SECTION SLUDGE HOLDING TANK DECANTER PUMP

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1 PART 1 GENERAL 1.01 SCOPE OF WORK A. The Contractor shall furnish and install all materials, labor and equipment to put into service the Sludge Holding Tank Decanter Pumping System in accordance with the Contract Drawings and these Specifications. B. Each pump shall be furnished complete with all accessories, pump guide rails, special tools, spare parts, base attachments mountings, anchor bolts, control panels, controls, wiring, wiring connections (except power supply) and others appurtenances as specified that may be required for a satisfactory and complete installation. C. The term system shall be defined as any functional grouping of pumps with the same design conditions RELATED WORK A. Division 16, Electrical General Provisions. B. Section 16220, Electric motors. C. Section 09900, Painting. D. Division 15, Piping and valves REFERENCED STANDARDS A. National Electric Code (NEC) B. American Society for Testing and Materials (ASTM) A SUBMITTALS A. Submittals shall be in accordance with Section B. Shop Drawings 1. Shop Drawings shall include, but not be limited to: a. Equipment specifications and data sheets identifying all materials used and methods of fabrication. b. Complete assembly, layout, installation and foundation drawings with clearly marked dimensions. HERITAGE GARDENS STP

2 C. Test Report c. Pump characteristic curves. d. Motor nameplate data. e. Assembled weight of units and approximate total shipping weight. f. Sample equipment nameplate data sheet. g. List of recommended lubricants. The manufacturer shall submit a list with a minimum of four manufacturer s standard lubricants, which may be used interchangeably for each type of lubricant required. The contractor shall utilize this list in preparing his comprehensive lubrication survey as specified in Division 1. h. List of special tools and spare parts. i. Manufacturer s or distributor s name, address, and telephone number. Eight (8) certified copies of the test reports shall be furnished to the Engineer. These reports shall include a pump and motor speed torque curve. D. Operations and Maintenance Manuals The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements of the applicable section of Division 1. Two (2) copies of a preliminary O&M manual shall be included in the shop drawing submittal. Without inclusion of these manuals, the submittal will be considered incomplete and will be returned without review. E. Equipment Warranty 1.05 COORDINATION All equipment shall have a two (2) year warranty effective the date of acceptance by the Owner. Warranty shall cover defects in material and workmanship. A. The Contractor shall be responsible for supplying the Electrical Contractor with complete electrical specifications for the pump motors. These electrical specifications shall be supplied in a timely manner and transmitted to the electrical contractor. The General Contractor shall insure the proper installation of complete pumping systems furnished by the pump manufacturer(s) as well as the storage and handling of all the equipment furnished under this section. The contractor shall coordinate the storage of the equipment with the owner. The general contractor shall install all pumping systems in accordance with the requirements of the pump manufacturer and shall be responsible for proper installation of the guide pipes and upper guide brackets, lifting chain and cable holders in the submersible pump stations. HERITAGE GARDENS STP

3 1.06 QUALITY ASSURANCE A. Manufacturer s Qualifications The equipment covered by these Specifications is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed and installed in accordance with the best practices of the trade and shall be operated satisfactorily when installed as shown in the contract drawings. All submersible pumps of the same type shall be furnished by the same manufacturer. Equipment manufacturers shall have a minimum of five (5) years experience in manufacturing these types of equipment. B. Manufacturer s Responsibilities The submersible pump manufacturer(s) shall furnish a complete pump system including the discharge connection elbow with the anchor bolts, lifting handle, sliding bar guides and brackets, stainless steel lifting cable and power cable long enough to allow removal of the submersible pump from the sludge tank and any piping and fittings required to install the pump with the connecting pipe discharge as shown in the contract drawings. Pump manufacturer shall be responsible for furnishing the following: 1. Submersible pump and motor complete with the above-indicated appurtenances. 2. Float switches as required to accomplish specified pump system operation. In addition, the pump manufacturer(s) shall furnish: All items specified under subsection 1.03, Submittals. Shop testing. Tools and spare parts. C. Quality Control Before the pumping equipment is shipped, shop running and acceptance tests shall be made by the manufacturer and certified curves shall be submitted as specified in Division 1. Reports of shop tests shall be submitted prior to shipment. The running tests shall consist of standard IEEE tests of motors, operation of pumps and motors for proper balance of equipment, and all other requirements as specified under this section. In his submittal the manufacturer for pumps with motors 7.5 Hp and above shall submit information which fully describes the manufacturer s testing facilities. The Engineer reserves the right to inspect the manufacturer s testing facilities. The Contractor shall give at least 10 days notice of such tests and the Owner reserves the right to have a representative present when shop acceptance tests are run. In case of failure of any unit HERITAGE GARDENS STP

