ATTACHMENT 1-Blanchard Spgs Booster Pumps and Control Panel.pdf

USDA FOREST SERVICE PROJECT SPECIFICATION

BLANCHARD SPRINGS BOOSTER

PUMPS AND CONTROL PANEL REPLACEMENT

USDA FOREST SERVICE

OZARK-ST. FRANCIS NATIONAL FORESTS

SYLAMORE RANGER DISTRICT – BLANCHARD SPRINGS

74 BLANCHARD SPRINGS ROAD

FIFTY-SIX, AR 72533

12 January 2023

01 – General Requirements

1.1 Summary of Work

The Pumps and Control Panel Replacement is for Blanchard Springs Visitor

Information Center located near Fifty-Six, AR. The contractor shall provide all labor, tools, equipment, and materials to remove and replace existing pump package (4-pumps) and control panel unit and appurtenances. This will include demo, electrical, plumbing, and controls.

1.2 PROJECT COORDINATION

The contractor shall perform the work in a manner that will protect the safety of the public and employees. The building will not be occupied during installation;

however, pump station provides all water supply to Blanchard Springs Caverns and recreation areas. All quantities provided are approximate, contractor will verify all existing quantities before bidding, contractors will contact and coordinate with

COR for onsite pre-bid visit.

The contractor may perform the work on weekdays starting in February, between the hours of 6:00 AM and 7:00 P.M. No work shall be performed in March due to high visitation rates. Work from April 3rd thru May 25th shall be performed on

Tuesday and Wednesdays 6:00 AM to 7:00 PM or other days to be coordinated in advance with the COR. Water system cannot be offline during Memorial Day weekend. Work schedule will be modified to meet Blanchard Springs Cave operating hours, as to not disrupt the normal operations of tours from 9:30 am to

6:00 PM. Work shall not be performed on federal holidays or weekends unless prior approval has been arranged with the Contracting Officer Representative.

Work shall be performed within 180 days of Notice to Proceed.

1.3 SUBMITTAL PROCEDURES

Submittals shall be made prior to and approved before commencing any work that relates to respective submittal. Submittals will meet project specifications and all applicable codes, ANSI, and ASTM standards as required. Incomplete information on the proposed items will result in rejection. The contractor shall submit two sets of the manufacturer’s information (cut sheets). This information shall include:

1. Product name and model number

2. Manufacturer

3. Product description (include sizes if different from specified)

4. Technical data

5. Warranties

Submittals shall conform to the Build America Buy America Act.

(1) All iron and steel items used in covered projects must be produced in the

United States. This means all manufacturing processes, from the initial melting stage through the application of coatings, occurred in the United States.

(2) All manufactured products used in covered projects must be produced in the United States. This means the manufactured product was manufactured in the United States, and the cost of the components of the manufactured product that are mined, produced, or manufactured in the United States is greater than 55 percent of the total cost of all components of the manufactured product.

(3) All construction materials used in covered projects must be manufactured in the United States. This means that all manufacturing processes for the construction material occurred in the United States.

1.4 QUALITY CONTROL

Upon selection of the contractor and award for the project, coordination with the named COR in the award letter before work commences. It is the government’s intent that expert and experienced workers perform the work described in this contract. The contractor shall provide workers with the necessary skills and knowledge to complete the work in an expert and competent manner and provide factory representatives, subcontractors, or consultants as needed with no additional costs to Government. Workmanship shall result in an operable quality product free from defects and leaks. The contractor shall have a minimum of 5 years’ experience in installation of water lines and booster pump station construction.

1.5 CONTRACT CLOSEOUT

1. The contractor will provide all technical data and warranty information for the materials provided.

2. The contractor shall remove all materials, construction debris and impacted vegetation from the site.

3. The contractor is responsible for any damage to government property.

4. All work will be performed in accordance with applicable, local, state, and federal building codes and regulations, and OSHA Safety Requirements.

5. Contractor shall demonstrate the Package Pump System, Control Panel, and associated piping are operable and functioning as designed upon completion of installation to the COR before final payment.

6. Contractor shall provide 2 copies of Operation and Maintenance Manual in 3-

Ring binder to COR before approval of final payment.

