A2_Revised_Spec_333200_WASTEWATER_PUMPING_STATION.pdf

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SECTION 333200 – WASTEWATER PUMPING STATION

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes:

1. Submersible sewage pumps

2. Pump tank and cover

3. Hatch and guide rails

4. Valve vault

5. Check valves

6. Ball valves

7. Hoist and socket

B. Related Sections

1. Division 26, Section “Specialized Electrical Materials”

2. Division 31, Section “Earth Moving”

3. Division 33, Section “Sanitary Sewerage Piping”

1.3 PERFORMANCE REQUIREMENTS

A. Pressure Rating of Sewage Pumps and Discharge Piping Components: At least equal to sewage pump discharge pressure, but not less than 125 psig.

B. Pressure Rating of Other Piping Components: At least equal to system operating pressure.

C. All products and materials to comply with the “Buy American Act”.

1.4 SUBMITTALS

A. Product Data: Include rated capacities, operating characteristics, furnished specialties, and accessories.

1. Sewage pumps

2. Precast vaults and tanks

3. Hatches

4. Guide rail systems

5. Hoist and socket

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B. Shop Drawings: Include construction details, material descriptions, dimensions of individual components, rated capacities, operating characteristics, electrical characteristics, and furnished accessories.

1. Precast vaults and tanks

2. Wiring Diagrams: Power, signal, and control wiring.

C. Product Certificates: For each type of sewage pump, signed by product manufacturer.

D. Qualification Data: For Installer.

E. Source quality-control test reports.

F. Field quality-control test reports.

G. Operation and Maintenance Data: For equipment to include in emergency, operation, and maintenance manuals.

H. Warranty: Special warranty specified in this Section.

I. Materials List: Provide list of all components in XLS format with make model # source of supply.

J. Operations instructions: Functional description of control logic line by line, troubleshooting guide, and calibration instructions for entire system

1.5 QUALITY ASSURANCE

A. Installer Qualifications: Manufacturer's authorized representative who is trained and approved for installation of units required for this Project.

B. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7.

C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

D. Comply with UL 778, "Motor-Operated Water Pumps," for sewage pumps.

E. Comply with the standards of the ANSI Hydraulics Institute.

1.6 PROJECT CONDITIONS

A. Interruption of Existing Sanitary Sewer Service: Do not interrupt sanitary sewer service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary sanitary sewer service according to requirements indicated:

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1. Notify Contracting Officer no fewer than two days in advance of proposed interruption of sanitary sewer service.

2. Do not proceed with interruption of sanitary sewer service without Contracting Officer’s written permission.

1.7 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of sewage pumping stations that fail in materials or workmanship within specified warranty period.

1. Failures include, but are not limited to, the following:

a. Structural failures including wet well.

b. Faulty operation of sewage pumps, controls, or accessories.

c. Deterioration of metals, metal finishes, and other materials beyond normal use.

2. Warranty Period for Wet Well: One year from date of Substantial Completion.

3. Warranty Period for Sewage Pumps and Controls: Five years from date of Substantial

Completion.

4. Warranty Period for Accessories: One year from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 SUBMERSIBLE SEWAGE PUMPS

A. Submersible, Quick-Disconnect, Double-Seal Sewage Pumps:

1. Description: Factory-assembled and -tested sewage-pump unit with guide-rail supports.

2. Pump type: Submersible, non-clog, end-suction, single-stage, close-coupled, overhung-impeller, centrifugal sewage pump.

3. Pump Casing: ASTM A-48 Class 30 cast iron, with open inlet, and discharge fittings for connection to guide-rail support.

4. Impeller: Statically and dynamically balanced, ASTM A-48 Class 30 cast iron, non-clog, open, or semi-open design for solids handling, and keyed and secured to shaft.

5. Pump and Motor Shaft: Stainless steel, with factory-sealed, grease-lubricated ball bearings.

6. Seals: Mechanical.

7. Moisture-Sensing Probe: Internal moisture sensor and moisture alarm. Seal fail cord shall be a separate cord not combined with the power supply cord.

