Metron Section 22 11 24 – Municipal Packaged Pump Systems 4.22

8/10/2019 Metron Section 22 11 24 Municipal Packaged Pump Systems 4.22

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MUNICIPAL PACKAGED PUMP SYSTEMS 221124 - 1VER. 4.22

SECTION 22 11 24MUNICIPAL PACKAGED PUMP SYSTEMS

PART 1 - GENERAL .................................................................................................................................................. 2

1.01 WORKINCLUDED ................................................................................................................................. 21.02 RELATEDSECTIONS ............................................................................................................................ 21.03 MANUFACTURER.................................................................................................................................. 21.04 QUALITYASSURANCE/REFERANCESTANDARDS .................................................................... 31.05 WARRANTY ............................................................................................................................................ 4

PART 2 - PRODUCTS ................................................................................................................................................ 4

2.01 PERFORMANCEANDDESIGNREQUIREMENTS .......................................................................... 42.02 MECHANICAL ........................................................................................................................................ 42.03 PUMPSANDMOTORS ........................................................................................................................ 132.04 OPTIONALSKIDUPGRADES ............................................................................................................ 212.05 ELECTRICAL ........................................................................................................................................ 222.06 SEQUENCEOFOPERATION ............................................................................................................. 292.07 EQUIPMENTENCLOSUREUPGRADE............................................................................................ 292.08 MODULARSTRUCTURE&ENCLOSUREOPTIONS ................................................................... 47

PART 3 - EXECUTION ............................................................................................................................................ 52

3.01 INSTALLATION,STARTUP&CUSTOMERTRAINING .............................................................. 52ATTACHMENTATECHNICALDATASHEET .......................................................................................... 55


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221124 - 2 MUNICIPAL PACKAGED PUMP SYSTEMSVER. 4.22

SECTION 22 11 24MUNICIPAL PACKAGED PUMP SYSTEMS

PART 1 - GENERAL

1.01

WORK INCLUDED

A. It is the manufacturers responsibility to include all necessary appurtenances to provide for

a complete, fully automatic and reliable pumping system. The manufacturer shall supply acomplete set of general arrangement drawings, electrical power schematics, and controlschematics in the Installation, Operation & Maintenance Manual.

1.02 RELATED SECTIONS(I nsert Related Spec Section List Here)

1.03

MANUFACTURER

A.

The pumping system shall be of the type manufactured by Metron, Inc. Denver, Colorado,U.S.A., (303) 592-1903, or pre-approved equal, approved by the engineer prior to the bidopening. For consideration of a proposed equal system, the contractor shall furnish thefollowing data to the architect / engineer at least 15 days prior to the date of the bidopening.

B.

A complete Specification of the pumping system proposed as an equal.

C.

A Statement of Full Conformance to the following Specifications signed by an officer ofthe manufacturer.

D.

A General Arrangement Drawing showing the overall dimensions, piping, and components.

E.

A complete Submittal, with Data Sheets, for all major equipment: pumps, motors, variablefrequency drive (VFD), programmable logic controller (PLC), valves, and motor starters.

F.

An Electrical Schematic showing power wiring and controls.

G.

List of 5 factory trained service technicians, and 2 VFD factory trained service centers,within 100 mile radius of project site.

H.

List of 100 pump systems which have been in operation for a minimum of 3 years.

I.

Manufacturers IndustrialElectrical Control Panel UL 508A File Number.

J. Manufacturers Packaged Pumping Systems UL QCZJ File Number.

K.

ASME Section IX and AWS D 1.1 welding certificates for factory employees that will beworking on this project.


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L. A copy of manufacturers Certificate of Insurance showing as a minimum, a general

liability coverage of $1,000,000, and an excess liability coverage of $10,000,000.

M.

If, in the opinion of the purchaser, the data submitted shows the pumping system to beequal to the system specified, the bidding contractors shall be notified not less than seven(7) days prior to the bid opening date.

1.04 QUALITY ASSURANCE / REFERANCE STANDARDS

A.

The pump station manufacturer shall be required to affix an Underwriters Laboratories (UL)Label Packaged Pumping System (QCZJ) UL listing category to the pump system. This labelshall be inclusive of the entire pump station so as to demonstrate compliance with theNational Electric Code requirements for working clearances and wiring procedures.

B.

Manufacturer shall have at least 5 years experience in producing similar equipment.

C.

Systems shall be manufactured in the United States.

D.

The equipment furnished shall be designed, constructed, and installed in accordance with thebest practices and methods and shall operate satisfactorily when installed as shown on thecontract drawings and operated per manufacturers recommendations.

E.

Reference standard to include the following except as otherwise shown on the drawings orspecified.

1.

Hydraulic Institute Standards2.

National Electric Code3.

Standards of National Electrical Manufacturers Association4.

Institute of Electrical and Electronic Engineers5.

American National Standards Institute

6.

American Water Works Association7.

American Society of Mechanical Engineers8.

American Welding Society9.

Underwriters Laboratories10.

Occupational Safety and Safety Administration

F.

Quality Control and Testing

1.

Quality control and testing shall consist of the following components and shall beperformed by the pump station manufacturer employed personnel.

2.

Manufacturer shall provide quality control to applicable codes and standards. Ifquality control is less than applicable standards, Manufacturer shall supply details of

specific requirements needed to meet the standards.3.

Manufacturer shall be responsible for the testing and inspection of all material andwork in accordance with this specification and all applicable codes, laws andregulations.

4.

A copy of test reports and inspection for materials used shall be available uponrequest by Owner.

5.

Owner and representatives shall have all reasonable access to the work whether it isin preparation or progress.


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6.

Manufacturer shall provide proper facilities for such access and for inspection. Allequipment shall be provided with nameplates per approved drawings.

1.05 WARRANTY

A.

The warranty specified in this Article shall not deprive OWNER of other rights or remedies

OWNER may otherwise have under the Contract Documents and shall be in addition to, andrun concurrent with, other warranties made by CONTRACTOR under the ContractDocuments. The obligations of CONTRACTOR under the Contract Documents shall not belimited in any way by the provisions of this specified warranty.

B.

The equipment warranty shall be the sole responsibility of the station manufacturer and thatmanufacturer's warranty shall be provided in written form for inclusion with both thesubmittal covering the specified equipment and the O&M manuals provided with thatequipment.

C.

Said manufacturer's warranty shall at a minimum cover:

1.

A period of one (1) year commencing upon successful start-up, after authorizedmanufacturer's start-up, not to exceed eighteen (18) months from the date ofshipment.

2.

The warranty period shall be inviolate regardless of any component manufacturer'swarranty for equipment and components within the station.

3.

The manufacturer's warranty shall cover all equipment, components andsystems provided in or with the station by the manufacturer of the station, exclusiveof those components supplied by and/or installed by others independent of themanufacturer of record for this station.

4.

The warranty shall provide for the station manufacturer to bear the full cost ofmaterials for replacement and/or repair of faulty or defective components during thewarranty period.

5.

The manufacturer's warranty policy is amended only by the items consideredconsumables, i.e., light bulbs, pump seals, pump packing, lubricants and othermaintenance items consumed by usage.

6.

No assumption of contingent liabilities for any component failure duringmanufacturer's warranty is made.

7.

If the submitted written manufacturer's warranty does not meet the minimumrequirements set forth above, that submittal will forthrightly be rejected.

PART 2 - PRODUCTS

2.01

PERFORMANCE AND DESIGN REQUIREMENTS

A.

The pump station shall operate the pumps in the following manner, in order to producesystem flow of_____GPM at _____Psig

2.02 MECHANICAL


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A.

Pump station shall be a completely skid mounted pump station built by a single manufacturer.All equipment including, but not limited to pumps, motors, valves, instrumentation andcontrols shall be mounted on a common structural steel base to form a complete operatingpump station.

1.

The plate steel employed throughout the equipment base shall meet or exceed the

requirements for ASTM A-36.2.

The structural shapes (channels and angles) shall be of the thickness/weight as shownon the plans for this item and shall meet or exceed the requirements for ASTM A-36.

3.

The structural rectangular or square tubing shall be of the wall gauge as shown on theplans for this item and shall meet or exceed the requirements for ASTM A-500 GradeB.

4.

Field welding to complete the skid, structure or attach the internal piping system willnot be allowed.

5.

The design of all members shall be in accordance with the recommended practice fordesign as specified in the MANUAL OF STEEL CONS'IRUCTION, published bythe American Institute of Steel Construction, Inc.

6.

The steel plate and structural shapes used must be adequate to meet the purpose for

which they are intended plus the additional stresses from the lifting and setting of theequipment.

7.

All welds shall be completed by an AWS and ASME certified welder. Pump stationmanufacturer shall provide copies of the welding certificates of the employees whoare to perform the pipe welds.

