"Honey Brook Township Pumping Station Pump Spec"
HONEY BROOK TOWNSHIP BUILDING PUMP STATION CHESTER COUNTY, PENNSYLVANIA SEWAGE PUMPS, CONTROLLER AND APPURTENANCES SPECIFICATION 1.01 GENERAL A. Bidder shall supply all material and appurtenances required by the bid documents and these specifications to provide two (2) submersible centrifugal explosion proof submersible sewage grinder pumps for NEC class 1, division 1, group C, D Hazardous locations, control panel, floats, guiderails with hydraulic flange coupling and one day of field service by a factory approved technician for startup services and operator training as specified. 2.01 OPERATION CONDITIONS A. Each pump produce a minimum of 36 gpm at 65.5 feet TDH and a maximum of 54 gpm at 140 feet TDH. The pump shall operate on the system curve which is made part of this specification. The bidder shall indicate the operating point of the proposed pump on the system curve with their bid. Each pump motor shall be rated at 5.0 HP, 230 volts, single phase, 60 hertz. The pumps shall operate at 1,750 rpm. Any exceptions to these requirements shall be clearly identified on the bid and may be reason for rejection of the bid unless preapproved by the engineer. 3.01 CONSTRUCTION A. Each pump shall be of the sealed submersible type. The pump volute, motor and seal housing shall be high quality gray cast iron, ASTM A-48, Class 30. All external mating parts shall be machined and Buna N Rubber O-ring sealed on a beveled edge. Gaskets shall not be acceptable. All fasteners exposed to the pumped liquids shall be 300 series stainless steel. 3.02 ELECTRICAL POWER CORD A. Electrical power cord shall be water resistant 600V, 60°C, UL and/or CSA approved and applied dependent on amp draw for size. B. The power cable entry into the cord cap assembly shall first be made with a compression fitting. Each individual lead shall be stripped down to bare wire, at staggered intervals, and each strand shall be individually separated. This area of the cord cap shall then be fitted with an epoxy compound potting which will prevent water contamination to gain entry even in the event of wicking or capillary attraction. Honey Brook Township Pump Station Page 1 of 6 HONEY BROOK TOWNSHIP BUILDING PUMP STATION CHESTER COUNTY, PENNSYLVANIA C. The power cord leads shall then be connected to the motor leads with extra heavy duty crimp insulated connectors. D. The cord cap assembly where bolted to the motor housing shall be sealed with a Buna N Rubber O-ring on a beveled edge to assure proper sealing. 3.03 MOTOR A. The stator, rotor and bearings shall be mounted in a sealed submersible type housing. The stator windings shall have Class F insulation (155°C or 311°F) and dielectric oil filled motor, NEMA L design. B. The pump and motor shall be specifically designed so that they may be operated partially dry or completely submerged in the liquid being pumped. C. Stators shall be securely held in place with threaded fasteners so they may be easily removed in the field, and must be capable of being repaired or rewound by a local motor service station. No special tools shall be required for pump and motor disassembly. D. Pump shall be equipped with a heat sensor. The heat sensor shall be a low resistance, bi-metal disc that is temperature sensitive. It shall be mounted directly in the stator and sized to open at 120°C or 130°C and automatically reset at 30–35°C differential. The sensor shall be connected in series with the motor starter coil so that the starter is tripped if a heat sensor opens. The motor starter shall be equipped with overload heaters so all normal overloads are protected by external heater block. 3.04 BEARINGS AND SHAFT A. An upper radial bearing and a lower thrust bearing shall be required. These shall be permanently lubricated by the dielectric oil which fills the motor housing. B. The shaft shall be machined from a solid 416 stainless steel and be a design which is of large diameter with minimum overhand to reduce shaft deflection and prolong bearing life. 3.05 SEALS AND SENSORS A. The rotor and stator in the motor housing shall be separated and protected from the pumped liquid by an oil filled seal housing incorporating two carbon ceramic mechanical seals mounted in tandem. This seal housing shall be equipped with 2 Honey Brook Township Pump Station Page 2 of 6 HONEY BROOK TOWNSHIP BUILDING PUMP STATION CHESTER COUNTY, PENNSYLVANIA moisture sensing probes installed between the seals, and the sensing of moisture in the seal chamber shall be automatic, continuous, and not require the pump be stopped or removed from the wet well. The sensor probes shall be electrically isolated, with a resistor between each probe to eliminate grounding to the casing. 