A02-SOW-Lift_Station_FR__1-VC__2-IC__4.pdf

STATEMENT OF WORK

FOR

LIFT STATION REHAB

AT

MARK TWAIN LAKE, MISSOURI

12 July, 2016

STATEMENT OF WORK/SPECIFICATIONS

1. GENERAL.

1.1 SCOPE OF WORK. Rehabilitate three existing lift stations including: Frank Russell Recreation Area Lift Station #1, Indian Creek Recreation Area Lift Station #4 and MW Boudreaux Visitor Center Lift Station #2 in accordance with specifications. Replacement and installation of equipment and components shall be furnished and installed new.

1.2 CONTRACTOR. The "Contractor" is the individual whose contract bid was accepted by the U.S.

Army Corps of Engineers and who has gained the responsibility of performing the duties governed by the specifications of this contract.

1.3 CONTRACTING OFFICER. The term "Contracting Officer" shall mean the person executing this contract on behalf of the Government, and any other officer or civilian employee who is acting on his/her behalf.

1.3.1 CONTRACTING OFFICER’S REPRESENTATIVE (COR). An individual designated in writing by the Contracting Officer to be responsible for administration of the contract and Quality Assurance Representative.

1.4 REQUIRED INSURANCE.

1.4.1 As required by the Contract Clause entitled “Insurance--Work on a Government Installation,” following award and prior to commencement of work, the Contractor shall furnish to the Contracting Officer a written statement as evidence of the following minimum insurance.

Workmen’s Compensation - Amounts required by applicable jurisdictional statutes.

Employer’s Liability Insurance - $100,000.00

Comprehensive General Liability Insurance

Bodily Injury - $500,000.00

Comprehensive Automobile Insurance

Bodily Injury - $200,000.00 each person $500,000.00 each person Property Damage $ 20,000.00 each accident

1.4.2 Statements of insurance shall be submitted to the following address:

St. Louis District, Corps of Engineers Mark Twain Lake Project Office 20642 Highway J Monroe City, MO 63456

1.5 CONFINED SPACE ENTRY. The existing wet wells are confined spaces and require a “Confined Space Entry Permit” to perform work in this space. The Contractor shall complete a confined space entry permit for approval to enter the space daily or for each successive entry period. The Contractor shall submit a copy of their confined space program in accordance with 29 CFR 1910.146 to the Government.

All work in this confined space shall be accomplished in accordance with OSHA requirements and safety requirements set forth in Corps of Engineers Manual, EM 385-1-1, entitled “Safety and Health Requirements Manual”.

1.6 SAFETY. This paragraph applies to contracts and purchase orders that require the Contractor to comply with EM 385-1-1 (e.g., contracts that include the Accident Prevention clause at FAR 52.235-13 and/or other safety provisions). EM 385-1-1 and its changes are available at http://www.hq.usace.army.mil (at the HQ homepage, select Safety and Occupational Health). The Contractor shall be responsible for complying with the current edition and all changes posted on the web as of the effective date of this solicitation. The Government may inspect all equipment and materials. Any equipment or material found not in conformity with the requirements of this contract shall be removed from Government property immediately. The Contractor shall develop and submit an Accident Prevention Program using the forms located in Appendices A-1, A-2, and A-3 together with a copy of the Company Policy on Safety.

1.6.1 References. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the test by the basis designation only.

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 10 (2002) Portable Fire Extinguishers

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2003) Safety - Safety and Health Requirements

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

1.6.2 Site Safety and Health Officer (SSHO). Site Safety and Health Officer (SSHO) shall be provided at the work site at all times to perform safety and occupational health management, surveillance, inspections and safety enforcement for the Contractor. The Contractor Quality Control (QC) person can be the SSHO on this project. The SSHO shall meet the following requirements.

1.6.2.1 Work on similar projects

1.6.2.2 10-hour OSHA safety class or equivalent within the last three (3) years

1.6.2.3 Competent person training as needed

1.6.3 Accident Prevention Plan (APP)

1.6.3.1 The Contractor shall use a qualified person to prepare the written site-specific APP.

Prepare the APP in accordance with the format and requirements of USACE EM 385-1-1 and as supplemented herein. Cover all paragraph and subparagraph elements in USACE EM 385-1-1, Appendix A, ‘Minimum Basic Outline for Accident Prevention Plan”. Specific requirements for some of the APP elements are described below. The APP shall be job-specific and shall address any unusual or unique aspects of the project or activity for which it is written. The APP shall interface with the Contractor’s overall safety and health program. Any portions of the Contractor’s overall safety and health program referenced in the APP shall be included in the applicable APP element and made site-specific. The Government considers the Prime Contractor to be the “controlling authority” for all work site safety and health of the subcontractors. Contractors are responsible for informing their subcontractors of the safety provisions under the terms of the contract and the penalties for noncompliance, coordinating the work to prevent one craft from interfering with or creating hazardous working conditions for other crafts, and inspecting subcontractor operations to ensure that accident prevention responsibilities are being carried out.

The APP shall be signed by the person and firm (senior person) preparing the APP, the Contractor, the on-site superintendent, the designated site safety and health officer and any designated CSP and/or CIH.

1.6.3.2 Submit the APP to the Contracting Officer’s Representative (COR) for acceptance following award and prior to the post award conference for acceptance. Work cannot proceed without an accepted APP.

1.6.3.3 Once accepted by the COR, the APP and attachments will be enforced as part of the contract. Disregarding the provisions of this contract or the accepted APP will be cause for stopping of work, at the discretion of the COR, until the matter has been rectified.

