44 46 00.pdf

SABER Solicitation FA2517-08-R-5002

44 46 00-1 05/08/09

SECTION 44 46 00

PUMPS; SEWAGE AND SLUDGE

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 AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

a. ABMA 11 Load Ratings and Fatigue Life for Roller Bearings

b. ABMA 9 Load Ratings and Fatigue Life for Ball Bearings

1.1.1.2 ASME INTERNATIONAL (ASME)

a. ASME B40.100 Pressure Gauges and Gauge Attachments

1.1.1.3 ASTM INTERNATIONAL (ASTM)

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

Steel Hardware

1.1.1.4 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA ICS 1 Standard for Industrial Control and Systems General

Requirements

b. NEMA MG 1 Standard for Motors and Generators

1.1.1.5 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 70 National Electrical Code

1.2 SUBMITTALS

1.2.1 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.

1.2.1.1 SD-02 Shop Drawings

a. Equipment 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. Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances for maintenance and operation.

(2) SD-03 Product Data

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(a) Materials and Equipment

(b) Framed Instructions

1. 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.

(c) Spare Parts

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

1.2.1.2 SD-06 Test Reports

a. Field Testing and Adjusting Equipment

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

1.2.1.3 SD-10 Operation and Maintenance Data

a. Operating and Maintenance Manuals

(1) Copies of operation and copies of 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. Operation manuals shall include the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features. Maintenance manuals shall list 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 AND STORAGE

1.3.1 All equipment delivered and placed in storage shall be stored with protection from the weather, excessive humidity and excessive temperature variation; and dirt, dust, or other contaminants.

1.4 FIELD MEASUREMENTS

1.4.1 The Contractor shall become familiar with all details of the work, verify all dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing the work.

1.5 SPARE PARTS

1.5.1 The Contractor shall submit spare parts data for each different item of material and equipment specified, after approval of the related submittals. The data shall include a complete list of parts and supplies, with current unit prices and source of supply

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PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Materials and equipment shall be the standard products of a manufacturer regularly engaged in the manufacture of such products and shall 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 or ductile iron unless otherwise specified for rotors.

2.1.2 Nameplates

2.1.2.1 Each major item of equipment shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment.

2.1.3 Equipment Guards

2.1.3.1 Belts, pulleys, chains, gears, projecting setscrews, keys, and other rotating parts so located that any person may come in close proximity thereto shall be enclosed or guarded.

2.1.4 Special Tools

2.1.4.1 One set of special tools, calibration devices, and instruments required for operation, calibration, and maintenance of the equipment shall be provided.

2.1.5 Electric Motors

2.1.5.1 Motors shall conform to NEMA MG 1.

2.1.6 Motor Controls

2.1.6.1 Controls shall conform to NEMA ICS 1.

2.1.7 Bolts, Nuts, Anchors, and Washers

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

2.1.8 Pressure Gauges

2.1.8.1 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.

2.1.9 Seal Water Systems

2.1.9.1 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.

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2.1.9.2 Float Valve

a. 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.

2.1.9.3 Auxiliary Equipment

a. 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.

2.1.9.4 Controls

a. 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 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.

2.1.9.5 System Characteristics

a. The seal water systems for pump shall be sized for gpm, psi, and horsepower indicated.

2.2 CENTRIFUGAL SOLIDS HANDLING PUMPS

2.2.1 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.

2.2.2 Pump Characteristics

2.2.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Design Operating Point: (gpm) flow, (feet) head, percent efficiency.

c. Maximum Operating Point: (gpm) flow, (feet) head, percent efficiency.

d. Minimum Operating Point: (gpm) flow, (feet) head, percent efficiency.

e. Impeller Type:

f. Operating Speed: rpm.

g. Maximum NPSH Required at Maximum Operating Point:

h. Motor Type:

i. Electrical Characteristics: volts ac, phase, 60 Hz.

j. Size: Within rated load driving pump at specified rpm.

k. Pump Control:

2.2.3 Pump Casing

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2.2.3.1 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.

2.2.3.2 Impeller

a. 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.

2.2.3.3 Wearing Rings

a. 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 or cast iron.

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.

2.2.4 Pump Shaft

2.2.4.1 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.

