Section VII – Submersible Pump Station
Part 1 – GENERAL
1.01 WORK INCLUDED
A. The Contractor shall furnish and install a submersible wastewater pumping station consisting of two submersible pumps, controls, fall proof hatch covers, fast-out assemblies, guide rails, liquid level controls, panel, electrical connections, meter base, main disconnect switch, emergency transfer switch, wet well, valve box, and all necessary appurtenances, as shown on the drawings and specified herein, complete and ready for operation. All piping internal to the wet well and valve box shall be schedule 40 stainless steel including guide rails.
B. RELATED WORK
1. Section II – Structure Excavation & Backfill For Pump Station
2. Section III – Concrete
1.02 QUALITY ASSURANCE
A. DESIGN REQUIREMENTS
1. Wet Well Dimensions and Pump Design Capacity shall be as detailed on the drawings.
B. SUBMITTALS
1. Shop Drawings
The Contractor shall provide six sets of shop drawings prepared by the manufacturer and submitted to the Design Engineer for review prior to the manufacture of the equipment. The shop drawings shall include outline dimensions and external connection diagrams.
A list of components, curves showing complete pump performance from shutoff to at least 15 percent below rated head conditions, brake horsepower and NPSH required, control panel one-line wiring diagram and specifications, and a copy of the manufacturer’s warranty shall be included with each set of submitted data. Two copies of the approved submittals shall be provided to the Owner prior to the delivery of equipment or materials. All non-approved manufactures equipment shall be submitted in writing to GSUB and the engineer for review 30 days prior to final submittal acceptance.
2. Manuals
Operating, maintenance, and repair manuals (4 copies) for all major equipment and items shall be submitted to the Owner’s Engineer.
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C. GUARANTEE
All equipment shall be guaranteed against defects in material and workmanship for a period of one year from the date of Owner’s final inspection and acceptance to the effect that any defective equipment shall be repaired or replaced without cost or obligation to the Owner.
Part 2 – PRODUCTS
2.01 MATERIALS
A. SUBMERSIBLE PUMPS
1. General Standards
The sewage pumping unit shall be UL/FM explosion proof label certifying its use in a Class 1, Division 1, Groups C & D, vertical, non-clogging, centrifugal sewage pump with bottom inlet and side discharge. The pump shall be direct driven by integral squirrel, electric induction motor. Each pump shall include-quick removal system, Stainless Steel anchor bolts and all accessories within.
2. Manufacturers
Acceptable pump suppliers include Wilo-USA, Flygt, Sulzer, or pre-approved equal by GSUB. Manufacturer shall an established authorized service center within 100 miles of Gulf Shores. The service center shall have a spare parts stocking, full onsite repair facility and 24/7 service tech.
3. Types
Only continuous duty pumps designed and manufactured for use in conveying raw, unscreened wastewater are acceptable. Pumps must be submersible and grinder pumps are NOT acceptable.
4. Impellers
Pump impellers shall be manufactured from ASTM A48 Class 30B or higher cast iron. The impeller shall be non-clog, capable of passing a 3.1 inch solid non-deformable sphere through the bottom inlet and out the wo shrouds.
5. Volutes
The volute shall be constructed of ASTM A48 minimum Class 30B or higher cast iron capable of prolonged resistance to raw sewage. Suction and discharge flanges shall be 125# and meet ANSI standard B16.1. All nuts, bolts, washers and other fastening devices supplied with pumps shall be stainless. A wear ring system shall be used to provide efficient sealing between the volute and suction inlet of the impeller. Wear rings (rotating and stationery) material shall be a min of 304 Stainless Steel.
