DIVISION 11 EQUIPMENT - Thieneman Construction IN... · The Detection Systems shall be a Wallace & Tiernan Acutec 35 or approved ... The equipment shall be installed complete as shown

DIVISION 11

EQUIPMENT

11000-1

SECTION 11000

WASTEWATER TREATMENT PLANT AND APPURTENANT EQUIPMENT

PART 1 GENERAL 1.1 SCOPE

A. Under this section, the Contractor shall furnish and install wastewater treatment process

equipment items, including all appurtenant and related items of work required to complete this section of the project in accordance with the plans and specifications. Equipment items specified herein are major units required for transporting and processing the wastewater plus appurtenant items. Equipment requirements are not limited to those specified herein, and other units will be described in the plans and elsewhere in these documents.

B. The Engineer has designed the waste treatment facilities with the intent of using well

made and easily available equipment, which he feels, is best suited for the severe service and long life required. In these specifications, the named manufacturers or systems are the preferred choice of the Engineer. Brand names not listed may be proposed by the Contractor if sufficient information is submitted to the Engineer within 7 days of the bid date to determine that the equipment has the applicability, longevity and reliability of that specified, and that it is determined by him to be "approved equal." (Make sure this matches)

C. Contractor is reminded that electric motors above 5 H.P. are to be high efficiency type.

See Section 11990.

END OF SECTION

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SECTION 11234

DISINFECTION EQUIPMENT PART 1 GENERAL 1.1 WORK INCLUDED

A. Contractor shall disconnect and remove existing cylinder scales, chlorine gas feeder, sulfur dioxide feeder and automatic switchover units from the existing chemical building and shall furnish all labor, materials, equipment and incidentals to reinstall the gas chlorination and sulfur dioxide equipment in the proposed chemical building building and bring into operation as shown on the plans and specified in this section.

B. Contractor shall furnish all labor, materials, equipment and incidentals to provide, install and test the following disinfection equipment as shown on the plans and specified in this section.

1. Items included in this specification.

i. One (1) Chlorine gas detection system

ii. One (1) Sulfur Dioxide detection system

iii. Other items specified in section 2.6

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. Division 1 – General Requirements B. Section 11990 – Equipment Installation C. Division 16 - Electrical

1.3 SUBMITTALS

A. Shop Drawings and Product Data

1. Comply with the General Conditions, the supplemental requirements below, and Section 01300 (Shop Drawing Submittal and Correspondence).

2. Submit the following information:

a. Catalog bulletins. Mark out inapplicable options.

b. Dimensional sketches of units. c. List of materials used for construction of unit if not included in catalog

bulletins. d. Weight of total unit and weights of all components. e. Performance data as specified below. f. Motor data as specified in this section.

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g. Manufacturer’s installation instructions. h. Fabrication assembly and wiring diagrams.

B. Operation and Maintenance Data

1. Comply with the requirements of Section 01730 (Operation and Maintenance

Data) and supplemental requirements below.

2. Submit complete instruction for operation and maintenance of the system. Include the following data:

a. Operations, alignment, adjustment and repair instructions. b. Guide to troubleshooting. c. Lubrication instructions. d. Seal adjustment and replacement instructions. e. Recommend spare parts lists and predicted life of parts subject to wear.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Comply with the requirements of the specifications including Section 01600 (Material and Equipment).

1.6 GUARANTEE

A. Comply with the requirements of the General Conditions. B. The contractor shall guarantee the chlorine feed system and associated components to

be free from defects in material and factory workmanship for a period of one year from the date of substantial completion. The Contractor shall furnish and install a replacement for a component, which proves defective during the warrantee period, except such items, which are normally used in services such as oil and grease.

PART 2 PRODUCTS 2.1 CYLINDER SCALE – Not Applicable – Reuse the existing equipment

2.2 FEEDERS – Not Applicable – Reuse the existing equipment

2.3 AUTOMATIC SWITCHOVER UNIT – Not Applicable – Reuse the existing equipment 2.4 GAS DETECTION SYSTEM

A. Two (2) Gas Detection Systems. The system shall consist of a Receiver Module, and

system shall consist of 1 Receiver Module, and a separate Power Supply Module DIN rail mounted for flexibility in a NEMA 4X polystyrene enclosure suitable for wall mounting. A clear, hinged polycarbonate window with push-button latches shall be included to provide for easy access to the control module. The Sensor/Transmitter shall also be in a NEMA 4X enclosure remotely mounted in chlorine feed room. The Power Supply Module shall

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be able to accept any AC input between 85 and 255 volts, 50/60 HZ and automatically convert this input to 13.7 VDC output for powering 1 Receiver Module. Loss of input power shall be indicated by a built-in power failure alarm relay. Unit shall operate on 120 volt, single phase power.

B. The Receiver Module shall contain 4 separate LED indicators for operational and alarm

status: WARNING, ALARM, SENSOR FAILURE, POWER. There shall be three separate alarm relays that can be assigned to the 2 alarm set points and configurable for normal/fail-safe, latching/non-latching, and fast/slow operation. Relay contacts shall be rated 10A at 120VAC, SPDT. A fourth relay shall be provided in addition to a 4-20mA output signal proportional to gas concentration. The operating range of the sensor shall be field adjustable through DIP switches in the receiver module. An acknowledge/reset button shall provide for silencing the audible alarm, resetting the alarm circuit and alarm relay inhibition for servicing.

C. The Sensor/Transmitter shall be housed in a NEMA 4X enclosure suitable for wall

mounting. It shall be an electrochemical type, specific for chlorine gas and shall be provided with a 2 year operating life. The Sensor shall not require the addition of chemicals. The Transmitter shall be powered from the Receiver through a 2 conductor cable up to 1000 feet long. The same cable shall transmit a current pulse position signal, for improved noise immunity, representative of gas concentration back to the Receiver.

D. The Detection Systems shall be a Wallace & Tiernan Acutec 35 or approved equal.

2.5 FREE CHLORINE ANALYZER – Not Applicable 2.6 OTHER

A. One (1) Lot of chlorinator/dechlorinator fittings, tubing connectors and 200’ of

vacuum/vent tubing. B. One (1) Outside alarm light/horn. C. Four (4) 1” npt corporation Stop Main Connectors D. Two (2) Remote Pressure Relief Valves (W&T AKG 4135).

PART 3 EXECUTION 3.1 INSTALLATION

A. Installation shall be in accordance with manufacturer’s recommendations.

B. The equipment shall be installed complete as shown on the plans and described herein. 3.2 START UP SERVICES

A. The Contractor shall provide as part of his bid price, the services of a factory trained representative in accordance with Section 11990, Item 1.7 to inspect installation of equipment, place system into operation, instruct personnel in the operation and maintenance of equipment and to demonstrate satisfactorily the performance of each piece of equipment.

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3.3 OPERATION AND MAINTENANCE MANUAL

A. The Contractor shall provide operation and maintenance manuals including parts list, operating procedure, in accordance with Section 11990, Item 1.8.

END OF SECTION

11311-1

SECTION 11311

SUBMERSIBLE PUMPS FOR PLANT PUMP STATION PART 1 GENERAL 1.1 WORK INCLUDED

A. The Contractor shall furnish all labor, materials, equipment and incidentals to provide, install, and test two (2) submersible pumps in the existing plant pump station, complete and operational with motors, controls and accessories as shown and as specified in this section.

B. The pump manufacturer shall furnish and have overall system responsibility for field testing,

start-up, training, calibration and overall successful operation of the equipment.

C. The submersible pumps consist of the pump, motor and other associated appurtenances for a complete system. These pumps shall be designed to run at constant speed as shown on the plans.


A. Division 1 - General Requirements

B. Section 11010 – Process and Appurtenant Equipment

C. Section 11990 – Equipment Installation

D. Division 15 – Mechanical

E. Division 16 - Electrical 1.3 SYSTEM DESCRIPTION

A. Two (2) submersible pumps shall be installed in the existing Plant Pump Station. These pumps will be used to pump the wastewater plant drain water and sludge to either the sludge holding tank, sludge drying beds, aeration tank or sludge loading station.

B. Pumps will operate with float switches. 1.4 QUALITY ASSURANCE

A. Comply with the requirements of Section 11000. B. Manufacturer’s Qualifications

1. Manufacturer shall have previous experience in producing similar type submersible

pumps.

2. Show evidence of at least five installations using similar type submersible pumps in satisfactory operation for similar conditions.

C. Factory Testing

1. Pump manufacturer shall factory test pumps to detect any defects and demonstrate that they will function satisfactorily under all conditions specified in the Pump

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Schedule.

2. Conduct pump testing in accordance with the standards of the Hydraulic Institute.

3. Running Test:

a. Pump shall be operated from zero to maximum capacity as shown on the approved curve.

b. Results of the test shall be shown in a plot of test curves showing head, flow, horsepower, efficiency, and current.

c. Readings shall be taken at a minimum of 7 evenly spaced capacity points

including shutoff, design point, and minimum head for which pump is designed to operate.

4. Pump manufacturer shall also perform the following inspections and tests on each

pump before shipment from factory:

a. Check impeller, motor rating, and electrical connections for compliance to these specifications.

b. Test for motor and cable insulation moisture content for insulation defects.

c. Prior to submergence, run pump dry to establish correct rotation and mechanical integrity.

d. Run the pump submerged, a minimum of six (6) feet under water.

e. After operational test d., perform insulation test b. again.

1.5 SUBMITTALS

A. Comply with the requirements of Section 01300. B. Shop Drawings and Products Data

1. Include the following items with the pump performance data:

a. Head-capacity curves, efficiency curves, NPSH curves, BHP curves, shut-off heads and pump speeds at the minimum and maximum operating conditions specified.

b. Maximum capacity at which pump can operate continuously without cavitation.

c. Minimum capacity at which pump can operate continuously without overheating.

d. Indicate the specified operating points on each of the pump performance

curves.

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C. Operation and Maintenance Data

1. Submit complete instructions for operation and maintenance of pumps and power transmission components.

2. Include at a minimum, the following data:

a. Alignment, adjustment, and repair instructions. b. Guide to troubleshooting. c. Lubrication instructions. d. Seal adjustment and replacement instructions. e. Recommend spare parts list and predicted life of parts subject to wear.

1.6 DELIVERY AND HANDLING

A. Comply with the requirements of Section 01600. 1.7 WARRANTY

A. Comply with the requirements of Section 01700. B. Manufacturer will provide a warranty of all materials and equipment supplied under this

section. This warranty shall cover all defects in materials and factory workmanship for a period of one year from the date of substantial completion. The manufacturer shall furnish and pay for the installation and all other incidental costs for replacement components for any item that is proved to be defective during its warranty period.

PART 2 PRODUCTS 2.1 MANUFACTURER REQUIREMENTS

A. The submersible pumps shall be manufactured by one of the following manufacturers: 1. Xylem Flygt Corporation, Trumbull, CT 2. Or Engineer Approved Equal.

2.2 GENERAL

A. The submersible pumps shall be complete and operational with pumps, motors, mounting and supports, sliding guide brackets, discharge piping, and accessories as shown on the contract drawings and specified herein.

B. The system shall be designed to allow shutdown or removal of a pump without effecting the

operation of the remaining pumps.

C. The minimum pump system wire-to-water efficiency for the design condition is specified in the pump schedule. The pump system is defined to include the pump and motor.

D. The pump shall be constructed for installation in a Class I Division 2 Group D Environment.

All elements shall be rated for potentially explosive environments or explosion proof and/or non-sparking.

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2.3 PERFORMANCE AND DESIGN CRITERIA

A. General Requirements

1. Type: Submersible pump and motor.

2. Design to be easily removable for inspection and servicing.

3. No portion of the pump shall bear directly on the floor of the sump.

4. The pumps shall be designed to connect automatically to the discharge connection elbow. Sealing of pumping unit to the discharge connection elbow shall be accomplished by a simple linear downward motion of the pump.

5. A sliding guide bracket shall be provided as an integral part of the pump unit.

6. The unit shall be designed so that the entire weight of the pump unit shall be guided

and shall be designed to press tightly against the discharge connection elbow with metal-to-metal contact. A rigid discharge elbow to support the total weight of the pumping unit shall be bolted directly to the floor with the 90 degree elbow having a 125 lb. ANSI flange discharging vertically.

7. The pump, with all appurtenances and cable, shall be capable of continuous

submergence under water without loss of watertight integrity to a depth of 40 feet.

8. The pump shall be capable of delivering the flows at the specified heads in the pump schedule.

B. Service Conditions

1. Liquid Pumped: See Pump Schedule.

2. All pumps wet pit mounted.

C. Performance Requirements

1. Capable of pumping materials required under applicable service condition.

2. Capable of meeting detailed performance requirements specified in the Pump Schedule at the end of this part.

3. Continually decreasing head-capacity curve between shut-off and maximum

capacity.

4. Capable of operating continuously at all points on the head-capacity curve between minimum and maximum capacity without vibration, noise, cavitation, or overheating.

5. Capable of starting smoothly and proceeding from zero to normal operating speed

without vibration, noise, cavitation, or overheating.

6. Motors capable of meeting maximum pump brake horsepower requirements at all points on the head-capacity curve without exceeding the nameplate ratings of the motors and without taking advantage of the service factor unless specifically called for in the Pump Schedule.

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a. Capable of providing thermal overload alarm and pump shut down.

b. Capable of providing leak detection warning alarm prior to leak reaching the bearings in the stator housing.

2.4 PUMP CONSTRUCTION

A. Impeller

1. Impeller material shall be Hard Iron® HRC 60 ASTM 532.80 Alloy lll-A abrasion resistant high chrome cast impellers containing a minimum of 25% Chromium content.

2. Impeller waterways and clearance between the impeller periphery and volute cutwater shall be capable of passing a minimum 3" sphere and is to be matched to a constant velocity equalizing pressure volute.

3. The impeller must be able to perform as a non-clog pump during normal operation.

4. Impeller to be dynamically balanced and secured to a straight fit on the shaft by

means of a key and stainless steel fastener.

B. Volute

1. Close-grained cast iron conforming to ASTM A48 Class 35B.

2. One-piece construction, constant velocity equalizing pressure with smooth fluid passages large enough to pass any size solid that can pass through impeller.

