Appendix IV
CITY OF WADSWORTH
ENGINEERING DEPARTMENT
Construction Standards
For
Sanitary Sewer
Lift Stations
December, 2004
PUMPS .................................................................................................................5
1. GENERAL......................................................................................................5
1.1. SECTION INCLUDES.............................................................................5
1.2. REFERENCES .......................................................................................5
1.3. SYSTEM DESCRIPTION .......................................................................6
1.4. PERFORMANCE CRITERIA ..................................................................6
1.5. SUBMITTALS .........................................................................................7
1.6. QUALITY ASSURANCE .........................................................................8
1.7. MANUFACTURER'S WARRANTY .......................................................11
2. PRODUCT ...................................................................................................12
2.1. PUMP STATION BUILDING.................................................................12
2.2. UNITARY RESPONSIBILITY ...............................................................15
2.3
MANUFACTURER ...............................................................................15
2.4. UNIT BASE...........................................................................................16
2.5. PUMP DESIGN ....................................................................................16
2.6. VALVES AND PIPING ..........................................................................20
2.7
DRIVE UNIT .........................................................................................22
2.8. ENGINE................................................................................................23
2.9. DRIVE TRANSMISSION ......................................................................25
2.10.
FINISH ..............................................................................................26
2.11.
ELECTRICAL CONTROL COMPONENTS:......................................26
2.12.
LIQUID LEVEL CONTROL SYSTEM................................................32
3. EXECUTION................................................................................................43
3.1. EXAMINATION.....................................................................................43
3.2. INSTALLATION ....................................................................................43
3.3. FIELD QUALITY CONTROL.................................................................44
3.4. CLEANING ...........................................................................................44
3.5. PROTECTION ......................................................................................44
SEWAGE FLOW METER: ..................................................................................46
CONDUIT: ..........................................................................................................48
TELEMETRY SYSTEM.......................................................................................49
WET WELL .........................................................................................................51
December, 2004
DESCRIPTION:
Under these specifications, the contractor shall furnish all labor, materials, tools,
and equipment required to install standard suction lift pump stations as specified
herein and as shown on the standard drawings. Sanitary pump stations shall be
considered for installation in a proposed development only when there is no
practical or physical way to serve the development and connect to City sewers by
gravity. All work shall comply with current, applicable codes and standards
including, but not limited to, the Ohio Basic Building Code, the National Electric
Code, and Recommended Standards for Sewage Works (“Ten States
Standards”).
GENERAL:
A. Pump Station Components:
1. The contractor shall furnish and install one factory built above
ground, automatic pump station. The system shall be complete with
all equipment specified herein. The principal items of equipment
shall include two suction lift sewage pumps with hydraulic sealing
flanges; discharge piping and valves, flow meter, emergency pump
connections, with cam-lock connections, and any other necessary
appurtenances. Pumping systems shall be as manufactured by
Gorman-Rupp.
2. The contractor shall furnish and install a precast concrete wet
well of sufficient size and capacity for the application. The wet well
shall support the modular pumping system and shall meet all
requirements of “Recommended Standards For Wastewater
Facilities”. The wet well shall be as manufactured by Mack
Industries, United Precast, Lindsay Concrete Products, or approved
equal.
3. The contractor shall furnish and install a control and telemetry
system in the pumping station compatible with the City of
Wadsworth control and telemetry system located at the Wastewater
Treatment Plant. The system shall include all pump controls
(PLC’s) and alarms, level control systems, alarm light, wiring,
stainless steel panels, and any other necessary appurtenances.
The telemetry system shall transmit pump station operation data
and alarms via radio communication to the main computer and
control system at the Wadsworth Water Pollution Control Plant.
4.Discharge Bypass Piping - The station header pipe shall
incorporate a 2-way plug valve to permit emergency access to the
pump station force main after isolation of the pumps. The plug
valve shall be non-lubricated, tapered type. Valve body shall be
semi-steel with flanged end connections drilled to 125 pound
City of Wadsworth, Ohio
Page 3
Lift Station Standards
12/2004
standard. Valve shall be furnished with a drip-tight shutoff plug
mounted in stainless steel or teflon over phenolic bearings, and
shall have a resilient facing bonded to the sealing surface.
5.
The Contractor shall furnish a complete building to house the
pumps and related equipment. The building shall include plumbing
systems for potable water, washdown, and drainage; mechanical
systems for heating and ventilation as required by the selected
station equipment and applicable codes; appropriate sound
attenuation for noise created by pumping, mechanical, or electrical
systems, including a standby generator; electrical systems for
lighting, power, communications, security, control, and
instrumentation. The building shall be of sufficient size to allow a
minimum clear area of 48” from all equipment to allow for
maintenance.
ACCESSIBILITY:
The pump station and all associated facilities shall be readily accessible by
maintenance vehicles during all weather conditions. The facility shall be located
off the traffic way of streets and alleys, but not more than 100 feet from a publicly
owned street or right-of-way. When the pump station will be publicly owned,
operated and maintained, the developer shall provide the necessary easements.
The minimum easement dimensions shall provide 20 feet around the entire pump
station and associated facilities. A minimum 30-foot access easement shall also
be provided from the publicly owned street or right-of-way to the pump station
facilities. A paved access drive with a minimum width of 10 feet shall be provided
within the access easement. The minimum pavement section shall be 8” of 304
limestone. If asphalt or concrete drive access is provided, it shall meet City of
Wadsworth
Standard
specifications
for
residential
streets.
City of Wadsworth, Ohio
Page 4
Lift Station Standards
12/2004
PUMPS
1.
PART - GENERAL
1.1.
SECTION INCLUDES
A.
1.2.
Work under this section includes, but is not limited to, furnishing
and installing a factory built duplex pump station as indicated on the
project drawings, herein specified, as necessary for proper and
complete performance.
REFERENCES
A.
Publications listed below form part of this specification to extent
referenced in the text by basic designation only. Consult latest
edition of publication unless otherwise noted.
1.
American National Std. Institute (ANSI) / American Water
Works Assoc. (AWWA)
a. ANSI B16.1Cast iron pipe flanges and flanged
fittings.
b. ANSI/AWWA C115/A21.51Cast/ductile iron pipe with
threaded flanges.
c. ANSI 253.1Safety Color Code for Marking Physical
Hazards.
d. ANSI B40.1Gages, Pressure and Vacuum.
e. AWWA C508Single Swing Check Valves.
2.American Society for Testing and Materials (ASTM)
a. ASTM A48 Gray Iron Castings.
b. ASTM A126 Valves, Flanges, and Pipe Fittings.
c. ASTM A307 Carbon Steel Bolts and Studs.
d. ASTM A36 Structural Steel.
3.Institute of Electrical and Electronics Engineers (IEEE)
a.
ANSI/IEEE Std 100 Standard Dictionary of
Electrical Terms.
b.
ANSI/IEEE Std 112 Test Procedure for Polyphase Induction Motors.
c.
IEEE Std 242 Protection of Industrial and Control Power Systems.
4.
National Electric Code (NEC) / National Electrical
Manufacturers Assoc. (NEMA)
a.
NEC National Electric Code.
b.
NEC 701National Electric Code article 701.
c.
NEMA Std MG1Motors and Generators.