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6. Motors
Each pump shall be furnished with a squirrel cage, induction motor enclosed in a watertight housing (shrink fit) constructed of ASTM A48 of higher cast iron. The Stator windings shall be VPI dipped with a minimum varnish rating of class H insulation (180 degrees C ) All motors must be INVERTER RATED (Nema standard MG-1) and shall be capable of sustaining 15 starts per hour (unlimited starts with VFD) at a minimum ambient temperature of 40 degrees C. Air filled or water/glycol medium filled coolant jacket motors shall be used. Motor Service Factor (SF) shall not be used to meet duty point. Bearing life shall be L-10 and shall be sealed, lubricated and have a minimum life of 10,000 hours. Multiple row lower bearings for axel thrust and a single row bearing shall support pump shaft. Shafts shall be AISI 420 stainless steel and one piece construction without joints or stubs attached. Mechanical seal faces shall be silicon carbide vs silicon carbide upper and lower. Overheating and moisture detection are required on all pumps. Pump cables shall be furnished in lengths to run un-spliced from the pump to the control panel. Cable shall be suitable for submersible pump applications. Pump Cable length shall 50 feet.
7. Mounting
The manufacture shall provide cast iron fast-out fixtures to allow the pumps to be installed or removed without requiring personnel to enter wet well. The fixtures shall consist of a discharge elbow (base 90 shall not be smaller than 4 inch) permanently mounted to the floor of the wet well, (Flygt style) sliding guide brackets which shall be an integral part of the unit and stainless-steel guide rails which will guide the pump into position. All hardware shall be Stainless Steel.
8. Warranty
The pumps and motors will be covered by a five (5) year 100% warranty parts and labor.
B. PUMP CONTROL PANEL
1. Scope and Panel Operation
The control logic shall operate two electrical submersible pumps at the power characteristics as specified: The control logic shall provide for the operation of the lead pump under normal conditions. If the incoming flow exceeds the pumping capacity of the lead pump, the lag pump will automatically start to handle the increased flow. As the liquid level decreases, the pumps will shut off at the elevations shown on the plans. In the event of a malfunction or a flow that exceeds the capacity of the pumps, a high level light will be excited to indicate alarm conditions. Pumps shall alternate as lead and lag pumps on a continuous basis. Panel Shall be UL508 Certified. A Nema 4X Type 304 Stainless Steel Vent box shall be installed between wet well and main control panel to eliminate moisture and gases from entry. Cable glands and cord grips shall be used for watertight, strain relief entry into panels. Each lift station shall have a main Nema 4X Type 304 Stainless Steel disconnect (non fused) directly off the power company meter.
2. Construction and Materials
The control panel enclosure shall be NEMA 4X, Type 304 stainless steel with dead front aluminum inner door and mounted as shown on the drawings per engineer.
3. Panel Exterior
Mounted on the exterior enclosure shall be a red LED alarm light. All exterior mounted accessories shall be constructed of corrosion proof materials such as stainless steel or aluminum. All pump, control, and instrumentation wiring from the wet well shall bottom entry only to the panel.NO TOP ENTRY. Each pump power cable shall have its own conduit with separate conduits for control and instrumentation wiring. All Grounding for wet well and all panel components shall be done to meet NEC Code. All conduits shall be Aluminum or Schedule 80 PVC Consult with GSUB for Guidance.
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4. Panel Inner Door
The inner aluminum door mounted on a continuous hinge, will be furnished for protection against exposed wiring and will have cutouts for access to the circuit breakers, hand-off-automatic switches, elapsed time meters, main circuit breaker, duplex receptacle breaker, motor circuit breakers. A permanently affixed 11” x 17” (minimum laminated panel wiring schematic and pump data sheet) shall be installed on the interior of the enclosure door.
5. Control Circuits
In order to ensure maximum safety, the control circuit breakers shall be run at 115 volts.
6. Panel Components
The following power, control and alarm components shall be provided.
A. Circuit Breakers: All circuit breakers shall be heavy duty thermal-magnetic molded case as manufactured by Square D or equal approved by GSUB. The main circuit breaker shall be provided with provisions for locking in an “on or off” position. Each pump shall also have its own circuit breaker.
B. Duplex Service Receptacle: A circuit breaker protected duplex service receptacle suppling 15 amps at 115 volts shall be provided on the inner panel door. The duplex receptacle shall be provided with ground fault protection.
