44 42 56 - Base Mounted Pumping System.pdf

44 42 56 – BASE MOUNTED PUMPING SYSTEM

Herbert, Rowland & Grubic, Inc. 44 42 56 - 1 000483.0450

SECTION 44 42 56 – BASE MOUNTED PUMPING SYSTEM

PART 1 - GENERAL

1.01 SUMMARY

A. Contractor shall furnish and install one factory built base mounted pumping system. The system shall be complete with all equipment specified herein, factory assembled on steel bases.

B. Principal items of equipment shall include two horizontal, self-priming, centrifugal 2-stage sewage pumps, V-belt drives, electric motors, piping, valves, motor control center, automatic liquid level control system, and integral wiring.

C. Factory built pump station design, including materials of construction, pump features, valves and piping, and motor controls shall be in accordance with requirements listed under PART 2 - PRODUCTS of this section.

D. Electrical power to be furnished to the site will be 3 phase, 60 hertz, 480 volts, maintained within plus or minus 10 percent. The available fault current provided at the pump station motor control center is 25 kA rms symmetrical. 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. Control voltage shall not exceed 132 volts. All panels and individual MCC sections shall be Arc-Flash labeled

E. Equipment manufacturer shall perform control logic changes to NCCMA’s existing Cupola pump station as described in paragraph 2.07 K 3 q i. Reference Gorman-Rupp Station Serial No.: 19-3518-

LE.

F. The pumping equipment shall be manufactured by The Gorman-Rupp Company, Mansfield, OH as supplied by Envirep, Inc., Camp Hill, PA (717-761-7884).

1.02 SUBMITTALS

A. Product Data: Prior to fabrication, submit the following to the engineer for approval:

1. Shop drawings providing layout of the mechanical equipment and anchor bolt locations and indicating the use of Unified National Standard bolts and fasteners.

2. Electrical ladder logic drawings illustrating motor branch and liquid level control circuits to extent necessary to validate function and integration of circuits to form a complete working system.

3. Catalog cut sheets for major items of equipment, materials of construction, major dimensions, motor and v-belt drive data, pump characteristics curves showing design duty point capacity (GPM), head (FT), net positive suction head (NPSHR), and hydraulic brake horsepower.

4. Pump Manufacturer’s v-belt drive selection calculation summary sheet showing corrected H.P.

Per Belt, total H.P. developed, pitch diameter of sheaves, center distance between driver and driven shafts and combined arc-length correction factor applied to theoretical horsepower transmission per v-belt, and all calculations to demonstrate a minimum Safety Factor of 1.5.

5. Certified dimensional drawings indicating size, locations and the spherical solids passing capability of the primary recirculation port.

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6. Letter from pump manufacturer certifying that the pump(s), exclusive of the motor, base, drive, controls, or other associated components are constructed with cast iron, ductile iron, and steel that has been mined, melted, cast, machined, and assembled in the United States.

7. Copy of certificate with course I.D. number for pump manufacturer’s PADEP approved Wastewater Operator training Program in Pump Maintenance and Troubleshooting course that counts toward Pennsylvania pre-certification experience and continuing education unit requirements.

B. Certified Tests: Prior to shipment of the equipment from the pump manufacturer’s facility, submit the following certified tests to the engineer for approval.

1. Certified copies of factory run pump performance tests.

a. Tests shall be conducted in accordance with Hydraulic Institute Standards 14.6.3.4 Acceptance Grade 2B, or 14.6.3.4.1 for input power below 13 HP, at the specified head, capacity, rated speed and horsepower

b. The performance tests will validate the performance of the equipment at the design head, capacity and speed.

2. Certified reprime performance test data in accordance with procedures herein specified.

3. Tests shall be certified by a registered professional engineer.

C. Certified System Performance Tests: All components, including the pumps, motors, and controls, will be tested as a complete working system at the pump manufacturer’s facility. Tests shall be conducted in accordance with Hydraulic Institute Standards at the specified head, capacity, rated speed and horsepower. Factory operational tests shall simulate actual performance anticipated.

Submit certified tests data to the engineer for approval.

D. Operation and Maintenance Manuals:

1. Operation shall be in accordance with written instructions provided by the pump system manufacturer. Comprehensive instructions supplied at the 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.

2. Documentation shall be specific to the pumping equipment supplied and collated in functional sections.

3. Each section shall combine to form a complete system manual covering all aspects of equipment supplied by the manufacturer. Support data for any equipment supplied by others, even if mounted or included in overall system design, shall be provided by those supplying the equipment. Instructions shall include the following as a minimum.

