Exhibit 27 - 1 Oct 20.pdf

SECTION 44 42 53 Page 1

SECTION 44 42 53

PARALLEL PLATE, GRAVITY OIL-WATER SEPARATOR

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA 10084 (2005) Standard Methods for the Examination of Water and Wastewater

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2008) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B16.5 (2003) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24

ASTM INTERNATIONAL (ASTM)

ASTM A 36/A 36M (2008) Standard Specification for Carbon Structural

Steel

ASTM E 165 (2002) Standard Test Method for Liquid Penetrant

Examination

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 10 (2007) Near-White Blast Cleaning

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-P-24441 (Rev C; Supp 1; INT Am 1) Paint, Epoxy-Polyamide

MIL-S-45180 (Rev D; Notice 1; Notice 2) Sealing Compound, Gasket, Hydrocarbon Fluid and Water Resistant

U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)

EPA 600/4-79/020 (1983) Methods for Chemical Analysis of Water and Wastes

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS SS-S-210 (Rev A, Am 1) Sealing Compound, Preformed Plastic, for Expansion Joints and Pipe Joints

1.2 SYSTEM DESCRIPTION

SECTION 44 42 53 Page 2

1.2.1 Applications

The separator shall remove free oil and emulsified oil and suspended solids from oil-in-water mixtures of freshwater originating from operations. The influent oil-in-water mixture will flow by gravity to the unit which will not be located in an area with a corrosive atmosphere.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Accessory equipment; G

Submit shop drawings for separator and accessory equipment including principal dimensions, location of fittings and unit foundation. Include data to verify center of gravity with the unit empty and filled with water.

SD-05 Design Data

Accessory equipment; G

Submit analysis, signed by a registered professional engineer, which indicates that at the calculated overflow rate, the separator will be provided with the required square feet of projected plate separation area to achieve the specified performance under laminar flow (i.e. Reynolds number of less than 500) conditions.

Calculations shall take into account the rate of flow, potential surge flow, influent concentrations, particle characteristics, fluid temperature, fluid specific gravities, and pH.

SD-06 Test Reports

Shop hydrostatic test; G

Submit results of hydrostatic and dynamic testing.

Inspection

Field hydrostatic test

Preoperational test

In-service test

SD-07 Certificates

Separator corrosion protection; G

Submit written verification on the fabricator's letterhead that surface preparation and coating application were performed in

SECTION 44 42 53 Page 3 accordance with the manufacturer's printed recommendations for the coating system.

SD-08 Manufacturer's Instructions

Separator system; G

SD-10 Operation and Maintenance Data

Separator system, Data Package 3; G

Accessory equipment, Data Package 3; G

Submit in accordance with Section 01 78 23 OPERATION AND

MAINTENANCE DATA.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery and Storage

Inspect materials delivered to site for damage; unload and store with minimum handling. Store materials on-site in enclosures or under protective coverings. Protect materials not suitable for outdoor storage to prevent damage during periods of inclement weather, such as subfreezing temperatures, precipitation, and high winds. Store materials susceptible to deterioration by direct sunlight under cover and avoid damage due to high temperatures. Do not store materials directly on ground. If special precautions are required, prominently and legibly stencil instructions for such precautions on outside of equipment or its crating.

1.4.2 Handling

Handle separator in such a manner as to ensure delivery to final location in sound, undamaged condition. Take special care not to damage interior and exterior surfaces of separator, coalescing plates, and associated supports and pipe coatings or linings. Make satisfactory repairs to damaged materials at no cost to Government. Carry and do not drag materials.

PART 2 PRODUCTS

2.1 MATERIALS

Use 3/16 inch minimum thick carbon steel conforming to ASTM A 36/A 36M or material having equivalent structural properties and corrosion resistance for separator, hoppers, stationary and adjustable weirs, nozzles, flow distributor and energy dissipation device, bolts, seals, stiffeners, washers, separator cover and nuts. Weld in accordance with AWS D1.1/D1.1M to provide watertight separator that will not warp or deform under load.

Use welders qualified in accordance with AWS Standard Qualification Procedure. Grind welds smooth and remove weld spatter. Fabricate free of kinks and sharp bends in a manner not to reduce the strength of steel to a value less than that intended by the design. Size and shape of bends shall be uniform. Clean and finish carbon steel surfaces as described in paragraph entitled "Separator Corrosion Protection."

2.1.1 Separator Corrosion Protection

SECTION 44 42 53 Page 4

2.1.1.1 Steel Separator

After shop conducted hydrostatic tests have been successfully completed, provide a MIL-P-24441 coating system to the interior and exterior surfaces of the separator. Prior to shop painting, abrasive blast clean the surfaces in accordance with SSPC SP 10 to a surface profile of 1 to 2 1/2 mils.

Apply primer conforming to MIL-P-24441/1, Formula 150 applied to a minimum dry film thickness of 3 to 4 mils. Apply intermediate coat conforming to MIL-P-24441/2, Formula 151 applied to a minimum dry film thickness of 3 to 4 mils. Apply topcoat conforming to MIL-P-24441/3, Formula 152 applied to a minimum dry film thickness of 3 to 4 mils. Total dry film thickness shall not be less than 9 mils. Repair and replace areas of the coating system which are found to be damaged or defective upon delivery of equipment to the site or found to be defective due to work of the applicator. An interior polytetrafluoroethylene liner with a minimum thickness of 1/8 inch may be provided in lieu of paint coating the interior separator surfaces.

