PROGRESSING CAVITY PUMPS

Here is another progressing cavity pump spec from the same project as the spec in the last post. If this isn't the type of pump you are looking for try this pump: "Dominator Wastewater and Sewage Pump - 9S Series"

PROGRESSING CAVITY PUMPS

PART 1   GENERAL

1.1      DESCRIPTION OF WORK

A.   The Work of this section includes all labor, materials, tools and equipment necessary to furnish and install progressive cavity pumps specifically designed to convey primary sludge  (3-4 percent solids concentrations), Waste Activated Sludge (WAS) and Trickling Filter Sludge (3 percent solids concentrations), centrifuge thickened sludge (4-6.5 percent solids concentrations) and digested sludge (3-4 percent solids concentrations), active and dilute polymer as specified herein and shown on the Drawings.

1.2      DESIGN CRITERIA

A.   The  materials  and  equipment covered  by  this  Specification are  intended  to  be standard materials and equipment of proven ability as manufactured by reputable companies.  Equipment shall be designed and constructed in accordance with the best practice of the industry and shall be installed in accordance with the manufacturer's recommendations and  the  Contract  Documents. The  Specifications call  attention  to certain features but do not purport to cover all details entering into the construction of the equipment.   All Work  shall conform  to  the  requirements of  Section 11210,  Pumps, General.

1.3      RELATED SECTIONS

A.   The requirements of the following sections and divisions apply to the Work of this section.  Other sections and divisions of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work.

1.   Additional General Requirements

2.   Operation and Maintenance Manuals

3.   Commissioning

4.   Training of OCSD Personnel

5.   Protective Coating

6.   Pumps and Equipment, General

7.   Electric Motors

8.   Variable Frequency Drives Below 100 HP

9.   Variable Frequency Drives 100 HP and Above

10. Electrical, applicable sections

11. Process Instrumentation and Control

1.4      REFERENCES

A.   XXXXXXXXXX

1.5      SUBMITTALS

A.   The CONTRACTOR shall submit complete shop drawings for acceptance in accordance with Shop Drawing Submittals of the General Requirements and as specified herein.

B.   In addition to the submittal requirements of Section 11210, Pumps, General, the following shall be submitted:

1.   Shop drawings showing complete fabrication and construction details, materials, weights, dimensions, clearances, anchorage locations and bolt detail, piping and utility requirements, and step-by-step sequence of controls.

2.   Pump manufacturer, type and model, rpm  at design point condition, size of suction and discharge flanges, and maximum bhp requirement at maximum differential pressure condition.

3.   Certified Pump Curves showing maximum and minimum speeds.

4.   For pump control panels, complete master wiring diagrams, elementary or control schematics, including required coordination with other electrical control devices operating in conjunction with the pumping system and acceptable outline Drawings shall be furnished for acceptance before proceeding with manufacture.  Due to the complexity of the control functions, it is imperative the above Drawings be clear and carefully prepared to  facilitate interconnections with  other  equipment.   Standard preprinted sheets or Drawings simply marked to indicate applicability to this Contract will not be acceptable.

5.   Coordination letter stating that the pump manufacturer has coordinated with the manufacturer of the Variable Frequency Drives specified in Specification section 16418,  Variable  Frequency Drives  below  100  Horsepower and  16419,  Variable Frequency Drives 100 Horsepower and Above for complete compatibility.

6.   Bearing Life Calculations.

7.   Operation and Maintenance Manuals.

1.6      DELIVERY, STORAGE, AND HANDLING

A.   All materials and equipment shall be shipped, stored, handled and installed in such a manner as not to degrade quality, serviceability or appearance.  The equipment shall be stored in a clean, dry location free from construction dust, precipitation and excess moisture. If stored for more than two weeks, the equipment shall receive all maintenance considerations required by the manufacturer for proper storage of the equipment.

1.7      DESIGN CONDITIONS

A.   The design conditions and other pertinent requirements for the progressive cavity pumps are listed in Table 1, at the end of this section.   The pumps shall be as manufactured by Moyno Inc., Springfield, OH, Seepex Inc., Enon, OH, or NETZSCH Pumps North America, LLC, Or Equal.