3. Centerline flange discharge.

4. Diffusion vanes shall not be permitted.

5. The volute shall be fitted with High Chrome HRC 60 ASTM 532.80 Alloy lll-A Cast

Iron replaceable suction cover insert ring. The Chromium content of the High Chrome Cast Iron shall be a minimum of 25%.

C. Pump Shafts and Shaft Bearings

1. Shafts shall be ASTM A479 S43100-T stainless steel.

2. Minimum of two bearings permanently lubricated but capable of being re-greased,

minimum L10 bearing life of 50,000 hours.

D. Pump Shaft Seals

1. Each pump provided with a tandem mechanical rotation shaft seal system.

2. Each seal shall be held in place by its own spring system and require neither maintenance nor adjustment, but shall be easily inspected and replaceable.

3. Seal faces shall be of corrosion and abrasion-resistant tungsten carbide vs. tungsten

carbide or a combination of these two materials for the lower seal and shall be manufacturer’s standard seal for the upper seal.

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4. The lower, primary seal unit, located between the pump and the lubricant chamber,

shall contain one stationary and one positively driven rotating, corrosion and abrasion resistant tungsten-carbide ring. The upper, secondary seal unit, located between the lubricant chamber and the motor housing, shall contain one stationary and one positively driven rotating, corrosion and abrasion resistant tungsten-carbide seal ring.

5. Each seal interface shall be held in contact by its own spring system. The seals shall require neither maintenance nor adjustment nor depend on direction of rotation for sealing. The position of both mechanical seals shall depend on the shaft. Mounting of the lower mechanical seal on the impeller hub will not be acceptable.

6. Each pump shall be provided with a lubricant chamber for the shaft sealing system.

The lubricant chamber shall be designed to prevent overfilling and to provide lubricant expansion capacity. The drain and inspection plug, with positive anti-leak seal shall be easily accessible from the outside. The seal system shall not rely upon the pumped media for lubrication. The motor shall be able to operate dry without damage while pumping under load.

7. Where a seal cavity is present in the seal chamber, the area about the exterior of the

lower mechanical seal in the cast iron housing shall have cast in an integral concentric spiral groove. This groove shall protect the seals by causing abrasive particulate entering the seal cavity to be forced out away from the seal due to centrifugal action.

E. Protection 1. All stators shall incorporate thermal switches in series to monitor the temperature of

each phase winding. The thermal switches shall open at 125°C (260°F), stop the motor and activate an alarm.

2. A leakage sensor shall be available as an option to detect water in the stator chamber. A FLS (Float Leakage Sensor) shall be provided be provided in the stator housing to detect seal failure. When activated, the FLS will stop the motor and send an alarm both local and/or remote.

3. Use of voltage sensitive solid state sensors and trip temperature above 125°C

(260°F) shall not be allowed.

4. The thermal switches and FLS shall be connected to a Mini CAS (Control and Status) monitoring unit. The Mini CAS shall be designed to be mounted in any control panel.

F. Fasteners and Subassembly Mating

1. All mating surfaces shall be machined and fitted and sealed with nitrile rubber O-rings.

2. Fittings shall be accomplished by metal-to-metal contact between each machined surface resulting in controlled compression with nitrile rubber o-rings, without the requirement of specific torque limit.

3. No secondary sealing compounds or devices permitted.

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G. Sliding Guide Bracket

1. Sliding bracket assembly shall be part of the pumping unit, constructed so that when lowered to the discharge base/elbow, providing a self-cleaning, non-clogging, and non-sparking assembly without exception.

2. Stainless steel guide rails or cables shall be provided on which the pump rides when being raised or lowered in the sump and mount on the discharge base/elbow. The rails align the pump with the discharge base/elbow when it is lowered into place.

3. A stainless steel upper guide bar bracket shall be furnished to support and align the

rails at the top of the sump.

4. Due to depth of well and corresponding guide rail length, stainless steel intermediate guide bar brackets shall be installed per the manufacturer’s instructions.

5. Pump guide rails or cables shall be of 316 stainless steel construction without

exception.

H. Discharge Connection

1. Sealing of the pumping unit to the discharge connection shall be accomplished by a metal-to-metal seal; no portion of the pump shall bear directly on the floor of the sump.

2. The machined metal-to-metal seal is to be provided to insure a water tight discharge

connection. Rectangular cross sectioned gaskets requiring specific torque limits to achieve compression shall not be considered as adequate or equal. No secondary sealing compounds, elliptical O-rings, grease or other devices shall be used.

I. Lifting Lugs and Pump Removal System

1. Lifting lugs shall be supplied on the motor, sufficient to carry the load of the motor, pump, cable and pull-up attachment.

2. Stainless steel lifting bale shall be attached to the lugs.

3. Adequate length of stainless steel lifting chain shall be provided on each pump to facilitate removal.

J. Vibration Limits

1. The limits of vibration set forth in the standards of the Hydraulic Institute shall govern.

K. Motors

1. Submersible, suitable for operation on 460 VAC, 3 phase, 60 Hz. The motor construction and characteristics shall comply with NEC locked rotor indicating letter J per NEC Section 430.7 derived from NEMA MG-1-10.36.

2. The pump motor shall be a NEMA B design, induction type with a squirrel cage rotor, shell type design, housed in an air filled, watertight chamber.

3. The stator windings shall be insulated with moisture resistant Class H insulation

rated for 180°C (356°F). The stator shall be insulated by the trickle impregnation

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method using Class H monomer-free polyester resin resulting in a winding fill factor of at least 95%.

4. The motor shall be inverter duty rated in accordance with NEMA MG1, Part 31.

The stator shall be heat-shrink fitted into the cast iron stator housing. The use of multiple step dip and bake-type stator insulation process is not acceptable. The use of bolts, pins or other fastening devices requiring penetration of the stator housing is not acceptable.

5. The motor shall be designed for continuous duty handling pumped media of 40°C

(104°F) and capable of no less than 30 evenly spaced starts per hour.

6. The rotor bars and short circuit rings shall be made of cast aluminum.

7. Thermal switches set to open at 125°C (260°F) shall be embedded in the stator end coils to monitor the temperature of each phase winding. These thermal switches shall be used in conjunction with and supplemental to external motor overload protection and shall be connected to the control panel.

8. The junction chamber containing the terminal board, shall be hermetically sealed

from the motor by an elastomer compression seal. Connection between the cable conductors and stator leads shall be made with threaded compression type binding posts permanently affixed to a terminal board.

9. The motor and the pump shall be produced by the same manufacturer.

10. The combined service factor (combined effect of voltage, frequency and specific

gravity) shall be a minimum of 1.15. The motor shall have a voltage tolerance of plus or minus 10%. The motor shall be designed for operation up to 40°C (104°F) ambient and with a temperature rise not to exceed 80°C. A performance chart shall be provided upon request showing curves for torque, current, power factor, input/output kW and efficiency. This chart shall also include data on starting and no-load characteristics. The motor horsepower shall be adequate so that the pump is non-overloading throughout the entire pump performance curve from shut-off through run-out.

11. The motor shall be capable of continuous submergence underwater without loss

of watertight integrity to a depth of 65 feet or greater.

12. Motor Protective Control Sensors

a. Three thermistors in end of stator winding coils (one per phase) wired to leads in the junction chamber.

b. Leakage sensor in stator cavity, wired to leads in the junction chamber and with supervision relay in control panel. Supervision relay to provide for alarm in the event of seal leakage.

13. Power Cables

a. The power cable shall be sized according to the NEC and ICEA standards

and shall be of sufficient length to reach the junction box without the need of any splices. The power cable shall be of a shielded design in which an overall tinned copper shield is included and each individual phase conductor is shielded with an aluminum coated foil wrap.

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b. The outer jacket of the cable shall be oil resistant chlorinated polyethylene rubber. The cable shall be capable of continuous submergence underwater without loss of watertight integrity to a depth of 65 feet or greater.

2.5 PUMP STATION CONTROLLER

A. Basic Description

1. Panel will be built in one single enclosure and shall be supplied with all the necessary components for correct, safe, and specified operation. The panel shall be of two pump or duplex operation with pump alternating circuitry to equalize pump wear and override circuitry to run the second pump if the primary pump fails or if tank level rises above the specified level. The panel shall include a high level indicating system to include a minimum of flashing visual alarm, audio alarm, and alarm silence circuitry. Visual and audible alarm will automatically reset upon correction of the high level condition. The panel shall be operated on a 3 float system control system.

2. Float Levels - Pump(s) Off/Lead Pump On/Lag Pump On/High Water Alarm

B. Enclosure

a. The panel shall be enclosed in a Fiberglass/FRP enclosure that meets a NEMA 4X

rating. The enclosure shall have a continuous hinged outer door and stainless steel latches for closure.

C. Floats

1. Four (4) floats shall be provided in the lift station wet well for pump operation.

2. The float level sensors shall consist of weighted floats with mercury contacts rated

for low volt operation at milliwatt levels. Each a high level and a low level float switch shall be provided. Each level sensor shall be furnished complete with sufficient cable length to run to the terminal box below the pump station controller and leave slack for future level adjustment.

3. Floats shall meet the requirements for Class 1, Division 1, Group C & D or

“intrinsically safe” for installation an explosion hazard environment.

4. Furnish a stainless steel bracket for hanging the sensor cables

2.6 FACTORY ASSEMBLY AND FINISHINGS

A. Shop Assembly

1. Preassemble items in the shop to the greatest extent possible, so as to minimize field splicing and assembly of units at the project site.

2. Disassemble units only to the extent necessary for shipping and handling limitations.

3. Clearly mark units for reassembly and coordinated installation.

B. Use 300 Series, non-galling stainless steel fasteners unless otherwise specified.

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C. Factory Finish

1. Apply primer to surfaces to be painted.

2. Contractor shall coordinate primer and finish paint systems with paint manufacturer. No equipment shall be painted until paint systems have been submitted and approved.

3. Apply finish coat.

4. Color to be selected by owner from manufacturer's standard colors.

2.8 ACCESSORIES

A. Provide for installation the following accessories:

1. Cable grip of stainless steel

2. Safety hook and cable holder assembly of stainless steel

3. Guide bars - stainless steel

4. Stainless steel lifting cable or chain.

5. Stainless steel lifting cable fittings

6. Lifting cable hook assembly 2.9 PUMP SCHEDULE

A. Plant Pump Station

1. Number of Units: 2 total 2. Pump Performance (with Single Pump Running)

a) Flow Rate: 135 gpm

b) TDH: 32 ft

c) Speed: 1750 rpm

d) Efficiency: 42%

e) Min. Shutoff Head: 38’

f) NPSHR: N/A

g) Discharge Size: 3”

h) Max. Motor HP: 5 hp

i) Type Drive: Constant speed

3. Fluids to be Pumped

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a. Description: Raw Wastewater/Sludge from Wastewater Treatment Plant

b. Solid Size: 3 inch diameter.

4. Maximum Pump Speed: Not to exceed 1750 rpm.

5. Maximum design speed operating point shall be to the right of pump/impeller BEP

(Best Efficiency Point)

6. Stability: Stable at and between all operating conditions.

7. Horsepower: Pump shall not exceed the nameplate horsepower rating of the motor throughout the entire pump curve.

Max Motor Rating: 5 HP.

8. Minimum Size Connections: a. Suction: 3-15/16 inch b. Discharge: 3-15/16 inch


A. Installation shall be in strict accordance with contract documents and requirements of the manufacturer’s written instructions and shop drawings. It is the Contractor’s responsibility to verify the accuracy of all necessary dimensions in the field to ensure compatibility with the specifications and equipment.

B. In the event that equipment is supplied which is different than specified, it shall be the

responsibility of the Contractor to coordinate and make all changes to related structures, controls, drawings and documentation. All changes must be reviewed and approved by the engineer prior to any installation of equipment. In addition all costs associated with such changes, including additional time require for review of the changes by the engineer, shall be borne by the Contractor.

C. The equipment shall be capable of being set in place and field erected by the Contractor

with minimal field assembly. D. The pump cable end shall be sealed with a high quality protective covering to make it

impervious to moisture or water seepage prior to electrical installation. 3.2 START-UP AND OPERATOR TRAINING

A. Comply with the requirements of Section 01655. B. After complete installation of equipment by installing contractor, including placement of

equipment, setting and leveling the equipment, piping and electrical connections to all the equipment specified herein, the manufacturer’s service representative will approve the installation.

C. Upon approval of the installation, the services of the manufacturer's factory trained representative shall be provided at the project site for equipment start-up and calibration.

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D. During the start-up and calibration phase the manufacturer's representative shall inspect all

system components for proper connection and alignment and assist the installation contractor in placing the equipment in a proper operating condition.

E. Upon satisfactory completion of the start-up and calibration, a representative of the

manufacturer shall be provided to instruct Owner's personnel in the proper operation and maintenance of the equipment. The manufacturer's representative who will be providing the instruction shall have prior operation, maintenance and instructing experience.

F. All of the above services shall be completed in a total of one trip to the jobsite by the

manufacturer’s representative for the number of days shown, exclusive of travel time. Services Number of 8 hour days Inspection / Start Up and Calibration 1 Operator Training 1

G. The equipment manufacturer will request in writing that all installation prior to arriving at the jobsite be completed by the contractor. If the equipment manufacturer arrives at the jobsite and equipment installation is not complete, the equipment manufacturer shall bill the installing contractor at the manufacturer's standard service rates, or as agreed to at the time of the service request.

H. Start-up and operator training shall be coordinated with start-up and operator training for the

adjustable speed drives.

I. Additional services, other than those provided for by warranties or as specified herein, may be charged to the Owner/Contractor at the manufacturer's standard service rates or as agreed to at the time of the service request.

3.3 FIELD QUALITY CONTROL

A. Comply with the requirements of Section 01655 and 01400. B. Performance Testing shall be provided by the Manufacturer’s Technical Representative.

1. After plant start-up, the Manufacturer shall conduct a performance test using the

Owner’s influent to determine the actual system operating conditions and verify that the unit meets the minimum requirements specified.

2. In the case of non-acceptable performance, the Manufacturer shall then have 30 days in which to perform at its sole expense, any supplemental testing, equipment adjustments, changes or additions and to perform a retest of the non-acceptable system. The provisions shall be in addition to any other liquidated damages due to Owner.

