SECTION 11310 NON-CLOG CENTRIFUGAL … 11310-3 Non-Clog Centrifugal Wastewater Pumps City of Newport...

ARCADIS 11310-1 Non-Clog Centrifugal Wastewater Pumps City of Newport News, VA ADDENDUM NO. 1 Pump Station 39 Rehabilitation

SECTION 11310

NON-CLOG CENTRIFUGAL WASTEWATER PUMPS PART 1 - GENERAL 1.01 SCOPE

This section covers the requirements for furnishing all labor, materials, equipment and appurtenances for the complete and satisfactory installation and testing of the new vertical dry-pit non-clog type wastewater pumping units, as indicated on the Drawings.

1.02 SUBMITTALS

A. Submit the following Shop Drawings for the pumps in accordance with Section 01300, entitled SUBMITTALS:

1. Predicted performance curves showing total dynamic head (TDH)

versus capacity; NPSHR versus capacity; efficiency versus capacity and brake horsepower versus capacity at the minimum and maximum speeds as indicated herein.

2. Rotating assembly moment of inertia (WR2), weight, and predicted

minimum and maximum thrust.

3. Materials lists, including material specification references.

4. Dimensioned outline/assembly drawing of the pump with weights indicated. Shop drawings shall include a Bill of Material which shall be keyed by numbers to all components of the pump identifying them by name and part or catalog number. The drawings shall, in all respects, provide clear, detailed information which shall facilitate the ordering of spare or replacement parts.

5. Details showing construction and means of securing for impeller

wear rings.

6. Computations of L-10 bearing life, showing all factors for the motors.

B. Submit the following Shop Drawings for the pump motors in accordance with Section 01300:


1. Dimensioned outline drawing of the motor with weights of major sub-assemblies indicated.

2. Dimensional drawing of the motor with individual components

identified and positions and sizes of pipe taps indicated. This shop drawing shall be, minimum 11" x 17", and shall include all required exploded views. Drawing shall include a bill of material which shall be keyed by numbers to all components of the pump identifying them by name and part or catalog number. Drawing shall, in all respects, provide clear, detailed information which shall facilitate the ordering of spare or replacement parts. Drawings shall be provided as part of the Operation and Maintenance Manual, as specified herein.

3. Motor nameplate data submitted in accordance with NEMA Standard

MG-1 and including the following:

a. manufacturer's name and machine serial number

b. output

c. time rating

d. temperature rise

e. rpm at full load

f. voltage, frequency, number of phases

g. full load current

h. code letter

i. service factor

j. power factor

4. Materials lists for all specified motor assembly items, including material specification references.

5. Computations of L-10 bearing life, showing all factors for the motors.

6. Predicted motor performance data to be submitted:

a. inrush kVA


b. locked rotor amperes

c. locked rotor, minimum and breakdown torques

d. temperature rise at 1.0 and 1.15 service factor

e. maximum no load vibrational level (peak to peak, in.)

f. guaranteed efficiency at: full, 3/4 and ½ load as described in

latest revision of IEEE Standard No. 112 and NEMA Standard MG-1.

g. power factor at ½ , 3/4 and full load

h. motor performance curves, computed over the entire range

from zero to full load, shall be prepared and shall provide the following information

(1) speed vs. torque (2) efficiency vs. load (3) saturation

i. Limitations for starting motor.

7. Motor Construction Details

a. Motor outline drawing(s) showing all principal overall

dimensions and construction notes.

b. Motor cross-section and assembly drawings showing the construction of the following: (1) Stator and frame with windings (2) Rotor. (3) Bearing assemblies including details of oil lubrication

systems; bearing temperature location; shaft current insulation at bearing assemblies. Bearing babbitt composition, alloy numbers and characteristics.


(4) Space heater wattage and connection details. (5) Embedded temperature detectors, quantity and

connection details. (5) Access covers, if supplied, for bearings and space

heaters. (6) The shop drawings shall include a bill of material,

which shall be keyed by numbers to all of the components of the motor identifying them by name and part or catalog number. The drawings shall, in all respect, provide clear, detailed information which shall facilitate the ordering of spare or replacement parts by the Owner.

8. Motor Service and Maintenance Details and Information

a. Detailed drawings of shaft-end alignment which shall clearly

indicate application areas for dial indicators and other devices for the purpose of shaft and coupling alignment for motor and pump.

b. Detailed drawings and adjustment procedure for motor shaft

end play.

c. Complete specification, weight, type, purchasing data, and maintenance recommendations for motor bearing lubrication oil.

9. Thrust bearing load capability.

10. Outline drawing of the motor stand, indicating overall dimensions,

material of construction, and anchoring details.

C. Provide certification that the pump can operate continuously at a reduced speed, in the vicinity where the single pump performance curves including the reduced speed curves and the system curve intersect, as indicated on the Drawings.

D. Provide certification indicating adequacy of the proposed pump baseplate, as

specified herein.

