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Lift Station Docst' 1 r (f," G� 6 tr �% NAS t UT'eR- Suburban E-77dn ineerin , Inco 'lain Office 6875 Aigltway To. 65 5q. C —Tinneapolis,—Tinnesota 55432 784-6o66 City of Fridley 6431 University Ave. N.E. Fridley, Minnesota 55432 Attn: Darrel Clark Dear Darrel: �7�� /� South Office 2o1 West Buinsville 6osstown Bmnsville, -91innesotu 55378 8yo=6510 Associates No6ett 31inde4, -CR, q. &g1. CWm. e Jensen, -'eg. enga. Btuce A. 2atetson, -'Reg. &91. C, J. (B.d) -'Rathbun, -'Reg. Sutveyos Civil & 516icipa1 f ngineeling -Land &veyots !and � canning Soil gestiny March 12, 1971 Re: Georgetown Court Phase III Lift Station After several conversations with Fadden Pump Company and yourself, it is our recommendation that a Smith and Loveless 6'6" station with two 2 horse power pumps be utilized in the above location. This is a standard wet well, dry well lift station. The amount of flow to be expected at this location is above the economical range for the ejector type pumps, which would require 5 horse power motors, and would be more expensive. We would appreciate a conformation of this choice at the earliest time possible to facilitate completion of the plans. Thank you. Very truly yours, SUBURBAN ENGINEERING, INC. William K. Meyer, P.E. WKM:mlz BODY OF SPECS REPRODUCED BY PERMISSION OF FADDEN PUMP CO. c00 y ;,t'eh, y that YrJ ion cc,^s': • p �a.c,, ed �. dup;:c: p0/lU�jO tCtiq� fro„ o tJ jT �4e � 3 rl�r�� er- 'OCTA1 SPECIFICATIONS FACTORY -BUILT PUMPING STATION ' GENERAL The contractor shall furnish and install one "Econo-Flo" factory -built, automatic pumping station as manufactured by Smith & Loveless, Division -Union Tank Car Company, Lenexa, Kansas. The station shall be complete with all needed equip- ment factory -installed in a welded steel chamber withwelded steel entrance tube and with ladder to provide access. The principal items of equipment shall include two vertical, line mounted, motor driven, non -clog sewage pumps; valves; internal piping; central control panel with circuit breakers; motor starters and automatic pumping level controls; lighting; sump pump; ventilator; dehumidifier and all internal wiring. OPERATING CONDITIONS Each pump shall be capable of delivering 120 GPM of raw, unscreened sewage against a total dynamic head of 24.5 feet. The maximum allowable speed shall be 11.70 RPM. The minimum rated horsepower of each pump motor shall be 2 H. P. , All openings and passages shall be large enough to permit the passage of a sphere 3" in diameter and any trash or stringy material which can pass through a 4" house collection system. The anticipated operating head range is from_2,a,a_ feet minimum to 25.0 feet maximum. PUMP CHAMBER The station shall be built by the Manufacturer in twomajor sections, consisting of the pump chamber and the required section (s) of entrance tube, for ease in shipment and. handling. These„sectiops shall be joined at the job site by welding. . ... 1 '+.i i t., tY' „ , t .. y { '.I1 (S rIi ! '� 1 }.". 1 'r 1 3 w '.1: +•1. ., i, + • :rt, t.; +.. {.,: tyle .: •;'. r' i, 1 r :�) ;.• �. j.I. ! ' The field joint shall then be cleaned and heavily coated with "Versapox" epoxy resin, provided by the Manufacturer. The pump chamber shall contain all pumps and other equipment and shall be a vertical cylinder of circular cross-section with shell of ASTM A-36 steel plate, and nominaloutside diameter of 6'6". The top and the bottom of the station shall be ASTM 283 Grade C steel flanged and dished heads welded to the station. shell. The exterior of the station shall be designed so that all welds exposed to ground water after installation are continuous throughout their length so that water cannot seep between uncoated steel surfaces and cause corrosion. In addition, the structure shall be designed so that sharp corners and similar difficult to coat conditions are held to an absolute minimum. The thickness of the steel cylinder and of the domed heads shall be determined by the structural requirements for the depth of buryinvolvedand shall be a minimum of 3/16" unless heavier steel is required due to depth of bury. It shall be the responsibility of the manufacturer to determine the structural requirements of the shell based on the external loads specified on the plans. 'Lifting eyes adequate to support the entire weight of the completed chamber shall be provided and welded to the station head. Tie down loops for anchoring the station to the slab shall be provided on the bottom of the station and additional tie down loops shall be provided for anchoring the discharge line at the point it leaves the station. Lifting loops shall also be located on the ceiling of the pump station over each pump at an adequate height to permit a hoist to be used for pump disassembly. A 20" diameter by 8" deep sump withwalls of 3/16" structural -grade steelplate shall be provided in the center of the station. Where the cast iron suction and discharge lines pass through the station walls, they shall be reinforced with 3/16" thick steel sleeves, welded inside and out to the station wall. The space between the cast iron pipes and the steel sleeves shall be packed tight with Portland Cement grout containing Embecco aggregate to prevent leakage. ENTRANCE TUBE The entrance tube shall be provided in one or more sections as required and shall be a 36" diameter vertical cylinder of ASTM A-36 structural grade steel plate. The length shall be adequate to place the cover above the surrounding ground and any anticipated local flooding. The entrance tube shall be adequately stiffened and the field joints arranged so that the joint may be welded from the outside of the tube with all welding being performed in a down -hand position. The bottom of the tube shall be attached to an angle, shop welded, to the head of the pump station. This field joint shall also be weldable in the down -hand position. Two lifting loops shall be provided on each se ction of e4trance tube for handling and installation. The entrance tube cover shall be of fiber glass reinforced plastic and shall have a reflective color to reduce heat absorption. The cover shall have a suitable drip lip around the edge and shall be provided with a weather-proof lock of the pin tumbler type which can be opene(I :rom the inside without a key. The lock shall be self locking upon slammb,I; the lid. The fiberglass cover shall be fastened to a steel ladder having two rungs which form an extension of the access ladder when the cover is latched in the open position. The steel ladder shall act as the cover hinge and a latch mechanism shall be provided to keep the cover open under any normal load. A continuous -mold neoprene gasket shall be pro- vided on the top of the tube to seal the cover and protect the top edge of the entrance tube. The access ladder shall have rungs of 1" outside diameter aluminumtube spaced on 12" centers. The side rails of the ladder shall be 3" x 4" rectangular steel tubing which shall also serve as air ducts for the station ventilation