Attachment 1- Pump Inspection and Maintenance or Repair.docx

MICHIGAN

DEPARTMENT OF TRANSPORTATION

Attachment 1:

Specification FOR

PUMP INSPECTION AND MAINTENANCE OR REPAIR

a. Description. This work consists of inspecting existing vertical turbine and submersible pumps, performing general maintenance and reporting on the pumps, and repairing or replacing major components of the pumps. Coordinate the work with the specification for refurbishing stormwater pump station motors. Schedule B Pricing, tab 2 for Pump Station Information, which includes pump and motor make along with model and/or serial number information for pump repair items.

b. Materials. Provide all new materials that meet the current standards and practices of the NEC, ANSI, ASTM, UL, NEMA, the standard specifications, manufacturer specifications, MIOSHA and this specification.

Ensure the material and construction of the listed items is equal to or exceeds the strength and performance of the original manufactured equipment. Dimensions and tolerances must meet that of original manufactured equipment.

Pump Repair Warranty. Provide a 1-year non-pro-rated warranty against material and workmanship defects covering parts and labor on motors, pumps, and repairs. Ensure these warranties are provided by the manufacturer, their representative, or by an insurance policy obtained by the Contractor naming the Department as the policy holder.

c. Work Activities. Complete the work in accordance with the following:

1. Ensure that pump inspection and maintenance or repair is performed by qualified staff specializing in manufacturing, inspecting, maintaining, and repairing the products specified in this special provision with a minimum of 10 years documented experience. Provide qualifications electronically to the Program Manager for approval.

2. Preferably, the Contractor should have established factory authorized service and repair facility within the State Of Michigan.

3. Complete all work in accordance with industry standards and applicable codes. The Contractor must have a minimum of 10 years of experience installing and repairing industrial, municipal or state-owned pump stations. Inspect and repair the pumps as requested. Provide a preliminary inspection report and recommendations for major component replacement to the Program Manager prior to undertaking the work. The Program manager will then authorize or reject major component replacement. Major components include enclosing tubes, enclosing tube bearings, pump shaft, intermediate shaft, head shaft, impeller, impeller repair, bowl assembly, bowl assembly repair, column, column repair, discharge head and discharge head repair.

4. Install equipment and devices in accordance with manufacturer’s recommendations.

5. Provide and install all lubrication for the pump and motor in accordance with the manufacturer’s recommendations.

6. Electronically provide shop drawings and operation and maintenance (O&M) manuals to the Program Manager for all equipment and devices in PDF format. Include in the manuals details for vertical pumps and bowl assembly; motors including flexible shaft coupling joint located at the motor head location; discharge column assembly; columns; shaft enclosing tube; bowl shaft and line shaft; shaft coupling; bearings at line shaft; suction bowl and discharge bowl; enclosing tube tension device; lubrication system including bypass ports with riser, grease line locations with fittings; and the assembly drawing showing the discharge piping.

7. Electronically provide pump curves and O&M manuals for final equipment configuration in PDF format.

8. Provide any brackets, hangers, supports, miscellaneous steel, etc., as required in connection with distributing piping loads, equipment supports, etc.

9. Support all hanging mechanical equipment loads, including piping, from the building structure with welded attachments or clamps of appropriate strength.

10. Replace basic hardware (screws, keys, etc.), grease seals and O-rings as necessary to reassemble pump(s).

11. Replace tension nut assembly including packing gland, packing rings, lock ring tension nut and tension nut body.

12. Provide new wear rings and bowl liners for each pump as recommended by the pump manufacturer.

13. Special Coatings.

A. Surface Preparation. Clean and prepare surfaces to be coated in accordance with the manufacturer’s instructions for each particular substrate condition, except provide a uniform blast profile from 1.0 mil to 2.0 mils.

B. Material Preparation. Carefully mix and prepare materials in accordance with the manufacturer’s directions.

C. Coating Application Schedule.

(1) Interior Ferrous Metal: All new and existing non-galvanized surfaces.

(2) Exterior Ferrous Metal: All non-galvanized surfaces.

(3) Submerged or Intermittently Submerged Ferrous Metal: All non-galvanized surfaces

D. Coating Systems. Select coating system products from the list of products provided below or approved equals. Do not mix colors or products from more than one manufacturer or source.

(1) Interior Ferrous Metal. Zinc/Epoxy/Epoxy Coating. Provide one finish coat over intermediate coat and primer with total dry film thickness (DFT) not less than 9.0 mils not to exceed 15.0 mils.

Primer: DFT of 3.0 to 5.0 mils.

