35_45_01.pdf

American River Common Features (ARCF) Spec No. 2122 Riverside Canal Relocation and Natomas Basin - Reach B Addendum No. 1

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 45 01

VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE

02/16

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Detail Drawings

1.3.2 Welding

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 General

1.4.2 Processing for Storage

1.5 PROJECT/SITE CONDITIONS

1.5.1 Datum

1.5.2 Static and Pool-To-Pool Head

1.6 MAINTENANCE

1.6.1 Special Tools

1.6.2 Extra Materials

1.7 WARRANTY

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Design Requirements

2.1.2 Capacities

2.1.2.1 Start-Up Condition

2.1.3 Pump Curves

2.2 MATERIALS

2.3 METALWORK FABRICATION

2.3.1 Designated Materials

2.3.2 Bolted Connections

2.3.2.1 Bolts, Nuts, and Washers

2.3.2.2 Materials Not Specifically Described

2.3.3 Metalwork

2.3.3.1 Flame Cutting of Material

2.3.3.2 Alignment of Wetted Surfaces

2.3.3.3 Stress-Relieving Procedure

2.3.4 Examination of Castings

2.3.4.1 Examination Procedures

2.3.4.1.1 Ultrasonic

2.3.4.1.2 Magnetic Particle

2.3.4.2 Acceptance and Repair Criteria

2.4 VERTICAL PUMPS

2.4.1 Speed

2.4.2 Reverse Rotation and Flow

2.4.3 Efficiency

2.4.4 Suction Bell

2.4.5 Impeller Bowl

SECTION 35 45 01 Page 1

2.4.6 Pump Column and Discharge Elbow

2.4.6.1 Column and Discharge Elbow

2.4.6.2 Column and Discharge Elbow Support

2.4.6.3 Flanges

2.4.6.4 Flanged Joints

2.4.6.5 Nuts and Bolts

2.4.6.6 Galvanic Protection

2.4.6.7 Harnessed Coupling

2.4.6.8 Wall Thimble

2.4.6.9 Discharge Piping

2.4.6.10 Flap Gate

2.4.7 Impeller

2.4.7.1 Removal and Prior To Finishing

2.4.7.2 Balance

2.4.8 Shafting

2.4.8.1 Shaft

2.4.8.2 Couplings

2.4.8.3 Journals

2.4.8.4 Circumferential Line

2.4.9 Shaft Enclosure

2.4.10 Guide Bearings and Seals

2.4.10.1 Guide Bearings

2.4.10.2 Oil Lubrication Shaft Seals

2.4.11 Bearing Heat Sensors

2.4.12 Thrust Bearing

2.4.13 Packing Gland

2.4.14 Siphon Breaker Valve

2.5 LUBRICATION SYSTEM

2.6 PAINTING

2.7 TESTS, INSPECTIONS, AND VERIFICATIONS

2.7.1 Critical Speeds

2.7.2 Lubricating System Tests

2.7.3 Factory Test

2.7.3.1 General

2.7.3.2 Instrumentation and Procedures

2.7.3.2.1 Head Measurements

2.7.3.2.2 Capacity

2.7.3.2.3 Rotational Speed of Pump

2.7.3.2.4 Power Input

2.7.3.2.5 Cavitation Tests

2.7.3.3 Pump Test

2.7.3.4 Test Procedure

2.7.3.4.1 Performance of The Pump

2.7.3.4.2 Sump Elevations

2.7.3.4.3 Tests Results

2.7.3.4.4 Demonstration

2.7.3.5 Cavitation Tests

2.7.3.5.1 Model Test

2.7.3.5.2 NPSHR

2.7.3.5.3 Value of NPSHR

2.7.3.5.4 Plotting Test Results

2.7.3.5.5 Curves

2.7.3.6 Witness Test

2.7.3.7 Test Report

2.8 BASEPLATE AND SUPPORTS

2.9 PUMP DRAINAGE

2.10 FACTORY ASSEMBLY

PART 3 EXECUTION

SECTION 35 45 01 Page 2

3.1 INSTALLATION

3.1.1 Equipment

3.1.2 Pipes and Joints

3.2 FIELD TESTS

3.2.1 Dry Tests

3.2.2 Wet Tests

ATTACHMENTS:

Figure 2

-- End of Section Table of Contents --

SECTION 35 45 01 Page 3

SECTION 35 45 01

VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE

02/16

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 PETROLEUM INSTITUTE (API)

API RP 686 (2009) Recommended Practice for Machinery Installation and Installation Design

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C200 (2012) Steel Water Pipe - 6 In. (150 mm) and Larger

AWWA C203 (2008) Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot-Applied

AWWA C207 (2013) Standard for Steel Pipe Flanges for Waterworks Service-Sizes 100 mm through 3600 mm 4 in. through 144 in.

AWWA C208 (2017) Dimensions for Fabricated Steel Water Pipe Fittings

AWWA C210 (2007) Standard for Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines

AWWA M11 (2016) Steel Pipe: A Guide for Design and Installation

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B17.1 (1967; R 2017) Keys and Keyseats

ASME B31.1 (2016; Errata 2016) Power Piping

ASME B36.10M (2015; Errata 2016) Welded and Seamless Wrought Steel Pipe

ASME B46.1 (2009) Surface Texture, Surface Roughness, SECTION 35 45 01 Page 4

Waviness and Lay

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A126 (2004; R 2014) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A217/A217M (2014) Standard Specification for Steel Castings, Martensitic Stainless and Alloy, for Pressure-Containing Parts, Suitable for High-Temperature Service

ASTM A27/A27M (2017) Standard Specification for Steel Castings, Carbon, for General Application

