Diaphragm Metering Pumps

PUMPING EQUIPMENT: DIAPHRAGM METERING PUMPS

PART 1 - GENERAL

1.1      SUMMARY

A.   The CONTRACTOR shall furnish and install chemical feed diaphragm pumps and necessary appurtenances as shown on the Drawings and specified herein, including speed and stroke controls, calibration cylinders, back pressure valves and pulsation dampeners for complete operation.

1.2      RELATED SECTIONS

A.   The Work  of  the  following Section applies to  the  Work  of  this  Section.    Other Sections, not referenced below, shall also apply to the extent required for proper performance of this Work.

1.3      CONTRACTOR SUBMITTALS

A.   Shop  Drawings:     The  CONTRACTOR  shall  submit  shop  drawings  showing fabrication, assembly, foundation, and installation details, along with detailed specifications   and   data   covering   materials   of   construction,   devices,   and   other accessories forming a part of the equipment.  The shop drawings shall be provided in accordance with this Section and the requirements of Section 11005, Equipment:  Basic Requirements, and Section 11210, Pumps, General.

B.   Documentation:  The CONTRACTOR shall submit documentation that all equipment and piping is compatible with chemical in service.

C.  Diaphragm Metering Pumps:  For diaphragm metering pumps, the CONTRACTOR shall submit capacity, discharge pressure, HP and data on assembly, anchor bolts, and mounting.   The CONTRACTOR shall provide data on variable speed drives that shall include catalogue cuts on all drive equipment, controls, accessories, and wiring requirements.

D.  Motors:   For motor driven equipment, the CONTRACTOR shall submit motor data meeting the requirements of Section 16220, Electric Motors.

E.   Instrumentation:  For instrumentation associated with chemical feed equipment, the
CONTRACTOR shall submit catalogue cuts, wiring diagrams, and equipment data.

F.   Instructions:    The  CONTRACTOR shall  provide  field  assembly,  installation  and operation and maintenance instructions in conformance with Section 11005, Equipment: Basic Requirements.

1.4      QUALITY ASSURANCE

A.   All equipment furnished shall be new and of best quality entirely suitable for the purpose intended.

1.5      WARRANTY

A.   The metering pump drive train, including gear reducer, transmission, hydraulic make- up system, and housing and all components specified in this Section shall be warranted by the manufacturer for a minimum five (5) year period after beneficial occupancy of the Work pursuant to “Use Prior to Final Completion” of the General Conditions, against defects in workmanship and materials.    Other components shall have a one (1) year warranty period after beneficial occupancy.

PART 2 - PRODUCTS

2.1      DIAPHRAGM METERING PUMPS

A.   General:  The metering pumps shall be hydraulically balanced diaphragm type with non-loss motion drive. The drive motor shall actuate a flat, Teflon diaphragm. The liquid ends shall provide for easy maintenance. The feed pumps shall be capable of feeding the indicated fluid of service from the corresponding storage tank to the injection point as shown on the Drawings.

B.   Pump Features:
1.   Pumps shall accept readily available "off-the-shelf" NEMA 56C flange motor in accordance with requirements of Section 11005, Equipment: Basic Requirements.
2.   Capacity adjustment shall be 0 to 100 percent by calibrated external stroke adjustment accurate to  approximately 1  percent  which shall show stroke length setting.
3.   Valves shall be flange-mounted or union coupled to permit easy access for cleaning and  service so  that  piping  does  not  have  to  be  disconnected.   Valve chambers shall be such that individual components can be replaced rather than entire assemblies.
4.   Pumps shall have a manual stroke adjustment from 0 to 100 percent that can be accomplished while idle or operating. An auto-lock for the manual stroke adjustment shall be provided.
5.   The drive mechanism and gearing shall be of hardened and ground steel and bronze. Gear box shall be water resistant. Plastic gear boxes will not be acceptable.
6.   Pumps shall be able to operate dry indefinitely without damage.
7.   All pumps, fittings, gear boxes, etc. shall be chemical and corrosion resistant.
8.   A relief valve shall be provided, which, in the event of discharge line stoppage, shall recycle hydraulic fluid back to the reservoir.
9.   At a constant motor speed, the metering pumps shall feed within plus or minus 1 percent of the set rate throughout a 10:1 feed range. The repeatability of the set point shall be within plus or minus 1 percent of actual.
10. Pulsation dampeners shall be provided.
11. Pump head shall have gravity seated ball-type check valves on the inlet and outlet sides. Valve ball shall be ceramic with PTFE seats. Spring loaded check valves are not acceptable. Valves and seat shall be individually replaceable and sealed with PTFE O-ring or flat gasket.