2.2.5 Pump Shaft Sleeve

2.2.5.1 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.

2.2.6 Stuffing Box

2.2.6.1 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.

2.2.7 Mechanical Seals

2.2.7.1 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.

2.2.8 Bearings

2.2.8.1 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.

2.2.9 Lubrication

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2.2.9.1 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

2.2.10 Pump Support

2.2.10.1 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.

2.2.11 Coupling

2.2.11.1 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

2.3.1 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.

2.3.2 Pump Characteristics

2.3.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Design Operating Point: (gpm) flow, (feet) head, percent efficiency.

c. Maximum Operating Point: (gpm) flow, (feet) head, percent efficiency.

d. Minimum Operating Point: (gpm) flow, (feet) head, percent efficiency.

e. Impeller Type:

f. Operating Speed: rpm.

g. Depth of Submergence: feet.

h. Motor Type:

i. Electrical Characteristics: volts ac, phase, 60Hz.

j. Size: Within rated load driving pump at specified rpm.

k. Pump Control:

2.3.3 Pump Casing

2.3.3.1 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

44 46 00-7 05/08/09 unobstructed flow through the pump.

2.3.4 Mating Surfaces

2.3.4.1 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.

2.3.5 Coatings

2.3.5.1 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.

2.3.6 Impeller

2.3.6.1 The impeller shall be of the single or double 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.

2.3.7 Wearing Rings

2.3.7.1 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.

2.3.8 Pump Shaft

2.3.8.1 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.

2.3.9 Seals

2.3.9.1 A tandem mechanical shaft seal system running in an oil bath shall be provided. Seals shall have 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.

2.3.10 Bearings

2.3.10.1 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.

2.3.11 Motor

2.3.11.1 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.

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2.3.12 Power Cable

2.3.12.1 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. Epoxies, silicones, or other secondary sealing systems are not acceptable.

2.3.13 Installation Systems

2.3.13.1 Rail Mounted Systems

a. 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.

2.3.13.2 Bolt Down Systems

a. 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.

2.3.13.3 Lifting Chain

a. Lifting chain to raise and lower the pump through the limits indicated shall be provided. The chain shall be galvanized and shall be capable of supporting the pump.

2.4 SELF-PRIMING CENTRIFUGAL PUMPS

2.4.1 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.

2.4.2 Pump Characteristics

2.4.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Design Operating Point: (gpm) flow, (feet) head, percent efficiency.

c. Maximum Operating Point: (gpm) flow, (feet) head, percent efficiency.

d. Minimum Operating Point: (gpm) flow, (feet) head, percent efficiency.

e. Maximum Priming Lift: feet.

f. Maximum Reprime Lift: feet.

g. Impeller Type:

h. Rotation Direction: Clockwise or Counterclockwise.

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i. Operating Speed: rpm (maximum).

j. Motor Type:

k. Electrical Characteristics: volts ac, phase, 60 Hz.

l. Size: Within rated load driving pump at specified rpm.

m. Pump Control:

2.4.3 Pump Casing

2.4.3.1 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.

2.4.4 Impeller

2.4.4.1 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.

2.4.5 Wear Plate

2.4.5.1 A replaceable wear plate constructed of cast iron or alloy steel shall be provided.

2.4.6 Pump Shaft

2.4.6.1 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 wattage (horsepower) with a liberal safety factor.

2.4.7 Pump Shaft Sleeve

2.4.7.1 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.

2.4.8 Seals

2.4.8.1 The pump shaft shall be sealed against leakage by oil lubricated or water lubricated mechanical seal. The stationary sealing member shall be tungsten carbide or silicon carbide and the rotating member shall be tungsten carbide or silicon 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.

2.4.9 Bearings

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

2.4.10 Lubrication

2.4.10.1 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 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.

2.4.11 Suction Check Valve

2.4.11.1 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.

2.4.12 Pump Support

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

2.4.13 Coupling

2.4.13.1 Power shall be transmitted from the motor to the pump by a flexible coupling or V-belt drive assembly. Flexible couplings shall be of the heavy duty type, keyed or locked to the shaft. The

V-belt drive assembly shall have a minimum of two belts. The drive assembly shall be selected on the basis of the power to be transmitted from the motor to the pump. The drive shall be enclosed on all sides by a solid metal guard.