1.6.3.4 Once work begins, changes to the accepted APP shall be made with the knowledge and concurrence of the COR, project superintendent, SSHO and quality control manager. Should any hazard become evident, stop work in the area, secure the area, and develop a plan to remove the hazard. Notify the COR within 24 hours of discovery. Eliminate/remove the hazard. In the interim, all necessary action shall be taken to restore and maintain safe working conditions in order to safeguard onsite personnel, visitors, the public and the environment.

1.6.3.5 Copies of the accepted plan will be maintained at the Mark Twain Lake Project Office.

The APP shall be continuously reviewed and amended, as necessary, throughout the life of the contract.

Unusual or high-hazard activities not identified in the original APP shall be incorporated in the plan as they are discovered.

1.6.4 Activity Hazard Analysis (AHA)

1.6.4.1 The Activity Hazard Analysis (AHA) format shall be in accordance with USACE EM 385-1-1. Submit the AHA to the COR for review following award and prior to the post award conference.

Format subsequent AHAs as amendments to the APP. The analysis should be used during daily inspections to ensure the implementation and effectiveness of the activities safety and health controls.

1.6.4.2 The AHA list will be reviewed periodically and updated as necessary when procedures, scheduling or hazards change.

1.6.4.3 The activity hazard analyses shall be developed for activities being performed. The AHAs will be developed by the contractor, supplier or subcontractor and provided to the prime contractor for submittal to the COR.

1.6.5 Emergency Medical Treatment. Contractors will arrange for their own emergency medical treatment. Government has no responsibility to provide emergency medical treatment.

1.6.6 Reports

1.6.6.1 Accident Reports. For recordable injuries and illnesses, and property damage accidents resulting in at least $2,000 in damages, the Prime Contractor shall conduct an accident investigation to establish the root cause(s) of the accident, complete USACE Accident Report Form 3394 and provide the report to the COR within Two (2) calendar days of the accident. The COR will provide copies of any required special forms.

1.6.6.2 Accident Notification. Notify the COR as soon as practical, but not later than Four (4) hours, after any accident meeting the definition of Recordable Injuries or Illnesses or High Visibility Accidents, or property damage equal to or greater than $2,000. Information shall include contractor name;

contract title; type of contract; name of activity, installation or location where accident occurred; date and time of accident; names of personnel injured; extent of property damage, if any; extent of injury, if known, and brief description of accident (to include type of equipment used, PPE used, etc. Preserve the conditions and evidence on the accident site until the Government investigation team arrives on-site and Government investigation is conducted.

1.6.6.3 Monthly Exposure Reports. Monthly exposure reporting to the COR is required to be attached to the monthly billing request. This report is a compilation of employee-hours worked each month for all site workers, both prime and subcontractor. The COR will provide copies of any special forms.

1.6.7 Meetings

1.6.7.1 Post Award Conference

1.6.7.1.1 Contractor representatives who have a responsibility or significant role in accident prevention on the contract shall attend the post award conference. This includes the project superintendent, site safety and health officer, quality control supervisor, or any other assigned safety and health professionals who participated in the development of the APP (including the Activity Hazard Analyses (AHAs) and special plans, program and procedures associated with it).

1.6.7.1.2 The Contractor shall discuss the details of the submitted APP to include incorporated plans, programs, procedures and a listing of anticipated AHAs that will be developed and implemented during the performance of the contract. This list of proposed AHAs will be reviewed at the conference and an agreement will be reached between the Contractor and the COR as to which phases will require an analysis. In addition, a schedule for the preparation, submittal, review and acceptance of AHAs shall be established to preclude delays.

1.6.7.1.3 Deficiencies in the submitted APP will be brought to the attention of the Contractor at the post award conference and the Contractor shall revise the plan to correct deficiencies and resubmit it for acceptance. Work shall not begin until there is an accepted APP.

1.6.7.2 Safety Meetings. Shall be conducted and documented as required by EM 385-1-1.

1.7 LOCATION AND CONTRACT LIMITS. The location of the work to be performed is at the Frank Russell Recreation Area Lift Station #1, MW Boudreaux Visitor Center Area Lift Station #2 and Indian Creek Recreation Area Lift Station #4, Mark Twain Lake Project, Monroe and Ralls Counties, Missouri.

1.8 SCHEDULE OF WORK. The Contractor shall perform all work between the hours of 7 a.m. and 5 p.m. Monday through Friday. No work shall be performed on weekends or holidays. All work shall be completed no later than December 31, 2016. NOTE 1: The Contractor may begin work on the Frank Russell Lift Station on September 12, 2016. Work may begin on the Visitor Center Lift Station on September 19, 2016. Work may begin on the Indian Creek Lift Station on September 26, 2016. The Indian Creek Lift Station must be available for use November 14 through November 21, 2016. NOTE 2: The Contractor shall have 5 consecutive work days to complete work on each lift station and back in service once the lift station is taken out of service. Additionally, the Contractor may only take one lift station out of service at a time.

1.9 ACCESS. The Contractor shall be responsible for access to, into and through all locations. Access into and through Government property shall be by routes approved by the Contracting Officer in advance prior to entry. Access through Government locked barricades or gates will be provided by the Government to the Contractor provided that notification is given a minimum of twenty-four (24) hours in advance.

1.10 UNUSUAL CONDITIONS. The Contractor shall inform the Contracting Officer of any unusual conditions observed such as dumping or vandalism. NOTICE: The Contractor shall be required to cooperate with, and coordinate with the Government any operations in and around any other Contractors, work crews, Government employees or the public which may be working or entering the area within the contract limits.

1.11 QUALITY CONTROL. The Contractor shall establish and maintain quality control for all operations to assure compliance with contract requirements and maintain records of his quality control for all construction operations.

