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SECTION 431133 - POSITIVE DISPLACEMENT BLOWERS

PART 1 - GENERAL

1.1 SCOPE

A. Provide all labor, materials, tools, equipment and incidentals required to provide and install positive displacement blowers with appurtenances as shown on the Drawings, as specified in this Section and other related sections. Install two (2) blowers in the existing Pump/Blower Building and three (3) blowers in the existing Control Building where shown on the drawings.

B. The overall dimensions of the blowers shall enable them to be installed in the existing space provided, with all fixtures specified herein, shown on the Drawings and as Scheduled at the end of this Section. Contractor shall field verify existing blower rooms to obtain necessary information for installation of new blowers and existing pipe connections prior to shop drawing submittal.

C. The Positive Displacement Blower shall include the following:

1. Blower and fabricated steel base. 2. Motor and drive. 3. Accessory equipment. 4. Anchor Bolts and Threaded Fasteners. 5. Repair parts and special tools. 6. Testing, installation, cleaning, training, commissioning, maintenance and other

services and provisions as called for herein. 7. Vibration Pad.

D. Connections of electrical, control and instrumentation components shall be furnished and installed by the ELECTRICAL CONTRACTOR as part of Division 26.

E. All manufacturer/supplier electrical work including original equipment manufacturers work is to be in strict conformance with the requirements of Division 26.

1.2 QUALITY ASSURANCE

A. The specifications in this Section are subject to the administrative and procedural requirements specified in Division 1, as well as the broader requirements of the General Conditions.

B. Reference Standards: Comply with all Federal and State of Ohio laws and ordinances, as well as applicable codes, standards, regulations and/or regulatory agency requirements including the partial listing below:

1. ANSI: American National Standards Institute. 2. ASME: American Society of Mechanical Engineers. 3. NEMA: National Electrical Manufacturers Association. 4. NEC: National Electrical Code.

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5. CAGI: Compressed Air and Gas Institute.

1.3 SUBMITTALS

A. Product Data: Comply with Section 013300, and provide the following:

1. Manufacturer's literature, illustrations, specifications and engineering data. 2. Air flow rates and pressures.

B. Shop Drawings: Comply with Section 013300 and provide the following:

1. Complete description in sufficient detail to permit an item-by-item comparison with the Specifications.

2. Dimensional and materials shop drawings for all equipment to be furnished under this Section (include weights).

3. Layout drawings for all equipment showing typical and specific installation details, as well as layout drawings of the proposed blowers in the existing space.

4. Wiring diagrams for all electrical and instrumentation equipment (schematic and point-to-point).

5. Electrical power requirements. 6. Details of all accessories. 7. Manufacturer's installation and testing instructions. 8. Manufacturer's standard guaranty.

C. Maintenance and Operating Instructions: Comply with Section 017823 and provide the following information:

1. Detailed parts lists. 2. Repair data. 3. Electrical diagrams. 4. Mechanical diagrams. 5. Trouble shooting data. 6. Test data. 7. Repair parts and maintenance materials.

D. Repair Parts and Maintenance material: Comply with Section 017823 for new and replacement equipment.

E. Quality Control Submittals:

1. Design Data. 2. Test Reports. 3. Installation Instructions. 4. Field Installation Reports.

F. Project Record Documents: Comply with Section 017839.

G. Installation Instructions: Furnish manufacturer's printed instructions for assembly and complete installation and connection of all equipment.

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PART 2 - PRODUCTS

2.1 EQUIPMENT

A. Manufacturers:

1. Excelsior Heliflow Series 2. Roots URAI Series 3. Or Equal.

B. Blowers:

1. Each blower shall be of the rotary positive displacement type and be constructed with inlet and discharge connections so that the blowers can be installed on the existing equipment pads and connect to the existing piping.

2. Casing shall be of one piece with separate head plates, and shall be made of close grained gray cast iron suitably ribbed to prevent distortion under service conditions.

3. Fabricate drive end and gear end head plates of close grained cast iron which are precision machined for exact bearings housing fit.

4. Impeller and shaft shall be made from common cast iron. Impeller shall be of the Helical Twist 3 Lobe Design. Straight three lobe impellers are acceptable. Blower shall be positively timed by a pair of accurately machined heat-treated alloy steel, timing gears. Gear diameters smaller than 5” are not acceptable.

5. Each impeller/shaft shall be supported by double row ball or spherical roller bearings sized for a minimum of 50,000 hours of B-10 life.

6. Provide a piston ring type oil seal at each bearing, designed to prevent lubricant from leaking into the air stream. Provisions shall be made to vent the lubrication system to prevent any possible carryover of lubricant into air stream.

7. The timing gears and the bearings shall be splash oil lubricated from oil slingers mounted on the drive shaft and dipping in the oil. Sight glasses for oil level observation shall be provided. Grease lubrication is not acceptable.

8. All fasteners shall be SAE J429 Grade 5, ASTM A449-Type 1, material minimum. 9. The blower speed shall not exceed 80% of the maximum design speed of the

blower.

C. Motors and Drives:

1. Provide a single speed, constant torque, TEFC 1800 RPM motor, 1.15 S.F., Premium efficiency suitable for mounting on a slide base and connecting to the blower shaft by a V- belt and sheave drive assembly. Motor shall have a normally closed thermostats embedded in the windings. Motors shall be as manufactured by Marathon, Baldor, WEG Electric, Toshiba, or World Wide Electric. The motor shall not be overloaded nor have their service factor reduced when the blower is operating at the speed and differential pressure shown in Schedule.

2. Provide V-belt drive assembly consisting of Sheaves, quick detachable bushings, V-belts, and sliding motor base. Provide drive assembly with a 1.4 service factor based on motor nameplate horsepower.

3. Voltage Rating: 460 volts, 3 phase, 60 Hertz.

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4. Provide OSHA Style steel belt guard to enclose drive and belts. Design guard for easy removal. The guard shall be constructed to allow visual inspection of the drive system without removing the guard.

D. Accessory Equipment:

1. The blower packages shall be fabricated and assembled with the following accessories and shipped complete.

2. Equipment Base: The base shall be built so that the blower and the motor are mounted to provide for horizontal tensioning of the v-belt drive. The base shall be a minimum of 1/4” plate steel with angle legs. These items shall also have a minimum thickness of 1/4". Bases constructed of all angle iron will not be acceptable. Combination base discharge silencers are also not acceptable. The silencer may not be welded to the base in any way.