2.5 SCREW PUMPS

2.5.1 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.

2.5.2 Pump Characteristics

2.5.2.1 Pumps shall have the following characteristics as indicated:

a. Pump Service:

b. Total Lift: feet.

c. Angle of Inclination: 22, 30, 38 or indicated degrees from horizontal.

d. Spiral Screw Diameter: inches.

e. Flight Thickness: inches.

f. Quantity of Flights: 1, 2, 3 as required

g. Design Capacity: gpm.

h. Tube Diameter: inches.

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i. Screw Speed: rpm

j. Motor Type:

k. Electrical Characteristics: volts ac, phase, 60 Hz.

l. Size: Within rated load driving pump at specified rpm.

m. Pump Control

2.5.3 Lower Bearing Assembly

2.5.3.1 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.

2.5.3.2 Seals

a. 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.

2.5.3.3 Bearing Shield

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

2.5.4 Spiral Screw

2.5.4.1 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.

2.5.4.2 Torque Tube

a. 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.

2.5.4.3 Shafts

a. 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.

2.5.5 Flow Defector Plates

2.5.5.1 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

44 46 00-12 05/08/09 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.

2.5.6 Upper Bearing Assembly

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

2.5.6.2 Housing

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

2.5.6.3 Bearing

a. 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.

2.5.6.4 Seals

a. 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 contamination from entering the bearing top side. The other seal shall be on the bottom side to retain the grease within the bearing.

2.5.6.5 Mounting Plate

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

2.5.6.6 Cover

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

2.5.7 Drive Assembly

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

2.5.7.2 Gear Reducer

a. 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. The gear reducer shall be designed with a service factor based on the torque requirements of the screw or based on the motor horsepower, whichever is greater. 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.

2.5.7.3 Backstop

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a. 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.

2.5.7.4 Drive

a. 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.

2.5.8 Lubrication System

2.5.8.1 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 have the indicated hp, volts ac, phase, 60 Hz motor. 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.

2.5.9 Radius Screed

2.5.9.1 A radius screed and any additional sheaves and belts as necessary to adjust screw speed shall be provided to enable the Contractor to install the grout in the trough with the screw installed.

2.6 PLUNGER PUMPS

2.6.1 Plunger pumps shall be of the positive displacement type designed to pump sewage sludges with a minimum amount of clogging.

2.6.2 Pump Characteristics

2.6.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Design Capacity: gpm.

c. Design Head: feet.

d. Suction Lift: feet.

e. Stroke Speed: strokes per minute.

f. Pump Type: simplex, duplex, triplex, or quadraplex.

g. Motor Type:

h. Electrical Characteristics: volts ac, phase, 60 Hz.

i. Size: Within rated load driving pump at specified rpm.

j. Pump Control:

2.6.3 Pump Base

2.6.3.1 A common, welded steel, drip-rim base with a 1-inch threaded drain connection shall be provided for the pump and motor. The base shall be of heavy section, fully braced to withstand all shock loads and to resist buckling when properly anchored.

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2.6.4 Pump Body

2.6.4.1 The pump body shall be cast iron. The pump shall be of heavy construction, designed to handle its maximum rated capacity and head on a continuous duty basis and shall be hydrostatically tested at 1.5 times the maximum rated head of the pump. The pump body shall be of sectional construction so that the stuffing box, valve bodies, and air chamber adapters are independently removable. The construction shall permit removal of the stuffing box, plunger, and connecting rod without disturbing the body, valve chambers, manifolds, piping, or shaft.

2.6.5 Valves

2.6.5.1 Valve chambers shall be provided on both the inlet and discharge connections of each cylinder.

The valve chambers shall be constructed with contoured interiors to minimize clogging. Valves shall be ball type, at least 5-1/8 inches in diameter, and constructed of neoprene. Valve seats shall be independent, fully machined plates which may be replaced without disturbing valve bodies or piping.

2.6.6 Connecting Rod, Eccentric, Eccentric Bearings, and Shaft

2.6.6.1 The connecting rod and eccentric strap assembly shall be cast as one piece and shall have a quality hot-poured Babbitt lining. The eccentric, bearings, and shaft shall be designed to handle the stresses and deflections imposed upon it by the specified service. The shaft shall be offset from the vertical centerline of the cylinder by an amount appropriate to the cylinder diameter to reduce lateral thrust on the cylinder during the discharge stroke.

