43 21 13.pdf

SABER Solicitation FA2517-08-R-5002

43 21 13-1 05/08/09

SECTION 43 21 13

PUMPS: WATER, CENTRIFUGAL

PART 1 GENERAL

1.1 REFERENCES

1.1.1 The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. Unless other wise noted, the latest published version and/or revision shall be used.

1.1.1.1 ASME INTERNATIONAL (ASME)

a. ASME B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

b. ASME B16.1 Standard for Gray Iron Threaded Fittings; Classes 125 and 250

c. ASME B16.5 Standard for Pipe Flanges and Flanged Fittings: NPS 1/2

Through NPS 24

d. ASME B40.100 Pressure Gauges and Gauge Attachments

1.1.1.2 ASSOCIATION FOR IRON AND STEEL TECHNOLOGY (AIST)

a. AIST PB-224 Stainless Steels

1.1.1.3 ASTM INTERNATIONAL (ASTM)

a. ASTM A 123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

b. ASTM A 153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and

Steel Hardware

c. ASTM A 307 Standard Specification for Carbon Steel Bolts and Studs, 60 000

PSI Tensile Strength

d. ASTM D 975 Standard Specification for Diesel Fuel Oils

e. ASTM F 593 Stainless Steel Bolts, Hex Cap Screws, and Studs

1.1.1.4 HYDRAULIC INSTITUTE (HI)

a. HI 1.1-1.2 Centrifugal Pump Nomenclature

1.1.1.5 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA MG 1 Standard for Motors and Generators

1.1.1.6 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 20 Installation of Stationary Pumps for Fire Protection

b. NFPA 30 Flammable and Combustible Liquids Code

c. NFPA 37 Installation and Use of Stationary Combustion Engines and Gas

Turbines

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d. NFPA 70 National Electrical Code - 2008 Edition

1.1.1.7 THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

a. SSPC Paint 21 Paint Specification No. 21 White or Colored Silicone Alkyd

Paint (Type I, High Gloss and Type II, Medium Gloss)

b. SSPC Paint 25 Paint Specification No. 25 Zinc Oxide, Alkyd, Linseed Oil

Primer for Use Over Hand Cleaned Steel Type I and Type II

1.1.1.8 U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

a. 47 CFR 15 Radio Frequency Devices

1.1.1.9 UNDERWRITERS LABORATORIES (UL)

a. UL 448 Pumps for Fire-Protection Service

1.2 SYSTEM DESCRIPTIONS

1.2.1 Selection Criteria

1.2.1.1 Design pumps using hydraulic criteria based upon actual model developmental test data. Select pumps at a point within the maximum efficiency for a given impeller casing combination.

Deviations within 3 percent of maximum efficiency are permissible, provided the lesser efficiency is not less than the scheduled efficiency. Pumps having impeller diameters larger than 90 percent of the published maximum diameter of the casing or less than 15 percent larger than the published minimum diameter of the casing will be rejected. Acceptable maximum impeller diameter calculations shall not be based on percentage of impeller diameter range for a given casing.

1.2.2 Conformance With Agency Requirements

1.2.2.1 Where materials or equipment are specified to be an approved type, the seal or label of approval from a nationally recognized testing agency, adequately equipped and competent to perform such services, shall be attached thereto. A written certificate from the testing agency shall accompany the materials or equipment and shall be submitted to the Contracting Officer stating that the items have been tested and that they conform to the applicable requirements of the specifications and to the standards listed herein. The certificate shall indicate the methods of testing used by the testing agency. In lieu of a certificate from a testing agency, published catalog specification data, accompanied by the manufacturer's certified statement to the effect that the items are in accordance with the applicable requirements of the specifications and the referenced standards, will be considered by the Contracting Officer and may be acceptable as evidence that the items conform with agency requirements.

1.2.3 Governing Requirements

1.2.3.1 Fire pumps and appurtenances shall conform in all respects to NFPA 20.

1.2.4 Safety Requirements

1.2.4.1 Fully enclose or properly guard gears, couplings, projecting set-screws, keys, and other rotating parts, so located that any person can come in close proximity thereto.

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1.3 SUBMITTALS

1.3.1 Government approval may be required on any of the following items. Items requiring submittals will be listed on the Submittal Register. Provide copies of all submittals per the requirements in

Section 01 33 00, Submittal Procedures, or as listed on the Submittal Register.

1.3.1.1 SD-02 Shop Drawings

a. Installation

(1) 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. Provide a complete listing of equipment and materials.

1.3.1.2 SD-03 Product Data

a. Materials and Equipment

(1) Manufacturer's descriptive data and technical literature, performance charts and curves for all impeller sizes for a given casing, catalog cuts, and installation instructions. Spare parts data for each different item of material and equipment specified, after approval of the detail drawings. Data shall include a complete list of parts and supplies, with current unit prices and source of supply.

b. Instructions

(1) Proposed diagrams, instructions, and other sheets, prior to posting. Approved wiring and control diagrams showing the complete layout of the entire system, including equipment, piping valves, and control sequence, framed under glass or in approved laminated plastic, shall be posted where directed. Condensed operating instructions explaining preventive maintenance procedures, methods of checking the system for normal safe operation, and procedures for safely starting and stopping the system shall be prepared in typed form, framed as specified above for the wiring and control diagrams, and posted beside the diagrams. The framed instructions shall be posted before acceptance testing of the systems.

c. Training Period

(1) Training course curriculum and training instructions shall be furnished to the Contracting

Officer 14 days prior to the start of training.

