to assist in removal of rotating assembly. Pusher bolt threaded holes shall be sized to accept same capscrews as used for retaining rotating assembly.

4. Adjustment of the impeller face clearance (distance between impeller and wearplate) shall be accomplished by external means.

a. Clearances shall be maintained by a four point external shimless coverplate adjustment system, utilizing a four collar and four adjusting screw design allowing for incremental adjustment of clearances by hand as required. Each of the four points shall be lockable to prevent inadvertent clearance increases or decreases due to equipment vibration or accidental operator contact. The four point system also allows for equal clearance gaps at all points between the impeller and wear plate. Requirement of realignment of belts, couplings, etc., shall not be acceptable. Coverplate shall be capable of being removed without disturbing clearance settings. Clearance adjustment systems that utilize less than four points will not be considered.

b. There shall be provisions for additional clearance adjustment in the event that adjustment tolerances have been depleted from the coverplate side of the pump. The removal of stainless steel shims from the rotating assembly side of the pump shall allow for further adjustment as described above

c. Clearance adjustment which requires movement of the shaft only, thereby adversely affecting seal working length or impeller back clearance, shall not be acceptable.

5. Suction check valve shall be molded Neoprene with integral steel and nylon reinforcement. A blow-out center shall protect pump casing from hydraulic shock or excessive pressure. Removal or installation of the check valve must be accomplished through the coverplate opening, without disturbing the suction piping. Sole function of check valve shall be to save energy by eliminating need to reprime after each pumping cycle. Pumps requiring a suction check valve to assist reprime will not be acceptable.

6. Spool flanges shall be one-piece cast iron, class 30 fitted to suction and/or discharge ports. Each spool shall have one 1-1/4" NPT and one 1/4" NPT tapped hole with pipe plugs for mounting gauges or other equipment.

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B. Serviceability

1. The pump manufacturer shall demonstrate to the Contracting Officer's satisfaction that consideration has been given to reducing maintenance costs by incorporating the following features.

2. No special tools shall be required for replacement of any components within the pump.

C. Pump drain kit

1. The pump drain kit shall consist of a 10' length of plastic hose with a quick connect female

Kamlock fitting on one end of hose and two sets of fittings for pump drains. Each set of fittings for pump drain includes a stainless steel pipe nipple, stainless steel bushing, stainless steel ball valve and an aluminum quick connect male Kamlock fitting.

D. Spare parts kit

1. There shall be furnished with the pump station the following minimum spare parts:

a. One spare pump mechanical seal (complete), and with it all gaskets, seals, sleeves, O-rings, and packing required to be replaced during replacement of the seal.

b. One set of impeller clearance adjustment shims.

c. One set cover plate O-ring.

d. One rotating assembly O-ring.

2.05 VALVES AND PIPING

A. Check Valve: Each pump shall be equipped with a full flow type check valve capable of passing a 3" spherical solid. Valve shall be constructed with flanged ends and fitted with an external lever and torsional spring. Valve seat shall be constructed of stainless steel, secured to the body to ensure concentricity, sealed by an O-ring, and shall be replaceable. The valve body shall be cast iron incorporating a clean-out port large enough to allow removal and/or replacement of the valve clapper without removing valve or piping from the line. Valve clapper shall have a molded neoprene seating surface incorporating low pressure sealing rings. Valve hinge pin and internal hinge arm shall be stainless steel supported on each end in brass bushings. Shaft nut shall have double O-rings which shall be shall be easily replaceable without requiring access to interior of valve body. All internal hardware shall be stainless steel. Valve shall be rated at 175 PSI water working pressure, 350 PSI hydrostatic test pressure. Valves other than full flow type or valves mounted in such a manner that prevents the passage of a 3" spherical solid shall not be acceptable.

B. Plug Valve: The discharge header shall include a 3 way plug valve to permit either or both pumps to be isolated from the common discharge header. Valves shall have ports designed to pass spherical solids equal to the pumps capability. The plug valve shall be non lubricated, tapered type. Valve body shall be semi steel with flanged end connections drilled to 125 pound standard.

Valve shall be furnished with a drip tight shutoff plug mounted in stainless steel bearings, and shall have a resilient facing bonded to the sealing surface. Valve shall be operated with a single lever actuator providing lift, turn, and reseat action. The lever shall be equipped with a locking device to hold the plug in the desired position.

