Attachment 9 - Updated Specification Section 33 32 16.pdf

REPAIR VARIOUS DRY WELL LIFT STATIONS JOINT BASE CHARLESTON

SOUTH CAROLINA

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 32 16

UTILITY WASTEWATER PUMPING STATIONS

11/19

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY CONTROL

1.3.1 Installer Qualifications

1.4 DELIVERY, STORAGE, AND HANDLING OF MATERIALS

1.4.1 Delivery and Storage

1.4.2 Handling

1.5 WARRANTY

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.2 SUBMERSIBLE SEWAGE NONCLOG PUMPS & WALL MOUNTED GRINDER UNIT

2.2.1 Pump Construction

2.2.1.1 Casing

2.2.1.2 Impeller

2.2.1.3 Bearings

2.2.1.4 Lubrication

2.2.1.5 Balance

2.3 PUMP MOTOR

2.4 PUMP CONTROL SYSTEM

2.4.1 General

2.4.2 Enclosure

2.4.3 Level Control System

2.4.4 Alternator

2.4.5 Sewage Pump Alarm and Control Panel

2.4.5.1 Alarms

2.4.5.2 Circuit Breakers

2.4.5.3 Variable Frequency Drives

2.4.5.4 Power Lugs

2.4.5.5 Anti-Condensation Heater

2.4.5.6 Trouble Light

2.4.5.7 Additional Requirements

2.4.6 Electrical Requirements

2.5 WET WELL AND VALVE VAULT

2.5.1 Wet Well and Valve Vault

2.5.1.1 Precast Concrete Structures

2.5.2 Access Hatch Covers

2.5.3 Wet Well Base Material

2.5.3.1 Vent

2.6 STATION PIPING

2.6.1 Ductile-Iron Pressure Pipe and Associated Fittings

2.6.1.1 Flanged Pipe

2.6.1.2 Fittings

SECTION 33 32 16 Page 1

2.6.1.3 Joints

2.6.2 Insulating Joints

2.6.3 Accessories

2.6.4 Flexible Flanged Coupling

2.7 VALVES AND OTHER PIPING ACCESSORIES

2.7.1 Isolation Gate Valves in Valve Vault

2.7.1.1 Valves Larger Than 2 Inches

2.7.2 Check Valves 4 inch and Larger Diameter

2.7.3 Identification Tags and Plates

2.7.4 Pipe Support

2.7.5 Miscellaneous Metals

2.7.6 Quick Disconnect System with Hydraulic Sealing Flange and Rail

System

2.7.7 Wet Well Vent

2.7.8 Pressure Gauges

2.8 EXCAVATION, TRENCHING, AND BACKFILLING

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Equipment Installation

3.1.2 Installation of Ductile-Iron Pressure Pipe and Fittings

3.1.3 Valves

3.2 FIELD QUALITY CONTROL

3.2.1 Testing Procedure

3.2.2 Field Representative

3.3 CLOSEOUT ACTIVITIES

3.3.1 Operation and Maintenance

-- End of Section Table of Contents --

SECTION 33 32 16 Page 2

SECTION 33 32 16

UTILITY WASTEWATER PUMPING STATIONS

11/19

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B16.1 (2020) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASME B16.3 (2016) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C110/A21.10 (2012) Ductile-Iron and Gray-Iron Fittings for Water

AWWA C111/A21.11 (2017) Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings

AWWA C115/A21.15 (2020) Flanged Ductile-Iron Pipe With Ductile-Iron or Gray-Iron Threaded Flanges

AWWA C151/A21.51 (2017) Ductile-Iron Pipe, Centrifugally Cast

AWWA C500 (2019) Metal-Seated Gate Valves for Water Supply Service

AWWA C509 (2015) Resilient-Seated Gate Valves for Water Supply Service

AWWA C515 (2020) Reduced-Wall, Resilient-Seated Gate Valves for Water Supply Service

AWWA C600 (2017) Installation of Ductile-Iron Mains and Their Appurtenances

AWWA C605 (2021) Underground Installation of Polyvinyl Chloride (PVC) and Molecularly Oriented Polyvinyl Chloride (PVCO) Pressure Pipe and Fittings

SECTION 33 32 16 Page 3

ASTM INTERNATIONAL (ASTM)