E. Details of pump and motor extended shaft arrangement showing


construction, diameter, length and coupling/joint configuration. Provide calculations, signed and stamped by a professional engineer, for the sizing, torsional and lateral analysis of the extended shaft and steady bearing arrangement and supporting framework to connect the pump and the motor.

F. Submit the pump factory performance test procedure and dimensioned test

stand outline drawing, prior to pump factory performance testing. Outline drawing shall indicate pump and valve locations and static water elevation relative to the pump shaft centerline. Factory test procedure shall state all data to be recorded and all equations to be used in determining pump performance.

G. Prior to pumping unit shipment to the site, submit six copies of certified

drawings and certified factory pump and motor test reports including test data and certified performance curves which include Head, Pump Efficiency and Brake Horsepower versus Capacity curves. Provide the Head versus NPSHA curve showing determination of the NPSHR value as indicated in this section based on historical manufacturer’s data. Provide test results and certification of pump casing hydrostatic test. For the motors, include all test data and certified curves of motor test performances. A registered Professional Engineer shall certify the test results prior to shipment.

H. Submit recommended mounting locations for the vibration monitoring

system probes. Provide an acknowledgement letter stating that all monitoring devices shall be coordinated between the pump manufacturer and the instrumentation supplier(s).

I. Provide Manufacturer's Certificates for the pumping unit in accordance with

Section 01300, entitled SUBMITTALS.

J. Submit Operation and Maintenance Manuals for the pump and motor in accordance with Section 01300, entitled SUBMITTALS.

K. Submit extended warranty terms and conditions, for the pumping unit, as

specified herein. L. Provide a letter from the manufacturer identifying a local manufacturer’s

representative who is capable and competent to act, as required, in place of the representative from the manufacturer’s plant with respect to required field testing and inspection.

1.03 QUALITY ASSURANCE

A. General


1. All applicable requirements of Section 15010 shall apply to this

Section. 2. All pumping units shall be supplied and warranted by a single pump

manufacturer, who shall take single source responsibility for supplying the units.

3. A representative from the pump manufacturer shall be available at the

job site during the installation and testing of the equipment specified herein.

4. Pumping unit components shall be to the greatest extent possible,

pre-assembled at the factory, to allow minimum time for field assembly of components.

5. All motors, couplings, and extended shafts supplied, shall be of the

same manufacturer for that item.

6. Unless otherwise specified herein, starters, Variable Frequency Drives (VFDs), H-O-A switches, pushbuttons, and other electrical devices shall be specified and provided under DIVISION 16 and DIVISION 13, as applicable. All such equipment shall be arranged as shown on the Drawings.

7. The Contractor shall correct any item or equipment that fails to meet

any overall specified performance requirements at no additional cost to the Owner.

8. The Contractor shall coordinate the associated piping layout shop

drawing submittals with the pumping unit furnished, as indicated in Section 15060.

B. Pumping Unit - Factory Performance Tests

1. The pumping units shall be fully tested at the manufacturer’s

facilities before shipment in accordance with the standards of the Hydraulic Institute unless otherwise specified. The Engineer shall be notified of scheduled pump witness tests not less than thirty (30) days in advance in the event that the Owner or Engineer wish to attend. All costs for travel, lodging and time associated with witness testing by the Owner or Engineer shall be paid by the Owner. All calibratable instrumentation used in performance testing shall be calibrated to Hydraulic Institute accuracy and shall be calibration


traceable to an approved HI firm.

2. The pumps shall be performance tested using the job motors. Pump testing shall be done at minimum and maximum speeds of the job motor. Pump testing shall only occur after the motor factory testing specified herein. Pumps shall be tested to obtain all curves and points as specified herein, and as approved by the Engineer. The Hydraulic Institute standards shall govern all procedures and calculations for these tests, unless otherwise specified herein.

3. Performance test shall consist of simultaneous readings to determine:

speed, discharge and suction pressure, capacity, efficiency, brake horsepower, electrical kilowatts, power factor, voltage and current, at such conditions of head and capacity to properly establish the performance curve.

a. Test shall be conducted at a minimum six (6) operating

points, and shall include the pump design operating point, shutoff point, and a point near pump runout. Flow measurement shall be made with a magmeter or approved equal measuring device.

b. Performance curves generated from this testing shall be

plotted as measured with no speed correction.

c. As per Hydraulic Institute Requirements, when the speed and the total head (Design or Supplemental) is provided in the specification: 1) The corresponding flow shall be not less than that specified and no more than 10 percent greater than that specified. 2) The corresponding efficiency must be equal to or greater that specified.

d. Performance test results which indicates that, a trim of the

impeller is needed, either where the amount to be trimmed would be greater than 2 percent of the nominal diameter, or where the job pump motor is operating in a overloaded condition, shall be cause to correct the pump impellers and retest.

4. The pumps shall be hydrostatically tested at the manufacturer’s plant

prior to shipment. The pressure rating of the pump unit shall be within the limits set forth by the Hydraulic Institute. This test need not be witnessed, however, certified copies of the test results shall be submitted.