2.1.1.2 Other Than Steel Separator

After shop conducted hydrostatic tests and have been successfully completed, provide a coating system which will protect the separator from the oil-in-water mixture and in situ soil conditions specified herein.

2.1.1.3 Cathodic Protection

For below ground or partially above and partially below ground metal separators, provide cathodic protection with test stations as specified in Section 26 42 14.00 10 CATHODIC PROTECTION SYSTEM (SACRIFICIAL ANODE) and 26 42 17.00 10 CATHODIC PROTECTION SYSTEM (IMPRESSED CURRENT) in addition to the protective coating.

2.1.2 Substitutions

Separators constructed of reinforced fiberglass may be provided in lieu of carbon steel. Provide fiber glass separator with lifting straps. Glass fiber reinforced plastic weirs may be accepted as a suitable weir and baffle material provided that necessary requirements for anchorage of these items include provisions for contraction and expansion. Surfaces shall be seamless, chemically resistant to oil-in-water mixture, and resistant to ultraviolet deterioration.

2.1.3 External Surfaces

External surfaces and appurtenances shall be resistant to corrosion from the in situ soil, groundwater, and surface runoff.

2.1.4 Internal Surfaces

Parallel plate material and orientation shall enhance oil coalescence and solids removal, and be corrosion and chemically resistant to the oil-in-water mixture as specified in paragraph entitled "SYSTEM DESCRIPTION."

2.1.5 Hardware

Bolts, stiffeners, washers, nuts, screws, pins, and fittings as required shall be corrosion resistant. Provide materials that are inherently

SECTION 44 42 53 Page 5 corrosion resistant and not merely treated with a corrosion-resistant coating, such as provided by the galvanizing process.

2.1.6 Accessibility

Do not bury tops of separators. Make the entire top area of the separator visible from ground surface. Separators below grade with access manholes and extension tubes to the surface will not be permitted. Use separators with an open top or a completely removable cover. Use open top separators with removable grating unless otherwise shown. Use top cover and grating that is easily removable by two persons. As a minimum provide access hatches over the following areas: parallel plates, oil storage compartments, Influent sampling area, effluent sampling area, oil skimmer, and weirs.

Parts subject to wear or requiring adjustment, inspection, cleaning or repair shall be accessible and capable of convenient removal when required.

2.2 SEPARATION CHAMBER

Provide below ground separator to withstand hydraulic and soil loadings under static and dynamic conditions while empty and during operating conditions. Provide adequate support for additional loadings from separator appurtenances including weirs, hoppers, internal supports, parallel plate oil coalescers, equipment transportation, and rapid lowering and braking of load during handling operations. Bolt separator and accessories to weld-fabricated, structural steel skid base, or mount on manufacturer's standard base.

2.2.1 Lifting Mechanism

Fit separator with lifting pad eyes for handling and installation. Each pad eye shall carry the total dry weight of the separator and attendant appurtenances. Prominently display lifting instructions on anodized aluminum plate located on outside of separator.

2.2.2 Flanges

Use only flat face flanges and drill 150 pound ANSI Standard bolt circle and remove burrs. Use flanged piping connections that conform to ASME B16.5, welding neck type.

2.2.3 Weirs

Attach stationary weirs and adjustable weir supports to separator side walls to provide a watertight seal between adjoining compartments and trough to prevent hydraulic short-circuiting. Use carbon steel for weir plates and baffles. Provide sharp crested weirs of size and section specified by manufacture. Provide slotted holes in weir plates and baffles or supports to permit horizontal and vertical adjustment of weir or baffle. Use nondeteriorating sealant or gaskets for mounting weir plates. Fill voids between separator wall and weir plate with sealant to make watertight.

2.2.4 Low Point Drains

Provide means at low points for dewatering separator.

2.2.5 Identification Plates

SECTION 44 42 53 Page 6

Provide anodized aluminum identification and instruction plates and stamp necessary data. Securely affix plates, in prominent location, to separator with nonferrous screws or bolts of not less than 1/8 inch in diameter.

2.2.6 Instruction Plates

Instruction plates shall describe special or required procedures to operate and service equipment, and shall include warnings of hazardous procedures and notice of safety and health requirements. Plates shall be durable and legible throughout equipment life.

2.2.7 Warning Sign

On entrances to the separator (and entrances to the vault) place a permanent sign which states the following: "DO NOT ENTER separator (OR VAULT) OR PERFORM HOT WORK ON OR IN separator UNTIL THE ATMOSPHERE HAS BEEN TESTED AND

CERTIFIED GAS FREE AND SAFE."

2.3 INLET COMPARTMENT

Provide inlet compartment of sufficient volume to effectively reduce influent suspended solids and dissipate energy. Use inlet compartment that provides a minimum of 45 minutes detention ahead of the oil coalescing compartment. Provide nonclogging flow distributor and energy dissipation device. Locate adjustable, primary surface oil overflow weir and sample ports as recommended by the manufacturer.

2.4 OIL SEPARATION COMPARTMENT

2.4.1 General

The maximum surface loading rate for the oil separation compartment shall be per plans. The separator will also provide a minimum detention time within the oil separation compartment of 45 minutes at design flow. Detention time will recomputed by calculating the volume of the separation zone within the separator and dividing this volume by the design flow rate. For computing detention time, total volume shall be reduced by 20% for the space occupied by settled solids (sediment) and accumulated oil at the surface.

