PUMPS, GENERAL

PUMPS, GENERAL

PART 1 - GENERAL

1.1      THE REQUIREMENT

A.   The CONTRACTOR shall furnish and install all tools, equipment, materials, and supplies and shall perform all labor necessary for the installation, testing, and placing into operation of all pumps and pumping appurtenances, complete and operable, in accordance with the requirements of the Contact Documents.

B.   The provisions of  this section shall apply to all pumps and pumping equipment specified, except where otherwise specified in the Contract Documents.

C.  The CONTRACTOR shall assign to a single manufacturer full responsibility for the furnishing and functional operation of the complete pump system including the pumps, drive motors, and accessories.  The designated single manufacturer, however, need not manufacture more than one part of the unit (pump or motor), but shall coordinate the design, assembly, testing, and erection of the unit(s) as specified herein.

1.2      RELATED WORK SPECIFIED ELSEWHERE

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.   Division 01, Additional General Requirements

2.   Section 05500, Miscellaneous Metalwork

3.   Section 09800, Protective Coating

4.   Division 11, Equipment, applicable sections

5.   Division 15, Mechanical, applicable sections

6.   Section 16010, Electrical General Provisions

7.   Section 16220, Electric Motors

8.   Section 16418, Variable Frequency Drives Below 100 hp

9.   Section 16419, Variable Frequency Drives 100 hp and Above

10. Section 17034, Gauges

11. Section 17405, Process Instrumentation and Control

1.3      SPECIFICATIONS, CODES, AND STANDARDS

A.   All Work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following publications to the extent that the provisions thereof are not in conflict with other provisions of these Specifications.

B.   Comply  with  the  applicable  editions  of  the  following  codes,  regulations  and standards.

1.   Industry Standards:

ANSI/ASME B16.1                     Grey Iron Pipe Flanges and Flanged Fittings

ANSI/ASME B16.5                     Pipe Flanges and Flanged Fittings

 ANSI/ASME B31.1

ANSI/ASME B73.1                       Power Piping

Specification    for    Horizontal    End    Suction Centrifugal Pumps for Chemical Process  

 
Specification  for   Vertical   In-Line   Centrifugal Pumps for Chemical Process  

 
Specification for Gray Iron Castings  

 
Specification for  Vacuum-Treated Carbon  and Alloy Forgings for Turbine Rotors and Shafts  

 
Specification for Ductile Iron Castings  

 
Specification for Composition Bronze or Ounce Metal Castings  

 
Standard  Practice  for  Scleroscope  Hardness Testing of Metallic Materials  

2. Other Standards:  

HI Hydraulic Institute

C.  Comply  with  the  applicable reference  Specifications as  directed  in  the  General
Requirements and the Additional General Requirements.

1.4      CONTRACTOR SUBMITTALS

A.   Submittals shall be made in accordance with the General Requirements, Additional General Requirements and as specified herein.

B.   The following submittals and specific information shall be provided.

1.   Pump name, identification number and specification number.

2.   Performance curve and pump data.

3.   The CONTRACTOR shall require the manufacturer to indicate points on the H/Q curves, and the limits recommended for stable operation between which the pumps may be operated without surge, cavitation, and vibration.  The stable operating range shall be as wide as possible based on the pumps actual hydraulic and mechanical tests.

4.   Pump detailed description and specification.

5.   Electrical data including control and wiring diagrams.

6.   Assembly and installation drawings including shaft size, seal, coupling, anchor bolt plan, part nomenclature, material list, outline dimensions and shipping weights.

7.   Pump drive and motor in accordance with Section 16220, Electric Motors.

8.   Bearing life calculations.

C.  Certification:   The CONTRACTOR shall obtain written certification from the pump manufacturer, addressed to OCSD, stating that the equipment will efficiently and thoroughly perform the required functions in accordance with these Specifications and as shown, and that the pump manufacturer accepts joint responsibility with the CONTRACTOR for  coordination  of  all  equipment,  including  motors,  variable  speed drives, controls, and services required for proper installation and operation of the completely assembled and installed pumps.  The CONTRACTOR shall submit all such certificates to the ENGINEER.

D.  Technical  Manuals:    Prior  to  startup,  the  CONTRACTOR  shall  furnish  OCSD complete operations and maintenance manuals in accordance with the General Requirements, Additional General Requirements and as specified herein.

