11_82_02_Submersible_NonClog_Pump_Add1.docx
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11 82 02 Submersible NonClog Pump_Add1
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INFRASTRUCTURE IMPROVEMENTS FOR THE
SOUTH BAY INTERNATIONAL WASTEWATER TREATMENT PLANT
San Diego County, California
SPECIFICATION 11 82 02
SUBMERSIBLE NON-CLOG PUMPS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS, CONTRACT CLAUSES, AND SPECIFICATIONS
The following may not include all related documents, contract clauses, and technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification in accordance with all terms of the Contract herein.
Division 1, General Requirements:
SPECIFICATION 01 33 00, Submittal Procedures SPECIFICATION 01 75 01, Starting and Placing Equipment in Operation SPECIFICATION 01 75 02, Field Tests of Equipment SPECIFICATION 01 78 36, Warranty SPECIFICATION 01 78 23, Operation and Maintenance Data Division 3, Concrete Division 5, Metals Division 9, Finishes SPECIFICATION 09 91 00, Painting Division 11, Equipment SPECIFICATION 11 80 00, General Equipment Provisions Division 25, Integrated Automation Division 26, Electrical Division 40, Process Integration
1.2 DESCRIPTION
A. Scope: The Contractor shall furnish and install all labor, materials, equipment, appurtenances, specialty items, and services required for complete and operable submersible mixing equipment as shown and specified in the Contract Documents.
B. Equipment Coordination: To ensure that all the equipment is properly coordinated and will function in accordance with the requirements of the Contract Documents, the Contractor shall obtain all the equipment specified herein from a single supplier. However, the Contractor shall retain ultimate responsibility under this Contract for equipment coordination, installation, operation and guarantee, and the Contractor shall furnish and install all labor, equipment, materials, appurtenances, specialty items and services not provided by the suppliers but required for a complete and operable system. The equipment covered by this specification is intended to be standard equipment of proven ability as manufactured by reputable concerns having extensive experience in the production of such equipment. The equipment furnished shall be manufactured and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed as shown and specified in the Contract Documents.
C. The General Equipment Provisions (Specification 11 80 00) shall apply to all equipment furnished under this Specification.
D. Motors: All motors shall be submersible type and shall be sized to be non-overloading under continuous duty operation.
E. The manufacturer of the equipment specified herein shall be required to review and satisfy all relevant requirements of other Specifications of the Contract Documents and the requirements of the Contract Drawings. The Contractor, manufacturer, supplier, fabricator and/or subcontractors furnishing and/or installing equipment, services and specialties associated with this Specification shall fully coordinate their efforts to avoid potential claims that are based on failure to review all relevant Contract Documents, including the Contract Drawings.
F. The exterior surfaces of all motor housings and gearbox housings shall be painted as specified in Specification 09 91 00, Painting.
1.3 QUALITY ASSURANCE
A. Manufacturer's Qualifications: Manufacturer of the mixing equipment specified herein shall have experience in providing similar type equipment and shall show evidence with his submittal of at least five (5) installations in the United States of America where equipment of the same material and same application of the type specified herein have been in satisfactory operation for at least five (5) years. The list of installations shall include the name and telephone number of the Plant Superintendent at each of the five (5) qualifying installations.
| B. | Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. |
| (1) | Standards of the American Society for Testing and Materials. |
| (2) | National Electrical Code. |
| (3) | Standards of National Electrical Manufacturers Association. |
| (4) | Institute of Electrical and Electronics Engineers. |
| (5) | American National Standards Institute. |
| (6) | AGMA Standards. |
| (7) | Standards of the Hydraulic Institute. |
| (8) | Standards of the American Water Works Association. |
1.4 SUBMITTALS
| A. | Drawings and Data: Complete fabrication, assembly, foundation, and installation drawings, certified performance curves, and operation, maintenance and storage instructions, together with detailed specifications and data covering materials used, power drive assembly, parts, devices and other accessories forming a part of the equipment furnished, shall be submitted for review in accordance with the procedures and requirements set forth in Specification 01 33 00, Submittal Requirements. All engineering calculations required for submittal shall be signed by a California Registered Professional Engineer at the Contractor's expense and shall be included in the Contractor's bid. Data and specifications for the equipment shall include, but shall not be limited to the following: |
| (1) | Pump horsepower. |
| (2) | Impeller diameter. |
| (3) | Pump curve including flow rate and head. |
B. Technical Manuals: Complete operation and maintenance instruction, lubrication schedules and troubleshooting guides shall be submitted for review in accordance with the procedures and requirements set forth in Specification 01 78 23, Operation and Maintenance Data, and as specified in Divisions 25 and 26.