1.12 WARRANTY. All items furnished under this section shall be warranted to be free from defect in workmanship and materials for a minimum period of one (1) year after date of start-up assistance.

1.13 REFERENCE PUBLICATIONS. These specifications, standards and descriptions are not available from Government sources. They may be obtained from the publishers listed below:

American National Standards Institute (ANSI) 11 West 42ND Street New York, NY 10036 www.ansi.org

American Society of Testing and Materials (ASTM) 100 Barr Harbor Drive West Conshohocken, PA 19428 www.astm.org

American Water Works Association (AWWA) 666 West Quincy Denver, CO 80235 www.awwa.org

Underwriters Laboratories Inc.

333 Pfingsten Road Northbrook, IL 60062-2096 www.ul.com

American Society of Mechanical Engineers ASME International Three Park Avenue New York, NY 10016-5990 www.asme.org

American Iron and Steel Institute 1140 Connecticut Ave. NW Suite 705 Washington D.C. 20036 www.steel.org

2. DESCRIPTION OF WORK. Lift Station components to be furnished and installed shall conform to the following requirements.

2.1 FRANK RUSSELL LIFT STATION (LS-1). The Contractor shall remove and replace two (2) submersible wet-pit pumps, discharge bases, discharge piping, guide rails, float switches, control panel and valve vault at the lift station. The Contractor shall also remove the existing aeration system and base.

Basic details of installation of lift station components and valve vaults are shown in Appendix C-1.

2.1.1 GENERAL. The existing pre-cast concrete wet well at LS-1 is 6-feet in diameter and approximately 10 feet deep. Note: This is a “Confined Space Entry Permit” required spaces.

2.1.2 DEMOLITION AND REPAIR. The existing pumps, discharge bases, vertical piping, float switches, brackets in the wet-wells, control panel, control panel supports, valve vault, aeration system and related base shall be removed. All embedded anchor bolts shall be cut off and ground smooth. Electrical conduits may be reused. The existing wet-wells interior section joints shall be cleaned by high-pressure water blasting and/or other methods. The pipe openings in the wet-well wall and the joints between the wet-well section rings shall be trowel filled with water stop to completely fill the void space and prevent the infiltration of groundwater and the exfiltration of sewage. The Contractor shall be responsible for repairing any physical damage caused to the existing wet-well during demolition and for the removal and disposal of waste water and debris. All demolished equipment and material become property of the contractor.

2.1.3 PUMPS. Furnish and install two (2) ABS Submersible Grinder Pumps as described herein. LS- 1 shall receive submersible grinder pumps and the motor shall be connected for operation on a 230 volt, 60 HZ, single phase service and shall be an integral part of the pumping unit. The pump discharge size for LS-1 shall be 1 ¼”. The grinder unit shall be capable of shearing and reducing to a fine slurry all material normally found in domestic and commercial sewage such as sanitary napkins, disposable diapers, cloth diapers, wash rags, wood, plastic, etc. The slurry shall be capable of freely passing through a 1 ¼” piping system including check and gate valves.

Lift Station # LS-1 Curve Number PE45/2W Flow, GPM 93 TDH, Feet 60 Motor HP 6.0 Rated speed, RPM 3536 Efficiency,% 25 Power 230V-60-1

2.1.4 PUMP CONSTRUCTION.

2.1.4.1 Self Cleaning Wear Plate. The pump shall be of the centrifugal type with the rotating cutter mounted on the pump shaft directly against the impeller. The stationary cutter shall be mounted in an adjustable bottom plate. The bottom plate shall be cast with grooves threading outward from the center opening of the plate to the outer diameter. The impeller shall be a multiple vane centrifugal type. The cutter material shall be similar to an AISI 440C stainless steel with the addition of cobalt, vanadium, and molybdenum for superior abrasion resistance and a hardness of 58-62 Rockwell C.

2.1.4.2 Impeller. The impeller shall be constructed of corrosion resistant chilled gray iron and shall be of the semi-open, non-clogging, dynamically balanced single-vane design capable of passing a minimum of 1.25-inch spherical solids. The impeller shall have a slip fit onto a shaft and drive key and shall be fastened by a stainless steel bolt.

2.1.4.3 Pump Volute. The pump volute shall be constructed of gray cast iron with smooth internal surfaces free of rough spots or flashing. The volute shall have a horizontal discharge.

2.1.4.4 O-Rings and Fasteners. All mating surfaces of the pump and motor shall be machined and fitted with BUNA-N O-Rings where water sealing is required. Sealing shall be accomplished by the proper fitting of the parts not by compression or special torque requirements.

2.1.4.5 Shaft and Bearings. The common pump and motor shaft shall be 420 stainless steel supported by a heavy duty lower single row ball bearing and an upper sealed single row ball bearing, all models. The cutting elements and impeller shall be designed to keep the overhung load distance to a minimum. All fasteners shall be 304 stainless steel.

2.1.4.6 Shaft Seals. Each pump shall be equipped with two seals. The lower seal (pump side) shall be of the mechanical type with silicon carbide faces. The upper seal shall be a lip type seal, mounted at a slight angle to the shaft

2.1.4.7 Seal Failure Warning System. An oil chamber shall separate the seals. An electronic probe shall be provided in the oil chamber to detect the leakage of water. Solid-state device mounted in the pump control panel or in a separate enclosure shall send a low voltage, low amperage signal to the probe.

If water enters the oil chamber, the probe shall activate a warning light in the control panel.

2.1.5 SUBMERSIBLE ELECTRIC MOTOR. The motor shall be air-filled and shall have Class “F” insulation. The rotor and stator shall be enclosed in a cast iron outer housing. Bi-metallic thermal switches shall be imbedded in each phase of the winding to sense high temperature. The rating of the switch shall be 130C +/- 5C. The control circuit shall be connected through the bi-metallic switches so the motor is shut down should a high temperature condition exist. The switches shall be self-resetting when the motor cools.

