2-331444 00 Booster Pump.pdf

Fillmore City 33 14 44 Booster Pump Cemetery Booster Pump Page 1 of 10

SECTION 33 14 44

BOOSTER PUMP

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes:

1. Booster pumps and motors.

2. Motor starter panel and control panel.

1.2 REFERENCE STANDARDS

A. American Iron and Steel Institute (AISI).

B. American National Standards Institute (ANSI).

C. Anti-Friction Bearing Manufacturer’s Association (AFBMA).

D. ASTM International (ASTM):

1. ASTM A36 – Standard Specification for Carbon Structural Steel.

2. ASTM A48 – Standard Specification for Gray Iron Castings.

3. ASTM A276 – Standard Specification for Stainless Steel Bars and

Shapes.

4. ASTM B505 - Standard Specification for Copper Alloy Continuous

Castings.

5. ASTM B584 - Standard Specification for Copper Alloy Sand Castings for General Applications.

E. American Water Works Association (AWWA):

1. AWWA E103 - Standard for Horizontal and Vertical Line-Shaft

Pumps.

F. Hydraulic Institute.

G. National Electrical Manufacturer’s Association (NEMA).

1.3 SUBMITTALS

A. Product Data: Submit for booster pumps, motors, starter panel, control panel, pressure switch, pressure transducer, accessories, and other required equipment.

B. Pump Equipment Data:

1. Provide guaranteed pump performance curve giving head capacity performance over entire range up to shutoff head, together with efficiencies and required brake horsepower.

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2. Provide data indicating motor efficiencies and power factors for ½, ¾, and full load conditions.

C. Pump Equipment Drawings: Provide drawings showing overall dimensions of equipment.

D. Certificates: Submit certificate of compliance indicating that each pump and motor assembly meets requirements of this Section.

E. Installation Instructions: Submit copy of manufacturer’s installation instructions.

F. Manufacturer’s Field Report: Submit manufacturer’s report for system startup.

G. Test Reports:

1. Submit copy of source quality control test results for each pump and motor assembly.

2. Submit one copy of test results for each bacteriological test.

1.4 CLOSEOUT SUBMITTALS

A. Project Record Documents: Record actual installation locations of piping, pumps, controls and other equipment.

B. Operation and Maintenance Data: Provide PDF and hard copies of system information as indicated in Section 01 70 00.

C. Name Plates: Provide duplicate nameplates for each pump and motor.

1.5 QUALIFICATIONS

A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum five years' experience.

B. Installer: Company specializing in performing Work of this Section with minimum three years' experience and approved by manufacturer.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Deliver materials in manufacturer's packaging.

B. Inspection: After delivery, inspect for damage.

C. Store according to manufacturer's instructions.

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1.7 WARRANTY

A. Furnish five year 10,000 hour manufacturer's warranty for each pump and motor. Indicate appropriate serial numbers in warranty.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Booster Pump Manufacturers:

1. Grundfos Duplex Pressure Boosting Pump Skid (2) CR20-4 Vertical

Multistage Pumps

a. 10HP Premium Motor

b. TEFC, 3500RPM

c. 1 Ph, 230V, 60Hz,

d. Liquid Level Switch Dry Run Protection.

e. 4" ANSI Flanged Manifold Connections, Class 150#

f. Standard Control Panel w/Panel Mounted VFD's

1) Panel Options Include:

1. Emergency/Normal Switches, Surge Protection,

2. Pump Run Indicator Lights, Alarm Circuit,

3. Side Mount External Disconnect Switches Per

Pump, & 100kA

4. SCCR Fault Current Rating

2. Or equal.

2.2 EQUIPMENT

A. Electric Motor:

1. Type: Squirrel cage induction type.

2. Frame: NEMA MG-1, cast iron.

3. Enclosure: TEFC type enclosure, drip and splash proof, cast iron.

Provide stainless steel screen to prevent entrance of rodents.