C.  Pump Quality:   All pumping equipment furnished under this Section including the variable speed drives shall be of a design and manufacture of:
1.   MilRoyal by Milton Roy.
2.   Pulsar by Pulsafeeder.
3.   Or Equal.

D.  Sodium Hypochlorite Feed Pump

1.   Design Conditions:

a.   Tag  Numbers:    XXXXX
b.   Capacity (gallons/hour): 12
c.   Minimum Flowrate (gallons/hour): 4
d.   Operating Backpressure (pounds per inch): 50
e.   Maximum Backpressure (pounds per inch): 150 f.    Fluid: Sodium Hypochlorite 12.5 percent
g.   Wetted Parts: PVDF
h.   Diaphragm: PTFE
i.    Inlet/Outlet Size NPT: 1 inch ID

2.   Pump Requirements:

a.   Pump shall be equipped with auto-degassing device to prevent gas locking the pump. Degassing device shall be integral to pump and supplied by pump manufacturer.
b.   Pump shall be equipped with leak detection to detect diaphragm failure. Leak detection shall be by the original pump manufacturer.
c.   All wetted parts, O-rings and seals shall Teflon.

E.   Sodium Hydroxide Feed Pump:

1.   Design Conditions:

a.   Tag  Numbers:     XXXXX
b.   Capacity (gallons/hour): 5
c.   Minimum Flow rate (gallons/hour): 0.5
d.   Operating Backpressure (pounds per inch): 50
e.   Maximum Backpressure: 150
f.    Fluid: Sodium Hydroxide 25 percent
g.   Wetted Parts: CPVC or PVDF
h.   Diaphragm: PTFE
i.    Inlet/Outlet Size NPT: 1 inch ID

2.   Pump Requirements:

a.   Pump shall be equipped with leak detection to detect diaphragm failure. Leak detection shall be by the original pump manufacturer.
b.   All wetted parts, O-rings and seals shall be Teflon.

F.   Sulfuric Acid Feed Pump:

1.   Design Conditions:

a.   Tag Numbers: XXXXXX
b.   Capacity (gallons/hour): 12
c.   Minimum Flowrate (gallons/hour): 0.3
d.   Operating Backpressure (pounds per inch): 50
e.   Maximum Backpressure (pounds per inch): 150
f.    Fluid: Sulfuric Acid 93 to 98 percent
g.   Wetted Parts: PVDF or PTFE
h.   Diaphragm: PTFE
i.    Inlet/Outlet Size NPT: 1 inch ID

2.   Pump Requirements:

a.   Pump shall be equipped with leak detection to detect diaphragm failure. Leak detection shall be by the original pump manufacturer.

b.   All wetted parts, O-rings and seals shall be Teflon.

G.  Pump Controls:
1.   Metering pumps shall  be  controlled as  described in  Section  17300,  Control Strategies and as shown on the P&IDs. Failure of the duty pump shall close a set of contacts and actuate alarms. The speed of  the feed pumps shall be controlled through speed indicating controllers and shall be flow paced from a 4-20 mA DC signal from the programmable logic controller (PLC). The speed indicating controllers shall be mounted in the field control panel (FCP). Remote contacts shall be provided to indicate operating lights and alarms on the face of the UCP. The chemical pumps shall be capable of remote starting and stopping through two sets of voltage free contacts from the PLC. The chemical pumps shall be provided with a low suction pressure switch and a high discharge pressure switch for pump protection. The pump shall be shutdown in either condition. Reset switches shall be provided to reset alarms.