8.

The equipment base design shall accommodate lifting the unit from above by a cranewithout undue bending or stress.

B.

Structural Skid

1. The packaged systems skid shall be designed, fabricated and assembled to provide

proper structural support for all attached equipment.

2.

The skid shall provide sufficient rigidity to withstand the stresses of reasonable andcompetent transportation to site, off loading, installation, and operation that iscompatible with the pad design. Main structural members shall be constructed withASTM A-36 square tube, channel or I-beam steel, as identified in the Technical DataSheet. The base structural members shall not interfere with or obstruct the areasdesignated for routing of power cables or control wiring.

3.

Structural grid base shall be designed with a deflection no greater than 1/360 of thedistance between floor stiffener members, when the packaged system is in its normaloperating position, installation, off-loading or during shipment.

4.

The floor shall be designed to accommodate the required insulation R value andmaterial as outlined in the Data Sheet.

5.

The base shall have removable lifting devices to facilitate handling and installation.

The normal lifting for transportation and installation shall be by means of a cranemaking a single point lift using suitable spreader bars and rigging, provided byothers. Rigging diagrams, total dry weight and center of gravity information shall beprovided by the Manufacturer.a.

The skid shall be designed for laying flat on a structural pad. The pad design andanchoring shall not be the packaged pumps system manufacturers responsibility.

b.

The skid shall be designed for laying flat on a structural pad, but one endcantilevered as shown in the drawings. The pad design and anchoring shall not

be the packaged pumps system manufacturers responsibility.


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c.

The skid shall be designed for attaching to piers, as supplied by others. The paddesign and anchoring shall not be the packaged pumps system manufacturersresponsibility.

6.

Floor - The floor shall be a minimum of 3/16 inch ASTM A-36 steel plate and have acontinuous weld, skip welding is not acceptable, to the perimeter and to the

longitudinal and/or transverse structural members of the base.

C.

Piping

1.

In all cases, short circuit transfer, spray transfer or pulse-arc transfer modes of the gasmetal arc welding process shall be applied semi-automatically.

2.

When utilizing the short circuit mode, shielding gas consisting of 50% carbondioxide and 50% argon gas shall be used.

3.

When utilizing the spray or pulse-arc transfer modes, a shielding gas consisting of5% carbon dioxide and 95% argon shall be used.

4.

In all cases, welding wire with a minimum tensile strength of 70,000 psi shall beutilized.

5.

All flange welds and butt welds of equal size pipe shall be a single continuous non-stop weld around the complete circumference of the pipe.

6.

Whenever possible, vertical up weld passes will be applied to all pipe welds. Novertical down weld passes will be allowed.

7.

Completed welding assemblies shall create no internal obstruction, restriction orcreate any unintended sources of water deflection.

8.

Piping of six (6) inch diameter and larger shall require a minimum of two (2) weldpasses to complete each weld.

9.

The first pass, or root pass, shall he applied at the bottom of the bevel cut using theshort circuit transfer welding mode, and the second pass, or cap pass, shall be appliedover the root pass using the spray or pulse arc transfer welding modes to insure thatat a minimum the total weld thickness shall be equal to thinnest of the two pieces

being welded together.

D.

Pipe Fittings

1.

Elastomer Pipe Connectors

d.

The inlet side of each pump (up to 12 pipe) shall include an elastomerconnectorto help isolate vibration and noise in the piping system. This does not apply tovertical turbine pumps with buried suction connections.

e.

The elastomer connector shall be of single sphere design, constructed of EPDMor neoprene with bias-ply tire reinforcing cord to provide a 225 PSI workingpressure at a minimum of 120 degrees F.

f.

The elastomer connector shall pass through the plate steel flanges designed togrip the connector so the connector seals without gaskets when the flange boltsare tightened.

g.

A control joint or cable shall be included to limit the movement of the pipeconnector.

2.

Compression Couplings


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h.

The discharge piping of each pump (and any other location as indicated in thedrawing) is to include a compression coupling to relieve strain and provide aservice connection.

i.

In lieu of a compression coupling, a restrained, removable flanged couplingadaptor (FCA) may be provided. The flanged coupling adaptors are to be of thesame manufacturer as the couplings used elsewhere within the pump system and

shall be a regular product of the coupling manufacturer. Flanged couplingadaptors shall be complete on the flanged end with an integral rubber flangegasket and follower ring. Bolts for the FCA will be individual to the FCA and areto be supplied with the unit.

j.

All compression couplings or flanged coupling adaptors are to include controljoint rods or actuated gripping wedges with torque limiting screws to providerestraint for the coupling.

3.

Butterfly Valves, Flanged - AWWA C504

k.

Where shown on the drawings lug style butterfly valves shall be provided.l.

The butterfly valves shall be designed, manufactured and tested in accordance to

ANSI/AWWA C504 standards and certified to ANSI/NSF 61 Drinking WaterComponentsHealth Effects.

m.

The butterfly valves will have class 150B valve bodies made from grade B grayiron. The valves discs shall be ASTM A536 grade 65-45-12 ductile iron. Theshafts shall be ASTM A276 type 304, or ASTM A564, Type 640 stainless steel.The seats shall be Buna-n on the valve disc and have 316 stainless steel retaininghardware.

n.

The valves interiors will include an ANSI/NSF 61 epoxy coating approved forpotable water service.

o.

Valves eight (8) inch, and smaller shall have a 10-position locking handle.Valves ten (10) inch, and larger shall have gear operator with hand wheel. Allvalves shall be rated at 250 PSIG bubble shut off.

p.

Flanged AWWA C504 Butterfly Valves shall be Val-matic model American-BFV.

4.

Butterfly Valves, Lug Style

q.

Where shown on the drawings lug style butterfly valves shall be provided.r.

The butterfly valves shall be one piece ASTM A126 Grade B cast iron, including416 stainless steel stems. Valve disc shall be nickel plated ductile iron. Its stembushings shall be Acetyl to prevent stem seizure to body during prolongedperiods of non-use. Its seat shall be EPDM, one piece construction, and shallalso form the flange sealing gaskets.

s.

Valves eight (8) inch, and smaller shall have a 10-position locking handle.

Valves ten (10) inch, and larger shall have gear operator with hand wheel. Allvalves shall be rated at 250 PSIG bubble shut off.

t.

Lug Style Butterfly Valve(s) shall be a Keystone 222.

5.

Gate Valves - AWWA C509

u.

Where shown on the drawings, the pump system shall be provided with gatevalves.

v.

The valve(s) shall meet AWWA C509 standards.


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w.

The gate valves will be cast iron body, bronze mounted, resilient seat, NRS (non-rising stem) and include potable fusion bonded epoxy coatings.

x.

Valve flange pattern will be ANSI B 16.1 Class 125.y.

The valve will be complete with handwheel operator and include a maximumworking pressure of 200 psi.

z.

Gate Valve(s) will be M&H model 4067-02.

6.

Swing Check Valves - AWWA C508

aa.

Check valves shall be provided for each pump discharge and anywhere else asindicated on the drawings.

bb.

The check valve shall comply with AWWA C508cc.

The swing check valves shall be of the full body type, with a domed access coverand two moving parts, the flexible disc and the disc accelerator.

dd.

Valves shall be provided with flanges in accordance to the ANSI B16.1, Class125.

ee.

Materials:

1) Body and cover: Grade 65-45-12 Ductile Iron.

2)

Disc: precision molded Buna- N.ff.

Design Requirements:

11))

The valve body shall be full flow equal to the nominal pipe diameter at allpoints through the valve. The seating surface shall be on a 45 degree angelto minimize disc travel. A threaded port with pipe plug shall be provided onthe bottom of the valve to allow for field installation of the backflow actuatorwithout special tools or removing the valve from the line.

22))

The top access port shall be full size, allowing removal of the disc withoutremoving the valve from the line. The access cover shall be domed in shapeto provide flushing action over the disc for operating in lines containing highsolids content. A threaded port with pipe plug shall be provided in the accesscover to allow for field installation of a mechanical disc position indicator.

33))

The disc shall be of one-piece construction, precision molded with anintegral o-ring type sealing surface, and contain alloy steel and nylonreinforcement in the flexible hinge area. Non-slam closing characteristicsshall be provided through a short 35 degree disc and a disc accelerator.

44))

The exterior and interior of the valve shall be coated with fusion bondedepoxy coating.

55))

Swing check valve(s) shall be a Valmatic Series 500.

7.

Swing Check Valves w/ Surge Reduction - AWWA C508gg.


hh.

The check valve shall comply with AWWA C508

ii.

The swing check valves shall be of the full body type, with a domed access coverand two moving parts, the flexible disc and the disc accelerator.

jj.