Power cable UL and CSA approved and shall have a minimum length of 30'. Oil filled motors are not acceptable. Single phase motors shall be of the capacitor start, capacitor run type for high starting torque.

2.1.6 GUIDE RAIL BASE AND SYSTEM

A cast iron ball check guide rail base shall be mounted on the floor of the pump station. The grinder pump shall be guided onto the cast iron discharge base by a single stainless steel guide rail supported at the top by an upper guide bracket and at the bottom by the discharge base. The pump base shall be equipped with a straightening vane, which properly aligns the pump on the discharge base just prior to the final seating.

The pump slide bracket shall include a fully ported ball check valve. The pump and check valve shall be removable from the guide rail base as a single unit. When the pump is in position, the weight of the pump shall compress the gasket and seal the connection. The area under the pump shall be free and clear of any additional support legs or guides pipes to insure free entrance of solids to the impeller. The pump guide rail shall be Schedule 40 stainless steel pipe and shall be threaded into the pump base. Pumps requiring two guide rails are not acceptable.

2.1.7 DUPLEX CONTROL PANEL.

2.1.7.1 Control Panel Requirements. It is the intent of these specifications that all motor controls and control components be supplied by a single supplier. Controls shall not be assembled on site. System supplier shall be a UL 508 certified facility and shall be regularly engaged in the manufacture of controls for the municipal water industry. A company having at least five years experience in the construction of such control equipment shall assemble the pump control panel. Specific panel specifications and control component specifications are included within these documents. Note: An additional start pack including a start capacitor with resistor, run capacitor and switching relay as well as a motor starter with overload shall be provided for future repair needs.

2.1.7.1.1 Control Panel Supports. The new control panel shall be mounted on two new, treated 6”x6” wooden control panel supports. The bottom of the control panel shall be installed a minimum of 3 feet above the surface of the ground.

2.1.7.2 Control Panel Operation. Basic operation of the pumps will be as a pump-down, lead/lag, common “off” system with high level alarm. Operation of the lag pump shall be independent from the lead pump. Panel shall accommodate connection of floats with the following functionality:

a. High Level

b. Lag Demand

c. Lead Demand

d. Stop

2.1.7.2.1 Hand-Off-Auto Switch. Each pump shall be controlled through a “Hand-Off-Auto” switch. In the Auto position, the floats in the wet-well shall control the pump. A demand for each pump shall be delayed through adjustable time delay relays with a range of .1 - 10 seconds. Initially, lead demand time delay shall be set at 8 seconds; lag time delay shall be set at 16 seconds. Operation of the lag pump shall not be run through the lead float. In the Hand position, the pump shall run continuously until the selector switch is turned to off or Auto.

2.1.7.2.2 Thermal Trip. A thermal trip via a normally closed thermal switch in the pump shall stop the pump from running in either Hand or Auto, but the pump will resume operation when the switch automatically resets.

2.1.7.2.3 Alarm Circuit. An alarm circuit shall be activated when “high level” condition occurs.

2.1.7.3 Control Panel Equipment.

2.1.7.3.1 Enclosure. Control equipment shall be mounted in a NEMA 4X stainless steel enclosure that is a minimum size of 24 inches wide by 30 inches tall by 12 inches deep, equipped with a separate sub panel and inner door. All control switches, elapsed time meters, reset buttons indicating lights and circuit breaker toggles, and receptacle shall be mounted on the inner door. The outer door shall have a secure padlock hasp attached to the enclosure. (The padlock is to be provided by the owner.) All panel wiring and equipment layout shall be performed per NEMA specifications.

2.1.7.3.2 Power Distribution Block. The main power distribution block shall be 600 volt rated, 100-amp minimum capacity, sized for incoming power to the panel. Each pole of the block shall be supplied with a clear cover for operator protection.

2.1.7.3.3 Circuit Breakers. Individual thermal magnetic breakers shall be provided for branch disconnect service and short circuit protection of all motor and auxiliary circuits. Combination circuit breaker and overload mechanism shall not be allowed. Circuit breakers for motors and other loads shall have a minimum rating of 10,000 AIC (230-vac breakers) or 14,000 AIC (480-vac breakers). Provide two 1-pole, 15-amp circuit breakers for the following loads:

a. Control circuit

b. Panel G.F.I. receptacle

2.1.7.3.4 Contactors/Overload Relay. A magnetic across the line horsepower/current rated motor contactor with ambient temperature compensated overload relay shall be provided for each motor load served.

2.1.7.3.5 Receptacle. A 15-amp G.F.I. duplex receptacle connected to a separate circuit breaker shall be mounted on the control panel. A weatherproof guard or cover shall be installed over the receptacle.

2.1.7.3.6 Fuse holders and Fuses. A fuse for the control circuit shall be installed with a minimum rating of 5 amps (ampacity not to exceed relay contact rating). Fuse holders for control fuses shall be finger safe with neon light indication for a blown fuse.

2.1.7.3.7 Terminal Blocks. Numbered terminal blocks shall be supplied for all field terminations. Current capacity of terminal strips shall be equal to the load served. Terminal blocks shall be suitable for minimum 12 AWG wire at not less than 300 volts.

2.1.7.3.8 Time Delay Relays. Time delay relays shall be dial or D.I.P. switch selectable, and shall have contact ratings of not less than 10 amps. Switch settings shall be labeled on the relay. Note:

One additional time delay relay shall be provided for future repairs.

