SECTION 11215 - BOOSTER PUMP STATION
PART 1 - GENERAL
1.1 SCOPE OF WORK
1. The contractor shall furnish and install one (1) factory built, factory delivered, above ground Water-Shed® water booster pump station, with all the necessary internal piping, pumps, motors, valves, and controls and other necessary appurtenances installed on a fabricated steel base and enclosed in a structure as shown on the plans and as specified herein. The Water-Shed® water booster station shall be complete when delivered and will not require internal contractor construction except to install the power service through the service conduit provided for that purpose.
2. The above ground Water-Shed® water booster pump station shall be manufactured by Engineered Fluid, Inc. (EFI), Centralia, Illinois, represented by Joe Melton, of Applied Engineering/Vaden, Inc., Midlothian, VA.
1.2 RELATED SECTIONS
1. Section 16800 - Telemetry and Control System
2. Section 16900 - Controls and Alarms
1.3 QUALITY ASSURANCE
1. The equipment and materials covered by these specifications are intended to be standard equipment of proven reliability and as manufactured by reputable manufacturers having experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practices and methods and shall operate satisfactorily when installed as shown on the contract drawings and operated per manufacturer's recommendations.
2. It is intended that the manufacturer of the selected equipment shall be a business regularly engaged in the manufacture, assembly, construction, start-up and maintenance of water distribution equipment of the type required for this project. The manufacturer shall have at least ten (10) years of successful experience in providing stations of the type, design, function and quality as required for this project. As such, the pump station manufacturer shall be required to affix an UNDERWRITER'S LABORATORIES (UL) LABEL attesting to the compliance of that assembled equipment under the PACKAGED PUMPING SYSTEMS (QCZJ) UL Listing Category. This label shall be inclusive of the entire station with enclosure so as to demonstrate compliance with the National Electrical Code requirements for working clearances and wiring procedures. Equipment manufactured without this third party certification label or equipment manufactured by an outside source or "brokered equipment" defined as systems not assembled on the premises of the named manufacturer by that company's employees WILL NOT be allowed.
1.4 SUBMITTAL
1. Equipment submittals shall be bound and in a minimum of six (6) copies. The submittals shall contain a minimum of two (2) full size drawings, size 24" x 36"; one (1) each covering the booster pump station and the electrical control schematic. The booster pump station drawing shall be specific to this project, in at least three (3) different views, be to scale and illustrate the National Electrical Code (NEC) clearances per Section 110-26 of the Code. The submittal booklets will be complete with data sheets covering all individual components that make up the booster pump station and the UL file number under which the manufacturer is listed, service department personnel statement as detailed in the specifications and be complete with the manufacturer's formal warranty policy. The submittal booklets shall be complete with a full size photocopy of the manufacturer's combination UL/manufacturer logo Packaged Pumping Systems label.
2. Two (2) submittal reviews of this item will be accomplished at no cost to the submitting contractor. However, all subsequent reviews will be charged to the submitting contractor at the design engineer's standard hourly billing rate.
PART 2 - PRODUCTS
2.1 EQUIPMENT ENCLOSURE
1. The equipment enclosure size as shown on the drawings for this project is appropriate for National Standard mandated clearances and for proper clearances above, below and around equipment to provide for safe servicing, removal and reinstallation of that equipment.
2. The drawing for this equipment illustrates centerline and clearance/maintenance dimensions about major equipment items. These dimensions are minimum. Dimensions less than those shown will not be accepted.
2.2 PREFABRICATED STRUCTURE
1. The booster pump station will be complete with a factory assembled prefabricated building affixed to the steel deck structure supporting the booster pumps as shown on the plans. The completed booster station shall be one (1) piece when delivered and require only off loading, installation on the prescribed foundation, pipe line hook up and electrical service to complete the installation. FIELD ERECTED BUILDINGS WILL NOT BE ACCEPTABLE.
2. The prefabricated building is designed to withstand wind load of 90 MPH, a roof live load of 30 PSF.
3. All exposed outside surfaces are fiberglassed including the underside, with an exterior finished of "Stone Flake" in "Desert Sand" color. In addition to the fiberglass coating, the building exterior shall be covered with Owens Corning HomeSide Supreme vinyl siding. The siding shall have a rich wood grain finish that resembles rough-sawn oak. The siding shall have double nailing hems and locks to hold the panel flat and secure against the wall. The vinyl shall be .044" gauge. The vinyl siding shall be warranted for fifty years under Owens Corning's Limited Lifetime Warranty.
4. All exterior surfaces have a minimum of 1/8" of fiberglass reinforced polyester resin applied over AC fir exterior grade plywood.
5. All structural joints between the wall sections and the floor and the wall sections and the roof, both inside and out, are secured with polyester resin adhesive and stainless steel bolts.
6. All joints and cracks in the exterior sheathing are filled with polyester resin filler prior to fiberglassing.
7. The exterior surface is 25 and 30 percent chopped glass.
8. All exterior hardware shall be attached with stainless steel bolts or screws.
9. The walls and roof of the building are insulated with Flame Spread insulation material with a rating of 200 or less. The insulation of the roof is R-19 and the walls are R-11.
10. The roof is fully insulated and fabricated with 2x6 (or larger) rafters that are sloped from the center to prevent water accumulation & to form a building with a 4:12 pitched roof. In addition to the fiberglass coating, the roof shall be covered with 30 lb. felt underlayment and 24 ga., 30 year, shadow, shingled roof with aluminum facia and soffit.