5. After testing, the Contractor shall furnish certified prints of each test

performance curve, and all test data.

6. If a pumping unit fails to meet the specified performance requirements, the manufacturer shall make all necessary corrections to the unit and shall conduct all additional shop certified tests to ensure full compliance with the specified requirements. All expenses incurred in making the correction and in conducting such additional shop certified tests, shall be borne by the Contractor at no additional cost to the City.

C. Motors

1. Perform all factory tests described below on each of the motors being

supplied under this Contract. Test results from similar motors will not be accepted.

2. Conduct motor tests at the factory as specified in NEMA Standard

MG-1 and IEEE Standard No. 112. 3. Certified motor tests at the factory must be conducted and test reports

submitted before the motor will be finally approved. These tests shall be as follows:

a. Insulation resistance

b. Winding resistance

c. Stator resistances - Hot and Cold

d. Measurement of air gap by gage

e. Accelerating time for starting at rated voltage

f. Balance

g. Efficiency and Power Factor at full, 3/4 and ½ loads

h. Temperature rise

i. Starting characteristics, including starting torque and current

and accelerating torque and current.


j. A speed-torque and speed-current test shall be performed on each motor with results submitted as a plot of torque and current against speed.

k. Conduct and record all tests in accordance with the latest

revisions of the following standards.

(1) IEEE Standard No. 43, Recommended Practice for Testing Insulation Resistance of Rotating Machinery.

(2) IEEE Standard No. 112, Test Procedure for Polyphase Induction Motors and Generators

PART 2 - PRODUCTS 2.01 PUMP

A. The Contractor shall furnish and install two (2) new non-clog type wastewater pumps as shown on the Drawings and as specified herein. Equipment specified herein shall be suitable for pumping raw sewage.

B. The pump shall be the non-clog type, constructed in accordance with and be

capable of performing as described in the table below:

Parameter Value Discharge Diameter: 4-inch minimum Discharge Position: Coordinate left discharge

position with piping Suction Diameter: 4-inch minimum Maximum Pump Operating Speed: 1800 rpm Minimum Shutoff Head: 96 feet 1st Design Point Total Head (1 Pump @ 100% Speed): 66 feet 1st Design Point Flow Rate: 525 GPM 1st Design Point Minimum Efficiency: 62 % 1st Design Point NPSHR: 12 feet 2nd Design Point Total Head (1 Pump @ 100% Speed): 80 feet 2nd Design Point Flow Rate: 240 GPM 2nd Design Point Minimum Efficiency 3rd Design Point Total Head (1 Pump @ 100% Speed):

44 % 52 feet

3rd Design Point Flow Rate: 900 GPM 3rd Design Point Minimum Efficiency 67 % Maximum Brake Horsepower Requirement at any point on the operating curve:

20 HP


Parameter Value Minimum Passing Solid Size (Min. Diameter): 3 inches Motor Mounting Arrangement: Extended Shaft (field

coordinate dimensions) Range of Pump Operating Speeds: Minimum Pump Speed: Maximum Pump Speed:

1,236 rpm (See 2.01.C) 1,765 rpm (100%)

C. Minimum Pump Speed

1. Pump shall be capable of operating continuously at reduced speeds down to, but not limited to, the speed required to meet the Required Minimum Speed Point as shown on the drawings.

2. Pump speed shall be controlled by Variable Frequency Drive (VFD)

as specified in Section 16690.

D. Manufacturers

The pump shall be the following manufacturer/model, or approved equal.

Manufacturer

Pump Model No.

Suction Size (in.)

Discharge Size (in.)

Fairbanks Morse 5413K 4 4

E. Pump Assembly

The pump shall include, but not be limited to, the following components: pump casing, pump impeller, impeller wear ring, casing wear ring, pump shaft, shaft sleeve, bearing frame, bearings, packing, retaining gland, associated hardware (bolting, nuts, shims, etc.) and sealing materials.

F. The pump shall be fitted with at least two lifting eyes or lugs, or a heavy duty lifting bail capable of supporting the entire weight of the pump, pump base, and suction elbow.

G. Pump Casing

1. The pump casing shall be of the tangential discharge type and be constructed of close grained cast iron ASTM A-48, Class 30 (minimum). Centerline discharge type pumps are not acceptable. The casing shall be of sufficient thickness to withstand all mechanical and hydraulic stresses and strains of service at full operating


pressures. The casing shall be suitably reinforced to support the combined weight of the pump/motor assembly. The casing shall have smooth internal surfaces, free of rough spots.

2. The pump casing shall have an integrally cast handhole cleanout.

The handhole cover shall be constructed of the same material as the pump casing and shall have surfaces matching the internal casing contours to minimize turbulence and localized wear. Each pump casing shall be provided with all necessary vent and gauge connections.

3. The suction and discharge flanges shall be Class 125 flat face ANSI

standard flanges with slotted or drilled holes and shall be oriented as shown on the drawings.