E.   Tools:  Special tools necessary for maintenance and repair of the pumps and one pressure grease gun for each type of grease required for pumps and motors shall be furnished as a part of the Work hereunder; such tools shall be suitably stored in metal tool boxes and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box.

F.   Field  Procedures:     Instructions  for  field  procedures  for  erection,  adjustments, inspection, and testing shall be provided prior to installation of the pumps.

1.5      QUALITY ASSURANCE
A.   General
1.   Performance Curves:   All centrifugal pumps shall have a continuously rising curve.  In no case shall the required horsepower at any point on the performance curve exceed the rated horsepower of the motor or engine.

2.   Equipment   Testing:      The   CONTRACTOR  shall   be   responsible   for   the coordination of the following tests of each pump, drive, and motor:

a.   General:   Tests shall be performed in accordance with the Test Code for Centrifugal Pumps of the Standards of the Hydraulic Institute, Inc.  Tests shall be performed  on  the  actual  assembled  unit  from  shutoff  head  condition  to 125 percent of the required maximum design capacity. Prototype model tests will not be acceptable. Pumps and motors shall be factory tested, as defined herein.
b.   Factory Tests of Pumps:   All pumps and motors of sizes 10 to 125 hp (inclusive) shall be factory-tested, in accordance with the above Specifications. Seven sets of certified test data shall be submitted to the ENGINEER.  These data shall include, but not be limited to the following:

1)   Hydrostatic test with data recorded.

2)   Hydraulic test with a minimum of 5 readings between shutoff head and 125 percent of the maximum design capacity, recorded on data sheets as defined by the Hydraulic Institute, signed, dated, and certified.

3)   Certified pump curves showing head/flow, bhp, efficiency, and NPSH curves.  NPSH required shall be at least 5 feet of water absolute greater than NPSH available.

4)   Certification that the pump hp demand will not exceed the rated motor hp beyond the 1.0 service rating at any point on the curve.

c.   Factory W itnessed Tests: All pumps, variable speed drives, and motors, 150 hp and larger, shall be factory-tested as complete, assembled units, as specified above, and witnessed by a representative of the ENGINEER.  The manufacturer shall give the ENGINEER a minimum of 2 weeks notification prior to the test. Test results in triplicate shall be submitted to the ENGINEER, and no equipment shall be shipped until the test data have been accepted by the ENGINEER.

d.   Acceptance:  In the event of failure of any pump to meet any of the above requirements or efficiencies, the CONTRACTOR shall make all necessary modifications, repairs, or replacements to conform to the requirements of the Contract Documents and the pump shall be retested at no additional compensation, until found satisfactory.

3.   Field  Tests:     All  pumping  units  shall  be  field  tested  after  installation,  in accordance with the Contract Documents, to demonstrate satisfactory operation, without causing excessive noise, vibration, cavitation, and overheating of the bearings. The field testing shall be performed in the presence of an experienced field representative of  the  manufacturer of  each major  item  of  equipment, who  shall supervise the following tasks and shall certify in writing that the equipment and controls have been properly installed, aligned, lubricated, adjusted, and readied for operation:

a.   Start up, check, and operate the equipment over the entire speed range. The vibration shall be within the amplitude limits recommended in the Hydraulic Institute Standards, and it shall be recorded at a minimum of 4 pumping conditions defined by the ENGINEER.

b.   Pump performance shall be documented by obtaining concurrent readings, showing motor voltage, amperage, pump suction head, and pump discharge head, for at least 4 pumping conditions at each pump design rpm.  Each power lead to the motor shall be checked for proper current balance.

c.   Bearing temperatures shall be determined by a contact-type thermometer. A running time of at least 20 minutes shall be maintained for this test, unless liquid volume available is insufficient for a complete test.

d.   Electrical and instrumentation testing shall conform to applicable sections of these Specifications.

e.   The field testing shall be witnessed by ENGINEER  .  In the event any of the pumping equipment fails to meet the above test requirements, it shall be modified and retested in accordance with the requirements of these Specifications.  The CONTRACTOR shall then certify in writing that the equipment has been satisfactorily tested, and that all final adjustments thereto have been made. Certification shall include date of Final Acceptance test, as well as a list of all persons present during tests and resulting test data.   The costs of all Work performed according to this paragraph by factory-trained representatives shall be borne by the CONTRACTOR.   OCSD will pay for costs of power and water. When available, the OCSD operating personnel will provide assistance in the field testing.

