Duplex Submersible Sewage Pumps Controls

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					                                  SECTION 19100
                               SEWAGE PUMP STATION

PART 1-GENERAL

1.1    Scope- The Contractor shall furnish, install and place into satisfactory operation, a
      duplex sewage pump station complete with two(2) submersible sewage pumps and
      a pump control panel, piping, valves and associated appurtenances as shown on
      the drawings and specified herein.

      These specifications were prepared for the purpose of establishing a minimum
      standard of quality acceptable to the Owner. The Contractor may offer to provide
      equipment manufactured or marketed by other vendors: however, final evaluation
      and acceptance of the equipment remains the responsibility of the Engineer. The
      Engineer’s judgment of equipment will be based on the following criteria: pump
      hydraulic performance, pump and motor efficiency, mechanical construction,
      mechanical design features which result in reduced maintenance time and cost to
      the Owner, solids handling capabilities of the pumps and valves as set forth in the
      Ten State Standards, and compliance with the electrical specifications contained
      herein relating to the pump control center and liquid level control system.

      Any pump station manufacturer, other than specified, proposing to offer the
      following equipment must submit sufficient information to the Engineer to determine
      that the equipment complies with the requirements of the Contract Documents.
      This information must be received by the Engineer not less than 14 days prior to
      the Bid Date. The Engineer will issue an addendum prior to the bid date which lists
      any preapproved equipment. Contractors and manufacturers are advised that a
      manufacturer named as an approved supplier is not excused from meeting all of
      the technical and performance requirements of this specification.

      Each manufacturer shall include, as a minimum, the following information in their
      prebid qualification package:

      1. Complete dimensional layouts of all pumps, piping, controls and wiring.

      2. Complete pump performance data.

      3. Detailed calculations showing total friction losses in pump station discharge
      piping.

      4. Detailed calculations showing the pump system head curve at pump ON and
      pump OFF elevations including station piping.

      5. Complete bill of materials listing pumps, valves, fittings and electrical
      components.




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      6. Detailed drawings and description of the level control system.

      7. Standard catalog data sheets, performance curves and a reference list with
      names and telephone numbers demonstrating at least 5 years experience in the
      production and operation of pump stations.

1.2   Related Work Specified Elsewhere- The provisions and intent of the Contract
      Documents, including the General and Special Conditions, apply to the work
      specified in this Section.

1.3   Submittals- Shop drawings shall submitted for all items of equipment specified in
      this Section and as outlined in Division 1.

1.4   Quality Assurance- The equipment provided in this Section shall be of identical
      manufacture as the Owner’s existing equipment for ease of renewal purposes. No
      substitutions allowed.

PART 2-SUBMERSIBLE PUMPS

2.1   General- The Contractor shall provide and install the duplex nonclog submersible
      wastewater pumps as manufactured by US Filter/Davis EMU or preapproved equal
      and as indicated on the drawings. Pumps shall be slide rail mounted to allow pump
      maintenance without entry into the wetwell. All openings and passages shall be
      large enough to permit the passage of a 3” spherical solid and any trash or stringy
      material which can pass through a 4 inch house lateral. Each pump shall be
      capable of the following performance:

                   Design Point
                   Flow: 175 GPM
                   Head: 133 feet TDH
                   Shutoff Head: 155 feet
                   Minimum Motor Horsepower: 20.0 HP
                   Maximum Motor Speed: 1740 rpm
                   Minimum Hydraulic Efficiency: 44%

                   Alternate Design Point
                   Flow: 325 GPM
                   Head: 120 feet TDH


2.2   Casing- The pumps shall be designed and constructed to pump sewage, storm
      water, heavy sludge and fibrous materials without injurious damage during
      operation. Lifting cover, stator housing, volute casing and impeller shall be
      constructed of ASTM 48, Class 30 gray cast iron. The volute shall be of the center
      discharge design and shall be fitted with ANSI 125# flanges and tested to Hydraulic
      Institute Standards at 150% of shut-off head. The interfaces between the major



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      castings shall be machined and fitted with Buna-N O-rings. All nuts, bolts, washers
      and other fastening devices shall be constructed of 316 stainless steel.