City of Wadsworth, Ohio
Page 5
Lift Station Standards
12/2004
5.
Miscellaneous References
a.
b.
c.
d.
1.3.
1.4.
Ten-State Standards
Recommended Standards for Sewage Work
Hydraulic InstituteStd for Centrifugal, Rotary and Reciprocating Pumps.
NMTBA and JIC Std.National Machine Tool
Builders
Association
and Joint Industrial Council Standards
ISO 9001 International Organization for
Standardization.
SYSTEM DESCRIPTION
A.
Contractor shall furnish and install one factory built, automatic
pump station. The station shall be complete with all equipment
specified herein, factory assembled on a common steel baseplate.
B.
The principal items of equipment shall include two self-priming,
horizontal, centrifugal, v-belt motor driven sewage pumps, one
water cooled standby engine, valves, and piping. A pump motor
control panel with thermal-magnetic circuit breakers, magnetic
motor starters, automatic liquid level control systems for normal and
standby operation, and internal wiring.
C.
Factory built pump station design, including materials of
construction, pump features, valves and piping, and motor controls
shall be in accordance with requirements listed under PART
2 - PRODUCTS of this section.
PERFORMANCE CRITERIA
A.
Pumps must be designed to handle raw, unscreened, domestic
sanitary sewage. Pumps shall have 4" suction connection, and 4"
discharge connection. Each pump shall be selected to perform
under following operating conditions:
Capacity (GPM)
Total Dynamic Head (FT)
Total Dynamic Suction Lift(FT)
Maximum Repriming Lift (FT)
Maximum Static Suction Lift(FT)
B.
______
______
______
______
______
Station Power Requirements
1.
Site power furnished to pump station shall be three phase,
60 hertz, 240 volts, 3 wire, maintained within industry
City of Wadsworth, Ohio
Page 6
Lift Station Standards
12/2004
standards. Voltage tolerance shall be plus or minus 10
percent. Control voltage shall not exceed 132 volts.
1.5.
SUBMITTALS
A.
Product Data
1.
Prior to fabrication, pump station manufacturer shall submit
eight (8) copies of submittal data for review and approval.
2.
Submittal shall include shop drawings, electrical ladder logic
drawings, and support data as follows: Catalog cuts sheets
reflecting characteristics for major items of equipment,
materials of construction, major dimensions, motor and vbelt drive data, pump characteristic curves showing the
design duty point capacity (GPM), head (FT), net positive
suction head required (NPSHr), and hydraulic brake
horsepower (BHP). Electrical components used in the motor
branch and liquid level control shall be fully described.
B.
Shop drawings shall provide layout of mechanical equipment and
anchor bolt locations for equipment baseplate. The electrical
ladder logic drawings shall illustrate motor branch and liquid level
control circuits to extent necessary to validate function and
integration of circuits to form a complete working system.
C.
Operations Maintenance Manuals
1.
Installation shall be in accordance with written instructions
provided by the pump station manufacturer. Comprehensive
instructions supplied at time of shipment shall enable
personnel to properly operate and maintain all equipment
supplied. Content and instructions shall assume operating
personnel are familiar with pumps, motors, piping and
valves, but lack experience on exact equipment supplied.
2.
Documentation shall be specific to the pump station supplied
and collated in functional sections. Each section shall
combine to form a complete system manual covering all
aspects of equipment supplied by the station manufacturer.
Support data for any equipment supplied by others, even if
mounted or included in overall station design, shall be
provided by those supplying the equipment. Instructions
shall include the following as a minimum:
City of Wadsworth, Ohio
Page 7
Lift Station Standards
12/2004
3.
1.6.
a.
Functional description of each major component,
complete with operating instructions.
b.
Instructions for operating pumps, engine and pump
controls in all modes of operation.
c.
Calibration and adjustment of equipment for initial
start-up, replacement of level control components, or
as required for routine maintenance.
d.
Support data for commercially available components
not produced by the station manufacturer, but
supplied in accordance with the specifications, shall
be supported by literature from the prime
manufacturer and incorporated as appendices.
e.
Electrical schematic diagram of the pump station
circuits shall be in accordance with NFPA70.
Schematics shall illustrate, to the extent of authorized
repair, pump motor branch, control and alarm system
circuits including interconnections. Wire numbers and
legend symbols shall be shown. Schematic diagrams
for individual components, not normally repairable by
the station operator, need not be included. Details for
such parts shall not be substituted for an overall
system schematic. Partial schematics, block
diagrams, and simplified schematics shall not be
provided in lieu of an overall system diagram.
f.
Mechanical layout drawing of the pump station and
components, prepared in accordance with good
commercial practice, shall provide installation
dimensions and location of all pumps, motors, engine,
valves and piping.
Operation and maintenance instructions which rely on
vendor cut-sheets and literature which include general
configurations, or require operating personnel to selectively
read portions of the manual shall not be acceptable.
Operation and maintenance instructions must be specific to
equipment supplied in accordance with these specifications.
QUALITY ASSURANCE
A.
The pumps and pump station manufacturer must be certified to ISO
9001 by an accredited certification agency.
City of Wadsworth, Ohio
Page 8
Lift Station Standards
12/2004
B.
Upon request from the engineer, the pump station manufacturer
shall prove financial stability and ability to produce the station within
the specified delivery schedules. Evidence of facilities, equipment
and expertise shall demonstrate the manufacturer's commitment to
long term customer service and product support.
C.
Pump Performance Certifications
1.
All internal passages, impeller vanes, and recirculation ports
shall pass a 3" spherical solid. Smaller internal passages
that create a maintenance nuisance or interfere with priming
and pump performance shall not be permitted. Upon request
from the engineer, manufacturer’s certified drawings
showing size and location of the recirculation port(s) shall be
submitted for approval.
2.
Reprime Performance
a.
b.
c.
City of Wadsworth, Ohio
Consideration shall be given to the sanitary sewage
service anticipated, in which debris is expected to
lodge between the suction check valve and its seat,
resulting in the loss of the pump suction leg, and
siphoning of liquid from the pump casing to the
approximate center line of the impeller. Such
occurrence shall be considered normal, and the pump
must be capable of automatic, unattended operation
with an air release line installed.
During unattended operation, the pump shall retain
adequate liquid in the casing to insure automatic
repriming while operating at its rated speed in a
completely open system. The need for a suction
check valve or external priming device shall not be
required.
Pump must reprime ______ vertical feet at the
specified speed and impeller diameter. Reprime lift is
defined as the static height of the pump suction above
the liquid, while operating with only one-half of the
liquid remaining in the pump casing. The pump must
reprime and deliver full capacity within five minutes
after the pump is energized in the reprime condition.
Reprime performance must be confirmed with the
following test set-up:
Page 9
Lift Station Standards
12/2004
1.
1)
A check valve to be installed down stream from
the pump discharge flange. The check valve
size shall be equal (or greater than) the pump
discharge diameter.
2)
A length of air release pipe shall be installed
between pump and the discharge check valve.
This line shall be open to atmosphere at all
times duplicating the air displacement rate
anticipated at a typical pump station fitted with
an air release valve.