8. Motor: Hermetically sealed with built-in overload protection; lifting eye or lug; and three-conductor, waterproof power cable of length required and with grounding plug and cable-sealing assembly for connection at pump.

a. Motor Housing Fluid: Oil.

b. Motor Size: 3/4 Horsepower

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9. Electrical Characteristics:

a. Volts: 208

b. Phases: Three

c. Hertz: 60

10. Discharge Size: 1-1/2 inches NPT

11. Operating Characteristics: 20 U.S. GPM at 23 feet TDH

12. Solids Handling Capability: 5/8” spherical solids

13. Power Cord: STW-A water resistant, 600V, 60 C. Provide separate cord for seal fail probes and thermal detectors.

14. Guide-Rail Supports:

a. Standard: SWPA's "Submersible Sewage Pumping Systems (SWPA) Handbook."

b. Guide Rails: Vertical pipes or structural members, made of stainless steel, attached to baseplate and tank cover access hatch frame.

c. Baseplate: Corrosion-resistant metal plate, attached to tank floor, supporting guide rails and stationary elbow.

d. Pump Yoke: Specify a slip lock fitting at pump to allow pump to be removed with no tools or pipe fittings to disconnect in wet well. Motor-mounted or casing-mounted yokes or other attachments for aligning pump during connection of Movable Elbow to Stationary Elbow.

e. Movable Elbow: Elbow fitting made to slide along the guide rails with threaded connection to pump discharge, positioning device, and flange/seal that mates to the Stationary Elbow with a slip lock fitting which allows the pump to be removed with no tools or disconnecting pipe fittings in wet well

f. Stationary Elbow: Fixed discharge-elbow fitting with threaded connection to discharge pipe, flange that mates to flange/seal of the Movable Elbow, and a support attached to baseplate.

15. Lifting Cable: Stainless steel; attached to pump and cover at manhole.

2.2 PUMP TANK AND COVER

A. Tank: Watertight, rectangular chamber with openings for pipe connections. Openings may be factory-cast or core drilled on site.

1. Material: Reinforced precast concrete conforming to ASTM C-478.

2. Internal Dimensions: Length 126 inches, Width 60 inches

3. Wall Thickness: 6 inches (minimum)

4. Depth: 108 inches (underside of cover to floor of tank)

5. Inlet Pipes: One (1) 6” gravity sewer inlet

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6. Outlet Pipes: Two (2) 2” pump discharge pipes

B. Basin Cover: Precast concrete flat top manhole cover

1. Load Rating: H20 traffic loading

2. Access Hatch: Galvanized steel hatch with lockable latch, spring-assisted door, and 30 inch by 48 inch clear opening. Compatible with sewage pump guide rails.

2.3 VALVE VAULT

A. Vault: Watertight, rectangular chamber with openings for pipe connections. Openings may be factory-cast or core drilled on site.

1. Material: Reinforced precast concrete conforming to ASTM C-478.

2. Internal Dimensions: Length 66 inches, Width 42 inches inside diameter

3. Wall Thickness: 4 inches (minimum)

4. Depth: 42 inches (underside of cover to floor of vault)

5. Inlet Pipes: One (1) 2” pressure sewer

6. Outlet Pipes: One (1) 2” pressure sewer

B. Basin Cover: Precast concrete flat top manhole cover

1. Load Rating: H20 traffic loading

C. Access Hatch: Galvanized steel hatch with lockable latch, spring-assisted door, and 30 inch by 48 inch clear opening.

2.4 CONTROLS

A. The existing sewage pump station control panel at the project site shall be relocated to a temporary enclosure and utilized to control the existing pump station during construction of the new office building.

B. Once the new office building and the new sewage pump station are both complete, the con-trol panel shall be relocated from its temporary enclosure to the electrical room of the new office building and used to control the new pump station. Contractor must modify the pan-el with new overload heaters for the new pumps, verify MCP sizes, and test the system

1. Pump station to contain two (2) pumps that shall run in a duplex alternating (one at a time) fashion, using an “on-demand” scheme controlled by float switch inputs and a programmable controller.

2. The pumping mode of the submersible pumps shall depend on the input of four (4) float switches installed in the wet well:

i. High Level Alarm

ii. Lag Pump On

iii. Lead Pump On

iv. Pumps Off

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v. Low Water Alarm/Redundant Off

3. Normal system operation shall keep the wastewater liquid level between the “Pumps On” and “Pumps Off” floats.

4. Dosing to the sand filter shall not exceed 10% of the 1200 gallon daily sewage vol-ume (120 gallons per dose). Control panel shall be equipped with capability to only allow one pump cycle every 2.4 hours (144 minutes). Pump shall run at 20 gpm for a period of no more than 6.0 minutes each cycle.

5. The timed pump cycles shall begin when the “Pump On” float is raised and shall continue at the frequency and duration noted above until the “Pumps Off” float drops.

6. In the event that the wastewater level drops below the “Low Water Alarm/Redundant Off” float, all automatic pump activity is ceased and an alarm shall be set to notify the operator of the low wastewater liquid level condition.

7. In the event that the wastewater level rises above the “High Level Alarm” float, an alarm shall be set to notify the operator of the high wastewater liquid level condi-tion. Timed pump cycles shall not be modified or interrupted by a high level alarm.