2.1.7.3.9 Relays. Relays shall be general purpose plug-in relays with standard mounting configurations. The relays shall have the number of poles as shown on the drawings. The units shall have neon indicating lamp and test button integral to each relay. Note: One additional relay of each type shall be provided for future repairs.

2.1.7.3.10 Alternator. Provide an automatic electronic alternator for alternating pump operation on successive automatic cycles. Relay shall incorporate LED position indicators and a toggle switch to select pump #1 or pump #2 as the lead pump, or to allow automatic alternation. Note: One additional adjustable alternating relay shall be provided for future repairs.

2.1.7.3.11 Selector Switches. Selector switches shall be 30 mm oil tight type with lever operators and 10 amp contacts. Knob operators will not be accepted. Contact blocks shall be provided as required and shall be rated for a nominal voltage of 500 vac and 10 amps. Provide selector switches for the following functions:

a. Pump “Hand-Off-Auto”

b. Three-position

2.1.7.3.12 Pilot Lights. Pilot lights shall be push-to-test, oil-tight industrial units utilizing 120-volt bulbs (unless otherwise specified). Lenses lens shall be colored as shown on the drawings. LED type lights will not be acceptable. Provide pilot lights for the following functions (per pump where applicable):

a. Pump Run Green

b. Pump Seal Fail Amber

c. Pump Thermal Trip Red

d. High Level Red

2.1.7.3.13 Pushbuttons. Pushbuttons shall be oil-tight industrial units. Contact blocks shall be provided as required and shall be rated for a nominal voltage of 500 vac and 10 amps. Provide push buttons for the pump thermal reset (One pushbutton resets both pumps)

2.1.7.3.14 Elapsed Time Meters. Provide an elapsed time meter for each pump controlled.

Meter shall be 6-digit, non-resettable, reading in hours and tenths of hours.

2.1.7.3.15 Seal Fail Relay. Provide a conductance actuated moisture-sensing relay for each submersible pump controlled with field adjustable sensitivity. Note: One additional seal fail relay shall be provided for future repairs.

2.1.7.3.16 Alarm Light. Provide a red strobe light mounted to the top, exterior of the enclosure. Minimum ratings shall be 1.5 Joules at 70 flashes per minute. The strobe light shall be fully sealed to prevent water from entering the enclosure and be attached by mounting screws from inside the enclosure to prevent tampering. The alarm light is to be activated by the high-level alarm float mounted in the wet-well.

2.1.7.3.17 Ground Buss/Lugs. Provide a ground lug sized for incoming power ground near the power distribution block. Provide a ground lug sized for pump ground near pump power wire terminations.

Provide a ground buss for control equipment grounding, minimum 6 termination points.

2.1.7.3.18 Corrosion Inhibitor. Provide a corrosion inhibitor mounted inside the control panel.

2.1.7.3.19 Wiring. Power distribution wiring on the line side of panel fuses or circuit breakers shall be sized for the load served and be a minimum 12 AWG. Control wiring shall be minimum #16 gauge SIS type stranded wire for internal control panel circuits. All control wires shall be numbered at each termination corresponding to the master wiring diagram with clip-sleeve or heat-shrink type wire markers. Wrap-on or adhesive wire markers shall not be allowed. 120-vac wiring (except for neutrals) shall have red insulation. 120-vac neutral wiring shall have white insulation. 50-vac or less shall have yellow insulation. 12/24-vdc wiring shall have blue insulation.

2.1.7.3.20 Nameplates. Provide engraved phenolic nameplates, black letters on white background, for all internal devices such as contactors, circuit breakers, and relays; and for door-mounted devices such as selector switches, push buttons, and pilot lights. Nameplates shall be secured firmly to the panel.

2.1.8. ACCESSORIES.

2.1.8.1 Lifting Chains. Pump lifting chains shall be sized and provided by the pump manufacturer. The chain shall be sized to accommodate the installed pump weight and shall be type 304 or 316 stainless steel. The chain length shall be five feet greater than the station depth.

2.1.8.2 Float Switches. Float switches shall contain a single pole mercury switch, which activates when the longitudinal axis of the float is horizontal, and dictates when liquid level falls 1" below the actuation elevation. The casing shall be chemical resistant polypropylene and have an internal stabilizing weight. A PVC type STO, 2 - #18 AWG conductor cable shall protrude from one end of casing. One end of the cable is permanently connected to the glass enclosed mercury switch and the entire assembly is encapsulated to form a completely watertight and impact resistant unit. The electrical cable shall have a minimum length of 30'.

2.1.8.2.1 Float Switch Adjustment. The float switches shall be field adjusted to the Governments satisfaction.

2.1.8.3 Cable Holder. One (1) stainless steel cable holder constructed of type 304 SS shall be provided. Each cable holder shall have six (6) hooks and be wall mounted.

2.1.8.4 Cable Grips. The pump and float switch cables shall be hung from their hooks with “Kellum” strain relief grips.

2.1.9 ANCHOR BOLTS AND HARDWARE. New anchor hardware consisting of expansion or adhesive anchors shall be used.

2.1.9.1 Expansion Anchors. All expansion anchors shall be either AISI 304 or 316 stainless steel stud type expansion anchors with a single piece wedge that performs as three independent wedges if necessary to provide consistent performance in a wide variety of medium-duty applications. Each expansion anchor shall be provided with a stainless steel nut and washer. Expansion anchors shall be of the diameter required by the pump manufacturer with anchor and threading lengths suitable to provide indicated minimum embedment. Install expansion anchors in accordance with manufacturer's recommendations.