Valves shall be provided with flanges in accordance to the ANSI B16.1, Class125.

kk.

Body and cover: Grade 65-45-12 Ductile Iron.ll.

Disc: precision molded Buna- N.mm.

Disc Accelerator: 302 SS.nn.

Design Requirements:


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11))

The valve body shall be full flow equal to the nominal pipe diameter at allpoints through the valve. The seating surface shall be on a 45 degree angelto minimize disc travel. A threaded port with pipe plug shall be provided onthe bottom of the valve to allow for field installation of the backflow actuatorwithout special tools or removing the valve from the line.

22))

The top access port shall be full size, allowing removal of the disc without

removing the valve from the line. The access cover shall be domed in shapeto provide flushing action over the disc for operating in lines containing highsolids content. A threaded port with pipe plug shall be provided in the accesscover to allow for field installation of a mechanical disc position indicator.

33))

The disc shall be of one-piece construction, precision molded with anintegral o-ring type sealing surface, and contain alloy steel and nylonreinforcement in the flexible hinge area. Non-slam closing characteristicsshall be provided through a short 35 degree disc and a disc accelerator.

44))

The disc accelerator shall be of one piece construction and provide rapidclosure of the valve. The disc accelerator shall be enclosed within the valveand shall be field adjustable and replaceable without removal of the valvefrom the line. The disc accelerator shall be securely held in place by be

captured between the cover and disc.55))

The exterior and interior of the valve shall be coated with fusion bondedepoxy coating.

66))

Swing check valve(s) shall be a Valmatic Series 7200 Surgebuster.

8.

Non-Slam Check Valves

oo.


pp.

Valves shall be of the silent operating type that begins to close as forwardvelocity diminishes, and be fully closed at zero velocity preventing flow reversal.The check valve bodies shall be ASTM A126 Grade B cast iron, or better, and

shall be free from blowholes, sand holes, and other impurities. The check valvedesign shall be center guided, spring loaded poppet guided at opposite ends, andhaving a short linear stroke that generates a flow area equal to the pipe diameter.The internals shall be machined bronze disc seat, and stem guide. The seat shallcontain a Buna-N seal to provide zero leakage.

qq.

The valves shall be sized to permit full pump capacity to discharge through themwithout exceeding a pressure drop of 2.0 PSIG.

rr.

Non-slam pump check valve(s) shall be a Valmatic Series 1400-BN.

9.

Pressure Relief Valves

ss.

The relief valve shall be pilot controlled, hydraulically operated, diaphragm type

automatic control valve.tt.

The main valve shall include a resilient, replaceable seat and have potable epoxycoatings on wetted valve parts, have a ductile iron body and bronze trim.

uu.

The control pilot shall be a direct-acting, spring loaded, normally closed pilotdesigned to close the main valve whenever the sensed pressure is below the pilotspring setting.

vv.

The relief valve shall function to limit the discharge header pressure to thepressure value set into the control pilot.


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ww.

The valve shall be sized and configured as shown on the plan and willinclude ANSI Class 125 flanges and a maximum pressure rating of 250 psi. Ifsystem pressure is to be greater than this value, valves shall be appropriatelysized for the proper pressure ratings.

xx.

The valve shall have a replaceable spring that allows for a setpoint settingranging from 20-200 PSIG.

yy.

Relief valve(s) shall be Cla-Valve Model 50-01BKC.

10.

Pressure Relief Valve with Surge Anticipating Feature

zz.

The surge anticipating pressure relief valve shall be pilot controlled,hydraulically operated, diaphragm type automatic control valve.

aaa.

The main valve shall include a resilient, replaceable seat and have potable epoxycoatings on wetted valve parts, have a ductile iron body and bronze trim.

bbb.

The control pilot shall be a direct-acting, spring loaded, normally closedpilot designed to close the main valve whenever the sensed pressure is below thepilot spring setting.

ccc.

The relief valve shall function to limit the discharge header pressure to the

pressure value set into the control pilot.ddd.

The valve shall be sized and configured as shown on the plan and willinclude ANSI Class 125 flanges and a maximum pressure rating of 250 psi. Ifsystem pressure is to be greater than this value, valves shall be appropriatelysized for the proper pressure ratings.

eee.

The valve shall have a replaceable spring that allows for a set point settingranging from 20-200 PSIG.

fff.

Relief valve(s) with surge anticipating shall be Cla-Valve Model 52-03BKC.

11.

Pressure Gauges

ggg.

Pressure gauges shall include a built-in pressure snubber and 4

minimum face diameter. Gauge to be turret style, black phenolic case with clearglass face.

hhh.

The bourdon tube and tip material are made from grade A phosphorbronze tube, brass tip and silver brazed.

iii.

Movement shall be rotary, of 400 series stainless steel with Teflon coated piniongear and segment.

jjj.

The gauge shall be bottom connected with NPT male thread. Gauges to beliquid glycerin filled for vibration dampening purposes.

kkk.

Pressure gauge range and scale graduations shall be in PSI as follows:

11))

Suction pressure: (30 Hg-100 psi, 10 psi figure intervals with graduatingmarks every 1 psi).

22))

Discharge pressure: (0-200 psi, 20 psi figure intervals, with graduating marks

every 2 psi).

lll.

One gauge will be provided with each manifold. All gauges are to be panelmounted off the skid piping and flexible connected to their respective sensingpoints. The gauge trim tubing shall be complete with both isolating and ventvalves. The gauges shall be so arranged to easily vent air and facilitate gaugeremoval. Gauges mounted directly to the pipeline or sensing point will not beaccepted.


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mmm.

A single, right angle outlet, smooth nose, brass sample tap shall beaffixed to the manual vent valve for the low suction lockout and suction pressuregauge assembly.

11))

Pressure gauge assemblies shall include the following accessories:

22))

Cross tee at point of process connection.

33))

Air release valve mounted on highest point of cross tee.

44))

Sampling/vent valve on one side of cross tee.55))

Trim tubing to panel mounted pressure gauge.

nnn.

Gauge(s) shall be Ashcroft model 1279 RSL or Wika model 212.34.

12.

Air Release Valves with Vacuum Checkooo.

A properly sized air release valve shall be installed where identified onthe drawing or at the highest point on the discharge pipe manifold.

ppp.

The air release shall allow for the release of air, generated by the startingof the pump.

qqq.

The valve shall have a cast iron body, and cover, with stainless steelinternal trim, and a viton orifice button to prevent malfunctions due to corrosion.

rrr.

The valve shall include an NSF/ANSI 61 certified. The check valve shall includea vacuum check to prevent the inflow of air into the piping system.

sss.

Air release valve(s) shall be a Val-Matic 15AVC.

E.

Hardware

1.

Hardware requiring special tools shall not be used. In the assembly of the pumpsystem, all machine bolts, nuts and cap screws shall be of the hex head type.ttt.

All hardware shall be furnished in 304 stainless steel.uuu.

All hardware shall be zinc coated per ASTM A153.

F.

Pipe Supports

1.

Pipe supports by minimum sizing for:

vvv.

8" and smaller piping shall be 2" x 3" x 3/16" wall rectangular tubing.www.

10" and larger piping shall be 3" x 4" x 1/4" wall rectangular tubing.xxx.

6" and larger piping shall be provided with "kick" bracing projectingfully from the underside of the pipe to the floor at an angle of no less than 15degree from vertical out at right angle to the run of the pipe being supported.These "kick" braces shall be in addition to the vertical pipe supports called outabove.

yyy.

Pipe supports are to be fully welded at both end points to the pipe andsteel floor where required.

zzz.

Simple pipe stands made of pipe welded only at the floor and upholding a yokeor bracket with or without a threaded jack bolt or a U-bolt are not acceptable, asno lateral or transverse support is provided.

G.

Corrosion Protection / Paint - Ferrous Surfaces

1.

Exterior Pipe and Skid


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aaaa.

All surfaces of the entire structure shall be sandblasted equal tocommercial blast cleaning to SSPC-SP6.

bbbb.

Following grit blasting, all weldments will be pretreated by hand withbrush using Tnemec Series 69 epoxy coating to provide additional corrosionprotection.

cccc.

The full protective coating shall take place immediately after surface

preparation.dddd.

The protective coating shall be Tnemec Series 69 Hi-Build Epoxoline 11consisting of a two-component, high solids, epoxy system formulated for highbuild application for protection and finishing and having excellent chemical andcorrosion resistant properties.

eeee.

The epoxy system shall be self-priming and require no intermediatecoatings.

ffff.

The protective coating shall provide to a total dry mil thickness of 8.0 mils forthe pipe exterior and a total dry mil thickness of 14 mils for the skid. Color shallbe Safety blueSC06

gggg.

All walking areas that do not have diamond plate shall include a AS-250skid resistant adder to the coating.

hhhh.