C. Automatic air release valves:

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1. An automatic air release valve shall be furnished for each pump designed to permit the escape of air to the atmosphere during initial priming or unattended repriming cycles. Upon completion of the priming cycle or repriming cycle, the valve shall close to prevent recirculation. Valves shall provide visual indication of valve closure and shall operate solely on discharge pressure. Valves which require connection to the suction line shall not be acceptable.

2. All valve parts exposed to sewage shall be constructed of cast iron, stainless steel, or similar corrosion resistant materials. Diaphragms, if used, shall be of fabric reinforced neoprene or similar inert material.

3. A cleanout port, three inches in diameter, shall be provided for ease of inspection, cleanout, and service.

4. Valves shall be field adjustable for varying discharge heads.

5. Connection of the air release valves to the station piping shall include stainless steel fittings.

D. Curb Stops

1. All curb stops shall be manufactured by a single manufacturer and be of service brass conforming to AWWA Standard C800.

2. Curb stops shall be ball valve type

3. Curb stop ball valves shall be designed and manufactured to conform to AWWA Standard

C800-89 (ASTM B-62-Index 115-85-5-5-5). Ball valves shall be individually inspected and tested for leaks by air pressure under water. They shall have packed compression or copper flare connections.

4. Provide stainless steel rod and brass pin from service box so that the valve can be operated from the upper surface of the wet well slab

E. Gauge Kit

1. A gauge kit shall be supplied for each pump. Suction pressure must be monitored by a glycerin-filled compound gauge, and discharge pressure by a glycerin-filled pressure gauge.

Gauges to be at least 4 inches in diameter, graduated in feet water column. Rated accuracy shall be 1% of full scale reading. Compound gauge shall be graduated -34 to +34 feet water column minimum. Pressure gauge to be graduated 0 to 140 feet water column minimum.

2. Gauges to be factory mounted on a resilient panel with frame assembly secured to pumps or piping. Gauge installations shall be complete with all hoses and stainless steel fittings, including a shutoff valve for each gauge line at the point of connection to suction and discharge pipes.

F. Station Enclosure Low Temperature Alarm

1. Pump station shall be supplied with a thermostat which shall monitor interior station temperature. The control shall incorporate an unpowered dry contact wired to terminal blocks for field connection to a remote alarm device. The contact will close in the event that the temperature within the enclosure falls below approximately 35 degrees F.

G. Piping

1. Flanged header pipe shall be centrifugally cast, ductile iron, complying with ANSI/AWWA

A21.51/C115 and class 53 thickness.

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2. Flanges shall be cast iron class 125 and Comply with ANSI B16.1.

3. Pipe and flanges shall be threaded and suitable thread sealant applied before assembling flange to pipe.

4. Bolt holes shall be in angular alignment within 1/2 degree between flanges. Flanges shall be faced with a gasket finish having concentric grooves a minimum of 0.01 inch deep by approximately 0.03 inch wide, with a minimum of three grooves on any given surface spaced a maximum of 1/4 inch apart.

H. Supports and Thrust Blocks: Contractor must insure all pipes connected to the pump station are supported to prevent piping loads from being transmitted to pumps or station piping. Pump station discharge force main piping shall be anchored with thrust blocks where shown on the contract drawings.

2.06 DRIVE UNIT

A. Motors

1. Pump motors shall be 15 HP, 3 phase, 60 hertz, 480 VAC, horizontal ODP, 2050 RPM (VFD controlled), NEMA design B with cast iron frame with copper windings, induction type, with class F insulation and 1.15 SF for normal starting torque and low starting current characteristics, suitable for continuous service. The motors shall not overload at the design condition or at any head in the operating range as specified.

2. Motors shall be tested in accordance with provisions of ANSI/IEEE Std. 112.

3. Motor of engine shall be of double shaft configuration.

2.07 ENGINE

A. Standby engine shall be a four (4) cylinder or six (6) cylinder, (diesel) fueled water cooled type, and shall have continuous duty power rating suitable for the horsepower requirements of the pump, after derating to factors set forth under performance. Engine shall be cooled by an integral water cooling system capable of maintaining safe engine operating temperature under expected operating loads, and subject to the expected maximum ambient temperatures in the pump station enclosure.

