LIFTSTATION BINDERWITHELECTRICAL.pdf

STATEMENT OF WORK

Repair Lift Station (Maintenance Facility) Garrison Project Riverdale, ND

1.0 General Information.

1.1 Background. Currently the duplex lift station system consists of two Fairbanks Morse 4-inch model 5432M vertical pull up submersible sewage pumps, a guide rail system, lifting chains and lifting system, and controls components. These pumps are Explosion Proof Class I, Division I, Groups C and D. Design conditions of the pumps are 250 GPM, 95 TDH, 55% efficiency at 1755 RPM and 10 NPSHR. Each pump is driven by a submersible 15 horsepower motor with a 1.15 service factor. Operation of the motor runs at 1755 RPM on 460 volts, 3 phase, 60 Hz (see appendix). The system puts out a combined 42 amperes under full load or 21 amperes per pump.

1.2 Scope of Work. This is a non-personal services contract to provide new equipment and materials for the outside maintenance facility lift station. Services include removal and disposal of existing equipment inside the wet well and valve pit and installing new:

a. Power and Control Cables

b. Conduit between Control Equipment Cabinet and Wet Well

c. Guide Rails and Pump Supports

d. Air Release Valves and Venting

e. Lifting Chains, Floats, and Float Support Pipe

f. 4-inch Discharge Piping, Fittings, Check Valves, Plug Valves, and flexible couplings includes piping a minimum of 2 feet outside the valve pit and connect to existing SDR 21 PVC force main.

g. 3-inch PVC Valve Pit Drain Pipe, Fittings, and Check Valve

h. Valve Pit Ladder i . Biological Blocks to aid in control of lift station grease accumulation j . Wet Well Concrete Cover with 30”x54” Aluminum Hatch, hinged and lockable aluminum grating panel for fall protection, and Vent Pipe NOTE: For fall protection grating panel, see Halliday Products protective grating options for access covers, safety orange in color, or equal.

k. Pumps (both to be same: 250 GPM, 95 TDH, 55% efficiency at 1755 RPM and 10 NPSHR) l . Controller and control cabinet with heater and mounting posts.

Basically, the scope of work includes replacement of all equipment in the wet well and valve pit with the exception of the underground 8-inch gravity sewer line to the wet well and the concrete wet well and valve pit basins.

Washdowns of the wet well and valve pit are required. Washdown water can be disposed of in the onsite lagoon.

The government shall not exercise any supervision or control over the contract service providers performing the services herein. Such contract service providers shall be accountable solely to the contractor who, in turn is responsible to the government. This is a fixed priced, performance based service contract where the government defines and measured desired outcomes, while contractor methods are generally not constrained or directed. All replacement equipment and materials shall be per Section 33 32 13.13 PACKAGED SEWAGE LIFT STATIONS, WET WELL TYPE.

1.3 Period of Performance. The period of performance is 270 calendar days after award. Contractor shall provide government two weeks notification of start date so government can procure temporary sanitary facilities.

1.4 Contractor Personnel.

1.4.1 The contractor shall perform all work under this contract using his or her own forces except as provided in Paragraph 1.4.2 Subcontracting. Employees who perform this work shall be qualified persons on the contractor’s own payroll.

1.4.2 Subcontracting. The contractor shall not subcontract any work unless approval is given by the Contracting Officer. Compliance with the provisions of this contract by subcontractors shall be the responsibility of the contractor.

1.5 Quality Control.

1.5.1 The contractor shall designate, in writing, an employee who shall serve as the contact for matters involving quality and performance or nonperformance of the required work stated in this SOW. The employee(s) shall be qualified and fully competent with full authority to act for, and on behalf of, the contractor as necessary to insure that the required work is performed in accordance with the standards contained herein. The contractor shall furnish the above written designation to the COR no later than the first day of work. The contractor shall include the name(s), address(s), and telephone number(s) of the responsible individual(s).

1.5.2 The Contracting Officer reserves the right to disapprove any individual whom he considers incompetent to perform the work required. The Contracting Officer will provide a written notice of any disapproval to the contractor.

1.6 Quality Assurance. The government will use the methods stated in the SOW to ensure that the Contractor is performing the services required by this SOW in an acceptable manner. The Government may use Quality Assurance Evaluators (QAE(s)) to provide assistance with the quality assurance methods.

1.6.1 The government has the right to inspect all services called for by the contract, to the extent practicable at all times and places during the term of the contract. The government shall perform inspections in a manner that will not delay the work.

1.6.2 If any of the services do not conform to contract requirements, the government may require the contractor to perform the services in conformity with contract requirements and at no increase in cost. If the contract requirements are not met after a second attempt the government may (1) require the contractor to take necessary action to ensure that future performance conforms to contract requirements and (2) reduce the contract price to reflect the reduced value of the services performed.