system. The. ladder rungs shall be installed between the,side rails so that the support of the operator is not dependent upon a weld in shear. The ladder section in the entrance tube shall be lined up accurately with the section in the pump chamber by self -aligning projections. Neoprene rubber sleeves shall be provided to seal the joint between the adjoining vent sections. WELDING All steel in the station structure shall be joined by electric arc welding with fillets of adequate section for the joint involved. All welds on the exterior of the station shall be •continuous welds through their length and shall prevent the entry of water between uncoated steel surfaces or into the station. PROTECTION AGAINST CORROSION After welding, all inside and outside surfaces of the structure shall be blasted with steel grit, to remove rust, mill scale, weld slag, etc. All weld spatter and surface roughness shallbe removed by grinding. Immediately following cleaning, a single heavy inert coating shall be factoryapplied to all inside and outside surfaces prior to shipment. This coating shall be of "Versapox" epoxy resin, especially formulated by Smith & Loveless for abrasion and corrosion resistance. The dry coating shall contain a minimum of 8576 epoxy resin with the balance being pigmento and thixotropic agents. A touch-up kit shall be provided for repair of any mars or scratches occuring during installation. This kit shall contain detailed instructions for use and shall be a material which is compatible with the original coating. The touch-up coating shall contain a minimum of 85%epoxy resin. Two 17 -pound magnesium anode packs shall be provided for cathodic protection. The anode packs shall be provided with minimum 6' long insulated copper leads. Copper lugs shall be provided by the Manufacturer on opposite sides of the station for anode con- nections. A heavy synthetic rubber mat shall be cemented to the station floor plates to protect the steel floor from abrasion. PUMPS The pumps shall be vertical line mounted "Non -Clog" sewage pumps of heavy cast iron construction especially designed for the use of mechanical seals. In order to minimize seal wear caused by lineal movement of the shaft, the shaft bearing nearest the pump impeller shall be locked in place so that thermal ex- pansion of the shaft is held to a minimum and so that end play is limited to the clearance within the bearing. To minimize seal wear resulting from shaft de- flection in the mechanical seal caused by the radial thrust at the cut water of the pump, the shaft shall be a minimum of 1-7/8" diameter from the top of the im- peller through the pump or motor bearings supporting the impeller. The di- mension from the lowest bearing to the top of the impeller shall not exceed 6". The bearing nearest the impeller shall be designed for the combined thrust -and radial load for a B-10 life of 8800 hours when the pump is operating continuously at a flow rate of 100 gallons per minute at the total dynamic head developable by the impeller which will meet the operating conditions given in these specifications. The upper bearing shall be free to move lineallywith the thermal expansion of the shaft and shall be designed for radial load only and for a B-10 life of 8800 hours. In calculating bearing life, no credit shall be assumed for the use of vacuum de- gassed steel. The shaft shall be a solid one piece stainless steel shaft through the pump and both bearings to eliminate corrosion within the pump or the mechanical seal. Removable shaft sleeves will not be acceptable unless the solid shaft under the sleeve meets the specified minimum diameter. The pump impeller shall be of the enclosed type made of close -grained cast iron and shall be balanced. The impeller shall be keyed and secured to the motor - pump shaft by a stainless steel cap screw equipped with a "Nylock" or other suitable self-locking device. The impellA-r shallnot be screwed or pinned to the motor -pump shaft and shall be readily removable without the use of special tools. To prevent the buildup of stringy materials, grit and other foreign particles around the pump shaft, all impellers less than full diameter shall be trimmed inside the impeller shroud. The shroud shall remain full diameter so that 1. close, minimum clearance from shroud to volute is maintained. Both the end of the shaft and the bore of the impeller shall be tapered to permit easy removal of the impeller from the shaft. The pump shaft shall be sealed against leakage by a double mechanical seal, .r installed in a bronze seal housing constructed in two sections with registered fit. The housing shall be recessedinto the pumpbackhead and securely fastened thereto with stainless steel cap screws. The inside of the seal housing shall be tapered to facilitate the replacement of the seal parts. The seal shall be of double carbon and ceramic construction, with the mating surfaces lapped to a flatness tolerance of one light band. The rotating ceramics shall be held in mating position with the stationary carbons by a stainless steel spring. The seal housing, with assembled parts, shall be so constructed as to be readily removable from the shaft as a unit and shall be providedwith tapped jack -screw openings to assist in removing it from the backhead. The seal shall be pressurized and lubricated by water taken directly from the pump backhead through a filter to the seal housing and introduced between the upper and lower sealing surfaces. The filters shall be of corrosion resistant materials and shall screen out all solids larger than 50 microns. The seal system shall contain a brass valve connected near the top of the seal housing to permit the relief of any .air trapped in the seal unit. A manually operated brass valve shall also be provided to vent the pump volute. The pump shall be supported by fabricated steel brackets welded to the bottom head and bolted to the pump suction and discharge nozzle flanges. The height shall be sufficient to permit the use of an increasing suction elbow which shall be provided when the nominal pump size is smaller than the suction line. The suction and discharge openings shall be flanged, faced and drilled 125 -pound American Standard. MOTORS The pump motors shall be specially built NEMA P base, open drip -proof in- duction type, suitable for 3 phase, 60 cycle, 220 volt electric current. They shall have normal starting torque and low- starting- current, as specified for NEMA Design B characteristics. The motors shall not be over- loaded at the design condition, nor at any head in the operating range as specified under "Operating Conditions. " The motor shall be fitted with heavy lifting eyes, each capable of supporting the entire weight of the pump and motor. A special varnish treatment shall be applied to the stator windings and rust pre- ventative compounds shall be used to coat the rotor and stator air gap surfaces and protect the.motor against corrosion. ` CONTROL The control equipment shall be mounted in a NEMA Type 1 steel dead front enclosure. The enclosure