2.6.7 Plungers

2.6.7.1 Plungers shall be ductile iron and shall have a plugged drain hole in the bottom which shall be accessible through the top of the plunger.

2.6.8 Cylinders

2.6.8.1 Cylinders shall be machined to a smooth bore to provide a uniform surface throughout the full travel of the plunger.

2.6.9 Stuffing Box

2.6.9.1 The cylinder and plunger shall have an effective packing arrangement to provide lubrication for the plunger and maintain the most effective vacuum. The stuffing box shall be of heavy cast construction and shall be provided with a circular drain lip and 1 inch threaded drain connection. The stuffing box shall be provided with a minimum of four rings of packing.

2.6.10 Air Chambers

2.6.10.1 Air chambers shall be provided on both suction and discharge sides of the pump. Air chambers shall have a minimum capacity of 1800 cubic inches and a minimum 3 inch diameter opening.

2.6.11 Sampling Valve

2.6.11.1 A 2 inch sampling valve shall be provided on the discharge side of the pump.

2.6.12 Pressure Relief Valve

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2.6.12.1 A pressure relief valve shall be provided with a bypass line from the main suction and discharge manifolds. The valve shall be factory set to prevent motor overload or pump damage.

2.6.13 Lubrication

2.6.13.1 Each pump eccentric shall be provided with a sight-feed oil lubricator.

2.6.14 Chain Drive

2.6.14.1 Capacity variations shall be provided by stroke adjustment accomplished at each eccentric assembly, through the use of eccentric flanges coupled to the eccentric body. Overall drive reduction shall be obtained through the combination of a gearhead motor and silent roller chain.

Motor gearhead shall be totally enclosed and running in oil. Chain capacity shall be at least

150 percent of the chain manufacturers published horsepower rating. The entire chain drive assembly shall be completely enclosed in a sealed lip, dust resistant steel guard.

2.6.15 V-Belt and Integral Gear Drive

2.6.15.1 Capacity variations shall be provided by stroke adjustment accomplished at each eccentric assembly, through the use of eccentric flanges coupled to the eccentric body. Overall drive reduction shall be obtained through a combination of gears and V-belts. Gears shall run in an oil bath contained in an oil-tight cast iron or aluminum enclosure. The gear reduction design, gear materials and face widths, shafting, and bearings shall be selected for the specified operating conditions. The entire V-Belt drive assembly shall be covered by a rigid safety guard.

2.6.15.2 Gear Reducer Drive

a. Capacity variations shall be provided by pump speed change only. The low speed shaft of the reducer shall be directly connected to the main shaft of the pump through a flexible coupling with shear pin protection. The shear pin overload protection shall be designed for release at

150 percent to 175 percent of normal torque. The high speed shaft of the reducer shall be connected to the motor by a heavy duty flexible coupling. The entire gear reduction unit shall be enclosed in a dustproof and oil-tight housing.

2.7 PROGRESSIVE CAVITY PUMPS

2.7.1 Progressive cavity pumps shall consist of a single helical rotor rotating in a double helical stator.

2.7.2 Pump Characteristics

2.7.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Design Capacity: gpm maximum to gpm minimum.

c. Operating Head: feet maximum to feet minimum.

d. Operating Speed: rpm.

e. Single or Double stage.

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f. Motor Type: .

g. Electrical Characteristics: volts ac, phase, 60 Hz.

h. Size: Within rated load driving pump at specified rpm.

i. Pump Control:

2.7.3 Casing

2.7.3.1 The pump body shall be cradle mounted such that the suction chamber can be rotated to allow the suction port to accommodate any piping configuration. Two inspection ports shall be incorporated 180 degrees apart in the suction housing to provide access to internal parts. A drain plug shall be provided in the casing.

2.7.4 Rotor

2.7.4.1 The pump rotor shall be a helix constructed of machined and polished high quality tool steel or stainless steel and shall be covered with a layer of hard chrome plate.

