CONFORMED
Bid Evaluation Documents
Contract C-1
Pumping Units and Motors
Ward County Water Supply Expansion
Project – Transmission, Odessa, and
Well Field Pump Stations
DOCUMENTS ISSUED FOR CONSTRUCTION
These “Issued for Construction” Contract Documents have been prepared by revising the Bidding Documents
to record references to addenda, field orders or change orders issued as of February 7, 2012.
The Bidding Documents may have been revised to incorporate these revisions directly into the “Issued for
Construction” Contract Documents. Contractor is responsible for determining that these documents are
consistent with their understanding of the Bidding Documents as modified per the appropriate provisions of
the Contract Documents, The Bidding Documents, as modified per the appropriate provisions of the Contract
Documents, take precedence over these “Issued for Construction” documents.
November 2011
CMD11269
th
400 East 24 Street P.O. Box 869 Big Spring, Texas 79721-0869
432-267-6341 www.crmwd.org Fax 432-267-3121
SEAL SHEET
Division 22, 44 - Freese and Nichols, INC. Texas Registered Engineering Firm F – 2144
THE SEAL THAT ORIGINALLY APPEARED ON THIS DOCUMENT WAS AUTHORIZED BY
NICHOLAS LESTER, P.E., TEXAS NO. 97365 ON OCTOBER 6, 2011. FREESE AND
NICHOLS, INC. TEXAS REGISTERED ENGINEERING FIRM F- 2144. ALTERATION OF A
SEALED DOCUMENT WITHOUT PROPER NOTIFICATION OF THE RESPONSIBLE
ENGINEER IS AN OFFENSE UNDER THE TEXAS ENGINEERING PRACTICE ACT.
Division 22, 44 - Freese and Nichols, INC. Texas Registered Engineering Firm F – 2144
THE SEAL THAT ORIGINALLY APPEARED ON THIS DOCUMENT WAS AUTHORIZED BY
RUSSEL GIBSON, P.E., TEXAS NO. 61883 ON OCTOBER 6, 2011. FREESE AND NICHOLS,
INC. TEXAS REGISTERED ENGINEERING FIRM F- 2144. ALTERATION OF A SEALED
DOCUMENT WITHOUT PROPER NOTIFICATION OF THE RESPONSIBLE ENGINEER IS AN
OFFENSE UNDER THE TEXAS ENGINEERING PRACTICE ACT.
Division 22, 44 - Freese and Nichols, INC. Texas Registered Engineering Firm F – 2144
THE SEAL THAT ORIGINALLY APPEARED ON THIS DOCUMENT WAS AUTHORIZED BY
BRYAN C. JANN, P.E., TEXAS NO. 86952 ON OCTOBER 6, 2011. FREESE AND NICHOLS,
INC. TEXAS REGISTERED ENGINEERING FIRM F- 2144. ALTERATION OF A SEALED
DOCUMENT WITHOUT PROPER NOTIFICATION OF THE RESPONSIBLE ENGINEER IS AN
OFFENSE UNDER THE TEXAS ENGINEERING PRACTICE ACT.
Seal Sheet
CMD11269 – Contract C-1 – Pumping Units and Motors
10/06/11
1
SEAL SHEET
Division 44 - Freese and Nichols, INC. Texas Registered Engineering Firm F – 2144
THE SEAL THAT ORIGINALLY APPEARED ON THIS DOCUMENT WAS AUTHORIZED BY
JAMES K. JOHNSON, P.E., TEXAS NO. 105037 ON OCTOBER 6, 2011. FREESE AND
NICHOLS, INC. TEXAS REGISTERED ENGINEERING FIRM F- 2144. ALTERATION OF A
SEALED DOCUMENT WITHOUT PROPER NOTIFICATION OF THE RESPONSIBLE
ENGINEER IS AN OFFENSE UNDER THE TEXAS ENGINEERING PRACTICE ACT.
Division 22, 44 - Freese and Nichols, INC. Texas Registered Engineering Firm F – 2144
THE SEAL THAT ORIGINALLY APPEARED ON THIS DOCUMENT WAS AUTHORIZED BY
REBECCA SANDOVAL, P.E., TEXAS NO. 102369 ON OCTOBER 6, 2011. FREESE AND
NICHOLS, INC. TEXAS REGISTERED ENGINEERING FIRM F- 2144. ALTERATION OF A
SEALED DOCUMENT WITHOUT PROPER NOTIFICATION OF THE RESPONSIBLE
ENGINEER IS AN OFFENSE UNDER THE TEXAS ENGINEERING PRACTICE ACT.
Seal Sheet
CMD11269 – Contract C-1 – Pumping Units and Motors
10/06/11
2
TABLE OF CONTENTS
TECHNICAL SPECIFICATIONS
22 11 23.01 Horizontal Centrifugal Pumping Units ........................................ 22 11 23.01-1
44 42 56.02 Vertical Turbine Pumping Units ................................................. 44 42 56.02-1
APPENDIX A – System Curves
Transmission Pump Station System Curve
Odessa Pump Station System Curve
APPENDIX B – DRAWINGS
Sequence
No.
Sht.
No.
1
2
3
4
5
6
7
8
P-1
P-2
P-3
P-4
P-5
P-6
P-7
P-8
Table of Contents
Sheet Title
Cover
TPS Floor Plan
TPS Pump and Piping Section
OPS Floor Plan
OPS Pump and Piping Section
WPS Floor Plan
WPS Pump and Piping Section (Not Included)
TPS and OPS Pump and Barrel Details
WPS Pump Details (Not Included)
CMD11269 – Contract C-1 – Pumping Units and Motors
10/06/11
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Division 22
22 11 23.01
HORIZONTAL CENTRIFUGAL PUMPING UNITS
NOTE TO SPECIFIER: THIS IS A TEMPORARY GUIDE SPECIFICATION. THE USER SHOULD USE
THIS SPECIFICATION WITH CAUTION AND VERIFY ALL REQUIREMENTS.
1.00
GENERAL
1.01
WORK INCLUDED
1.02
Furnish labor, materials, equipment and incidentals necessary to design, manufacture,
fabricate, test, and deliver a total of [six three horizontal centrifugal] pumping units to be
used in the Owner’s Well-Field Transfer Pump Station (WPS)s [21 and 22.. Three Three
identical units shall be furnished for Pump Station 21WPS and shall be designated as units
P21WPS-P1, P21WPS-P2, and and P21WPS-P3. Three identical units shall be furnished for
Pump Station 22 and shall be designated as units P22-1, P22-2, and P22-3. All six three
pumps shall be of the same manufacturer. All six three motors shall be of the same
manufacturer].
A.
B. The units shall consist of horizontal, split-case, double suction centrifugal pumps with side
suction and side discharge, with horizontal motor, coupling, and common pump and motor
base. Accessories shall be furnished as required for a complete functioning pumping unit in
accordance with the specified performance and installation conditions. Pump shall be
suitable for outdoor service, and shall have freeze protection for all appurtenances.
C. The WPS motors will be controlled by a Solid State Reduce Voltage Starter (soft starter)
(which is provided under a separate contract.)
A.
[The horizontal pump and motors (except the impellers) to be provided shall be oversized
initially to meet the requirements of the specified future rated conditions].
B. [The Vendor shall be the pump manufacturer and shall also furnish a total of two variable
frequency drives as specified in Section 26 29 23.01 “Variable Frequency Motor Controllers”
and shall be responsible to coordinate the design, testing and installation of the Variable
Frequency Drives (VFD) and motors. One VFD shall be furnished for Pump Station 21 and
one VFD shall be furnished for Pump Station 22. Both [Pump Station 21 and Pump Station
22 will be designed so that the starter and VFD leads can be swapped so that the VFD can be
used with an alternate pumping unit. The motors furnished shall be suitable for use with a
VFD. The Vendor shall be responsible for the adequacy and compatibility of the pump,
motor, and VFD. The motor manufacturer shall act as a subcontractor to the pump
manufacturer, and the VFD manufacturer shall act as a subcontractor to the motor
manufacturer. The motor manufacturer shall provide a representative who is capable of
coordinating the design, testing, and installation of the motors, capacitors and VFD].
1.031.02
ACCEPTABLE MANUFACTURERS
orizontal Centrifugal Pumping Units
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A. Pumps:
1. Fairbanks Morse.
2. FlowserveIngersoll-Dresser.
3. Patterson.
B. Motors:
1. General Electric
1. TECO-Westinghouse.
2. Reliance (Baldor).
3. Siemens.
4. TECO-Westinghouse
4.5. No other manufacturers will be accepted.General Electric.
1.041.03
QUALITY ASSURANCE
A. Experience Requirements: Pumps and motors shall be the product of manufacturers who
have had at least 10 years of successful experience in the design, manufacture and
application of pumping units of the type, size, and performance capabilities as specified.
B.
Factory Inspection and Pump Tests:
1.
General:
a. Equipment furnished under these specifications shall be subject to inspection during
manufacture by a representative of the Owner who shall be afforded proper facilities for
determining compliance with the specifications.
b. The Owner may, at his option, elect to have the factory tests witnessed by the Owner, or a
designated representative of the Owner. If the option is taken to witness the tests, then
payment will be in accordance with the appropriate item of the Proposal.
c. If tests are to be witnessed by the Owner or Owner’s representative, the Vendor shall notify
the Owner at least 10 days in advance of the dates that tests will be made, so that the
Owner can make arrangements for his representative to be present. The Owner will pay for
the cost of the representative’s time, travel, lodging, meals and other expenses for the tests,
for a maximum of two trips for the pump tests and two trips for the motor tests. The
Vendor shall bear all other costs for performing the witnessed tests. If a test must be re-run
due to failure in meeting the specified requirements, then the witness expenses for the retest shall be borne by the Vendor.
d.B. [All six pumps shall be tested with the six previously tested job motors at maximum speed.
Units P21-1, P21-2, and P21-3 shall be tested with each of their specified job motors and
units P22-1, P22-2, and P22-3 shall be tested with each of their specified job motors.
Factory testing with the variable frequency drive is not required].
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2.1. Pumps:
a. Pumps shall be factory tested and four certified copies of test data and test curves
shall be furnished to the Engineer. The efficiency, capacity, head, and horsepower
requirements shall be determined for not less than ten points throughout the
specified head range from shut-off to maximum specified operating capacity. Test
procedures, interpretation and conversion of data, shall conform to the latest
requirements of the Test Code of the Hydraulic Institute standards. The pump test
results shall indicate that the performance of the pump from run-out head to shutoff head is similar to the pump curve submitted with the bid submittal. If the test
results indicate that the pump performs substantially different from the curve
submitted with the bid, the Owner, at his option, may accept the unit at a reduced
price, or may refuse to accept the unit as a consequence of breach of contract on
the part of the Vendor.
1). Test results shall show no minus tolerance or margin with respect to capacity,
total head or guaranteed efficiency at the specified conditions. Pumps shall be
within the following plus tolerance at the evaluated points:
At rated heads
+ 10% of rated capacity
At rated capacities
+ 5% of rated heads
2). Pumps shall have a continuous down slope in the head-capacity curve.
b. Following completion of factory tests, the Vendor shall furnish to the Engineer for
review and approval, four certified copies of all test data and test curves for each of
the pumps. Test curves shall also show calculated curves for expected performance
at 90, 80, 70 and 60 percent of rated speed. The Engineer shall promptly review test
data and, upon determining that the pump meets contract requirements,
authorization will be given for shipment. Shipment shall not be made without
written approval of test data by the Engineer, except at the risk of the Vendor.
c. The manufacturer shall perform a hydrostatic pressure test of the pump castings at
1.5 times future shut-off head for a minimum of 5 minutes.
d. The manufacturer or his representative shall make metallurgical analysis from
coupons cast on the piece of each pour of metal going into the case and impeller
castings, and shall provide certified reports to the Owner, showing that the specified
alloys are being provided.
2. 460 VOLT MOTORS
a. All motors shall receive a short commercial test in accordance with NEMA MG-1 and
IEEE 112, latest version.
b. In addition, all motors shall receive a complete test in accordance with IEEE 112, and
certified copies of the test data recorded on appropriate forms of IEEE 112, together
with a certified statement of compliance with minimum specified power factor and
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efficiencies shall be furnished to the ENGINEER. The recorded data on the forms
shall be in sufficient clarity and detail to permit third-party longhand validation and
verification of any computer generated results. Any longhand calculations shall be
done in English.
c. Tests to be performed on each motor shall include, but not be limited to the
following:
1). Reference Resistance per IEEE Std. 112, latest version.
2). Reference Ambient of 25 degrees centigrade.
3). Efficiency using one of the following:
a). Efficiency using an equivalent circuit with direct measurement of stray load
loss per IEEE Method F.
b). Efficiency at rated voltage and frequency by dynamometer (IEEE Method B),
six points minimum. Dynamometer correction shall be applied.
4). Bearing Loss Stabilization.
5). Locked Rotor Test (two line method).
6). Slip.
7). Core Losses and Friction and Windage Losses.
8). Power Factor.
9). Load test at rated temperature rise (Stable to 1° within 30 minutes).
10). Speed-Torque and Speed Current Curves.
11). Stator Temperature Rise Measurements by embedded detector and resistance
at rated load per IEEE Std. 112, latest version.
12). High Potential Tests.
13). Winding Resistance Measurements.
14). Bearing Insulation Tests.
15). Noise Measurements per IEEE Std. 85, latest version (4 positions).
16). No load amps and power factor
17). Locked rotor power factor
18). Vibration measurements
19). Substitutions for or waivers of the tests and methods listed above will not be
permitted.
d. The ENGINEER or OWNER may witness the tests of all motors.
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e. Following completion of factory tests, the Equipment Manufacturer shall furnish to
the ENGINEER for review and approval four (4) certified copies of all test data and
test curves for each motor. The ENGINEER shall promptly review test data and,
upon determining that the motor meets contract requirements, authorization will
be given for shipment. Shipment shall not be made without written approval of test
data by the ENGINEER, except at the risk of the Equipment Manufacturer.
3. SOFT STARTERS
a. Low voltage soft starters are provided under a separate contract.
3. 41604680-Volt Motors:
a. All motors shall receive a short commercial test in accordance with IEEE 112, latest
edition, and the results tabulated on Form A-1.
b. In addition, all motors shall receive a complete test in accordance with IEEE 112, and
certified copies of the test data recorded on Forms A-2 and B, together with a
certified statement of compliance with minimum specified power factor and
efficiencies shall be furnished to the Engineer. The recorded data on Forms A-2 and
B shall be in sufficient clarity and detail to permit third-party longhand validation
and verification of any computer generated results.
c. Tests to be performed on each motor shall include, but not be limited to the
following:
1). Reference Resistance per IEEE Std. 112, latest version.
2). Reference Ambient of 25 C.
3). Efficiency using an equivalent circuit with direct measurement of stray load loss
per Method F.
a). As an alternate bid the motor supplier shall include efficiency testing at
rated voltage and frequency by a dynamometer, Method B (6 point
minimum). Dynamometer correction shall be applied.
4). Bearing Loss Stabilization.
5). Locked Rotor Test (two line method).
6). Slip.
7). Core Losses and Friction and Windage Losses.
Note to Specifier: Motor manufacturer will be required to test the motor with the power factor
correction capacitors installed to verify minimum 95 percent power factor.
8). Power Factor.
9). Load test at rated temperature rise (Stable to 1 degree within 30 minutes).
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10). Speed-Torque and Speed Current Curves.
11). Stator Temperature Rise Measurements by embedded detector at rated load
per IEEE Std. 112, latest version.
12). High Potential Tests.
13). Winding Resistance Measurements.
14). Bearing Insulation Tests.
15). Noise Measurements per IEEE Std. 85, latest version (four positions).
16). Vibration Measurements.
d. Substitutions for or waivers of the tests and methods listed above will not be
permitted.
e. Following completion of factory tests, the Vendor shall furnish to the Engineer for
review and approval four certified copies of all test data and test curves for each
motor. The Engineer shall promptly review test data and, upon determining that
the motor meets contract requirements, authorization will be given for shipment.
Shipment shall not be made without written approval of test data by the Engineer,
except at the risk of the Vendor.
4. Variable Frequency Drive: Refer to Section 26 29 23.01 “Variable Frequency Motor
Controllers” for factory inspection and test requirements.
C. Assembly: All of the job motors for units [P21-1, P21-2, and P21-3 and all of the job motors
for units P22-1, P22-2, and P22-3]WPS-P1, WPS-P2, and WPS-P3 shall be shipped to the
pump manufacturer for testing and alignment with the pump. [rs1]The pumps and motors
may be disassembled for shipment but the Vendor shall certify that at a factory, prior to
shipment, the units have been completely assembled, each part to each adjoining part and
match-marked if appropriate. The pump manufacturer shall be responsible for coordination
with the motor manufacturer to insure that no undue difficulty in assembly will be
occasioned when units are received at the project site. If the motor does not match
properly, the defect shall be corrected to the satisfaction of the Owner. Any delays beyond
the scheduled delivery time which are caused by these defects shall be subject to liquidated
damages as provided for late delivery. The pump and motor base shall be drilled for
assembly of the pump and motor and installation onto the foundation bolts. Leveling shims
shall be furnished by the pump manufacturer.
D. Marking: Each pump and motor shall each have a stainless steel nameplate securely affixed
with stainless steel tapping screws in a conspicuous place, showing the ratings, speed,
rotation, serial number, model number, manufacturer, and other pertinent data.
E. Service of Manufacturer’s Representative:
1. Pump Manufacturer Representative:
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a. The pump manufacturer shall furnish the services of a competent factory technician,
who shall have had a minimum of 5 years of’ experience in the installation,
adjustment, and operation of the equipment which is being furnished under this
contract. This service is for the purpose of insuring proper installation and
adjustment of the equipment; instructing operating personnel in proper operation,
maintenance, and care of the equipment; for making operation tests of equipment
and making recommendations for obtaining the most efficient use thereof.
b. The service representative shall be at the site at any time the Construction
Contractor is assembling, setting, aligning, connecting or adjusting and testing the
pump and motor assembly, and shall direct such work and certify in writing to the
Owner that it has been properly installed and operates satisfactorily during
acceptance tests.
c. The minimum time required to be on-site for 8 hours, not including travel time, is as
follows:
Pump and motor installation
10 days (3 trips minimum)
Pump start-up and testing
10 days (3 trips minimum)
Trouble-shooting
4 days (3 trips minimum)
Personnel training
1 day (1 trip minimum)
2. Motor Manufacturer Representative
a. The motor manufacturer shall furnish the services of a competent factory
technician, who shall have had a minimum of five (5) years of experience in the
installation, adjustment, and operation of the equipment which is being furnished
under this contract. This service is to ensure proper installation and adjustment of
the motor, instruct personnel in proper operation, maintenance, and care of the
equipment, for making operation tests of equipment, and recommendations for
obtaining the most efficient use thereof. The motor technician shall be an
employee of the motor manufacturer unless otherwise approved by the ENGINEER.
b. The service representative shall verify the proper installation, alignment, wiring,
lubrication, and connection of all appurtenances prior to start-up. He shall be
present during testing, and start-up and shall certify to the OWNER in writing that
the motor has been properly installed and operate satisfactorily.
c. The minimum time required to be on-site for 8 hours, not including travel time, is as
follows:
Check Motor Installation
4 days (2 trips minimum)
Pump Start-Up and Testing
10 days (3 trips minimum)
Troubleshooting
4 days (3 trips minimum)
Personnel Training
1 day (1 trip minimum)
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2. Motor Manufacturer Representative:
a. The motor manufacturer shall furnish the services of a competent factory
technician, who shall have had a minimum of 5 years’ experience in the installation,
adjustment, and operation of the equipment which is being furnished under this
contract. This service is to ensure proper installation and adjustment of the motor,
instruct personnel in proper operation, maintenance, and care of the equipment,
for making operation tests of equipment, and recommendations for obtaining the
most efficient use thereof.
b. The service representative shall arrive at the site after the motor installation but
prior to testing and start-up. He shall verify the proper installation, alignment,
wiring, lubrication, and connection of all appurtenances prior to start-up. He shall
be present during testing, and start-up and shall certify to the Owner in writing that
the motors have been properly installed and operate satisfactorily.
c. The minimum time required to be on-site for 8 hours, not including travel time, is as
follows:
Check motor installation
4 days (2 trips minimum)
Pump start-up and testing
10 days (3 trips minimum)
Troubleshooting
4 days (3 trips minimum)
Personnel training
1 day (1 trip minimum)
F. Lateral and Critical Speed Analysis:
1. The pump speed of any of the pumps (only one at any given time at each pump station)
will be varied by a Variable Frequency Drive (VFD) controller and will operate for
extended periods of time at speeds from 60 percent to 100 percent of the rated
synchronous motor speed. Pumps may operate at different speeds simultaneously.
2. The Vendor shall perform both a lateral and critical speed analysis of the complete
pump and motor assembly to verify that there shall be no resonant vibration of the unit
at any operating speed from full synchronous motor speed to 60 percent of
synchronous speed. A review shall be made with respect to the pump shaft diameter in
order to ensure sufficient pump rigidity in terms of good engineering practice. In
addition, a Reed Frequency review of the pump and motor assembly shall be conducted
on the pump and motor to verify its structural integrity. The Vendor shall advise the
Owner of the calculated resonant frequency of the pumping unit and shall verify its
accuracy when the unit is installed at the project site. If a resonant frequency problem
exists for the installed unit, the Vendor shall be responsible for correcting the problem.
G. Torsional Analysis: The Vendor shall provide information to the Variable Frequency Drive
(VFD) Manufacturer as required to make a Torsional Analysis. Submit copies of
information and analysis to the Owner.
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1.051.04
SUBMITTALS
A. Submittals shall be in accordance with this Section, the General Requirements, Section 01 33
00 “Submittal Procedures” and shall include:
1. Pre and Post submittal meeting: Vendor shall include in his bid the cost of attending a
one-day pre-submittal meeting and a one-day post-submittal meeting in the offices of
Freese and Nichols, in Fort Worth, Texas. The Project Manager and Project Engineer for
both the Pump and Motor Manufacturer must be present. A sales person may attend,
but not as a substitute for Project Manager or Project Engineer. Vendor shall determine
the number of people attending the meeting and cover each person’s cost.
2. Bid Submittal: In order to evaluate the bids, submit the following information.
a. General: Furnish a complete description of all equipment offered under these
specifications, including catalogs, cuts and pertinent engineering data. Where the
Bidder’s product differs from the specified requirements and/or catalog description,
each point of difference shall be clearly stated. This requirement is set forth to
facilitate the review of bids and not to be construed by the Bidder as waiving any of
the requirements of the specifications.
b. Characteristic Curves: Characteristic curves for the pumps offered shall be
submitted with the bid. Curves shall show the capacity, head, efficiency, required
NPSH, and brake horsepower throughout the operating range of the pump from
shut-off to maximum specified operating capacity. Characteristic curves shall have
the capacity plotted as abscissa and the operating head, brake horsepower,
efficiency and required NPSH plotted as ordinates.
c. Outline Drawings: Submit outline drawings of the pumps, motors and
appurtenances, showing layout dimensions of the proposed equipment.
1
1
d. Data Sheet: Submit information requested on the Data Sheet included with the Bid
Proposal forms. The Data Sheets are included as “Attachment A” and “Attachment
B” to this specification.
e. Provide copies of the motor starting analysis and preliminary motor curves as
indicated in Paragraph 2.02.A.8.a.
f.
Provide a list of at least three similar units in service supplied in the last 5 years and
a name and telephone number for a reference for each of these installations.
g. Provide a description of the components that will be shipped separately, thus
requiring field assembly.
h. Provide a plan and schedule indicating dates for submittals, manufacturing, testing
and delivery.