4. Terminal Box: ASTM A48, cast iron, bolted with gaskets, sufficient space for connections and permanently marked motor leads in accordance with connection diagram.

5. Insulation: Class H, non-hydroscopic with multiple dips and bakes of insulating varnish. Insulate and brace windings for full voltage operation.

6. Temperature Rise: NEMA Design B, rated for operation at 104 degrees Fahrenheit (40 degrees Celsius).

7. Over Temperature Protection: Provide automatic reset normally closed thermal overloads in each phase of motor windings.

8. Junction Box: Provide power junction box for motor. Provide auxiliary junction box for over temperature switch.

9. Shaft: Solid, extending through both bearings with sufficient length to close couple directly to pump impeller.

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10. Bearings:

a. Type: Use angular contact ball thrust bearings, spherical roller thrust bearings or plate thrust bearings as necessary to meet required thrust loads and bearing life.

b. Life: AFBMA B-10 life of 50,000 hours.

c. Bracing: Brace and lock bearings to prevent shaft movement and to withstand thrust loads in all directions.

d. Lubrication: Pre-lubricated grease at factory.

11. Dynamic Balancing: Balance, test and ship pump and motor as unit.

12. Nameplate:

a. Type 316 stainless steel, permanently attached to frame with information impressed, engraved or embossed into plate.

b. Indicate manufacturer’s name, model, serial number, year, speed, horsepower, flow rate, head, net positive suction head, and impeller diameter.

B. Booster Pump:

1. Casing:

a. ASTM A48, Class 30, cast iron free of blow holes, sand holes, and other faults.

b. Provide air release or pump priming tap on high point.

c. Provide drain tap on low point.

d. Line water passages with vitreous enamel or fusion bonded epoxy to 12 mil thickness in accordance with AWWA Standards.

2. Suction and Discharge Flanges: 4” ANSI 150# Stainless Steel Manifolds:

a. Check and isolation valves each pump.

b. Discharge pressure sensor.

c. Suction liquid level switch for dry run protection.

3. Impellers:

a. ASTM B584 836 or 835 alloy, bronze, enclosed, and dynamically balanced.

b. Accurately fit and securely fastened to shaft to prevent loosening during operation.

c. Removable without damaging bowl or shaft, and provide vertical adjustment by external means.

d. ASTM B505 Alloy 932, bronze wear rings.

4. Shaft:

a. ASTM A276 AISI Type 416 stainless steel, turned, ground and polished.

b. Sleeve: ASTM B505 Alloy 932, bronze.

5. Bearings:

a. B-10 life of 50,000 hours.

b. Provide bearings fully enclosed and protected from abrasives.

6. Pump Seals: Mechanical seals.

7. Pump Lubrication: Oil lubricated

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8. Nameplate:

a. Type 316 stainless steel, permanently attach to frame with information impressed, engraved or embossed into plate.

b. Indicate manufacturer’s name, model, serial number, year, speed, horsepower, voltage, phase, full load current, locked rotor KVA code, motor type, frame, insulation class, and centigrade degree rise.

C. Accessories:

1. Fasteners, Bolts, Cap Screws, Anchor Bolts, Nuts, Washers and

External Hardware: AISI, Type 316, stainless steel.

2. Flexible Connectors: Neoprene or rubber pipe connector. Do not use braided or unbraided flexible metal hose.

3. Provide anchors and connections for structural, mechanical and electrical equipment in accordance with manufacturer’s recommendations, applicable building codes and standards.

D. Power Cable: Sized for voltage drop not to exceed 3 percent between starter and motor. Provide sufficient length to connect to motor starter panel without splices.

E. Control Panel: Standard CU352: NEMA 12 wall or pedestal mounted enclosures. Protect controls from lightning and power surges.

1. 1 Ph, 230V with surge protection.

2. Pump run lights.

3. Alarm circuit (fault light and audible alarm).

4. 100kZ SCCR Fault Current Rating.

