33_52_43.23.pdf

Replace POL Facilities, Hill AFB, Utah HU05

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 52 43.23

AVIATION FUEL PUMPS

02/10

PART 1 GENERAL

1.1 REFERENCES

1.2 ADMINISTRATIVE REQUIREMENTS

1.3 SUBMITTALS

PART 2 PRODUCTS

2.1 FUELING PUMPS (FP-1 THROUGH FP-3)

2.1.1 Capacity

2.1.2 General Requirements

2.1.3 Service Nameplate

2.1.4 Identification Nameplate

2.1.5 Exterior Primer Coat

2.1.6 Exterior Topcoat

2.1.7 Motors

2.2 FUELING PUMPS (FP-4 AND FP-5)

2.2.1 Capacity

2.2.2 General Requirements

2.2.3 Service Nameplate

2.2.4 Identification Nameplate

2.2.5 Exterior Primer Coat

2.2.6 Exterior Topcoat

2.2.7 Motors

2.3 OFFLOAD PUMPS (OL-1 and OL-2)

2.3.1 Capacity

2.3.2 General Requirements

2.3.3 Service Nameplate

2.3.4 Identification Nameplate

2.3.5 Exterior Primer Coat

2.3.6 Exterior Topcoat

2.3.7 Motors

2.4 FUEL TRANSFER PUMPS FTP-1

2.4.1 Capacity

2.4.2 Assembly

2.4.3 Materials

2.4.3.1 Mechanical Seal

2.4.4 Construction

2.4.4.1 Couplings

2.4.4.2 Impeller

2.4.4.3 Wear Rings

2.4.4.4 Shaft

2.4.4.5 Finishing

2.4.4.6 Bearings

2.4.4.7 Drilling and Tapping

2.4.4.8 Mounting Flange

SECTION 33 52 43.23 Page 1 Revised in Accordance with Am #0002

2.4.4.9 Special Tools

2.4.4.10 Service Nameplate

2.4.4.11 Identification Nameplate

2.4.4.12 Exterior Primer Coat

2.4.4.13 Exterior Topcoat

2.4.5 Motor

2.5 PRODUCT RECOVERY PUMP

2.5.1 Assembly

2.5.2 Materials

2.5.3 Motor

PART 3 EXECUTION

3.1 PREPARATION FOR SHIPMENT

3.1.1 Rust Preventative

3.1.2 Closure of Openings

3.1.3 Assembly

3.1.4 Bracing

3.1.5 Vapor Inhibiting Wraps

3.1.6 Shipping Identification

3.2 INSTALLATION

3.2.1 Anchoring

3.2.2 Grouting

3.2.3 Leveling and Aligning

3.2.4 Direct Drives

3.2.4.1 Rotation Direction and Speed

3.2.4.2 End Play

3.2.4.3 Shaft Leveling and Radial Alignment

3.2.4.4 Angular Alignment and End Clearance

3.2.4.5 Final Recheck

3.2.5 Start-up Representative

-- End of Section Table of Contents --

SECTION 33 52 43.23 Page 2

SECTION 33 52 43.23

AVIATION FUEL PUMPS

02/10

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 in the text by basic designation only.

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 7 (1995; Stabilized (S) 2013) Shaft and Housing Fits for Metric Radial Ball and Roller Bearings (Except Tapered Roller Bearings) Conforming to Basic Boundary Plan

AMERICAN PETROLEUM INSTITUTE (API)

API STD 682 (2014) Pumps Shaft Sealing Systems For Centrifugal and Rotary Pumps

API Std 610 (2010; Errata 2011) Centrifugal Pumps for Petroleum, Petrochemical, and Natural Gas Industries

ASME INTERNATIONAL (ASME)

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings:

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME BPVC SEC VIII D1 (2015) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A182/A182M (2014b) Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A276 (2013a) Standard Specification for Stainless Steel Bars and Shapes

ASTM A356/A356M (2011) Standard Specification for Steel Castings, Carbon, Low Alloy, and Stainless Steel, Heavy-Walled for Steam Turbines

ASTM A487/A487M (2014) Standard Specification for Steel Castings Suitable for Pressure Service

ASTM A582/A582M (2012; E 2012) Standard Specification for Free-Machining Stainless Steel Bars

SECTION 33 52 43.23 Page 3

ASTM A743/A743M (2013a; E 2014) Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application

ASTM C827/C827M (2016) Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures

HYDRAULIC INSTITUTE (HI)

HI M100 (2009) HI Pump Standards Set

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 112 (2004) Standard Test Procedure for Polyphase Induction Motors and Generators

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2016; SUPP 2016) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14) National Electrical Code

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC PA 1 (2016) Shop, Field, and Maintenance Coating of Metals

SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-24441 (2009; Rev D) Paint, Epoxy-Polyamide, General Specification for

MIL-PRF-4556 (1998; Rev F; Am 1 1999; CANC Notice 1 2011) Coating Kit, Epoxy, for Interior of Steel Fuel Tanks

1.2 ADMINISTRATIVE REQUIREMENTS

Design conditions shall be as specified in Section 33 52 43.11 AVIATION

FUEL MECHANICAL EQUIPMENT.

a. Tests: Hydrostatic, performance, vibration, and NPSH tests shall be conducted at the factory on each pump in accord with API 610. Test each pump with the actual motor which will drive the pump in the field, unless the water test media will cause overload of the motor. If so, provide vibration test report for motor separately. Vertical turbine pump vibration test must be run with field driver. All tests will be observed by the Contracting Officer or the designated representative.

SECTION 33 52 43.23 Page 4

Provide the Contracting Officer 30 days notice prior to performance of factory tests in order to schedule observing such tests. Performance testing shall not occur prior to acceptance of shop drawing submittal.

b. Test reports shall bear the serial number of both pump and driver.