C. Lighting Arrestor and Surge Capacitor: A Square D or equivalent lighting arrestor and surge capacitor shall be installed and wired to protect motors and control equipment from lighting, induced surges and transient voltage surges.
D. Elapsed Time Meters: Elapsed time meters shall be 115 volt non-reset types and shall indicate pump running times in hours and tenths of hours to 99999.9 hours, one for each pump.
E. Motor Controllers: The panel shall contain two NEMA Rated (FVNR) starters. The motor starters shall be across the line magnetic starters with individual overload protection on each power leg with motor resets installed through the dead front door. Any panel with larger than 20HP shall have Soft Starts or Variable speed drives. Acceptable manufacturers are Square-D for starters, Weg SSW07 for soft starts, and ABB ACS 580 or TECO E510 for Variable Speed Drives or approved equal approved by GSUB.
F. Phase Monitors: An 8 pin phase monitor shall be installed and wired to disconnect control power from the motor starters in the event of loss of power, phase reversal, loss of any phase or phase balance, or low voltage. The phase monitor shall automatically reset upon removal of any and all of the preceding conditions and shall be RL electronics model or equal.
G. Pump Run and Fault Lights: A 115 volt pump run light shall be connected in parallel with each motor starter and indicate when a particular pump is running. A 115 volt Fault light shall be connected in parallel with each motor starter and indicate when a particular pump is faulted.
H. Control System: The control system shall consist of:115 volt, Mercoid Model MPCJR or MPE SC2000 controller, plug-in three phase monitor and stainless steel control floats or 4/20 mv submersible weighted transducer as determined by GSUB.
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I. Alarm Lights: The alarm light shall consist of a red weatherproof LED light to indicate a high level in the wet well.
J. Telemetry Monitoring: As determined by GSUB, a Hightide (model Gen2) Monitoring Unit shall be integrated into panel. Each panel shall be provided with terminal block with dry contacts for termination with the scada system.
1. Pump 1 run and fault
2. Pump 2 run and fault
3. High level and low level
4. Moisture/winding overload failure
5. Phase loss or reversal
K. Pump Terminal Blocks: The panel shall be provided with raised terminal blocks for terminations.
L. Wiring and Termination:
1. All wiring shall follow NEC color coding scheme.
2. All wiring shall be run parallel to side walls of panels and/or in wiring troughs. Wires passing across hinged areas shall be protected by abrasion resistant cabling materials.
3. Identification: All conductors shall be labeled at end with numbers matching submittal data sheets and all wire terminations shall be identified by the component terminal numbers as shown on panel drawings.
M. Cooling Fans and Ventilation
1. Some Panels may require Cooling fans or ventilation depending on application. Please refer to engineered drawings and GSUB for direction.
2. Condensation Heaters
Minimum of 100w with thermostat as manufactured by Hoffman model DAH1001A. Shall be installed in each panel.
GSUB will not accept any single-phase power pump stations.
C. WET WELL AND VALVE VAULT
Wet Well and Valve Vault shall be of precast concrete or fiberglass and shall conform to the applicable requirements of Section III or fiberglass as specified in Section C.1 specified below.
C.01 FIBERGLASS WET WELLS
A. Design Requirements
1. Approved Manufacturers – Wet wells shall be manufactured by L.F. manufacturing, Inc. (LFM),
or Associated Fiberglass Enterprises (AFE).
2. Warranty – The fiberglass manufacturer shall warrant the fiberglass wet well against defects for at least twenty (20) years after the date of acceptance by GSUB. Defects are defined as cracking, delaminating, or leaking. The warranty shall require the manufacturer to supply all necessary labor, materials, and equipment to repair defects to the satisfaction of GSUB. The contractor and/or manufacturer shall not make any exemption or exception to the above stated conditions or warranty. Manufacturer’s recommended installation procedures to assure 20-year warranty provided to GSUB to be included in submittal package.