1.3.1.3 SD-06 Test Reports

a. Field Tests

(1) 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 completion and testing of the installed system. Each test report shall indicate the final position of controls.

1.3.1.4 SD-07 Certificates

a. Manufacturer's Representative

(1) The names and qualifications of the manufacturer's representative and training engineers

43 21 13-4 05/08/09 and written certification from the manufacturer that the representative and trainers are technically qualified.

1.3.1.5 SD-10 Operation and Maintenance Data

a. Operation and Maintenance Manuals

(1) Complete sets of instructions containing the manufacturer's operating and maintenance instructions for each piece of equipment. One complete set at the time the tests procedure is submitted; remaining sets before the contract is completed. Each set shall be permanently bound and shall have a hard cover. The following identification shall be inscribed on the covers: the words "OPERATING AND MAINTENANCE

INSTRUCTIONS," name and location of the building, name of the Contractor, and contract number. Flysheets shall be placed before instructions covering each subject.

Instruction sheets shall be approximately 8-1/2 by 11 inches, with large sheets of drawings folded in. Instructions shall include, but not be limited to, the following:

(a) System layout showing piping, valves, and controls.

(b) Approved wiring and control diagrams.

(c) A control sequence describing startup, operation, and shutdown.

(d) Operating and maintenance instructions for each piece of equipment, including lubrication instructions and troubleshooting guide.

(e) Manufacturer's bulletins, cuts, and descriptive data; and parts list and recommended spare parts.

1.4 QUALITY ASSURANCE

1.4.1 Provide the services of a manufacturer's representative experienced in the installation, adjustment, and operation of the equipment specified. The representative shall supervise the installation, adjustment, and testing of the equipment. Up to 7 days service shall be provided at no expense to the Government.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Protect all equipment, delivered and designated for storage, from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Provide materials and equipment which are as specified below, as shown, and are suitable for the service intended. Provide materials and equipment which are new and unused, except for tests.

Where two or more pieces of equipment performing the same function are required, they shall be duplicate products of the same manufacturer.

2.1.2 Standard Products

2.1.2.1 Provide material and equipment which are the standard products of a manufacturer regularly

43 21 13-5 05/08/09 engaged in the manufacture of such products and that essentially duplicate equipment that has been in satisfactory waterworks operation 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 jobsite. Pumps and motors and engines of the same types shall each be the product of one manufacturer.

2.1.3 Description

2.1.3.1 The pumps shall be horizontal or vertical centrifugal water pumps of the types indicated and specified. The single and dual driving units as indicated for the pumps shall be electric motors, gasoline engines or diesel engines as indicated and specified. On dual drive units, each type of drive shall be equipped with an approved free-wheeling clutch.

2.1.4 Nameplates

2.1.4.1 Pumps and motors shall have a standard nameplate securely affixed in a conspicuous place showing the manufacturer's name, address, type or style, model, serial number, and catalog number. In addition, the nameplate for each pump shall show the capacity in gpm at rated speed in rpm and head in feet of water. Nameplate for each electric motor shall show at least the minimum information required by 10.38 NEMA MG 1. Nameplate for each gasoline and diesel engine shall show the horsepower and the speed in rpm to produce rated output from the pump. Such other information as the manufacturer may consider necessary to complete identification shall be shown on the nameplate.

2.2 CENTRIFUGAL WATER PUMPS

2.2.1 The pumps shall be the centrifugal, single-stage or multi-stage type as indicated, designed for waterworks service in the following configurations as noted on the drawings:

Pump No.

Horizontal _____

Vertical _____

2.2.2 Pump Service

2.2.2.1 The pumps shall be utilized for the following service as noted on the drawings:

Fire Pump _____

Water treatment plant pump _____

Elevated storage pump _____

Line pressure booster pump _____

2.2.3 Pump Drives

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2.2.3.1 The pumps shall have the following driving units as noted on the drawings and shall be directly connected to the driving units through solid shafts, flexible couplings, or free wheeling clutches

(as appropriate):

Electric motor drive _____

Gasoline engine drive _____

Diesel engine drive _____

Combination electric motor and gasoline or diesel engine drive _____

Variable speed drive _____

2.2.4 Pump Construction

2.2.4.1 Except as below specified, centrifugal water pumps including required priming equipment shall be constructed in accordance with the Hydraulic Institute HI 1.1-1.2. Additionally, fire pumps shall be constructed in accordance with NFPA 20 and UL 448.

2.2.5 Pump Characteristics

2.2.5.1 The pumps shall be capable of discharging quantities at total discharge heads measured at the discharge flange, between the following limits as noted on the drawings.

Pump Discharge No. gpm @ total discharge gpm @ total head, ft. H(2)O head, ft. H(2)O

______________ and _______________ ____________

______________ and _______________ ____________

______________ and _______________ ____________

2.2.5.2 Pumps shall operate at optimum efficiencies to produce the most economical pumping system under the conditions encountered and shall be sized to make optimum match with the system head curve as shown. Pumps shall furnish not less than 150 percent of rated capacity at a total discharge head of not less than 65 percent of total rated head. The shutoff total head shall be not greater than 120 percent of total rated head.