2.1.9.2 Adhesive Anchors. Adhesive anchors shall consist of AISI 304 stainless steel all-thread rod, nut and washer, and adhesive capsule. Adhesive anchors shall be of the diameter required by the pump manufacturer with anchor and threading lengths suitable to provide indicated minimum embedment.

Adhesive capsules shall contain a vinyl ester resin with a dibenzyl peroxide hardener. Anchor rods shall be of diameter indicated furnished with compatible diameter of adhesive capsules. Adhesive anchors shall be installed in accordance with manufacturer’s recommendations.

2.1.9.3 Hardware. All fabricated hangers, supports and brackets shall be 304 stainless steel.

2.1.10 PRECAST WET-WELL LID AND ACCESS HATCH. The existing pre cast wet well lid and access hatch shall remain in use and undisturbed.

2.1.11 PIPE AND VALVES. New piping, valves, and related accessories inside the sewage wet well.

2.1.11.1 Station Piping. Provide threaded joint fittings within wet well as indicated. All new piping inside the wet–well shall be 1 ¼” schedule 40 stainless steel. The Contractor shall install 1 ¼” stainless steel station discharge piping and connect to the existing 4” PVC force main outside the wet-well.

Piping extending thru the wet-well shall be grouted with non-shrink grout to form a water-tight seal.

2.1.11.2 Ball Valves/Swing Check Valves. Each pump shall have a horizontal pipe with a threaded brass swing check valve and threaded brass ball valve separated by a threaded brass union to allow their removal. The ball valves shall have stainless steel handles that allow their operation from outside the station. There shall be no need for personnel to enter the wet well to operate the shut-off valves.

2.2 INDIAN CREEK LIFT STATION #4 & VISITOR CENTER LIFT STATION #2. The Contractor shall remove and replace two (2) submersible wet-pit pumps, discharge bases, discharge piping, valves, guide rails, float switches, and control panels at each of the Indian Creek and Visitor Center lift stations.

The Contractor shall remove and replace the wet-well lid and hatch at the Indian Creek Lift Station. Basic details of installation of lift station components are shown in Appendix C-2.

2.2.1 GENERAL. The existing fiberglass wet well at the Indian Creek Lift Station #4 and Visitor Center Lift Station #2 is 4-feet in diameter and approximately 8 feet deep. Note: These are “Confined Space Entry Permit” required spaces.

2.2.2 DEMOLITION AND REPAIR. The existing pumps, discharge bases, piping, valves, float switches, brackets in the wet-wells and the control panel shall be removed. All embedded anchor bolts shall be cut off and ground smooth. Electrical conduits may be reused. The existing wet-wells interior shall be cleaned by high-pressure water blasting and/or other methods. The pipe openings in the wet-wells wall shall be patched to completely fill the void space and prevent the infiltration of groundwater and the exfiltration of sewage. The fiberglass wall shall be patched and sealed as recommended by the wet-well manufacturer. The Contractor shall be responsible for repairing any physical damage caused to the existing wet-well during demolition and for the removal and disposal of waste water and debris. The existing piping and valves shall be removed. The discharge piping holes in the existing wet-well shall be used for the placement of new discharge piping and shall be done in a manner to prevent infiltration. All demolished equipment and material become property of the contractor. See Appendix C – 2 for typical layout of existing lift stations.

2.2.3 PUMPS. Furnish and install two (2) ABS Submersible Grinder Pumps as described herein.

Indian Creek and Visitor Center shall receive submersible grinder pumps and the motor shall be connected for operation on a 230 volt, 60 HZ, single phase service and shall be an integral part of the pumping unit.

The pump discharge size for the Indian Creek and Visitor Center lift stations shall be 1 ¼”. The grinder unit shall be capable of shearing and reducing to a fine slurry all material normally found in domestic and commercial sewage such as sanitary napkins, disposable diapers, cloth diapers, wash rags, wood, plastic, etc. The slurry shall be capable of freely passing through a 1-1/4" piping system including check and gate valves.

Lift Station # Indian Creek & Visitor Center

Curve Number PE25/2W Flow, GPM 75 TDH, Feet 45 Motor HP 3.4 Rated speed, RPM 3564 Efficiency,% 25 Power 230V-60-1

2.2.4 PUMP CONSTRUCTION.

2.2.4.1 Self Cleaning Wear Plate. The pump shall be of the centrifugal type with the rotating cutter mounted on the pump shaft directly against the impeller. The stationary cutter shall be mounted in an adjustable bottom plate. The bottom plate shall be cast with grooves threading outward from the center opening of the plate to the outer diameter. The impeller shall be a multiple vane centrifugal type. The cutter material shall be similar to an AISI 440C stainless steel with the addition of cobalt, vanadium, and molybdenum for superior abrasion resistance and a hardness of 58-62 Rockwell C.

2.2.4.2 Impeller. The impeller shall be constructed of corrosion resistant chilled gray iron and shall be of the semi-open, non-clogging, dynamically balanced single-vane design capable of passing a minimum of 1.25-inch spherical solids. The impeller shall have a slip fit onto a shaft and drive key and shall be fastened by a stainless steel bolt.

2.2.4.3 Pump Volute. The pump volute shall be constructed of gray cast iron with smooth internal surfaces free of rough spots or flashing. The volute shall have a horizontal discharge.

2.2.4.4 O-Rings and Fasteners. All mating surfaces of the pump and motor shall be machined and fitted with BUNA-N O-Rings where water sealing is required. Sealing shall be accomplished by the proper fitting of the parts not by compression or special torque requirements.

2.2.4.5 Shaft and Bearings. The common pump and motor shaft shall be 420 stainless steel supported by a heavy duty lower single row ball bearing and an upper sealed single row ball bearing, all models. The cutting elements and impeller shall be designed to keep the overhung load distance to a minimum. All fasteners shall be 304 stainless steel.