Submit manufacturer's certified reports of hydrostatic, performance, and NPSH tests. Submit manufacturer's certified test curves..

c. Operation and Maintenance Manuals shall be submitted for the pumps and appurtenance specified herein. Refer to Section 01 78 23.33OPERATION AND MAINTENANCE MANUALS FOR AVIATION FUEL SYSTEMS for the information to be submitted.

d. Motors, manual or automatic motor control equipment, except where installed in motor control centers, and protective or signal devices required for the operation specified herein shall be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Any wiring required for the operation specified herein, but not shown on the electrical plans, shall be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

Motors shall be high efficiency type and in accordance with Section

26 20 00 INTERIOR DISTRIBUTION SYSTEM.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

[Am-2]

SD-02 Shop Drawings

Fueling Pumps (FP-1 through FP-3); G-OMA.

Offload Pumps (OL-1 and OL-2); G-OMA.

Fuel Transfer Pumps FTP-1; G-OMA.

Product Recovery Pump; G-OMA Fueling Pumps (FP-4 and FP-5); G, OMA

SD-03 Product Data

Fueling Pumps (FP-1 through FP-3); G-OMA.

Offload Pumps (OL-1 and OL-2); G-OMA.

Fuel Transfer Pumps FTP-1 ; G-OMA.

Fueling Pumps (FP-4 and FP-5); G, OMA

SD-06 Test Reports

Certified Test Curves

SD-07 Certificates

Fueling Pumps (FP-1 through FP-3); G-OMA.

Offload Pumps (OL-1 and OL-2); G-OMA.

Fuel Transfer Pumps FTP-1; G-OMA.

Product Recovery Pump; G-OMA Fueling Pumps (FP-4 and FP-5); G, OMA

SD-10 Operation and Maintenance Data

SECTION 33 52 43.23 Page 5

Operation and Maintenance Manuals; G-RO.

PART 2 PRODUCTS

2.1 FUELING PUMPS (FP-1 THROUGH FP-3)

[*Am-2]

2.1.1 Capacity

Capacity shall be 600 gpm against a total head of 514 feet when driven at 3600 rpm. Overall efficiency at design conditions of pump and driver, connected, shall be minimum of 50 percent. Pump head capacity shall be continually rising and shall be free of dips and valleys from design point to shut-off head. Pump shut-off head shall have a 10 to 20 percent head rise to shut off. Pump shall be capable of at least a 10 percent head increase at rated conditions by installing a new impeller. Pumps shall not overheat or be damaged in any way while operating continuously at a minimum flow condition of 150 gpm and continuously at a maximum flow condition of 125 percent required capacity. The unit will also be required to operate at a flow of 12.5 percent required capacity GPM without exceeding the vibration limits given in API Std 610 at that flowrate. These pumps are for parallel operation and shall have equal head at minimum continuous stable flow, plus or minus 2 percent.

2.1.2 General Requirements

a. The pumps shall meet the requirements of API Std 610, latest edition.

Whenever the information contained herein conflicts with said standard, the information herein shall govern. The pumps shall run at a nominal 3600 rpm and shall be single stage centrifugals, horizontally mounted, vertical or radial split case, enclosed impeller, with end suction and top vertical discharge. Pumps shall be of the back pull-out design to permit removing case half from rear for access to internal parts without disturbing the suction or discharge piping or the driver. All parts shall be factory inspected so that parts are interchangeable.

Pumps and motors shall be furnished as complete units as herein specified. Pump assembly shall be statically and dynamically balanced for all flow rates from minimum flow to 120 percent of design flow.

b. The pump shall require no more than 15-feet of net positive suction head (NPSHR) when it is operated with water at a capacity of 600 gpm at rated head and speed. A hydrocarbon reduction or correction factor shall not be used. Pump suction specific speed shall be less than 12,000.

c. The pump shall be horizontal, single stage, single suction with double volute construction to assure radial balance. It shall be designed to permit removal of the impeller, shaft, bearings and bearing housing as an assembly, without disconnecting the suction or discharge piping.

d. The pump case shall be end suction, centerline discharge type for ease of piping alignment. Flange ratings shall be class 300-pound per ASME B16.5. The case shall be designed for maximum discharge pressure at pumping temperature but not less than 550 psig, with a minimum corrosion allowance of 1/8-inch. The suction and discharge flanges as well as the cover bolting surfaces shall be backfaced or spotfaced for positive bolt seating. The radial case to cover split shall be a metal-to-metal fit with a confined, controlled compression gasket.

SECTION 33 52 43.23 Page 6

e. The pump cover shall contain a stuffing box designed to accept an unbalanced mechanical seal. The stuffing box shall have a minimum of 3-inch studs for seal gland bolting. The gasket fit for seal gland to stuffing box shall be of the controlled compression type with metal-to-metal joint contact.

f. Both case and cover are to be fitted with renewable wear rings.

g. The impeller shall be of the enclosed type, dynamically and hydraulically balanced. It shall be key driven, held in place by a positive lock, threaded against rotation. The running clearance between the impeller and case-cover wear rings shall be no less than 0.018-inches.

h. Mechanical Seal: A single unbalanced mechanical seal per API Std 610 code USTHN, unbalanced single seal with throttle bushing seal gland, a nitrile seal-ring-to-sleeve gasket and carbon against silicon carbide faces, of multiple spring design shall be supplied. The seal gland shall be tapped for three connections and each shall be stamped for identification as follows: Q for quench; F for flush; and D for drain. A non-sparking throttle bushing pressed into the seal end plate against an outside shoulder shall be provided to minimize leakage on complete seal failure.

i. Bearing Housing: Oil lubricated anti-friction, radial and thrust bearings of standard design shall be supplied. The bearings shall be selected to give a minimum L-10 rating life of 25,000 hours in continuous operation. Bearings shall be retained on the shaft and fitted into housings in accordance with ABMA 7. Locking of the ball thrust bearing to the shaft shall be by series W tank type washer.