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

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

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

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

e. Electrical schematic diagram of the pump control circuits shall be in accordance with 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 system operator, need not be included. Details for such parts

Herbert, Rowland & Grubic, Inc. 44 42 56 - 3 000483.0450 shall not be substituted for an overall system schematic. Partial schematics, block diagrams, and simplified schematics shall not be provided in lieu of overall system diagram.

f. Mechanical layout drawing of the pumping equipment and components, prepared in accordance with good commercial practice, shall provide installation dimensions and location of all pumps, motors, valves and piping.

4. 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 a manual shall not be acceptable. Operation and maintenance instructions must be specific to equipment supplied in accordance with these specifications.

E. Manufacturer’s Field Performance Test Report: The manufacturer’s technical representative shall inspect the completed installation, correct or supervise the correction of any defect or malfunction, instruct operating personnel in the proper operation and maintenance of the equipment. Owner and Engineer shall be given advance notice of test date and a mutually acceptable date shall be agreed upon such that all parties can witness the field tests. A written report covering the equipment startup shall be mailed from the manufacturer’s startup technician directly to the owner. At a minimum, the report shall include:

1. Nameplate information.

2. Recordings of gauge readings, static discharge head, and total dynamic head for each pump.

3. Recordings of operating speed for each pump, measured with a tachometer.

4. Recordings of level control settings

5. Certification that equipment has been properly installed and lubricated and is in accurate alignment.

6. Certification that the v-belt drive system has been properly aligned using a laser alignment instrument and that v-belts have been tensioned using a belt tensioning instrument.

7. Certification that check valves have been properly adjusted as necessary to prevent valve slam upon sudden shut off. Sudden shut off caused by a power failure shall be simulated by use of the emergency E-Stop which shall cause the pumps to immediately be de-energized without the normal VFD gradual ramp down.

8. Results of electrical test include voltage readings and amperage readings of all motors.

9. Certification that the equipment has been operated fully loaded and that it operated satisfactorily.

10. Outline in detail any deficiencies noted, and proposed remedial corrections.

11. Confirm that all spare parts are on site. Include photographs of spare parts in startup report

12. Include the following photographs in the startup report:

a. Overall pump station job site

b. Pumps and motors

c. Discharge header piping

d. Variable Frequency Drives (VFD’s)

e. Motor Control Center

f. Wet well

1.03 QUALITY ASSURANCE

A. Manufacturer’s Qualifications: Upon request from the engineer, the pumping equipment manufacturer shall demonstrate the following:

1. Proof of financial stability and ability to produce the pumping equipment within the specified delivery schedules.

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2. Evidence of the facilities, equipment, and expertise to demonstrate the manufacturer’s commitment to long-term customer service and project support.

3. Evidence of adequate local and factory spare parts inventory to provide timely delivery of spare parts

4. Evidence that the pump manufacturer is an Underwriters Laboratories (UL) panel builder.

5. Evidence that the pumps and pumping equipment are constructed, assembled and tested in the United States by the pump manufacturer. All pump parts including the casing shall be machined at the pump manufacturer’s facility located within the United States.

6. To ensure compatibility to existing tools and equipment, all pump internal and external nuts, bolts, and hardware, shall be Unified Thread Standard (UNC) per ASME/ANSI standards.

7. Evidence that the pump manufacturer can provide operator training that counts toward Pennsylvania water and wastewater continuing education requirements.

8. Consideration will be given only to pump manufacturer’s meeting the following qualifications:

a. Twenty-five years minimum experience successfully producing pumping equipment of the type specified herein.

b. A minimum of twenty-five installations of pumping equipment of the type specified herein in successful operation for a minimum of ten years

9. Pump manufacturer must be ISO 9001:2000 certified, with scope of registration including design control and after sales activities.

B. Manufacturer’s Representative Qualifications: Upon request from the engineer, the equipment manufacturer’s local representative shall demonstrate the following:

1. Evidence of adequate local spare parts inventory to provide timely delivery of spare parts.

2. Evidence of established locally based factory-trained service personnel.

3. Evidence that representative offers comprehensive equipment service agreements for the equipment specified.

4. List of at least ten local municipalities with installations similar to the specified equipment.

5. Evidence that the representative offers full-day operator training seminars on Centrifugal Pump

Maintenance and Troubleshooting.

6. Evidence that the representative offers technical design assistance and hydraulic recommendations for pump station design.

7. Certification from manufacturer that the service technician has been factory-trained and is authorized for such duties by the manufacturer.

C. Pump Performance:

1. Design and construct the pumps in accordance with standards of the Hydraulic Institute. The efficiency of the pumps, when operating under conditions of the specified capacities and heads shall be as near peak efficiency as practicable.