shall have a hinged door on which shall be mounted the thermostat, humidistat and blower timer. The circuit breakers, overload reset buttons, and control switches shall be operable without opening the door. The pressure switches shall be mounted on the side of the control and shall be adjustable without removing the cover. A grounding type convenience duplex outlet shall be provided for operation of 115 volt A. C. auxiliary devices. Thermal magnetic air circuit breakers shall be provided for branch disconnect service and short circuit protection of all motor control, and auxiliary circuits. Magnetic across -the- line starters with under -voltage release and overload coils for each phase shall be provided for each pumpmotor to give positive protection against single phasing. Each single phase auxiliary motor shall be equipped with an over -current protection device, in addition to its branch circuit breaker or shall be impedance protected. All switches shall be labeled and a color - coded wiring diagram shall be provided. To control the operation of the pumps with variations of sewage level in the wet well, an air -bubbler system shall be provided, complete with two air com- pressors, flow indicator, bubbler line to the wet well and a sensitive pressure switch for each pump. The two air compressors shall be of the close -coupled, oil -less type. Each compressor shall have a minimum capacity of 0. 2 cubic feet of free air per minute at 10 p. s. i. It shall incorporate a single, phase, 60 cycle, 115 volt drip -proof, brushless type, electric motor. The air compressors will alternate simultaneously with the alternation of the pumps. The pressure switches shall be of the mercury -tube type, with sensitive pressure elements and independent high and low adjustments for each pump capable of a minimum differential of 18" of water. An automatic .alternator with manual •"ON-OFF" switch shall be provided to change the sequence of operation of the pumps on the completion of each pumping cycle. Provisions shall also be made for the pumps to operate in parallel, should the level in the wet well continue to rise above the starting level for the low-level pump. For the convenience of the operator and service man and to contribute to the cleanliness of the station, a chrome -plated, drawer type ash tray shall be fur- nished at the bottom of the control panel, and a polyethylene trash container shall be provided. DEHUMIDIFIER AND VENTILATING BLOWER A dehumidifier assembly with hermetically sealed Freon refrigeration type compressor, expansion coil, fan and condenser coil shall be furnished to main- tain the relative humidity of the air in the pump chamber low enough to keep the electrical equipment dry and to prevent condensation on the walls. The moisture removing capability of the dehumidifier will vary with the temp- erature and relative humidity within the station. The capacity at 800 F. and 90% relative humidity shall be 21 pints per day. The dehumidifier shall be con- trolled automatically by an adjustable humidistat and low air temperature cut- out with contacts of adequate capacity for the dehumidifier motor. The dehumidifier shall be housed in a heavy, steel enclosure behind the ladder. The condensate shall be drained to the sump. Fresh air shall be drawn into the pump chamber through an air -inlet vent line which forms the right side rail of the ladder. A ventilating blower, mounted on the left ladder rail shall draw air from the station 18" above the floor and shall discharge it through the vent line forming the left side rail of the ladder. The squirrel -cage, high -efficiency, type blower shall be controlled by a 10 -minute cycle timer with a range of 0 to, 100% so as to provide essentially continuous ventilation without exceeding the capabilities of the dehumidifier. When the entrance cover is raised, the lights and ventilating blower shall be turnedon automaticallyby a springoperated entrance switchmounted justunder the cover. A manual switch shall be mounted in the side of the duct just below the spring operated switch for operation of the lights and ventilating blower with the cover closed. The steel vent lines shall have suitable covers to prevent the entrance of rain or snow and screened openings to prevent the entrance of rocks or other foreign matter. LIGHTING Adequate lighting, consisting of a twin 20watt fluorescent lamp fixture shall be provided for the convenience and safety of the operator. The lighting shall pro- vide illumination for all areas in the station. The lighting shall be controlled by the spring -operated entrance switch and a manual switch located at the top of the personnel entrance tube. The spring -operated switch shall turn the lights on automatically when the entrance lid is raised. The manual switch shall main- tain the lighting circuit when the lid is closed in inclement weather. SUMP PUMP A submersible sump pump with close -coupled, verticalmotor shall be installed in the sump. It shall have a minimum capacity of 1000 GPH at design head. The design head this pump will operate against is the static head from the sump to 3' below grade, plus allowance for pipe frictionboth inside and outside the pump chamber. A mechanical seal on the shaft shall exclude water from the motor housing. The sump pump shall be controlled automatically by a built-in float switch, capable of operation on a 5" differential. It shall discharge into the wet well through a 1-1/411 galvanized steel pipe, with two check valves and a gate valve within the sump chamber. An enclosure of 1/4" galvanized steel mesh shall surround the sump and the sump pump to keep out debris. PIPING Pump suction lines shall be (4") , Class 150, cast iron pipe with mechanical joint bell outside the pump chamber and with bronze -fitted, double -disc gate valve inside the chamber. The discharge line from each pump shall be fitted with a bronze -fitted check valve and a (41.') bronze -fitted, double -disc. gate valve. The check valve shall be of the spring-loaded lever type so that the clapper can be lifted to backflush the pump and suction line. The check valves shall have stainless steel shafts with double "O" rings and grease fittings at both ends where the shaft passes through the body of the valve. The common discharge pipe and the discharge outlet shall be (4") , Class 150, cast iron pipe with a mechanical joint bell just outside the pump chamber. The air bubbler line furnished by the station Manufacturer in the station shall be 1/211 nominal tubing, terminating in a fitting in the entrance tube to accept the 3/4" piping extending to the wet well. An angle bracket shall be welded to the outside of the chamber, just over the bubbler line connection, to receive a 3" x 3" x 1/4" angle brace to protect the ,bubbler line. A return loop in the bubbler line shall be provided to protect the station from flooding and a valve shall be provided to bleed off condensate accumulation in the air -bubbler system. All steel pipe in contact with the soil or with the sewage shall be