Attachment D - Spec 232223.pdf

Upgrade Steam System – Patient Areas VAMC Perry Point, Maryland Project Number: 512A5-24-011

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SECTION 23 22 23

STEAM CONDENSATE PUMPS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Steam condensate pumps for Heating, Ventilating and Air Conditioning.

B. Definitions:

1. Capacity: Liters per second (L/s) (Gallons per minute (gpm)) of the fluid pumped.

2. Head: Total dynamic head in kPa (feet) of the fluid pumped.

C. A complete listing of common acronyms and abbreviations are included in

Section 23 05 10, COMMON WORK RESULTS FOR BOILER PLANT AND STEAM

GENERATION and Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

1.2 RELATED WORK

A. Section 01 00 00, GENERAL REQUIREMENTS.

B. Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES.

C. Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREMENTS.

D. Section 01 91 00, GENERAL COMMISSIONING REQUIREMENTS.

E. Section 23 05 10, COMMON WORK RESULTS FOR BOILER PLANT AND STEAM

GENERATION.

F. Section 23 05 11, COMMON WORK RESULTS FOR HVAC.

G. Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC AND STEAM

GENERATION EQUIPMENT.

H. Section 23 05 41, NOISE AND VIBRATION CONTROL FOR HVAC PIPING AND

EQUIPMENT.

I. Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

J. Section 23 22 13, STEAM AND CONDENSATE HEATING PIPING.

1.3 SUBMITTALS

A. Submittals, including number of required copies, shall be submitted in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND

SAMPLES.

B. Information and material submitted under this section shall be marked

“SUBMITTED UNDER SECTION 23 22 23, STEAM CONDENSATE PUMPS”, with applicable paragraph identification.

C. Manufacturer's Literature and Data including: Full item description and optional features and accessories. Include dimensions, weights, materials, applications, standard compliance, model numbers, size, and capacity.

1. Pumps and accessories.

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2. Motors and drives.

D. Characteristic Curves: Head-capacity, efficiency-capacity, brake horsepower-capacity, and NPSHR-capacity for each pump.

E. Complete operating and maintenance manuals including wiring diagrams, technical data sheets, information for ordering replacement parts, and troubleshooting guide:

1. Include complete list indicating all components of the systems.

2. Include complete diagrams of the internal wiring for each item of equipment.

3. Diagrams shall have their terminals identified to facilitate installation, operation and maintenance.

F. Completed System Readiness Checklist provided by the Commissioning

Agent and completed by the contractor, signed by a qualified technician and dated on the date of completion, in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

G. Submit training plans and instructor qualifications in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

1.4 QUALITY ASSURANCE

A. Design Criteria:

1. Pumps design and manufacturer shall conform to Hydraulic Institute

Standards.

2. Pump sizes, capacities, pressures, operating characteristics and efficiency shall be as scheduled.

3. Select pumps so that required net positive suction head (NPSHR) does not exceed the net positive head available (NPSHA).

4. Pump Driver: Furnish with pump. Size shall be non-overloading at any point on the head-capacity curve including one pump operation in a parallel or series pumping installation.

5. Provide all electric-powered pumps with motors, impellers, drive assemblies, bearings, coupling guard and other accessories specified. Statically and dynamically balance all rotating parts.

6. Furnish each pump and motor with a nameplate giving the manufacturers name, serial number of pump, capacity in gpm and head in feet at design condition, horsepower, voltage, frequency, speed and full load current and motor efficiency.

7. Test all pumps before shipment. The manufacturer shall certify all pump ratings.

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8. After completion of balancing, provide replacement of impellers or trim impellers to provide specified flow at actual pumping head, as installed.

9. Furnish one spare seal and casing gasket for each pump to the COR.

B. Allowable Vibration Tolerance for Pump Units: Section 23 05 41, NOISE

AND VIBRATION CONTROL FOR HVAC PIPING AND EQUIPMENT.

1.5 AS-BUILT DOCUMENTATION

A. Submit manufacturer’s literature and data updated to include submittal review comments and any equipment substitutions.

B. Submit operation and maintenance data updated to include submittal review comments, VA approved substitutions and construction revisions shall be in electronic version on CD or DVD. All aspects of system operation and maintenance procedures, including applicable piping isometrics, wiring diagrams of all circuits, a written description of system design, control logic, and sequence of operation shall be included in the operation and maintenance manual. The operations and maintenance manual shall include troubleshooting techniques and procedures for emergency situations. Notes on all special systems or devices shall be included. A List of recommended spare parts

(manufacturer, model number, and quantity) shall be furnished.

Information explaining any special knowledge or tools the owner will be required to employ shall be inserted into the As-Built documentation.