3. Each blower shall be provided with an inlet filter, inlet silencer, expansion joints, discharge silencer, pressure relief valve, check valve, butterfly valve, wafer type butterfly valve, high temperature cut-off switch, vibration pad, and other accessories as shown on the Drawings.

4. Filter: Provide each blower for the Pump/Blower Building with a suitably sized air filter. Filters to be Model CCS manufactured by Universal Silencer.

5. Intake Silencer: Provide a heavy duty, all welded, noise attenuation unit constructed of carbon steel sheet and plate and featuring an acoustically treated outlet for pulse control. Provide silencer equal to Model RISY on silencers larger than 4" and RIS type on sizes 4" and smaller. Silencers to be Model RIS manufactured by Universal Silencer or equal.

6. Discharge Silencer: Provide a heavy duty, all welded, noise attenuation unit constructed of carbon steel sheet and plate and featuring an acoustically treated outlet for pulse control. Provide silencer equal to Model SDY on sizes larger than 4" and SD type on 3" and smaller. Silencers to be Model SD manufactured by Universal Silencer or equal. a. Supports: Provide two (2), carbon steel, clamp type supports at each end of

silencer for rigidly mounting silencer horizontally to the blower package base.

7. Expansion Joints: Provide threaded sleeved or flanged cylindrical type, three ply bias fiberglass reinforced silicone rubber connectors for blower inlet and discharge connections. Furnish units which are capable of withstanding 25 psi and handle operating temperatures of 250 degrees F. Expansion joints to be equivalent to XL-Fab Series 500, General Rubber Corp. or Metra Flex Co.

8. Pressure Relief Valve: Provide spring or weight type relief valve with proper sizing and weights for set point pressure. Provide valves equal to Sutorbilt PL. Spring type or Kunkle valves are acceptable.

9. Check Valves: Provide threaded sleeved or flanged type, cast iron body, aluminum internals for mounting on blower discharge piping. Provide valve equivalent to Flexi-Hinge Model 502 or 518 or equal.

10. Discharge Butterfly Valve: Provide wafer type, resilient seated, lever operated butterfly valve for isolating the blower from the manifold. Furnish valve with cast iron body and disc of nodular iron; Stainless steel stem; Acetal Bushing; EPDM, Valve shall be Deltech model 50 or equal.

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11. Discharge Pressure Gauge: Provide a discharge pressure gauge on the blower package to be equivalent to U.S. Gauge, McDaniel Instruments or approved equal.

12. Range: 0-15 psig. Accuracy: 2% of Scale, dial: 2.5” 13. Inlet Restriction Gauge: Provide each blower with a Dwyer Model 2020 inlet gauge

to measure loss through the inlet filter. 14. Instrument Spool: Each blower package shall be supplied with a fabricated steel

spool piece for mounting the relief valve, pressure gauge, and any other instruments required by the specifications. Gauges and instruments mounted in the silencer body are not acceptable.

E. Controls:

1. High temperature cut-off switch shall be SPDT output; NEMA 4 enclosure; internal adjustment with reference dial and immersion stem for each blower. Provide a SPDT NEMA 4 thermostat to control the exhaust fan for each enclosure.

2. The blowers shall be operated manually by equipment described in Division 26.

F. Discharge Sound Reduction Skirt:

1. The discharge section of the blower package shall be furnished with a weather tight, sound attenuating skirt. The skirt shall be manufactured of 16 gage aluminum, and shall be lined with acoustical foam with a 22 gauge perforated galvanized steel retention liner. Foam thickness must be sufficient to meet a free-field noise level of 88 dBA at one meter from any exterior surface of the blower package. All oil drains must be plumbed to the exterior of the acoustic skirting. Skirting that requires removal for oil drain access will not be allowed.

2. All pipe penetration holes in the skirting enclosure shall be sized to allow for passage of pipe fittings and/or flanges. Flashing rings shall be provided to seal all pipe penetration holes after final assembly.

G. Anchor Bolts and Threaded Fasteners:

1. Supply Type 316 stainless steel anchor bolts, fasteners, nuts, washers and screws for all equipment under this Section.

H. Repair Parts and Special Tools:

1. Any special tool required to perform routine maintenance functions, such as replacement of gears and bearings, shall be furnished with the blowers.

2. Provide the following repair parts for each blower: a. One (1) complete set of gaskets, seals, a-rings and bearings. b. One (1) complete set of belts. c. One (1) complete set of filter elements. d. One Case of AEON Synthetic Blower Oil – six (6) total

2.2 FABRICATION

A. Shop Assembly: Each blower shall be completely factory assembled by a factory authorized distributor or representative.

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B. Shop/Factory Finishing:

1. Blowers shall be painted as specified in Section 099000. 2. Machined, polished and nonferrous surfaces shall be coated with corrosion

prevention compound.

C. Field Painting:

1. Touch up per Section 099000.

2.3 SOURCE QUALITY CONTROL

A. Manufacturer's Requirements:

1. Blower manufacturer shall have in place a full capability service organization. 2. Such service organization shall include at least one stocking distributor in the State

of Ohio.

PART 3 - EXECUTION

3.1 EXAMINATION AND VERIFICATION OF CONDITION

A. Assure that all materials delivered to the job site have been fabricated in accordance with the approved Shop Drawings and are free from obvious shipping damage or defects.

B. Examine locations to receive blowers for proper anchor bolt locations and any unevenness, irregularities or incorrect dimensions.

C. Notify the OWNER immediately of all unsatisfactory or non-conforming conditions.

3.2 PREPARATION

A. Delivery and Handling of Equipment:

1. Inspect all equipment and materials against approved Shop Drawings at time of delivery.

2. Equipment or materials damaged or not meeting the requirements of the approved Shop Drawings shall be immediately returned for replacement or repaired.

3. Blowers shall come completely assembled and protected on wooden skids. Blower suction and discharge ports shall be protected against entry of foreign objects.

B. Storage:

1. Carefully prepare for storage and label all equipment and materials after they have been inspected.

2. Store all equipment and materials in a dry, covered, ventilated location and protected from harm according to the Manufacturer's instructions.