C. Motor Field Tests

1. Assembly details, motor-rating, and electrical connection, etc. shall be checked for

compliance to the customer's purchase order. 2. A motor and cable insulation test for moisture content or insulation defects shall be

made. 3. The unit shall be run dry to establish correct rotation and mechanical integrity.

D. Field Tests

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1. Demonstrate to the Owner’s representatives that each unit can operate at the performance design points specified in this section:

a) Field testing reports.

b) Description of installation deficiencies not resolved to the Owner

satisfaction.

c) Description of problems or potential problems.

d) Names of Owner personnel who attended the operation and maintenance training sessions.

e) Three record copies of materials used for the training sessions including an

outline summary of the course.

2. Demonstrate that pumps can be removed with retrieval system. 3.4 MANUFACTURER’S INSTALLATION REPORT

A. Comply with the requirements of Section 01400.

END OF SECTION

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SECTION 11312

SUBMERSIBLE PUMPS FOR FEB PUMP STATION PART 1 GENERAL 1.1 WORK INCLUDED

A. The Contractor shall furnish all labor, materials, equipment and incidentals to provide, install, and test two (2) submersible pumps in the new flow equalization basin (FEB) pump station complete and operational with motors, controls and accessories as shown and as specified in this section.

B. The pump manufacturer shall furnish and have overall system responsibility for field testing,

start-up, training, calibration and overall successful operation of the equipment.

C. The submersible pumps consist of the pump, motor and other associated appurtenances for a complete system. These pumps shall be designed to run at constant speed as shown on the plans.



B. Section 11010 – Process and Appurtenant Equipment


D. Division 15 – Mechanical

E. Division 16 - Electrical 1.3 SYSTEM DESCRIPTION

A. Two (2) submersible pumps shall be installed in the new FEB Drain Pump Station. These pumps will be used to pump the sewage stored in the flow equalization basin to the influent structure for treatment.

B. Pumps will operate with float switches. 1.4 QUALITY ASSURANCE

A. Comply with the requirements of Section 11000. B. Manufacturer’s Qualifications

1. Manufacturer shall have previous experience in producing similar type submersible

pumps.

2. Show evidence of at least five installations using similar type submersible pumps in satisfactory operation for similar conditions.

11312-2

C. Factory Testing

1. Pump manufacturer shall factory test pumps to detect any defects and demonstrate that they will function satisfactorily under all conditions specified in the Pump Schedule.

2. Conduct pump testing in accordance with the standards of the Hydraulic Institute.

3. Running Test:

a. Pump shall be operated from zero to maximum capacity as shown on the approved curve.

b. Results of the test shall be shown in a plot of test curves showing head, flow, horsepower, efficiency, and current.

c. Readings shall be taken at a minimum of 7 evenly spaced capacity points

including shutoff, design point, and minimum head for which pump is designed to operate.

4. Pump manufacturer shall also perform the following inspections and tests on each

pump before shipment from factory:

a. Check impeller, motor rating, and electrical connections for compliance to these specifications.

b. Test for motor and cable insulation moisture content for insulation defects.

c. Prior to submergence, run pump dry to establish correct rotation and mechanical integrity.

d. Run the pump submerged, a minimum of six (6) feet under water.

e. After operational test d., perform insulation test b. again.

1.5 SUBMITTALS

A. Comply with the requirements of Section 01300. B. Shop Drawings and Products Data

1. Include the following items with the pump performance data:

a. Head-capacity curves, efficiency curves, NPSH curves, BHP curves, shut-off heads and pump speeds at the minimum and maximum operating conditions specified.

b. Maximum capacity at which pump can operate continuously without cavitation.

c. Minimum capacity at which pump can operate continuously without overheating.

d. Indicate the specified operating points on each of the pump performance

curves.

11312-3

C. Operation and Maintenance Data

1. Submit complete instructions for operation and maintenance of pumps and power transmission components.

2. Include at a minimum, the following data:

a. Alignment, adjustment, and repair instructions. b. Guide to troubleshooting.

c. Lubrication instructions.

d. Seal adjustment and replacement instructions.

e. Recommend spare parts list and predicted life of parts subject to wear.

1.6 DELIVERY AND HANDLING

A. Comply with the requirements of Section 01600. 1.7 WARRANTY

A. Comply with the requirements of Section 01700. B. Manufacturer will provide a warranty of all materials and equipment supplied under this


PART 2 PRODUCTS 2.1 MANUFACTURER REQUIREMENTS

A. The submersible pumps shall be manufactured by one of the following manufacturers: 1. Keen Pump Company, Inc, Ashland Ohio

2. Or Engineer Approved Equal.

B. The submersible pumps and accessories specified herein shall be provided complete by a

single supplier which shall have sole source responsibility for said equipment and all appurtenances.

2.2 GENERAL

A. The submersible pumps shall be complete and operational with pumps, motors, mounting and supports, sliding guide brackets, discharge piping, and accessories as shown on the contract drawings and specified herein.

B. The system shall be designed to allow shutdown or removal of a pump without effecting the

operation of the remaining pumps.

C. The minimum pump system wire-to-water efficiency for the design condition is specified in the pump schedule. The pump system is defined to include the pump and motor.

11312-4

D. The pump shall be constructed for installation in a Class I Division 2 Group D Environment.

All elements shall be rated for potentially explosive environments or explosion proof and/or non-sparking.

2.3 PERFORMANCE AND DESIGN CRITERIA

A. General Requirements

1. Type: Submersible pump and motor.

2. Design to be easily removable for inspection and servicing.

3. No portion of the pump shall bear directly on the floor of the sump.

4. The pumps shall be designed to connect automatically to the discharge connection elbow. Sealing of pumping unit to the discharge connection elbow shall be accomplished by a simple linear downward motion of the pump.

5. A sliding guide bracket shall be provided as an integral part of the pump unit.

6. The unit shall be designed so that the entire weight of the pump unit shall be guided

and shall be designed to press tightly against the discharge connection elbow with metal-to-metal contact. A rigid discharge elbow to support the total weight of the pumping unit shall be bolted directly to the floor with the 90 degree elbow having a 125 lb. ANSI flange discharging vertically.

7. The pump, with all appurtenances and cable, shall be capable of continuous

submergence under water without loss of watertight integrity to a depth of 65 feet.

8. The pump shall be capable of delivering the flows at the specified heads in the pump schedule.

B. Service Conditions

1. Liquid Pumped: See Pump Schedule.

2. All pumps wet pit mounted.

C. Performance Requirements

1. Capable of pumping materials required under applicable service condition.

2. Capable of meeting detailed performance requirements specified in the Pump Schedule at the end of this part.

3. Continually decreasing head-capacity curve between shut-off and maximum

capacity.

4. Capable of operating continuously at all points on the head-capacity curve between minimum and maximum capacity without vibration, noise, cavitation, or overheating.

5. Capable of starting smoothly and proceeding from zero to normal operating speed

without vibration, noise, cavitation, or overheating.

6. Motors capable of meeting maximum pump brake horsepower requirements at all

11312-5

points on the head-capacity curve without exceeding the nameplate ratings of the motors and without taking advantage of the service factor unless specifically called for in the Pump Schedule.

a. Capable of providing thermal overload alarm and pump shut down.

b. Capable of providing leak detection warning alarm prior to leak reaching the

bearings in the stator housing. 2.4 PUMP CONSTRUCTION

A. Impeller

1. Impeller shall be ASTM A536 ductile cast iron. ASTM A48 grey cast iron is not acceptable.

2. The design shall be one-piece.

3. Impeller waterways and clearance between the impeller periphery and volute cutwater shall be capable of passing a minimum 3” sphere and is to be matched to a constant velocity equalizing pressure volute.

B. Volute

1. Shall be ASTM A48 gray cast iron.

2. One-piece construction, constant velocity equalizing pressure with smooth fluid passages large enough to pass any size solid that can pass through impeller.

3. Centerline flange discharge.

4. Diffusion vanes shall not be permitted.

5. Discharge shall be 3” ABSI Standard.

C. Pump Shafts and Shaft Bearings

1. Shaft shall be of Ferritic grade Type 400 series grade stainless steel.

D. Pump Shaft Seals

1. Each pump provided with a tandem mechanical rotation shaft seal system.

2. Each seal shall be held in place by its own spring system and require neither maintenance nor adjustment, but shall be easily inspected and replaceable.

3. The seals shall require neither maintenance nor adjustment nor depend on direction

of rotation for sealing.

E. Fasteners and Subassembly Mating

1. All mating surfaces shall be machined and fitted and sealed with nitrile rubber O-rings.

2. Fittings shall be accomplished by metal-to-metal contact between each machined surface resulting in controlled compression with nitrile rubber o-rings, without the requirement of specific torque limit.

11312-6

3. No secondary sealing compounds or devices permitted.

F. Sliding Guide Bracket

1. Sliding bracket assembly shall be part of the pumping unit, constructed so that when lowered to the discharge base/elbow, providing a self-cleaning, non-clogging, and non-sparking assembly without exception.

2. Stainless steel guide rails or cables shall be provided on which the pump rides when being raised or lowered in the sump and mount on the discharge base/elbow. The rails align the pump with the discharge base/elbow when it is lowered into place.

3. A stainless steel upper guide bar bracket shall be furnished to support and align the

rails at the top of the sump.

4. Due to depth of well and corresponding guide rail length, stainless steel intermediate guide bar brackets shall be installed per the manufacturer’s instructions.

5. Pump guide rails or cables shall be of 316 stainless steel construction without

exception.

G. Discharge Connection

1. Sealing of the pumping unit to the discharge connection shall be accomplished by a metal-to-metal seal; no portion of the pump shall bear directly on the floor of the sump.

2. The machined metal-to-metal seal is to be provided to insure a water tight discharge connection. Rectangular cross sectioned gaskets requiring specific torque limits to achieve compression shall not be considered as adequate or equal. No secondary sealing compounds, elliptical O-rings, grease or other devices shall be used.

H. Lifting Lugs and Pump Removal System

1. Lifting lugs shall be supplied on the motor, sufficient to carry the load of the motor, pump, cable and pull-up attachment.

2. Stainless steel lifting bale shall be attached to the lugs.

3. Adequate length of stainless steel lifting chain shall be provided on each pump to facilitate removal.

I. Vibration Limits

1. The limits of vibration set forth in the standards of the Hydraulic Institute shall govern.

J. Motors

1. Submersible, suitable for operation on 230 VAC, 3 phase, 60 Hz. The motor construction and characteristics shall comply with NEC locked rotor indicating letter J per NEC Section 430.7 derived from NEMA MG-1-10.36.

2. The pump motor shall be induction type with a squirrel cage rotor, shell type design, housed in an air filled, watertight chamber, NEMA B type.

11312-7

3. The stator windings and leads shall be insulated with moisture resistant Class F

insulation rated for 155°C (311°F). The stator shall be dipped and baked three times in Class F varnish and shall be heat-shrink fitted into the stator housing. The use of bolts, pins or other fastening devices requiring penetration of the stator housing is not acceptable.

4. The motor shall be designed for continuous duty handling pumped media of 40°C

(104°F) and capable of no less than 15 evenly spaced starts per hour.

5. The rotor bars and short circuit rings shall be made of cast aluminum.

6. The motor and pump shall be designed and assembled by the same manufacturer.

7. The combined service factor (combined effect of voltage, frequency and specific

gravity) shall be a minimum of 1.15. The motor shall have a voltage tolerance of plus or minus 10%. The motor shall be designed for operation up to 40°C (104°F) ambient and with a temperature rise not to exceed 80°C. A performance chart shall be provided showing curves for torque, current, power factor, input/output kW and efficiency. This chart shall also include data on starting and no-load characteristics.

8. The power cable shall be sized according to the NEC and ICEA standards and shall

be of sufficient length to reach the junction box without the need of any splices. The outer jacket of the cable shall be oil resistant chlorinated polyethylene rubber. The motor and cable shall be capable of continuous submergence underwater without loss of watertight integrity to a depth of 40 feet or greater.

9. The motor horsepower shall be adequate so that the pump is non-overloading

throughout the entire pump performance curve from shut-off through run-out.

2.5 PUMP STATION CONTROLLER


1. Panel will be built in one single enclosure and shall be supplied with all the necessary components for correct, safe, and specified operation. The panel shall be of two pump or duplex operation with pump alternating circuitry to equalize pump wear and override circuitry to run the second pump if the primary pump fails or if tank level rises above the specified level. The panel shall include a high level indicating system to include a minimum of flashing visual alarm, audio alarm, and alarm silence circuitry. Visual and audible alarm will automatically reset upon correction of the high level condition. The panel shall be operated on a 3 float system control system.

2. Float Levels - Pump(s) Off/Lead Pump On/High Water Alarm

B. Enclosure

1. The panel shall be enclosed in a Fiberglass/FRP enclosure that meets a NEMA 4X rating. The enclosure shall have a continuous hinged outer door and stainless steel latches for closure.

11312-8

C. Floats

1. Three (3) floats shall be provided in the lift station wet well for pump operation.

2. The float level sensors shall consist of weighted floats with mercury contacts rated for low volt operation at milliwatt levels. Each a high level and a low level float switch shall be provided. Each level sensor shall be furnished complete with sufficient cable length to run to the terminal box below the pump station controller and leave slack for future level adjustment.

3. Floats shall meet the requirements for Class 1, Division 1, Group C & D or

“intrinsically safe” for installation an explosion hazard environment.

4. Furnish a stainless steel bracket for hanging the sensor cables

2.6 FACTORY ASSEMBLY AND FINISHINGS

A. Shop Assembly

1. Preassemble items in the shop to the greatest extent possible, so as to minimize field splicing and assembly of units at the project site.

2. Disassemble units only to the extent necessary for shipping and handling limitations.

3. Clearly mark units for reassembly and coordinated installation.

B. Use 300 Series, non-galling stainless steel fasteners unless otherwise specified. C. Factory Finish

1. Apply primer to surfaces to be painted.

2. Contractor shall coordinate primer and finish paint systems with paint manufacturer.

No equipment shall be painted until paint systems have been submitted and approved.