3. Handling – The wet well shall not be dropped or impacted. Wet wells shall be chocked if stored horizontally. If wet wells must be moved by rolling, the ground transverses shall be smooth and free of rocks, debris, etc. FRP wet wells may be lifted by the installation of three lifting lugs as specified by the manufacturer in the outside surface near the top or by a sling or “choker” connection around the center. Use of chains or cables in contact with the wet well surface is prohibited. Wet wells shall be lifted horizontally using one support point.
B. Materials
1. Resin – The resin used shall be commercial grade unsaturated polyester resins with fiberglass reinforcements.
2. Reinforcing Materials – The reinforcing materials shall be a commercial Grade “E” type glass in the form of mat, continuous roving, chopped roving, roving fabric, or a combination of the above, having a coupling agent that will provide a suitable bond between the glass reinforcements and the resin.
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3. Surfacing Materials – If reinforcing materials are used on the surface exposed to the contained substance, it shall be a commercial grade chemical-resistant glass that will provide a suitable bond with resin and leave a resin rich surface.
4. Fillers and Additives – Fillers, when used, shall be inert to the environment and wet well construction. Additives, such as thixotropic agents, catalysts, promoters, etc., may be added as required by the specific manufacturing process to be used. The resulting reinforced plastic material must meet the requirement of this specification.
5. Color – Inside surface and outside surface of wet well shall preferably be white in color. Light gray or light tan is acceptable.
6. Quality Assurances – Comply with the latest published editions of AWWA and ASTM Standards
ASTM D883 – Standard Terminology Related to Plastics
ASTM D3299 – Standard Specification for Filament-Wound Glass-Fiber-Reinforced Thermoset Resin Corrosion-Resistant Tanks
ASTM D3753 – Standard Specifications for Glass-Fiber- Reinforced Polyester Manholes and Wet wells
ANSI/AWWA D120-09 AWWA – Standard for Thermosetting Fiberglass-Reinforced Plastic Tanks
C. Physical Requirements
1. Load Rating – The complete wet well shall have a minimum dynamic-load rating of 16,000 ft-lbs when tested in accordance with ASTM 3753, Section 8, test methods D 790 and D 695. To establish this rating the complete wet well shall not leak, crack, or suffer other damage when load tested to 40,000 ft-lbs and shall not deflect vertically downward more than ¼ inch at the point of load application when loaded to 24,000 lbs.
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2. Stiffness – The wet well cylinder shall have a minimum pipe-stiffness value as shown in the following table when tested in accordance with ASTM D3757, Section 8.
Stiffness
Length – Ft. F/AY – PSI 10 to 20 2.01 21 to 30 3.02 31 to 40 5.24 Physical Properties Property Hoop Direction (psi) Axial Direction (psi) Tensile Strength 18,000 5,000 Tensile Modules 0.8 x 10 (6) 0.7 x 10 (6) Flexural Strength 26,000 4,500 Flexural Modules (no ribs – 48”, 60”, 72”) 1.4 x 10(6) .07 x 10(6) (with ribs – 96”, 144”) .07 x 10(6) .07 x 10(6)
D. Fabrication
1. One Piece Unit – Unless otherwise approved by GSUB, wet well shall be a one piece unit.
2. Exterior Surface – The exterior surface shall be relatively smooth with no sharp projections.
Hand-work finish is acceptable if enough resin is present to eliminate fiber show. The exterior surface shall be free of blisters larger than ½ inch in diameter, delamination and fiber show.
3. Interior Surface – The interior surface shall be resin rich with no exposed fibers. The surface shall be free of crazing, delamination, blisters larger than ½ inch in diameter, and wrinkles of 1/8 inch or greater in depth. Surface pits shall be permitted if they are less than ¾ inch in diameter and less than 1/16 inch deep.