3. Cap all pipe connections. 4. Blowers shall remain on original skid until time of actual installation.

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3.3 INSTALLATION

A. Installation shall be in complete accordance with approved Shop Drawings, Manufacturer's instructions, and recommendations, and as specified herein.

B. Piping shall be supported independent of blowers. Blowers are to be installed on existing concrete pads and connected to existing piping where indicated on Contract Drawings. Provide new piping and appurtenances as shown on the Contract Drawings.

C. Field verification and dimensioning is critical and required prior to shop drawing submittal.

D. Connect all piping, valves and accessories as detailed on the Drawings and approved Shop Drawings.

E. Installation shall include furnishing and applying lubricants as recommended by the manufacturer.

F. Complete all job-site-installed electrical and control system wiring and components in compliance with Division 16 of the specifications.

G. Grease bearings as per manufacturer's recommendations prior to starting blowers.

H. Check for proper rotation.

I. Adjust vibration mountings to remove excessive vibration.

J. CONTRACTOR shall verify that structures, pipes and equipment are compatible.

K. Make adjustments required to place system in proper operating condition and leave blowers in working order.

3.4 FIELD QUALITY CONTROL

A. Manufacturer's Field Service Report: Manufacturer's representative shall perform field inspection of all components prior to placing in operation and submit Manufacturer's Installation Inspection Report addressing the following:

1. List of deficiencies found. 2. Recommended corrective action for all deficiencies. 3. Certification by Manufacturer's representative that items are properly installed and

adjusted.

B. Manufacturer's representative shall revisit the jobsite as often as necessary until all trouble is corrected and the OWNER is completely satisfied.

3.5 CLEANING

A. Comply with Section 017800.

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3.6 INSTRUCTION OF PERSONNEL

A. On-Site Training: The manufacturer’s representative shall visit the job site and train the operations staff on proper operation of the blower system including background training of positive displacement compression, safety features, troubleshooting, maintenance requirements and timing, belt and sheave replacement, and instrumentation.

B. Operations, Maintenance, Electric and Instrumentation: Four (4) hours minimum.

3.7 STARTING OF SYSTEMS/COMMISSIONING

A. Comply with Section 017517.

3.8 EQUIPMENT SCHEDULE

A. Blowers shall not exceed 80% of maximum design speed.

B. Aeration Blowers:

Blowers to be located indoors in the existing Pump/Blower Building

Process PTP1 Aeration

Quantity 2 (1 replacement, 1 new)

Design Flow 337 SCFM

Pressure 7 PSIG

Site Conditions 732 feet elevation 85% RH 95 DEG F

Motor HP 20

Inlet/Outlet Size 4 inch or as required

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Blowers to be located indoors in the existing Control Building

Process PTP2 Aeration

Quantity 2 (replacement)

Design Flow 525 SCFM

Pressure 7 PSIG

Site Conditions 732 feet elevation 85% RH 95 DEG F

Motor HP 25

Inlet/Outlet Size Match existing pipe connections

Process Sludge Storage Aeration

Quantity 1 (replacement)

Design Flow 400 SCFM

Pressure 7 PSIG

Site Conditions 732 feet elevation 85% RH 95 DEG F

Motor HP 20

Inlet/Outlet Size Match existing pipe connections

END OF SECTION

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SECTION 432140 – SCREW CENTRIFUGAL PUMPS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of Contract, including General and Supplementary Conditions and all Specification Sections, apply to work of this section.

1.2 DESCRIPTION OF WORK

A. The contractor shall furnish and install a total two (2) horizontal, screw flow pumps, specifically designed to pump secondary sludge.

B. Each pumps shall be equipped with a drive, couplings, base plate, necessary guards, flexible expansion joints for the pump suction and discharge, anchor bolts, and other appurtenances required for a complete installation, as shown on the Contract Drawings and specified herein.

C. The pump and the motor shall be supplied as complete unit by the same manufacturer.

D. All work performed under this section shall be in accordance with all approved trade practices and manufacturer's recommendations.

1.3 QUALITY ASSURANCE

A. All pumping equipment furnished under this Section shall be of a design and manufacture that has been used in similar applications and it shall be demonstrated to the satisfaction of the Owner that the quality is equal to equipment made by that manufacturer specifically named herein. Qualified suppliers shall have a minimum 5 years successful field operation of the actual proposed equipment and a minimum 20 installations at equivalent applications. Supplier shall provide a list of names and dates of installations for verification by the engineer or Owner’s Representative.

B. The horizontal screw centrifugal solids-handling pumps specified in this section shall be furnished by and be the product of one manufacturer.

C. The pump, complete with electric motor, base frame, coupling and coupling guard shall be factory assembled at the pump manufacturer's facility. The pump manufacturer shall have complete unit responsibility.

D. Pump, complete with motor, base, coupling, necessary guards and all other specified accessories and appurtenances shall be furnished by the pump manufacturer to insure compatibility and integrity of the individual components, and provide the specified warranty for all components.

E. Pump and motor shall meet the requirements of the following industry standards: 1. NEC, National Electric Code.

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2. NEMA Standards, National Electrical Manufacturers Association. 3. UL, Underwriters Laboratory 4. ISO 9001, International Organization for Standardization. 5. ANSI, American National Standards Institute. 6. ASTM, American Society for Testing and Materials 7. Standards of the Hydraulic Institute. 8. AISI, American Iron and Steel Institute. 9. ASME, American Society of Mechanical Engineers 10. IEEE, Institute of Electrical and Electronic Engineers. 11. OSHA, Occupational Safety & Health Administration

F. Performance Tests: 1. All pumps shall be given hydrostatic and performance testing in accordance with the

test code for centrifugal pumps of the Standards of Hydraulic Institute, latest edition and as required by the specifications.

2. All pumps shall undergo certified testing at the factory test facility for capacity, power requirements, and efficiency at specified extremes for rated head, shutoff head, and operating head, and at as many other points (a minimum of six point, including shutoff) as necessary for accurate plotting of performance curves, with the completely assembled pump and motor that will be furnished.

3. Performance testing shall establish that the pump is free of overheating, cavitation and excessive vibration over the specified conditions.