2.2.6 Pump Casings

2.2.6.1 Pump casings shall be cast iron design as noted on the drawings:

Horizontal shaft, horizontal split casing _____

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Horizontal shaft, vertical split casing _____

Vertical shaft, dry pit _____

Vertical shaft, wet pit _____

2.2.6.2 The casings shall be designed to permit replacement of wearing parts. Horizontal-split casings shall have the suction and discharge nozzles cast integrally with the lower half, so that the upper part of the casings may be removed for inspection of the rotating parts without disturbing pipe connections or pump alignment. Pump casings shall be of uniform quality and free from blowholes, porosity, hard spots, shrinkage defects, cracks and other injurious defects. Defects in casings shall not be repaired except when such work is approved and is done by or under the supervision of the pump manufacturer, and then only when the defects are small and do not adversely affect the strength or use of the casing. Casings shall be single or double volute with flanged piping connections conforming to ASME B16.1, Class 125. The direction of shaft rotation shall be conspicuously indicated. The casing shall have tapped openings for air venting, priming, draining, and suction and discharge gauges. A brass or bronze umbrella or vent cock shall be furnished for venting except where automatic air vents are indicated. Drain openings in the volute, intake, or other passages capable of retaining trapped water shall be located in the low point of such passages.

2.2.7 Impellers

2.2.7.1 Impellers shall be of enclosed design and shall be constructed of bronze, carefully finished with smooth water passageways, and shall be statically and dynamically balanced. Impellers shall be securely keyed to the pump shaft. Provisions shall be made for vertical impeller adjustment at the top of the motor. Impellers on vertical-split pumps shall be additionally secured with a self-locking nut.

2.2.8 Wearing Rings

2.2.8.1 Wearing rings of bronze shall be provided for impellers. Wearing rings of a different composition or of a suitable ferrous material shall be provided for pump casings. Casing rings shall be securely fixed in position to prevent rotation. Rings shall be renewable and designed to ensure ease of maintenance.

2.2.9 Shaft

2.2.9.1 Shaft shall be of high grade steel, accurately machined, and shall be of sufficient size and strength to perform the work required. Vertical shafts shall be the open or closed type and shall be adequately provided with alignment bearings. Bronze renewable shaft sleeves shall be provided for protection of the shaft in contact with water, and in the stuffing boxes. Shaft sleeves shall be keyed to the pump shaft.

2.2.10 Packing Seals

2.2.10.1 Packing shall be non-asbestos. Pump shall be shipped to the site without the packing inserted and shall be packed onsite in the presence of the pump or packing manufacturer's representative. At no time during startup or run-in shall the gland drip less water than 80 drops

43 21 13-8 05/08/09 per minute. After not less than 40 operating hours and upon permission of the Contracting

Officer, leakage rate may be reduced to 50 drops per minute or to the rate recommended by packing manufacturer.

2.2.10.2 Gland

a. Gland shall be split-bronze type with ASTM F 593 stainless steel eyebolts and pins or studs.

Hex-nuts shall be bronze or nongalling stainless steel.

2.2.10.3 Stuffing boxes

a. Stuffing boxes exposed to below atmospheric pressure at any operating condition, including starting, shall be provided with a water seal. Water seal shall consist of nonferrous lantern ring or a seal cage and required connections to the pump case.

2.2.11 Mechanical Seals

2.2.11.1 Mechanical seals shall be balanced or unbalanced, as necessary to conform to specified service requirements. Mechanical seals shall be constructed in a manner and of materials particularly suitable for the temperature service range and quality of water being pumped. Seal construction shall not require external source cooling for pumped-fluid service temperatures up to 250 degrees F. Seal pressure rating shall be suitable for maximum system hydraulic conditions. Materials of construction shall include AIST PB-224 series stainless steel, solid tungsten-carbide rotating-seal face, and Buna-N vinylidene-fluoride-hexafluoropropylene, EPT, or tetrafluoroethylene seals. Bypass flushing water supply shall be free of iron rust products and other abrasive materials and shall be directed onto face of seal without dead ending. All piping and accessories shall be provided. Throttling bushing shall have clearances to minimize leakage in case of complete seal failure without restriction of flushing water. Mechanical seals shall not be subjected to hydrostatic test pressures in excess of the manufacturer's recommendations.

2.2.12 Couplings

2.2.12.1 Couplings shall be of the heavy-duty flexible type, keyed and locked to the shaft. The outside surface of the couplings for horizontal pumps and close-coupled vertical pumps shall be machined parallel to the axis of the shaft. The faces of the couplings shall be machined perpendicular to the axis of the shaft. Disconnecting the couplings shall be accomplished without removing the driver half or the pump half of the couplings from the shaft. Couplings for vertical pumps other than close-coupled vertical pumps may be of the universal type.

Flexible couplings shall not be used to compensate for misalignment of pump.