ASTM A276/A276M (2017) Standard Specification for Stainless Steel Bars and Shapes

ASTM A285/A285M (2012) Standard Specification for Pressure Vessel Plates, Carbon Steel, Low- and Intermediate-Tensile Strength

ASTM A312/A312M (2017) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A351/A351M (2016) Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

ASTM A352/A352M (2017) Standard Specification for Steel Castings, Ferritic and Martensitic, for Pressure-Containing Parts, Suitable for Low-Temperature Service

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A48/A48M (2003; R 2012) Standard Specification for Gray Iron Castings

ASTM A53/A53M (2018) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A609/A609M (2012) Standard Specification for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof

ASTM A668/A668M (2017) Standard Specification for Steel Forgings, Carbon and Alloy, for General

SECTION 35 45 01 Page 5

Industrial Use

ASTM B148 (2014) Standard Specification for Aluminum-Bronze Sand Castings

ASTM B584 (2014) Standard Specification for Copper Alloy Sand Castings for General Applications

ASTM B98/B98M (2013) Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F1476 (2007; R 2013) Standard Specification for Performance of Gasketed Mechanical Couplings for Use in Piping Applications

HYDRAULIC INSTITUTE (HI)

HI 9.1-9.5 (2000) Pumps - General Guidelines for Types, Applications, Definitions, Sound Measurements and Documentation

HI 9.6.4 (2009) Rotodynamic Pumps for Vibration Analysis and Allowable Values

HI ANSI/HI 14.6 (2011) Rotodynamic Pumps for Hydraulic Performance Acceptance Tests - A136

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1940-1 (2003; R 2008) Mechanical Vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1:

Specification and Verification of Balance Tolerances

INTERNATIONAL SOCIETY OF AUTOMATION (ISA)

ISA RP2.1 (1978) Manometer Tables

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2013; with Change 1) Seismic Design of Buildings

1.2 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:

SD-02 Shop Drawings

Detail Drawings; G

SECTION 35 45 01 Page 6

Pump Base Plate And The Anchoring Bolts; G

SD-03 Product Data

Humidity-Controlled Storage

Materials; G

Spare Parts

Total Head; G

Shipping Bills

Pump Curves; G

Preliminary Pump Curves; G

Installation and Erection Instructions Manual

Field Tests

Impeller Weight

SD-04 Samples

Materials; G

SD-05 Design Data

Dynamic Analysis; G

Stress-Relieving Procedure; G

Piping; G

Baseplates and the Anchoring Bolts

SD-06 Test Reports

Witness Test.

Factory Test

Balancing Procedure; G

Results Of Impeller Balancing

SD-07 Certificates

Qualified Welders

Examination Procedure And Qualification Of The Examiner; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Instructions Manual; G

SECTION 35 45 01 Page 7

1.3 QUALITY ASSURANCE

Furnish one or more competent erecting engineers fluent in English language who is knowledgeable about the installation of vertical pumps and associated drive machinery. Erecting engineers provided by this section include those from the Contractor's suppliers. When so requested, erecting engineers must provide and be responsible for providing complete and correct direction during initial starting and subsequent operation of equipment until field tests are completed. The erecting engineer must initiate instructions for actions necessary for proper receipt, inspection, handling, uncrating, assembly, and testing of equipment. The Erecting Engineer(s) must also keep a record of measurements taken during erection, and furnish one copy to the Contracting Officer on request or on completion of installation of the assembly or part. The erecting engineer must instruct the Contracting Officer in operation and maintenance features of work.

1.3.1 Detail Drawings

Submit drawings of sufficient size to be easily read, within 30 days of notice of award of contract. Submit information in the English language.

Provide with English (IP) dimensions. Drawings must consist of complete designs of the pump, pump installation instructions, performance charts, brochures, and other information required to illustrate that the entire pumping system (including the pump and motor) has been coordinated and will function as a unit.

a. Outline drawings of the pump showing pertinent dimensions and weight of each component of the pump. Prepare drawings to scale.

b. Drawing showing details and dimensions of pump mounting design or layout including any embedded items and the FSI.

c. Cross-sectional drawings of the pump showing each component. Show major or complicated sections of the pump in detail. Indicate on each drawing an itemized list of components showing type, grade, and class of material used and make and model number of standard component used.

d. Drawings covering erection and installation, that are intended to be furnished to the erecting engineer.

e. Drawings of the pump and base plate showing its dimensions. Include calculations used in the design of the thickness of the pump base plate and the anchoring bolts to ensure that the proper forces (shear, torsion, etc.) have been considered.

1.3.2 Welding

For all welding, procedures and welders must be qualified in accordance with ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by a previously qualified employer may be accepted as permitted by ASME B31.1. Perform welder qualification tests for each welder whose qualifications are not in compliance with the referenced standards. Notify the Contracting Officer 24 hours in advance of qualification tests. Perform the qualification tests at the work site if practical. The welder or welding operator must apply their assigned symbol near each weld made as a permanent record.

SECTION 35 45 01 Page 8

The names of all qualified welders, their identifying symbols, and the qualifying procedures for each welder including support data such as test procedures used, and standards tested to.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 General

Furnish major pump components with lifting lugs or eye bolts to facilitate handling. Design and arrange lugs or bolts to allow safe handling of pump components singly or collectively as required during shipping, installation, and maintenance. Submit copies of certified shipping bills to the Contracting Officer or memorandums of all shipments of finished pieces or members to designated site, giving designation mark and weight of each piece, number of pieces, total weight, and if shipped by rail in carload lots, car initial and number.