2. Design the pumps designated as self-priming centrifugal to pump raw sewage containing solids up to ten percent and stringy materials with a minimum of clogging. Pumps may be protected by screening equipment, but materials passing through may combine by a felting or balling process.

D. Source Quality Control:

1. Obtain pumping equipment, motors, motor starters, variable frequency drives (VFD’s), Motor Control Center, pump control system with level controls, and appurtenances from the pump manufacturer whose responsibility it is to ensure that the pumping equipment is properly furnished, coordinated, and tested in accordance with these specifications. The products of

Herbert, Rowland & Grubic, Inc. 44 42 56 - 5 000483.0450 third party packagers, assemblers or distributors shall neither be considered equal, not shall they be acceptable.

2. The Motor Control Center (MCC) including the VFD’s, pump and level controls shall be constructed at the pump manufacturer’s facilities. The pump manufacturer shall be an Underwriters Laboratories (UL) panel builder. The MCC and the pump control panel shall meet all UL and Joint Industrial Council (JIC) standards.

3. The manufacturer of the pumping equipment shall provide a listing of similar self-priming sewage pumping systems located in the State of Pennsylvania, for review by the engineer. This listing shall include locations and contract names. Project references provided should include similar size self-priming pumps utilized with reduced voltage solid state starters, variable speed drives and PLC based logic control. These references must serve to demonstrate the pump manufacturer’s ability to design complete, fully integrated pumping systems with similar flow rate, total dynamic head, and suction lift requirements.

1.04 MANUFACTURER’S WARRANTY

A. All components of the pumping equipment shall be manufactured, assembled and tested as a unit by the pump manufacturer. The pumping equipment must be a standard catalog item with the manufacturer. The pump manufacturer must assume system responsibility, i.e. the pumping equipment must be warranted by the manufacturer as described herein. Individual component warranties are desirable. However, individual warranties honored solely by the manufacturers of each component will not be acceptable.

B. The pump 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. All equipment, apparatus, and parts furnished shall be warranted for one (1) year, excepting only those items that are normally consumed in service, such as light bulbs, oils, grease, packing, gaskets, O-rings, etc. The pump manufacturer shall be solely responsible for warranty of the pumping equipment components when installation is made and use and maintenance is performed in accordance with the manufacturer’s recommendation.

2. The pump shall be warranted for five (5) years from date of shipment.

3. Components failing to perform as specified by the engineer, 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 without cost of parts to the owner.

C. It is not intended that the pump manufacturer assume liability for consequential damages or contingent liabilities arising from failure of any vendor supplied product or part which fails to properly operate, however caused. Consequential damages resulting from defects in design, or delays in delivery are also beyond the manufacturer's scope of liability.

D. The warranty shall become effective upon the acceptance by the purchaser or the purchaser's authorized agent, or sixty (60) days after installation, or ninety (90) days after shipment, whichever occurs first.

1.05 MANUFACTURER

A. These specifications and accompanying drawings specify and show equipment and materials manufactured by The Gorman-Rupp Company, deemed most suitable for the service anticipated.

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The contractor shall prepare his bid on the basis of the particular equipment and materials specified for the purpose of determining the low bid. The awarding of the contract shall constitute a contractual obligation to furnish the specified equipment and materials.

B. After execution of the contract, the contractor may request to substitute equipment other than that specified in the contract. Substitutions will only be considered in the event that the equipment proposed for substitution is superior in construction and efficiency to that specified in the contract, and higher quality has been demonstrated by service in a sufficient number of similar installations.

C. In the event the contractor obtains engineer's approval of equipment other than that for which the system was originally designed, the contractor shall, at his own expense, make any changes in the structures, buildings or piping necessary to accommodate the equipment, and shall provide as-built drawings to the engineer.

D. It will be assumed that the cost to the contractor of the equipment proposed to be substituted is less than that of the equipment specified in the contract and, if substitution is approved, the contract price shall be reduced by an amount equal to the savings.

PART 2 - PRODUCTS

2.01 PUMPS

A. Pump Description:

1. Pumps shall be Gorman-Rupp Model VS6A60-B horizontal, self-priming, centrifugal pumps, specifically designed for pumping raw, unscreened, domestic sanitary sewage.

2. Each pump shall be vertically staged incorporating a lower and upper volute casing united by a ductile iron transition chamber, allowing for a direct and smooth flow path to the impeller in the upper casing. Each pump shall be equipped with a single electric motor with a v-belt drive system to both pump shafts.

3. Pump suction and discharge connections of the lower casing shall be vertically inline with one another.

4. The cover plates and rotating assemblies shall be interchangeable between both casings.

5. The discharge port of the upper casing shall be capable of being rotated to allow for multiple pipe connection orientations.

