CC-4601-22_Technical_Specs.pdf

BFP Cake Pump & Hopper R&R Ductile Iron Process Pipe

40 05 19-1 7/15/2022

SECTION 40 05 19

DUCTILE IRON PROCESS PIPE

PART 1 GENERAL

1.01 SUMMARY

A. This Section covers the materials and installation of ductile iron process piping.

1.02 REFERENCES

A. Standard

1. American Society for Testing and Materials (ASTM)

a. ASTM A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

b. ASTM A536 - Standard Specification for Ductile Iron Castings

2. American Society of Mechanical Engineers (ASME)

a. ASNI/ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250

3. American Water Works Association (AWWA)

a. ANSI/AWWA C104/A21.4 - Cement-Mortar Lining for Ductile-Iron Pipe

b. ANSI/AWWA C105/A21.5 - Polyethylene Encasement for Ductile-Iron Pipe

Systems

c. ANSI/AWWA C110/A21.10 - Ductile-Iron and Gray-Iron Fittings

d. ANSI/AWWA C111/A21.11 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings

e. ANSI/AWWA C115/A21.15 - Flanged Ductile-Iron Pipe with Threaded Flanges

f. AWWA C150 - Thickness Design of Ductile-Iron Pipe

g. ANSI/AWWA C151/A21.51 - Ductile-Iron Pipe, Centrifugally Cast

h. ANSI/AWWA C153/A21.53 - Ductile-Iron Compact Fittings for Water Service

i. AWWA C600 – Installation of Ductile-Iron Water Mains and Their Appurtenances

4. Ductile Iron Pipe Research Association (DIPRA)

a. Installation Guide for Ductile Iron Pipe

1.03 SUBMITTALS

A. Action Submittals

1. Shop drawings

2. Product data

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1.04 QUALITY ASSURANCE

A. The Manufacture of the ductile iron process pipe shall have demonstratable experience in the manufacturing of ductile iron pipe.

B. The Installer of the pump shall have demonstratable experience in the installation of ductile iron process pipe.

C. At the request of the Owner, provide three (3) references of prior installations.

1.05 DELIVERY, STORAGE AND HANDLING

A. Follow the DIPRA’s “Installation Guide for Ductile Iron Pipe” and the manufacturer’s recommendations for handling and storing ductile iron process pipe.

B. Care shall be taken in loading, transporting, and unloading to prevent damage to materials. Examined all materials before installation, no materials shall be installed which is found to be defective. Do not transport pipe using forklift devices where forks are inserted into pipe openings.

C. When not being handled, support the pipe on timber cradles or on properly prepared ground, graded to eliminate all rock points and to provide uniform support along the full length

D. When being transported, support the pipe in a manner which will not permit distortion or damage to the lining or coating.

E. Inspect all pipe prior to installation to ensure no cracked, broken, or otherwise defective materials are being used.

F. Maintain pipe clean and free of foreign matter and dirt before, during and after installation. If the materials cannot be placed without getting earth into it, the Owner may require a suitable plug be placed over each end before lowering the material. Leave the plugs in place until the connection is to be made to the adjacent material.

G. Repair or replace any damaged materials to at no additional expense to the Owner.

1.06 WARRANTY

A. Installation shall be warrantied for a period no less than twelve (12) months from install.

PART 2 PRODUCTS

2.01 DUCTILE IRON PROCESS PIPE & FITTINGS

A. Ductile Iron Pipe

1. All ductile iron pipe shall be centrifugally cast conforming to AWWA C150 and C151/A21.51, of ductile iron conforming to ASTM A536.

2. Ductile iron pipe shall be a minimum of Pressure Class 250.

3. Ductile iron pipe shall be marked in accordance to ANSI/AWWA C151/A21.51.

4. Utilize push on or mechanical joint ductile iron pipe for below-grade applications.

5. Utilize flanged joint ductile iron pipe for all above-grade, vault, or other exposed applications.

6. Ductile iron process pipe shall be manufactured by American Ductile Iron Pipe, McWane Ductile, US Pipe, or approved equal.

B. Ductile Iron Fittings

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1. All fittings shall be manufactured in accordance with ANSI/AWWA C110/A21.10 or C153/A21.53, of ductile iron conforming to ASTM A536.