field -coated with one coat of "Versapox" epoxy resin after installation. WIRING The pump station shall be completely wired at the factory, except for the power feeder lines. All wiring in the pump station shall be color -coded as indicated on the wiring diagram. All wiring outside the panel shall be in conduit, except for 115 volt accessory items which are provided with connecting insulated service cord by the Manufacturer. The Manufacturer shall provide conduit from the control panel across the ceiling, and up the entrance tube to receive the feeder lines. The conduit shall terminate in a threaded conduit connection through the wall of the entrance tube above ground level. Accessory items such as the sump pump, dehumidifier and air compressor shall be plugged into polarized, grounded convenience outlets, located close to their 'installed position so that such items can be readily removed and .serviced if necessary. FACTORY TESTS All components of the pump station shall be given an operational test of all equip- ment at the factory to check for excessive vibration, for leaks in all piping or seals and for correct operation of the automatic control system and all auxiliary equipment. The pump suction and discharge lines shall be coupled to a reservoir and the pumps shall recirculate water for at least one hour under simulated service conditions. The automatic control shall be adjusted to start and stop. the pumps at approximately the levels required by the job conditions.. SPARE PARTS A complete replacement pump shaft seal assembly shall be furnishedwith each, lift station. - The spare seal shall be securely fastened to the control panel and shall include complete installation instructions. A spare volute gasket shall be. provided. A spare filter cone for the seal filter shall also be provided, in the. same container as the pump shaft seal. INSTALLATION AND OPERATING INSTRUCTIONS .r Installation of the pump chamber, entrance tube and related appurtenences shall, be done in accordance with written instructions provided by the Manufacturer. . These instructions shall be securely attached to and readily visible -on the out- side of the main chamber of the pump station. A convenient Maintenance and Operating Instruction Chart and Daily Maintenance Inspection Record Chart, with ample 'room for recording daily inspections of the pump station, shall be securely ;nounted on the interior wall,of the main pump chamber. In addition to the Maintenance and Operating Chart, the Manufacturer shall further provide a complete and detailed Operating and Maintenance Manual. This Manual shall cover, in addition to general operating procedures, the oper- ation, maintenance and servicing procedures of the major individual components provided with the pump station. This Manual shall be shipped with the pump station. The Manufacturer shall further provide the services of a factory -trained repre- sentative for a maximum period of one day to perform initial start-up of the pump station and to instruct the owner's operating personnel in the operation and .maintenance of the equipment provided by them. EXPERIENCE AND WORILMANSHIP The pump station shall be the product of a Manufacturer with a minimum of five years of experience in the design and building of such automatic, factory -built, underground pump stations and all workmanship and materials throughout shall be of the highest quality. MANUFACTURED EQUIPMENT In these specifications and on accompanying drawings there are specified and shown certain equipment and materials most suitable for the service anticipated. This is not done, however, to eliminate others equally as good and efficient. The contractor shall prepare his bid on the basis of the particular equipment and materials specified for the purposes of determining the low bid. Any substitution of makes other than those named inthe specifications will be considered for one reason only: That the equipment proposed for substitution is superior or equal in construction and/or efficiency to that named in the specifications and that high quality has been demonstrated by at least five years of service in similar installations. If prior to the execution of the contract the engineer's approval is obtained for alternate equipment the contractor shall, at his own expense, make any changes in the structures, building, piping or electrical necessary to accommodate the equipme.zt and if engineering is required due to substitution of other material the contractor shall pay the engineer for the engineering service. It will be assumed that the cost to the contractor of the equipment proposed to be substituted is less than the equipment named in the specifications and if the substitution is approved, the contractor's bid price chall be reduced by an amount equal to the net servings. x' Substitution of equipment other than that specified and shown will not be con- sidered after the execution of the contract. GUARANTEE The Manufacturer of the lift station shall guarantee for one year from date of shipment that the structure and all equipment will be free from defects in de- sign, material and workmanship. Warranties and guarantees by the suppliers of various components in lieu of a single source responsibility by the Manufacturer will not be accepted. The Manufacturer shall assume prime responsibility for the guarantee of the station and all components. In the event a component fails to perform as specified or is proven defective in service during the guarantee period, the Manufacturer shall provide a replace- ment part without cost to the owner. He shall further provide, without cost, such labor as may be required to replace, repair or modify major components. such as the station structure, pumps, pump motors, sewage piping manifold, etc. After start-up service has beenperformed, the labor to replace accessory items, such as dehumidifier, sump pump, alternator, etc., shall be the re- sponsibility of others. The replacement or repair (including cost of parts and labor) of those, items normally consumed in service, such as pump seals, fluorescent tubes, oil grease, etc. , shall be considered as part of routine maintenance and station upkeep. It is not intended that the Manufacturer assume responsibility for contingent liabilities or consequential damages of any nature resulting from defects in de- sign, material, workmanship or delays in delivery, replacement or otherwise. ALARM SYSTEMS High Wetwell Level - An adjustable mercury tube type, pressure switch shall be provided to sense a high water level condition. The switch shall be connected to the bubbler line and shall activate a contact to indicate the high water condition. A waterproof bracket fixture for -100 watt lamp shall be supplied. The fixture shall be'provided with a red enclosing glass globe and a metal globe guard and shall be suitable for operation with 115 V AC power. ELECTRIC HEATER A 1320 X 1650 watt, dual range, electric heater with automatic recirculating fan, thermostat control and an on-off control switch to be provided. The heater is to operate from the AC outlet in the control panel. Suburban Engineering, Inc. ,%ain Office 6875 Sighway 5%. 