B. Equipment

1. The engine shall be equipped with all controls and components required for manual and automatic operation when used with the engine controls and DC level control system described in these specifications. Such components shall include, but not be limited to, the following:

a. 12 Volt dc electrical system including starter and alternator

b. Storage battery, 84 ampere hour capacity minimum

c. Elapsed running time meter

d. Sensors for engine temperature, oil pressure, and overspeed

e. Critical grade exhaust silencer to limit engine exhaust noise.

f. Switch for manual operation of the cranking motor, mounted on or near the engine

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g. Voltmeter

h. Solenoid fuel lock-off valve suitable for use with natural gas or LPG service

i. Lube oil pressure gauge

j. Jacket water temperature gauge

k. Tachometer

2. Engine electrical equipment shall be wired to a terminal board on the engine and pre-wired to the base secured control panel. (Note: If control panel is opted to be shipped loose, connection to matching terminals in the control panel shall be by contractor.)

3. Because the engine shall be required to operate during emergency situations, the following minimum performance standards shall be used for engine selection:

a. Engine speed shall be controlled by an electronic, governor controlled throttle which shall maintain the preset speed over the range of expected pumping loads. This speed shall not be less than 1800 rpm to insure adequate cooling, nor more than 3000 rpm so that internal engine wear is held to a minimum. This governed speed shall not be acceptable if it is greater than that speed at which the engine torque and horsepower curves intersect. Engine manufacturer's published performance curves shall be submitted for review to support engine selection.

b. The engine shall develop approximately 95 percent of manufacturer's published performance after a reasonable run in period.

c. For selection of engine size, engine performance shall be derated according to manufacturer's specifications to allow for decreased performance if installed at elevations more than 1000 feet above sea level.

d. For selection of engine size, engine performance shall be derated according to manufacturer's specifications to allow for decreased performance in an ambient temperature of 100 degrees

F, which can reasonably be expected in the pump station.

e. Engine rating shall be further reduced to conform to engine manufacturer's recommendations for continuous service applications.

B. Brake horsepower requirements of pump shall not exceed calculated engine horsepower after derating for power available after run in, temperature compensation, and altitude compensation.

2.08 DRIVE TRANSMISSION

A. Power shall be transmitted from engine to pump by a v-belt drive assembly through a centrifugal clutch mounted on a jackshaft, which shall be coupled or otherwise interfaced with a shaft extension on the pump motor. Jackshaft shall be constructed of steel, not less than 1 1/2 inches in diameter, and shall be mounted in two pillow blocks furnished with anti-friction roller bearings.

B. Each drive assembly shall have a minimum of two v-belts or one synchronized belt system. Each v-belt drive assembly shall be selected on the basis that adequate power will be transmitted from driver to pump based on the data developed in accordance with drive calculations.

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C. Precise alignment tolerances of the drive assemblies shall be achieved by means of a belt/sheave laser alignment system resulting in the reduction of vibration, accelerated wear, and premature failure.

D. Centrifugal clutch shall be designed to remain disengaged until engine has reached some speed greater than idle speed to reduce starting loads. Once engaged, clutch shall be rated to transmit power continuously until engine speed has been reduced below disengagement speed. Clutch shall disengage completely while engine is not operating.

E. Belt guards

1. Pump drive transmissions shall be enclosed on all sides in a guard constructed of any one or combination of materials consisting of expanded, perforated, or solid sheet metal, except that maximum perforated or expanded openings shall not exceed 1/2 inch.

2. Guards shall be manufactured to permit complete removal from the pump unit without interference with any unit component, and shall be securely fastened to the unit base.

3. All metal shall be free of burrs and sharp edges. Structural joints shall be continuously welded.

Panels may be riveted to frames with not more than five-inch spacing. Tack welds shall not exceed four-inch spacing.

4. The guard shall be finished with one coat of gray W.R. non-lift primer and one coat of orange acrylic alkyd W.R. enamel in accordance with section 3, Color Definitions of ANSI 253.1; Safety

Color Code for Marking Physical Hazards.

2.09 Finish

A. Pumps, piping and exposed steel framework shall be cleaned prior to coating using an approved solvent wipe or phosphatizing cleaner. The part must thoroughly dry before paint application. Open joints shall be caulked with an approved polyurethane sealant. Exposed surfaces to be coated with two coats of a semi gloss white 2-component epoxy/polyamide to a dry film thickness of a minimum of 10 mils (5 mils minimum per coat). Coating shall be a high solids, 2 component epoxy/polyamide semi-gloss white coating for optimum illumination enhancement. The coating shall be corrosion, moisture, oil, and solvent resistant when completely dry. The factory finish shall allow for over-coating and touch-up for 6 months after coating. Thereafter, it will generally require sanding to accept a topcoat or touch-up coating. Provide Product Data Sheet to Government.