3. Shop Drawings:
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a. Drawings shall show complete physical description and performance capabilities of
the pumping equipment, including, but not necessarily limited to dimensions,
weights, materials, assemblies, outline views, sectional views, performance curves,
power requirements and ratings, rated voltage and amperage, color charts and
wiring diagrams as may be applicable.
b. Submit drawings with dimensional tolerances for connecting parts for use to aid in
future repairs and making field connections. Provide analysis of the backspin speed
analysis during power failure, and confirmation from the motor supplier that the
motor is suitable for the maximum backspin speed speed(TPS only).
c. Provide alarm and trip temperatures for pump RTDs.
d. Provide wiring/interconnection diagram for pump RTDs. Diagram shall clearly
identify which RTDs connected to the specific terminal blocks.
e. Submit drawings as a complete package of all equipment furnished. Partial
drawings will not be reviewed.
1
f.
Subsequent shop drawings shall include results from lateral and critical speed
analysis, torsion analysis, forces and moment analysis of discharge head.
g. Prior to testing, submit lab set-up sketches, test procedures, testing equipment, test
equipment calibration certification, and sample calculations.
h. Submit motor documentation as required per paragraph 2.02.I of this specification.
Incomplete data submitted will not be reviewed and will be returned “Not
Approved, Revise and Resubmit”.
i.
Quality Control plan for pump materials and components.
4. Operation and Maintenance Data:
a. Submit Manuals with instructions for installation, adjustment, lubrication, operation
and maintenance of the equipment in accordance with Special Conditions and
Section 01 33 00 “, Submittal Procedures”.
b. Manuals shall be prepared by the equipment Manufacturer per Section 01 78 23
“Operations and Maintenance Data” and shall incorporate storage and installation
instructions and operation and maintenance procedures, appropriate final certified
shop drawings, performance curves, and test data. Manuals may be Manufacturer’s
standard instructions, but shall be supplemented as necessary to cover any special
feature not included in standard material. Submit preliminary manuals for review
prior to delivery of the equipment.
5. Certified Test Reports: Submit certified test reports for factory performance tests and
metallurgical tests.
6. Equipment Installation Report: Submit Equipment Installation Reports from the motor
manufacturer and pump manufacturer.
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A. Submittals shall be in accordance with this section, the General Requirements, Section 01 33
00 “Submittal Procedures” and shall include:
Pre and Post submittal meeting: Vendor shall include in his bid the cost of attending a
one-day pre-submittal meeting and a one-day post-submittal meeting in the offices of
Freese and Nichols, in Fort Worth, Texas. The Project Manager and Project Engineer for
both the Pump and Motor Manufacturer must be present. A sales person may attend,
but not as a substitute for Project Manager or Project Engineer. Vendor shall determine
the number of people attending the meeting and cover each person’s cost.
1. Shop Drawings:
Drawings shall show complete physical description and performance capabilities of
the pumping equipment, including, but not necessarily limited to dimensions,
weights, materials, assemblies, sectional views, color charts, performance curves,
power requirements and ratings, rated voltage and amperage, and wiring diagrams
as may be applicable.
a. Submit machine drawings with dimensional tolerances for connecting parts for use
to aid in future repairs and making field connections. Provide results of lateral and
critical speed analysis. Provide analysis of the backspin speed analysis during power
failure, and confirmation from the motor supplier that the motor is suitable for the
maximum backspin speed.
b. Submit drawings as a complete package of all equipment furnished. Partial
drawings will not be reviewed.
Submit lab set-up sketches, test procedures, testing equipment, test equipment
calibration certification, and sample calculations.Submit motor documentation as
required per paragraph 2.02.I of this specification. Incomplete data submitted will
not be reviewed and will be returned “Not Approved, Revise and Resubmit”.
c.
Operation and Maintenance Manuals:
2. Manuals shall be prepared by the equipment manufacturers per Section 01 78 23
“Operation and Maintenance Data” and shall include storage and installation
instructions, operation and maintenance procedures, appropriate final certified
shop drawings, performance curves, wiring diagrams and test data. Manuals may
be the manufacturer’s standard instructions, but shall be supplemented as
necessary to cover any special feature not included in standard material. Submit
preliminary manuals for review prior to delivery of the equipment.
3. Bid Submittal: In order to evaluate the bids, submit the following information:
a. General: Furnish a complete description of all equipment offered under these
specifications, including catalogs, cuts and pertinent engineering data. Where the
Bidder’s product differs from the specified requirements and/or catalog description,
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each point of difference shall be clearly stated. This requirement is set forth to
facilitate the review of bids and not to be construed by the Bidder as waiving any of
the requirements of the specifications. General dimension drawings shall be in
sufficient detail to permit the Engineer to evaluate the application to the facilities
for which equipment will become part.
b. Characteristic Curves: Characteristic curves for the pumps offered shall be
submitted with the bid. Curves shall show the capacity, head, efficiency, required
NPSH, and brake horsepower at the specified operating throughout the operating
range of the pump from shut-off to maximum specified operating capacity for initial
and future conditions. Separate curves showing the above data shall be submitted
for 60, 70, 80, 90 and 100 percent speed.points. Characteristic curves shall have the
capacity plotted as abscissa and the operating head, brake horsepower, efficiency
and required NPSH plotted as ordinates.
c. Data Sheet: Submit information requested on the Data Sheet included with the Bid
Proposal forms.
d. Outline Drawings: Submit outline drawings of the pumps, motors and
appurtenances, showing layout dimensions of the proposed equipment for use in
the final design of the pump stations. The drawings shall indicate the flange drilling
pattern and orientation. Any revisions to these dimensions must be approved by
the Engineer. If changes are made to these layout dimensions, the Owner reserves
the right to reduce payment to the supplier for extra work by the Engineer as a
result of such changes.
e. Provide copies of the motor starting analysis as indicated in Paragraph [2.02 A.109].
f.
Provide certification that the Vendor has complied with the contract tier
relationship as specified in Section [22 11 23.01 “Horizontal Centrifugal Pumping
Units.”]
g. Provide a list of at least three similar pumping units that have been in service for at
least 5 years and the name and telephone number of a reference for each unit.
h. Provide a description of the components that will be shipped separately, thus
requiring field assembly.
i.
Provide an estimated schedule indicating dates, for manufacturing and submittals.
Certified Test Reports: Submit certified test reports for factory performance tests and
metallurgical tests. Submit the following certified test reports for pump and motor.
INSERT PUMP CTR LIST HERE
Provide CTR for motor factory performance tests.
Provide CTR (with EIR) for motor field tests.
4.
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5. Equipment Installation Report: Submit Equipment Installation Reports from the motor
manufacturer and pump manufacturer.
1.061.05
STANDARDS
A. The applicable provisions of the following standards shall apply as if written here in their
entirety:
1. American Water Works Association (AWWA).
2. American National Standards Institute (ANSI).
3. American Standards for Testing and Materials (ASTM).
4. Test Code of the Hydraulic Institute Standards (HIS).
5. National Electrical Manufacturers Association (NEMA).
6. Institute of Electrical and Electronic Engineers (IEEE).
6.7. National Electric Code (NEC)
1.071.06
DELIVERY AND STORAGE
A. The Vendor shall be responsible for delivery of the pump, driver, and accessories, f.o.b. to
the job site or to such storage site as may be designated by the Owner or Construction
ContractorCMAR in good condition and undamaged. The Vendor shall submit a shipping
notice and storage and installation instructions at least 1 week prior to shipment.
B. Unloading and storage of the equipment shall be the responsibility of the Construction
Contractor who shall inspect the equipment for apparent damage. Equipment which is
found to be damaged will not be accepted until properly repaired or replaced by the
Vendor.
C. The pumps, motors, and accessories shall be stored indoors, and the motor space heaters
shall be energized upon delivery.
1.081.07
JOB CONDITIONS
A. Performance Requirements:
1. Liquid to be pumped is untreated well ground water with no abnormal amount of sialt
or abrasives.
2. Each pump will be started and stopped with a partially closed control valve and a check
valve on the pump discharge. The control valve will be slow opening and slow closing.
Opening and closing speed of the valve will be adjustable, normally from 6 3 to 10 5
minutes. The control valve may be closed for up to 3 minutes while the pump is started.
The pump casing, discharge flange, and seals shall be designed for extended up to one
minute operation at shut-off head.
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a.2. [The pumping units at Pump Station 21 will be started with a variable frequency drive or
soft starter. The pumping units at Pump Station 22 will be started with a variable
frequency drive or with full voltage non-reversing starters.. The top of the pump casing
shall have an outlet for an air valve assembly].
3. In the event of power or motor failure, water from the system may flow in reverse
through the pumps while the pump control check valve is slowly closing. The complete
pumping unit, including motor, shall be suitable for reverse rotation without damage to
any part at a speed of 130 140 percent of normal operating speed, or at the maximum
speed due to water flowing from the system at maximum discharge head, back through
the pump into the suction tank, upon failure of power to that pump.
a. Maximum discharge head is as follows:
1). [Pump Station 21: 520 ft.]Well-Field Transfer Pump Station: 260200 ft
2). [Pump Station 22: 230 ft.]
4. The system curves [Figure 1 and Figure 2] included as Figure 13 in the appendix of this
in the specification appendix shows the system heads at the design conditions at which
the pumps will operate, and the pumps will operate alone as well as in parallel with
other pumps. The performance requirements listed below (rated conditions) are the
capacities and heads required for average static head conditions. Pump curves for
single pump operation should extend sufficiently below the minimum static head
system curves shown on Figure 1 and Figure 2 and the NPSH required shall be less than
the NPSH available as determined from the pump setting requirements in Paragraph
[1.07B]. Pumps shall have a continuously rising performance curve from pump run-out
to shut-off head with no intermediate flat places.
5. The pumping heads shown below are total dynamic heads (TDH) under field conditions
and are exclusive of all internal pump losses.
6. Listed below are the performance requirements of the pumping units at the rated, or
average static head conditions. In evaluating the bids the Owner will take into
consideration the overall wire-to-water efficiency of the complete pumping units at
various rated conditions as described below in Paragraph [1.08], Bid Evaluation.
7. Pump Station [21] Pump Selection: Listed below are the performance requirements for
the Pump Station 21 pumps. Pumps [P21-1, P21-2, and P21-3]WPS-P1, WPS-P2, and
WPS-P3 shall be identical units with the same impeller size for each unit. The motors
provided under this contract shall be of sufficient size to drive the pumps with the
impellers required to meet the future maximum flow. The pumps shall be designed such
that only impeller replacement is needed to meet the future conditions. The pump
selection criteria shall be as follows:
a. Each pump shall have a rated capacity of [17,4006,95045 gpm at 375 179 feet TDH].
[Two of these pumps operating in parallel at full speed shall provide the initial
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maximum rated flow of 34,800 gpm at 375 feet TDH. For bid evaluation purposes,
these pumps will also be evaluated at a rated head of 300 feet TDH.]
b. The initial intermediate flow shall be provided by one pump [of the size specified in
Aa@] operating at a reduced speed.
c. The initial minimum flow shall be provided by one pump [of the size specified in
Aa@] operating at a reduced speed.
d. The future maximum flow shall be accomplished by changing to larger impellers in
each of the three initial pumps. The future pumps shall have identical impeller size
and the maximum flow shall be accomplished by three pumps operating in parallel.
b. Pump curves for one two pumps in operation at full speed shall extend sufficiently
below the minimum static head system curve such that one two pumps can operate
alone together (without cavitation) with the pump Allowable Operating Range
(A.O.R.) during both initial and future flow conditions.
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e.
f.
The pumps chosen shall be able to operate at reduced speeds by the use of one VFD such that
two pumps can provide flows anywhere on the system curve from the initial minimum flow to the initial
maximum flow for initial flow conditions. Similarly, three pumps with the future impeller size and one
VFD shall be able to provide flows anywhere on the system curve from initial minimum flow to future
maximum flow.
g.
The pumps chosen shall be able to operate at a reduced speed by the use of one VFD to provide
a minimum flow of [5000 gpm].
Note to Specifier: Verify and change requirements per project.
Performance Requirements
No. Of Units
Initial Max. Rated Flow at Point 1
(Two All pumps in parallel at full speed)
Initial Max. Rated Head at Point 1, ft.
Initial IntermediateRated Flow (min) at
Point 2
(One Two One pumps alone in parallel at
reduced full speed)
Initial Intermediate Head at Point 2, ft.
Pump
[P21-1, P21-2, P213]WPS-P1, WPS-P2,
& WPS-P3
33
34,80020,833 gpm
375179
17,80016,6678,333
gpm
25510025
Maximum Motor Horsepower (HP)
400
Motor Voltage (V)
460
Maximum Speed
1800 RPM
Initial Minimum Flow
(One pump alone at reduced speed)
Initial Minimum Head, ft.
Future Max. Flow
(Three pumps in parallel at full speed)
Future Max. Head, ft.
11,900 gpm
230
44,500 gpm
470*
Motor Voltage
4160
Max. Motor Speed, rpm
1200
*The future maximum head at [44,500 gpm] may be reduced, if
necessary, to [445 ft.] by adjusting tank levels if required to meet
the [44,500] gpm requirement.
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8. [Pump Station 22] Pump Selection: Listed below are the performance requirements for
the [Pump Station 22] pumps. Pumps [P22-1, P22-2, and P22-3] shall be identical units
with the same impeller size for each unit. The motors provided under this contract shall
be of sufficient size to drive the pumps with the impellers required to meet the future
maximum flow. The pumps shall be designed such that only impeller replacement is
needed to meet the future conditions. The pump selection criteria shall be as follows:
a. Each pump shall have a rated capacity of [16,200 gpm at 115 feet TDH]. One of
these pumps operating alone at full speed shall provide the initial intermediate
rated flow. For bid evaluation purposes, these pumps will also be evaluated at a
rated head of [130 feet TDH, with a minimum capacity of 13,450 gpm at the 130
feet TDH].
b. The initial minimum flow shall be accomplished by operating one pump [of the size
specified in Aa@] at a reduced speed.
c. The initial maximum flow shall be accomplished by operating two of the pumps [of
the size specified in Aa@] in parallel at full speed. The initial maximum flow
specified below is the minimum amount of flow required. It is anticipated that the
two pumps will provide more than the minimum specified, which will be acceptable.
d. The future maximum flow shall be accomplished by changing to larger impellers in
each of the three initial pumps. The future pumps shall have identical impeller size
and the maximum flow shall be accomplished by three pumps operating in parallel.
e. Pump curves for one pump operation shall extend sufficiently below the minimum
static head system curve such that one pump can operate alone (without cavitation)
during both initial and future flow conditions.
f.
The pumps chosen shall be able to operate at reduced speeds by the use of one VFD
such that [two] pumps can provide flows anywhere on the system curve from the
initial minimum flow to the initial maximum flow for initial flow conditions.
Similarly, [three] pumps with the future impeller size and one VFD shall be able to
provide flows anywhere on the system curve from initial minimum flow to future
maximum flow.
g. The pumps chosen shall be able to operate at a reduced speed by the use of [one
VFD] to provide a minimum flow of [5000] gpm.
Note to Specifier: Verify and change requirements per project.
Performance Requirements
No. Of Units
Initial Intermediate Rated Flow
(one pump alone at full speed)
orizontal Centrifugal Pumping Units
Pump
[P22-1,P22-2,P22-3]
3
16,200 gpm
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Initial Intermediate Rated Head, ft.
Initial Minimum Flow
(1 pump alone at reduced speed)
Initial Minimum Head, ft.
Initial Max. Rated Flow
(2 pumps in parallel at full speed, min. required)
Initial Max. Rated Head, ft.
Future Max. Flow
(3 pumps in parallel at full speed)
Future Max. Head, ft.
115
10,800 gpm
105
26,900 gpm
130
44,500 gpm
180
Motor Voltage
4160
Max. Motor Speed, rpm
1200
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B. Pump Setting Requirements:
B. Note to Specifier: Verify and change requirements per project.
Pump Setting Requirements
Elev. Top of Concrete Block for Pumps
Elev. Suction Tank Max. Water Level
Elev. Suction Tank Min. Water Level
Max. Pump Suction Size
Max. Pump Discharge Size
Pump
[P21-1WPS-P1, WPSP2P21-2,
& WPS-P3 P21-3]
2650.03013.52650.0
3063.02679.52678.0
3028.02647.52650.0
2652.0
24” or 30”20”
1
20”18”
Suction Pump Piping Friction Loss – Assume 24.0 ft.
1.091.08
BID EVALUATION
A. General: The Bidder shall fill in the blanks in the Bid Proposal indicating his guaranteed
wire-to-water efficiency of the pumping units at the specified rated conditions, and the
guaranteed overall efficiencies of the variable frequency drives.. The guaranteed overall
efficiency of the VFD shall be rated as specified in Section 26 29 23.01 “Variable Frequency
Motor Controllers.”
B. Pumping Units:
1. In comparing bids, the Owner will take into consideration the guaranteed efficiencies of
the pumps at the specified rated head and flow conditions as stated in the bid proposal.
For the purposes of evaluation, the overall efficiency of the pumping units shall be the
average of the efficiency at the first rated condition and the efficiency at the second
rated condition. The value of 1 percent in overall wire to water efficiency for each
pump shall be worth $3,500[$5000]. Due consideration will also be given to pump
performance at other operating conditions in evaluating the pumping units, in order to
select the pumping unit best suited to the operation of the system, in the opinion of the
Owner.
2. The Owner will also evaluate the NPSH required for the pumps at the various specified
pumping conditions, and the fact that the required NPSH is just barely below the
available NPSH, may be justification to reject the offering.
C. Variable Frequency Drives:
1. Bids will be evaluated on submitted guaranteed minimum efficiencies of the VFD
system, input and output filters, isolation transformers, contactor, power factor
correction capacitors, fan(s), controls and all other accessories. The value of 1 percent
in guaranteed efficiency at each operating speed shall be [$5,000].
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2. The bids will also be evaluated for the space requirements of the drives and accessory
equipment. The drawings in the Appendix indicate the space allowed for the drives and
accessories. Based on the outline dimensions provided by the bidders, the Engineer will
evaluate the space requirements of the pump building. For each linear foot that the
equipment requires the building size to be increased, a penalty of [$30,000] will be
assessed to the bid evaluation price. The evaluation factor may be applied to the
building width and building length. The maximum height of the equipment shall be
limited to 7 feet-8 inches. No credit in the bid evaluation will be given for equipment
dimensions smaller than shown in the drawings in the Appendix.
3. The bids will be evaluated on other criteria listed in the specifications, and the Owner
reserves the right to award the bid to the lowest responsive bidder who proposes the
best offering in the opinion of the Owner.
4. Should the successful bidder not meet the guaranteed minimum efficiency
requirements, a contract adjustment shall be assessed for efficiency at 100 percent
speed and 80 percent speed as indicated in the attached example. Owner may, at his
discretion, reject the equipment if the stated efficiency is too far below the guaranteed
point specified. The contract adjustment will be assessed and levied on the Supplier if,
however, the Owner chooses to accept the equipment. The contract adjustment will be
calculated using the same formula used to award the Contract. The contract adjustment
will be calculated based on [$5,000] per efficiency point per each VFD. One efficiency
point is equal to 1 percent.
5. In addition, should the successful bidder not meet the dimensions guaranteed in the
outline drawings submitted with his bid, a contract adjustment shall be assessed for
each additional foot of building length and building width. Owner may, at his discretion,
reject the equipment if the final dimensions are too far greater than the bid dimensions.
Additionally, if the equipment outline dimensions require a re-design of the pump
station or related facilities, the Owner may assess the re-design cost to the
manufacturer.
D. Pumping Units and Variable Frequency Drives: The following hypothetical example is shown
to explain the bid evaluation factors:
C. Note to Specifier: Verify and change requirements per project.
Bidder
No. 1
Bidder
No. 2
88% 87%,
86%
86%, 84%
8784%, 85%
87%
87%85%
87%86%
0
$103,5,000
$$5,00010,
Description
1
Pumps P21-1, P21-2, P21-3 WPS-P1, WPS-P2,
& WPS-P3: Stated Eff. @ 375 179 feet TDH,
300 feet TDH
Efficiency for Evaluation
(P21-1, P21-2, P21-3WPS-P1, WPS-P2, &
WPS-P3)
Pump Calculated Penalty/Credit
orizontal Centrifugal Pumping Units
Bidder
No. 3
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Bidder
No. 1
Description
Bidder
No. 3
500
0
$3010,0005
00
$1531,0005
00
86%, 80%
87%, 85%
84%, 80%
83%
86%
82%
Pump Calculated Penalty/Credit
$15,000
$0
$20,000
Applied Penalty/Credit for 3 Pumping Units
$45,000
$0
$60,000
VFD Stated Bid Eff @ 100% Speed
97%
98%
96%
VFD Calculated Penalty/Credit @ 100%
Speed
$5,000
$0
$10,000
VFD Stated Bid Eff @ 80% Speed
96%
97%
95%
VFD Calculated Penalty/Credit @ 80% Speed
$5,000
$0
$10,000
VFD Additional Building Length
0’
0’
4’
VFD Penalty for Building Length
$0
$0
$120,000
VFD Additional for Building Width
0’
1’
1’
VFD Penalty for Building Width
$0
Total Penalty/Credit
$70,0000
$30,000
$31,500$27
0,000
Stated Bid Price
$2,000,000
$30,000
$10,500$70
,000
$21,100850
,000
Evaluated Bid Price
$2,070000,
000
Applied Penalty/Credit for 3 Pumping Units
Pumps P22-1, P22-2, P22-3: Stated Eff. @
115 feet TDH, 130 feet TDH
Efficiency for Evaluation
(P22-1, P22-2, P22-3)
1
Bidder
No. 2
orizontal Centrifugal Pumping Units
$21,170865
,000
$1,950,000
$21,220995
,000
$1,981,500
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1. The following hypothetical example is shown to explain the contract adjustments for
failure to meet guaranteed efficiencies of the pumping units and variable frequency
drives and the outline dimensions of the variable frequency drives:
1. Note to Specifier: Verify and change requirements per project.
Description
1
Evaluated
Bid
Efficiency
Test
Efficiency
Difference
Pump Tests
(WPSP21-P1, P21-2WPSP2, & P21-3WPS-P3)
8687%
8786%
+1%
Pump Tests
(P22-1, P22-2, P22-3)
85%
83%
-2%
VFD Test @ 100% Speed
97%
96.5%
VFD Test @ 80% Speed
96%
96.1%
-0.5%
+0.1%
Penalty
Or Credit
3 x $5,000 =
($15,000)
3X$3,500 =
($10,500)
3 x $10,000 =
$30,000
1 x $2,500 =
$2,500
1 x ($500) =
($500)
Note to Specifier: Verify and change requirements per project.
1
2. Hence, the contract amount will be adjusted downward by [$4715,000 $10,500]. No
credit will be awarded for VFD equipment sizes smaller than the bid submittal outline
dimensions. In no event will the overall contract amount be adjusted upwards, even if
the test efficiencies are greater than the bid efficiencies.
2.
3. The contract adjustment to be assessed in the event of failure to meet guaranteed
efficiency and outline dimensions is not to be construed as a penalty, but as a
reasonable contract adjustment due to the impracticality and extreme difficulty in
calculating actual damages. By submitting a Bid Proposal and executing the Contract
Agreement, the Vendor agrees to such contract adjustment assessments.
1.10
GUARANTEES
A. Vendor shall warrant the equipment furnished under this specification for a period of two
years against defects in materials and workmanship and operational failure.
B. In the event of failure of any part or parts of the equipment during the warranty period,
provided that the equipment has been operated and maintained in accordance with good
practice, the Vendor shall furnish, deliver and install the defective part or parts at his own
expense.
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C. The warranty period shall be interpreted as the 24-month period following the installation,
adjusting and acceptance testing, and the start of actual operation of the equipment, or 30
months following delivery of all of the equipment, whichever comes first.
