High-Head Test Facility Pumping Unit Replacement Building 56, Denver Federal Center Solicitation No.140R4026Q0073

Vertical Turbine Pumping Unit

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SECTION 33 12 71

VERTICAL TURBINE PUMPING UNIT

PART 1 GENERAL

1.01 REFERENCE STANDARDS

A. American National Standards Institute (ANSI)

1. ANSI B1.20.1-2013 Pipe Threads, General Purpose, Inch

B. American Society of Mechanical Engineers (ASME)

1. ASME BPVC-IX-2025 Boiler and Pressure Vessel Code – Section

IX – Welding, Brazing and Fusing Qualifications

C. American Society of Civil Engineers

1. ASCE 7-2022 Minimum Design Loads and Associated

Criteria for Buildings and Other Structures

D. ASTM International (ASTM)

1. ASTM E10-2023 Test Method for Brinell Hardness of

Metallic Materials

E. American Water Works Association (AWWA)

1. AWWA C207-2023 Steel Pipe Flanges for Waterworks Service, Sizes 4 In. through 144 In.

F. American Welding Society (AWS)

1. AWS D1.1/D1.1M-2025 Structural Welding Code - Steel

G. Hydraulic Institute Standards (HI)

1. HI 9.1-9.5-2021 Pumps General Guidelines – for Materials, Sound Testing, and Decontamination

2. HI 9.6.1-2024 Rotodynamic Pumps - Guideline for NPSH

Margin

3. HI 9.6.3-2024 Rotodynamic Pumps – Guideline for

Operating Regions

4. HI 9.6.4-2022 Rotodynamic Pumps – for Vibration

Measurements and Allowable Values

5. HI 9.8-2024 Rotodynamic Pumps - for Pump Intake

Design

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6. HI 14.1-14.2-2024 Rotodynamic Pumps - for Nomenclature and Definitions

7. HI 14.3-2024 Rotodynamic Pumps - for Design and Application

8. HI 14.4-2024 Rotodynamic Pumps - for Installation, Operation, and Maintenance

9. HI 14.6-2022 Rotodynamic Pumps - for Hydraulic Performance Acceptance Tests

H. International Electrotechnical Commission (IEC)

1. IEC 61800 Adjustable Speed Electrical Power Drive

Systems

I. Institute of Electrical And Electronics Engineers (IEEE)

1. IEEE 112-2017 Test Procedure for Polyphase Induction

Motors and Generators

2. IEEE 519-2022 Harmonic Control in Electric Power

Systems

J. International Standard Organization (ISO)

1. ISO 21940-11 Mechanical vibration. Rotor balancing.

K. National Electrical Manufacturers Association (NEMA)

1. NEMA ICS 7-2020 Industrial Control and Systems: Adjustable Speed Drives

2. NEMA KS 1-2013 Heavy Enclosed and Dead-Front Switches (600 Volts Maximum)

3. NEMA MG 1-2024 Motors and Generators

L. National Fire Protection Association (NFPA)

1. NFPA70-2026 National Electric Code

M. Underwriters Lab (UL)

1. UL 508-2024 UL Standard for Safety Industrial Control

Equipment

1.02 DEFINITIONS

A. NPSHa: Net Positive Suction Head Available.

B. NPSHr: Net Positive Suction Head Required.

C. Pumping Unit: Complete pump and motor assembly.

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D. Brinell hardness (BHN): A measure of the resistance to indentation of a material, as defined in ASTM E10.

E. PID: Proportional-Integral-Derivative

F. RCF: Reed Critical Frequency.

G. VFD: Variable Frequency Drive.

1.03 SYSTEM DESCRIPTION

A. Background:

1. The high-head test facility background is provided in the project Statement of

Work (SOW).

1.04 QUALIFICATIONS

A. Pump Manufacturer Qualifications:

1. Documentation of similar pumping units designed and manufactured with 5-years of successful operation.

2. Provide the following information:

a. Location city and state.

b. Clients' and/or customers' names, addresses, telephone numbers and names of projects.

c. Application for each pumping unit.

d. Pump capacity, total head, rotational speed, impeller size, and working fluid.