C. Lift Station Control Panel Features

1. In the event of an alarm, the control panel shall activate a local light and an audible alarm on the exterior of the District Office, the remote annunciator at the reception desk, and the auto dialer.

2. Control Sequence of Operation: Cycle each sewage pump on and off automatically in timed cycles to maintain wet-well sewage level. Automatic alternator, with man-ual disconnect switch, changes sequence of lead-lag sewage pumps at completion of each pumping cycle.

D. Duplex Pump Operation

1. Liquid surface level in the tank rises to “lead pump on”, pumps alternately run in timed cycles until the liquid surface level in the tank is lowered to the level of the “pumps off” float switch.

2. Low level alarm is redundant pump off, pump turns on/off with low level float.

3. High level alarm sounds general alarm and strobe.

4. If one pump overloads / breaker trips, remaining pump is lead pump until reset, tie into alternator circuit.

5. If one pump is taken out of service with HOA switch in off, remaining pump be-comes lead pump with each pump cycle.

E. Control Panel Mounting: Inside electrical room of new District Office.

F. Connection for Portable Generator: None required.

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2.5 ACCESSORIES

A. High-Water/Low-Water Audio Alarm: 24 VDC 3.5 watt horn for audio indication of station high-water level/low-water level, energized by separate level-detecting device. Include alarm test switch and alarm silencer switch, and relay in control panel. Alarm horn to be mounted outside the temporary enclosure during construction of the new building and outside the electrical room when construction is complete.

B. High-Water/Low-Water Visual Alarm: 24VDC 3.5 watt strobe light wired to turn on in conjunction with the audio alarm. Strobe light to be mounted outside the temporary enclosure during construction of the new building and outside the electrical room when construction is complete.

C. Provide a remote annunciator in office that will detect a contact closure over a #22AWG con-trol cable at pump station and provide the following functions.

1. Provide a 24VDC power supply to drive 24VDC relay to monitor a contact clo-sure in pump station control panel for any alarm, power loss, or any other alarm.

2. Provide on the annunciator face the following controls:

24VDC power on light

3. General alarm red light for pump station Telephone dialer on / off switch

4. Energize an external alarm annunciator consisting of a 24VDC sonalets and a 24VDC LED pilot light fed from the alarm light 24VDC output in the existing control panel to be mounted at the reception area in a 4"x6" J box with a silence switch for sonalert.

5. Provide a voice dialer in annunciator to dial up to 4 people with tone acknowl-edgement of alarm in remote annunciator panel.

6. Provide a dialer on/off switch. Dialer shall dial out on internal battery if annun-ciator panel loses power.

7. Provide a schematic diagram, physical wiring diagram, wire numbers on all wires.

2.6 VALVES

A. Check Valves: Check valves shall be designed to allow full flow through the valve in only one direction and be used in sewage and effluent pumping applications.

1. Valve body: Bronze (Addendum 02).

2. Flapper: Neoprene polyester reinforced (smooth edge design) with stainless steel fastener

3. Pressure rating: Minimum 50 psig at 130 degrees F.

4. End connections: 2-inch NPT (female).

B. Ball Valves: Ball valves shall be

1. Valve body: All bronze construction

2. Handle: Galvanized steel lever-type handle with rubber cover

3. Pressure rating: Minimum 125 psig

4. End connections: 2-inch NPT (female)

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2.7 HOIST AND SOCKET

A. Hoist: Hoist shall be Halliday Products model D1B36C or Contracting-Officer approved equal.

1. Lifting capacity: 300 pounds

2. Frame material: Type-304 stainless steel

3. Cable: 1/4inch stainless steel (minimum length of 30 feet)

4. Winch: Marine grade by Dutton-Lainson

5. Hook: Galvanized 1-ton

B. Socket: Halliday Products model D1S lined or Contracting-Officer approved equal

1. Material: Type-304 stainless steel

2. Lining: Polymer

3. Weep hole: 3/4-inch diameter

2.8 MISCELLANEOUS MATERIALS

A. Grout: ASTM C 1107, Grade B, non-shrink cement grout.

1. Design Mix: 5000-psi, 28-day compressive strength.

B. Concrete: Concrete is specified in Division 03 Section "Cast-in-Place Concrete."

2.9 SEWAGE PUMPING STATION FABRICATION

A. Air Vent: Duct fabricated from 3” Schedule-40 steel pipe, extended to above grade, outlet turned down, painted, and with insect screen in outlet.

B. Field fabricate piping between unit components.

1. Pipe and fittings shall be schedule-40 304 stainless steel pipe conforming to ASTM A- 312 with NPT threaded connections.