2.7.5 Stator

2.7.5.1 The rotor shall revolve in a helix elastomeric stator consisting of Buna-N chemically bonded to a steel tube.

2.7.6 Drive Shaft and Connecting Rod

2.7.6.1 The rotor shall be driven by a connecting rod between the rotor and drive shaft, connected at each end with a crowned gear or pin or cardan type universal joint. The universal joints shall be of adequate design to transmit the required thrust and torque. The connecting rod and universal joint in combination shall impart no thrust on the seal. Universal joints shall be grease lubricated and totally sealed and shielded. The seal shall prevent liquid from contaminating the joints, and the shields shall prevent foreign objects from damaging the seal.

2.7.7 Flexible Drive Shaft

2.7.7.1 The rotor shall be driven by a one-piece, flexible, high strength spring steel drive shaft with a corrosion and abrasion-resistant thermoplastic coating.

2.7.8 Seals

2.7.8.1 Pump seals shall be a stuffing box with a split packing gland and lantern ring or shall be a mechanical seal. Fittings for grease or water lubrication shall be provided.

2.7.9 Bearings

2.7.9.1 Bearings shall be designed for an ABEMA L-10 life of at least 50,000 hours minimum, as specified in ABMA 9 or ABMA 11, and shall be grease lubricated. Lubrication fittings in the bearing housing shall be provided.

2.8 DIAPHRAGM PUMPS

2.8.1 Diaphragm pumps shall be of the self-priming, positive displacement type designed to pump

44 46 00-17 05/08/09 sludge of various concentrations and levels of abrasiveness. The pump shall be designed such that operating the pump without liquid in the pump casing will not damage any portion of the pump.

2.8.2 Pump Characteristics

2.8.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Operator: mechanical or air.

c. Peak Capacity: (gpm) flow.

d. Total Dynamic Head: feet.

e. Suction and Discharge Check Valve Size: inches.

f. Pump Speed: strokes per minute.

g. Diaphragm Material:

h. Motor Type:

i. Electrical Characteristics: volts ac, phase, 60 Hz.

j. Size: Within rated load driving pump at specified strokes per minute.

k. Pump Control.

2.8.3 Casing

2.8.3.1 All interior wetted parts shall be lined with 1/4 inch thick chlorosulfonated polyethylene. The pump body shall be designed to permit access to the casing interior without disassembling the suction and discharge piping.

2.8.4 Suction and Discharge Check Valves

2.8.4.1 The suction and discharge check valves shall be of the quick opening ball check type, in-line ball check type, or in-line flap check type. Quick-opening ball check valves shall have replaceable stainless steel, bronze, or cast iron seats and an easily removable cover plate to permit inspection and cleaning of the valve interior without disassembling the adjacent piping.

In-line ball check valves shall have a streamlined internal design, eliminating projections on which material can collect. In-line flap check valves shall have an elastomeric seal on the disc to insure sealing and shall have a removable cover to permit inspection and cleaning of the valve interior without disassembling the adjacent piping.

2.8.5 Pulsation Dampers

2.8.5.1 An air chamber type pulsation damper shall be provided on the pump inlet and discharge.

2.8.6 Air-Operated Actuators

2.8.6.1 A complete air operated actuator shall be provided, with all accessories required for proper operation, including the following:

a. Valve

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(1) A three-way solenoid valve on the air supply line. The valve shall operate on a signal from the flow control timer.

b. Timer

(1) An adjustable solid state flow control timer to control pump stroke rate and length.

Stroke rate shall be adjustable from 0 to 40 strokes per minute. Stroke length shall be adjustable from 0.75 to 1.25 seconds.

c. Muffler

(1) An air exhaust muffler to ensure quiet operation.

d. Pressure Regulator

(1) An air pressure regulator to maintain a constant air supply pressure to the pumping system. The air pressure regulator shall be field adjustable.

e. Strainer

(1) An air supply strainer to remove particles from the air supply. The strainer shall have a removable cover to permit cleaning without dismantling adjacent piping.

f. Assist

(1) Spring assist or air cylinder assist as required for adequate suction lift.

2.8.6.2 Mechanical Actuators

a. The mechanical actuator shall consist of an electric motor and gear reducer or belt drive connected to the diaphragm by a connecting rod and eccentric.