C. Manufacturer's Qualifications: In accordance with Part 1.3, Quality Assurance, of this Specification.
D. Certified Test Results: In accordance with Paragraph 3.2.A of this Specification.
E. Other Certifications: In accordance with Paragraph 3.3.A of this Specification.
1.5 MEASUREMENT AND PAYMENT
The work performed by the Contractor under this Specification shall not be measured and paid for directly, but shall be considered to be included in the Lump Sum Bid for this Contract.
PART 2 – MATERIALS, EQUIPMENT, AND PRODUCTS
2.1 GENERAL
| A. | The Contractor shall furnish and install the following equipment, appurtenances and support services under this Specification: |
| (1) | Submersible non-clog pumps as detailed in the project drawings for the pumping from the equalization tank to the activated sludge tanks. |
| (2) | Spare parts as listed in Part 2.8. |
B. Each unit shall be furnished with a stainless steel nameplate securely mounted to the body of the equipment. As a minimum, the nameplate shall include the equipment number, manufacturer's name and model number, serial number, rated capacity, speed, and all other pertinent data. As a minimum, nameplates for motors shall include the motor number, manufacturer's name, and model number, serial number, horsepower, speed, input voltage, amps, number of cycles, and power and service factors.
C. All parts of mechanisms shall be amply proportioned for all stresses that may occur during fabrication, shipping, erection, and intermittent or continuous operation. All units shall be constructed such that dismantling and repairing can be accomplished without difficulty.
2.2 PERFORMANCE REQUIREMENTS
A. The submersible non-clog pumps shall be designed to pump wastewater with standard water characteristics from the equalization thank to the activated sludge tanks.
B. Continuous Submergence Rating: 65 feet.
C. The impeller shall be a non-clogging design and shall be capable of handling solids and fibrous materials found in normal activated sludge treatment applications and pass a 4-inch diameter solid object.
2.3 DETAILS OF CONSTRUCTION
| A. | General: |
| (1) | Each pump shall be of the submersible type. All components of the pump, including the motor and gear box, shall be designed and rated for continuous duty at the submergence specified in Part 2.2, Performance Requirements. |
| (2) | All mating surfaces of housing components shall provide watertight sealing machined and fitted with nitrile rubber O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between machined surfaces, resulting in compression of the O-rings without secondary sealing compounds, rectangular gaskets, elliptical O-rings, grease, or other devices. |
| (3) | All exposed nuts, bolts, washers, and connecting hardware shall be 316 SS. |
| B. | Impeller: |
| (1) | The impeller shall consist of grey cast iron, Class 35B, dynamically balanced, multiple vaned, double shrouded non clogging design having long throughlets without acute turns. |
| (2) | The impeller shall be capable of handling solids, fibrous materials, heavy sludge and other matter found in wastewater. Impeller shall be keyed to the shaft, retained with an expansion ring and shall be capable of passing a minimum 4- inch diameter solid. |
| (4) | The impeller shall be coated with an acrylic dispersion zinc phosphate primer. |
C. Wear Ring:
(1) The pump shall be equipped with a brass ring insert that is drive fitted to the volute inlet.
