B09_Amd8_-_Spec_33_32_00_-_WASTEWATER_PUMPING_STATIONS_0008.pdf

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WASTEWATER PUMPING STATION

SECTION 33 32 00 – WASTEWATER PUMPING STATION

PART 1 - GENERAL

1.1 SUMMARY

A. The work of this section consists of installing a precast concrete lift station including access hatch, two submersible pumps, float switches, piping, controls and alarms, and other appurtenances in accordance with the manufacturer’s recommendations, the construction drawings, and all state and local regulations. This section also covers the work consisting of the lift station valve vault and overflow tank.

1.2 RELATED SECTIONS

A. Carefully examine all of the Contract Documents for requirements which affect the work in this

Section. Other Specification Sections which directly relate to the work of this Section include, but are not limited to, the following:

1. Division 26 – ELECTRICAL

2. Section 31 21 00 – TRENCH EXCAVATION AND BACKFILL FOR PIPELINES AND

APPURTENANT STRUCTURES

3. Section 33 31 11 – SANITARY SEWER COLLECTION SYSTEMS

1.3 REFERENCES

A. ASTM A312-19 Standard Specification for Seamless, Welded, and Heavily Cold Worked

Austenitic Stainless Steel Pipes

B. ASTM D1785-15e1 Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80 and 120

C. ASTM C478 Standard Specification for Circular Precast Reinforced Concrete

Manhole Sections

D. ASTM C913 Standard Specification for Precast Concrete Water and Wastewater

Structures

E. Hydraulic Institute Standard for Centrifugal, Rotary and Reciprocating Pumps

F. NEC National Electrical Code

G. NEMA National Electrical Manufacturers Association

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1.4 DESIGN REQUIREMENTS

A. Utility Power Requirements

1. Power furnished to submersible solids handling pumps shall be 3-phase, 60-hertz, 460-volts, maintained within industry standards. Voltage tolerance shall be plus of minus 10 percent. Phase-to-phase unbalance shall not exceed 1% average voltage as set forth in

NEMA Standard MG-1.

B. Submersible Solids Handling Pumps

1. Design requirements as specified on the construction drawings

1.5 SUBMITTALS

A. Per Section 01 33 23

B. Provide set of shop drawings and technical data sheets

C. The submittals shall clearly specify the materials of construction, equipment compatibility, along with drawings for each unique package being supplied.

1.6 OR-EQUAL EVALUATIONS

A. Refer to Section 01 33 23, 1.3.E.

1.7 OPERATION AND MAINTENANCE

A. Operation and Maintenance manuals will be provided as specified in Section 01 78 23 – Operation and Maintenance Data.

1.8 DELIVERY, STORAGE, AND HANDLING

A. Deliver products to project properly identified with names, model numbers, types, grades, compliance labels, and similar information needed for distinct identifications; adequately packaged and protected to prevent damage during shipment, storage and handling.

B. Store equipment and materials at the site. Protect stored equipment and materials from damage.

PART 2 - PRODUCTS

2.1 LIFT STATION EQUIPMENT

A. EPOXY COATED CARBON STEEL BASEPLATE

1. The supporting floor plate shall be minimum [½” (13 mm), 1” (25 mm)] thick carbon steel with reinforcing, as required, to prevent deflection and ensure an absolutely rigid support.

Steel plate shall meet or exceed ASTM A-36 specifications.

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B. Corrosion-Resistant Stainless-Steel Baseplate

1. The baseplate of the pump station structure shall be fabricated of ½” (13 mm) corrosion-resistant lean duplex series 2100 stainless steel alloy, or 316L stainless steel. 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.

2. All stainless steel surfaces shall be dry abrasive blast cleaned to remove rust, mill scale, weld slag, etc. Cleanliness shall be to SSPC-SP16. The nominal surface profile shall be

0.75 mils. All blasted surfaces, including welds and cut edges, shall be coated completely with an environmentally friendly passivation solution and then thoroughly rinsed.to provide a uniform finish, and to add a transparent oxide film to protect the surface from future contamination.