B.   All chemical feed pumps shall be manufactured by a single manufacturer.

C.  All sludge pumps shall be manufactured by a single manufacturer.

D.  Different manufacturers may provide the sets of chemical feed and sludge pumps.

E.   Pumps shall be designed to operate continuously.

1.8      WARRANTY

A.   The pumping units shall be warranted by the manufacturer for a minimum three (3) 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. Wear items such as seals, bearings, impellers, motor rotors and stators may be prorated during the three year period.

1.9      SPECIAL TOOLS

A.   If required for pump operation and maintenance, two sets of special tools required for pump operation and maintenance shall be provided at the time of pump deliver.

PART 2   PRODUCTS

2.1      PROGRESSIVE CAVITY PUMPS

A.   Pumps  shall  conform  to  applicable  provisions  listed  in  Section  11210,  Pumps, General.

B.   The pumps shall be horizontal, heavy duty, positive displacement, progressive cavity pumps. The pump and drive shall be direct coupled and mounted as shown on the Drawings.

1.   Pump Casing:

a.   The casing shall be close-grained cast iron of sufficient strength, weight and metal thickness to insure long life, accurate alignment and reliable operation. The  volute  shall  be  a  symmetrical  waterway  to  provide  an  unobstructed discharge flow.  Two inspection ports with removable covers having its interior surfaces matching the volute contour shall be provided located 180 degrees apart on the casing housing.  The pump shall be mounted to permit the suction port to be rotated in 90 degree increments perpendicular to the centerline of the pump.   Pump shall be supplied with adequate number of connections for seal water flushing, stuffing box drainage, pump drainage and gauge connections.

2.   Casing Connections:

a.   Suction  and  discharge  connections  shall  be  ANSI  125  pound  flat  face flanges. Suction and discharge flanges shall be provided with 1/2 inch NPT drilled and tapped holes with threaded plugs.

3.   Rotor and Drive Train:

a.   The pump rotor shall be machined from chrome-plated tool steel with a minimum chromium content of 11-13.5 percent, air hardened to a Rockwell "C" hardness of 57 to 60 and covered with a minimum 0.01 inch thick layer of hard chrome plating for abrasion resistance.   The rotor shall be joined to the drive shaft by a connecting rod and crown gear type oil or grease-lubricated, single sealed universal joints of adequate design to transmit the required thrust and torque while allowing the rotor to move through its required eccentric path without distortion or vibration.  The universal joint shall be sealed by a Buna-n bellows clamped positively at both the I.D. and O.D. and protected on the outer diameter from damage by foreign materials by a thick walled steel casing on the rotor end and the shaft end.

b.   Rotor for polymer pumps XXXXX shall be polished 316 stainless steel and shall have no surface coating.

4.   Stator:

a.   The  rotor  shall  rotate  within  a  Buna-n  rubber  stator  of  approximate 70 Durometer hardness (Shore A) chemically bonded to high strength steel tube. The stator shall be attached to the suction housing by four thru-bolts for ease of assembly and disassembly.   The stator end shall be sealed or gasketed to prevent the material being pumped from contacting the stator bonding and tube.

b.   Stator for polymer pumps XXXXXX shall be Fluoroelastomer (FPM) material.

5.   Shaft:

a.   The drive shaft shall be mounted in two bearings.   The connecting rod operating angle shall not exceed 1 degree off-center (2 degree total operating angle).  Driveshaft where it passes through the stuffing box shall be hard chrome plated. Designs which rely on the gear reducer for radial and axial thrust of the pump are not acceptable except on polymer service. Bearings must be held in place with solid metal shoulders. Snap ring designs are not acceptable, except on polymer service.

b.   Shaft for polymer pumps (XXXXX) shall be 316 stainless steel.

6.   Bearings:

a.   The shaft shall be mounted in two ball bearings or two tapered roller bearings designed for all radial and thrust loads encountered in the service conditions. The bearings shall be pre-lubricated and fully sealed and shall have a minimum B-10 life of 100,000 hours. Manufacturer shall submit proof that bearings meet this requirement.

b.   Bearings  for  polymer  pumps  (XXXX) shall be 316 stainless steel.