In applications where the skid will be exposed to UV, the coatings inthose areas should be top coated as follows:

11))

Type: gloss aliphatic polyurethane topcoate

22))

Series: Amercoat 450H

33))

Manufacturer: Ameron

44))

Thickness: total dry mil thickness of 3-4 mils

H.

Interior of pipeWet Coat1.

The pipe surfaces to be coated shall be blast cleaned to achieve a near white surfaceconforming to SSPC-SP10.

2.

The epoxy product shall be National Sanitation Foundation (NSF) Standard 61certified material. The polyamidoamine epoxy shall be Series 140 Pota-Pox Plus

from Tnemec. Total dry mil thickness of 12-15 mils. Color shall be white.

I.

Interior of PipePowder Coat

1.

Fusion Bonded Epoxy Coating - Steel Piping:iiii.

Steel piping shall have applied to it a Fusion Bonded Epoxy Coating on theinterior pipe surface that conforms to AWWA C-213-91 for steel water pipelines.

jjjj.

The powder coating product shall be National Sanitation Foundation (NSF)Standard 61 certified material.

kkkk.

The final product shall be capable of meeting Salt Spray ResistanceASTM B117 (1000 hour) with no blistering, undercutting or rust bleed; HumidityResistance ASTM D2247 (1000 hour) with no blistering, undercutting or rust

bleed; and Impact Resistance of ASTM G14-72 (160 in. lbs.).llll.

The Fusion Bonded Epoxy Coating shall provide a minimum total dry milthickness of 12-16 mils. The epoxy powder coating shall be Pipe Clad 1500Red latest revision from Valspar, Inc.

2.

Prior to shipment of the station, the station manufacturer shall provide in writing tothe Engineer certification that the fusion bonded epoxy coating has been applied toall internal surfaces of the steel piping using the proper method. Said certificationshall show under the station manufacturer's letterhead.


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a.

Date of application.b.

Material manufacturer and product designation including a product data sheet forthe coating.

c.

Applier of the fusion bonded coating, name, address and phone number.d.

Notarized signature of an officer of the station manufacturing company statingthe fusion bonded epoxy coating was applied to AWWA Standard C213-91 or

the latest revision.

J.

Control Panel

1.

The control panel shall be spray cleaned, acid etched and neutralized, and powdercoated with a finish coat of grey hammer 2-4 mil baked-on polyester powder.

2.03 PUMPS AND MOTORS

A.

Vertical Turbine Pumps and Motors

1.

Operating Conditionsmmmm.

Each pump tohave the followingcapacities:

11))

Design: xxxx GPM @ xxx Feet TDH (boost)

22))

Maximum: xxxx GPM @ xxx Feet TDH (boost)

33))

Minimum efficiency at design flow: xx.x%

44))


55))

Rated horsepower: xxx HP

66))

Speed: 1760 RPM

77))

Maximum required NPSH: 15 Feet

88))

Minimum available NPSHa: 15 Feet

99))

Altitude of installation: 2500 Feet

nnnn.

The pump motor shall be sized so that the nameplate horsepower ratingshall not be exceededat any point on performance curve without considerationof the service factor.

oooo.

The pump motor shall include a 1.15 service factor.

2.

Vertical Turbine Pump(s)pppp.

The pumps within this station shall be of the vertical turbine type.qqqq.

The pump shall be supplied with a flange mounted discharge head with asuction can flange including 125 LB ANSI drilling the centerline of which islocated in the vertical plane 90 degrees from the centerline of the dischargeflange which also includes 125LB ANSI drilling.

rrrr.

The top diameter of the pump discharge head shall be sized to match the diameterof the motor base to distribute the load uniformly.

ssss.

The discharge head will be complete with cast iron stuffing box withsuitable packing and a split gland ring.

tttt.

The head shall include a suitable packing gland drain connection. This drainconnection shall be piped to a building unless otherwise specified.


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3.

Pump Colum Assemblyuuuu.

The column pipe shall be furnished in sections not over 10 Feet in lengthand shall include flanged connections between sections.

vvvv.

The line shaft shall be 416SS and is to be turned, ground and polishedprecision shafting of ample size to operate the pump without distortion orvibration.

wwww.

The drive shaft shall be furnished in interchangeable sections not over 10Feet in length and shall be coupled with 416SS steel couplings.

xxxx.

Column assembly bearing retainers shall be water lubricated (unlessotherwise specified) of cut-less rubber designed for vertical turbine pumpservice. Maximum bearing spacing to be 10 Feet.

4.

Cup Bowl Assemblyyyyy.

The pump bowls shall be of close grained cast iron having a tensilestrength of 30,000 lbs per square inch, free of blow holes, sand holes and anyother faults, accurately machined to close dimensions. Pump bowls to be ceramiclined interior.

zzzz.

The impeller shall be of bronze, accurately machined and finished, also

to be mechanically balanced.aaaaa.

The impeller shaft shall be supported by a combination of waterlubricated, fluted rubber and bronze bearings.

bbbbb.

Impellers to be fastened to the shaft with a tapered bushing.ccccc.

Each bowl shall have an impeller seal ring to prevent slippage of waterbetween bowl and impeller.

ddddd.

The impeller/shaft assembly shall be adjustable by means of a top shaftnut at the top of the motor.

eeeee.

Pump(s) shall be manufactured by Fairbanks Morse, Aurora, Goulds orpre-approved equal.

5.

Suction Barrel

fffff.

The suction barrel shall be constructed of fabricated steel piping eitherschedule 40 piping or .375 inch wall thickness and be provided with a suitableflange arrangement to support the entire pumping unit and connection to thedischarge head. The barrel/pump discharge head connection shall provide thesealing capability necessary as dictated by the suction pressure of the system.

ggggg.

The barrel shall be sufficient inside diameter to provide clearance for thepump fluid without pump cavitation. The pump barrel sizes and clearances shallbe as approved by the pump manufacturer.

hhhhh.

Suction barrel shall be provided with the necessary fixtures to be boltedthrough the pump station floor once delivered to the jobsite.

iiiii.

Barrels welded to/through the floor will not be approved.jjjjj.

Pump suction barrels are to be direct buried.

kkkkk.

The suction barrels are to be back filled with graded material or concreteas specified by the engineer or as described elsewhere in these specifications.

6.

Corrosion Protection / Paintlllll.

Coatings for pumps shall be as approved by NSF 61. Coating system toinclude inside and outside of pump column pipe, inside of pump suction barrel,and outside of pump bowl assembly. Outside of suction barrel to be painted withthe same paint system as the rest of the pump station piping.


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7.

Motor Couplingmmmmm.

A suitable non-reverse coupling shall be provided to connect the verticalhollow shaft motor to the two piece drive shaft assembly.

nnnnn.

The coupling shall be designed to form a unit with the head shaftimpeller adjustment nut to provide a variable adjustment to the pump impellers.

ooooo.

The coupling shall be bolted down to prevent pump damage from

momentary hydraulic balance.

8.

Vertical Hollow Shaft Motorppppp.

The electric motor shall be a vertical hollow shaft, 1750 RPM, 480 Volt,3 phase, 60 hz unit with non-reverse ratchet, P base and squirrel cage inductiondesign.

qqqqq.

Enclosure shall beet NEMA weather protected Type 1, WP1 withstainless steel screens to prevent entrance of rodents.

rrrrr.

Motor shall have Class F insulation with temperature rise as specified byNEMA standards for class of insulation used and shall include a 1.15 servicefactor.

sssss.

Motor thrust bearing shall be provided to handle the continuous down

thrust as specified by the pump manufacturer with an L-10 lift of (1) yearminimum and an average life of (5) years under design conditions.

ttttt.

Provisions shall be made for momentary up-thrust equal to 30% of rateddown thrust.

uuuuu.

The motor rating shall be such that it will not be loaded beyondnameplate rating at any point on the pump curve without consideration of themotor service factor.

vvvvv.

Provide each motor with 120 volt space heaters designed to maintain thewindings at a temperature above ambient temperature when not in service.

wwwww.

The motors shall be standard efficiency and inverter rated.xxxxx.

Motor(s) shall be manufactured by US Motor or pre-approved equal.

B.

End Suction Horizontal Pumps and Motors1.

Operating Conditions - The pump station shall be capable of delivering the fluidmedium at the following capacities and heads when operating at 0 Feet minimumsuction pressure.yyyyy.


11))


22))


33))


44))


55))

Speed: 1760 RPM66))


77))


88))


2.

The pump motor shall be sized so that the nameplate horsepower rating shall not beexceededat any point on performance curve without consideration of the servicefactor.

3.



16/56


4.

End Suction Horizontal Pump (s)zzzzz.

CasingThe casing shall be cast iron with smooth water passages.aaaaaa.