H. Pump Support

1. The pump shall be supported by a heavy cast iron or fabricated steel

baseplate. The baseplate shall be of adequate strength and mass to support the entire weight of the pump and simultaneously carry all hydraulic and mechanical loads imposed by the pump over its entire operating range, from shutoff head to runout condition. The base plate shall have sufficient cross section to avoid vibrations due to base flexibility.

2. The pump manufacturer shall certify the adequacy of the final pump

support system to support the pump and its associated loads.

I. Pump Impeller

1. The impeller shall be of a single-vaned, enclosed, non-clogging design and shall have large passages to provide smooth flow transition and unimpeded passage of large spherical solids. Impellers shall be designed to convey raw unscreened wastewater. Impellers shall be dynamically (two-plane) balanced to Hydraulic Institute (HI) standards to provide vibration-free operation over the entire operating range.

2. The impeller shall be constructed of ASTM A-48, Class 30

(minimum) close grained cast iron and shall be securely fastened to the shaft with a stainless steel key and impeller locknut, or heavy capscrew.

J. Wearing Rings


1. Renewable, hardened 400 series stainless steel radial or axial wear

rings shall be provided on the impeller inlet and in the casing or suction cover inlet to reduce the effects of abrasive wear and provide the ability to renew the running clearance. The impeller rings shall be hardened to a minimum of 300 BHN, and the casing/suction cover rings shall be hardened to a minimum of 350 BHN. A 50 BHN differential between the two rings shall be maintained.

2. Wear rings which are secured to their mating components by means

of capscrews shall have the screw heads recessed a minimum of 3/32 inch below the face of the ring. The counterbores around screw heads shall be filled with epoxy. Each ring shall be a minimum thickness of 3/8 inch.

K. Pump Shaft

1. The pump shaft shall be one piece construction of high strength

stainless steel or high strength carbon steel and shall be precision machined, ground and polished to ensure proper tolerances at all bearing and seal fits. The entire rotating assembly shall be designed with sufficient rigidity and balanced to provide for minimal shaft deflection at the specified operating range. The shaft shall be the maximum diameter manufactured which can be used in the unit.

L. Shaft Sleeve

1. Carbon steel shafts shall be completely isolated from the pumped

liquid by a stainless steel shaft sleeve with an adhesive compound, or by a keyed shaft sleeve with an O-ring type seal between the shaft and sleeve.

M. Bearing Frame Assembly

1. Provide a removable bearing frame of ASTM A48 cast iron

construction, designed to provide a self-indexing and self-centering fit on top of the existing pump casing/volute. The frame shall provide permanently aligned supports for the pump bearing housings and stuffing box. An opening shall be provided to facilitate access to the stuffing box to facilitate packing adjustment and replacement. The bearing frame shall contain provisions for axial adjustments of the rotating element so that proper clearance between then impeller and the suction cover can be maintained.


2. The bearing frame shall be provided with radial and thrust bearings, removable bearing housings and lip seals. Bearings shall be the anti-friction type capable of withstanding all radial and thrust loads created by the rotating assembly, with its maximum impeller size. Bearings shall be designed for a minimum L-10 life of 100,000 hours. Bearing housings shall be provided with Zerk fittings for grease lubrication.

N. Mechanical Seals

1. Split Mechanical seal shall be comprised of four component parts,

two rotating halves and two stationary halves, for ease of assembly and installation. All seal faces shall be constructed of silicon carbide. For pumped media seal lubrication, provide a 416 stainless steel bushing capable of solids rejection while letting liquid pass.

2. The split mechanical seal shall be the Chesterton Model 442, split

mechanical Seal with SpiralTrac bushing Version D, Type A. No substitutions shall be permitted.

3. If mechanical seals are installed on the pumping unit for the specified

factory testing, then those seals shall not be installed on the pumping units in the field.

O. Temperature Detectors

1. Provide two (2) RTD’s to be embedded in the pump bearings, one per

bearing.

2. RTD’s shall be the 120-ohm at 0°C, Nickel type, 3-wire, characteristic No.7.

3. RTD’s for the bearings shall be the tip sensitive type. RTD’s for

thrust bearings shall be the miniature tip embedded type. The pump bearing housing shall be drilled, milled and tapped to place the sensitive detector tip within 1/8 inch of the Babbitt for sleeve guide bearings and within 1/16 inch of the Babbitt of thrust bearing shoes.

4. Suitable accessories and associated hardware to include holders, head

connection and seals shall be provided to enable the complete mounting and installation of each RTD in accordance with the manufacturer’s recommendations.

5. RTD’s shall be manufactured by MINCO Products or equal.


P. Vibration Detectors

1. Two (2) vibration sensors shall be mounted on each pump, one at each bearing.

2. Vibration sensors shall be coordinated with the pump manufacturer for mounting and supply. Suitable accessories and associated hardware shall be provided as necessary for a complete installation.