2.4.2 Parallel Plates

Provide parallel plates at an angle from 40 to 60 degrees with respect to longitudinal axis of the plate corrugations and space not less than 3/4 inch apart for removal of free oil and settleable solids. Configuration used shall not promote solids buildup on plates which would increase velocities to point of discharging an effluent of unacceptable quality. Maintain laminar flow at maximum design flow rate throughout plate packs including entrance and exit so as to prevent re-entrainment of oil(s) with water.

Flow through plate packs shall be in a downflow mode parallel to plate corrugations or cross-flow perpendicular to plate corrugations, so that the oil collects and coalesces at high point of corrugations and rises to top of pack without clogging from oil or settleable solids.

2.4.3 Supports

Brace and support individual plates or plate packs to withstand loads associated with transportation and operation of units, including in place

SECTION 44 42 53 Page 7 cleaning. Equip each plate pack with lifting lugs or other attachments for handling and installation. Each lug shall carry total weight of plate pack.

Provide adequate structural supports to facilitate in place cleaning of plate pack bundles.

2.4.4 Baffles

Provide oil retention baffle, adjustable surface oil overflow weir with trough, and stationary underflow baffle. Position underflow baffle to prevent resuspension of solids that have accumulated in secondary solids hopper.

2.5 OUTLET COMPARTMENT

Provide outlet compartment, an adjustable overflow effluent weir, a sampling port, and nozzles.

2.6 ACCESSORIES AND ACCESSORY EQUIPMENT

Provide bolts, stiffeners, washers, nuts, screws, pins, gaskets, and fittings as required for adjustable weirs, separator covers and parallel plate packs.

2.7 FABRICATION

Provide shop fabricated, skid mounted oil-water separator, or other shop fabricated unit approved by the Contracting Officer, which is comprised of a separator containing an inlet compartment, parallel plate oil coalescing compartment, outlet compartment.

2.7.1 Shop Hydrostatic Test

Prior to applying coatings, perform hydrostatic test at atmospheric pressure by filling separator with water in the shop for a minimum of 4 hours.

Testing shall be conducted after all seams have been cleaned and all welds have been inspected in accordance with ASTM E 165. Acceptance criteria, for the hydrostatic test, is no leakage after 4 hours using a thorough visual inspection for the leaks.

2.7.2 Reduction of Solids

Inlet compartment shall reduce suspended solids to nonclogging level for parallel plates and provide a uniform oily wastewater hydraulic loading across inlet face of oil coalescing compartment, under laminar flow conditions. Equip compartment with an inlet nozzle with wastewater sampling port, nonclogging flow distributor and energy dissipation device. The oil-water separator shall be preceded by a solid water basin which includes a removable solids or trash basket. Equip the solid water basin with a hoist for servicing the trash basket. Size the basket to retain all solids larger than 3 inches in any dimensions. The solid waste basin shall have a minimum storage volume of 250 gallons.

2.7.3 Oil Coalescing Compartment

Equip oil coalescing compartment with easily removable and reinstallable, parallel, corrugated plates arranged to optimize separation of free oil from liquid carrier. Use parallel plates that are easily removable without

SECTION 44 42 53 Page 8 dismantling packs and without confined space entry. Provide adjustable surface oil overflow weir with trough, oil outlet nozzle and stationary underflow baffle, oil retention baffle positioned to prevent discharge of free oil that has been separated from the carrier liquid in inlet and oil coalescing compartments. Provide access to each plate pack from top. Each bundle shall be equipped with handles or lifting rings. Plate designs that permit cleaning of plate packs in place are not acceptable.

2.7.4 Wastewater Sampling Port

Equip inlet and outlet compartments, adjustable overflow effluent weir, effluent trough, and wastewater outlet nozzle with wastewater sampling ports permitting easy access for obtaining isokinetic influent and effluent samples.

2.7.5 Connections

Connect the separator at the inlet and outlet pipe invert elevations indicated. Follow equipment manufacturer's recommendation for setting and adjusting top of weir elevations throughout unit.

2.7.6 Storage

Provide oil and suspended solids collection, storage, and transfer systems as an integral part of proposed oil-water separator system. As a minimum, the separator oil storage compartment shall have a capacity of not less than 10 percent of the total separator volume.

PART 3 EXECUTION

3.1 INSPECTION

Inspect each component of separator for compliance with requirements specified in PART 2 PRODUCTS. Redesign or modification of equipment to comply with specified requirements, or necessary redesign or modification following failure to meet specified requirements, shall receive particular attention for adequacy and suitability. This element of inspection shall encompass visual examinations and dimensional measurements. Noncompliance with specified requirements, or presence of one or more defects preventing or lessening maximum efficiency of separator operation, shall constitute cause for rejection.

3.2 INSTALLATION

Lift separator as required without parallel plate packs in place onto level foundation using lifting mechanism provided. Level separator and bolt to supports to prevent hydrostatic uplift and ensure unit stability. Use a lifting bar through lugs to insert plate packs into separator and place on supports. Caulk around packs and pack supports with sealing compound conforming to FS SS-S-210 or to MIL-S-45180 to prevent hydraulic short-circuiting. Avoid abrupt contact between the packs and the separator walls and pack supports to avoid damage. Separator system installation shall be conducted in accordance with manufacturer's recommendations.