2.2.13 Balance

2.2.13.1 All rotating parts of the equipment shall operate throughout the required range without excessive end thrust, vibration, or noise. Defects of this type that cannot be eliminated by installation adjustments will be sufficient cause for rejection of the equipment. Pump impeller assemblies shall be statically and dynamically balanced to within 1/2 percent of W times R squared, where W equals weight and R equals impeller radius. Shaft construction shall be substantial to prevent seal or bearing failure due to vibration. Total shaft peak-to-peak dynamic deflection measured by vibrometer at pump-seal face shall not exceed 2.0 mils under shutoff-head operating conditions. Flow from 1/4 inch iron pipe size (ips) pipe shall be provided during testing.

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2.2.14 Bearings

2.2.14.1 Bearings shall be ball or roller type, and the main bearings shall take all radial and end thrust.

Pumps that depend only on hydraulic balance to overcome end thrust will not be acceptable.

2.2.15 Lubrication

2.2.15.1 Bearings on horizontal-shaft pumps shall be either oil-bath type or grease type. Each oil reservoir shall be liberal in size and provided with an opening for filling, an overflow opening at the proper location to prevent overfilling, an oil-level sight glass, and a drain at the lowest point. Bearings on vertical shaft wet-pit pumps shall be either oil or water type. Pumps with oil-lubrication systems shall be designed so that all shaft bearings will be isolated from the pumped liquid. An automatic sight feed oiler shall be provided on a suitable mounting bracket with connection to the shaft tube. Bearings on vertical-shaft dry-pit pumps shall be grease type.

Grease type bearings shall be provided with fittings for a grease gun and, if the bearings are not easily accessible, with grease tubing extending to convenient locations. The grease fittings shall be of a type that prevent over lubrication and the buildup of pressure injurious to the bearings.

2.2.16 Base Plates

2.2.16.1 Horizontal-shaft centrifugal pumps shall be provided with a common base for mounting each pump and driving unit of the pump on the same base. Each base shall be constructed of cast iron with a raised lip tapped for drainage, or of welded steel shapes with suitable drainage pan.

Horizontal-shaft end suction pumps shall be mounted on a factory furnished channel steel frame. With the exception of close-coupled pumps, horizontal-shaft end suction pumps shall be frame mounted. Vertical-shaft pumps shall be provided with complete mounting suitable for the type of pump furnished, with the base for the pump separate from the base of the driving unit.

The drainage structure shall collect the packing box leakage and shall have a 1/2 inch NPT connection to connect it to a drain.

2.2.17 Cocks, Plugs, and Accessories

2.2.17.1 The pumps shall be equipped with air cocks, drain plugs, and duplex gauges indicating discharge pressures for all pumps and suction pressures for pumps without suction lift. Gauges, equipped with a shutoff cock and snubber, shall conform to ASME B40.100, and shall be calibrated in psi and feet of water in not more than 2 psi and 5 foot increments. Gauge ranges shall be appropriate for the particular installation. Normal operating suction and discharge pressures of the pump shall be indicated on the mid-point range of the gauges. Pressure relief valve shall be furnished and installed where indicated. Suction lift pipe shall be provided with a foot valve as shown, capable of preventing loss of prime when the pump rotation is stopped.

2.2.18 Piping Connections

2.2.18.1 The pump suction and discharge shall be provided with flanged connections of suitable size and suitably arranged for piping shown. Pipe flanges shall conform to ASME B16.1 and ASME

B16.5. Piping shall be installed to preclude the formation of air pockets.

2.2.19 Finish

2.2.19.1 Pump shall have painted or enameled finish as is standard with the manufacturer except that

43 21 13-10 05/08/09 fire pumps shall be red in color.

2.3 ELECTRICAL WORK

2.3.1 Electrical motor driven equipment specified herein shall be provided complete with motors, motor starters, and controls. Electric equipment and wiring shall be in accordance with Section

26 20 00 Interior Distribution System. Electrical characteristics shall be as indicated. Equipment for control of automatic fire pumps shall be in accordance with NFPA 20. Motor starters shall be provided complete with properly sized thermal overload protection in each phase and other appurtenances necessary for the motor control specified. Each motor shall be of sufficient capacity to drive the equipment at the specified capacity without exceeding the nameplate rating of the motor when operating at proper electrical system voltage and frequency. Manual or automatic control and protective or signal devices required for the operation herein specified and any control wiring required for controls and devices but not shown on electrical plans shall be provided under this section of the specifications.

2.4 ELECTRICAL EQUIPMENT

2.4.1 Electrical equipment shall conform to Section 26 20 00 Interior Distribution System. Electrical motor driven equipment herein specified shall be provided complete with motors, motor starters, and controls. Motor controls, equipment, and wiring shall be in accordance with NFPA 70.

2.4.2 Electric Motors

2.4.2.1 Each electric motor-driven pump shall be driven by a weather-protected, Type I or II totally-enclosed fan cooled continuous-duty electric motor. Motor shall have the indicated service factor. Motors shall be squirrel-cage induction or synchronous motors having normal-starting-torque and low-starting-current characteristics, and shall be of sufficient size so that the nameplate horsepower rating will not be exceeded throughout the entire published pump characteristic curve. Integral size motors shall be the premium efficiency type in accordance with NEMA MG 1. Motor bearings shall provide smooth operations under the conditions encountered for the life of the motor. Adequate thrust bearing shall be provided in the motor to carry the weight of all rotating parts plus the hydraulic thrust and shall be capable of withstanding upthrust imposed during pump starting and under variable pumping head conditions specified. Motors shall be the rated volts and phase indicated, 60 Hz and such rating shall be stamped on the nameplate. Motors for fire pumps shall conform to NFPA 20. Motors, not driving fire pumps, shall conform to NEMA MG 1.

