Attachment 2 - Salient Characteristics.pdf

SALIENT CHARATERISTICS FOR SIX INCH CAST IRON DIESEL DRIVEN SEWAGE PUMP

PART 1 – DESIGN

1.1 DESIGN REQUIREMENTS

1.1.1 The pump specified will be used to pump raw sewage.

1.1.2 The pump and accessories shall be supplied by the pump manufacturer.

1.1.3 The pump priming system shall be capable of generating 25 in Hg (28 feet) of vacuum at sea level. It shall also be capable of operation using extended suction lines.

1.2 DESIGN REQUIREMENTS

OPERATING SPEED (MAXIMUM) 2200 RPM

MAXIMUM SOLIDS HANDLING SIZE 3.0 INCHES

IMPELLER DIAMETER 11.2 INCHES

SUCTION SIZE 6 INCHES

DISCHARGE SIZE 6 INCHES

MAXIMUM SUCTION LIFT 28 FEET

MAXIMUM DUTY POINT 1000 GPM AT 160 FT TDH

(INCLUDING A 15 FT DYNAMIC SUCTION LIFT)

1.3 REFERENCES

1.3.1 ANSI (16.5) - Standard for Cast Iron Pipe Flanges and Flanged Fittings.

PART 2 – PUMP PARAMETERS

2.1 PUMP CHARACTERISTICS

2.1.1 PRIMING SYSTEM: Pump shall be fitted with a fully automatic priming system incorporating an air compressor and air ejector assembly. The compressor shall be mounted as an integral part of the pump rotating assembly and be driven via a HTD cog belt off of the pump shaft. It shall be lubricated via the diesel engine oil pump. The compressor belt shall be tensioned via an adjustable belt tensioner. The belt shall be removable without separating the engine flywheel (bell housing) from the pump-end. The priming system shall require no fail-safe protection float gear or any adjusting at high or low suction lifts. The pump must be capable of running totally dry for periods up to 24 hours, then re-priming and returning to normal pumping volumes. Pump and priming system must be capable of priming the pump from a completely dry pump casing. Equipment must have the ability to run continuously at full speed in a completely dry condition.

Attachment 2 - Salient Characteristics

FA460824QC104

2.1.2 CASING, SUCTION COVER, AND SEPARATION TANK: Pump castings shall be cast iron. Pump design shall incorporate a direct suction flow path that is in axial alignment with the impeller eye. There shall be no turns, chambers, or valves between the suction flange and the impeller eye.

2.1.3 IMPELLER: The pump impeller shall be a two-bladed type fabricated from hardened cast steel (minimum Brinell Hardness 200 HB). The impellers and shaft fixing shall be splined.

2.1.4 WEARPLATES: Shall be fully adjustable and replaceable, fabricated of cast iron. Wear plate clearances shall have no relationship to the ability of the pump to achieve a prime.

2.1.5 BEARINGS AND SHAFTS: Pump shall be fitted with a bearing bracket to contain the shaft and bearings.

Bearings shall be roller bearings of adequate size to withstand imposed loads for sustained pumping at maximum duty points. Minimum ISO L10 bearing life to be 100,000 hours. The installation of the pump shaft and bearings shall not require shims or adjustment. The splined impeller shaft shall be fabricated of carbon steel.

2.1.6 SEALS: Seals shall be high pressure, mechanical, self-adjusting type with silicon carbide faces capable of withstanding suction pressures up to 58 psi. The mechanical seal shall be cooled and lubricated in a liquid bath reservoir, requiring no maintenance or adjustment. The lip-seal shall ride on the mechanical seal sleeve and make no contact with the pump shaft. Pump shall be capable of running dry, with no damage, for periods up to 24 hours. All metal parts shall be of stainless steel. Elastomers shall be Viton.

2.1.7 PUMP SUCTION AND DISCHARGE FLANGES: Shall be cast iron ANSI (16.5) Class 150, flat faced.

2.1.8 PUMP GASKETS: Shall be compressed fiber and/or Teflon.

2.1.9 CHECK VALVE: Pump shall be supplied with a ball-type check valve mounted on the discharge of the pump, allowing unrestricted flow from the impeller.