ImpellerThe impeller shall be one-piece bronze casting of a diameternot greater than 90% of the casing cutwater diameter. Impellers shall be finishedall over, the exteriors being turned and the interiors being finished smooth and

cleaned of all burrs, trimmings and irregularities. All impellers are to bebalanced and securely fastened to the shaft by the key and screw locked shaftsleeves.

bbbbbb.

Stuffing BoxThe stuffing box shall be cast integral with the pumpcasing. The stuffing box shall provide sufficient area for incorporation of themechanical seals. The mechanical seals shall be face type. The seal shall have acarbon rotating head against a Ni-Resist stationary face and be complete with aBuna-N boot with stainless steel spring and spring retainer.

cccccc.

Shaft SleevesThe shaft sleeves shall be extended from the hub of theimpeller, through the seal box area, and beyond the gland. They shall be sealedat the impeller hub by a teflon coated steel gasket to prevent pumped liquid fromcontacting the shaft. They shall be threaded to hold them securely in place, and

designed so as to lock the impeller.dddddd.

The pump shaft shall be one-piece, finished and polished on all sections.The shaft shall be of ample strength and rigidity and the shortest practicabledistance between bearing shall be used to keep deflection and vibration to aminimum. The maximum allowable deflection of the shaft is 0.002 at any pointof operation on the pump curve.

eeeeee.

CouplingPump shall be horizontal close coupled to motor. If pumpand motor are too large to be close coupled, they shall be base mounted andinclude a coupling and drive guard rated for inverter duty service.

ffffff.

Air ReleaseEach pump discharge shall have an air release valvebetween the pump discharge volute and the check valve to remove any air whichwill accumulate in this area.

gggggg.

Pump(s) shall be as manufactured by Bell & Gossett, Armstrong,Cornell, Goulds, or pre-approved equal.

5.

Close Coupled Motorhhhhhh.

Pump motor to be horizontal shaft, foot mounted, squirrel cage inductiontype with Nema C flange, enclosure, 1750 RPM, 480 Volt, 3 phase, 60 hertz. Ifpump and motor are too large to be close coupled, motor shall be a framemounted, Nema T style motor.

iiiiii.

Enclosure shall be ODP (Open Drip Proof).jjjjjj.


kkkkkk.


llllll.

The motors shall be standard efficiency and inverter rated.mmmmmm.

Motor(s) shall be manufactured by Baldor, US Motor or pre-approved equal.

C. Vertical Multistage Inline Pumps and Motors


17/56


1.

Operating Conditions - The pump station shall be capable of delivering the fluidmedium at the following capacities and heads when operating at 0 Feet minimumsuction pressure.nnnnnn.


11))


22))


33))


44))


55))

Speed: 1760 RPM

66))


77))


88))


2.

The pump motor shall be sized so that the nameplate horsepower rating shall not beexceededat any point on performance curve without consideration of the service

factor.3.


4.

Vertical Multistage Pump (s)

oooooo.

CasingThe casing shall be cast iron with smooth water passages.pppppp.

ImpellerThe impeller shall be one-piece stainless steel, full diameter.Impellers shall be fully machined to provide smooth passageway surfaces. Allimpellers are to be balanced and securely fastened to the shaft by the key andscrew locked shaft sleeves.

qqqqqq.

Mechanical SealThe stuffing box shall provide sufficient area forincorporation of the mechanical seal. The seal shall have a carbon rotating head

against a silicon carbide stationary face, complete with viton elastomers.rrrrrr.

Shaft SleevesThey shall made of tungsten carbine and be sealed at theimpeller hub to prevent pumped liquid from contacting the shaft. They shall bethreaded to hold them securely in place, and designed so as to lock the impeller.

ssssss.

ShaftThe pump shaft shall be one-piece, finished and polished on allsections. The shaft shall be of ample strength and rigidity and the shortestpracticable distance between bearing shall be used to keep deflection andvibration to a minimum. The maximum allowable deflection of the shaft is0.002 at any point of operation on the pump curve. The pump shaft shall be ofstainless steel.

tttttt.

CouplingPump shall be vertical close coupled to motor.uuuuuu.

Air ReleaseEach pump discharge shall have an air release valve

between the pump discharge volute and the check valve to remove any air whichwill accumulate in this area.

vvvvvv.

Pump(s) shall be by Grundfos, Goulds, Aurora or pre-approved equal.

5.

Close Coupled Motorwwwwww.

Pump motors to be vertical shaft, pump mounted, squirrel cage inductiontype with Nema P base, 1750 RPM, 480 Volt, 3 phase, 60 hertz. Motor bearingsshall be designed specifically to be oriented in the vertical direction and besubject to any thrust from the pump.


18/56


xxxxxx.

Enclosure shall be ODP (Open Drip Proof).yyyyyy.


zzzzzz.


aaaaaaa.

The motors shall be standard efficiency and inverter rated.bbbbbbb.

Motor(s) shall be manufactured by Baldor, US Motor or pre-approvedequal.

D.

Split Case Horizontal Pumps and Motors

1.

Operating Conditions - The pump station shall be capable of delivering the fluidmedium at the following capacities and heads when operating at 0 Feet minimumsuction pressure.ccccccc.


11))


22))


33))


44))


55))

Speed: 1760 RPM

66))


77))


88))


2.

The pump motor shall be sized so that the nameplate horsepower rating shall not beexceededat any point on performance curve without consideration of the service

factor.3.

The pump motor shall include a 1.15 service factor.4.

Split Case Horizontal Pumpsddddddd.

CasingThe casing shall be cast iron with smooth water passages.Casing will be split horizontally with suction and discharge nozzles at oppositesides of the lower half and in such positions that upper portion of casings can beremoved for access to interior parts without disturbing suction and dischargepiping connections. Flanges shall be in accordance with ANSI standards, 125 lbor sized as necessary to support system pressure. Components to includeregistered fits for precision alignment. Pump feet to be integral to bottom half ofcasing.

eeeeeee.

ImpellerThe impeller shall be one-piece bronze, double suction, not

greater than 95 percent of full diameter. Impellers shall be fully machined toprovide smooth passageway surfaces. All impellers are to be balanced andsecurely fastened to the shaft.

fffffff.

Mechanical SealThe stuffing boxes shall provide sufficient area forincorporation of the mechanical seal. The seals shall include materialsappropriate for the fluid being pumped.

ggggggg.

Shaft SleevesPumps to be provided with shaft sleeves made ofappropriate materials for the fluid being pumped. Default material for the sleevesshall be bronze.


19/56


hhhhhhh.

ShaftThe pump shaft shall be one-piece, finished and polished on allsections. The shaft shall be of ample strength and rigidity and the shortestpracticable distance between bearing shall be used to keep deflection andvibration to a minimum. The maximum allowable deflection of the shaft is0.002 at any point of operation on the pumpcurve.

iiiiiii.

CouplingPump and motor to be provided with a flexible coupling and

guard which are specifically designed to run in an inverter duty application.jjjjjjj.

Wear RingsPumps to be provided with both casing and impeller wearrings.

kkkkkkk.

Air ReleaseEach pump discharge shall have an air release valvebetween the pump discharge volute and the check valve to remove any air whichwill accumulate in this area.

lllllll.

Pump(s) shall be by Bell & Gossett, Fairbanks Morse or pre-approvedequal.

5.

Frame Mounted Motor(s)mmmmmmm.

Pump motors to be horizontal shaft, frame mounted, squirrelcage induction type with NEMA configuration, 1750 RPM, 480 Volt, 3 phase,

60 hertz.nnnnnnn.

Enclosure shall be ODP (Open Drip Proof).ooooooo.


ppppppp.


qqqqqqq.

The motors shall be standard efficiency and inverter rated.rrrrrrr.

Motor(s) shall be manufactured by Baldor, US Motor or pre-approvedequal.

E.

Pump TestsNon-witness

1.

Test pump casings under a hydrostatic head of at least 150 percent of the ratedshutoff head. Test casing with pump assembled.

2.

Provide certified performance tests as specified herein for all pumps and sparerotating assemblies except those specified to be witness tested.

3.

Certified performance testing:sssssss.

Run pump at full speed rating point for 60 minutes prior to start of anytesting.

ttttttt.

Full speed test:

11))

Test pumps at the conditions specified and indicated in a take not less than

seven operating points between shut-off and run out. Test points must be atthe conditions specified and indicated.

22))

Take readings to determine flow, differential pressure, RPM, horsepower,and efficiency.

33))

Operate each pump for not less than one hour and take readings to determinethat the pump will operate as specified and indicated without cavitation at thespecified minimum head condition with not more than the specified NPSHavailable. Test with the appropriate submergence as required.


20/56


uuuuuuu.