2. Ductile iron fittings shall have a minimum working pressure of 250 psi.

3. Mechanical joint ductile iron fittings shall be used for below-grade applications.

4. Flanged joint ductile iron fittings shall be used for all above-grade, vault, or exposed applications.

5. Ductile fittings shall be manufactured by American Ductile Iron Pipe, Sigma, Star, Tyler

Union, or approved equal.

C. Joints

a. Restrained Push-on-Joints for Ductile Iron Process Pipe

i. All push-on-joints and gaskets shall be in accordance of ANSI/AWWA C111/A21.11.

ii. Restrain all ductile iron process pipe as specified in this Section.

b. Mechanical Joints for Ductile Iron Pipe and Fittings

i. Mechanical joint fittings and glands shall be manufactured in accordance with ANSI/AWWA C110/A21.10 or C153/A21.53.

ii. Utilize gaskets in accordance with ANSI/AWWA C111/A21.11, carrying the approval of NSF/ANSI 61.

iii. Utilize tee-bolts and nuts with low alloy, corrosion resistant steel.

c. Flanged Joints for Ductile Iron Pipe and Fittings

i. Flanged joint fittings shall be manufactured in accordance with ANSI/AWWA C110/A21.10, C111/A21.11 or C153/A21.53, and to the drilling and facing standards of ANSI/ASME B16.1 Class 125 flanges, unless specifically noted.

ii. Flange gaskets shall be full face, one-eight (1/8) inch thick, cloth impregnated rubber, suitable for water pressures of 350 psi at a temperature of 180°F, and shall carry the approval of NSF/ANSI 61.

iii. Flange bolts shall be Type 316 stainless steel conforming to ASTM A193, with the nuts being of lesser hardness to prevent galling during installation.

2.02 ACCESSORIES

A. Ductile Iron Pipe Polyethylene Encasement

1. Where required due to corrosive soils, or where shown on the Plans, encase ductile iron process pipe in tube shaped polyethylene encasement, colored with black or white lettering indicating service, minimum 8 mil thickness, and meeting the specifications of ANSI/AWWA C105/A21.5. Secure and seal ends and slack in polyethylene encasement with approved PVC tape.

B. Ductile Iron Pipe Joint Restraints

1. Ductile Iron Pipe Push-on-Joint Restraint

a. New ductile iron process pipe four (4) inches to twelve (12) inches in nominal diameter, or existing ductile iron pipe all sizes:

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i. Restraint for ductile iron pipe push-on-joints shall be manufactured of ductile iron conforming to ASTM A536 and be enamel or epoxy coated.

ii. Split ring restraints shall be serrated to grip the pipe and use enough bolts to provide restraint.

iii. Non-split restraints shall utilize a backup ring behind the pipe bell, a restraint ring incorporating a plurality of individually-actuating gripping surfaces, and use a sufficient number of bolts to provide restraint.

b. Restrain new ductile iron pipe fourteen (14) inches in nominal diameter or greater with integrated restraint systems, such as “gripper gaskets” or lock rings meeting the requirements of ANSI/AWWA C111/A21.11.

2. Ductile Iron Pipe Mechanical Joint Restraint

a. Mechanical joint restraint devices shall be manufactured of ductile iron conforming to ASTM A536, be enamel or epoxy coated and consist of multiple gripping wedges incorporated into a follower gland meeting the applicable requirements of ANSI/AWWA C110/A21.10 or C153/A21.53.

3. Restrained Flange Coupling Adaptors

a. Utilize restrained flange coupling adaptors in lieu of threaded or welded flanges on plain end pipe as indicated on the Plans.

b. Restrained flange coupling adaptors shall be manufactured of ductile iron conforming to ASTM A536, be enamel or epoxy coated, consist a multiple gripping edges incorporated into the adaptor and use a sufficient number of bolts to provide restraint.

4. Ductile iron pipe joint restraints shall be manufactured by EBBA Iron, Sigma, Smith Blair, Star, or approved equal.

2.03 FINISHES

A. Interior Lining

1. All ductile iron pipe and fittings for potable use shall have a standard cement-mortar lining with a seal asphaltic coat in accordance with ANSI/AWWA C104/A21.4 and carrying the approval of NSF/ANSI 61.

