Attachment_E_-_Section_11209.pdf

JRR/pt/specs/11209 Tt #200-76510-23002 11209-1 070125

SECTION 11209

SUBMERSIBLE WELL PUMPS FOR SURFICIAL AQUIFER WELLS

PART 1 - GENERAL

1.01 DESCRIPTION

A. Scope of Work

1. Furnish all labor, materials, equipment, and incidentals required and install, place in operation, and field test stainless steel submersible well pumps, and motors as hereinafter specified, and/or as shown on the Drawings.

2. These Specifications are intended to give a general description of what is required, but do not cover all details which will vary in accordance with the requirements of the equipment application. It is, however, intended to cover the furnishing, the shop testing the delivery and complete installation and field testing, of all materials, equipment and appurtenances for the complete pumping units as herein specified, whether specifically mentioned in these Specifications or not.

3. For all units there shall be furnished and installed all necessary and desirable accessory equipment and auxiliaries whether specifically mentioned in these Specifications or not, as required for an installation incorporating the highest standards for this type of service.

B. Related Work Described Elsewhere

1. Concrete work is included in Division 3.

2. Painting, except as specified herein, is included in Division 9.

3. Mechanical piping, valves, pipe hangers and supports are included in their respective Sections of Division 15.

4. Concrete bases for pumps and pump motors and installation of anchor bolts is included in Division 3, but anchor bolts shall be furnished under this Section by the Contractor of the size and type recommended by the pump manufacturer.

C. General Design

1. Two (2) surficial aquifer submersible well pumps shall be installed as shown on the Drawings. The pumps shall start and stop based upon local and remote operator selected control strategies.

2. All working parts of identical pumps and motors, such as bearings, wearing rings, shafts, sleeves, motors, etc., shall be of standard dimension built to limit

Tt #200-76510-23002 11209-2 070125 gauges or formed to templates such that parts will be interchangeable between like units and such that the Owner may at any time in the future obtain replacement and repair parts for those furnished in the original machines. All parts shall be properly stamped for identification and location in the machines as shown on the Operation and Maintenance Manuals furnished.

1.02 QUALITY ASSURANCE

A. Qualifications

1. To assure unity of responsibility, the cable and surface motor plates shall be furnished and coordinated by the pump manufacturer. The Contractor shall assume full responsibility for the satisfactory installation and operation of the entire pumping system including pumps and motors.

2. The pumps covered by these Specifications are intended to be standard pumping equipment of proven ability as manufactured by a reputable manufacturer having a minimum 10-years’ experience in the production of such pumps. The pumps furnished shall be designed, constructed, and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed. Pumps shall be manufactured in accordance with the Hydraulic Institute Standards.

3. All equipment furnished under this Specification shall be new and unused and shall be the standard product of manufacturers having a successful record of manufacturing and servicing the equipment and systems specified herein.

4. All submersible well pumps and motors shall be supplied by a single manufacturer to ensure uniformity, and unit responsibility.

B. Manufacturers

1. The naming or reference to a specific manufacturer does not indicate that the manufacturer’s standard equipment is acceptable in lieu of the specified component features. This reference is only an indication that the named manufacturers may have the capability of supplying the equipment as specified.

2. The pumps shall be manufactured by:

a. Grundfos, or Approved Equal

3. The motors shall be as manufactured by:

a. Franklin

b. Hitachi

c. Approved Equal 2

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1.03 SUBMITTALS

A. Materials and Shop Drawings

B. Copies of all materials required to establish compliance with the specifications shall be submitted in accordance with the provisions of Section 01340: Shop Drawings, Working Drawings and Samples of these Specifications. Submittals shall include at least the following:

1. Certified shop and erection drawings showing all important details of construction, dimensions, and anchor bolt locations. Long term storage requirements.

2. Descriptive literature, bulletins, and/or catalogs of the equipment.

3. Data on the characteristics and performance of each pump. Data shall include guaranteed performance curves, based on actual shop tests of the actual units, which show that they meet the specified requirements for head, capacity, efficiency, NPSHR, and horsepower. Curves shall be submitted on 8-1/2-inch by 11-inch sheets, at as large a scale as is practical. Curves shall be plotted from no flow at shut off head to pump capacity at minimum specified total head.