3. Apply finish coat.

4. Color to be selected by owner from manufacturer's standard colors.

2.7 ACCESSORIES

A. Provide for installation the following accessories:

1. Cable grip of stainless steel

2. Safety hook and cable holder assembly of stainless steel

3. Guide bars - stainless steel

4. Stainless steel lifting cable or chain.

5. Stainless steel lifting cable fittings

6. Lifting cable hook assembly

11312-9

2.8 PUMP SCHEDULE

A. FEB Pump Station

1. Number of Units: 2 total 2. Pump Performance (with Single Pump Running)

a) Flow Rate: 54 gpm

b) TDH: 19’

c) Speed: 1150 rpm

d) NPSHR: N/A

e) Discharge Size: 3”

f) Max. Motor HP: 2 hp

g) Type Drive: Constant speed

3. Fluids to be Pumped

a. Description: Raw Wastewater from Sanitary Sewer System

b. Solid Size: 3 inch diameter.

4. Maximum Pump Speed: Not to exceed 1150 rpm.

5. Maximum design speed operating point shall be to the right of pump/impeller BEP

(Best Efficiency Point)

6. Stability: Stable at and between all operating conditions.

7. Horsepower: Pump shall not exceed the nameplate horsepower rating of the motor throughout the entire pump curve.

Max Motor Rating: 2 HP. 8. Minimum Size Connections:

a. Suction: 3 inch b. Discharge 3 inch


A. Installation shall be in strict accordance with contract documents and requirements of the manufacturer’s written instructions and shop drawings. It is the Contractor’s responsibility to verify the accuracy of all necessary dimensions in the field to ensure compatibility with the specifications and equipment.

11312-10

B. In the event that equipment is supplied which is different than specified, it shall be the responsibility of the Contractor to coordinate and make all changes to related structures, controls, drawings and documentation. All changes must be reviewed and approved by the engineer prior to any installation of equipment. In addition all costs associated with such changes, including additional time require for review of the changes by the engineer, shall be borne by the Contractor.


with minimal field assembly. D. The pump cable end shall be sealed with a high quality protective covering to make it

impervious to moisture or water seepage prior to electrical installation. 3.2 START-UP AND OPERATOR TRAINING



C. Upon approval of the installation, the services of the manufacturer's factory trained

representative shall be provided at the project site for equipment start-up and calibration.

D. During the start-up and calibration phase the manufacturer's representative shall inspect all system components for proper connection and alignment and assist the installation contractor in placing the equipment in a proper operating condition.


manufacturer shall be provided to instruct Owner's personnel in the proper operation and maintenance of the equipment. The manufacturer's representative who will be providing the instruction shall have prior operation, maintenance and instructing experience.

F. All of the above services shall be completed in a total of one trip to the jobsite by the

manufacturer’s representative for the number of days shown, exclusive of travel time. Services Number of 8 hour days Inspection / Start Up and Calibration 1 Operator Training 1


H. Start-up and operator training shall be coordinated with start-up and operator training for the

adjustable speed drives.

I. Additional services, other than those provided for by warranties or as specified herein, may be charged to the Owner/Contractor at the manufacturer's standard service rates or as agreed to at the time of the service request.

11312-11


A. Comply with the requirements of Section 01655 and 01400. B. Performance Testing shall be provided by the Manufacturer’s Technical Representative.



2. In the case of non-acceptable performance, the Manufacturer shall then have 30 days in which to perform at its sole expense, any supplemental testing, equipment adjustments, changes or additions and to perform a retest of the non-acceptable system. The provisions shall be in addition to any other liquidated damages due to Owner.

C. Motor Field Tests

1. Assembly details, motor-rating, and electrical connection, etc. shall be checked for

compliance to the customer's purchase order. 2. A motor and cable insulation test for moisture content or insulation defects shall be

made. 3. The unit shall be run dry to establish correct rotation and mechanical integrity.

D. Field Tests

1. Prepare manufacturer’s installation reports and submit within 30 days after

completion of field testing and operation instruction. The reports shall include the following:

a) Field testing reports.

b) Description of installation deficiencies not resolved to the Owner

satisfaction.

c) Description of problems or potential problems.

d) Names of Owner personnel who attended the operation and maintenance training sessions.

e) Three record copies of materials used for the training sessions including an

outline summary of the course.

2. Demonstrate that pumps can be removed with retrieval system. 3.4 MANUFACTURER’S INSTALLATION REPORT


END OF SECTION

11333-1

SECTION 11333

CHANNEL MACERATOR

PART 1 GENERAL

1.1 SUMMARY

A. This section of the specification describes the grinder and controller. The equipment shall be installed as shown on the plans, as recommended by the supplier, and in compliance with all OSHA, local, state and federal codes and regulations.

B. The number of channel macerators and controllers shall be one (1).

1.2 REFERENCES A. Grinder shall, as applicable, meet the requirements of the following industry standards:

1. American Society for Testing and Materials (ASTM) A36: Carbon Steel Plate

2. American Society for Testing and Materials (ASTM) A536-84: Ferritic Ductile Iron

Castings

3. American Society for Testing and Materials (ASTM) A48-83: Grey Iron Casting

4. American National Standards Institute (ANSI) B16.42-1979, Class 150 Flanges

5. American Iron and Steel Institute (AISI) 303 Stainless Steel



8. American Iron and Steel Institute (AISI) 4130 Heat Treated Alloy Steel



11. American Iron and Steel Institute (AISI) 17-4 Stainless Steel

12. Society of Automotive Engineers (SAE) 660 Bearing Bronze

B. Controller shall, as applicable, meet the requirements of the following Regulatory Agencies: 1. National Electrical Manufacturer’s Association (NEMA) Standards

2. National Electric Code (NEC)

3. Underwriters Laboratory (UL and cUL)

4. International Electrotechnical Commission (IEC)

11333-2

1.3 DOCUMENTS A. Submittals

Supplier shall submit six (6) sets of submittals. Submittals shall include equipment descriptions, functional descriptions, dimensional and assembly drawings, catalog data, and job specific drawings.

B. Operation and Maintenance Manuals.

The supplier shall provide three (3) Operation & Maintenance manuals. An electronic version shall be supplied to create additional copies. The manuals shall include equipment descriptions, operating instructions, drawings, troubleshooting techniques, a recommended schedule, and the recommended lubricants.

1.4 QUALITY ASSURANCE

A. Identification

1. Equipment shall be identified with a corrosion resistant nameplate affixed in a

conspicuous location.

2. Nameplate information shall include manufacturer’s name and address, equipment model number, and serial number.

B. Manufacturer

1. Supplier shall have a minimum 15 years experience as a manufacturer of municipal

waste water equipment and a minimum 500 prior installations of similar equipment in the United States, with 25 installations within the state of Indiana.

2. Supplier shall provide a list of reference sites for similar equipment for verification

by the Engineer or Owner’s Representative.

3. Supplier shall conduct factory testing and verification of equipment prior to shipment.

C. Installation & Start-up

1. Supplier shall provide services of a factory trained representative to check

installation and review start-up of equipment and controls. 2. Supplier Representative shall inspect and approve site installation and supervise a

review of the operation of the equipment.

3. Supplier Representative shall provide training on operation and maintenance requirements of the equipment.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Packaging

1. Containers or skids shall be constructed for normal shipping, handling, and

storage.

2. Containers shall provide adequate protection for the equipment in a dry indoor environment between +40o F (+4.5o C) and +100o F (+37.8o C).

11333-3

1.6 WARRANTY Manufacturer’s standard 12-month limited warranty shall be provided on equipment.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Grinder and controller shall be in accordance with these specification and plans and shall be supplied by one of the following manufacturers:

1. JWC Environmental, 290 Paularino Ave, Costa Mesa, CA 92626; Tel: 800-331-

2277 www.jwce.com JWC Environmental Series 30005 -0008-DI Muffin Monster. JWC Environmental Series HPA10504 Power Pack. JWC Environmental Series PC2200 Controller.

2. Approved equal.

B. Manufacturers requesting to be selected as an approved equal shall submit certified

documentation including installation lists with phone numbers, equipment drawings, flow performance curves, electrical schematics and cut sheets, O&M draft showing compliance with these specifications a minimum of seven (7) days prior to bid opening. Selected equipment manufacturers shall be added to the list of approved manufacturers.

C. Selected approved equal manufacturers shall conduct an onsite test within ten (10) days of installation demonstrating compliance with all areas of this specification.

2.2 GRINDER

A. General

Grinder shall reduce or shred influent solids for protection of downstream equipment. Grinder shall be two shafted design consisting of individual cutters and spacers of equal diameter on both shafts. Grinder shall have high flow or slotted side rails. Grinder shall have a motor and speed reducer for cutter drive.

B. Components

1. Cutters and Spacers

a. Cutting stack shall be a nominal height of 8 inches.

b. Cutter shall be an individual disk constructed of AISI 8620 alloy steel surface

ground to thickness of .438-inches +.000/-.001 (11.1 mm +.000/-.003).

c. Cutters shall be heat treated to produce a hardness of 60-65 Rockwell C.

d. Cutters shall have 7 cam shaped teeth. Tooth height shall not be greater than ½-inch (13 mm) above the root diameter of the cutter. OD shall be 4.71-inches (120MM)

e. Spacers shall be an individual disk constructed of AISI 8620 alloy steel surface

ground to a thickness of .446-inches +.001/-.000 (11.3 mm +.003/-.000).

f. Spacers shall have a hardness of 34-38 Rockwell C.

http://www.jwce.com/

11333-4

g. Spacers shall have a smooth outside diameter with no tooth profiles.

2. Shafts a. Shafts shall be constructed from AISI 4140 alloy steel with a minimum tensile

strength of 149,000 PSI (1,027 kPA).

b. Shafts shall be measure a nominal 2-inches (51 mm) across flats of hex.

c. Shafts shall be hardened to 38-42 Rockwell C.

3. Intermediate Shaft Supports

a. Intermediate shaft supports shall be constructed of ASTM A743 stainless steel, AISI 17-4 stainless steel and SAE 660 bearing bronze.

b. Shaft supports shall be lubricated with high temperature marine grade grease

at the factory.

d. Intermediate shaft supports shall provide additional support to the shafts during severe grinding demands.

d. Intermediate shaft supports shall be provided only for cutter stacks of 40 inches (1016 mm) and greater.

4. Seal Cartridges

a. Seal cartridges shall be rated to a maximum of 90 PSI (620 kPA).

b. Seal cartridges shall not require flushing.

c. Dynamic and rotating seal faces shall be constructed of tungsten carbide with

6% nickel binder.

d. O-rings shall be constructed of Buna-N (Nitrile).

e. Radial and axial loads shall be borne by sealed, oversized, deep-groove ball bearings.

5. Housings and Covers

a. Top cover and end housings shall be ASTM A536-84 ductile iron.

b. Bottom cover shall be ASTM A36 steel.

c. End housing shall have integral bushing deflectors to guide solids away from

seal cartridges.

d. End housings shall have directional flow arrows cast into external side wall.

6. Side Rails

a. Side rails shall be ASTM A536-84 ductile iron. b. Side rails shall have evenly-spaced horizontal slots to increase flow and

decrease water head loss through the grinder. Slots shall only be located on the upstream or influent side of the rail and the effluent side of the rail shall be void of slots to allow for unobstructed flow.

11333-5

c. Inside profile of the cutters shall be concave and follow the radial arc of the cutters.

d. Clearance between the outside diameter of cutters and concave arc of the side

rail shall not exceed 5/16-inch (7.9 mm).

7. Speed Reducer

a. Reducer shall be manufactured by Sumitomo Machinery Corporation of America.

b. Reducer shall be internal planetary mechanism with trochoidal curved tooth profile.

c. Reducer shall be a vertically mounted with 29:1 single reduction.

d. Reducer shall be grease lubricated.

8. Motor

a. Motor shall be manufactured by Baldor Electric Company.

b. Motor shall be 3 hp (2.25 kW), TEFC, 1725 rpm, 460V, 3 phase, 60 Hz.

c. Motor shall have a minimum service factor of 1.15, 84% minimum efficiency at full load, minimum 82% power factor at full load.

C. Performance 1. Grinder shall be capable of processing 243 GPM. 2. Grinder shall provide a minimum peak shaft torque of 4752 lb-in/hp (721 Nm/kW). 3. Grinder shall provide a minimum peak force at cutter tip of 2051 lbf/hp (512,235

N/kW).

2.3 FRAME AND SUPPORTS

A. General

Frame and/or supports shall provide a method for securing grinder in a structure that allows for proper operation.

B. Components 1. Tank

a. Frame and/or supports shall be AISI 304 stainless steel. b. Frame shall provide proper support and interface to guide influent flow into the

grinder.

2.4 CONTROLLER

A. General Controller shall provide control of the grinder and be designed to control one (1) 3 hp

motor at 460 volts, 3 phase, 60 Hz. The controller shall have an indicator lights, switches and other control devices.

11333-6

B. Components 1. Enclosures

a. Enclosure shall be fiberglass reinforced polyester NEMA 4X . b. Enclosure shall house the control devices, motor starters, and PLC.

2. Grinder ON-OFF/RESET-REMOTE three-position 22mm type, NEMA 4X selector

switch

a. In the OFF/RESET position, the grinder shall not run. b. In the ON position, the grinder shall run continuously.

d. In the REMOTE position, the grinder shall start and stop as controlled by an

external device.

d. Selector switch shall be the only method of resetting the controller after a failure.

3. Pilot Lights

a. Lights shall be LED type 22 mm, rated NEMA 4X. b. Lights shall indicate POWER ON, RUN, and FAIL.

4. Programmable Logic Controller (PLC)

a. PLC shall be manufactured by Panasonic. b. PLC shall have a minimum of 16K of memory.

5. Motor Starter

a. Starter shall be a full-voltage reversing type with 120 volt operating coils. b. Overload relays shall be adjustable and sized to full load amperes (FLA) of the

motor.

6. Control Transformer

a. Control transformer shall be minimum 130 VA. b. Control transformer primary and secondary shall be fused for over current

protection.

7. Current Transducer

a. Current transducer shall be manufactured by Veris Industries. b. Current transducer shall have adjustable set point from 1-135A with 200 ms or

less response time.