2.4.3 Control Equipment

2.4.3.1 Manually controlled pumps shall have START-STOP pushbutton in cover. Automatically controlled pumps shall have three-position "MANUAL-OFF-AUTOMATIC" selector switch in cover. Additional controls or protective devices shall be as indicated. Control equipment for fire pumps shall conform to NFPA 20. A pump low-water cutoff shall be installed in the well or on the suction pipe and shall shut the pump off when the water level in the well reaches the level shown.

2.4.4 Variable Speed Controls

2.4.4.1 The variable speed motor controller shall convert 460 volt plus 15 percent, minus 5 percent, 43 21 13-11 05/08/09 three phase, 60 Hz (plus or minus 2 Hz) utility power to adjustable voltage/frequency, three phase, ac power for stepless motor control from 5 percent to 105 percent of base speed.

2.4.4.2 Description

a. The variable speed drive shall produce an adjustable ac voltage/frequency output for complete motor speed control. The variable speed drive shall be automatically controlled by a pneumatic, 3-15 psig, control signal or a grounded electronic control signal. The variable speed drive shall be self contained, totally enclosed in a NEMA MG 1 ventilated cabinet and capable of operation between 32 and 104 degrees F. The variable speed drive maximum output current rating shall be equal to or exceed the motor nameplate full load. The manufacturer shall advise the maximum recommended motor sine wave current for each controller rating. Variable speed drive multiple motor operation at same frequency/speed shall be possible as long as the sum of connected motor full load sine wave currents are less than or equal to the variable speed drive maximum continuous current rating. Variable speed drive shall be 95 percent efficient at 100 percent rated output power, 60 Hz.

2.4.4.3 Governing Requirements

a. Variable speed drives shall conform to the following requirements:

(1) Variable speed drive shall comply with 47 CFR 15 regulation of RF1/EM1 emission limits for Class A computing devices. The FCC label of compliance shall be displayed on the variable speed drive.

(2) The variable speed drive and options shall comply with the applicable requirements and the standards of the American National Standards Institute (ANSI).

(3) Variable speed drive and option design and construction thereof shall comply with all applicable provisions of NFPA 70, Article 43D, Sections A-L.

2.4.4.4 Quality Assurance

a. To ensure quality the variable speed drive shall be subject to the following tests:

(1) The integrated circuits shall undergo a 160-hour "burn-in" to test reliability. During the

"burn-in" the temperature shall be cycled between 32 and 158 degrees F.

(2) The completed unit shall undergo a fully loaded 24-hour "burn-in."

(3) The unit shall be subject to a series of in-plant quality controlled inspections before approval for shipment from manufacturer's facilities.

2.4.4.5 Service

a. The variable speed drive shall be supplied with the following:

(1) One-year parts and labor warranty.

(2) A troubleshooting guide to help the building operator determine what steps must be taken to correct any problem that may exist in the system.

2.4.4.6 Basic Features

a. The variable speed drive shall have the following basic features:

(1) Hand/Off/Auto Operation.

(2) Manual/Auto speed reference switch.

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(3) Minimum/maximum adjustable speeds.

(4) Speed potentiometer.

(5) Auto restart.

(6) Linear timed acceleration and deceleration for soft starting/stopping.

(7) 3-63 Hz controlled speed range. (Factory set at 15 Hz minimum).

(8) Terminal connections for time clock control, fire, smoke, freeze detectors, and EP relay pre-set speed override.

(9) Output frequency terminals for remote metering.

2.4.4.7 Protective Circuits and Features

a. The variable speed drive controller shall include the following protective circuits/features:

(1) Current limits to 100 percent design by slowing down motor.

(2) Instantaneous Electronic Trip - automatically shutdown motor if current exceed 120 percent of design or phase-to-phase output short circuit occurs.

(3) The variable speed drive will restart automatically when input line returns to normal in the event of intermittent power outage or phase loss or overvoltage shutdown.

(4) Input power protection shuts down the unit if the following faults occur; low input line voltage or loss of an input phase.

(5) Insensitive to incoming power phase.

(6) Fast acting current limiting input fuses, (Class J) rated with 200,000 interrupting amperes capability.

(7) Isolated 115 volt control circuit and dedicated control transformer.

(8) Line-to-line fault protection.

(9) Line-to-ground short circuiting and accidental motor grounding protection.

(10) Output thermal overload relay trip.

2.4.4.8 Adjustments

a. The variable speed drive has the following adjustments available via potentiometers located on the faceplate of a single, regulator printed circuit board.

(1) Minimum speed: 0-75 percent.

(2) Maximum speed: 100 percent.

