11095 (S) Refurbishment of Existing Raw Sewerage … · REFURBISHMENT OF EXISTING PUMPS ......

PC – 795 Bulletin No. 2

Attachment 2

DIVISION 11 SUPPLEMENTAL SPECIFICATIONS (2013) REFURBISHMENT OF EXISTING PUMPS – SUPPLEMENTAL PC-795

Supplemental Specifications are issued separately from the Master Specifications on a per contract basis to provide information not provided in the Master Specifications. All Conditions of the Contract apply to information provided in this Supplemental Specification.

Water and Sewerage Department City of Detroit 11095 - 1 - Supplemental

SECTION 11095 - SUPPLEMENTAL REFURBISHMENT OF EXISTING RAW SEWAGE PUMPS PART 1 - GENERAL 1.1 SCOPE. Contractor shall furnish all labor, materials, tools, equipment, and Supervision required to refurbish Raw Sewage pump units (P-11 and P-14) at the Pump Station No. 2 located at the Detroit Wastewater Treatment Plant at 9300 West Jefferson Street, Detroit Michigan and is for the City of Detroit Water and Sewerage Department. Refer to the site plan in the Drawings for particular location of the Work of CS-1444 within the plant. These specifications must be used together with Master Specification Sections 11100, Pump Application General Requirements and 11050, Equipment General Provisions. Errors due to failure to reference these sections will be borne by Contractor. 1.2 GENERAL. 1.2.01 Coordination. The manufacturer of the equipment specified herein shall be required to review and satisfy all relevant requirements of other Sections of the Contract Documents including the requirements of the Contract Drawings. The Contractor, manufacturer, fabricator and/or subcontractors furnishing and/or installing equipment, services and specialties associated with this Section shall fully coordinate their efforts to avoid potential claims that are based on failure to review relevant Contract Documents, including the Contract Drawings. Contractor shall coordinate and review installation procedures under other Sections and coordinate the installation of items that must be installed to comply with the requirements of the Work specified under this Section. Pump and connecting piping shall be designed to fit within the space and openings provided in the existing structure. To insure minimum pump down time, pump refurbishment shall not begin until all of the required pump and piping components for the pump have been received at PS 2. Pump Shutdown and refurbishment work shall be completed only during dry weather season (October 1 through February 28). 1.3 RELATED WORK.

Section 01620 Witness Testing Section 09900 Painting

1.4 DESIGN REQUIREMENTS. It is not the intent to specify all the details of refurbishment. All components required to provide complete and operational pumps 11 and 14 shall be included

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herewith. Refurbish pumps in accordance with the manufacturer's standard practices where they do not conflict with this Specification.

1.5 QUALITY ASSURANCE. 1.5.01 Shop and Field Testing.

a. Factory test the pump. Pump test shall be in accordance with the Hydraulic Institute

Standards ANSI-HI 14.6 (2011). Pump test shall include:

i. General:

1. Perform test as soon as possible following approval of shop drawings and fabrication of all components.

2. Do not ship equipment without approval of test reports. 3. Pump Manufacturer (PM) shall conduct tests at his expense. 4. Shop performance tests shall be witnessed as specified in Section 01180. 5. If the shop tests results indicate that a pump does not conform to specified or

guaranteed performance, the pump shall be modified and retested, at no additional cost to the OWNER, until full compliance with specified and guaranteed performance can be demonstrated.

6. Pumps shall not be shipped until the Engineer has approved the factory test

reports. 7. Hydrostatic test shall be witnessed by a licensed professional engineer (PE)

who may be an employee of the manufacturer. The PE shall certify the test results.

8. Retest:

a. If results of initial pump testing indicate a failure to meet specified performance requirements, the equipment shall be modified and retested until full compliance can be demonstrated.

b. The results of all the testing and a description of the modifications, if

any, shall be submitted with the shop tests.

9. Test Procedure and Reports: Comply with ANSI-HI 14.6– (2011)

ii. Tests Required:

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1. Hydrostatic 2. Test duration: Test pressure shall be maintained for not less than 15 minutes.