2.02 MOTOR

A. Conditions of Service:

New 20 HP capacity motors shall be used to drive the new pumping units, via an extended shaft arrangement. The motors shall be set indoors in a damp environment with a maximum temperature of 104°F (40°C). All motors shall be capable of being driven via the use of variable frequency drives (VFDs), to be located in the same room as the pump motors.

B. The motors shall be the vertical, quiet running, invertor duty, alternating

current, squirrel cage induction type of premium efficiency and suitable for continuous service. Motors shall be built and tested in accordance with the latest version of NEMA Standard MG-1 and all other standards specified herein.

C. The motors shall be capable of continuous operation at reduced operating

motor (and pump) speeds and loads. The motor shall be capable of continuously operating at 1,236 rpm with a corresponding power output not less than 20 horsepower, at rated ambient temperature.

D. The motor shall be fitted with at least two lifting eyes or lugs, or a heavy

duty lifting bail capable of supporting the entire weight of the motor and cable.

E. Each motor shall meet the following requirements:

1. Rating

a. Voltage - 460 V, for operation in a variable frequency drive

arrangement. The motor shall be capable of operating in a nominal 480 volt, 3 phase, 60 hertz system.


b. Size – 20 horsepower, continuous, at 1800 rpm nominal full load speed.

c. Maximum Full Load Current at rated voltage: 234 Amperes

d. NEMA Design - B

e. Insulation - Class H

f. Temperature Rise - 80°C over 40° C ambient, at nameplate rated horsepower.

g. Service Factor - 1.15.

h. Minimum Guaranteed Efficiency, per IEEE Standard No. 112

Method A or B:

Full Load 95.0% 3/4 Load 94.5% ½ Load 94.0%

i. Locked rotor, pull-in and pull-out torque shall not be less than those specified in NEMA Standard MG-1 and shall be as required by the pump.

2. Number of starts shall be in accordance with NEMA Standard MG-1.

Provide nameplate on motor identifying limitations.

3. Overload and short-circuit requirements shall be in accordance with the latest revisions of ANSI Standards.

4. Balance of motor shall not exceed a maximum amplitude of 0.0015

inches and shall be measured in accordance with NEMA Standard MG-1.

5. Direction of rotation shall be as required by the pumps to be

furnished. Direction of rotation shall be verified in respect to phase rotation.

F. Enclosure

1. The enclosure for each motor shall be the open, dripproof, fully

guarded type, WP-1. No air filters shall be installed on any openings on the enclosure. It shall be of cast iron or welded plate construction.


Note: WP-1 is defined as follows: Its ventilating passages are constructed to minimize the entrance of rain, snow, and airborne particles to the electric parts, and its ventilation openings are constructed to prevent the passage of a ¾” diameter cylindrical rod.

2. Each motor shall be self-ventilated; the enclosure shall have a

sufficient number of generously sized openings to provide adequate ventilation throughout the motors. Ventilation air discharged shall be upward, from the top or sides of the unit. Motors shall be suitable for continuous operation with an ambient air temperature of 40C.

3. The enclosure shall be provided with readily removable access covers

or other means to suit, to facilitate inspection and maintenance of bearings and space heaters.

G. Motor Heaters

1. Strip heater(s) shall be arranged in a uniform design around the

interior of each motor for the purpose of maintaining an interior temperature above ambient to prevent the accumulation of moisture within the motor during periods of shutdown. The strip heaters shall be suitable for 120 volt, single phase, 60 Hz and sized as required for this duty. Individual conductors from each heater terminal shall be brought out to a terminal strip in an external terminal connection box.

H. Rotors

1. The rotor shall be capable of operating at 125% of rated speed, in

either direction of rotation.

2. Rotor blocking for shipping shall be provided.

I. Shaft

1. The motor shaft shall be solid 1040 type carbon steel, machined and polished.

2. The motor shaft shall be prepared to accommodate a new half

coupling to attach to the new extended shaft described in this Section.

J. Bearings

1. Each motor shall be provided with a thrust bearing located at the top of the motor and a guide bearing at the bottom of the motor. The


bearings shall be suitable for the loads caused by the new pump rotating assembly to be mounted inside the existing pump casing. Bearings shall be constructed for full load 24 hours per day duty continuous service and shall have a rated L-10 service life of at least 50,000 hours.

2. Bearings shall be oil lubricated. Bearings shall be mounted in a oil

reservoir supplied with sight gauges and fill and drain connections and plugs.

3. Thrust bearing

Bearing shall be of normal thrust design, using the angular contact type. Deep groove ball bearings shall not be acceptable for thrust bearing purposes. If required, bearings mounted back-to-back or in tandem may be furnished per the manufacturer’s standard design.

4. Guide Bearing

Bearing shall be deep groove ball type. If required, bearings mounted back-to-back or in tandem may be furnished per the manufacturer’s standard design. Guide bearing shall be provided with sufficient means to prevent the leakage of lubricant or the entrance of foreign matter along the shaft.