4. Results of the performance tests shall be certified by a Registered Professional Engineer and submitted for approval before final shipment.

G. Pumps shall be manufactured and assembled in an ISO-9001:2000 certified facility.

1.4 SUBMITTALS

A. Submittals shall be in accordance with the General Requirements.

B. Product Data: 1. Manufacturer's Certificates, including certified test curves with the design points

clearly marked (computer model printouts are not acceptable). Performance curves shall be submitted for each pump to be supplied.

C. Shop Drawings: Submit for review Shop Drawing showing the following: 1. Complete description in sufficient detail to permit an item-by item comparison with

the Specification. 2. Dimensions and required clearances 3. Weights 4. Performance data including pump curves showing overall pump efficiencies, low

rate, head, brake horsepower, motor horsepower, speed and shut-off head 5. Material of Construction for all components 6. Layout drawing for all equipment showing installation details and anchor bolt layout 7. Motor Data, including starting kVA, starting torque, full load current, full load

torque efficiency curves, and power factor curves. 8. Wiring diagrams for all electrical equipment. 9. Deviations from Contract Documents 10. Manufacturer’s installation drawings

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11. Manufacturer’s standard guarantee.

D. Maintenance and Operating Instructions

E. Factory Testing Report: Each pump shall be shop tested for capacity, head, speed, power, and efficiency in accordance with Standards of the Hydraulic Institute. Certified copies of each test curve shall be furnished to the Engineer for approval. The pump hydrostatic and performance testing shall be submitted 30 days prior to delivery. The pumps shall not leave the manufacturer's plant until receipt of the Engineer's approval.

1.5 WARRANTY

A. The pump liquid end (Suction Cover, Casing, Impeller and Rear Liner) shall be provided with a guarantee against mechanical failure due to materials and workmanship or abrasive wear under the original specified operating conditions. Comply with Section 007000, General Conditions, and 008000, Supplemental General Conditions.

1.6 DELIVERY, STORAGE AND HANDLING

A. Delivery, storage, and handling shall meet the manufacturer requirements.

B. Acceptance at Site 1. Inspect all equipment and materials against reviewed Shop Drawings at time of

delivery. 2. Equipment and materials damaged or not meeting the requirements of the reviewed

Shop Drawings shall be immediately returned for replacement or repair.

C. Storage and Protection 1. Carefully prepare for storage and label all equipment and materials after they

havebeen inspected. 2. Store all equipment and materials in a dry, covered, ventilated location and protect

from harm according to the manufacturer's instructions.

PART 2 - PRODUCTS

2.1 MANUFACTURER

A. Acceptable Manufacturers 1. Hidrostal 2. Or approved equal

2.2 PUMP CONSTRUCTION

A. General: 1. The design shall be a single-passage, clog-free pump, utilizing a screw-flow pump

impeller. 2. The overall pump design shall combine high efficiency, low required NPSH, a large

solid passage, and the ability to handle rags or other furious material without plugging.

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3. The hydraulic design of the impeller shall combine the action of a positive displacement screw with the action of a single-vane centrifugal impeller to provide a single, non-bifurcated flowstream with only gradual changes in flow direction. a. The impeller flange or impeller shall contain a spiral groove on the rear face so

that any solids in the pumped media are discharged from the space between the backplate and the rear of the impeller.

4. The geometry of the impeller and suction liner shall be conical, so any axial adjustment of the impeller will cause the clearance between the impeller and suction piece to change uniformly along the entire length of the impeller. Designs incorporating curved, or combination curved/conical impeller and suction piece are not acceptable because in such designs clearances cannot be adjusted uniformly over the full length of the impeller.

5. Suction and discharge flanges shall be drilled to meet ANSI 125 lb. bolting.

B. Materials of Construction 1. The pump volute, backplate, and impeller flange shall be of close-grained cast iron,

ASTM A 48, CL 30, heavy duty construction. 2. Replaceable suction liner shall be made of materials of ASTM A 532 High Chrome

Iron, minimum 450 Brinell hardness. a. A regulable liner, the suction piece shall be externally adjustable to

compensate for wear by means of three stainless steel regulating screws so that the necessary running clearances between the liner and impeller can be maintained for optimum hydraulic efficiency.

3. Impeller material of construction shall be ASTM A 532 High Chrome Iron, minimum 450 Brinell hardness. All impellers shall be dynamically balanced.

4. Suction Cover Cast Iron ASTM A48 Class 30B. 5. Pump Shaft: Forged Steel, AISI 1045 or 4140 if non-wetted, otherwise, 316L

stainless steel. 6. Bearings: Radial and thrust, roller or ball bearings, 50,000 hours L-10 life, oil or

grease lubricated. 7. Shaft Sealing: Shaft sealing shall be by independently-mounted, tandem mechanical

seals contained in an oil chamber that is formed as an intrinsic part of the motor frame and allows the seals to be completely submerged in and lubricated by the oil bath. a. The mechanical seal nearest the bearing shall utilize carbon/silicon carbide

faces, and shall isolate the seal cooling oil from the motor frame. b. The mechanical seal nearest the impeller shall be a rubber bellows-type

construction with the bellows designed to prevent contaminants from contacting the stainless-steel spring which loads the seal face. The seal faces shall be a solid tungsten carbide rotating face running against a solid silicon carbide stationary face. Seals with both faces of similar materials, or seals with bonded, soldered, or converted face surfaces are not equal or acceptable.

c. The mechanical seal nearest the impeller shall be contained in a seal chamber formed by the impeller flange and a recess cast into the motor frame. To prevent debris from entering the chamber and to prolong the mechanical seal life, a flush port shall be provided so that an optional external water flush can be supplied directly into the seal chamber.

d. The mechanical seal nearest the impeller shall be isolated from contaminants in the pumped media by a labyrinth-fit between the backside of the impeller

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and the back plate, as well as by pump-out grooves cast into the impeller back shroud and into the back plate, to minimize debris reaching the shaft seal.

8. O-Rings: Nitrile Rubber 70 IRH, or Buna N. 9. Suction and Discharge Flanges: Suction and discharge flanges shall conform to

ANSI B16.1, Class 125 lb., flat face, of standard size with drilled holes. 10. Pump Base: Cast-iron or steel pan pump and motor base. Seal leakage shall be

collected in the pump frame or base and piped to drain.