6. All openings, internal passages, and internal recirculation ports shall be large enough to permit the passage of the specified spherical solids passing capacity, and any trash or stringy material which may pass through the average house collection system. Screens or any internal devices that create a maintenance nuisance or interfere with priming and performance of the pump shall not

7. be permitted.

8. The pumps shall have the following characteristics:

a. Suction connection, flanged, in 8

b. Discharge connection, flanged, in 6

c. Minimum shutoff head, each pump, ft 410

d. Pump design speed, rpm 2000

f. Minimum reprime lift capability, ft 21

g. Spherical solids passing capability, in. diameter 3.0

h. Motor horsepower 150

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i. Motor speed, rpm 1750

j. Impeller diameter, in 12-3/8

B. Pump Performance:

1. Each pump must have the necessary characteristics and be properly selected to perform under these operating conditions:

Low Speed Design Speed Max. Speed

a. Capacity, gpm 400 698 1050

b. Total dynamic head, ft 141 210 327

c. Total dynamic suction lift, ft 15.49 15.92 16.91

d. Maximum static suction lift, ft 15.33 15.33 15.33

e. Discharge static head, ft 104 104 104

f. NPSH Required 5.5 7.5 11.5

g. Pump Operating Speed (rpm) 1280 1580 2000

2. Consideration shall be given to the sanitary sewage service anticipated, in which occasionally debris will lodge between the pump suction check valve and seat, resulting not only in loss of the suction leg, but also in the siphoning of liquid from the pump casing to the approximate center line of the impeller. Such occurrence shall be considered normal with proper installation of air release line to atmosphere.

3. In consideration of such occurrence and of the unattended operation anticipated, each pump shall be so designed as to retain adequate liquid in the pump casing to insure unattended automatic repriming while operating at its rated speed in a completely open system without suction check valves and with a dry suction leg.

C. Reprime Performance Tests:

1. Each pump must be capable of the specified reprime lift while operating at the selected speed and impeller diameter. Reprime lift is defined as the static height of pump suction centerline above liquid that the pump will prime; and delivery within five minutes on liquid remaining in the pump casing after a delivering pump is shut down with the suction check valve removed.

Systems requiring ancillary vacuum generating devices shall not be acceptable. Additional standards under which reprime tests shall be run are:

a. Piping shall incorporate a discharge check valve down stream from the pump. Check valve size shall be equal (or greater than) the pump discharge diameter.

b. A ten-foot length of one-inch pipe shall be installed between pump and discharge check valve. This line shall be open to atmosphere at all times to duplicate the air displacement rate of a typical pump system fitted with an air release valve.

c. No restrictions shall be present in pump or suction piping that could serve to restrict the rate of siphon drop of the suction leg. Suction pipe configuration for reprime test shall incorporate a minimum horizontal run of 2 feet and one 90-degree elbow.

d. The pipe size used for the reprime performance test shall be the same size as the pump suction diameter.

e. Impeller shall be set at the clearances recommended by the manufacturer in the pump service manual.

f. Reprime lift repeatability shall be demonstrated by five sequential reprime cycles.

g. Liquid to be used for reprime test shall be water.

D. Serviceability:

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

a. No special tools shall be required for replacement of any components within the pump. All internal and external threaded fasteners shall be of the Unified National Standard type.

b. The mechanical seal shall be a one-piece cartridge type to allow for easy replacement.

Mechanical seals requiring assembly of individual components shall not be acceptable.

c. The pump must be equipped with a removable cover plate, allowing access for service and repair without removing suction or discharge piping.

d. The pump shall be fitted with a replaceable wear plate. Replacement of the wear plate, impeller, and seal shall be accomplished through the removable cover plate without removing suction or discharge piping.

e. The entire rotating assembly, which includes bearings, shaft, seal, and impeller, shall be removable as a unit without removing the pump volute or piping.

f. Atmospheric isolation: The shaft bearings shall be isolated from the seal cavity with an air gap to provide positive protection of the bearings in the event of a seal leak and to provide for external monitoring of the seal integrity.

g. Cover plate impeller clearance adjustment: Adjustment of the impeller face clearance (distance between impeller and wear plate) shall be accomplished by external shimless cover plate adjustment utilizing collar and adjusting screw design for incremental adjustment of clearances

h. by hand. Pumps requiring realignment of belts, couplings, etc., due to clearance readjustment shall not be acceptable. Cover plate shall be capable of being removed without disturbing clearance settings.

i. Rotating assembly impeller clearance adjustment: Additional adjustment of the impeller face clearance (distance between impeller and wear plate) shall be accomplished by moving the entire rotating assembly towards the wear plate, to compensate by removal of stainless steel shims between the rotating assembly and the volute.

j. Clearance adjustment which requires movement of the shaft without movement of the entire rotating assembly, thereby adversely affecting seal working length or impeller back clearance, shall not be acceptable.