4. Data including principle dimensions, materials of construction, space required, clearances, piping and electrical connections and requirements, controls, type of finish, installation instructions and other pertinent information.

5. A complete total bill of materials of all equipment including the weights of equipment furnished.

6. A list of the manufacturer's recommended spare parts in addition to those specified in Paragraph 1.05, with the manufacturer's current price for each item.

Include gaskets, packing, etc., on the list. List bearings by the bearing manufacturer's numbers only.

7. Complete motor data. Long term storage requirements for the motor.

8. Copies of all factory test results, as specified in PART 2 - PRODUCTS of this Section of the Specifications.

C. Additional Information

1. In the event that it is impossible to conform with certain details of the specifications due to different manufacturing techniques, describe completely all nonconforming aspects.

2. Upon receipt and review of submitted material, provide the required number of certified prints and one reproducible tracing of all Drawings as specified in Section 01340: Shop Drawings, Working Drawings and Samples.

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1.04 OPERATIONS AND MAINTENANCE DATA

A. Operating and Maintenance Instructions

1. Operating and Maintenance Manuals shall be furnished. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc., that are required to instruct operation and maintenance personnel unfamiliar with such equipment. The number and special requirements shall be as specified in Section 01730:

Operating and Maintenance Data.

2. A factory representative of all major component manufacturers, who has complete knowledge of proper operation and maintenance, shall be provided to instruct representatives of the Owner and the Engineer on proper operation and maintenance. With the Owner's permission, this work may be conducted in conjunction with the inspection of the installation and test run as provided under PART 3. If there are difficulties in operation of the equipment due to the manufacturer's design or fabrication, additional service shall be provided at no cost to the Owner.

1.05 TOOLS AND SPARE PARTS

A. Furnish to the Owner a list of all manufacturer-recommended spare parts and special tools for normal operation, adjustment and maintenance of the equipment supplied.

1.06 PRODUCT DELIVERY, STORAGE AND HANDLING

A. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed, and the units and equipment are ready for operation.

B. All equipment and parts must be properly protected against any damage during a prolonged storage period at the site.

C. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer.

D. Finished surfaces of all exposed pump openings shall be protected by wooden blanks, strongly built and securely bolted thereto.

E. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.

F. After hydrostatic or other tests, all entrapped water shall be drained prior to shipment, and proper care shall be taken to protect parts from the entrance of water during shipment, storage and handling.

G. Each box or package shall be properly marked to show its net weight in addition to its contents.

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1.07 WARRANTY AND GUARANTEES

A. The manufacturer's written warranty shall be submitted for all major pieces of equipment, as specified in Section 01740: Warranties and Bonds. The manufacturer's warranty period shall be concurrent with the Contractor's correction period for 2 years after the time of completion and acceptance.

PART 2 - PRODUCTS

2.01 GENERAL

A. A special data plate shall be attached to the pump frame which shall contain identification of frame and bearing numbers, specifying number and manufacturer of installed lubricants and specification number and manufacturer of at least two compatible lubricants to those installed (if applicable).

B. Hardware: All machine bolts, nuts and cap screws shall be of the hex head or socket head type. Hardware requiring special tools or wrenches shall not be used. All hardware shall be stainless steel.

C. Parts Numbering: Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number, and those parts which are identical for more than one size unit shall have the same number to effect minimum spare parts inventory.

D. All parts that come in contact with raw water shall be 304 stainless steel.

E. The motor, pumps, column pipe, brackets, and all attached cables and devices shall be sized to fit into the existing well casing with a 11.04-inch I.D.

F. Each submersible pumping unit shall be designed and constructed for 24 hours per day, 365 days per year, continuous service at any and all points within the range of operation without overheating or cavitating and without excessive vibration or strain.

G. All working parts of each submersible pumping unit shall be standard dimensions such that parts can be interchanged between like units.