C. The installing contractor shall maintain as-built drawings of each completed phase for verification; and, shall provide the complete set at the time of final systems certification testing. Should the installing contractor engage the testing company to provide as-built or any portion thereof, it shall not be deemed a conflict of interest or breach of the ‘third party testing company’ requirement. Provide record drawings as follows:

1. As-built drawings are to be provided, with a copy of them on AutoCAD version 2019 provided on CD or DVD. The CAD drawings shall use multiple line layers with a separate individual layer for each system.

D. The as-built drawings shall indicate the location and type of all lockout/tagout points for all energy sources for all equipment and pumps to include breaker location and numbers, valve tag numbers, etc.

Coordinate lockout/tagout procedures and practices with local VA requirements.

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E. Certification documentation shall be provided to COR 21 working days prior to submitting the request for final inspection. The documentation shall include all test results, the names of individuals performing work for the testing agency on this project, detailed procedures followed for all tests, and provide documentation/certification that all results of tests were within limits specified. Test results shall contain written sequence of test procedure with written test results annotated at each step along with the expected outcome or setpoint. The results shall include all readings, including but not limited to data on device (make, model and performance characteristics), normal pressures, switch ranges, trip points, amp readings, and calibration data to include equipment serial numbers or individual identifications, etc.

1.6 APPLICABLE PUBLICATIONS

A. The publications listed below form a part of this specification to the extent referenced. The publications are referenced in the text by the basic designation only:

B. American Iron and Steel Institute (AISI):

AISI 1045 2013..........Cold Drawn Carbon Steel Bar, Type 1045

AISI 416 2016...........Type 416 Stainless Steel

C. American National Standards Institute (ANSI):

ANSI B15.1-2000....Safety Standard for Mechanical Power Transmission

Apparatus

ANSI B16.1-2015.........Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250 and 800

D. American Society for Testing and Materials (ASTM):

A48-2016................Standard Specification for Gray Iron Castings

B62-2016................Standard Specification for Composition Bronze or Ounce Metal Castings

E. Maintenance and Operating Manuals in accordance with Section 01 00 00, GENERAL REQUIREMENTS.

PART 2 - PRODUCTS

2.1 CONDENSATE PUMP, PAD-MOUNTED

A. General: Factory assembled unit consisting of vented receiver tank, motor-driven pumps, interconnecting piping and wiring, motor controls

(including starters, if necessary) and accessories, designed to receive, store, and pump steam condensate.

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B. Receiver Tank: Cast iron with threaded openings for connection of piping and accessories and facilities for mounting float switches.

Receivers for simplex pumps shall include all facilities for future mounting of additional pump and controls.

C. Furnish seals for condensate pump with a minimum temperature rating of 121 degrees C (250 degrees F).

D. Centrifugal Pumps: Bronze fitted with mechanical shaft seals.

1. Designed to allow removal of rotating elements without disturbing connecting piping or pump casing mounting.

2. Shafts: Stainless steel, Type 416 or alloy steel with bronze shaft sleeves.

3. Bearings: Regreaseable ball or roller type.

4. Casing wearing rings: Bronze.

E. Motors: Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC

AND STEAM GENERATION EQUIPMENT.

F. Pump Operation:

1. Float Switches: NEMA 4, mounted on receiver tank, to start and stop pumps in response to changes in the water level in the receiver and adjustable to permit the controlled water levels to be changed.

Floats and connecting rods shall be copper, bronze or stainless steel.

2. Alternator: Provide for duplex units to automatically start the second pump when the first pump fails in keeping the receiver water level from rising and to alternate the order of starting the pumps to equalize wear. For units 0.25 kW (1/3 hp) and smaller, the alternator may be the mechanical type for use in lieu of float switches.

G. Control Cabinet for 3 Phase (0.37 kW (1/2 hp) and larger) Units: NEMA

4, UL approved, factory wired, enclosing all controls, with indicating lights, manual switches and resets mounted on the outside of the panel.

Attach cabinet to the pump set with rigid steel framework, unless remote mounting is noted on the pump schedule.

1. Motor starters: Magnetic contact types with circuit breakers or combination fusible disconnect switches. Provide low voltage control circuits (120-volt maximum) and HOA switches for each pump.

2. Indicating lights for each pump: Green to show that power is on, red to show that the pump is running.

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H. Electric Wiring: Suitable for 94 degrees C (200 degrees F) service;

enclosed in liquid-tight flexible metal conduit where located outside of control cabinet.

I. Receiver Accessories:

1. Thermometer: 38 to 216 degrees C (100 to 420 degrees F), mounted below minimum water level.

2. Water level gauge glass: Brass with gauge cocks which automatically stop the flow of water when the glass is broken. Provide drain on the lower gauge cock and protection rods for the glass.