1.4.2 Processing for Storage

Prepare pumps (and spare parts) for storage indoors. Indoor storage consists of a permanent building that has a leak-proof roof, full walls to contain stored equipment, and a concrete floor or temporary trailers. A temporary structure may also be built at the job site for equipment storage that will contain features of the permanent building above except that provision for ventilation will be provided and floor may be crushed rock.

A vapor barrier will be provided below the crushed rock. Crushed rock will be of sufficient thickness so that settlement of equipment will not occur.

Equipment stored on crushed rock will have cribbing under each support location so that equipment does not come in contact with crushed rock. A plastic barrier will be placed between equipment and wood cribbing. Submit a list of equipment and materials requiring humidity-controlled storage to the Contracting Officer no later than 30 days prior to shipment of pumping units. Store long term (greater than 6 months) in accordance with pump manufacturer's recommendations.

1.5 PROJECT/SITE CONDITIONS

1.5.1 Datum

Elevations shown or referred to in specifications, are above or below mean sea level National American Vertical Datum (NGVD) 1988.

1.5.2 Static and Pool-To-Pool Head

Static head is the difference, in feet, between water surface elevation in the sump immediately inside trash rack and top of discharge pipe at highest elevation. Total head includes static head, friction losses outside of equipment being furnished, plus velocity head loss.

Pool-to-pool head is the difference in feet between the water surface elevation in the sump and water surface elevation in the river. The pump manufacturer must determine total head. Submit computations of total head and losses. Total head includes losses from the water surface on the suction side of the pump to discharge water surface.

SECTION 35 45 01 Page 9

1.6 MAINTENANCE

1.6.1 Special Tools

Furnish one set of all "special tools" required to completely assemble, disassemble, or maintain the pumps. "Special tools" refer to oversized or specially dimensioned tools, special attachments or fixtures, or any similar items. If required, provide a device for temporarily supporting the pump shaft and impeller during assembly, disassembly, and reassembly of the motor when the thrust bearing is not in place. Provide a portable steel cabinet large enough to accommodate all "special tools" furnished under this paragraph and as required by Section 26 29 01 ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE. Mount the cabinet on four rubber-tired casters. Provide drawers to accommodate tools. Fit front of cabinet with doors hinged to swing horizontally. Furnish doors with necessary stops, catches, and hasps for completely securing the cabinet with a padlock.

Furnish the padlock complete with three keys. Pack "special tools" in wooden boxes if the size and weight do not permit storage in the tool cabinet. Provide slings if the box and tools are heavier than 75 pounds.

1.6.2 Extra Materials

Furnish the following spare parts:

a. One complete replacement set of bearings, bearing shells, journal sleeves, shaft coupling, if applicable, and seals for each size pump.

b. One complete replacement set of wearing parts for the packing gland for each size pump, and sufficient packing for all pumps.

gc Provide copies of manufacturer's complete parts list showing all parts, spare parts, and bulletins for each size pump. Clearly show all details and parts, and adequately describe parts or have proper identification marks.

1.7 WARRANTY

The manufacturer of the axial-flow impeller-type vertical pumps must provide a warranty all equipment furnished under this section against defective workmanship, materials, design, and performance for a period of one (1) year from the date the equipment is accepted. If the equipment or any part thereof does not conform to these warranties, and the Government so notifies the manufacturer within a reasonable time after its discovery, the manufacturer must thereupon promptly correct such nonconformity by repair or replacement. Coordinate the down time for the equipment with the Government, and be kept to a minimum duration that is mutually agreed to by the manufacturer and the Government. The manufacturer is liable during the warranty period for the direct cost of removal of the equipment from the installed location, transportation to the manufacturer's factory or service shop for repair and return, and reinstallation on site. The manufacturer will be given the opportunity to perform the removal and reinstallation and to select the means of transportation. The expense of removing adjacent apparatus, installing spare equipment, costs of supplying temporary service, is not included in this warranty provision.

SECTION 35 45 01 Page 10

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Design, furnish, and install vertical mixed-flow, single stage impeller-type pumps, as indicated. The pumping systems include pumps. The pump manufacturer is responsible for the equipment of the entire pumping systems. Therefore, the electric motors, should be selected by the pump manufacturer.

2.1.1 Design Requirements

a. Pumps are for the purpose of pumping water from a drainage canal into the Sacramento River. Water pumped will not exceed 80 degrees F, will be relatively turbid, and may contain sand, silt, and vegetative trash capable of passing through the trash rack.

b. Drive the pumps with the vertical motors described in Section 26 29 01 ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE as indicated.

c. Design pumps so that no major modifications, alterations, or additions will be required to the pumping station or suction bays to accommodate them. However, requests for changes in setting of pump, supports, and accessories that would involve only minor modifications, will be considered. Design pump so that pump parts will fit within the limiting horizontal and vertical dimensions shown. Pumps must be capable of being lowered through floor openings shown with a minimum of 1 inch clearance around each side.

d. Each pump must discharge into discharge system shown. System loss curve, which includes friction losses from pump discharge elbow to end of discharge line, including bend losses, exit loss, and velocity head, is included in this section to permit determination of total head.

Determine losses within the pump.

d. Each pump discharge system downstream of pump discharge must be designed by the pump manufacturer. It must be of type shown and fit within limiting dimensions and elevations shown. Determine all losses for discharge system and submit for approval.

de. Accomplish priming of siphon without assistance of vacuum equipment.

f. The design (drawings, computations, etc.) must be signed and sealed by a professional engineer registered in the State of California.