2.02 VERTICAL TURBINE PUMPS

A. General: The pumps shall be of the submersible motor vertical turbine type complete with direct coupled submersible motor driver, discharge column pipe, in-line check valve, surface plate, and accessories. Final pump length shall be as shown on the Drawings. The entire pumping unit including the discharge head, column piping, bowl assembly and suction bell shall be pickled and passivated following fabrication.

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B. Submersible Motors:

1. The motor shall be capable of continuous operation at nameplate rating submerged under water at a maximum temperature of 30 degrees C ambient water temperature with a minimum of 1/2 foot per second cooling flow past the motor. The motor must be suitable for variable speed control utilizing a variable frequency drive.

2. The motor shall be rated at 460 volt, 3 phase, 60 Hz, 3500 RPM with a minimum Service Factor of 1.15. Minimum efficiency at full load shall be 85% inclusive of fully loaded thrust bearing. Minimum Power Factor a full load shall be 78%.

The maximum actual motor diameter shall not exceed 12” in diameter at the stator casing. Motor shall be provided with internal overtemperature switches.

3. The motor shall be of the water filled “wet winding” type, suitable for rewinding. Oil filled and encapsulated or “can” type motors shall not be acceptable. The motor shall be filled with a 65/35 to 50/50 solution of water and propylene-glycol. The motor winding insulation shall consist of an epoxy enamel layer over the copper conductor, covered by a denatured polypropylene insulation layer and an external nylon or PVC cover.

4. Motor housing material shall be stainless steel.

5. The motor is to be totally enclosed, utilizing an elastomer expansion diaphragm for the equalization of internal and external pressure.

6. The motor shall be equipped with a single mechanical shaft seal, to seal the motor at the point that the shaft extends through the casing.

7. Replaceable carbon composite sleeve type radial bearings shall be provided at each end of the rotor. A rotor balance ring shall be provided for dynamic balancing of the entire rotating assembly. Dynamic balancing shall not exceed

1.0 mils, peak to peak.

8. The motor shall be equipped with a Kingsbury type thrust bearing, with a carbon composite pad, capable of carrying the weight of all rotating elements plus the hydraulic thrust of the pump at shutoff head. Thrust bearing shall be water lubricated, self-aligning, self-equalizing assembly capable of operation in either direction without damage.

9. The motor shall have a splined or keyed stainless steel shaft for connection to the pump shaft.

10. The motor shall be designed to accept all thrust loads imposed by the pump during starting and running.

11. All wetted fasteners and washers, cable glands, and fill/vent valves shall be of stainless steel.

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12. The motor shall be equipped with one (1) set of three separate, continuous leads. The leads are to be internally spliced directly to the stator winding. The motor leads shall have a minimum length of 15’. Each motor shall be supplied with a removable water-block lead or a compression type cable assembly to prevent ingress of water into the motor terminals.

13. Exposed fasteners, plugs, and shafting shall be stainless steel.

14. Tests:

a. All motors shall be completely assembled at the factory and shall be given routine tests conducted in accordance with NEMA Standards, and/or within the intent of NEMA Standards which includes the following non-witness tests as follows:

1) Unvarnished stator electrical test.

2) Varnished stator electrical test.

3) Motor-washout test.

4) No-Load Current test.

5) Meggar Readings to Ground.

6) Phase to Phase Resistance.

7) Final assembly electrical test.

b. If the motor fails any of the tests as defined by NEMA Standards, it shall be rejected.

C. Power Cable

1. The downhole power cable shall be sized to conform to National Electrical Code for 125 percent of motor full load current at a conductor temperature rating of 75 degrees C submerged, and a voltage drop at the motor not to exceed 5%.

2. The cable shall have three continuous conductors rated for 600V operations.

The individual conductors shall be class “B” stranding or better, with a synthetic rubber or thermoplastic insulation. The three conductor cables shall be contained in a flat or round jacket composed of synthetic rubber or thermo plastic with non-hygroscopic fillers between the conductor cables. The cable shall conform to U.L. standard 44 or 83 for submersible pump cable. A compression fitting shall be used for passing the cable into the motor. Pump cable shall have integral conductors for internal temperature over temperature switches.