3.3 FIELD QUALITY CONTROL

SECTION 44 42 53 Page 9

3.3.1 Field Hydrostatic Test

After separator has been leveled and secured to foundation and parallel plate packs are in place, level effluent overflow weir at elevation specified by manufacturer and hydrostatically test unit at atmospheric or operational pressure (for no leakage) for an additional 8 hours by filling with water. Perform the hydrostatic test prior to backfilling below ground or partially below ground installations.

3.3.2 Preoperational Test

The manufacturer's service representative shall inspect, operate, and test unit before in-service testing by the contractor.

3.3.2.1 Tests

Tests shall include but not be limited to the following:

a. Soundness (without cracked or otherwise damaged parts).

b. Completeness in all details, as specified.

c. Correctness of setting, alignment, and relative arrangement of each component.

d. Verification of proper operation for all system components.

3.3.2.2 Preoperational Investigation and Test Report

Submit manufacturer's service representative's preoperational test report.

Document inspections, operations, adjustments, and tests performed and indicate whether they were acceptable or not. For unacceptable items, describe corrective action taken or recommended. Include detailed descriptions of points inspected, tests and adjustments made, quantitative results obtained if such are specified, and suggestions for precautions to be taken to ensure proper maintenance. Include the manufacturer's certificate that equipment conforms to specified requirements and is ready for permanent operation and that nothing in installation will render manufacturer's warranty null and void.

3.3.3 In-Service Test

After hydrostatic test and preoperational test have been successfully completed and unit has been properly connected to influent and effluent piping, allow influent oil-in-water mixture previously described in paragraph entitled "SYSTEM DESCRIPTION" to flow into separator filled with water. Adjust and level primary and secondary surface oil overflow weirs to optimize oil skimming and minimize water overflow to oil recovery. Optimize operation of unit within 5 working days. Operate unit for a minimum of ten separator volume changes prior to testing for removal of contaminants and document testing results.

3.3.3.1 Analytical Methods

Test and sample preservation methods for test contaminants shall be in accordance with the latest revisions of AWWA 10084, APHA Standard Methods for the Examination of Water and Wastewater, EPA 600/4-79/020, EPA Methods

SECTION 44 42 53 Page 10 for Chemical Analysis of Water and Wastes, or those substitute methods approved by the governing regulatory agencies having jurisdiction.

3.3.3.2 Test for Contaminants

Verify the separator efficiency by testing influent and effluent for contaminants described in paragraph entitled "Performance Requirements." If effluent quality is found to be unacceptable, then verify influent to effluent performance in particle size removal at the site. Tests shall be performed by an independent certified testing laboratory.

3.3.3.3 Sampling Procedures

Within an 8 hour period and at regular intervals collect a minimum of 10 influent and effluent samples from sampling ports provided as part of the separator. Purge each sampling port to remove built-up solids or other material prior to collecting sample. Collect wastewater samples isokinetically in clean glass containers with polytetrafluoroethylene lined caps. Collect duplicate wastewater samples in separate glass containers.

Do not attempt to split sample. Use containers for other contaminants as recommended in references listed in paragraph entitled "Analytical Methods."

3.3.3.4 Acceptance Criteria

90 percent of the effluent samples taken shall not exceed the specified daily maximum limit for grease and oil and petroleum hydrocarbon contaminants. If the separator does not meet requirements of this specification, due to poor workmanship and wrong fabrication dimensions, the unit may be rejected. If the unit is not operating at design efficiency 5 days after installation, Government may reject system. In the event Government rejects unit, contractor shall remove separator or defective components and replace with acceptable unit or components and test as specified above.

-- End of Section --

SECTION 44 46 00 Page 1

JOINT BASE LEWIS-MCCHORD DESIGN STANDARDS

SECTION 44 46 00

PUMPS; SEWAGE AND SLUDGE

Design Requirements

a. All sewage lift stations on Joint Base Lewis-McChord shall be of a wetwell configuration. Submersible pump shall be capable of remote removal (on rails), shall have float controls and above-ground enclosed electrical control panel.

b. System shall be redundant (at least two pumps), 100% capacity.

Provide lockable hatch access to wetwell, audible and visual high level alarms.

c. Provide 2 inch water service to site with minimum 1 ½ inch washdown hose and nozzle.

d. Site shall be fenced, with lockable 12 foot gate (see Section 32 31

13) and driveway access.

e. Provide area lighting which illuminates lift station, valve box and control panel for night work.

SECTION 44 46 00

PUMPS; SEWAGE AND SLUDGE

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 11 (1990; R 1999) Load Ratings and Fatigue Life for

Roller Bearings

ABMA 9 (1990; R 2000) Load Ratings and Fatigue Life for Ball

Bearings

ASME INTERNATIONAL (ASME)

ASME B40.100 (2006) Pressure Gauges and Gauge Attachments

ASTM INTERNATIONAL (ASTM)

ASTM A 153/A 153M (2005) Standard Specification for Zinc Coating (Hot- Dip) on Iron and Steel Hardware

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2005; R 2008) Standard for Industrial

Control and Systems General Requirements

NEMA MG 1 (2007; Errata 2008) Standard for Motors and

Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

SECTION 44 46 00 Page 2

NFPA 70 (2007; AMD 1 2008) National Electrical Code - 2008

Edition

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Equipment Installation; G

Two complete hard copies and one electronic copy in Adobe Acrobat (.pdf) and AutoCAD (.dwg) format on CD or DVD of drawings containing complete wiring and schematic diagrams and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Show on the Drawings proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances for maintenance and operation.