2.1.2 Capacities

a. PMP-100 Minimum Required Priming Operation (Static Head) - 44.5 cfs at

35.5 FT TDH

Siphon Operation (Pool-to-Pool Head) - 45 cfs at 35 FT TDH Maximum Pump Speed - 900 rpm Maximum Pump Motor hp - 250 hp

b. PMP-200 Minimum Required Priming Operation (Static Head) - 44.5 cfs at

35.5 FT TDH

SECTION 35 45 01 Page 11

Siphon Operation (Pool-to-Pool Head) - 45 cfs at 35 FT TDH Maximum Pump Speed - 900 rpm Maximum Pump Motor hp - 250 hp

c. PMP-300 Minimum Required Priming Operation (Static Head) - 56.35 cfs at

34.6 FT TDH

Siphon Operation (Pool-to-Pool Head) - 57 cfs at 34 FT TDH Maximum Pump Speed - 900 rpm Maximum Pump Motor hp - 300 hp

d. PMP-400 Minimum Required Priming Operation (Static Head) - 66.8 cfs at

35.7536.9 FT TDH

Siphon Operation (Pool-to-Pool Head) - 68 cfs at 35.75 FT TDH Maximum Pump Speed - 900 rpm Maximum Pump Motor hp - 350 hp

2.1.2.1 Design Criteria

The pumps provided shall be capable of meeting the priming and siphon operating conditions as specified herein. System curves developed are provided at the end of this specification section. The following has been utilized as a basis of design; the field conditions shall reflect the pump size accordingly.

Minimum Sump Elevation - 8.3 FT Maximum Sump Elevation - 13.0 FT (100-year) Minimum Sacramento River Elevation - 7.5 FT 100-yr Flood Sacramento River Elevation - 36.7 FT 200-yr Flood Sacramento River Elevation - 37.6 FT Pipe Apex Invert Elevation - 38.45 FT

2.1.2.1 Start-Up Condition

Upon startup, each pump must discharge sufficient water for the pumps to become primed and siphon recovery to begin. Since the head conditions will be higher prior to the pump discharge pipe becoming filled, the pump may be operated at a higher speed for a short period of time. The pump flow must be sufficient to result in a flow velocity in the discharge pipe of no less than 7 feet per second. The pump speeds may be changed during the pump priming period, but after priming is accomplished, the pumps will operate as constant-speed pumps. Siphon breaker valves will be used to help prime the pumps.

2.1.3 Pump Curves

Indicate on the pump curves for the submitted pumps that the pumps are capable of operating over the entire total head corresponding to the full pool-to-pool and static head range.

Submit preliminary pump curves with the initial pump submittal. Indicate the pump's expected total head, static heads, brake horsepower, and efficiency, as ordinates. Plot against the pump discharge as the abscissa. The curves must indicate that the pump meets all specified conditions of capacity, head, brake horsepower, and efficiency.

SECTION 35 45 01 Page 12

2.2 MATERIALS

Material selection not specified is guided by HI 9.1-9.5 for corrosion, erosion, and abrasion resistance. Submit copies of purchase orders, deviations from the specified materials, mill orders, shop orders for materials, and work orders, including orders placed or extended by each supplier. Furnish a list designating materials to be used for each item at time of submittal of drawings. Furnish, within 60 days of notice of award, names of manufacturers of machinery and other equipment contemplated to be incorporated in the work, together with performance capacities and other relevant information pertaining to the equipment. Submit samples of materials as directed. Equipment, materials, and articles installed or used without the approval of the Contracting Officer are at risk of subsequent rejection.

a. Identify each pump by means of a separate nameplate permanently affixed in a conspicuous location. The plate must bear the manufacturer's name, model designation, serial number if applicable, and other pertinent information such as horsepower, speed, capacity, type, direction of rotation, etc. Make the plate of corrosion-resisting metal with raised or depressed lettering and a contrasting background.

b. Equip each pump with suitably located instruction plates, including any warnings and cautions, describing any special and important procedures to be followed in starting, operating, and servicing the equipment.

Make the plates of corrosion-resisting metal with raised or depressed lettering and contrasting background.

c. Provide safety guards and/or covers wherever necessary to protect the operators from accidental contact with moving parts. Make guards and covers of sheet steel, expanded metal, or another acceptable material and removable for disassembly of the pump.

2.3 METALWORK FABRICATION

2.3.1 Designated Materials

Designated materials must conform to the following specifications, grades, and classifications.

MATERIALS SPECIFICATION GRADE, CLASS

Aluminum-Bronze ASTM B148 Alloy No. C95500 Castings

Cast Iron ASTM A48/A48M Class Nos. 150A 150B, and 150C; 30A, 30B, and 30C

Cast Steel ASTM A27/A27M Grade 65-35, annealed

Coal Tar Protective Coatings

AWWA C203

Cold-Rolled Steel Bars ASTM A108 min, Wt. Strm 450 MPa 65,000 psi

Copper Alloy Castings ASTM B584 Alloy No. C93700

SECTION 35 45 01 Page 13

MATERIALS SPECIFICATION GRADE, CLASS

Corrosion-Resistant Alloy Casting

ASTM A217/A217M Grade CA15

ASTM A352/A352M CA6NM

ASTM A351/A351M CF8M

Dimensions for Steel Water Piping Fittings

AWWA C208

Ring Flanges AWWA C207 Class B

Seamless and Welded Austenitic Stainless Steel Pipe

ASTM A312/A312M

Stainless Bars and Shapes

ASTM A276/A276M Grades S30400 and S41000

Steel Forging ASTM A668/A668M Class F

Steel Pipe 150 mm 6 inch and Larger

AWWA C200

Steel Plate, Structural Quality

ASTM A285/A285M Grade B

Structural Steel ASTM A36/A36M

Surface Texture (Surface Roughness, Waviness, and Lay)

ASME B46.1

2.3.2 Bolted Connections

2.3.2.1 Bolts, Nuts, and Washers

Bolts, nuts, and washers must conform to requirements of paragraph MATERIALS AND METALWORK FABRICATION, subparagraph DESIGNATED MATERIALS, and paragraph VERTICAL PUMPS, subparagraph PUMP COLUMN AND DISCHARGE ELBOW, subparagraph NUTS AND BOLTS for types required. Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to bolt axis.