4 to meet the test requirements, the manufacturer shall make such alterations as are necessary, and the tests shall be repeated, without additional costs to the owner, until the equipment is satisfactory. 1. Submersible pump tests. In addition to the above, the submersible pump manufacturer shall perform the following inspections and tests on each pump before shipment from factory. a. Impeller, motor rating and electrical connections shall first be checked for compliance with the customer s purchase order. b. A motor and cable insulation test for moisture content or insulation defects shall be made. c. Prior to submergence, the pump shall be run dry to establish correct rotation and mechanical integrity. d. The pump shall be submerged. e. After operational test (d), the insulation test (b) is to be performed again. Pumping running tests shall conform to standards of the Hydraulic Institute with the pumps tested at rated full speed for at least six (6) points on the entire pump characteristic curve including the specified operating conditions of head and capacity, shutoff and runout. The standards of the Hydraulic Institute shall govern all procedures and computations for the tests. The pumps shall be tested with job motors or a job variable speed drive in case of variable speed systems. For the latter, running tests shall be made for the specified range of conditions. A written report signed by an officer of the company, stating that the foregoing steps have been done shall be supplied with each pump at the time of shipment PRODUCT DELIVERY, STORAGE AND HANDLING A. The Contractor shall deliver, handle and store the equipment furnished under this Section in compliance with the instructions of the equipment manufacturer and as outlined in Section B. The Owner shall approve any equipment storage at the plant site before the equipment is delivered to the plant. PART 2 - PRODUCTS 2.01 SLUDGE DECANTER PUMP HERITAGE GARDENS STP

5 A. General 1. A centrifugal submersible grinder/chopper pump(s) designed to reduce all material found in normal domestic and light industrial sewage, including plastics, rubber, sanitary napkins and disposable diapers into a finely ground slurry. The pump(s) shall be capable of pumping liquid with a continuous temperature of 104 degree F, and intermittent temperature of 160 degree F. The pump(s) shall be capable of running dry for extended period of time. 2. The pump(s) shall have a 1.25-inch horizontal national pipe thread discharge fitting. 3. The pump(s) shall be designed to operate on 208 volt, 3 phase, 60 cycle power. 4. The pumps provided shall meet the requirements outlined in Schedule , which is found at the end of the Section. 5. Acceptable manufactures of the pumps shall be: a. Barnes Pumps Inc. b. Or equal B. Pump Construction 1. The volute, seal plates, impeller and motor housing shall be constructed of high quality ASTM A-48 class 30 cast iron with a bronze wearing ring. 2. Pump(s) shall be painted with a water based air dry enamel of 2.0 mils minimum thickness. All painting shall be in accordance with Section 09900, Painting. 3. All exposed hardware shall be 300 series stainless steel. No exceptions will be allowed. 4. The pump construction shall contain no points of critical clearances nor require periodic adjustment or replacement to maintain reasonable operating efficiency. 5. The pump discharge connection shall be a standard 1-1/4 NPT in the horizontal position. A 1-1/4 NPT to 2 quick connect coupling shall be provided. 6. All gaskets provided shall be of the o-ring type. 7. The pump lifting handle shall be constructed of stainless steel. C. Cutting Mechanism 1. The cutting mechanism shall consist of a cutter bar, abrader and a wear plate. 2. The cutter bar and abrader shall rotate with the motor shaft and provide two stage cutting against the wear plate. HERITAGE GARDENS STP