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3. The cable shall be of sufficient length to allow easy connection in terminal box at the well head.

4. The motor lead to power cable splice shall be a rubber tape type splice, suitable for continuous submerged operation.

5. The spliced connection between the motor leads and the power cable shall be HI/POT tested while submerged at the factory prior to shipment.

6. The power cable shall be attached to the pump discharge pipe at maximum 10 foot intervals using 316 stainless steel banding straps. The power cable shall be attached at the pump inlet and at the pump to motor coupling using 316 stainless steel banding straps. A 1/4-inch thick neoprene pad shall be installed between the power cable and banding straps to prevent damage to the cable.

Cable shall have neoprene jackets and ethylene propylene rubber insulation.

D. Motor Adapter Bracket

1. Provide a stainless-steel bracket, specifically designed and fabricated for connecting the motor to the pump.

2. The bracket shall have a double set of bearings to maintain shaft alignment and to minimize deflection at the coupling. The coupling shall be fabricated of stainless steel and shall be held to the motor and pump shafts using hex-head or socket-head set-screws. Motor and pump shafts shall be splined or keyed.

3. Suction velocity shall not exceed 6 ft/sec between the motor and adapter bracket (exist casing I.D. 11.04”).

4. Each bowl assembly shall be designed to accommodate a working pressure not less than 150 percent of the shut off head.

E. Bowl Assembly

1. Each bowl assembly shall consist of the discharge bowl, impeller and impeller shafting and bearings. Bearings shall be located above and below the impeller.

Impellers shall be statically and dynamically balanced.

2. Pump bowls shall be sufficiently rigid to prevent adverse changes in bearing alignment and to maintain the running clearance of seal rings. Pump bowls shall be provided with wear rings.

3. Bowls shall be flanged with male and female rabbet for joining to the suction bell and the discharge column. Bowl to bowl fits shall be male and female register fits. Waterways and the diffusion vanes shall be smooth and free from nodules, bumps, and dips.

F. Impellers

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1. Machine to fit the contour of the bowl, hand file in the waterways, and equip with replaceable wearing rings. Bowl wear rings shall be minimum 50 BHN higher than impeller wear rings.

2. Attach impellers to the shaft keys and split-ring or collets such that they cannot become loose under any operating condition or under reverse rotation.

G. Discharge Column and Surface Plate

1. The drop pipe shall be with splined couplings at 20-foot intervals. The maximum coupling diameter shall be less than 7.84 inches. Column pipe shall be minimum Schedule 80 thickness.

2. Surface plate, drop pipe, and bowls shall be pressure tested to 150% of pump shut-off head.

3. The discharge shall be flanged. Class 125 or 150 flanges shall comply with AWWA C207, Class D. Class 300 flanges 24 inches and smaller shall comply with ANSI B16.5, Class 300. Class 300 flanges larger than 24 inches shall comply with ANSI B16.1, Class 250. Flanges shall be flat face. The discharge elbow shall be as shown on the contract drawings, with lifting lugs sufficiently sized to support the weight of the pump, motor, column piping, cable, and water in the column.

4. The surface plate shall be fabricated stainless steel capable of supporting the pump, motor, drop pipe, and fluid not less than 1 3/4” thick. The plate shall be cut to the diameter of, and provided with, a bolt hole pattern of 125 lb. flat face flange. A mating flange and Neoprene gasket shall be provided for the top of the well casing. The nominal diameter of well casing is 12”. The discharge elbow shall have a minimum wall thickness of 3/8” and shall be fitted with a flange which has the same outside diameter, bolt circle diameter and number of bolts as ANSI B 16.5.

5. The surface plate shall be provided with two lifting eye bolts, 2-inch well vent hole (nipple with threaded plugged), a 2.5-inch instrumentation access water tight nipple with one quarter turn plug valve, and a power cable entry hole.

Cable gland shall be stainless steel.

H. Balancing

1. All pump and motor units shall be statically and dynamically balanced.

2. Vibration allowance in the combined motor/pump units shall not exceed 1 mil peak to peak.

2.03 FACTORY TESTS

A. Performance Tests:

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1. Each pumping unit, complete with the job motor driver or a factory calibrated motor, shall be subjected to a non-witnessed laboratory performance test.