11333-7

C. Performance

1. When a grinder obstruction occurs, the controller shall stop the grinder, then reverse the rotation to clear the obstruction. If the obstruction is cleared, the controller shall return the grinder and power pack to normal operation. If three (3) reverses occur within a 30 second interval, the controller shall stop the grinder motor in a jam condition and activate the grinder FAIL indicator and relay.

2. When a power failure occurs while the grinder is operating, the grinder will resume

operation once power is restored.

3. When a power failure occurs while the grinder is in a fail condition, once power is restored the fail indicator shall reactivate and remain until reset.

4. Reset of the grinder shall be accomplished from the controller only.

PART 3 EXECUTION

3.1 INSTALLATION

Grinder and controller shall be installed in accordance with supplier’s installation instructions, and in accordance with all OSHA, local, state, and federal codes and regulations.

3.2 TESTING

Test of grinder shall demonstrate smooth operation and correct rotation. Test period shall demonstrate simulated jam conditions for grinder.

3.3 TRAINING

A field training course shall be provided for operation and supervisory staff members. Field instruction shall cover items for successful operation contained in the operation & maintenance manuals.

END OF SECTION

11374-1

SECTION 11374

FLOATING AERATORS PART 1 GENERAL 1.1 WORK INCLUDED

A. Contractor shall provide all labor, materials, equipment, incidentals and services required to furnish, transport, test, install and place into operation two (2) Floating Aerator units in the new Flow Equalization Basin complete and operational with motors, base plates, control equipment and accessories as shown and specified in this section.

B. The contractor shall furnish and have overall system responsibility for coordination of all

parts of the Secondary Clarifier systems. Overall system responsibility shall include field testing, start-up, training, calibration and overall successful operation of the equipment.



B. Section 11000 - Process and Appurtenant Equipment


D. Division 16 - Electrical 1.3 SYSTEM DESCRIPTION

A. Two (2) floating aerator units shall be provided and installed that rest on concrete pads with the flow equalization basin empty. As the basin fills, the units will float on the surface of the rising water and be held in place by mooring posts mounted to the concrete base. The aerators will be active to mix and maintain oxygen levels in the basin as long as the depth of water is greater than 2 feet. As the basin drains, the aerators will lower back down to the concrete pad.

1.4 QUALITY ASSURANCE

A. Comply with the requirements of Section 01600. B. The manufacturer shall factory test components of the system as required to detect any

defects and demonstrate that they will function satisfactorily under all conditions specified.

C. The manufacturer shall prepare a written report on the scope and results of the factory testing and remedial actions taken, if any.

1.5 SUBMITTALS

A. Comply with the requirements of Section 01300. 1.6 DELIVERY AND HANDLING


11374-2

1.7 WARRANTY

A. Comply with the requirements of Section 01700. B. Manufacturer will provide a warranty for all materials and equipment supplied under this


PART 2 EQUIPMENT 2.1 MANUFACTURER REQUIREMENTS

A. The Equipment shall be manufactured by one of the following:

1. Evoqua Water Technologies, Alpharetta, GA. 2. Aqua Aerobic Systems, Rockford, IL. 3. Aerator Solutions, Roscoe, IL.

B. The equipment and accessories specified herein shall be provided complete by a single supplier which shall have sole source responsibility for said equipment and all appurtenances.

2.2 MOTORS

A. The motors shall utilize a high efficiency motor delivering 3 horsepower at 1800 rpm and will be wired for 460 volts, 60 cycle, 3 phase supply.

B. The motors will be totally enclosed, fan cooled, (TEFC), and generally rated for severe

chemical duty and will have a 1.15 service factor. C. The motor winding will be non-hygroscopic and insulation will be equal to or exceed NEMA

class “F”. D. A condensate drain will be located at the lowest point in the lower end-bell housing. E. Because of the operating environment, the motor will be provided with a 304 stainless steel

rain cap so as to minimize the possibility of the cap rusting. F. All motor frame parting surfaces will be deep registered and Permatex sealed to minimize

the possibility of moisture penetration. G. All through bolts, nuts and screws will be of a type 18-8 stainless steel. H. A stainless steel nameplate will be provided with each motor and shall be securely fastened

to the motor housing. The voltage, speed, insulation class, amperage, service factor, wiring diagram, motor serial number, the manufacturer’s name and address shall be steel stamped or otherwise permanently marked.

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2.3 MOTOR SHAFT

A. The aerator will have a one piece motor shaft continuous from the top motor bearing, through the lower bearing and down to and through the propeller. This shaft will have a minimum diameter of 1-3/8” and be manufactured from 17-4 PH stainless steel, or comparable stainless steel having a minimum yield strength of 100,000 psi.

B. The motor shaft will be machined to a tolerance of plus or minus 0.003 inches total

indicated runout. 2.4 MOTOR BEARINGS

A. Motor bearings shall be regreasable. Sealed bearings are not acceptable. Top bearing shall be shielded on the bottom side only. Bottom bearing shall be open.

B. The top and bottom motor bearings will be of the combined radial and axial thrust type

and will be packed at the factory with a “high performance” grease, such as CHEVRON Black Pearl, that does not require routine lubrication for 3 years.

C. The lower motor bearing inner race will be locked to the motor shaft by a special washer

and locking nut arrangement. The shaft will be threaded just below the lower bearing and will have a keyway cut into the motor shaft. This keyway will accept a tab from the I.D. of the locking washer to prevent the nut from backing off. Snap ring type bearing retainers will not be acceptable.

2.5 DIFFUSION HEAD

A. The design of the diffusion head will be such that the liquid spray will discharge at an angle of 90 degrees to the motor shaft and over a 360 degree pattern in the horizontal plane and will be a 304 stainless steel monolithic casting.

B. The diffusion head casting will act as a base for the aerator motor and alignment of the

motor to this base will be controlled by a machined index fittings that engage the P-base of the motor. The diffusion head/motor arrangements that are dependent upon bolt holes only for alignment will not be acceptable. All diffusion head hardware will be 304 stainless steel and safety wired.

C. The diffusion head casting will act as a thrust block to deflect the high velocity, pumped

volume of the aerator from the vertical to the horizontal direction. In order to minimize vibration and to provide adequate strength, the diffusion head casting will weigh no less than 19 pounds. The full bottom side of this casting will have a 90 degree radius transition to effect the hydraulic right angle change in direction with a minimum of head loss.

D. The diffusion head shall absorb all normal and shock loads encountered by the propeller

and transmitted to the diffusion head via the motor shaft and lower motor end-bell. The diffusion head shall distribute these forces into the float via webs that terminate in a flange or ring that is an integral part of the diffusion head. This flange shall mate with a similar flange that is an integral part of the float/volute to spread the stresses generated by the propeller uniformly around the float so that no point loading of the float is allowed. These flanges shall be machined flat to provide proper bearing surfaces. The alignment of the diffusion head flange to the float/volute shall be by use of a 360° index pilot.

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E. The diffusion head will contain an anti-deflection journal insert to limit the radial deflection of the motor shaft.

F. The anti-deflection journal insert will be located in the lower extremity of the diffusion

head. G. The journal insert shall be machined from Delrin or molded from moly-filled urethane and

shall be a minimum of 0.060" diameter or larger through the bore than the diameter of the motor shaft.

H. There will be a fluid deflector located on the motor shaft immediately below the anti-

deflection journal insert that will completely cover the anti-deflection insert and the lower portion of the diffusion head.

2.6 FLOTATION

A. Each aerator shall have 850 lbs. reserve buoyancy to ensure stability and to provide support flotation required during aerator servicing. Floats shall be one piece, i.e.; segmented floats are not acceptable.

B. Flotation stability will be mandatory. Under no circumstances will unstable floatation

designs requiring counter balancing, ballast of liquid, solid mass or submerged major fabricated assemblies to stabilize the operation of the aerator be allowed. Only aerators demonstrating stable operational characteristics, without rocking or oscillating will be acceptable.

C. The float shall be a minimum of 64.5" in diameter and 11" thick, and shall be fabricated of

approved fiberglass construction as later described herein.

D. All floats shall be constructed so that the internal void can be filled full of closed cell polyurethane foam having a minimum 2.0 lbs/ft3 density and shall be completely sealed water tight.

E. All floats shall have six mooring points, spaced for 3 or 4-point mooring around the outer

circumference. No mooring connections will be allowed to be attached to the upper or lower float covers. Only tension type connections perpendicular to the outer sidewall will be approved. All mooring connections shall be stainless steel.

F. Floats shall be constructed of polyester fiberglass resins and shall have a resin/glass

content of 70% resin and 30% glass. A minimum 0.014" thick gel coat shall cover the entire outer float shell.

G. A moisture inhibitor, such a N.P.G. (neopenthal glycol) or equal, and an ultraviolet

inhibitor, such a UV9 or equal, shall be used to protect the float from moisture and sunlight damage.

H. The construction of the float shall be such that no under-water joints shall be used. Joints

used to connect the top coverlid shall be overlapped a minimum of 1-1/2", both parts of all joints shall be ground to glass fiber and a resin/glass adhesive shall be applied to complete a 100% monolithic glass-to-glass bond.

I. The float construction shall be such that the volute will distribute the load of the entire

motor, drive, diffusion head and volute static load plus, the entire dynamic load from the propeller thrust and radial forces by spreading these forces uniformly around the full 360°

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circumference of the float's central core. Point connected joints or point stressed connections will not be accepted.

J. The minimum flexural strength of the fiberglass construction materials shall be 26,000 psi

and the minimum tensile strength shall be 10,000 psi.

2.7 VOLUTE

A. The propeller shall operate in a volute made of 304 stainless steel and shall be a minimum of 9" in diameter. It shall be round and true so that propeller blade tip clearance is uniform within the volute as it rotates. The volute shall have a minimum of 3/16“ wall thickness, and a minimum of four full-length stainless steel gussets shall be welded on a 90° spacing around the circumference of the volute between the top and bottom flanges.

B. The volute shall have a large machined flange at its top extremity that completely

encircles the volute, and this flange shall match a similar flange on the bottom of the diffusion head to provide for a bolted, machined flange-to-flange fit to provide uniform distribution of the dynamic loads generated by the propeller and the static weight of the motor and drive. A 360° machined index in the upper flange shall provide concentric alignment of the propeller in the volute by engaging the inside diameter of the mating flange on the diffusion head. Bolt holes alone will not be acceptable to locate the important alignment of the propeller.

C. Fiberglass volutes, or carbon steel volutes that are fiberglass, steel or stainless steel lined

are not acceptable. 2.8 INTAKE CONE

A. The intake cone shall be fabricated from .075" 304 stainless steel having a gradually expanding opening outward to the intake end. The length and inlet diameter shall be sufficient to provide uniform inlet hydraulics so that no increase in vibration is caused due to its shape or size. The minimum acceptable length is 6" and minimum inlet diameter is 12-1/4".

B. The material used to fabricate the intake cone shall be structurally sufficient to support the

weight of the entire aerator assembly when the aerator is freestanding on dry ground.

C. For maximum in-depth mixing efficiency, the intake cone shall be designed so that the suction lift from the aerator propeller is vertical from the liquid depth below the aerator. Unless specifically required for anti-erosion requirements, side or angle entry suction inlets will not be approved. Fiberglass intake cones are not allowed.

2.9 PROPELLER

A. The propeller shall be a two-blade, left-handed, marine type precision casting of 316 stainless steel, 8-1/4" diameter, and shall be specifically designed for the application intended. It shall be a self-cleaning type that will not accumulate fibers, rags, stringy materials, etc. The propeller will have a diameter not allowing a greater clearance with the volute of 1/4".

B. Each propeller blade shall be pitched so that the pitch angle and rake angle are within ± 2

percent of the other blade(s).

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C. The propeller shall be pitched so that the drive motor is loaded between 88% and 95% of full load nameplate horsepower.

D. Units using inclined screw impellers will not be acceptable.

E. The propeller must be attached to the motor shaft with a hardened stainless steel pin and set screw. No tapered, threaded shafts with nut fasteners will be acceptable.

2.10 BALANCING

A. The entire rotating assembly including the motor rotor, shaft, shaft accessories, and

impeller shall be dynamically balanced to within 2.0 mils peak-to-peak horizontal displacement measured at the upper and lower motor bearing. Measurements shall be taken at a frequency equivalent to the motor RPM.

B. Measurements shall be taken with the motor in a vertical, shaft down position and with the

entire power section mounted on resilient pads.

2.11 MOORING FRAMES AND POSTS

A. To allow for water level variation, a 304 stainless steel restrained mooring frame shall be utilized. A triangular (Delta) mooring frame shall be fastened to the bottom of the aerator float, and will consist of 304 stainless steel mooring arms to which are attached removable U-bolts which shall fit around 304 stainless steel 4” diameter posts, which shall permit the unit to rise and fall with the varying water level. Mooring arms attached to side skins of the float are not acceptable.

B. A 304 stainless “J” bolt shall be utilized to connect the frame to the flotation unit. A

minimum of three (3) connections is required.

2.12 ELECTRICAL SERVICE CABLE

A. Electrical service cable shall be provided and shall be a continuous length (non-spliced). The cable shall have three power conductors and a ground conductor.

B. Conductors shall be flexible type annealed copper stranded. Each conductor, including

the ground conductor, shall be insulated. Cables containing an uninsulated ground conductor will not be acceptable.

C. The insulated conductors shall be assembled together with a non-hygroscopic filler

material.

D. Outer jacket shall be high quality CPE, PVC, TPE or equal, and shall be rated at a conductor operating temperature of not less than 90°C.

E. The cable shall be rated for hard usage outdoor service and shall be resistant to oil,

sunlight, ozone, grease, acids, water, abrasion and impact. 2.13 OPERATION SEQUENCE

A. The operation sequence shall be controlled by the aerator control panel. If there is a water level of at least 3 ft. in the tank, the aerator shall run. Once the water level drops below 3 ft. the aerator shall turn off.

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2.14 CONTROL PANEL


1. Panel will be built in one single enclosure and shall be supplied with all necessary components for correct, safe, and specified operation. The panel shall be of one aerator or simplex operation. The panel shall be operated on a 2 float control system located in the FEB lift station wet well.