11. Interior walls are a sandwich construction of 2x4 at 16" on center with a minimum thickness of 4".
12. The interior walls and ceiling shall be finished with 15/32" AC plywood with fiberglass textured laminate (FRP) in white color with matching trim.
13. All openings in walls are fiberglassed from the outside in for a complete seal.
14. Door frames are constructed of heavy extruded aluminum sections with anchors. Sections are extruded from 6063-TS aluminum alloy, thickness of 1/8" or greater. All screws, nuts and anchors are stainless steel. The finish is in accordance with the "Alumilite" Specification No. 204-A1R1. All joints are cut to fit flush. All hardware preparation is accomplished in a workmanlike manner, accurately milled and properly reinforced.
15. The pump room door is copper free aluminum by JRJ Alumfab. The door is a heavy-duty, fully insulated aluminum door with doorknob, door closure and weather stripping. Two (2) coats of clear colorless lacquer are applied to our door. The doors are installed with non-rusting hinges, wedge locks and backup plates for closures and doorstops. Keys are provided. The entrance openings shall be double doors with a clear opening size of 72" x 84". The main passage door shall include a 12" x 12" plexiglass window.
16. The building size is as shown on the plans for this item.
17. Safety Floor Matting: The walkway areas (that space from the entrance to the control panel and the entire NEC clearance area) shall be covered with a Nyracord industrial safety matting. The mat shall be a heavy duty, 1/2 inch minimum thickness Nyracord compound (rubber blend with fiber reinforcement) of open slot design with a ribbed safety pattern (ribbed in two directions) to promote sure footing. The underside of the safety mat shall also be ribbed (in one direction only) to permit aeration and drainage. The safety mat shall not be glued to the floor surface.
18. Delivery Lifting Device - An adjustable spreader type lifting device, built to lift the building structure without impinging the lifting chains/cables on the building sidewalls, shall be provided by the pumping station manufacturer for use by the installing contractor for the purpose of unloading station from trailer.
19. THE PREFABRICATED STRUCTURE SHALL BE AS MANUFACTURED BY DUPONT BUILDING, INC.
2.3 BUILDING SUBSTRUCTURE
1. The Water-Shed® base/floor system substructure shall be made up of steel plate and standard structural steel shapes of the sizes and weights as shown on the plans for this item. The substructure shall be designed to support the building live and dead loads plus the burden imposed by loading, transporting and unloading of this equipment. All steel plates used in the substructure shall meet or exceed the requirements of ASTM-A36. The structural shapes (channels and angles) shall be of the thickness/ weight as shown on the plans for this item and shall meet or exceed the requirements for ASTM A-36. The structural rectangular or square tubing shall be of the wall gauge as shown on the plans for this item and shall meet or exceed the requirements for ASTM A-500 Grade B. Field welding to complete the capsule or attach the entrance hatch will not be allowed.
2. The station shall have floor drains as shown on the drawing.
3. Where suction and discharge piping, or any other pressure piping, passes through the station base/floor system substructure that area of the floor shall be provided with a grout sleeve. The installing contractor shall be responsible for furnishing and installing grout.
2.4 CORROSION PROTECTION
1. All surfaces of the exposed steel structure, interior and exterior, shall be gritblasted equal to commercial blast cleaning (SSPC‑SP6).
2. Following grit blasting, all weldments will be pretreated by hand with brush using Tnemec Series 61 Hi-Build Epoxoline, gray in color, coating to provide additional corrosion protection. Following the pretreatment full coating application shall take place.
3. The full protective coating shall take place immediately after surface preparation. The protective coating shall be Tnemec Series 61 Hi‑Build Epoxoline, gray in color, consisting of a two-component, high solids, amide‑cured epoxy system formulated for high build application having excellent chemical and corrosion resistant properties. The epoxy system shall be self-priming and require no intermediate coatings. The protective coating shall provide in two (2) applications a total dry mil thickness of 8.0 mils.
4. The floor area of the completed Water-Shed®, not protected by the floor matting, shall receive an additional top of "non-skid" Tnemec Series 61 Hi-Build Epoxoline, gray in color. The total dry mil thickness on the unprotected floor area shall provide a 14.0 mil coverage.
2.5 BOOSTER PUMPS
1. The pump station shall be capable of delivering the fluid medium at the following capacities and heads when operating at 0 feet minimum suction pressure.
1) Domestic Water Pumps: Two (2) service pumps shall be provided. Each shall have a design point of 87 GPM @ 93 feet TDH. Pumps shall be Peerless Model C610GAM-BF-1X2X6. Pump efficiency at design 64%. The pump driver shall be a premium efficient, A.C. induction motor, open drip‑proof construction, of the horizontal extended shaft, normal thrust type and shall be 5 h.p., 3500 rpm nominal and suitable for 3 phase, 60 cycle, 240 volt electrical service. Motors shall be suitable for use with variable frequency drives.
2) High Service Water Pump: One (1) high service pump shall be provided. The pump shall have a design point of 1,087 GPM @ 141 feet TDH. The high service pump shall be Peerless Model C1440M-BF-4X5X14. Pump efficiency at design 76%. The pump driver shall be a standard, A.C. induction motor, open drip-proof construction, of the horizontal extended shaft, normal thrust type and shall be 50 h.p., 1750 rpm nominal and suitable for 3 phase, 60 cycle, 240 volt electrical service. Motor shall be suitable for use with variable frequency drives.