65 A E. ,51finneapolis, %innesota 55439 78µ•6o66 &Ut4 Office aos CW est gutnsville Ctosstown gutnsville, ainnesota 55378 8go-65so GEORGETOWN COURT PHASE III Lift Station Design GPM [4][42][2.5][100][400%]/24.60 = 117 GPM Wet well - maximum 10 min avg flow (4)(42)(2.5)(100) = 3.9 cfm 24 60 7.48 10 min @ 3.9 = 39 ft3 Jlssocfates .Ilobett .511indev, Neq. Engt. Wn. C. c7ensen, -(Reg. Eng'. -Btuee A 2atetson, -'Reg. f ngt. C. A. (-Bud) JqZathbun, YZeg. Sutveyot Civil & -Tunicipal eingineeting Rand Sutveyots -L�nd banning 'Soil Besting use 120 GPM 2 x 5= 12.5+.8 x 5= 33 cu.ft. Invert wet well = 821.04 - 5.0 = 816.04 T.D.H. Total Lift = 833.36 - 816.04 = 17.32 Dynamic losses 4" gate valve 3.4' 4" check valve 28.0 wye (450) 2.2 1 - 220 2.2 F.M. 4" CIP 350.0 385.8 l.f. 120 G.P.M. in 4" CIP hl = 18'/1000', 386", = 7.0 24.3 H.P. = 120 24.5 = 1.5 3960 °50 Use 2 H.P. that this is a duP13cate referred to In a Per^ it cool of the 9 3-1ttl3 piitiT a to Ar action from for ccn�•' ?ottution O C.� N r371 Q ' BODY OF SPECS REPRODUCED BY PERMISSION OF FADDEN PUMP CO. . °°pr it the _{„y that taxa I. for ccs:,.yctrpfa^a rofe red to`_je.dupn . polluhdq qn rr°ri tt.,4 a Permit Ag en^yIttcs . .00T2 ` SPECIFICATIONS ' FACTORY -BUILT PUMPING STATION GENERAL ' The contractor shall furnish and install one "Econo-Flo” factory -built, automatic pumping station as manufactured by Smith & Loveless, Division -Union Tank Car. .Company, Lenexa, Kansas. The station shall be complete with all needed equip ' ment factory -installed in a welded steel chamber withwelded steel entrance tube and with ladder to provide access. ' The principal items of equipment shall include two vertical, line mounted, motor driven, non -clog sewage pumps; valves; internal piping; central control panel with circuit breakers; motor starters and automatic pumping level controls; ' lighting; sump pump; ventilator; dehumidifier and all internal wiring. ' OPERATING CONDITIONS Each pump shall be capable of delivering 120 GPM. of raw, unscreened sewage against a total dynamic head of 24.5 feet. The maximum allowable '• speed shall be 1170 RPM. The minimum rated horsepower of each pump motor shall be 2 H. P. . ' All openings andpassages shall be large enough topermit the passage of a sphere 3" in diameter and any trash or stringy material which can pass. through a 4" ' house collection system. The anticipated operating head range is from 20.0 feet minimum to 25.0 feet maximum. ' PUMP CHAMBER The station shall be built by the. Manufacturer in two major sections, consisting ' of the pump chamber and the required section (s) of entrance tube, for ease in shipment and. handling. These . sections shall be joined at the job site-bywelding. r ' The field joint shall then be cleaned and heavily coated with "Versapox" epoxy resin, provided by the Manufacturer. The pump chamber shall contain allpumps and other equipment and shall be a vertical cylinder of circular cross-section with shell of ASTM A-36 steel plate, and nominal outside diameter of 6'6". The top and the bottom of the station shall be ASTM 283 Grade C steel flanged and dished heads welded to the station..shell. The exterior of the station shall be designed so that all welds exposed to ground water after installation are continuous throughout their length so that water cannot ' seep between uncoated steel surfaces and cause corrosion. In addition, the structure shall be designed so that sharp corners and similar difficult to coat conditions are held to an absolute minimum. The thickness of the steel cylinder and of the domed heads shall be determined by the structural requirements for the depth of buryinvolvedand shall be a minimum of 3/16" unless heavier steel is required due to depth of bury. It shall be the re spons ibility of the manufacturer ' to determine the structural requirements of the shell based on the external loads specified on the plans. ' Lifting eyes adequate to support the entire weight of the completed chamber shall be provided and welded to the station head. Tie down loops for anchoring the ' station to the slab shall be provided on the bottom of the station and additional tie down loops shall be provided for anchoring the discharge line at the point it leaves the station. Lifting loops shall also be located on the ceiling of the pump 'station over each pump at an adequate height to permit a hoist to be used for pump ,r disassembly. ' A 20" diameter by 8" deep sump with walls of 3/161, structural -grade steel plate shall be provided in the center of the station. Where the cast iron suction and discharge lines pass through the station walls, they shall be reinforced with 3/16" thick steel sleeves, welded inside and out to the station wall. The space between the cast iron pipes and the steel sleeves shall be packed tight with Portland Cement grout containing Embecco aggregate to prevent leakage. ' ENTRANCE TUBE ' The entrance tube shall be provided in one or more sections as required and shall be a 36" diameter vertical cylinder of ASTM A-36 structural grade steel plate. The length shall be adequate to place the cover above the surrounding ground and ' any anticipated local flooding. The entrance tube shall be adequately stiffened and the field joints arranged so that the joint may be welded from the outside of the tube with all welding being performed in a down -hand position. The ' bottom of the tube shall be attached to an angle, shop welded, to the head of the pump station. This field joint shall also be weldable in the down -hand position. Two lifting loops shall be provided on each section of e4trance tube for handling and installation. The entrance tube cover shall be of fiberglass reinforcedplastic and shall have a reflective color to reduce heat absorption. The cover shall have a suitable drip lip around the edge and shall be provided with a weather-proof lock of the pin tumbler type which can be opene(a ;rom the inside without a key. The lock shall be self locking upon slammii,j; the lid. The fiberglass cover shall be fastened to a steel ladder having two rungs which form an extension of the access ladder when the cover is latched in the open position. The steel ladder shall act as the cover hinge and a latch mechanism shall be provided to keep the cover open under any normal load. A continuous -mold neoprene gasket shall be pro- vided on the top of the tube to seal the cover and protect the top edge of the entrance tube. The access ladder shall have rungs of 1" outside diameter aluminumtube spaced on 12" centers. The side rails of the ladder shall be 3" x 4" rectangular steel tubingwhich shall also serve as air ducts for the station ventilation system. The. ladder rungs shall be installed between the,side rails so that the support of the operator is not dependent upon a weld in shear. The ladder section in the entrance tube shall be lined up accurately with the ' section in the pump chamber by self -aligning