SPECIAL SPECIFICATION. Automatic Pump Station

Transcription

1 2004 Specifications CSJ SPECIAL SPECIFICATION 5182 Automatic Pump Station 1. Description. Construct a pump station near Station of Ramp E of the Inner Loop Interchange (US 54 to Loop 375). This pump station compliments storm water systems of Airport Road depression. The construction drawings shall be complete with a functional, operation, and fully automatic pump station, consisting of the following items: Stormwater Pumps with Control Panel Electrical Systems Water Level Control System 2. Submittals. A. Submittal of Equipment, Materials and Details The Engineer shall approve the following Items A. thru G. prior to their use on this project. The submittal shall include 8 copies of each with each copy bound in a durable flexible back binder and containing a table of contents. (Large drawings may be submitted separate from the bonder). 1. Pumps Certified performance curves for pumps, complete electrical characteristics of motors and installation details. 2. Electrical Certified manufacturer s outline dimensioned drawings, brochures and descriptive bulletins of all equipment to be used. The submittal shall also include scaled layouts of all switchgear, and shop prints for all fabricated items. All components shall have UL labels and certification and overall panel shall have the FM Approved Mark. 3. Pump Columns Detailed fabrication drawings. 4. Control Panel As called for in this specification with installation Details. 5. Detailed Shop Drawings All fabricated equipment and fixtures. 6. Pipe, Couplings, Valves, etc. Manufacturers brochures and specifications. 7. Combination High Water and Pump Failure Alarm Manufacturers brochures and installation diagrams. B. Approval Upon approval of the above items, the Contractor may proceed with construction of the pump station or any portion thereof pertaining to approved items

2 Where an approved item requires dimensional changes or alterations of the project plans, the Contractor shall, at his own expense, prepare the necessary drawings and submit 8 copies of same to the Engineer for approval. Upon approval, the Contractor may proceed with that portion of the pump station affected by the change. The list of equipment of shop drawings can not change once approved, unless with Engineer s written authorization. Such equipment and drawings approved shall constitute final plans for construction of the pump station. Approval shall, in no way, relieve the Contractor or equipment suppliers of any responsibilities described elsewhere in these specifications. C. Operation Manuals Upon completing installation of all equipment to be used in this station and prior to final acceptance of this project, the Contractor shall furnish the Engineer 3 books each containing the following. All portion of data required for approval of above items A through G in section 2 Submittal. All drawings shall be as built. Include complete lubrication, operation manual, service, maintenance instructions and parts list. Complete sequence and description in full of operation instructions, noting all precautions. Parts list for each item of mechanical and electrical equipment. Bound copies of warranties and guarantees with dates of expiration, also names and addresses of persons providing warranties and guarantees. Diagram Contractor shall furnish electrical circuit diagram(s), laminated with clear plastic, showing in detail each circuit of all control devices with each wire individually numbered. The diagram(s) shall be properly sized for placing in the control panel. The Engineer shall approve the laminated diagram(s) before Contractor places it. 3. Construction. A. Civil. 1. Concrete shall be in accordance with Item 421, Hydraulic Cement Concrete, Class C. Non-shrinkable grout, where specified, shall conform to ASTM C827, and shall have a specified compressive strength at 28 days of 5000 psi. The reinforcing and detailing of concrete reinforcement bars and accessories shall conform to Item 440, Reinforcing Steel, ASTM a 615, Grade 60. The pump station shall be constructed in accordance with Item 420, Concrete Structures