2. The pumps employed within the pump station shall be of the horizontal end suction, centrifugal type. The pumps shall be of close grain cast iron construction complete with bronze trim. The pumps shall conform to the detailed specifications as set forth below:
3. Casing: Volute type, bolted to adapter, with recessed lock fit to insure alignment. No stud or bolt holes are tapped through casing to liquid ways. Tapping openings provided for priming, venting, draining and suction and discharge gauge connections. Piping connection to be as shown per pump data sheets.
4. Impeller: Enclosed, single suction type, cast in one piece. All impellers are to be statically balanced to insure smooth operation, also hydraulically balanced except in some small sizes where end thrust is but a minor factor.
5. Wearing Rings: Renewable type; maintain proper running clearance with impeller hubs to minimize leakage between suction and discharge.
6. Shaft Sleeves: To be shouldered on shaft near impeller and covers full length of shaft from impeller hub to motor end bracket. Seals by compression between shaft sleeve and impeller hub, also between sleeve and shoulder on shaft, protecting shaft from contact with liquid.
7. Stuffing Box: The stuffing box shall be cast integral with the pump casing. The stuffing box shall contain a single face type mechanical seal. The seal shall have a carbon rotating head against a Ni‑Resist stationary face and be complete with a Buna‑N boot with stainless steel spring and spring retainer.
8. Adapter: Maintains rigid assembly between motor and casing. Machined lock between adapter and motor end bracket keeps adapter and casing in permanent alignment with motor and extended motor shaft.
9. Motor: Assembled as integral part of the complete units. Shaft carries impeller and sleeve. Motor bearings are ball bearing type, designed to carry all radial and thrust loads, and are installed in sealed housings which retain lubricant and exclude dirt and moisture. Motors shall be open drip proof, premium efficient and suitable for use with variable frequency drives.
10. The pump/motor assembly shall be mounted to a fabricated steel base built specifically for the pump/motor to be mounted. Each mounting or attachment point shall be complete with a vibration isolation pad. The pad will be in two (2) parts, a 1/4" base layer followed by a 5/8" upper layer and be a nominal 2" x 2" square size for pump/motor combinations weighing up to 1500 pounds.
11. The inlet side of each booster pump shall include an elastomer connector to help isolate vibration and noise in the piping system. The elastomer connector shall be of single sphere design, constructed of neoprene and nylon with bias-ply tire reinforcing cord to provide a 225 psi working pressure rating to a minimum of 120 F. The elastomer connector shall pass through the plate steel flanges designed to grip the connector so the connector seals without gaskets when the flange bolts are drawn up. A control joint limiting pipe connector movement shall be supplied with each pipe connector.
2.6 PIPING
1. Piping shall be steel and conform to material specification ASTM A-53(CW) for nominal pipe size four (4) inch and smaller and ASTM A-53(ERW) Grade B for nominal pipe size five (5) inches and larger. Steel butt-welding fittings shall conform to material specification ASTM A-234 Grade WPB and to the dimensions and tolerances of ANSI Standards B16.9 and B16.28 respectively.
2. Forged steel flanges shall conform to material specification ASTM A-105 Class 60 and/or ASTM A-181 for carbon steel forgings and to the dimensions and tolerances of ANSI Standards B16.5 as amended in 1992 for Class 150 and Class 300 flanges.
3. The piping sizes shall be as shown on the drawing.
Size 10 inch and below ‑ Schedule 40
Size 12 inch and above ‑ Standard weight (.375" wall)
4. All pipe welds shall be performed by certified welders employed by the pump station manufacturer. As part of the equipment submittal, the pump station manufacturer shall provide copies of the welding certificates of the employees who are to perform the pipe welds.
5. All piping surfaces shall be prepared by gritblasting, or other abrasive blasting, prior to any welds taking place. Piping of 5" diameter and smaller may be cut by saw. Piping of 6" diameter and larger shall be bevel cut, and Oxyfuel or Plasma-arc cutting techniques shall be used to assure and facilitate bevel pipe cuts. No saw cuts or other form of abrasive cut-offs are allowed on 6" and larger diameter pipe.
6. In all cases, short circuit transfer, spray transfer or pulse-arc transfer modes of the gas metal arc welding process shall be applied semi-automatically. When utilizing the short circuit mode, shielding gas consisting of 50% carbon dioxide and 50% argon gas shall be used. When utilizing the spray or pulse-arc transfer modes, a shielding gas consisting of 5% carbon dioxide and 95% argon shall be used. In all cases, welding wire with a minimum tensile strength of 70,000 psi shall be employed. All flange welds and butt welds of equal size pipe shall be a single continuous nonstop weld around the complete circumference of the pipe. Whenever possible, vertical up weld passes will be applied to all pipe welds. No vertical down weld passes will be allowed. Completed welding assemblies shall create no internal obstruction, restriction or create any unintended sources of water deflection.
7. Piping of six (6) inch diameter and larger shall require a minimum of two (2) weld passes to complete each weld. The first pass, or root pass, shall be applied at the bottom of the bevel cut using the short circuit transfer welding mode, and the second pass, or cap pass, shall be applied over the root pass using the spray or pulse arc transfer welding modes to insure that at a minimum the total weld thickness shall be equal to thinnest of the two pieces being welded together.
8. Pipe Supports: Pipe supports by minimum sizing for:
1. 8" and smaller piping shall be 2" x 3" x 3/16" wall rectangular tubing;
2. 10" and larger piping shall be 3" x 4" x 1/4" wall rectangular tubing;
3. 6" and larger piping shall be provided with "kick" bracing projecting fully from the underside of the pipe to the floor at an angle of no less than 15 from vertical out at a right angle to the run of the pipe being supported. These "kick" braces shall be in addition to the vertical pipe supports called out above.