2.5 DIESEL ENGINES

2.5.1 Diesel engines shall be water-cooled, heavy duty, compression-ignition, cold-starting engines with removable cylinder sleeves. Engines may be 2-cycle or 4-cycle and may be either naturally aspirated, scavenged or turbocharged and shall operate satisfactorily on No. 2D diesel fuel conforming to ASTM D 975. Engines shall be provided with a manual clutch and arranged for connection to the pump through a flexible shaft with a splined joint. Engines shall be current models of a type in regular production and shall be complete with all devices specified and normally furnished with the engine. Engines shall have a published continuous horsepower rating

43 21 13-13 05/08/09 at least 120 percent greater than that required at any point on the pump performance curve at the specified pump speed plus power required for any engine driven accessories. Naturally aspirated ratings shall be decreased by 3 percent for every 1,000 feet of altitude, and 1 percent for every 10 degrees F that the engine performance conditions exceed the published rating conditions.

Scavenged or turbocharged engine ratings shall be decreased as indicated by the engine manufacturer's engine performance data. Engine shall be suitable for performance at indicated degrees F ambient and indicated foot elevation. Engine speed shall not exceed 1,800 rpm when driving the pump at rated conditions. Engines driving fire pumps shall conform to NFPA 20.

Engines shall be capable of starting and assuming full load within 10 to 15 seconds, with a minimum ambient temperature of indicated degrees F. Approved engine jacket water and lube oil heaters shall be provided as recommended by the manufacturer. Lube oil heaters shall be of the circulation type.

2.6 GASOLINE ENGINES

2.6.1 Gasoline engines shall be heavy-duty, 4-cycle, water cooled, spark ignition engines designed to operate efficiently on gasoline having an octane rating of 85 or higher. Engines shall be provided with a manual clutch and arranged for connection to the pump through a flexible shaft with a splined joint. Engines shall be current models of type in regular production and shall be complete with all devices specified and normally furnished with the engine. Engine shall have a published continuous rating at least 120 percent greater than that required at any point on the pump performance curve at the specified pump speed plus power required for any engine driven accessories. Engine rating shall be decreased by 3-1/2 percent for every 1,000 feet of altitude, and 1 percent for every 10 degrees F that the engine performance conditions exceed the published rating conditions. Engine shall be suitable for performance at indicated degrees F ambient and indicated feet elevation. Engine speed shall not exceed 1,800 rpm when driving the pump at rated conditions. Engine shall be capable of starting and assuming full load within 10 to 15 seconds, with a minimum ambient temperature of indicated degrees F. Approved engine jacket water and lube oil heaters shall be provided as recommended by the manufacturer. Lube oil heaters shall be of the circulation type. Automatically controlled engines shall be provided with an approved antidieseling feature that will shut off the fuel supply and air to ensure positive shut down.

2.7 ENGINE EQUIPMENT AND ACCESSORIES

2.7.1 Governor

2.7.1.1 Engine shall be equipped with an adjustable constant speed governor set to maintain pump speed within 3 percent of rated speed at rated load. A separate, manual reset, overspeed device shall be provided which shall shut down the engine in the event the speed reaches approximately 15 percent above rated speed.

2.7.2 Cooling System

2.7.2.1 Cooling system shall be the forced-circulation, closed type and shall include a fan and an engine mounted radiator or a remote mounted radiator with expansion tank, if required. Heat exchanger tube bundle shall be readily removable for cleaning without disturbing the engine piping. Heat exchanger shall be of sufficient capacity to operate the engine at full rated load with a raw water temperature of indicated degrees F and a fouling factor of 0.001 on the raw water side. Raw cooling water circuit shall be thermostatically controlled by a self-contained, single-seated, reverse-acting, adjustable valve with a remote bulb supplied with the engine by

43 21 13-14 05/08/09 the engine manufacturer. Valve shall be arranged to provide full flow of cooling water through the exchanger in event of failure of the valve. A solenoid shut-off valve and bronze body strainer with stainless steel screen shall be installed ahead of the thermostatic valve. Isolation valves with manual bypass shall be factory piped on the engine requiring only the raw water connection to be made in the field. Flexible connections shall be used to connect the inlet and outlet radiator connections to the engine. Radiator shall be of sufficient capacity to operate the engine at full rated load at indicated degrees F ambient temperature. Radiator shall be provided with a flange for connection to the exhaust air duct. Closed jacket water circuit shall be thermostatically controlled, and shall include an integral circulating pump. Drain cocks shall be provided at low points of the closed jacket water system. Exhaust manifolds shall be water jacketed or provided with an insulating jacket furnished by the engine manufacturer. Engine cooling system shall be charged with an inhibited ethylene-glycol solution to provide antifreeze protection to indicated degrees F.

2.7.3 Lubrication

2.7.3.1 Engine lubrication shall be a pressure circulation system with an engine driven pump and engine mounted oil cooler. Full flow type filters with automatic bypass or bypass type filters shall be provided. Filter elements shall be of replaceable type and shall be readily accessible.

2.7.4 Exhaust System

2.7.4.1 Engine exhaust system shall be equipped with an industrial type silencer with drains and flexible, stainless steel connection. Flexible connector shall be provided with factory fabricated expanded metal personnel protection guards. Silencers shall be mounted inside or outside as indicated and shall be of the straight through, or side inlet type as required to suit the space available and the engine exhaust arrangement. An engine with dual exhaust outlets and provided with one exhaust silencer shall have dual inlets on the silencer or a factory fabricated

Y-branch or equivalent fitting to join the two exhausts together.