SD-03 Product Data

Materials and Equipment Framed Instructions

Pump characteristic curves showing capacity in gpm, net positive suction head (NPSH), head, efficiency, and pumping horsepower from 0 gpm to 110 percent (100 percent for positive displacement pumps) of design capacity. A complete list of equipment and material, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Diagrams, instructions, and other sheets proposed for posting.

Spare Parts

Spare parts data for each different item of material and equipment specified.

General-purpose, single-speed, polyphase induction motors

Submit manufacturer documentation demonstrating that the included model meets the premium efficiency rating requirements in accordance with NEMA MG 1.

SD-06 Test Reports

Field Testing and Adjusting Equipment

Performance test reports in booklet form showing all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria, upon

SECTION 44 46 00 Page 3 completion and testing of the installed system. In each test report indicate the final position of controls.

SD-10 Operation and Maintenance Data

Operating and Maintenance Manuals; G

Two complete hard copies and one electronic copy in Adobe Acrobat (.pdf) format on CD or DVD of operation manuals and maintenance manuals for the equipment furnished. One complete set prior to performance testing and the remainder upon acceptance. Operation manuals shall detail the step-by-step procedures required for system startup, operation, and shutdown. Include in the operation manuals the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features.

List in the maintenance manuals routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides.

Maintenance manuals shall include piping and equipment layout and simplified wiring and control diagrams of the system as installed.

Manuals shall be approved prior to the field training course.

1.3 DELIVERY, STORAGE, AND HANDLING

Protect from the weather, excessive humidity and excessive temperature variation; and dirt, dust, or other contaminants all equipment delivered and placed in storage.

1.4 EXTRA MATERIALS

Submit spare parts data for each different item of material and equipment specified, after approval of the related submittals, and not later than 3 months prior to the date of beneficial occupancy. Include in the data a complete list of parts and supplies, with current unit prices and source of supply

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of such products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site. Pump casings shall be constructed of cast iron of uniform quality and free from blow holes, porosity, hard spots, shrinkage defects, cracks, and other injurious defects. Impellers shall be cast iron unless otherwise specified for rotors.

2.1.1 Nameplates

Provide each major item of equipment with the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment.

2.1.2 Equipment Guards

SECTION 44 46 00 Page 4

Enclose or guard belts, pulleys, chains, gears, projecting setscrews, keys, and other rotating parts so located that any person may come in close proximity thereto.

2.1.3 Special Tools

Provide one set of special tools, calibration devices, and instruments required for operation, calibration, and maintenance of the equipment.

2.1.4 Electric Motors

Motors shall conform to NEMA MG 1 General-purpose, single-speed, polyphase induction motors shall meet the premium efficiency rating requirements in accordance with NEMA MG 1 (the FEMP standard) unless as stated on the Task or Delivery Order allowing for an exception as defined in the Energy Policy Act of 2005, Section 104.

2.1.5 Motor Controls

Controls shall conform to NEMA ICS 1.

2.1.6 Bolts, Nuts, Anchors, and Washers

Bolts, nuts, anchors, and washers shall be steel; galvanized in accordance with ASTM A 153/A 153M.

2.1.7 Pressure Gauges

Compound gauges shall be provided on the suction side of pumps and standard pressure gauges on the discharge side of pumps. Gauges shall comply with ASME B40.100. Gauge ranges shall be as appropriate for the particular installation.

2.1.8 Seal Water Systems

Pumping systems requiring seal water shall utilize potable water. A package seal water system, consisting of a 50 gallon galvanized tank, float valve mounted directly on the tank, and 2 centrifugal pumps of equal capacity, with close coupled motors, shall be factory assembled and supplied as a single self-contained unit.

2.1.8.1 Float Valve

The float valve shall be mounted on the tank to maintain a water level below an overflow provided near the top of the tank and to maintain a 6 inch air gap between the water system and the top of the tank.

2.1.8.2 Auxiliary Equipment

Auxiliary equipment required to complete the system shall be as indicated and shall include the necessary piping, valving, pressure gauges, pressure regulators, pressure switches, solenoid valves, strainers, and accessories.

2.1.8.3 Controls

The solenoid valve shall open whenever the process pump motor is energized.

The pressure switch shall signal an alarm and stop the process pump whenever

SECTION 44 46 00 Page 5 the seal pressure is below a set point. The pressure regulating valve shall be located on a bypass line back to the seal water reservoir tank. The pressure switch and pressure regulating valve set points shall be determined by the process pump manufacturer. A valved bypass around each solenoid valve shall also be provided.

2.2 CENTRIFUGAL SOLIDS HANDLING PUMPS

Centrifugal solids handling pumps shall be of the nonclogging centrifugal type designed to pump solids up to 3 inches in diameter and which provide no internal interstices that catch solids and stringy materials to cause clogging.

2.2.1 Pump Characteristics

Pump number(s) shall have the operating characteristics per the Design Order.