2. All ductile iron pipe for wastewater, sludge, or sludge cake shall be lined with a corrosion resistant ceramic epoxy lining from the manufacturer, Protecto 401 or approved equal.

B. Exterior Coating

1. All ductile iron pipe and fittings installed below-grade shall have a shop asphaltic coating in accordance with ANSI/AWWA C151/A21.51.

2. All ductile iron pipe installed above-grade shall have a shop applied rust inhibitive primer or fusion bonded epoxy coating compatible with field top coat materials.

PART 3 EXECUTION

3.01 PREPARATION

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A. Inspect all ductile iron pipe and fittings with the Owner. Bring to the attention of the owner any pipe found damaged. Repair interior linings and exterior coatings per the manufacturer’s recommendations. Mark any cracked pipe or pipe with damaged lining or coating and immediately remove from the Project Site.

B. Thoroughly clean any pipe and fittings before laying.

3.02 INSTALLATION

A. General

1. Take care in handling, cutting, or laying ductile iron pipe and fittings.

2. Keep pipes clean of any sand, silt, gravel or foreign materials, before and during installations. During breaks in work, place an approved plug over the end of the pipe to prevent foreign material entering the pipe.

3. When cutting pipe take care to avoid damage to pipe, interior linings or exterior coatings. Repair interior linings and exterior coatings per the manufacturer’s recommendations. Flame cutting of ductile iron pipe is not permitted. Ensure cut ends are square and rough edges or burrs are smoothed. Bevel push on joints to prevent gasket damage during joint assembly.

4. Excavation, backfilling and compaction shall in in accordance with other Sections this Project Manual.

B. Below-Grade Installation

1. Install ductile iron pipe in accordance with the manufacture’s recommendations and

AWWA C600.

2. Install and maintain pipe at required lines and grades. Provide line stakes at a one hundred (100) foot maximum spacing and at all line change locations. Provide a temporary benchmark at a maximum one thousand (1000) foot intervals.

3. Maintain a minimum cover of thirty-six (36) inches from the top of the pipe to final finish grade.

4. Utilize fittings at all changes in pipe direction. The Owner may permit on case by case basis that long radius curves, either horizontal or vertical, may be installed with pipe deflections at the joints. If permitted by the Owner, maximum deflections at pipe joints and radii for the various pipe lengths shall be no greater than seventy (70) percent of the pipe manufacturer’s recommendations.

5. Install polyethylene encasement where corrosive environments exist along the pipe alignment, or as directed by the Owner, to the requirements of ANSI/AWWA C105/A21.5.

6. Prepare pipe bedding as outlined in other Sections of the Project Manual. Lower pipe into the trench carefully to avoid damage. Under no condition shall pipe be rolled into or dropped into the trench.

7. Thoroughly clean the grove and bell socket of the pipe or fitting as well as the plane end of the mating pipe. Gaskets should be installed in the factory when possible or installed per the manufacture’s requirements. Lubricate the gasket and plain end of the pipe in accordance with the pipe manufacture’s recommendations.

8. Ensure the plain end of the pipe is beveled per the manufacture’s recommendations, and that all square or sharp edges are removed prior to joint installation to prevent damage or dislodging of the gasket.

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9. Push mating pipe into the bell socket or fitting with appropriate force. Keep the joint straight while pushing, deflections at bells shall be made after the joint is assembled.

A timber header should be used between the pipe and any pushing equipment to prevent damage to the pipe.

10. Assemble pipes only to the insertion line or the manufacture’s recommendations.

Joints assembled beyond the insertion line or manufacture’s recommendations are be considered over-assembled and will be corrected at the direction of the Owner.

11. Install restrained push on, restrained mechanical joints or flanged connections where required by the Plans and in accordance with the manufacture’s guidelines and requirements. Fasten joint hardware to the torque specifications of the manufacture.

12. Paint the bells of push-on-joints with integral restraints (i.e. “gripper gaskets” or “lock-rings”) red to indicate restraint.

C. Above-Grade, Exposed, or Vault Installation

1. Install all pipe and fittings true to alignment, properly supported in a manner to prevent any load and strain to be transferred to adjacent equipment.

