ATTACHMENT_1_Revised_Specifications_Pump_2_May_2018.pdf

EQUIPMENT SPECIFICATION

BOOSTER PUMP SKID

1. Summary: Specification for a stainless steel vertical, multi-stage centrifugal pump with automatic discharge pressure control, variable frequency drive, and specified accessories, all mounted on a hot dip galvanized steel welded skid. Unit to be delivered fully assembled, wired, tested, and ready for use, except as noted. The pump will be operated outdoors in a coastal marine environment, where it will continuously pressurize a temporary fire system, using a pressure sensor and variable frequency drive to maintain a user selected pump discharge pressure. Typical system flow is zero in the warm months, except for leakage, and 2 to 20 GPM during freeze protection season. Flow quantities between 20 GPM and the full rated system flow of 226 GPM will occur during periodic tests and in the event of an emergency. Expected service life is 20 years. The skids are portable units, moved and connected to temporary systems by the government.

2. Summary of Supporting Deliverables – This paragraph contains drawings, documentation, notifications and test certifications which warrant separate deliverables in addition to the delivery of the equipment and spare parts described in the Scope of this document. Additional testing requirements and standards (e.g. ASTM B117 Salt Spray Test) are referenced in this specification to identify selection criteria for individual parts;

however, certification is only required as listed below:

a. General Notes:

• Contractor/manufacturer shall notify Contracting Officer, upon shipment, via email, that the item(s) in question have been shipped and to include shipping company, tracking information, and estimated time of delivery.

b. Pre-Deliverables:

• Drawing: Pre-construction component sketch or drawing

Item: Booster Pump skid

Performance: Prior to Construction: A system sketch or drawing, in “.pdf” format, shall be delivered to the contracting officer for technical acceptability based on the specification requirements. Submitted data shall include major components, pipe details, and approximate dimensions. The drawing may be developed using methods of the vendor (e.g. hand drawn or Computer Aided Drafting Sofware) and shall be delivered no more than 10 days after award.

• Calculations: Lifting Structure Design Calculations

Items: Booster Pump structure

Performance: Prior to Construction: Lifting Structure Design Calculations in accordance with the Skid and Lifting Structure Calculations section of this specification, and stamped by a Licensed Professional Structural Engineer shall be delivered to the contracting officer for technical acceptability based on the specification requirements.

Lifting Structural Design Calculations shall be delivered no more than 14 days after Pre-construction sketch approval.

ATTACHMENT 1 - SPECIFICATIONS

Acceptance: The initial review of the calculations by C/270TS shall take no more than 14 days once received by the Government.

c. Other Deliverables:

• Manual: Engineering Data Manual

Item: Operator’s Manual

Performance: Four hard (4) copies plus one (1) electronic copy on CD or DVD of the data listed in the Operator’s Manual section of this specification shall be delivered at the same time as pump skid delivery. If more than one pump skid is ordered, only four total sets of data are required. Each set shall include both a hard copy and a electronic copy of the data on CD. Electronic copies shall include electronic drawing files created for unit design (if CAD is used, AutoCad or Solid Edge 3D format preferred but not required).

Acceptance: The final delivery review of the manuals by C/270TS shall take no more than 21 days once received by the Government. To aid in manual development, vendor is encouraged to provide, during compilation, periodic draft copies for review to Technical POC via Contracting Officer prior to final shipment and submission into iRAPT (e-Business Suite: Invoice, Receipt, Acceptance, and Property Transfer).

• Spare Parts

Item: Spare Parts

Performance: One (1) set of spare parts shall be delivered with initial set of nine (9) pump skids ordered and one (1) set of spare parts delivered with each option exercised. Spare parts are listed in this specification.

Acceptance: The initial inspection of the spare parts by C/270TS shall take no more than 7 days once received by the Government.

3. Service:

a. Pump Rated Flow and Pressure: 226 GPM at 75 psi differential

b. System design pressure and temperature: Fluid system components shall have a rated pressure of at least 250 psig at 100°F, except as noted.

c. Environment

• Operated and stored in the weather. Marine environment.

