SECTION INFLUENT EQUALIZATION TANK PUMPS

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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 Influent Equalization Pumps 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 other 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 shall include, but not be limited to: 1. Equipment specifications and data sheets identifying all materials used and methods of fabrication. 2. Complete assembly, layout, installation and foundation drawings with clearly marked dimensions. 3. Pump characteristic curves. TALL OAKS STP

2 4. Motor nameplate data. 5. Assembled weight of units and approximate total shipping weight. 6. Sample equipment nameplate data sheet. 7. List of recommended lubricants. The manufacturer shall submit a list with a minimum of four manufacturer s standards 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 List of special tools and spare parts. 9. Manufacturer s (or distributor s) name, address, and telephone number. C. Test Report 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 from zero to 100 percent full load speed for the variable speed pump systems. D. Operation 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 All equipment shall have a two (2) year warranty effective the date of acceptance by the regulatory agency and the Owner. Warranty shall cover defects in material and workmanship COORDINATION 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. TALL OAKS 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 on the contract drawings. All submersible pumps 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 wet well, and any piping fittings required to install the pump with the connecting pipe discharge as shown on the contract drawings. The pump manufacturer of the variable speed submersible pumps shall be responsible for furnishing the following. 1. Submersible pump and motor complete with the above-indicated appurtenances. 2. A portable hoist and associated hoist bases for the pumps station as shown on the contract drawings. 3. A complete set of electrical specifications for the pump motors. Pump manufacturer furnishing any of the constant speed submersible pumps 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: 1. All items specified under subsection 1.04, Submittals. 2. Shop testing. 3. 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 TALL OAKS STP

4 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 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 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. In addition to the above, the submersible pump manufacturer shall perform the following inspections and tests on each pump before shipment from factory. 1. Impeller, motor rating and electrical connections shall first be checked for compliance with the customer s purchase order. 2. A motor and cable insulation test for moisture content or insulation defects shall be made. 3. Prior to submergence, the pump shall be run dry to establish correct rotation and mechanical integrity. 4. The pump shall be submerged. 5. After operational test (4), the insulation test (2) is to be performed again. Pump 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. TALL OAKS STP

5 PART 2 - PRODUCTS 2.01 INFLUENT EQUALIZATION PUMPS A. General 1. Each pump shall be capable of handling raw unscreened domestic sewage consisting of water, fibrous materials, and 2 inch diameter spherical solids. The pump(s) shall be capable of handling liquids with temperature to 104 degree F continuous and shall be capable of running dry for extended periods. 2. The pump(s) shall have a 2 inch discharge. 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., Piqua, Ohio. b. ITT Flygt Corporation, Trumbell, Ct. c. 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. 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 125 pound, 2 inch flange. 6. All gaskets provided shall be of the o-ring type. C. Impeller 1. The impeller shall be of the non-clog design with pump out vanes on the backside. 2. The impeller shall be dynamically balanced to ISO G6.3 specifications. TALL OAKS STP

6 3. The impeller shall be constructed of ASTMA-48 Class 30 Cast Iron. D. Motor 1. The motor shall meet the requirements of Section 16220, Electric Motors. 2. The motor shall be designed to be non-overloading throughout the entire pump curve. 3. The pump and motor shall be listed with Underwriters Laboratories as Class I, Group C and D, Division 1, explosion-proof, for installation in water or sewage. 4. All electrical parts shall be housed in an air-filled, cast iron, water-tight structure enclosure. The enclosure shall be sealed by the use of o-rings and shall have rabbet joints with a large overlap. 5. The motor shaft extension and all external hardware shall be stainless steel. 6. The motor windings shall have Class F insulation system minimum and a 1.15 service factor. 7. Shaft seals shall be of a tandem design and operate in an oil filled enclosure. The seal materials shall be carbon for the rotating faces and ceramic for the stationary faces, lapped and polished to a tolerance of one light band, 300 series stainless steel hardware, and all elastomer parts to be of Buna-N. E. Sensor 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. F. Power Cable 1. The pump shall be equipped with 40 feet of submersible cable. All incoming lead wires shall be spliced in the motor terminal housing. After splicing, the terminal housing shall be filled with epoxy to seal the outer cable jacket and the individual strands to prevent water from entering the motor housing. 2. A secondary rubber pressure grommet shall be provided as an additional sealing point and strain relief at the point of cable entry. G. 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: TALL OAKS STP