02 – Execution

2.1 TECHNICAL SPECIFICATIONS

A. GENERAL

1. The contractor shall remove all construction debris and dispose in accordance with state and local regulations.

2. Materials not approved for installation will be removed and replaced at contractors’ expense with no additional costs to Government. Contractor will receive in writing approval of submittals by the COR prior to commencing work.

3. Project materials to be stored on site will be securely covered and protected from weather elements when not in use.

4. Housekeeping will be conducted daily, and project site is to kept neat and orderly.

5. All manufacturer’s recommendations and instructions shall be followed during installation.

2.2 WORK INCLUDED

A. Demo and disposal of existing Grundfos Variable Speed Packaged Pumping

System (4-pumps) and Control Panel, demo and disposal of Peabody Pump and controls, associated piping, and appurtenances. Provide and install new Variable Speed Packaged Pumping System (4-pumps) and associated piping, and appurtenances.

2.3 REFERENCE STANDARDS

The work in this section is subject to the requirements of applicable portions of the following standards:

A. Hydraulic Institute

B. ANSI – American National Standards Institute

C. ASTM – American Society for Testing and Materials

D. IEEE – Institute of Electrical and Electronics Engineers

E. NEMA – National Electrical Manufacturers Association

F. NEC – National Electrical Code

G. ISO – International Standards Organization

H. UL – Underwriters Laboratories, Inc.

03 – PRODUCTS

3.1 VARIABLE SPEED PACKAGED PUMPING SYSTEM

A. Furnish and install a new prefabricated and tested variable speed packaged pumping system to maintain constant water delivery pressure of 30-60 psi.

B. The packaged pump system shall be a standard product of a single pump manufacturer. The entire pump system including pumps and pump logic controller, shall be designed, built, and tested by the same manufacturer before installation, testing certifications shall be provided with submittals.

C. The complete packaged water booster pump system shall be certified and listed by UL (Category QCZJ – Packaged Pumping Systems) for conformance to U.S. and Canadian Standards.

D. The complete packaged pumping system shall be NSF61 / NSF372 Listed for drinking water and low lead requirements.

E. The packaged pump system shall be ASHRAE 90.1 – 2010 compliant without the need of a remote mounted sensor. The control logic used to simulate a remote mounted sensor shall be proportional pressure control with squared or linear adaptation. An actual flow rate or calculated flow rate based on performance curves (5th order polynomial) loaded into the controller; shall be used to adjust setpoint pressure in proportional pressure control.

3.2 PUMPS

A. All pumps shall be ANSI NSF 61 / NSF372 Listed for drinking water and low lead requirements.

B. The pumps shall be of the in-line vertical multi-stage design.

C. The head-capacity curve shall have a steady rise in head from maximum to minimum flow within the preferred operating region. The shut-off head shall be a minimum of 20% higher than the head at the best efficiency point. Pump Curve and Flow Data provide on page 21.

D. Small Vertical In-Line Multi-Stage Pumps (Nominal flow from 3 to 125 gallons per minute) shall have the following features:

1. The pump impellers shall be secured directly to the pump shaft by means of a splined shaft arrangement.

2. The suction/discharge base shall have ANSI Class 250 flange or internal pipe thread (NPT) connections as determined by the pump station manufacturer.

3. Pump Construction.

a. Suction/discharge base, pump head, motor stool: Cast iron (Class 30)

b. Impellers, diffuser chambers, outer sleeve: 304 Stainless Steel

c. Shaft: 316 or 431 Stainless Steel

d. Impeller wear rings: 304 Stainless Steel

e. Shaft journals and chamber bearings: Silicon Carbide

f. O-rings: EPDM

Shaft couplings for motor flange sizes 184TC and smaller shall be made of cast iron or sintered steel. Shaft couplings for motor flange sizes larger than 184TC shall be made of ductile iron (ASTM 60-40-18).

Optional materials for the suction/discharge base and pump head shall be cast 316 stainless steel (ASTM CF-8M) resulting in all wetted parts of stainless steel.