B.   Manufacturer’s Qualifications:

1.   Manufacturer's Service Representative:

a.   Erection and Startup Assistance:  Service and instruction assistance by the manufacturer's engineering representative for each pump 10 HP and larger shall be provided by the CONTRACTOR during the following periods:

               1)   During erection.

                2)   During startup.

b.   Instruction of OCSD Personnel:   The CONTRACTOR shall provide for the services of a factory service representative to instruct OCSD personnel in the operation and maintenance of the equipment.  This service shall consist of a one day's visit to the plant for each type of similar pumps.

1.6      WARRANTY

A.   After  completion, the  CONTRACTOR shall  furnish  to  OCSD  the  manufacturer's written guarantees that the pumping equipment will operate with the published efficiencies, heads, and flow ranges and shall meet these Specifications.   The CONTRACTOR shall  also  furnish the  manufacturer's warranties as  specified  in  the individual pump Specification sections.

PART 2 - PRODUCTS

2.1      GENERAL

A.   The CONTRACTOR shall furnish and install only such pumping equipment as the designated single manufacturer certifies is suitable for use with its equipment and the service conditions.

B. All manufactured items provided under this section shall be new, of current manufacture, and shall be the products of reputable manufacturers specializing in the manufacture of such products; such manufacturers shall have had previous experience in such manufacture and shall, upon request of the ENGINEER, furnish the names of not less than five (5) successful installations of its equipment of comparable nature to that offered under this Contract.

C. All combinations of manufactured equipment that are provided under these Specifications shall be entirely compatible, and the CONTRACTOR and the designated single manufacturer shall be responsible for the compatible and successful operation of the various components of the units conforming to specified requirements.  Each unit of pumping equipment shall incorporate all basic mechanisms, coupling, electric motor, or engine drive and unit mounting.  All necessary mountings and appurtenances shall be included.

D.  Where two or more units of the same type and/or size of pumping equipment are required, such units shall be produced by the same manufacturer.

2.2      MATERIALS

A.   All materials furnished as part of the pumping equipment shall be suitable for its intended use and service.   Materials not specifically called for shall be high grade, standard commercial quality, free from all defects and imperfection that might affect the serviceability of the product for the purpose for which it is intended, and shall conform to the following requirements:

1.   Cast iron pump casings and bowls shall be of close-grained gray cast iron, conforming to ASTM A 48.

2.   Bronze pump impellers shall conform to ASTM B 62.

3.   Stainless  steel  pump  shafts  shall  be  of  Type  400,  Series.    Miscellaneous stainless steel parts shall be of Type 316, except in septic environment.

4.   All anchor bolts, nuts and washers shall be hot-dip galvanized, unless otherwise specified in individual pumping equipment Specifications. Buried or submerged bolts, nuts and washers shall be of Type 316 stainless steel.

2.3      PUMP APPURTENANCES

A.   Nameplates:    Each  pump  shall  be  equipped  with  a  stainless  steel  nameplate indicating rated head and flow, impeller size, pump speed, and manufacturer's name and model number.

B.   Solenoid Valves:  The pump manufacturer shall furnish and install solenoid valves on the water or oil lubrication lines and on all cooling water lines.  Solenoid valve electrical rating shall be compatible with the motor control voltage and shall be furnished complete with all necessary conduit and wiring installation from control panel to solenoid.

C.  Pressure Gauges:  All pumps (except sample pumps, sump pumps, and hot water circulating pumps) shall be equipped with pressure gauges installed at pump suction and discharge lines.  Pressure gauges shall be located in a representative location, where not subject to shock or vibrations, in order to achieve true and accurate readings.  Pressure gauges shall be furnished in conformance with Section 17034, Gauges.

D.  Pump suctions shall be equipped with compound gauges. Where subject to shock or vibrations, the pressure gauges shall be provided with a snubber and be wall mounted or attached to galvanized channel floor stands and connected by means of flexible connectors.