3.06 IMPELLERS A. Impeller shall be bronze multi-vane, semi-open, non-overloading design. They can either be factory or field trimmed to meet specific performance conditions. Impellers shall be dynamically balanced at the factory, and machined for threading on to the pump shaft. Wear or field trimming shall not deter the factory balance. 3.07 GRINDER CUTTERS A. The combination centrifugal pump impeller and grinder unit shall be attached to the common motor and pump shaft made of 416 stainless steel. The grinder unit shall be on the suction side of the pump impeller and discharge directly into the impeller inlet leaving no exposed shaft to permit packing of ground solids. The grinder shall consist of two stages. The cutting action of the second stage shall be perpendicular to the plane of the first cut for better control of the particle size. The grinder shall be capable of grinding all materials found in normal domestic sewage, including plastics, rubber, sanitary napkins, disposable diapers, and wooden articles into a finely ground slurry with particle dimensions no greater than 1⁄4 inch. Both stationary and rotating cutters shall be made of 440C stainless steel hardened to Rockwell 55-60C and ground to close tolerance. B. The upper (axial) cutter and stationary cutter ring shall be reversible to provide new cutting edges to double life. The stationary cutter ring shall be a slip fit into the suction opening of the volute and held in place by three (3) 300 series stainless steel screws and a retaining ring. The lower (radial) cutter shall macerate the solids against the I.D. of the cutter ring and extrude them through the slots of the cutter ring. The upper (axial) cutter shall cutoff the extrusions as they emerge from the slots of the cutter ring to eliminate any roping effect which may occur in single stage cutting action. The upper (axial) cutter shall fit over the hub of the impeller and the lower (radial) cutter shall be slip fit and secured by means of peg and hole and rotate simultaneously with the rotation of the shaft and impeller. The grinding mechanism shall be locked to the shaft by a 300 series stainless steel countersunk washer in conjunction with a 300 series stainless steel hex serrated head screw threaded into the end of the shaft. Honey Brook Township Pump Station Page 3 of 6 HONEY BROOK TOWNSHIP BUILDING PUMP STATION CHESTER COUNTY, PENNSYLVANIA 3.08 PAINTING A. The pump shall be painted after assembly and testing, with a water reducible air dry enamel. The paint shall be applied in one coat covering all exterior surfaces. The pump shall be air dried after testing and before painting. 4.01 DISCHARGE BASE ELBOW WITH BASE PLATE A. The discharge elbow/base plate assembly is designed to rest squarely on the wet-well floor assuring perfect alignment and a smooth surface for the pump. The base plate shall also include bolt down holes, a leveling bolt, and adjustable guide rail supports. The sealing face of the base elbow shall be spray coated with zinc to provide a smooth, corrosion and abrasion resistant surface. All fasteners shall be 300 series stainless steel. 5.01 GUIDE RAIL SYSTEM A. A cast iron sealing flange, complete with BUNA-N rubber diaphragm type sealing gasket, shall be mounted on each pump discharge. This diaphragm shall be held in place by a clamp ring with stainless steel fasteners. B. The guide rail system with hydraulic flange coupling allows the submersible pump to be installed or removed without requiring personnel to enter the wet well. The guide rail assembly is made of 304 stainless steel. The guide rail mounts to an upper horizontal bracket attached to the wet well wall. The discharge piping and a stainless steel support bracket gives support to the lower portion of the guide rail. The stainless steel guide rail supports the pump at a distance of 4” from the basin floor. The guide rail brackets are attached to the pump for positioning of the unit on the guide rail during installation and removal. The stationary and moveable portions of the hydraulically sealed discharge are machine cast iron. The cast iron moveable fitting is held against the stationary fitting by the construction of the guide rail. Aligning the moveable fitting to the flexible diaphragm for proper sealing of the two surfaces. The flexible diaphragm also serves as an anti-siphon device in cases of negative head conditions. 