• Ambient temperature: 7°F to 100°F (vendor installed heat tape shall prevent freeze damage)

• Ambient pressure: Sea level atmosphere

d. User connections:

• 460VAC, 3 phase, 60 Hz

• 120VAC, 60 Hz (for heat tape only)

• Clean, fresh water at pump suction, 20 psig to 110 psig (varying during use).

4. Pump: Vertical, multi-stage, centrifugal, close coupled, direct drive, with replaceable wear rings. Pump body and impeller shall be stainless steel alloy 304 or 316 (alloy UNS S30400 or S31600). Pump shall have ANSI B16.5 Class 150 flanged connections. The pump shall include a mechanical shaft seal; packing shall not be used in place of the mechanical seal. Goulds Pumps Model 46SV20NL4F60 or equal.

5. Motor:

a. 20 hp TEFC, inverter duty.

b. The motor shall be rated “severe duty” per IEEE 841-2009.

c. The motor shall meet the requirements of NEMA MG-1.

d. Motor bearings shall include zerk fitting and grease relief fitting for each bearing requiring lubrication.

• Baldor Model VECP84106T-4 or equal.

6. Electrical Controls:

a. Variable Frequency Drive (VFD) - The pump controller shall automatically start, stop, go into a “Sleep” mode while maintaining a discharge pressure with no flow, and adjust the speed of the pump to maintain the discharge pressure set point within a nominal band as both the inlet pressure and discharge flow rate vary.

• Cooling fins shall be constructed of A413.0 aluminum alloy which is appropriate for marine applications when used with no coating. Other aluminum alloys with or without a coating or surface treatment added to provide corrosion resistance are not an acceptable substitute.

• The controller shall prevent the discharge pressure from exceeding 200 psig.

• Enclosure with VFD shall include a door mounted “RUN/STOP” switch, wired in series with inlet pressure switch, which will turn VFD on and off as necessary, without de-energizing VFD.

• A green indicator light shall illuminate when the drive is in “RUN” mode, including when the speed is equal to zero. Bulb shall be LED type.

• VFD controller operating parameter and setpoint adjustments (discharge pressure) shall be capable from front panel of VFD door so as not expose workers to exposed, energized conductors. Operating speed, pressure setpoint, sensing pressure and motor load shall be visible on front panel. Controller shall be capable of motor over-speed.

• NEMA 4X enclosure, alloy 304 (UNS S30400) or other 300 series alloy, hinged access door. Manufacturer shall ensure all penetrations through NEMA 4X enclosure meet NEMA4X requirements.

• “Leeson Speedmaster, Model 174753” or equal.

b. Padlockable service disconnect switch with current limiting fuses rated 200kAIC.

Fuses supplying the variable frequency drive shall meet the variable frequency drive manufacturer requirements in addition to the other requirements of this specification.

• Electrical power lead shall be installed through the bottom of the electrical disconnect enclosure, sealed with a watertight cable penetration and with a strain relief device to protect the conductor exiting the enclosure. Conductor shall extend only far enough so the end of the disconnect cannot hang over any edge of the skid base.

1. 8 AWG, 4 Conductor, 600 V, 90 Degree C, Type W, UL Listed, Copper, Round Style, Black Color, Flexible Cord.

2. Disconnect to be installed at end of power lead shall be 30A, 480VAC, 3-phase, male quick disconnect (IEC 60309-1 & 60309-2, 3P, 4W, North American-Rated Pin & Sleeve Plug, Industrial Grade, IP67, Watertight – Red). “Hubbell HBL430P7W, Leviton LEV430P7” or equal.

c. NEMA 4X (or similar). All electrical enclosures shall be stainless steel, alloy 304 (UNS S30400) or other 300 series alloy. Enclosure doors shall be hinged. All penetrations made in original NEMA 4X enclosures shall be made watertight equivalent to NEMA 4X.

d. Choke – A line reactor with 5% (or greater) impedance at rated motor horsepower shall be installed on the line side of the variable frequency drive. The reactor shall be UL Listed or UL Recognized. A DC link reactor installed internal to the VFD may be used in place of the 5% Line Reactor if the installed VFD is rated for 100Kaic.