1.6.2.1 Upon verification of a validated customer complaint or corrective action report, the COR will notify the contractor that they are required to re-perform specific services.

1.6.3 The government may take action, if the contractor fails to perform the services again or to take the necessary action to ensure future performance is in conformity with the contract requirements. The government may (1) by contract, or otherwise, perform the services and charge to the contractor any cost incurred by the government that related to the performance of such service or (2) terminate the contract in whole or in part.

1.6.4 The contractor is responsible to replace/repair any damage to government property due to negligence, at his or her own cost. The government may take action, if the contractor fails to replace/repair any damage to government property. The government may (1) by contract, or otherwise, replace/repair damaged government property and charge to the contractor any cost incurred by the government to replace/repair any damage.

1.7 Hours of Operation. The contractor is responsible for conducting business, between the hours of 7AM to 530PM Monday thru Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. The Contractor must maintain an adequate workforce for the uninterrupted performance of all tasks defined within this SOW when the Government facility is not closed for the above reasons. When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential.

1.8 Pre-Work Meeting. Prior to commencing any activities, the contractor shall arrange a Pre-work Meeting with the COR. The Meeting shall discuss the work requirements, scheduling, submittal process, review of the Activity Hazard Analysis (AHA), and Accident Prevention Plan (APP). At least one (1) week prior to commencing work, the Contractor shall coordinate their proposed work schedule with the COR.

1.9. Submittals. Prior to commencement of services, the Contractor shall submit the following documents to the COR for review and approval:

a. Activity Hazard Analysis

b. Accident Prevention Plan (APP) per the attached Accident Prevention Plan Checklist.

c. List of Personnel

d. Submittals as required by SECTION 33 32 13.13 PACKAGED SEWAGE LIFT STATIONS, WET WELL

TYPE

1.10 Standards and Regulations.

a. The Contractor shall perform to the standards in the contract and comply with all Local, State, and Federal

Regulations during the services performed. The Contractor is responsible for ascertaining the extent to which these regulations affect the operations resulting from this contract. The Contractor shall comply will all applicable regulations. Applicable regulations include, but are not limited to the following: Code of Federal Regulations (CFR), Title 36, Chapter III, Part 327, Rules and Regulations Governing Public Use on Corps of Engineers Water Resource Development Projects EP 1165-2-316 (http://www.publications.usace.army.mil/Portals/76/Publications/EngineerPamphlets/EP_1165-2- 316.pdf?ver=2013-08-22-104526-670)

a. Engineering Manual (EM) 385-1-1 (USACE – Safety and Health Requirements Manual), dated November 2014; http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1.pdf

b. Occupational Safety and Health Standards (29 CFR 1910);

1.10.1 Activity Hazard Analysis (AHA). The contractor shall prepare the AHA in accordance with Paragraph

01. A.14 or 01.A.15 of the EM 385-1-1. If using Paragraph 01.A.15, prepare the AHA IAW Figure 1-2. An AHA template is attached.

Note: Contractors and other individual employer’s typically use Job Safety Analyses (JSAs), Job Hazard Analyses (JHAs), or similar Risk Management assessment tools. The government considers equivalent to, and acceptable substitutes for, the USACE’s AHA provided the data collected is the same as that required by the AHA, commensurate with the type of services the contractor is performing.

1.10.2 Accident Prevention Plan (APP). EM 385-1-1 in its entirety may be too complex for the type of work performed under these contracts; contractors may reference Appendix A, for the Accident Prevention Plan (APP). The contractor shall only need to submit items in Appendix A in accordance with the attached checklist that are pertinent to the contract. The contractor shall use a qualified person to prepare the site-specific Accident Prevention Plan (APP).

The contractor shall prepare the APP in accordance with the format and requirements of the EM 385-1- 1 and supplemented herein. The contractor shall sign and submit the APP for approval prior to the start of work onsite.

1.11 Physical Security.

1.11.1 The contractor shall be responsible for safeguarding all government facilities, property, and materials provided for contractor use. The contractor shall secure at all times all government facilities, property, and materials. Specific security conditions may change based on threats to national defense, and based on the risk of specific facilities to these threats. The contractor shall abide by these changing conditions at all times, as applicable.

1.12 Antiterrorism/Operation Security Requirements.

1 .1 2 .1 Access and General Protection/Security Policy and Procedures. All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative).

1.12.2 Pre-screen candidates using E-Verify Program. The Contractor must pre-screen Candidates using the E-verify Program (http://www.dhs.gov/E-Verify) website to meet the established employment eligibility requirements.