9. Pipe supports are to be fully welded at both end points to the pipe and steel floor where required.
10. Simple pipe stands made of pipe welded only at the floor and upholding a bracket with or without a threaded jack bolt or a U-bolt are not acceptable, as no lateral or transverse support is provided.
11. Fusion Bonded Epoxy: Steel piping shall have applied to it a Fusion Bonded Epoxy Coating on the interior pipe surface that conforms to AWWA C-213-91 for steel water pipelines. The powder coating product shall be National Sanitation Foundation (NSF) Standard 61 certified material. The final product shall be capable of meeting Salt Spray Resistance ASTM B117 (1000 hour) with no blistering, undercutting or rust bleed; Humidity Resistance ASTM D2247 (1000 hour) with no blistering, undercutting or rust bleed; and Impact Resistance of ASTM G14-72 (160 in. lbs.). The Fusion Bonded Epoxy Coating shall provide a minimum total dry mil thickness of 12-16 mils. The epoxy powder coating shall be Pipe Clad® 1500 Red latest revision from Lilly Industries, Inc.
12. Prior to shipment of the station, the station manufacturer shall provide in writing to the Engineer certification that the fusion bonded epoxy coating has been applied to all internal surfaces of the steel piping using the proper method. Said certification shall show under the station manufacturer's letterhead:
1) Date of application;
2) Material manufacturer and product designation including a product data sheet for the coating;
3) Applier of the fusion bonded coating, name, address and phone number;
4) Notarized signature of an officer of the station manufacturing company stating the fusion bonded epoxy coating was applied to AWWA Standard C213-91 or the latest revision.
13. All plumbed devices within the station eventually requiring service, such as meters, control valves, pumps and like equipment, shall be easily removed from the piping by the presence of appropriately placed and sufficient quantity of adaptors and couplings as shown on the drawings; no less than the quantity of couplings and adaptors shown shall be allowed.
14. The main inlet and outlet piping to the station shall each be provided with two (2) or four (4) restraining points as welded on "eyes" or similar device welded to the framing to facilitate the attachment of joint restraint tie rods or other device to be used in retarding any pipe movement at the connections.
15. The booster station piping shall include a compression type, flexible coupling to prevent binding and facilitate removal of associated equipment where shown on the plans for this item. In lieu of a compression coupling, a Uni‑Flange or a flanged coupling adapter (FCA) may be used.
16. All compression couplings, Uni-Flanges, flanged coupling adapters (FCA), and flexible connectors/expansion joints shall include a minimum of two (2) control joint rods with appropriate restraining points.
2.7 MECHANICAL EQUIPMENT
1. Combination pressure gauges: Gauges shall be glycerine filled with a built-in pressure snubber and have 4‑1/2 inch minimum diameter faces and be turret style, black phenolic case with clear glass face. The movement shall be rotary, of 400 Series stainless steel with teflon coated pinion gear and segment. The gauge shall be bottom connected and accept a 1/4" NPT female thread. Combination pressure gauge range and scale graduations shall be in psi and feet of water as follows:
1) SUCTION PRESSURE ‑ 0 to 100 psi, 10 psi figure intervals, with graduating marks every 1 psi (0-230 feet).
2) DISCHARGE PRESSURE ‑ 0 to 200 psi, 20 psi figure intervals, with graduating marks every 2 psi (0-460 feet).
All gauges will be panel mounted off the pipeline and be flexible connected to their respective sensing point. The gauge trim tubing shall be complete with both isolating and vent valves and the tubing shall be so arranged as to easily vent air and facilitate gauge removal. Gauges mounted directly to the pipeline or at the sensing point will not be accepted. GAUGES SHALL BE ASHCROFT MODEL 1279ASL.
2. Sample Tap: A single, right angle outlet, smooth nose, brass sample tap shall be affixed to the manual vent ball valve for the low suction lockout and suction pressure gauge assembly.
3. Hose Bibb with Vacuum Breaker: There shall be provided a standard hose bibb with valve and vacuum breaker on the suction piping. The hose bibb connection shall be through a pressure regulator if the header pressure would exceed 35 psi.
4. Frost-Proof Hose Bibb: There shall be provided a frost-proof hose bibb with valve and vacuum breaker on the station exterior as shown on the plans. The hose bibb connection shall be through a pressure regulator if the header pressure would exceed 35 psi.
5. Butterfly Valves: The butterfly valves shall be AWWA Class 150B, wafer design. The body shall be cast iron ASTM A126, Class B. The valve disc shall be cast iron ASTM A48, Class 40 with a Type 316 stainless steel seating edge. Valve shaft shall be stainless steel Type 304, one piece through design with self-compensating split-U Chevron style packing. The valve seat shall be Buna-N rubber simultaneously bonded and vulcanized within a recessed cavity in the valve body. Butterfly valve designs mounting the seat on the disc are unacceptable. Manually operated butterfly valves size 6" and smaller shall be equipped with Pratt lever style operators capable of withstanding 450 ft. lbs. of input torque and mounted to the valve trunnion with 4 bolts. Manually operated butterfly valves size 8" and larger shall be equipped with Pratt MDT travelling nut style handwheel operators capable of withstanding 450 ft. lbs. of input torque and mounted to the valve trunnion with 4 bolts. THE BUTTERFLY VALVES SHALL BE HENRY PRATT MODEL MKII.