2.9 RECESSED IMPELLER PUMPS

2.9.1 Recessed impeller pumps shall be of the vortex type designed to handle fluids containing solids, air, and stringy material normally found in sewage. Pumps shall be designed to pump solids up to

3 inches in diameter.

2.9.2 Pump Characteristics

2.9.2.1 Pumps shall have the following operating characteristics as indicated:

a. Pump Service:

b. Design Operating Point: (gpm) flow at (feet) head.

c. Maximum Operating Point: (gpm) flow at (feet) head.

d. Minimum Operating Point: (gpm) flow at (feet) head.

e. Discharge Diameter: inches.

f. Suction Diameter: inches.

g. Operating Speed: rpm.

h. Maximum NPSH Required at Maximum Operating Point:

i. Seal Type: packing or mechanical.

j. Motor Type:

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k. Electrical Characteristics: volts ac, phase, 60 Hz.

l. Size: Within rated load driving pump at specified rpm.

m. Pump Control:

2.9.3 Pump Casing

2.9.3.1 Pump casing shall be constructed with tapped and plugged holes for priming, venting, and drainage of the pump. The casing shall be capable of withstanding pressures 50 percent greater than the maximum operating pressure. All internal casing clearances shall be equal to the discharge nozzle diameter so that all material that can pass through the discharge nozzle can pass through the casing. Casing connections shall be flanged.

2.9.4 Impeller

2.9.4.1 The impeller shall be of the recessed design. The impeller shall be securely keyed to the shaft with a locking arrangement whereby the impeller cannot be loosened from either forward or reverse direction.

2.9.5 Pump Shaft

2.9.5.1 Pump shaft shall be of high grade alloy steel or stainless steel and shall be sized to provide a minimum amount of deflection.

2.9.6 Sleeve

2.9.6.1 The pump shaft shall be protected throughout the packing area by a removable stainless steel or bronze sleeve.

2.9.7 Seals

2.9.7.1 A stuffing box, designed for the interchangeable use of packing or mechanical seals, and suitable for use of grease, oil, or water as the sealing liquid, shall be provided.

2.9.7.2 Packing

a. The stuffing box shall be designed to accommodate rings of graphite or oil impregnated nonasbestos or metallic packing with lantern ring and packing gland. Packing shall be readily removable from the shaft.

2.9.7.3 Mechanical Seals

a. Mechanical seals shall be of the single or double type of carbon-ceramic or tungsten carbide construction. Each seal interface shall be held in place by its own stainless steel spring system.

The seal system shall be constructed to be readily removable from the shaft.

2.9.8 Bearings

2.9.8.1 Pump bearings shall be antifriction ball or roller type bearings designed to carry all radial or thrust loads. Bearings shall be grease or oil lubricated and shall be contained in dust- and moisture-proof housings. An oil reservoir with overflow and drain openings shall be provided.

A grease fitting of the type that prevents overlubrication shall be provided. If the grease fitting is not readily accessible, an extension tube shall be provided.

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2.10 ROTARY LOBE PUMPS

2.10.1 Rotary lobe pumps shall be of the positive displacement type and shall consist of two tri-lobe rotors which draw product into pockets formed between the rotors and rotor case and push pumped material 180 degrees around the interior of the contoured rotor case and out through the discharge port.

2.10.2 Pump Characteristics

2.10.2.1 Pumps shall have the following characteristics as indicated:

a. Pump Service:

b. Design Capacity: gpm to gpm.

c. Operating Head: feet maximum to feet minimum.

d. Operating Speed: rpm.

e. Discharge Diameter: inches.

f. Suction Diameter: inches.

g. Motor Type:

h. Electrical Characteristics: volts ac, phase, 60 Hz.

i. Size: Within rated load driving pump at specified rpm.

j. Pump Control:

2.10.3 Casing

2.10.3.1 Rotor casing shall be constructed of ductile iron or cast iron. The gear casing shall be constructed of cast iron. A removable end cover shall allow access to tri-rotor elements without need to disturb packing glands, bearings, suction, or discharge connections.

2.10.4 Rotors

2.10.4.1 Pump rotors shall be tri-lobe form profile machined in cast iron or high quality tool steel encapsulated in urethane or stainless steel. A removable and replaceable wear plate shall be provided between the rotors and rotor case to protect the rotor case from wear. Rotors shall be located on shafts by positive locking assembly.