B. Welding Qualifications:

1. Welding procedures, welders, and welding operators:

a. At Contractor's option:

1) ASME BPVC Section IX, or,

2) AWS D1.1, or,

3) equivalent.

C. Pump and Motor Manufacturer Erection Engineer Qualifications:

1. Pump and motor erection engineer can be one and the same.

2. Minimum five (5) years of experience in the erection of pumping equipment, specifically pumps and motors, of similar size and type.

3. Provide a project list of recent related projects that the erection engineer was directly involved in.

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D. Millwright Qualifications:

1. Millwright qualifications to include a minimum five (5) years of experience installing rotating pumping equipment of similar scope and size.

2. Provide name, experience, and formal education of primary tradesman and assistants who will be performing the work.

3. Provide a project list of recent millwright related projects that the primary tradesman was directly involved in.

4. Provide a complete list of available precision levels and laser alignment tools used to perform work.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Prevent damage to pumping unit components and associated equipment during loading, transportation, unloading, and storage.

B. Repair damage to the pumping units and associated equipment as directed if, in the opinion of the COR, a satisfactory repair can be made; otherwise replace damaged pumping unit components and associated equipment.

C. Protect from corrosion, deformation, and other types of damage.

1.06 EXTRA MATERIALS

A. Spare Parts:

1. Provide spare parts that are “new” and not refurbished and properly packaged for long-term storage.

2. Furnish spare parts that are interchangeable with and of the same materials and workmanship as corresponding original pump and motor parts.

3. Clearly mark or tag each part to identify size and type of pumping unit it is intended. Specifically identify with part unit number and specific part number.

4. Furnish the one set of the following spare parts:

a. Gaskets, seals, as applicable.

B. Special Tools:

1. Furnish one set of special tools required for assembly and disassembly of the pumping unit (pump and motor) and other appurtenances and accessories that may be required for assembling, installing, aligning, or dismantling part of the pump and to make the unit complete and ready for operation. (Special tools are considered to be those tools, which because of their limited use, are not normally available but which are necessary for the particular equipment.)

2. Furnish tools of high-grade, forged alloy, tool steel.

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3. Furnish major parts of the pump with eyebolts, lugs, or lifting devices (i.e., lifting beam) to facilitate handling with a mobile crane. Lifting equipment to comply with performance standards.

PART 2 PRODUCTS

2.01 VERTICAL PUMPING UNIT

A. Design Requirements:

1. One (1) pumping unit.

2. Vertical rotodynamic pump, complete with all accessories and special tools, suitable for connection to the motor.

3. Design and construct pump in accordance with these specifications and HI 14.1-

14.4, 9.1-9.5, 9.6.1-9.6.4, 9.8, and 14.3.

4. Weight of pump rotating parts, including unbalanced hydraulic thrust of impeller(s), to be carried by motor thrust bearing. Rotation may be in either direction.

5. Pumping unit to be suitable for operation at site elevation with expected ambient air and water temperatures.

6. Design pump bowls, column pipe, and discharge head for working pressure equivalent to or greater than pump shutoff head.

7. Design pump to transfer forces and loads to structure for specified operating conditions.

8. Pumping units shall be seismically restrained to meet ASCE 7 Chapter 13 – Seismic Design Requirements for Nonstructural Components.

B. Performance Requirements:

1. Pump performance requirements listed in Table 33 12 71A – Performance

Requirements. Either design point is acceptable as the guarantee point. The design point not chosen as the guarantee point must be attainable with the use of a VFD not exceeding 100-percent design speed.

2. Pump performance and design requirements shall be at motors full load speed for specified voltage and frequency, unless otherwise specified.

3. Select pump with a head-capacity curve that has a continuously rising head with decreasing capacity from minimum expected head to shutoff head without dips and valleys.

4. Select pumping unit with manufacturer’s required submergence less than submergence available.

5. Pump curves to satisfy the following requirements for the design points:

a. Must meet or exceed minimum continuous stable flow (MCSF);

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b. Must not exist at flows higher than those outlined on the published pump curves. Theoretical or extrapolated extensions of published pump curves will not be acceptable.

c. Must exist within the pump’s allowable operating range (AOR), per HI 9.6.3.