2.1.10 DRIVE UNIT: The drive unit shall be an Isuzu 4LE2X FT4 diesel engine, water-cooled engine. The engine shall drive the pump by use of a direct-connected intermediate drive plate. Starter shall be 12VDC. A control panel consisting of a low oil pressure safety shutdown, high temperature shutdown, tachometer, and hour-meter shall be integrated into the engine control panel. Unit shall include a tachometer and an hour meter. Battery shall have 180 amp hour rating. Drive unit shall be rated at 74 HP. A certified continuous duty engine curve shall be supplied.

The engine shall be rated for Emergency Standby Use only. Engines not certified for emergency operation will not be considered.

2.1.11 GOVERNOR: Governor shall be a mechanical type. Engine speed shall be adjustable to operate the pump between maximum and minimum design operation speeds.

2.1.12 FUEL SOURCE: Integral skid fuel tank capacity shall be sufficient to provide at least 22 hours of operating time at full load.

2.1.13 EXHAUST: Engine shall include a muffler of suitable size.

2.1.14 FACTORY PAINTING: Unit shall be shop primed and finish painted at the place of manufacturer. Materials and dry film thickness for priming and finish paint shall be in accordance with manufacturer's standards.

Attachment 2 - Salient Characteristics

2.2 ENGINE CONTROL SPECIFICATION

2.2.1 The engine shall be started, stopped, and controlled by a high performance, state-of-the-art digital controller. The controller shall be weatherproof enclosed, and contain an external, weatherproof, 12-position keypad accessible without the need to remove or open any protective cover or enclosure. It shall be designed to start/stop the engine at a signal supplied by high- and low-level floats or a 4-20 mA transducer. The Control Panel shall provide the following functions without modification, factory recalibration, or change of chips or boards by simply accessing the keypad.

2.2.1.1 The keypad shall be a capacitive, touch-sensing system. No mechanical switches will be acceptable. The keypad shall operate in extreme temperatures, through ice, snow, mud, grease, etc., and maintain complete weather-tight sealing

2.2.1.2 During periods of inactivity the unit shall conserve energy and go to “sleep” (115mA parasitic battery draw).

2.2.1.3 The controller shall function interchangeably from float switches, pressure switch, or transducer, as well as manual start/stop by selection at the keypad. No other equipment or hardware changes to be required.

2.2.1.4 The controller shall be capable of varying the engine speed to maintain a constant level in a process without a change to the panel other than via the keypad.

2.2.1.5 The controller shall have the capability to be programmed to start and stop the pump-set up to three times daily or three times a week (i.e. a start, exercise cycle on three separate times for a varying length of time all via the keypad).

2.2.1.6 Manual-Automatic Button

2.2.1.6.1 In Manual Mode, the “Start” button starts the engine and runs until “Stop” is pressed or an emergency shutdown occurs.

2.2.1.6.2 In Automatic Mode, start/stop sequencing is initiated by either one (1) high-level N/O and one (1) low-level N/C narrow angle float switches, a 4-20mA transducer, a signal from a digital input, or a single analog 4-20mA speed reference. As a backup, the controller shall also have the option to operate off a transducer with one (1) high-level N/O narrow angle float switch.

2.2.1.6.3 The controller shall integrate the engine safety shut-off for low-oil temperature and high-temperature, and provide over-speed protection.

2.2.1.6.4 The controller shall include standard, field-adjustable parameters for engine cycle crank timer, shutdown time delay, warm-up time delay, and cool-down time delay.

2.2.1.6.5 The controller shall have two circuit boards, one for the control board and one capacitive touch keypad board.

The capacitive keypad circuit boards has eight (8) available relays that can be programmable to output desired parameter on the display and to be used as dry-contacts for communication with other control systems such as SCADA. All via the key play without changing relays, chips, printed circuits, or any hardware or software.

2.2.1.6.6 Standard components shall consist of (6) digital inputs, (8) analog inputs, (1) magnetic pick-up input, (6) 10-amp form “C” relays, (2) 20-amp form “C” relays, (1) RS485 port, (1) J1939 port, and (1) 3.8in 320x240 pixel QVGA

Attachment 2 - Salient Characteristics full graphic LCD display with backlight, (1) 12 position keypad, LED lamps for visual indication of shutdown (red), warning (amber) and power (green).

2.2.1.6.7 The industrially-hardened controller shall withstand vibration of 3g, 3 axis, frequency swept 5-2000 Hz, in an operating temperature range of -40° to 185°F (-40° to 85°C) and an operating humidity range of 0-70% non-condensing at 85°C.