2.2.2 Pump Casing

Pump casing shall be constructed with tapped and plugged holes for venting and draining the pump. The casing shall be capable of withstanding pressures 50 percent greater than the maximum operating pressure. The volute shall have smooth passages. The casing shall be such that the impeller can be removed without disturbing the suction and discharge connections. The casing shall have a handhole to permit inspection and cleaning of the pump interior. Lifting eyes shall be provided to facilitate handling of the pump.

2.2.3 Impeller

The impeller shall be designed with smooth passages to prevent clogging and pass stringy or fibrous materials. The impeller shall be statically, dynamically, and hydraulically balanced within the operating range and to the first critical speed at 150 percent of the maximum operating speed. The impeller shall be securely keyed to the shaft with a locking arrangement whereby the impeller cannot be loosened by torque from either forward or reverse direction.

2.2.4 Wearing Rings

Renewable wearing rings shall be provided on the impeller and casing and shall have wearing surfaces normal to the axis of rotation. Wearing rings shall be constructed of steel. Wearing rings shall be designed for ease of maintenance and shall be secured to prevent rotation. Replaceable steel wear plates fastened to casing may be used in lieu of wearing rings on casing and impeller.

2.2.5 Pump Shaft

Pump shaft shall be of stainless or high grade alloy steel and shall be of adequate size and strength to transmit the full driver horsepower with a liberal safety factor.

2.2.6 Pump Shaft Sleeve

SECTION 44 46 00 Page 6

The pump shaft shall be protected from wear by a stainless steel, high grade alloy steel, or bronze shaft sleeve. The joint between the shaft and sleeve shall be sealed to prevent leakage.

2.2.7 Stuffing Box

The stuffing box shall be of the same material as the casing and shall be grease or water sealed. The stuffing box shall be designed for a minimum of five rings of packing and shall have easily removable split type glands.

2.2.8 Mechanical Seals

Double mechanical seals shall be provided to seal the pump shaft against leakage. Each seal interface shall be held in contact by its own spring system, supplemented by external liquid pressures. The seal system shall be constructed to be readily removable from the shaft.

2.2.9 Bearings

Pump bearings shall be ball or roller type designed to handle all thrust loads in either direction. Pumps depending only on hydraulic balance end thrust will not be acceptable. Bearings shall have an ABEMA L-10 life of 50,000 hours minimum, as specified in ABMA 9 or ABMA 11.

2.2.10 Lubrication

Bearings shall be oil bath or grease lubricated. An oil reservoir shall be provided for oil bath lubricated bearings. The reservoir shall have an overflow opening to prevent overfilling and shall have a drain at the lowest point. A grease fitting shall be provided for grease-lubricated bearings.

The grease fitting shall be of the type that prevents overlubrication and the building up of pressure injurious to the bearings. If the grease fitting is not easily accessible, grease tubing shall be provided to a convenient location.

2.2.11 Pump Support

Horizontal centrifugal pumps shall be provided with a common base plate for the pump and motor. Vertical shaft centrifugal pumps shall be provided with separate bases for the pump and motor. Vertical dry pit centrifugal pumps shall be supported by a heavy cast iron base with adequate legs to provide maximum rigidity and balance.

2.2.12 Coupling

Couplings shall be of the heavy-duty flexible type, keyed or locked to the shaft. Disconnecting of the coupling shall be possible without removing the driver half or the pump half of the coupling from the shaft. Couplings for extended shaft vertical centrifugal pumps may be of the universal type.

2.3 SUBMERSIBLE CENTRIFUGAL PUMPS

Submersible centrifugal pumps shall be centrifugal type pumps designed to pump solids up to 3 inches in diameter and shall be capable of withstanding submergence as required for the particular installation.

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2.3.1 Pump Characteristics

Pump number(s) shall have operating characteristics per the Design Order.

2.3.2 Pump Casing

The casing shall be capable of withstanding operating pressures 50 percent greater than the maximum operating pressures. The volute shall have smooth passages which provide unobstructed flow through the pump.

2.3.3 Mating Surfaces

Mating surfaces where watertight seal is required, including seal between discharge connection elbow and pump, shall be machined and fitted with nitrile rubber O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between mating surfaces, resulting in proper compression of the O-rings without the requirement of specific torque limits.

2.3.4 Coatings

Exterior surfaces of the casing in contact with sewage shall be protected by a sewage resistant coal tar epoxy coating. All exposed nuts and bolts shall be stainless steel.

2.3.5 Impeller

The impeller shall be of the single shrouded non-clogging design to minimize clogging of solids, fibrous materials, heavy sludge, or other materials found in sewage. The impeller shall be statically, dynamically, and hydraulically balanced within the operating range and to the first critical speed at 150 percent of the maximum operating speed. The impeller shall be securely keyed to the shaft with a locking arrangement whereby the impeller cannot be loosened by torque from either forward or reverse direction.

2.3.6 Wearing Rings

Wearing rings, when required, shall be renewable type and shall be provided on the impeller and casing and shall have wearing surfaces normal to the axis of rotation. Material for wear rings shall be standard of pump manufacturer. Wearing rings shall be designed for ease of maintenance and shall be adequately secured to prevent rotation.

2.3.7 Pump Shaft

The pump shaft shall be of high grade alloy steel and shall be of adequate size and strength to transmit the full driver horsepower with a liberal safety factor.

2.3.8 Seals

A tandem mechanical shaft seal system running in an oil bath shall be provided. Seals shall be of tungsten carbide with each interface held in contact by its own spring system. Conventional mechanical seals which require a constant pressure differential to effect sealing will not be allowed.