4. Defects Not Permitted –
a. Exposed fibers – Glass fibers not wet out with resin. Resin runs: runs of resin and sand on
the surface. Dry areas: areas with glass not wet out resin. Delamination: separation in the
the laminate.
b. Blisters – Light colored areas larger than ½ inch in diameter. Crazing: cracks caused by sharp
objections.
c. Pits or Voids – Air pockets.
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d. Wrinkles – Smooth irregularities in the surface.
e. Sharp Projections – Fiber or resin projections requiring gloves for handling.
5. Mounting of Brackets – Manufacturer shall affix minimum ¼” thick stainless steel backer plates to exterior of wet well at locations where brackets attach to wet well. Manufacturer shall determine quantity and size of 316 stainless steel hardware to be used for fastening. The bolts shall be inserted through backer plates, with bolt heads welded to backer plates. Bolts and nuts shall be fastened together to bracket on interior of wet well. Exterior backer plates shall be glassed over at factory.
6. Markings – Each wet well shall have wet well data integrated into fiberglass and affixed to top inside and top outside walls. Data required included manufacturer’s name, ASTM designation, production and/or serial number, production date, length and diameter, and warranty length.
7. Markings – Make with hole-saw and fill annular space with watertight fitting.
8. Discharge Pipe Installation – Discharge wall penetrations shall fiberglass necks large enough to accept O.D. of pipe discharge flange and shall be installed via a glass tight-water tight Link Seal system.
9. Influent Pipe Installation – It is preferable that the manufacturer install at factory a laminated fiberglass neck at location of influent pipe per plans. The neck diameter and length shall be sized to accept the Link Seal required for the influent pipe diameter. Annular spaces on both sides of Link Seal shall be filled with fiberglass. Alternatively, and with GSUB prior approval, the manufacturer may install the laminated fiberglass neck in the field. Any performed field installations shall meet or be covered by the original manufacturer’s 20 year warranty.
E. Excavation and Installation
1. General – The limit of excavation shall be such to allow for placing and removing forms, installing sheeting, shoring, bracing. etc. Excavation shall meet OSHA Excavation Standards (29 CFR sub-part P). The contractor shall pile excavate material in manner that will not endanger the work and will avoid obstructing sidewalks, driveways, power poles, etc. Drainage shall be kept clear.
2. Unauthorized Excavation – Excavation for slabs, footings, etc., that bear on earth shall not be carried below the elevation shown on the drawings.
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In the event the excavation is carried on below the indicated elevation, the contractor shall bring the slab, footing etc., to the required grade by filling with concrete having a minimum compressive strength of at least 3,000 psi at 28 days.
3. Vertical Sides (Sheeting, Shoring and Bracing) – When necessary to protect existing or proposed structures or other improvements, the Contractor shall maintain vertical sides of the excavation. The limit shall not exceed three feet outside the footing on a vertical plane except where specifically approved by the ENGINEER. The CONTRACTOR shall provide and install any sheeting, shoring, and bracing as necessary to provide a safe work area to protect workers, structures, equipment, power supply and property. The sheeting, shoring and bracing shall be removed as the excavation is backed filled in such manner as to prevent injurious caving.
4. Sloping Sides – Where sufficient space is available, the CONTRACTOR shall be allowed to back slope the sides of the excavation. The back slope shall be such that the excavation shall be safe from caving. The type of material being excavated shall govern the back slope used, but in any case the back slope shall be no steeper than 1 foot vertical without sheeting or shoring.
5. De-Watering – The CONTRACTOR shall keep excavation free from water by use of cofferdams, baling, pumping, well pointing, or any combination as the particular situation may warrant. All de-watering devices shall be installed in such a manner as to provide clearance for construction, removal of forms, and inspection of exterior of form work. It is the intent of these specifications that the foundation be placed on a firm dry bed. The foundation bed shall be kept in a dewatered condition a sufficient period of time to ensure the safety of the structure. The excavation shall be protected from excessive rainfall, drainage and drying. The excavation shall be inspected and approved by GSUB’s representative before work on the structure is started. It is the intent of these specifications that the CONTRACTOR provides a relatively smooth, firm foundation bed for footing and slabs that bear directly on the undisturbed earth without additional cost, regardless of the soil conditions encountered. The ENGINEER will be the sole judge as to whether these conditions have been met.