6. Non-Slam Check Valves: Each pump discharge pipe run shall include a wafer‑type, non‑slam check valve. The body of the check valve shall be cast iron. The plug and seat shall be bronze and conform to ASTM Designation B‑584. The seat shall contain a Buna-N seal to provide zero leakage. The seal design shall provide for both a metal to metal low and high pressure without over-loading or damaging the Buna-N seal. The guide bushings shall be bronze copper alloy and conform to ASTM Designation B-584. The valve spring and seat retainers shall be stainless steel and conform to ASTM Designation A‑313. The valve plug shall be guided at both ends by a center shaft integral with the valve plug. Alignment of the center shaft shall be provided by guide bushings. THE NON-SLAM CHECK VALVES SHALL BE VAL-MATIC SERIES 1400-BN.
7. Dual Disc Check Valve: The bypass pipe run shall include a dual disc, wafer style check valve. The body shall be of one piece construction incorporating a vulcanized synthetic seal. Disc shall fully overlap the synthetic seal, preventing pressure indentations. The stop and pivot pins shall be stabilized by use of synthetic spheres to prevent wear and vibration during operating conditions. The body shall be cast iron, ASTM A126 Class B with vulcanized BUNA-N seal, bronze disc, ASTM B148-9A, stainless steel spring type 316 and 316 stainless steel pins and thrust bearings. THE DUAL DISC CHECK VALVE SHALL BE A VAL-MATIC SERIES 8800.
8. Relief Valve: The relief valve shall be pilot controlled, hydraulically operated, diaphragm type automatic control valve. The main valve shall be furnished with a resilient, replaceable seat. The control pilot shall be a direct‑acting, adjustable, spring loaded, normally closed pilot designed to close the main valve whenever the sensed pressure is below the pilot spring setting. The relief valve shall function to limit the discharge header pressure to the value set into the control pilot. The valve shall be sized as shown on the plan and be globe pattern, flanged to meet ANSI Class 125 and have a maximum pressure rating of 250 psi. THE RELIEF VALVE SHALL BE CLA-VAL MODEL 50G-01B.
9. Hydro-Pneumatic Storage Tank: The booster station shall include one (1) diaphragm type hydro‑pneumatic ASME coded storage tank. The storage tank volume will be a minimum of 528 gallons with a maximum working pressure of 125 psi. The hydro‑pneumatic storage tank shall feature deep drawn steel upper and lower domes with side shell construction specifically designed for diaphragm type storage tanks. Storage tank welding shall be carefully done to eliminate rough spots and sharp edges. The storage tank base shall be designed so as to permit free airflow to prevent moisture from accumulating beneath the storage tank. The hydro‑pneumatic storage tank internals shall include two (2) separate pieces. The first piece shall be a heavy‑duty butyl diaphragm that effectively separates the air chamber from the water chamber. The shape of the diaphragm shall conform exactly to the shell configuration and shall be of seamless construction meeting FDA requirements for potable water. The second piece shall be a polypropylene liner that conforms exactly to the lower dome and acts as the water receptacle. Water shall never touch steel. The polypropylene liner shall be 100% non‑corrosive and will not be bonded to the steel shell wall or lower dome. A mechanical clamping ring shall permanently affix the diaphragm and the liner to the shell groove. The polypropylene liner shall be tested and accepted by the National Sanitation Foundation. Storage tanks without either or both diaphragm and liner will not be accepted. THE HYDRO‑PNEUMATIC STORAGE VESSEL SHALL BE AS MANUFACTURED BY WESSELS COMPANY, MODEL FXA-2000.
2.8 PRESSURE TESTING
1. When the station plumbing is completed, the pressure piping within the station (including valves, pumps, control valves, and fittings), connections as make up the entire system shall be hydrostatically tested at a pressure of 100 psi or a pressure equal to the lowest test pressure rating of the equipment within the tested system, whichever is greater pressure. The test pressure shall be applied for a minimum of 20 minutes, during which time all joints, connections and seams shall be checked for leaking. Any deficiencies found shall be repaired and the system shall be retested.
2. The results of this testing shall be transmitted in writing to the Engineer prior to shipment of the station and shall note test pressure, time at full pressure and be signed by the Quality Control Manager or test technician.
2.9 ELECTRICAL DESIGN, ASSEMBLY & TEST
1. The electrical apparatus and control panel design, assembly, and installation, and the integration of component parts will be the responsibility of the manufacturer of record for this booster pumping equipment. That manufacturer shall maintain at his regular place of business a complete electrical design, assembly and test facility to assure continuity of electrical design with equipment application. Control panels designed, assembled or tested at other than the regular production facilities or by other than the regular production employees of the manufacturer of record for this booster pumping equipment will not be approved.
2. Conformance to Basic Electfical Standards: The manufacturer of electrical control panels and their mounting and installation shall be done in strict accordance with the requirements of UL Standard 508 and the National Electrical Code (NEC) latest revision so as to afford a measure of security as to the ability of the eventual owner to safely operate the equipment. No exceptions to the requirements of these codes and standards will be allowed; failure to meet these requirements will be cause to remove the equipment and correct the violation.
3. U.L. Listing: All service entrance, power distribution, control and starting equipment panels shall be constructed and installed in strict accordance with Underwriter's Laboratories (UL) Standard 508 "Industrial Control Equipment." The UL label shall also include an SE "Service Entrance" rating stating that the main distribution panel is suitable for use as service entrance equipment. The panels shall be shop inspected by UL, or constructed in a UL recognized facility. All panels shall bear a serialized UL label indicating acceptance under Standard 508 and under Enclosed Industrial Control Panel or Service Equipment Panel. In addition, a photocopy of the UL labels for this specific project shall be transmitted to both the project engineer and the contractor for installation within their permanent project files, prior to shipment of the equipment covered under these specifications.