H.  The UCP shall interface with the PLC, as shown on the Drawings.

I.    Variable Speed Drives: Variable speed drives shall be of the direct current drive type equipped to follow a 4 to 20 mA signal from the PLC.  Variable speed drives shall have the following features.

1.   Drive controllers shall be in a dust and oil tight enclosure with speed adjustment dial, manual-automatic, on-off, and start-stop switches.

2.   Input power shall be 115 V, 60 Hz, single phase.

3.   Drives shall be capable of overload up to 150 percent of full load torque for one minute.

4.   Drives shall be equipped to follow output signals (4 to 20 mA DC).  Full motor speed shall occur at maximum input signal; minimum motor speed shall occur at minimum input signal. Drive shall have isolated input for receiving PLC output signal of 4-20mA.

5.   Drives shall have a tachometer feedback for speed regulation with 1 percent accuracy over a 95 percent load change and shall provide 4-20 mA signal to pump station PLC. Drive shall have isolated output for providing PLC input signal of 4-20mA corresponding to speed of the pump with 20mA at maximum speed.

6.   The drive controller shall be provided with spare contactors for interconnection with remote devices.

7.   The   drive   manufacturer   shall   provide   isolation   transformers   and   other accessories to produce an operating system responsive to the requirements herein.

8.   The drive controller shall be mounted in the corresponding UCP and each drive controller shall be contained in a NEMA 4X 316 Stainless Steel enclosure.

9.   The drive controller shall have adjustments for maximum speed, minimum speed, current limit and torque.

10. The  pump  supplier  shall  have  unit  responsibility  for  the  performance  and operation of the variable speed chemical feed pumps and drives.

11. EMI and RFI emissions shall not exceed the levels referenced in FCC Rules and Regulations Volume 2 Part 15 Subpart J Class A. If after installation, any interference or  noise occurs, the  supplier shall take corrective action by installing additional equipment or corrective measures required, at no additional cost to the OCSD.

J.   Motors: Motors shall be 1/2 HP, 3 phase, totally enclosed non-ventilated (TENV) with NEMA 56C face with mounting feet and thermal overload and 1,750 rpm base speed. Thermal overload shall be connected to the failure alarm.  Motors shall be in accordance with Section 16220, Electric Motors.

K.   Fasteners:  All bolts and cap screws shall be Type 316 stainless steel. All anchor bolts, nuts and washers shall be Type 316 stainless steel and of sufficient length to allow
1-1/2 inches of grout under pump bases.

L.   Guards:   Guards shall be provided at all exposed couplings, drives and shafts in compliance with Section 11005, Equipment: Basic Requirements.

2.2      CALIBRATION CYLINDERS

A.   Calibration cylinders shall be designed for chemical pump calibration. The calibration cylinders shall consist of a plastic, graduated cylinder with a capacity and mounting nipple as indicated below. Calibration cylinders shall be supplied by Griffco, Koflo, Milton Roy, Pulsafeeder, Or Equal.

2.3      PULSATION DAMPENERS

A.   Sodium Hypochlorite and Sodium Hydroxide Service:   Each diaphragm metering pump shall be equipped with a pulsation dampener and isolation ball valves. Pulsation dampeners shall be single diaphragm type and shall limit pressure oscillation above and below mean pressure to a maximum of 5 percent with the air chamber charged to a pressure of 50 percent of mean line pressure.   Pulsation dampeners shall of the chargeable type and shall include a  2-1/2-inch stainless steel pressure gauge. The bottom chamber shall be CPVC or PVDF, the top air chamber shall be CPVC or PVDF, and the diaphragm shall be Hypalon.  Pulsation dampener shall be rated for 150 pounds per inch pressure. Pump manufacturer shall submit calculation for the size of the dampener based on stroke volume of the selected pump. Pulsation dampeners shall be Blacoh, Milton Roy, Pulsafeeder, Or Equal.