The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible candidates must be http://www.publications.usace.army.mil/Portals/76/Publications/EngineerPamphlets/EP_1165-2-316.pdf?ver=2013-08-22-104526-670 http://www.publications.usace.army.mil/Portals/76/Publications/EngineerPamphlets/EP_1165-2-316.pdf?ver=2013-08-22-104526-670 http://www.publications.usace.army.mil/Portals/76/Publications/EngineerPamphlets/EP_1165-2-316.pdf?ver=2013-08-22-104526-670 http://www.publications.usace.army.mil/Portals/76/Publications/EngineerPamphlets/EP_1165-2-316.pdf?ver=2013-08-22-104526-670 http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1.pdf http://www.dhs.gov/E-Verify) provided to the COR no later than 7 business days after the initial contract award. When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility Verification, with the designated Government representative. This Form will be provided to the Contracting Officer and shall become part of the official contract file.

1.13 Payment.

1.13.1 The government will make payment after the government has inspected and accepted the services, and the government has reviewed, approved, and processed the contractor’s invoice. The contractor shall submit the invoice to the COR and/or any other person that has been designated in the contract to receive the invoice.

1.13.2 The contractor must provide the contractor’s name, address, contract number, period of services completed (i.e., for the month of January or for the period of performance of January 1 through February 23), CLIN number and specific quantities of work performed (i.e., 1 Month, 40 days, 100 acres, etc.), and total requested, for an invoice to be considered proper. The contractor shall submit the invoice by the fifth (5th) of the month for services completed the previous month or submit the invoice upon completion of all services, in accordance with the period of performance stated in the CLIN.

2.0 Definitions. The following definitions and descriptions apply wherever the word(s) or phrase(s) is/are stated in this SOW:

Acceptable Level of Performance (ALP): The maximum percent defective, the maximum number of defects per hundred units, or the number of defects in a lot considered satisfactory on the average. The allowable leeway or variance from a standard before the government will reject the specific service.

Contracting Officer’s Representative (COR): means an individual designated and authorized in writing by the Contracting Officer to perform specific technical or administrative functions.

Performance-Based Contract (FAR 2.101): Structuring all aspects of an acquisition around the purpose of the work to be performed with the contract requirements set forth in clear, specific, and objective terms with measurable outcomes as opposed to either the manner by which the work is to be performed or broad and imprecise.

Performance Requirements Summary (PRS): The PRS shows contract requirements, the component requirements related to each contract requirement, the price of each work requirement as a percentage of the associated contract requirement (Fixed Price Contracts), the standard of performance, and the acceptable level of performance (ALP) for each work requirement.

Quality Assurance Surveillance Plan (QASP): An organized written document used by the Government for quality assurance surveillance. Document contains sampling/evaluation guides, checklists, and the performance requirements summary (PRS).

3.0 Government Furnished Items and Services.

3.1 Services. N/A

3.2 Facilities. N/A

3.3 Utilities. Government will provide potable water at the Outside Maintenance Facility for the contractor’s use.

The Contractor shall coordinate in advance with the COR on date and time water will be used. The Contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions that preclude the waste of utilities, which include turning off the water faucets or valves after using the required amount. Wastewater can be disposed of in the onsite sewage lagoon located 2500 feet southeast of the lift station.

3.4 Equipment. N/A

3.5 Materials. N/A

4.0 Contractor Furnished Items and Responsibilities.

4.1 General. The Contractor shall furnish all supplies, equipment, facilities, materials, and services required to perform work under this contract that are not listed under Section 3 of this SOW.

5.0 Specific Tasks.

5.1 Services. The contractor shall provide all required services, equipment, materials, and labor to completely remove, dispose of, and replace the wet well and valve pit equipment. Work to also include new controls, cabinet, and concrete wet well cover. It is the intent after the contract scope is completed that the contents of the lift station shall be new, free of defect, and the system shall operate automatically.

6.0 Performance Requirements Summary. The contractor service requirements are summarized into performance objectives that relate directly to mission essential items. The performance threshold briefly describes the minimum acceptable levels of service required for each requirement. These thresholds are critical to mission success.

Performance Objective

(The Service required— usually a shall statement)

Standard Performance Threshold (This is the maximum error rate. It could possibly be “Zero deviation from standard”)

Method of Surveillance

PRS #1

The contractor shall replace all power and control cables.

The contractor shall follow all AHA requirements, lock out/tag out requirements, and safe work practices to perform installation.

USACE electrical engineer will review and approve installation is in accordance with plans and specifications.

Zero deviation from standard. Electrical Engineer performs 100% inspection.

PRS #2

The contractor shall replace all conduit between control equipment cabinet and wet well.

The contractor shall follow all AHA requirements, lock out/tag out requirements, and safe work practices to perform installation.

USACE electrical engineer will review and approve installation is in accordance with plans and specifications.

Zero deviation from standard. Electrical Engineer performs 100% inspection.

PRS #3

The contractor shall replace guide rails and pump supports.

COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #4

The contractor shall replace air release valves and install new air venting.

COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #5

The contractor shall replace lifting chains, floats, and float support pipe.

COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #6

The contractor shall replace check valves, plug valves, flexible couplings of 4-inch discharge piping including pipe and fittings a minimum of 2 feet outside of valve pit and connect to existing PVC force main.

All piping to be 100% leak free upon final installation. Final connection downstream of valve pit to be reviewed and approve by COR. COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #7

The contractor shall replace 3-inch PVC valve pit drain pipe, fittings, and check valve.

Drain to be sloped. Piping to be 100% leak free. Piping through walls of pit and well to be 100% sealed. COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #8

The contractor shall replace valve pit ladder.

Ladder to meet all OSHA standards. COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #9

The contractor shall install biological blocks to aid in control of lift station grease accumulation.

Mounting of biological blocks to be 100% secure and rated for wet well environment. COR to approve mounting prior to installation. Stainless steel materials shall be required. COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS #10

The contractor shall replace wet well concrete cover with hatch, aluminum grating panel, vent piping, and conduit.

Contractor to perform 100% dimension verification prior to ordering. COR will inspect and approve to ensure installation is in accordance with plans and specifications.

Zero deviation from standard. COR performs 100% inspection.

PRS # 11

The contractor shall replace submersible sewage pumps.

The contractor shall follow all AHA requirements, lock out/tag out requirements, and safe work practices to perform removal.

COR will inspect and approve to ensure installation is in accordance with plans and

Zero deviation from standard COR performs 100% inspection.

PRS #12

The contractor shall replace controller and control cabinet with heater and mounting posts.

The contractor shall follow all AHA requirements, lock out/tag out requirements, and safe work practices to perform installation.

USACE electrical engineer will review and approve installation is in accordance with plans and specifications.

Zero deviation from standard. Electrical Engineer performs 100% inspection.

AHA Template

7.0 Attachments

Appendix A: Maintenance Facility Lift Station Data

Appendix B: SECTION 33 32 13.13 PACKAGED SEWAGE LIFT STATIONS, WET WELL TYPE

Appendix A: Maintenance Facility Lift Station Data

A-2 (inside of wet well basin containing pumps)

A-2 (high water float)

A-2 (control cables to high water float)

A-2 (4” inch vent on pump basin)

A-2 (end connection of guide system)

A-2 (control panel for lift system)

A-2 (Control Panel for Lift System)

A-2 (4” vent)

A-2 (outside view of wet well basin with pumps)

A-2 (valve pit cover)

A-2 (valve pit interior)

A-3 Existing Pump Data

FIO

A-4 Existing Pump Motor Data

A-5 Existing Pump Component Features

A-6 Existing Pump Drawing

A-7 Existing Pump Drawing

A-8 Existing Wet Well Hatch Drawing

A-9 Existing Lift Station Electrical Drawings

A-9 Contd.

A-9 Contd.

Appendix B: SECTION 33 32 13.13 PACKAGED SEWAGE LIFT STATIONS, WET WELL TYPE

SECTION 33 32 13.13

PACKAGED SEWAGE LIFT STATIONS, WET WELL TYPE

11/14

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN WATER WORKS ASSOCIATION (AWWA)

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

AWWA C500 (2009) Metal-Seated Gate Valves for Water Supply Service

AWWA C509 (2015) Resilient-Seated Gate Valves for

Water Supply Service

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

AWWA C-517 (2016) Resilient-Seated Cast Iron

Eccentric Plug Valves

ASME INTERNATIONAL (ASME)

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

Threaded

ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2015) Standard Specification for Zinc

(Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A126 (2004; R 2014) Standard Specification for

Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A36/A36M (2014) Standard Specification for Carbon

Structural Steel

ASTM C478 (2015a) Standard Specification for Precast Reinforced Concrete Manhole Sections

ASTM C478M (2015a) Standard Specification for Precast

Reinforced Concrete Manhole Sections (Metric)

HYDRAULIC INSTITUTE (HI)

HI M100 (2009) HI Pump Standards Set

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C62.11 (2012) Standard for Metal-Oxide Surge Arresters for Alternating Current Power Circuits (>1kV)

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

ISO 2858 (1975) End Suction Centrifugal Pump

(Rating 16 Bar) Designation Nominal Duty Point and Dimensions - International Restrictions

ISO 5199 (2002) Technical Specifications for

Centrifugal Pumps, Class II

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 820 (2016) Standard for Fire Protection in Wastewater Treatment and Collection Facilities

UNDERWRITERS LABORATORIES (UL)

UL 1449 (2014; Reprint Jul 2017) UL Standard for

Safety Surge Protective Devices

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only.