6. The pump minimum net positive suction head available (NPSHa) of approximately 37 feet shall exceed the pump net positive suction head required (NPSHr) for the pump by the amount of margin and margin ratio specified in HI 9.6.1.

7. Shutoff head shall not exceed 300 psi for the pumping unit as determined by shop performance testing.

8. Perform motor RCF calculations and minimum of Level 3 lateral, torsional, and structural dynamic analyses in accordance with HI 9.6.8 Rotodynamic Pumps Guideline for Dynamics of Pumping Machinery.

Table 33 12 71A – Performance Requirements

Pumping Units Design Point 1 Design Point 2

Capacity at total head (gpm) 500 2250

Rated TDH (ft) 600 225

C. Pump.

1. Coatings:

a. Provide manufacturer recommended coatings to all surfaces. Government to approve color selection.

2. Bowl Assembly:

a. Design bowl assembly for easy removal of impeller and bearings.

b. Provide suction case with bellmouth inlet and bell-mounted vortex suppression basket.

c. Provide sand collar on bowl shaft above suction case bearing.

d. Bowl wearing ring of aluminum-bronze material. Bowl wearing ring shall be renewable. Bowl and impeller wear ring faces shall have minimum Brinell hardness difference of 100BHN.

e. Provide bowl shaft bearings above and below each impeller.

f. Inspect castings thoroughly. Ensure waterways and vanes are smooth and free from nodules, bumps, and dips. Casings shall be free of blow holes, sand holes, and other imperfections determined to decrease performance of pump outside of Table 33 12 71A – Performance Requirements or increase likeliness of cavitation or premature wear.

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g. Impeller:

1) Impellers made of stainless-steel.

2) Impeller wearing rings to be integral to the impeller and of the same material.

3) Securely fastened to shaft in such manner as to make it easily removable.

4) Dynamically balance rotating parts to ISO 21940-11 balance quality grade G6.3 or better.

5) Inspect castings thoroughly. Ensure waterways and vanes are smooth and free from nodules, bumps, and dips. Casings shall be free of blow holes, sand holes and other imperfections determined to decrease performance of pump outside of Table 33 12 71A – Performance Requirements or increase likeliness of cavitation.

3. Column Pipe Assembly:

a. Provide manufacturer recommended coatings to all surfaces. Government to approve color selection.

b. Column pipe designed to support column weight, bowl weight, and bearing loads, supported by the pump discharge head.

4. Discharge Head Assembly:

a. Provide manufacturer recommended coatings to all surfaces. Government to approve color selection.

b. Materials of Construction:

1) Be compatible with discharge piping material, avoiding dissimilar metals.

2) Flanges:

i. Suitable for connection to the existing discharge piping.

ii. Compliant with AWWA C207.

c. Design discharge head with enough stiffness to fully support pumping unit without deflection that exceeds one half clearance between shaft and bearing and allowable deflection of mechanical seal manufacturer.

d. Meet allowable vibration requirements of HI 9.6.4 and separation margin dynamic analyses performed defined in HI 9.6.8.

e. Design discharge head to support hanging weight, hydraulic thrust loads, and torque of pumping unit and transmit loads into the I-beam frame.

f. Discharge head outlet pipe interior diameter to match discharge piping interior diameter such that there is no hydraulic jump.

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g. Terminate the discharge head outlet pipe flange with a flange size, class, bolt pattern, and location that is compatible with the discharge piping flange.

h. Discharge head to be mounted on the pump riser on the existing baseplate and I-beam frame.

1) Pump discharge head shall be removable from the pump riser without removal of baseplate.