E. Construction:

1. Pump casing: Made of Gray Iron 30 (lower) and Ductile Iron 65-45-12 (upper). Lower casing shall be foot supported, and shall have a horizontal centerline suction and vertical discharge. Suction connection and discharge connection shall be vertically in-line with one another.

a. The casing shall have a top mounted 3-1/2 inch priming fill port with a safety lock bar cover. 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.

b. Casing shall have no openings of smaller diameter than the specified sphere size.

c. Casing shall be designed to retain sufficient liquid to ensure automatic repriming and unattended operation.

d. A minimum 1-1/4 inch diameter drain hole shall be provided for attachment of the pump drain kit and to ensure complete and rapid draining.

e. Bolts and other threaded fasteners shall have Unified National Standard threads.

f. Pump shall be provided with a separate capped threaded port for use of an optional casing heater.

2. Cover plate: Cover plate shall be Gray Iron 30.

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a. Cover plate shall be retained by four (4) nuts for complete access to pump interior. Cover plate removal must provide ample clearance for removal of stoppages, and the allow removal or service to the impeller, seal, or wear plate.

b. Replaceable wear plate: Secured to the cover plate by welded studs and nuts. The wear plate shall be 316 Stainless Steel. The wear plate shall be of sufficient width to maintain the manufacturer’s recommended clearance between the entire edge of each impeller vane and the wear plate. Wear plate attachment hardware shall have Unified National Standard threads and shall be located out of the direct flow path of the liquid into the impeller. Two (2) Buna-N o-rings shall seal cover plate to the pump casing. The wear plate shall be constructed with a minimum of six (6) semi-circular machined channels and

c. a tapered face designed to provide self-cleaning action and ensure that debris is cleared away from and does not collect between the impeller and the wear plate.

d. O-ring Seals: Two (2) Buna-N o-rings shall seal cover plate to the pump casing. The inner cover plate o-rings shall provide a seal between the suction chamber and the discharge chamber of the pump casing to eliminate the possibility of recirculation at the wear plate.

e. In consideration for safety, a pressure relief valve shall be supplied in the cover plate. Relief valve shall open at 75 – 200 PSI.

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

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

3. Rotating assembly:

a. Impeller: Two-vaned, semi-open, non-clog, 316 Stainless Steel with integral pump out vanes on the back shroud. Impeller shall be balanced and shall thread onto the pump shaft and be secured with a lockscrew and conical washer.

b. Shaft: Shaft shall be constructed of 17-4 PH Stainless Steel.

c. Mechanical seal: Shaft seal shall be oil lubricated mechanical type. The stationary and rotating seal faces shall be silicon 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 seal plate, 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. The seal shall be warranted for five (5) years from date of shipment.

d. Lubrication: Separate oil filled cavities, vented to atmosphere, shall be provided for shaft seal and bearings. Oil 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 with 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. 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 plug with vent. The clear sight gauge shall provide easy monitoring of the seal cavity oil level and condition of oil without removal of the vented fill plug.

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

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e. Atmospheric isolation: The shaft bearings shall be isolated from the seal cavity with an air gap to provide positive protection of the bearings in the event of a seal leak and to provide for external monitoring of the seal integrity.

f. Seal plate: Replaceable seal plate shall be constructed of 316 Stainless Steel, and shall be bolted to the bearing housing. Seal plate shall be equipped with anti-rotation ribs cast into the seal plate to reduce internal wear and to maximize seal plate and mechanical seal life.

g. Radial and thrust bearings: Double row, anti-friction ball bearings, of ample size and proper design to withstand all radial and thrust loads which can reasonably be expected during normal operation. Pump designs in which the same oil lubricates both the shaft bearings and the shaft seal shall not be acceptable.

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

4. Suction and discharge spools: Each pump shall be equipped with one-piece, cast iron spools, flanged on each end. Each spool shall have one 1 1/4-inch NPT and one 1/4-inch NPT tapped hole with pipe plugs for mounting of gauges or other instrumentation.