SECTION 44 46 00 Page 8

2.3.9 Bearings

Pump bearings shall be ball or roller type designed to handle all thrust loads in either direction. Pumps depending only on hydraulic balance end thrust will not be acceptable. Bearings shall have an ABEMA L-10 life of 50,000 hours minimum, as specified in ABMA 9 or ABMA 11.

2.3.10 Motor

The pump motor shall have Class F insulation, NEMA B design, in accordance with NEMA MG 1, and shall be watertight. The motor shall be either oil filled, air filled with a water jacket, or air filled with cooling fins which encircles the stator housing.

2.3.11 Power Cable

The power cable shall comply with NFPA 70, Type SO, and shall be of standard construction for submersible pump applications. The power cable shall enter the pump through a heavy duty entry assembly provided with an internal grommet assembly to prevent leakage. The cable entry junction chamber and motor shall be separated by a stator lead sealing gland or terminal board which shall isolate the motor interior from foreign material gaining access through the pump top.

2.3.12 Installation Systems

2.3.12.1 Rail Mounted Systems

Rail mounted installation systems shall consist of guide rails, a sliding bracket, and a discharge connection elbow. Guide rails shall be of the size and type standard with the manufacturer and shall not support any portion of the weight of the pump. The sliding guide bracket shall be an integral part of the pump unit. The discharge connection elbow shall be permanently installed in the wet well along with the discharge piping. The pump shall be automatically connected to the discharge connection elbow when lowered into place and shall be easily removed for inspection and service without entering the pump well.

2.3.12.2 Bolt Down Systems

The pump mount system shall include a base designed to support the weight of the pump. The base shall be capable of withstanding all stresses imposed upon it by vibration, shock, and direct and eccentric loads.

2.4 SELF-PRIMING CENTRIFUGAL PUMPS

Self-priming centrifugal pumps shall be designed to pump solids up to 3 inches in diameter and shall be of the centrifugal type capable of repeated reprime when handling trash-laden sewage.

2.4.1 Pump Characteristics

Pump number(s) shall have operating characteristics per the Design Order.

2.4.2 Pump Casing

SECTION 44 46 00 Page 9

The casing shall be capable of withstanding pressures 50 percent greater than the maximum operating pressures. The pump casing shall contain no openings of smaller diameter than the specified sphere size. There shall be no internal devices that will inhibit maintenance or interfere with priming and performance. The pump shall be designed to retain sufficient liquid in the casing to ensure unattended operation. The casing shall be such that the impeller can be removed without disturbing the suction and discharge connections. Front access shall be provided to the pump interior to permit inspection and cleaning of the pump interior without removing suction or discharge piping.

2.4.3 Impeller

The impeller shall be of the two-vane, semi-open, non-clog type with pump-out vanes cast integrally on its backside. The impeller shall be statically, dynamically, and hydraulically balanced within the operating range and to the first critical speed at 150 percent of the maximum operating speed. The impeller shall be securely keyed to the shaft with a locking arrangement whereby the impeller cannot be loosened by torque from either forward or reverse direction.

2.4.4 Wear Plate

A replaceable wear plate constructed of alloy steel shall be provided.

2.4.5 Pump Shaft

Pump shaft shall be of high grade alloy steel or stainless steel and shall be of adequate size and strength to transmit the full driver horsepower with a liberal safety factor.

2.4.6 Pump Shaft Sleeve

The pump shaft shall be protected from wear by a high grade alloy steel or stainless steel shaft sleeve. A seal, if needed, shall be placed between the shaft and sleeve to prevent leakage.

2.4.7 Seals

The pump shaft shall be sealed against leakage by oil lubricated mechanical seal. The stationary sealing member shall be tungsten carbide and the rotating member shall be tungsten carbide. The seal shall be such that the faces will not lose alignment during shock loads that cause deflection, vibration, and axial or radial movement of the pump shaft.

2.4.8 Bearings

Pump bearings shall be ball or roller type designed to handle all thrust loads in either direction.

2.4.9 Lubrication

Bearings shall be oil bath or grease lubricated. An oil reservoir for oil bath lubricated bearings shall be provided. The reservoir shall have an overflow opening to prevent overfilling and shall have a drain at the lowest point. A grease fitting shall be provided to add grease for grease-lubricated bearings. The grease fitting shall be of the type that prevents

SECTION 44 46 00 Page 10 overlubrication and the building up of pressure injurious to the bearings.

If the grease fitting is not easily accessible, grease tubing to a convenient location shall be provided.

2.4.10 Suction Check Valve

The pump shall contain a suction check valve to maintain prime. The suction check valve shall be removable without disturbing the suction piping. The pump shall be capable of prime or reprime in the event of check valve failure.

2.4.11 Pump Support

A common fabricated steel base plate shall be provided for the pump and motor.

2.4.12 Coupling

Power shall be transmitted from the motor to the pump by a flexible coupling. Flexible couplings shall be of the heavy duty type, keyed or locked to the shaft. The drive shall be enclosed on all sides by a solid metal guard.

2.5 SCREW PUMPS

Screw pumps shall have a spiral flight screw operating in a concrete trough with the screw rotation elevating the liquid up the inclined trough. The pump shall consist of a lower bearing assembly, a spiral screw with deflectors, an upper bearing assembly, a drive assembly, and an automatic grease lubricated system for the lower bearing.