6. Bottom of Excavation and Anti-Flotation Base – Consult Delegated Engineering Document on compaction requirements for bottom of excavation, structural reinforcement requirements, and concrete anti-floatation base dimensions. Install wet well per Manufacturer’s and Delegated Engineering Documents requirements.
7. Installation – CONTRACTOR shall install wet well to meet final grades per plans and shall insure wet well is plum and level.
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D. ACCESS COVERS/BYPASS
1. Wet Well: The Contractor shall furnish and install a single or multiple door non-draining angle frame access hatch covers of aluminum construction for cast in place installation for all new construction. Covers shall be hinged and hasp-equipped, including stainless steel guide rail bracket and holders with safety loops for lifting cable and motor cable. Access cover shall be provided with stainless steel hardware and shall have bituminous coating on all aluminum in contact with concrete. Minimum opening dimensions shall be in accordance with pump manufacturer’s recommendations.
Reference Standards
1. Comply with applicable provisions and recommendations of the following,
2. 2. O.S.H.A. Standard 1919.23 (fall-through protection) Aluminum Association, Inc, 5th Edition- Bridge Type Structures (safety grate design)
3. ANSI/AWS D1.2-90 Structural Welding Code for Aluminum
4. ASTM B221
The access Hatch Covers Shall be manufactured by
1. Halliday Products
2. US Fabrication
Fall Proof Protection
Each access hatch frame cover assembly shall be provided with fall through protection in accordance with OSHA 1910.23
The fall proof protection shall be composed of aluminum grate spanning the opening.
The grate shall be designed to withstand a minimum live load of 300 pounds per square foot with a deflection not to exceed 1/150th of the span.
The fall proof protection grate shall be 5”x 5” for visual inspection of the wet well.
Each grate shall be provided with a permanent hinging system; the grate shall lock open in a 90-degree position.
The grate shall be painted OSHA orange and shall also have opening handle.
2. Valve Box: The Contractor shall furnish and install one double-leaf aluminum access door. Door leaf shall be 1/4-inch aluminum diamond pattern plate to withstand a live load of 150 pounds per square foot. Access covers shall be hinged and hasp-equipped with stainless steel hardware and shall have bituminous coating on all aluminum in contact with concrete. Interior of valve box shall have a minimum of 24-inches clearance between inside wall and any pipe, valve or device. The Discharge piping for both pumps shall have a ¼ inch NPT fitting (female) for a gauge connection prior to the check valve.
3. Manual Lift Station By-Pass: The contractor shall install a manual bypass connection on the outside of the check valve vault. Connection shall be installed with a MJ or flanged tee, MJ or flanged gate valve w/cast iron valve box and top, MJ or flanged 90-degree elbow turned vertical, ductile spool piece with minimum 24” above grade level and another 90-degree flanged elbow w/6” male cam lock fitting.
1. Materials
Pipe – Schedule 40 Stainless Steel
Gate Valve – Resilient seat w/2” operating nut
Fittings – Tee 150# Schedule 40 Stainless Seel
90-degree elbow 150# Schedule 40 Stainless Steel
6” 150# threaded RF flange X 6” male cam
6” cam lock dust cap aluminum
4. Suction By-pass pipe: A suction bypass pipe shall be installed inside wet well. Pipe size and materials to be determined by GSUB.
Part 3 – EXECUTION
3.01 PREPARATION
A. All site preparation, excavation, and backfill shall be performed in accordance with Section II – STRUCTURE EXCAVATION AND BACKFILL FOR PUMP STATION.
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3.02 INSTALLATION
A. WET WELL
Wet Well shall be installed in accordance with Drawings and applicable portions of Section III – CONCRETE or Section C.01-2 Fiberglass Wet Well.