projections. Neoprene rubber sleeves shall be provided to seal the joint between the adjoining vent sections. WELDING All steel in the station structure shall be joined by electric arc welding with fillets of adequate section for the joint involved. All welds on the exterior of the station shall be 'continuous welds through their length and shall prevent the ' entry of water between uncoated steel surfaces or into the station. PROTECTION AGAINST CORROSION ' After welding, all inside and outside surfaces of the structure shall be blasted with steel grit, to remove rust, mill scale, weld slag, etc. All weld spatter and ' surface roughness shallbe removed by grinding. Immediately following cleaning, a single heavy inert coating shall be factory` applied to all inside and outside surfaces prior to shipment. This coating shall be of "Versapox" epoxy resin, especially formulated by Smith & Loveless for abrasion and corrosion resistance. The dry coating shall contain a minimum of 85% epoxy resin with the balance being pigments and thixotropic agents. ' A touch-up kit shall be provided for repair of any mars or scratches occuring during installation. This kit shall contain detailed instructions for use and shall ' be a material which is compatible with the original- coating. ; The touch-up coating shall contain a minimum of 85%epoxy resin. Two 17 -pound magnesium ' anode packs shall be provided for cathodic protection. The anode packs shall be provided with minimum 6' long insulated copper leads. Copper lugs shall be provided by the Manufacturer on opposite sides of the station for anode con- nections. A heavy synthetic rubber mat shall be cemented to the station floor plates to protect the steel floor from abrasion. ' PUMPS The pumps shall be vertical line mounted "Non -Clog" sewage pumps of heavy ' cast iron construction especially designed for the use of mechanical seals. In' ` order to minimize seal wear caused by lineal movement of the shaft, the shaft bearing nearest the pump impeller shall be locked in place so that thermal ' ex- pansion of the shaft is held to a minimum and so that end play is limited to the clearance within the bearing. To minimize seal wear resulting from shaft de- flection in the mechanical seal caused by the radial thrust at the cutwater of the pump, the shaft shall be a minimum of 1-7/8" diameter from the top of the im- peller through the pump or motor bearings supporting the impeller. The di- mension from the lowest bearing to the top of the impeller shall not exceed 6". The bearing nearest the impeller shall be designed for the combined thrust and ' radial load for a B-10 life of 8800 hours when the pump is operating continuously at a flow rate of 100 gallons per minute at the total dynamic head developable by the impeller which will meet the operating conditions given inthese specifications. ' The upper bearing shall be free to move lineallywith the thermal expansion of the - shaft and shall be designed for radial load only and for a B-10 life of 8800 hours. In calculating bearing life, no credit shall be assumed for the use of vacuum de- gassed steel. The shaft shall be a solid one piece stainless steel shaft through the pump and ' both bearings to eliminate corrosion within the pump or the mechanical seal. Removable shaft sleeves will not be acceptable unless the solid shaft under the sleeve meets the specified minimum diameter. TheP impeller P uieller shall be of the enclosed type made of close -grained cast iron and shall be balanced. The impeller shall be keyed and secured to the motor - rpump shaft by a stainless steel cap screw equipped with a "Nylock" or other suitable self-locking device. The impeller shallnot be screwed or pinned tothe ' motor -pump shaft and shall be readily removable without the use of special tools. To prevent the buildup of stringy materials, grit and other foreign particles around the pump shaft, all impellers less than full diameter shall be trimmed inside the impeller shroud. The shroud shall remain full diameter so that close, minimum clearance from shroud to volute is maintained. Both the end of the shaft and the bore of the impeller shall be tapered to permit easy removal of the impeller from the shaft. The pump shaft shall be sealed against leakage by a double mechanical seal, ,r installed in a bronze seal housing constructed in two sections with registered fit. The housing shall be recessed into the pump backhead and securely fastened thereto with stainless steel cap screws. The inside of the seal housing shall be tapered to facilitate the replacement of the seal parts. The seal shall be of double carbon and ceramic construction, with the mating surfaces lapped to a flatness tolerance of one light band. The rotating ceramics shall be held in mating position with the stationary carbons by a stainless steel spring. The seal housing, with assembled parts, shall be so constructed as to be readily removable from the shaft as a unit and shall be provided with tapped jack -screw openings to assist in removing it from the backhead. The seal shall be pressurized and lubricated by water taken directly from the pump backhead through a filter to the seal housing and introduced between the upper and lower sealing surfaces. The filters shall be of corrosion resistant materials and shall screen out all solids larger than 50 microns. The seal system shall contain a brass valve connected near the top of the seal housing to permit the relief of any .air trapped in the seal unit. A manually operated brass valve shall also be provided to vent the pump volute. The pump shall be supported by fabricated steel brackets welded to the bottom head and bolted to the pump suction and discharge nozzle flanges. The height shall be sufficient to permit the use of an increasing suction elbow which shall be provided when the nominal pump size is smaller than the suction line. The suction and discharge openings shall be flanged, faced and drilled 125 -pound ' American Standard. MOTORS The pump motors shall be specially built NEMA P base, open drip -proof in- duction type, suitable for 3 phase, 60 cycle, 220 volt electric current. They shall have normal starting torque and low -starting -current, as specified for NEMA Design B characteristics. The motors shall not be over- loaded at the design condition, nor at any head in the operating range as specified ' under "Operating Conditions. " The motor shall befitted with heavy lifting eyes, each capable of supporting the entire weight of the pump and motor. A special varnish treatment shall be applied to the stator windings and rust pre- ventative compounds shall be used to coat the rotor and stator air gap surfaces and protect the .motor against corrosion. ' �CnNTR(�T. 1 The control equipment shall be mounted in a NEMA Type 1 steel dead front enclosure. The enclosure shall have a hinged door on which shall be mounted r the thermostat, humidistat and blower timer. 