D. The wire-to-water efficiency of the pumping units shall be guaranteed at the rated
conditions as specified and stated in the proposal. In the event the Factory Tests show that
the actual overall wire-to-water efficiency of a pumping unit is less than that guaranteed,
the Owner, at his option, may accept the unit at a reduced price or may refuse to accept the
units as a consequence of breach of contract on the part of the Vendor. The reduction in
price, if the actual efficiency is less than the guaranteed efficiency provided on the proposal,
shall be computed as previously indicated. In addition, if the Factory Test results indicate
that the pump performs substantially different from the curve submitted with the bid, the
Owner, at his option, may accept the unit at a reduced price, or may refuse to accept the
unit as a consequence of breach of contract on the part of the Vendor.
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2.00
PRODUCTS
1.112.01
PUMPS
A. General:
1. Pumps shall be horizontal, single-stage, split-case, double-suction, double volute,
centrifugal pumps with side suction and side discharge for pumping untreated well
ground water. When viewed from the driver end, the discharge shall be on the left
hand side of the pump and rotation shall be clockwise.
2. The pump supplier shall furnish all bolts, nuts, and gaskets for the pumping units, except
bolts, nuts, and gaskets for the suction and discharge flanges, which shall be supplied by
the Installation Contractor. All bolts and nuts shall be stainless steel.
B. Casing:
1. Pump casing shall be of strong close-grain cast iron in accordance with ASTM A48 Class
30, or ductile iron in accordance with ASTM A536 designed for heavy duty service,
double volute design, free of blow holes, or other detrimental defects. The casing shall
be horizontally split with the suction and discharge flanges cast integrally with the lower
half in order that the upper part may be removed for inspection of the rotating element
without disturbing pipe connections or pump alignment. The joint between halves of
the casing shall be heavily flanged and bolted, and provided with dowel pins to insure
accurate alignment. The interior shall be smooth and free from surface defects. The
diameter and drilling dimensions of suction and discharge flanges shall be ANSI Standard
and shall be adequate to withstand shut-off pressure plus 50 percent.
2. Casings shall be drilled and tapped for air/vacuum valve, gauge, and drain connections.
Suitable lifting lugs or eye bolts shall be provided. Casing shall be tested in accordance
with Hydraulic Institute Standards under a hydrostatic pressure of 150 percent of
maximum (future) shut-off head.
C. Impeller: Impeller shall be of the double suction enclosed type, made of bronze entirely of
cast nickel aluminum bronze, ASTM B148 C95800, or of cast stainless steel, ASTM A487, CA6MN Class “B” containing 13 percent chrome and 4 percent nickel. Impeller shall be
finished smooth finished smooth all over and of ample strength and stiffness for maintaining
the maximum capacity of the unit. It shall be statically and dynamically balanced and shall
be keyed to the shaft and securely held in axial position on the shaft by means of stainless
steel sleeves properly secured to the shaft so that it cannot become unfastened when the
pump is reversed. All rotating parts of pumps shall be machined true to insure rotational
balance with the impeller, coupling, and other parts that may be mounted on the shaft, such
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that the pump shall operate within vibration tolerances specified in Hydraulic Institute
Standards.
D. Wearing Rings: At the running joint between the suction and discharge chambers, there
shall be provided on both the casing and impeller, renewable wearing rings with large
running surface area and designed for smooth flow areas. The casing rings shall be secured
by stainless steel screws or other suitable method. Impeller rings shall be securely attached
and so fastened that they cannot become loose when the pump is reversed. Wearing ring
material shall be 400 Series stainless steel for the stainless impeller or bronze for the bronze
impeller and shall be compatible with the impeller material and shall be an alloy with a
Brinnel hardness of 100 points greater than the impeller wear ring.
E. Shaft: Pump shaft shall be of ample conservative design such that it will be suitable to
transmit the future maximum brake horsepower required by the pump, and be of sufficient
stiffness to prevent contact of the wearing rings under any condition of operation. Shaft
shall be heat treated steel, accurately machined and ground, with non-corrosive stainless
steel sleeves in the pump and through the stuffing box area.
F. Stuffing Boxes: Stuffing boxes shall be water sealed, and shall be designed to insure tight
packing without excessive wear or friction on the shaft sleeve, and to prevent air leakage
into the pump under all conditions of operation. Glands shall be of stainless steel, shall be
the split type, and shall be held in place by stainless steel gland bolts. Packing shall be
braided synthetic fibers impregnated with lubricating compounds. Drip pockets shall be
provided for all water sealed glands and the Vendor shall provide piping to common drains
to take care of leakage. Piping with pressure regulating valves, needle valve and pressure
gauge shall be provided on the upper half of the pump casing from the discharge volute to
the stuffing box for lubricating the packing with the liquid being pumped. Piping shall be
protected from freezing with heat trace and insulation.
G. Bearings: Bearings shall be oil lubricated anti-friction ball type adequately sized to carry
radial and thrust loads without the addition of external cooling. Anti-friction bearings shall
have a L-10 bearing life of 100,000 hours at the rated head and flow of the pump in
accordance with the standards of the Bearings Manufacturers Association.
H. Bearing Temperature Sensors: Each pump shall be equipped with two 100-ohm platinum
RTDs to detect bearing temperatures. RTDs shall be mounted on the inboard and outboard
bearing, and not the bearing oil bath. The RTDs leads shall terminate in one electrical box
on barrier type terminals with stainless steel screws. Terminations to the terminals shall be
with ring type connectors. Terminal blocks shall be 600V, NEMA rated. Leads shall be
suitably marked and identified with heat shrink markers. Accessories boxes shall have
phenolic nameplates, white with black lettering, attached with stainless steel screws. The
nameplates shall say “PUMP BEARING RTD’S.” Accessories boxes shall be bottom or side
entry. Conduit shall beAccessories boxes shall be located on the discharge side of the pump.
Conduit shall be rigid aluminum, and conduit location shall not interfere with pump
maintenance. Accessories box shall be sized to accept 1” conduit for bearing RTDs. Boxes
shall have a NEMA 4X rating and be 316 Stainless Steel.
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I.
Coupling And Guard: Flexible couplings shall be the heavy duty type, designed so that the
pump shaft may be removed without disturbing the position or adjustment of the driving
unit. Coupling shall be all metal, Fast’s Self-Aligning Couplings as manufactured by the
Kooper’s Company of Baltimore, Maryland, or approved equal. Horizontal surface of the
coupling shall be machined parallel to the axis of the shaft, and faces shall be machined
perpendicular to the axis of the shaft. Provide an appropriate coupling guard, acceptable to
OSHA, securely attached to the pump base with stainless steel bolts and nuts.
J.
Pump and Motor Base: Pump and motor shall have a common one-piece base. The length
and width of the base shall be of suitable size to fit within the limits of the concrete block
pump support as shown on the drawings. The base shall be fabricated steel of sufficient
strength and depth to insure rigidity and so designed as to make a good appearance, and
provided with adequate grout holes. The base shall be heat induced stress relieved, at the
factory prior to shipment. The base shall be provided with planed supports or bearing pads
for the pump and motor. Base shall be drilled to receive a suitable number of foundation
bolts. Base shall have a minimum of eight heavy duty jacking bolts welded to the base,
positioned around the motor base to aid in alignment. Stainless steel foundation bolts
complete with sleeves, washers, nuts, etc., shall be furnished for each pumping unit by the
pump manufacturer. The pump and motor shall be mounted on the supports or bearing
pads with full faced brass shims. Foundation bolts and sleeves shall be furnished and
shipped ahead of the pumps as necessary to meet the schedule of installation by the
Construction Contractor. Furnish templates to Installation Contractor for setting anchor
bolts. Foundation bolts and sleeves only shall be furnished for the fourth, future pumping
unit.
K. Pump Painting: Interior pump surfaces shall be coated with liquid epoxy, AWWA C210, to
give a minimum total dry film thickness of 15 mils and shall be Tnemec Pota-Pox Series 20 or
approved equal. All exterior surfaces, including the pump base, shall be cleaned, primed,
and painted with two coats of manufacturers standard exterior machinery enamel. Furnish
extra touch-up paint for Installation Contractor’s use. Color shall be selected and approved
by the Owner.Pump Painting:
1. Immersion Exposures
a. All interior pump surfaces shall be coated with an epoxy coating system.
b. All metal surfaces shall be abrasively blasted to an SSPC SP5, white metal blast, and
coated with three coats of polyamide epoxy. Between the prime coat and the
intermediate coat, apply a separate strip coat of polyamide epoxy on all angles,
edges, welds, and bolted connections where coating film build will be reduced.
Alternate color of each coat of epoxy with final color. Color for visible surfaces shall
be selected and approved by the Owner.
1
c. Final coating shall be factory applied and have a minimum dry film thickness of 12
mils and shall not exceed manufacture’s maximum film build recommendations.
Furnish five gallons of touch-up paint.
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1. Coat interior of pump casings with a ceramic epoxy coating to enhance pump
efficiency. Prepare surface to SSPC-SP-10 minimum, or as recommended by the
coating manufacturer. Prime and finish coat shall be 10 mils each DFT Belzona
1341NSF efficiency enhancement coating system for potable water. Perform a holiday
test and correct all defects.
2. Atmospheric Exposure
a. All other metal surfaces above the floor shall be cleaned, primed, and painted with
two coats of manufacturer’s standard exterior machinery enamel.
b. Surface preparation shall be in accordance with coating Manufacture’s
recommendations SSPC SP-10 surface abrasive blast, whichever is more stringent.
K.c. Color shall be selected and approved by the Owner. Furnish one gallon of extra
touch-up paint.
1.122.02
MEDIUM 4860 VOLTAGE MOTORS
A. GENERAL:
1. Motors shall be horizontal, air cooled, solid shaft, copper wound stator, copper bar
rotor construction, squirrel cage induction type. The three three mMotors at WPSpump
[Station 21] shall be designed for starting using solid state reduced voltage soft starters
and across the line starters. or a variable frequency drive. The three motors at [Pump
Station 22] shall be designed for starting using full voltage non-reversing starters or a
variable frequency drive. Motors at [Pump Station 21] shall be identical to each other.
and motors at [Pump Station 22] shall be identical to each other.
a. All of the pumping units (only one at any given time, at each pump station) may be
varied by Variable Frequency Drive (VFD) motor controllers and will be operated for
extended periods of time at speeds from 60 percent to 100 percent of rated
synchronous motor speed.
b. The VFD and motor shall be completely compatible electrically. The VFD supplier
and the Motor supplier shall together issue a guarantee of compatibility at the time
of submittal. The VFD supplier and motor supplier shall determine the insulation
voltage rating required to accommodate common mode voltages and prevent
insulation failure.
c. The motor supplier shall also be responsible for coordinating with the soft-starter
supplier (to be determined at a later date) to meet the requirements of this
specification.
d. The selection and adequacy of the VFD shall be the responsibility of the motor
manufacturer.
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2. Horsepower nameplate rating of motor, at the 1.0 service factor, shall be equal to or
greater than the total horsepower requirement of the pump when operating at any
head between shut-off and minimum specified operating heads for the future pump
configuration as specified herein. Motor shall have a service factor of 1.15 and shall be
designed and manufactured in accordance with applicable provisions of the latest NEMA
Standard Publication for Motors and Generators, MG1 Part 20, subject to modifications
and additions as herein set forth.
3. The locked rotor torque and breakdown torque shall not be less than shown in NEMA
MG- 1 20.1037 and 12.38 for centrifugal pumps.
4. The locked rotor KVA/HP shall not exceed NEMA code Letter F, 5.596 KVA/HP.
5. Motor shall have a sound power level of no more than that shown in NEMA MG1, Table
20-2.
5. Motor shall have a sound power level of no more than 85 dBA average at 1 meter (3.3
ft) distance when measured per IEEE Std. 85 “Test Procedure for Airborne
Measurements on Rotating Electrical Machinery”.
6. Rotor shall be “precision” balanced to within an amplitude peak to peak in accordance
with the requirement of NEMA MG-1.
7. Motor shall be rated at 4000 4860 volts, three-phase, 60 Hertz.
8. Motors at Pump Station 21 shall not exceed an inrush of 7680 2070 KVA at 4160 4860
volts when being started by a VFD or soft starter. Motors shall be capable of bringing
the pumps up to speed with a closed control valve and 80 percent of rated voltage.
9.
10. Motors at Pump Station 22 shall not exceed an inrush of 7500 KVA at 4160 volts
when being started by a VFD or across the line.
11.a. Motor supplier shall be responsible for doing a preliminary motor starting
analysis to verify the motor will properly start while meeting the requirements
specified abovegiven in items 8 and 9 above. This preliminary motor starting
analysis shall be included with the bid package. Also with the bid package, the
motor supplier shall furnish preliminary motor curves with following information:
Acceleration Time Curve, Speed Torque/Speed Current Curve, and Safe Stall
Time/Thermal Limit Curve.
12. Motor efficiency shall not be less than 95 percent and uncorrected power factor not less
than 985 percent when operating at full load and rated voltage and frequency. The
motor manufacturer may furnish correction capacitors if required to achieve this power
factor. Correction capacitors will not be required for the VFD motors.
13.9.
Motors shall be capable of bringing the pumps up to speed with a closed control
valve and 80 percent of rated voltage.
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14.10.
Motors shall be painted with two (2) coats of manufacturer’s standard exterior
enamel. Color shall be selected and approved by the Owner.
B. ENCLOSURE: Motor enclosure shall be Totally Enclosed Fan Cooled (TEFC) in accordance
with NEMA MG-1Weather Protected NEMA Type I in accordance with NEMA MG-1. Arrange
air discharge louvers to direct air in a. Motor shall be suitable for an outdoor environment.
n upward direction. At least one air intake shall be located on same side as air handling
units. See attached plans for location.
C. INSULATION: Motor windings shall be full Class F insulated. The motor stator windings shall
receive an epoxy resin coating. The windings shall comply with the latest applicable
provisions of NEMA MG 1, and end winding coils shall be braced to limit displacement to no
more than 5.0 mils under any condition of starting or running. Motors shall operate
continuously at rated voltage and frequency at 40 C ambient temperature, with a
temperature rise not to exceed a Class B rise, per NEMA MG 1-20.40, measured by an
embedded detector when operating at 100 percent of the nameplate rated horsepower.
1. Motor shall operate continuously at rated voltage and frequency at 50°C ambient
temperature, with a temperature rise not to exceed both
a. a Class B rise (70 degrees C), per NEMA MG-1 20.8 measured by resistance at a 1.0
service factor when operating at 100% of the nameplate rated horsepower.
b. and a Class B rise (80 degrees C) per NEMA MG-1 20.8 measured by embedded
detector (RTD) at a 1.0 service factor when operating at 100% of the nameplate
rated horsepower.
2. Insulation shall be capable of preventing failure as a result of common mode voltages.
C.
D. BEARINGS: Bearings shall be ring oiled, split-sleeve type. Bearings shall be insulated to
prevent shaft-bearing-frame current. Insulating means shall also be provided for any oilsupply connections and monitoring equipment to prevent electrical bypassing of the bearing
insulation.
E. MOTOR TERMINAL BOX: Motor terminal box shall be oversized to accept two sets of 500
kcmil conductors per phase and #3/0 ground conductor (3-4” conduits) without exceeding
the minimum bending radius of the conductors per the National Electrical Code. Motor
terminal box shall be NEMA Type II with motor leads landing on three phase, insulated bus
drilled with NEMA 2-hole pads to terminate the feeder cables. Direct cable to cable
connections shall not be permitted. The box shall be located on the right (NEMA F2) side of
the motor when viewed from the connecting shaft. Terminal box shall be designed for
bottom entry and shall have removable sides to allow for easy access. Terminal box shall be
adequately insulated to prevent excessive vibration. Terminal box size, position, and layout
shall be submitted to the Engineer for approval.Motor terminal box shall be
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E. oversized to accommodate The box shall be located on the right side (NEMA F2) of the
motor when viewed from the connecting shaft. Terminal box shall be designed for bottom
entry and shall have removable sides to allow for easy access. Terminal box shall be
adequately insulated to prevent excessive vibrationstress cones to make up cable
terminations of 5000-volt shielded cable. The box shall be located on the right side (NEMA
F2) of the motor when viewed from the connecting shaft. Terminal box shall be designed
for bottom entry and shall have removable sides to allow for easy access. Terminal box shall
be adequately insulated to prevent excessive vibration.
F. ACCESSORIES TERMINAL BOX: Motor shall have accessory leads from space heaters and
RTDs terminated in separate boxes on barrier type terminals with stainless steel screws.
Leads shall be suitably marked and identified with heat shrink markers. Accessories boxes
shall also be located on the same side of motor as motor terminal box. Motor shall have
accessory leads from space heaters and RTDs terminated in separate boxes. Leads for space
heaters and RTDs shall be terminated on barrier type terminals with stainless steel screws.
Terminations to the terminals shall be with spade type connectors Leads for bearing and
winding RTDs shall be brought to the same box. Leads shall be suitably marked and
identified with heat shrink markers. Accessories terminal boxes shall be located on the
same side of motor as motor terminal box. Accessories boxes shall have stainless steel
nameplates, black with white lettering, attached with stainless steel screws. The
nameplates shall say “SPACE HEATER”, “BEARING RTD’S”, “WINDING RTD’S”, etc.
Accessories boxes shall be bottom or side entry. Accessories boxes shall be sized to accept
conduits of the following sizes: 1-½” for winding/bearing RTDs and 1” for motor space
heater.
F.
G. GROUNDING MEANS: Provide a grounding lug threaded into the motor frame within the
motor terminal box and other motor conduit boxes. Lug shall be similar and equal to
Burndy KC Servit and suitable for terminating #3/0 ground wire.. Prove Ttwo stainless steel
grounding pads shall be furnished on diagonally opposite corners of motor frame. Ground
pads shall be stainless steel and suitable for terminating #4/0 ground conductor..
H. APPURTENANCES: All wires and electrical connections shall be copper. All wiring
penetrating motor frame shall be protected against chaffing with a rubber grommet.
H.
1. Space Heaters: Motor shall be equipped with space heaters for operation on 120 volt,
60 hertz, single-phase. They shall maintain the internal temperature above dew point
when motor is not operating. Space heaters shall not be located directly in the access
holes where they may pose a danger of burn or shock to servicemen. Space heater
wiring shall be routed to prevent wire being between the frame and the space heater.
2. Temperature Monitors: Motor shall be equipped with six 100-ohm platinum resistance
temperature detectors (RTD), two per phase, spaced around the motor windings and
located at the hot spots of the stator. In addition, each bearing shall have a 100-ohm
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platinum RTD installed for sensing bearing temperature and integral to the bearing
housing.
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3. Conduits
a. Liquidtight flexible metal conduit shall be Anaconda Sealtite, Type HTUA by Anamet
Electrical, or equal. Fittings used with liquidtight flexible metal conduit shall be of
the screw-in type with insulated throat by Thomas & Betts Co.; no equals.
b. Rigid aluminum conduit, couplings, factory elbows, and fittings shall be 6063 alloy
by Allied Tube & Conduit Co., or approved equal. Conduit hubs shall be insulated
throat by Crouse-Hinds.
c. Liquidtight strain relief cord and cable connectors shall be Series LS by Crouse-Hinds,
or approved equal.
d. Design neat layout of conduit from sensors to the accessory terminal boxes. Submit
a detailed layout Drawing to the ENGINEER for review.
e. All conduits and wire shall be routed and installed in an identical fashion for like
motors.
f.
Minimum conduit size shall be 3/4-in.
4. Mounting Hardware- All mounting hardware including but not limited to strut channels,
clamps, etc. shall be 316 stainless steel.
5. All appurtenance boxes shall be laid out to avoid overlap and access limitations to the
boxes. Appurtenance boxes shall be secured with stainless steel screws.
I.
DOCUMENTATION
1. Motor Manufacturer shall supply documentation for the motors as follows:
a. Complete dimensional data including the following:
1). dimensional outline drawings
2). maintenance clearances
3). locations and sizes of lubrication connections, vents, drains, etc.
b. Data Sheet: Fill out and submit with the Shop Drawing submittal the information
requested on the Motor Submittal Data Sheet (Attachment B).
c. Complete nameplate data.
d. Allowable time periods between starts.
e. Subtransient reactance and X/R.
f.
Speed-torque curve at 100% and 80% of rated voltage.
g. Speed-current curve at 100% and 80% of rated voltage.
h. Acceleration time at 100% and 80% of rated voltage.
i.
Thermal damage curve (I2t).
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j.
Locked rotor withstand time.
k. Rotor inertia.
l.
Schematic and interconnection diagrams.
m. Bearing descriptions.
n. Motor weights.
o. Alarm and shutdown values for temperatures of the winding and bearing RTDs.
p. Detailed conduit layout for motor.
q. Dimensions and layouts of terminal box and accessories terminal boxes.
r.
Results of tests.
s. Measured locked rotor current and torque and locked rotor power factor.
t.
Motor no load data (i.e. amps, power factor, etc.).
u. Maximum kVar allowed for power factor correction. Maximum kVar shall be
included on motor nameplate as well.
v. Motor insulation voltage rating
w. Instruction manual.
x. Bill of Materials with manufacturer’s cut sheets for all major equipment, RTD’s,
bearings, terminal blocks, etc. Clearly identify on cut sheets the exact model
number being provided.
Note: All documentation listed above shall be supplied with the motor’s initial
submittal with the exception of the motor test results, photographs, and instruction
manual which shall be furnished later in the project. Incomplete submittals will be
returned “NOT APPROVED, REVISE AND RESUBMIT”
1. All wires and electrical connections shall be copper. All wiring penetrating motor frame
shall be protected against chaffing with a rubber grommet.
2. Space Heaters: Motor shall be equipped with space heaters for operation on 120-volt,
1-phase, 60-Hertz. They shall maintain the internal temperature above dew point when
motor is not operating. Space heaters shall not be located directly in the access holes
where they may pose a danger of burn or shock to servicemen. Space heater wiring
shall be routed to prevent wire being between the frame and the space heater.
3. Temperature Monitors: Motor shall be equipped with six 100-ohm platinum resistance
temperature detectors (RTD), two per phase, spaced around the motor windings and
located at the hot spots of the stator. In addition, each bearing shall have a 100-ohm
platinum RTD installed for sensing bearing temperature and integral to the bearing
housing.
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4. Power Factor Correction Capacitors: Capacitors, if required, shall be enclosed, threephase capacitor equipment consisting of a complete assembly including non-PCB, threephase capacitors, decoupling reactors, terminal compartment, fuses and extended
mounting frames for floor mounting. Solderless connectors shall be provided on each
line terminal. Each unit shall have discharge resistors to reduce the charge to 50 volts or
less within 5 minutes after de-energization. Capacitor equipment shall be provided with
current limiting fuses, 50,000-ampere interrupting capacity, and a visual indication of
blown fuse. Capacitor units shall be the required KVAR size, 4160480-volt, 3-phase, 60
Hertz Gilbert/K&M or approved equal. Capacitors shall be floor mounted and will be
remotely mounted from motors.
5. All appurtenance boxes shall be laid out to avoid overlap and access limitations to the
boxes. Appurtenance boxes shall be secured with stainless steel screws.
1.132.03
SPECIAL TOOLS
A. Furnish with the equipment, one set of any special tools or devices required for the
assembly, operation, and maintenance of all equipment furnished.
B. The motor manufacturer shall furnish one testing apparatus to check the proper installation
and calibration of spare RTDs, prior to final acceptance.
1.142.04
LUBRICANT
A. Furnish with the equipment, oil of the recommended type and grade, in sufficient quantity
for initial filling and for operation during acceptance tests. Advise Owner of type and
available sources of lubricants. In addition, provide Owner with 1 year’s supply (8000 hours)
of lubricants for each pump and motor.
3.00
EXECUTION
1.153.01
INSTALLATION
A. Installation of equipment shall be performed by the Construction Contractor who shall be
required to assemble the equipment where required and install it in accordance with
Installation, Operation and Maintenance instructions which shall be furnished by the Vendor
or Manufacturer, the installation drawings for this project and applicable Installation
Instructions of the Hydraulic Institute Standards.