3)
The pump suction check valve shall be
removed. No restrictions in the pump or suction
piping will prevent the siphon drop of the
suction leg. Suction pipe configuration for
reprime test shall incorporate a 2 feet minimum
horizontal run, a 90o elbow and vertical run at
the specified lift. Pipe size shall be equal to the
pump suction diameter.
4)
Impeller clearances shall be set as
recommended in the pump service manual.
5)
Repeatability of
demonstrated by
reprime cycles. Full
be achieved within
cycle.
6)
Liquid to be used for reprime test shall be
water.
performance shall be
testing five consecutive
pump capacity (flow) shall
five minutes during each
d.
Upon request from the engineer, certified reprime
performance test results, prepared by the manufacturer, and
certified by a registered professional engineer, shall be
submitted for approval prior to shipment.
D.
Factory System Test
All components including the pumps, motors, engine, valves, piping
and controls will be tested as a complete working system at the
manufacturer's facility. Tests shall be conducted in accordance with
Hydraulic Institute Standards at the specified head, capacity, rated
speed and horsepower. Factory operational test shall duplicate
actual performance anticipated for the complete station.
City of Wadsworth, Ohio
Page 10
Lift Station Standards
12/2004
2.
E.
1.7.
Upon request from the engineer, the operational test may be
witnessed by the engineer, and/or representatives of his
choice, at the manufacturer's facility.
The manufacturers technical representative shall inspect the
completed installation, correct or supervise the correction of any
defect or malfunction, and instruct operating personnel in the
proper operation and maintenance of the equipment as described
in Part 3 of this section.
MANUFACTURER'S WARRANTY
A.
The pump station manufacturer shall warrant all equipment to be of
quality construction, free of defects in material and workmanship. A
written warranty shall include specific details described below.
1.
All other equipment, apparatus, and parts furnished shall be
warranted for five (5) years, excepting only those items that
are normally consumed in service, such as light bulbs, oils,
grease, packing, gaskets, O-rings, etc. The pump station
manufacturer shall be solely responsible for warranty of the
station and all components.
2.
Components failing to perform as specified by the engineer,
or as represented by the manufacturer, or as proven
defective in service during the warranty period, shall be
replaced, repaired, or satisfactorily modified by the
manufacturer without cost of parts or labor to the owner.
B.
It is not intended that the station manufacturer assume liability for
consequential damages or contingent liabilities arising from failure
of any vendor supplied product or part which fails to properly
operate, however caused. Consequential damages resulting from
defects in design, or delays in delivery are also beyond the
manufacturer's scope of liability.
C.
The warranty shall become effective upon the acceptance by the
purchaser or the purchaser's authorized agent, or sixty (60) days
after installation, or ninety (90) days after shipment, whichever
occurs first.
City of Wadsworth, Ohio
Page 11
Lift Station Standards
12/2004
2.
PART - PRODUCT
2.1.
PUMP STATION BUILDING
A.
Enclosure Construction and Design:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
The pump station configuration shall conform to the attached
standard drawing as close as possible. Sizes may be
increased due to larger models of equipment or other design
changes. The standard drawing is included to show
minimum dimensions. Other equipment and materials may
be required as part of this standard that are not shown on
the drawings.
The building shall be above ground construction with a
gabled roof. The exterior of the building will be reviewed by
the City of Wadsworth Architectural Design Commission and
will be similar in appearance to surrounding construction.
Water service shall be supplied to the building with a faucet
for attachment of hoses to washdown equipment and
building. A minimum of 16 feet of hose will be supplied by
the contractor.
There shall be at least one electrically powered exhaust fan
that can be activated by a wall mounted switch.
Shelving shall be provided for stacking of maintenance
equipment and materials.
There shall be a floor drain located in the building with the
floor slab sloped to it.
Appropriate means of humidity control shall be included,
whether an air conditioner of dehumidifier.
Electrical GFCI outlets shall be provided on all walls.
Adequate lighting will be required.
Some installations may require the use of sound deadening
material to control nuisance noise.
One set of double-entry doors shall be provided and located
on the wall opposite of the wet well. The doors shall have no
center frame.
A single entry man door will be required on a wall adjacent to
the double door.
When possible, all conduits for the pumps shall be placed
below slab.
A high capacity station heater shall be provided for the
protection of the pumping equipment. The heater shall
maintain an inside/outside differential temperature of 60
degrees F while operating on the supplied fuel (natural gas;
LPG) to the station. The heater shall be provided with an
City of Wadsworth, Ohio
Page 12
Lift Station Standards
12/2004
adjustable
15.
B.
thermostat.
The station enclosure shall be furnished with an extra
double-wide door, to facilitate removal of equipment. A
double hung door design with 3-point locking hardware, door
closer, and hinges on each section shall allow complete
access to the 6'-0" x 6'-8" full door opening without the need
for
a
center
sill.
Enclosure Functional Equipment:
1.
The interior of the station shall be illuminated by factory
installed 120 volt, 40 watt, two (2) lamp fluorescent light
fixtures providing two (2) watts illumination per square foot.
All lights will be prewired and run to the control panel
through PVC conduit and a weatherproof switch shall be
installed adjacent to each station entrance. A length of
flexible conduit shall provide for quick connection of the
lighting circuit to the pump control panel. The lighting circuit
shall be protected by a thermal-magnetic circuit breaker.
2.
A thermostatically controlled 120 VAC exhaust fan with
screen and weatherproof shutters shall be installed in the
wall approximately opposite the fresh air intake vent. The
fan shall have a minimum capacity of 1600 CFM at free air
and be capable of changing the air in the enclosure a
minimum of six times per hour. The exhaust fan shall be
protected by a thermal-magnetic circuit breaker.
3.
Two (2) self-contained, unpowered, thermally actuated fresh
air intake vents shall progressively open or close exterior
louvers as a result of thermal expansion or contraction of a
wax-like material contained in an enclosed plunger actuator.
Movement for the plunger rod shall drive the louver vane
mechanical linkage. The louvers will progressively open at
75 degrees F, and progressively close at 60 degrees F.
Operation of the intake louvers shall not require use of
motors, solenoids, or other electrically related devices. The
plunger actuator shall be mounted out of the incoming air
flow, and shall hold the louvers fully open based on the
ambient temperature of the pump station interior. The louver
vanes and frame shall be constructed of anodized aluminum,
with zinc plated steel actuator mounting and linkage. The
louver
vanes
shall
pivot
on
plastic
bearings.
City of Wadsworth, Ohio
Page 13
Lift Station Standards
12/2004
C.
4.
Two (2) sets of unpowered, thermally actuated exhaust
vents shall be supplied for each engine used. The louvers
will progressively open at 75 degrees F, and progressively
close at 60 degrees F. Operation is the result of thermal
expansion or contraction of wax in an enclosed plunger
which is used to drive the louver vane mechanical linkage.
Functional operation is identical to the intake vents, except
the plunger actuator is mounted directly in the path of the air
flow in order to sense the ambient temperature of the air
exiting
the
pump
station
interior.
5.
A critical grade spiral muffler and flexible exhaust pipe will be
supplied for each engine. The pump station enclosure shall
incorporate provisions for installation of the exhaust
equipment through the wall panel.
6.
The pump control panel for the Auto-start Pump station shall
be shipped completely prewired to the pumps, motors, and
engine(s) through conduit secured to the pump base. Upon
installation, the contractor shall remove any temporary
shipping hardware and brackets, and anchor the control
panel permanently to the concrete station pad.