1 The circuit breakers, overload reset buttons, and control switches shall be operable without opening the door. The pressure switches shall be mounted on the side of the control and shall be adjustable without removing the cover. A grounding type convenience duplex 1 outlet shall be provided for operation of 115 volt A. C. auxiliary devices. 1 Thermal magnetic air circuit breakers shall be provided for branch disconnect service and short circuit protection of all motor control, and auxiliary circuits. Magnetic across -the - line starters with under -voltage release and overload coils .for each phase shall be provided for each pumpmotor to give positive protection 1 against single phasing. Each single phase auxiliary motor shall be equipped with an over -current protection device, in addition to its branch circuit breaker ' or shall be impedance protected. All switches shall be labeled and a color - coded wiring diagram shall be provided. 1 To control the operation of the pumps with variations of sewage level in the wet well, an air -bubbler system shall be provided, complete with two air com- pressors, flow indicator, bubbler line to the wet well and a sensitive pressure 1 switch for each pump. The two air compressors shall be of the close -coupled, oil -less type. Each 1 compressor shall have a minimum capacity of 0. 2 cubic feet of free air per minute at 10 p. s. i. It shall incorporate a single, phase, 60 cycle, 115 volt drip -proof, brushless type, electric motor. The air compressors will alternate simultaneously with the alternation of the pumps. The pressure switches shall be of the mercury -tube type, with sensitive pressure elements and independent high and low adjustments for each pump capable of a minimum differential of 1 18" of water. Al, automatic alternator with manual ."ON-OFF" switch shall be provided to 1 change the sequence of operation of the pumps on the completion of each pumping cycle. Provisions shall also be made for the pumps to operate in parallel, should the level in the wet well continue to rise above the starting level for the 1 low-level pump. For the convenience of the operator and service man and to contribute to the 1 cleanliness of the station, a chrome -plated, drawer type ash tray shall be fur- nished at the bottom of the control panel, and a polyethylene trash container shall be provided. 1 1 ' DEHUMIDIFIER AND VENTILATING BLOWER ' A dehumidifier assembly with hermetically sealed Freon refrigeration type compressor, expansion coil, fan and condenser coil shall be furnished to main- tain the relative humidity of the air in the pump chamber low enough to keep jthe electrical equipment dry and to prevent condensation on the walls. The moisture removing capability of the dehumidifier will vary with the temp- erature and relative humidity within the station. The capacity at 800F. and 90% relative humidity shall be 21 pints per day. The dehumidifier shall be con- trolled automatically by an adjustable humidistat and low air temperature cut- out with contacts of adequate capacity for the dehumidifier motor. The dehumidifier shall be housed in a heavy, steel enclosure behind the ladder. The condensate shall be drained to the sump. Fresh air shall be drawn into the pump chamber through an air -inlet vent line which forms the right side rail of the ladder. A ventilating blower, mounted on the left ladder rail shall draw air from the station 18" above the floor and shall discharge it through the vent line forming the left side rail of the ladder. The squirrel -cage, high -efficiency, type blower shall be controlled by a 10 -minute cycle timer with a range of 0 to 10076 so as to provide essentially continuous ventilation without exceeding the capabilities of the dehumidifier. When the entrance cover is raised, the lights and ventilating blower shall be turned on automaticallyby a spring operated entrance switch mounted justunder the cover. A manual switch shall be mounted in the side of the duct just below the spring operated switchfor operation of the lights and ventilating blower with the cover closed. The steel vent lines shall have suitable covers toprevent the entrance of rain or snow and screened openings to prevent the entrance of rocks ' or other foreign matter. LIGHTING Adequate lighting, consisting of a twin 20watt fluorescent lamp fixture shall be provided for the convenience and safety of the operator. The lighting shall pro ' vide illumination for all areas in the station. The lighting shall be controlled by the spring -operated entrance switch and a manual switch located at the top of the 1 personnel entrance tube. The spring -operated switch shall turn the lights on automatically when the entrance lid is raised. The manual switch shall main- tain the .lighting circuit when the lid is closed in inclement weather. SUMP PUMP A submersible sump pump with close -coupled, verticalmotor shall be installed in the sump. It shall have a minimum capacity of 1000 GPH at design head. The design head this pump will operate against is the static head from the sump to 3' below grade, plus allowance for pipe frictionboth inside and outside the pump chamber. A mechanical seal on the shaft shall exclude water from the motor ' housing. The sump pump shall be controlled automatically by a built-in float switch, t capable of operation on a 5" differential. It shall discharge into the wet well through a 1-1/411 galvanized steel pipe, with two check valves and a gate valve within the sump chamber. An enclosure of 1/411 galvanized steel mesh shall surround the sump and the sump pump to keep out debris. PIPING ' Pump suction lines shall be (4") Class 150, cast iron pipe with mechanical joint bell outside the pump chamber and with bronze -fitted, double -disc gate valve inside the chamber. The discharge line from each pump shall be fitted with a bronze -fitted check valve and a (4!') bronze -fitted, double -disc. gate valve. ' The check valve shall be of the spring-loaded lever type so that the clapper can be lifted to backflush the pump and suction line. The check valves shall have ' stainless steel shafts with double "O" rings and grease fittings at both ends where the shaft pas s e s through the body of the valve. The common di s charge pipe and the discharge outlet shall be (4") , Class 150, cast iron pipe with a mechanical . joint bell just outside the pump chamber. ' The air bubbler line furnished by the station Manufacturer in the station shall be 1/211 nominal tubing, terminating in a fitting in the entrance tube to accept the 3/4" piping extending to the wet well. An angle bracket shall be welded to the ' outside of the chamber, just over the bubbler line connection, to receive a 3" x 3" x 1/4" angle brace to protect the ,bubbler line. A return loop in the bubbler ` line shall be provided to protect the station from flooding and a valve shall be ' provided to bleed off condensate accumulation in the air -bubbler system. All steel pipe in contact with the soil or with the sewage shall be field -coated with one coat of "Versapox" epoxy resin after installation. ' WIRING The pump station shall be completelywired at the factory, except