ASTM A48/A48M (2003; R 2021) Standard Specification for Gray Iron Castings

ASTM A53/A53M (2020) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A126 (2004; R 2019) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A536 (1984; R 2019; E 2019) Standard Specification for Ductile Iron Castings

ASTM A615/A615M (2020) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM C443 (2020) Standard Specification for Joints for Concrete Pipe and Manholes, Using Rubber Gaskets

ASTM C478 (2018) Standard Specification for Circular Precast Reinforced Concrete Manhole Sections

ASTM C618 (2019) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1940-1 (2003; R 2008) Mechanical Vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1:

Specification and Verification of Balance Tolerances

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2018) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 67 (2018; Reprint Jul 2020) UL Standard for Safety Panelboards

UL 489 (2016; Rev 2019) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

SECTION 33 32 16 Page 4

1.2 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Fabrication Drawings

Erection/Installation Drawings

SD-03 Product Data

Submersible Sewage Nonclog Pumps; G

Pump Performance Curve; G

Pump Motor; G

Pump Control System; G

Wet Well and Valve Vault; G

Flexible Flanged Coupling; G

Station Piping and fittings; G

Valves; G

Spare Parts Data; G

Access Hatch Covers

Grinder Unit

SD-06 Test Reports

Pump Test

Float Test; G

SD-07 Certificates

Submersible Sewage Nonclog Pumps; G

Recycled Material Content; G

Access Hatch Covers

Gate Valves; G

Check Valves; G

Pump Motor; G

SECTION 33 32 16 Page 5

Pressure Gauges; G

SD-08 Manufacturer's Instructions

Access Hatch Covers

Pump Control System; G

Gate Valves; G

Check Valves; G

Pump Motor; G

Special Tools; G

Posted Instructions; G

SD-10 Operation and Maintenance Data

Operation And Maintenance Manuals

SD-11 Closeout Submittals

Warranty; G

1.3 QUALITY CONTROL

1.3.1 Installer Qualifications

Provide manufacturer's authorized pump representative who is trained and approved for installation of pumps and packaged pump station required for this project.

1.4 DELIVERY, STORAGE, AND HANDLING OF MATERIALS

1.4.1 Delivery and Storage

Inspect materials delivered to site for damage. Unload and store with minimum handling. Store materials in enclosures or under protective covering. Rubber gaskets which are not to be installed immediately must be stored under cover, out of direct sunlight. Do not store materials directly on the ground. Keep the interior of pipes, valves and fittings free of dirt and debris.

1.4.2 Handling

Handle pipe, fittings, valves, and other accessories in such manner as to ensure delivery to the trench in sound, undamaged condition. Avoid injury to coatings and linings on pipe and fittings; make repairs if coatings or linings are damaged. Carry pipe to the trench; do not drag it. Do not use any device or fitting inserted into (such as loader forks) or attached to (such as chain hooks) the bell or spigot ends of the pipe to transport pipe. Handle ductile iron pipe, fittings, and accessories in accordance with AWWA C600. Handle PVC pipe, fittings, and accessories in accordance with AWWA C605.

SECTION 33 32 16 Page 6

1.5 WARRANTY

Provide manufacturer's standard warranty for a minimum of one year for pump station including pumps, valves, controls, and accessories.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Provide a complete sewage pump station with submersible nonclog pumps including equipment and materials, installed and ready for operation. The pump supplier furnishes the controls, pumps and rail system to ensure unit integrity.

Submit fabrication drawings before installation. Submit drawings covering necessary or recommended changes to accommodate the equipment offered.

Show on the drawings the design of the chamber, with dimensions, types, and thicknesses of materials, and elevation levels with reference to those elevations indicated.

Submit erection/installation drawings for the manhole chamber with the required equipment and accessories. Provide precast reinforced concrete manhole sections conforming to ASTM C478. Show the design of the concrete wet well, with dimensions, types, and thicknesses of materials, and elevation levels with reference to those elevations indicated.