2. Align joint bolt holes and mating surfaces. Do not use bolts to align or pull flanges together. Place gasket with bolt holes aligned.

3. Insert all bolts, washers, and nuts. Ensure that the mating surfaces are flush against the gasket prior to tightening.

4. Hand tighten bolts until snug, then using a torque wrench apply uniform pressure across the flange by tightening bolts in five (5) ft-lb increments in a diametric pattern (180°) until proper torque is achieved. Do not overtighten.

3.03 FIELD QUALITY CONTROL

A. Test all ductile iron process pipe and fittings according AWWA C600, or to other Sections of this Project Manual.

3.04 CLEANING

A. Clean all ductile iron process pipe and fittings according AWWA C600, to other Sections of this Project Manual.

END OF SECTION

BFP Cake Pump & Hopper R&R Progressive Cavity Pumps

43 23 57-1 7/15/2022

SECTION 43 23 57

PROGRESSIVE CAVITY PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. This Section covers the materials, installation, startup and testing of progressive cavity pumps for municipal activated sludge cake service.

B. Two (2) progressive cavity pumps are to be replaced under this Contract. Each pump shall be manufactured by the same supplier, sized to the same capacity. Any changes in overall configuration of the pump system, components, or accessories to successfully complete the Work under existing conditions shall be the Contractor’s responsibility to determine prior to installation.

1.02 SUBMITTALS

A. Action Submittals

1. Shop Drawings

a. Progressive Cavity Pump

2. Testing Data

a. Pressure Testing Data

b. Performance Testing Data

B. Informational Submittals

1. Certificates

a. Manufactures Certificate of Installation

1.03 QUALITY ASSURANCE

A. The Manufacturer of the pump shall have demonstratable experience in the production of progressive cavity pumps for the sludge cake service.

B. The Installer of the pump shall have demonstratable experience in the installation of progressive cavity pumps for sludge cake service.

C. At the request of the Owner, provide three (3) references of prior installations.

1.04 DELIVERY, STORAGE AND HANDLING

A. The Contractor shall be responsible for proper delivery, offloading, storage, and handling of pumps. Owner does not guarantee onsite equipment for delivery or handling of pumps.

B. Contractor to supply all necessary equipment and rigging to safely unload, move within site, and install pumps.

C. Pumps shall be received and stored palletized.

D. Store covered to protect from weather in a location away from daily vehicular paths.

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1.05 SCHEDULING

A. Coordinate shutdown of existing equipment and startup of new equipment with the Owner’s representative.

1.06 WARRANTY

A. Pumps, pump parts, and accessories shall be warrantied for a period no less than twelve

(12) months from install or eighteen (18) months from the date of shipment, which ever period expires first.

B. Installation shall be warrantied for a period no less than twelve (12) months from install.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Progressive cavity pumps shall be by Moyno, Nemo, Seepex, or preapproved equal.

B. Pump drive motors shall be by Baldor-Reliance, or preapproved equal.

2.02 EXISTING PRODUCTS

A. Existing progressive cavity sludge cake pumps are outlined in other Contract Documents.

B. The Contractor is responsible with evaluating existing conditions prior to installation, preferably prior to proposal. Any issues or discrepancies shall be brought to the attention of the Owner representative prior to installation.

2.03 PROGRESSIVE CAVITY PUMP

A. Pumps shall be of the progressive cavity type, a metal rotor turning in an elastomer stator.

Pumps shall incorporate a minimum of four (4) stages. Suction section shall be equipped with an auger screw to progress the material into the pump, without the use of bridge breakers.

B. Provide the equipment in a complete unit mounted on a common baseplate or frame, inclusive of pump, drive system, motor, and gearbox. Provide the common base plate with a four( 4) lifting lugs, one at each corner, capable of lifting the entire pumping unit, drive, motor and gearbox.