2. Float Levels – Low Water Alarm; Aerator On/Off

B. Enclosure

1. The controls for operation of the aerator shall be furnished in a 304 stainless steel enclosure that meets a NEMA 4X rating. Enclosure to include mild steel (10 gauge) sub-panel mounted with collar studs.

C. Main Disconnect Switch 1. A disconnect breaker shall be provided to for both manual opening of the circuit

and automatic opening of the circuit under overload or short circuit conditions.

2. The disconnect breaker will have a door mounted operating mechanism with trip indication. Power distribution connectors will be mounted integrally to the circuit breaker for multiple load connections.

D. Power Distribution Fusing

1. Properly rated fuses and fuse blocks are to be provided for primary and

secondary protection of the transformer and overload protection for the aerator motor starter supplied in the control enclosure. Each fuse will be equipped with a thermoplastic finger-safe cover to protect against accidental contact.

E. Transformer

1. A step-down multi-tap transformer is to be supplied to reduce incoming 3-phase

power to 120 VAC single phase. The transformer power wire connections (incoming and outgoing) are protected with a finger-safe cover to protect against accidental contact. Primary and secondary fuse protection will be provided.

F. Circuit Breakers

1. All single-phase (branch or supplementary) circuits will be protected with a single-

pole, B-Curve rated circuit breaker. The circuit breaker also provides the capability of shutting down power to a particular circuit for trouble shooting or service without shutting down the primary power to the enclosure.

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G. Fuses

1. Properly rated fuses and fuse blocks will be provided for protection of individual control devices (discrete and analog signals) mounted outside of the enclosure. Each fuse will be housed in a hinged type fuse block to protect against contact with the fuse. Hinged style fuse holder rated up to 600 VAC and 30 amps.

H. Motor Starters

1. A full voltage, non-reversing NEMA rated IEC motor starter will be provided for

the three-phase motor having a nominal voltage of up to 600VAC. The starter will consist of a contactor, overload relay, auxiliary contact(s) and motor circuit protection.

2. Contactors are to be compact in size and DIN rail mounted with a touch-safe design, which protects all connection terminals against an accidental touch.

3. Thermal overload relays are to be provided for protection of the motor. Relay

setting range is to be graduated in amps and built to be self- protecting in the event of an overload until the short circuit protection device is activated. Each overload relay is to be provided with a trip indication light and manual test feature.

I. Terminal Blocks

1. Standard feed-through screw terminal blocks, DIN rail mounted, are supplied for

all point to point wiring connections. All terminals will be numbered per the wiring schematic with printed markers.

J. Operator Devices

1. Operator device shall be a Hand-Off-Auto selector switch type and allow the

pump to be run in a manual (Hand) mode, in an automatic (Auto) mode via level controls, or be turned OFF. The selector switch shall be mounted through the control enclosure door for operation of the aerator motor. Transformer type pilot lights and illuminated pushbuttons are provided for indication of an operation status. Color-coding is as follows:

Amber – Alarm active, caution (Low Water Level) Green – Motor running Red – Motor stopped White - Information

2. All operator devices are 30.5mm style, NEMA 4X rated with finger-safe guards

located on the contact blocks to prevent accidental contact with wire connections. Indicating lights will be provided.

3. Operator device function is identified with an engraved white gravoply nameplate with black letters.

K. Elapsed Time Meter

1. A panel mounted elapsed time meter (ETM) shall be supplied to provide the

operator with the capability to record the total run-time of each aerator motor up to 99,999 hours. The ETM offers an automatic recycle to zero function.

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2.15 LEVEL SENSOR FLOAT ASSEMBLY


1. One (1) level sensor assembly shall be provided consisting of 316 stainless steel

mast, 316 stainless steel float weight and float switch (Anchor Scientific Model GSI 40NONC or approved equal) with smooth chemical resistant polypropylene casing.

2. The mast shall two (2) level sensors with three conductor electrical cable. Electrical cable shall terminate at a junction/disconnect located at the basin wall. Field wiring and junction/disconnect shall be provided by electrical contractor.


A. Installation shall be in strict accordance with contract documents and requirements of the

manufacturer’s written instructions and shop drawings. It is the Contractor’s responsibility to verify the accuracy of all necessary dimensions in the field to ensure compatibility with the specifications and equipment.

B. In the event that equipment is supplied which is different than specified, it shall be the

responsibility of the Contractor to coordinate and make all changes to related structures, controls, drawings and documentation. All changes must be reviewed and approved by the engineer prior to any installation of equipment. In addition all costs associated with such changes, including additional time require for review of the changes by the engineer, shall be borne by the Contractor.


with minimal field assembly. 3.2 START-UP AND OPERATOR TRAINING



C. Upon approval of the installation, the services of the manufacturer's factory trained

representative shall be provided at the project site for equipment start-up and calibration.

D. During the start-up and calibration phase the manufacturer's representative shall inspect all system components for proper connection and alignment and assist the installation contractor in placing the equipment in a proper operating condition.


manufacturer shall be provided to instruct Owner's personnel in the proper operation and

11374-10

maintenance of the equipment. The manufacturer's representative who will be providing the instruction shall have prior operation, maintenance and instructing experience.

F. All of the above services shall be completed in a total of two trips to the jobsite by the

manufacturer’s representative for the number of days shown, exclusive of travel time. Services Number of 8 hour days Equipment installation inspection (Trip1) 1 Inspection / Start Up and Calibration (Trip 2) 1 Operator Training (Trip 2) 1


H. Additional services, other than those provided for by warranties or as specified herein,

may be charged to the Owner/Contractor at the manufacturer's standard service rates or as agreed to at the time of the service request.


A. Comply with the requirements of Sections 01655 and 01400. B. Performance Testing shall be provided by the Manufacturer’s Technical Representative.



2. In the case of non-acceptable performance, the Manufacturer shall then have 30

days in which to perform at its sole expense, any supplemental testing, equipment adjustments, changes or additions and to perform a retest of the non-acceptable system. The provisions shall be in addition to any other liquidated damages due to Owner.

3.4 MANUFACTURER’S INSTALLATION REPORT A. Comply with the requirements of Section 01400. 3.5 OPERATION AND MAINTENANCE MANUAL

A. The Contractor shall provide 5 copies of the operation and maintenance manual including parts list, operating procedure, lubricating instruction, and maintenance instructions.

END OF SECTION

11377-1

SECTION 11377

AERATION BLOWERS (POSITIVE DISPLACEMENT)

PART 1 GENERAL 1.1 SCOPE

A. Description of Work

1. Provide all labor, material and equipment to furnish and install three (3) positive displacement blower systems as specified herein and shown on the Drawings. The existing header, piping, silencers, intake, gauges, valves and controls shall remain. This work includes removing the existing blower, motor, check valves and related mounting equipment and replacing in like kind.

2. This Specification covers the general requirements for the design, fabrication

and testing of the blowers and their appurtenances.

B. Work and components included, but not limited to the following items for each blower package. 1. Positive displacement blower 2. Drive unit

3. V-Belt drive

4. Drive guard

5. Common elevated structural steel base

6. Check valve

7. Vibration isolator pad

8. Finish paint

9. Spare parts

C. Manufacturer's Experience

1. The equipment manufacturer shall have not less than fifty (50) successful systems of

the type specified in operation for a period of not less than 5 years. The Engineer may require evidence in the form of operating records from these plants to substantiate any claims concerning the ability of the equipment to perform as required.

2. Blower Manufacturer shall be responsible for the blower selection and assembly of the

entire blower package (blower, motor, bases, belts & guards, sheaves, intake & discharge silencers, etc.). The only acceptable exception to this requirement will require the Blower Packager to have written authorization from the Blower Manufacturer that the Blower Packager has the knowledge for the proper blower selection and blower fabrication. Blower Manufacturer must also state that Blower Packager is authorized to do all blower Warranty work. All documentation will be required before shop drawing approval.

11377-2

3. The blower package/system shall be as manufactured by Howden Roots, to match

existing blowers. 1.2 SUBMITTAL

A. Submit in accordance with Section 01300.

B. Shop Drawings shall show layout of all equipment; including layout and erection details for all blowers; include mounting details.

C. Certification shall show characteristic curves for blowers; including pressure and brake

horsepower plotted against CFM capacity for full blower range.

D. Operating and Maintenance Manuals and Drawings 1. Manufacturer submit 5 sets of operating and equipment maintenance instructions and

detailed drawings in accordance with Section 01730.

E. Blower Packager Certification (if required, see 1.1, C, 2): PART 2 PRODUCTS 2.1 DESIGN CRITERIA

A. Blower shall be a positive displacement rotary type like existing. B. Blower shall be V-belt driven by an electric motor.

C. All piping shall be so installed that no weight or strain will be imposed on the blower.

2.2 ACCESSORIES

A. Check Valve

1. Provide wafer, steel body, double disc-type check valve for mounting on blower discharge piping. Furnish valve with 304 SS internals, 304 SS spring, and EPDM seat material. Provide valve equivalent to Style 5050 by Techno Corp. or equal.

B. Vibration Isolator Pads

1. Provide molded, synthetic rubber and cork, vibration isolation pads for each blower,

sized to fit the structural steel base. Provide isolators as manufactured by Korfund or equal.

2.3 SHIPPING

A. All equipment supplied in this section, with the exception of the inlet filters, shall be assembled as one unit at the factory and shipped as one unit.

2.4 PAINTING

A. Shop paint assembly frame, blower, silencers, motor, and sliding motor base separately and then assemble using grade 5 zinc plated hardware.

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1. Preparation: Remove weld splatter, grind smooth sharp edges and welds, contour to

rounded shape, and pressure (2000 psig) clean.

2. Primer Coat: Apply one coat at 3 to 4 mils DFT equivalent to Tnemec Series 66-1211.

3. Interim Coat: Apply one coat, 3 to 4 mils DFT, equivalent to Tnemec Series 66 Epoxoline after all components are assembled and system has been performance tested.

4. Finish Coat: Apply one coat of 2 to 3 mils DFT equivalent to Tnemec Series 73 Endura

Shield III Polyurethane.

5. Touch Up Paint: Provide two quarts of finish coat paint for touch ups after installation of the blower package.

2.5 SPARE PARTS

A. The Contractor shall deliver the following spare parts for each blower.

1. One (1) set of V-belts


A. All piping shall be supported to prevent exerting undue forces and moments on the blower flanges. Suitable expansion joints shall be furnished to isolate the blowers from the piping system. Each blower unit will be mounted on a flat and level concrete pad suitable for supporting the dead weight of the unit.

B. The blower manufacturer will furnish the services of a factory based engineer to check the

installation of the blower and make any field adjustments necessary to insure proper mechanical operation. The blower manufacturer will submit, to the Engineer, a written report certifying that the equipment has been satisfactorily installed and lubricated.

3.2 EQUIPMENT MANUFACTURER'S SERVICE

A. Equipment Startup: Provide for equipment startup of one eight (8) hour working day.

B. Operating Instructions: Provide for one (1) eight (8) hour working day total to instruct Plant Operators on the equipment supplied. The training period will be integrated by the Owner with overall training.

PART 4 BLOWER AND MOTOR DATA SHEET 4.1 BLOWER AND MOTOR DATA

A. Number of Blower assemblies: 3 units B. Location: Wastewater Treatment Facility Building, replacing existing blower units C. Roots Model 56URAI

D. Blower Characteristics:

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1. Air Flow 680 SCFM at 8 psi atmosphere. 2. Design Brake Horsepower - 20 BHP (min.)

3. Drive Motor(s)

a. Designed, manufactured, and tested in accordance with the latest revised

edition of NEMA MG-1. The motor shall be a squirrel cage induction type, single-speed, horizontally mounted. The motors shall conform to the following: 1) Horsepower rating: 20

2) Synchronous Speed: 1800 RPM 3) Voltage, Phase, & Frequency: 230/460 volts, 3 phase, 60 Hz 4) Enclosure: TEFC

5) Service Factor: 1.15

6) Duty Cycle: Continuous

7) Ambient Temperature Rating: 40 degrees C

8) Starting Method: Full voltage, across the line

9) Bearing Lubrication: Manufacturer's standard

10) Bearing Life: 50,000 hours rating life as defined by AFBM standards

END OF SECTION

11378-1

SECTION 11378

AERATION DIFFUSERS – CIRCULAR PART 1 GENERAL 1.1 WORK INCLUDED

A. Contractor shall furnish all labor, materials, equipment and incidentals to provide, install and test a replacement diffuser system as shown on the plans and specified in this section.


A. Division 1 – General Requirements B. Division 3 – Concrete C. Division 5 – Metals D. Section 11000 – Waste Treatment Plant and Appurtenant Equipment E. Section 11990 – Equipment Installation F. Division 16 - Electrical

1.3 SUBMITTALS

A. Shop Drawings and Product Data

1. Comply with the General Conditions, the supplemental requirements below, and Section 01300 (Submittals).

2. Submit the following information:

a. Catalog bulletins. Mark out inapplicable options. b. Dimensional sketches of diffuser system.

c. List of materials used for construction of unit if not included in catalog

bulletins.

d. Aeration system performance data including standard oxygen transfer efficiency.

e. Diffuser, diffuser connector, and system headloss curves. f. Complete test data including certified oxygen transfer performance curves,

sufficient to determine the oxygenation capacity of the fine bubble membrane disc aeration equipment proposed. The data supplied shall be for tests conducted as specified under PERFORMANCE TESTS. Testing facility arrangement shall be submitted to the Engineer for review prior to testing, and certified calculations shall be submitted to the Engineer subsequent to the SOTE testing. The Engineer shall be notified 2 weeks prior to the test date so that the tests may be witnessed.

11378-2

g. Calculations showing the distribution and balancing of air to each zone within the basin for the average and maximum airflow rates.

h. Fabrication assembly diagrams.

i. Manufacturer’s installation instructions.

B. Operation and Maintenance Data

1. Comply with the requirements of Section 01700 (Contract Closeout) and

supplemental requirements below. 2. Submit complete instruction for operation and maintenance of the aeration

diffuser system components. Include the following data:

a. Operations, alignment, adjustment and repair instructions. b. Guide to troubleshooting. c. Seal adjustment and replacement instructions.

d. Recommend spare parts lists and predicted life of parts subject to wear.