4. E.T.L. Listing: All control panels shall be E.T.L. Listed by Interek Testing Services (ITS) under Category 4 - Industrial Control Equipment. Each completed panel shall bear an E.T.L. listing label. The listing label shall include the station manufacturer's name, address and telephone number. The station manufacturer shall have quarterly inspections performed by ITS at the manufacturer's facilities to ensure that the products being listed comply with the report and procedural guide for that product.
5. Equipment Grounding: Each electrical equipment item in the station shall be properly grounded per Section 250 of the National Electrical Code. Items to be grounded include, but are not limited to, pump motor frames, control panel, transformer, convenience receptacles, dedicated receptacle for heater, air conditioner, dehumidifier, lights, light switch, exhaust fans and pressure switches.
6. All ground wires from installed equipment shall be in conduit and shall lead back to the control panel to a plated aluminum ground buss specific for grounding purposes and so labeled. The ground buss shall be complete with a lug large enough to accept the installing electrician's bare copper earth ground wire. The bus shall serve as a bond between the earth ground and the equipment ground wires.
7. Metal framing channel shall be used exclusively for mounting of all electrical panels and electrical components except for those specifically designated otherwise.
2.10 ELECTRICAL APPARATUS
1. Control Panel: All circuit breakers, time delay relays and control relays shall be incorporated into one (1) NEMA I control panel. The electrical service provided for this station will be 240 volt, single phase, 60 cycle, 3 wire. There shall be provided, thermal‑magnetic trip circuit breakers as follows:
One (1) Main Breaker, 200 amps;
Three (3) Branch Breakers, one per pump, 45/45/125 amps; One (1) Phase Monitor Breaker, 15 amps;
Eight (8) Auxiliary Circuit Breakers, as follows:
1. Controls 5. Convenience Outlets
2. Lights 6. Telemetry
3. HVAC Unit 7. Spare
4. Dehumidifier 8. Spare
2. Running time meter: A running time meter shall be supplied for each pump to show the number of hours of operation. The meter shall be enclosed in a dust and moisture proof molded plastic case, suitable for flush mounting on the main control panel. The meter dial shall register in hours and tenths of hours up to 99999.9 hours before repeating. The meter shall be suitable for operation from a 115 volt, 60 cycle supply.
3. Phase Monitor: A phase monitor shall be supplied to protect three-phase equipment against phase loss, undervoltage and phase reversal conditions. When a fault is sensed, the monitor output relay opens within two seconds or less to turn the equipment off and/or cause an audio or visual alarm. Both Delta and Wye systems may be monitored. The monitor shall have an automatic reset and shall also include an adjustable voltage delay. The monitor shall have an indicator LED (glows when all conditions are normal and shall monitor phase sequence: ABC operate (will not operate CBA). The phase monitor shall be UL approved and CSA certified.
4. Surge Arrestor: A secondary surge arrestor shall be provided. Housing shall be Noryl and be ultrasonically sealed. Valve blocks shall be metal oxide with an insulating ceramic collar. Gap design shall be annular. The lead wire shall be permanently crimped to the upper electrode forming part of the gap structure. Arrestors shall be UL and CSA listed Lightning Protective Devices.
5. PLC Pressure Control System - Operation Description: The system shall control two (2) service pumps and one (1) emergency flow pump based upon discharge pressure with safety cutouts based upon suction pressure. The PLC shall be furnished by the station supplier and is specified in Section 16900 – Controls and Alarms.
6. Pressure Transmitters: The pressure transmitters shall be as specified in Section 16900 – Controls and Alarms.
7. Low Suction Pressure Alarm/Cutout: The site operation shall have logic that shall suspend the operation of pump calls and activate alarm indicators and outputs in the event the suction pressure of the station falls to a point equal to or less than the low suction cutout setpoint. The pressure must remain equal to or less than the low suction alarm setpoint for a period of no less than 60 seconds, after which the low suction alarm/cutout will latch on. The low suction alarm/cutout will turn off when the suction pressure of the station rises to a point equal to or greater than the low suction cutout/alarm restore setpoint and a period of no less than 120 seconds has elapsed.
8. Adjustable Frequency AC Controllers: The station manufacturer shall furnish and install a complete Adjustable Frequency Controller System as described in this specification and as detailed on the applicable drawings. The station manufacturer shall be responsible for the installation and start-up of the equipment covered by this specification. The Adjustable Frequency Controller shall be furnished by a single vendor who has actively been manufacturing Adjustable Frequency Controllers for a period of at least five (5) years.
The Adjustable Frequency Controller shall be UL and CSA certified and shall comply with the latest applicable standards of ANSI, IEEE and NEMA. The controllers shall be rated as shown on drawings. As a minimum the full load output current of the controller shall be equal to the equivalent motor horsepower as listed by National Electrical Code Table 430‑150.
The Adjustable Frequency Controller manufacturer shall maintain, as part of a national network, engineering service facilities within 250 miles of project, to provide start-up service, emergency service calls, repair work, service contracts, maintenance, and troubleshooting training of customer personnel.
There shall be provided three (3) Variable Frequency Drive (VFD) units. The VFD’s shall be capable of having properly sized and rated 240 VAC single phase power input to it and output 3 phase power to the load. The system manufacturer shall ensure the size of the VFD is adequate to operate the 3 phase load.