B. The Manufacturer’s Representative has responsibilities in the installation and field testing of
the equipment as described in this section. The Contractor shall schedule the service of the
Manufacturer to direct and assist in the assembly, installation, adjustment, and acceptance
test of the equipment.
1.163.02
FIELD QUALITY CONTROL
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A. Upon completion of installation of equipment, an acceptance test to verify the satisfactory
installation and operation of the equipment shall be conducted by the Manufacturer. The
test shall be conducted in a manner approved by and in the presence of the Contractor,
Engineer and Owner. Equipment shall be checked for excessive noise, alignment, vibration,
general performance, etc. Vibration of the units shall not exceed 50 percent of the
“Acceptable Field Vibration Limits” of the Hydraulic Institute Standards for Centrifugal
Pumps. The units must perform in a manner acceptable to the Engineer before final
acceptance will be made by the Owner. A minimum of 30 days of satisfactory operation will
be required prior to final acceptance.
B. A field bump test of the installed pump and motor shall be made under the supervision of
the Service Representative to confirm that the Reed Frequency is not within 25 percent of
the operational exciting frequency.
C. The pumping units shall be operated throughout their full range of operating heads, if
possible, and at pump speeds from maximum speed to 60 percent speed, recording pump
suction and discharge pressure, water level, flow, motor voltage and current, vibrations,
noise, pump movements and bearing temperatures, as applicable.
D. The pump and motor representatives shall each submit a written Equipment Installation
Report certifying the equipment is properly installed, lubricated, is in accurate alignment, is
free from undue stress from connecting appurtenances, that it has been operated under all
operating conditions and that it is operating satisfactorily.
END OF SECTION
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ATTACHMENT A
SUBMITTAL DATA SHEET
HORIZONTAL CENTRIFUGAL PUMPING UNITS AND MOTORS FOR:
WELL FIELD PUMP STATION
1
Submit the following data with Proposal for each size of Pumping Unit:
Pump Data
1.
2.
3.
4.
5.
6.
7.
8.
9.
Manufacturer
Rated speed
Impeller Diameter and Material
Shut-off Head
Specific Speed
Maximum Brake Horsepower Requirements of Pump
Efficiency at BEP
NPSH Required at Rated Head
NPSH Required at Minimum Head for Rated Design
Point 1
10. Wire-to-water efficiency at 20,833 GPM and 179 feet
TDH
Weight
Pumps WPS –P1, WPS-P2,
& WPS-P-3
Pumps WPS –P1, WPSP2, & WPS-P-3
1. Weight of Pump
2. Weight of Motor
3. Total Weight of Pump, Motor, and Frame
Note: Also attach or enclose with the Proposal additional description of all equipment offered as
requested in the equipment specifications, including but not limited to the physical dimensions,
performance, characteristic curves and pertinent engineering data to permit easy review and evaluation
by the Engineer and Buyer.
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1
22 11 23.01 ATTACHMENT A
SUBMITTAL DATA SHEET
HORIZONTAL CENTRIFUGAL PUMPING UNITS AND MOTORS FOR:
WELL FIELD PUMP STATION
Submit the following data with Proposal for each size of Pumping Unit:
Pump Data
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Manufacturer
Rated speed
Impeller Diameter and Material
Shut-off Head
Specific Speed
Maximum Brake Horsepower Requirements of Pump
Efficiency at BEP
NPSH Required at Rated Head
NPSH Required at Minimum Head for Rated Design
Point 1
Wire-to-water efficiency at 20,833 GPM and 179 feet
TDH
Suction Flange Diameter
Discharge Flange Diameter
Suction Specific Speed
Maximum Backspin Speed
Weight
Pumps WPS –P1, WPS-P2,
& WPS-P-3
Pumps WPS –P1, WPSP2, & WPS-P-3
1. Weight of Pump
2. Weight of Motor
3. Total Weight of Pump, Motor, and Frame
Note: Also attach or enclose with the Proposal additional description of all equipment offered as
requested in the equipment specifications, including but not limited to the physical dimensions,
performance, characteristic curves and pertinent engineering data to permit easy review and evaluation
by the Engineer and Buyer.
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ATTACHMENT B
MOTOR SUBMITTAL DATA SHEET – HORIZONTAL CENTRIFUGAL PUMPING UNITS
1
Submit the following data with shop drawing submittal for each size and type of Motor:
Manufacturer
Frame
Type
Voltage
Starting Method
Shaft Size
Insulation Class
Motor HP
Enclosure
RPM
Phase
Hertz
Full Load Amps
Locked Rotor Amps
Locked Rotor Torque
Locked Rotor KVA/HP
No Load Amps
Locked Rotor Torque
% Breakdown Torque
Rotor WK2 (lb-ft2)
Duty
NEMA Design
Service Factor
Inrush Current (% of Full Load)
Max Safe Stalled Time (seconds)
Number of Safe Starts Per Day
Number of Consecutive Starts
*Full Load Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.0 S.F.)
*Service Factor Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.15 S.F.)
*Limiting Temperature Rise
Resistance (at 25C):
Bearings: Type/Size
Life
Lubrication: ______________
Exhaust Air (CFM): ____________________________
Exhaust Air Temp Rise (oF): ____
Efficiency
Power Factor
Current
1.15 S.F. Load
4/4 Load
3/4 Load
1/2 Load
1/4 Load
RTD Types and Mounting
RTD Alarm and Trip Set Point
Motor Sound Power Level
Motor Recommended Power Factor
orizontal Centrifugal Pumping Units
H
22 11 23.01 - 38
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Date9/20/11
0
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Space Heater Voltage
orizontal Centrifugal Pumping Units
Wattage
H
22 11 23.01 - 39
CMD11269 – Contract C-1 – Pumping Units and Motors
10/067/112Project #CMD11269 – Project Name – WPS Horizontal Centrifugal Pumping Units
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1
ATTACHMENT B
MOTOR SUBMITTAL DATA SHEET – HORIZONTAL CENTRIFUGAL PUMPING UNITS
Submit the following data with Proposal and with shop drawing submittal for each size and type of
Motor:
Manufacturer
Frame
Type
Voltage
Starting Method
Shaft Size
Insulation Class
Motor HP
Enclosure
RPM
Phase
Hertz
Duty
Full Load Amps
Locked Rotor Amps
Locked Rotor Torque
Locked Rotor KVA/HP
No Load Amps
Locked Rotor Torque
% Breakdown Torque
Rotor WK2 (lb-ft2)
NEMA Design
Service Factor
Inrush Current (% of Full Load)
Max Safe Stalled Time (seconds)
Number of Safe Starts Per Day
Number of Consecutive Starts
*Full Load Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.0 S.F.)
*Service Factor Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.15 S.F.)
*Limiting Temperature Rise
Resistance (at 25o C):
Bearings: Type/Size
Life
Lubrication: ______________
Exhaust Air (CFM): ____________________________
Exhaust Air Temp Rise (oF): ____
Efficiency
Power Factor
Current
1.15 S.F. Load
4/4 Load
3/4 Load
1/2 Load
1/4 Load
RTD Types and Mounting
RTD Alarm and Trip Set Point
Motor Sound Power Level
orizontal Centrifugal Pumping Units
H
22 11 23.01 - 40
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Motor Recommended Power Factor
Space Heater Voltage
orizontal Centrifugal Pumping Units
Wattage
H
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Division 44
44 42 56.02
VERTICAL TURBINE PUMPING UNITS
NOTES TO SPECIFIER:
1. SEE #23 IN DESIGN TIPS DATABASE.
2. THIS IS A TEMPORARY GUIDE SPECIFICATION. THE USER SHOULD USE THIS SPECIFICATION
WITH CAUTION AND VERIFY ALL REQUIREMENTS.
1.00
GENERAL
1.01
WORK INCLUDED
A. Furnish labor, materialsmaterials, equipment and incidentals necessary to design,
manufacture, fabricate, test, and deliver a total of four vertical line shaft pumping units to
be used in the Owner’s Intake and Booster Pump Station as shown in the schedule belows.
Two Four uThe units shall be furnished for the Intake Ppump sStation and shall be
designated as units P1-1 and P1-2P1, P2, P3, and P4shown in the schedule. The pumps
within an individual pump station must be of the same manufacturer, however, the same
manufacturer is not required to supply pumps at both pump stations. The motors within an
individual pump station must be of the same manufacturer, however, the same
manufacturer is not required to supply motors at both pump stationsTwo units shall be
furnished for the Booster Pump Station and shall be designated as units P2-1 and P2-2. All
four pumps shall be of the same pump manufacturer. All four motors shall be of the same
manufacturer. The pumping units shall be purchased by the CMAR. The pump cans shall be
installed by the Contractor who receives the slab and under-slabbelow work. The pumps
and motors shall be installed by the Installation Contractor who receives the above-slab
work.
Transmission Pump Station
(TPS)
Odessa Pump Station
(OPS)
TPS-P1
OPS-P1
TPS-P2
OPS-P2
TPS-P3
OPS-P3
TPS-P4
A.
B. Pumping units shall include, but not necessarily be limited to, bowl and impeller assembly,
line shaft, shaft bearings, column, above floor discharge, motor stand, motor, sole plate,
pump barrels for Booster pPump sStation pumps, and anchor bolts, suction screen, and
lower floor column brace. Provide anchor bolts for the pump sole plate and lower floor
column brace for the third (future) pump at the Intake Pump Station. Provide a suction
barrel with barrel top for the third (future) pump at the Booster Pump Station. Accessories
shall be furnished as required for a complete functioning pumping unit in accordance with
the specified performance and installation conditions. The intake barrel, slide gates, barrel
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support, and barrel sole plate for Pump P1-2 shall be supplied by the Installation Contractor,
and are not part of the package included in the alternate bids for the pumping units.
C. All column, discharge bend and barrel flange bolts furnished by pump manufacturer.
The Vendor shall be the pump manufacturer and shall also furnish a total of two one
variable frequency drives (VFD) as specified in Section 26 29 23.01 “Variable Frequency
Motor Controllers” and shall also be responsible to coordinate the design, testing and
installation of the VFDs and motors. One VFD shall be furnished for the Intake Pump Station
(P1-2) and one VFD shall be furnished for the Booster Pump Station (P2-2). The Vendor shall
be responsible for the adequacy and compatibility of the pump, motor and VFD. The motor
manufacturer and the VFD manufacturer shall act as a subcontractor of the pump
manufacturer. The motor manufacturer shall provide a representative who is capable of
coordinating the design, testing, and installation of the motors, capacitors and VFDs.
D. The proposed overhead crane in the TPSpump station will be rated for 4240,000 pounds
with a maximum lifting range (floor to hook eye) of 215 feet. The fully assembled pumping
unit, plus rigging less motor only, shall not exceed the crane’s 4240,000-pound rated
capacity. The unit shall be segmented to allow installation with a 215-foot crane, including
the rigging.
The WPS will not have an overhead crane for installation.
E. The proposed overhead crane in the OPS will be rated for 40,00030,000 pounds with a
maximum lifting range (floor to hook eye) of 25 21 feet. The fully assembled pumping unit,
plus rigging less motor only, shall not exceed the crane’s 40,00030,000-pound rated
capacity. The unit shall be segmented to allow installation with a 25-21-foot crane,
including the rigging.
F. The TPS and OPS motors will be controlled by a VFDVariable Frequency Drive (VFD) (which is
provided under a separate contract.)
G. The discharge header at the TPS and OPS will be anchored to the floor to allow movement
as follows:
1. Four anchor rods will be placed in the slab with leveling nuts.
2. A lower base plate, with standard holes, will be placed over the anchor rods and allowed
to rest on the leveling nuts, which will be set about 1.5” above the floor. The plate will
be leveled and then grout will be placed under the plate.
3. Two sheets of 1/16-inch PTFE pads will be placed over the lower base plate.The WPS
motors will be started across the line. The lower sheet of PTFE will have standard holes.
The upper sheet will have 1.25” x 2.25” slots to allow movement relative to the anchor
rods.
4. The base plate of the pipe support saddle will have 1.25” x 2.25” slots to allow
movement relative to the anchor rods. This will be installed over the anchor rods and
placed on the upper PTFE pad.
1. The anchor rod nuts will be installed and be tightened to a “snug tight” condition per
AISC.
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1
5.
1.02
ACCEPTABLE MANUFACTURERS
1.02A. The acceptable manufacturers are listed in the schedule below. No other manufacturers
will be accepted.
TPS
OPS
Pump
Motor
Pump
Motor
Flowserve
TECO-Westinghouse
FlowserveBrya
n Jann
TECOWestinghouseBryan
Jann
Ruhr Pumpen
Reliance (Baldor)
Ruhr
PumpenBryan
Jann
Reliance
(Baldor)Bryan Jann
Siemens
PeerlessBryan
Jann
SiemensBryan Jann
General Electric
FlowayBryan
Jann
Bryan JannGeneral
Electric
Floway
Fairbanks
MorseBryan
Jann
Bryan Jann
Fairbanks Morse
SulzerBryan
Jann
Bryan Jann
Goulds
Goulds Bryan
Jann
Bryan Jann
Sulzer/
Johnston
Peerless
A. Pumps:
1. Flowserve.
2. Ruhr Pumpen.
3. Johnston.
4. Peerless.
5. Floway.
6. Fairbanks Morse.
B. Motors:
1. TECO-Westinghouse.
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2. Reliance (Baldor).
3. Siemens.
General Electric
4. No other manufacturers will be accepted.
1.03
QUALITY ASSURANCE
A. Experience Requirements: Pumps and motors shall be the product of manufacturers who
have had at least 10 years of successful experience in the design, manufacturer and
application of pumping units of the type, size, and performance capabilities as specified.
B. Factory Inspection and Tests:
1. General:
a. Equipment furnished under these specifications shall be subject to inspection during
manufacture by a representative of the Owner who shall be afforded proper
facilities for determining compliance with the specifications.
b. The Owner may, at his option, elect to have the factory tests witnessed by his
representativeand Engineer reserve the right to witness factory tests at their
discretion. The Manufacturer shall notify the Owner at least one month in advance
of the dates that test will be made. The Owner or Engineer will pay for the cost of all
travel and accommodations to the testing site if they choose to witness the test. .
The Vendor shall does not need to include the cost for Owner/Engineer to witness
witness the tests of the pumps, and motors, and VFDs in the bid.
c. Factory testing with the “job motors” is not required. All units must be tested at full
speed with a calibrated factory motorThe Manufacturer shall notify the Owner
sufficiently in advance of the dates that tests will be made, so that the Owner can
make arrangements for his representative to be present. The Owner will pay for the
cost of the representative’s travel, lodging, meals and expenses for the tests, for a
maximum of two trips for the pump tests and two trips for the motor tests. If a test
must be re-run due to failure in meeting the specified requirements, then the
witness expenses for the re-test shall be borne by the Manufacturer or Vendor. All
witnessed testing shall be conducted in North America. If tests are outside North
America, the Vendor shall pay for airfare for two representatives of the Owner from
DFW airport to the closest commercial airport near the testing site.
a. All four pumps shall be tested with the four previously tested “job motors” at
maximum speed. All Units P1-1 and P1-2 shall be tested with each of their specified
“job motors” .and units P2-1 and P2-2 shall be tested with each of their specified
“job motors.” Factory testing with the variable frequency drive is not required.
d.b. All tests shall be witnessed and stampedcertified by the Plant Engineer (a registered
professional engineer). If the testing is conducted outside the United States, then a
registered Professional Engineer from the United States shall be present to witness
the tests and certify the test reports.
2. Pumps:
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a. Pumps shall be factory tested and certified copies of test data and test curve shall
be furnished to the Engineer. The efficiency, capacity, and horsepower
requirements for field conditions shall be determined for not less than 10 points
throughout the specified head range from shut-off to maximum specified operating
capacitylowest specified operating head. Test procedures, interpretation and
conversion of data, shall conform to the latest requirements of the Test Code of the
Hydraulic Institute standards, except as modified herein.
b. During the factory performance tests, the Manufacturer shall make continuous
measurements and record the maximum down-thrust and maximum up-thrust, for
all conditions of its operation. Pumping unit shall be capable of withstanding all
upthrust and downthrust conditions at any pump setting and/or pump operating
condition, including momentary loads from start-up or shut-down.
c.b. Pumps shall be tested using one of the previously tested “job motors” at maximum
rated speed and with the complete pump bowl assembly, less the suction screen.
d.c. The pump test results shall indicate that the performance of the pump from run-out
head to shut-off head is similar to the pump curve submitted with the bid proposal.
If the test results indicate that the pump performs substantially different from that
indicated in the bid submittal, the Owner, at his option, may accept the unit at a
reduced price, or may refuse to accept the unit.
e.d. Test results shall show no minus tolerance or margin with respect to capacity, total
head or guaranteed efficiency at the specified conditions. Pumps shall have a
continuous down slope in the head-capacity curve.
f.e. Pumps shall be within the following plus tolerance:
1). At rated head: Plus 10 percent of rated capacity.
2). At rated capacity: Plus 5 percent of rated head.
g. The Engineer and Owner reserve the right to will witness the test of all pumping
units.
h.f. Following completion of factory tests, the Vendor shall furnish to the Engineer for
review and approval four certified copies of all test data and test curves for each
pump. Test curves shall also show calculated curves for expected performance at
90, 80, 70, 60 and 560 percent of rated speed for P1-2 and P2-2P1 through P4all
pumps. The Engineer shall promptly review test data and, upon determining that
the pump meets contract requirements, authorization will be given for shipment.
Shipment shall not be made without written approval of test data by the Engineer
and approval of the CMAR.
i.g. The Owner Manufacturer will visit the manufacturing site at the time of witness
tests or prior to shipping for the purpose of inspecting andshall verify and certify
(with a certified test report submitted to the engineer) verifying tthe concentricity
of the pump column sections as to the accurate machining of the shaft bearings and
register fits of the column flanges. The Manufacturer shall make available to the
Owner, the pump parts to be inspected, and such tools and facilities required to
verify the alignment accuracies. It is not the intent to inspect all column sections,
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butverify all at least three column sections for each pump, that are randomly
selected by the Owner to verify concentricity and parallelism.
j.h. The Manufacturer or his representative shall make metallurgical analysis from
coupons cast on the piece of each pour of metal going into the castings and
shafting, and shall provide certified reports to the Owner, showing that the specified
alloys are being furnished.
k.i. The Manufacturer shall perform a hydrostatic pressure test on the bowl assembly at
1.5 times the shut-off head for a minimum of 5 minutes.
l.
Where applicable provide certified test reports indicating the castings comply with
NACE MR-01-75.
3. 4860 and 4000 VOLT MOTORS
a. All motors shall receive a short commercial test in accordance with NEMA MG-1 and
IEEE 112, latest version.
b. In addition, all motors shall receive a complete test in accordance with IEEE 112, and
certified copies of the test data recorded on appropriate forms of IEEE 112, together
with a certified statement of compliance with minimum specified power factor and
efficiencies shall be furnished to the ENGINEER. The recorded data on the forms
shall be in sufficient clarity and detail to permit third-party longhand validation and
verification of any computer generated results. Any longhand calculations shall be
done in English.
c. Tests to be performed on each motor shall include, but not be limited to the
following:
1). Reference Resistance per IEEE Std. 112, latest version.
2). Reference Ambient of 25 degrees centigrade.
3). Efficiency using one of the following:
a)a). Efficiency using an equivalent circuit with direct measurement of stray
load loss per IEEE Method F.
b)b). Efficiency at rated voltage and frequency by dynamometer (IEEE
Method B), six points minimum. Dynamometer correction shall be applied.
4).
5).
6).
7).
8).
Bearing Loss Stabilization.
Locked Rotor Test (two line method).
Slip.
Core Losses and Friction and Windage Losses.
Power Factor (see item-d below).
9). Load test at rated temperature rise (Stable to 1° Celsius within 30 minutes).
10). Speed-Torque and Speed Current Curves.
11). Stator Temperature Rise Measurements by embedded detector and resistance
at rated load per IEEE Std. 112, latest version.
12). High Potential Tests.
13). Winding Resistance Measurements.
14). Bearing Insulation Tests.
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15). Noise Measurements per IEEE Std. 85, latest version (4 positions).
16). Vibration Measurements.
17). No load amps and power factor
18). Locked rotor power factor
Substitutions for or waivers of the tests and methods listed above will not be
permitted.
b.d. The ENGINEER or OWNER may witness the tests of all motors.
c.e. Following completion of factory tests, the Equipment Manufacturer shall furnish to
the ENGINEER for review and approval four (4) certified copies of all test data and
test curves for each motor. The ENGINEER shall promptly review test data and,
upon determining that the motor meets contract requirements, authorization will
be given for shipment. Shipment shall not be made without written approval of test
data by the ENGINEER, except at the risk of the Equipment Manufacturer.
Insert LOW VOLTAGE MOTORS specification
4. VARIABLE FREQUENCY DRIVES
a. Refer to Section 26 29 23.01, MEDIUM VOLTAGE VARIABLE FREQUENCY DRIVES
(VFD), for factory inspection and test requirements. Insert LOW VOLTAGE VARIABLE
FREQUENCY DRIVES (VFD) specification reference.Low voltage and medium voltage
variable frequency drives (VFDs) are provided under a separate contract.
C. Assembly: It is anticipated that pump and motor may be shipped from separate points for
assembly at the project site. Pumps P1-1 and P1-21 to P4 shall be disassembled for
shipment. Pumps P2-1 and P2-2 may be disassembled for shipment, at the option of the
vendor. The pump manufacturer shall be responsible for coordination with the Motor
Manufacturer to einsure that no undue difficulty in assembly will be occasioned when units
are received at the project site. If the motor does not match properly, the defect shall be
corrected to the satisfaction of the Owner. Any delays beyond the scheduled delivery time
which are caused by these defects shall be subject to liquidated damages as provided for
late delivery.
D. Marking: Pump and motor shall each have a standard Manufacturer’s nameplate securely
affixed with tapping screws in a conspicuous place, showing the ratings, speed, rotation
direction, serial number, model number, manufacturer, and other pertinent data. Pump
Column sections and shafts shall be marked to indicate the installation sequence.
E. Service of Manufacturer’s Representatives:
1. Pump Manufacturer Representative:
a. The Pump manufacturer shall furnish the services of a competent factory technician,
who shall have had a minimum of 5 years’ experience in the installation,
adjustment, and operation of the equipment which is being furnished under this
contract. This service is for the purpose of insuring proper installation and
adjustment of the equipment; instructing operating personnel in proper operation,
maintenance, and care of the equipment; for making operation tests of equipment
and making recommendations for obtaining the most efficient use thereof.
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b. The service representative shall be at the site at any time the CMAR or Construction
Contractor is assembling, setting, aligning, connecting or adjusting and testing the
pump and motor assembly. He shall direct and assist the Construction Contractor in
the installation and certify in writing to the Owner that it has been properly installed
and operates satisfactorily during acceptance tests.
c. The minimum time required to be on-site for 8 hours, not including travel time, is as
follows:
Troubleshooting
TPS
20 2510 days (5 3 trips
minimum)
10 5 days (3 2 trips
minimum)
4 days (3 trips minimum)
Personnel Training
1 day (1 trip minimum)
Pump and Motor
Installation
Pump Start-Up and Testing
OPS
8 days (3 trip minimum)
5 days (2 trip minimum)
4 days (3 trip minimum)
1 day (1 trip minimum)
2. Motor Manufacturer Representative
a. The motor manufacturer shall furnish the services of a competent factory
technician, who shall have had a minimum of five (5) years of experience in the
installation, adjustment, and operation of the equipment which is being furnished
under this contract. This service is to ensure proper installation and adjustment of
the motor, instruct personnel in proper operation, maintenance, and care of the
equipment, for making operation tests of equipment, and recommendations for
obtaining the most efficient use thereof. The motor technician shall be an
employee of the motor manufacturer unless otherwise approved by the ENGINEER.
b. The service representative shall verify the proper installation, alignment, wiring,
lubrication, and connection of all appurtenances prior to start-up. He shall be
present during testing, and start-up and shall certify to the OWNER in writing that
the motor has been properly installed and operate satisfactorily.
c. The minimum time required to be on-site for 8 hours, not including travel time, is as
follows:
Troubleshooting
TPS
20 10 days (5 3 trips
minimum)
10 5 days (3 2 trips
minimum)
4 days (3 trips minimum)
Personnel Training
1 day (1 trip minimum)
Check Motor Installation
Pump Start-Up and Testing
OPS
8 days (3 trip minimum)
5 days (2 trip minimum)
4 days (3 trip minimum)
1 day (1 trip minimum)
F. Lateral and Critical Speed Analysis:
1. The pump speed of one each pump at each pump station will be varied by a Variable
Frequency Drive (VFD) controller and will operate for extended periods of time at
speeds from 60 50 to 100 percent of the rated synchronous motor speed. Pumps may
operate at different speeds simultaneously.