Perform tests in conformance with the applicable provisions of AWWA E101 or the standards of the Hydraulic Institute. To successfully pass a laboratory performance test, a pumping unit shall meet all performance requirements specified.

2. Performance tests shall be “full-scale.”

3. Conduct tests preferably at the same minimum submergence that will be realized in the field. The pump performance shall be guaranteed for the actual field conditions.

4. The pressure tap for head measurement shall be located not less than 10 pipe diameters downstream from the discharge elbow of the test pump.

5. Tests shall consist of checking the unit at its rated speed, head, capacity, efficiency and brake horsepower, and at such other conditions of head and capacity to properly establish the performance curve. Certified copies of test reports shall be submitted. The Standards of the Hydraulic Institute shall govern the procedures and calculations for these tests. During these tests, the pumps with drive motors shall be checked for balance. The tested pumps shall meet Hydraulic Institute acceptance level 1U (0% negative deviation) to be approved for shipment.

6. No motor overload above nameplate horsepower shall be allowed.

7. Should results of the full-scale tests indicate, in the opinion of the Engineer, that the pumps shall fail to meet any of the specified requirements, the Engineer shall notify the Contractor of such failure. The manufacturer shall thereupon, at no expense to the Owner, make such modifications and perform additional tests as may be necessary to comply with these Specifications.

PART 3 – EXECUTION

3.01 INSTALLATION

A. Installation shall be in strict accordance with the Manufacturer’s instructions and recommendations in the locations shown on the Drawings. Installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the Manufacturer’s recommendations. Anchor bolts shall be set in accordance with the Manufacturer’s recommendations.

B. The Contractor shall submit a certificate from the equipment manufacturer stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication, and care of each unit.

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C. During installation of the pump, do not drop or submerge the cable ends. If the cable end is submerged after the service end seal is broken, the entire cable shall be replaced with new cable.

3.02 INSPECTION AND TESTING

A. General

1. The equipment manufacturer shall furnish the services of a competent and experienced representative who has complete knowledge of proper operation and maintenance of the equipment to inspect the installed equipment, supervise the initial test run, and to provide instructions to the plant personnel.

The first visit will be for checking and inspecting the equipment after it is installed. The second visit will be to operate and supervise the initial field test.

At least one (1) day shall be allocated solely to the instruction of plant personnel in operation and maintenance of the equipment. This instruction period shall be scheduled at least ten days in advance with the Owner and shall take place prior to plant start-up and acceptance by the Owner. The final copies of operation and maintenance manuals specified in Section 01730: Operating and Maintenance Data must have been delivered to the Engineer prior to scheduling the instruction period with the Owner.

2. Field tests shall not be conducted until such time that the entire installation is complete and ready for testing.

B. Pumps

1. After all pumps have been completely installed, and working under the direction of the Manufacturer, conduct in the presence of the Engineer, such tests as are necessary to indicate that the pumping system operates satisfactorily and meets the conditions of service specified. The factory tests are the basis of equipment efficiency demonstration, the field test shall demonstrate correct mechanical operation after pump start-up. Field tests shall include all pumps included under this section. The Contractor shall supply all labor, equipment and incidentals required to complete the field tests.

2. The Demonstration Test shall demonstrate that all items of these Specifications have been met by the equipment as installed and shall include, but not be limited to, the following tests:

a. That all units have been property installed and are in correct alignment and rotation.

b. That the units operate without overheating or overloading any parts and without exceeding specified limits for objectionable noise and vibration.

c. That there are no mechanical defects in any of the parts.

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d. That the pumps can deliver the specified pressure and quantity (±5% certified curves).

e. That the pumps shall be capable of pumping the specified service liquid.

f. That the pump sensors and controls perform satisfactorily and proper alarm functions.

3. If the pump performance does not meet the Specifications, corrective measures shall be taken, or pumps shall be removed and replaced with pumps which satisfy the conditions specified. A 7-day operating period of the pumps will be required before acceptance.