The unit(s) shall tolerate a 10% overvoltage and 15% undervoltage, a line frequency between 57-63 Hz, and have a 100% load rating. The VFD shall operate at 100% rated capacity, without derating, up to 3,300 feet MSL. The unit shall operate in environments of 5%-95% noncondensing humidity, at an ambient temperature between -10 and +40 C (+14 F to +122 F). The VFD shall have a displacement power factor of no less than 95%. The drive shall have a 98% efficiency at FLA.
The VFD shall output a coded pulse width modulation power output to the load over a frequency range of 0-400 Hz, 1Hz stop settings. The drive shall have a frequency regulation of ±0.2% of maximum output frequency.
The drive shall have the following protective features: overcurrent, ground fault, undervoltage, overvoltage, input phase loss, overheating of heatsink, external alarm, overheating internally, overheating of braking resistor, motor 1 overload, motor 2 overload, inverter overload, blown fuse, memory error, keypad panel communication error, CPU error, option error, operating error, output wiring error, and modbus RTU error. The drive shall have a keypad through which operator personnel can manually start/stop drive, manual control speed, job drive motor, and adjust drive parameters. THE DRIVES SHALL BE AS MANUFACTURED BY GENERAL ELECTRIC CO., OF PLAINVILLE, CT, MODEL AF-300PII.
9. EMI/RFI Filters: Each variable frequence drive (VFD) unit shall be equipped with an electromagnetic interference/radio frequency interference filter unit. The filter unit shall meet EMC Class A "CE" International Standards. The filter shall be current rated for the application. Filter units shall connect to the line side of the VFD. FILTER UNITS SHALL BE AS MANUFACTURED BY MTE CORPORATION and shall be supplied completely pre-wired to the variable speed drive unit(s) by the station manufacturer of record. Field installation of filter units will NOT be allowed.
Wiring and handling shall be per manufacturer's recommenda-tions. The Adjustable Frequency Controller shall be protected against damage at all times. The controller shall be stored in a clean, dry environment with temperature and humidity within the range as specified by the controller manufacturer. Space heaters shall be energized during storage, as recommended by the manufacturer. Testing, checkout and start-up of the Adjustable Frequency Controller equipment shall be performed under the technical direction of the station manufacturer's service technician. Under no circumstances are any portions of the drive system to be energized without authorization from the station manufacturer's representative.
10. Automatic Dialing Alarm Monitor: The dialer shall be furnished in Section 16900 – Controls and Alarms. The following alarms/status points shall be included within the booster pump station:
1) Booster Pump #1 Fail
2) Booster Pump #2 Fail
3) Booster Pump #3 Fail
4) Low Suction Pressure
The pump fail alarms and low suction pressure alarm shall be provided via the programmable logic controller specified in Section 16900 – Controls and Alarms.
11. Telemetry Interface Panel: It will be the responsibility of the booster station manufacturer to provide one (1) 3/4" telemetry entrance conduit complete to telemetry panel, a size 12" x 12" NEMA 1 telemetry interface panel, a separate 120 volt single phase power circuit in conduit to the telemetry interface panel, telemetry control circuits made up and in conduit from main control panel to telemetry interface panel terminal strip, and metal framing channel to mount telemetry equipment.
12. Hand‑Off-Automatic Switches: The H-O-A switches shall be oil tight, 3‑position maintained and be located on the main control panel door.
13. Indicating Lights: Indicating lights shall be oil tight, with a full voltage pilot light and be provided:
1. Red ‑ Low Suction Pressure
2. Green ‑ Pump #1 in Operation
3. Green ‑ Pump #2 in Operation
4. Green - Pump #3 in Operation
5. Red - Pump #1 Fail
6. Red - Pump #2 Fail
7. Red - Pump #3 Fail
14. Nameplates: Nameplates shall be furnished on all panel front mounted switches and lights.
15. Panel Schematic: The control panel door shall be complete on the interior with a stick-on transparency containing an "as-built" reproduction of the electrical control panel schematic. The wiring diagram shall be a corrected "as‑built" copy and contain individual wire numbers, circuit breaker numbers, switch designations and control function explanations.
2.11 CONDUIT AND WIRING
1. The service entrance conduits shall be rigid steel conduit, individually sized to accept the inbound service conductors and telemetry/telephone/radio cables, and shall be installed from the main power or control panel through the equipment enclosure floor and terminate exterior to the equipment enclosure. The service entrance exterior conduit connection points shall be capped or plugged for shipment.
2. All wiring within the equipment enclosure and outside of the control panel or panels shall be run in conduit except for the watertight flexible conduit and fittings properly used to connect pump drivers, fan motors, solenoid valves, limit switches, etc., where flexible connections are best utilized. Only the dehumidifier where furnished by the original manufacturer with a UL approved rubber cord and plug, may be plugged into a receptacle.
3. Equipment Enclosure Conduit: Rigid, heavy wall, Schedule 40 PVC with solvent weld moisture‑proof connections, in minimum size 3/4" or larger, sized to handle the type, number and size of equipment conductors to be carried ‑ in compliance with Article 347 of the National Electrical Code and NEMA TC‑2, Federal WC‑1094A and UL‑651 Underwriter's Laboratory Specifications.
4. Flexible Connections: Where flexible conduit connections are necessary, the conduit used shall be liquid‑tight, flexible, totally nonmetallic, corrosion resistant, nonconductive, U.L. listed conduit sized to handle the type, number and size of equipment conductors to be carried ‑ in compliance with Article 351 of the National Electrical Code.
5. Motor Circuit Conductors: Sized for load. All branch circuit conductors supplying a single motor of one (1) horsepower or more shall have an ampacity of not less than 125 percent of the motor full load current rating, dual rated type THHN/THWN, as set forth in Article 310 and 430‑B of the National Electrical Code, Schedule 310‑13 for flame retardant, heat resistant thermoplastic, copper conductors in a nylon or equivalent outer covering.