4. The shaft seal shall be a balanced O-ring cartridge type with the following features:

a. Collar, Drivers, Spring: 316 Stainless Steel

b. Shaft Sleeve, Gland Plate: 316 Stainless Steel

c. Stationary Ring: Graphite embedded Silicon Carbide

d. Rotating Ring: Graphite embedded Silicon Carbide

e. O-rings: EPDM

5. Shaft seal replacement shall be possible without removal of any pump components other than the coupling guard, shaft coupling and motor. The entire cartridge shaft seal shall be removable as a one-piece component.

6. Pumps with motors equal to or larger than 15 hp (fifteen horsepower) shall have adequate space within the motor stool so that shaft seal replacement is possible without motor removal.

3.3 INTEGRATED VARIABLE FREQUENCY DRIVE MOTORS

• Efficiency: The motors shall be of permanent magnet design meeting IE5 efficiency levels where the combined motor and VFD efficiency exceed NEMA Premium Efficiency standards.

• Bearing Current Mitigation: Motors shall use WSB (Winding Set Back) and/or CHS (Coil Head Shield) designs that reduce the Bearing Voltage Ratio (BVR) far enough to eliminate damaging bearing currents. Shaft grounding rings/brushes or common mode filters shall not be required.

• Motor Enclosure/Cooling: The motor shall be Totally Enclosed Fan Cooled (TEFC) with a standard NEMA C-Face with Class F insulation and a temperature rise class no higher than Class B. The cooling design of the motor and VFD shall be such that a Class B motor temperature rise is not exceeded at full rated load and speed at a minimum switching frequency of 9.0 kHz.

• The power and control electronics shall be housed in a UL Type 3 enclosure and the combined motor/VFD rating shall be IP55 (protection against dust and nozzle directed water from any direction).

• The VFD shall be of the PWM (Pulse Width Modulation) design using IGBT (Insulated Gate Bipolar Transistor) technology.

• The VFD shall convert incoming fixed frequency three-phase AC power into a variable frequency and voltage for controlling the speed of motor. The motor current shall closely approximate a sine wave. Motor voltage shall be varied with frequency to maintain desired motor current suitable for centrifugal pump control and to eliminate the need for motor de-rating.

• The VFD shall automatically reduce the switching frequency and/or the output voltage and frequency to the motor during periods of sustained ambient temperatures that are higher than the normal operating range. The switching frequency shall be reduced before motor speed is reduced.

• An integral RFI filter shall be standard in the VFD.

• The VFD shall have a minimum of two skip frequency bands which can be field adjustable.

• The VFD shall have internal solid-state overload protection designed to trip within the range of 105-110% of rated current.

• The integrated VFD motor shall include protection against input transients, phase imbalance, loss of AC line phase, over-voltage, under-voltage, VFD over-temperature, and motor overtemperature. Three-phase integrated VFD motors shall be capable of providing full output voltage and frequency with a voltage imbalance of up to 10%.

• The integrated VFD motor shall have, as a minimum, the following input/output capabilities:

1. Speed Reference Signal: 0-10 VDC, 4-20mA

2. Digital remote on/off

3. Fault Signal Relay (NC or NO)

4. Fieldbus communication port (RS485)

• Motor drive end bearings shall be adequately sized so that the minimum L10 bearing life is 20,000 hours at the minimum allowable continuous flow rate for the pump at full rated speed.

3.4 PUMP SYSTEM CONTROLLER

A. The pump system controller shall be a standard product developed and supported by the pump manufacturer.

B. The controller shall be microprocessor based capable of having software changes and updates via personal computer (notebook). The controller user interface shall have a color display with a minimum screen size of 3- 1/2” x 4-5/8” for easy viewing of system status parameters and for field programming. The display shall have a back light with contrast adjustment.

Password protection of system settings shall be standard.

C. Galvanic Isolation: The controller shall provide internal galvanic isolation to all digital and analog inputs as well as all fieldbus connections.

D. Backup Battery: The controller shall have the ability to be connected to a backup battery to supply power to the controller during periods of loss of supply power.