Variable speed tests:

11))

Conduct tests as specified above for full speed then at reduced speeds. Testsfor cavitation at run out are not required.

22))

Run one speed test at speed required to discharge the minimum rating pointspecified and indicated with one point for test at the minimum rating point.

33))

Run a second test at a speed approximately midway between full and

minimum speed.44))

Run additional tests for each reduced speed operating condition specified andindicated.

55))

Use factory calibrated test drives.

vvvvvvv. Run all tests in accordance with the latest standards of the

Hydraulic Institute and as specified.

wwwwwww.

Testing Tolerances:

11))

ANSI/HI 1.6 Acceptance Level A

22))

Tolerance: Pump test results shall be judged at rated rate of flow and RPMwith applicable total head and efficiency as defined by ANSI/HI 1.6 for the

pump conditions specified and indicated.33))

If pumps do not meet the tolerances specified, trim or replace the impellerand retest until the specified results are obtained.

xxxxxxx.

Test Reports - Copies of all test results shall be submitted to the Engineerfor review. The number of copies of the tests shall be the same as the number ofSubmittals to be submitted as specified herein immediately upon completion ofsuch tests.

F.

Motor TestsNon-witness

1.

Motor Tests

yyyyyyy.

All electric motors shall comply with ANSI/NEMAMG-1 and MG-2.Each motor shall be manufactured and shop tested in compliance with therequirements of the IEEE, ANSI, and NEMA.

zzzzzzz.

Tests, with certified test results, shall be as required by NEMA MG-1.Each motor shall be subjected to a standard, short commercial test including thefollowing:

11))

Running current, no load

22))

Locked rotor current

33))

High potential

44))

Winding resistance

55))

Bearing inspection

aaaaaaaa.

Test Reports - Copies of all test results shall be submitted to theEngineer for review. The number of copies of the tests shall be the sameas the number of Submittals to be submitted as specified hereinimmediately upon completion of such tests. Efficiency index, nominalefficiency, and minimum efficiency shall be defined in accordance withANSIINEMA MG 1-12.53.b; these values shall be stated in the ShopDrawing submittal. Motor nameplate data shall include the nominalefficiency value.


21/56


2.04 OPTIONAL SKID UPGRADES

A.

Hydropneumatic Tank

B.

Mechanical Seals for Vertical Turbine Pumps

1.

Each vertical turbine pump provided in the pump station shall include a mechanicalseal. In addition to the mechanical seal, an appropriately sized riser stand shall beprovided on the pump discharge head for seal maintenance access if necessary.

2.

Mechanical seal shall be designed and selected to appropriately seal based on theoperating conditions of the pump system.

C.

VFD Bypass

D.

Soft Start Motor Starter with Soft Start Bypass1.

The soft start shall be supplied ready for use in a standard duty application with Class10 motor thermal overload protection and appropriately sized for the selected motors.

2.

The soft start shall have an equally sized back up soft start that can be used in the

event the first one fails. This bypass shall be a manual change by the operator via ahand switch Main Soft Start bypass Alternate Softstart.

3.

All devices include a built-in keypad display which can be used to modify theconfiguration to adapt it to the application and individual customer requirements.

4.

Soft Start performance functions:a. Exclusive torque control system (TCS); Constant control of the torque supplied to

the motor during acceleration and deceleration periods (significantly reducingpressure surges)

b.Adjustments for ramp and the starting torquec. The soft start can be bypassed using a contactor at the end of the starting period

while maintaining electronic overload protection (bypass function)d.Wider frequency tolerance for generator set (source) power supplies Machine and

motor protection functions.e.Built-in motor thermal overload protectionf. Processing of information from PTC thermal probesg.

Monitoring of the starting timeh.Protection against underloads and overcurrents during continuous operation.i. Extended I/O functions for integration into control systems: 4 logic inputs, 2 logic

outputs, 3 relay outputs, and 1 analog outputj. Pull-apart terminal connectors

k.Function for configuring a second set of motor parameters and easy-to-adaptsettings

l. Display of electrical values, running conditions, and operating timem.RS-485 serial link for connection to a Modbus system.

n.

The soft start shall be a Square D model Altistart 48.

E.

Conduit1.

Conduit shall be used in all necessary areas to protect the power and control/signalwires. Flexible metal conduit may be used for motor feeds as allowed by NEC. Thesystem shall have the following conduit:a.PVC ConduitPolyvinylchloride (PVC) plastic tube or pipe.

b.EMT ConduitGalvanized Electrical Metallic Tubing (EMT).c.Galvanized Rigid Conduit


22/56


d.PVC Coated Galvanized Rigid Conduit - Polyvinylchloride (PVC) plastic coatingon galvanized rigid conduit.

F.

Floor Mats

G.

Pump Room Dehumidifier

1.

One (1) each, installed as shown.2.

Capacity 30 pints per 24 hours.3.

Compressor rated 115 volts, 60 Hz, 3.4 operating amps.4.

126 CFM fan, 2 fan speed.5.

Humidity range 35 to 90% RH, ambient temperature range of 42 to 105F, Type R22refrigerant.

6.

Washable filter.7.

Condensate piped direct to sump.8.

UL listed rubber cord.9.

EPA compliant.

H.

Ladder for Equipment Access

I.

Ancillary Monitoring and Alarm

1.

The skid shall have the following sensors and monitoring by the system PLC:a.Temperature Monitor for Building

b.Alarm Switch for Door - The door(s) shall be fitted and wired to an interlockmicroswitch which will be wired to the control panel to register and record whenthe door has been opened.

c.Water on Floor Monitor - The control panel shall be fitted and wired with aninterlock level switch which will alarm when actuated.

J.

Crane Hoist and Trolley for Equipment Removal

K.

Transient Voltage Surge Supression

L.

Telemetry Panel, Remote Monitoring of Pump System

M.

Power for Telemetry Panel (panel by others)

N.

Generator Set with Transfer Switch

O.

Uninterruptible Power Supply

P.

Extended Warranty

2.05 ELECTRICAL

A.

Provide complete instrumentation and controls to automatically start, stop and modulatepump speed(s) to smoothly, efficiently and reliably deliver variable flow rates at a constantdischarge pressure. To provide alarms, and safety features needed to protect the equipment,personnel, and water piping system.


23/56


B.

The control panel design, assembly, and installation along with integration of componentparts will be the responsibility of the pump station manufacturer.

1.

The pump station manufacturer shall maintain at his regular place of business, acomplete electrical design, assembly and test facility to assure continuity of electricaldesign with equipment application.

2.

Control panels designed, assembled or tested at any facility other than the pump

station Manufacturersfacility or by anyone other than regular production employeesof the pump station manufacturer will not be approved or accepted.

3.

The control panel door shall be complete with stick-on schematics containing the as-built drawings for the pump system control panel.

4.

The end users engineer shall have completed a harmonics survey that includes thecomponents of this system and all other associated components to ensure that thefollowing control panel and electrical system shall meet the requirements of IEEE519.

C.

Control Panels1.

Controls shall be housed in a UL508 listed NEMA 12 enclosure with integral doorlatches. The control enclosure shall be constructed of 12 gauge steel, and the back

plate assembly shall be constructed of 12 gauge steel.2.

The enclosure shall be painted as specified. All indicating lights, reset buttons, speedpotentiometers, selector switches and the operator interface device shall be mountedon enclosure door and have the same or stricter NEMA classification as theenclosure.

3.

All internal components shall be mounted and secured to the removable back plateassembly. Pilot devices shall run from secondary, control voltage (24 VDC or 120VAC). The short circuit interrupt rating of the panel shall be 5 KAIC.

D.

Main Disconnect1.

A non-fusible main disconnect shall be provided to completely isolate controls, andmotor starting equipment from incoming power. The main disconnect shall have an

interlocked, through-the-door, operator, and shall be sized appropriately for thecomplete pump system. The Main disconnect shall be as manufactured by Square D.

E.

Hand Switches and Indicator Lights1.

Each panel shall include: One (1) hand-off-automatic (HOA) hand switch for eachpump; one (1) green light indicating the pump is in operation; and one (1) red generalsystem fault light.

F.

Control Panel Cooling1.

A fan and filter or air conditioner with proper NEMA classification shall be includedon the control panel and be properly sized in order to provide adequate cabinetcooling for all the components in the panel.

2.

This shall be achieved while working in conjunction with the pump houses cool ingsystem and taking into account all heat loads in the pump house and the panel.

3.

Heat exchangers and open type cooling systems allowing outside ambient air toenter the panel is not acceptable.No water line connections shall be permittedinside of the control enclosure.

G.

Transient Voltage Surge Suppression (TVSS)1.