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2. The Vendor shall perform both a lateral and critical speed analysis of the complete
pump and motor assembly to verify that there shall be no resonant vibration of the unit
at any operating speed from full synchronous motor speed to 650 percent of
synchronous speed. A review shall be made with respect to the pump shaft diameter
and column thickness in order to insure sufficient pump rigidity in terms of good
engineering practice. In addition, a Reed Frequency review of the pump and motor
assembly shall be conducted on the pump and motor to verify its structural integrity.
The Vendor shall advise the Owner of the calculated resonant frequency of the pumping
unit and shall verify its accuracy when the unit is installed at the project site. If a
resonant frequency problem exists for the installed unit, the Vendor shall be responsible
for correcting the problem.
3. The pump manufacturer shall perform a Forces and Moments analysis of the pump
discharge head for the piping arrangement shown on the plans to be assured that the
discharge is designed to properly withstand the forces and moments associated with a
full speed closed valve startup, shutdown, and normal operation for this application.
The discharge head shall be designed to accommodate maximum thrust conditions, with
a non-restrained discharge pipe and header. Certified calculations shall be submitted to
the Owner.
G. Torsional Analysis: TORSIONAL ANALYSIS
1. The Equipment Manufacturer shall conduct a torsional analysis covering the motor,
shaft coupling and driven equipment combination to identify torsional resonance and
vibration problems in the system speed range. The torsional analysis shall be performed
for all operating conditions, all continuous operating conditions, (constant load), all
dynamic (accelerating and decelerating) operating conditions and worst case electrical
fault conditions. Equipment manufacturer shall obtain all data from the pump and
motor manufacturers as required to conduct the torsional analysis.
G.2.
Submit copies of information and analysis to the Owner. The Vendor shall
provide information to the Variable Frequency Drive (VFD) Manufacturer as required to
make a Torsional Analysis. Submit copies of information and analysis to the Owner and
Engineer.
1.04
SUBMITTALS
A. Submittals shall be in accordance with this Section, the General Requirements, Section 01 33
00 “Submittal Procedures” and shall include:
1. Pre and Post submittal meeting: Vendor shall include in his bid the cost of attending a
twoone-day pre-submittal meeting and a twoone-day post-submittal meeting in the
offices of Freese and Nichols, in Fort Worth, Texas. The Project Manager and Project
Engineer for both the Pump and Motor Manufacturer must be present. A sales person
may attend, but not as a substitute for Project Manager or Project Engineer. Vendor
shall determine the number of people attending the meeting and cover each person’s
cost.
2. Bid Submittal: In order to evaluate the bids, submit the following information.
a. General: Furnish a complete description of all equipment offered under these
specifications, including catalogs, cuts and pertinent engineering data. Where the
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Bidder’s product differs from the specified requirements and/or catalog description,
each point of difference shall be clearly stated. This requirement is set forth to
facilitate the review of bids and not to be construed by the Bidder as waiving any of
the requirements of the specifications.
b. Characteristic Curves: Characteristic curves for the pumps offered shall be
submitted with the bid. Curves shall show the capacity, head, efficiency, required
NPSH, and brake horsepower throughout the operating range of the pump from
shut-off to maximum specified operating capacity. The Allowable Operating Range
and Preferred Operating Rang shall be clearly identified on the curves. Separate
curves showing the above data shall be submitted for 6050, 60, 70, 80, 90 and 100
percent speed for Pumps P1 through P4all pumps. Characteristic curves shall have
the capacity plotted as abscissa and the operating head, brake horsepower,
efficiency and required NPSH plotted as ordinates.
c. Outline Drawings: Submit outline drawings of the pumps, motors and
appurtenances, showing layout dimensions of the proposed equipment.
1
d. Data Sheet: Submit information requested on the Data Sheet included with the Bid
Proposal forms. The Data Sheet is Sheets are included as “Attachment A” and
“Attachment B” to this specification.
e. Provide a list of at least three similar units in service supplied in the last 5 years and
a name and telephone number for a reference for each of these installations.
f.
Provide maximum backspin speed during power failure, and confirmation from the
pump and motor manufacturers that the equipment is suitable for the maximum
backspin speed for the TPS only.
g. Provide a plan and schedule indicating dates for submittals, manufacturing, testing
and delivery.
1.3. Shop Drawings:
a. Drawings shall show complete physical description and performance capabilities of
the pumping equipment, including, but not necessarily limited to dimensions,
weights, materials, assemblies, outline views, sectional views, performance curves,
power requirements and ratings, rated voltage and amperage, color charts and
wiring diagrams as may be applicable.
b. Submit machine drawings with dimensional tolerances for connecting parts for use
to aid in future repairs and making field connections. Provide results of lateral and
critical speed analysis. Provide analysis of the backspin speed analysis during power
failure, and confirmation from the motor supplier that the motor is suitable for the
maximum backspin speed (TPS only).
c. Submit drawings as a complete package of all equipment furnished. Partial
drawings will not be reviewed except the pump barrel submittals in order to
expedite delivery..
d. Subsequent shop drawings shall include results from lateral and critical speed
analysis, torsion analysis, forces and moment analysis of discharge head.
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e. Prior to testing, Ssubmit lab set-up sketches, test procedures, testing equipment,
test equipment calibration certification, and sample calculations.
f.
Submit motor documentation as required per paragraph 2.02.I and 2.03 .I of this
specification. Incomplete data submitted will not be reviewed and will be returned
“Not Approved, Revise and Resubmit”.
g. Quality Control plan for pump materials and components.
d.
4. Operation and Maintenance Data:
a. Submit Manuals with instructions for installation, adjustment, lubrication, operation
and maintenance of the equipment in accordance with Special Conditions and
Section 01 33 00 “SubmittalS Procedures”.
2.b. Manuals shall be prepared by the equipment Manufacturer per Section 01 78 23
“Operations and Maintenance Data” and shall incorporate storage and installation
instructions and operation and maintenance procedures, appropriate final certified
shop drawings, performance curves, and test data. Manuals may be Manufacturer’s
standard instructions, but shall be supplemented as necessary to cover any special
feature not included in standard material. Submit preliminary manuals for review
prior to delivery of the equipment.
3. Bid Submittal: In order to evaluate the bids, submit the following information.
a. General: Furnish a complete description of all equipment offered under these
specifications, including catalogs, cuts and pertinent engineering data. Where the
Bidder’s product differs from the specified requirements and/or catalog description,
each point of difference shall be clearly stated. This requirement is set forth to
facilitate the review of bids and not to be construed by the Bidder as waiving any of
the requirements of the specifications.
b. Characteristic Curves: Characteristic curves for the pumps offered shall be
submitted with the bid. Curves shall show the capacity, head, efficiency, required
NPSH, and brake horsepower throughout the operating range of the pump from
shut-off to maximum specified operating capacity. Separate curves showing the
above data shall be submitted for 60, 70, 80, 90 and 100 percent speed for Pumps
P1-2 and P2-21 through P4. Characteristic curves shall have the capacity plotted as
abscissa and the operating head, brake horsepower, efficiency and required NPSH
plotted as ordinates.
c. Outline Drawings: Submit outline drawings of the pumps, motors and
appurtenances, showing layout dimensions of the proposed equipment.
d. Data Sheet: Submit information requested on the Data Sheet included with the Bid
Proposal forms.
e. Provide a list of at least three similar units in service supplied in the last 5 years and
a name and telephone number for a reference for each of these installations.
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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5. Certified Test Reports: Submit certified test reports for factory performance tests and
metallurgical tests. Provide written certification that column pipe and discharge head
were stress relieved prior to machining. Submit the following certified test reports for
pump and motor.
a. Provide CTR for pump factory performance tests.
b. Provide CTR for motor factory performance tests.
Provide CTR for variable frequency drive factory performance tests.
c. Provide CTR for metallurgical analysis of castings and shafting.
d. Provide CTR for bowl hydrostatic tests.
e. Provide CTR for pump concentricity and parallelism machining measurements.
f.
Provide CTR for stress relieving of components.
g. Provide CTR for barrel mounting flange level measurements.
h. Provide CTR (with EIR) for pump field tests.
i.
Provide CTR (with EIR) for motor field tests.
Provide CTR (with EIR) for variable frequency drive field tests.
4.
5.6. Equipment Installation Report: Submit Equipment Installation Reports from the motor
manufacturer, VFD manufacturer and pump manufacturer.
1.05
STANDARDS
A. The applicable provisions of the following standards shall apply as if written here in their
entirety:
1. American Water Works Association (AWWA) Standards:
AWWA C210
Liquid Epoxy Coating Systems
AWWA E101
Vertical Turbine Pumps - Line Shaft Type
2. American National Standards Institute (ANSI).
3. American Standards for Testing and Materials (ASTM).
4. National Electrical Manufacturers Association (NEMA).
5. Test Code of the Hydraulic Institute Standards (HIS).
6. Institute of Electrical and Electronic Engineers (IEEE).
6.7. National Electrical Code (NEC).
1.06
DELIVERY AND STORAGE
A. The Vendor shall be responsible for delivery of the pump, driver, and accessories, f.o.b. to
the job site or to such storage site as may be designated by the Owner or Construction
Contractor, in good condition and undamaged.
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B. Unloading and storage of the equipment shall be the responsibility of the Construction
Contractor who shall inspect the equipment for apparent damage. Equipment which is
found to be damaged will not be accepted until properly repaired or replaced by the
Vendor.
C. The pumps, motors, and accessories shall be stored indoors, and the motor space heaters
shall be energized upon delivery.
D. Furnish pump barrels and anchor bolts as necessary to meet the Installation Contractor’s
schedule.
E. The initial pump setting for Pumps P1-1P1 through P4 will be with the suction bell at
elevation 1514 2642.25 feet, thus 30 feet of pump column and shaft will be stored by the
Owner for later use. The extra shaft and pump column shall be shipped to a separate
location as designated by the Owner. Each component shall be packed in crates for long
term storage and greased. The crates shall be clearly marked to indicate the appropriate
pump serial number.
1.07
PERFORMANCE REQUIREMENTS AND SETTING
A. General:
1. Liquid to be pumped is screened, untreated lake water groundwater andgroundwater
and surface water with no abnormal amount of silt or abrasives. The pumps for the
Intake Pump Station will pump from the new intake pump station building. The pumps
will discharge above the operating floor with the motor stand and sole plate supported
on four sides by concrete beams. The pumps at the Booster Pump Station willwill pump
from a closed suction barrel and be supported on the top flange of the suction barrel.
2. TPS Pumps will be started and stopped against a closed pump control valve which will
open and close very slowly to minimize transient pressure surges in the discharge
pipeline, and the pump bowls, column and discharge shall be designed for these
pressures. Control valve may be closed for up to 3 minutes with only minimal flow
passing through the bypass line around the control valvepump.
2.3. OPS pumps will be started against a partially open butterfly valve and fully closed check
valve.
3. At the Intake Pump Station, pump columns will drain down to the lake level when the
pump is not operating. The pump shall have oil lubricated shaft bearings. Pump 1-1 will
have an across-the-line starter. Pump P1-2 will be started with a variable frequency
drive which will ramp from 0 percent speed to 60 percent speed in 6 seconds, or less,
thus filling the pump column with water. The pump column shall have a flanged outlet
for an air valve assembly which will release air at pump start-up and allow air into the
pump column when the pump stops.
4. At the Booster Ppump sStation, the sSuction barrels will be filled with water with
submergence equal to the water elevation in the storage tanks or reservoirs. The
pumps shall have product lubricated shaft bearings. The Ppumps P1-2 will be started
with a variable frequency drives which will ramp from 0 percent speed to 6100 percent
speed in 6 seconds, or less, thus filling the pump column with water. The air in the pump
column will be vented by an air valve on the discharge piping. The can pump column
Vertical Turbine Pumping Units
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shall have a flanged outlet for an air and vacuum valve assembly which will release air at
pump start-up and allow air into the pump column when the pump stops.
5. In the event of power or pump failure at the TPS, water from the system will flow in
reverse through the pumps while the pump control valve is slowly closing. The
Manufacturer shall guarantee and design Tthe pump and motor shall be designed so
that no damage will occur from turning at speeds of 1450 percent of rated speed or at
speeds which will be generated by the operating head in the pipe discharge system,
whichever is greater. The maximum operating head generated at the Intake Pump
Station will be 250 psi. The maximum operating head generated at the Booster Ppump
sStations will be will be 200275 psi at the TPS and125...
6. The design of the pumping units shall be compatible with the mode of operation as set
forth in Section 26 29 23.01 “Variable Frequency Motor Controllers.”
7.6. The system curves (Figures 1 for the TPS and, Figure 2 for the WPS, and Figure 23 for the
OPS and 2) included in the specification Appendixin Appendix A show the system heads
and flows at the design conditions at which the pumps will operate,at which the pumps
will operate. The pumps and the pumps will operate alone or in parallel with other
pumps at the range of speeds specified.
8.7. The pumping heads tabulated below in the following sections B and C are total dynamic
heads (TDH) under field conditions and are exclusive of all pump losses from suction bell
to pump discharge. It is desired that the pump have its highest efficiency near the rated
points, and this efficiency, as well as the pump’s efficiency at its minimum and
maximum operating heads, will be used in evaluating the pumps.
B. Intake Pump Station:
1. Pump Selection: Listed below are the performance requirements for the Intake Pump
Station. Pumps P1-1 and P1-2 shall operate in parallel to pump a minimum of 14,000
gpm at 560 feet of head (Rated Condition #1). The pumps must also meet the minimum
flow requirements (Rated Condition #2) when operating by themselves. For each pump,
the efficiencies at the two rated heads will be averaged for the bid evaluation.
2. Pumping Conditions: The tabulations below show the required flows and various head
conditions at which the pumps must operate and the pump setting requirements for
Pumps P1-1 and P1-2.
Pumping Conditions at Full Speed
P1-1 Alone
P1-2 Alone
Rated Condition #1 = 14,000 gpm with two pumps in parallel @ 560 ft. of head
Minimum Capacity, gpm
4200
8800
Rated Head, ft.
560.0
560.0
Minimum Capacity, gpm
7300
10,300
Rated Head, ft.
420.0
475.0
Maximum Shutoff Head, ft.
880
880
Maximum Operating Head, ft.
600
660
Rated Condition #2
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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Minimum Operating Head, ft.
320
Minimum Operating Speed
Maximum Specific Speed
420
60% of Max.
3200
3200
Pump P1-1
Pump P1-2
Elev. Operating Floor
1570.0
1570.0
Elev. Bottom of Sole Plate
1570.25
1570.25
Column Pipe Diameter
36”
24”
Pump Discharge Diameter
16”
20”
Maximum Length of Discharge Head
30”
30”
Elev. of Discharge Centerline
1573.0
1573.0
Elev. Bottom of Suction Bell
1484.0*
1484.0
Elev. Maximum Water Level
1551.5
1551.5
Elev. Design Water Level
1530.0
1530.0
Elev. Minimum Water Level
1490.0
1490.0
5’
5’
10’ Square
10’ Square
3. Pump Settings:
Pump Setting
Minimum Submergence of Suction Bell
Sole Plate Size
Floor Opening
8’ Square
8’ Square
* Pump P1-1 suction is subject to being adjusted from Elevation 1484.0 to
1514.0 in 5 ft. increments by removing upper sections of the column and shaft,
as necessitated by lake level or water quality. Initial pump setting will be at
1514.0.
C.B. Booster Pump StationTransmission Pump Station:
1. Pump Selection - Listed below are the performance requirements for the Booster
Ppump Stationstation. All four pumps shall be identical. Any three of the four
pumpsPumps P2-1 and P2-2P1 through P3 (with P4fourth as a backup) shall operate in
parallel seriesparrallel to pump 30 MGD 14,00030 mgd gpm at 386 625 feet of head
(Rated Condition #1)at the rated condition. The pumps must also operate in parallel at
the maximum head duty point. Each pump must be able to operate at the minimum
head duty point (at reduced or full speed) when operated by itself.o meet the minimum
flow requirements (Rated Condition #2) when operating by themselves. For each pump,
the efficiencies at the two rated heads will be averaged for the pump evaluation. The
flow for Pump P2-1 at Rated Condition #2 shall match the flow for Pump P1-1. It is
preferable that the flow rates for P1-2 and P2-2 match, as closely as possible.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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2. Pumping Conditions :Conditions:
Pumping Conditions At Maximum Rated Speed
PUMP NO. TPS-P1,
P2, P3, P4through
P4
Rated Capacity (per pump)
Rated Head (at 100% speed)
10 MGD
601’625’
Maximum Head Duty Point (at 100% speed)
Minimum Head Duty Point (at 100% or reduced
speed) (at 100% speed)
Efficiency Evaluation Point A Head
Efficiency Evaluation Point B Head
Maximum Motor Horsepower (HP)
Motor Maximum Voltage (V)
Maximum Shut-Off Head
Maximum Speed
Minimum Speed
Reduced Speed Capacity
Maximum Specific Speed
621901.06’
Pumping Conditions at Full Speed
105475’
162601’
172’
1500
4000
2401050’
1182005 RPM
550%
35 MGD
3200
P2-1 Alone
Minimum Capacity, gpm
4200
Rated Head, ft.
386.0
Minimum Capacity, gpm
7000
Rated Head, ft.
239.0
Maximum Shutoff Head, ft.
600
Maximum Operating Head, ft.
410
Minimum Operating Head, ft.
170
Minimum Operating Speed
Maximum Specific Speed
3200
3. Pumping Settings
Elev. of Discharge Centerline
TPS-P1, through
P4Pump P2-1
1875.52664.02658.5
Elev. of Barrel Flange
1876.02661.52656.0
Elev. Operating Floor
1875.02655.060.5
1867.026469.72554.
75
1859.026346.27564
2.25
Pump Setting
Elev. Suction Barrel Inlet
Elev. Bottom of Suction Bell*
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Pump Setting
Elev. Bottom of Can*
Elev. Maximum Water Level
TPS-P1, through
P4Pump P2-1
1856.526324.27540.
25
1913.02700.0
Elev. Design Water Level
269085.01893.0
Elev. Minimum Water Level****
1873.0266055.0
Suction Barrel Inlet Diameter (I.D.)
3630”
Barrel Diameter (OOI.D.)
4842”
Pump Discharge Diameter (I.D.)
1618”
Maximum Dimension Pump CL to Discharge
3036”
Flange
* To be verified by pump manufacturer
** This represents an empty tank which can be used to determine NPSHA.
C. Odessa Pump Station:
1. Listed below are the performance requirements for the pump station. All fourBoth
pumps shall be identical. Any three of the four pumps (with fourth as a backup)Both
pumps shall operate in seriesparallel to pump 3025 MGD at the rated condition. The
pumps must also operate in parallel at the maximum head duty point. Each pump must
be able to operate at the minimum head duty point when operated by itself.
2. Pumping Conditions:
Pumping Conditions At Maximum Rated Speed
OPS-P1 and P2
Rated Capacity (per pump)
Rated Head
101812.5 MGD
625170’
Maximum Head Duty Point
Minimum Head Duty Point (at 100% speed)
Efficiency Evaluation Point
Maximum Motor Horsepower (HP)
Motor Maximum VoVolltage (V)
Maximum Shut-Off Head
Maximum Speed
Minimum Speed
Reduced Speed Capacity
Maximum Specific Speed
640200’
47095’
625170’
600
460
960300’
1200 RPM
80650%
6 MGD
3200
3. Pumping Settings
Pump Setting
OPS-P1 and P2
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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Pump Setting
Elev. of Discharge Centerline
26642943.5.0
Elev. of Barrel Flange
26612941.0.5
Elev. Operating Floor
26602940.5.0
Elev. Suction Barrel Inlet Centerline
26542922.75.75
Elev. Bottom of Suction Bell*
26422909.75.25
Elev. Bottom of Can*
26402908.25.25
Elev. Maximum Water Level
Elev. Design Water Level
1
OPS-P1 and P2
Elev. Minimum Water Level
Suction Barrel Inlet Diameter (I.D.)
27002954.0
26902937.5.0
26602921.0
2922.75
3036”
Barrel Diameter (I.D.) (O.D.)
4248”
Pump Discharge Diameter (I.D.)
Maximum Dimension Pump CL to Discharge
Flange
1824”
3029”
*To be verified by pump manufacture
7.5r
Well Field Pump Station:
Listed below are the performance requirements for the pump station. All four pumps
shall be identical. Any three of the four pumps (with fourth as a backup) shall operate in
series to pump 30 MGD at the rated condition. The pumps must also operate in parallel
at the maximum head duty point. Each pump must be able to operate at the minimum
head duty point when operated by itself.
Pumping Conditions:
WPS-P1 through P3
Pumping Conditions At Maximum Rated Speed
Rated Capacity (per pump)
Rated Head
10 MGD
625
Maximum Head Duty Point
Minimum Head Duty Point (at 100% speed)
Efficiency Evaluation Point
Maximum Shut-Off Head
Maximum Speed
Minimum Speed
Reduced Speed Capacity
640’
470’
625’
960’
1200 RPM
80%
6 MGD
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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1
Maximum Specific Speed
3200
Pumping Settings
Pump Setting
WPS-P1 through P3
Elev. of Discharge Centerline
2664.0
Elev. of Barrel Flange
2661.5
Elev. Operating Floor
2660.5
Elev. Suction Barrel Inlet
2654.75
Elev. Bottom of Suction Bell*
2642.25
Elev. Bottom of Can*
2640.25
Elev. Maximum Water Level
2700.0
Elev. Design Water Level
2690.0
Elev. Minimum Water Level
2660.0
Suction Barrel Inlet Diameter (I.D.)
30”
Barrel Diameter (I.D.)
42”
Pump Discharge Diameter (I.D.)
Maximum Dimension Pump CL to Discharge
Flange
18”
30”
*TO BE VERIFIED BY PUMP MANUFACTURER
1.08
EQUIPMENT WARRANTY
A. Vendor shall warrant the equipment furnished under this specification for a period of 2
years against defects in materials and workmanship and operational failure.
B. In the event of failure of any part or parts of the equipment during the first 2 years of
service, provided that the equipment has been operated and maintained in accordance with
good practice, the Vendor shall furnish, deliver and install the defective part or parts at his
own expense.
C. The first 2 years of service shall be interpreted as the 24-month period following the
installation, adjusting and acceptance testing, and the start of actual operation of the
equipment, or 30 months after delivery, whichever occurs first.
1.09
BID EVALUATION
A. General: The Bidder shall fill in the blank(s) in the data sheets at the end of the Bid Proposal
indicating his guaranteed wire-to-water efficiency of the pumping units at the specified
operating heads., and the guaranteed overall efficiencies of the variable frequency drives.
The guaranteed overall efficiency of the VFD shall be rated as specified in Section 26 29
23.01 “Variable Frequency Motor Controllers.”