2.3.2.2 Materials Not Specifically Described

Materials not specifically described must conform to latest ASTM specification or to other listed commercial specifications covering class or kinds of materials to be used.

SECTION 35 45 01 Page 14

2.3.3 Metalwork

2.3.3.1 Flame Cutting of Material

Flame cutting of material other than steel is subject to approval of the Contracting Officer. Shear accurately, and neatly finish all portions of work. Steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a smooth surface free from cracks and notches is secured. Prepare surfaces and edges to be welded in accordance with AWS D1.1/D1.1M. Chipping and/or grinding will not be required except where specified and as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Visible or exposed hand-guided cuts must be chipped, ground, or machined to metal free of voids, discontinuities, and foreign materials.

2.3.3.2 Alignment of Wetted Surfaces

Exercise care to assure that correct alignment of wetted surfaces being joined by a flanged joint is being obtained. Where plates of the water passage change thickness, transition on the outer surface, leaving inner surface properly aligned. When welding has been completed and welds have been cleaned, but prior to stress relieving, carefully check joining of plates in the presence of the Government inspector for misalignment of adjoining parts. Localized misalignment between inside or wetted surfaces of an adjoining flange-connected section of pump or formed suction intake cannot exceed the amount shown in Column 4 of Table 1 for the respective radius or normal distance from the theoretical flow centerline. Correct misalignments greater than the allowable amount by grinding away offending metal, providing the maximum depth to which metal is to be removed does not exceed amount shown in Column 5 of Table 1. Do not remove metal until assuring the Contracting Officer that no excessive stresses will occur in the remaining material and that excessive local vibration will not result from removal of the material. Where required correction is greater than the amount in Column 5 of Table 1, reject pipe for use. Proposed procedure for all corrective work, other than minor grinding, must be approved by the Contracting Officer prior to start of corrective work. Finish corrective work by grinding corrected surface to a smooth taper. Length of the taper along each flow line element must be 10 times the depth of the offset error at the flow line. Wetted surface irregularities that might have existed in an approved model cannot be reason for accepting comparable surface irregularities in the prototype pump.

TABLE 1

(1) (2) (3) (4) (5)

Pipe Diameter

(mm) (inches)

Pipe Radius or Distance

(mm) (inches)

Pipe Thickness

(mm) (inches)

Maximum Offset

(mm) (inches)

Grind-Not More Than (mm)

(inches)

60024 30012 103/8 1.61/16 2.43/32

75030 37515 103/8 1.61/16 2.43/32

90036 45018 103/8 2.43/32 2.43/32

105042 52521 131/2 2.43/32 3.21/8

SECTION 35 45 01 Page 15

TABLE 1

(1) (2) (3) (4) (5)

Pipe Diameter

(mm) (inches)

Pipe Radius or Distance

(mm) (inches)

Pipe Thickness

(mm) (inches)

Maximum Offset

(mm) (inches)

Grind-Not More Than (mm)

(inches)

120048 60024 131/2 3.21/8 3.21/8

2.3.3.3 Stress-Relieving Procedure

After all fabrication welding is completed, and prior to any machining, stress-relieve the bell and the impeller (if it is fabricated) by heat treatment. Submit proposed stress-relieving procedure.

2.3.4 Examination of Castings

Clean and carefully examine all castings for surface defects. Further examine all defects by nondestructive means. Examination personnel must be qualified/certified in accordance with applicable ASTM requirements.

Submit the examination procedure and qualification of the examiner.

Conduct examination tests in the presence of the Contracting Officer.

Choose the examination procedure best suited for the application.

2.3.4.1 Examination Procedures

2.3.4.1.1 Ultrasonic

Conform inspection to the applicable provisions of ASTM A609/A609M.

2.3.4.1.2 Magnetic Particle

Conform inspection to the applicable provisions of ASTM E709.

2.3.4.2 Acceptance and Repair Criteria

Acceptance and repair criteria must be in accordance with Section 05 50 13

MISCELLANEOUS METAL FABRICATIONS.

2.4 VERTICAL PUMPS

2.4.1 Speed

Rotative speed of pump must be no greater than 900 rpm.

2.4.2 Reverse Rotation and Flow

Each pump must withstand, with no damage, full rotative speed caused by subjecting the pump to reverse flow. The head used to determine this reverse rotative speed is calculated from specified highest discharge side water elevation and lowest pump intake side water elevation.

Pump must withstand, with no damage, the full force exerted on it, with the impeller subjected to reverse flow and the upper end locked in place by a backstop. Calculate the head to determine the force developed by this reverse flow from the specified highest discharge side water elevation and

SECTION 35 45 01 Page 16 lowest pump intake side water elevation. Reverse rotative speed must be

0.0 with instantaneous activation of the backstop.

2.4.3 Efficiency

Efficiency at head-capacity condition(s) specified in paragraph CAPACITIES must not be less than shown when calculated as follows:

Q x H Efficiency = ---------- x 100 3960 x BHP

Where: Q = Discharge, gallons per minute H = Total head, feet BHP = Pump brake horsepower

Pump efficiency, as defined in HI ANSI/HI 14.6, must include losses from the suction bell to the discharge elbow outlet and must not be less than specified at the head-capacity condition(s) specified.