6. Control And Accessory Wiring: Sized for load, type MTW/AWM (Machine tool wire/appliance wiring material) as set forth in Article 310 and 670 of the National Electrical Code, Schedule 310‑13 and NFPA Standard 79 for flame retardant, moisture, heat and oil resistant thermoplastic, copper conductors in compliance with NTMA and as listed by Underwriter's Laboratories (AWM), except where accessories are furnished with a manufacturer supplied UL approved rubber cord and plug.
2.12 ELECTRICAL CONVENIENCE
1. Receptacles: Four (4) duplex, ground fault circuit interrupter type receptacles shall be furnished about the periphery of the equipment enclosure, with one (1) receptacle adjacent to the main control panel.
2. Lighting: There shall be one or more two‑tube, 32 watt per tube, electronic start, enclosed and gasketed, forty‑eight (48) inch minimum length fluorescent light fixtures installed within the equipment enclosure, as shown on the plan for this item. One (1) light fixture shall be located directly over the main control panel. The light switch shall be of the night glow type and be located conveniently adjacent to the door. Open fluorescent or incandescent fixtures will not be accepted.
3. Heating/Cooling/Exhaust Unit: The unit shall be one piece, wall mounted, factory assembled, precharged, prewired, tested and ready to operate. The unit shall have a limited warranty of five years on parts and five years on the compressor. The unit shall be approved and listed by Underwriters' Laboratories, Inc., and Canadian Underwriters' Laboratories (CUL). Unit performance shall be certified in accordance with Air Conditioning and Refrigeration Institute Standard 210/240-89 for Unitary Air-Source air conditioners or latest standard.
1) Exterior wall mounted, hard-wired as shown;
2) Enclosed weatherproof casing constructed of 20 gauge galvanized steel, finished with baked-on polyester enamel paint;
3) Washable filter;
4) Remote adjustable thermostat;
5) Cooling capacity in tons: 1;
6) Cooling Capacity: 11,100 BTUH at 230 volts, 1 phase;
7) Amps: 30;
8) Twin indoor blowers, SCFM maximum/minimum: 325/300 at 0.2" static pressure;
9) Electrical supplemental heater: 3 kW;
10) Unit shall include built-in economizer system with exhaust air damper providing up to 100% outside air through the air inlet opening. The economizer is designed to provide "free cooling" when the outside air temperature is cool enough to provide needed cooling without running the compressor.
4. Dehumidifier: The station manufacturer shall provide one (1) dehumidifier, installed as shown. The unit shall have a capacity of 25 pints per 24 hours (AHAM Standard DH-1); with a compressor rated 1/5 HP, 4.1 amps, 400 watts; and 120 volt A.C. operation by dial-controlled adjustable humidistat. Condensate shall be piped direct to sump. The rubber cord shall be UL listed.
PART 3 EXECUTION
3.1 FACTORY START‑UP SERVICE
1. Start-up service technician shall be a regular employee of booster station manufacturer.
2. As part of the submittal covering this equipment, list the factory service manager, his employee number, his telephone number with extension and his number of years with the company. List also each start-up service technician, his employee number and years of service with the company.
3. Verify that one (1) or more of the service technicians listed above will perform the required start-up service on the equipment covered in the submittal.
4. One (1) full day at job site for start-up and training.
5. Start-up service to include two (2) bound O&M manuals.
6. Start-up service report attested to by start-up technician and representative of owner or engineer.
7. Service report distributed to:
1) Manufacturer's File
2) Engineer's File
3) Contractor's File
4) Owner's File
3.2 MANUFACTURER'S WARRANTY
1. The warranty is the sole responsibility of the station manufacturer and that manufacturer's warranty shall be provided in written form for inclusion with both the submittal covering the specified equipment and the O&M manuals provided with that equipment.
2. Said manufacturer's warranty shall at a minimum cover:
1) A period of one (1) year commencing upon successful start-up, after authorized manufacturer's start-up, not to exceed eighteen (18) months from the date of shipment.
2) The warranty period shall be inviolate regardless of any component manufacturer's warranty for equipment and components within the station.
3. The manufacturer's warranty shall cover all equipment, components and systems provided in or with the station by the manufacturer of the station, exclusive of those components supplied by and/or installed by others independent of the manufacturer of record for this station.
4. The warranty shall provide for the station manufacturer to bear the full cost of labor and materials for replacement and/or repair of faulty or defective components so there shall be no cost incurred by the Owner for this work during the warranty period.
5. The manufacturer's warranty policy is amended only by the items considered consumables, i.e., light bulbs, pump seals, pump packing, lubricants and other maintenance items consumed by usage.
6. No assumption of contingent liabilities for any component failure during manufacturer's warranty is made.
7. It is the intent of this manufacturer's warranty to gain for the owner a single source responsible party for all components specified herein. "Second party" or "pass through" warranties will not be accepted.
8. If the submitted written manufacturer's warranty does not meet the minimum requirements set forth above, that submittal will forthrightly be rejected.
3.3 GENERAL LIABILITY INSURANCE
1. The booster pump station manufacturer shall furnish premises/ operations and products/completed operations general liability insurance from an insurance company with a rating of A-V according to the most recent Best's Key Rating Guide, in an amount equal to $5,000,000 per occurrence. The insurance certificate must be included with the manufacturer's submittal. The coverage must be provided by an insurance carrier licensed and admitted in the state of manufacture.