3 The reinforcement designated as continuous shall lap in accordance with Item 440, Reinforcing Steel. The reinforcement bar splices in grade beams shall be located at the centerline of supports for bottom bars and at mid-span for top bars. The Contractor shall provide standard hooks for top and bottom bars at discontinuous ends of all grade beams. 2. Caisson The Contractor has the option of using caisson method for construction of the pump station or an alternate method. The Contractor shall submit any proposed alternate method for approval prior to construction. The caisson segments may be fabricated at the site within the right-of-way or may be deliver fabricated to the site. Excavate shaft to the line and grade as shown on the drawings for subsequent installation of inlet and discharge pipes. The contractor shall take extreme care to prevent tilting the caisson. The caisson shall not be more than 2 in. off center. The Contractor may use cutting edge and/or lubricate outside walls by bentonite slurry to sink the caisson. Provide ground water control and drainage from the shaft when work is in progress. The Contractor shall direct surface water runoff away from the caisson. A seal slab shall be installed immediately as the final depth is reached. Any over excavation or annular space or slurry outside the concrete wall shall be backfilled with cement grout injected through a grout pipe by pressure pumping. The Contractor shall adhere to OSHA requirements for the construction of caisson. 3. Structural Steel for ump Station The structural steel rolled shapes and plates shall conform to, Item 442, meeting requirements ASTM A36, and all structural steel shall be hot-dip galvanized. B. Electrical. Expansion anchors shall be stainless steel as shown on drawings and the expansion anchors shall be installed in accordance with the manufacturer s recommendations. All structural steel detailing, fabrication and erection shall conform to Item 441, Steel Structures. All electrical work shall be done in accordance with all applicable codes, standards and ordinance. A licensed master electrician shall directly supervise the Contractor forces. The master electrician shall be licensed in a Texas City with population of 100,000 or larger. The Contractor shall provide master electrician to certify all electrical submittals. All persons performing electrical work shall have appropriate electrical license. The Contractor shall also provide the Engineer with documentation that proves the Contractor has a minimum of 5 years experience and is qualified in this type and scope of work. The Contractor shall provide all necessary equipment, materials and labor to provide a

4 complete electrical system as shown in the plans and described in the specifications at the direction of the Engineer. Electrical service installation shall be as shown in the plans and as required by the electrical utility company. Contractor shall provide any temporary electrical necessary for construction of pumping station. This shall include dewatering. The Contractor shall provide electricians to make necessary connections of the portable load banks to the load lugs of the generator so that the required generator set testing can be performed. C. Stormwater Pumps. 1. Pump Station Equipment. The Contractor shall provide on lot of Flygt, or equal, pump station equipment with rated flow of 1000 gpm at 23.4 feet TDH. The pumps shall be electric submersible axial flow type. Motors shall meet NEMA standards and shall have minimum power factor of.81 at any load and shall not exceed unity. The lot shall include as minimum the following equipment / services: 2-Flygt NL , 10 hp, 3ph-60hz-460 VAC, 1750 rpm, 50ft. cable 2-Flygt FLS Leakage Sensors 2-Flygt Mini Gas Relays (mounted in duplex control panel) 2-Relays for monitoring pump failure. 2-Discharge Columns, 20 diameter x 30.5 ft. long 1-SS Cable Holder 2-12 Flap Gates 1-Duplex Pump Control Panel, NEMA 4X, SS Painted Steel, 3ph-60hz-460 VAC 4-Flygt Level Sensors, 40 long cable each 2-Aluminum Access 42 x 42 Cover for 20 diameter column 2-SS Chains with SS Shackles 2-SS Cable Grips to hold power cables 1-start Up Assistance & Training by Supplier 1 set of Submittals and O&M/Parts Manuals The pumps shall be electric submersible axial flow type. Motors shall meet NEMA standards. Each pump shall be equipped with moisture sensor and high stator temperature sensor. Moisture sensor shall turn on the alarm light in motor starter section that must be manually reset, but not inhibit pump operation. Stator high temperature sensor shall disable pump until manually reset. The pumps shall be complete with all accessories required for operation as described herein. All storm water pumps shall be the product of one manufacturer and shall be identical. Power monitoring and control cables shall be heavy duty haypalon jacketed submersible type. Experienced pump installation personnel or qualified representative of the pump manufacturer shall supervise the installation of the pumps. 2. Pump Performance