3. The manufacturer of the station shall warrant the stainless steel baseplate for twenty-five

(25) years from date of shipment against structural failure and perforation due to corrosion.

4. To allow on-site maintenance of the pumps, a stanchion with lifting arm shall be provided to lift each pump. The lifting arm shall have a hook over the center of the motor to support a hoist (provided by others) for removal of the motors, impellers and pumps from the station.

C. MANWAY

1. A two-piece manway cover of 1/4” (6.3 mm) aluminum treadplate, with stainless steel piano hinges and hardware, located exterior to the fiberglass pump chamber shall be provided, complete with padlocking provisions. A two-piece manway shall be required to facilitate visual checking of the float switch settings.

2. The manway shall be an integral part of the station 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

(0.39 m²).

3. The manway cover shall have a three-color 7” x 10” (178 mm x 254 mm) (minimum) corrosion-resistant sign permanently affixed to it, reading “DANGER - Before Entering, Test For Explosive Atmosphere. Test For Oxygen Deficiency. Supply Fresh Air To Work

Area”.

4. The aluminum manway cover sections shall be secured with tamperproof fasteners to prevent unauthorized removal.

D. WELDING

1. 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.

E. PROTECTION AGAINST CORROSION

1. All structural steel and cast iron 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 and cleanliness shall comply with SSPC-SP6 specifications. The surface profile shall be 2.0 mils (0.05 mm). Sandblasting is specifically prohibited. After blast cleaning, all surface contaminants, such as grease or oil, shall be removed before coating.

2. Immediately following cleaning, a single 6 mil (0.15 mm) minimum dry film thickness self-priming Cycloaliphatic Amine Epoxy coating shall be factory applied to the cleaned components. After curing, a 2.5 mil (0.06 mm) minimum DFT top coating of semi-gloss moisture-cured Aliphatic Polyurethane protective finish, for abrasion resistance and

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weather protection, shall be applied to the exterior areas, including the pumps and piping and the top and sides of the base, if carbon steel.

3. 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 shall be furnished with the original manufacturer’s coating.

4. Finish coating shall be accomplished prior to shipment of the equipment from the factory and shall comply fully with the intent of these specifications. A touch-up kit shall be provided by the pump station manufacturer for repair of any mars or scratches occurring during shipping and installation. This kit shall contain detailed instructions for use.

F. MAIN PUMPS

1. The pumps shall be 4” vertical, centrifugal non-clog type of heavy cast-iron construction, especially designed for the use of mechanical seals and vacuum priming. 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 end play 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” (48 mm) for motor frame sizes 213 through 286; 2-

1/8” (54 mm) for motor frame sizes 324 and 326; and 3” (76 mm) 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.

2. Pump shall have operating point to 250 GPM at 83ft Total dynamic head.

3. Pumps with less than a standard 4” (100 mm) suction or 4” (100 mm) discharge connection, or with less than a 3” (76 mm) spherical solids handling capacity will be rejected for this application.

4. 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.

5. 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.

6. 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.

7. 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.

8. 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. As an additional measure to prevent

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plugging, all passages in the priming system which contain liquid shall be at least equivalent to a 2-1/2” (64 mm) opening. The priming bowl shall be transparent, enabling the operator to monitor the priming level.

9. 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.

10. 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 that 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.

11. 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.

12. The pump volute shall be furnished with fronthead mounting adapters, bolted to the station floor for rigidity, and gasketed for a gas-tight seal.

G. NON-CLOG TWO-PORT IMPELLER

1. 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.

2. 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.

H. MOTORS

1. The pump motors shall be vertical, solid shaft, NEMA P-base, squirrel-cage induction type, suitable for phase, cycle, volt electric current.

2. 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 have forced air circulation by an 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.

3. 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.

4. 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).

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5. 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.

6. 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.

7. The motor shall be fitted with heavy lifting eyes or lugs, each capable of supporting the entire weight of the pump and motor.