1.4 DELIVERY, STORAGE, AND HANDLING A. Comply with the requirements of the specifications including Section 01600 (Material and

Equipment). 1.5 GUARANTEE

A. Comply with the requirements of the General Conditions. B. The contractor shall guarantee the post aeration diffusers and associated components to

be free from defects in material and factory workmanship for a period of one year from the date of substantial completion. The Contractor shall furnish and install a replacement for a component which proves defective during the warrantee period.

PART 2 PRODUCTS 2.1 GENERAL

A. The fine bubble membrane disc aeration equipment furnished under this section shall be the

end products of one Manufacturer in order to achieve standardization for operation, maintenance, spare parts, and Manufacturer's service.

2.2 MANUFACTURERS

A. Fine bubble membrane disc aeration equipment for this project shall be manufactured by

Wilfley Weber, Inc. or approved equal.

2.3 SERVICE CONDITIONS

A. Aeration Tank

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2.4 EQUIPMENT DESCRIPTION A. General 1. The diffuser equipment system shall be of the fixed header, fine bubble, membrane

disc air type. The system shall be suitable for installation in the structures shown on the Drawings.

2. The aeration basin shall have one air diffuser zone. The locations and size of the

drop pipe to each diffuser train is shown on the drawings. The diffuser equipment shall include, but not be limited to an air manifold, air headers, diffusers, supports, expansion joints, air manifold and header joints, gaskets, bolts, nuts, and washers.

3. The design, fabrication, and installation of the diffuser equipment shall be such that,

upon completion of installation, all diffusers are leveled to within + 1/4 inch of a common horizontal plane.

4. The fine bubble membrane disc aeration equipment shall be designed for easy

installation and shall include provisions for level adjustment, rotational adjustment, and thermal expansion.

5. The entire system shall be designed to allow for expansion and contraction over a

temperature range of 20 to 100 degrees F when installed.

6. All welded pipe supports and assemblies shall be shop fabricated from Type 304L stainless steel with a 2D finish conforming to AISI 304L and ASTM A240-78a. Unless specified otherwise, all non-welded pipe supports and pieces shall be shop fabricated from sheets and plates of 304 stainless steel conforming to AISI 304 and ASTM A240-78a.

B. Air Manifold, and Headers:

1. The air headers shall be constructed of either schedule 40 PVC, or Class 160 PVC conforming to ASTM D-2241 for 2 to 3.5 inch diameter pipe or schedule 40 PVC conforming to ASTM D-1785 for 4-inch diameter and over. Class 160 pipe shall have SDR rating of 26. The headers shall connect to the air manifold as indicated above. The air headers shall be perpendicular to the air manifold. Headers shall be fabricated in sections up to a maximum of 25 feet in length. Sections shall be joined with fixed

joints or expansion joints as required.

2. All PVC piping shall contain 2 percent by weight titanium dioxide ultraviolet light inhibitor.

C. Purge System: Every diffuser shall be equipped with a liquid drainer stem to insure the

evacuation of water from the entire submerged aeration piping system or each aeration zone shall be furnished with a PVC drain line, sump, and airlift purge system.

D. Diffuser Assemblies:

1. Air diffuser assemblies shall be of the round, non-clog, fine bubble type with a flexible perforated air release membrane. The perforations shall be die cut I-shaped slits. Tube shaped diffusers are not acceptable. Diffuser shall be Wilfley Weber Dura-Disc DPR-10-21 or approved equal.

11378-4

2. The diffuser membrane shall be constructed from injection molded EPDM rubber and be suitable for continuous or intermittent aeration. The membrane shall include UV inhibitor and compounds designed for resistance to chemical attack, weathering and aging.

3. The membrane shall be molded in a tapered thickness, becoming thicker in the

center, in order to prevent ballooning and non-uniform bubble size. The maximum deflection of the center of the membrane under normal operating conditions shall be less than two (2) inches.

4. The diffuser assemblies shall have double backflow prevention to prevent liquid

from passing into the aeration header. 5. The diffuser assembly shall have no metallic parts. Diffusers, which utilize metallic

center restraint bolts or metallic band clamps to secure the membrane to the base, are not acceptable.

6. The diffuser assembly shall be shipped completely assembled to the job site.

Diffusers, which require field assembly, are not acceptable. 7. The membrane exterior surface shall be smooth as to inhibit biological film growth.

The membrane shall inflate during aeration and deflate when the airflow is discontinued, further restricting biological film growth. The membrane shall be cleanable in place with water from a high-pressure wash. Acid or other chemical cleaning methods shall not be required to restore the diffuser to like-new performance conditions.

8. Diffuser membrane shall have a minimum thickness of 2mm and shall meet the

following Specifications:

a. Durometer, Shore A: 45+5. b. Minimum Tensile Strength: 1,250 psi. c. Minimum Elongation: 500 percent or greater.

d. Maximum Durometer, Shore A, Change Allowed: 10 points.

e. Maximum Loss of Tensile Strength: 25 percent. g. Maximum Loss of Elongation: 25 percent. f. Maximum Compression Set: 25 percent.

9. The approved maximum airflow rate per diffuser shall be:

i. 10 inch diameter, 21 row: 7.0 SCFM

10. In order to assure quality equipment and product longevity, the following tests shall

be performed on the diffuser by a certified independent testing agency. This data shall be submitted for review by the Engineer with general submittal documents. Full size membranes, which have undergone the testing described below, shall be provided for examination by the Engineer. In lieu of the certified test data, the manufacturer shall supply 100% spare diffuser sites and 50% spare membranes.

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a. The diffuser assembly shall be tested to a minimum of 200,000 expansion and contraction cycles. Minimum cycle time shall be 10 seconds on and 10 seconds off. The air rate during testing shall be 13.7 SCFM per square foot of perforated membrane area. Testing shall be done with a full sized membrane and base assembly. The assembly shall be submerged under a minimum of 12 inches of water column. The testing shall demonstrate that the membrane experiences less that 0.1% change in elasticity, elongation, pressure drop, SOTE and membrane volume.

b. The diffuser shall be placed in a test fixture with water covering the

membrane and the base exposed to atmosphere pressure. The membrane shall then be subjected to 25 psig in order to insure that no water will leak through the membrane slits, check valve or membrane to base connection during shut down periods.

c. Air Leakage Testing: The diffuser shall be continuously operated at a

maximum flux rate of 57 SCFM per square foot of perforated membrane area for a period of seven days. The diffuser shall exhibit no air leakage at the membrane to base connection during testing. After this testing, the same diffuser shall be re-tested for oxygen transfer efficiency and pressure drop and shall exhibit no chance in these parameters as compared to a new diffuser.

d. An un-perforated membrane shall be installed on a standard diffuser base.

Air shall be fed into the diffuser. The membrane to base connection shall withstand a differential pressure of 4.0 psig with no leakage or failure.

E. Diffuser Connections: The connection between the air distribution header and the diffuser

connector shall be capable of withstanding a horizontal or vertical moment of 1,000 inch-pounds, as well as an air pressure of 50 psi, without permanent deformation. This connection shall be a shock absorbent type that is unaffected by system vibration.

F. Supports:

1. Supports shall be fabricated of Type 304 stainless steel for non-welded and 304L for welded. The supports shall be designed to provide + 1/2-inch lateral and + 1-inch vertical adjustment of the header. Adjustment shall be continuous and possible without removing the air piping from the support. All pipe ends and joints shall be provided with a pipe support.

2. Air manifold piping shall have a maximum spacing between supports of 10 feet.

Manifold supports shall be attached to the tank floor with anchor bolts and shall be designed for ten (10) times the normal uplift force.

3. Diffuser headers shall have a maximum spacing between supports of 8 feet.

Header supports, shall allow longitudinal movement of the header section to prevent stress buildup in the header due to thermal expansion/contraction forces. Maximum horizontal thrust of 20 pounds or less shall initiate movement of the header relative to the mechanism under full buoyant up-lift load.

4. Anchor bolts for fastening the supports to the aeration basin concrete slab and walls

shall by Type 304 stainless steel. Minimum anchor bolt diameter to be used is 3/8 inch. Supports shall be located such that concrete anchors are not installed within 6 inches of any concrete expansion joint.

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G. Header Joints:

1. Connections between sections of the air distribution header shall be special flanged joints or slip joints. These joints shall be designed so that individual header sections can be rotated independently of adjacent header sections for alignment purposes. The flanged joints shall be structurally designed to transmit the longitudinal forces caused by expansion and contraction in the air distribution header. Slip joints shall be designed to allow for expansion and contraction of the air distribution header.

2. Expansion joints shall be capable of handling the expansion and contraction of the

air distribution system over a temperature range of 100 degrees F. H. Gaskets: Expansion joints and couplings shall be provided with gaskets forming an airtight

connection at 20-psig minimum. Gaskets shall be neoprene, 45 to 55 durometer. I. Miscellaneous: Nuts, bolts, washers, and other non-welded parts directly exposed to the

wastewater shall be Type 304 or 18-8 stainless steel. Threaded assemblies shall be chemically treated or lubricated prior to assembling to prevent galling.

2.7 SPARE PARTS

A. The following spare parts shall be furnished and shall be suitably marked and boxed

(protected from UV light) for shipment and storage: 1. 10 diffusers

PART 3 EXECUTION 3.1 FABRICATION

A. Continuously weld both sides of face rings and flanges. All welding on the aeration equipment shall be completed in the factory. Field welding will not be permitted. All stainless steel welding shall be by the shielded arc, inert gas, MIG, or TIG method. Filler wire shall be added to all welds to provide a cross section of weld metal equal to, or greater than, the parent metal. Butt welds shall have full penetration to the interior surface, and gas shielding shall be provided to the interior and exterior of the joint.

B. Interior weld beads shall be smooth, evenly distributed, with an interior projection not

exceeding 1/16 inch beyond the inner diameter of the air header or fitting. C. All outside weld areas shall be wire-brushed to remove weld splatter. Brushes shall be of

stainless steel and used only stainless steel.

D. Solvent weld all PVC joints in the factory. 3.2 PREPARATION FOR SHIPMENT A. The fine bubble membrane disc aeration equipment shall be packaged and shipped by the

Manufacturer ready for unloading, storage, and installation by the Installation Contractor. The Contractor will provide a suitable storage space for the aeration equipment.

3.3 MANUFACTURER'S CERTIFICATE A. A Manufacturer's certificate of satisfactory installation is required for work under this section.

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3.4 CLEAN WATER FUNCTIONAL TESTS A. After installation of the fine bubble membrane disc aeration equipment is complete, witness

functional testing conducted by the Installation Contractor to check for leaks, uniformity of air release, and verification of level installation. Functional testing shall be performed with clean water at a depth over the diffusers as recommended by the aeration system Manufacturer. The Installation Contractor shall repair any leaks in the headers, diffusers, pipes, or any part of the system. The test shall be repeated until the installation is void of air leaks.

3.5 MANUFACTURERS' SERVICES

A. A technically qualified Manufacturer's representative for the equipment specified herein shall

be present at the job site and/or classroom designated by the Owner for the minimum person-days for the services listed below, travel time excluded:

1. 1- person-days for installation, assistance, inspection, and certification of the

installation in tone aeration basins. 3. 1- person-days for startup, checkout, and functional testing.

END OF SECTION

11990-1

SECTION 11990

EQUIPMENT INSTALLATION PART 1 GENERAL 1.1 GENERAL REQUIREMENTS

A. The Contractor shall accomplish complete installation of all process and appurtenant equipment items, in the project in a workmanlike manner, and leave items in working condition satisfactory to the Engineer. Whereas the drawings do not always show the exact setting and connections required for various items, due to variations in shape and manufacture, it shall be the Contractor’s responsibility to provide all materials and work necessary to complete the job. If it becomes apparent that adequate space is not available for installation of an item, the Contractor shall notify the Engineer at once in writing and cease work on installation until the situation is clarified. Equipment manufactures and Contractors shall review the plans prior to bidding and make themselves aware of any space requirement revisions or problems. Minor revisions from plans in piping, equipment foundations, operating decks, etc., necessary to properly install equipment shall be included in the Contractor’s work and no extra payment will be allowed for such changes. Refer to Section 11000 of these specifications regarding application of equipment.

B. If other equipment is accepted in lieu of the specified equipment, any revisions to

structures, piping, electrical, etc., necessary to accommodate alternate material shall be included in the bid prices as no extra payment will be allowed for such work.

C. Contractor is reminded here that premium efficiency motors are required above certain

sizes, as listed in a table in this section.

D. The following publications and standards of the issues listed below, but referred to thereafter by basic designation only, form a part of this specification to the extent indicated by the references thereto.

1. National Sanitary Foundation Testing Laboratory 2. National Electrical Manufactures Association 3. Underwriter’s Laboratory 4. All codes, regulations and requirements of all federal, state and local government

agencies where applicable.

E. Where equipment specified connects to equipment and/or work furnished by others, the Contractor shall check the equipment and/or work in the field and he will be held responsible for the proper connections to such equipment and/or work.

F. The equipment to be furnished shall be unloaded, hauled and installed in accordance with

manufacturer’s drawings and instructions. All materials and parts comprising the units specified shall be new and unused, of current manufacture and of the highest grade, free of all defects or imperfections affecting performance.

G. All equipment shall be received at the site fully protected. It shall be the responsibility of

each equipment contractor to protect his equipment until accepted by the Engineer.

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H. It is required that all manufactured and/or fabricated equipment described in the various sections be manufactured and/or fabricated by an equipment manufacturer who has complete facilities for manufacturing such equipment. This manufacturer and/or contractor shall have maintained a reputable and financially successful operation.

I. Workmanship of material and installation shall be of the highest grade in accordance with

modern current practice. The units offered under these specifications shall be covered by the manufactures’ standard warranty or guarantee of new machinery.

J. The items of machinery or equipment specified shall be products of firms regularly

engaged in the manufacture of these products and who maintain service and parts departments from which service repairs and replacements may be obtained quickly at all times. The components of auxiliary equipment other than the major units shall be products of this type. All equipment shall be of designs, which have been tried and tested by the construction and operation of equipment of the exact type and comparable size in similar installations.