5 The electric motors for the storm water pumps shall not exceed 10 H.P., 460V, 3 Phase, 60HZ. Motors shall have a NEMA design B rating or better with moistureresistant calls F insulation and a locked rotor starting current rating of code F maximum. Pumps shall deliver 1000 GPM at T.D.H. of 23.4 ft. The pumps shall operate satisfactorily between ft. and 23.4 ft. of head. 3. Pump Construction. a. Casing shall be fine grain cast iron with sooth surface; ASTM a 48 Class 35 minimum. No exceptions. All exposed nuts and bolts shall be of AISI type 304 SS or brass construction. b. The design depth for continuous submergence of casing seals is 65 ft. c. Wear ring shall provide seal between impeller and volute. d. Pump and motor shaft shall be the same unit. The pump shaft is an extension of the motor shaft. Couplings shall not be acceptable. The shaft shall be AISI type 431 stainless steel or 316 stainless steel. Other shaft materials are not acceptable with or without shaft sleeves. Shaft seal shall be tandem mechanical rotating type running in oil. Seal wear rings shall have characteristics of tungsten carbide. e. Seals shall be capable of sealing pressure equal to 65 ft. of head. f. The impeller shall be of gray cast iron, Class 35B, dynamically balanced, semiopen, multi-vane, back-swept, non-clog design. The impeller vane leading edges shall be mechanically self-cleaned upon each rotation as they pass across a spiral groove located on the volute suction which shall keep them clear of debris, maintaining an unobstructed leading edge. The impeller(s) vanes shall have screw-shaped leading edges that are hardened to Rc45 and shall be capable of handling solids, fibrous materials, heavy sludge and other matter found in storm water. The screw shape of the impeller inlet shall provide an inducing effect for the handling of rag-laden storm water. Impellers shall be locked to the shaft and shall be coated with alkyd resin primer. g. The pump volute shall be of A48 class 35B gray cast iron and shall have integral spiral shaped cast grooves at the suction of the volute. The internal volute bottom or insert ring shall provide effective sealing between the pump volute and the multi-vane, semi-open impeller. The sharp spiral grooves shall provide the shearing edges across which each impeller vane leading edge shall cross during its rotating in order to remain unobstructed. The clearance between the internal volute bottom and the impeller leading edges shall be adjustable. h. Pump shall be capable of being run dry without damage. i. Pump shall be drop-in type removable from surface leaving column in place. j. The pump manufacturer shall submit to the Engineer for his approval, certified test results stating that pumps will operate as required, in column supplied and as installed. 4. Pump Retrieval System. The pump design shall incorporate the pump retrieval System. This design shall allow the lifting cable from the pump to lower and lift the pumps easily. 5. Stormwater Pump Discharge Line

6 a. Steel pipe 12 x.375 w. Per ASTM A 53 Type E. Grade A or B, API-5L or equal. b. Pipe Coupling, straight 12 in., steel pipe plain end to plain end steel pipe without pipe stop, with grade 30 gasket, high strength bolts and nuts, shopcoat finish, as manufactured by Dresser, Rockwell, or equal. c. Flanges 12 mechanical joint type for steel pipe, ductile iron ASTM A536, grade , drilled to ANSI B16.5 class 150, set screw restrained, mechanical joint type gasket (buna-s). d. T-bolt Hinged Closure - shall be carbon steel and have a semi ellipsoidal head hinged to a matching hub prepared for welding to the pipe column, and a suitable number of T-bolts. Must be quickly and easily opened with cover swung back on its hinges to allow complete and unrestricted access. T-bolts are to be supplied with attached break-over wrenches. Closure shall be hot dip galvanized with proper pipe coupling(s) for pump cables welded in place. D. Pump Control System. 1. Control System Equipment The duplex pump control system shall be of the ultrasonic Non-contact Level type transmitter incorporating sensors as the level sensing and signal control device. The control panel shall be provided by the pump manufacturer. The factory assembled system shall include: a. Duplex full voltage 460V, 3ph, 60hz. Full Voltage starters with alternating lead at each cycle. b. The level detector shall be ultrasonic, Magnetrol Echotel Model 344 System with transducer Model 384, with 10: insertion and with a 2 process connection or equal. c. NEMA 4X SS Enclosure d VAC control transformer with capacity to include 500 W 120V lighting controls e. Furnish 4-15A 120 V circuit breakers within Pump Control Penal f. Login Controls Chassis g. Logic Panel h. Alarms and sensors as specified herein i. Two year warranty on all components 2. Control System Operation he control system shall provide total automatic control for 2 electric motor driven pumps at 10 horsepower, 460 volt, 3 phase, and 3 wire. The pump station level shall be monitored and controlled as follows: Level 4 High Level Alarm Level 3 - Start Lag pump Level 2 Start Lead Pump Level 1 Stop Lead and Lag pumps Contingent upon the wet well level, the liquid level sensors shall energize the appropriate control contacts. The water level control system for the storm-water