B. Pumping Units:
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1. In comparing bids, the Owner will take into consideration the guaranteed efficiencies of
the pumps at the specified rated head and flow conditions as stated in the bid proposal.
For the purposes of evaluation, the overall efficiency of the pumping units shall be the
average of the efficiency at the first rated condition and the efficiency at the second
rated condition. The value of 1 percent in overall wire to water efficiency for each
pump at the intake pump station shall be worth $27,600$10,000 for the TPS and ,
$10,000 for the WPS, and $10,000 for the OPS. The value of 1 percent in overall wire to
water efficiency for each pump at the booster station shall be worth $5,000. The
specified duty points must be in the pump’s Allowable Operating Range in order for the
pump to be acceptable. At the TPS, the low head duty point can be in the pump’s
Allowable Operating Range at full or reduced speed. Due consideration will also be given
to pump performance at other operating conditions in evaluating the pumping units, in
order to select the pumping unit best suited to the operation of the system, in the
opinion of the Owner.
2. The Owner will also evaluate the NPSH required for the pumps at the various specified
pumping conditions, and the fact that the required NPSH is just barely below the
available NPSH, may be justification to reject the offering.
3. In the event that the Factory Tests show that the actual efficiency of a pumping unit is
less than that guaranteed, the Owner, at his option, may accept the unit at a reduced
price, or may refuse to accept the unit as a consequence of breach of contract on the
part of the Vendor. If accepted, the reduction in price shall be computed on the basis of
the evaluation set forth for comparing bids.
C. Variable Frequency Drives:
1. Bids will be evaluated on submitted guaranteed minimum efficiencies of the VFD
system, input and output filters, isolation transformers, contactor, fan(s), controls and
all other accessories. The value of 1 percent in guaranteed efficiency at each operating
speed shall be $10,000 for the VFD at the intake pump station and $5,000 for the VFD at
the booster pump station. The overall efficiency of the VFD shall be the average of the
efficiency at 100 percent speed and the efficiency at 80 percent speed.
2. The bids will also be evaluated for the space requirements of the drives and accessory
equipment. The table below indicates the maximum space allowed for the drives and
accessories. The manufacture will provide dimensions for the drive and accessories or
the bid submittal. Owner may, at his discretion, reject the equipment if the final
dimensions are greater than the dimensions shown below. Additionally, if the final
equipment outline dimensions require a re-design of the pump station or related
facilities, the Owner may assess the re-design cost to the manufacturer.
Dimension
Max Height (not including blower)
VFD @ Intake (P12)Pump Station
7’-8”
Max Depth
3’-6”
Max Length
16’-0”
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3. The bids will be evaluated on other criteria listed in the specifications, and the Owner
reserves the right to award the bid to the lowest responsive bidder who proposes the
best offering in the opinion of the Owner.
4. In addition, should the successful bidder not meet the guaranteed minimum efficiency
requirements, a contract adjustment shall be assessed for the average efficiency at 100
percent speed and 80 percent speed as indicated in the attached example. OWNER
may, at his discretion, reject the equipment if the stated efficiency is too far below the
guaranteed point specified. The contract adjustment will be assessed and levied on the
SUPPLIER if, however, the OWNER chooses to accept the equipment. The contract
adjustment will be calculated using the same formula used to evaluate the bids. The
contract adjustment will be calculated based on $10,000 per efficiency point for the VFD
at the intake pump station and $5,000 per efficiency point for the VFD at the booster
pump station. One efficiency point is equal to one percent.
D.C.
Pumping Units and Variable Frequency Drives:
1. The following hypothetical example is shown to explain the bid evaluation factors. This
example will be applied to the TPS andS, WPS, and the OPS:
Bidder
No. 1
Bidder
No. 2
Bidder
No. 3
88%, 86%
86%, 84%
87%, 85%
87%
85%
$220,80020,
000
86%
$110,40010,
000
86%, 86%
86%, 84%
87%, 85%
86%
85%
86%
Pump P1-2Calculated Penalty
Pump P2-1, Stated Eff. @ 386 ft. TDH,
239 ft. TDH
Efficiency for Evaluation (P2-1)
$0
$10,000
$0
86%, 80%
87%, 85%
84%, 80%
83%
86%
82%
Pump P2-1 Calculated Penalty
Pump P2-2, Stated Eff. @ 386 ft. TDH,
295 ft. TDH
Efficiency for Evaluation (P2-2)
$15,000
$0
$20,000
86%, 82%
87%, 85%
84%, 82%
84%
86%
83%
Pump P2-2 Calculated Penalty
VFD Stated Bid Eff @ 100%, 80% Speed
(P1-2)
Efficiency for Evaluation (P1-2)
$10,000
$0
$15,000
97%, 96%
98%, 97%
96%, 95%
96.5%
97.5%
95.5%
VFD Calculated Penalty (P1-2)
VFD Stated Bid Eff @ 100%, 80% Speed
(P2-2)
$10,000
$0
$20,000
97%, 96%
98%, 97%
97%, 95%
Description
Pump P1-1 Stated Eff. @ 56062501 ft.
TDH, 420 ft. TDH
Efficiency for Evaluation (P1-1)
Pump P-1 Calculated Penaltypenalty
for four pumps
Pump P1-2 Stated Eff. @ 560 ft. TDH,
475 ft. TDH
Efficiency for Evaluation (P1-2)
$0
Vertical Turbine Pumping Units
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County Pump Stations
RLG – 02/01/05
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Efficiency for Evaluation (P2-2)
Bidder
No. 1
96.5%
Bidder
No. 2
97.5%
Bidder
No. 3
96%
VFD Calculated Penalty (P2-2)
$5,000
$0
$7,500
TOTAL PENALTY
State bid price for pumpsTATED BID
PRICE
Evaluated bid price for
pumpsEVALUATED BID PRICE
$40,000
$1,042,5001
,500,000
$1,500,000$
1,082,500
$30,000
$11,100700,
000
$1,920,800
$1,130,000
$72,500
$1,030300,0
00
$1,410,400$
1,102,500
Description
2. The following hypothetical example is shown to explain the contract adjustments for
failure to meet guaranteed efficiencies of the pumping units and variable frequency
drives.
Stated
Average
Evaluated Bid
Eff.efficiency
on Bid Form
Average
Rated
Point Test
Eff.
Average
Difference
(Penalty) /
Credit
8687%
8786%
+-11%
(+$1027,000600)
87%
87%
0%
0
Pump Tests TPS-P3
87%
87%
0%
0
Pump Tests TPS-P4
87%
86%
-1%
($27,600)
Pump Tests (P1-2)
85%
85%
0%
$0
Pump Tests (P2-1)
85%
83%
-2%
- $10,000
Pump Tests (P2-2)
84%
84.5%
+0.5%
+$2,500
VFD Test (P1-2)
97%
96.5%
-0.5%
-$5,000
VFD Test (P2-2)
98%
97%
-1.0%
-$5,000
Description
Pump Tests (P11)TPS-P1
Pump Tests TPS-P2
TOTAL PENALTY
($755,5200)
3. Hence, the contract amount will be adjusted downward by $55,27,500. In no event will
the amount be adjusted upwards, even if the test efficiencies are greater than the bid
efficiencies.
4. The contract adjustment to be assessed in the event of failure to meet guaranteed
efficiency and outline dimensions are not to be construed as a penalty, but as a
reasonable contract adjustment due to the impracticality and extreme difficulty in
calculating actual damages. By submitting a Bid Proposal and executing the Contract
Agreement, the Vendor agrees to such contract adjustment assessments.
2.00
PRODUCTS
2.01
PUMPS
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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A. General:
1. Pumps shall be line shaft type, single or multi-stage vertical turbine pump with enclosed
impellers, and above floor discharge.
2. Pumps shall be designed, manufactured, inspected and tested in accordance with the
applicable requirements of AWWA E101, the Hydraulic Institute Standards and special
requirements of this specification.
3. The down-thrust load imposed on the impellers and line shaft will be carried by the
upper thrust bearing of the motor, which shall be designed for the maximum load
imposed. The impellers may be thrust balanced at the option of the manufacturer to
assure the adequacy of the motor bearings to carry the load.
a. If an up-thrust load occurs at any specified pumping condition, including pump startup, the pumping unit shall be designed to withstand the worst case load without
any damage to the unit. The Vendor shall make such measurementsverify during
the acceptance tests to determine that no damaging up-thrust condition exists, and
shall be responsible for correcting such problems that may occur.
4. Pumps P2-1 and P2-2P1 through P4 at the Booster Ppump sStation shall have water
lubricated shaft bearings with an open line shaft. Pumps P1-1 and P1-2 at the Intake
Pump Station shall have oil lubricated shaft bearings and a shaft enclosing tube.
5. Pumps shall be designed, manufactured, and installed to have lessmeet than 50 percent
of the “Acceptable Field Vibration Limits” as defined by the latest edition of the
Hydraulic Institute Standards.
5.6. The Manufacturer shall stress relieve all fabricated components, column pipe, motor
stand, and discharge head prior to final machining in accordance with ASME Code,
Section VIII. Division 1, ASME Code Section IX, and API Standard 610.
B. Bowl Assembly:
1. Bowls:
a. The suction bell and pump bowls shall be of cast iron, ASTM A48, Class 30,; cast
ductile iron, ASTM A536;, or cast steel ASTM A27, Class 65-35 or ASTM 216 Grade
WCB, free of blow holes, sand holes, or other detrimental defects, with smooth
water passages.
1.b. Coat interior of pump casings with a ceramic epoxy coating to enhance pump
efficiency. Prepare surface to SSPC-SP-10 minimum, or as recommended by the
coating manufacturer. Prime and finish coat shall be 10 mils each DFT Belzona
1341NSF efficiency enhancement coating system for potable water.
2. Bearings: The lower bowl shall have a suitable suction bell and a sealed permanently
grease lubricated lower bearing. Bowl assembly shall have a shaft bearing above and
below each impeller. Bearings shall be bronze, ASTM B271, alloy C93200, and shall be
product lubricated and cooled..
3. Wear Rings:
a. Bowls for enclosed impellers shall be fitted with renewable wear rings at the
running joints between the impeller and bowl. Rings shall be securely attached or
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
doweled to prevent rotation in their seats. Rings shall be forged or machined. Wear
rings shall have straight-face only, no L-shaped rings will be allowed.
b. If stainless steel impellers are selected, then the Wwear ring material shall be Type
304L stainless steel and compatible with the stainless steel impeller material and
and shall be an alloy with a Brinell hardness of 100 points greater than the impeller
wear rings. If bronze impellers are selected, then the wearing ring material shall be
bronze and compatible with the bronze impeller.
4. Intake Screen (P1-1):
a. Provide an intake screen for each pump, attached to the pump suction bell,
designed especially to minimize submerged vortices and to obstruct entrance of
fish. Screen shall have solid top and bottom and baffling to promote uniform,
smooth flow. Screen material shall be Type 316L stainless steel and screen mesh
shall be 3/16-inch wire with 3/4-inch openings. All fasteners shall be stainless steel.
The pump supplier shall be responsible to design baffling to prevent pre-rotation,
submerged vortices, or other undesirable flow conditions for all pumping conditions
as specified herein.
b. The dimension of the screen (4 feet in diameter and 3 feet-6 inches high) is
determined such that the average approach water velocities will not exceed 0.50
fps.
5. Suction Screen (P1-2, P2-1, P2-2):
a. Provide a basket type suction screen for attaching to the suction bell for suppression
of submerged vortices in the suction barrel. Screen shall be cylindrical in shape with
a structural frame, solid bottom, baffles or inverted cones, and wire mesh on the
sides. All material shall be ASTM Type 316L stainless steel.
b. Basket frame shall attach securely to the outside edge of the suction bell with
stainless steel fasteners. Bottom of the basket shall clear the sump floor or bottom
of the suction barrel by at least 6 inches, or as recommended by the Vendor.
c. The design of the basket screen height and mesh selection shall be the responsibility
of the pump manufacturer, so that it will be both efficient and effective in
suppressing vortices and preventing cavitation.
C. Rotating Assembly:
1. Impeller Shaft: The impeller shaft shall be ASTM A582 Type 416 stainless steel that is
rotary stress relieved, ASTM A479 Type 410, Condition 1. Keyways in the shaft shall be
provided with Type 410304 stainless steel keys which shall properly space the impellers
on the shaft and transfer thrust and torsion loads from impeller to shaft. Assemble
using anti-seize compound on fasteners as necessary to prevent galling.
2. Impellers:
a. Impellers shall be of strong dense castings free of structural defects with uniform
thickness of vanes and shrouds. They shall have smooth water passages for high
efficiency and shall be statically and dynamically balanced to ISO 2.5. The impellers
shall be enclosed type.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
b. Impellers shall be bronze, ASTM B584 Grade 903 (Pumps 20 inch and smaller) or
ASTM B148 Grade C952 (Pumps above 20 inch) or be of cast stainless steel, ASTM
A487, CA-6NM Class “B” containing 13 percent chrome and 4 percent nickel.
3. Wear Rings:
a. Enclosed impellers shall be fitted with renewable wear rings at the running joints
with the bowl. Rings shall be securely attached or doweled to prevent rotation in
their seats. Rings shall be forged or machined. Wear rings shall have straight-face
only, no L-shaped rings will be allowed.
b. If stainless steel impellers are selected, then the wear ring material shall be Type
304L stainless steel and compatible with the stainless steel impeller material and
shall be an alloy with a Brinell hardness of 100 points softer than the bowl wear
rings. If bronze impellers are selected, then the wearing ring material shall be
bronze and compatible with the bronze impeller.
b. Wear ring material shall be Type 304L stainless steel and compatible with the
stainless steel impeller material, and shall be an alloy with 100 points Brinell softer
than the bowl wear rings.
D. Line Shaft and Bearings:
1. Shaft: Line shaft and couplings shall be stainless steel, ASTM A479A478, Type 410
Condition 1, of size conforming to AWWA E101 and shall be furnished in
interchangeable sections with lengths not greater than 10 feet. Shafts shall have
butting faces, machined square to the axis of the shaft to insure accurate alignment.
The top line shaft section shall have a hardened chrome surface where it passes through
the shaft seal and bushing. Assemble using anti-seize compound on fasteners to
prevent galling. Shafting shall be straight to within 0.003 inch TIR at any point along the
length of the shaft. Any shaft not meeting this requirement shall be replaced. Repairing
or straightening shafts shall not be allowed.
2. Couplings: Shaft couplings shall be designed with a safety factor of 1-1/2 times the shaft
design strength. Couplings may be threaded for shafts less than 2-1/2 inches in
diameter. Couplings for shafts 2-1/2 inches and larger shall be keyed, lock type
couplings to prevent loosening from reverse torque of the shaft. All parts shall be
stainless steel, and threaded parts shall be assembled using an anti-seize compound.
3. Bearings:
a. Enclosed line shaft bearings (Pumps P1-1 and P1-2) shall be bronze ASTM B271,
alloy C93200. The bearings must contain oil grooves or a separate bypass hole
which allow the oil to flow through and lubricate the bearings below.
b.a. Open line shaft bearings (Pumps P2-1 and P2-2) shall be of the marine type-bronze
backed fluted rubber, Neoprene 65 shore. The rubber shall be of “low swell”
material to prevent the rubber from seizing the line shaft and preventing rotation by
hand.
c.b. Bearings for pumps at the Booster Pump Station (P2-1, P2-2) shall be lubricated with
the liquid being pumped. Bearings for the Intake Pump Station (P1-1, P1-2) shall be
oil lubricated. All bearings shall be mounted securely in stainless steel 316Lbronze
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
lined bearing retainers which are welded integrally to the pump column near each
coupling. The retainer bore shall be machined concentric to the column flange
aligning registers.
E. Shaft Enclosing Tube (P1-1 and P1-2): The shaft enclosing tube shall be furnished as an
integral component with the outer column welded to the column sections at both ends with
spider ribs. Tube shall contain the shaft bearing retainer, and shall be joined at each column
flange with “O” ring seals.
F.E. Pump Column:
1. Intake Pump Station: For Pump P1-1, the minimum column pipe outside diameter shall
be 36 inches and minimum column pipe wall thickness of 0.50 inch. For Pump P1-2, the
minimum column pipe outside diameter shall be 24 inches and minimum column pipe
wall thickness of 0.50 inch. The pipe shall be furnished in interchangeable sections of
not more than 10-foot lengths. Two sections of column and shaft just below the pump
discharge shall be interchangeable 5-foot lengths. Column pipe shall be connected with
flanged type connections using stainless steel bolts and nuts, and anti-seize compound.
Use anti-seize on column flange faces. Column pipe shall be stress relieved with heat
prior to machining of flanges and shaft retainers. The ends of each flanged section shall
be faced parallel and machined accurately with a register fit, to insure proper alignment
when assembled. All flange registers shall be identical so that any section of column
and shaft can be installed in any location in the column. Column pipe material shall
conform to ASTM A53 or ASTM A120. Provide two lifting lugs and support brackets on
all column sections and bowl assemblies. Coordinate attachment of lower strut
assembly for Pump P1-1.
Booster Pump Station: For Pump P2-1, tThe minimum column pipe outinside
diameter and minimum wall thickness shall be 16 42as shown below inches. For Pump
P2-2, the minimum column pipe outside diameter shall be 20 inches. Minimum column
pipe wall thickness shall be 0.375 inch. Column pipe diameter shall be such that friction
loss does not exceed 5 feet per 100 feet of column pipe at the highest rated flow
conditions. Maximum column pipe section length shall be 610 feet. Column pipe shall be
connected with flanged type connections using stainless steel bolts, washers, and nuts,
and anti-seize compound. The ends of each flanged section shall be faced parallel and
machined accurately with a register fit to insure proper alignment when assembled.
Concentricity of shaft bearing to column flange resister fit shall be 0.003” or
manufacturer’s recommended tolerance, whichever is less. Parallelism of column pipe
shall be 0.003” or manufacturer’s recommended tolerance, whichever is less. All flange
registers shall be identical so that any section of column and shaft can be installed in any
location in the column. Column flanges shall have an O-ring suitable for pump shut-off
pressure. O-ring groove shall be on the bottom flange. Column pipe shall be stre
Maximum column pipe section length shall be 10 feet. Use anti-seize on flange faces.
Column pipe shall be stress relieved with heat prior to machining of flanges and shaft
retainers. The ends of each flanged section shall be faced parallel and machined
accurately with a register fit, to insure proper alignment when assembled. All flange
registers shall be identical so that any section of column and shaft can be installed in any
location in the column. Column pipe material shall conform to ASTM A53 or ASTM
A120. Provide two lifting lugs and support brackets on all column sections and bowl
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
assemblies. Lifting lugs and support brackets on each column section shall be capable of
supporting the full weight of the pump assembly including the discharge head.
An integral bearing support shall be provided in each column section to house
and support the line shaft bearings. The bore of the bearing shall be concentric with the
mating registers on the column flanges. The bearing hub (housing shall be stainless
steel.
Pump Station
Column inside
diameter (in)*
Minimum column wall thickness
(in)
TPS
30 24”
0.5”
WPS
Xyz
Xyz
OPS
Xyz24
Xyz0.375
2.
*Pump manufacturer to verify
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
1
G.F. Discharge Head Assembly:
1. The horizontal discharge shall be located above the pump base and shall terminate with
a flange end, as shown in the Appendix. Coordinate with discharge piping. Discharge
shall be drilled and tapped for pressure gauge connection and flow switchmotor
bearing cooling connection. Coordinate flow switch connection with the Installation
Contractor. Drill and tap for a 12-inch NPT connection. The 90-degree elbow shall be
designed to minimize turbulence and pressure drop and shall consist of at least 3 mitre
sections. Stress relieve prior to machining.
2. Pump base shall be designed to support the pump and driver and shall be rectangular of
the size to bear on a pump supporting structure over the pump opening, or shall be
round for mounting on the flange of a suction barrel, as appropriate. Provide stainless
steel flange bolts and Oo-ring gasket to form a water-tight seal for suction barrel
mounting. Design shall be suitable for 2100-psi pressure without leaking or damage.
Flat-faced gaskets are not allowed. Pump base shall be connected to pump can using
stainless steel bolts, washers, nuts, and anti-seize compound.
3. For pumps at the Intake Pump Station, mounted on a structural floor, provide a steel
sole plate for anchoring to the structure with appropriate size opening to remove the
pump. Sole plate opening shall be sufficient size to allow complete pump removal
without removing the sole plate. Pump base shall attach to the sole plate.
4. For Pump P1-1, provide a system for bracing the pump column at the lower pump
station floor level below the pump discharge. Braces are for the purpose of resisting
lateral movement of the column due to wind or wave forces on the pump column from
any direction. Braces shall be adjustable and removable to permit removal of the
column and screen. Bracing details are shown on the drawings.
5. Furnish stainless steel anchor bolts for the pump sole plate and the pump brace at the
lower pump floor. Jack bolt and nuts for pump brace shall be stainless steel.
H.G.
1
Shaft Seal:
1. General: The motor stand shall be provided with a renewable bronze bushing, ASTM
B271, Alloy C93200, and a shaft packing box with split stainless steel 316L packing gland
and stainless steel gland bolts. Provide 5/8-inch Rains-Flow (GFM) (Granulated,
Flowable Metallic) packing material.
2. Enclosed Shaft (P1-1 and P1-2):
a. Shaft enclosing tube shall terminate at motor stand and there shall be provided
accessories for oil lubrication of bearings, including a minimum two-gallon oil
reservoir, a solenoid operated automatic drip feeder with sight glass and a manual
bypass drip feeder. Oil feeder solenoid shall be for 120 volts, 60 Hertz and shall be
energized to close. The oil reservoir shall have a level switch which shall shutoff the
pump when the oil in the reservoir is near depletion. Level switch shall have
normally open and normally closed contacts rated for 5 amps at 120 volts and shall
be mounted in a NEMA-4 enclosure.
b. The head for pumps at the Intake Pump Station shall contain a prepublication
connection designed to properly wet down the top bushing and line shaft bearings
before starting the pump.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
c. A forced feed oil lubrication system shall be provided if it is required for proper
operation of the pump. The power source for the oil feed pump shall be the same
as for the oil feeder solenoid and shall be 120 volts, 60 Hertz.
I.H. Motor Stand:
1. A motor stand shall be provided above the pump base to support the motor and it may
be an integral part of the pump base or a separate stand bolted to the pump base.
Motor stand shall be provided with openings with heavy duty hinged stainless steel
guard screens on opposite sides, to permit access to the shaft seal, lubrication
connections and shaft coupling. Top of stand shall be machined square with the pump
axis and shall have a register fit with the motor base. Provide stainless
steelmanufacturers standard bolts for bolting motor to motor stand.
2. Provide connections for the motor bearings cooling systems (if required). Provide
pressure regulating or flow control valves. Field piping will be furnished and installed by
othersthe Installation Contractor.
3. Provide drain connection and facilities to completely drain all packing discharge and all
water which collects in the motor stand. Motor base shall be adequately sloped to
drains so the water does not pond. Manufacturer may use catch basin or grouted
bottom for slope to drain.
J.I. Motor Coupling: Motor-to-pump coupling for solid shaft motors shall be three-piece rigid
adjustable couplings for adjusting the impeller setting. Furnish all coupling bolts, nuts,
washers and keys.
J.
Pump Painting:
1. Immersion Exposures
a. All interior metal surfaces of column pipe and discharge, and all outside surfaces of
bowl and column surfaces below the pump discharge base plate shall be coated
with an epoxy coating system.
b. All metal surfaces shall be abrasively blasted to an SSPC SP5, white metal blast, and
coated with three coats of polyamide epoxy. Between the prime coat and the
intermediate coat, apply a separate strip coat of polyamide epoxy on all angles,
edges, welds, and bolted connections where coating film build will be reduced.