C. Mounting 1. The pumps shall have a horizontal mounting arrangement with horizontal direct

connected electric motor, and OSHA approved safety guards. The pump manufacturer shall provide a common pump and motor base constructed of a minimum 3/8 inch thick fabricated steel, suitably reinforced to support the full weight of the pump, motor, coupling and guard.

2. The pump supplier shall furnish and install a flexible spacer coupling between the motor shaft and pump shaft. The guards shall be of 316 stainless steel constructions.

D. Drive 1. Direct Connected with horizontal, heavy-duty, TEFC electric motor suitable for

inverter duty at 480-volt, 3-phase, 60-Hz AC power supply. All pumps shall have 1.15-service factor at 1800 RPM. The motor shall be supported from the pump base.

E. Mechanical Seals 1. A moisture sensor shall be furnished to sense moisture intrusion for each pump. This

sensor shall be wired to the Pump Control Panel and shall activate an alarm light upon moisture intrusion. The sensor probe shall be mounted in the seal chamber and shall be of the conductive type, sensing moisture intrusion above the lower seal, but below the upper seal. Designs that sense moisture intrusion above the upper seal using a float switch as the only moisture sensor are not acceptable.

2. In addition to the two mechanical seals, the sealing system shall feature an auxiliary sealing ring constructed of stainless steel. The sealing ring shall be mounted above the upper seal and shall direct any moisture to a diversion chamber and away from the air-filled motor cavity. The diversion chamber shall be fitted with a float switch to indicate the presence of moisture. The float switch output shall be a redundant indication of moisture intrusion.

2.3 ACCESSORIES

A. Flexible Expansion Pump Connectors: Expansion joints shall be a rubber spool type of a single, open wide arch design. Joint construction shall consist of a Butyl tube and cover, reinforced with a suitable woven fabric. Joints shall be designed to meet the design pressures and temperature for the system. Expansion joints ends shall be flanges drilled to 150 lbs class standards, and be full rubber faced and integral to the body. Flange backing rings of cast iron with a built-in support sleeve shall be provided. Expansion joints shall be Flexicraft Industries, Flextra 150 Model, or equal.

B. Pressure Gauges and Connections: 1. Pump discharge flanges shall be tapped for gauge connections as indicated in the

Specifications. 2. Gauge connections shall be 1/2-inch diameter.

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3. Each connection shall include a shutoff needle valve and necessary lengths of pipe to allow the mounting of a pressure gauge. The open end on the gauge connection shall be plugged to prevent the accumulation of debris.

C. Each pump shall be supplied with one (1) liquid filled pressure gauges with snubber and diaphragm seals. Liquid shall be silicone, capable of withstanding a temperature range of -60oF to +150oF. One gauge shall be adequately sized to indicate discharge pressure while the other shall be adequately sized to indicate the suction conditions. The gauges shall be properly installed on the pump suction and discharge lines. The gauges shall operate over a range of 30 inches of mercury vacuum to 50 psig pressure. Gauges shall be a product of H.O. Trerice, Ashcroft, or equal.

2.4 SHOP PAINTING

A. All metal surfaces coming into contact with the pumped media, other than stainless steel, shall be protected by a factory-applied epoxy resin coating system comprised of a 1.6 mil (dry film thickness) zinc rich epoxy primer with a 14 mil (total dry film thickness) gray, epoxy gloss finish coat, applied in three coats.

B. All surfaces shall be thoroughly cleaned of dirt, grease, oil, rust, scale, or other injurious substances. All metal surfaces shall be sandblasted in accordance with SSPC-SP10, Near-White Blast Cleaning.

C. A factory applied impact –resistance powder coating finish on the exterior of the pump shall protect all metal surfaces being exposed to the pumped media, other than stainless steel.

D. Primer: primer paint with one coat of Carboline Carboguard 890, DFT or 4-6 mils.

E. Top Coat: Apply top coat with Carboline Carboguard 890, DFT of 4 to 8 mils.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The equipment shall be installed in accordance with the manufacturer's recommendations.

B. Contractor shall verify existing conditions, elevations before starting work.

3.2 PREPARATION

A. The contractor shall shut down and disconnect existing equipment prior to proceed with associated work.

B. Remove existing pumps and accessory equipment not required in the installation of the new pump as shown on the Drawings

C. Furnish all labor, materials and equipment necessary to perform demolition required.

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D. Dispose of Existing Equipment: Contractor shall deliver such items of salvage to a storage location as designated by the Owner. Should the Owner not wish to retain any such material, it, along with all unsalvageable shall become the property of the Contractor and be disposed of by him off the project site.

3.3 INITIAL LUBRICATION

A. Initial lubrication required for startup and field test operation shall be furnished and applied in accordance with the manufacturer's recommendations.

3.4 SERVICES OF MANUFACTURER

A. Furnish the services of a qualified factory-trained serviceman who shall assist, as necessary, in the installation of the equipment, check the installation before it is placed into operation, supervise testing, supervise initial operation, and instruct the plant operators in the care , operation and maintenance of the equipment.

B. Inspection, Startup and Field Adjustment: The service representative of the Manufacturer shall be present at the site for a minimum of two (2) work days, to furnish Inspection, Startup and Field Adjustment Services. For the purposes of this section, a workday is defined as an eight-hour period at the Site, excluding travel time.

C. Conduct Field Tests 1. Motor Test: Tests shall be performed in accordance with the American Standard Test

Code. 2. Field/functional testing shall be performed to insure proper mechanical operation at

the jobsite. 3. Demonstrate the pumps can operate as specified, installed and as submitted. The

pumping units operate as specified without excessive noise, cavitation, vibration, and without overheating of the bearings.

D. Furnish sufficient supervision, data, and information from the manufacturer to train operators in the proper operation and maintenance of the pump(s) furnished.

3.5 OPERATION AND MAINTENANCE MANUALS

A. Operation and maintenance (O&M) manuals shall be provided prior to or with the delivery of the equipment. The O & M manuals shall include instructions on storage, installation, start-up, and operation and maintenance, together with a complete parts list and a recommended spare parts list. The O & M manuals shall be in compliance with the General Requirements.