Minimum spacing between bearing centerlines shall be 6.5-inches.

j. A sight glass for checking oil level with a permanent indication of proper oil level shall be supplied.

k. Bearing housings shall be equipped with labyrinth type end seals and deflectors where the shaft passes through the housing; lip-type seals shall not be used. Deflectors shall be made of non-sparking material.

The deflector design shall effectively retain oil in the housing and prevent entry of foreign material into the housing.

l. Shafts shall be of ample size to transmit the maximum torque required under specified operating conditions, and to withstand continuously all stresses resulting from supported weights, thrusts and starting, including across-the-line motor starting. It shall be key seated to provide positive drive for the coupling, shaft sleeve and impeller.

The shaft stiffness factor shall be under 70. The radial bearing centerline to impeller centerline, distance and the pump shaft diameter under the sleeve shall be provided to calculate the factor.

m. A spacer coupling shall be supplied. The spacer length shall permit the removal of the assembled pullout element without disturbing the driver or the suction and discharge piping. Couplings shall be properly keyed in place. Cylindrical fits shall be light enough to permit easy removal of the hub in the field without the need for heating. A service factor of at least 1.5 shall be used in selecting couplings based on manufacturer's ratings.

n. Removable coupling guards of the non-sparking type shall be supplied.

SECTION 33 52 43.23 Page 7

They shall comply with the requirements of OSHA.

o. Total indicated shaft runout at coupling end shall be 0.001-inches or less. Total shaft deflection shall be no more than 0.002-inches at face of stuffing box.

p. Baseplate: The baseplate shall be of fabricated steel construction. It shall be of the drain pan style, sloping from back to front.

Connections for a drain shall be tapped (1-inch minimum) at the pump end and located to accomplish complete drainage. A grout hole of at least 8-inches minimum diameter shall be supplied and shall have 1/2-inch minimum raised lip edge. Pump pedestals shall be trapezoidal in design.

q. Materials: No zinc, brass, bronze or other copper bearing alloy shall come in contact with the fuel. Materials shall be material class C-6, unless otherwise noted.

r. The case and cover shall be constructed of stainless steel ASTM A487/A487M GR CF8M or ASTM A487/A487M GR CA6NM or aluminum

ASTM A356/A356M GR T6.

s. Impeller material shall be stainless steel ASTM A487/A487M GR CF8M or ASTM A743/A743M CA 6NM or CA 15.

t. Wear rings shall be stainless steel ASTM A182/A182M GR F6 or ASTM A276 TP410 or 416.

u. Shaft shall be stainless steel ASTM A276 type 410 or 416 or ASTM A582/A582M Type 410 or 416.

v. Testing: All shop testing shall be performed in accordance with the API Std 610.

2.1.3 Service Nameplate

A pump service nameplate, of type 18-8 stainless steel or monel, attached by stainless steel pins at an accessible point on the pump, shall be furnished in addition to the identification nameplate. The pump service nameplate shall be stamped with the following information:

Manufacturer's name Serial number of pump Capacity, gpm Pumping head, ft.

Maximum specific gravity of fluid to be pumped Revolutions per minute Horsepower of driver

2.1.4 Identification Nameplate

A pump identification nameplate of Type 18-8 stainless steel or monel shall be provided and securely attached by stainless steel pins to a conspicuous place on the pump head. Tagging in letters 1/4-inch high shall bear the equipment number as shown on the drawings.

2.1.5 Exterior Primer Coat

Exterior surfaces of the baseplate shall be primed by the manufacturer.

SECTION 33 52 43.23 Page 8

Coating shall be applied meeting requirements of SSPC PA 1. Surface cleaning shall meet requirements of SSPC SP 10/NACE No. 2. Metal primer shall be zinc rich paint conforming to specification MIL-DTL-24441, Type 1, Class 3. Dry film thickness shall be 2 to 4 mils.

2.1.6 Exterior Topcoat

Manufacturer's standard exterior topcoat shall be applied at factory to the base plate.

2.1.7 Motors

a. Motor shall be furnished by the pump manufacturer and shall be non-overloading with 10 percent head increase, and suitable for the environment and operating conditions to which it will be subjected.

Motors for vertical turbine pumps shall be provided with anti-reversing ratchet. Provide space heaters suitable for operation on 460 or 120 volts as indicated on the drawings within the motor enclosure to prevent moisture condensation after shut-down. Motor shall be UL listed for use in Class 1, Division 1, Group D hazardous areas, and shall have a maximum temperature rating of T2D ( 419 degrees F) as defined by NFPA 70. The motor nameplate shall include the temperature rating of the motor and locked-rotor indicating code letters in accordance with NFPA 70, Table 430-7(b).

b. Voltage rating shall be 460 volts, 3 phase, 60HZ. Motor nominal speed shall match pump. Motors shall be capable of delivering rated horsepower output successfully and continuously under conditions of voltage variations of 10 percent above or below rated voltage.

c. Pump manufacturer shall assure the specified output and proper operation of the pump without being overloaded at unity service factor when operating at any point on the pump performance curve. In addition to having sufficient horsepower-output rating at rated speed, motor shall have performance characteristics which will allow, without injurious overheating of the motor, accelerating the load from standstill to rated speed under conditions of 10 starts per hour.