5. Hand/Off/Auto switch per pump.

6. Side mount external disconnect switch.

7. System will require external start/stop command (connect to system

SCADA for command).

F. Pressure Gage: Bourdon tube pressure gage, 2.5 inch diameter, liquid filled, copper alloy internal parts, stainless steel case, and 2.5 percent accuracy.

Provide for suction and discharge piping.

G. Vault: Cast-in-place concrete in accordance with Section 03 30 00.

2.3 PERFORMANCE AND DESIGN CRITERIA

A. Booster Pump Operating Conditions: Design point.

1. Single Pump Capacity: 90 gallons per minute.

2. Total Dynamic Head: 220 feet.

3. Net Positive Suction Head Available: 12.4 ft.

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B. Total pumping head does not include losses in pumping unit. Allow for losses in pumping unit.

C. Pump Speed: 3,500 revolutions per minute.

D. Motor Operating Conditions:

1. Voltage: 230 volt, single phase.

2. Frequency: 60 Hertz.

3. Horsepower: 10 horsepower.

4. Service Factor: 1.15

5. Continuous duty with premium efficiency.

6. At design loads, do not exceed motor nameplate rating and do not exceed service factor at any point along pump curve.

E. Provided pump and motor rated for continuous duty and that operate smoothly throughout specified pumping range without surging, cavitation or vibration.

2.4 OPERATION

A. Booster Pump Operation: System consists of two booster pumps with controls. Control operation of each booster pump by position of selector switch, Hand-Off-Automatic, on front of booster pump starter panel.

1. Hand Operation: Under normal conditions when selector switch is turned from Off to Hand, relays will be energized, which energizes booster pump motor. One or both booster pumps may be operated at same time. When selector switch is turned from Hand to Off, relays are de-energized which cuts power to motor and stops booster pump motor. Timer delay relay prevents booster pump motor from starting during booster pump back spin. Provide relay to shut booster pumps off if low water level is sensed in suction piping.

2. Automatic Operation: When selector switch is switched to Automatic, start and stop sequences for booster pumps will initiate at predetermined downstream pressures and flow rates, as well as water levels in tanks as determined by pressure transducers. Switch lead and lag pump after each operation. Provide relay to shut booster pumps off if low water level is sensed in suction piping.

3. Alarm: Activate alarm system for conditions as follows:

a. Low water level in tanks.

b. Failure of pump motor to start.

c. Excessive high downstream pressure.

B. Pump Control System Input Variables: In accordance with Table 1 of this Section.

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Table 1. Booster Pump Control System Input Variables

Item Variable Description

Input Signals (Analog)

Discharge 4-20 ma flowmeter signal to cut out power on no flow condition.

Input Signals (Discrete)

Pressure Switches

Low discharge pressure discrete (Mercoid) signals to turn on each pump.

High discharge pressure discrete (Mercoid) signals to turnoff each pump

Low suction pressure safety (Mercoid) signal to turn off all pumps

Temperature Switches

Motor over temperature sensor on windings of each motor

Motor over temperature sensor on bearings of each motor

Input (Manual)

Operation Mode (Selectors)

Hand-off-auto switch on each pump

Lead / lag rotation switch

Alarm reset

Settings Time delay 0-3 minutes on start of each pump

Time delay 0-3 minutes on stop of each pump

C. Pump Control System Output Variables: In accordance with Table 2 of this Section.

Table 2. Booster Pump Control System Output Variables

Item Variable Description

Output Signals (Analog)

Discharge 4-20 ma flowmeter signal

Pressure

4-20ma discharge pressure signal on high pressure side of pressure relief valve

4-20ma suction pressure signal on low pressure side of pressure relief valve.