Submit the following submittals to the Garrison Project Office:

SD-01 Components

SD-01-1: Materials, Equipment, Fixtures List; G-PO

SD-02 Shop Drawings

SD-02-1: Fabrication Drawings; G-PO

SD-02-2: Erection/Installation Drawings; G-PO

SD-02-3: Electrical Schematics; G-PO

SD-03 Product Data

SD-03-1: Spare Parts Data; G-PO

SD-03-2: Entrance Covers; G-PO

SD-03-3: Pumps; G-PO

SD-03-4: Pump Controller, Cabinet, and Supports; G-PO

SD-03-5: Check Valves; G-PO

SD-03-6: Electric Motors; G-PO

SD-03-7: Plug Valves; G-PO

SD-03-8: Piping and Fittings; G-PO

SD-03-9: Pump Rails; G-PO

SD-03-10: Float Controls; G-PO

SD-03-11: Ladder; G-PO

SD-03-12: Power and Control Cables; G-PO

SD-03-13: Conduit and Fittings; G-PO

SD-03-14: Wet Well concrete cover with hatch; G-PO

SD-05 Design Data

SD-05-1: Motor/Pumps; G-PO

SD-08 Manufacturer's Instructions

SD-08-1: Entrance Covers; G-PO

SD-08-2: Pumps; G-PO

SD-08-3: Pump Controls; G-PO

SD-08-4: Plug Valves; G-PO

SD-08-5: Check Valves; G-PO

SD-08-6: Electric Motors; G-PO

SD-10 Operation and Maintenance Data

SD-10-1: Operation and Maintenance Manuals; G-PO

SD-10-2: Preventative Maintenance and Inspection Procedure; G-PO

SD-11 Closeout Submittals

SD-11-1: Warranty; G-PO

1.3 QUALITY CONTROL

Verify conformance of materials and equipment for package lift station to the referenced publications or as specified. Verify that the manufacturer is regularly engaged in the manufacture of such products. Provide manufacturer’s authorized pump representative who is trained and approved for installation.

1.4 DELIVERY, STORAGE, AND HANDLING

Inspect materials delivered to site for damage. Unload and store with minimum handling. Store materials on site in enclosures or under protective covering. Do not store materials directly on the ground. Keep inside of pipes, fittings, valves, pumps, etc. free of dirt and debris.

Handle pipe, fittings, and other accessories in such manner as to ensure delivery to the site in sound undamaged condition.

1.5 WARRANTY

Provide a manufacturers' warranty for pumps, hatch covers, floats, control panel, valves. Create a list or reference all specific operation and maintenance procedures that are required to keep the warranty valid.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Provide lift station with two submersible sewage nonclog pumps with grinder units and controls capable of operating the pumps either simultaneously or individually, depending on the load conditions.

Furnish and install all components required for a complete unit with necessary appurtenances, installed within a pump chamber and access ladder, all designed for the following:

Service life - 15 years

Pump capacity - 250 gallons per minute (gpm)

Total head - 95 feet

Submit fabrication drawings for the wet well cover after receiving tentative approval of the equipment and the materials list but before installation. Submit drawings covering necessary or recommended changes to accommodate the equipment offered.

Submit erection/installation drawings for new equipment in the existing wet well and valve pit with the required equipment and accessories. Show the design of the equipment in the existing wet well and valve pit, with dimensions, types, and elevation levels with reference to those elevations indicated.

Submit electrical schematics displaying all contractor-supplied electrical components and wiring, as well as all connection points designated for customer connection.

Provide the following motor/pumps design information prior to final turnover - number of motor rotor bars and stator slots; number of cooling fan blades; RPM of motor; bearings, bearing manufacturer, bearing type, bearing style and number of balls/elements; and number of pump impellers.

2.1.1 Design Requirements

2.1.1.1 Pump Construction

Fabricate castings in cast iron or steel free from injurious defects.

Design castings to permit easy replacement of parts. Gasket all joints to prevent leakage. Design and install passageways to permit the smooth flow of sewage and free from sharp turns and projections. Provide pump castings with cleanout plates in the suction line and drain plugs.

a. Electric Motors

Provide 60-hertz, 460 Volt, 3-phase motors with a Class I, Division 1, Group D hazardous classification.

b. Impellers

Provide stainless steel impeller for grinder pump with stainless steel cutter, grinder, or slicer assembly. Provide free flowing impellers which permit objects in the sewage that enter the pump to pass into the discharge pipe. Provide each impeller keyed, splined, or threaded on the shaft and locked in such manner that lateral movement is prevented and reverse rotation cannot cause loosening.

2.2 COMPONENTS

Submit a material, equipment, and fixtures list of all major components including manufacturer's catalog numbers, specification and drawing reference number, warranty information, and fabrication site.

2.2.1 Wet Well Concrete Cover

Fabricate new cover with 5000 psi precast concrete. Fabricate with electrical conduits and vent pipe.

2.2.2 Wet Well Base Material

N/A

2.2.2.1 Wet Well and Valve Pit

Chambers to be reused.