e. Run dry protection. The control system shall sense pump skid inlet pressure upstream of the check valve. When the measured pressure is lower than the user adjustable setpoint (pressure switch), the pump control shall stop the pump and prevent restart until the pressure rises above the setpoint. Initial setpoint shall be 10 psi.

f. The Electrical system shall be UL Listed or bear the certification label of a third party accredited Field Evaluation Body. The system shall be designed and installed in accordance with the National Electrical Code.

g. Heat Tape: Thermostat controlled heat tape shall be installed on the system to prevent freeze damage while the system is filled with water, and not experiencing flow.

• A 30 mA Ground Fault Equipment Protector (GFEP) circuit breaker shall be provided in a dead-front NEMA 4X enclosure to protect against heat trace faults, per the National Electrical Code and heat trace manufacturer’s instructions.

Thermostat controller may be mounted to exterior of enclosure but must be visible and adjustable by user.

• The heat tape shall be energized by a NEMA 5-15, grounded 120V AC plug recessed in the GFEP panel. A light adjacent to the plug shall illuminate when power is supplied to the thermostat. A second light shall illuminate when the heat trace is energized. The lights shall be recessed in the freeze protection electrical enclosure.

• Installation and all connections shall be in accordance with the heat tape manufacturer’s instructions.

• Pump shall be freeze protected per pump mfr. recommended installation. ALL lines that will contain water are to be freeze protected to include all piping to instruments and vents/drains. Fiberglass tape shall be used to maintain contact between the tracing and the pump and piping to the greatest extent possible.

• There shall be no electrical connection between the heat tape electrical system and any other electrical components of the skid. No thermal insulation is required.

• All components shall be UL listed for installation in the weather, appropriate for the application and installed in accordance with the manufacturer’s instructions.

• PECO Model No. TF115 or equal.

h. Electrical enclosure component corrosion protection. Prior to shipping unit(s) from manufacturer a Vapor Corrosion Inhibitor (A-A-59411, Type 1, 2-year protection) shall be installed interior to each electrical enclosure for circuitry corrosion protection. Four (4) each unopened (original individual wrapped) VCI units, for each enclosure, shall be shipped with each unit.

7. Diaphragm Tank: Shall be piped to the pump discharge. Tank shell alloy: Stainless 304L (UNS S30403) or other 300 series stainless steel. ASME pressure vessel stamp.

Tank volume 10 gallons minimum. Pressure rated to 250 psi (min.). The AATank Model FXA 35 is an example of a diaphragm tank meeting these specifications. The tank shall be bolted to the lifting structure of the metal skid. Initial charge pressure shall be approximately 130 psi. AATank Model SS-FXA-HP-35-10 or equal.

8. Fluid connections shall be as shown in Figure 1.

a. Pipe, fittings, and other metal components in contact with the system liquid shall be constructed of stainless steel (alloy UNS S30400 or other 300 series alloy), copper, brass, or bronze. The fittings shall be domestic, constructed in accordance with ASTM standards. All pipe and fittings shall be capable of working pressures up to 250 psig.

b. Non-metal pipe, and fittings shall not be used.

c. Connections shall be NPT, flanged, welded, or brazed (except where specific connection types are required elsewhere in this specification). Solder connections and compression connections are not allowed. Threaded pipe connections shall utilize heavy wall (a.k.a. extra strong, a.k.a. schedule 80 or higher) pipe.

i. NOTE: Stainless steel NPT threads shall be mated with copper alloy NPT threads to avoid galling.

d. Sensors and gauges shall be connected directly in gauge ports on the process flow path or piping connected to flow path. Tubing or sensing gauge lines shall not be used.

e. Cam and Groove (C&G) fittings shall be per Commercial Item Description A-A- 59326 (with pressure rating exception). The fittings shall also meet these additional requirements, which take precedence in case of conflict: pressure rating 300 psi (minimum); stainless steel cam arms with passive locking feature, SS pull rings, and SS cam arm pivot pins; ASTM B584 C92200 bronze. PT Coupling adapter p/n “1290125H, 25AHD Brass” and coupling p/n “1290340HL2, 25DHD Brass SLS” with “Sta-Lok II” locking arms or equal. C&G dust cap and plug shall have 1/8” hole drilled through for pressure relief and shall be tethered near the connection via braided stainless cable.