7 pumps shall consist of Ultrasonic Non-Contact Transmitters for level, installed to form a complete level control system. The pump start and stop settings will be as shown on the plans or as directed by the Engineer. All components required shall be as follows: a. Sensors shall be sealed Ultrasonic Non-Contact supply voltage 120VAC, 60Hz and output signal 4-20 ma isolated (1,000 Ώ load). The controls shall have adequate number of poles to perform functions required. b. Control relays shall be industrial type: Square D Type X, General Electric Class CR122B, or equal. The time delay relays shall be pneumatic type manufactured by Square D Class 9050 Type B, Allen Bradley Bulletin 700 ACNPT or equal. c. The control system shall perform the following functions in addition to the functions necessary to make the pumping station fully automatic. 1) Pumps shall automatically alternate as the lead pump at every cycle. 2) Provide time delay for every pump. 3) Stop all motors completely, allow 20 sec before transfer. 4) Provide a switch to turn flashing light off manually. Labeled Acknowledge and AUTO (Acknowledge momentary contact with spring return to Auto position). 5) Provide manually a reset for high water level alarm initiated by ultrasonic level detection, all indication and alarm lights shall have push to test button. 6) Provide a control relay for the flashing alarm when an alarm condition is present from high water level or when activated by high water toggle switch labeled TEST, AUTO, simulating high level. (Spring return to AUTO ) 7) Provide a control relay that monitors high water level that operates an indicator light labeled HIGH WATER LEVEL. 8) Provide momentary toggle switches to simulate all four levels. They shall be permanently mounted in auto-sensory section. Label switches as AUTO TEST. (print return to AUTO ) 9) Provide relay that monitors pump failure and operates indicator light labeled Pump Failure. 10) Provide indicator light labeled Pump Failure that just be manually reset. 11) Phase failure relay to shut down all pumps and reset all timers with adjustable delay. 12) Flashing Light Shall be a U.L. listed, self-contained unit with built-in tamper switch and operate on 12v DC. The unit shall be suitable for exterior use, manufactured from weather resistant materials. 13) Provide a momentary push button to test all lights. E. Control Panel Requirements. The Control Panel shall include the following items: Power terminals for 460 Volts, 3 Phase, 4 Wire, 60 Hertz main power terminals with an equipment ground lug system ground within control panel. Two magnetic starters, NEMA rated for motors 10 horsepower and 10 million full load electrical operations

8 Two heavy-duty E frame thermal magnetic circuit breakers 10 KAIC with trip test button for short circuit protection. Two overloads, ambient compensated, with external reset buttons mounted on hinged dead front Set main power and ground lugs Control transformer 750 VA (minimum), 460 VAC primary and 120 VAC and 24 VAC secondary Circuit breakers/fuses for primary and secondary sides of the control transformer All control circuits including pilots, contactors and any floats shall operate on 24 VAC. Dead front panel shall include 2-HOA switches, 2-pump running green lights, 2-6 digit elapsed time meters, 24 VAC power yellow indicating light, high level red indicating light, alarm silence push button, lag pump start yellow indicating light, 2- overload reset push buttons, 2-red overload trip pilot lights, 2-high temperature stator red pilot lights with reset buttons. A Duplex Panel made of anodized aluminum shall be furnished which has all components and terminals permanently and clearly labeled with photo etched name or graphic symbol. The Duplex Panel shall contain the following components and functions: F. Motor. a. Five sealed, plug in, interchangeable relays with 3PDT contracts rated at 10 amp, 120 VAC and LEG indicating light for each relay b. One electro-mechanical type plug-in alternator. c. 120 VAC power switch d. 4 Circuit breakers for 120 VAC (15 amp) and 24 VAC (3 amp) power e. 120 VAC/24 VAC transformer f. 120 VAC duplex and single convenience outlet g. Twelve and twenty point terminal blocks for level control input and control outputs respectively h. Auto/manual alternation sequence selector switch i. A high level shall be indicated by a NEMA 4X red lexan alarm light flashing mounted on the top of the enclosure respectively j. Enclosure shall be NEMA 4X fabricated from SS, and shall include stainless steel hardware, removable back panel. k. All level control wiring shall be specially numbered/labeled as to function l. Complete schematics and connection diagram shall be furnished m. The control panel shall start pumps step wise on rising level and stop pumps simultaneously at low level n. The control panel shall have a lightning arrestor, a surge arrestor, and a line monitor/projection relay The Contractor shall provide a 2 year warranty for the control panel and five year warranty for the level controller. The pump motor shall be induction type with a squirrel cage rotor, shell type design, housed in an air filled, watertight chamber. Oil filled motors are not acceptable. The