7.   Stuffing Box:

a.   Stuffing box shall be provided with tapped connection for seal liquid. The stuffing box shall be sealed with a split mechanical seal per Section 11210, Pumps and Equipment, General.  Stuffing box shall be sealed with a source of water external from the pump.   A 3/4 inch drain in the stuffing box shall be provided.

b.   All wetted components including seals metal parts for the polymer pumps (XXXXXX) shall be 316 stainless steel.

8.   Baseplate:

a.   Each pump and drive unit shall be mounted on a common baseplate of neat design, with rounded corners.  All exposed seams and contact surfaces of steel plates and shapes shall be continuously welded and ground smooth.   Pipe tapped openings shall be provided to ensure positive drainage from the base. At least one drain opening shall be provided for each base.  A ½ inch NPT drain connection shall be provided to convey leakage to the nearest floor drain.

b.   Openings shall be provided in the top of the base to facilitate grouting.  An opening shall also be provided, if necessary, for electrical conduit to the drive unit.

9.   Anchor Bolts

a.   Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter and length as shown on the Standard Drawings.

b.   Anchor bolts for the polymer pumps (XXXXXX) shall be 316 stainless steel.

2.2      MOTORS AND DRIVES

A.   Motors shall conform to the requirements listed in Table 1.  All motors shall be TEFC, with a  Class 1,  Division 2 rating, suitable for  wet and corrosive environments, and conform  to  the  requirements  specified  in  Section  16220,  Electric  Motors.  Motor orientation shall be as shown on the Drawings.

B.   Motor nameplate horsepower shall be the maximum noted in Table 1 except that the pump motor shall not be overloaded nor operate within the service factor at any point on the published pump curve up to the maximum pump speed and the pressures noted in Table 1.

C.  Selection of the motor bearing sizes shall be based on a B-10 life of 100,000 hours.

D.  Motors shall be driven by constant torque VFD’s and shall be inverter duty rated, compatible with the variable frequency drive controllers specified under Section 16418 and  16419.    Each motor shall be  of  adequate power for  starting and  continuously operating its respective pumping unit under all specified load conditions without overloading. .

E.   The drive unit shall operate the pump at the speed noted in Table 1.

F.   The pumps shall be suitable for Class 1, Division 2 and wet and corrosive area installation.

2.3      ACCESSORIES

A.   Each pump shall be equipped with suction vacuum switch and discharge pressure switch to protect against a closed suction or discharge valve situation. Switches shall be mounted on stainless steel annular pressure sensors mounted off-line with isolation ball valves mounted above, and below the pressure sensor ring to allow removal of the unit, or facilitate sampling. They shall be wired under Division 16, Electrical.

B    Each pump shall be supplied with a three (3) inch minimum diameter pressure relief valve with an integral limit switch. The pressure relief valve shall be constructed with a cast iron body and ductile iron cover, to withstand severe shock conditions. The body shape shall be 90° angle pattern to permit side or downward discharge. The cover shall provide an air gap between the surge valve and the hydraulic cylinder. The valve stem shall  be  connected to  the  hydraulic cylinder  by  means  of  a  self  aligning universal connector to provide smooth positive opening, without binding.  The hydraulic cylinder shall be removable from the valve without dismantling or removing the valve from the line. The closing speed shall be externally adjustable by means of a coded micrometer control valve. The valve disc shall be normally closed against the system operating pressure by means of a spring or springs. When the system pressure exceeds the factory setting of 90 psig the surge relief valve shall open immediately to relieve the pressure surge and close slowly as the system pressure returns to normal. The hydraulic cylinder shall be capped on both ends (totally enclosed) to prevent dirt or dust from fouling up the cylinder operation. It shall be fitted with an atmospheric oil reservoir. The relief pressure shall be set at the factory. The valve shall be field adjustable by increasing or decreasing the tension on the externally adjustable springs. The surge relief valve shall be constructed of the following materials:

1.   Body shall be Cast Iron ASTM A126 Grade B

2.   Body Seat Ring shall be Aluminum Bronze ASTM B148

3.   Cover shall be Ductile Iron ASTM A536

4.   Disc Seat shall be Buna-N

5.   Disc shall be Steel ASTM A36

C.  Each polymer pump (XXXX) shall be supplied with 1 1/2-inch diameter pressure relief valve. Valve body, top, spring and all wetted components shall be 316 stainless steel. Diaphragm shall be Teflon/Viton or 316 stainless steel disc. Seals and/or O-rings shall be Teflon or Teflon encapsulated Viton. Valve shall be adjustable in the range of 10 to 250 pounds per inch. Valve shall be rated for pressure of 400 pounds per inch. Valve shall have flanged connections. Pressure relief valve shall be manufactured by, Or Equal:

1.   Tyco/Kunkle Valve Model 171S

2.   Griffco Valve, Model G-Series

D.  The couplings shall be effectively covered by means of protective metal guards, conforming to OSHA standards.

E.   The pump, motor, speed reducer and couplings shall all be accurately aligned and mounted on a fabricated structural steel base.

F.   A seal water system shall be provided for each pump as shown on the Drawings.

G.  Provide rotor locking to prevent reverse rotation.

PART 3   EXECUTION

3.1      INSTALLATION

A.   All materials and equipment shall be installed in a neat, workmanlike manner.

B.   All wiring of the equipment shall be as specified under Division 16, Electrical, of these Specifications.

C.  All   equipment   specified   herein   shall   be   installed   in   accordance   with   the manufacturer's recommendations and the Drawings.

D.  Where anchor bolts and other parts to be embedded in concrete are required, such parts shall be furnished to the site in advance of the equipment along with templates and instructions for their installation.

E.   Such installation shall be done under Division 3, Concrete.

3.2      PAINTING

A.   Shop painting and the surface preparation is a part of the Work specified in this section and shall be as specified in Section 09800, Protective Coatings.  Stainless steel shall not be painted.

3.3      CLEAN-UP

A.   Prior to start-up and field testing, all foreign matter shall be removed from the pumps, interconnecting piping, and spillage of lubricants used in servicing the equipment shall be cleaned from pumps, piping and concrete surfaces.

3.4      LUBRICATION REQUIREMENTS

A.   All lubricants required for the first year of operation shall be provided for the system.

3.5      MAINTENANCE OF INSTALLED EQUIPMENT

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

3.6      MANUFACTURER’S 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.   Conduct multiple separate site visits as follows:

1.   Inspection of equipment installation – four trips

a.   Trickling Filter Sludge Pumps – two trips (4 hours minimum, each)

b.   Polymer Pumps (8 hours minimum)

c.   Centrifuge Feed Pumps (8 hours minimum)

2.   Training of OCSD Personnel. See Specification section XXXX for requirements.

3.   Commissioning.  See Specification section XXXXX for requirements.  Number of trips and hours shall be as required to meet all testing and commissioning requirements, but shall not be less than 60 hours.

3.7      SPARE PARTS

A.   Spare parts shall be provided for the equipment furnished as outlined in Table 1.

3.8      PUMP TESTS

A.   Pump tests shall be performed for all equipment supplied under this section.


B.   Manufacturers’ field services shall be as specified in Section 01810, Commissioning.

C.  Manufacturers’ training of OCSD personnel shall be as specified in Section 01820, Training of OCSD Personnel. D.  The following spare parts shall be furnished, one set for each system:
1.   Rotor

2.   Stator

3.   Shaft sleeve



SEE FOLLOWING TABLE 1

TABLE 1
SPECIFIC CONDITIONS AND REQUIREMENTS PROGRESSING CAVITY PUMPS

A.   Design Conditions:


Tag #: PMP110, 210, 310

System: Thickening Centrifuge Feed Pump

Location: Centrifuge Building Basement

Fluid Conveyed: 0.5-3.5 percent WAS/Primary Sludge

Design Flow Condition (gpm): 1600

Design Pressure (psig): 70

Suction Diameter (inch): 12

Discharge Diameter (inch): 12

Maximum Pump Speed (rpm): 300

Motor (hp): 125

Type of Seal: Single Seal

Mfg No./ Or Equal: Chesterton 442 Split Seal w/ Flushing

Motor Voltage & Drive Type:  480 V, 3 PH, 60 HZ, Class 1, Division 2 motor with VFD