4. Stainless steel pumping units shall show no signs of corrosion upon final acceptance by the Owner.

C. Motors

1. The Contractor shall megger each motor winding before energizing the motor, and, if insulation resistance is found to be low, shall notify the Engineer and shall not energize the motor.

2. The Contractor shall check all motors for correct clearances and alignment and for correct lubrication in accordance with Manufacturer's instructions. The Contractor shall check direction of rotation of all motors and reverse connections if necessary.

3.03 WELL DEVELOPMENT, DISINFECTION, AND CLEARANCE

A. The Contractor shall be responsible for supplying, installing, removal, and restoration of temporary discharge piping required in order to dispose of raw surficial aquifer water during pump installation, testing, development, and disinfection.

B. After the permanent well pump has been installed, the well shall be developed with the well pump at a flow rate of no less than the design pumping rate for a period of up to 20 hours. The turbidity of the raw water shall be monitored by the Contractor during development. Development shall be considered complete when the turbidities are less than 0.5 NTU for at least an hour based upon measurements taken every ten minutes and the turbidities are not decreasing more than twenty percent from the beginning to end of the hour.

C. After the well has been successfully redeveloped, the Contractor shall disinfect the well, well pump installation, and raw water main. The Contractor shall introduce sufficient chlorine solution into the well, well piping, and raw water main to produce a chlorine residual of 50 mg/L in accordance with AWWA C651 and C654. The Contractor shall submit his procedures for disinfection to the Engineer for review and comment prior to proceeding with disinfection. The chlorine residual shall be measured until it drops to zero, at which time the well shall be pumped to waste for a minimum of 15 minutes and

Tt #200-76510-23002 11209-13 070125 turbidities checked to be less than those specified in 3.03B, the well shall be ready for bacteriological evaluation.

D. The Contractor shall furnish the necessary labor and equipment to assist the County in obtaining daily bacteriological sample for 20 consecutive days. The samples shall be obtained using the permanent pump and taken after 20 to 30 minutes of pumping. If all 20 samples show the absence of coliform bacteria, the Engineer shall submit the results to FDEP and request clearance of the well for service. After receipt of clearance from the FDEP, the Contractor shall connect the well discharge piping to the raw water mains and proceed with final testing of the well installation.

E. If the wells fail the initial bacteriological evaluation, the Contractor shall redisinfect the well in accordance with 3.03C and assist the Owner in obtaining additional bacteriological samples as described in 3.03D, all at no additional cost to the Owner. If the second effort to clear the well fails, the Contractor may request a change order for the additional work required to obtain clearance of the well for service.

3.04 START-UP AND INSTRUCTION

A. Manufacturer's Representative: Present at site or classroom designated by Owner, for minimum person-days listed below, travel time excluded:

1. One (1) person-day for installation assistance and inspection.

2. One (1) person-day for functional and performance testing and completion of Manufacturer's Certificate or Proper Installation and prestartup classroom or site training.

B. See Section 01650 – Start-Up and Demonstration.

C. Disinfection: Following completion of installation and prior to placing each potable water supply well and discharge piping into operation, the Contractor shall disinfect each well in accordance with the latest revision of AWWA A-100, C-654, and C-651 and as set forth in Chapter 62-555.315 of the Florida Administrative Code (FAC). Each well and discharge piping shall then be bacteriologically tested in accordance with state and local requirements (i.e., 62-555.315 FAC). A representative of the Owner must be present during taking of all water samples.

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TABLE 11209-B

SURFICIAL WELL PUMP SCHEDULE

1. Type of Pump Submersible Well

2. Number Required (each) 2

3. Pump Speed (rpm) 3,500, maximum

4. Existing Casing Diameter (inches) 12

5. Bowl Diameter (inches) 7.05, maximum

6. Column Length (ft) 40

7. Primary Design Point 318 gpm @ 180 ft

8. Shut-off Head (ft) 296, maximum

9. Type of Motor Submersible

10. Motor Power (hp) 20

11. Motor Speed (rpm) 3,500, maximum

12. Pump, Impeller and Motor Materials 304 SST

END OF SECTION