2.10 ELECTRICAL CONTROL COMPONENTS

A. The pump station control panel will be tested as an integral unit by the pump station manufacturer.

The control panel shall also be tested with the pump station as a complete working system at the pump station manufacturer's facility.

B. Panel Enclosure

1. Enclosure shall be constructed in conformance with applicable section of National Electrical

Manufacturers Association (NEMA) standards for type 1 electrical enclosures. Enclosure shall be fabricated of steel having a minimum thickness of not less than 0.075 Inch (14 gauge). All seams shall be continuously welded, and shall be free of burrs and voids. Interior and exterior surfaces shall be coated with a paint finish suitable for the NEMA classification of the enclosure.

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There shall be no holes through the external walls of the enclosure for mounting the enclosure or any components contained within the enclosure. Panel enclosure up to 60" x 36" x 12" shall be mounted on floor stands and secured to pump base.

2. Enclosure shall be equipped with a door mounted on a continuous steel hinge, and sealed around its perimeter. Door shall be held closed with clamps that are quick and easy to operate. The door shall accommodate the mounting of switches and indicators.

3. Enclosure shall be furnished with a removable back panel, fabricated of steel having a thickness of not less than 0.106 Inch (12 gauge), which shall be secured to the enclosure with collar studs.

Such panel shall be of adequate size to accommodate all basic components.

4. All control components shall be securely fastened to a removable back panel with screws and lock washers. Switches, indicators and instruments shall be mounted through the control panel door. All control devices and instruments shall be secured to the sub-plate with machine screws and lockwashers. Mounting holes shall be drilled and tapped; Self-tapping screws shall not be used to mount any components. All connections from the back panel to door mounted or remote devices shall be made through terminal blocks. All control devices shall be clearly labeled to indicate function.

C. UL Label Requirement

1. Pump station controls shall conform to third party safety certification. The panel shall bear a serialized UL label listed for "Enclosed Industrial Control Panels". The enclosure, and all components mounted on the sub-panel or control cover shall conform to UL descriptions and procedures.

D. Auxiliary Power Transformer:

1. The lift station shall be equipped with a 3 KVA step-down transformer to supply 115 volt, AC, single phase for the control and auxiliary equipment. The primary and secondary side of the transformer to be protected by a thermal magnetic circuit breaker, sized to meet the power requirements of the transformer. An operating mechanism shall penetrate the control panel door. and a padlockable operator handle shall be secured on the exterior surface.

Interlocks must prevent opening the door until circuit breakers are in "OFF" position. An additional mechanism(s) shall be provided on the circuit breaker permitting the breaker to be operated and/or locked with the control panel door in the open position.

E. 5 KVA Auxiliary Power Transformer

1. The lift station shall be equipped with a 5 KVA step-down transformer to supply 115 volt, AC, single phase for the control and auxiliary equipment. The primary and secondary side of the transformer to be protected by a thermal magnetic circuit breaker, sized to meet the power requirements of the transformer. An operating mechanism shall penetrate the control panel door. and a padlockable operator handle shall be secured on the exterior surface.

Interlocks must prevent opening the door until circuit breakers are in "OFF" position. An additional mechanism(s) shall be provided on the circuit breaker permitting the breaker to be operated and/or locked with the control panel door in the open position.

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F. Motor Branch Components

1. Main connections

a. A main terminal block and ground lug shall be furnished for field connection of the electrical supply. The connections shall be designed to accept copper conductors of sufficient size to serve the pump station loads. The main terminal block shall be mounted to allow incoming wire bending space in accordance with article 373 of the National Electric Code (NEC). A separate terminal strip shall be provided for 115 volt, single phase control power and shall be segregated from the main terminal block. Ten percent of the control terminals shall be furnished as spares.

b. All motor branch and power circuit components shall be of highest industrial quality. The short circuit current rating of all power circuit devices shall be a tested combination or evaluated per the National Electrical Code Article 409. The lowest rated power circuit component shall be the overall control panel short circuit rating and shall not be less than the fault current available. The minimum control panel rating shall not be less than 10 kA, rms symmetrical. Control assemblies operating at 120 volts nominal or less may be provided with transformers which limit the fault current and may be rated less than the minimum required short circuit rating.