B.   Sulfuric Acid Service:   Each diaphragm metering pump shall be equipped with a pulsation dampener and isolation ball valves. Pulsation dampeners shall be single diaphragm type and shall limit pressure oscillation above and below mean pressure to a maximum of 5 percent with the air chamber charged to a pressure of 50 percent of mean line pressure. Pulsation dampeners shall be of the chargeable type and shall include a 2-1/2-inch stainless steel pressure gauge. For the sulfuric acid service, the pressure gauge shall be 2-1/2-inch molded PVDF. The bottom chamber shall be PVDF, the top air chamber shall be PVDF, and the diaphragm shall be Teflon.  Pulsation dampener shall be rated for 150 pounds per inch pressure. Pump manufacturer shall submit calculation for the size of the dampener based on stroke volume of the selected pump. Pulsation dampeners shall be Blacoh, Milton Roy, Pulsafeeder, Or Equal.

2.4      ACCESSORIES

A.   The  CONTRACTOR  shall  provide  discharge  pressure  gauges  with  isolation diaphragm seals and valves for chemical feed systems as shown on the Drawings and specified in Section 17405, Process Instrumentation and Control.

2.5      UNIT CONTROL PANEL

A.   Refer to Section 16442, Control Panels, and applicable section of Section 17405, Process Instrumentation and Control.

2.6      OTHER MATERIALS

A.   Fabrications: Steel fabrications for mountings and anchorages shall conform to the requirements of ASTM A-36 for fabricated steel.

B.   Shop Coatings: Shop coat exposed ferrous metal surfaces in conformance with
Section 09800, Protective Coating.

PART 3 - EXECUTION

3.1      INSTALLATION AND STARTUP

A.   The CONTRACTOR shall examine the equipment delivered to the site to determine that it is in conformance with the approved shop drawings.   The equipment shall be installed in conformance with Section 11005, Equipment: Basic Requirements.   The CONTRACTOR  shall  coordinate  activities  with  the  instrumentation,  monitoring  and control work specified in Division 17. At no additional cost to the OCSD, the CONTRACTOR shall furnish the services of a competent factory-trained representative of equipment supplier or manufacturer to assist in and supervise the initial operation.

3.2      FIELD COATING

A.   Field coat exterior surfaces in conformance with Section 09800, Protective Coating. Before placement of any equipment, the CONTRACTOR shall finish coat any exterior surfaces which will rest on slabs or be otherwise covered up.

3.3      SPARE PARTS

A.   One complete set of spare parts to include a diaphragm, a set of check valve seats and balls, gaskets, O-rings, and other consumable parts shall be included for each pumping head on each of the systems.

3.4      MAINTENANCE OF INSTALLED EQUIPMENT

A.   Maintain the operability and functionality of all installed equipment valves between the time of installation and the commissioning period. See Specification section 01660 for requirements.

3.5      FIELD SERVICES

A.   Furnish the services of authorized technical representatives of the Manufacturer to assist/inspect the installed equipment and to certify that the equipment has been properly installed and is ready to operate, train OCSD personnel, conduct pre-operational mechanical checkout of the equipment, place equipment into operation, optimize the performances of the equipment and perform the field performance testing.

B.   At a minimum, conduct four separate site visits as follows:

a.   Inspection of equipment installation – two trips (8 hours minimum, each)

b.   Training of  OCSD  personnel.  See  Specification section  01820,  Training  of OCSD Personnel, for requirements.

c. Commissioning.    See Specification section 01810, Commissioning, for requirements.   Number of hours shall be as required to meet all testing and commissioning requirements, but shall not be less than 16 hours.

3.6      EQUIPMENT TESTING

A.   Equipment testing shall conform to the requirements of Section 11005, Equipment: Basic Requirements.