Additional Enclosure Features:
1.
A battery back-up 12 volt DC emergency lighting system
shall provide 50 watts of illumination for 1-1/2 hours in the
event of power outage. The system shall be fully selfcontained for automatic operation of (2) two sealed beam
lamps powered by a maintenance free pure-lead 12 volt
battery. An automatic solid state battery charger with
integral transfer circuit shall maintain the battery in a
constant state of readiness. A charge rate pilot light and test
switch shall be provided. The charging circuit shall be
protected by a thermal-magnetic circuit breaker.
2.
A high capacity electric blower type station heater shall be
provided for the protection of the pumping equipment. The
heater shall maintain an inside/outside differential
temperature of 60 degrees F while operating on the primary
voltage supplied to the station. The heater shall be provided
with an adjustable thermostat, circuit breaker, and contactor.
3.
A wall mounted duplex GFI utility receptacle providing 120
volt AC power shall be installed and prewired through PVC
City of Wadsworth, Ohio
Page 14
Lift Station Standards
12/2004
conduit with the station lighting. The receptacle shall be
protected by thermal magnetic circuit breaker.
2.2.
2.3
UNITARY RESPONSIBILITY
A.
The pump station system integrator must be certified to ISO 9001
by an accredited certification agency.
B.
In order to unify responsibility for proper operation of the complete
pumping station, it is the intent of these Specifications that all
system components be furnished by a single supplier (unitary
source). The pumping station must be of standard catalog design,
totally warranted by the manufacturer. Under no circumstances will
a system consisting of parts compiled and assembled by a
manufacturer's representative or distributor be accepted.
MANUFACTURER
A.
The specifications and project drawings depict equipment and
materials manufactured by The Gorman-Rupp Company which are
deemed most suitable for the service anticipated. It is not intended,
however, to eliminate other products of equal quality and
performance. The contractor shall prepare his bid based on the
specified equipment for purposes of determining low bid. Award of
a contract shall constitute an obligation to furnish the specified
equipment and materials.
B.
After execution of the contract, the contractor may offer
substitutions to the specified equipment for consideration. The
equipment proposed for substitution must be superior in
construction and performance to that specified in the contract, and
the higher quality must be demonstrated by a list of current users of
the proposed equipment in similar installations.
C.
In event the contractor obtains engineer's approval for equipment
substitution, the contractor shall, at his own expense, make all
resulting changes to the enclosures, buildings, piping or electrical
systems as required to accommodate the proposed equipment.
Revised detail drawings illustrating the substituted equipment shall
be submitted to the engineer prior to acceptance.
D.
It will be assumed that if the cost to the contractor is less for the
proposed substitution, then the contract price shall be reduced by
an amount equal to the savings.
City of Wadsworth, Ohio
Page 15
Lift Station Standards
12/2004
2.4.
UNIT BASE
A.
2.5.
The unit base shall be comprised of structural steel with a perimeter
flange and reinforcements. Perimeter flange and reinforcements
shall be designed to prevent flexing or warping under operating
conditions. Perimeter flange shall be drilled for hardware used to
secure unit base to concrete pad as shown on the contract
drawings. Unit base shall contain provisions for lifting the complete
pump unit during shipping and installation.
PUMP DESIGN
A.
B.
General
1.
The manufacturer of the pumps must be certified to ISO
9001 by an accredited certification agency.
2.
Pumps shall be horizontal, self-priming centrifugal type,
designed specifically for handling raw, unscreened, domestic
sanitary sewage. Pump solids handling capability and
performance criteria shall be in accordance with
requirements listed under PART 1 - GENERAL of this
section.
Materials and Construction Features
1.
Pump casing:
Casing shall be cast iron Class 30 with
integral volute scroll. Casing shall incorporate following
features:
a.
Mounting feet sized to prevent tipping or binding when
pump is completely disassembled for maintenance.
b.
Fill port coverplate, 3 1/2" diameter, shall be opened
after loosening a hand nut/clamp bar assembly. In
consideration for safety, hand nut threads must
provide slow release of pressure, and the clamp bar
shall be retained by detent lugs. A Teflon gasket shall
prevent adhesion of the fill port cover to the casing.
c.
Casing drain plug shall be at least 1 1/4" NPT to
insure complete and rapid draining.
d.
Liquid volume and recirculation port design shall be
consistent with performance criteria listed under
PART 1 - GENERAL of this section.
City of Wadsworth, Ohio
Page 16
Lift Station Standards
12/2004
2.
3.
Coverplate: Coverplate shall be cast iron Class 30. Design
must incorporate the following maintenance features:
a.
Retained by hand nuts for complete access to pump
interior. Coverplate removal must provide ample
clearance for removal of stoppages, and allow service
to the impeller, seal, wearplate or check valve without
removing suction or discharge piping.
b.
A replaceable wearplate secured to the coverplate by
weld studs and nuts shall be AISI 1015 HRS.
c.
In consideration for safety, a pressure relief valve
shall be supplied in the coverplate. Relief valve shall
open at 75-200 PSI.
d.
Two O-rings of Buna-N material shall seal coverplate
to pump casing.
e.
Pusher bolt capability to assist in removal of
coverplate. Pusher bolt threaded holes shall be sized
to accept same retaining capscrews as used in
rotating assembly.
f.
Easy-grip handle shall be mounted to face of
coverplate.
Rotating Assembly: A rotating assembly, which includes
impeller, shaft, mechanical shaft seal, lip seals, bearings,
sealplate and bearing housing, must be removable as a
single unit without disturbing the pump casing or piping.
Design shall incorporate following features:
a.
Sealplate and bearing housing shall be cast iron
Class 30. Separate oil filled cavities, vented to
atmosphere, shall be provided for shaft seal and
bearings. Cavities must be cooled by the liquid
pumped. Three lip seals will prevent leakage of oil.
1)
City of Wadsworth, Ohio
The bearing cavity shall have an oil level sight
gauge and fill plug check valve. The clear sight
gauge shall provide easy monitoring of the
bearing cavity oil level and condition of oil
without removal of the fill plug check valve. The
Page 17
Lift Station Standards
12/2004
check valve shall vent the cavity but prevent
introduction of moist air to the bearings.
2)
The seal cavity shall have an oil level sight
gauge and fill/vent plug. The clear sight gauge
shall provide easy monitoring of the seal cavity
oil level and condition of oil without removal of
the fill/vent plug.
3)
Double lip seal shall provide an atmospheric
path providing positive protection of bearings,
with capability for external drainage monitoring.
b.
Impeller shall be ductile iron, two-vane, semi-open,
non-clog, with integral pump out vanes on the back
shroud. Impeller shall thread onto the pump shaft and
be secured with a lockscrew and conical washer.
c.
Shaft shall be AISI 4140 alloy steel unless otherwise
specified by the engineer, in which case AISI 17-4 pH
stainless steel shall be supplied.
d.
Bearings shall be anti-friction ball type of proper size and
design to withstand all radial and thrust loads expected
during normal operation. Bearings shall be oil lubricated
from a dedicated reservoir. Pump designs which use the
same oil to lubricate the bearings and shaft seal shall
not be acceptable.
e.