2.2 SUBMERSIBLE SEWAGE NONCLOG PUMPS & WALL MOUNTED GRINDER UNIT

Provide submersible sewage nonclog pumps as indicated. Provide UL listed pumps for explosion proof Class 1, Division 1, Groups C and D hazardous locations. Provide submersible, centrifugal sewage pumps of the nonclogging type with passageways designed to pass 3 inch diameter spheres without clogging . Provide pump capacity, number of pumps and motor characteristics as indicated on the drawings. Select pumps to continuously operate in a submerged or partially submerged condition.

Each pump shall be configured to only run one pump at a time for normal and emergency generator conditions. Please refer to each lift stations site plan (CS101-CS103) general notes for the specific pump selection along with applicable Details sheet.

Provide separate grinder units capable of grinding the materials found in normal domestic sewage, including plastics, rubber, sanitary napkins, disposable diapers, animal hair and wooden articles into a finely ground slurry with particle dimensions no greater than 1/3 inch. The Grinder Unit shall be Dimminutor unit or an approved equal that has capacity of 4.2 MGD and maximum flow of 5.0 MGD along with a slot width of .312 inches. The Grinder unit shall be composed of multiple stainless steel cutters mounted angularly on support arms of a single rotor shall sweep oversized solids from a special concave semicircular screen in a continuous 360 degree rotation and shred them against vertically mounted stationary cutters. The unit shall have continuous available torque throughout its 360 degree rotation. The performance of the machine shall be the same for either direction of rotation. The grinder motor shall be: Submersible-Explosion Proof design, 3 HP (2.2 kW), 230/460 Volt, 3-phase, 60 Hz. A Model CF-4000 wetwell frame or an approved equal shall be provided for convenient installation in the wetwell. It shall consist of an angle frame, integral overflow bar screen and a guide rail system. The guide rails shall be attached to the wet-well walls, and shall allow grinder to be easily slid up and down and fixed at operating position without fasteners.

SECTION 33 32 16 Page 7

2.2.1 Pump Construction

2.2.1.1 Casing

Provide hard, close-grained cast iron casing that is free from blow holes, porosity, hard spots, shrinkage defects, cracks, and other injurious defects. Provide casings permitting replacement of wearing parts. Ensure all joints are gasketed to prevent leakage. Ensure passageways permit smooth flow of sewage and are free of sharp turns and projections.

2.2.1.2 Impeller

Provide nonclogging type cast-iron impeller, conforming to ASTM A48/A48M, Class 30, for a submersible nonclog pump. Ensure the impeller has a smooth surface and allows free flowing with the clearance to permit objects in the sewage to pass. Fit and key, spline, or thread impeller on shaft, and lock in such manner that lateral movement is prevented and reverse rotation will not cause loosening.

2.2.1.3 Bearings

Provide heavy duty ball thrust bearing or roller type bearing sized to withstand imposed loads. Bearings shall be permanently sealed greased for life type, lubricate bearings.

2.2.1.4 Lubrication

Bearings shall be permanently sealed greased for life type that do not require service.

2.2.1.5 Balance

Balance rotating parts of the equipment mechanically and hydraulically to operate throughout the required range without excessive end thrust, vibration, and noise. Conform allowable vibration limits with ISO 1940-1 , Table 1. The existence of defects that cannot be eliminated by adjustment will be sufficient cause for rejection of the equipment.

2.3 PUMP MOTOR

Provide hermetically sealed electric motors with moisture and temperature-sensing probes in the wet well NEMA MG 1. Refer to drawings for site specific motor details for submersible pumps. Motor horsepower must not be less than pump horsepower at any point on the pump performance curve. Fit motors with lifting "eyes" capable of supporting entire weight of pump and motor. Seal the power cable inside the motor end bell.

Provide a waterproof power cable for its full length. Motors shall be UL listed for explosion proof Class 1, Division 1, Groups C and D. Air filled motors are not acceptable. Oil used must be able to be disposed as non-hazardous waste. Pump Motors Shall include a Closed-Loop Cooling Jacket that circulates a Propylene Glycol cooling liquid, that is Non-Toxic, and provides Freeze and Corrosion Protection. Pumps with cooling jackets that circulate the raw wastewater for cooling (AKA:

Open-Loop Cooling Jackets) are not permitted.