B. PUMP SYSTEM
All pumping equipment and accessories shall be installed in accordance with Manufacturer’s recommendations.
3.03 FIELD QUALITY CONTROL
A. MANUFACTURER’S REPRESENTATIVE
The services of a factory trained, qualified representative shall be provided to inspect the completed installation, make all adjustments necessary to place the system in trouble-free operation, and instruct the operating personnel in the proper care and operation of the equipment, prior to the final acceptance of the station.
B. INSULATION TEST
Circuit insulation tests shall be performed to prove each circuit free of faults after all wiring is completed prior to equipment and fixture connections, and again after the installation is complete and ready for use.
Tests shall be conducted at the main electrical service connection between all conductors and between line conductors and ground. Tests shall be conducted with a minimum 500 Vdc instrument capable of accurately measuring the resistance involved. Readings shall be taken in the presence of the Design Engineer or his representative for each test and the written results of each test shall be submitted to the Engineer.
C. FIELD TEST
When the pumping facility is complete and ready for operation, then the station shall be inspected and tested for compliance to the contract documents. Test of the equipment shall be conducted by the Contractor in the presence of the Design Engineer, the Electrical Subcontractor (if used), the equipment manufacturer’s representative, and GSUB. The equipment tests shall include, but not be limited to, the following:
1. Pumps and Motors: Pumps shall be run and a determination made of the pumping capacity. Performance of the pumps shall meet the specified criteria when field tested. A pressure test shall be performed on each pump in the field. Drawdown Test Dated shall be provided.
2. Electrical: Recorded readings shall be made of voltage and amperage on all electrical components at start and operating conditions. Such readings shall be recorded on a form provided by the manufacturer and the results shall meet the manufacturer’s prescribed limits. If a tested item fails to meet its requirements, then it shall be replaced. Results of the tests shall be given to the Design Engineer with the serial number of the accessory tested.
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3. Controls: Controls shall be tested to determine satisfactory performance for starting and stopping at the proper liquid levels, pump sequence and alarm actuation.
4. Equipment: Equipment shall be operated to determine if the alignment is visually correct, that there is no overload or overheating or objectionable vibration and that all the operating features are in working order. Submersible pumps and level sensors shall be raised completely and reset to assure proper seating and operation.
5. Inspection: A thorough inspection of all mechanical and electrical equipment and controls, piping, valves, fittings, brackets, mountings, seals, conduit, painting, sleeves, components, and features shall be made while the station is being tested to determine performance and compliance with design requirements and specifications.
6. Structure: The station shall be inspected for performance, structural soundness, and water tightness.
7. Repairs, Adjustment and Replacements: The Contractor shall make any and all necessary repairs, adjustments, and replacements until performance has been demonstrated to the satisfaction of the Owner’s Engineer. The Contractor shall bear the cost of any repair, adjustment, and replacement.
D. SPARE PARTS
Spare parts for routine maintenance and repair as recommended by the equipment manufacturer shall be provided by the Contractor.
E. AS-BUILT DOCUMENTATION
As-Built documentation of the finished installation shall be made as a part of final acceptance and shall include certified record drawings, corrected submittals, operation and maintenance publications, and other data necessary to accurately define the final field installation.