Alternate color of each coat of epoxy with final color. Color for visible surfaces shall
be selected and approved by the Owner.
c. Final coating shall be factory applied and have a minimum dry film thickness of 12
mils and shall not exceed manufacture’s maximum film build recommendations.
Furnish five gallons of touch-up paint.
Holiday test coating using high voltage spark testing at a maximum voltage of 125
volts per mil. Wet sponge holiday testing will not be acceptable.
d. Refer to bowl section for painting of pump bowl.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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0Date8/3/1110/067/11
2. Atmospheric Exposure
a. All other metal surfaces above the floor shall be cleaned, primed, and painted with
two coats of manufacturer’s standard exterior machinery enamel.
b. Surface preparation shall be in accordance with coating Manufacture’s
recommendations SSPC SP-10 surface abrasive blast, whichever is more stringent.
c. Color shall be selected and approved by the Owner. Furnish one gallon of extra
touch-up paint.
K. Grit blast to SSPC-SP-10 near white the outside of bowl assembly, inside and outside
of the pump column, and inside and outside of discharge head/motor stand prior to
coating. Inside of column pipe and discharge, and outside of bowls and column
which is submerged or obscured from view, shall be coated with liquid epoxy,
AWWA C210, to give a minimum total dry film thickness of 15 mils. Inside of bowls
shall be coated with Plasite or other approved coating. Other exposed surfaces shall
be cleaned, primed, and painted with two coats of manufacturer’s standard exterior
machinery enamel. Color shall be selected and approved by the Owner. Furnish
extra touch-up paint for Installation Contractor’s use.
L.K. Impeller Jacking Unit: The pumps shall be furnished with a hydraulic jacking unit for setting
the bowl-impeller clearance. The jacking assembly shall consist of a minimum of two
hydraulic ram jacks, a hydraulic hand pump, pressure gauge, hose and hose fittings. The
pump and jacks shall be capable of lifting the weight of the shaft impeller assembly with the
rams bearing against the hub of the pump shaft half-coupling and extension legs which bear
on the pump base. The pressure gauge shall be such that, at three-quarters of full scale, it
will indicate a pressure equal to the weight of the rotating elements divided by the total ram
piston area, in pounds per square inch.
M.L.
Suction Barrel (Pump P2-1, P2-2, and Future P2-3):
1. Barrel: Suction barrels shall be welded steel construction with a flat bottom, cylindrical
walls, inlet pipe and heavy flanged top. Top flange shall support the pump and motor
and shall match the pump base. Furnish top oO-ring gasket and stainless steel flange
bolts, nuts and washers to anchor pump base and seal the connection. O ring shall be
suitable for 502100-psi pressure. Provide four lifting lugs below the floor level for
setting barrels. The top surface of the suction barrel mounting flange shall be
sufficiently flat to allow the installing contractor to level these surfaces to within 0.002
in./ft. of diameter. The suction barrel mounting flange may shall be shipped loose for
field leveling and welding. The flange may be factory welded to a short spool pXXpiece
to facilitate field welding. Provide leveling nut assembly for field leveling. Provide
sufficient instruction to the installing contractor so that the leveling and welding process
is accomplished without undue trouble. After installation, it is anticipated that the top
flange will notshall be level within 0.002 inches per foot of diameter. If this is not the
case, then the manufacturer shall re-machine the top flange in the field to be within
0.002 inches per foot of diameter, no exception.
2. Dimensions: All barrels shall have the diameter and side wall thickness dimensions
shown in the schedule belowbe 4848-inch outside diameter and of the length indicated
in the pump setting schedule. The bottom wall thickness shown is a minimum value and
shall be verified by the manufacturer for the internal pressure of the pump barrel. The
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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bottom and wall of the barrel shall be 1/2 inch thick. Provide 2(8)-by-2-inch 1/2” thick
vertical straightening vanes on the inside of the barrel from the bottom of the can to the
top flange, to reduce pre-rotation. The detailed design of the suction hydraulic preconditioning features shall be performed by the pump manufacturer. Provide anchor
rings on the outside of the barrel to anchor into the concrete encasement of the barrel.
Provide leveling legs at the bottom the barrel. Barrels for future pumps shall be
furnished with an oO-ring gasketed flange cover with lifting lugs. Provide Oo-ring gasket
and stainless steel flange bolts, nuts and washers.
Vertical Turbine Pumping Units
44 42 56.02 - 31
Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
Pump Station
Outside
diameter (in)
Bottom wall
thickness (in)
Side wall thickness
(in)
TPS
42
2.0
0.5
OPS
Xyz48
2.00X2.5
0Xyz.5
WPS
Xyz
Xyz
xyz
2.
3. Painting: Grit blast to SSPC-SP-10 near white the inside and outside of pump suction
barrel prior to coating. The outside of the barrel shall receive a coat of rust preventative
primer and interior shall be coated with liquid epoxy, AWWA C210, to produce a
minimum dry film thickness of 15 mils. Furnish extra touch up paint for Installation
Contractor’s use.
a. Exterior of barrel below the mounting flange shall receive a coat of rust preventative
primer. All other iInterior and exterior metal surfaces of suction barrel shall be
coated with a polyamide epoxy coating system.
b. All metal surfaces shall be abrasively blasted to an SSPC SP5, white metal blast, and
coated as specified. Where polyamide epoxy is required, three coats shall be
required. Between the prime coat and intermediate coat, apply a separate strip coat
of polyamide epoxy on all angles, edges, welds, and bolted connections where
coating film build will be reduced. Alternate color of each coat of epoxy with final
color. Color shall be selected and approved by the Owner.
c. Final coating shall have a minimum dry film thickness of 12 mils and shall not exceed
manufacturer’s maximum film build recommendations.
3. Holiday test coating using high voltage spark testing at a maximum voltage of 125
volts per mil. Wet sponge holiday testing will not be acceptable.
2.02
4860 VOLT MOTORS
A. GENERAL
1. Motors at the OPS shall be vertical, air cooled, solid shaft, copper wound stator, NEMA
design B, random wound, copper bar rotor construction, squirrel cage induction type.
Motors shall be designed for use with variable frequency drives controller and acrossthe-line starters. See 480V one-line diagram in the Plans.
2. Motors shall be of a premium efficiency design and rated for inverter duty in accordance
with MG-1, Part 31. The variable speed pumps will be varied by a variable frequency
drive motor controller and will be operated for extended periods of time at speeds from
650% to 100% of rated synchronous motor speed.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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0Date8/3/1110/067/11
3. Horsepower nameplate rating of motor, at the 1.0 service factor, shall be equal to or
greater than the total horsepower requirement of the pump when operating at any
head between maximum and minimum specified operating heads, including power
requirements for bowl assembly, column and line shaft bearing loss, and motor thrust
bearing loss from pump load. Motor shall have a service factor of 1.15 and shall be
designed and manufactured in accordance with applicable provisions of the latest NEMA
Standard Publication for Motors and Generators, MG-1 Part 20, subject to modifications
and additions as herein set forth. The brake horsepower from maximum operating head
to minimum operating head shall not exceed 95% of the horsepower nameplate rating
of the motor specified at a 1.0 service factor.
4. The locked rotor torque and breakdown torque shall not be less than shown in NEMA
MG-1 20.10.
5. The locked rotor KVA/HP shall not exceed NEMA code Letter GF, 6.25.59 KVA/HP.
6. Motor shall have a sound power level of no more than 85 dBA average at 1 meter (3.3
ft) distance when measured per IEEE Std. 85 “Test Procedure for Airborne
Measurements on Rotating Electrical Machinery”.
7. Rotor shall be precision balanced to within an amplitude, peak to peak, in accordance
with the requirement of NEMA MG-1.
8. Rotor bars and end rings shall be copper or copper alloy (no substitution). The rotor
bars shall be swaged. The end rings shall be joined to the rotor bars by high frequency
induction brazing. The rotor cores shall be held together by through-bolts and end
plates.
9. The stator shall have all connections brazed with silver brazing alloy. The stator shall be
braced and supported to eliminate any detrimental winding movement.
10. Motor shall be rated at 4860 volts, 3-phase, 60 hertz.
11. Motor efficiency shall not be less than 95% and (uncorrected) power factor not less than
85% when operating at maximum speed, full load, and rated voltage and frequency.
12. Motors shall be capable of bringing the pumps up to speed with a closed control valve
and 80% of rated voltage.
13. The motor leads shall have the same insulation level as the motor.
14. Motors shall be painted in the factory with two (2) coats of manufacturer’s standard
exterior enamel. Furnish touch-up paint for Contractor’s use. Motor color shall be
selected by the Owner.
B. ENCLOSURE: Motor enclosure shall be Weather Protected NEMA Type I in accordance with
NEMA MG-1. Cooling air discharge shall be directed upward through the louvers. Air intake
shall be at the front of the motor (the same side as pump discharge). Provide adequate
circulation for all operating speeds and loads.
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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C. INSULATION: Motor windings shall be full Class F insulated. After stator assembly, the
stator assembly shall be sealed vacuum-pressure impregnation (VPI) of epoxy resin. The
stator shall receive two VPI treatments, each treatment consisting of a dip followed by an
oven bake. After the final cure, the stator assembly shall receive a final (third) coating of a
durable epoxy varnish to further protect against dust, moisture, and chemical degradation.
The windings shall comply with the latest applicable provisions of NEMA MG 1, and end
winding coils shall be braced to limit displacement to no more than 5.0 mils under any
condition of starting or running.
1. Motor shall operate continuously at rated voltage and frequency (6 to 60 Hz) at 50°C
ambient temperature, with a temperature rise not to exceed both
a. a Class B rise (70 degrees C), per NEMA MG-1 20.8 measured by resistance at a 1.0
service factor when operating at 100% of the nameplate rated horsepower.
b.
at 50°C ambient temperature, with a temperature rise not to exceed a Class B rise
(70 degrees C), per NEMA MG-1 20.8, measured by resistance and a Class B rise (and
80 degrees C) per NEMA MG-1 20.8 , measured by embedded detector (CRTD) at a
1.0 service factor when operating at 100% of the nameplate rated horsepower.
2. Insulation shall be capable of preventing failure as a result of common movde voltages.
Vertical Turbine Pumping Units
44 42 56.02 - 34
Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
D. BEARINGS:
1. Motor bearings shall be designed for the maximum load imposed by the pump and
motor, and shall be selected for a 5-year minimum life and a 25-year average life as
defined by the AFBMA. Bearings shall be insulated as necessary to prevent shaftbearing-frame current. Insulating means shall also be provided for any oil-supply
connections and monitoring equipment to prevent electrical bypassing of the bearing
insulation.
2. Thrust bearing on top of motor shall be of the anti-friction or plate type with oil
reservoir and other necessary appurtenances. Lower radial guide bearings shall be oillubricated, anti-friction with oil reservoir. Thrust bearing shall be of the air cooled type.
E. MOTOR TERMINAL BOX: Motor terminal box shall be oversized to accept twothree sets of
350 kcmil #4/0 conductors per phase and #2/0 ground conductor (3-4” conduits) (2-3”
conduits) without exceeding the minimum bending radius of the conductors per the
National Electrical Code. Motor terminal box shall be NEMA Type II with motor leads
landing on three-phase, insulated bus drilled with NEMA 2-hole pads to terminate the
feeder cables. Direct cable-to-cable connections shall not be permitted. Motor terminal box
shall be located 180° clockwise from the pump discharge.See Drawings for location of motor
terminal box. Bottom and front of box shall be removable. Motor terminal box shall receive
motor cables from the bottom. Terminal box shall be adequately insulated to prevent
excessive vibration. Terminal box size, position, and layout shall be submitted to the
Engineer for approval.
F. ACCESSORIES TERMINAL BOXES:
1
1. Motor shall have accessory leads from space heaterss, and and RTDs and vibration
sensors terminated in separate boxes. Leads for space heaters and RTDs shall be
terminated on barrier type terminals with stainless steel screws. Leads from vibration
sensors shall be terminated on vibration switch terminals. Leads for bearing and
winding RTDs shall be brought to the same box. Leads shall be suitably marked and
identified with heat shrink markers. Accessories terminal boxes shall be located 90
degrees clockwise from motor terminal box. See electrical plans for locations.
Accessories boxes shall have stainless steel phenolic nameplates, black and white
letters, attached with stainless steel screws. The nameplates shall say “SPACE HEATER”,
“BEARING RTDs”, “WINDING RTDs”, “VIBRATION SWITCHES”, etc. Accessories boxes
shall be bottom or side entry.
2. Terminal boxes shall have provisions for terminating the following conduits:
a. RTD Terminal Box: one (1) 1-1/2” conduit
b. Space Heater Box: one (1) ¾1” conduit
1
c. Vibration Switches: one (1) 1.5” conduit, one (1) 1” conduit
G. GROUNDING MEANS: Provide a grounding lug threaded into the motor frame within the
motor terminal box and other motor conduit boxes. Lug shall be similar and equal to
Burndy KC Servit and suitable for terminating #2/0 ground wire. Provide two NEMA 2-hole
ground pads located near the base of the motor mounted 180° apart. Ground pads shall be
stainless steel and suitable for terminating #4/0 ground conductor.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
H. APPURTENANCES: All wires and electrical connections shall be copper. All wiring
penetrating motor frame shall be protected against chaffing with a rubber grommet.
1. Space Heaters: Motor shall be equipped with space heaters for operation on 120 volt,
60 hertz, single-phase power. They shall maintain the internal temperature above dew
point when motor is not operating. Space heaters shall not be located directly in the
access holes where they may pose a danger of burn or shock to servicemen. Space
heater wiring shall be routed to prevent wire being between the frame and space
heater.
2. Temperature Monitors: Motors shall be equipped with nine six 100-ohm platinum
resistance temperature detectors (RTD), three two per phase, spaced around the motor
windings and located at the hot spots of the stator. In addition, each thrust and guide
bearing shall have a 100-ohm platinum RTD installed for sensing bearing temperature.
RTDs for bearings shall be integral to the bearing housing.
3. Vibration sensor:
a. s – Two (2) vibration sensors (transducers) shall be located on top of the pump
motor X and Y axes and wired back to vibration switches (one switch for each axis)
located in a NEMA 4 junction box located on the motor. All control wires shall be
brought to the junction box. Junction box shall be termination point for vibration
sensors’ control cable. All vibration sensors shall be provided with an integral cable
of sufficient length to be routed to the junction box located on the motor. Motor
vibration sensors shall be factory mounted to the motor, and cable installed in
conduit from the sensor to the junction box.
b. Vibration switches shall be provided with a 4-20 mA output for remote monitoring.
Vibration switches shall be provided with isolated contacts for external alarm and
shutdown purposes. Vibration switches (X and Y axes) shall have their normally
open alarm contacts wired in parallel and their normally open shutdown contacts
wired in parallel in the junction box to be used by Owner for remote indication of
common alarm and common shutdown.
c. An external terminal strip shall be mounted in junction box for terminating field
wiring for 120VAC power, common alarm and common shutdown signals, and also
the 4-20mA signals. Any wiring between the vibration switches and the terminal
strips is the responsibility of the vibration switch/ motor supplier. Terminals shall be
NEMA rated 600V. Cable for wiring of 4-20mA signals shall be shielded, twisted
pair, 600 Volt rated.
d. Vibration sensors (transducers) shall be PMC/Beta, Model 160A or approved equal.
Vibration switches shall be PMC/Beta, Model 440DR or equalor approved equal.
4. Conduits
a. Liquidtight flexible metal conduit shall be Anaconda Sealtite, Type HTUA by Anamet
Electrical, or equal. Fittings used with liquidtight flexible metal conduit shall be of
the screw-in type with insulated throat by Thomas & Betts Co.; no equals.
b. Rigid aluminum conduit, couplings, factory elbows, and fittings shall be 6063 alloy
by Allied Tube & Conduit Co., or approved equal. Conduit hubs shall be insulated
throat by Crouse-Hinds.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
1
c. Liquidtight strain relief cord and cable connectors shall be Series LS by Crouse-Hinds,
or approved equal.
d. Design neat layout of conduit from sensors to the accessory terminal boxes. Submit
a detailed layout Ddrawing to the ENGINEER for review.
e. All conduits and wire shall be routed and installed in an identical fashion for like
motors.
f.
Minimum conduit size shall be 3/4-in.
5. Mounting Hardware- All mounting hardware including but not limited to strut channels,
clamps, etc. shall be 316 stainless steel.
6. All appurtenance boxes shall be laid out to avoid overlap and access limitation to the
boxes. Appurtenance boxes shall be secured with stainless steel screws.
I.
DOCUMENTATION
1. Motor Manufacturer shall supply documentation for the motors as follows:
a. Complete dimensional data including the following:
1). dimensional outline drawings
2). maintenance clearances
3). locations and sizes of lubrication connections, vents, drains, etc.
b. Data Sheet: Fill out and submit with the Shop Drawing submittal the information
requested on the Motor Submittal Data Sheet (Attachment B).
c.
d.
e.
f.
g.
h.
i.
Complete nameplate data.
Allowable time periods between starts.
Subtransient reactance and X/R.
Speed-torque curve at 100% and 80% of rated voltage.
Speed-current curve at 100% and 80% of rated voltage.
Acceleration time at 100% and 80% of rated voltage.
Thermal damage curve (I2t).
j.
k.
l.
m.
n.
o.
p.
1
Locked rotor withstand time.
Rotor inertia.
Schematic and interconnection diagrams.
Bearing descriptions.
Motor weights.
Alarm and shutdown values for temperatures of the winding and bearing RTDs.
Alarm and Sshutdown values for vibration swithchesswitches.
[Clarification: Although the requirement to provide vibration sensors/switches
has been deleted, the motor manufacturer is still required to provide alarm and
shutdown values for vibration switches for future use by the Owner.]
q. Detailed conduit layout for motor.
r. Dimensions and layouts of terminal box and accessories terminal boxes.
s. Motor insulation voltage rating.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
t.
u.
v.
w.
Results of tests.
Measured locked rotor current and torque and locked rotor power factor..
Motor no load data (i.e. amps, power factor, etc.).
Max Maximum kVarar allowed for power factor correction. Maximum kVarar shall
be included on motor nameplate as well.
x. Instruction manual.
y. Bill of Materials with manufacturer’s cutsheetscut sheets for all major equipment,
RTD’s, bearings, vibration sensors/switches, terminal blocks, etc. Clearly identify on
cutsheetscut sheets the exact model number of equipment being provided.
Note: All documentation listed above shall be supplied with the motor’s initial submittal
with the exception of the motor test results, photographs, and instruction manual which
shall be furnished later in the project. Incomplete submittals will be returned “NOT
APPROVED, REVISE AND RESUBMIT”
2.022.03
4000 VOLT MOTORS
A. GENERAL
1. Motors shall be vertical, air cooled, solid shaft, copper wound stator, copper bar rotor
construction, squirrel cage induction type. Motors shall be , designed for use with
variable frequency drives and across-the-line starters.. See 4160V one-line diagram in
Appendix for more information.
2. Motors shall be of a premium efficiency design and rated for inverter duty in accordance
with MG-1, Part 31. The variable speed pumps will be varied by a variable frequency
drive motor controller and will be operated for extended periods of time at speeds from
50% to 100% of rated synchronous motor speed.
2.3. Horsepower nameplate rating of motor, at the 1.0 service factor, shall be equal to or
greater than the total horsepower requirement of the pump when operating at any
head between shutoff and minimum specified operating heads, including power
requirements for bowl assembly, column and line shaft bearing loss, and motor thrust
bearing loss from pump load. Motor shall have a service factor of 1.15 and shall be
designed and manufactured in accordance with applicable provisions of the latest NEMA
Standard Publication for Motors and Generators, MG-1 Part 20, subject to modifications
and additions as herein set forth.
3. The variable frequency drive, and motor shall be completely compatible electrically.
The variable frequency drive supplier and the motor supplier shall together issue a
guarantee of compatibility at the time of submittal. The motor supplier shall determine
the insulation voltage rating required to accommodate common mode voltages and
prevent insulation failure.
4. Motors shall be rated for inverter duty per NEMA MG-1, Part 31.
5.4. The locked rotor torque and breakdown torque shall not be less than shown in NEMA
MG-1 20.10.
6.5. The locked rotor KVA/HP shall not exceed NEMA Code Letter r EF, 5.594.99 KVA/HP.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
7.6. Motor shall have a sound power level of no more than 85 dBA average at 1 meter (3.3
ft) distance when measured per IEEE Std. 85 “Test Procedure for Airborne
Measurements on Rotating Electrical Machinery”.
8.7. Rotor shall be “precision” balanced to within an amplitude peak to peak in accordance
with the requirement of NEMA MG-1.
9.8. Rotor bars and end rings shall be copper or copper alloy (no substitution). The rotor
bars shall be swaged. The end rings shall be joined to the rotor bars by high frequency
induction brazing. The rotor cores shall be held together by through-bolts and end
plates.
10.9.
The stator shall have all connections brazed with silver brazing alloy. The stator
shall be braced and supported to eliminate any detrimental winding movement.
11.10.
The stator core shall be built up with high grade, non-aging laminated silicon
steel C5 or better in accordance with ASTM A345. Each lamination core shall be plated
to minimize eddy current losses. The laminations shall be adequately secured to the
stator frame and securely held in place at each end. There shall be no perceptible
buzzing or laminations during operation. Provide slot wedges for rigidity.
12.11.
Stator windings to be designed to have surge capability of 3.5 p.u. at rise time of
0.1 to 0.2 µs and 5 p.u. at a rise time of 1.2 µs or longer.
13.12.
Motor shall be rated at 4000 volts, 3-phase, 60 hertz.
14.13.
Motor efficiency shall not be less than 95% and (uncorrected) power factor not
less than 985% (minimum uncorrected value of 85%) when operating at full load and
rated voltage and frequency. Motor manufacturer shall furnish power factor correction
capacitors if required to achieve this power factor.
15.14.
Motors shall be capable of bringing the pumps up to speed with a closed control
valve and 80% of rated voltage.
15. The motor leads shall have the same insulation level as the motor.
16. Motors shall be painted in the factory with two (2) coats of manufacturer’s standard
exterior enamel. Color shall be selected by the Owner.
B. ENCLOSURE: Motor enclosure shall be Weather Protected NEMA Type I in accordance with
NEMA MG-1. Arrange air discharge louvers to direct air in an upward/outward direction.
Air intake shall be at the back of the motor (opposite pump discharge).
Motor enclosure shall be Weather Protected NEMA Type I in accordance with NEMA
MG-1. Arrange air discharge louvers to direct air in an upward/outward direction. Air
intake shall be at the back of the motor (opposite pump discharge).
C. INSULATION: Motor windings shall be full Class F insulated or better. After stator assembly,
the stator assembly shall be sealed vacuum-pressure impregnation (VPI) of epoxy resin. The
stator shall receive two VPI treatments, each treatment consisting of a dip followed by an
oven bake. After the final cure, the stator assembly shall receive a final (third) coating of a
durable epoxy varnish to further protect against dust, moisture, and chemical degradation.
The windings shall comply with the latest applicable provisions of NEMA MG 1, and end
winding coils shall be braced to limit displacement to no more than 5.0 mils under any
condition of starting or running.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
1. Motor shall operate continuously at rated voltage and frequency (30 to 60 Hz) at 50°C
ambient temperature, with a temperature rise not to exceed both
a. a Class B rise (70 degrees C), per NEMA MG-1 20.8 measured by resistance at a 1.0
service factor when operating at 100% of the nameplate rated horsepower.
b. and a Class B rise (80 degrees C) per NEMA MG-1 20.8 measured by embedded
detector (RTD) at a 1.0 service factor when operating at 100% of the nameplate
rated horsepower.
2. Insulation shall be capable of preventing failure as a result of common mode voltages.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
C.