Attention is specifically directed to the fact that thermal characteristics of motors with regard to capability for accelerating the load may vary greatly from motor manufacturer to motor manufacturer, notwithstanding that the horsepower rating may be the same. It is the pump manufacturer's responsibility to provide motors with adequate thermal starting characteristics as well as adequate rated-speed operating characteristics. Service factors shall conform with NEMA standards; however, service factors are only applicable at rated nameplate voltage and frequency. Since all system voltages are subject to variation, service factors above unity shall not be applied in sizing motor.

d. Motor shall be squirrel-cage induction type. Motor shall be NEMA Design B (normal-torque, low starting current).

e. Motor insulation shall be non-hydroscopic, NEMA Class H, 82 degrees F for motors over 10 hp and NEMA Class F, 302 degrees F for 10 hp and smaller. Stator windings shall be epoxy impregnated. The impregnations shall be applied by the vacuum and pressure process.

f. Winding temperature rise, (based on a maximum ambient temperature of 4 degrees F at 3300-feet altitude) shall not exceed 176 degrees F.

SECTION 33 52 43.23 Page 9

g. Bearings shall be ABMA minimum L10 life of 60,000 hours or L50 life of 300,000 hours suitable for the size, type, and application when the pump is operating at the specified flow and head.

h. Motor enclosures shall be totally enclosed, weather sealed, fan cooled, explosion-proof and shall be listed and labeled for Class 1, Group D areas. Provide bronze ground bolt on motor enclosure. All motor external electrical connections shall be terminated within a single terminal housing.

i. The dynamic balance, overspeed withstand capability, and sound power levels of the motor shall conform with NEMA standard requirements.

j. The pump manufacturer shall furnish the Contracting Officer with the recommended minimum run time for the motor.

k. Pump motor shall be provided with temperature limiting thermostats within the motor frame when required to meet Class 1, Group D requirements.

l. Pump motor shall be furnished with lifting lugs on the motor casing.

m. Unless indicated otherwise, motors for conventional applications over 15 horsepower shall be the premiumy efficient type. This requirement is not applicable to hermetically sealed motors, integrally mounted motors, motors specified as part of energy efficient equipment, wound rotor motors, or any application involving special construction or performance. Guaranteed minimum full load efficiencies shall be (based on 3600, 2 pole, totally enclosed):

20 hp 92.0 percent 75 hp 95.5 percent

25 hp 92.0 percent 100 hp 93.5 percent

30 hp 92.0 percent 125 hp 94.5 percent

40 hp 92.0 percent 150 hp 94.5 percent

50 hp 92.5 percent 200 hp 94.5 percent

60 hp 92.5 percent 600 hp 94.5 percent

n. Other motors of different speed or housing classification shall also be of the premium efficient type, as advertised by the motor manufacturer, with efficiency greater than the standard line. Motor efficiencies shall have been verified in accordance with NEMA MG 1, 12.53.a., and determined using the dynamometer method as described in IEEE 112, Method B. All shop drawing submittals on motor driven equipment shall include the motor efficiency.

[*Am-2]]

2.2 FUELING PUMPS (FP-4 AND FP-5)

2.2.1 Capacity

Capacity shall be 800 gpm against a total head of 365 feet when driven at 3600 rpm. Overall efficiency at design conditions of pump and driver, SECTION 33 52 43.23 Page 10 connected, shall be minimum of 50 percent. Pump head capacity shall be continually rising and shall be free of dips and valleys from design point to shut-off head. Pump shut-off head shall have a 10 to 20 percent head rise to shut off. Pump shall be capable of at least a 10 percent head increase at rated conditions by installing a new impeller. Pumps shall not overheat or be damaged in any way while operating continuously at a minimum flow condition of 150 gpm and continuously at a maximum flow condition of 125 percent required capacity. The unit will also be required to operate at a flow of 12.5 percent required capacity GPM without exceeding the vibration limits given in API Std 610 at that flowrate. These pumps are for parallel operation and shall have equal head at minimum continuous stable flow, plus or minus 2 percent.

2.2.2 General Requirements

a. The pumps shall meet the requirements of API Std 610, latest edition.

Whenever the information contained herein conflicts with said standard, the information herein shall govern. The pumps shall run at a nominal 3600 rpm and shall be single stage centrifugals, horizontally mounted, vertical or radial split case, enclosed impeller, with end suction and top vertical discharge. Pumps shall be of the back pull-out design to permit removing case half from rear for access to internal parts without disturbing the suction or discharge piping or the driver. All parts shall be factory inspected so that parts are interchangeable.

Pumps and motors shall be furnished as complete units as herein specified. Pump assembly shall be statically and dynamically balanced for all flow rates from minimum flow to 120 percent of design flow.

b. The pump shall require no more than 15-feet of net positive suction head (NPSHR) when it is operated with water at a capacity of 800 gpm at rated head and speed. A hydrocarbon reduction or correction factor shall not be used. Pump suction specific speed shall be less than 12,000.

c. The pump shall be horizontal, single stage, single suction with double volute construction to assure radial balance. It shall be designed to permit removal of the impeller, shaft, bearings and bearing housing as an assembly, without disconnecting the suction or discharge piping.

d. The pump case shall be end suction, centerline discharge type for ease of piping alignment. Flange ratings shall be class 300-pound per ASME B16.5. The case shall be designed for maximum discharge pressure at pumping temperature but not less than 550 psig, with a minimum corrosion allowance of 1/8-inch. The suction and discharge flanges as well as the cover bolting surfaces shall be backfaced or spotfaced for positive bolt seating. The radial case to cover split shall be a metal-to-metal fit with a confined, controlled compression gasket.

e. The pump cover shall contain a stuffing box designed to accept an unbalanced mechanical seal. The stuffing box shall have a minimum of 3-inch studs for seal gland bolting. The gasket fit for seal gland to stuffing box shall be of the controlled compression type with metal-to-metal joint contact.

f. Both case and cover are to be fitted with renewable wear rings.

g. The impeller shall be of the enclosed type, dynamically and hydraulically balanced. It shall be key driven, held in place by a positive lock, threaded against rotation. The running clearance