2.4.4 Suction Bell

Make each suction bell of cast iron. Provide a flanged connection for mating with the impeller bowl with a rabbet fit or four equally spaced dowels installed in the vertical position for initial alignment purposes and to maintain concentric alignment of the pump. Each suction bell must be made in one piece. Support each suction bell entirely by the pump casing. Supports from sump floor will not be acceptable.

2.4.5 Impeller Bowl

Make each impeller bowl of ASTM A48/A48M Class cast iron. Heat-treat and stress-relieve welds before final machining. Provide flanges for mating with the suction bell and the impeller bowl or two-piece construction of the impeller. Provide flanged connections with the suction bell or split construction with a rabbet fit or four equally spaced dowels installed in the vertical position for initial alignment purposes and to maintain concentric alignment of the pump. Machine finish the impeller-swept area in the impeller bowl to at least 125 microinch rms and concentric with the impeller axis. For mixed-flow impellers, the angle in the impeller bowl must equal the outside angle of the impeller blade tips. Tolerance for concentricity of the impeller with the impeller axis is not greater than 20 percent of the operating clearance between the impeller and the impeller bowl.

2.4.6 Pump Column and Discharge Elbow

2.4.6.1 Column and Discharge Elbow

Make each column and discharge elbow of cast ironsteel conforming to ASTM A53/A53M. Material shall be coated to same standards of welded steel piping meeting AWWA C210. Do not use turning vanes. Design column and discharge elbow to withstand internal pressures and external loadings associated with various conditions of pump operation. Flanges must have rabbeted fits or four equally spaced dowels installed in flanges for initial alignment purposes and to maintain concentric alignment. Terminate the elbow in a plain-end circular section. Provide diameter of discharge end of elbow as indicated and allow standard diameter flexible couplings to be used. Use adjustable thrust rods and thrust lugs to transfer the load

SECTION 35 45 01 Page 17 by bridging the coupling between the pump discharge elbow and discharge piping. Determine the size and number of thrust rods needed for the expected loading. Use a minimum of four thrust rods. Maintain complete access to the discharge piping until the discharge pipe installation is complete, inspected, and approved.

2.4.6.2 Column and Discharge Elbow Support

Design pump column and discharge elbow for suspension from a baseplate assembly specified in paragraph BASE-PLATE AND SUPPORTS and located at operating floor level.

2.4.6.3 Flanges

Machine flanges and drill bolt holes concentric with pump shaft vertical centerline, having a tolerance of plus or minus one fourth of the clearance between the bolt and bolt hole. When fabricated from steel plate, flanges must not be less than 1 inch thick after machining. Flange thickness after machining cannot vary more than 10 percent of greatest flange thickness.

Provide external stiffeners, if needed. Construct fabricated flanges, as a minimum, to the dimensions of AWWA C207, Class B. Design flanges on major components of pump casing (suction bell, impeller bowl, and column and elbow piping) such that blind holes necessitating use of cap screws or stud bolts are not used. Design flanges for connection to column pipe by at least two continuous fillet welds. Connect the inside diameter of the flange to pump column with one weld, and connect the outside diameter of the pump column to the flange with the other weld. Final design of welds rests with the manufacturer, and specified welds are the minimum requirement. Parallel machine, when provided on each end of the same component, and mount parallel to a plane that is normal to pump shaft centerline. Flanges on each end of the same component must have parallel tolerance of 0.002 inch. Finish machine mating surface on flange to 125 microinch finish or better. Provide flanges with a minimum of three jacking bolts to aid in disassembly of the pump.

2.4.6.4 Flanged Joints

Design flanged joints to be air-and water-tight, without the use of preformed gaskets, against positive and negative operating pressures that will be experienced, except that permanent gasketing compound will be permitted. Provide mating flanges, unless of the male-female rabbet type, with not less than four tapered dowels equally spaced around each flange.

If rabbeted fit is not used, then provide the method used to determine concentricity of connected pieces.

2.4.6.5 Nuts and Bolts

Use 300 series stainless steel for bolts used in assembling the pump and its supporting members, including anchor bolts and dowels. Use only bronze nuts and hexagonal bolts and nuts. Also use 300 series stainless steel washers.

2.4.6.6 Galvanic Protection

When dissimilar metals are used, electrically isolate dissimilar parts.

Verify isolation by checking joint with an ohmmeter.

SECTION 35 45 01 Page 18

2.4.6.7 Harnessed Coupling

Provide a flexible mechanical coupling or split-sleeve type coupling that either conforms to ASTM F1476, Type II, Class 3, stainless steel (as manufactured by Teekay or Straub Couplings), ASTM F1476, Type 1 (as manufactured by Victaulic), or Dresser Couplings style 38 or approved equal, to connect the pump discharge elbow as shown on the drawings.

Install a minimum of four harness bolts (sized by the pump manufacturer) at each coupling.

2.4.6.8 Wall Thimble

Provide each wall thimble with one plain end to accommodate the flexible mechanical coupling and one flanged end to mate with the flap gate and discharge piping. The plain end must match the pump discharge elbow in thickness and diameter and drill the flanged end to match, and be capable of supporting without distortion, the flap gate. Provide the seal ring on the wall thimble located so that it is centered in the wall when embedded.

Fabricate the wall thimble from steel plates.

2.4.6.9 Discharge Piping

At outfall structure, provide discharge piping consisting of a transition section and a wall thimble. Provide a transition section with one plain end and one flanged end. On the plain end, match the pump discharge elbow in thickness and diameter. Arrange the wall thimble for embedment and with the flanges on each end. Mate one end with the flange on the transition section and mate the other end with the flap gate. Fabricate the discharge flange with a minimum dimension of AWWA C207, Class D, and drill to match.