7 H. Accessories a. A check of the motor voltage and frequency shall be made as shown on the nameplate. b. A motor and cable inspection test for moisture content or insulation defects shall be made per UL criteria. c. The pump shall be completely submerged and run to determine that the unit meets three pre-determined hydraulic performance points. d. 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 chain of adequate strength to permit raising and lowering the pump SLIDING GUIDE BRACKET A. A sliding guide bracket shall be an integral part of the unit and the pump casing shall have a machined angle connection with yoke to connect with cast iron discharge connection. B. There shall be provided a cast iron discharge connection, which shall be bolted to the floor of the pump pit and so designed as to receive the movable connection without the need of any bolts or nuts. The pump shall bolt to the moveable bronze section, which is free to ride up and down the guide rails. A complete and positive seal shall be assured and shall operate without hydraulic leakage, over a wide range of discharge pressures. The pump connection shall be non-sparking BREAK AWAY FITTING A. The stationary portion of the Break Away Fitting (BAF) shall be a specially designed cast iron elbow, which is to be bolted to the floor of the wet well. B. The pump bolts to the bronze moveable portion of the BAF, which is free to ride up and down on the guide rails. C. The BAF shall be provided with an O-Ring, which shall be pressed into a dovetailed groove on the tapered face of the movable portion of the BAF. The tapered faces of the movable and base elbow shall provide a positive mating of the O-Ring to the base. This elastomer to cast iron contact shall ensure a complete and positive seal, which will allow the pump to operate without hydraulic leakage, over a wide range of discharge pressures. D. The mating parts shall allow a Non-Sparking joint which is required in hazardous locations. TALL OAKS STP

8 2.04 GUIDE RAILS A. The guide rails shall attach to the base elbow of the Break Away Fitting at one end and to a stainless steel guide cap on the other. The guide cap shall attach to the underside of the wet well cover. B. Both the guide cap assembly and the base elbow shall have cast iron plugs with O-rings mounted in them which aid in locating the guide rails and in reducing noise and vibration of the guide rails C. The guide rails shall serve only to guide; they shall not carry any of the pump weight. D. 2 inch diameter stainless steel schedule 40 pipe shall be used for the guide rails. E. An intermediate guide pipe bracket shall be used for all depths greater than 13 feet CONTROL PANEL A. Furnish and install an automatic duplex pump control panel in a NEMA 4X stainless steel enclosure with quick operating latches for 208 volt, 3 phase, 60 cycle, 3 wire power supply. B. Each pump motor will be supplied with a circuit breaker and an across the line NEMA rated motor starter with three phase overload protection. C. The panel will provide lead-lag auto alternation and high and low water alarms (visual and audible). D. The panel will include Hand-Off-Auto selector switches to control the operation of each pump, as well as a pump sequence selector switch to override automatic alternation. E. The level control system shall float control, using one of two sets of float tree. Each influent equalization tank shall contain a float tree. A selector switch shall be provided to select which float tree will be used to control level. F. Panel shall include a GFCI convenience receptacle protected by a 2OA CB and a thermostatically controlled heater for condensation protection. G. Panel shall include a main disconnect with externally operable handle. H. Two running time meters shall be supplied, one for each pump. The control panel shall be constructed that a low level alarm condition will sound the audible and visual alarm but will allow the pumps to continue to operate until the alarm condition has been cleared. I. The control panel shall contain a white power on light to indicate power to the control circuits. TALL OAKS STP

9 J. The panel shall include two Flygt Corp. C.A.S. relays, one per pump, to detect pump seal failure and overtemperature. K. Enclosure panels shall be provided with door stop kits to secure the outer door in the open position. L. The control panel shall be constructed that a low level alarm condition will sound the audible and visual alarm but will allow the pumps to continue to operate until the alarm condition has been cleared LEVEL SENSORS A. Provide two (2) sets of six (6) mercury filled polypropylene level sensor per tank (12 floats total), with forty (40) foot cable for connection to the control panel. Floats shall be provided with intrinsically safe relays. B. The levels sensor shall serve as low water level, pump off, lead pump on, lag pump off, lag 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 START-UP A. A qualified representative of the manufacturer shall test the pump(s) at start-up. A start-up 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. TALL OAKS STP

10 C. Operational tests shall include checking the operation of all pumps and controls including all alarms, safety interlocks, status signals, etc. D. Testing checkout and start-up of the adjustable frequency controller equipment (if applicable) shall be performed under the technical direction of the manufacturer s service engineer. E. 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 Influent Equalization Pumps Spare Influent EqualizationTank General Information Fluid Pumped Suspended Solids Concentration Temperature Size of Solids (spherical dia. inches) 1 Minimum Discharge Elbow Connection Screened Municipal Wastewater 320 MG/L Ambient 2 diameter Primary Design Point Capacity (gpm) 29 GPM Total Dynamic Head (feet) 25 FT. Minimum Pump Efficiency (%) 47.6 % Pump Speed (rpm) 3345 RPM Minimum Horsepower 1.8 HP Impeller Type Seal Type Non-clog / Self-cleaning N/A END OF SECTION TALL OAKS STP

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