SECTION 33 52 43.23 Page 11 between the impeller and case-cover wear rings shall be no less than 0.018-inches.

h. Mechanical Seal: A single unbalanced mechanical seal per API Std 610 code USTHN, unbalanced single seal with throttle bushing seal gland, a nitrile seal-ring-to-sleeve gasket and carbon against silicon carbide faces, of multiple spring design shall be supplied. The seal gland shall be tapped for three connections and each shall be stamped for identification as follows: Q for quench; F for flush; and D for drain. A non-sparking throttle bushing pressed into the seal end plate against an outside shoulder shall be provided to minimize leakage on complete seal failure.

i. Bearing Housing: Oil lubricated anti-friction, radial and thrust bearings of standard design shall be supplied. The bearings shall be selected to give a minimum L-10 rating life of 25,000 hours in continuous operation. Bearings shall be retained on the shaft and fitted into housings in accordance with ABMA 7. Locking of the ball thrust bearing to the shaft shall be by series W tank type washer.

Minimum spacing between bearing centerlines shall be 6.5-inches.

j. A sight glass for checking oil level with a permanent indication of proper oil level shall be supplied.

k. Bearing housings shall be equipped with labyrinth type end seals and deflectors where the shaft passes through the housing; lip-type seals shall not be used. Deflectors shall be made of non-sparking material.

The deflector design shall effectively retain oil in the housing and prevent entry of foreign material into the housing.

l. Shafts shall be of ample size to transmit the maximum torque required under specified operating conditions, and to withstand continuously all stresses resulting from supported weights, thrusts and starting, including across-the-line motor starting. It shall be key seated to provide positive drive for the coupling, shaft sleeve and impeller.

The shaft stiffness factor shall be under 70. The radial bearing centerline to impeller centerline, distance and the pump shaft diameter under the sleeve shall be provided to calculate the factor.

m. A spacer coupling shall be supplied. The spacer length shall permit the removal of the assembled pullout element without disturbing the driver or the suction and discharge piping. Couplings shall be properly keyed in place. Cylindrical fits shall be light enough to permit easy removal of the hub in the field without the need for heating. A service factor of at least 1.5 shall be used in selecting couplings based on manufacturer's ratings.

n. Removable coupling guards of the non-sparking type shall be supplied.

They shall comply with the requirements of OSHA.

o. Total indicated shaft runout at coupling end shall be 0.001-inches or less. Total shaft deflection shall be no more than 0.002-inches at face of stuffing box.

p. Baseplate: The baseplate shall be of fabricated steel construction. It shall be of the drain pan style, sloping from back to front.

Connections for a drain shall be tapped (1-inch minimum) at the pump end and located to accomplish complete drainage. A grout hole of at least 8-inches minimum diameter shall be supplied and shall have

SECTION 33 52 43.23 Page 12

1/2-inch minimum raised lip edge. Pump pedestals shall be trapezoidal in design.

q. Materials: No zinc, brass, bronze or other copper bearing alloy shall come in contact with the fuel. Materials shall be material class C-6, unless otherwise noted.

r. The case and cover shall be constructed of stainless steel ASTM A487/A487M GR CF8M or ASTM A487/A487M GR CA6NM or aluminum

ASTM A356/A356M GR T6.

s. Impeller material shall be stainless steel ASTM A487/A487M GR CF8M or ASTM A743/A743M CA 6NM or CA 15.

t. Wear rings shall be stainless steel ASTM A182/A182M GR F6 or ASTM A276 TP410 or 416.

u. Shaft shall be stainless steel ASTM A276 type 410 or 416 or ASTM A582/A582M Type 410 or 416.

v. Testing: All shop testing shall be performed in accordance with the API Std 610.

2.2.3 Service Nameplate

A pump service nameplate, of type 18-8 stainless steel or monel, attached by stainless steel pins at an accessible point on the pump, shall be furnished in addition to the identification nameplate. The pump service nameplate shall be stamped with the following information:

Manufacturer's name Serial number of pump Capacity, gpm Pumping head, ft.

Maximum specific gravity of fluid to be pumped Revolutions per minute Horsepower of driver

2.2.4 Identification Nameplate

A pump identification nameplate of Type 18-8 stainless steel or monel shall be provided and securely attached by stainless steel pins to a conspicuous place on the pump head. Tagging in letters 1/4-inch high shall bear the equipment number as shown on the drawings.

2.2.5 Exterior Primer Coat

Exterior surfaces of the baseplate shall be primed by the manufacturer.

Coating shall be applied meeting requirements of SSPC PA 1. Surface cleaning shall meet requirements of SSPC SP 10/NACE No. 2. Metal primer shall be zinc rich paint conforming to specification MIL-DTL-24441, Type 1, Class 3. Dry film thickness shall be 2 to 4 mils.

2.2.6 Exterior Topcoat

Manufacturer's standard exterior topcoat shall be applied at factory to the base plate.

SECTION 33 52 43.23 Page 13

2.2.7 Motors

a. Motor shall be furnished by the pump manufacturer and shall be non-overloading with 10 percent head increase, and suitable for the environment and operating conditions to which it will be subjected.

Motors for vertical turbine pumps shall be provided with anti-reversing ratchet. Provide space heaters suitable for operation on 460 or 120 volts as indicated on the drawings within the motor enclosure to prevent moisture condensation after shut-down. Motor shall be UL listed for use in Class 1, Division 1, Group D hazardous areas, and shall have a maximum temperature rating of T2D ( 419 degrees F) as defined by NFPA 70. The motor nameplate shall include the temperature rating of the motor and locked-rotor indicating code letters in accordance with NFPA 70, Table 430-7(b).

b. Voltage rating shall be 460 volts, 3 phase, 60HZ. Motor nominal speed shall match pump. Motors shall be capable of delivering rated horsepower output successfully and continuously under conditions of voltage variations of 10 percent above or below rated voltage.

c. Pump manufacturer shall assure the specified output and proper operation of the pump without being overloaded at unity service factor when operating at any point on the pump performance curve. In addition to having sufficient horsepower-output rating at rated speed, motor shall have performance characteristics which will allow, without injurious overheating of the motor, accelerating the load from standstill to rated speed under conditions of 10 starts per hour.