2.3   Impeller- The A536 cast iron impeller shall be of nonclog design, double shrouded
      with a smooth, long thoroughfare having no acute angles. The wear ring system
      shall be constructed of Series 400 stainless steel with a Brinell hardness of 200-
      300. The system shall provide efficient sealing between the volute and impeller.

2.4   Seal- The pump shall be provided with a balanced tandem mechanical seal
      cartridge. The seal case shall be constructed of 316 stainless steel with all seal
      faces and springs immersed in oil. The upper set of faces shall be tungsten
      carbide while the lower set of faces shall be silicon carbide. Seal faces shall be
      self-aligning, positively driven and each shall be held by separate spring systems.
      The construction shall be such that no spring is exposed to the pumped media.

2.5   Shaft- The pump and motor shaft shall be of Series 400 stainless steel with a
      Brinell hardness of 200. The shaft shall be designed such that the diameter of the
      shaft where it passes through the lower seal shall be 1.97 inches with a maximum
      shaft deflection due to axial and radial thrust loads of 0.16 mm. The shaft shall not
      extend more than 2.5 times its diameter below the nearest support bearing and
      shall be supported by double row lower and single row upper bearings with a B-10
      life of 50,000 hours minimum at any point on the flow versus head curve.

2.6   Quick Removal System- Each pump shall be supplied with a universal coupling,
      ANSI 125# cast iron, which bolts to the pump discharge flange and accepts the
      discharge elbow provided by the pump manufacturer. Seal of the pump at the
      discharge flange shall be accomplished by a simple downward linear motion of the
      pump with the entire weight of the pump guided to and pressing against the
      discharge connection. There shall be no need for personnel to enter the wet well.
      No part of the pump shall bear directly on the sump floor and no rotary motion of
      the pump shall be required for sealing. Sealing at the discharge shall be effected
      by a replaceable rubber seal fitted to the machine discharge coupling to insure and
      guarantee a positive leakproof system and for ease of removal of the pump.

      Furnish a T-bar guide rail system and stainless steel lifting chain for each pump to
      permit raising and lowering the pump. Guide rails shall be 2” X 2” X 1/4” angles of
      adequate length to extend from the lower guide holder on the pump discharge
      connection to the upper guide holder mounted on the access frame. Guide rails
      shall be constructed of stainless steel.

2.7   Motor- The pump motor shall be integral to the pump for submersible or dry pit
      operation. The squirrel cage induction type motor shall be designed with Class H
      slot liners with service factor of 1.25. The dual voltage copper wound stator, which
      will allow field changeability of voltage, shall be triple dipped in epoxy enamel to
      withstand a heat rise to 155 degrees C as defined in NEMA Standard MG-1. The
      NEMA starting code shall be G or less. The rotor shall be constructed of laminated



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      steel plates with poured aluminum shorting bars. The rotor shall be both statically
      and dynamically balanced. All castings shall be machine fit utilizing metal-to-metal
      contact. All machine fits shall be additionally protected with Buna-N O-rings. The
      motor shall be oil-filled and positively cooled by movement of the oil through the
      windings to passages within the unit designed to transfer heat to the pumped fluid.
      Motors shall have thermal sensors for overload protection built into the motor
      casing. Air-filled motors or static oil-filled motors without an integral heat
      exchanger shall not be acceptable. A minimum of 85% of the heat generated by
      the motor must be conducted through the heat exchanger into the pumped liquid.
      This shall be supported with certified heat transfer calculations.