(2) The pump shall also have a stainless steel impeller wear ring heat shrink fitted onto the suction inlet of the impeller.
| D. | Volute: |
| (1) | The pump volute shall be single piece grey cast iron, Class 35B, non-concentric design with smooth passages large enough to pass any solids that may enter the impeller |
| E. | Pump Motor: |
| (1) | The pump motor shall be squirrel-cage, induction type design, housed in an air-filled, watertight chamber. The stator windings shall be insulated with moisture resistant Class H insulation, which shall resist temperatures of 356F. The stator shall be insulated by the trickle impregnation method using Class H monomer-free polyester resin resulting in a winding fill factor of at least 95%. The motor shall be inverter duty rated in accordance with NEMA MG1, Part 3.The motor shall be designed for continuous-duty, capable of sustaining a maximum of 10 evenly spaced starts per hour. The rotor bars and short circuit rings shall be made of aluminum. The motor shaft, delivered with the rotor as an integral part, shall be shaft steel AISI 431 or Type 420 stainless steel. The stator housing shall be of gray cast iron AISI A48-40B. |
| (2) | The stator shall incorporate three thermal switches, connected in series, to provide over temperature protection of the motor winding |
| (3) | The pump motor shaft shall rotate on three permanently lubricated bearings. The inner and outer bearing shall be single row, deep-groove ball bearings calculated for an L-10 life of 100,000 hours at full load. |
| (4) | Pump motor shall be rated for 460V, 3Φ, 60 Hz with a 1.15 service factor. |
| (5) | Provide stainless steel cable and stainless wire braid sleeve to support power cable from the underside of wet well roof slab or access frame. |
| F. | Acceptable Manufacturers: |
| (1) | Flygt, |
| (2) | Compliance-confirmed equal. |
| G. | Accessories |
| (1) | Discharge Elbow: Construct of ASTM A890 SST with ANSI Class 125 flanged outlet. For pumps without legs, design to support entire weight of pumping unit. |
| (2) | Discharge Interface: |
| a. | Sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal-to-metal watertight contact. |
| b. | Self-aligning without having to enter the wet well. |
| c. | Discharge elbow to mate to pump discharge and transition to discharge piping. |
| (3) | Guide Rails and Brackets: Provide sliding guide bracket of 316 stainless steel (SS). Guide rails to be minimum 2-inch-diameter, Schedule 40, 316SS pipe. Upper guide bar support to be fabricated from 316SS. Lower guide bar support to be integrally cast boss on discharge elbow, arranged so that guide bar is held in position by sliding over boss. Provide intermediate guide bar supports, fabricated from 316SS, when guide bars exceed 8 feet in length. Bolts to be type 316SS. |
| (4) | Lift System: Furnish for each unit type 316 stainless steel Flygt "grip-eye" system or equal sized by pump manufacturer; secure with type 316 stainless steel fittings. |
2.4 SPARE PARTS
| A. | The Contractor shall furnish the following equipment for use as spare parts in operations and maintenance of the equipment: |
| (1) | 1 complete spare pump of each type with electrical cable. |
| (2) | 3 sets of each type of mechanical seal. |
| (3) | 3 sets of each type of lip seal. |
| (4) | 3 complete sets of all O-rings. |
| (5) | 3 cable entry gaskets where applicable. |
| (6) | 3 power cable seal assemblies. |
| (7) | 3 sets of motor shaft bearings. |
| (8) | 3 sets of propeller shaft ball bearings. |
| (9) | 1 lip seal installation tool |
| (10) | 1 package spare oil plugs, sealing washers, grease fittings, and support washers. |
PART 3 - CONSTRUCTION AND EXECUTION METHODS
3.1 INSTALLATION
Install equipment as specified herein, as described in the Contract Documents, as shown on the Compliance-confirmed shop drawings, and as directed by the manufacturer's representative.