3.6 EQUIPMENT SCHEDULE

A. The pumps shall be designed for continuous operation and shall be operated continuously under normal service. To minimize operation power costs, the hydraulic efficiencies for each pump are the minimum acceptable and must be guaranteed by the manufacturer.

B. Operation Criteria:

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Type of Pump Screw Flow Centrifugal Pumped Liquid Secondary solids Liquid Temperature 35-75 degrees F Location Sludge Pump Station Number Required 2 Design Capacity, each 430 gpm TDH 42 ft Pump Efficiency 75% Minimum non-compressible solids passage 3 inch Min Motor Size 7.5 HP Motor Speed, RPM 1740 Power Requirements 460 volt, 3 phase, 60 Hz Min Suction Size 4 Min Discharge 4

END OF SECTION 432140

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SECTION 11314CT 432313.01 – SELF-PRIMING CENTRIFUGAL PUMPS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of Contract, including General and Supplementary Conditions and Divisions 1 through 16 Specification sections, apply to work of this section.

1.2 DESCRIPTION OF WORK

A. This section includes the furnishing and installation of raw sanitary wastewater pumps, as shown on the drawings and as described in this section.

B. Pump Manufacturer is to provide and Contractor is to install a total of two (2) complete, functional pumps stations to pump wastewater to other downstream treatment processes as follows:

1. Influent Pumps, pumping to splitter chamber

C. All material, equipment, products, incidentals and testing required and necessary to provide a complete and operational system. Install where noted on the drawings and as specified within these specifications.

D. Coordinate all work with this equipment and any other associated equipment, installed and specified under other sections of these specifications.

E. All work performed under this section shall be in accordance with all approved trade practices and Manufacturer's recommendations.

F. The contract drawings and specifications were prepared based on the named manufacturer in this item and the Contractor shall include in his base bid proposal, equipment by the specified manufacturer.

G. All work performed under this section shall be in accordance with all approved trade practices and Manufacturer's recommendations.

1.3 SUBMITTALS

A. The Contractor shall submit manufacturer’s technical data and application instruction in accordance with the General and Supplementary Conditions and Division 1 Specifications and any additional information listed herein.

B. Product Data: Submit Manufacturer's technical data and application instructions.

A. Shop drawings shall be presented to the Engineer for approval. All shop drawings shall clearly identify the specific equipment and material being supplied, the quantity being supplied, and all accessories, dimensions, descriptions, mounting and connection details, and any other information necessary to determine compliance with the plans and

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specifications. Shop drawings shall include plan and section layouts of the equipment, dimensions, clearances required, power requirements, and wiring diagrams.

B. Sizes shown on Contract Drawings are typical. Individual Manufacturer’s dimensions shall be as shown on the Contract Drawings. Any deviation from given dimensions may interfere with site characteristics. Manufacturer shall be responsible for providing Engineer with drawings showing proposed changes and/or equipment locations. Any additional engineering costs associated with these changes will be the sole responsibility of the Manufacturer with no additional cost to the Owner.

C. Prior to or with the delivery of equipment, the Manufacturer shall provide copies of an operation and maintenance manual including storage, installation, startup, operating and maintenance instructions, and a complete parts list and recommended spare parts list. The O&M Manuals shall be in compliance with the General Requirements.

D. O&M Manuals: Provide three (3) bound paper copies and one (1) digital electronic copy of operating and maintenance manuals containing copies of the approved shop drawings, operating and greasing instructions, and parts list.

E. Operation Data: Provide description of system operation, adjusting and testing required.

F. Maintenance Data: Provide system maintenance requirements, servicing cycles, lubrication requirements, and local sources for spare parts.

1.4 WARRANTY

A. The pump manufacturer shall warrant all equipment to be of quality construction, free of defects in material and workmanship. A written warranty shall include specific details described below.

B. Components failing to perform as specified by the engineer, or as represented by the manufacturer, or as proven defective in service during the warranty period, shall be replaced, repaired, or satisfactorily modified by the manufacturer.

1.5 QUALITY ASSURANCE

A. Manufacturer Qualifications: Five (5) years demonstrated experience in providing packaged pump stations.

B. The pump manufacturer must be ISO 9001:2008 certified, with scope of registration including design control and service after sales activities.

C. All equipment and materials shall be new and of the best quality.

PART 2 - PRODUCTS

2.1 PUMPS AND MOTOR

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A. Horizontal Self-Priming Centrifugal Pumps

1. Pumps shall be horizontal, self-priming centrifugal type, designed specifically for handling raw, unscreened, domestic sanitary sewage. Pump solids handling capability and performance criteria shall be in accordance with requirements listed further below.

2. Materials and Construction Features a. Pump casing shall be cast iron Class 30 with integral volute scroll. Casing

shall incorporate following features: b. Mounting feet sized to prevent tipping or binding when pump is completely

disassembled for maintenance. c. Fill port cover plate, 3 1/2" diameter, shall be opened after loosening a hand

nut/clamp bar assembly. In consideration for safety, a clamp bar screw must provide slow release of pressure, and the clamp bar shall be retained by detente lugs. A Teflon gasket shall prevent adhesion of the fill port cover to the casing.

d. Casing drain plug shall be at least 1 1/4" NPT to insure complete and rapid draining.

e. Liquid volume and recirculation port design shall be consistent with performance criteria listed below.

3. Suction Head shall be Class 30 cast iron. Its design must incorporate following maintenance features:

4. The suction head will be secured to the pump casing by using hex head cap screws and lock washers. Access to the impeller and mechanical seal shall be accomplished by removing the suction head. a. Removal of any blockages in the impeller shall be accomplished by removing

the suction head, or through a cleanout cover on the suction head. In consideration of safety, two clamp bar screws must provide slow release of pressure on two clamp bars securing the cleanout cover. A Teflon gasket shall prevent adhesion of the cleanout cover to the suction head casing.

b. Removal of the suction check valve shall be accomplished through the removable cleanout cover on the suction head.

c. In consideration for safety, a pressure relief valve shall be supplied in the suction head. The relief valve shall open at 75-200 PSI.

d. A replaceable hardened ductile iron wear plate shall be secured up against the pump casing by the suction head. Measurement of the clearance between this wearplate and impeller shall be accomplished through the cleanout cover plate.