2.2.1.6.8 AUTO-THROTTLE: The engine shall be fitted with an auto-throttle and integrated into the control panel for variable engine speed control.

2.2.2 FIELD SMART TECHNOLOGY: The unit shall be equipped with Field Smart Technology (FST) integrated with the controller. Field Smart shall allow remote communication with the pump-set via password protected cloud-based webserver. FST shall have the ability to communicate anywhere in the world and offer 3 modes of communication—GPS, Cellular, Satellite. FST shall allow the unit to be started, stopped, and vary the speed from the web hosted platform and transmit the following data at a minimum:

• Timestamp

• Engine hours

• Engine on/off

• Engine Temp

• Battery Voltage

• RPM

• Oil Pressure

• Optional voice alarm notifications

FST shall read data from the controller and, on electronic engines, directly from the ECU. All Data shall be recorded in one minute intervals and available for download. The web hosted platform shall enable users to set alarms for engine on, engine off, geo-fence barriers and ECU alarms.

2.2.3 ELECTRONIC FUEL SENDER: The unit shall be supplied with (1) custom length fuel sensor assembly. Fuel sensor will have a 1½in NPT brass pipe plug and a sensor output of 33-240ohms. The sensor shall integrate with the engine control panel via the analog inputs on the on-board controller.

2.2.4 FLOAT SWITCHES: Unit must have one-normally open and one-normally closed narrow angle (10° to 20°) float switches integrated into the automatic pump controller. The floats shall be constructed with tilt sensation switches enclosed within stainless steel. Each float will have a minimum 25 ft. waterproof cable wired into a twist-lock wiring harness that connects directly to the on-board controller.

2.2.5 LEVEL TRANSDUCER: The unit shall be supplied with (1) one sewage compatible level transducer assembly including a single 4-20 mA level transducer (0-10 psig), which shall integrate with the engine control panel via a single multi-pin plug.

2.2.6 ENGINE BLOCK HEATER: The drive unit shall be supplier with an integral 1000-Watt engine block heater.

Heater to be supplied with three wire plug, 110 VAC required.

2.2.7 FULLY AUTOMATIC TRICKLE CHARGER: The unit shall include a fully automatic trickle charger powered by 6-amps, 115 VAC.

2.2.8 INTERIOR LIGHT: The unit shall include a single switch operated 12 VDC interior dome light mounted within the enclosure.

Attachment 2 - Salient Characteristics

2.2.9 WORKING LIGHT: The unit/s shall include two (2) externally base mounted, adjustable, 12 VDC flood light/s, rearward facing the suction and discharge piping operated by a single switch.

2.2.10 PUMP RUNNING STROBE LIGHT: The unit shall include a 12 VDC Yellow strobe light mounted on the enclosure to operate while the engine is running.

2.2.11 PUMP OFF STROBE LIGHT: The unit shall include a 12 VDC Red strobe light mounted on the enclosure to operate while the engine is off.

2.2.12 DC / AC INVERTOR: The unit shall include one (1) 12 VDC to 110 VAC volt single-phase inverter, 1750 watts, mounted inside enclosure, single 15-amp GFI outlet, one (1) fusible link.

PART 3 – START-UP/TESTING/TRAINING, DELIVERABLES, AND WARRANTY

3.1 START-UP/TESTING/TRAINING

3.1.1 The manufacturer shall furnish the services of a competent factory representative to do the following:

3.1.1.1 Inspect the system prior to delivery, supervise the start-up and testing of the system, and certify the system has been properly furnished and is ready for operation.

3.1.1.2 Instruct operating personnel in the proper operation and maintenance of the system for a period of not less than one half day.

3.2 TOOLS AND SPARE PARTS DELIVERABLES

3.2.1 The manufacturer shall furnish the following on or prior to delivery of the pump.

3.2.1.1 A recommended list of spare parts.

3.2.1.2 An Operations and Maintenance manual.

3.3 WARRANTY

3.3.1 The manufacturer shall furnish the following:

3.3.1.1 A copy of the engine manufacturer's parts and labor warranty.

3.3.1.2 A one year Parts and Labor Warranty issued by the manufacturer on the raw sewage pump system. This warranty must cover all pump parts, including the mechanical seal.

Attachment 2 - Salient Characteristics