2) If modifications or replacement of the existing baseplate are required, the modifications or replacement must not compromise the structural integrity of the existing I-beam frame.

i. Machine mating surfaces of motor mounting flange, discharge head motor mounting flange surface, and lower discharge head flange flat and parallel to obtain installation tolerances specified herein.

j. Provide a minimum 1/2-inch NPT (ANSI B1.20.1) threaded drainpipe connection and tubing to drain seal leakage back to pump basin. Route tubing as directed by Government.

k. Provide a 3/4-inch threaded connection suitable for pressure transducer installation.

l. Provide lifting lugs with capacity to lift weight of pumping unit.

m. Provide OSHA compliant coupling guard designed for easy installation and removal.

n. Stainless steel pump nameplate securely mounted to discharge head containing the following information at minimum, engraved with minimum 1/2-inch black lettering:

1) Pump manufacturer name;

2) Design flow, in gallons per minute;

3) Design Total Dynamic Head, in feet;

4) Rotational speed, in rotations per minute;

5) Impeller diameter, in inches;

6) Pump model and serial numbers;

7) Number of stages.

5. Pump Riser:

a. Material of Construction:

1) Steel.

b. Suitable for connection to discharge head and existing baseplate.

c. Designed to transmit all forces and torques from the pumping unit to the baseplate.

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d. Provide baseplate modifications or improvements, if necessary.

e. Provide stainless-steel hardware as needed for connection of the discharge head and baseplate.

f. Provide manufacturer recommended coatings to all surfaces. Government to approve color selection.

6. Shafts:

a. Materials of Construction:

1) Stainless steel.

b. Size the line shaft to operate without distortion, stress, or vibration at maximum speed in both forward and reverse directions that exceeds pump design.

c. Design line shaft to handle all loading conditions.

7. Bearings:

a. Provide suction case bearing below first-stage impeller.

b. Provide bearing immediately above impeller in each bowl.

c. Provide product-lubricated line shaft bearings of sufficient number to maintain the alignment of shaft and prevent vibration in excess of limits specified in this specification.

8. Coupling:

a. Provide coupling for connecting the pump line shaft to motor shaft while assuring proper clearances and providing access for mechanical seal installation, removal, and maintenance.

b. Sized for a minimum 1.25 service factor at rated motor horsepower and maximum rotational speed.

c. Type: Gear, Rigid

d. Manufacturer: Kop-Flex or equivalent.

9. Mechanical Seal:

a. Design pumping unit to allow removal and install mechanical seal without removal of motor from discharge head.

1) Split type mechanical seals not acceptable.

b. Designed for operating pressures and rotational speeds.

c. Designed for specified operating conditions at starting and shutdown of unit.

d. Designed for use with vertical pumping unit.

e. Seal face materials selected for specified product being pumped.

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f. Seal water provided by pumping unit. External seal water supply system not permitted.

D. Motor:

1. Motor Name Brand or equal: US Motors (Nidec) HT250P2CLJX.

2. Motor Specifications:

a. Horsepower: 250 hp.

b. Voltage: 480V, 3-phase, 60 Hz.

c. Power Factor: VFD (duty) rated motor.

d. Enclosure: Totally Enclosed Fan Cooled (TEFC).

e. Service Factor: 1.15 minimum.

f. Full Load Amps (approx.): 302A

g. Efficiency: NEMA Premium Efficiency (IE3 or better).

h. Frame Size: NEMA 449TP.

i. Duty: Continuous.

j. Service Conditions:

1) Altitude: 5560 feet.

2) Maximum ambient temperature: 40 degrees Celsius.

3) Minimum ambient temperature: 0 degrees Celsius.

k. Temperature Rise:

1) Armature winding: Not to exceed 105 degree Celsius when measured by resistance.

2) Other motor parts: In accordance with NEMA MG 1.

l. Starting Method:

1) The motor shall be started and controlled via a VFD.

The VFD shall provide smooth, controlled acceleration and deceleration, eliminating mechanical and electrical stress associated with traditional across-the-line starting.

m. Stator:

1) Stranded copper conductors.

2) Insulation: Class F.

3) VFD compatible.

4) Winding configuration: Manufacturer’s standard wye.

n. Rotor:

1) Squirrel-cage windings of suitable impedance for starting under specified conditions.