2.02 PUMP ACCESSORIES

A. Spare Parts: Furnish the following spare parts:

1. Four (4) Spare Parts Kits, each including one (1) mechanical cartridge seal, one (1) set of rotating assembly adjustment shims, one (1) cover plate O-ring, one (1) rotating assembly O-ring

2. One (1) complete rotating assembly (with 316 Stainless Steel impeller and seal plate, and 17-4 PH Stainless Steel shaft)

3. One (1) impeller (316 Stainless Steel)

4. Two (2) wear plates (316 Stainless Steel) with attachment hardware

5. One (1) impeller shaft (17-4 PH Stainless Steel)

6. One (1) impeller socket head cap screw

7. One (1) impeller washer

8. One (1) belt tensioning gauges – spring loaded

9. Two (2) quarts of seal lubricant

10. One (1) air pump for bubbler level control system

11. Two (2) air pump repair kits for bubbler level control system

12. Two (2) air pump connector rod kits for bubbler level control system

13. Two (2) air pump inline check valves

14. Two (2) air release valve diaphragms

15. Two (2) air release valve springs

16. One (1) ARV spring compression tool

17. One (1) gallon touch-up paint, white

18. One (1) quart touch-up paint, safety orange

B. Gauge Kit With Vibration Isolation Frame:

1. Each pump shall be equipped with a glycerin-filled compound gauge to monitor suction pressures, and a glycerin-filled pressure gauge to monitor discharge pressures. Gauges shall be a minimum of 4-inches in diameter, and shall be graduated in feet water column. Rated accuracy shall be 1 percent of full-scale reading. Compound gauges shall be graduated -34 feet to +34 feet water column minimum. Pressure gauges shall be graduated 0 to 460 feet water column minimum.

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2. Gauges shall be mounted on a vibration isolation frame assembly with resilient panel, frame, and adjustable brackets which shall be firmly secured to pumps or piping. Gauge installations shall be complete with all hoses and fittings, and shall include a shutoff valve installed in each gauge inlet at the point of connection to suction and discharge pipes.

3. Gauge kit shall be supplied with stainless steel fittings.

C. Pump Drain Kit:

1. A pump drain kit shall be provided, including the following:

a. One set of drain fittings for each pump. Each set of drain fittings includes a pipe nipple, bushing, bronze ball valve and aluminum quick connect male Kamlock fitting.

b. One drain hose for common use among all pumps. Drain hose shall consist of a 10’ length of plastic hose with an aluminum quick connect female Kamlock fitting on one end.

2. All fittings shall be supplied as stainless steel, unless specified otherwise above.

2.03 VALVES AND PIPING

A. Check Valves, 8-inch:

1. Each pump shall be equipped with two (2) full flow type check valves as specified in section 50 05 65.23.

2. Each check valve shall be provided with a ¼-inch treaded tap with plug on the downstream side of the valve for installation of a pressure gauge.

B. Plug Valves 8-inch:

1. Each pump shall be equipped with a full flow type plug valve, capable of passing a 3” spherical solid, with flanged ends to permit the pump to be isolated from the common discharge header.

The plug valve shall be non-lubricated, tapered type. Valve body shall be semi-steel with flanged end connections drilled to 125 pound standard. The drip-tight shutoff plug shall be mounted in stainless steel bearings and shall have a resilient facing bonded to the sealing surface. Valve shall be operated with a chain wheel.

C. Air Release Valves (Diaphragm Type):

1. Each pump shall be equipped with one pressure actuated automatic air release valve, designed to permit the escape of air to the atmosphere during initial priming or unattended repriming cycles. Upon completion of the priming or repriming cycle, the valve shall close to prevent recirculation. Valves shall provide visible indication of valve closure and shall operate solely on discharge pressure. Level/float actuated air release valves 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 shall be fabric-reinforced neoprene or similar inert material.

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

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

5. Air release valves shall be connected to pump station piping using stainless steel pipe fittings.

6. Each air release valve shall be provided with an isolation ball valve.

7. Air release valve piping must discharge directly into wet well. ARV piping shall not discharge to a sump.

8. Each air release valve shall have a separate air release discharge pipe back to the wet well for each air release valve. Discharge pipe shall be minimum 1-½-inch diameter.

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D. Header Piping:

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

A21.51/C115 and Class 53 thickness. Flanges shall be cast iron Class 125 and comply with ANSI B16.1. All piping pipe and flanges shall be threaded and suitable thread sealant applied before assembling flange to pipe.

2. Bolt holes shall be in angular alignment within ½-degree between flanges. Flanges shall be faced and a gasket finish applied that shall have 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 ¼ inch apart.

E. Supports and Thrust Blocks:

1. Contractor must insure all pipes connected to the pumping system are supported to prevent piping loads from being transmitted to pumps or system piping.

2. Pump station discharge force main piping shall be anchored with thrust blocks by the contractor where shown on the contract drawings.

F. Gauge Connection Assembly:

1. The header piping shall be equipped with a gauge connection assembly located between the discharge check valve and force main isolation plug valve allowing the operator to easily attach a discharge gauge on any pump for troubleshooting.