Shaft seal shall be oil lubricated mechanical type. The
stationary and rotating seal faces shall be tungsten
titanium carbide alloy. Each mating surface shall be
lapped to within three light bands flatness (35
millionths of an inch), as measured by an optical flat
under monochromatic light. The stationary seal seat
shall be double floating by virtue of a dual O-ring
design; an external O-ring secures the stationary seat
to the sealplate, and an internal O-ring holds the
faces in alignment during periods of mechanical or
hydraulic shock (loads which cause shaft deflection,
vibration, and axial/radial movement). Elastomers
shall be viton. Cage and spring to be AISI 316
stainless steel. Seal shall be oil lubricated from a
dedicated reservoir. The same oil shall not lubricate
both shaft seal and shaft bearings. Seal shall be
warranted in accordance with requirements listed
City of Wadsworth, Ohio
Page 18
Lift Station Standards
12/2004
under PART 1 - GENERAL of this section.
f.
4.
Pusher bolt capability to assist in removal of rotating
assembly. Pusher bolt threaded holes shall be sized
to accept same capscrews as used for retaining
rotating assembly.
Adjustment of the impeller face clearance (distance between
impeller and wearplate) shall be accomplished by external
means.
a.
Clearances shall be maintained by external shimless
coverplate adjustment, utilizing collar and adjusting
screw design for incremental adjustment of
clearances by hand. Requirement of realignment of
belts, couplings, etc., shall not be acceptable.
Coverplate shall be capable of being removed without
disturbing clearance settings.
b.
There shall be provisions for additional clearance
adjustment in the event that adjustment tolerances
have been depleted from the coverplate side of the
pump. The removal of stainless steel shims from the
rotating assembly side of the pump shall allow for
further adjustment as described above
c.
Clearance adjustment which requires movement of
the shaft only, thereby adversely affecting seal
working length or impeller back clearance, shall not
be acceptable.
5.
Suction check valve shall be molded Neoprene with integral
steel and nylon reinforcement. A blow-out center shall
protect pump casing from hydraulic shock or excessive
pressure. Removal or installation of the check valve must be
accomplished through the coverplate opening, without
disturbing the suction piping. Sole function of check valve
shall be to save energy by eliminating need to reprime after
each pumping cycle. Pumps requiring a suction check valve
to assist reprime will not be acceptable.
6.
Spool flanges shall be one-piece cast iron, class 30 fitted to
suction and/or discharge ports. Each spool shall have one 11/4" NPT and one 1/4" NPT tapped hole with pipe plugs for
mounting gauges or other equipment.
City of Wadsworth, Ohio
Page 19
Lift Station Standards
12/2004
C.
D.
Serviceability
1.
The pump manufacturer shall demonstrate to the engineer's
satisfaction that consideration has been given to reducing
maintenance costs by incorporating the following features.
2.
No special tools shall be required for replacement of any
components within the pump.
Pump drain kit
1.
E.
The pump drain kit shall consist of a 10' length of plastic
hose with a quick connect female Kamlock fitting on one end
of hose and two sets of fittings for pump drains. Each set of
fittings for pump drain includes a stainless steel pipe nipple,
stainless steel bushing, stainless steel ball valve and an
aluminum quick connect male Kamlock fitting.
Spare parts kit
1.
There shall be furnished with the pump station the following
minimum spare parts:
a.
b.
c.
d.
2.6.
One spare pump mechanical seal (complete), and
with it all gaskets, seals, sleeves, "o"-rings, and
packing required to be replaced during replacement of
the seal.
One set of impeller clearance adjustment shims.
One set cover plate "o"-ring.
One rotating assembly "o"-ring.
VALVES AND PIPING
A.
Each pump shall be equipped with a full flow type check valve
capable of passing a 3" spherical solid. Valve shall be constructed
with flanged ends and fitted with an external lever and torsional
spring. Valve seat shall be constructed of stainless steel, secured
to the body to ensure concentricity, sealed by an O-ring, and shall
be replaceable. The valve body shall be cast iron incorporating a
clean-out port large enough to allow removal and/or replacement of
the valve clapper without removing valve or piping from the line.
Valve clapper shall have a molded neoprene seating surface
incorporating low pressure sealing rings. Valve hinge pin and
internal hinge arm shall be stainless steel supported on each end in
brass bushings. Shaft nut shall have double O-rings which shall be
shall be easily replaceable without requiring access to interior of
City of Wadsworth, Ohio
Page 20
Lift Station Standards
12/2004
B.
C.
D.
valve body. All internal hardware shall be stainless steel. Valve
shall be rated at 175 PSI water working pressure, 350 PSI
hydrostatic test pressure. Valves other than full flow type or valves
mounted in such a manner that prevents the passage of a 3"
spherical solid shall not be acceptable.
The discharge header shall include a 3-way plug valve to permit
either or both pumps to be isolated from the common discharge
header. Valves shall have ports designed to pass spherical solids
equal to the pumps capability.
The plug valve shall be
non-lubricated, tapered type. Valve body shall be semi-steel with
flanged end connections drilled to 125 pound standard. Valve shall
be furnished with a drip-tight shutoff plug mounted in stainless steel
bearings, and shall have a resilient facing bonded to the sealing
surface. Valve shall be operated with a single lever actuator
providing lift, turn, and reseat action. The lever shall be equipped
with a locking device to hold the plug in the desired position.
Air Release Valves
1.
Each pump shall be equipped with one automatic air release
valve, designed to permit the escape of air to the
atmosphere during initial priming or unattended repriming
cycles. Upon completion of the priming or repriming cycle,
the valve shall close to prevent recirculation. Valves shall
provide visible indication of valve closure, and shall operate
solely on discharge pressure.
Valves which require
connection to the suction line shall not be acceptable.
2.
All valve parts exposed to sewage shall be constructed of
cast iron, stainless steel, or similar corrosion resistant
materials. Diaphragms, if used, shall be fabric-reinforced
neoprene or similar inert material.
3.
A clean out port, 3 inches or larger in diameter, shall be
provided for ease of inspection, clean out, and service.
4.
Valves shall be field adjustable for varying discharge heads.
5.
Connection of the air release valves to the station piping
shall include stainless steel fittings.
Gauge kit
1.
Each pump shall be equipped with a glycerin-filled
compound gauge to monitor suction pressures, and a
glycerin-filled pressure gauge to monitor discharge
City of Wadsworth, Ohio
Page 21
Lift Station Standards
12/2004
pressures. Gauges shall be a minimum of 4 inches in
diameter, and shall be graduated in feet water column.
Rated accuracy shall be 1 percent of full scale reading.
Compound gauges shall be graduated -34 feet to +34 feet
water column minimum.
Pressure gauges shall be
graduated 0 to 70 feet water column minimum.
2.
E.
Station Enclosure Low Temperature Alarm
1.
F.
G.
2.7
Gauges shall be mounted on a resilient panel and frame
assembly which shall be firmly secured to pumps or piping.
Gauge installations shall be complete with all hoses and
stainless steel fittings, and shall include a shutoff valve
installed in each gauge inlet at the point of connection to
suction and discharge pipes.
Pump station shall be supplied with a thermostat which shall
monitor interior station temperature. The control shall
incorporate an unpowered dry contact wired to terminal
blocks for field connection to a remote alarm device. The
contact will close in the event that the temperature within the
enclosure falls below approximately 35 degrees F.