I. CONTROLS

1. The control equipment shall be mounted in a NEMA Type 4 steel enclosure with two hinged, lockable doors and a steel barrier partition down the middle. One side of the divider shall house the three-phase circuits (motor starters and circuit protectors, etc.), and the other shall house the single-phase control circuits and low voltage components. The microprocessor and low voltage controls shall be accessible without exposing the three-phase high voltage supply, and the pump station controller shall be operable without opening the enclosure door. The control panel shall be supported on adjustable, extruded aluminum mounting legs, secured to the station baseplate. The slotted legs shall also serve as mounting points for auxiliary items, such as the vacuum priming subassembly.

2. All components within the control panel shall be UL listed or recognized, and the complete station control panel itself shall be labeled as a UL 508A General Use Industrial Control Panel.

The electrical equipment in the panel shall be protected by a surge protective device.

3. To facilitate wire tracing and servicing, the control wiring shall be run in enclosed wireways, with removable covers, rather than tied up in bundles.

4. Control relays up to 6-amp capacity shall be the modular, plug-in type, with integral LED indicating lights to show activation. Larger control relays and vacuum pump contactors shall be enclosed to be “finger safe”.

5. A duplex GFI protected convenience outlet shall be provided in the station for operation of

120-volt AC devices.

6. Thermal magnetic air circuit breakers shall be provided for branch disconnect service and short-circuit protection of all auxiliary circuits, and motor circuit protectors with lockout capability shall be provided for each pump motor. Only instantaneous trip magnetic type motor circuit protectors, matched to the motor inrush current, shall be used for the motor circuits, for added protection from low-level faults. Thermal magnetic circuit breakers will not be allowed for pump motor service.

7. Magnetic across-the-line starters with 24-volt coils and solid-state overload protection for each phase shall be provided for each pump motor to give positive protection against phase unbalance, thermal overload, phase loss and ground fault. To provide the fastest trip speed and for ground fault protection, only solid-state overload protection will be used, and motor starters using heater coils will not be acceptable. Each single-phase auxiliary motor shall be equipped with an over-current protection device in addition to the branch circuit breaker, or shall be impedance protected. All wiring shall be labeled with thermal transfer self-laminating labels and a coded wiring diagram shall be provided.

8. Individual NEMA 4 oil-tight Hand-Off-Automatic selector switches shall be provided for each pump. The switches shall be 3-position rotary-type with spring return on the Hand position, and mounted on the top of the station control panel for easy access from either side.

9. To control the operation of the pumps with variations of liquid level in the wet well, and monitor the station control, environmental and alarm functions, a specially preprogrammed, dedicated PLC-based control system shall be provided.

10. The controller shall interface with the wet well level transducer, panel display unit, motor starters, environmental system, accessories and alarm functions through isolated digital and analog input and output ports as required. The digital controls shall operate on 24 volts or

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less, to eliminate shock hazard. The 24-volt power supply shall be overload protected to be

“crowbar safe” and will return to operation when a short is removed. Program integrity shall be maintained by battery-backed RAM.

11. A NEMA 4 rated display unit shall be mounted through the front of the panel to provide operator input to and visual output from the PLC controller. This interface shall be a

7”(178mm) / 9.7”(246mm) wide screen graphic interface with DSTN 65K-color Liquid

Crystal Display with backlighting and resistive-type touch screen, for data input and programming. An aluminum hood to shade the HMI display from direct sunlight shall be mounted on the face of the control panel. The metal shade shall cover the entire display, shield the top and sides of the display, and shall be hinged to fold over the display and stow against the front of the panel.