E. Home Status Screen: The controller shall display the following as status readings from a single display on the controller (this display shall be the default):

• Current value of the control parameter, (typically differential pressure)

• Most recent existing alarm (if any)

• System status with current operating mode

• Status of each pump with current operating mode and rotational speed as a percentage (%)

• Estimated flow-rate, (or actual flow if flow sensor is used)

• One user defined measured parameter (i.e. power consumption)

F. Inputs/Outputs: The controller shall have as a minimum the following hardware inputs and outputs:

• Three analog inputs (4-20mA or 0-10VDC)

• Three digital inputs

• Two digital outputs

• Ethernet connection (built-in web server)

• Field Service connection to PC for advanced programming, software and/or firmware upgrades and data logging

G. Pump system programming: As a minimum, the following parameters shall be available and/or field adjustable:

• Sensor Settings: Suction, Discharge, Differential Pressure [analog supply/range]

• PI Controller: Proportional gain (Kp) and Integral time (Ti)

• Low suction: Pressure/level shutdown via digital contact

• Limit Exceeding function: For low system, low suction warnings and shut down [via analog input]

• Flow meter settings (if used, analog signal)

H. Pump Curve Data: The actual pump performance curves (5th order polynomial) shall be loaded (software) into the pump system controller.

Pump curve data shall be used for the following:

• Display and data logging of calculated flow rate

• Variable pressure control (quadratic or proportional)

• Pump outside of duty range protection

• Sequence pumps based on efficiency

I. Variable Pressure Control: The controller shall have variable pressure control to compensate for pipe friction loss by decreasing the pressure set-point at lower flow-rates and increasing the pressure set-point at higher flow-rates by using the actual flow rate or calculated flow rate. Variable pressure control that uses power consumption and speed only shall not be considered equal to variable pressure control that uses actual differential pressure measurement along with pump power and speed.

J. Multi-Sensor: The controller shall be able to control using up to six differential pressure (DP) sensors (zones). Each zone shall have a programmable maximum and minimum DP range. The controller shall be capable of an energy optimal mode where pump speed/energy shall be reduced until any of the zones reach the minimum DP setting.

K. Check Valve Failure Detection (Systems with integrated VFD motors): The system controller shall be able to detect motors turning in the opposite direction and give check valve failure notification.

• For minor leaks the pump shall start with a warning indicated.

• For major leaks the pump shall remain off to prevent damage with an alarm indication.

L. Pulse flow meter: The system controller shall be able to receive pulse readings from a digital pulse meter and log/display accumulated flow.

M. DP Subtraction: The system controller shall be able to control off subtraction of two pressure or temperature sensors for differential pressure or differential temperature control.

N. Programmable Setpoints: The system controller shall be able to accept up to seven programmable set-points via a digital input, (additional input/output module may be required).

O. Setpoint Influence: The system pressure set-point shall be capable of being automatically adjusted by using an external set-point influence. The set-point influence function enables the user to adjust the control parameter (typically differential pressure) by measuring an additional parameter.

(Example: Lower the system differential pressure set-point based on a flow or outdoor temperature measurement).

P. Remote Control: The controller shall be capable of receiving a remote analog set-point (4-20mA or 0-10 VDC) as well as a remote system on/off (digital) signal.

Q. Setpoint Ramp: The controller shall be able to adjust the ramp time of a change in set point (increase and decrease).

R. Warnings and Alarms: The pump system controller shall store warnings and alarms in memory. The time, date and duration of each alarm shall be recorded. A potential-free relay shall be provided for alarm notification to the building management system. The controller shall display the following alarm conditions:

Individual pump failure Check valve failure

VFD trip/failure Loss of sensor signal (4-20 mA)

Loss of remote set-point signal (4-20mA) External Fault

Pump outside of duty range Limit 1 and 2 exceeded*

NOTE: The controller shall be capable of monitoring two analog signals (i.e.

suction pressure and discharge pressure) for additional pump or system protection.

S. Built-in data log: The controller shall have built-in data logging capability.

Logged values shall be graphically displayed on the controller and shall be downloadable to a notebook/pc as a delimited text file. A minimum of 7200 samples per logged value shall be available for the following parameters:

• Estimated flow-rate (or actual flow if flow sensor is connected)

• Speed of pumps

• Process Value/sensor feedback (usually differential pressure)

• Power consumption

• Controlling parameter (setpoint)

• Inlet pressure (when remote differential pressure is the primary sensor)

T. Redundant Primary Sensor: The controller shall be capable of receiving a redundant sensor input to function as a backup to the primary sensor.