K. Vibration Detectors

1. Two (2) vibration sensors shall be mounted on each motor, one each the thrust and guide bearings.

2. Vibration sensors shall be coordinated with the pump manufacturer for mounting and supply. Suitable accessories and associated hardware shall be provided as necessary for a complete installation.

L. Boxes

1. All connection and terminal boxes shall be located on the exterior of

the motor frame where shown on the Drawings with an orientation keyed to the location of the motor stator, motor main leads, connection box.

2. The motor main stator winding shall be brought out of the stator into

a removable connection box.


a. The connection box shall be sized to provide adequate interior capacity to conveniently contain the stator leads.

b. The motor stator leads shall have identification tags. Tags

shall be of brass with stamped characters or engraved, laminated plastic, or equal.

3. The exterior of the motor stator frame shall be provided with a

connection box for motor space heaters and temperature detectors. This box shall be provided with terminal strips to permit rapid disconnect and positive identification of each conductor. The cover shall have an engraved, laminated plastic nameplate identifying the service, in the box.

M. Temperature Detectors

1. Provide three (3) RTD’s which are embedded in the windings of the

motor, one per phase. Provide two (2) RTD’s to be embedded in the motor bearings, one per bearing.

2. RTD’s shall be the 120-ohm at 0°C, Nickel type, 3-wire,

characteristic No.7.

3. RTD’s for the stator shall be suitable in all respects for placement in the motor stator by the motor manufacturer.

4. RTD’s for the bearings shall the tip sensitive type. RTD’s for thrust

bearings shall be the miniature tip embedded type. The motor bearing housing shall be drilled, milled and tapped to place the sensitive detector tip within 1/8 inch of the Babbitt for sleeve guide bearings and within 1/16 inch of the Babbitt of thrust bearing shoes.

5. Suitable accessories and associated hardware to include holders, head

connection and seals shall be provided to enable the complete mounting and installation of each RTD in accordance with the manufacturer’s recommendations.

6. RTD’s shall be manufactured by MINCO Products or equal.

N. Manufacturers:

Motors shall be manufactured by one of the following:


Ideal Electric and Manufacturing Company; U. S. Electrical Motors; Siemens Energy and Automation, Inc.; Reliance Electric Company; Toshiba International Corporation; General Electric Company; or Continental Electric Company Inc.

2.03 MOTOR STAND / ANCHORING

A. Provide a motor stand to allow the motor to be anchored to the associated concrete motor equipment pad and to allow access to the shaft coupling as depicted in the Drawings. Motor stand shall be fabricated of steel.

B. Cast in place anchors or epoxy anchors shall be used to connect the motor

stand to the concrete pad. Wedge type anchors shall not be acceptable.

C. Provide all associated mounting hardware. 2.04 EXTENDED SHAFT ASSEMBLY

A. The pump and motor for the wastewater pumps shall be connected by a hollow tube flexible type intermediate universal joint shafting designed for continuous 24-hour per day operation, of sufficient diameter and thickness to transmit the full motor driver horsepower.

B. The number of shaft sections required for each pump shall be verified by the

supplier, taking into consideration the proposed pumping unit lateral and torsional inertias and all applicable site conditions.

C. All shaft sections shall be dynamically balanced to 150% of the indicated

design speed.

D. Calculations shall be submitted to determine both lateral and torsional critical speeds for the entire pumping unit rotating assembly (motor, shafting, pump shaft, impeller, etc.). Calculations shall identify that:

1. The first lateral critical speed is at least 25% above the maximum

operating pump speed.

2. The rotating assembly lateral natural frequency is not within plus or minus twenty (20) percent of any exciting resonant frequencies, (integer multiples of pump speed, e.g. vane passing frequency) caused by pumping unit operation, from the specified minimum to maximum running speed.

3. The rotating assembly torsional natural frequency is not within plus


or minus twenty (20) percent of any exciting resonant frequencies, caused by pumping unit operation, from the specified minimum to maximum running speed.

E. Shaft assembly sizing and design calculations shall be submitted for review

and approval. F. Calculations shall be submitted to determine the natural frequency of the

intermediate steady bearing support structure for the pumping units, as shown in the Drawings. Calculations shall identify that the support structure natural frequency is at least four (4) times greater than the maximum running speed (forcing frequency) of the pumping unit.

G. Joints shall be flange type and each section shall be provided with needle

bearing type universal joints. Universal joint bearing shall be designed for a L-10 life of not less than 50,000 hours. The section connected to the pump shall be slip spline joint for vertical adjustment. The sliding spline sections shall be at its midpoint of travel ½ inch when installation is complete. Grease lubricated double spherical, anti-friction type shaft steady bearings contained in dust and moisture-proof housings, shall be provided for each shaft section and shall have pressure grease fittings. Steady bearings shall have a L-10 life of at least 50,000 hours.

H. Pillow Block Lubricators shall be provided to suit. If required, lubricating

lines shall be type hard ‘K’ hard copper extending from the pillow block to the platforms and shall terminate with Zerk type grease fittings. Individual lines shall be provided for each point of lubrication. Headers with multiple takeoffs will not be permitted.