2.2.4.6 Shaft Seals. Each pump shall be equipped with two seals. The lower seal (pump side) shall be of the mechanical type with silicon carbide faces. The upper seal shall be a lip type seal, mounted at a slight angle to the shaft

2.2.4.7 Seal Failure Warning System. An oil chamber shall separate the seals. An electronic probe shall be provided in the oil chamber to detect the leakage of water. Solid-state device mounted in the pump control panel or in a separate enclosure shall send a low voltage, low amperage signal to the probe.

If water enters the oil chamber, the probe shall activate a warning light in the control panel.

2.2.5 SUBMERSIBLE ELECTRIC MOTOR. The motor shall be air-filled and shall have Class “F” insulation. The rotor and stator shall be enclosed in a cast iron outer housing. Bi-metallic thermal switches shall be imbedded in each phase of the winding to sense high temperature. The rating of the switch shall be 130C +/- 5C. The control circuit shall be connected through the bi-metallic switches so the motor is shut down should a high temperature condition exist. The switches shall be self-resetting when the motor cools.

Power cable UL and CSA approved and shall have a minimum length of 30'. Oil filled motors are not acceptable. Single phase motors shall be of the capacitor start, capacitor run type for high starting torque.

2.2.6 GUIDE RAIL BASE AND SYSTEM

A cast iron ball check guide rail base shall be mounted on the floor of the pump station. The grinder pump shall be guided onto the cast iron discharge base by a single stainless steel guide rail supported at the top by an upper guide bracket and at the bottom by the discharge base. The pump base shall be equipped with a straightening vane, which properly aligns the pump on the discharge base just prior to the final seating.

The pump slide bracket shall include a fully ported ball check valve. The pump and check valve shall be removable from the guide rail base as a single unit. When the pump is in position, the weight of the pump shall compress the gasket and seal the connection. The area under the pump shall be free and clear of any additional support legs or guides pipes to insure free entrance of solids to the impeller. The pump guide rail shall be Schedule 40 stainless steel pipe and shall be threaded into the pump base. Pumps requiring two guide rails are not acceptable.

2.2.7 DUPLEX CONTROL PANEL.

2.2.7.1 Control Panel Requirements. It is the intent of these specifications that all motor controls and control components be supplied by a single supplier. Controls shall not be assembled on site. System supplier shall be a UL 508 certified facility and shall be regularly engaged in the manufacture of controls for the municipal water industry. A company having at least five years experience in the construction of such control equipment shall assemble the pump control panel. Specific panel specifications and control component specifications are included within these documents. Note: One additional start pack including a start capacitor with resistor, run capacitor, switching relay and a motor starter with overload shall be provided for future repairs.

2.2.7.1.1 Control Panel Installation. The Visitor Center Lift Station control panel shall be mounted on the comfort station concrete block wall in the same location as the original control panel that is being removed. Control Panel shall be anchored with approved concrete block anchors. The Indian Creek Lift Station Control Panel shall be mounted on two 6” x 6” treated posts. The bottom of both control panels shall be installed a minimum of 3 ½ feet above the surface of the ground.

2.2.7.2 Control Panel Operation. Basic operation of the pumps will be as a pump-down, lead/lag, common “off” system with high level alarm. Operation of the lag pump shall be independent from the lead pump. Panel shall accommodate connection of floats with the following functionality:

a. High Level

b. Lag Demand

c. Lead Demand

d. Stop

2.2.7.2.1 Hand-Off-Auto Switch. Each pump shall be controlled through a “Hand-Off-Auto” switch. In the Auto position, the floats in the wet-well shall control the pump. A demand for each pump shall be delayed through adjustable time delay relays with a range of .1 - 10 seconds. Initially, lead demand time delay shall be set at 8 seconds; lag time delay shall be set at 16 seconds. Operation of the lag pump shall not be run through the lead float. In the Hand position, the pump shall run continuously until the selector switch is turned to off or Auto.

2.2.7.2.2 Thermal Trip. A thermal trip via a normally closed thermal switch in the pump shall stop the pump from running in either Hand or Auto, but the pump will resume operation when the switch automatically resets.

2.2.7.2.3 Alarm Circuit. An alarm circuit shall be activated when “high level” condition occurs.

2.2.7.3 Control Panel Equipment.

2.2.7.3.1 Enclosure. Same as required in paragraph 2.1.7.3.1.

2.2.7.3.2 Power Distribution Block. The main power distribution block shall be 600 volt rated, 100-amp minimum capacity, sized for incoming power to the panel. Each pole of the block shall be supplied with a clear cover for operator protection.

2.2.7.3.3 Circuit Breakers. Individual thermal magnetic breakers shall be provided for branch disconnect service and short circuit protection of all motor and auxiliary circuits. Combination circuit breaker and overload mechanism shall not be allowed. Circuit breakers for motors and other loads shall have a minimum rating of 10,000 AIC (230-vac breakers) or 14,000 AIC (480-vac breakers). Provide two 1-pole, 15-amp circuit breakers for the following loads:

a. Control circuit

b. Panel G.F.I. receptacle

2.2.7.3.4 Contactors/Overload Relay. A magnetic across the line horsepower/current rated motor contactor with ambient temperature compensated overload relay shall be provided for each motor load served.

2.2.7.3.5 Receptacle. A 15-amp G.F.I. duplex receptacle connected to a separate circuit breaker shall be mounted on the control panel. A weatherproof guard or cover shall be installed over the receptacle.

2.2.7.3.6 Fuse holders and Fuses. A fuse for the control circuit shall be installed with a minimum rating of 5 amps (ampacity not to exceed relay contact rating). Fuse holders for control fuses shall be finger safe with neon light indication for a blown fuse.