C. Pumps shall be capable of moving activated sludge cake with the following characteristics

1. Rate of Flow: 20 gpm

2. Suction Pressure: 0 psig

3. Discharge Pressure: 150 psig

4. Apparent Viscosity: 10,000 CP

5. Specific Gravity: ~1.04

6. Temperature: 70° F

7. Abrasion Level: Medium

8. Fluid Type: Slurry

9. Percent Solids: 18 %

10. Max Particle Size: 0.5”

11. Average Particle Size: 0.15”

D. Provide the pump with

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1. a rectangular open hopper (suction casing) with vertical walls, matching the belt filter press width,

2. an “extension tube” between the hopper opening and rotor, incorporated in the suction casing to provide a compression zone,

3. an enlarged single helix auger running the entire length of the suction casing and extension tube, capable of transmitting rotational forces from the drive shaft to rotor,

4. a minimum 2” hopper drain to facilitate cleaning,

5. inspection ports in the hopper at each joint,

6. a holdback designed to prevent reversal of flow when the pump is not in operation,

7. factory packed grease lubricated thrust and axial bearings, integral type with tapered roller design,

8. gear or universal type shaft joints,

9. removable coupler guard,

10. mechanical seals not requiring external seal water, and

11. maximum of an eight (8) inch, Class 150 flat faced flanged discharge connection with a 3/8” or larger plugged tap to permit the installation of pressure instruments.

E. Pump materials shall be:

1. Suction Housing: Type 316 SS

2. Rotor: Type 316 SS w/ min 0.010 chrome plating

3. Stator: Nitrile (Buna N)

4. Drive shaft: Type 316 SS w/ min 0.010 chrome plating

5. Coupling Rod Screw Conveyor: Type 316 SS w/ min 0.010 chrome plating

6. Other wettable parts: Type 316 SS w/ min 0.010 chrome plating

7. Base: ASTM A36 carbon steel

8. Mechanical Shaft Seals: Type 316 SS w/ Viton bellows and Si-Car faces

F. Drive motor shall be:

1. HP: Maximum 15HP

2. Phase: 3

3. Voltage: 460

4. RPM: 1750 rpm

5. Motor Service Factor: 1.15 (1.0 on VFD duty, 30-60 Hz, Constant Torque)

6. Insulation: Class H

7. Enclosure: TEFC

8. Thermal Protection: Thermostats Normally Closed

9. Options: foot mounted, premium efficient, sever duty, inverter duty, 1-60-120 space heaters, 65C ambient.

2.04 ACCESSORIES

A. Hopper Extension

1. Material: Min. 11 gauge Type 304 Stainless Steel for all hopper and hardware.

2. Connections: Min. 1/4” rectangular flanges made to mate with new pump and existing belt filter press.

3. Dimensions: Sized to mate with proposed pump with sufficient area to receive cake from the existing belt filter press without loss of material. Top of hopper shall be

43 23 57-4 7/15/2022 within twelve (12) inches of belt filter press discharge chute. Sides shall be vertical or near vertical to insure no impaction of material.

4. Manufacture hopper with removable front access panel with reinforced frame.

5. Include framing to remount existing level transmitter, material to match hopper.

B. Spare Parts

1. No spare parts are required.

2.05 SOURCE QUALITY CONTROL

A. Pressure Testing

1. Hydrostatically test casing and body for a minimum of 10 minutes at one and one-half times the maximum design operating pressure, but not less than 20 psig.

2. Casing and body shall show zero leakage.

B. Performance Testing

1. Each pump shall be subjected to a non-witnessed performance test.

2. Conduct tests in accordance with ANSI/HI 3.6 Rotary Pump Tests using the actual job driver.

3. Tests shall be Type I and Type III. Acceptance levels for Type III tests shall be Level A.

4. No motor overload above nameplate rating will be allow at any of the specified operating points and speeds, including the overspeed provision specified for VFDs.

PART 3 EXECUTION

3.01 PREPARATION

A. Existing Conditions

1. Inspect existing conditions, dimensions, and equipment prior to the installation of new pumps.

2. Bring to the Owner’s attention any discrepancies or issues with the installation of new pumps in the existing location prior to installation.

B. Inspection of New Pumps

1. Prior to installation, inspect new pumps with of Owner’s representative.

2. Any damage or deficiencies in pump materials, components, and coatings shall be replaced or repaired at no expense to the Owner.