6 3. The wear plate shall have micrometer adjustment eliminating the need for shims. 4. All cutter parts shall be 300 series stainless steel hardened to a minimum Rockwell C The pump shall be capable of operating in either rotational direction. The pump shall be capable of automatically reversing direction in the case of a locked rotor condition, while maintaining consistent hydraulic performance. D. Impeller 1. The pump impeller shall be constructed of ductile iron hardened to a minimum Rockwell C-55. It shall be designed to offer thirty (30) degree discharge flow, reducing clogging and allowing high efficiency. E. Mechanical Shaft Seal F. Motor 1. The unit shall utilize a single mechanical shaft seal, which will operate in an oil atmosphere. 2. The materials of construction shall be carbon for the rotating face and ceramic for the stationary face, lapped and polished, to a tolerance of one light band, 300 series stainless steel hardware, and all elastomer parts to be of Buna-N. 3. A secondary Buna-N lip seal shall be provided between the mechanical seal and the pumped fluid. The seal shall be commercially available and not a proprietary design of the pump manufacturer. 1. The motor shall meet the requirements of Section 16220, Electric Motors. 2. Single-phase motors shall be of the capacitor start, capacitor run design. Three phase motors shall be of the dual voltage 120/208 design. 3. The motor shall be designed to be non-overloading throughout the entire pump curve. 4. The pump and motor shall be designed for installation in water or sewage. 5. The rotor and stator assembly shall be of the standard frame design and secured to the pump seal plate by four threaded fasteners allowing for easy serviceability. Motor designs incorporating shrink or press fit assembly between the stator and motor housing shall not be acceptable. 6. The motor shall be constructed with the winding operating in a sealed environment containing clean dielectric oil, making it capable of operating in a totally, partially or non-submerged conditions for extended periods of time without damage due to the heat being generated. Air-filled motors shall not be acceptable. HERITAGE GARDENS STP

7 G. Sensor 7. The motor windings shall be of Class B insulation. The motor shall meet the standard NEMA Design L for single phase and NEMA Design B for three phase. 8. The motor shaft be 416 stainless steel. 9. The lower bearing seal shall be of the single ball type to accept radial and thrust loads, and the upper bearing of the sleeve design for radial loads. Bearings shall operate in an oil bath atmosphere for superior life. Permanently lubricated bearings are not acceptable. 1. Two moisture-sensing probes shall be used to detect any influx of liquid past the outer seal and provide ample warning to the first seal failure. 2. Thermal sensors shall be equipped with a thermal switch embedded in the end coil of the stator winding. This shall be used in conjunction with and supplemental to external motor overload protection and wired to the control panel. H. Power Cable 1. The pump shall be equipped with 30 feet of type SOW submersible power and control cable. 2. Heat shrink tubes shall be used to connect the power cord leads with the motor leads. A master heat shrink tube shall be provided and filled with epoxy to seal the outer cable jacket and the individual strands to prevent water from entering the motor housing. 3. A secondary rubber pressure grommet shall be provided as an additional sealing point and strain relief at the point of cable entry. 4. Cable entry designs utilizing terminal boards to connect power cord leads with motor leads shall not be acceptable. I. Pump Test 1. The pump manufacturer shall perform the following inspections and tests in accordance with Hydraulic Institute Type B standards before shipment from the factory: c. A check of the motor voltage and frequency shall be made as shown on the nameplate. d. A motor and cable inspection test for moisture content or insulation defects shall be made per UL criteria. e. The pump shall be completely submerged and run to determine that the unit meets three pre-determined hydraulic performance points. HERITAGE GARDENS STP