3. Test all pressure containing components (piping and castings).

iii. Performance Test:

1. Tolerance shall be based on acceptance level "1U" at the design point. 2. Test may be run using a calibrated manufacturers motor at full speed. 3. Obtain at least eight points between shut-off and minimum operating head, including one point at specified design condition. Operate pump for not less than two hours within 5% of the design point head and take readings to determine that the pump will operate satisfactorily without vibration or cavitation at the specified minimum head condition with not more than specified NPSH available.

iv. Factory test on pump may, at manufacturer's option, be conducted using manufacturer's drive motor or may use the witness tested motor that is shipped to the plant for use in the pump test. v. Provide a minimum of 15 days written notice to the Engineer prior to witness test.

b. Material Hardness Tests: Factory test component materials including impeller, wear

rings and shaft sleeves for compliance with specified BHN. Furnish test reports with results of the testing from the manufacturer.

1.5.02 Factory-Trained Service. Provide services of factory-trained Service Engineer, specifically trained on type of equipment specified. Submit qualifications of Service Engineer for approval. Man-days listed below are based on 8-hour days and are exclusive of travel time. They are minimum requirements and do not relieve Contractor of obligation to provide sufficient service to place equipment in satisfactory operation.

a. Installation: Assist in setting, leveling, field erection, etc.; coordination of piping, electrical,

miscellaneous utility connections; check intermediate shafting alignment. i. Two man-days.

b. Start-up and Field Testing:

i. Two man-days for start-up. ii. Seven man-days for Field Acceptance Test.

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iii. One man-day for vibration analysis of pump, shaft and motor assembly.

iv. Check all protective relays shown in I/O list, electrical, and P&ID drawings.

v. Check all I/O listed for proper operation and inputs and outputs. Testing shall include actual operation of each device and not by simulation of inputs and outputs when practicable.

c. Operation and Maintenance instruction:

i. Provide one session for each of three shifts (4 hours each session for total of 12 hours).

1.5.03 Manufacturer Responsibility. The pump manufacturer shall be responsible for coordinating and submitting one complete pumping system Shop Drawing Package. 1.5.04 Manufacturer Certification. The pump manufacturer shall certify that the drawings, specifications, existing site conditions, Hydraulic Model Study - Raw Wastewater Pumping Station No. 2 dated January, 1988; Pump Station No. 2 Pump Test Data; have been reviewed and that there is a clear understanding of them for guaranteeing that the pumping unit will perform satisfactorily in the field in accordance with the design conditions. If the pumping units do not meet performance requirements as demonstrated during acceptance testing, it shall be modified or replaced and retested at no cost to the OWNER. 1.5.05 Reference Standards.

a. Comply with applicable provisions and recommendations of the following reference

standards:

i. Hydraulic Institute: ANSI-HI 14.6 (2011). ii. American National Standards Institute Standards:

1. B16.1-1975, AN Standard for Cast Iron Pipe Flanges and Flanged Fittings,

125 lb.

2. P3.15-1972 AFBMA Standard, Load Ratings and Fatigue Life for Ball Bearings.

3. P3.16-1972 AFBMA Standard, Load Ratings and Fatigue Life for Roller

Bearings.

iii. American Society for Testing and Materials.

1. A48-76, Specification for Grey Iron Castings.

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2. A278-85, Specification for Grey Iron Casting for Pressure-Containing Parts for Temperature up to 650 deg. F.

3. A743-06, Specification for corrosion Resistant, Iron-Chromium, Iron-Chromium-Nickel, and Nickel-Base, Alloy Casting for General Applications.

iv. Michigan Occupational Safety and Health Administration (OSHA) – Federal and

State. v. American Iron and Steel Institute AISI 1045, Heat Treated Steel. vi. Anti-Friction Bearing Manufacturer's Association. vii. American Water Works Association. viii. Federal Specifications issued by the Federal Supply Service, General Services

Administration, U.S. Government. ix. National Fire Protection Association (NFPA). x American welding Society Code. xi. Underwriters Laboratories (UL). xii. City of Detroit Buildings and Safety Departments.

b. These standards shall include all the latest amendments and errata applicable at the time the bids are opened.

c. In case of conflict, the standards with the most stringent requirements shall apply.