2. The gauge assembly shall consist of a 1/4" brass pipe nipple, 1/4" brass full port ball valve and a quick connect fitting.

3. The gauge connection assembly shall be installed in the discharge header piping such that the static and dynamic pressure in the force main can be read at all times unless the force main isolation plug valve is closed for that particular pump.

2.04 FABRICATED STEEL BASE

A. One fabricated steel base shall be provided for each 2-stage pump and motor assembly. The base shall comprise a base plate, perimeter flange, and reinforcements. Base plate shall be fabricated of steel not less than ¼” thick, and shall incorporate openings for access to all internal cavities to permit complete grouting of unit base after installation. Perimeter flange and reinforcements shall be designed to prevent flexing or warping under operating conditions. Base plate and/or flange shall be drilled for hardware used to secure unit base to concrete pad as shown on the contract drawings. Unit base shall contain provisions for lifting the complete pump unit during shipping and installation.

2.05 DRIVE UNIT

A. Motors:

1. Provide motors as specified herein. Any additional motor requirements specified in another Specification Section, but not specified herein, shall not apply to the motors for this equipment.

2. The pump motors shall be horizontal, totally enclosed fan cooled, induction type, with normal starting torque and low starting current characteristics.

3. The motors shall not be overloaded at the design condition or at any head in the operating range as specified.

4. Motors shall be suitable for use with variable frequency drives.

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

Herbert, Rowland & Grubic, Inc. 44 42 56 - 13 000483.0450

6. Each motor shall be in current NEMA design B cast iron frame with copper windings.

7. Motors shall be NEMA Premium Efficient, per NEMA MG-1, Table 12-12.

B. Drive Transmission:

1. Power shall be transmitted from motors to pumps by means of v-belt drive assemblies. The drive assemblies must be selected to establish proper pump speed to meet the specified operating conditions.

2. Each drive assembly shall have a minimum of two v-belts. In no case will a single belt drive be acceptable. Each v-belt drive assembly shall be selected on the basis that adequate power will be transmitted from driver to pump. Drive systems with a safety factor of less than 1.5 shall not be considered sufficient for the service intended. Computation of safety factors shall be based on performance data published by the drive manufacturer.

3. V-belts shall be the banded type.

C. 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 ½ 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.

2.06 FINISH

A. Surface Preparation and Painting:

B. 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.

C. Exposed surfaces to be coated with one coat of Tnemec Series 69 Polymide Epoxy primer and one finish coat of Series 73 Aliphatic Acrylic Polyurethane for a total dry film thickness of 4-6 mils.

Finish coat shall be semi-gloss white for optimum illumin

D. ation and enhancement.

E. The finish coat shall be corrosion, moisture, oil, and solvent resistant when completely dry.

F. The factory finish shall allow for over-coating and touch up for 6 months after coating. Thereafter, sanding may be required to accept a topcoat or touch-up coating.

2.07 PUMP CONTROL SYSTEM

A. General:

1. This specification covers a pump control system for a duplex pumping station including: Motor Control Center (MCC), bubbler, liquid level control system, programmable Log Controller (PLC), HMI, motor circuit breakers, variable frequency drives (VFD’s), door-mounted operator controls. and all accessories as specified and shown on the drawings.

Herbert, Rowland & Grubic, Inc. 44 42 56 - 14 000483.0450

2. The pump control system shall consist of a motor control center (MCC) with sections as shown on the drawings. The initial sections shall include all 3-phase 480 volt equipment and motor branch circuits and shall have an Arc Flash Hazard rating no higher than Category 2. The end section shall include all single phase 120 volt control components and shall be isolated from the 480- volt sections such that it can be labeled for an Arc Flash Hazard rating of Category 0 which requires no Personal Protective Equipment (PPE). See specification section 26-24-19.

3. The primary liquid level control will include an air bubbler-type level sensor, pump sequence control, alarms, and pump safety shutdowns.

4. The backup liquid level control will include an independent small PLC and FOGROD level sensor.

5. Hartd wired, redundant high and low water float switches shall also be provided.

B. UL Listing:

1. The pump controls shall be manufactured by a UL panel builder, and each assembly shall bear a serialized UL label listed for "Enclosed Industrial Control Panels."

2. It is essential that the control panel manufacturer maintain a local parts and service organization within 150 miles of the pumping station site.

3. The enclosure and all components mounted on the sub-panel or control cover shall conform to

UL descriptions and procedures. Listing for open-style industrial control panels or an assembly of listed or recognized components shall not be acceptable.