U. Secondary Sensor: Upon loss of signal from the remote sensor, the controller shall be capable of reverting control to the pump system mounted sensors with a programmable setpoint. The pumps shall maintain a constant, proportional, or quadratic pressure across the system until the remote setpoint signal is restored.

V. Pump Test: The controller shall have a pump “Test Run” feature such that pumps are switched on during periods of inactivity (system is switched to the “off” position but with electricity supply still connected). The inoperative pumps shall be switched on for a period of three to four seconds every 24 hours, 48 hours or once per week and at a programmable time of day.

W. Reduced Operation: During backup generator operation, the controller shall be capable of reducing the power consumed by the pump system by either limiting the number of pumps in operation or by limiting the amount of power consumption (kW). The controller shall receive a digital input indicating backup generator operation.

X. Power and Energy Consumption: The controller shall be capable of displaying instantaneous power consumption (Watts or kilowatts) and cumulative energy consumption (kilowatt-hours).

Y. Specific Energy: When a flow sensor is connected, the controller shall be capable of displaying instantaneous specific energy in Watt-hours per gallon (Wh/gal) or Watt-hours per 1,000 gallons (Wh/kgal).

Z. Built-in Ethernet: The controller shall have an Ethernet connection with a built-in web server allowing for connection to a building computer network with read/write access to the controller via a web browser.

AA. Service Contact Information: The controller shall have a programmable Service Contact Field that can be populated with service contact information including: contact name, address, phone number(s) and website.

3.5 CONTROL PANEL

SCCR: The complete control panel assembly shall have a Short Circuit Current Rating of 100 kA

BMS Integration: Standard shall be BACnet MS/TP

Other protocols available: BACnet IP, Ethernet IP, Modbus RTU, Modbus TCP, LON

The pump system controller shall be mounted in a UL Type 3R rated enclosure. A self-certified NEMA enclosure rating shall not be considered equal. The entire UL Type 3R control panel shall be UL 508 listed as an assembly. The control panel shall include a main disconnect, circuit breakers for each pump and the control circuit and control relays for alarm functions. The control panel shall include the following:

• 80 dB System Fault Audible Alarm with push button to silence

• Emergency/Normal Operation Switches (Control bypass)

• Individual Service Disconnect Switches (accessible outside of panel)

• Pump Run Lights

• System Fault Light

• Surge Arrestor

3.6 SEQUENCE OF OPERATION

A. The system controller shall operate equal capacity variable speed pumps to maintain a constant differential pressure (system set-point from remote DP sensor) or proportional pressure differential pressure setpoint (system setpoint from local mounted sensor(s)), depending on the application. The system controller shall receive an analog signal [4-20mA] from the factory installed pressure transducer on the discharge and suction manifolds, indicating the actual system pressure and inlet pressure. The controller shall be capable of controlling off the subtraction of discharge minus suction transducers for differential pressure across the manifolds.

Standard Cascade Control (Pumping Efficiency Based):

The pump system controller shall adjust pump speed as necessary to maintain system set-point pressure as flow demand increases. Utilizing the pump curve information (5th order polynomial), the pump system controller shall stage on additional pumps when pump hydraulic efficiency will be higher with additional pumps in operation. Exception: When the flow and head are outside the operating pump(s) allowable operating range the controller shall switch on an additional pump, thus, distributing flow and allowing all pump(s) to operate in allowable operating range.

When the system pressure is equal to the system set-point, all pumps in operation shall reach equal operating speeds. The pump system controller shall have field adjustable Proportional Gain and Integral time (PI) settings for system optimization.

Optional Cascade Control (Pump Start Speed Based):

As flow demand increases the pump speed shall be increased to maintain the system set-point pressure. When the operating pump(s) reach 96% of full speed (adjustable), an additional pump will be started and will increase speed until the system set-point is achieved. When the system pressure is equal to the system set-point all pumps in operation shall reach equal operating speeds. The pump system controller shall have field adjustable Proportional Gain and Integral time (PI) settings for system optimization.

B. The system controller shall be capable of switching pumps on and off to satisfy system demand without the use of flow switches, motor current monitors or temperature measuring devices.