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o. Bearings:

1) Motor shall be equipped with Hybrid ceramic bearings suitable for vertical orientation and VFD operation.

2) Shaft grounding ring.

p. Indication and Protective Devices:

1) RTD: 100 ohm platinum, 3-wire.

2) Bearing temperature sensors for both upper (thrust) and lower (radial) bearings.

3) Provide oil sight glass for oil lubricated bearings.

q. Main Lead Terminal Box:

1) Size: Oversized and suitable for terminating main leads with stress cones.

2) Provide clamp-type ground lug suitable for connecting conductor shields.

3) Manufacturer’s standard cover with gasket.

4) NEMA 4X.

r. Low Voltage Terminal Box:

1) Size: Suitable for terminating leads from indicating and protective devices, and motor accessories.

2) Provide terminal blocks for terminating indicating and protective devices, and motor accessories.

3) Manufacturer’s standard cover with gasket.

4) Provide with back panel for mounting terminal blocks.

5) NEMA 4X rated.

s. Accessories:

1) Grounding Provisions: Provide pad with drilled and tapped bolt holes on motor enclosure. Pad to be machined flat and left unpainted.

2) Provide means for lifting the entire pumping unit and/or individual components. This will entail below-the-hook devices required to lift these components. Lifting eyes attached to motor housing that are suitable for attaching slings for lifting with a crane. Lifting hooks or similar devices are not acceptable.

3) Wire Markers:

4) Type: Machine-printable, self-laminating label or tubular heat-shrink sleeve label.

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5) Color: White.

E. Variable Frequency Device:

1. VFD Name brand or equal: Galt Model G540-03050UL-03 or equal.

2. VFD Specifications:

a. Service Conditions:

1) Increase rating of VFD from the values listed in this

SOW to account for derating due to altitude at project site.

2) Altitude: 5560 feet.

3) Maximum ambient temperature: 40 degrees Celsius.

4) Minimum ambient temperature: 0 degrees Celsius.

b. Horsepower Rating: 250 hp.

c. Input Voltage: 480V, 3-phase.

d. Output Voltage: 0-480V, 3-phase, variable frequency.

e. Overload Capacity: 150% for 60s.

f. Enclosure: NEMA 4, suitable for control cabinet.

g. Provide VFD with adjustable carrier frequencies and high frequency switching modes from 8 kHz to 16 kHz and allow skipping of resonant frequencies.

h. Standards:

1) Conform to IEC 61800, IEEE 519, NEMA ICS 7.0 and

NFPA 70.

2) UL 508 Listed.

i. Functionality:

1) Start-up assistant.

2) Variable speed control with adjustable acceleration and deceleration ramps and up to seven preset speeds.

3) Automatic reset after power loss or fault.

4) Motor parameter tuning (auto-tune or manual entry).

5) PID Sleep function.

j. Operator Control Panel:

1) Graphical Display, keypad with keys for Hand, Off, and

Auto.

2) Start/Stop Control.

3) Speed reference adjustment (via keypad).

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4) Real-time display of:

i. Output Frequency (Hz).

ii. Output voltage and current.

iii. Motor status (running, stopped, faulted).

iv. Fault and alarm codes.

5) Navigation buttons for parameter access and configuration.

6) Password protection for parameter changes.

k. Motor Protection Functions:

1) Overload protection (I²t-based).

2) Overtemperature protection via:

i. Motor RTD inputs.

3) Phase loss and imbalance detection.

4) Ground fault protection.

5) Short circuit protection.

6) Overvoltage and undervoltage protection.

7) Current limit and torque limit functions.

8) Stall protection.

l. Input/Output and Integration:

1) 6 Digital Inputs 12 to 24VDC.

2) 3 form C relay contact digital outputs.

3) 2 Analog inputs, selectable from 0-10V or 0/4-20mA.

4) 2 Analog Outputs 0/4-20mA.

m. Serial Communications:

1) RS-485.

2) Modbus RTU.

3) EtherNet/IP.

3. Power Devices:

a. Disconnect Switch:

1) Flange-mounted non-fusible, 3-pole, single-throw.