C. Equipment Marking

1. Permanent corrosion-resistant name plate(s) shall be attached to the control and include the following information:

a. Equipment serial number

b. Control panel short circuit rating

c. Supply voltage, phase, and frequency

d. Current rating of the minimum main conductor

e. Electrical wiring diagram number

f. Motor horsepower and full-load current

g. The motor overload heater element

h. Motor circuit breaker trip current rating

i. Name and location of equipment manufacturer

2. Control components shall be permanently marked using the same identification keys shown on the electrical diagram. Labels shall be mounted adjacent to device being identified.

3. Switches, indicators, and instruments mounted through the control panel door shall be labeled to indicate function, position, etc. Labels shall be mounted adjacent to, or above the device.

D. Motor Control Center (MCC)

1 The motor control center enclosure shall be NEMA 1.

2 Each vertical section shall be approximately 92-1/2” high and 15”deep. Total overall width of the motor control center shall be 200-inches. Vertical sections shall have internal base mounting angles at the bottom and external lifting angles at the top running continuous within each shipping block. Lifting eyelets at the top are not acceptable.

3 Horizontal wireways of standard sections, both top and bottom, shall be not less than 6” high. To prevent damage to cable insulation, the wireway opening between sections shall have rounded corners and the edges shall be rolled back.

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4 A full height vertical wireway door being 4.37” wide and hinged shall be provided in each standard vertical section containing multiple units. A permanent vertical wireway wall shall separate the units from the vertical wireway, and remain intact even when the units are removed. Units that occupy a full section do not require vertical wireway.

5 The power bus system shall be supported, braced, and isolated by a bus support molded of a high strength, non-tracking glass-filled polyester material. Bus bracing shall not be rated less than 42kA rms symmetrical.

6 The horizontal bus shall be continuously braced within each section. It shall be aluminum rated 600A.

7 Both ends of the horizontal bus splices shall have at least two (2) bolts and each bolt shall be capable of handling the load.

8 The vertical bus shall be continuously braced and sandwiched in a glass-filled polyester molding. The bus shall be isolated from the user by a red non-metallic molded cover. The vertical bus shall accommodate plug-in loads totaling up to 600A.

9 The horizontal ground bus bar shall be copper and located in the bottom horizontal wireway. The size of the horizontal ground bus shall be ¼” x 1”.

10 A grounding point shall be provided at each starter unit for purposes of landing the ground wire coming from the motor. This grounding point shall be directly tied to the horizontal ground bus.

11 Plugs shall be provided for unused bus stab openings so that personnel are not exposed to live vertical bus bars and so that the bus is isolated from arcing faults.

12 All control devices and instruments shall be mounted using threaded fasteners, and shall be clearly labeled to indicate function.

13 VFD sections shall be constructed such that VFD load wiring may exit the top of the VFD. Provide adequate space to allow motor wiring the bend 180 degrees within the VFD section.

b. UL Listing:

1 The pump controls shall be manufactured by the pump manufacturer who shall be a UL panel builder, and each assembly shall bear a serialized UL label listed for "Enclosed Industrial Control Panels."

2 The enclosure and all components mounted on the sub-panel or control cover shall conform to UL descriptions and procedures. Listing for open style industrial control panels or an assembly of listed or recognized components shall not be acceptable.

c. Wiring Class:

1 All motor control center wiring to be Nema class IIB including interwiring and interlocking between units and the liquid level control. Units shipped separately because of shipping requirements shall be equipped with wiring harnesses with match-marked and keyed connectors for field assembly.

2 Complete control system engineering shall be supplied by the pump manufacturer and shall include system drawings showing all control units as they are interwired.

Diagrams of individual units will not be acceptable.

d. Main Connections:

1 Each control assembly shall be furnished with main terminals and ground lug for field connection of the electrical supply. The connections shall be designed to

Herbert, Rowland & Grubic, Inc. 44 42 56 - 16 000483.0450 accept copper conductors of sufficient size to serve the loads. The main terminals 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 terminals. Ten percent of the control terminals shall be furnished as spares.

2 The pump control panel shall be designed, manufactured, and tested in facilities registered to ISO 9001 quality standards.

E. Motor Branch Components:

1. All motor branch components shall be of the highest industrial quality. Operating coils of all AC control devices shall be rated for 120 volts, and shall be suitable for use in a voltage range of 108 to 132 volts, 60 hertz. The short circuit rating of all power circuit devices shall be a tested combination or evaluated per the National Electric 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 that 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, and shall have a symmetrical RMS interrupting rating of 25,000 amperes at 480 volts. 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.

F. Variable Frequency Drives:

1. The inverter shall be suitable for operation of NEMA Design B, 4 pole motors. The inverter will have a diode bridge rectifier on the input to minimize the generation of electrical noise back into the line and provide near unity power factor. Output devices shall be transistors.

2. Environment Conditions: The…