3.2 TESTS
| A. | Factory Tests: The pump manufacturer shall perform the following inspections and tests on each pump before shipment: |
| (1) | An insulation test of the windings and balancing of the rotor. |
| (2) | A full-load test of the pump motor running dry for 5 minutes. |
| (3) | A submerged test of the pump. |
| (4) | A motor and cable insulation test for moisture content and insulation defects. |
| (5) | A check of impeller, motor rating, and electrical connections for compliance with purchase order. |
| B. | Field Tests: The Contractor shall perform the following field tests on each pump: |
| (1) | With the pump installed, the Contractor shall energize the motor to check rotation. |
| (2) | With the pump installed on the guide rail assembly, the Contractor shall run the pump for 30 minutes submerged and check pump current draw at the motor control center. Remove each unit and repeat insulation and moisture test. |
3.3 MANUFACTURER'S SERVICES
| A. | Manufacturer's Field Services: The Contractor shall provide the following services in addition to any other services specified herein, and required by these Specifications. |
| (1) | A factory-trained manufacturer's representative shall be provided for a minimum of two (2) trips and a minimum of two (2) eight-hour days to provide installation supervision, startup and field testing services (one day) and O&M training services (one day). The installation services shall be coordinated between the Contractor and the manufacturer. The startup and field testing, and the O&M services shall be coordinated with the COR. |
| (2) | After installation supervision and field testing services by the manufacturer, the Contractor shall submit to the COR, per the requirements of Specification 11 80 00, General Equipment Provisions, a certification letter on the manufacturer's letterhead and signed by the manufacturer certifying that the equipment was installed per the manufacturer's recommendations and requirements and shall furnish all field test data per Specification 11 80 00, General Equipment Provisions. |
B. All costs, including travel, lodging, meals and incidentals for manufacturer services shall be included in the Contractor's bid.
3.4 OPERATIONAL REQUIREMENTS
An overview of the key operational requirements for the submersible non-clog pump is provided below for the convenience of the Contractor. Divisions 25, 26, and 40 describe these operational requirements more fully.
A. Each pump is furnished with a REMOTE/OFF/LOCAL and an ON/OFF switch at the pump location and an ON/OFF switch located at a local control panel. In the REMOTE position, the ON/OFF switch will control the operation of the pump and the pump will run continuously. In case of SCADA system failure, the local ON/OFF switch will allow manual operation.
B. On motor overload, the pump will shut down and the pump failure alarm at the local control panel will be initiated. This alarm will be part of a common “PUMP SYSTEM FAILURE” alarm at the ADMIN-PCC.
ATTACHMENT A
Pump Performance and Size
| 1. | Quantity: | 6 (six) pumps |
| 2. | Location: | RAS Pump Station Pumps |
| 3. | Service: | Wastewater |
| 4. | Rated Capacity Each: | 3,000 gpm |
| 5. | TDH at Rated Capacity: | 1615 feet |
| 66. | TDH at 2000 gpm flow: | 12 feet |
| 7. | TDH at 1500 gpm flow: | 10 feet |
| 8. | Minimum Pump Efficiency at rating point: | 75% |
| 79. | Maximum Driven Speed: | 1,160 rpm |
| 810. | Voltage: | 460 Volt - 3 phase - 60 Hz |
| 911. | Maximum Motor Horsepower: | 27 HP |
| 1012. | Minimum Pump Discharge Size: | 10″ |
ATTACHMENT B
Pump Performance and Size
| 1. | Quantity: | 2 (two) pumps |
| 2. | Location: | EQ Tank Wetwell Pumps |
| 3. | Service: | Wastewater |
| 4. | Rated Capacity Each: | 10,600 gpm |
| 5. | TDH at Rated Capacity: | 28.4 feet |
| 66. | TDH at 5000 gpm flow: | 15.5 feet |
| 7. | TDH at 8000 gpm flow: | 21.5 feet |
| 8. | Minimum Pump Efficiency at rating point: | 82.2% |
| 79. | Maximum Driven Speed: | 500 rpm |
| 810. | Voltage: | 460 Volt - 3 phase - 60 Hz |
| 911. | Maximum Motor Horsepower: | 110 HP |
| 1012. | Minimum Pump Discharge Size: | 20″ |
- End of Specification -
THIS PAGE INTENTIONALLY BLANK
| July 31August 24, 2015 | Submersible Non-Clog Pump |
| USIBWC IBM15B0002 | Page 11.82.02 - 10 |
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