6.01 PUMP CONTROLLER A. The motor control panel shall be assembled and tested by a shop meeting U.L. Standard 508 for industrial controls. The motor control panel shall be assembled and tested by the same manufacturer supplying the pump so as to insure Honey Brook Township Pump Station Page 4 of 6 HONEY BROOK TOWNSHIP BUILDING PUMP STATION CHESTER COUNTY, PENNSYLVANIA suitability and assurance of experience in matching controls to motors and to insure single source responsibility for the equipment. B. The pump controller shall be capable of operating a duplex pumping system utilizing float switches for control. The pumps shall operate in a lead/lag arrangement. The controller shall alternate the duty of the pumps. The pump controller shall connect to the floats through an intrinsically safe module (UL Listed). C. The panel shall be a NEMA 4X enclosure with lockable door. The panel shall be by the pump manufacturer to ensure compatibility and be sized for two 5HP explosion proof grinder pumps. A nameplate shall be permanently affixed to the panel and include the pump model number, voltage, phase, hertz, pump full load ampere rating and pump horsepower rating. A warning label against electric shock shall be permanently affixed to the outer door. D. The control panel shall include the following: 1. Main Circuit Breaker – 240 V AC, 2 Pole, 125 AMP 2. Lightening Suppressor 3. Run Time Meters for Each Pump 4. 0 – 30 Second Time Delay Relay for Both Lead and Lag Pump* 5. Lead Pump Selector Switch 6. Hand/Off/Auto Switch for Each Pump 7. Redundant Pump Off/Low Level Switch 8. Convenience Outlet 9. Eight Channel Autodialer – Microtel with 6 Hour Battery Backup 10. Seal Failure Alarm 11. Pump Failure Alarm 12. High Water Level/Low Water Level Alarms 13. Red Alarm Beacon 14. 100 Watt Heater 7.01 TESTING A. Commercial testing shall be required and include the following: 1. The pump and controls shall be visually inspected to confirm that it is built in accordance with the specification as to HP, voltage, phase and hertz. 2. The motor and seal housing chambers shall be hi-potted to test for moisture content and/or insulation defects. 3. Pump shall be allowed to run dry to check for proper rotation. 4. Discharge piping shall be attached, the pump submerged in water and amp readings shall be taken in each leg to check for an imbalanced stator winding. If there is a significant difference in readings, the stator windings shall be Honey Brook Township Pump Station Page 5 of 6 HONEY BROOK TOWNSHIP BUILDING PUMP STATION CHESTER COUNTY, PENNSYLVANIA checked with a bridge to determine if an unbalanced resistance exists. If so, the stator will be replaced. B. The bidder shall supply one day of field service by a factory approved technician with a minimum of three years of experience to perform stat up services, verify installation pumps and controls in a accordance with the manufacturer's requirements and provide operator training to the township staff. The technician shall submit a written report confirming that the pumps and controls were installed in accordance with the manufacturer's requirements. 8.01 DOCUMENTATION A. The bidder shall provide manufacturer’s information with the bid for all material proposed including manufacturer and model number, impeller size, motor information, catalogue material, performance curve, dimension sheets and operating point against the attached systems curve and any exceptions to the bid. B. Provide five (5) copies of operating and maintenance manuals with operating points indicated and information not associated with the equipment furnished crossed out. 9.01 WARRANTY A. All equipment furnished herein shall be warranted against defects in material or workmanship within one year from date of installation or 18 months from date of manufacture, whichever comes first, and shall be repaired or replaced at no charge with a new or remanufactured part, F.O.B. factory or authorized warranty service station. Honey Brook Township Pump Station Page 6 of 6