Provide a seal ring on the wall thimble and locate it so that it is centered in the wall when embedded. Fabricate the discharge piping from steel plate.

Install the discharge piping as indicated. Match the plain end of each discharge pipe with the pump discharge elbow in thickness and diameter and be able to allow a flexible mechanical coupling to connect it to the pump discharge elbow. Provide the discharge pipe with pipe supports or cradles as recommended by the pump manufacturer. Locate the supports between the flexible coupling and the wall, as indicated. Provide suitably-sized thrust restraints at each flexible coupling as indicated. The supports must provide support for the weight of the pipe, the water that will pass through the pipe, and any dynamic forces that may develop due to water flowing through the pipe. The discharge pipe must be non-galvanized piping of welded or seamless pipe or welded steel plate. Use steel pipe conforming to AWWA C200 with dimensional requirements as given in ASME B36.10M. Provide fittings in compliance with AWWA C208.

2.4.6.10 Flap Gate

Design the flap gate for pump discharge service with flange-frame with a resilient seat of neoprene or BUNA-N to prevent closing shock. Make the size of the flap gate the same as the discharge pipe size. Use cast iron for the body of the valve and the flap in compliance with ASTM A126. Use high-tensile bronze ASTM B584- CA 865 for the hinge arms. Design the hinge pins in double shear and of silicon bronze, ASTM B98/B98M- CA 655. Provide lubrication fittings on the hinge arms. Extend the grease lines to a convenient location for lubricating. Provide an anti-locking bar to prevent excessive rotation about the lower hinge pin. Provide a stainless steel leaf spring with rubber pad to safely limit the travel of the flap

SECTION 35 45 01 Page 19 gate during pumping. Install flap gate in location shown on the drawings.

2.4.7 Impeller

Pump impeller shall be made of cast bronze and secured to the shaft by a key and thrust collars, both made of 416 stainless steel. Fabricated propellers will not be accepted.

2.4.7.1 Removal and Prior To Finishing

After removal from mold, and prior to finishing of surface imperfections, the Contracting officer will inspect castings. Fill and grind minor surface imperfections as necessary to preserve correct contour and outline of impeller and to restore surface imperfections to the same degree of finish as surrounding surfaces. Correct surface pits, depressions, projections, or overlaps showing greater than 1/16 inch variation from the general contour for that section. Castings that exhibit surface imperfections (as defined above) covering an area of more than 10 percent of blade surface will be rejected.

2.4.7.2 Balance

Balance each impeller by the two-plane balancing technique. Balance each impeller at maximum operating speed. Check the balance at 110 percent of balance speed, and make needed corrections. Amount of allowable unbalance is in accordance with grade G6.3 of ISO 1940-1. Securely fasten weights needed to obtain the required level of balance to the inside cavity of the impeller hub. In no case can portions of the impeller be removed or weights be added to the outside of the hub, vanes, or water passages.

Submit balancing procedure at least four weeks prior to the date of balancing. Weigh each finished impeller and weight stamped on the bottom of the hub with weight accurate to 0.5 percent of the total weight of the impeller. Weighing and balancing will be witnessed by the Contracting Officer. Submit all impeller weights and the results of impeller balancing.

2.4.8 Shafting

2.4.8.1 Shaft

Each impeller shaft must be stainless steel and intermediate shaft(s) must be cold-rolled carbon steel. Design shafting so that shaft sections do not exceed 10 feet in length and that any necessary vertical adjustment of the impeller can be made interfering with shaft alignment. Also provide for removal of the impeller from below without disassembly of the pump above the impeller bowl. If the pump is multi-staged, design to permit the lower bowls and impeller to be easily removed for in-place inspections of upper propeller and bowl. Design shafts for two different design cases. The first uses a factor of safety of 5 based on ultimate tensile strength of the shaft material and rated horsepower of the motor. The second uses 75 percent of the yield strength of the shaft material and the locked rotor torque of the motor.

2.4.8.2 Couplings

Couple the pump and motor shafts together using rigid flanged coupling capable of transmitting the forces and torques involved. Bolt coupling halves together and maintain concentric with each other, by means of a rabbet fit, to within 0.002 inch. Retain a shaft coupling nut, if used, by fitted bolts, and comply with all tolerances specified for the coupling.

SECTION 35 45 01 Page 20

Finish machine the flange and bore in one setup to insure that the flange of the coupling is true to the bore. Each flange must be perpendicular to the bore, and parallel to the opposite end and mating flanges to within

0.002 inch. Each flange must be concentric to the centerline of the shaft to within 0.002 inch. Join together pump shaft sections with sleeve-type couplings capable of taking rotation in either direction. Threads, except on fasteners, cannot be employed in construction of sleeve-type couplings.

Construct couplings, including keys and fasteners, of stainless steel materials. All keys and keyseats (keyways) must meet the requirements of ASME B17.1. The finished shaft assembly must be concentric about the shaft centerline to within 0.004 inch. Shop assemble couplings and the pump shaft, and inspect for compliance with contract requirements. After inspection, matchmark parts, including fitted bolts, to their mating pieces.

2.4.8.3 Journals

Provide replaceable stainless steel one-piece journal sleeves at each guide bearing, packing gland and seal locations. Finish sleeves at all bearings and packing gland locations to at least 32 rms and finish sleeves at seal locations to 16 rms. Securely fasten sleeves to the shaft to prevent movement. Make keys and fasteners, if used, from corrosion resisting steel; fastening by adhesive or welding is not acceptable. All keys and keyseats (keyways) must meet the requirements of ASME B17.1. The surface hardness of the sleeves at the bearing and packing gland locations must be as recommended by the pump manufacturer.