I. Corrosion resistant coated steel mesh shaft guards shall be provided all

around the shafting and as required elsewhere to meet OSHA regulations and as indicated in the Drawings. Screen guards shall be easily removable for shaft maintenance. Provide hinged access door as required for steady bearing, shaft coupling and U-joint.

J. Extended shaft assembly shall be provided by Johnson Power or equal. K. Extended shaft shall reuse the existing g stabilizer beam and beam location.

2.05 VIBRATION MONITORING

A. Each pump and motor shall be furnished with vibration monitoring.This monitoring system will include two field installed accelerometers on each pump and two field installed accelerometers on each motor. Pumping Unit


supplier will provide written recommendations for the locations of these accelerometers.

2.06 TEMPERATURE MONITORING MODULE

A. One Temperature Monitoring Module shall be provided for each pump. B. RTD Temperature Monitoring Module: The RTD Temperature Monitoring

Module shall consist of a 12-channel monitor including all necessary software. The monitor shall include a RS485/RS232 interface and shall include windows compatible software for system configuration and data logging for over-temperature protection.

C. Temperature monitor shall be UL Listed.

D. Monitor shall be compatible with installed temperature sensors / RTDs.

Monitor shall utilize 4-20mA current loop. Scan rate shall be 1.5 seconds max. to scan all 12 channels.

E. Accuracy shall be 3ºF at 32-158ºF ambient temp.

F. Unit shall be self-calibrating and shall include input fault detection and

power-loss protection, trip points and program parameters shall be stored in non-volatile memory to restore upon return of power.

G. Monitor shall include minimum five output relays, Type C, SPDT 10 A @

250 VAC resistive load.

H. Unit shall be capable of storing 24 independent trip points (2 for each of the 12 channels), programmable deadband, and shall be self calibrating and have an integral display with minimum 20x4 line display.

I. Unit shall include a steel NEMA 4 panel mount enclosure and shall be

powered by 85-240 VAC.

J. Temperature Monitoring Module shall be Minco Model CT224 or approved equal.

2.07 SPARE PARTS

The following spare parts shall be furnished and delivered by the Contractor to the site. Motors:


-One complete set of bearings, (thrust and guide) per motor -Six months supply of lubricating oil per motor

Pumps:

-One Impeller of equal diameter to those provided per pump -One complete set of wear rings and attaching hardware (impeller and casing) per pump -One complete set of bearings (thrust and guide) per pump -One shaft sleeve per pump -One mechanical seal repair kit per pump

Extended Shaft Assembly:

-One complete universal joint shaft assembly per extended shaft assembly 2.08 FACTORY FINISH

Motors shall be factory finished with the manufacturer's standard heat-resistant enamel coating system. Pump and motor stand shall be factory primed on exposed (non-machined) surfaces.

2.09 LIFTING AND HOISTING REQUIREMENTS

The motor and pump shall be provided with lifting eyes to allow the motor to be hoisted by a crane or monorail. Lifting eyes shall be designed to support the full weight of the motor assembly.

PART 3 - EXECUTION 3.01 INSTALLATION

A. General

1. Unless specified otherwise, installation and alignment of the new pumping units shall be in accordance with Hydraulic Institute Installation Standards (ANSI/HI 1.4).

2. The Contractor shall have on site for the duration of pumping unit

installation activities, the pump manufacturer’s factory authorized service technician.

3. The Contractor shall install the new pump, including the bearing

frame and the extended shaft assembly.


4. The mechanical seal shall be field installed by a seal manufacturer authorized field service technician. Seal installation shall be integrated into a Training class session as specified herein, below.

5. Bearing temperature detectors and vibration sensors shall be field

installed, per pump manufacturer recommendations.

6. Vibration system accelerometers shall be field installed, per pump manufacturer recommendations.

B. Motor

1. Connect space heaters and power cables to each motor. Protect the

motors from dust and other construction debris before and after installation. Contractor shall hire a qualified motor repair outfit to clean the motors at no additional cost to the City, if in the opinion of the City, motors are subjected to dust and construction debris.

2. Connect all new motor winding and bearing temperature detection

devices (RTD’s) as indicated in the Drawings.

3. Vibration system accelerometers shall be field installed, per motor manufacturer recommendations.

C. Alignment

1. Verify alignment of the extended shaft assembly at the motor and

pump, is in accordance with motor, pump, and extended shaft assembly manufacturer recommendations and Hydraulic Institute requirements.

2. Extended shaft assemblies shall be set near plumb, with the offset

angle at any U-joint, being installed within all extended shaft assembly manufacturer tolerances, (minimum and maximum).

3. Steady bearing installation elevations shall be adjusted as necessary

as determined by the extended shaft assembly manufacturer. New steady bearing elevations do not have to match existing.

3.02 INSTRUCTION PERIOD

A. During field installation of the mechanical seal, the factory authorized servicemen will arrange to install the seals in the presence of City personnel over a minimum of two (2) separate days.


