A.01.13_B2_Head_Cover_Pump_Supply_Specifications.pdf

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MECHANICAL EQUIPMENT

PART 1 GENERAL

1.1 GENERAL INFORMATION

This section specifies the following work:

a. Furnish sixteen rotary lobe pump skid assemblies and suction and discharge hose assemblies for main units, plus three spare pump skid assemblies. Include four rebuild kits.

b. Furnish four rotary lobe pump skid assemblies and suction and discharge hose assemblies for fishwater units, plus one spare pump skid assembly. Include two rebuild kits.

1.2 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.

ASME INTERNATIONAL (ASME)

ASME B1.20.1 (2013) Pipe Threads, General Purpose (Inch)

ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2010) Nuts for General Applications:

Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B18.21.1 (2009; R 2016) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A269/A269M (2015a) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM B88 (2016) Standard Specification for Seamless Copper Water Tube

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2016) Motors and Generators

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. Submit the following to the contracting officer as outlined in this specification:

SD-01 Preconstruction Submittals

Schedule of Materials and Product Data; G, HDC

SD-02 Shop Drawings

Detailed Shop Drawings; G, HDC

SD-06 Test Reports

Pressure Test Report; G, HDC

Operational Test Report; G, HDC

SD-08 Manufacturer's Instructions

Inspection and Test Notification; G

Testing Procedure; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals

1.4 GENERAL REQUIREMENTS

1.4.1 Warranty

Provide a 1 year wear warranty that begins when the pumps are put into service and a 4 year workmanship warranty that begins when the pumps arrive on site. The wear warranty will cover needed replacements of the wear plates, lobes, pump housings, pressure discs, belts, and seals during the warranty window. The workmanship warranty will cover needed replacements of major component parts that are found to be functioning abnormally due to defective machining, incorrect material, or improper assembly during the warranty window. The workmanship warranty also includes all spare parts that are anticipated to be needed during the extended time, calculated based upon the number of hours the pumps are in use, if they are in use, or a general total time that has passed, if they are being stored.

1.4.2 System Configuration

Each pump assembly must be in a configuration to allow for easy access to the pump wet-end for in-place wear part replacement and routine operation and maintenance. This can be achieved by ensuring that each pump's wet-end is facing the center of the main and fishwater units once installed.

Additionally, the typical wear parts must be accessible with minimal pump disassembly. Note that the pump assemblies are constrained by surrounding existing equipment. Sketches of how the new pumps will fit within surrounding existing equipment and the general arrangement of the skid assemblies are shown on the FIO drawings.

Provide Manufacturer's standard coating systems for all components of the pump skid, skid base and frame, and piping components for use in industrial environments.

PART 2 PRODUCTS

2.1 GENERAL

a. Materials and equipment must conform to the requirements of these specifications. When materials and equipment are specified to be replaced in kind, at minimum they must be of equal design as existing equipment being replaced, unless specified otherwise. Submit materials and equipment certificates of compliance, where materials or equipment are specified to comply with requirements of ASME or other standards organizations, in the schedule of materials and product data submittal. The label or listing of the specified agency will be acceptable evidence. In lieu of the label or listing, a written certificate may be submitted from an approved, nationally recognized testing organization equipped to perform such services, stating that the items have been tested and conform to the requirements and testing methods of the specified agency.

b. Materials and equipment must be the products of manufacturers regularly engaged in the manufacture of such products. Items of equipment must essentially duplicate equipment that has been in satisfactory use at least 2 years prior to proposal submission.

Materials differing in minor respect from that specified may be proposed, provided such differences are clearly stated. Any materials required which are not covered in the piping material schedule or these specifications must conform to applicable specifications. In cases where material is not covered by one of the listed specification groups, the Contractor must furnish the highest commercial grade of material or product available. Particular attention must be given to the marking of valves to indicate body and trim material and pressure rating.

2.2 SCHEDULE OF MATERIALS AND PRODUCT DATA

Submit a complete schedule of materials for all items specified in this specification and any other material that the Contractor may use to complete this work at least 30 days prior to construction, purchase, or manufacturing of the part/material in question. The schedule must contain the names and addresses of the manufacturers, their catalog numbers and trade names. The schedule must indicate, by description, where the items will be used. The schedule of materials and equipment must be supported by sufficient product data, which includes, but is not be limited to, catalogs, diagrams, pump cut sheets (dimensional drawings), data sheets (product specifications), pump performance curves, pump and motor rotational speed, motor and gearbox performance characteristics, any specific equipment options proposed, and other data published by the manufacturer, as well as evidence of compliance with safety and performance standards, to demonstrate conformance to the specification requirements.