2.5.1 Pump Characteristics

Pumps shall have characteristics per the Design Order.

2.5.2 Lower Bearing Assembly

The lower bearing assembly shall be sleeve or roller bearing type design.

If sleeve bearing is utilized, either the bronze phosphor sleeve shall rotate around stationary shaft or shaft shall be attached to bronze bushing which rotates inside stationary cartridge. Sleeve bearing shall be hermetically sealed, automatic grease lubricated. Roller bearings shall be oil lubricated and designed to guard against oil leakage. Labyrinth arrangement shall protect fire seal from damage. Bearings shall have L-10 life of 100,000 hours. The bearing housing shall permit precise adjustment in the field. A spare lower bearing assembly shall be provided.

2.5.2.1 Seals

Contaminants shall be prevented from entering the bearing by two spring-loaded lipseals, one to exclude wastewater and contaminants and one to retain the grease in the bearing, or by a fixed journal with hollow axis to allow grease to the top end of the bearing where it flows the length of the bearing sealing out contaminants.

2.5.2.2 Bearing Shield

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A heavy-duty bearing shield shall be provided to protect the bearing assembly from heavy debris.

2.5.3 Spiral Screw

The spiral screw shall consist of a steel torque tube with steel flights welded to the exterior of the tube, a drive shaft, and lower stub shaft.

2.5.3.1 Torque Tube

The torque tube shall be sealed at both ends with welded steel plates. Care shall be taken to insure that the end plates are parallel after welding.

The flights shall be continuously welded to the tube on both sides. The drive shaft and lower stub shaft shall be bolted to the torque tube ends with a registered fit to ensure axial alignment of the tube and shafting.

2.5.3.2 Shafts

The upper and lower shafts and the outside diameter of the flights of the completed spiral screw shall have the same axis. The maximum deflection at midspan shall not exceed 5/32 inch when calculated as a uniformly loaded horizontal simple beam supported between the upper and lower bearings. The completed spiral screw shall be statically balanced.

2.5.4 Flow Defector Plates

Flow deflector plates shall be provided for installation in the pump trough along the uptake side of the spiral screw for the full length of the spiral.

The deflector plates shall be concave to effect an extension of the circular arch of the trough to at least the height of the top surface of the torque tube. The deflector plates shall be fabricated from not less than 1/8 inch thick steel plate and shall be complete with stiffeners and anchors where required.

2.5.5 Upper Bearing Assembly

The upper bearing assembly shall consist of an upper bearing housing, bearing, seals, mounting, and cover.

2.5.5.1 Housing

The upper bearing housing shall be cast iron and shall have grease fittings on the exterior of the housing for periodic manual lubrication.

2.5.5.2 Bearing

The upper bearing shall have an ABEMA L-10 life of 50,000 hours minimum, as specified in ABMA 9 or ABMA 11, and shall be one of the following: a dual bearing consisting of a spherical roller thrust type bearing for pump thrust loads and a spherical roller bearing for radial loads; or a single combination radial and thrust, self-aligning, spherical roller bearing.

2.5.5.3 Seals

Two seals shall be provided for protection of the upper bearings. One seal shall be attached to the extended shaft of the spiral screw to prevent

SECTION 44 46 00 Page 12 contamination from entering the bearing top side. The other seal shall be on the bottom side to retain the grease within the bearing.

2.5.5.4 Mounting Plate

A fabricated steel mounting plate and anchor bolts shall be provided for mounting the upper bearing assembly.

2.5.5.5 Cover

A fabricated steel cover shall be provided to close the opening in the wall for the spiral shaft.

2.5.6 Drive Assembly

The drive assembly shall consist of a motor, gear reducer, and backstop.

2.5.6.1 Gear Reducer

The gear reducer shall have the torque rating for the spiral speed based upon continuous operation with a uniform load. The gear reducer shall have an outer cast iron housing, totally enclosed and rigidly constructed to maintain precise alignment of the gears and bearings. Gears and bearings shall be splash lubricated or, if necessary, pressure lubricated to ensure oil is provided to all gears and bearings. Shaft-mounted gear reducers shall be positively secured to the screw shaft and shall have a torque arm anchored to the floor. Double lip oil seals shall be provided on the shaft.

Non-shaft-mounted gear reducers shall be provided with an adjustable base and shall be connected to the screw shaft by a flexible coupling.

2.5.6.2 Backstop

A backstop shall be provided to prevent the reverse rotation of the spiral screw and drive assembly when the power to the motor is disconnected.

2.5.6.3 Drive

The gear reducer shall be connected to the drive motor by means of belts and sheaves designed with the same service factor as the gear reducer. A safety cover shall be provided for the belt drive.

2.5.7 Lubrication System

An automatic grease lubricator with grease pump and reservoir shall be provided to continuously grease the lower bearing when the pump is operating. The grease pump shall be interlocked with the screw pump motor to prevent the screw pump from operating if the lubricator malfunctions. A visual or automatic indicator shall be provided to confirm that the lower bearing is receiving grease from the lubrication system.

2.5.8 Radius Screed

Provide a radius screed and any additional sheaves and belts as necessary to adjust screw speed to enable the installation of the grout in the trough with the screw installed.

SECTION 44 46 00 Page 13

2.6 PLUNGER PUMPS

Plunger pumps…