2. Circuit breakers and operating mechanisms

a. A properly sized heavy duty air circuit breaker shall be furnished for each pump motor. All circuit breakers shall be sealed by the manufacturer after calibration to prevent tampering.

b. A padlocking operating mechanism shall be installed on each motor circuit breaker.

Operator handles for the mechanisms shall be located on the exterior of the control compartment door, with interlocks which permit the door to be opened only when circuit breakers are in the "off" position. An additional mechanism(s) shall be provided on the circuit breaker permitting the breaker to be operated and/or locked with the control panel door in the open position.

3. Motor Starter/Controller

a. Motors shall be controlled by Variable Frequency Drives (VFD). The VFD’s, control package, readouts and monitoring system shall be provided by the station manufacturer as an integral part of the delivered station and not be provided separate from the station. This system shall include all drives, wiring, controls, readouts and other required appurtenances to provide a complete, operable motor control system. The intent is to provide soft start on the motor and control of motors to allow pump RPM adjustments.

b. VFD’s shall be sized for the motors, voltage and system characteristics by the pump station manufacturer.

c. The variable frequency drive shall be capable of operation under any combination of the following conditions without mechanical or electrical damage.

1) Ambient Temperature: 0 to + 40 degrees C

2) Relative Humidity: Less than 95% non-condensing

3) Altitude: Less than 1,000M (3300 ft) above sea level

4) Vibration: .006 inches displacement, 1G peak

5) Shock: 15G peak for 11mS (+/- 1.0mS)

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6) Control Specification

7) Control System: Sinusoidal pulse width modulated voltage waveform

8) Frequency Accuracy: +/- 0.4% of max. frequency

9) Volts/Hertz Ratio: V/Hz user programmable

10) Operation Frequency: 0 to 400 Hz

11) Overload Capacity: 110% Overload capability for up to 1 minute, 150% Overload capability for up to 3 seconds

d. Digital Readout and Monitor

Interface to the drive is provided via a module with integral LCD display. Unit is a 7 line by

21 character backlit LCD display with graphics capability. It is used to display drive operating conditions, fault / alarm indications and programming information with full text support in multiple languages, including but not limited to English, German, French, Italian, Spanish, Portuguese and Dutch. The unit will display standby status (power on, not running), output frequency (drive run), set-up parameters and fault. With keypad, user can monitor current, voltage, frequency, acceleration and deceleration time, minimum frequency and maximum frequency. Readout also provides inverter status and protective circuit status.

e. Protection

The variable speed drive system shall include a diode or fully gated bridge rectifier, capacitor filter, and transistorized inverter section. Base driver signals to control firing of the power transistors will be designed with optically coupled isolators for maximum protection of the control circuits from high voltage and noise. The output will be a sinusoidal, pulse width modulated, voltage waveform for reduced harmonic heating in the motor.

f. The system protection will provide the following:

1) Intermittent overload - 50 to 150%

2) Current limit - 50 to 115%

3) Overcurrent - 220-300% of rated output current

4) Inverse time overload - 50 to 100%

5) Short circuit - Phase to phase or phase to ground

6) Overvoltage - 10% above input line or DC bus voltage

7) Undervoltage - 10% below line voltage

8) Power loss ride-through - 500mS

g. When the inverter trips out on a fault, the fault relay shall activate and the display shall indicate the reason for the trip as follows:

1) Overcurrent

2) Short circuit

3) Overload

4) Overvoltage

5) Undervoltage

6) Overheat

7) Ground fault

8) Motor stalled

9) Power supply fault

h. Auto restart shall occur when the inverter faults. Auto restart shall be adjustable up to 9 attempts with a 0.5 to 30 second interval. Auto restart will not be attempted for ground fault, output shorted, transistor shorted or internal microprocessor fault but will trip out immediately, activate the fault relay and make the appropriate indication on the display.

i. In the event of a fault trip, the microprocessor shall save the status of the inverter at the time of the fault and make that information available on the digital display. Information regarding the last 4 faults is maintained in event of a power loss.

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j. Operational Functions:

1) Acceleration and deceleration time independently adjustable from 0.1 to 3600.0 seconds

(selectable ranges).

2) Volts/Hertz patterns user selectable.

3) Maximum and minimum frequency limit adjustments.

3. Motor Starters

a. An open frame, across-the-line, NEMA rated magnetic motor starter shall be furnished for each pump motor. Starters of NEMA size 1 and above shall be designed for addition of at least two auxiliary contacts.