9. Skid: All components mounted on a single weld-fabricated metal skid.

a. Skid dimensions:

i. Footprint: 36” x 30” or smaller. A smaller footprint is preferred.

ii. Height: 58” or less. Height includes the swivel hoist ring. Adequate clearance shall be maintained for pump motor fan cooling.

iii. The skid arrangement and dimensions shall position the center of gravity of the assembly per the following:

Y

Center of Gravity

Skid

X

X 0.3Y for all 4 sides

b. Structure (including lifting pad-eye): Welded. Carbon steel galvanized per ASTM A123.

c. Fully enclosed forklift slots (6” x 3” x ¼” thick, approximate outside dimensions) on all four sides. Mechanical steel square tubing is recommended for use as the four forklift slots. The forklift slots shall prevent the vertical structure of a forklift from contacting system components.

d. A single, steel pad-eye crane lift point above the center of gravity.

• Lift attachment points may be commercially available, original equipment manufacturer (OEM) integral pad-eyes. These are suitable for use at PSNS &IMF provided the attachment points accommodate common rigging gear (e.g., shackles, wire rope pendants/grommets, etc.) and comply with all applicable ASME visual inspection standards. An example of a commercially available lifting point meeting this specification is ‘RUD, Model ABA’.

• The pad-eye and attaching structure shall provide a 3 to 1 (minimum) safety factor based on material yield strength, or, 5 to 1 (minimum) based on ultimate strength.

• Pad-eye shall be installed per manufacturer requirements.

e. Components shall be arranged, supported, and guarded to prevent mechanical damage.

f. NO component shall extend past the four vertical planes formed by the skid outside edges, to include piping caps and plugs.

10. Fasteners:

a. Fasteners shall be Silicone Bronze bolts with stainless steel washers and lock nuts, except motor and pump foundation bolts shall be as noted.

Note: Vertical skid structure is not shown.

b. Motor and pump foundation bolts shall be grade 8 with 1,000 hours of salt spray resistance per ASTM B117. McMaster Carr p/n’s 91286A405 and 98180A160 are examples of items meeting this specification. Self-locking stainless steel nuts shall be installed on each bolt.

c. Fasteners shall not be installed which protrude into forklift slots.

11. Approval Drawing: Prior to ordering parts or starting construction, the contractor shall submit a sketch of the proposed components, arrangement, and approximate dimensions to the Contracting Officer for approval.

12. Label Plates: Shall be constructed of stainless steel with engraved, paint-filled markings. Labels shall be installed with stainless steel fasteners at each corner. Where label plates are attached to carbon steel, a weather-stable and adhesive RTV shall be applied to the fastener holes in the steel and the back of the label immediately prior to installation of the label using mechanical fasteners. Dow Corning 832 is an example of an RTV which is appropriate for this application. Label plates can be combined.

a. Operation instructions, (start, stop, adjust pressure, vent, and drain)

b. Electrical service requirement, (voltage, frequency, minimum circuit current rating)

c. Fluid system data, (design pressure in psig, rated pressure and flow in psid & GPM)

Note: psid stands for “pounds per square inch, differential”.

d. Lifting schematic showing basic profile of skid, dimensions, weight, and center of gravity.

e. Date of hydrostatic test and test pressure.

f. Electric control and indication device labels (ON, OFF, RESET switch positions, etc.)

g. Motor rotation direction.

h. all settings shall be adjusted by the vendor to match the requirements of the specification. The assembly shall then be filled,Motor grease type.

i. Setpoint warning: “do not exceed 200 psig”

j. Freeze protection instructions.

k. PCB Certification information, permanently affixed to the equipment in the vicinity of the manufacturer’s identification plate.