The system manufacturer shall provide transient voltage and surge suppression for allPLC data communication devices whenever the communications cable is located


24/56


outside the building in which the panel resides. This also applies to all outdoorpanels with communications cables exiting the PLC panel enclosure.

2.

The TVSS unit shall be UL 497B listed.3.

The TVSS unit shall have a maximum DC operating voltage of 9.6 VDC, a clampingvoltage of 81V, and an 8 x 20 US surge current rating of 1000 amps.

4.

Transient voltage and surge suppression shall also be provided for 10-32 VDC

instrumentation signal systems.5.

The TVSS units shall be employed when the signal cable extends beyond theboundaries of the building in which the PLC panel is located.

6.

TVSS units must be as manufactured by Leviton, Inc., of Little Neck, New York,Model 3803-485/DHP for PLC communications and Model 3420-009/035 for 10-32VDC signal wiring, or approved equal.

H.

Lightning & Surge Arrestor1.

All electrical equipment shall be protected by a UL approved category C surgearrestor to suppress voltage surges on incoming power. The surge arrestor should beintended for use on three-phase, 600 VAC systems and designed to discharge thefollowing amperages: 1.5kA @ 1640 V; 5 kA @ 2340 v; 5 kA @ 2510 V; 10 kA @

2920V. The Lightning and Surge Arrestor shall be an Intermatic AG6503.

I.

Incoming Power Requirements & UPS Enclosure1.

Controls shall operate from a source of 120 volts, 1 phase, 60 Hz. Each panel shallbe accompanied with an uninterruptible power supply (UPS) enclosure.

2.

The UPS shall condition the power as well as provide 500 VA of power duringoutages.

3.

A 6-amp control power circuit breaker shall be employed as both a method ofequipment protection and as a means of power disconnection.

4.

The circuit breaker shall be a single pole, thermal, magnetic type with a 10,000 Ampinterrupt rating. The circuit breaker shall be UL listed.

J.

Control Power1.

Power for the controls shall be provided by a control power transformer (CPT),which will provide 120 volt, single-phase power for the pumping system controloperation. The CPT shall not be used for any other external load.

2.

It shall be protected on the primary side by current limiting fuses of adequate size andvoltage rating. All controls will be protected by time delay circuit breakers ofadequate size.

K.

Phase Monitor1.

A phase monitor shall be included to provide protection of all three-phase equipmentagainst phase loss, under voltage, and phase reversal; when fault is sensed themonitor output relay opens to turn the equipment off and/or cause an alarm;

automatic reset; LED indicator light.

L.

Motor Starting Equipment1.

Unless specified otherwise, all motor starters for the pumping station shall bemounted on a back pan in the control panel enclosure.

2.

Motor starters shall meet I.E.C. Standards, be UL Listed, and shall be rated for aminimum of 1,250,000 operations.

3.

Motor overload relays shall be I.E.C. rated class 10 ambient compensated.


25/56


4.

Fuses shall supply short circuit protection to each motor, and shall be rated for aminimum 200,000 amp interrupting capacity.

5.

Motor starters and overload relays shall be UL Listed.6.

The Motor Starting Equipment shall be as manufactured by Square D.M.

Variable Frequency Drive1.

A variable frequency drive shall be included for each main pump.

2.

The variable frequency drive (VFD) shall be digital, pulse width modulation (PWM)with IGBT transistors.

3.

The VFD shall be 98% efficient or better at full speed and load and shall be rated tooperate at the specified system voltage +10/-10, 48 to 63 HZ. The overvoltage triplevel shall be a minimum of 30% over nominal, and the undervoltage trip level shallbe a minimum 35% under the nominal voltage.

4.

Any VFD error messages shall be displayed on a 4 x 20 character LCD readout inEnglish and any one of eight (8) other languages.

5.

The following fault protection circuits shall be included: Over-current (200%), Over-voltage (130%), Under-voltage 65%, Over-temperature (70 DEG. C), Ground fault,and Motor-overload.

6.

The VFD shall have automatic extended power loss ride through circuit that will

utilize the inertia of the pump to keep the drive powered.7.

Minimum power loss ride-through shall be one cycle based on full load and noinertia.

8.

The VFD shall be configured for a 3 kHz carrier frequency to reduce motor noise.The VFD shall provide a tripless operation.

9.

The following operating information shall be displayed on the VFDs LCD: kWh,elapsed time, output frequency (Hz), motor speed (RPM), motor current (amps), andvoltage.

10.

DC swinging choke will be installed on input of VFD to protect against voltagetransients. Each main pump shall include its own individual variable frequencydrive.

11.

Any system jockey or pressure maintenance pump will not include a VFD unless

otherwise specified.12.

A manually adjustable speed potentiometer shall be included on the control panel foreach VFD. All motors that operate from a VFD shall be inverter rated.

13.

The VFD shall be an ABB ACS 550 Adjustable Speed Drive.

N.

Pressure Transducer, High Accuracy1.

The pump system shall be provided with suction and discharge pressure transducers.The specific pressure ranges for each of these transducers shall be as appropriate forthe specific conditions for the pump system.

2.

The pressure transducer shall provide 4-20 mA pressure signals for the PLC.3.

The accuracy shall be .15% of full scale, and constructed of 316 SS wetted parts.4.

It shall provide gauge pressure output with the following ranges: suction manifold, -

14.7 to 150 PSIG; discharge manifold, -14.7 to 800 PSIG.5.

The Pressure Transducer shall be a Rosemount 3051T.

O.

Pressure Transducer1.

The pump system shall be provided with suction and discharge pressure transducers.The specific pressure ranges for each of these transducers shall be as appropriate forthe specific conditions for the pump system. Pressure transducer shall providepressure signals for the control logic.


26/56


2.

The accuracy shall be 1.0 of full scale, and constructed of 316L SS wetted parts. Itshall provide gauge pressure output.

3.

The Pressure Transducer shall be a Dwyer Series 628.

P.

Magnetic Flow Meter1.

Electromagnetic flow meter to include polyurethane liner, ANSI B16.5 flanged ends,

316L SS electrodes, and includes 0.5% calibration.2.

Meter shall also include NEMA 4X housing and require a 24 VAC power supply.Output of meter to be 4-20mA based on full scale range.

3.

Meter to include grounding rings mounted in each end of the meter. Grounding ringsare not necessary if internal potable coatings have been removed from thisspecification.

4.

Meter shall be sized as indicated on the drawings. Meter output shall be displayed onthe pump system OID.

5.

The magnetic flow meter shall be an Endress Hauser Promag model 50W.

Q.

Controls1.

All control logic shall be handled by an industrial grade programmable logic

controller (PLC) with a 4x20 character backlit LCD providing data entry and display.PLC shall provide demand controlled variable frequency drive start, shutdown andsafety features through its pressure sensing, flow sensing and voltage sensingdevices.

2.

PLC shall have LED indicators for input, output, and diagnostic read outs showingPC Run, CPU Fault, and two communications ports. An LED visual status light isprovided for each I/O to indicate on/off status.

3.

PLC shall be provided with a built in EEPROM, and capacitor for memory backup. Aseparate set point controller is not acceptable.

4.

The PLC shall have a built in clock calendar.5.

A standard PLC program shall be as provided and maintained by the pumpmanufacturer only. This PLC program will be customized to meet the specific

performance conditions of the pump application.6.

Control software shall be parameter driven, fully documented, and allow user toeasily change all operator parameters.

7.

Standard control features, and equipment that need to be included as a minimum areas follows:bbbbbbbb.

Alarms and Shutdowns

11))

Low suction pressure

22))

Low discharge pressure (with a means of override if desired)

33))

High discharge pressure

44))

Phase Loss (attempts restart)*

55))

Low voltage (attempts restart)*

66))

Phase reversal (attempts restart)*

77))

Individual motor overload/phase loss (indicates which individual motor wasshut down)

88))

VFD fault (shuts down VFD faulted pump only and attempts restart)*

cccccccc.

*Three unsuccessful restarts in a 15 minute period will give hardshutdown as configured from the factory. Number of restarts during a period andthe length of period can be re-configured in the field.


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dddddddd.

All alarms will be indicated by a red general alarm light. Specific alarmconditions along with will be displayed in English on the operator interfacedisplay (OID).

8.

Panel Face Switches and Lightseeeeeeee.

Individual pump run lights

ffffffff.

Individual pump Hand/Off/Automatic switchesgggggggg.

System Hand/Off/Automatic switchhhhhhhhh.

Controls in OID to automatically alternate main pumps based on runhours

iiiiiiii.

ResetAcknowledges pumping station alarms/ Silence Horn/ Lamp Testjjjjjjjj.

Speed potentiometerin system manual mode allows user to adjustindividual VFD pump speed

kkkkkkkk.

Low discharge pressure override disables low discharge pressure alarm(through OID)

9.