E.   Drives:  Drive motors, speed control equipment, and accessories shall be furnished in accordance with applicable Division 11 and 16 sections. Pumps and associated gear trains shall be designed such that the VFD shall not be required to operate higher than 60 Hz at full load.

2.4      PUMP REQUIREMENTS - GENERAL

A.   Flanges: Suction and discharge flanges shall be as specified for the attached pipe.

B.   Lubrication:  Vertical pump shafts shall be product water lubricated, unless otherwise specified.    Deep-well pumps  and  pumps  with  dry  barrels  shall  have  water-  or  oil- lubricated bearings and seals.

C.  Handholes:  Handholes on pump casings shall be shaped to follow the contours of the casing to avoid any discontinuity in the water passage.

D.  Vortex Suppressors: Vertical pumps with insufficient submergence shall be furnished with vortex suppressors.

E.   Drains:   All gland seals, air valves, cooling water drains, and drains from variable speed drive equipment shall be piped to the nearest floor sink, or drain, with galvanized steel pipe or copper tube, properly supported with brackets.

F.   Grease Lubrication:  For all vertical-propeller, mixed-flow, and turbine pumps other than deep-well pumps of bowl sizes 10 inches and larger, the CONTRACTOR shall provide a stainless steel tube attached to the column for grease lubrication of bottom bearing.

G.  Stuffing Boxes:  Where stuffing boxes are specified for the pump seal, they shall be of the best quality, using the manufacturer's suggested materials best suited for the specific application. For sewage, sludge, drainage, and liquids containing sediments, the seals shall be fresh water flushed, using lantern rings.  If fresh water is not available, the seal shall be flushed with product water, cleaned by means of a solids separator as furnished by John Crane Co., Lakos (Claude Laval Corp.), Or Equal.  Unless otherwise specified, the packing material shall be interlaced Teflon braiding, containing 50 percent ultrafine graphite impregnation to satisfy the following Specification:

Shaft speeds                              -up to 2500 fpm
Temperature                               -up to 500 degrees F
pH range                                     -0 - 14

H.  Mechanical Seals:   Unless otherwise specified, mechanical seal designs shall be selected for highest reliability and for rugged service.  Mechanical seals shall be provided where called out, and they shall be water flushed, unless otherwise specified.   Water flushing shall be as described above.   Unless the pump manufacturer recommends a better seal for a specific application, the following mechanical seals shall be furnished with the pumps:

Sewage, Sludge, or                          Single split seal with flushing:
Wastewater Pumps                           Chesterton 442, Flowserve PSS III Or Equal.

Abrasives, Grit,                                 Single split seal with flushing:
Lim Slurry Pumps                             Chesterton 442, Flowserve PSS III Or Equal.

Chemicals and Corrosive                  Cartridge double Seal with silicon carbide faces:

Liquid Pumps                                    Chesterton 280, Flowserve SL-5200 Or Equal.

Clean Water Pumps,                         Single split seal with flushing:

Hot and Cold                                     Chesterton 442, Flowserve PSS III Or Equal.

I.    For all seal arrangements, a buffer fluid shall be circulated a minimum 20 pounds per inch above suction pressure, or as required by manufacturer, in order to maintain reliable seal performance.

J.   Preferred seals  for  all  services  other  than  chemicals and  corrosives should  be equipped with nonclogging, single coil springs and nonsliding, internal, secondary elastomers. Metal parts are to be of 300 series, corrosion-resistant materials.

PART 3 - EXECUTION

3.1      INSTALLATION

A. General:   Pumping equipment shall be installed in accordance with approved procedures submitted with the shop drawings and as shown, unless otherwise accepted by the ENGINEER.

B.   Alignment:  Equipment shall be field tested to verify proper alignment, operation as specified, and freedom from binding, scraping, vibration, shaft runout, and other defects. Pump drive shafts shall be measured just prior to assembly to ensure correct alignment.

C.  Lubricants:   The installation work  shall include furnishing the necessary oil  and grease for initial operation.

3.2      PROTECTIVE COATING

A.   All exposed materials, except corrosion-resistant metals that have not been shop painted shall be field coated as specified in Section 09800, Protective Coating.  Shop- painted items that suffered damage to the shop coating shall be touched up as specified in Section 09800, Protective Coating.