Spec 33 32 16.pdf

ATS REPLACEMENT AT FC445, FC443, FC442 24-0015

SECTION 33 32 16

PACKAGED UTILITY WASTEWATER PUMPING STATIONS

11/19, CHG 1: 11/23

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 B16.3

ASME B16 .11

(2021) Malleable Iron Threaded Fittings, Classes 150 and 300

(2022) Forged Fittings, Socket-Welding and

Threaded

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA Cll0/A21.10

AWWA CS00

AWWA C509

AWWA C515

AWWA C517

AWWA C600

AWWA C605

(2021) Ductile-Iron and Gray-Iron Fittings

(2019) Metal-Seated Gate Valves for Water

Supply Service

(2023) Resilient-Seated Gate Valves for

Water Supply Service

(2020) Reduced-Wall, Resilient-Seated Gate

Valves for Water Supply Service

(2009) Resilent-Seated Cast-Iron Eccentric

Plug Valves

(2023) Installation of Ductile-Iron Mains and Their Appurtenances

(2021) Underground Installation of

Polyvinyl Chloride (PVC) and Molecularly

Oriented Polyvinyl Chloride (PVCO)

Pressure Pipe and Fittings

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M

ASTM A126

(2024) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

(2004; R 2023) Standard Specification for

Gray Iron Castings for Valves, Flanges, and Pipe Fittings

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1940-1 (2003; R 2008) Mechanical Vibration -

SECTION 33 32 16 Page 1

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 (2021) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70

1.2 SUBMITTALS

(2023; ERTA 1 2024; TIA 24-1) National

Electrical Code

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for

Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Fabrication Drawings

SD-03 Product Data

Pump Performance Curve; G

Pump Motor; G

Pump Control System; G

Flexible Flanged Coupling; G

Station Piping and fittings; G

Valves; G

Spare Parts Data; G

SD-06 Test Reports

Pump Test; G

Pressure Sensor Test

SD-07 Certificates

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ATS REPLACEMENT AT FC445, FC443, FC442

Gate Valves

Check Valves; G

Pump Motor; G

SD-08 Manufacturer's Instructions

Pump Control System; G

Gate Valves; G

Check Valves; G

Pump Motor; G

Special Tools

Posted Instructions

SD-10 Operation and Maintenance Data

Operation And Maintenance Manuals

SD-11 Closeout Submittals

Warranty

1.3 QUALITY CONTROL

1.3.1 Installer Qualifications

24-0015

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. Store rubber gaskets which are not to be installed immediately under cover, out of direct sunlight. Do not store materials directly on the ground. Keep interior of pipes, valves and fittings free of dirt and debris.

SECTION 33 32 16 Page 3

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.

1.5 WARRANTY

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

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

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. Provide piping layout with elevations, fittings and sizes for both above and below grade piping.

2.2 DIESEL POWERED BACKUP SEWAGE GRINDERNONCLOGPUMPS

Provide diesel powered sewage nonclog pumps with grinder units as indicated. Provide Provide pump capacity, number of pumps and motor characteristics as indicated on the drawings. Select pumps to provide automatic pump priming.

2.2.1 Pump Construction

2.2.1.1 Casing

Provide cast iron 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.Black steel hardware is not permitted.

Pump casings shall be cast iron. Pump design shall incorporate a direct suction flow path that is in axial alignment with the impeller eye. There shall be no turns, chambers, or valves between the suction flange and the impeller eye.

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24-0015ATS REPLACEMENT AT FC445, FC443, FC442

2.2.1.2 Impeller

Provide a cast steel impeller for the 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. Oil lubricate bearings. Pump shall be fitted with a bearing bracket to contain the shaft and bearings. Bearings shall be tapered roller bearings of adequate size to withstand imposed loads for sustained pumping at maximum duty points. Minimum ISO Ll0 bearing life to be 100,000 hours. Impeller shafts shall be fabricated of carbon steel.

2.2.1.4 Seals

Seals shall be high pressure, mechanical, self-adjusting type with silicon carbide faces capable of withstanding suction pressures up to 58 psi. The mechanical seal shall be cooled and lubricated in a liquid bath reservoir, requiring no maintenance or adjustment. Pump shall be capable of running dry, with no damage, for periods up to 24 hours. All metal parts shall be of stainless steel.

2.2.1.5 Lubrication

Provide the pump manufacturer's standard type grease fittings.

2.2.1.6 Balance

Balance rotating parts operate throughout the vibration, and noise.

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

2.3 AIR COMPRESSOR AND VACUUM PUMP

Provide packaged pump system capable of self priming pump at indicated operational levels and suction pipe depths on contract drawings. Air compressor and vacuum pump casings shall be suitable for marine and hydrosulfurous environments. Provide vacuum pump capable of 28 feet of vacuum at sea level.