12. The display shall have a “sleep” feature to prolong screen life. A minimum of 11 (eleven) menu screens shall be available for display and management of pump and station control functions including, but not limited to:

a. Standard Features Graphical pump running indication

b. General alarm indication

c. Individual alarm indicators for each alarm function (with time and date)

d. Lead pump indication

e. Alarm silencing

f. Digital indication of air temperature

g. Digital and graphical indication of wet well level

h. Digital indication of elapsed run time for each pump

i. Digital indication of elapsed run time for parallel pump operation

j. Digital indication of level control and alarm settings

k. Date & time indication with set time functionality

l. Heater/blower running indication

m. Alarm logging, coded for “time active” or “return time“ time cleared for the last 500 events by date and time

n. “Help” screens

o. Wet well simulation

p. Prime mode selection (On-demand or CONSTANT PRIME®)

13. Field Programming Functions:

a. Select English or Spanish language display mode

b. Reset wet well On, Off and alarm levels or return to default settings

c. Reset heater or vent fan thermostat set points or return to default settings

d. Select sequenced or timed pump alternation and select alternation time interval

e. Select any pump to remain as lead pump

f. Silence audible alarm

g. Reset running time meters

h. Set date/time

i. Set max starts per hour

j. Wet well level simulation from touch screen, overriding submersible pressure transducer signal

k. Prime mode selection (On-demand or CONSTANT PRIME®)

14. The control system shall be designed to allow alternation of the pumps by either a time clock or alternation at the end of each pumping cycle. Selection of the alternation method and setting of the interval for timed alternation shall be easily done without opening the panel. The panel display shall indicate which pump is currently the lead pump.

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15. The panel display shall be capable of indicating the total running time, in hours and tenths of an hour, of each pump individually, as well as the total time that both pumps have been running in parallel. Provision shall be made so that it is possible to reset the timers to zero, if necessary.

16. A “Maximum Number of Starts per Hour” may be programmed into the unit, which, if exceeded, will signal an alarm.

17. A resistance temperature device (RTD) shall be provided to monitor the ambient temperature in the pump station, and to control the operation of the ventilation blower and the 500-watt station heater. The RTD shall also provide a continuous signal of the panel ambient temperature, and the temperature shall be indicated on the panel display unit in degrees

Fahrenheit.

18. The liquid level in the wet well shall be monitored by a submersible hydrostatic pressure transducer with stainless steel sensor diaphragm, providing a 4-20 mA signal to the pump control unit. The body of the transducer shall be made of 316 stainless steel. The transducer shall have dual arrestor technology for lightning and surge protection.

19. The pressure transducer shall have a permanent hermetically sealed connection to a polyurethane cable, which shall support the transducer 12” (300 mm) from the bottom of the wet well, and shall pass through a cord grip seal in the station base. The pressure transducer unit shall be rated for wastewater or potable water service.

20. The digital pump controller shall take the signal from the level transducer and provide a continuous readout of the wet well level in feet and tenths of a foot, through the panel display unit. It shall also be the means of setting the pump on and off points and alarm levels. As a minimum, the controller shall be capable of digitally setting “On” levels for lead and lag pumps, an “Off” level, and alarm levels. Provisions shall be made for the pumps to operate in parallel should the level in the wet well continue to rise above the starting level for the low-level pump. A high water alarm setting shall also be provided for remote or local alarm indication.

21. Three (3) displacement switches shall be provided to automatically operate the pump in back-up mode, in case of failure of the digital control system or the submersible level transducer.

The back-up system shall be entirely independent of the digital system. A 30’ (9 m) color-coded cord shall be provided with each switch. The cord shall have a corrosion-resistant vinyl jacket and be multi-stranded in order to prevent fatigue. The displacement switch cords and the cable for the submersible pressure transducer shall enter the wet well through cord grip seals mounted to a removable, gasketed floor plate. The floor plate shall allow the displacement switches and transducer to be adjusted or removed and replaced without having to enter or reach into the wet well.

22. Room shall be left on the on the single-phase and low voltage side of the panel for Site

Contractor to install and wire a radio that will be approximately the same size as the end-of-life ProSoft RadioLinx Industrial Frequency Hopping Ethernet radio and powered by 24VDC from the panel. Coordinate with Site Contractor for needed panel penetration for antenna connection. Allow Site Contractor to adjust data from controller that will be communicated via Modbus TCP/IP over ethernet to Radio for Site to receive status and alarm information at

Site Maintenance Headquarters.