13. Vendor testing: Prior to delivery with fresh water, vented, and hydrostatically tested for at least 10 minutes at 275 psig. No leakage is allowed. The pump shall then be operated for at least 5 minutes to demonstrate run dry protection and the 140 psi setpoint while flowing. After testing, drain all water to prevent freeze damage during shipping and storage. Ship with the drain and vent valve(s) open and with the specified cap and cover installed on the 2 ½” cam and groove fittings.

14. Coatings: No coatings are required on hot dip galvanized steel, stainless steel, 5000 and 6000 series aluminum, or copper alloy. Galvanized coating damage shall be repaired by removing surface oil with a solvent and then touching up with cold galvanizing compound. Where coatings are required, a primer and compatible topcoat, each designed for use in a marine environment, shall be applied in accordance with the coating manufacturer’s instructions.

15. Sharp edges: The finished assembly shall have no sharp edges, burrs, or other personnel contact hazards.

16. Welding: All welding shall be performed in accordance with AWS D1.1-2010. Welders shall be qualified for the welds used per AWS D1.1-2010. Both inspection and verification shall be performed by the contractor.

17. Operator’s Manual: Regardless of the number of pumps ordered, the vendor shall deliver four (4) hard copies of the operator’s manual in binders plus one (1) electronic copy on CD or DVD. The manual shall provide complete operating instructions, maintenance requirements including periodicity, parts list for each component (electrical and mechanical), mfr. cut-sheets with specific make/model identified (highlighted) for each component, electrical schematic(s), structural drawing of the skid, to scale arrangement drawing of the completed pump assembly, test data, copy of the lifting schematic label plate, copy of the stamped calculations for the lifting structure, initial settings for all components, performance specifications, warranty document, and OSHA compliance report. A Copy of PCB Certification Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) part-per-million (ppm))shall be included. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide it. Electronic copies shall include electronic drawing files created for unit design (if CAD, AutoCad or Solid Edge 3D format preferred but not required). The Operator’s Manual’s shell be delivered at the same time as the pump skids. To aid in manual development, vendor is encouraged to provide, during compilation, periodic draft copies for review to Technical POC via Contracting Officer prior to final shipment and submission into iRAPT.

18. OSHA Requirements: The equipment installation and its component parts shall be in compliance with the applicable OSHA regulations in accordance with CFR Title 29, Chapter XVII, Part 1910 and installed in accordance with NEC/NFPA requirements.

Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399. The OSHA Compliant Report shall be included in the Operator’s Manual to be provided at the time of equipment delivery. Failure to provide this compliance report will delay acceptance of the equipment, and could result in rejection for failure to comply with the terms of the contract. This report documents the results of all tests performed, provides an assessment of the equipment performance for compliance with the contract requirements, and forms a basis for recommending a safety certification. The report, test and evaluation shall be a composite of those inspection requirements specified in the contract. The report shall be prepared in an orderly manner to clearly and accurately set forth the collected data and conclusion resulting from these inspection requirements, opinions and subjective conclusions shall be clearly identified. The inspecting body shall affix a label certifying conformance with standards. The report shall include, but is not limited to, the following:

a. List of all tests performed and by whom witnessed.

b. List of data used for evaluation.

c. Tabulation of all discrepancies related to specification performance requirements.

d. Description of limitations revealed by data utilized.

e. Actions taken to mitigate each discrepancy and limitation.

f. Recommendations for subsequent actions.

g. Summary conclusions.

h. Manufacturer Certification that equipment has been manufactured and installed in compliance with OSHA CFR 1910.399 (per definition of “acceptable”).

19. Warranty: Warranty period shall be 12 months, beginning from the date of delivery to the Government. The contractor shall warrant all parts, materials, and workmanship to be free from defects during this period. Warranty document shall be included in the Operator’s Manual.