2) 480V sized appropriately for the motor’s full-load current.

3) Type HD (Heavy Duty).

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4) Conform to NEMA KS 1.

5) Enclosure Type NEMA 4.

6) Lockable in open position.

7) Clearly labeled with motor and VFD identification.

b. Emergency Stop (E-Stop) Switch:

1) Mushroom-head, maintained-contact type (push-to-stop, twist-to-release).

2) Wired to the VFDs digital input configured for Safe

Torque Off (STO) of Fault trip.

3) Enclosure type NEMA 4.

4) Labeled “Emergency Stop – Pump Motor”.

4. Control Panel Specifications:

a. Panel to house the VFD and associated control equipment

b. Includes a National Electrical Manufacturers Association (NEMA) 1 rated enclosure with blower for cooling

c. Includes an operator panel for control of the VFD

d. Able to mount to rack provided by the Government that is approximately

40” inch high by 24” wide. Exact dimensions of the rack should be verified with the Government prior to start of work.

2.02 DYNAMIC ANALYSES

A. Certified statement that dynamic analyses have been completed in accordance with HI

9.6.8 and specified limitations will be met as defined in these specifications.

B. Lateral Analysis:

1. Determine potential for critical lateral frequency occurring within design range of pump specified. Lateral dynamic analysis performed in accordance with HI 9.6.8.

Acceptance criteria for minimum frequency separation margin in accordance with HI 9.6.8 based on level of analysis performed.

C. Torsional Analysis:

1. Determine potential for critical torsional frequency occurring within design range of pump specified. Torsional analysis performed in accordance with HI 9.6.8.

Acceptance criteria for the minimum frequency separation margin in accordance with HI 9.6.8 based on level of analysis performed.

D. Structural Analysis, Vertical Pump Structures:

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1. Determine potential for critical structural natural frequency occurring within design range of pump specified. Structural analysis performed in accordance with HI 9.6.8. Acceptance criteria for minimum frequency separation margin in accordance with HI 9.6.8 based on level of analysis performed.

2.03 CONTRACTOR SOURCE QUALITY TESTING

A. Motor Shop Test:

1. To be performed prior to pump shop assembly and testing.

2. Assemble and test motor at the manufacturer’s shop to establish that performance requirements of these specifications and warranties under this contract have been fulfilled.

3. Perform manufacturer’s routine factory tests and the following routine tests required by Part 20 of NEMA MG 1.

a. Measurement of winding resistance.

b. No-load motoring readings of current, power, and nominal speed at rated voltage and frequency.

c. Alternating-current (AC) high-potential test. A direct-current (DC) high-potential test is not acceptable.

4. Perform tests in accordance with requirements of NEMA MG1 and IEEE 112.

B. Pumping Unit Shop Assembly and Testing:

1. Completely assemble mating parts of pumping unit in shop to ensure correct fitting of all parts. Match-mark pump components before disassembly for shipment, unless shipped completely assembled, to ensure correct field assembly.

2. Hydrostatic Pressure Testing:

a. Government may witness hydrostatic test of the pumping unit.

b. Hydrostatically test pump bowls, column pipe, and discharge head in accordance with HI 14.6 except as modified herein:

1) Minimum test pressure of parts 1.5 times shutoff head pressure.

3. Pump Performance Testing:

a. Government will witness performance test of the pumping unit.

b. Certified Pumping Unit Performance test made with pumping unit assembled as complete operating unit. Test with field motor at manufacturer's shop or at another test facility to establish that specified performance requirements are achieved.

c. Test in accordance with HI 14.6.

d. Acceptance of test results based on pump performance.

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e. Acceptance of test results based on water at 70-degrees F.

f. Best fit curve for acceptance of test results must pass through test data points.

g. Perform performance testing with all internal pump final coatings applied.

h. Conduct performance test with complete pumping unit.

1) Reduced stage testing not permitted.

i. Conduct performance tests at rated speed:

1) When determining pump horsepower from power input to motor perform test at job voltage plus or minus 5-percent and at rated frequency plus or minus 1-percent.