J. STATION ADVANCED WARNING SYSTEM (SAWS)

1. To facilitate good station monitoring and maintenance practices, the following features shall be incorporated:

K. PUMP FAILURE TO PUMP ALARM (CHECK VALVE SWITCH TYPE)

1. To sense failure to deliver normal flow for any reason, including failure to prime, each pump shall be provided with a sealed, non-contact, non-mercury type solid state, UL labeled sensor switch mounted with an adjustable universal mounting bracket to the

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external arm of each discharge check valve. The mounting bracket shall allow the adjustment of the sensor switch with a single locking pivot adjustment. A red LED indicating light shall be provided on each switch unit to facilitate accurate setting of the switch for proper operation. The sensor switch shall monitor the movement of the check valve arm and thereby detect failure of the pump to deliver normal operating flow when called on to run. An auxiliary time delay relay shall be provided to prevent an alarm signal during the pump priming and startup period.

L. MAXIMUM NUMBER OF PUMP STARTS AND LOGGING.

1. A “Maximum Number of Starts per Hour” may be programmed into the unit, which, if exceeded, will signal an alarm. The controller shall further log the number of pump starts in the last hour and the last week, to aid in analyzing station operation and identifying flow anomalies.

M. PUMP FAILURE TO PRIME ALARM

1. To sense failure to prime, each pump shall be provided with a programmable timer to sense excessive time to prime and send an alarm signal, during the pump startup period.

N. HIGH WATER ALARM

1. A high water alarm level setting shall also be provided through the transducer and controller for remote or local alarm indication.

O. VACUUM LEAK DETECTION

1. In the Constant Prime mode, the controller shall monitor the frequency of reprime starts in one hour, and if over a pre-set maximum, shall signal an alarm to signal a vacuum leak.

P. PUMP PRIME MONITORING

1. The Average Prime Time per Day feature shall monitor the average length of time it takes to prime each pump over a 24 hour period.

2. The Number of Primes per Day counter shall monitor the total number of reprime starts for each pump.

Q. PRIME SENSOR CLEANING REQUIRED NOTIFICATION

1. The QUICK SMART™ controller shall test for proper operation of the WAVESTART™ prime sensor daily, or at an adjustable pre-set interval, or when a Pump Failure Alarm occurs. A Prime Sensor Cleaning Required message shall be displayed on the HMI if a malfunction is detected.

2. In addition, a Service Reminder Message to clean the priming sensor shall be shown on the

HMI screen after an adjustable pre-set number of operating hours has been met.

R. SERVICE REMINDER

1. Automatic reminders of scheduled service to the pumps, motors or station, in accordance with the Manufacturer’s operation and maintenance instructions, shall be displayed on the

HMI screen, to facilitate proper and timely maintenance.

S. PUMP RUN TIME MONITORING

1. The panel display shall be capable of indicating the total running time, in hours and tenths of an hour, of each pump individually, as well as the total time that both pumps have been running in parallel. The panel shall run a pump cycle counter for each pump. Provision shall be made so that it is possible to reset the timers to zero, if necessary.

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T. WET WELL LEVEL INDICATION AND TRENDING

1. The digital pump controller shall take the signal from the level transducer and provide a continuous readout of the wet well level in feet and tenths of a foot (meters), through the panel display unit. The controller shall log the history of wet well levels over time for up to one week, for analysis.

U. STATION TEMPERATURE

1. The RTD installed in the panel for environmental control shall also provide a continuous signal of the panel ambient temperature, and the temperature shall be indicated on the panel display unit in degrees Fahrenheit.

V. WET WELL CLEANING

1. An integral timer shall be provided to perform a wet well cleaning cycle to discharge floatables and solids accumulations at pre-set intervals (daily to weekly) or manually. The cleaning cycle shall over-ride the “off” level, and pump to a pre-set cleanout off level set point. The automatic wet well cleaning cycle includes a clock start time set point and is adjustable from once a day to once a week. The automatic wet well cleaning cycle feature can also be disabled by the user if needed.