for the power feeder lines. All wiring in the pump station shall be color -coded as indicated e on the wiring diagram. All wiring outside the panel shall be in conduit, except for 115 volt accessory items which are provided with connecting insulated service ' cord by the Manufacturer. The Manufacturer shall provide conduit from the control panel across the ceiling, and up the entrance tube to receive the feeder lines. The conduit shall terminate in a threaded conduit connection through the ' wall of the entrance tube above ground level. Accessory items such as the sump pump, dehumidifier and air compressor shall ' be plugged into polarized, grounded convenience outlets, located close to their 'installed position so that such items can be readily removed and serviced if necessary. FACTORY TESTS All components of the pump station shall be given an operational test of all equip- ment at the factory to check for excessive vibration, for leaks in all piping or seals and for correct operation of the automatic control system and all auxiliary equipment. The pump suction and discharge lines shall be coupled to a reservoir and the pumps shall recirculate water for at least. one hour under simulated service conditions. The automatic control shall be adjusted to start and stop. the pumps at approximately the levels required by the job conditions. ' SPARE PARTS A complete replacement pump shaft seal assembly shall be furnishedwith each ' lift station. • The spare seal shall be securely fastened to the control panel and shall include complete installation instructions. A spare volute gasket shall be. provided. A spare filter cone for the seal filter shall also be provided, in the: ' same container as the pump shaft seal. i INSTALLATION AND OPERATING INSTRUCTIONS Installation of the pump chamber, entrance tube and related appurtenences shall. be done in accordance with written instructions provided by the Manufacturer. These instructions shall be securely attached to and readily visible.on the out- side of the main chamber of the pump station. ' A convenient Maintenance and Operating Instruction Chart and Daily Maintenance Inspection Record Chart,'with ample room for recording daily inspections of the pump station, shall be securely mounted on theinterior wall. of the. main pump ' chamber. In addition to the Maintenance and Operating Chart, the Manufacturer shall ' further provide a complete and detailed Operating and Maintenance Manual. This Manual shall cover, in addition to general operating procedures, the oper- ation, maintenance and servicing procedures of the major individual components provided with the pump station. This Manual shall be shipped with the pump station. ' . The Manufacturer shall further provide the services of a factory -trained repre- sentative for a maximum period of one day to perform initial start-up of the pump station and to instruct the owner's operating personnel" in the operation ' and maintenance of the equipment provided by them. EXPERIENCE AND WORKMANSHIP ' The um station shall be the productof a Manufacturer with a minimum of five' *pump P, years of experience in the design and building of such automatic, factory -built, runderground pump stations and all workmanship and materials throughout shall be of the highest quality. ' MANUFACTURED EQUIPMENT ' In these specifications and on accompanying drawings there are specified and shown certain equipment and materials most suitable for the service anticipated. This is not done, however, to eliminate others equally as good and efficient. The ' contractor shall prepare his bid on the basis of the particular equipment and materials specified for the purposes of determining the low bid. Any substitution of makes other than those named .in the specifications will be considered for one reason only; That the equipment proposed for substitution is superior or equal in construction and/or efficiency to that named in the specifications and that high quality has been demonstrated by at least five years of service in similar I installations. If prior to the execution of the contract the engineer's approval is obtained for ' alternate equipment the contractor shall, at his own expense, make any changes in the structures, building, piping or electrical necessary to accommodate the equipment and if engineering is required due to substitution of other material ' the contractor shall pay the engineer for the engineering service. It will be assumed that the cost to the contractor of the equipment proposed to' ' be substituted is less than the equipment named in the specifications and if the substitution is approved, the contractor's bid price shall be reduced by an amount equal to the net sAvings. + ' Substitution of equipment other than that specified and shown will not be con- ' .' sidered after the execution of the contract. ' GUARANTEE The Manufacturer of the lift station shall guarantee for one year from date of shipment that the structure and all equipment will be free from defects in de- sign, material and workmanship. ' Warranties and guarantees by the suppliers of various components in lieu of a single source responsibility by the Manufacturer will not be accepted. The Manufacturer shall assume prime responsibility for the guarantee of the station and all components. In the event a component fails to perform as specified or is proven defective in service during the guarantee period, the Manufacturer shall provide a replace- ment part without cost to the owner. He shall further provide, without cost, such labor as may be required to replace, repair or modify major components. ' such as the station structure, pumps, pump motors, sewage piping manifold, etc. After start-up service has been performed, the labor to replace accessory items, such as dehumidifier, sump pump, alternator, etc., shall be the re- sponsibility of others. The replacement or repair (including cost of parts and labor) of those. items normally consumed in service, such as pump seals, fluorescent tubes, oil grease, etc. , shall be considered as part of routine maintenance and station upkeep. ' It is not intended that the Manufacturer assume responsibility for contingent liabilities or consequential damages of any nature resulting from defects in de- sign, material, workmanship or delays in delivery, replacement or otherwise. ALARM SYSTEMS 1 High Wetwell Level - An adjustable mercury tube type, pressure switch shall be provided to sense a high water level condition. The switch ' shall be connected to the bubbler line and shall activate a contact to indicate the high water condition. A waterproof bracket fixture for -100 watt lamp shall be supplied. The ' fixture shall be'provided with a red enclosing glass globe and a metal globe guard and shall be suitable for operation with 115 V AC power. ' ELECTRIC HEATER A 1320 X 1650 watt, dual range, electric heater with automatic ' pecirculating fan, thermostat control and an on-off control switch to be provided. The heater is to operate from the AC outlet in the control panel.