Piping
1.
Flanged header pipe shall be centrifugally cast, ductile iron,
complying with ANSI/AWWA A21.51/C115 and class 53
thickness.
2.
Flanges shall be cast iron class 125 and Comply with ANSI
B16.1.
3.
Pipe and flanges shall be threaded and suitable thread
sealant applied before assembling flange to pipe.
4.
Bolt holes shall be in angular alignment within 1/2o between
flanges. Flanges shall be faced with a gasket finish.
Contractor must insure all pipes connected to the pump station are
supported to prevent piping loads from being transmitted to pumps
or station piping. Pump station discharge force main piping shall be
anchored with thrust blocks where shown on the contract drawings.
DRIVE UNIT
A.
Motors
City of Wadsworth, Ohio
Page 22
Lift Station Standards
12/2004
1.
Pump motors shall be _______ HP, three phase, 60 hertz,
240 VAC, horizontal ODP, 1800 RPM, NEMA design B with
cast iron frame with copper windings, induction type, with
class F insulation and 1.15 SF for normal starting torque and
low starting current characteristics, suitable for continuous
service. The motors shall not overload at the design
condition or at any head in the operating range as specified.
2.
Motors shall be tested in accordance with provisions of
ANSI/IEEE Std 112.
3.
Motor with engine shall be of a double shaft configuration.
2.8.
ENGINE
A.
Standby engine shall be a four (4) cylinder or six (6) cylinder,
(natural gas) fueled water cooled type, and shall have continuous
duty power rating suitable for the horsepower requirements of the
pump, after derating to factors set forth under performance. Engine
shall be cooled by an integral water cooling system capable of
maintaining safe engine operating temperature under expected
operating loads, and subject to the expected maximum ambient
temperatures in the pump station enclosure.
B.
Equipment
1.
The engine shall be equipped with all controls and
components required for manual and automatic operation
when used with the engine controls and DC level control
system described in these specifications. Such components
shall include, but not be limited to, the following:
a.
b.
c.
d.
e.
f.
g.
h.
City of Wadsworth, Ohio
12 Volt dc electrical system including starter and
alternator
Storage battery, 84 ampere-hour capacity minimum
Elapsed running time meter
Sensors for engine temperature, oil pressure, and
overspeed
Critical grade exhaust silencer to limit engine exhaust
noise.
Switch for manual operation of the cranking motor,
mounted on or near the engine
Voltmeter
Solenoid fuel lock-off valve suitable for use with
natural gas or LPG service
Page 23
Lift Station Standards
12/2004
i.
j.
k.
2.
3.
Lube oil pressure gauge
Jacket water temperature gauge
Tachometer
Engine electrical equipment shall be wired to a terminal
board on the engine and pre-wired to the base secured
control panel. (Note: If control panel is opted to be shipped
loose, connection to matching terminals in the control panel
shall be by contractor.)
Because the engine shall be required to operate during
emergency situations, the following minimum performance
standards shall be used for engine selection:
a.
Engine speed shall be controlled by an electronic,
governor-controlled throttle which shall maintain the
preset speed over the range of expected pumping
loads. This speed shall not be less than 1800 rpm to
insure adequate cooling, nor more than 3000 rpm so
that internal engine wear is held to a minimum. This
governed speed shall not be acceptable if it is greater
than that speed at which the engine torque and
horsepower curves intersect. Engine manufacturer's
published performance curves shall be submitted for
review to support engine selection.
b.
The engine shall develop approximately 95 percent of
manufacturer's published performance after a
reasonable run-in period.
c.
For selection of engine size, engine performance shall
be derated according to manufacturer's specifications
to allow for decreased performance if installed at
elevations more than 1000 feet above sea level.
d.
For selection of engine size, engine performance shall
be derated according to manufacturer's specifications
to allow for decreased performance in an ambient
temperature of 100-degrees f, which can reasonably
be expected in the pump station.
e.
Engine rating shall be further reduced to conform to
engine
manufacturer's
recommendations
for
continuous service applications.
City of Wadsworth, Ohio
Page 24
Lift Station Standards
12/2004
C.
2.9.
Brake horsepower requirements of pump shall not exceed
calculated engine horsepower after derating for power available
after run-in, temperature compensation, and altitude compensation.
DRIVE TRANSMISSION
A.
Power shall be transmitted from engine to pump by a v-belt drive
assembly through a centrifugal clutch mounted on a jackshaft,
which shall be coupled or otherwise interfaced with a shaft
extension on the pump motor. Jackshaft shall be constructed of
steel, not less than 1 1/2 inches in diameter, and shall be mounted
in two pillow blocks furnished with anti-friction roller bearings.
B.
Each drive assembly shall have a minimum of two v-belts or one
synchronized belt system. Each v-belt drive assembly shall be
selected on the basis that adequate power will be transmitted from
driver to pump based on the data developed in accordance with
drive calculations.
C.
Centrifugal clutch shall be designed to remain disengaged until
engine has reached some speed greater than idle speed to reduce
starting loads. Once engaged, clutch shall be rated to transmit
power continuously until engine speed has been reduced below
disengagement speed. Clutch shall disengage completely while
engine is not operating.
D.
Belt guards
1.
Pump drive transmissions shall be enclosed on all sides in a
guard constructed of any one or combination of materials
consisting of expanded, perforated, or solid sheet metal,
except that maximum perforated or expanded openings shall
not
exceed
1/2
inch.
2.
Guards shall be manufactured to permit complete removal
from the pump unit without interference with any unit
component, and shall be securely fastened to the unit base.
3.
All metal shall be free of burrs and sharp edges. Structural
joints shall be continuously welded. Panels may be riveted
to frames with not more than five-inch spacing. Tack welds
shall
not
exceed
four-inch
spacing.
4.
The guard shall be finished with one coat of gray W.R.
non-lift primer and one coat of orange acrylic alkyd W.R.
enamel in accordance with section 3, Color Definitions of
City of Wadsworth, Ohio
Page 25
Lift Station Standards
12/2004
ANSI 253.1; Safety Color Code for Marking Physical
Hazards.
2.10. FINISH
A.
Pumps, piping, and exposed steel framework shall be cleaned prior
to painting. Exposed surfaces to be coated with one coat gray
W.R. non-lift primer and one coat white acrylic alkyd W.R. enamel.
Paint shall be low VOC, alkyd based, high solids, semi-gloss white
enamel for optimum illumination enhancement, incorporating rust
inhibitive additives. The finish coat shall be 1.0 to 1.2 MIL dry film
thickness (minimum), resistant to oil mist exposure, solvent contact,
and salt spray. The factory finish shall allow for over-coating and
touch up after final installation.
2.11. ELECTRICAL CONTROL COMPONENTS:
A.
The pump station control panel will be tested as an integral unit by
the pump station manufacturer. The control panel shall also be
tested with the pump station as a complete working system at the
pump station manufacturer's facility.
B.
The electrical control components shall be provided by the pump
station supplier and shall be provided with the following features.
C.
Panel enclosure
1.