2. Use fittings for changes in direction and branch connections.

3. Flanged and union joints may be used instead of joints specified.

4. Use dielectric fittings for connections between ferrous- and copper-alloy piping.

5. Include plug valve and check valve on each discharge pipe.

2.10 SOURCE QUALITY CONTROL

A. Test and inspect sewage pumps according to ANSI Hydraulic Institute 1.6, "Centrifugal Pump Tests." Include test recordings that substantiate correct performance of pumps at design head, capacity, suction lift, speed, and horsepower.

B. Test accessories and controls through complete cycle. Include test recordings that substantiate correct performance.

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PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance.

B. Examine roughing-in of sewerage piping systems to verify actual locations of piping connections before sewage pumping station construction.

C. Proceed with construction only after unsatisfactory conditions have been corrected.

D. Examine roughing-in for plumbing piping to verify actual locations of sanitary drainage and vent piping connections before sewage pump installation

3.2 EARTHWORK

A. Excavation, trenching, and backfilling are specified in Division 31 Section "Earth Moving."

3.3 INSTALLATION

A. Install sewage pumping station components where indicated on the drawings, according to specific equipment and piping arrangement indicated.

B. Seal all concrete vault wall penetrations with non-shrink grout under and around shell.

C. Pump Installation Standards:

1. Comply with ANSI Hydraulic Institute 1.4 for installation of centrifugal pumps.

2. Comply with ANSI Hydraulic Institute 3.1-3.5 for installation of progressing-cavity sewage pumps.

D. Wiring Method: Comply with requirements in Division 26 Section "Low-Voltage Electrical Power Conductors and Cables."

E. Wiring within Enclosures: Bundle, lace, and train conductors to terminal points with no excess and without exceeding manufacturer's limitations on bending radii. Provide and use lacing bars and distribution spools

3.4 CONNECTIONS

A. Sanitary sewer piping installation requirements are specified in Division 22 Section "Facility Sanitary Sewers." Drawings indicate general arrangement of piping.

B. Install piping adjacent to equipment to allow service and maintenance.

C. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems."

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D. Connect wiring according to Division 26 Section "Low-Voltage Electrical Power Conductors and Cables."

E. Comply with requirements for piping specified in Division 22 Section "Sanitary Waste and Vent Piping." Drawings indicate general arrangement of piping, fittings, and specialties.

3.5 IDENTIFICATION

A. Install operating instruction signs permanently attached to equipment or on pumping station wall near equipment.

1. Float switches: Install stamped stainless steel nameplate for each float switch on the spreader bracket

2. Warning tape: Install green detectable warning tape over all underground sewage piping.

Tape materials and their installation are specified in Division 31 Section "Earth Moving."

3.6 FIELD QUALITY CONTROL

A. Testing Agency: Engage a qualified testing agency to perform field tests and inspections and prepare test reports.

B. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect, test, and adjust components, assemblies, and equipment installations, including connections.

Report results in writing.

C. Perform tests and inspections and prepare test reports.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.

2. Control and motor tests shall conform with specification 260000 3.31 Tests and 3.32 Final Tests.

D. Tests and Inspections

1. After constructing sewage pumping station and after electrical circuitry has been energized, test for compliance with requirements. Furnish water required for pump tests.

2. Notification: Notify the Contracting Officer at least 48-hours in advance of all tests.

3. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect, test, and adjust components, assemblies, and equipment installations, including connections.

4. Leak Test: After installation, charge system and test for leaks. Repair leaks and retest until no leaks exist.

5. Operational Test: After electrical circuitry has been energized, start units to confirm proper operation of all controls and components.

6. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

7. Remove and replace sewage pumping station components that do not pass tests and inspections and retest as specified above

E. Pumps and controls will be considered defective if they do not pass tests and inspections.

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F. Prepare test and inspection reports

3.7 ADJUSTING

A. Adjust pumps to function smoothly, and lubricate as recommended by manufacturer.

B. Adjust control set points

3.8 STARTUP SERVICE

A. Engage a factory-authorized service representative to perform startup service.

1. Complete installation and startup checks according to manufacturer's written instructions.

2. Adjust pumps, accessories, control settings, and safety and alarm devices.

3.9 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain the sewage pumping station. Refer to Division 01 Section "Demonstration and Training."+

3.10 SPARE PARTS

A. Provide to the Contracting Officer spare parts matching those installed as follows:

1. One (1) spare submersible effluent pump

2. Five (5) spare float switches

3.11 OPERATION AND MAINTENANCE MANUAL

A. For each type of product indicated, provide two (2) copies of manufacturer’s operation and maintenance manual.

1. Submersible effluent pumps

2. Hoist and socket

END OF SECTION 333200