2.2.3 Entrance Covers

2.2.3.1 Access Hatch Cover

Provide new aluminum access hatch cover and hinged aluminum grating panel for fall protection for wet well. Include lifting mechanism, automatic hold open arm, slam lock with handle, flush lift handle. Use automatic hold open arm that locks in the 90 degree position. Use access hatch cover capable of withstanding a live load of 300 lbs./sq. ft. Provide stainless steel cylinder lock with two keys per lock. Key all the locks the same. Access hatch cover shall be fabricated of materials suitable for contact with the elements and submitted for approval. Hinged aluminum grating panel for fall protection shall be supplied with stainless steel mounting hardware, positive locking latch, and padlock hasp.

2.2.4 Manhole Chamber

2.2.5 Pumps

Provide pumps of the nonclogging, submersible type designed to pump unscreened sewage. Provide pumps with a rated capacity as specified and is capable of passing 3-inch solids of various normal domestic sewage materials such as plastics, rubber, sanitary napkins, disposable diapers, and animal hair.

to exceed 1800 RPM.

2.2.5.1 Alternator

Conform to the requirements of HI M100. Pump speed not

Provide an alternator control switch to operate in connection with each float. Use an alternator control switch to alternate the operation of the pumps and operate both pumps if the water level rises above the second high water level. Incorporate time delay function and devices in the alternator controls such that both sewage pumps cannot be started simultaneously for an adjustable period of 10 to 120 seconds after shutdown. Use the delay function designed to operate in any condition of start-up in either normal or emergency operational mode.

2.2.6 Valves

2.2.6.1 Plug Valves in Valve Pit

Conform to MSS SP-78 (AWWA C517) for cast iron plug valves. Provide valves with handwheels that open by counterclockwise rotation of the valve stem. Bolt and construct stuffing boxes to permit easy removal of parts for repair. Use valves from one manufacturer.

2.2.6.2 Check Valves Less than 4-Inch Diameter

Provide neoprene ball or swing check valve with integral hydraulic sealing flange, designed for a hydraulic working pressure of 175 psi.

2.2.6.3 Check Valves 4-Inch and Larger Diameter

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

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 stainless steel gate, gate seats, shaft, studs, and nuts. Check valves to have manual actuator.

2.2.6.4 Air Release Valves

Provide automatic air release valves designed to permit release air from an empty pipe during filling and discharging accumulated air in the line during operation under pressure. Valves shall be attached by threaded pipe connections. Valves must be the compound lever type capable of withstanding operating pressures of 150 psi. The valves shall have a ½ inch outlet.

Provide iron valve with stainless steel float. All internal parts should be stainless steel or bronze adapted for use with sewage. Each valve shall be complete with hose and blow-off valves to permit backflushing without dismantling the valve. Vent shall be added for air release valves in valve pit as shown on package drawing.

2.2.7 Piping

Use ductile iron pressure pipe per AWWA C151/A21.51, pressure class 350.

Flanged pipe to be per AWWA C115/A21.15, ductile iron. Fittings to be AWWA C110/A21.10, flanged. Provide flanged joint fittings within wet well and valve pit as indicated. Joints to be per AWWA C115/A21.15 for flanged joints. Use bolts, nuts, and gaskets for flanged connections in appendix to AWWA C115/A21.15. Provide ductile iron flanges per ASTM A536, Grade 70-50- 05 or 60-42-10, meeting ASME B16.1, Class 125. Use 190,000 psi tensile strength, heat treated, and zinc coated steel setscrews for setscrewed flanges. Conform to AWWA C111/A21.11 for setscrewed flange gaskets.

2.2.7.1 Piping Connections

Provide pump suction and discharge with flanged connections of the proper size for the pump type and capacity. 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.

2.2.7.2 Accessories

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

2.2.7.3 Flexible Flanged Coupling

Provide flexible flanged couplings applicable for sewage as indicated. Use flexible flanged coupling designed for a working pressure of 350 psi.

2.2.7.4 Guide Rail

Provide 2” stainless steel guide rails for use in guiding pumps to discharge pipe. Ensure guiderails are sized such that lowering of pumps into wet well via chains ensures a 100% leakproof fitup.

2.2.8 Ventilating Blower

2.2.9 Nameplates

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

2.2.10 Pump Controls

2.2.10.1 General

Pump operating controls are the automatic type including all necessary components to function reliably. Mount controls in a NEMA 3R rated stainless steel control panel. Ensure equipment in wet well as well as those subject to contact with sewage or sewage gases is of corrosion-resistant metal. Provide an electronic controller that automatically activates and alternates the pump operation. If the liquid level continues to rise to the plans-specified level, the controller engages both pumps to operate simultaneously until both shut off at the specified low level.

Provide hand-off-auto switches to choose the mode of operation for each pump.

Protect pumping stations from lightning and transient voltage surges and equip with phase protection.