1.5.06 Pump Manufacturer Scope of Supply. Pump manufacturer shall design and supply suction piping from the suction gate valve to the pump. Piping shall comply with the applicable Piping Sections and shall be of stainless steel. Note suction piping shown on the Drawings from the suction valve to the pump is illustrative of a general arrangement. Actual piping shall be as recommended by the pump manufacturer and approved by the Engineer. Guide vanes, if required, shall be designed to minimize hang up of rags and stringy material. All process equipment measuring devices and appurtenant testing equipment must be calibrated and traceable to the NIST.

Beginning with final acceptance of the field test, a full 12 months parts and labor warranty on all components furnished under this specification shall be provided.

Contractor shall furnish all components covered by this specification.

All material vendors shall maintain adequate quality control records.

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Quality Assurance records shall be maintained detailing the repairs made and each pump component replaced. The records shall be submitted to the Engineer. 1.5.07 Acceptable Pump Manufacturers

Flowserve Pump Division Taneytown, MD.

Approved equal with a registered ISO 9000 Quality System. 1.6 SUBMITTALS. 1.6.01 Shop Drawings. Submit for approval the following:

Manufacturer's literature, illustrations, specifications and engineering data including: dimensions, materials, size, weight, performance data and curves showing overall pump efficiencies, required net positive suction head, allowable suction lift, flow rate, head, brake horsepower, speed and shut-off head.

Shop Drawings, Showing: Fabrication, assembly, installation, wiring diagram and 1’=1/4” scale suction elbow and pump construction shop drawings shall be provided, including the bill of materials, parts list, part number, etc.

Operation and Maintenance Manuals Including: Complete installation, operation and maintenance data including copies of all approved Shop Drawings.

Guarantee / Warranty

Submit any additional information the ENGINEER may request to permit intelligent judgment of the acceptability of items submitted as alternatives to the acceptable manufacturer specified.

Shop drawing for suction piping. Submit ISO 9000 Registration certificate.

1.6.02 Data Regarding Pump Characteristics and Performance.

a. Submit proposed testing arrangement and details of test equipment to be used for approval.

b. Certified test results and performance curves based on shop test as specified in Section 1.5.01.

i. Submit performance curves on 8-1/2 in. by 11 in. sheets. ii. Submit results in format described by Hydraulic Institute.

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iii. Data shall show that unit meets specified requirements for head, capacity,

efficiency, NPSH, and horsepower for various capacity points specified. 1.6.03 Provide Torsional Vibration Analysis of the pump assembly. 1.6.04 Shop drawing data for accessory items. 1.6.05 Pump parts list and materials list. 1.6.06 Cross sectional drawing with dimensions of pump on 24-inch x 36-inch sheet. Indicate which parts are new and which will be reused. 1.6.07 Coupling drawing and operating characteristics on 24-inch x 36-inch sheet.

1.6.08 Bearing Life Certification.

1.6.09 Calculated NPSH curves. 1.6.10 Certificates of hydrostatic tests on pressure containing castings.

1.6.11 Manufacturer's certification as specified in Section 1.5.01.a.i.7.

1.6.12 Inspection Reports. Prepare and submit to Engineer a report that fully discloses the defects, details, materials, recommended replacement parts, and methods of refurbishment. Indicate pump components found to be unsuitable for reuse and not included as part of the Work as specified. 1.7 WARRANTY. 1.7.01 Pumping Equipment and Appurtenances.

a. The Contractor shall warrant against any defect in material, construction, or performance of the Pumping Equipment and Appurtenances for a period of one calendar year from the date of final acceptance for the Pumping Equipment and Appurtenances.

b. Any defects occurring during this one-year period shall be reported by the Engineer to the Contractor, who shall make all necessary repairs at no cost to the OWNER.

i. The Contactor shall warrant against any defect in material construction or

performance of the repair work for a period of one calendar year from the date of acceptance of the repair work.

ii. Defects in repair work that occur within this one year period shall be reported by

the Engineer to the Contractor who shall make necessary repairs at no cost to the OWNER.

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c. Pumping Equipment and Appurtenances shall be defined as all material and equipment

covered in Specification Section 11095, including but not limited to pump, suction piping, and spare parts.