W. FORCE MAIN CLEANING

1. An integral timer shall be provided to perform a cleaning cycle to flush solids accumulations from the force main at pre-set intervals (daily to weekly) or manually.

When the cleaning cycle is started then both pumps shall pump the wet well down to

“off”. The automatic force main cleaning cycle includes a clock start time set point, and is adjustable from once a day to once a week. The automatic force main cleaning cycle feature can also be disabled by the user if needed.

X. VACUUM-PRIMING SYSTEM

1. 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 air discharged from the vacuum pumps shall be piped into the wet well.

2. The vacuum pumps shall be mounted on adjustable extruded aluminum slotted rail supports, and shall be operated through finger safe relays with a “push-to-operate” manual override feature.

3. 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.

4. 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. The solenoid valve shall be capable of being disassembled without the use of special tools.

5. 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.

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6. 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.

7. 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.

8. 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.

9. 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.

10. 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. (The low temperature dropout will override the Constant Prime mode, if selected).

2.2 PRECAST CONCRETE wet well (6-FOOT DIAMETER)

A. Precast concrete wet well shall be furnished in accordance with Specification Section 33 31 11;

Part 2.3A.

B . Wet well shall be structurally sound and watertight.

C . Wet well to be designed for AASHTO HS-20 wheel loading.

D . Wet well testing shall be in accordance with Specification Section 33 31 11; Part 3.5.

E. Inlet plumbing

1. Inlet tee: As shown on drawings

2.3 PRECAST CONCRETE OVERFLOW TANK (15,000-gallons)

A. Precast overflow tank structure shall be furnished in accordance with ASTM C913.

B. All joints in the overflow tank shall be in accordance with Specification Section 33 31 11; Part

3.2.

C. Furnish frames and covers meeting the Construction Drawings.

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D . Overflow tank to be designed for AASHTO HS-20 wheel loading.

E. Overflow tank testing shall be in accordance with Specification Section 33 31 11; Part 3.5.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install pre-cast concrete manhole, lift station system and electrical components in accordance with the manufacturer’s recommendations, the construction drawings, and all state and local regulations. Do not fill lift station manhole wastewater until sufficiently supported by backfill.

3.2 EQUIPMENT CONFIGURATION/ LOCATION

3.3 Mount the pump control panel on an exterior H-Frame as shown in construction drawings.

A. Install where accessible for maintenance

3.4 FACTORY TESTS

A. All components of the pump station shall be given an operational test at the pump station manufacturer’s facility to check for excessive vibration or leaks in the piping or seals, and to correct operation of the automatic control and vacuum priming systems and all auxiliary equipment. Installed pumps shall take suction from a deep wet well, simulating actual service conditions. The control panel shall undergo both a dry logic test and a full operational test with all systems operating.

B. Factory test instrumentation must include flow measuring with indicator; compound suction gauge; Bourdon tube-type discharge pressure gauge; electrical meters to measure amperes, volts, kilowatts and power factor; speed indicator; and a vibrometer capable of measuring both amplitude and frequency.

3.5 SPARE PARTS

A. 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.

B. A spare 24v DC control power supply unit shall be provided to be available as an emergency replacement.

C. 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

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how to place the pump back into service. The video shall include footage of an actual seal replacement.

3.6 INSTALLATION AND OPERATING INSTRUCTIONS

A. Installation of the pump chamber shall be done in accordance with the written instructions provided by the manufacturer.

B. Operation and maintenance manuals shall be furnished which will include parts lists of components and complete service procedures and troubleshooting guide.

3.7 STARTUP

A. The Manufacturer shall provide the services of a factory-trained representative for a maximum period of one day on-site to perform initial startup of the pump station and to instruct the owner’s operating personnel in the operation and maintenance of the equipment.

3.8 WARRANTY

A. 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.

B. 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.

C. 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.

D. 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.

E. 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.

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

G. 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.

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H. 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.

I. The manufacturer shall provide a warranty certificate covering specific details.

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