C. All pumps in the system shall alternate automatically based on demand, time, and fault. If flow demand is continuous (no flow shut-down does not occur), the system controller shall have the capability to alternate the pumps every 24 hours, every 48 hours or once per week. The interval and actual time of the pump change-over shall be field adjustable.

D. The system controller shall be able to control a pressure maintenance pump, (jockey pump), in the system in pressure boosting applications. The set point of the pressure maintenance pump shall be able to be any value above or below the pump system’s set point. The pressure maintenance pump shall be able to be staged on as back-up pump when capacity of pump system is exceeded.

3.7 LOW FLOW STOP FUNCTION (Constant Pressure Applications)

The system controller shall be capable of stopping pumps during periods of low-flow or zero-flow without wasting water or adding unwanted heat to the liquid. Temperature based no flow shutdown methods that have the potential to waste water and add unwanted temperature rise to the pumping fluid are not acceptable and shall not be used.

Standard Low Flow Stop and Energy Saving Mode:

If a low or no flow shut-down is required (periods of low or zero demand) a bladder type diaphragm tank shall be installed with a pre-charge pressure of 70% of system set-point. The tank shall be piped to the discharge manifold or system piping downstream of the pump system.

When only one pump is in operation the system controller shall be capable of detecting low flow (less than 10% of pump nominal flow) without the use of additional flow sensing devices. When a low flow is detected, the system controller shall increase pump speed until the discharge pressure reaches the stop pressure (system set-point plus 50% of programmed on/off band, adjustable). The pump shall remain off until the discharge pressure reaches the start pressure (system setpoint minus 50% of programmed on/off band, adjustable). Upon low flow shut-down a pump shall be restarted in one of the following two ways:

A. Low Flow Restart: If the low flow condition still exists, the pump shall start, and the speed shall again be increased until the stop pressure is reached, and the pump shall again be switched off.

B. Normal Flow Restart: If the pump system controller determines a low flow condition no longer exists the pump shall start, and the speed shall be increased until the system pressure reaches the system set-point.

[OPTIONAL] Low Flow Stop and Energy Saving Mode

The pump system controller shall be capable receiving a digital signal from a flow switch or an analog signal from a flow meter to indicate a low flow condition. A bladder type diaphragm tank shall be installed with a pre-charge pressure of 70% of system set-point. The tank shall be piped to the discharge manifold or system piping downstream of the pump system.

When low flow is detected (signal from flow switch or meter), the system controller shall increase pump speed until the discharge pressure reaches the stop pressure (system set-point plus 50% of programmed on/off band).

The pump shall remain off until the discharge pressure reaches the start pressure (system set-point minus 50% of programmed on/off band). The pump shall remain in the energy saving on/off mode during low flow indication. When low flow is no longer present (low flow indication ceases), the pump(s) shall resume constant pressure operation.

It shall be possible to change from the standard low flow stop to the optional low flow stop (and vice-versa) via the user interface.

3.7 SYSTEM CONSTRUCTION

A. Suction and discharge manifold construction shall be in way that ensures minimal pressure drops, minimize potential for corrosion, and prevents bacteria growth at intersection of piping into the manifold. Manifold construction that includes sharp edge transitions or interconnecting piping protruding into manifold is not acceptable. Manifold construction shall be such that water stagnation cannot exist in manifold during operation to prevent bacteria growth inside manifold.

B. The suction and discharge manifolds material shall be 316 stainless steel.

Manifold connection sizes shall be as follows: 4 inch through 8 inch: ANSI Class 150 rotating flanges.

C. Pump Isolation valves shall be provided on the suction and discharge of each pump. Isolation valve sizes 2 inch and smaller shall be nickel plated brass full port ball valves. Isolation valve sizes 3 inch and larger shall be a full lug style butterfly valve. The valve disk shall be of stainless steel. The valve seat material shall be EPDM and the body shall be cast iron, coated internally and externally with fusion-bonded epoxy.