2.2 CONDENSATE PUMP, SUMP TYPE

A. General: Factory assembled unit consisting of motor-driven pump(s) mounted on a horizontal cover plate bolted to a vented sump-type receiver, interconnecting wiring and piping, motor controls and accessories, designed to receive, store, and pump steam condensate.

B. Receiver Tank: Vertical, cylindrical, cast iron sides and bottom, designed for service underground or below the floor. Inlet connection shall be located nine inches below the cover plate. Provide floor mounting gasket.

C. Receiver Cover Plate: Heavy gauge steel designed to support weight of pumps, motors, and accessories and support foot traffic with no deflection. Provide for mounting of pumps, motor and accessories by bolting to the cover. Provide threaded openings for piping connections and a bolted inspection plate for viewing interior of receiver. All bolted connections to cover plate, and between cover plate and receiver, shall be gasketed so that no vapor will escape into the room.

D. Furnish seals for condensate pump with a minimum temperature rating of 121 degrees C (250 degrees F).

E. Pumps: Centrifugal type, vertical extended shaft, bronze fitted, flexible-coupled, designed for submerged operation.

1. Shaft: Stainless steel, Type 416.

2. Shaft bearings: Bronze, water lubricated.

3. Shaft seal at cover plate: Packed type with bronze packing gland.

4. Thrust bearings: Regreaseable ball type located above the cover plate.

5. Discharge pipes: Terminate above the cover plate.

6. Pump-motor mounting: Bolted to brackets bolted to the cover plate.

Removal of one pump shall not affect operation of the second pump.

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F. Motors: Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC

AND STEAM GENERATION EQUIPMENT.

G. Pump Operation:

1. Float Switches: NEMA 1, mounted on receiver tank, to start and stop pumps in response to changes in the water level in the receiver, and adjustable to permit the controlled water levels to be changed.

Floats and connecting rods shall be copper, bronze or stainless steel.

2. Alternator: Provide for duplex units to automatically start the second pump when the first pump fails in keeping the receiver water level from rising and to alternate the order of starting the pumps to equalize wear. For units 0.25 kW (1/3 hp) and smaller, the alternator may be the mechanical type for use in lieu of float switches.

H. Electric Wiring: Suitable for 94 degrees C (200 degrees F) service;

enclosed in liquid-tight flexible metal conduit where located outside of control cabinet.

PART 3 - EXECUTION

3.1 INSTALLATION

A. If an installation is unsatisfactory to the COR, the Contractor shall correct the installation at no additional cost or time to the

Government.

B. Follow manufacturer's written instructions for pump mounting and startup. Access/Service space around pumps shall not be less than minimum space recommended by pumps manufacturer.

C. Sequence of installation for base-mounted pumps:

1. Level and shim the unit base and grout to the concrete pad.

2. Shim the driver and realign the pump and driver. Correct axial, angular or parallel misalignment of the shafts.

3. Connect properly aligned and independently supported piping.

4. Recheck alignment.

D. Pad-mounted Condensate Pump: Level, shim, bolt, and grout the unit base onto the concrete pad.

E. Sump Type Condensate Pump: Apply two coats of asphalt or bituminous compound on the exterior of the receiver tank, and mount level and flush in the floor with waterproofing gaskets and grouting to prevent ground water from entering the building from around the receiver.

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F. Coordinate location of thermometer and pressure gauges as per Section

23 22 13, STEAM AND CONDENSATE HEATING PIPING.

3.2 STARTUP AND TESTING

A. Perform tests as recommended by product manufacturer and listed standards and under actual or simulated operating conditions and prove full compliance with design and specified requirements. Tests of the various items of equipment shall be performed simultaneously with the system of which each item is an integral part.

B. When any defects are detected, correct defects and repeat test at no additional cost or time to the Government.

C. The Commissioning Agent will observe startup and contractor testing of selected equipment. Coordinate the startup and contractor testing schedules with COR and Commissioning Agent. Provide a minimum notice of

10 working days prior to startup and testing.

D. Verify that the piping system has been flushed, cleaned and filled.

E. Lubricate pumps before startup.

F. Prime the pump, vent all air from the casing and verify that the rotation is correct. To avoid damage to mechanical seals, never start or run the pump in dry condition.

G. Verify that correct size heaters-motor over-load devices are installed for each pump controller unit.

H. Field modifications to the bearings and or impeller (including trimming) are prohibited. If the pump does not meet the specified vibration tolerance send the pump back to the manufacturer for a replacement pump. All modifications to the pump shall be performed at the factory.

3.3 COMMISSIONING

A. Provide commissioning documentation in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

B. Components provided under this section of the specification will be tested as part of a larger system.

3.4 DEMONSTRATION AND TRAINING

A. Provide services of manufacturer’s technical representative for 4 hours to instruct each VA personnel responsible in operation and maintenance of the system.

B. Submit training plans and instructor qualifications in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

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