9 stator windings and stator leads shall be insulated with moisture resistant Class H insulation rated for 180 C (356 F). The stator shall be insulated by the trickle impregnation method using Class H monomer-free polyester resin resulting in a winding fill factor of at least 95%. The stator shall be heat-shrink fitted into the cast iron stator housing. The use of multiple step dip and bake-type stator insulation process is not acceptable. The use of bolts, pins or other fastening devices requiring penetration of the stator housing is not acceptable. The motor shall be designed for continuous duty handling pumped media of 104 F and capable of up to 15 evenly spaced starts per hour. The material for rotor bars and short circuit rings shall be cast aluminum. Thermal switches set to open at 260 F shall be embedded in the stator lead coils to monitor the temperature of each phase winding. These thermal switches shall be used in conjunction with and supplemental to external motor overload protection and shall connect to the control panel. The junction chamber containing the terminal board shall be hermetically sealed from the motor by an elastomer compression seal. Connection between the cable conductors and stator leads shall be made with threaded compression type binding posts permanently affixed to a terminal board. Wire nuts or crimping type connection devices are not acceptable. The motor and the pump shall be produced by the same manufacturer. The combined service factor (combined effect of voltage, frequency and specific gravity) shall be a minimum of The motor shall have a voltage tolerance of ±10%. The motor shall be designed for operation up to 104 F ambient and with a temperature rise not to exceed 176 F. The Contractor shall provide a performance chart showing curves for torque, current, power factor, input/output kw and efficiency. This chart shall also include data on starting and no-load characteristics. The power cable shall meet the NEC and ICEA standards and shall be of sufficient length to reach the junction box without the need of any splices. The outer jacket of the cable shall be of neoprene. The motor and cable shall be capable of continuous submergence underwater without loss of water tight integrity to a depth of 65 ft. The motor horsepower shall be adequate so that the pump is non-overloading throughout the entire pump performance curve from shut-off through run-out. G. Construction Dewatering - Any dewatering required during construction shall be the responsibility of the Contractor. Contractor shall install temporary pumps for dewatering and shall be considered incidental to this special specification. The Contractor shall not use the permanent storm water pumps as called for in this specification for construction dewatering. 4. Inspection and Tests. The Contractor shall do the work under this Item in such a manner that when complete it shall constitute a complete operational automatic pumping unit. The Contractor shall make the installation as shown on the plans. Prior to testing the pumps and motors, the Contractor shall pump out the sump and clean the sump of all debris and sediment. After completion of the installation in every detail, the Contractor shall perform functional tests of the automatic pumping unit. The Contractor shall initiate the tests within 45 days

10 after completion of the installation. The tests may be made during a rainfall of sufficient magnitude to allow the unit to function as designed or the Contractor shall fill sump with clean water for testing. The Contractor shall repeat this test as many times as necessary to secure a properly tested working unit. The Contractor shall be responsible for making any changes and assume all costs for Equipment that does not meet specifications or operational requirements. After the completion of the above described tests and prior to acceptance, the Contractor shall furnish the Engineer with certificates from the respective manufacturers, guaranteeing all equipment against defects in acceptance. In addition, the Contractor shall furnish the Engineer with certified statements from the manufacturers or their authorized representatives that the installation has been thoroughly inspected by them and that it is in accordance with manufacturer's design. Final inspection conducted on a walk-thru basis shall take place 12 months after job acceptance. The TxDOT, Traffic Engineer, and/or TxDOT representatives shall conduct the final inspection in the presence of the Contractor, or appointed representative of the Contractor. The Contractor shall correct any and all defects due to quality of workmanship or materials, and/or not in accordance with the plans and submittal, and shall be at the expense of the Contractor prior to final acceptance. The Contractor shall provide a minimum 14 day notice to TxDOT, Maintenance Section to arrange the inspection which shall take place during working hours Monday thru Friday. 5. Measurement. The pump station, caisson, pumps, motors, electrical controls, pump columns, 12 in. discharge pipes with flap gates, equipment pad, fence with gate, and flexible base satisfactorily completed in accordance with the plans and specifications to form an automatic pump station will be measured as a complete unit by the lump sum. The 30 in. intake pipe, 24 in. & 30 in. discharge pipes, and manhole will be measured separately. 6. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under "Measurement" will be paid for at the unit price bid for "Automatic Pump Station". This price shall be full compensation for furnishing and installing a fully operational automatic pump station and shall have all equipment required by this Item including caisson, pumps, motors, pump columns, discharge pipes, flap gates, sensors, controls, switchgear, electrical systems, and for all other materials, labor, tools, equipment, accessories and incidentals