Catalog numbers alone will not be acceptable. Submit all data for any new equipment supplied as part of this specification. Approval of materials and equipment will be based on manufacturers' published ratings, and must be submitted. Product data for major items included in the schedule of materials and product data submittal must include but not be limited to the following:

a. Pump skid assemblies;

b. Suction hose foot valves;

2.3 BOLTS, NUTS, STUDS, AND WASHERS

Conform threaded bolts and studs to ASME B18.2.1. Conform threaded nuts to ASME B18.2.2. Conform lock and plain washers to ASME B18.21.1. Galvanize all bolts, nuts, studs, and washers in contact with galvanized surfaces.

Conform all galvanized coatings to ASTM A123/A123M.

2.4 PIPE AND FITTINGS

2.4.1 Piping

Piping 3-inch IPS and larger and piping modifications for the water side of the pumps must be schedule 40 seamless black steel conforming to

ASTM A53/A53M.

2.5 PUMP ASSEMBLIES

2.5.1 Main Unit Rotary Lobe Pumps

The pumps must be self priming, positive displacement, rotary lobe type pumps, LobePro Series M50 or approved equal. Pump orientation must be horizontal with overhead motor drive using belt and sheave assembly configuration. The fluid to be pumped is water with oil contamination, with a temperature range from 33 to 70 F. The pump must be designed to be suitable to pump sludge, mud and slurries. Pumps must be capable of pumping at 130 gpm at 50 psi with a speed no greater than 400 rpm.

Required power must not exceed 10 hp at these conditions. Rated pressure must be 150 psi or greater. Pumps must be capable of self priming at 25 feet of suction lift. Goose neck inlet and outlet fittings must be provided for the pump to allow self priming. Net inlet pressure (NPSH) required must not exceed 8 psia in the specified range of conditions.

Rotor housing and pump cover must be high tensile gray iron ASTM A48 or approved equal. Gaskets must be non-asbestos fiber and suitable for the service. Mechanical seals must be stainless steel type 316 or approved equal. Pump inlet and outlet must be flanged. Anti-friction bearings must be external to the fluid pumped and separately lubricated.

The size of each main unit pump skid assembly is restricted by existing piping and equipment within the turbine pit headcover area. The dimensions of the area that each pump skid assembly, including gooseneck flanged fittings, must fit into are approximately 27 inches x 34 inches (flange to flange) x 40 inches (L x W x H), as shown on FIO Drawing SK001. Orient the pump assembly as shown on FIO Drawing SK001. Each of the main unit pumps overall weight must not exceed 700 pounds. Provide suction and discharge nozzles to match the existing 4 inch intake and discharge connections.

2.5.2 Fish Unit Rotary Lobe Pumps

The pumps must be self priming, positive displacement, rotary lobe type pumps, LobePro Series S16p or approved equal. Pump orientation must be horizontal with right angle gears and vertical motor orientation. The fluid to be pumped is water with oil contamination, with a temperature range from 33 to 70 F. The pump must be designed to be suitable to pump sludge, mud and slurries. Pumps must be capable of pumping at 80 gpm at 50 psi with a speed no greater than 620 rpm. Required power must not exceed 5 hp at these conditions. Rated pressure must be 150 psi or greater. Pumps must be capable of self priming at 25 feet of suction lift. Goose neck inlet and outlet fittings must be provided for the pump to allow self priming. Net inlet pressure (NPSH) required must not exceed 8 psia in the specified range of conditions. Rotor housing and pump cover must be high tensile gray iron ASTM A48 or approved equal. Gaskets must be non-asbestos fiber and suitable for the service. Mechanical seals must be stainless steel type 316 or approved equal. Pump inlet and outlet must be flanged.

Anti-friction bearings must be external to the fluid pumped and separately lubricated.

The size of each fish unit pump skid assembly is restricted by existing piping and equipment within the turbine pit headcover area. The dimensions of the area that each pump skid assembly, including gooseneck flanged fittings, must fit into are approximately 22 inches x 31 inches (flange to flange) x 30 inches (L x W x H), as shown on FIO Drawing SK002. Orient the pump assembly as shown on FIO Drawing SK002. Each of the fish unit pumps overall weight must not exceed 400 pounds. Provide suction and discharge nozzles to match the existing intake and discharge connections.

2.5.3 Pump Motors

2.5.3.1 General

The pump motor must operate on a supply voltage of 480 VAC, 60 Hz, 3 Phase, and be direct on line start. Motors must be squirrel-cage, premium efficient induction motors. Each electric motor must be Totally Enclosed Fan Cooled (TEFC) and continuous duty. Pump motors must have a 1.15 service factor and be rated for operation at 40 degree Celsius ambient.

The pump motors must conform to NEMA MG 1 and be of sufficient size so that the nameplate horsepower rating is not exceeded throughout the entire published pump characteristic curve and service required. Motor bearings must be of the sealed and permanently lubricated type and provide smooth operations under the conditions encountered for the life of the motor.

Coating must meet requirements for severe industrial environment with high humidity.

2.5.3.2 Windings and Insulation

Class F or H, must be used on the motor windings and must be of a type designed and constructed to withstand the severe moisture condition and accompanying wide ambient temperature variations to which the motor will be subjected.