Design the control system to operate two (2) pumps. Ensure all controls and wiring meet or exceed the requirements of the National Electrical Code (NEC), Latest Edition.

For pumps specified as explosion proof, have pump power, all control circuits, and any other electrical devices meet NEC requirements for Class 1, Division 1, Group D Hazardous Location, including seal-offs on all electrical conduits entering the wet well. Provide components that are UL listed or FM approved.

Schedule 40 PVC shall be used for any conduits buried in the earth.

Schedule 40 galvanized rigid metal conduit shall be used for any exposed conduits above grade. Separate conduits shall be provided for power cables and control cables. Conduits shall be sized in compliance with the National Electrical Code.

Conduits shall penetrate the wet well cover and terminate with cable glands or cord grips. Conduits shall only extend into the wet well as far as necessary to accommodate the cable glands or cord grips. Require the control function to provide for the operation of the pumps under normal conditions and alternates the pumps on each pump down cycle.

In the event the incoming flow exceeds the pumping capacity of the lead pump, the offline pumps automatically start to handle the increased flow.

As the flow decreases, the pumps cut off at the elevations set on the controller.

All installed cabling shall allow for disconnection from outside of the wet well through the use of watertight connections.

2.2.10.2 Enclosure

Provide a NEMA 3R 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 a3-point latch and handle securable by padlock.

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, 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.

Provide an enclosure ventilator located near the top of the enclosure.

Provide a rain and vermin proof ventilator and made of fire retardant thermoplastic material. Mount panel on new posts provided by contractor.

2.2.10.3 Power Distribution

Provide a panel power distribution that includes all necessary components and is completely wired with stranded copper conductors rated at 90 degrees C. Install all conductor terminations as recommended by the device manufacturer. Installed power cables shall be listed for extra-hard usage as per NEC.

Provide a main circuit breaker in the control panel. The main circuit breaker shall be a thermal magnetic breaker with a trip rating suitable for the lift station operating characteristics. The main circuit breaker interrupting rating shall be a minimum of 18 kA at 480 VAC.

Size each motor breaker to meet the pump motor operating characteristics.

Individually protect the control circuit and the duplex receptacle by circuit breakers.

Install indicating type circuit breakers, providing "On/Off/Trip" positions of the operating handle. When the breaker is tripped automatically, the handle assumes a middle position indicating "Trip".

Provide quick-make and quick-break thermal magnetic breakers on manual and automatic operation and have inverse time characteristics secured through the use of bimetallic tripping elements supplemented by a magnetic trip for instantaneous protection. Design breakers so that an overload on one pole automatically trips and opens all legs. Field installed handle ties are not acceptable.

Ensure motor starters are across the line and full voltage with individual overload protection for each phase. Ensure motor starter contact and coil is replaceable from the front of the starter without removing from its mounted position.

Provide motor overload protection via melting alloy type or solid-state thermal overload relays. Provide overloads that are interchangeable and sized per NEC. Motor overloads shall be resettable from buttons on the dead front.

Provide control transformers for 120 VAC requirements in the control panel. Provide fused transformers and grounded secondaries.

Provide incoming power with both lightning surge arresters (line side, IEEE C62.11) and transient voltage surge suppression (load side, UL 1449).

Use solid state devices with LED indicator lights for power and protective status. As a minimum, rate devices for 50,000 amps per phase with response time less than 5nSec.

2.2.10.4 Alarm System

Provide a horn and a weatherproof-shatterproof red LED strobe light fixture that energize upon alarm conditions.

Mount the alarm horn on the exterior of the cabinet. The alarm horn provides a signal of not less than 90db at 10 feet. Deactivate the alarm horn with an alarm silence switch, however, the alarm light flashes until the alarm condition ceases to exist. At that time the alarm reset function resets for normal operation.

2.2.10.5 Control System

Provide a control system for the automatic and manual control and alternation of the pumps to maintain a pumped down condition of the wet well.

As the level in the wet well rises, the lead pump as determined by the alternator, starts and pump the station to the "off" position. In the event the incoming flow exceeds the capacity of the lead pump, the lag pump starts and both pumps run to the off level. The alternator switches when the off level is reached.

If the level continues to rise, alarm functions are activated via a high-level float switch (intrinsically safe for Class I, Division 1, Group D hazardous installations).

Controls shall include H.O.A. switches and LED indicating lights.

Indicating lights shall be as follows: Pump 1 Running (red), Pump 2 Running (red), Pump 1 Seal Failure (amber), Pump 2 Seal Failure (amber), Pump 1 Overtemp (amber), Pump 2 Overtemp (amber), Phase Failure Alarm (amber), High Level Alarm (amber). A green LED shall also be provided that will be energized to indicate that power is available to the controller, and de-energized when power is lost. Any other alarm indicating lights not mentioned above that the contractor prefers to include as part of a standard control system offering must also be amber colored, and are subject to Government approval.