2.7.5 Air Intake Equipment

2.7.5.1 Each engine shall be provided with a dry combination silencer-filter type intake air cleaner.

Filter shall be engine mounted or remote mounted as indicated and furnished with flexible connection for attachment of intake piping to the engine.

2.7.6 Starting Equipment

2.7.6.1 Engine shall be provided with an electric starting motor suitable for the starting service specified.

2.7.7 Batteries

2.7.7.1 Each engine shall be provided with heavy-duty nickel-cadmium alkline or lead acid type starting batteries. Batteries shall have sufficient capacity at indicated degrees F to provide the necessary cranking speed through indicated minutes of cranking cycles specified. Batteries shall be provided with a battery rack, and if material is not inherently resistant to acid, coating shall be applied to the stand. Connecting cables shall be provided as required. A dual battery set sized to NFPA 20 requirements with rack and cables shall be provided for fire service systems where indicated.

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2.7.8 Battery Charging

2.7.8.1 Engine shall be equipped with an engine driven battery charging alternator with a regulator for use when the engine is running. A separately mounted battery charger shall also be furnished.

Battery charger shall be an automatic, float type providing continuous taper charging. Output characteristics shall match the requirements of the battery furnished. Charger shall be suitable for operation on indicated volt, single-phase, indicated Hz current and shall be rated not less than 6 amperes dc. A dual battery charger of proper type for batteries used shall be provided for fire service systems. Where wall mounting is indicated, enclosure shall be suitable for conduit connection, and ventilating openings shall be guarded. An interlock is required between the engine driven charging system and the charger. Battery charger shall have the following features:

a. Direct current voltage regulation shall be within plus or minus 2 percent for variations in line voltage of plus or minus 10 percent.

b. Direct current voltmeter and direct current ammeter, each with numerical scales.

c. Automatic surge suppressor.

d. Automatic current limiting to prevent overloading due to engine cracking, shorted output or reversed battery connections.

e. Alternating current line fusing.

f. Equalize charge rate with manually set timer.

g. Integral protection to prevent battery discharge through the charger on loss of alternating current line voltage.

h. Terminal block with terminals for all external connections.

2.7.9 Safety Controls

2.7.9.1 Each engine shall be equipped with automatic shut down features to stop the engine for high jacket water temperature, low oil pressure, and engine overspeed. Shutdown features shall be connected to the annunciator on the instrument panel and each shutdown feature will be identified.

2.7.10 Instrument Panel

2.7.10.1 Each engine shall be furnished with an instrument panel mounted with vibration isolators on the unit. Instruments shall be of the direct reading type and shall be factory mounted and connected. Panel shall include the following features and instruments:

a. Three-position MANUAL-OFF-AUTO switch.

b. Manual starting switch.

c. Water temperature gauge.

d. Ammeter-charging circuit.

e. Tachometer.

f. Lubricating oil pressure gauge.

g. Running time meter.

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h. Alarm annunciator with single audible alarm and with contacts to operate a remote alarm and individual indicating lights for low-oil pressure, high-water temperature, engine overspeed, and failure of engine to start.

i. Manual engine speed regulating device.

j. Additional instruments or devices that are required for use in conjunction with the engine controls specified.

k. Auxiliary contacts.

2.7.11 Engine Control

2.7.11.1 Single Units

a. Each engine shall be automatically started by a pilot-control circuit. A control panel enclosing all relays, contactors, and timers shall be mounted on or in the floor, wall, or engine panel.

Panel shall be provided with hinged cover and latch. Engine starting circuit shall provide for 3 or 4 interrupted cranking periods of approximately 15 seconds with equal rest periods between, unless the engine starts before the end of that time. At the end of the period, the starter circuit shall be de-energized. Starter motor shall be automatically de-energized when the engine starts.

Engines shall be stopped manually with the switch on the instrument panel.

2.7.11.2 Multiple Units

a. Engines shall be automatically started by a pilot-control circuit as indicated. A control panel enclosing all relays, contactors, timers, and selector switches shall be wall or floor mounted and provided with hinged cover and latch. The controller for each unit of multiple pump units shall incorporate a sequential timing device to prevent any one engine from starting simultaneously with any other engine. If water requirements call for more than one pumping unit to operate, the units shall start at intervals of 5 to 10 seconds. Failure of a leading engine to start shall not prevent subsequent engines from starting. Engines shall be stopped manually with the switch on instrument panel. Automatic pump controller shall conform to NFPA 20.

2.7.12 Fuel System

2.7.12.1 Fuel system consisting of storage tank, day tank, connecting piping, and accessories shall conform to the applicable items of NFPA 30 and NFPA 37. A horizontal underground storage tank with a capacity of indicated gallons shall be provided for the storage of No. 2 diesel or gasoline fuel as indicated.

2.8 EQUIPMENT APPURTENANCES

2.8.1 Attachments

2.8.1.1 All necessary bolts, nuts, washers, bolt sleeves, and other types of attachments for the installation of the equipment shall be furnished with the equipment. Bolts shall conform to the requirements of ASTM A 307 and nuts shall be hexagonal of the same quality as the bolts used.