Attention is specifically directed to the fact that thermal characteristics of motors with regard to capability for accelerating the load may vary greatly from motor manufacturer to motor manufacturer, notwithstanding that the horsepower rating may be the same. It is the pump manufacturer's responsibility to provide motors with adequate thermal starting characteristics as well as adequate rated-speed operating characteristics. Service factors shall conform with NEMA standards; however, service factors are only applicable at rated nameplate voltage and frequency. Since all system voltages are subject to variation, service factors above unity shall not be applied in sizing motor.

d. Motor shall be squirrel-cage induction type. Motor shall be NEMA Design B (normal-torque, low starting current).

e. Motor insulation shall be non-hydroscopic, NEMA Class H, 82 degrees F for motors over 10 hp and NEMA Class F, 302 degrees F for 10 hp and smaller. Stator windings shall be epoxy impregnated. The impregnations shall be applied by the vacuum and pressure process.

f. Winding temperature rise, (based on a maximum ambient temperature of 4 degrees F at 3300-feet altitude) shall not exceed 176 degrees F.

g. Bearings shall be ABMA minimum L10 life of 60,000 hours or L50 life of 300,000 hours suitable for the size, type, and application when the pump is operating at the specified flow and head.

h. Motor enclosures shall be totally enclosed, weather sealed, fan cooled, explosion-proof and shall be listed and labeled for Class 1, Group D areas. Provide bronze ground bolt on motor enclosure. All motor external electrical connections shall be terminated within a single terminal housing.

SECTION 33 52 43.23 Page 14

i. The dynamic balance, overspeed withstand capability, and sound power levels of the motor shall conform with NEMA standard requirements.

j. The pump manufacturer shall furnish the Contracting Officer with the recommended minimum run time for the motor.

k. Pump motor shall be provided with temperature limiting thermostats within the motor frame when required to meet Class 1, Group D requirements.

l. Pump motor shall be furnished with lifting lugs on the motor casing.

m. Unless indicated otherwise, motors for conventional applications over 15 horsepower shall be the premiumy efficient type. This requirement is not applicable to hermetically sealed motors, integrally mounted motors, motors specified as part of energy efficient equipment, wound rotor motors, or any application involving special construction or performance. Guaranteed minimum full load efficiencies shall be (based on 3600, 2 pole, totally enclosed):

20 hp 92.0 percent 75 hp 95.5 percent

25 hp 92.0 percent 100 hp 93.5 percent

30 hp 92.0 percent 125 hp 94.5 percent

40 hp 92.0 percent 150 hp 94.5 percent

50 hp 92.5 percent 200 hp 94.5 percent

60 hp 92.5 percent 600 hp 94.5 percent

n. Other motors of different speed or housing classification shall also be of the premium efficient type, as advertised by the motor manufacturer, with efficiency greater than the standard line. Motor efficiencies shall have been verified in accordance with NEMA MG 1, 12.53.a., and determined using the dynamometer method as described in IEEE 112, Method B. All shop drawing submittals on motor driven equipment shall include the motor efficiency.

2.3 OFFLOAD PUMPS (OL-1 and OL-2)

2.3.1 Capacity

Capacity shall be 600 gpm against a total head of 480 feet when driven at 3600 rpm. Overall efficiency at design conditions of pump and driver, connected, shall be minimum of 60 percent. Pump head capacity shall be continually rising and shall be free of dips and valleys from design point to shut-off head. Pump shut-off head shall have a 10 to 20 percent head rise to shut off. Pump shall be capable of at least a 10 percent head increase at rated conditions by installing a new impeller. Pumps shall not overheat or be damaged in any way while operating continuously at a minimum flow condition of 150 gpm and continuously at a maximum flow condition of 125 percent required capacity GPM. The unit will also be required to operate at a flow of 12.5 percent required capacity without exceeding the vibration limits given in API Std 610. These pumps are for parallel operation and shall have equal head at minimum continuous stable flow, plus

SECTION 33 52 43.23 Page 15 or minus 2 percent.

2.3.2 General Requirements

a. The pumps for this service shall meet the requirements of API Std 610, latest edition. Whenever the information contained herein conflicts with said standard, the information here in shall govern. The pumps for this service shall run at a nominal 3600 rpm and shall be single stage centrifugals, horizontally mounted, vertical or radial split case, enclosed impeller, vertical-in-line with end suction and discharge. All parts shall be factory inspected so that parts are interchangeable. Pumps and motors shall be furnished as complete units as herein specified. Pump assembly shall be statically and dynamically balanced for all flow rates from no flow to 120 percent of design flow.

b. The pump shall require no more than 15.5-feet of net positive suction head (NPSHR) when it is operated with water at a capacity of 600 gpm at rated head and speed. A hydrocarbon reduction or correction factor shall not be used. Pump suction specific speed shall be less than 12,000.

c. The pump shall be vertical in-line, single stage, single suction with double volute construction to assure radial balance. It shall be designed to permit removal of the impeller, shaft, bearings and bearing housing as an assembly, without disconnecting the suction or discharge piping.

d. The pump case shall be vertical in-line type for ease of piping alignment. Flange ratings shall be class 300-pound per ASME B16.5.