2) When determining pump horsepower from dynamometer, or torque meter and speed perform test at full speed rating with an allowable tolerance on rotational speed of plus or minus 1-percent.

j. Use HI 14.6 acceptance grade 1U for rate of flow and total head.

k. Guarantee point is the total head and capacity of either design point shown in Table 33 12 71A – Performance Requirements.

1) Take readings at minimum of four points while operating at pump rated speed including:

i. One point between 0- and plus 5-percent of the guarantee point flow rate.

ii. One point between 0- and minus 5-percent of the guarantee point flow rate.

iii. One point at shutoff head.

iv. One point between minus 5- and plus 5-percent of the design point flow rate.

2) Changes in impeller diameter or other rework to pumping units requires retesting of pumping unit performance.

l. Prepare and submit test reports:

1) Certified Pump Performance curves at rated speed showing pump efficiency, horsepower input to the pump, and pump discharge heads from the minimum head specified in Table 33 12 71A – Performance Requirements to pump shutoff head.

2) Present test data at both test speed and corrected to rated speed for acceptance. Portion of curve above maximum head operating point to shutoff head may be plotted from previous shop test data.

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3) Test conditions: Test liquid temperature, instrument calibration records with serial numbers and photos of matching instruments used, NPSHa, motor data, and test standard and acceptance grade.

2.04 WITNESS INSPECTION POINT (HOLD POINT)

A. Provide 30-day notice before the start of the witness point milestone for Government technical engineers or Government representative to verify:

1. Hydrostatic pressure testing.

2. Motor shop test.

3. Pumping unit shop assembly and test.

B. Inspection(s) shall be conducted at a location that is approved for travel by the Department of State (www.travel.state.gov), without additional protective services or safety requirements.

1. The location shall have all the necessary equipment and tools to perform an adequate inspection of the runner and associated equipment.

2. If the inspection location does not meet these requirements, the Contractor shall relocate the components/equipment within the United States, for inspection.

3. This relocation will be at the expense of the Contractor.

PART 3 EXECUTION

3.01 PUMP AND MOTOR MANUFACTURER’S ERECTION ENGINEER

A. No work is to be performed on pump or motor without applicable Manufacturer’s Erection Engineer being on-site to direct/oversee the work.

B. Manufacturer’s qualified erection engineer to provide technical assistance to the Contractor during installation of the equipment. Applicable Manufacturer’s Erection Engineer is required to be on-site, at minimum, for the following operations:

1. Installation of the pump.

2. Installation of the motor.

3. Coupling and alignment of the pumping unit.

4. Functional and operational testing.

3.02 INSTALLATION

A. Servicing of pumping unit to include complete lubrication, adjusting, and cleaning of the unit.

http://www.travel.state.gov/

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B. After being serviced, pumping unit shall be installed by a qualified millwright(s) under the supervision of the erection engineer from the pumping unit or pump and motor manufacturers and manufacturer's installation instructions.

C. Correctly assemble and align all parts of the pumping unit.

D. Tighten discharge head mounting bolts, motor flange bolts, pump riser, and pump shaft coupling bolts to pumping unit manufacturer’s recommended torque using calibrated tools before operating tests.

E. Mount vertical motor on top of machined surface of discharge head:

1. Clearance between mating surfaces not to exceed 0.004-inch prior to bolting down the motor:

a. Re-machine discharge head or motor if not within tolerance.

2. Any excess oil installed in the motors, while they were stored, shall be drained.

3. Verify alignment of motor shaft with pump top shaft is within manufacturer’s allowable tolerance. Maximum shaft runout 0.0015-inch per inch of shaft diameter.

4. Connect pump top shaft to motor shaft. Vertical adjustment of the pump impeller shall be made in accordance with manufacturer’s instructions.

F. Provide and connect ground connection from the motor and pumping unit to the facility grounding system.

G. Terminate armature leads and external motor cables. Make terminations in accordance with manufacturer’s instructions and recommendations.