Tnemec: Tneme-Zinc Series 90-97 Devoe: CATHACOAT 315

Intermediate Coat: DFT 3.0 to 5.0 mils.

Tnemec: Series N69 Hi-Build Epoxoline II Devoe: DEVRAN 224HS

Finish Coat: DFT 3.0 to 5.0 mils.

Tnemec: Series N69 Hi-Build Epoxoline II Devoe: DEVRAN 224HS

(2) Exterior Ferrous Metal. Zinc/Epoxy/Polyurethane Coating. Provide one finish coat over intermediate coat and primer with total dry film thickness 9.0 to 16.0 mils.

Primer: DFT 3.0 to 5.0 mils.

Tnemec: Tneme-Zinc Series 90-97 Devoe: CATHACOAT 315

Intermediate Coat: DFT 4.0 to 6.0 mils.

Tnemec: Series N69 Hi-Build Epoxoline II Devoe: DEVRAN 224HS

Finish Coat: DFT 2.0 to 5.0 mils.

Tnemec: Series 1075 Endura-Shield II Devoe: DEVTHANE 379

(3) Submerged or Intermittently Submerged Ferrous Metal. Epoxy/Epoxy Coating. Provide one finish coat over primer with total dry film thickness not less than 8.0 mils not to exceed 12.0 mils.

Primer: DFT 4.0 to 6.0 mils.

Tnemec: Series N69 Hi-Build Epoxoline II Devoe: DEVRAN 201H

Finish Coat: DFT 4.0 to 6.0 mils.

Tnemec: Series N69 Hi-Build Epoxoline II Devoe: DEVRAN 224HS

14. Utilize removable slabs in pump station roof to access, remove, and install equipment as required. Reinstall removable slabs and reseal removable concrete slabs with a rubberized asphalt-based mastic in accordance with manufacturer’s recommendations.

15. Remove the entire pump, including the column, from the pump station. Load the pump and column and transport to the Contractor’s facility. Prepare the pump for inspection by completely disassembling it and sandblasting all components. Measure all opening clearances and record on the inspection report. Determine and document justification for recommended major component repair or replacement. Assemble all rotating parts on shaft and place in balancing machine. Balance rotors in accordance with International Organization for Standardization (ISO) 1940/1 using a balance quality grade of G2.5. Install new cutlass bearings. Apply coatings to surfaces in accordance with this special provision. Measure and record all final operating clearances. Finish assembly of pump and verify proper lift and free rotation. Apply remaining coatings and prepare pump for return transport. Provide for transportation of pump back to pump station. Provide for installation of pump to original location.

16. Pump and Motor Testing. Assemble each pump at the factory or in place to ensure fit of adjoining parts. Test one pump per size of pump, , at the factory for operating efficiency. Perform the operating efficiency test, in a setup configured similar to the actual field installation.

For the operating efficiency test, take a minimum of six test readings, one each at maximum static head, starting static head, average static head, 115 percent of maximum static head, 85 percent of starting static head, and at the reduced static head. Compare results to existing pump curves, if available. Furnish certified copies of the test reports to the program manager in electronic portable document format (PDF).

17. Submittals. Electronically provide an inspection report detailing justification for each component major repair or replacement. Also provide an electronic balancing report summarizing the balancing performed and final clearances and tolerances. Submit all reports in PDF format.

18. Component Installation. If available, follow manufacturer’s procedures for installation of new or repaired components. Maintain working clearances to within original manufacturer’s tolerance specifications.

19. Component Repair. Ensure the re-work of pump components is done in a manner that maintains or restores the critical dimensions of the component to the condition of original manufactured state.

20. Sequence of Repair. Electronically submit a sequence of construction schedule prior to beginning the work; prepare the schedule in recognition of the following constraints:

A. Arrange work to provide for Department staff access of the existing facilities at all times.

B. Do not remove additional pump(s) or other support equipment until newly installed pump(s) are operational and accepted by the program manager.

C. Ensure that all newly installed pumps operate automatically utilizing the existing, temporary, or proposed automatic controls prior to removal of the next pump.

D. Coordinate with the electrical utility company to arrange for proper scheduling of any utility work.

21. Field Performance Tests. Before acceptance, make performance tests on all pumps as approved by the Program Manager (or designee). Supply the water for testing and provide competent personnel to make necessary adjustments or alterations in accordance with the operational guarantee.

The Program Manager (or designee) must be present during the field performance test and will document alterations made to the equipment.

d. Measurement and Payment. The completed work, as described, will be measured and paid for according to schedule B for each pump station site:

Pay Item Pay Unit

The above Pay items include all labor, equipment and materials necessary to complete the work as described.