The case shall be designed for maximum discharge pressure at pumping temperature but not less than 550 psig, with a minimum corrosion allowance of 1/8-inch. The suction and discharge flanges as well as the cover bolting surfaces shall be backfaced or spotfaced for positive bolt seating. The radial case to cover split shall be a metal-to-metal fit with a confined, controlled compression gasket.

e. The pump cover shall contain a stuffing box designed to accept an unbalanced mechanical seal. The stuffing box shall have a minimum of 3-inch studs for seal gland bolting. The gasket fit for seal gland to stuffing box shall be of the controlled compression type with metal-to-metal joint contact.

f. Both case and cover are to be fitted with renewable wear rings.

g. The impeller shall be of the enclosed type, dynamically and hydraulically balanced. It shall be key driven, held in place by a positive lock, threaded against rotation.

h. Mechanical Seal. A single unbalanced mechanical seal per API Std 610 code USTHN of multiple spring design shall be supplied. The seal gland shall be tapped for three connections and each shall be stamped for identification as follows: Q for quench; F for flush; and D for drain. A non-sparking throttle bushing pressed into the seal end plate against an outside shoulder shall be provided to minimize leakage on complete seal failure.

i. Bearing Housing. Grease lubricated anti-friction, radial and thrust bearings of standard design shall be supplied. The bearings shall be selected to give a minimum L-10 rating life of 25,000 hours in

SECTION 33 52 43.23 Page 16 continuous operation. Pumps may be provided with or without bearing brackets.

j. Shafts shall be of ample size to transmit the maximum torque required under specified operating conditions, and to withstand continuously all stresses resulting from supported weights, thrusts and starting, including across-the-line motor starting. It shall be key seated to provide positive drive for the line motor starting. It shall be key seated to provide positive drive for the coupling, shaft sleeve and impeller. The shaft stiffness factor shall be under 70. The radial bearing centerline to impeller centerline, distance and the pump shaft diameter under the sleeve shall be provided to calculate the factor.

k. A rigid type spacer coupling shall be supplied. The spacer length shall permit the removal of the assembled pullout element without disturbing the driver or the suction and discharge piping. Couplings shall be properly keyed in place. Cylindrical fits shall be light enough to permit easy removal of the hub in the field without the need for heating. A service factor of at least 1.5 shall be used in selecting couplings based on manufacturer's ratings.

l. Removable coupling guards of the non-sparking type shall be supplied.

They shall comply with the requirements of OSHA.

m. Total indicated shaft runout at coupling end shall be 0.001-inches or less. Total shaft deflection shall be no more than 0.002-inches at face of stuffing box.

n. Materials. No zinc, brass, bronze or other copper bearing alloy shall come in contact with the fuel.

o. The case and cover shall be constructed of stainless steel ASTM A487/A487M GR CF8M or ASTM A487/A487M GR CA6NM or aluminum

ASTM A356/A356M GR T6.

p. Impeller material shall be stainless steel ASTM A487/A487M GR CF8M or

ASTM A743/A743M CA 6NM.

q. Wear rings shall be stainless steel ASTM A182/A182M GR F6 or ASTM A276 TP410 or 416.

r. Shaft shall be stainless steel ASTM A276 type 410 or 416 or ASTM A582/A582M Type 410 or 416 with renewable shaft sleeve of ASTM A276 type 316L with hard facing under mechanical seal gasket.

s. Testing. All shop testing shall be performed in accordance with the

HI M100.

2.3.3 Service Nameplate

A pump service nameplate, of type 18-8 stainless steel or monel, attached by stainless steel pins at an accessible point on the pump, shall be furnished in addition to the identification nameplate. The pump service nameplate shall be stamped with the following information:

Manufacturer's name Serial number of pump Capacity, gpm Pumping head, ft.

SECTION 33 52 43.23 Page 17

Maximum specific gravity of fluid to be pumped Revolutions per minute Horsepower of driver

2.3.4 Identification Nameplate

A pump identification nameplate of Type 18-8 stainless steel or monel shall be provided and securely attached by stainless steel pins to a conspicuous place on the pump head. Tagging in letters 1/4-inch high shall bear the equipment number as shown on the drawings.

2.3.5 Exterior Primer Coat

Exterior surfaces of the baseplate shall be primed by the manufacturer.

Coating shall be applied meeting requirements of SSPC PA 1. Surface cleaning shall meet requirements of SSPC SP 10/NACE No. 2. Metal primer shall be zinc rich paint conforming to specification MIL-DTL-24441, Type 1, Class 3. Dry film thickness shall be 2 to 4 mils.

2.3.6 Exterior Topcoat

Manufacturer's standard exterior topcoat shall be applied at factory to the base plate.

2.3.7 Motors

a. Motor shall be furnished by the pump manufacturer and shall be suitable for the environment and operating conditions to which it will be subjected. Provide space heaters suitable for operation on 460 or 120 volts as indicated on the drawings within the motor enclosure to prevent moisture condensation after shut-down. Motor shall be UL listed for use in Class 1, Division 1, Group D hazardous areas, and shall have a maximum temperature rating of T2D ( 419 degrees F) as defined by NFPA 70. The motor nameplate shall include the temperature rating of the motor and locked-rotor indicating code letters in accordance with NFPA 70, Table 430-7(b).

b. Voltage rating shall be 460 volts, 3 phase, 60HZ. Motor nominal speed shall match pump. Motors shall be capable of delivering rated horsepower output successfully and continuously under conditions of voltage variations of 10 percent above or below rated voltage.

c. Pump manufacturer shall assure the specified output and proper operation of the pump without being overloaded at unity service factor when operating at any point on the pump performance curve. In addition to having sufficient horsepower-output rating at rated speed, motor shall have performance characteristics which will allow, without injurious overheating of the motor, accelerating the load from standstill to rated speed under conditions of 10 starts per hour.