Motor windings shall be full Class F insulated or better. After stator assembly, the stator
assembly shall be sealed vacuum-pressure impregnation (VPI) of epoxy resin. The stator
shall receive two VPI treatments, each treatment consisting of a dip followed by an oven
bake. After the final cure, the stator assembly shall receive a final (third) coating of a
durable epoxy varnish to further protect against dust, moisture, and chemical
degradation. The windings shall comply with the latest applicable provisions of NEMA
MG 1, and end winding coils shall be braced to limit displacement to no more than 5.0
mils under any condition of starting or running. Motor shall operate continuously at
rated voltage and frequency (30 to 60 hertz) at 50°C ambient temperature, with a
temperature rise not to exceed a Class B rise (70°C), per NEMA MG-1 20.8, measured by
resistance 80°C per NEMA MG-1 20.8 measured by embedded detector (RTD) at a 1.0
service factor when operating at 100% of the nameplate rated horsepower. Insulation
shall be capable of preventing failure as a result of common mode voltages. Motor
leads shall have the same insulation class as the windings.
D. BEARINGS
D.
1. Motor bearings shall be designed for the maximum load imposed by the pump and
motor, and shall be selected for a 5-year minimum life and a 25-year average life.
Bearings shall be insulated as necessary to prevent shaft-bearing-frame current.
Insulating means shall also be provided for any oil-supply connections and monitoring
equipment to prevent electrical bypassing of the bearing insulation.
1.
2. Thrust bearing on top of motor shall be of the anti-friction type with oil reservoir and
other necessary appurtenances. Lower radial guide bearings shall be oil-lubricated, antifriction or split-sleeve type bearing with oil reservoir. Thrust bearings shall be of the air
cooled type.
E. MOTOR TERMINAL BOX
1. Motor terminal box shall be of adequate size to accommodate stress cones to make up
cable terminations for 5000 volt shielded cable. Motor terminal box shall be suitable for
terminating 1 set of (3- #14/0, #4 G., 4” Conduit) without exceeding minimum bending
radius per National Electrical Code. Terminal box shall be provided with standoff
insulators and suitable for terminations using a NEMA two hole lug. Motor terminal box
shall not be less than the next standard NEMA size box for a NEMA Type II box.
Minimum vertical clearance from the bottom of the motor terminal lugs and the bottom
of the terminal box shall not be less than 26”.It shall be located 180° clockwise from the
pump discharge. Bottom and front of box shall be removable. Terminal box shall
receive motor cables from the side. Terminal box shall be adequately constructed to
prevent excessive vibration. Terminal box size, position and layout shall be submitted
to the Engineer for approval.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
F. ACCESSORIES TERMINAL BOXES
1. Motor shall have accessory leads from space heaters, and RTD's, and vibration sensors
terminated in separate boxes. Leads for space heaters, RTD’s and current transformers
shall be terminated on barrier type terminals with stainless steel screws. Leads for
bearing and winding RTD’s shall be brought to the same box. Leads shall be suitably
marked and identified with heat shrink markers. Accessories terminal boxes shall be
located on the same side of motor as motor terminal box. Accessories boxes shall have
phenolic nameplates, black with white lettering, attached with stainless steel screws.
The nameplates shall say “SPACE HEATER”, “BEARING RTD’S”, “VIBRATION SWITCHES”,
and “WINDING RTD’S”. Accessories boxes shall be bottom or side entry.
1
2. Terminal boxes shall have provisions for terminating the following conduits:
a. RTD Terminal Box: one (1) 1-1/2” conduit
b. Space Heater Box: one (1) ¾”1” conduit
c. Vibration Switches: one (1) 1.5” conduit, one (1) 1” conduit
1
G. GROUNDING MEANS
G. GROUNDING MEANS: Provide a grounding lug threaded into the motor frame within the
motor terminal box and other motor conduit boxes. Lug shall be similar and equal to
Burndy KC Servit and sutiablesuitable for terminating #4 ground wire. Provide two NEMA 2hole ground pads located near the base of the motor mounted 180 degrees apart. Ground
pads shall be stainless steel and suitable for terminating #4/0 ground conductor.
1.
H. APPURTENANCES: All wires and electrical connections shall be copper. All wiring
penetrating motor frame shall be protected against chaffing with a rubber grommet.
H.
All wires and electrical connections shall be copper. All wiring penetrating motor frame
shall be protected against chaffing with a rubber grommet.
1. Space Heaters: Motor shall be equipped with space heaters for operation on 120 volt,
60 hertz, single-phase power. They shall maintain the internal temperature above dew
point when motor is not operating. Space heaters shall not be located directly in the
access holes where they may pose a danger of burn or shock to servicemen. Space
heater wiring shall be routed to prevent wire being between the frame and space
heater.
2. Temperature Monitors: Motor shall be equipped with nine six 100-ohm platinum
resistance temperature detectors (RTD), three two per phase, spaced around the motor
windings and located at the hot spots of the stator. In addition, each thrust and guide
bearing shall have a 100 ohm platinum RTD installed for sensing bearing temperature
and integral to the bearing housing.
1
3. Vibration sensors and switches
Vertical Turbine Pumping Units
44 42 56.02 - 42
Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
a. Two (2) vibration sensors (transducers) shall be located on top of the pump motor X
and Y axes and wired back to vibration switches (one switch for each axis) located in
a NEMA 4 junction box located on the motor. All control wires shall be brought to
the junction box. Junction box shall be termination point for vibration sensors’
control cable. All vibration sensors shall be provided with an integral cable of
sufficient length to be routed to the junction box located on the motor. Motor
vibration sensors shall be factory mounted to the motor, and cable installed in
conduit from the sensor to the junction box.
b. Vibration switches shall be provided with a 4-20 mA output for remote monitoring.
Vibration switches shall be provided with isolated contacts for external alarm and
shutdown purposes. Vibration switches (X and Y axes) shall have their normally
open alarm contacts wired in parallel and their normally open shutdown contacts
wired in parallel in the junction box to be used by OWNER for remote indication of
common alarm and common shutdown.
c. An external terminal strip shall be mounted in junction box for terminating field
wiring for 120VAC power, common alarm and common shutdown signals and also
the 4-20mA signals. Any wiring between the vibration switches and the terminal
strips is the responsibility of the vibration switch/ motor supplier. Terminals shall be
NEMA rated 600V. Cable for wiring of 4-20mA signals shall be shielded, twisted
pair, 600 Volt rated.
d. Vibration sensors (transducers) shall be PMC/Beta, Model 160A or approved equal.
Vibration switches shall be PMC/Beta, Model 440DR or approved equal.
4. Conduits
a. Liquidtight flexible metal conduit shall be Anaconda Sealtite, Type HTUA by Anamet
Electrical, or equal. Fittings used with liquidtight flexible metal conduit shall be of
the screw-in type with insulated throat by Thomas & Betts Co.; no equals.
b. Rigid aluminum conduit, couplings, factory elbows, and fittings shall be 6063 alloy
by Allied Tube & Conduit Co., or approved equal. Conduit hubs shall be insulated
throat by Crouse-Hinds.
c. Liquidtight strain relief cord and cable connectors shall be Series LS by Crouse-Hinds,
or approved equal.
d. Design neat layout of conduit from sensors to the accessory terminal boxes. Submit
a detailed layout Drawing to the ENGINEER for review.
e. All conduits and wire shall be routed and installed in an identical fashion for like
motors.
f.
Minimum conduit size shall be 3/4-in.
5. Mounting Hardware- All mounting hardware including but not limited to strut channels,
clamps, etc. shall be 316 stainless steel.
6. All appurtenance boxes shall be laid out to avoid overlap and access limitation to the
boxes. Appurtenance boxes shall be secured with stainless steel screws.
I.
DOCUMENTATION
Vertical Turbine Pumping Units
44 42 56.02 - 43
Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
1. Motor Manufacturer shall supply documentation for the motors as follows:
a. Complete dimensional data including the following:
1). dimensional outline drawings
2). maintenance clearances
3). locations and sizes of lubrication connections, vents, drains, etc.
b. Data Sheet: Fill out and submit with the Shop Drawing submittal the information
requested on the Motor Submittal Data Sheet (Attachment B).
b.c. Complete nameplate data.
c.d. Allowable time periods between starts.
d.e. Subtransient reactance and X/R.
e.f. Speed-torque curve at 100% and 80% of rated voltage.
f.g. Speed-current curve at 100% and 80% of rated voltage.
g.h. Acceleration time at 100% and 80% of rated voltage.
h.i. Thermal damage curve (I2t)
i.j. Locked rotor withstand time.
j.k. Rotor inertia.
k.l. Schematic and interconnection diagrams.
l.m. Bearing descriptions.
m.n.
Motor weights.
o. Alarm and shutdown values for temperatures of the winding and bearing RTDs.
n.p. Alarm and shutdown valves for vibration switches.
[Clarification: Although the requirement to provide vibration sensors/switches
has been deleted, the motor manufacturer is still required to provide alarm and
shutdown values for vibration switches for future use by the Owner.]
q. Detailed conduit layout for motor.
o.r. Dimensions and layouts of terminal box and accessories terminal boxes.
p. Motor insulation voltage rating
q.s. Alarm and shutdown valves for vibration switches.
r.t. Results of tests.
1
s.u. Measured locked rotor current and torque, and locked rotor power factor.
t.v. Motor no load data (i.e. amps, power factor, etcetc.)
u. Maximum kVAR allowed for power factor correction. Maximum kVAR shall be
included on motor nameplate as well.
v.w.
Motor insulation voltage rating
Vertical Turbine Pumping Units
44 42 56.02 - 44
Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
1
w.x.
Instruction manual
x.y. Bill of Material with manufacturer’s cut sheets for all major equipment – RTDs,
bearings, vibration sensors/switches, terminal blocks, etc. Clearly identify on
cutsheetscut sheets the exact model number of equipment being provided.
y. Photographs of empty bearing oil reservoir shall be taken after testing and prior to
shipping and sent to the OWNER and ENGINEER.
Note: All documentation listed above shall be supplied with the motor’s initial submittal
with the exception of the motor test results, photographs, and instruction manual which
shall be furnished later in the project. Incomplete submittals will be returned “NOT
APPROVED, REVISE AND RESUBMIT”
INSERT LOW VOLTAGE MOTORS SPECIFICATION
2.032.04
SPECIAL TOOLS
A. Furnish with the equipment, a lifting bar/bracket for the motor and one set of any special
tools or devices required for the assembly, operation, and maintenance of all equipment
furnished.
B.A.Motor manufacturer shall furnish one Altek RTD calibrator model 211 or equal to check the
proper installation of RTDs prior to final acceptance.
2.042.05
LUBRICANT
A. Furnish with the equipment, oil of the recommended type and grade, in sufficient quantity
for initial filling and for operation during acceptance tests and installation. Advise Owner of
type and available sources of lubricants. In addition provide Owner with a sufficient
quantity of lubricant for required service during the first 12 months after start-up. Pump
lubrication oil shall be food grade.
3.00
EXECUTION
3.01
GENERAL
A. The Manufacturer’s Representative has responsibilities in the installation and field testing of
the equipment as described in this Section. Installation of equipment shall be performed by
the Construction Contractor who shall be required to assemble the equipment, if required,
and install it in accordance with Installation, Operation and Maintenance instructions which
shall be furnished by the vendor or manufacturer, the installation drawings for this project
and applicable Installation Instructions of the Hydraulic Institute Standards.
1. The Construction Contractor shall furnish all labor, tools, equipment and machinery
necessary to receive, inspect, unload, store, protect, and install completely, in proper
operating condition, the equipment. Contractor shall protect and store the motors
indoors and as recommended by the manufacturer, keeping bearings lubricated and the
motor space heaters energized during storage and until they are put into service.
2. He shall also furnish such incidental items not supplied with the equipment, but which
may or may not be described in the Plans and Specifications, for complete installation,
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such as welding, drain lines, gaskets, flange bolts, connecting piping, wiring, conduit,
ducts, mounting brackets, anchors and other appurtenances as necessary.
3. Certain items of equipment due to its size or character will be disassembled for
shipping, and shall be assembled by the Construction Contractor as it is installed. It is
the Contractor’s responsibility, in establishing his costs for installation, to determine the
degree of disassembly that the equipment will be shipped in.
B. The Contractor shall schedule the service of the manufacturer to assist in the assembly,
installation, lubrication, adjustment, and acceptance test of the equipment.
3.02
INSTALLATION
A. Install two vertical line shaft pumping units at the Intake Pump Station and twofour vertical
line shaft pumping units at the Booster Ppump sStatioTPS, and and two vertical line shaft
pumping units at the OPS..n.
B. Install At the Intake Pump Station, furnish and install sole plate anchor bolts and place nonshrink grout below the sole plates to be level within tolerances required by the
manufacturer. Install anchor bolts and cover for the future pump.
C.B. At the Booster pPump sStation, install three four pump cans to the required tolerances at
the TPS, TPS and and two pump cans to the required tolerances at the OPS..
D.C.
Assemble the suction basket screen, bowl assembly, column, line shaft and discharge
head and anchor to sole plate or pump can flange.
E.D. Set and align motor, assemble shaft coupling and adjust impeller setting. After running the
pumping unit, readjust impeller.
F.E. Furnish and install drain lines.
G. Install the motor lubricating oil furnished by the vendor to the proper level.
H. Install pump oiler at the Intake pPump sStation. Set flow control valves as necessary.
I.F. Furnish and install wiring, conductors, conduits, cable trays, and connections for motor
leads, control wiring, etc.
J.G. Conduct acceptance tests and submit an installation report as required in Paragraph
3.03[3.03].
3.03
FIELD QUALITY CONTROL
A. Acceptance Test:
1. Upon completion of installation of equipment, an acceptance test to verify the
satisfactory installation and operation of the equipment shall be conducted by the
Manufacturer’s Representative. The test shall be conducted in a manner approved by
and in the presence of the Installation Contractor, Engineer and Owner. Equipment
shall be checked for excessive noise, alignment, vibration, and lateral deflection, general
performance, etc. Vibration of the unit when measured at the top motor bearing shall
not exceed fifty percent of the “Acceptable Field Vibration Limits” of the Hydraulic
Institute Standards for Centrifugal Pumps. The unit must perform in a manner
acceptable to the Engineer before final acceptance will be made by the Owner. A
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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minimum of 30 days of satisfactory operation will be required prior to final acceptance.
Testing equipment shall be provided by the Manufacturer’s Representative.
2. A field “bump” test of the installed pump and motor shall be made under the
supervision of the Service Representative to confirm that the Reed Frequency is not
within 25 percent of any operational exciting frequency.
1
2.3. The pump manufacturer shall furnish calibrated testing device to measure setting,
alignment, noise and vibration of the pump. Vibration data shall be recorded with a
Vibscanner as manufactured by Pruftechnik, or approved equal.
3. The motor manufacturer shall provide a testing apparatus to check the proper
installation and calibration of spare RTDs, prior to final acceptance.
B. Test Data: The pumping units shall be operated throughout their full range of operating
heads, including backspin, if possible, and at pump speeds from maximum speed to 60 580
percent speed, recording pump discharge pressure, water level, flow, motor voltage and
current, vibrations, noise, deflection, and motor bearing temperatures, as applicable.
C. Equipment Installation Report: The pump and motor representatives shall each submit a
written report certifying the equipment is properly installed, lubricated, is in accurate
alignment, is free from undue stress from connecting appurtenances, that it has been
operated under all operating conditions and that it is operating satisfactorily.
3.04
PAINTING
A. Touch-up all damage of painting of the pumping unit with extra paint furnished by the
manufacturer.
3.05
PRELIMINARY OPERATIONAL TEST AND SYSTEM OPERATIONAL TEST
A. The Contractor shall perform preliminary operational tests over a period of not less than
two 10-hour tests or one 24-hour test. Data shall be recorded, such as reservoir levels,
pump discharge pressure, pump speed, flow rates, vibration, and pump and motor bearing
temperatures, power information, etc.
B. The equipment Vendor shall be responsible for operating the equipment and recording and
submitting the necessary data from this test. The Construction Contractor shall assist in the
performance testing.
C. The cost of power required for performing all tests will be borne by the Owner. Testing will
begin only after the pipeline and reservoirs are filled to their design levels. The Contractor
shall coordinate filling procedures with the Engineer.
D. After the preliminary operational test is completed, and when all pump stations and pipeline
construction is complete and prior to final acceptance of the pump stations, the pump
stations Construction Contractor shall cooperate in performing an overall 30 day system
operational test. The Owner will be responsible for operating the equipment and recording
data during this test. The Contractor and his vendors will be responsible for troubleshooting and adjustments to equipment. This 30-day system operational test is not
required as part of substantial completion. The purpose of the test is to demonstrate or
check the ability of the system to pump continuously with various pump combinations and
speeds.
Vertical Turbine Pumping Units
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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E. It is anticipated that the 30-day system operational testing may begin after work is
completed by others as indicated in Section [01 11 00 “Summary of Work”].. However, no
guarantee is made by the Engineer or Owner as to the date for starting testing. If testing
cannot begin as a sole result of delays in completion of work by other contractors, the pump
station contractor will be granted an extension of time. No additional compensation will be
provided to the Contractor as a result of delays in completion due to postponement of
testing.
END OF SECTION
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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1
ATTACHMENT A
SUBMITTAL DATA SHEET - VERTICAL PUMPING UNITS
Submit the following data with Proposal for each size of Pumping Unit:
Pump Data
TPS P1 THROUGH P4
OPS P1 AND P2
1. Make and Type Design
_______________
____________
2. Rated Speed
_______________
____________
3. Efficiency at rated point
_______________
____________
4. Bowl Size
_______________
____________
5. Number of Bowls
_______________
____________
6. Impeller Diameter and Material
_______________
____________
7. Bowl Shaft Diameter and Material
_______________
____________
8. Line Shaft Diameter and Material
_______________
____________
9. Column Diameter and Thickness
_______________
____________
10. Maximum Shaft Thrust Load
_______________
____________
(uncorrected)10. Number of Phases
_______________
____________
11. Frequency in Hertz _______________
____________
12. Full Load Amperes (FLA)
_______________
13. Enclosure Type
____________
_______________
____________
14. Locked Rotor Amperes (LRA) at rated
voltage
_______________
____________
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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15NEMA Starting Code Letter/
Weights
TPS P1 THROUGH P4
OPS P1 AND P2
1. Pump and Motor Stand
_______________
____________
2. Motor
_______________
____________
3. Complete Unit
_______________
____________
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County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
44 42 56.02 ATTACHMENT A
SUBMITTAL DATA SHEET - VERTICAL PUMPING UNITS
1
Submit the following data with Proposal for each size of Pumping Unit:
Pump Data
TPS P1 THROUGH P4
OPS P1 AND P2
1. Make and Type Design
_______________
____________
2. Rated Speed
_______________
____________
3. Efficiency at rated point
_______________
____________
4. Bowl Size
_______________
____________
5. Number of Bowls
_______________
____________
6. Impeller Diameter and Material
_______________
____________
7. Bowl Shaft Diameter and Material
_______________
____________
8. Line Shaft Diameter and Material
_______________
____________
9. Column Diameter and Thickness
_______________
____________
10. Maximum Shaft Thrust Load
_______________
____________
11. Pump Shut-Off Head
_______________
____________
12. Specific Speed
_______________
____________
13. Suction Specific Speed
_______________
____________
14. Maximum Backspin Speed (TPS Only)
_______________
____________
15. Maximum Brake Horsepower
_______________
____________
16. NPSHR @ Minimum Head
_______________
____________
17. NPSHR @ Rated Head
_______________
____________
Weights
TPS P1 THROUGH P4
OPS P1 AND P2
1. Pump and Motor Stand
_______________
____________
2. Motor
_______________
____________
3. Complete Unit
_______________
____________
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
0Date8/3/1110/067/11
1
ATTACHMENT B
MOTOR SUBMITTAL DATA SHEET - VERTICAL PUMPING UNITS
Submit the following data with shop drawing submittal for each size and type of Motor:
Manufacturer
Frame
Type
Voltage
Starting Method
Shaft Size
Insulation Class
Motor HP
Enclosure
RPM
Phase
Hertz
Full Load Amps
Locked Rotor Amps
Locked Rotor Torque
Locked Rotor KVA/HP
No Load Amps
Locked Rotor Torque
% Breakdown Torque
Rotor WK2 (lb-ft2)
Duty
NEMA Design
Service Factor
Inrush Current (% of Full Load)
Max Safe Stalled Time (seconds)
Number of Safe Starts Per Day
Number of Consecutive Starts
*Full Load Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.0 S.F.)
*Service Factor Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.15 S.F.)
*Limiting Temperature Rise
Resistance (at 25C):
Bearings: Type/Size
Life
Lubrication: ______________
Exhaust Air (CFM): ____________________________
Efficiency
Exhaust Air Temp Rise (oF): ____
Power Factor
Current
1.15 S.F. Load
4/4 Load
3/4 Load
1/2 Load
1/4 Load
RTD Types and Mounting
RTD Alarm and Trip Set Point
Motor Sound Power Level
Motor Recommended Power Factor
Space Heater Voltage
Wattage
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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ATTACHMENT B
MOTOR SUBMITTAL DATA SHEET - VERTICAL PUMPING UNITS
1
Submit the following data with Proposal and with shop drawing submittal for each size and type of
Motor:
Manufacturer
Frame
Type
Voltage
Starting Method
Shaft Size
Insulation Class
Motor HP
Enclosure
RPM
Phase
Hertz
Full Load Amps
Locked Rotor Amps
Locked Rotor Torque
Locked Rotor KVA/HP
No Load Amps
Locked Rotor Torque
% Breakdown Torque
Rotor WK2 (lb-ft2)
Duty
NEMA Design
Service Factor
Inrush Current (% of Full Load)
Max Safe Stalled Time (seconds)
Number of Safe Starts Per Day
Number of Consecutive Starts
*Full Load Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.0 S.F.)
*Service Factor Temp Rise, in Degree Celsius over 50 Celsius Ambient (at 1.15 S.F.)
*Limiting Temperature Rise
Resistance (at 25o C):
Bearings: Type/Size
Life
Lubrication: ______________
Exhaust Air (CFM): ____________________________
Efficiency
Exhaust Air Temp Rise (oF): ____
Power Factor
Current
1.15 S.F. Load
4/4 Load
3/4 Load
1/2 Load
1/4 Load
RTD Types and Mounting
RTD Alarm and Trip Set Point
Motor Sound Power Level
Motor Recommended Power Factor
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
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0Date8/3/1110/067/11
Space Heater Voltage
Wattage
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Project # – Project NameCMD11269 – Contract C-1 – Pumping Units and MotorsColorado River MWD – Ward
County Pump Stations
RLG – 02/01/05
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Figure 1
Colorado River Municipal Water District
Ward County Transmission Pump Station
Rated, Duty, and Evaluation Points
High Head Duty Point:
H = 621' TDH
Total Dynamic Head
700
Rated Point and Efficiency
Evaluation Point:
Q = 10 mgd, H = 601' TDH
600
500
Low Head Duty Point:
H = 475' TDH
System Operating Point:
3 pumps in parallel delivering
30 mgd at 601' TDH
400
0
5
10
TDH High Head
15
20
25
System Flow (mgd)
TDH Normal Head
Curve data:
L = 155,590' Normal static lift = 449' Minor losses = 5' Diameter = 48" C = 120
30
35
40
TDH Low Head
45
Figure 2
Odessa Pump Station System Curve
400
350
System Head (feet)
300
250
200
150
System Operating Point
2 Pumps Running
100
50
0
0
5
10
15
20
25
30
Flow (MGD)
TDH Low Head
TDH High Head
35
40
Figure 3
Well Field Pump Station System Curve
300
250
System Head (Feet)
200
150
Design Point 1 - 3
Pumps Running
30 MGD @ 179' TDH
Design Point 2 - 1 Pump
Running
12 MGD @ 100' TDH
100
50
0
5
10
15
20
25
Flow (MGD)
CRMWD Supply Line
Existing Luminant Line
30
35
40