2.2.10.6 Float Assembly Description

Use a direct-acting float switch consisting of a normally-open switch enclosed in a float. Use pipe mounted float assembly. 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 connecting cable with watertight seals and strain relief, and support pole in accordance with manufacturer’s recommendations. Mount floats at fixed elevations as shown. 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.

2.2.10.7 Ancillary Equipment

The control system includes, but not be limited to:

a. An elapsed time meter for each pump mounted on the dead front door. The meter operates on 120 VAC, indicates run time in hours, and is not resettable.

b. A control panel enclosure heater and thermostat.

c. Control wire is a minimum 10 and 12 AWG. (See drawings.) Route all control wires through a plastic wireway with snap on covers, bundled and tie wrapped to form a neat assembly. Existing conduit between enclosure and manhole to be replaced.

d. Provide a duplex, 15 amp, GFCI weather resistant receptacle providing

120 volts, 60 hertz, single phase power inside the panel on the dead front door.

e. 1-N/O and 1-N/C unpowered contact for high level, power/control power failure, and pump run indication wired to terminal strip.

f. Identification plate engraved to show white letters on a black background. Letters are uppercase. Identification Plate to indicate "LIFT STATION CONTROL PANEL" system voltage (e.g. 208V, 3PH or 480V, 3PH), and power source.

g. Time delay relay to prevent pumps from starting simultaneously.

2.3 PAINT

Treat and paint equipment in accordance with the manufacturer's standard practice for sewage resistance. For piping, steel pipe shall be painted per AWWA C203.

2.4 LADDER

Dry well ladder to be designed and constructed to withstand contact with sewage and be designed to meet OSHA standards. Length of ladder shall be field verified prior to ordering.

PART 3 EXECUTION

3.1 INSTALLATION

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

3.1.1 Emergency Overflow

Replace overflow line from the wet well in-kind. Include materials and coatings/paint per this specification.

3.1.2 Protection from Moving Parts/Lockout and Tagout

Locate guard belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts in accordance with applicable

OSHA standards and so that personnel are properly protected from injury.

Ensure OSHA standards are followed when working in confined spaces.

Provide mechanical ventilation where required. Work with USACE personnel on lockout/tagouts as required for mechanical and electrical safety PRIOR to starting any field demolition or installation.

3.1.3 Valves

Install per MSS SP-78 AWWA C517 for cast iron plug valves.

Install check valves in accordance with the applicable requirements of AWWA C600 for valve-and-fitting installation.

3.1.4 Piping

Install pipe and fittings in accordance with AWWA C600 for pipe installation, joint assembly, and valve and fittings installation. Make flanged joint with gaskets, bolts, and nuts specified for this type of joint. Make flanged joints up tight, avoid stain 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 such that the flanged joint cannot be made watertight.

Perform hydrostatic pressure test of piping, under a test pressure equal to 50 percent more than the pump discharge pressure or total dynamic head, whichever is greater.

3.1.5 Miscellaneous

As-built drawings to be provided upon project completion. CAD files not required, but redlined drawings indicating as-built field conditions shall be provided. Attach a final as built drawing, laminated in Mylar, to the inside of the front door and shown on the as-built drawings. Include a list of all legends. Identify the pump nameplate data on the drawing and on the as-built plans. Permanently mark all component parts in the control panel and identified as they are indicated on the drawing. Mark on the back plate adjacent to the component. Identify all control conductors with wire markers at each end as close as practical to the end of conductor.

3.2 FIELD QUALITY CONTROL

3.2.1 Tests

Perform tests, including hydrostatic pressure test of piping, under a test pressure equal to 50 percent more than the pump discharge pressure or total dynamic head, whichever is greater. Perform a pump test, and float test. Test functionality of entire system. 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 and System Test

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

Test pumps and controls in operation under design conditions to ensure operation of equipment. Provide appliances, materials, water, and equipment for testing. Conduct testing after equipment is installed, electrical service and piping are installed, liquid is flowing, and the pump station is ready for operation. Correct defects discovered to the satisfaction of the Contracting Officer.

3.3 CLOSEOUT ACTIVITIES

3.3.1 Operation and Maintenance

Submit preventative maintenance and inspection procedure for lift station.

Include in procedures the frequency of preventative maintenance, inspection, adjustment, lubrication, and cleaning necessary to minimize corrective maintenance and repair.

Submit spare parts data, including a complete list of parts and supplies with current unit prices and 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 station, a complete package of posted instructions, consisting of labels, signs, and templates of operating instructions.

Submit operation and maintenance manuals for lift station, including Equipment Description, Assembly and Installation Procedures, Adjustment and Alignment, Checkout Procedures, Procedures of Operation and Troubleshooting.

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