SECTION 33 32 16 Page 8

2.4 PUMP CONTROL SYSTEM

2.4.1 General

Provide an automatic type of pump operating control panel including all necessary components to function reliably. Mount controls in a NEMA 4X rated stainless steel control panel. Ensure equipment subject to contact with sewage or sewage gases is corrosion-resistant metal. Provide an electronic controller that automatically activates and alternates the pump operation. Due to electrical power and emergency generator limitations, the operation shall be limited to one pump running at at a time. Control Sequence of operation shall allow auto alternation and a user set defined Lead, lag1, lag2. Provide hand-off-auto switches to choose the mode of operation for each pump. Provide controls with a 12 or 24 VDC powered float switch connected to the alarm contact of the battery charger to activate high-level alarms.

Protect pumping stations from lightning and transient voltage surges and equip with lightening/surge protection.

Protect pumping stations from phase loss, phase reversal, and voltage irregularities with a combination Phase/Voltage Monitoring Relay.

Provide the station with applicable wiring for connection of a generator in case there is an external power outage.

Design the control system to operate pumps at the power characteristics as shown on the plans. Ensure all controls and wiring meet or exceed the requirements of NFPA 70 .

For pumps specified as explosion proof, have pump power and control installation meets NEC requirements for Class 1, Division 1, Group D Hazardous Location, including intrinsically safe controls. Provide components that are UL listed or FM approved. Float switch connections shall be intrinsically safe.

Require the control function to provide for the operation of the pumps under normal conditions and alternates the pumps on each pump down cycle.

If the lead pump is running but the wet well level continues to rise and reaches the Lag Float Level, the controls shall stop the Lead Pump, engage the alternator and then start the Lag Pump. If the Lead Pump fails for any reason the controls shall stop the Lead Pump, engage the alternator and then start the Lag Pump.

2.4.2 Enclosure

Provide a NEMA 4X rated enclosure manufactured from stainless steel. The enclosure is a wall mount type suitable for mounting on strut or channel with a minimum depth sized to adequately house all the components.

Provide a rubber composition door gasket and assures a positive weatherproof seal. Provide a door that opens a minimum of 180 degrees and is equipped with a 3-point latch and padlockable handle.

Provide a dead front mounted in the panel to provide protection of personnel from live internal wiring. Install cutouts for breaker handles to allow operation of breakers without entering the compartment.

Mount all control switches, indicator pilot lights, elapsed time meters, SECTION 33 32 16 Page 9 duplex receptacle and other operational devices on the external surface of the dead front.

Ensure the dead front opens a minimum of 150 degrees to allow access to equipment for maintenance.

Manufacture the back plate from 12-gauge (minimum) steel and finished with a primer coat and two (2) coats of baked on white enamel. Mount all hardware to the subpanel with machine thread tapped holes. Sheet metal screws are not acceptable. Permanently identify all devices to match the schematic diagram.

Provide a NEMA 4X enclosed control panel air conditioner sized as required to provide adequate cooling for the Variable Frequency Drives and other controls components housed inside the control panel enclosure. The control panel manufacturer shall be responsible for the sizing of the control panel enclosure and the control panel air conditioning system based on the anticipated heat loads from the controls equipment and the installation environment.

2.4.3 Level Control System

The Level Sensing Control System shall utilize a probe styled system as the primary. The probe system style shall be and/or meet requirements of the FOGRod by Wastewater Level or MultiTrode and/or approved equal. The probe shall be 7.5 foot with 50 foot cable length with ten sensors. The materials shall be PVC with AL6XN contacts (super-austenitic steel for very high corrosion resistance) along with aluminum powder coated mounting bracket with polyurethane cleaning pad. The panel shall include a backup or secondary level control system that utilizes four (4) floats for control. In the event of primary sensor failure, the backup or secondary float control system shall automatically engage to maintain pump operation.

Provide a submersible pressure type level sensor level control system and sealed, mercury-free float switch control system to sense variations of sewage level in the wet well.

Use a direct acting float switch consisting of a normally open mercury switch enclosed in a float. Use float molded of rigid high-density polyurethane foam, color-coded and coated with a durable, water and corrosion-resistant jacket of clear urethane.

Provide stainless steel float brackets in accordance with manufacturer's recommendations.

Mount floats at fixed elevations as shown on the drawings.

Use floats designed to tilt and operate their switches causing sequential turn-on turn-off of the pump, when the liquid level being sensed rises or falls past the float.