K. Bearings shall be ample in size and well lubricated. Bearings and similar parts shall have

a temperature rise not exceeding the limit of safety and good practice for such parts.

L. All points requiring lubrication shall be provided either with pressure grease connections of alemite type or oil caps at points requiring oil lubrications, or oil reservoirs wherever applicable. The Contractor shall provide all oil, grease or other lubricants necessary for preliminary operation and start-up procedures, all in accordance with the manufacturer’s recommendations.

1.2 DIMENSION AND FIT

A. The Contractor shall obtain sufficient shop drawing details to perform layout dimension and fit. Sufficient detail and centerline dimension is generally shown on the drawings. Where lacking, do not scale the drawings, but request further information from the Engineer unless the location is obvious. In setting equipment, consideration shall be given to sufficient access space around the unit and orientation of valves and operating handles for convenient operation. All equipment shall be erected and installed in accordance with the manufacturer’s directions and in the location shown on the drawings. Contractor shall place all units into operation and leave them functioning in proper order in the service intended before final plant approval is made.

B. The Contractor shall obtain from the manufacturer, detailed installation drawings in five

(5) copies, and submit same to Engineer for review. After review, three (3) copies of such drawings shall be furnished the Contractor. Pump curves shall be provided with all pump equipment with the efficiency and operation conditions shown thereon.

C. Review of the shop drawings by the Engineer is for general conformance with the design

concept and the information given in the Contract Documents. However, such review does not relieve the responsibility of the Contractor if there are errors or deficiencies in dimension, size, color, fit, capacity, support strength, prime coatings, etc. or for omission of required items on these drawings.

D. In layout and setting of any equipment, Contractor shall coordinate the work with all trades

involved, regarding such items as wall openings, floor slopes, foundation bolts, electrical conduit connections, floor drains, etc., so as to provide a neat appearing installation, convenient to operate and safe to move around. Failure to properly lay out in this regard will be just cause for the Engineer to require reconstruction of drains, connections, etc.,

11990-3

until installation is satisfactory to him.

1.3 FOUNDATIONS

A. The Contractor shall provide all bases, foundations of concrete or other material as called for or required and furnish and set all anchor bolts for equipment for the purpose of anchoring equipment securely to the bases or foundations. Equipment or control panel items mounted on a building floor (except conveyor belts) shall be set on a concrete base a minimum of 4 inches high (unless otherwise noted) and of a sufficient size greater than the machine to allow proper anchor bolt setting. Pumps and smaller items shall be set and leveled on anchor bolts, then the base poured underneath.

1. Care shall be taken to use well tamped, low slump concrete to minimize

shrinkage. 2. Hollow pump bases shall have the void filled with concrete where an access hole for this purpose is provided. Edges of concrete bases shall be chamfered 3/4".

B. Anchor bolts shall be carefully set with templates. Where equipment is set on prepared

base and anchor bolts, it shall be shimmed up or set on nuts 1 inch above base, then the void filled with non-shrink grout such as “Embeco.”. Where bolts or equipment base columns are set in drilled or precast holes in a concrete base, they shall be grouted in with a special bolt-setting grout such as “Por-Rok.” All anchor bolts, which are to be submerged in wastewater, sludge or water shall be stainless steel. Use hex head nuts and washers to finish equipment setting. After nuts are final set, cut off bolt protrusion 1/4" above nut.

1.4 PIPING CONNECTIONS

A. Where piping 2 inches and larger is connected to pumps, chemical feeders, etc., the piping shall be supported independently of the equipment so as not to put a strain on the machinery and cause shaft binding, bearing stresses, etc. All piping connections to any piece of equipment shall have a shut-off valve. Additional minor appurtenances on small piping required to complete an installation, such as pressure gauges, strainers, pressure reducing valves, unions, etc., shall be furnished and installed by the Contractor in his bid price, whether specifically called for on the drawing or not. All pump suction and discharge pipes and all water services to an area shall have a pressure gage with protective diaphragm or snubber. Gage shall have a shutoff stopcock.

B. Threaded pipe connections to equipment shall be made with unions. Flanged pipe

connections shall be made with a uni-flange on at least one side. 1.5 ELECTRIC MOTORS AND CONNECTIONS

A. The Contractor shall carefully lay out equipment locations on floors so that conduit stub-outs will be contained within the concrete base. Care shall be taken to determine location of motor terminal box so that excessive conduit or flexible lead will not be required on the machine.

B. No machinery shall be operated or tested until the proper rotation has been determined

with the electrician.

C. Where motor horsepower of equipment is specified, the size motor shall be considered a minimum. If additional size is required by the manufacturer to properly operate the

11990-4

machine, it shall be done at no extra cost to the Owner. All motors shall have horsepower ratings adequate for driving the units to which they are to be connected under all conditions of loading.

D. Motors shall be drip-proof, weatherproof, submersible, or explosion-proof construction as

specifically indicated, guaranteed to carry rated loads continuously without causing injurious heating. The design and manufacture of all motors shall be General Electric, , U.S. Electric Motors, Baldor, Reliance, Marathon or approved equal. Motors on specific equipment items shall conform to the requirements delineated in the specifications for that equipment item. The equipment shall conform to the electrical requirements specified in Division 16 of these specifications.

E. Motors shall be single or three phase and of the voltage as specified. All motors shall be

for 60 Hertz power supply.

F. Horizontal, three phase motors shall be squirrel cage, induction, premium efficiency type (1 HP or larger) unless otherwise specified. See motor efficiency table at the end of this section. This specification covers motors in NEMA frame sizes 143 and up including equivalent IEC Frames 90 and up; and the following types:

1. Drip-proof 2. Totally enclosed fan cooled (TEFC) 3. Totally enclosed fan cooled, sever duty

G. All motors shall be in accordance with NEMA Standard MG1Table 12-12, or the latest

revision in so far as it is applicable. Motors shall also comply with the applicable portions of the National Electric Code, ANSI, IEEE, ASTM and OSHA.

H. Motors shall meet or exceed the locked rotor (starting) and minimum breakdown torques

specified in NEMA standards for design before the ratings specified. Locked motor (starting) currents shall not exceed NEMA design B maximum values for the specified rating. Motors shall be capable of a 20 second stall at six times full load current without injurious heating to the motor components.

I. Motors shall have a minimum and nominal full load efficiency which will meet or exceed

the values listed in NEMA MG 1-2006 Table 12-12 at the end of this sction, when tested in accordance with NEMA test standard MG1-2006, IEEE Test Procedure 112, Method B, or CSA 390,using accuracy improvement be segregated loss determination including stray load loss measurements. The minimum efficiency shall be guaranteed. This requirement shall also pertain to foreign made motors.

J. The power factor for 3600 and 1800 rpm, 3 through 250 HP ratings at full load, at full

voltage shall be a minimum of 85%. Six-pole ratings will be excluded from this requirement.

K. Standard motors shall be rated for a 1.15 service factor in a 40 degrees C ambient

temperature. Standard motors shall have a full Class F insulation system. Standard motors shall be dipped and baked in non-hygroscopic polyester varnish to consolidate the winding.

L. Horsepower/frame relationship shall conform to the latest NEMA standard for T-frame

motors, or IEC Frames.

11990-5

M. Motors shall be drip-proof or TEFC, severe duty, or explosion proof construction as

specified. Motor frame shall be of rugged construction. Special endshields may be cast iron, if manufacturer’s standard. Conduit box may be either steel or aluminum.

N. All motors shall have anti-friction bearings, sized for a L-10 life of at least 26,280 hours for

a direct connected load. Aluminum endshields shall have a cast-in-steel or cast iron bearing insert. Bearing housings shall be regreasable with provisions for purging old grease. Bearings shall be preloaded with a bearing loading spring to minimize noise and increase bearing life. TEFC motors shall be equipped with ventilating fans of corrosion resistant, non-sparking material.

O. Conduit box shall be diagonally split and rotatable in 90-degree increments. For TEFC

sever duty motors, conduit box shall be gasketted with a lead bushing between the conduit box and motor frame. Grounding provision shall be provided in the conduit box. The conduit box shall be of heavy wall cast construction.

P. External hardware shall be plated to resist corrosion. External paint shall withstand

industrial environments. Paint of TEFC motors shall withstand outdoor environment also. On TEFC severe duty units, external paint shall be a high bond, heavy build double coat catalyzed epoxy enamel for maximum corrosion protection. Motor shaft shall be provided with an external slinger at the drive end to provide additional protection from moisture and foreign material. Rotor and stator air gap surfaces shall be coated so as to prevent corrosion during extended storage periods.

Q. Nameplates shall be of stainless steel or aluminum and stamped per NEMA Standards

MG1-20.60. Nameplate information shall include the nominal efficiency value per Standard MG1-12.53b and the manufacturer’s minimum guaranteed efficiency value.

R. Enclosures shall be cast iron construction. Aluminum or rolled steel frames shall not be

acceptable. Frame, end brackets, fan shroud, and conduit box shall all be cast iron construction.

S. Motors shall have drain openings suitably located for the type assembly being provided.

T. Shouldering lifting eye bolts shall be furnished for handling convenience. Motors (180

Frame and larger) shall have provisions for lifting eye or lugs capable of a safety factor of 5.

U. Motor enclosures shall have a bi-directional, spark proof abrasion and corrosive resistant

fan made of a material that is strong and durable. Fan will be keyed to shelf.

V. The total motor design sound pressure level, measured at 3 meters, shall not exceed 85dbA. The test shall be measured using IEE publication No. 85, latest revision. Vibration shall not exceed 0.15 inch per second, unfiltered peak.

W. Tests shall be performed on each design to assure compliance with the design criteria of

this specification.

X. Motor speed shall be as specified under equipment. Where required, provide multi-speed motors as specified under equipment. See equipment specifications for type of variable speed motor control. Motor shall be compatible and suitable for use with variable speed controller specified for use with motor. Motors being controlled by variable frequency drive control systems shall adhere to NEMA Standards Publication MG1 Part 30.

11990-6

Y. Electrical starters and disconnects are specified elsewhere, however, the equipment

manufacturer shall verify electrical characteristics and coordinate with the Contractor any special requirements necessary to properly operate the equipment. Starters and wire sizes shall be adequate for the furnished horsepower. Wire sizes for the project are selected for the expected motor size. If manufacturer’s equipment requires a larger motor, Contractor shall upsize wire and conduit as necessary at no additional cost to the Owner.

Z. Pumps specified shall have motors that are non-overloading throughout the pumping

range indicated. Where a single point is indicated rather than an operating range, the motor shall be sized to be non-overloading throughout the pump’s curve unless otherwise noted. The service factor of the motor shall not be considered in the motor’s required size.

AA. In addition to this specification, equipment shall comply with the current applicable

standards promulgated by the following organizations:

AFBMA Anti-Friction Bearing Manufacturers Association ANSI American National Standards Institute ASTM American Society of Testing Materials IEEE Institute of Electrical and Electronics Engineers (Testing) HI Hydraulic Institute NEMA National Electrical Manufacturers Association (NEMA Standards Publication MG 1)

1.6 DRAINAGE CONNECTIONS

A. The Contractor shall carefully coordinate floor drain or sump locations with layout of equipment.

1. All pumps or equipment requiring drains shall have the floor drain located adjacent to the unit or its foundation so that drip piping, tank drains, etc., may be run without extending along the floor across the walking space.

B. All pumps having drip pans shall have a minimum 3/4 inch drip line to a floor drain. All

equipment having liquid bearing tanks or sumps shall have a valve drain to a floor drain with valve in a convenient position.

1.7 MANUFACTURER’S START-UP

A. The Contractor shall arrange with the various equipment manufacturers to furnish qualified field engineers or representatives for whatever period of time as may be necessary to assist and direct the Contractor in the proper installation of the equipment furnished and whose duty it also shall be to instruct the plant operating personnel in the proper operating and maintenance procedures. The Contractor shall provide the services of the manufacturer’s field service men to the check the installations and place equipment into service. This field service will apply only to major items of equipment or those requiring intricate adjustment for proper operation. Items such as sump pumps, vent fans, unit heaters, small pumps, furniture and the like will not require such service.

11990-7

B. An additional 5% of the progress payment of each item requiring start-up services will be

retained until the Contractor has satisfactorily demonstrated proper operation of each item.

1.8 OPERATION AND MAINTENANCE MANUALS

A. The manufacturer shall provide five (5) complete manuals of operation and maintenance instructions for his equipment and submit them to the Engineer for distribution. Contractor shall submit all such manuals to the Engineer before total contract payments of 90% are approved.

1.9 STANDARDS OF CONSTRUCTION AND INSTALLATION

A. All equipment installed under these specifications shall be manufactured and installed in strict compliance with all codes, regulations and requirements of the various regulatory agencies involved.

1. The equipment contractor shall arrange a meeting with a representative of the

agency involved for inspection of the completed equipment installation.

a. A “satisfactory report” must be received by the Owner from the agency before final payment is approved.

2. All electric equipment shall conform to the standards of the NEMA and shall be

U.L. approved where applicable standards have been set or otherwise conform to the jurisdictional authorities.

3. The applicable agency regulations shall govern where the specifications and/or

drawings omit or delete applicable regulations. 1.10 PREPARATION FOR FINAL INSPECTION

A. Before final inspection and before full Owner operation of the facility, the Contractor shall remove all protective covering from this work and give all items of equipment a thorough cleaning and servicing, leaving all equipment free of defects, ready for operations. At final inspection all equipment shall be installed and in place as per these plans and specifications, readily visible. All floors shall be swept clean and windows washed. Equipment shall be wiped clean of construction dirt, dust, paint smears and cement splash. The Contractor is responsible during the progress of the work until final acceptance of the work by the Engineer and/or Owner for protection of the equipment against fire, theft and damage to the equipment or any part of the facility that may be the Contractor’s fault for any cause.

1.11 PROTECTIVE COATINGS

A. All equipment items to receive coatings shall be prepared for coating as specified for preparation of surfaces in Section 09800 of these specifications including sandblasting. Shop applied primers shall be compatible with the finished coatings as specified in Section 09800.

1.12 ELECTRIC MOTOR EFFICIENCY

11990-8

3-PHASE MOTORS

11990-9

END OF SECTION