20. Spare Parts: The vendor shall provide one (1) set of spare parts for initial order of 9 pump skids and one (1) set for each additional option exercised. Spare parts shall be delivered at the same time as pump skids. Spare parts include the following items.

a) 2 each, ASME Pressure Relief Valves

b) 1 each, Variable Frequency Drives

c) 2 each, Wafer check valves

d) 2 each, Pressure Transmitters

e) 2 each, Pressure Switches

f) 1 each, Expansion Tank Bladder

g) Spare Parts for the pump/motor assembly:

a. 1 Motor

b. 1 Coupling

c. 1 Mechanical Seal

d. 2 Replacement bearing sets (pump and motor)

e. 1 Impeller repair kit

21. Fluid Schematic and Parts Description. Note: Other parts needed to meet the specification requirements shall be supplied in addition to the components shown in Figure 1:

TRV

PI

PRV

PS PTPI

VFD

Motor

Controller

17 1516

18 18 vent/drain vent/drain

Figure 1

Booster Pump Skid

Schematic shown is one possible arrangement, but not mandatory. The listed components and descriptions are mandatory, except as noted. Or-Equal offers must be approved by PSNS & IMF Temporary Services Engineering, Code 270TS prior to construction. Additional component requirements are stated in earlier paragraphs:

1. Fluid inlet connection; 2 ½” Female Cam and groove (Coupling).

2. Cam and groove plastic dust plug (with 1/8” hole) attached via stainless steel braided wire tether.

3. Suction Pressure Gauge (PI); Industrial, SS or brass case, 4 in. face, ¼ in. NPT lower mount, ± 1% of full scale, glycerine filled, has a 24 month calibration period in the Navy METCAL program. Ashcroft 35-1009-SL-02L-XLL, WIKA 213.40 or equal.

Range: 0-120 psig.

4. Vent/blowdown/isolation ball valve; 1/4”

5. Inlet pressure switch (PS); Diaphragm sensing, 0-50 psig range, 250 psi max working pressure, one SPDT switch, switch rating 15A-125,250,480 VAC, sensitivity

– ½% of range, fixed deadband 1/4" NPT/F process connection, 1/2” NPT electrical connection, NEMA 4X, SS wetted components, switch shall be capable of pressure set point adjustment by user. Solon Model 2PSW1-2 or equal.

6. Discharge Pressure Transmitter (PT); 0-200 psig, ¼”-18 NPT/M Pressure Port, DIN 43650A Elec. Connector, 4-20 mA 2-wire output, ≤ 1.0% accuracy FS, vibration resistance ≥ 20G (IEC 60068-2-6), shock resistance ≥ 50G (IEC 60068-2-27). Gems Model 32CS-B-200PG-02-G-0-02 or equal. Sensor shall be protected from debris with in-line sintered filter.

7. Pump casing Temperature Relief Valve (TRV); High pressure in-line, stainless steel, heat actuated trap – reverse acting, EPDM/PTFE seals,. full open at 120 deg., ThermOmegaTech Model 154-010100-140 or equal. Adapt as necessary to install as close to casing vent port as possible but no further than 1”.

8. Discharge Pressure Gauge (PI); Gauge shall be identical to the Suction Pressure Gauge, (same model, and options). Range to be 0-300 psig

9. Pressure Relief Valve (PRV); Angled, ASME Section VII code stamped, 3/4" NPT/M inlet, 1” NPT/F outlet, brass/bronze construction (SB62), SS seat/disc/spring, packed lifting lever, minimum capacity of 50 gpm at 175 psig, pressure setpoint 200 psig. 1” outlet directed down (elbow and pipe acceptable.) Aquatrol model 740DFM3L-200 or equal.

10. Vent ball valve; 3/4", outlet directed down (elbow acceptable)

11. Pipe union; 3/4"

12. Diaphragm Tank.

13. Fluid outlet connection; 2-1/2” Male Cam and groove (Adapter).

14. Cam and groove plastic dust cap attached via stainless steel braided wire tether.

15. Vertical, Multi-stage, Centrifugal Pump with Variable Frequency Drive and flanged connections. Goulds Pumps Model 46SV20NL4F60 or equal.

16. Pump casing drain valve. Weld a SS round bar to drain valve for hand operation.

17. Resilient Seat Check Valve; 3”, Class 150, wafer style, 316 SS body /disc, Buna-N seal, API 594-Type A Dual plate, serrated face, Inconel spring, Crane 3” C-15-C-M- F-0-9 or equal. Install with hinge pin vertical.

18. Drain valve, ¼”