8 E. Accessories 2.02 CONTROLS f. A written report shall be available showing the aforementioned tests have been performed in accordance with the specifications. 1. Each unit shall be fitted with forty feet (40') of stainless steel lifting cable of adequate strength to permit raising and lowering the pump. 2. Each pump shall be supplied with thirty feet (30 ) of 3 rigid discharge hose with quick connect couplings meeting the requirements of the Engineer. 1. A portable hoist meeting the requirements of Section shall be supplied with each pump. 4. The last five feet of the force main shall be constructed of transparent polyetheline plastic pipe with fiberglass reinforcement for ease of monitoring the turbidity of the supernatant of the sludge A. Furnish and install one (1) manual duplex control panel in a NEMA-4X stainless steel enclosure with quick operating latches. The panel shall be operated that each tank operated as an independent system. An alarm condition in one tank shall not prevent the operation of the pump in the other tank. Enclosure panels shall be provided with door stop kits to secure the outer door in the open position. B. Control panel shall operate on 208 Volts, 3 Phase, 60 Hz power. C. The following components shall be included in the control panel: 1. Main disconnect switch with externally operated handle. 2. Combination NEMA rated motor starters, one per pump, including MCP type circuit breaker, contactor, and properly sized three phase thermal overload protection with resets. 3. Machine tool type transformer for 110 V control power. It shall be fused on the load side. 4. Relays, one per pump, to detect pump seal failure and overtemperature. 5. Thermostatically controlled panel heater to provide condensation protection. 6. One set of start-stop pushbuttons. 7. Adjustable timers (0-120 min) shall be provided in each pump s run circuit to stop the pump after the preset time in the event that no stop pushbutton is pressed in that time. 8. One white power on indicating light. 9. One motor run indicating light. HERITAGE GARDENS STP

9 2.03 LEVEL SENSORS 10. One running time meter. 11. One seal fail indicating light. 12. One pump over temperature light. 13. One common alarm horn and strobe light activated by any alarm condition. 14. One high level alarm lights activated by float switches to be furnished by pump manufacturer and installed by the contractor. 15. One GFCI convenience outlet protected by a 20A circuit breaker. 16. One alarm reset button. 17. Each float sensor assembly (pump off, pump on, high water level) should operate independent of each other. A. Provide one (1) sets of three (3) mercury filled polypropylene level sensor per tank (6 floats total), with thirty (30) foot cable for connection to the control panel. B. The level sensor shall serve as pump off, pump on and high water level. PART 3 EXECUTION 3.01 INSTALLATION A. All equipment supplied under this Section shall be installed in conformity with manufacturers recommendations and in locations shown on the Contract Drawings. B. The Contractor shall provide coordination with the Electrical Contractor to avoid any conflicts with electrical codes and regulations which could adversely affect the installation. C. The Contractor shall provide piping and valving as required to install a complete pumping system package. D. One pump shall be installed within each Sludge Holding Tank. The pump shall be suspended in the tank using a portable hoist, such that the operator can manually raise and lower the pump to accomplish decanting. HERITAGE GARDENS STP

10 3.02 START-UP A. A qualified representative of the manufacturer shall test the pump(s) at start-up. A startup report as provided by the manufacturer shall be completed before final acceptance of the pump(s) FIELD TESTING A. Field tests shall conform to the applicable sections of Division 1, including preliminary and final field tests. B. The Contractor shall field test all pumping systems specified under this Section. C. Operational tests shall include checking of the operation of all pumps and controls, including all alarms, safety interlocks, status signals etc. D. Under no circumstances are any portions of the drive system to be energized without authorization from the manufacturer s representative. SCHEDULE SUBMERSIBLE PUMP SCHEDULE Pump Name Quantity Location Sludge Holding Tank Decanter Pump Spare Sludge Holding Tank General Information Fluid Pumped Sludge Temperature Ambient Size of Solids (spherical dia. inches) N/A Minimum Discharge Connection (pump) 1.25 Primary Design Point Capacity (gpm) 25 GPM Total Dynamic Head 25 Pump Speed (rpm) 3450 Impeller Type Grinder/Chopper Minimum Horsepower 2 END OF SECTION HERITAGE GARDENS STP