H. Before connecting pump to discharge piping, ensure all construction waste and accumulated debris have been removed.

I. Connection of pump to discharge piping will be witnessed by Government and erection engineer.

J. After piping has been connected, re-verify alignment of motor shaft with pump top shaft is within manufacturer’s allowable tolerance. Maximum shaft runout 0.0015-inch per inch of shaft diameter.

K. Contractor shall install the new VFD, wiring (sized per NFPA 70), conduit (sized per NFPA 70), and emergency stop devices in accordance with the following requirements.

L. New VFD shall be installed on government supplied mounting location.

1. Mounting shall be secure and compliant with manufacture recommendations.

2. All terminations shall be clearly labeled and torqued to specifications.

M. Emergency Stop shall be installed where the motor is located.

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1. E-Stop shall be wired to the VFDs digital input and configured to initiate motor stop.

N. Contractor shall furnish and install all conduit and conductors from:

1. Disconnect switch to the VFD.

2. VFD to the motor.

3. E-Stop to the VFD control terminals.

4. All wiring shall be installed in accordance with NFPA 70 and local code requirements.

5. Conductors shall be VFD-rated cable where applicable with proper shielding and grounding.

O. Installation of disconnect switch shall be completed by the Government.

1. Contractor shall provide qualified personnel to configure new VFD to operate motor over complete pump range. VFD and motor will be left in fully functional state upon completion.

P. Contractor shall coordinate with government personnel to ensure proper handoff and readiness for final connection.

Q. Complete all electrical connections to the disconnect switch line-side shall be completed by Government.

3.03 FUNCTIONAL TESTING

A. Provide a minimum of 7-day’s notice to Government prior to testing.

B. Lubricate, adjust, and clean pumping unit after installing in accordance with pump manufacture’s recommendation.

C. Calibrate all gauges, instruments, and recording and sensing devices and adjust equipment to ensure proper pumping system operation. Instruments shall be factory set and calibrated to greatest extent possible. Record all set points and ranges in field test report.

D. Before initially energizing pump motor, successfully test all motor control, monitoring, and protective circuits. Successfully test all motor control, monitoring, and protective circuits.

E. After servicing, perform 1-hour field motor test with the motor uncoupled from the pump:

1. Record motor bearing temperatures, voltage, and amperage every 10-minutes.

2. Test conducted by Contractor and witnessed by Government for the motor.

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F. Include pumping unit bump test and start/stop test to make sure the pump will operate for the next test.

3.04 OPERATIONAL TESTING

A. Provide a minimum of 7-days’ notice to Government prior to pump testing.

B. After servicing and field motor test, perform an operating test under load:

1. Contractor to supply all testing equipment.

2. Take readings with gauges and meters with current calibration records as recommended by HI 14.6.

3. Test conducted by Contractor and witnessed by Government.

4. Record shaft alignment and runout measurements at the motor to pump shaft coupling before and after the operating test and compare to allowable tolerances.

5. During the test, for each observation point, observe and record pumping unit operation, water temperature, pump basin water elevation, flow rate from electro-magnetic flowmeter, discharge pressure, motor speed, noise level in accordance with HI 9.2, vibration analysis, and motor bearing temperatures, voltage, and amperage:

a. Point 1: Operate pump for 4 continuous hours at Design Point 1. Take readings for 4-hours: Once every 30-minutes.

b. Point 2: Operate pump for 4 continuous hours at Design Point 2. Take readings for 4-hours: Once every 30-minutes.

c. Record readings in tabular form.

d. Provide full spectrum vibration analysis using a monitor that records and prints analysis results prior to testing vibration levels. Vibration levels not to exceed acceptable field vibration limits established by HI 9.6.4.

1) If, after installation, pumping unit does not meet these requirements, modify pump and motor to meet these requirements. Use of frequency adjusting devices (such as washers and dampers) between discharge head assembly and motor is not permitted.

6. Inspect discharge pipe connection for leakage. If leaks are present repair and retest.

7. Inspect mechanical seal for leakage and record leakage rate if leakage is present.

If leakage from mechanical seal is greater than 2 drops per hour repair and retest.

8. Check all bolt torque values at conclusion of the tests using calibrated tools.

END OF SECTION