System HOA works with PLC bypass switch and allows user to manually operatepumps should PLC fail.

10.

LineFill Software will be included to automatically, and gradually increase the speedof the pump motor to maintain the desired operating pressure for the Irrigation watersystem (i.e., 1.5% every 4 seconds). This feature operates whenever pressure dropsbelow linefill set point pressure. The linefill set point is fully adjustable by theoperator. This control feature is based on an increase in pressure over a pre-definedtime period. The acceleration control on the VFD is NOT an acceptable means ofadjusting pressure ramp up speed.

11.

Neither flow meter nor VFD output frequency shall be used for shutting down lastVFD driven pump. Controls and software shall incorporate a method to eliminateexcessive cycling of VFD pump at very low flow conditions, yet not run the pumpexcessively at no-flow conditions.

12.

An integral real time clock calendar shall allow the PLC to internally provide all date,

and time functions.13.

Manual operation of the VFD driven pump shall be done with a door mounted speedpotentiometer to manually adjust the speed of the pump motor.

14.

A system manual, or automatic mode switch shall be provided. This mode switch,when in the manual mode, will allow all pump motors and the VFD to be operationalshould the PLC fail. When the system mode switch is in automatic, the controllerwill start, and stop all pumps automatically.

15.

All panel lights shall be tested by pressing the reset button for three (3) seconds.16.

A rate of pressure change algorithm shall rapidly determine if there is a waterdemand and immediately cycle on one of the VFD pumps, instead of waiting for thepressure to drop to a predetermined start pressure.

17.

Mechanical Hourmeters - A running time meter shall be supplied for each pump to

show the number of hours of operation. The meter shall be enclosed in a dust andmoisture proof molded plastic case, suitable for flush mounting on the main controlpanel. The meter dial shall register in hours and tenths of hours up to 99999.9 hoursbefore repeating. The meter shall be suitable for operation from a 115 volt, 60 cyclesupply.

18.

The PLC shall be as manufactured by Allen Bradley or Siemens.

R.

Operator Interface Device


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1.

The pumping system shall include a NEMA 4, 4 lines by 20 character backlit liquidcrystal display (LCD) keypad mounted on the control panel door. This device willallow the operator to view, and selectively modify system setpoints in the PLC. Itshall store its messages in a non-volatile memory.

2.

The OID shall incorporate password protection for protecting data integrity. TheOID will allow for display, and modification of timers, set points, and lockout times.

3.

The device shall communicate with the PLC through the programming port, and shallinclude a serial printer port allowing a printer to be attached for real time stationstatus logging.

4.

The OID shall be an information system only, and not required for pumping systemoperation. No switches, reset buttons, general alarm lights, run lights, or speedpotentiometers are to be included within this unit. The pumping system will be fullyfunctional in the event the OID should fail.

5.

In addition to normal data entry keys, the OID shall include a minimum of thefollowing screens:a. Event Log. Displays the last 254 sequential pumping system events with the

date, and time of occurrence. Events shall include but not be limited to: allalarms, starting of individual pumps, stopping of individual pumps, and changing

of selector switches. Individual pump Hand/Off/Automatic switches.b. Alarm Log. Shows the last nine (9) alarms recorded in memory, and are

displayed with related detailed information about the alarm, time of occurrence,date, pumps operating at time of alarm, and how to correct the alarm.

c. Status Screen. Will display the current operating status. When the pumpingsystem is running, the display will show the set point pressure, actual systempressure, flow, VFD pump frequency, and current date and time.

d. Daily Log. Will display the following: individual pump run times, total flow,and total flow since last reset.Configuration Menu. Used to scroll up, and down through the data and menuoptions.

6.

The OID shall be as manufactured by Allen Bradley or Siemens.

S.

Regulatory Codes

1.

The control panel with controls shall be built in accordance to N.E.C. and ULstandards. All equipment and wiring shall be mounted within the control panelenclosure, and labeled for proper identification. All user-required adjustments shallbe made from the front of the control enclosure. A wiring schematic complete withlegend, terminals, components, and wiring identification shall be provided. The maindisconnect shall be interlocked with door.

All control panels shall be constructed and installed in strict accordance with

Underwriters Laboratories (UL) standard 508 Industrial Control Equipment.

Panels must bear the UL serialized label indicating acceptance under Standard508 and must be manufactured and assembled at the pump station manufacturersfacility only. Any control panel manufactured at a facility other than the pumpsystem manufacturer will be immediately rejected.

A photocopy of the pump system manufacturers UL file # shall be provided withthe pump station submittals.

T.

Equipment Grounding


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1.

Each electrical equipment item in the station shall be properly grounded per section250 of the National Electric Code. Items to be grounded include, but are not limitedto, pump motor frames, control panel, transformers, and pressure transducers.

2.

All ground wires from installed equipment shall be in conduit and shall lead back tothe control panel to a plated ground buss specific for grounding purposes.

3.

The ground buss shall be complete with a lug large enough to accept the installing

electricians bare copper earth ground wire. The bus shall serve as the bond betweenthe earth ground and the equipment ground wires.

2.06 SEQUENCE OF OPERATION

A.

Sequence of Operation

1.

During low demand times, the pressure maintenance pump (PMP) or jockey pump (ifincluded) will cycle on and off as required to maintain pressure.

2.

The cycling pressures can be user selected, and can be set substantially below normalsystem pressure, if desired.

3.

If the PMP/Jockey pump cannot maintain the desired pressure, then the first VFD

based main pump will be started, and will gradually ramp the pressure up to thesystem pressure. The pump speed will be modulated to hold a constant dischargepressure regardless of flow.

4.

As the flow rate increases, and the first VFD pump can no longer maintain pressure

while at maximum speed, the next main pump will be started on its VFD, and theVFD driven pump will remain at full speed.

5.

This sequence will continue until all main VFD based pumps are running (Any pumpassigned as an installed back-up not designed to run, will not be included in thissequence, but will be alternated with the other main pumps).

6.

An algorithm shall be included for accurately modulating the VFD pump speed aspumps are started and retired so that no pressure surges are generated during thetransition.

7.

As the flow begins to decrease, pumps will be turned off sequentially until only asingle VFD driven pump is operating.

8.

When a no flow condition occurs, the VFD pump shall be turned off.9.

When there is a pressure set point change all other related set point variables changerelative to the new pressure set point.

2.07 EQUIPMENT ENCLOSURE UPGRADE

A.

Powder Coated Steel Pump Station Equipment Enclosure

1. The pre-packaged, pre-tested system with skid, equipment building anchored

to skid and associated equipment, shall be fabricated and assembled by a

single manufacturer consisting of a coordinated grouping of Manufacturersupplied equipment.

2. All equipment as identified in the plans with associated interconnecting

wiring, cabling, conduit, cable trays, hose, pipe and tubing shall be mountedon a common structural steel base to form a complete, self-contained,automated system contained within an all-weather enclosure designed for theseismic zone with appropriate snow and wind loads as outlined in the DataSheet.


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3. Upon installation and with minor electrical and mechanical hook-ups, the

system shall be fully operational. The packaged system shall be a Metronnumber as shown on the Technical Data Sheet.

4.

Mechanical

a.

Walls1) The walls shall be of self framing interlocking panels made from phosphoric

acid washed 16 gage paintable grade 5 galvanized steel material.2) The panels shall be configured with their flat side turned out, which can

service as a final finish.3) The interior walls shall be made from the materials identified in the

Technical Data Sheet.4) If an aesthetic external finish in required, it shall be as identified in the

Technical Data Sheet.

5) All wall panels shall be provided with stiffeners and adequate flanges tosupport roof snow and wind loads and seismic conditions as identified in theTechnical Data Sheet.

6)

Interior walls, and supporting panels and structures, shall be designed so thatinterior equipment loads may be attached to the wall without compromisingthe designed wind and seismic loads.

7) Similarly, the walls shall be designed to anchor to the floor to withstand thevarious loads.

8) The interior and exterior walls shall be designed to accommodate therequired insulation R value and material.

5.

Roof & Ceilinga. The roof shall be of self framing interlocking panels made from phosphoric acid

washed 16 gage paintable grade 5 galvanized steel material.b. The panels shall be configured with their flat side turned in. The interlocking

ridges shall be turned out and help channel water off the roof.c. If the exterior of the roof additional roofing material, it shall be as identified in

the Technical Data Sheet.d. The roof shall be single sloped, 1:12, to allow for adequate drainage and

include 6 of overhang on all sides.

e. The ceiling shall be designed to retain the insulation and to provide a smoothceiling surface.

f. Ceiling height from floor shall be as identified in the Technical Data Sheet.g. Interior ceiling, and supporting structures, shall be designed so that interior loads

may be suspended from the ceiling without compromisin

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