Attention is specifically directed to the fact that thermal characteristics of motors with regard to capability for accelerating the load may vary greatly from motor manufacturer to motor manufacturer, notwithstanding that the horsepower rating may be the same. It is the pump manufacturer's responsibility to provide motors with adequate thermal starting characteristics as well as adequate rated-speed operating characteristics. Service factors shall conform with NEMA standards; however, service factors are only applicable at rated nameplate voltage and frequency. Since all system voltages are subject to variation, service factors above unity shall not be applied

SECTION 33 52 43.23 Page 18 in sizing motor.

d. Motor shall be squirrel-cage induction type. Motor shall be NEMA Design B (normal-torque, low starting current).

e. Motor insulation shall be non-hydroscopic, NEMA Class F, 300 degrees F for motors. Stator windings shall be epoxy impregnated. The impregnations shall be applied by the vacuum and pressure process.

f. Winding temperature rise, (based on a maximum ambient temperature of 104 degrees F at 3300-feet altitude) shall not exceed 176 degrees F.

g. Bearings shall be ABMA minimum L10 life of 60,000 hours or L50 life of 300,000 hours suitable for the size, type, and application when the pump is operating at the specified flow and head.

h. Motor enclosures shall be totally enclosed, weather sealed, fan cooled, explosion-proof and shall be listed and labeled for Class 1, Group D areas. Provide bronze ground bolt on motor enclosure. All motor external electrical connections shall be terminated within a single terminal housing.

i. The dynamic balance, overspeed withstand capability, and sound power levels of the motor shall conform with NEMA standard requirements.

j. The pump manufacturer shall furnish the Contracting Officer with the recommended minimum run time for the motor.

k. Pump motor shall be provided with temperature limiting thermostats within the motor frame when required to meet Class 1, Group D requirements.

l. Pump motor shall be furnished with lifting lugs on the motor casing.

m. Unless indicated otherwise, motors for conventional applications over 15 horsepower shall be the premium efficient type. This requirement is not applicable to hermetically sealed motors, integrally mounted motors, motors specified as part of energy efficient equipment, wound rotor motors, or any application involving special construction or performance. Guaranteed minimum full load efficiencies shall be (based on 3600 rpm, 2 pole totally enclosed):

20 hp 92.0 percent 75 hp 95.5 percent

25 hp 92.0 percent 100 hp 93.5 percent

30 hp 92.0 percent 125 hp 94.5 percent

40 hp 92.0 percent 150 hp 94.5 percent

50 hp 92.5 percent 200 hp 94.5 percent

60 hp 92.5 percent 500 hp 94.5 percent

n. Other motors of different speed or housing classification shall also be of the premium efficient type, as advertised by the motor manufacturer, with efficiency greater than the standard line. Motor efficiencies shall have been verified in accordance with NEMA MG 1, 12.53.a., and

SECTION 33 52 43.23 Page 19 determined using the dynamometer method as described in IEEE 112, Method B. All shop drawing submittals on motor driven equipment shall include the motor efficiency.

[*Am-2]

2.4 FUEL TRANSFER PUMPS FTP-1

2.4.1 Capacity

Capacity shall be 50 gpm against a total head of 207 feet for the Fuel Transfer Pump, when driven at 1800 rpm. Overall efficiency at design conditions of pump and driver, connected, shall be minimum 50 percent.

Pump head capacity shall be continually rising and shall be free of dips and valleys from design point to shut-off head. Pump shall be capable of at least 10 percent head increase at rated conditions by installing a new impeller.

2.4.2 Assembly

The pump for this service shall meet the requirements of API Std 610, latest edition, seventh edition for vibration. Wherever the information contained herein conflicts with said standard, the information herein shall govern. The pump for this service shall run at a nominal 1800 rpm and shall be a single stage , vertical turbine pump. Pump and motor shall be furnished as a complete unit as herein specified. Pump assembly shall be statically and dynamically balanced for all flow rates from minimum flow to 120 percent of design flow.

2.4.3 Materials

The materials of construction for the pump shaft and the impeller shall be stainless steel. All other materials shall be material class S-1 with the wetted ferrous parts such as the bowl interiors enamel-lined, bowl exteriors, column interior and exterior, discharge head interior epoxy-coated per MIL-PRF-4556, and discharge head exterior epoxy-coated per

MIL-DTL-24441.

2.4.3.1 Mechanical Seal

API STD 682, balanced type, API Class Code BSTHN.

2.4.4 Construction

Castings used for any part of pumps shall be sound and free of shrink or blow holes, scale, blisters, and other similar casting defects. The surfaces of casting shall be cleaned by sand or shot blasting, pickling, or other standard methods used by the manufacturer. All mold parting fins and remains of gates and risers shall be either chipped, filed, or ground flush with the surface of the casting. The repair of casting leaks and defects by peening or by the use of cement compounds is prohibited.by

ASME BPVC SEC VIII D1.

2.4.4.1 Couplings

Couplings shall be flanged, rigid spacer type, CPAT or equal. The couplings shall be of the spacer-type with a spacer of sufficient length to permit replacement of the mechanical seal assembly without removing the motor. The pump half coupling shall be of such design that it can be removed without the use of heat. Coupling halves shall fit tightly to the

SECTION 33 52 43.23 Page 20 shafts of the pump and the driver so as not to become loose during operation. The coupling shall be provided with an OSHA approved coupling guard.

2.4.4.2 Impeller

Impeller shall be keyed to the shaft for radial loads and fixed in the axial position by shaft sleeve nuts, or other positive positioning device.

Impellers shall be held to the shaft so that the impeller will not become loose should the pump accidentally rotate in reverse direction. The impeller shall be statically and dynamically balanced.

2.4.4.3 Wear Rings

Renewable wearing rings shall be positively locked on the impeller.

Wearing rings shall fit with close tolerances so as to permit a minimum of recirculation.