Enclosure shall be constructed in conformance with
applicable section of National Electrical Manufacturers
Association (NEMA) standards for type 1 electrical
enclosures. Enclosure shall be fabricated of steel having a
minimum thickness of not less than 0.075 Inch (14 gauge).
All seams shall be continuously welded, and shall be free of
burrs and voids. Interior and exterior surfaces shall be white
enamel. There shall be no holes through the external walls
of the enclosure for mounting the enclosure or any
components contained within the enclosure.
Panel
enclosure up to 60" x 36" x 12" shall be mounted on floor
stands and secured to pump base.
2.
Enclosure shall be equipped with a door mounted on a
continuous steel hinge, and sealed around its perimeter.
Door shall be held closed with clamps that are quick and
easy to operate. The door shall accommodate the mounting
of switches and indicators.
City of Wadsworth, Ohio
Page 26
Lift Station Standards
12/2004
D.
3.
Enclosure shall be furnished with a removable back panel,
fabricated of steel having a thickness of not less than 0.106
Inch (12 gauge), which shall be secured to the enclosure
with collar studs. Such panel shall be of adequate size to
accommodate all basic components.
4.
All control components shall be securely fastened to a
removable back panel with screws and lock washers.
Switches, indicators and instruments shall be mounted
through the control panel door. Self-tapping screws shall not
be used to mount any components. All connections from the
back panel to door mounted or remote devices shall be
made through terminal blocks.
UL Label Requirement:
1.
E.
Pump station controls shall conform to third party safety
certification. The panel shall bear a serialized UL label listed
for "Enclosed Industrial Control Panels". The enclosure, and
all components mounted on the sub-panel or control cover
shall conform to UL descriptions and procedures.
Motor Branch Components:
1.
2.
Main connections
a.
A main terminal block and ground lug shall be
furnished for field connection of the electrical supply.
The connections shall be designed to accept copper
conductors of sufficient size to serve the pump station
loads. The main terminal block shall be mounted to
allow incoming wire bending space in accordance
with article 373 of the National Electric Code (NEC).
A separate terminal strip shall be provided for 115
volt, single phase control power and shall be
segregated from the main terminal block.
Ten
percent of the control terminals shall be furnished as
spares.
b.
All motor branch components shall be of the highest
industrial quality. Operating coils of all ac control
devices shall be rated for 120 volts, and shall be
suitable for use in a voltage range of 108 to 132 volts,
60 hertz.
Circuit breakers and operating mechanisms
City of Wadsworth, Ohio
Page 27
Lift Station Standards
12/2004
F.
a.
A properly sized heavy duty air circuit breaker shall be
furnished for each pump motor, and shall have a
symmetrical RMS interrupting rating of 10,000
amperes at 230 volts. All circuit breakers shall be
sealed by the manufacturer after calibration to prevent
tampering.
b.
A padlocking operating mechanism shall be installed
on each motor circuit breaker. Operator handles for
the mechanisms shall be located on the exterior of the
control compartment door, with interlocks which
permit the door to be opened only when circuit
breakers are in the "off" position.
3.
An open frame, across-the-line, NEMA rated magnetic motor
starter shall be furnished for each pump motor. Starters of
NEMA size 1 and above shall be designed for addition of at
least two auxiliary contacts. Starters rated "0", "00", or
fractional sizes shall not be acceptable. Power contacts
shall be double-break and made of cadmium oxide silver. All
motor starters shall be equipped to provide undervoltage
release and overload protection on all three phases. Motor
starter contacts shall be easily replaceable without removing
the motor starter from its mounted position.
4.
Overload relays shall be solid-state block type, having visual
trip indication with trip-free operation. Electrically resetting
the overload will cause one (1) normally open and one (1)
normally closed isolated alarm/control contact to reset, thus
re-establishing a control circuit.
Trip setting shall be
governed by solid-state circuitry and adjustable current
setting. Trip classes shall be 10, 15 and 20. Additional
features to include phase loss protection, selectable jam/stall
protection and selectable ground fault protection.
5.
Overload reset pushbuttons shall be mounted through the
door of the control panel in such a manner as to permit
resetting the overload relays without opening the control
panel door.
Secondary Lightning Arrestor:
1.
The control panel shall be equipped with a secondary
lightning arrestor to minimize damage to the pump motors
and control from transient voltage surges. The arrestor shall
City of Wadsworth, Ohio
Page 28
Lift Station Standards
12/2004
utilize
silicon-oxide
varistors
encapsulated
in
a
non-conductive housing. The arrestor shall have a current
rating of 60,000 Amps, and a Joule rating of 1500.
G.
Three Phase Voltage Monitor:
1.
H.
The control panel shall be equipped to monitor the incoming
power and shut down the pump motors when required to
protect the motor(s) from damage caused by phase reversal,
phase loss, high voltage, low voltage, and voltage
unbalance. An adjustable time delay shall be provided to
minimize nuisance trips. The motor(s) shall automatically
restart, following an adjustable time delay, when power
conditions return to normal.
Other Control Components:
1.
The control circuit shall be fused, and shall be provided with
a disconnect switch connected in such a manner as to allow
control power to be disconnected from all control circuits.
2.
Pump mode selector switches shall be connected to permit
manual start and manual stop of each pump motor
individually. Manual operation shall override shutdown
systems supplied with the level control system except motor
overload.
3.
Pump alternation shall be integral to the liquid level
controller. Provisions for automatic alternation or manual
selection shall also be integral to the liquid level controller.
4.
A selector switch shall provide manual alternation of the air
pumps in the bubbler system.
The switch shall be
connected in such a manner that either pump may be
selected to operate continuously.
5.
A pushbutton switch shall be provided to silence one of the
115 volt AC alarm circuits while corrective actions are
underway. Depressing the alarm silence pushbutton shall
also cause the high water alarm circuit (low water alarm
optional) to reset when the liquid level has been lowered.
6.
High pump temperature shutdown circuit
a.
City of Wadsworth, Ohio
The control panel shall be equipped with circuitry to
override the level control system and shut down the
Page 29
Lift Station Standards
12/2004
pump motor(s) when required to protect the pump
from damage caused by excessive temperature.
b.
7.
Six digit elapsed time meters (non-reset type) shall be
connected to each pump motor starter to indicate the total
running time of each pump in "hours" and "tenths of hours".
8.
A duplex ground fault indicating utility receptacle providing
115 VAC, 60 hertz, single phase current shall be mounted
on the side of the control enclosure. Receptacle circuit shall
be protected by a 15 ampere thermal-magnetic circuit
breaker.
9.
Indicating lights shall be oil tight type and equipped with
integral step-down transformers for long lamp life. Lamps
shall be incandescent type rated 14 volts or less. Lamps
shall be replaceable from the front without opening the
control panel door and without the use of tools. Indicating
lights will be provided for the following functions:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
I.
A thermostat shall be mounted on each pump to
detect its temperature. If the pump temperature
should rise to a level which could cause pump
damage, the thermostat shall cause the shutdown
circuit to drop out the motor starter. An indicator,
visible on the front of the control panel shall indicate
that the pump motor has been stopped because of a
high temperature condition. The pump shall remain
locked out until the pump has cooled and the circuit
has been manually reset. Automatic reset of such a
circuit shall not be acceptable.