C. Shutdown of Existing Pumps

1. Owner staff will shut down existing pumps and isolate sources of energy.

2. Contractor shall verify that existing pumps are fully de-energized, locked and tagged out with the Contractors locks prior to proceeding with any work.

D. Cleaning of existing pumps

1. Prior to removal, clean existing pumps of debris and caked on materials with washdown water, insuring material flows towards dedicated drains.

2. Drain all gear boxes and clean up excessive grease. Dispose of chemicals in approved manner

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3.02 ERECTION

3.03 INSTALLATION

A. Removal of Existing Pumps

1. Remove existing pumps in a manner to prevent damage to existing pump, structures, service connections, and adjacent equipment.

2. Cut off or remove existing anchor bolts, unless existing bolting pattern matches new pump base.

3. Return existing pumps to an Owner approved location.

B. Pump Installation

1. Mount each pump to existing concrete structure, with the suction of the pump centered on the belt filter press discharge chute. Take car to ensure that all components are in direct line.

2. Utilize existing anchor bolts if retained, or install new wedge or adhesive capsule anchors to secure pump to foundation. Install shims to insure pump is level.

3. If pump base permits, fill base with non-shrink grout. Allow grout to fully dry prior to fully tightening anchor bolts.

4. Check that pump and driver shafts are properly aligned per manufacturer’s recommendations before coupling.

5. Check gear and motor lubrication, and other lubrication points per manufacturer’s recommendations.

C. Service Connections

1. Modify existing discharge piping to accommodate and changes in pump discharge diameter or lay length. Utilize a breakaway spool, one end flanged, one end plain end with flange coupling adaptor, to make discharge connection.

2. Reconnect pump power connections utilizing existing power flexible conduit. Should modifications to the power or signal supply feeds become necessary as in longer or shorter conduit and wire runs, the Contractor shall provide the materials and labor required to perform the necessary modification at no additional cost to the Owner.

Where existing power connections are not longer utilized, such as for bridge breakers, remove power connections up to the panel, and plug panel opening.

D. Instrumentation and Controls

1. Reconnect all existing instrumentation and controls, including but not limited to:

a. Level transmitters

b. Pressure gauges, switches, and transmitters

c. Motor high temperature switches

d. Dry run indicators

2. Any required reconnection modifications shall be the responsibility of the Contractor at no additional cost to the Owner.

3. Report any required changes in control or operation with the Owner representative, who will coordinate task with approved integrator under separate contract.

E. Coating

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1. Inspect pump coating with Owner representative after installation. Repair and damaged coatings per the manufacturer’s recommendations at no additional cost to the Owner.

F. Startup

1. Do not start-up or run the pump dry, running the pump dry is harmful to the pump.

Any damage to the pump due to it running dry, prior to acceptance, will be repaired to the manufacturer’s recommendations at no additional cost to the Owner.

2. Ensure that all lubrication points are lubricated to manufacturer’s recommendations.

3. Coordinate with the Owner representative to remove all lockout protections.

4. Prior to first operation, fill the pump with water to lubricate the stator.

5. Once the pump has been filled with liquid, check for the direction of the pump rotation by momentarily starting and stopping the drive. Check rotation against arrow on pump or pump nameplate. Correct connections if needed.

6. Startup pump, while simultaneously filling pump suction to maintain wetted stator.

7. Operate the pump through its output range, at ten-percent increments of rated maximum capacity for a minimum of 10 minutes, or whatever length of time to demonstrate proper operation. Pumping units shall show that they can operate without excessive noise, cavitation, vibration, proper bearing temperature, under automatic and manual control, without overloading drive equipment. Ensure that the pump operates without exceeding the motor nameplate rating.

8. Demolish existing seal water line, if equipped, back to the nearest isolation valve.

9. Reconnect suction drain to existing drain line, replace existing drain valve with SS ball valve.

3.04 FIELD QUALITY CONTROL

A. Certification

1. Provide a written Manufacturer’s Certification of Installation from the equipment manufacturer, or their authorized representative, that the pumps have been properly installed according to the Contract and manufacturer’s recommendations, and that the equipment is operating normally.

2. Make all necessary corrections and adjustments, including but not limited to parts, labor, or freight at no additional cost to the Owner.

END OF SECTION