Float switches must be intrinsically safe relays. Provide an intrinsically safe barrier relay between the wet well and the control panel.

Also, provide the pump station with a submersible pressure type level sensor and an electronic pump controller. Sense levels by a submersible pressure transmitter provided by controller manufacturer. The transmitter shall have a 3-inch diameter sensing diaphragm to resist clogging and a

SECTION 33 32 16 Page 10 protective baffle plate to reduce risk of sensor damage. Construct the system as follows:

a. The pressure type level sensor is a submersible type, suspended on its cable.

b. Install the sensor per manufacturer's instructions for wet well installations, including any recommended mounting accessories.

c. The level sensor is as follows:

(1) Select the sensor range based on the wet well depth.

(2) The sensor output is 4-20mA proportional to water level, 2-wire type.

(3) Construct all exposed parts of 316 Stainless Steel.

(4) Fill the sensor with Oil.

(5) Power the Sensor by 24 VDC output from electronic pump controller.

d. Mount the electronic pump controller in the starter panel enclosure, and be visible from the front of the swing-out panel, with the enclosure door opened. The electronic pump controller is as follows:

(1) Accept a 4-20 mA, 2 wire level signal, and indicate the wet well level digitally in direct engineering units (feet).

(2) Provide pump control outputs, with independent adjustment for each pump starting and stopping setpoint. Indicate each level setpoint digitally in direct engineering units.

Provide an intrinsically safe barrier relay between the wet well and the control panel.

2.4.4 Alternator

Provide an alternator control switch to operate in connection with each float. Use an alternator control switch to alternate the operation of the pumps. Only one pump shall be able to run at any time whether on utility power or on back-up generator power. If the lead pump fails for any reason, the controls shall turn off the lead pump, engage the alternator function, and start the lag pump. If the lead pump is running and the liquid level in the wet well continues to rise and reaches the lag float, the controls shall turn off the lead pump, engage the alternator function, and start the lag pump.

2.4.5 Sewage Pump Alarm and Control Panel

Enclose alarm panel in NEMA 4X enclosure and with a flashing red light that is visible from 50 feet away, with long life bulb in guarded enclosure and 6 inch diameter horn. Use horns capable of emitting 120 DB at 10 feet. Power alarm horn and light from 12V DC power supply with battery backup. Provide a rechargeable battery rated to power both the horn and light for a minimum of two hours upon loss of main power. Provide circuitry to automatically recharge the battery after main power is restored. Use batteries capable of being fully recharged in no more than 20 hours. Use panel with power on light, push to test button for horn and

SECTION 33 32 16 Page 11 light and push to silence button for horn and light with automatic reset for next alarm.

2.4.5.1 Alarms

Provide a test function ability for the alarm system. Provide alarms to activate under the following conditions:

a. High liquid level as sensed by the level control system.

b. Loss of main power.

c. No flow light as sensed by limit switch on the check valve or as sensed by current sensors.

d. Pump failure via temperature overload or motor heat sensor trip;

provide motor high temperature light.

e. Seal failure with indication light.

2.4.5.2 Circuit Breakers

a. Provide an individual circuit breaker for each pump.

b. Include a control circuit breaker and an alarm circuit breaker in the control panel.

c. Provide circuit breakers in accordance with UL 489

d. Conform to UL 67 for circuit breaker mounting.

2.4.5.3 Variable Frequency Drives

Provide Variable Frequency Drives for Motor Starter, Overload, Phase Loss, Phase Reversal and Irregular Voltage Protection. The Variable Frequency Drives shall be Schneider Electric ATV630 Series or Engineer Approved Equal. The Variable Frequency Drives will be programmed for Reduced Speed/Voltage Soft Starting of the pump, and for Reduced Speed/Voltage Soft Stopping or Freewheel Stopping of the pump. When a pump is called to run, the Variable Frequency Drive will Ramp-Up/Soft Start the pump at the programmed ramp-up/start time and will then operate at full speed (60-Hz) for the duration of the pumping cycle until the off level is reached. When the off level is reached, the Variable Frequency Drive will Reduce the Speed/Voltage to Soft Stop the pump or Freewheel Stop the pump (whichever works best for the application as determined through testing at start-up.