2.4.8.4 Circumferential Line

Inscribe or etch a circumferential line on the shaft above the stuffing box and mount an adjustable pointer opposite this line in order to indicate a change in vertical position of shaft and to permit realignment after motor removal.

2.4.9 Shaft Enclosure

Provide a shaft enclosure to cover the intermediate shaft and coupling. It must be placed in tension or must be rigid enough to be self-supporting.

Do not use external supports or bracing located in the pump water passage for support of the enclosing tube unless necessary to support intermediate bearings or indicated to be necessary or advantageous by the dynamic analysis required in paragraph DYNAMIC ANALYSIS. Consider the effect of external supports, including rubber inserts, in the dynamic analysis required in paragraph TEST, INSPECTIONS, AND VERIFICATIONS, subparagraph DYNAMIC ANALYSIS. Design each enclosure to be watertight and for easy assembly and disassembly in the field. Split each enclosure longitudinally to permit easy removal without removing or disassembling the pump shaft.

Construct enclosing tubes, constructed with screw type joints and using tension in the tube to hold alignment, to prohibit the tension tube from unscrewing when the packing gland adjustments are made. On oil-lubricated pumps, fit the enclosing tube below the lowest bearing and above the oil seals with an oil/water drain line to the outside of the pump. The drain line must have a check valve outside of the pump to preclude the entrance of sump water.

2.4.10 Guide Bearings and Seals

2.4.10.1 Guide Bearings

Provide each pump with sleeve-type bearings designed for oil lubrication.

SECTION 35 45 01 Page 21

Each bearing must have a bronze lining in contact with shaft journal and must be replaceable type. Arrange the bearing liner for maximum distribution of oil for lubrication of journal surface. Bearings must have a surface finish of 32 microinches rms or better to match the journal finish. Since pumped water may contain some fine sand and silt in suspension, give special attention to the design and selection of bearing parts, especially seal rings, to preclude entrance of foreign material between the bearing and journal due to differential water pressure.

Bearings must be easily removable for servicing in the field.

2.4.10.2 Oil Lubrication Shaft Seals

Pumps designed for oil lubrication must have a shaft seal system located below the upper pump shaft bearing. The seal system consists of a seal containing two lip elements. The element facing the bearing must have a stainless steel garter spring back-up and be constructed of TFE (Teflon).

The secondary element faces the impeller and is constructed of TFE. Use a bullet-shaped assembly tool or other special tool over the end of the shaft or grooves in the shaft to preclude damage to the lip element during assembly. Assembly tools used are considered a special tool and must be furnished to the Government as part of special tools specified in paragraph SPECIAL TOOLS. Pumps having two stages must have seals to protect the extra bearings required by two stages of construction.

2.4.11 Bearing Heat Sensors

Fit the impeller shaft bearings with temperature-sensing elements, inserted in the bearings to within 1/8 inch of shaft. Provide these temperature-sensing elements with temperature readouts mounted on the motor instrument board. Provide a visual and audible alarm system to warn of bearing overheating. Provide temperature indicator with dual outputs that have setpoints that are separately adjustable. Support leads and protect them from water and mechanical damage. Terminate the leads outside of the pump casing in a waterproof connection head, Minco CH 339 or equal, and cap until final connections are made in the field. The connection head must be rated watertight to 25 psi. Lead protection consists of pipes fastened to the pump with brackets using bolts and nuts to permit their removal, and constructed with enough unions to be completely disassembled. Leads passing through the pump water passage in the pump must either be contained in a guide vane or be protected by Schedule 80 pipe. Make protection pipe removable if connected to the shaft-enclosing tube. Install bearing heat sensors as shown in Figure 2 at end of the section recommended by the pump manufacturer. Run leads and wiring to a junction box located on the baseplate. Provide a terminal strip in the junction box for connection of wiring to temperature readouts.

2.4.12 Thrust Bearing

Provide a thrust bearing in the motor to carry total thrust load.

2.4.13 Packing Gland

Provide grease-lubricated packing gland split longitudinally to facilitate removal or renewal. Arrange it to permit inspection, repair, removal, or replacement of packing without entering pump from below operating room floor. Provide eye bolts and tapped holes in each half of the split gland if halves weigh over 30 pounds each.

SECTION 35 45 01 Page 22

2.4.14 Siphon Breaker Valve

Provide a siphon breaker valve assembly for each of the pumps. Provide mechanical, self-actuating valves. Install each assembly at the top (summit) of the discharge pipe and must vent air from the discharge pipe when the pump is started. The assembly must also permit air to enter the discharge pipe through the siphon breaker valve to prevent reverse siphoning of water when the pump is stopped. Provide a means to operate the valve manually to stop back-siphoning through the pump in case the normal operator of the siphon breaker valve should fail. Siphon breaker valve shall be manufactured by Harris Valve. Valve models shall be as shown on the drawings.

2.5 LUBRICATION SYSTEM

Oil lubrication of shaft bearings consists of introducing oil at the top line shaft bearing and allowing oil to run down the shaft for the lubrication of the lower bearings. Oil lubrication consists of an oil reservoir mounted on the pump baseplate or pump driver at such height to permit gravity flow of oil to the highest lubrication point of the pump shaft. Construct the reservoir of transparent material to permit observation of the quantity of oil in the reservoir. The oil reservoir must have a minimum capacity of 1 quart. The reservoir must have a solenoid valve to permit oil flow whenever the pump driver is in operation. The flow rate from the oil reservoir must be adjustable from five drips per minute to constant flow. The reservoir valve must permit manual flow of oil when the pump driver is not operating for prelubrication of the shaft bearing.