2.10.5 Shafts and Sleeves

2.10.5.1 Shafts shall be of high grade alloy steel fitted with replaceable stainless shaft sleeves where passing through gland area. Shafts shall be timed in their rotation by zero backlash timing gears keyed to shafts and running in a separate oil chamber gear case. Seals shall prevent ingress of pumped material into gear case.

2.10.6 Packing Glands

2.10.6.1 Seals shall be of adjustable packing gland type. Stuffing box glands shall be provided with split lantern rings for through water flush.

2.10.7 Bearings

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2.10.7.1 Pump shall have heavy duty antifriction roller or ball type bearings for shaft support, with a

ABEMA L-10 life of 100,000 hours at maximum operating conditions. Oil seals shall prevent ingress of pumpage into gear case. A slinger for each shaft shall be provided.

2.11 ELECTRICAL WORK

2.11.1 Electrical motor driven equipment specified 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 specified or indicated.

Motor starters shall be provided complete with thermal overload protection and other appurtenances necessary for the motor control specified. Manual or automatic control and protective or signal devices required for the operation specified, and any control wiring required for controls and devices but not shown, shall be provided.

PART 3 EXECUTION

3.1 EQUIPMENT INSTALLATION

3.1.1 Pump Installation

3.1.1.1 Pumping equipment and appurtenances shall be installed in the position indicated and in accordance with the manufacturer's written instructions. All appurtenances required for a complete and operating pumping system shall be provided, including such items as piping, conduit, valves, wall sleeves, wall pipes, concrete foundations, anchors, grouting, pumps, drivers, power supply, seal water units, and controls.

3.1.2 Concrete

3.1.2.1 Concrete shall conform to Section 03 30 00 Cast-In-Place Concrete.

3.1.3 Grouting Screw Pump Flow Channel

3.1.3.1 After installation and adjustment of the screw pump, place grout in the flow channel to the configuration and dimensions indicated and as required to insure a proper fit between the screw pump and flow channel. A radius screed provided by the pump manufacturer shall be temporarily attached to provide proper clearance between the screw and the flow channel. The flow channel shall be grouted in strict accordance with the manufacturer's instructions.

3.2 PAINTING

3.2.1 Pumps and motors shall be thoroughly cleaned, primed, and given two finish coats of paint at the factory in accordance with the recommendations of the manufacturer. Field painting required for ferrous surfaces not finished at the factory is specified in Section 09 90 00 Paints and Coatings.

3.3 FIELD TESTING AND ADJUSTING EQUIPMENT

3.3.1 Operational Test

3.3.1.1 Prior to acceptance, an operational test of all pumps, drivers, and control systems shall be

44 46 00-22 05/08/09 performed to determine if the installed equipment meets the purpose and intent of the specifications. Tests shall demonstrate that the equipment is not electrically, mechanically, structurally, or otherwise defective; is in safe and satisfactory operating condition; and conforms with the specified operating characteristics. Prior to applying electrical power to any motor driven equipment, the drive train shall be rotated by hand to demonstrate free operation of all mechanical parts. Tests shall include checks for excessive vibration, leaks in all piping and seals, correct operation of control systems and equipment, proper alignment, excessive noise levels, and power consumption.

3.3.2 Retesting

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

3.4 MANUFACTURER'S SERVICES

3.4.1 Services of a manufacturer's representative who is experienced in the installation, adjustment, and operation of the equipment specified shall be provided. The representative shall supervise the installation, adjustment, and testing of the equipment.

3.5 FRAMED INSTRUCTIONS

3.5.1 Framed instructions containing wiring and control diagrams under glass or in laminated plastic shall be posted where directed. Condensed operating instructions, prepared in typed form, shall be framed as specified above and posted beside the diagrams. The framed instructions shall be posted before acceptance testing of the system.

3.6 FIELD TRAINING

3.6.1 A field training course shall be provided for designated operating and maintenance staff members. Training shall be provided for a total period of 8 hours of normal working time and shall start after the system is functionally complete but prior to final acceptance tests. Field training shall cover all of the items contained in the operating and maintenance manuals.

END OF SECTION 44 46 00