      The motor power cable shall consist of SJO type insulated cable with a double
      jacketed protection system consisting of neoprene on the outside with synthetic
      rubber on the inside. Individual conductors shall be of the RUW type. The power
      cable will enter the pump through a vellums type cable entry constructed of cast
      alloy metal and galvanized for corrosion resistance. The heavy duty cable entry
      with strain relief shall be provided with an integral rubber grommet to protect
      against leakage once the cable is secured. The power cable leads shall be
      connected to terminals on an isolated terminal board. The terminal board shall be
      constructed of bakelite and will include individually O-ringed brass lugs on both the
      upper and lower side of the terminal board. The terminal board shall be totally
      isolated from the motor using Buna-N O-rings fitted to the terminal board and
      mating with the machined terminal board housing in the motor. This system will
      prevent moisture from entering the motor should leakage occur through the cable
      entry. Motor shall be equipped with a moisture sensor to stop pump operation if
      moisture is detected in the seal cavity.

      The motor shall be sized to be nonoverloading throughout the entire range of the
      impeller curve.

PART 3-PUMP CONTROLS

3.1   Power Service- The incoming power service for the pump station shall be 240 volt,
      3 phase and 4 wire. The control panel shall be furnished with a lightning arrestor
      connected to each line of the incoming side of the power input terminals. The
      arrestor shall protect the panel against damage due to lightning strikes on the
      incoming power line.

3.2   Transducer- The level of the wet well shall be measured by a submersible level
      transducer with a minimum bottom diaphragm of 2-5/8” providing a 4-20 mA
      instrumentation signal. The transducer shall be of the solid state head pressure
      sensing type mounted using 304 stainless steel clamps attached to a Contractor
      furnished 1” vertical Sch. 80 PVC pipe. The transducer housing shall be fabricated
      of type 316 stainless steel. A hydraulic fill liquid behind the diaphragm shall
      transmit the sensed pressure to a solid state variable capacitance transducer
      element to convert the sensed pressure to a corresponding electrical value. The



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      sensed media shall exert its pressure against the diaphragm that flexes minutely so
      as to vary the proximity between an internal ceramic diaphragm and a ceramic
      substrate to vary the capacitance of an electrical created between the two surfaces.
      A stable, hybrid operational amplifier assembly shall be incorporated in the
      transducer to excite and demodulate the sensing mechanism. The internal
      pressure of the transducer assembly shall be relieved to atmospheric pressure
      through a urethane jacketed hose/cable assembly and a slack PVC bellows
      mounted in the upper assembly panel. The sealed breather system shall
      compensate for variations in barometric pressure and expansion and contraction of
      air due to temperature changes and altitude as well as prevent fouling from
      moisture and other corrosive elements.

      The transducer shall be a U.S. Filter/Consolidated Electric Company Model A1000
      or preapproved equal.

3.3   Pump Controller- The operation of the sewage pumps shall be controlled by a
      duplex pump controller. The controller shall receive a 4-20mA signal from the
      submersible transducer and display it on a 4” LED bargraph on the face of the
      controller. Directly aligned with the calibrated LED bar graph shall be 8 vertical
      receptacles with programming pins and adjacent range scales to match the
      calibrated bar graph giving full range, level differential ON/OFF operation of the
      pumps and alarms from the sensed level excursion. The controller shall provide
      automatic alternation of the pumps. The controller shall be a model D152 as
      manufactured by U.S. Filter/Consolidated Electric or preapproved equal.

3.4   Enclosure- The equipment shall be housed in a NEMA 3R, 14 gauge minimum
      galvanized steel enclosure painted with an exterior grade gray enamel coating.
      The outer door shall have a stainless steel hinge and pin and shall be padlockable.
      The enclosure shall be insulated and furnished with a condensation heater and
      thermoswitch and be suitable for wall or pedestal mounting where shown on the
      drawings.

3.5   Overtemperature Pump Protection- Overtemperature protection shall be provided
      in the control panel to operate in conjunction with the overtemperature switch in
      each pump motor. The control shall provide pump operation lockout upon the
      occurrence of high temperature. The circuitry shall also include a 1” diameter
      yellow “pump overtemperature” shutdown alarm indicating light and a manual reset
      pushbutton for two (2) pump motors.