1.8 DELIVERY, STORAGE AND HANDLING. 1.8.01 Shipping. Ship equipment, material, and spare parts complete except where partial disassembly is required by transportation regulation or for protection of components. Use all means necessary to protect the materials of this Section before, during and after installation. Provide property insurance coverage for the equipment for the duration of the Project; include coverage for the equipment while in transit and also during refurbishment at the factory. In the event of damage to the equipment, immediately make all repairs and replacements necessary to approval of OWNER. Pack spare parts in containers bearing labels clearly designating contents and pieces of equipment for which intended. Deliver spare parts at same time as pertaining equipment. Deliver to OWNER after completion of work. Store and safeguard equipment, material and spare parts.

1.9 PROJECT CONDITIONS. Perform vibration analysis for pump before removal of the unit. PART 2 – PRODUCTS

3.1 EXISTING RAW SEWAGE PUMP 11 AND 14:

Existing Pumps Pump Nos. 11and 14 Capacity (MGD) Dry/ Wet 107/115 Rated Head (Ft) 35 Speed 400 rpm HP 900 Voltage 4160V

2.1.01 Pump Operation Requirements:

a. Design Point – 74,500 gpm at 35 ft total Head 80% Minimum Pump Efficiency.

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b. Maximum head Point – Not less than 50,000 gpm at 49 ft Total Head 75% Minimum Pump Efficiency.

c. Minimum head Point – 84,000 gpm at 25 ft Total head at less than 48 feet NPSHr.

d. Pump shall be able to operate continuously at any head between the minimum head and the maximum head points (operating range) without:

i. Exceeding vibration limits. ii. Overheating. iii. Requiring more than 48 ft. NPSH. iv. Requiring more than 900 BHP. v. Cavitation. vi. Capacity performance requirement not less than 91 % of rated design capacity.

e. Pump shall be entirely suitable for exposure to a static or dynamic suction pressure of 45

feet under operating and non-operating conditions.

f. Sewage pumping unit will draw raw unscreened sewage from the wet well and discharge through a siphon into a discharge channel.

g. Sewage will consist of domestic sewage with groundwater infiltration, storm drainage and industrial waste. Temperature of wastewater may vary between 40 to 70 degrees F.

h. Reverse rotation will occur each time the pump is turned off, caused by the water in

discharge pipe flowing back through the pump. i. Pump specific speed, impeller vanes, and other hydraulic characteristics shall be

suitable for the suction conditions as shown on the drawings or with new suction elbow, as necessary.

j. Within the required pumping range, the minimum efficiency of the pumps, exclusive of

the motor, shall be at least 70%. The pumps, at maximum total head, shall not load the motors in excess of their rated horsepower under conditions of normal voltage, frequency, temperature, and sewer water.

2.2 SHOP TESTING. Pump shall be assembled at the factory to insure fit of adjoining parts. One pump selected at random by a representative of the Engineer shall be tested at the factory for operating efficiency. A minimum of eight flow points shall be taken to include one each at maximum head, design point, and at minimum head.

The tests shall be such as to satisfy the Engineer that the equipment complies with the specification requirements. The manufacturer shall furnish six certified copies of test curves to the Engineer. The Standard of the Hydraulic Institute shall govern the procedures and calculations for these tests. The limits of vibration as set forth in the Standards of the Hydraulics

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Institute shall govern.

PART 3 - EXECUTION 3.1 EXAMINATION. Verification of Existing Conditions: Prior to the removal of pump, perform a vibration spectrum analysis. Submit results to Engineer.

3.2 EQUIPMENT REMOVAL.

Disconnect electrical service.

Disconnect motor from pump.

Disconnect pump from suction piping. Provide blind flanges, plugs, etc., as required to keep pumping operations in service.

Provide temporary steel plate over openings left by pump removal. Secure in place.

Remove Pull Out Assembly (POA), pump suction head, and suction piping.

3.3 SHIPPING. Prepare, crate, and ship pump parts to respective refurbishment company. Comply with shipping instructions.

3.4 PUMP REBUILD. Redesign pumps for not more than the specified drift allowance as determined by manufacturer’s field performance testing. A Pump Pull Out Assembly (POA) is defined as a complete pump less casing and hand hole covers. DWSD to review all electrical and I &C equipment to show that all components are in proper operating condition before the contractor disconnects equipment for pump refurbishment.