5. Rotating assembly, which includes impeller, shaft, mechanical shaft seal, lip seals, bearings, sealplate and bearing housing, must be removable as a single unit without disturbing the pump casing or piping. Design shall incorporate following features: a. Seal plate shall be hardened ductile iron and bearing housing shall be cast

iron Class 30. Separate oil filled cavities, vented to atmosphere shall be provided for shaft seal and bearings. Cavities must be cooled by the liquid pumped. Three lip seals will prevent leakage of oil.

b. The bearing cavity shall have an oil level sight gauge and fill plug check valve. The clear sight gauge shall provide easy monitoring of the bearing cavity oil level and condition of oil without removal of the fill plug check

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valve. The check valve shall vent the cavity but prevent introduction of moist air to the bearings.

c. The seal cavity shall have an oil level sight gauge and fill/vent plug. The clear sight gauge shall provide easy monitoring of the seal cavity oil level and condition of oil without removal of the fill/vent plug.

d. Double lip seal shall provide an atmospheric path providing positive protection of bearings, with capability for external drainage monitoring.

e. Impeller shall be hardened ductile iron, two-vane, semi-open, non-clog, with integral pump out vanes on the back shroud. Impeller shall thread onto the pump shaft and be secured with a lock screw and conical washer.

f. Impeller shaft shall be AISI 17-4 pH stainless steel. g. Bearings shall be anti-friction ball type of proper size and design to withstand

all radial and thrust loads expected during normal operation. Bearings shall be oil lubricated from a dedicated reservoir. Pump designs which use the same oil to lubricate the bearings and shaft seal shall not be acceptable.

h. Shaft seal shall be cartridge oil lubricated mechanical type. The stationary and rotating seal faces shall be tungsten titanium carbide alloy. Each mating surface shall be lapped to within three light bands flatness (35 millionths of an inch), as measured by an optical flat under monochromatic light. The stationary seal seat shall be double floating by virtue of a dual O-ring design; an external O-ring secures the stationary seat to the seal plate, and an internal O-ring holds the faces in alignment during periods of mechanical or hydraulic shock (loads which cause shaft deflection, vibration, and axial/radial movement). Elastomers shall be viton; cage and spring to be stainless steel. Seal shall be oil lubricated from a dedicated reservoir. The same oil shall not lubricate both shaft seal and shaft bearings.

i. Pusher bolt capability to assist in removal of rotating assembly. Pusher bolt threaded holes shall be sized to accept same cap screws as used for retaining rotating assembly.

j. Pressurized water seals will not be accepted for horizontal self-priming centrifugal pumps.

6. Adjustment of the impeller face clearance (distance between impeller and wear plate) shall be accomplished by external means. a. Clearances shall be maintained by using external shims between the casing

ring of the rotation assembly and the pump casing itself. Shims will be of various sizes to allow precise adjustment of this clearance. The clearance can be measured by removing the cleanout cover on the suction head.

b. Clearance adjustment which requires movement of the shaft only, thereby adversely affecting seal working length or impeller back clearance, shall not be acceptable.

7. Suction check valve shall be molded Neoprene with integral steel and nylon reinforcement. A blow-out center shall protect pump casing from hydraulic shock or excessive pressure. Removal or installation of the check valve must be accomplished through the cleanout cover on the suction head without disturbing the suction piping. Sole function of check valve shall be to save energy by eliminating need to reprime after each pumping cycle. Pumps requiring a suction check valve to assist reprime will not be acceptable.

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8. Removal of the rotating assembly will be accomplished through the front or the back of the pump casing.

9. Serviceability a. The pump manufacturer shall demonstrate to the engineer's satisfaction that

consideration has been given to reducing maintenance costs. b. No special tools shall be required for replacement of any components within

the pump.

10. Each pump shall have a v-belt drive system and a cast iron or steel frame with anchor bolts. The pump and driver shall be mounted on this common frame.

11. Each pump shall be provided with a safety guard around each pump drive shaft and v-belt drive system conforming to OSHA requirements.

12. Motors a. Unless otherwise specified in the Equipment Schedule, each pump shall be

provided with a horizontal squirrel cage induction type motor of sufficient power such that no point on the pump curve requires more than the nameplate horsepower of the motor furnished.

b. The motors shall be NEMA Design B, with Class F insulation for a 60 degree C maximum temperature rise above 40 degree C ambient, and a 1.15 service factor. The motor enclosure shall be of the total enclosed fan cooled type.

c. The motors shall be in conformance with the latest recommendations of IEEE and NEMA, including noise requirements.

13. Each pump shall be shop tested for capacity, head, speed, power, and efficiency in accordance with Standards of the Hydraulic Institute. Certified copies of each test curve shall be furnished to the Engineer for approval. The pumps shall not leave the manufacturer's plant until receipt of the Engineer's approval.

B. The Pump Schedule is provided at end of this section.

2.2 INFLUENT PUMP ELECTRICAL AND CONTROL EQUIPMENT

A. General: Custom control packaged system for automatic variable speed motor/liquid level control. A pump power panel and separate level/logic panel shall be furnished in NEMA 1 painted steel enclosures. Include high pump temperature shutdown sensors.

1. Level/Logic Control Panel: a. Primary Level and Logic Control System: Primary liquid level controller to

be intrinsically safe submersible transducer type, operated through the operator interface. The primary controller will sense wet well level via an analog signal and will be scaled to control the speed of the drives to maintain/match inflow to the wet well. All control logic shall be through the PLC.

b. PLC to be supplied with Ethernet/IP communication for drives and operator interface.

c. Back-up Level Control System: Float switch liquid level controller with intrinsically safe floats (4 total) with 50’ cables depending on the application. This controller will also provide the means to bypass the primary level controller and operate as an independent/redundant level control system, in the event of primary level control failure. The back-up control will then

18030701 432313.01 - 6

activate start/stop of the pumps. Transfer back from the back-up to primary level control system to require local manual reset.

d. Stainless steel weight and chain for securing float cables. e. Stainless steel junction box with terminal strip supplied for transitioning of

float cable wiring and transducer. f. Pump automatic alternation via PLC logic. g. Pump priming protection (sensed via KW through the PLC). h. Adjustable time delays to eliminate simultaneous pump starts (PLC).