The compressor shall be installed on the engine auxilary drive and shall be gear driven, lubricated and cooled. The priming system shall require no fail-safe protection float gear or any adjusting at high or low suction lifts. The pump must be capable of running totally dry for periods up to 24 hours, then re-priming and returning to normal pumping volumes. Pump and priming system is capable of priming the pump from a completely dry pump casing. Equipment acceptance shall be contingent upon the pump's ability to run continuously at full speed in a completely dry condition

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ATS REPLACMENT AT FC445, FC443, FC442

24-0015

2.4 PUMP MOTOR

Provide hermetically sealed motors with moisture and temperature-sensing probes in the wet well NEMA MG 1. Motor horsepower must not be less than pump horsepower at any point on the pump performance curve. Seal the power cable inside the motor end bell. Provide a waterproof power cable for its full length. Provide motors UL listed for explosion proof Class 1, Division 1, Groups C and D. Air filled motors are not acceptable. Ensure oil used may be disposed as non-hazardous waste.

SECTION 33 32 16 Page 6

2.6 PUMP CONTROL SYSTEM

2.6.1 General

24-0015

Provide an automatic type pump operating control including all necessary components to function reliably. Mount controls in a NEMA 3Rrated 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.

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. Provide controls with a 12 VDC powered float switch connected to the alarm contact of the battery charger to activate high-level alarms.

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.

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.

2.6.2 Enclosure

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ATS REPLACMENT AT FC445, FC443, FC442 24-0015

2.6.3 Level Control System

Provide a 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. Provide three float stillwells for single pump applications for low water cutoff, pump activation, and high water level alarm. For two diesel pump configurations provide four floats with two intermediate elevation floats controlling pump activation, one per pump.

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

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

2. 6. 4 Sewage Pump Alarm and Control Panel

Enclose alarm panel in NEMA 3R 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 light and push to silence button for horn and light with automatic reset for next alarm.

2. 6. 4 .1 Alarms

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

<OLG>

<OLI>High liquid level as sensed by the level control system.</OLI>

<OLI>Loss of main power.</OLI>

<OLI>No flow light as sensed by limit switch on the check valve or as sensed by current sensors.</OLI>

<OLI>Pump failure via temperature overload or motor heat sensor trip; provide motor high temperature light.</OLI>

SECTION 33 32 16 Page 8

<OLI>Seal failure with indication light.</OLI>

</OLG>

2.6.4.2 Anti-Condensation Heater

<OLG>

24-0015

<OLI>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.</OLI>

<OLI>Power the heater from the control voltage transformer. </OLI>

<OLI>Control the heater by a thermostat, coming on at 50 degree F and going off at 65 degree F.</OLI>

<OLI>Clearly label panel directory for breakers.</OLI>

</OLG>

2.6.4.3 Trickle Charger

Provide trickle charger for pump controls and provide a block heater for cold weather operation. Trickle charger shall be sized per manufacturer's recommendations sufficient to operate the accessories and controls indentified in this specification. Provide trickle charger rated for ambient operation between 0 and 120 degree Fahrenheit. Provide with waterproof eclosure. Provide AGM type (absorbent glass mat) battery.

2. 6. 4. 4 Block Heater

Provide threaded plug type heater. Provide 3 prong cord with plug type heater of sufficient length to reach power supply.

2. 6. 4. 5

<OLG>

Additional Requirements

<OLI>Provide elapsed time meter for each pump that measures run time in hours to 9999.9.</OLI>

<OLI>Do not place junction boxes between pumps, control systems and control panels; provide conduit seals at all wet well penetrations. If this is unavoidable, use NEMA 7 construction.</OLI>

</OLG>

2.6.5 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.

2.7 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. 7 .1 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.

2.7.2 Cold Weather Operation

Provide block heater for cold weather operation. Size block heater per

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24-0015ATS REPLACEMENT AT FC445, FC443, FC442

manufacturer's recommendations.

2.7.3 Accessories

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

2. 7. 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.

2.8 VALVES AND OTHER PIPING ACCESSORIES

2.8.1 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.

2.8.1.1 Valves Larger Than 2 Inches

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

Resilient seat eccentric plug valves conforming to AWWA C517 with operating handle and flanged ends.

2.8.2 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 Cl10/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.

2.8.3 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 speed of rotation. Cast on the body of the pump the direction of rotation.

2. 8. 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.

2.8.5 Miscellaneous Metals

Use stainless steel bolts, nuts, washers, anchors, and supports for

SECTION 33 32 16 Page 10 installation of equipment.

2.8.6 Quick Disconnect System with Hydraulic Sealing Flange and Rail System

Use quick disconnect system consisting of a steel base plate for supporting the pumps, a hydraulic sealing flange, 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 basin. Build guides onto pump housing to fit the guide post to assure perfect alignment between pump and guide rails.

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 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 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 CS00.

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 as set forth in Division 01 . 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, pressure sensor test. Ensure all points required are visible on SCADA system. De-energize station primary pumps to allow float enable of diesel pumps and verify automatic operation. 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.

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ATS REPLACMENT AT FC445, FC443, FC442 24-0015

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.

3.3 CLOSEOUT ACTIVITIES

3.3.1 Operation and Maintenance

Submit operation and maintenance manuals in accordance with Section 01 78 23

OPERATION AND MAINTENANCE DATA for package 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 package 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 package lift stations.

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 package 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.

Instruct the owner's operating personnel in the proper operation and maintenance of the system for a period of not less than one half day

-- End of Section --

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