Refurbish one pump at a time.

Remove POA at the stuffing box head bolt circle.

Remove and save pump shaft coupling.

Remove pump casing, suction head, and suction piping.

Clean pump casing for coating.

Pump manufacturer shall perform casing volute modifications prior to coating.

Clean/ purge oil cooler lines.

Redesign impeller per Final CFD modeling.

Replace suction piping, suction head and pump POA.

Reassemble shaft coupling to pump shaft.

Refurbish or replace gland and water seal ring.

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Replace packing.

Replace all fasteners, keys and other hardware as required.

Replace all gaskets and seal, where required.

Reassemble completely.

Recoat exterior to per FMP standards.

Clean pump casing interior to SSPC standard SP-10 (near white metal) and NSF-61 approved epoxy of 16 dry mil thickness shall be applied.

Clean pump casing exterior to SSPC standard SP-6 and 10 dry mil thickness of water resistance polyamide Brown color paint shall be applied.

3.5 REINSTALLATION OF PUMP.

Repair damage to factory finishes.

Remove blind flanges, plugs, etc.

Reinstall pump and comply with manufacturer's instructions.

Reconnect all electrical service and instrument wiring. Reinstall vibration transmitters, temperature transmitters, and all other instrumentation.

Install and Reconnect newly designed and furnished suction piping.

Lubricate before start-up procedures.

Check pump, intermediate shaft, and motor alignment after piping and electrical connections are completed.

3.6 FIELD TESTS. Contractor shall submit qualifications of startup personnel to Engineer for approval. The startup personnel shall have worked in engineering for a major pump manufacturer for a minimum of 15 years with a minimum of 10 years experience in field installation and troubleshooting of pumps.

Provide vibration spectrum analysis test for pump after rehabilitation. Vibration readings shall be taken with a DWSD approved vibration analyzer and submitted to the Engineer. Vibrations levels shall be within Hydraulic Institute Standards or 0.22 inches per second RMS in any plane at the top of the bearing housing.

Provide a performance test for pump, including simulating of alarms and shutdowns. Test all protective relays shown on the electrical one-line I/O list, and P&ID drawings and calibrate per the pump manufacturer’s requirements.

The pump shall be free of vibration exceeding ANSI-HI 9.6.4 (2009), water leaks and excessive noise.

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Perform Certified Pump insitu Performance Test on pump set to determine pump head, flow, horsepower consumption and efficiency, under actual normal operating conditions, with certified instruments, with the Owner’s witness present. Design, manufacture and implement special fixtures, piping, support and electrical service and controls to accommodate such tests.

Measure and Record the Following Data:

Flow

Suction head

Discharge head

RPM

Kilowatts

Test data shall be recorded and displayed with an internet based system so that the pump performance may be observed by the engineer at any time from a remote site. The data shall be recorded once a minute for 10 cumulative days 24 hours per day. The intent of this web based testing is to document the pump capacity drift considering the effects of total heads on pump flow. The pump manufacturer guarantee will be that capacity drift shall not result in pump flow lower than 91% of the rated flow (74,500 GPM at 35 feet) on a repeatable basis. Random flow reductions (due to exceptionally high solids content) shall not be considered repeatable capacity drift. This guarantee shall be proven in the pump manufacturer's in situ performance test at full speed. Submit test results to Engineer. 3.7 SPARE PARTS. The contractor shall also furnish the following spare parts as well as any others agreed to during submittal process:

One Pump Impeller Assembly One Set of Pump Bearings One Set of casing and Impeller Wear Rings Pumps #11 and #14 – Remove and turn over to GLWA Price list and adjustment costs for next 5 years

3.8 MANUFACTURER’S START-UP SERVICES. Provide a minimum of two 8 hour workdays of field service supervision for pump installation and start up. Provide necessary field time for installation of sensors and collection of data to complete performance testing.

End of Supplemental Section

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11095 (S) Refurbishment of Existing Raw Sewerage … · REFURBISHMENT OF EXISTING PUMPS ......

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