If through testing at start-up it is determined that the pumps are operating too far to the right of their performance curve and producing more flow than desired, the maximum speed setting in the Variable Frequency Drive shall be adjusted as needed to reduce the maximum allowed pump speed and flow rate.

2.4.5.4 Power Lugs

a. Size the incoming power lugs for the proper voltage, amperage, and horsepower for each pump station.

b. Include grounding lugs for the incoming power. Provide a dedicated grounding lug in the control panel for each pump.

SECTION 33 32 16 Page 12

c. Size ground lug and rod according to local and base electrical codes and installed by a licensed electrician.

d. Use UL listed power lugs.

e. Conform to UL 67 for required power lug mounting.

2.4.5.5 Anti-Condensation Heater

a. Provide an anti-condensation heater in the control panel that is sized based upon the size of the particular pump station's control panel size.

b. Power the heater from the control voltage transformer for three phase pump motor units.

c. Control the heater by a thermostat, coming on at 50 degree F and going off at 65 degree F.

d. Clearly label panel directory for breakers.

2.4.5.6 Trouble Light

Provide an LED trouble shooting light in the panel that is hard-wired into an appropriately sized circuit breaker. It is acceptable for the light and one of the convenience outlets to share the same circuit breaker.

2.4.5.7 Additional Requirements

a. Provide elapsed time meter for each pump that measures run time in hours to 9999.9.

b. Do not place junction boxes between pumps, control systems and control panels; provide conduit seals within 12 inches of all control panel penetrations. If this is unavoidable, use NEMA 7 construction.

2.4.6 Electrical Requirements

Install labels to identify switches and controls. Provide internal wiring for components of packaged equipment as an integral part of the equipment. Provide power wiring and conduit for field installed equipment.

2.5 WET WELL AND VALVE VAULT

2.5.1 Wet Well and Valve Vault

Provide a precast concrete wet well ; include a separate precast concrete valve vault. Provide a wet well and valve vault with inside diameters as indicated and to the depths indicated on the drawings.

Precast structures may be provided in lieu of cast-in-place structures.

2.5.1.1 Precast Concrete Structures

Submit manufacturer's data indicating percentage of recycled material content in sewage lift stations to verify affirmative procurement compliance.

Fly ash is required as an admixture and is to conform to ASTM C618, Class F or C. Fly ash replacement of cement is not to exceed 20 percent (maximum

SECTION 33 32 16 Page 13 one part fly ash to four parts cement) by weight.

a. Buoyancy Calculations: Submit buoyancy calculations sealed by a licensed professional engineer assuming seasonal high groundwater elevation at proposed finished grade.

b. Construct precast concrete structures in accordance with ASTM C478, except as specified herein. Provide precast concrete structures with a compressive strength of 4000 psi at 28 days and an air entrainment of 6 percent, plus or minus 2 percent, and a minimum wall thickness of 5 inches. ASTM A615/A615M reinforcing bars. ASTM C443, Type B gaskets for joint connections. Use monolithic base and first riser.

2.5.2 Access Hatch Covers

Provide aluminum access floodtight hatch covers as indicated. Include lifting mechanism, automatic hold open arm, slam lock with handle, and flush lift handle with vinyl grip. Use automatic hold open arm that locks in the 90 degree position. Use cover that is 1/4 inch diamond plate with 1/4 inch channel frame and continuous anchor flange. Use access hatch cover capable of withstanding a live load of 300 lb/sq. ft. Provide stainless steel cylinder lock with two keys per lock. Key all the locks the same.

2.5.3 Wet Well Base Material

Provide crushed stone as indicated and specified in Section 31 00 00

EARHTWORK.

2.5.3.1 Vent

Provide vent to atmosphere with covers and screens to prevent the entrance of rain, insects, and rodents.

2.6 STATION PIPING

Provide pressure piping, emergency pump connection, air release valves, and related accessories for force main piping outside the sewage wet well and valve vault in accordance with Section 33 30 00 SANITARY SEWERAGE.

2.6.1 Ductile-Iron Pressure Pipe and Associated Fittings

Conform to AWWA C151/A21.51 , Pressure Class 350.

2.6.1.1 Flanged Pipe

Conform to AWWA C115/A21.15 , ductile iron.