2.5.3.3 Designation and Markings

Provide nameplates for each motor that conform to Section II, Part 10 of

NEMA MG 1.

2.5.4 Belt and Sheave Assembly

The overall speed ratio must be selected to provide the required pump operating speed and capacity. Select the belt for the rotary lobe pump assemblies with a minimum service factor of 1.6. Provide synchronous belts with a minimum 8mm pitch and a minimum 12mm width, Gates Corporation Poly Chain GT Carbon Synchronous Belts, or approved equal. Select and size sheaves to provide the proper speed ratio. Belts must provide resistance and protection from grime, grease and moisture. Size the sheave bushing to ensure the skid overall dimensional constraints outlined in sections "Main Unit Rotary Lobe Pumps" and "Fish Unit Rotary Lobe Pumps" are satisfied.

Provide a rigid belt guard, fully removable by hand for assembly and disassembly. Belt guards must be steel with minimum 10 gage thickness. The guard must cover the front and back of the belt/sheave assembly and be water- and oil-proof. Guards weighing over 25 pounds must have an integral lift lug or be provided with lift handles.

2.5.5 Pump Skid Base

Each pump assembly must be mounted on a rigid steel base. Base rigidity must be sufficient to ensure that pump and motor alignment requirements are sustained under operating conditions. Mounting surfaces must be machined or correctly shimmed to ensure alignment requirements are met. Include the skid base overall dimensions in the space limitations outlined in Sections "Main Unit Rotary Lobe Pumps" and "Fish Unit Rotary Lobe Pumps". Surface clean and prepare the skid base according to the manufacturer's standard specifications.

2.5.6 Pump Suction Hose Foot Valves

Provide foot valves for each of the sixteen main unit and four fish unit pumps' suction hoses (a total of twenty). A stainless steel strainer with 1/4 inch mesh must be provided on the suction hose. Ensure that the strainer size is 4 times the free opening area of the 3 inch suction hose cross sectional area.

2.5.7 Pump Rebuild Kits

Provide four main unit rebuild kits and two fish unit rebuild kits that include a set of seals, wear plate kit, and lobe kit (a set of lobes, the Belleville washers for the pressure disk that sits inside of the lobe, the strain bolt that bolts through the pressure disk into the shaft, the O-rings for the pressure disk and strain bolt).

PART 3 EXECUTION

3.1 INSPECTION AND TEST NOTIFICATION

Submit notification of date and location of all inspections and tests at least 14 days prior to the inspection or test.

3.2 DETAILED SHOP DRAWINGS

Submit Detailed Shop Drawings of the design for all items specified in this section, including the Pump Assemblies, at least 30 days prior to installation.

3.3 TESTING PROCEDURE

Submit a detailed testing procedure for the operational testing and pressure testing of the pump skid assemblies at least 21 calendar days prior to testing. The procedure must demonstrate that all requirements specified in this Section or otherwise referenced in this Section have been met.

3.4 PRESSURE TEST REPORT

Pressure test the pump skid assemblies up to their maximum rated pressure of 150 psi. Any defects or leaks disclosed by pressure testing of the pump skid assemblies must be repaired and retested at no expense to the Government. The Contracting Officer must be notified not less than 48 hours prior to starting any test to permit a representative of the Contracting Officer to witness the test(s). Submit pressure test reports and certificates for pump skids a maximum of 7 days after performing each test.

3.5 OPERATIONAL TEST REPORT

Shop testing of the pump skid assemblies must be performed. An Operational Test Report must be submitted that covers all aspects of the testing a maximum of 14 days after performing the tests. The testing must demonstrate that all operating conditions outlined in paragraphs "Main Unit Rotary Lobe Pumps" and "Fish Unit Rotary Lobe Pumps" are met by the pump skid assemblies. Provide all additional equipment necessary to perform the test. Organize all data in the Operational Test Report to clearly present the data shown above.

3.6 QUALITY CONTROL

In conjunction with quality control requirements, Quality Control includes but is not be limited to, the following:

a. Ensure that materials and equipment comply with the specifications and approved shop drawings.

b. Submit detailed shop drawings, operation and maintenance manuals, and testing procedure for approval.

c. Maintain testing and acceptance records and deficiency lists.

d. Verify qualifications of workers.

e. Inspect work for proper assembly.

f. Submit inspection and progress reports. Furnish a copy of records and tests, as well as the records of corrective action taken, in accordance with quality control requirements.

3.7 OPERATION AND MAINTENANCE MANUALS

Provide operation and maintenance manuals for all major equipment a maximum of 7 days after delivery of the pumps. Major equipment includes pump, motor, and gearbox. Submit five (5) hard copies and one (1) PDF copy of the Operations and Maintenance Manuals to the contracting officer a maximum of 7 days after delivery of the pumps. Manuals are to provide detailed pump installation procedures and instructions of care for the entire lifecycle of the pumps.

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