Threads shall be clean-cut and shall conform to ASME B1.1. Bolts, nuts, and washers specified to be galvanized or not otherwise indicated or specified, shall be zinc coated after being threaded, by the hot-dip process conforming to ASTM A 123, ASTM A 153 as appropriate. Bolts, nuts, and washers specified or indicated to be stainless steel shall be Type

316.

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2.8.2 Equipment Guards

2.8.2.1 Equipment driven by open shafts, belts, chains, or gears shall be provided with all-metal guards enclosing the drive mechanism. Guard shall be constructed of galvanized sheet steel or galvanized woven wire or expanded metal set in a frame of galvanized steel members. Guards shall be secured in position by steel braces or straps which will permit easy removal for servicing the equipment. The guards shall conform in all respects to all applicable safety codes and regulations.

2.8.3 Tools

2.8.3.1 A complete set of all special tools which may be necessary for the adjustment, operation, maintenance, and disassembly of all equipment shall be furnished. Special tools are considered to be those tools which because of their limited use are not normally available, but which are necessary for the particular equipment. Special tools shall be high-grade, smooth, forged, alloy, tool steel. One pressure grease gun for each type of grease required for motors and gasoline and diesel engines shall also be furnished. All tools shall be delivered at the same time as the equipment to which they pertain. Properly store and safeguard such tools until completion of the work, at which time they shall be delivered to the Contracting Officer.

2.8.4 Shop Painting

2.8.4.1 All motors, pump casings, and similar parts of equipment customarily finished in the shop shall be thoroughly cleaned, primed, and given two finish coats of paint at the factory in accordance with the recommendations of the manufacturer. Ferrous surfaces not to be painted shall be given a shop coat of grease or other suitable rust-resistant coating.

2.9 FACTORY TESTS

2.9.1 Pumps shall be tested by the manufacturer or a nationally recognized testing agency in compliance with Hydraulic Institute Standards. Where two or more identical pumps are specified, only one representative pump shall be tested. Certified test results shall be submitted to the Contracting Officer.

PART 3 EXECUTION

3.1 EXAMINATION

3.1.1 After becoming familiar with all details of the work, verify all dimensions in the field and advise the Contracting Officer of any discrepancy before performing the work.

3.2 INSTALLATION

3.2.1 Install each pump and engine in accordance with the written instructions of the manufacturer and under the direct supervision of the manufacturer's representative. Engine fuel supply system shall be installed as indicated and in conformance with NFPA 30 and NFPA 37. Concrete for equipment foundations and for any required ballast for fuel storage tanks shall be as specified in

Section 03 30 00 Cast-In-Place Concrete. Concrete foundations shall be integral with and of the same class as that of the building floor unless otherwise indicated. Concrete having a compressive

43 21 13-18 05/08/09 strength of at least 2,500 psi shall be used in foundations that are entirely separated from the surrounding floor. A premolded filler strip shall be installed between the foundation and floor slab as shown. Foundation bolts, as required, shall be furnished for proper positioning during the placement of the concrete.

3.3 FIELD TESTS

3.3.1 After installation of the pumping units and appurtenances is complete, operating tests shall be carried out to assure that the pumping installation operates properly. Make arrangements to have the manufacturer's representatives present when field equipment tests are made. Field tests for fire service pumps and engines shall conform to NFPA 20. Each pumping unit shall be given a running field test in the presence of the Contracting Officer for a minimum of 2 hours with each combination of electric motor and engine drive. Each pumping unit shall be operated at its rated capacity or such other point on its head-capacity curve selected by the Contracting Officer.

Provide an accurate and acceptable method of measuring the discharge flow. Each engine shall be operated for a minimum of 4 hours at a point of maximum horsepower indicated on the pump head-capacity curve or such other point on the curve selected by the Contracting Officer. For submersible pumping units, an insulation resistance test of the cable and the motor shall be conducted prior to installation of the pump, during installation of the pump, and after installation is complete. The resistance readings shall not be less than 10 megohms. Tests shall assure that the units and appurtenances have been installed correctly, that there is no objectionable heating, vibration, or noise from any parts, and that all manual and automatic controls function properly.

If any deficiencies are revealed during any tests, such deficiencies shall be corrected and the tests shall be reconducted.

3.4 FIELD PAINTING

3.4.1 Do not paint stainless steel, galvanized steel, and nonferrous surfaces.

3.4.2 Touch-Up Painting

3.4.2.1 Factory painted items requiring touching up in the field shall be thoroughly cleaned of all foreign material and shall be primed and topcoated with the manufacturer's standard factory finish.

3.4.3 Exposed Ferrous Surfaces

3.4.3.1 Exposed ferrous surfaces shall be painted with two coats of enamel paint conforming to SSPC

Paint 21. Factory primed surfaces shall be solvent-cleaned before painting. Surfaces that have not been factory primed shall be prepared and primed with one coat of SSPC Paint 25or in accordance with the enamel paint manufacturer's recommendations.

3.5 DEMONSTRATION

3.5.1 Upon completion of the work, and at a time designated by the Contracting Officer, the services of one or more competent engineers shall be provided for a training period of not less than 8 hours to instruct a representative of the Government in the contents of the operation and maintenance manuals for the equipment furnished under these specifications. These field instructions shall cover all the items contained in the bound instructions.

END OF SECTION 43 21 13