2. Fault/Status monitoring signals for data to be supplied as continuous files through the PLC and includes: a. High Water Alarm (Primary Level Control) b. Low Water Alarm (Primary Level Control) c. High Pump Temperature Shutdown, each pump. d. Pump Run, each pump. e. 3-Phase Voltage Monitor General Alarm f. Backup Float Switch Control System Activated g. Wet Well Level Sensed By Analog Signal h. Drive Speed Commands (via Ethernet) i. Drive Speed Indication (via Ethernet) j. Flow Meter Reading (analog) as applicable k. pH of wet well wastewater

3. Provide sensors and instrumentation to give appropriate signals indicated to PLC.

2.3 FACTORY TESTS

A. The pumps shall be given an operational test at the Pump Manufacturer’s facility to check for excessive vibration or leaks in the unit, and to correct operation. Installed pumps shall take suction from a deep wet well, simulating actual service conditions. The control panel shall undergo both a dry logic test and a full operational test with all systems operating.

B. Each pump shall be capable of achieving the operating reprime lift while operating at the selected speed and the selected impeller diameter. Reprime test report(s) shall be prepared and certified by the factory’s registered Professional Engineer.

C. Factory test instrumentation must include flow measuring with indicator; compound suction gauge; Bourdon tube-type discharge pressure gauge; electrical meters to measure amperes, volts, kilowatts and power factor; speed indicator.

D. Certified performance data based upon tests of each actual pump proposed to be furnished shall be submitted to the Engineer for acceptance. Tests shall be performed in accordance with the Test Code of the Hydraulic Institute Standards and shall demonstrate compliance with the operating conditions specified. The Engineer shall be notified and afforded the opportunity to witness the test.

E. Standard commercial test: A certified report of the standard commercial test of the model of motor proposed to be furnished shall be submitted to the Engineer for acceptance.

2.4 INSTALLATION AND OPERATING INSTRUCTIONS

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A. Installation of the pump chamber shall be done in accordance with the written instructions provided by the Manufacturer.

B. Operation and maintenance manuals shall be furnished which will include parts lists of components and complete service procedures and troubleshooting guide.

PART 3 - EXECUTION

3.1 MANUFACTURER'S SERVICES

A. The Manufacturer shall provide the services of a factory-trained representative for a period of not less than one (1) total working day, which shall be broken down into one or two trips as necessary on-site to perform initial startup of the pumps, make final adjustments, supervise initial startup of each pump, and prepare a written test report thereof for the Owner, and to instruct the owner’s operating personnel in the operation and maintenance of the equipment.

B. If there are difficulties in operation of the equipment due to the Pump Manufacturer’s fabrication and control panel programming, additional service shall be provided at no extra cost to the Owner.

3.2 HANDLING AND STORAGE

A. During loading, unloading and storage care shall be exercised to insure that the equipment is not dropped or otherwise damaged through impacting with solid surface.

3.3 ELECTRICAL

A. All motor starters, fusible safety switches, selector switches, pushbuttons, indicating lights, and all other pilot devices to form a complete operating electrical system will be supplied according to drawings.

B. All electrical equipment, conduit and wiring not indicated on the Drawings, but necessary to provide a complete operating system shall be provided in this item at no additional cost to the Owner.

C. Electrical Wiring: The external conduit and wiring required for power supply and control to electrical equipment supplied in this Section will be furnished according to drawings under Section 16.

D. Motor size: Any deviation in motor size must be approved by the Engineer. Any electrical equipment or wiring that must change to accommodate a different size motor will be at no additional cost to the Owner.

3.4 FIELD QUALITY CONTROL

A. Pumps

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1. The pumps provided shall be factory tested at three points to verify the pump performs at the design points and tested in the field at start-up to assure proper performance.

2. Tests shall consist of checking the unit at its rated speed, head, capacity, efficiency and brake horsepower, and at such other conditions of head and capacity to properly establish the performance curve.

3. The standards of the Hydraulic Institute shall govern the procedures and calculations for these tests.

3.5 OPERATION AND MAINTENANCE MANUALS

A. Prior or with the delivery of equipment, the Manufacturer shall provide copies of an operation and maintenance manual including storage, installation, start-up, operating and maintenance instructions, and a complete parts list and recommended spare parts list. The O&M Manuals shall be in compliance with the General Requirements.

3.6 DEMONSTRATION AND INSTRUCTIONS

A. Demonstration and Start-up Services: The equipment Manufacturer shall furnish the services of a qualified representative for a period of not less than two (2) 8-hour man days for Inspection, Start-up, Testing and Field Adjustment services. Manufacturer representative shall demonstrate satisfactory operation of the equipment and provide an “Installation Certification” to the Owner.

B. Field Training: The representative shall instruct the Owner’s personnel in the operation, electrical and mechanical maintenance of the equipment for a minimum period of one (1) 8-hour man day (travel time excluded). A minimum of 30 days’ notice is required to schedule manufacturer’s services.

C. Gorman-Rupp Academy: Gorman-Rupp shall provide two (2) days training session for two (2) Village of Shiloh employees held at the Gorman-Rupp Academy. This training session shall include a “Fundamentals of Pumping” and “Fundamentals of Electrical”. Contact Cindy Mireles with Craun-Liebing at 216-228-7900 extension 101 to register.

3.7 PUMP SCHEDULE

A. INFLUENT PUMPS

Type of Pump Horizontal Self-Priming, Top Discharge Mounting Option Pump furnished on

individual horizontal V-belt bases Number Required 2 Pumped Liquid Raw Municipal Wastewater Liquid Temperature 35-95 degrees F Design Capacity, each 300 gpm @ 22’ TDH Minimum Motor Horsepower 5 Maximum Motor Speed 1750 rpm Motor Drive Starter

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Power Requirements 460 volt, 3 phase, 60 Hz Solid Size, Maximum 3.0 in. Manufacturers/Model Gorman–Rupp Model T3C71SC-B

Super T Series with hardened impeller, wear plate and seal plate

Discharge Size 3 in. Suction Size 3 in. Lubrication Oil Materials of Construction:

Casing Ductile Iron Impeller Hardened Ductile Iron

END OF SECTION