B. After completion of field functional testing specified herein, provide the

pump, mechanical seal and the motor factory authorized servicemen jointly for a minimum of twelve (12) hours of training time, split into three (3), 4-hour sessions on separate, potentially non-consecutive days, to instruct the City in the operation and maintenance of the pumping units specified herein.

3.03 PUMPING UNIT CONTROL

Pumps shall automatically controlled (started, stopped and speed control) by the PLC in the Pump Control Panel issued to the Pumping Unit’s VFD Panel. Pump starting, stopping and emergency stopping operational sequences, shall be controlled using relay logic housed in the Pumping Unit’s VFD Panel. Written control descriptions for the pumping units are specified in DIVISION13.

3.04 FIELD TESTING

A. Uncoupled Motor Testing:

Each new motor shall be run uncoupled for a short period of time (approximately one minute) to determine correct direction of rotation and to verify ‘no load’ motor amperage and operational speed. The Contractor shall provide calibrated test instrumentation to take these measurements.

B. Pumping Unit Functional Testing:

1. After the motor is coupled to the pump and the pumping unit is

completely assembled and all new electrical equipment is installed, the following functional tests shall be performed, monitored and recorded on each of the new pumping units:

a. Pumping Unit - Normal Startup Sequence

b. Pumping Unit - Normal Shutdown Sequence

c. Pumping Unit Emergency Shutdown Sequence

d. Single Pump Operation with varying speeds proportional with

wet well level.

2. During this functional testing, electrical power and control system operation shall be demonstrated. Demonstration shall include but not be limited to functional testing of the new control system switches,


relays, alarms and displays, and variable speed drives.

3. Startup and Shutdown equipment operating sequences and VFD speed variation parameters are detailed herein.

4. Pumping unit functional testing must be completed for all new

pumping units prior to the station startup testing period as defined in Section 01650.

5. Contractor shall provide all fluids (water) for functional testing of

each pumping unit.

C. Pumping Unit Performance Testing:

1. After functional testing of each new pumping unit, during the station startup period specified in Section 01650, the pumping unit shall be operated for a minimum of two (2) separate times, for at least a 5-minute duration period each time:

a. at the minimum specified pump speed - single pump

operation

b. at the maximum specified pump speed - single pump operation

2. Hydraulic performance of the pump shall be monitored by using the

new station flow meter and level monitoring instrumentation. The Contractor shall provide calibrated test pressure gauges to monitor pump discharge pressure, and a calibrated tachometer or similar operating speed measuring device.

3. Electrical performance of the motor shall be monitored. The

Contractor shall provide calibrated electrical test instrumentation, which can monitor motor amperage, voltage, power factor, and electrical input in kilowatts.

4. Pumping unit performance testing may be performed during the

station startup testing period as defined in Section 01650. Should field performance testing indicate that the pumping unit is performing more than five (5) percent from its corresponding factory flow curve (speed corrected to the same speed as the factory test), at the observed operating head, the Contractor shall provide all necessary corrective actions and retest the unit. Should field performance testing show that a pumping unit is performing at or more than ten


(10) percent away from its corresponding factory flow curve (speed corrected to the same speed as the factory test), at the observed operating head:

a. The startup testing period must be repeated from day one, as

indicated in Section 01650.

b. The Contractor shall provide all necessary corrective actions and retest the unit.

D. Pumping Unit Vibration Testing:

1. The Contractor shall procure the services of an independent vibration

testing agency, approved by the Engineer, to measure the vibration and the operating speed of the modified pumping unit under actual operating conditions.

2. During the Performance testing of the new pumping units, vibration

shall be measured on all pump, extended shaft, and motor bearings in two directions, parallel and perpendicular to pump discharge.

3. Vibration data shall be presented in a report, which at a minimum

indicate the following:

a. At each bearing: overall displacement (vibration amplitude in mils).

b. For each individual reading: a graph of displacement

amplitude versus frequency of each individual reading, with multiples of pump running speed from 1 to 10 clearly indicated. Graphs shall be presented legibly, with no more than three graphs depicted per letter size page.

c. List of all equipment used to collect and process vibration and

pump speed data and corresponding calibration certifications.

d. All vibration readings shall be within the limits stated in the Hydraulic Institute Standards (ANSI/HI 1.4).

E. Testing Acceptance:

If as a result of field testing, the City determines that any field test results are unacceptable; the Contractor shall perform repairs as necessary and retest the unit(s) at no additional cost to the City.


3.05 FIELD FINISH

A. Pumps and motor stands shall be field finish coated in accordance with Section 09960.

END OF SECTION

SECTION 11310 NON-CLOG CENTRIFUGAL … 11310-3 Non-Clog Centrifugal Wastewater Pumps City of Newport...

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Transcript of SECTION 11310 NON-CLOG CENTRIFUGAL … 11310-3 Non-Clog Centrifugal Wastewater Pumps City of Newport...