2.6.1.2 Fittings

AWWA C110/A21.10 , flanged. Provide flanged joint fittings within wet well and valve vault as indicated. Provide mechanical joint fittings outside valve vault enclosure as indicated. Use fittings with pressure rating at least equivalent to that of the pipe.

2.6.1.3 Joints

AWWA C115/A21.15 for flanged joints. Use bolts, nuts, and gaskets for flanged connections recommended in the Appendix to AWWA C115/A21.15 .

SECTION 33 32 16 Page 14

Provide ductile iron flange for setscrewed flanges in accordance with ASTM A536, Grade 70-50-05 or 60-42-10, and meeting the applicable requirements of ASME B16.1 , Class 125. Use 190,000 psi tensile strength, heat treated, and zinc-coated steel setscrews for setscrewed flanges.

Conform to the applicable requirements for mechanical-joint gaskets specified in AWWA C111/A21.11 for setscrewed flange gaskets. Use setscrewed gasket designed to provide for confinement and compression of gasket when joint to adjoining flange is made.

2.6.2 Insulating Joints

Provide between pipes of dissimilar metals a rubber gasket or other approved type of insulating joint or dielectric coupling to effectively prevent metal-to-metal contact between adjacent sections of piping.

2.6.3 Accessories

Provide flanges, connecting pieces, transition glands, transition sleeves, and other adapters as required.

2.6.4 Flexible Flanged Coupling

Provide flexible flanged couplings applicable for sewage as indicated.

Use flexible flanged coupling designed for a working pressure of 350 psi.

2.7 VALVES AND OTHER PIPING ACCESSORIES

2.7.1 Isolation Gate Valves in Valve Vault

Conform to AWWA C500 for gate valves with outside-screw-and-yoke rising-stem type with double disc gates and flanged ends. Conform to AWWA C509 for valves with outside-screw-and-yoke rising-stem type with flanged ends. Provide valves that open by counterclockwise rotation of the valve stem. Use valves from one manufacturer.

2.7.1.1 Valves Larger Than 2 Inches

Resilient seat gate valves conforming to AWWA C509 with non-rising stems and flanged ends.

2.7.2 Check Valves 4 inch and Larger Diameter

Provide nonclogging swing check valve rated for not less than 175 psig working pressure capable of passing 3-inch diameter solids. Match cast iron to ASTM A126 and flanged ends to AWWA C110/A21.10 Buna-N disc and integral seat.

Provide a positive horizontal, swing check type check valves. Provide valves that permit a free flow of sewage forward and a positive check against backflow. Provide iron body valves with a removable cover for inspection and removal of the gate assembly. Provide bronze gate, gate seats, shaft, studs, and nuts.

2.7.3 Identification Tags and Plates

Provide the manufacturer's name or trademark on a corrosion-resistant identification plate or cast integrally, stamped, or otherwise permanently marked in a conspicuous place on each item of equipment. Include on the pump identification plate the pump capacity in gpm, pump head in feet and

SECTION 33 32 16 Page 15 speed of rotation. Cast on the body of the pump the direction of rotation.

2.7.4 Pipe Support

Use pipe support schedule 40 galvanized steel piping matching ASTM A53/A53M.

Provide either ASME B16.3 or ASME B16.11 galvanized threaded fittings.

All steel (galvy and painted) pipe supports and all other items lagged and mounted to concrete shall be drypacked with non shrink grout rather than in direct contact with the concrete to limit corrosion due to ponding around mounted appurtenances and pipe supports.

2.7.5 Miscellaneous Metals

Use stainless steel bolts, nuts, washers, anchors, and supports for installation of equipment.

2.7.6 Quick Disconnect System with Hydraulic Sealing Flange and Rail System

Use quick disconnect system consisting of a case iron base elbow for supporting the pumps, a hydraulic sealing flange for mounting the pump, stainless steel pump guide rails and the discharge pipe supports. Provide stainless steel guide rails, brackets and lifting chain for raising and lowering the pump in the wetwell. Build guides onto pump housing to fit the guide post to assure perfect alignment between pump and guide rails.