Output Signals (Discrete)

Run Condition (Lamp or LED)

Discrete signals ”condition to run,” “motor running and “motor fail”

Run Time Meter 6 digit non-resettable run time meter required on each motor

Alarms 1 alarm per cell (Red lamp or LED)

1 alarm for each safety interlock

Normal Start Sequence

Normal Start Signal

Low discharge pressure

Timed Start 0-3 minutes

Normal Stop Sequence

Normal Stop Signal High discharge pressure

Timed Stop 0-3 minutes

Safety Interlocks

No flow Low suction pressure

Motor bearing over temperature

Motor winding over temperature

Loss of control signal

D. Provide pumps, motors, controls and equipment for complete and fully operating system. Provide pump control system in accordance with Section 25 54 13.

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2.5 SOURCE QUALITY CONTROL

A. Test each booster pump and motor assembly prior to shipping.

1. Contract Compliance: Verify impeller, motor rating and electrical connections comply with specifications.

2. Motor Load: Test for no load current, full load current, winding resistance and high potential in accordance with NEMA Standards.

3. Shaft Straightness: Test shaft in accordance with ANSI B58.1.

4. Dynamic Balance: Test in accordance with NEMA, Method MG1

12.06.

5. Moisture Intrusion: Check for each pump assembly.

6. Run Test: Verify wear ring clearances and establish correct rotation and mechanical integrity.

7. Certified Pump Curve:

a. Run for 30 minute test period to prepare six-point curve.

b. On variable speed pumps, prepare six-point curve at four 100 rpm increments.

c. Test in accordance with AWWA E103 and Hydraulic Institute

Standards.

d. Test with vibration analyzer in accordance with Hydraulic

Institute Standards.

B. Provide static and dynamic balancing of equipment with resonant harmonics not occurring within normal operating speed range. Provide ratio of relative speed to critical speed less than 0.8 or more than 1.3 for pumping unit and components.

C. Complete final testing after completion of static and dynamic balancing.

D. If vibration level falls outside of acceptable limits established by Hydraulic Institute, shutdown pump and correct vibration before further testing.

PART 3 EXECUTION

3.1 PREPARATION

A. Coordinate construction of pump house with space, mounting and utility requirements for pump equipment.

B. Verify location where pump equipment and controls are to be installed in pump house.

C. Make field measurements needed to install pump before ordering equipment. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

D. Notify Engineer of any conflicts.

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3.2 INSTALLATION

A. Construct pump house as indicated on Drawings.

B. Install pumps, controls and equipment in accordance with manufacturer’s recommendations.

C. Connect pumps to piping with watertight connection.

D. Unless indicated otherwise on Drawings, securely mount pump starter panel and control panel on pump house wall.

E. Install electrical conductors and connections to pump equipment in accordance with manufacturer's recommendations.

F. Attach conduits and electrical connections to motor with slack. Provide flexible connectors located as close to mechanical equipment as possible.

3.3 SYSTEM STARTUP

A. After installation, provide services of qualified manufacturer’s representative to field check and test operation of pumps, controls and equipment.

B. Before startup, check equipment for proper lubrication, alignment, rotation, and freedom from excessive vibration.

C. Follow manufacturer’s recommended startup procedures.

D. Make field adjustments to equipment as required for proper installation and operation.

E. Continuously operate each pump for six hour test period to demonstrate that each pump, controls and equipment were installed properly and are operating properly.

F. Provide written certification from manufacturer’s representative indicating that pumps and equipment were installed properly and are operating properly.

3.4 CLOSEOUT ACTIVITIES

A. Demonstration: Demonstrate to Owner and Engineer that booster pumps, controls and equipment are operating properly.

B. Instruction: Instruct Owner’s personnel how to operate booster pumps, controls and equipment.

1. Indicate normal operating procedures and trouble shooting.

2. Indicate proper lubrication procedures.

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3. Indicate list of scheduled maintenance and service intervals.

4. Indicate what actions or non-actions would render manufacturer’s warranty null and void.

3.5 PROTECTION

A. Take precautions to prevent contaminated or undesirable water or other foreign matter from entering water system during construction operations.

Remove undesirable materials which water system.

B. Protect booster pumps, controls and equipment from damage. Repair or replace if damaged.

END OF SECTION