2.2.7.3.7 Terminal Blocks. Numbered terminal blocks shall be supplied for all field terminations. Current capacity of terminal strips shall be equal to the load served. Terminal blocks shall be suitable for minimum 12 AWG wire at not less than 300 volts.

2.2.7.3.8 Time Delay Relays. Time delay relays shall be dial or D.I.P. switch selectable, and shall have contact ratings of not less than 10 amps. Switch settings shall be labeled on the relay. Note:

One additional time delay relay shall be provided for future repairs.

2.2.7.3.9 Relays. Relays shall be general purpose plug-in relays with standard mounting configurations. The relays shall have the number of poles as shown on the drawings. The units shall have neon indicating lamp and test button integral to each relay. Note: One additional relay of each type shall be provided for future repairs.

2.2.7.3.10 Alternator. Provide an automatic electronic alternator for alternating pump operation on successive automatic cycles. Relay shall incorporate LED position indicators and a toggle switch to select pump #1 or pump #2 as the lead pump, or to allow automatic alternation. Note: One additional adjustable alternator shall be provided for future repairs.

2.2.7.3.11 Selector Switches. Selector switches shall be 30 mm oil tight type with lever operators and 10 amp contacts. Knob operators will not be accepted. Contact blocks shall be provided as required and shall be rated for a nominal voltage of 500 vac and 10 amps. Provide selector switches for the following functions:

a. Pump “Hand-Off-Auto”

b. Three-position

2.2.7.3.12 Pilot Lights. Pilot lights shall be push-to-test, oil-tight industrial units utilizing 120-volt bulbs (unless otherwise specified). Lenses lens shall be colored as shown on the drawings. LED type lights will not be acceptable. Provide pilot lights for the following functions (per pump where applicable):

a. Pump Run Green

b. Pump Seal Fail Amber

c. Pump Thermal Trip Red

d. High Level Red

2.2.7.3.13 Pushbuttons. Pushbuttons shall be oil-tight industrial units. Contact blocks shall be provided as required and shall be rated for a nominal voltage of 500 vac and 10 amps. Provide push buttons for the pump thermal reset (One pushbutton resets both pumps)

2.2.7.3.14 Elapsed Time Meters. Provide an elapsed time meter for each pump controlled.

Meter shall be 6-digit, non-resettable, reading in hours and tenths of hours.

2.2.7.3.15 Seal Fail Relay. Provide a conductance actuated moisture-sensing relay for each submersible pump controlled with field adjustable sensitivity. Note: One additional seal fail relay shall be provided for future repairs.

2.2.7.3.16 Alarm Light. Provide a red strobe light mounted to the top, exterior of the enclosure. Minimum ratings shall be 1.5 Joules at 70 flashes per minute. The strobe light shall be fully sealed to prevent water from entering the enclosure and be attached by mounting screws from inside the enclosure to prevent tampering. The alarm light is to be activated by the high-level alarm float mounted in the wet-well.

2.2.7.3.17 Ground Buss/Lugs. Provide a ground lug sized for incoming power ground near the power distribution block. Provide a ground lug sized for pump ground near pump power wire terminations. Provide a ground buss for control equipment grounding, minimum 6 termination points.

2.2.7.3.18 Corrosion Inhibitor. Provide a corrosion inhibitor mounted inside the control panel.

2.2.7.3.19 Wiring. Power distribution wiring on the line side of panel fuses or circuit breakers shall be sized for the load served and be a minimum 12 AWG. Control wiring shall be minimum #16 gauge SIS type stranded wire for internal control panel circuits. All control wires shall be numbered at each termination corresponding to the master wiring diagram with clip-sleeve or heat-shrink type wire markers. Wrap-on or adhesive wire markers shall not be allowed. 120-vac wiring (except for neutrals) shall have red insulation. 120-vac neutral wiring shall have white insulation. 50-vac or less shall have yellow insulation. 12/24-vdc wiring shall have blue insulation.

2.2.7.3.20 Nameplates. Provide engraved phenolic nameplates, black letters on white background, for all internal devices such as contactors, circuit breakers, and relays; and for door-mounted devices such as selector switches, push buttons, and pilot lights. Nameplates shall be secured firmly to the panel.

2.2.8. ACCESSORIES.

2.2.8.1 Lifting Chains. Pump lifting chains shall be sized and provided by the pump manufacturer. The chain shall be sized to accommodate the installed pump weight and shall be type 304 or 316 stainless steel. The chain length shall be five feet greater than the station depth.

2.2.8.2 Float Switches. Float switches shall contain a single pole mercury switch, which activates when the longitudinal axis of the float is horizontal, and dictates when liquid level falls 1" below the actuation elevation. The casing shall be chemical resistant polypropylene and have an internal stabilizing weight. A PVC type STO, 2 - #18 AWG conductor cable shall protrude from one end of casing. One end of the cable is permanently connected to the glass enclosed mercury switch and the entire assembly is encapsulated to form a completely watertight and impact resistant unit. The electrical cable shall have a minimum length of 30'.

2.2.8.2.1 Float Switch Adjustment. The float switches shall be field adjusted to the Governments satisfaction.

2.2.8.3 Cable Holder. One (1) stainless steel cable holder constructed of type 304 SS shall be provided. Each cable holder shall have six (6) hooks and be wall mounted.

2.2.8.4 Cable Grips. The pump and float switch cables shall be hung from their hooks with “Kellum” strain relief grips.

2.2.9 ANCHOR BOLTS AND HARDWARE. New anchor hardware consisting of expansion or adhesive anchors shall be used.

2.2.9…