3.6   Seal Failure Alarm- An inner door mounted 1” red seal failure alarm light and a
      panel mounted seal leakage relay shall be provided to indicate a pump seal failure
      alarm condition for two (2) sewage pumps.

3.7   Running Time Meters- An operator’s door mounted 120 VAC powered running time
      meter measuring hours and tenths of hours of operation up to 99999.9 hours shall
      be furnished for two (2) pump motors.



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3.8    Local Alarm System- A top mounted weatherproof high water alarm light assembly
       shall be furnished. A weatherproof audible alarm horn producing 87 dB minimum
       at 10 feet shall be provided.

3.9    Power Handling-A thermal magnetic circuit breaker shall be supplied as branch
       circuit protection for each motor. The circuit breaker shall have a minimum ampere
       interrupting capacity of 14,000 symmetrical RMS amps. The circuit breakers shall
       be operable through the inner door of the enclosure and shall have a trip rating to
       allow full voltage starting and continuous operation of the motors.

       A NEMA rated, full voltage, across the line magnetic motor starter with ambient
       compensated, quick trip class 10 overload sensing in each phase to provide
       overcurrent and running protection shall be provided for each motor less than 30
       HP. The overload trip setting shall be determined by replaceable heater elements.
       Overload relays with an adjustable trip or requiring replacement of the entire
       overload relay to change the trip settings shall not be acceptable. Inner door
       mounted overload reset pushbuttons shall be provided.

       A reduced voltage with ambient-compensated, quick-trip class 10 overload sensing
       in each phase to provide overcurrent and running protection shall be provided for
       any motor over 30 HP. Overcurrent protection shall be provided by accurately
       sized heater elements. Inner door mounted overload reset pushbuttons shall be
       provided. The pump motor starter shall be a solid-state reduced voltage type motor
       controller incorporating soft starting, motor overvoltage protection and energy
       saving characteristics. The controller shall include independent adjustments for the
       start time and initial torque on the soft start ramp as well as adjustments for
       overvoltage protection and energy savings. The starter shall include a line voltage
       limiter circuit to allow the output voltage of the control to be field adjusted to the
       motor nameplate value. The limiter shall prevent excessive voltage from reaching
       the motor in the event of a high line voltage condition.

       120 VAC control power for each motor starter coil and H-O-A selector switch with
       1” green run light shall be provided through a properly sized fuse.

3.10   Telephone Dialer Alarm conditions shall be forwarded via an automatic telephone
       dialer capable of dialing up to eight telephone numbers, each up to 24 digits in
       length. Telephone numbers shall be user programmable through the system
       keyboard or touch tone telephone. The dialer shall be a four channel device wired
       for the following alarms: Pump #1 Fail, Pump #2 Fail, High Water Alarm, Low Water
       Alarm and power failure.

       The user shall be able to record and re-record messages for each input channel
       and for the station identification. Acknowledgment of an alarm call is to be
       accomplished by pressing a code on the touch pad of the receiving phone. The




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      dialer shall continue to call the alarm status until it receives the acknowledgment
      code.

      The dialer shall operate on normal 115 volt, single phase power. The unit shall
      include a 6 hour gel cell battery to allow for operation in the event of temporary
      power loss.

      The dialer shall connect to a standard telephone line through a 4 pin modular jack
      (RJ-11). The dialer shall feature integral gas tube and solid state surge protection
      on all input lines including the telephone, power and input signal lines.


PART 4-EXECUTION

4.1   Warranty- All equipment shall be guaranteed against defect in material and
      workmanship for a period of one year from date of Owner’s final inspection and
      acceptance to the effect that any defective equipment shall be repaired or replaced
      without cost or obligation to the Owner.

4.2   Field Service- The services of a factory trained field service technician shall be
      provided to inspect the completed installation, make all adjustment necessary to
      place the system in satisfactory operation and instruct the operating personnel in
      the proper care and operation of the equipment. This allowance shall be a
      minimum of three (3) eight hour days.




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