Lift Station Piping Specification
1. Scope
Provide all piping, fittings, valves, supports, restraints, wall penetrations, and appurtenances for a complete lift station installation including:
A. Wet well piping
B. Valve and vault piping
C. Force main discharge piping to connection point
D. Drain, vent, and bypass piping
E. All stainless hardware and anchors
2. Codes and Standards
Work shall comply with latest:
A. ASTM applicable standards for pipe/fittings
B. AWWA C110/C153 ductile iron fittings
C. AWWA C151 Ductile iron pipe
D. AWWA C509/C152 resilient seated gate valves
E. AWWA C508 swing check valves with weighted lever arm
F. ANSI/ASME B16 flange and fitting standards
G. All local/state plumbing and environmental requirements
3.Design Requirements
Service
A. Fluid: Raw wastewater
B. Operating pressure ____psi
C. Surge pressure: ____ psi
D. Minimum pipe pressure class
Stainless Steel 304 SCH 40
4.Layout
Piping shall be arranged to:
A. Minimize head loss
B. Allow full pump removal
C. Provide isolation for each pump
D. Provide check valve for each pump
E. Provide pressure gauge for each pump
F. Provide means of force main flushing and maintenance
5. Materials
A. All piping, materials, and hardware for lift station shall be 304 stainless steel (SCH 40 Min on piping)
B. Flanges shall be 150 psi Stainless Steel (stainless steel nuts and bolts)
C. Base nineties and pump connection claws (Cast-iron epoxy coated)
D. Gaskets shall be full face
6. Valves
A. AWWA C509/C515
B. Non-rising stem
7. Check Valves
A. Full body bronze trim
B. Lever Arm and weight
C. Position locator
7. Bypass Connection
Provide full bypass connection for suction and discharge
A. Suction Straw installed vertically in wet well rising 36 inches above wet well top with ninety and cam lock connection with cap
B. Discharge connection installed into discharge header with check valve with isolation valve and camlock fitting with cap
C. All material shall be stainless steel 304 SCH 40
8. Air Relief/Vacuum Relief
A. Sewage rated air relief valves shall be installed on both pump discharge lines
B. Isolation valve on air relief connection
C. Vault with drain/vent
9. Aquifer Testing
A. Step-drawdown test
1. Minimum Three steps
2. Minimum 60 minutes per step
B. Constant Rate pumping test:
1. Minimum duration of 24 hours
2. At processed designed flow
C. Recovery monitored for minimum of 8 hours
D. Test results analyzed and submitted for approval
10. Disinfection
A. Chlorination per AWWA C654
B. Minimum chlorine concentration: 50-100 Mg/L
C. Minimum contact time: 24 hours
D. Well flushed and neutralized prior to sampling
11. Pumping Equipment
A. Pump Type: Vertical turbine (Submersible utility approved)
B. Capacity: ____ GPM
C. Total Dynamic Head: ____ Feet
D. Column pipe: Steel or epoxy coated steel
E. Check valve and flow meter provided
12. Wellhead Completion
A. Steel wellhead with sanitary seal
B. Casing extension minimum of 12 inches above final grade
C. Concrete pad:
1. Minimum 6 inches thick
2. Sloped away from casing
D. Lockable cap and identification signage
13. Water Quality Testing
1. Sampling and testing per Safe Drinking Water Act
2. Bacteriological testing required prior to service
3. Additional inorganic/organic testing as required by state
14. Motor Requirements
Vertical Turne Motor
A.Vertical Hollow Shaft inverter rated (NEMA MG-1)
B.Premium efficiency
C.Insulation class F or H
D.Enclosure type TEFC or WP-1/WP-2
E.Suitable for continuous operation
F.Pumps and motors shall be suitable for VFD operation
G. VFD range 30-60Hz
H. No Vibration or resonance in the required operating range. Duty points shall not be reached using Motor Service factor (SF)Material Certifications upon request.
15. Discharge Head
A. Designed for well casing and discharge piping
B. Must include
C. Stuffing box/mechanical seal (Refer to specifications)
D. Head and motor shaft, coupling, adjustment nut with locking mechanism
E. Base Plate and motor support
16. Accessories/Appurtenances
Provide as a minimum
A. Discharge head assembly
B. Check valve and isolation valve
C. Air release/vacuum relief provisions
D. Pump setting plate/well seat
E. Flow meter spool piece (if required)
F. Hydrostatic test where applicable
17. Submittals
Submit for Approval
A. Pump curves and efficiency at duty points
B. Certified dimensions and settings drawings
C. All electrical data (Motor FLA, LRA, service factor)
D. Installation instructions
E. O & M MANUALS
F. Recommended spare parts list