2.7.7 Wet Well Vent

Provide a flanged ductile iron pipe and bend, conforming to AWWA C115/A21.15 galvanized steel pipe and bend, conforming to ASTM A53/A53M with insect screening.

2.7.8 Pressure Gauges

Provide three (3) pressure gauges at each lift station. One pressure gauge shall be installed on the discharge piping of each pump prior to the check valve. The third pressure gauge shall be installed on the common force main pipe after the two discharge pipes tee together. All pressure gauges shall be installed above grade. Pressure gauges shall have a stainless steel case, be liquid filled and include a stainless steel liquid filled diaphragm seal to protect the gauge from contaminants. The Gauge scale shall be able to register up to the maximum discharge pressure or shut-off head/pressure rating of the pump.

2.8 EXCAVATION, TRENCHING, AND BACKFILLING

Provide in accordance with Section 31 00 00 EARTHWORK, except as specified herein.

PART 3 EXECUTION

3.1 INSTALLATION

Provide pump station in accordance with drawings and requirements of the respective equipment manufacturers. Dampen and isolate equipment vibration.

3.1.1 Equipment Installation

Install equipment in accordance with these specifications and the

SECTION 33 32 16 Page 16 manufacturer's installation instructions. Grout equipment mounted on concrete foundations before installing piping. Install piping to avoid imposing stress on equipment. Match flanges before securing bolts.

3.1.2 Installation of Ductile-Iron Pressure Pipe and Fittings

Unless otherwise specified, install pipe and fittings in accordance with the paragraph GENERAL REQUIREMENTS FOR INSTALLATION OF PIPELINES of Section 33 30 00 SANITARY SEWERAGE, and with the requirements of AWWA C600 for pipe installation, joint assembly, and valve-and-fitting installation.

Make flanged joint with gaskets, bolts, and nuts specified for this type joint. Make flanged joints tight, avoid strain on flanges, fittings, and other accessories. Align bolt holes for each flanged joint. Use bolts sized for the bolt holes; use of undersized bolts is not permitted. Do not allow adjoining flange faces to be out of parallel to such degree that the flanged joint cannot be made watertight without overstraining the flange.

3.1.3 Valves

Make and assemble joints to gate valves and check valves as specified for making and assembling the same type joints between pipe and fittings.

Install valves in accordance with manufacturer's installation instructions. Install gate valves as described in AWWA C500, AWWA C509, and AWWA C515 and with AWWA C600 for valve-and-fitting installation and with the recommendations of the Appendix ("Installation, Operation, and Maintenance of Gate Valves") to AWWA C500.

3.2 FIELD QUALITY CONTROL

Provide appliances, materials, water, and equipment for testing, except that water and electric power needed for field tests will be provided Conduct testing after equipment, electrical services, and piping are installed, and the pump station is ready for operation. Correct defects discovered to the satisfaction of the Contracting Officer, and tests repeated, at no expense to the Government, until the equipment functions as intended and designed.

3.2.1 Testing Procedure

Perform a pump test and float test. Submit the test results to the Contracting Officer.

Test all panels to the power requirements as shown on the plans to assure proper component operation. Activate each control function to check for proper operation and indication.

3.2.2 Field Representative

A representative of the pump manufacturer is to direct the startup of the station and instruct representatives of the Government in startup and operation procedures.

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3.3 CLOSEOUT ACTIVITIES

3.3.1 Operation and Maintenance

Submit operation and maintenance manuals for lift stations, including Equipment Description, Assembly and Installation Procedures, Adjustment and Alignment, Checkout Procedures, Procedures of Operation and Troubleshooting. Include preventative maintenance and inspection procedures for lift stations. Include in procedures the frequency of preventative maintenance, inspection, adjustment, lubrication, and cleaning necessary to minimize corrective maintenance and repair.

Supply special tools that are required for maintenance and testing of the lift stations.

Submit spare parts data, including a complete list of parts and supplies with source of supply. List parts and supplies that are either normally furnished at no extra cost with the purchase of equipment, or specified to be furnished as a part of the contract, and list additional items recommended by the manufacturer to ensure an efficient operation for a period of one year.

Install on or near the lift stations, a complete package of posted instructions, consisting of labels, signs, and templates of operating instructions.

Provide a list or reference all specific operation and maintenance procedures that are required to keep the warranty valid.

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