D. A spring-loaded non-slam type check valve shall be installed on the discharge of each pump. The valve shall be a wafer style type fitted between two flanges. The head loss through the check valve shall not exceed 5 psi at the pump design capacity. Check valves 1-1/2” and smaller shall have a POM composite body and poppet, a stainless-steel spring with EPDM or NBR seats. Check valves 2” and larger shall have a body material of stainless steel or epoxy coated iron (fusion bonded) with an EPDM or NBR resilient seat. Spring material shall be stainless steel. Disk shall be of stainless steel or leadless bronze.

E. Existing tank and connection shall be retained.

F. A pressure transducer shall be factory installed on the discharge manifold (or field installed as specified on plans). Systems with positive inlet gauge pressure shall have a factory installed pressure transducer on the suction manifold for water shortage protection. Pressure transducers shall be made of 316 stainless-steel. Transducer accuracy shall be +/- 1.0% full scale with hysteresis and repeatability of no greater than 0.1% full scale. The output signal shall be 4-20mA with a supply voltage range of 9-32 VDC.

G. A bourdon tube pressure gauge, 2.5-inch diameter, shall be placed on the suction and discharge manifolds. The gauge shall be liquid filled and have copper alloy internal parts in a stainless-steel case. Gauge accuracy shall be 2/1/2 %. The gauge shall be capable of a pressure of 30% above its maximum span without requiring recalibration.

H. Systems with a flooded suction inlet or suction lift configuration shall have a factory installed water shortage protection device on the suction manifold.

I. Rubber vibration dampeners shall be fitted between each pump and base frame to minimize vibration.

3.8 TESTING

A. The tester used for testing the pump system shall be constructed and calibrated according to the requirements of hydraulic test standard ISO 9906.

B. The entire pump station shall as a minimum be factory tested for functionality and documented results of functionality test supplied with pump station. Functionality testing shall include the following parameters:

1. Complete System Hydrostatic Test – 1.5 times the nameplate maximum pressure

2. No-Flow Detection Shutoff Test

3. Water Shortage Test

4. Two-Point Setpoint Performance Test.

C. Water used for testing shall be treated with three different filtration systems to ensure only clean water is used for testing pump station.

1. 25 micron mechanical filter – removes solid parts from water

2. Activated carbon filter – keeps water clear and eliminates odor

3. Ultraviolet light system – kills all bacteria growth

D. Optional performance testing shall include:

1. 10-Point Verified Performance Test

3.9 WARRANTY

A. The warranty period shall be a non-prorated period of 24 months from date of installation, not to exceed 30 months from date of manufacture.

Workmanship shall have no less than a one-year warranty from date of final completion.

04 – Plumbing

4.1 PIPE, FITTINGS, AND VALVES

A. All PVC Schedule 80 pipe and fittings shall be PVC Type I, cell classification

12454, conforming to ASTM Standard D 1784. All PVC injection molded

Schedule 80 fittings and extruded pipe shall be Certified for potable water service by NSF International. All Schedule 80 fittings shall be manufactured in strict compliance to ASTM D 2467 and Schedule 80 pipe shall be manufactured in strict compliance to ASTM D 1785. All PVC flanges shall be designed and manufactured to meet CL150 bolt pattern per ANSI

Standard B16.5 and rated for a maximum internal pressure of 150 psi, non-shock at 73°F.

B. Plastic piping systems should be ENGINEERED, INSTALLED and OPERATED in accordance with ESTABLISHED DESIGN AND ENGINEERING STANDARDS

AND PROCEDURES for plastic piping systems

PRIOR TO ASSEMBLY, all piping system components should be inspected for damage or irregularities. Mating components should be checked to assure that tolerances and engagements are compatible. Do not use any components that appear irregular or do not fit properly.

C. Fittings and Valves shall be lead-free and certified by NSF International for use in potable water systems. Weighted average lead content <=0.25%.

D. Contractor shall use a quality grade thread sealant. Contractor shall follow the sealant manufacturers' application/installation instructions.

E. All pipe, valves, unions, and fittings shall be free from defect, leaks, cracks, and unnecessary damage after completion of installation. This includes connections to existing piping. Contractor shall not be responsible for existing piping, valves, or fittings, unless damaged during construction.

F. Warranty, Workmanship shall have a one-year warranty from the date of final completion. PVC Pipe, Valves, Unions, and Fitting products shall have a limited lifetime manufacturer’s warranty.

05 – Attachments