Pump #1 high pump temperature shutdown
Pump #2 high pump temperature shutdown
High wet well level
Alarm silenced
Pump #1 run
Pump #2 run
Engine low oil pressure
Engine high temperature
Engine overspeed
Engine overcrank
115 volt power available
Wiring
City of Wadsworth, Ohio
Page 30
Lift Station Standards
12/2004
1.
The pump station components, as furnished by the
manufacturer, shall be completely pre-wired. (Note: If control
panel is opted to be shipped loose, the pump station as
furnished by the manufacturer shall be completely pre-wired
except for the power feeder lines and final connections to
pump motors, engine, and remote alarm devices. The
interconnecting wire, conduit, and other materials required
shall be furnished and installed by the electrical contractor.)
2.
All wiring, workmanship, and schematic wiring diagrams
shall be in compliance with applicable standards and
specifications for industrial controls set forth by the Joint
Industrial Council (JIC), National Machine Tool Builders
Association (NMTBA), and the National Electric Code (NEC).
3.
All user serviceable wiring shall be type MTW or THW, 600
volts, and shall be color coded as follows:
a.
b.
c.
d.
e.
f.
g.
4.
Line and load circuits, AC or DC power
black
AC control circuit less than line voltage
red
DC control circuit
blue
Interlock control circuit, from external sourceyellow
Equipment grounding conductor
green
Current carrying ground
white
Hot with circuit breaker open
orange
Wire identification and sizing
a.
Control circuit wiring inside the panel, with the
exception of internal wiring of individual components,
shall be 16 gauge minimum, type MTW or THW, 600
volts. Wiring in conduit shall be 14 gauge minimum.
Motor branch wiring shall be 10 gauge minimum.
b.
Motor branch conductors and other power conductors
shall not be loaded above the temperature rating of
the connected termination. Wires shall be clearly
numbered at each end in conformance with applicable
standards. All wire connectors in the control panel
shall be of the ring tongue type with nylon insulated
shanks. All wires on the sub-plate shall be bundled
and tied. All wires extending from components
mounted on door shall be terminated on a terminal
block mounted on the back panel. All wiring outside
the panel shall be installed in conduit.
City of Wadsworth, Ohio
Page 31
Lift Station Standards
12/2004
5.
J.
K.
Control conductors connecting components mounted on the
enclosure door shall be bundled and tied in accordance with
good commercial practice. Bundles shall be made flexible at
the hinged side of the enclosure. Adequate length and flex
shall be allowed so that the door can swing to its full open
position without undue mechanical stress or abrasion on the
conductors or insulation. Bundles shall be clamped and held
in place with mechanical fastening devices on each side of
the hinge.
Conduit requirements are as follows:
1.
All conduit and fittings shall be UL listed.
2.
Liquid tight flexible metal conduit shall be constructed of a
smooth, flexible galvanized steel core with smooth abrasion
resistant, liquid tight, polyvinyl chloride cover.
3.
Conduit shall be supported in accordance with articles 346,
347, and 350 of the National Electric Code.
4.
Conduit shall be sized according to the National Electric
Code.
Grounding
1.
The pump station manufacturer shall ground all electrical
equipment to the enclosure back panel. The mounting
surface of all ground connections shall have any paint
removed before making final connections.
2.
The contractor shall provide an earth driven ground
connection to the control panel at the main ground lug in
accordance with the National Electric Code (NEC).
2.12. LIQUID LEVEL CONTROL SYSTEM
A.
The manufacturer of the liquid level control system must be certified
to ISO 9001 by an accredited certification agency.
B.
Pump station shall operate on utility power while such power is
available, except for exercise periods as specified herein. When
operating on utility power, operation of pumps and motors shall be
controlled by the level control system as specified herein. During a
failure of utility power and during exercise periods, operation of the
City of Wadsworth, Ohio
Page 32
Lift Station Standards
12/2004
pump with the standby engine shall be controlled by the level
control system and engine control system specified herein.
Transfer from AC control and to DC control shall occur as follows.
1.
2.
C.
Relays and other controls shall be provided to accomplish
the following functions:
a.
Time delay after failure of utility power before transfer
from AC control to DC control. Relay shall be
manually adjustable from 0.2 To 60 seconds.
b.
Time delay after restoration of utility power before
transfer from DC control to AC control. Relay shall be
manually adjustable from 0 to 30 minutes.
c.
Automatic override of time delay after power
restoration, upon occurrence of: engine or engine
control failure as specified under engine control
system.
d.
Manual override of time delay on restoration of normal
power. Momentary pushbutton or similar device shall
be acceptable.
e.
Time delay after transfer from DC control to AC
control before application of AC power to motor of
pump with standby engine. Such relay shall be preset
at approximately 15 seconds to permit engine to stop
completely before motor is started.
f.
Indicate the presence of utility power. Such indicator
shall be the press-to-test type to permit the operator
to verify failure of utility power.
These functions and interlocks shall be applicable only to the
motor of the pump furnished with the standby engine. No
hindrance shall be included for the motor starter and motor
branch circuit for the pump which does not have the standby
engine. Immediately upon restoration of utility power after
power interruption, and during exercise periods, the pump
which does not have the standby engine shall be permitted
to run if operation of that pump is required by the AC control
system.
Controls shall be provided to cause regular use of the DC control
system and standby engine. Such exercise of standby components
City of Wadsworth, Ohio
Page 33
Lift Station Standards
12/2004
shall occur to maintain these components in a ready condition, and
to discover malfunctions before emergency conditions arise.
D.
1.
Exercise periods shall be established by a manually
adjustable exercise timer. Timer shall provide a 7-day timing
cycle, and shall permit the selection of one or more exercise
periods of 15 minute duration, or multiples thereof, which
shall repeat every 7 days.
2.
During exercise periods, timer shall simulate a loss of utility
power to transfer circuits described herein. After transfer
from AC control to DC control, the DC control system shall
operate the pump with the standby engine through the
engine control system as described in these specifications.
3.
If the standby engine is operating at the end of the exercise
period, it shall continue to operate until one of the following
conditions occurs:
a.
The DC control system stops the engine through the
engine control system, or
b.
The delay on restoration of utility power relay times
out.
4.
Upon occurrence of either of these conditions, operation of
the engine shall cease and revert to control by the AC
control system.
5.
During exercise periods, utility power shall remain available
to the motor of the pump which does not have the standby
engine.
LIQUID LEVEL CONTROL (AC/DC)
1.
The integral AC/DC level control system shall start and stop
the pump motors/engine in response to changes in wet well
level, as set forth herein.
2.
The DC control system shall start and stop the standby
engine through the engine control system and in response to
changes in the wet well liquid level during a failure of utility
power and during exercise periods.
3.
The level control system shall be capable of operating as
either an air bubbler type level control system, submersible
City of Wadsworth, Ohio
Page 34
Lift Station Standards
12/2004
transducer type system, or ultrasonic transmitter type
system.
4.
The level control system shall be designed to accomplish the
following tasks:
a.
Continuously monitor the level of liquid in the wet well.
b.
Start and stop pump motors/engine as required by the
level of liquid in the wet well.
c.
Select the sequence of pump operation upon operator
command for automatic alternation.
d.
Provide alarm indications
predetermined malfunctions.
e.
Upon restoration of utility power after a power outage,
the system shall delay the application of power to the
engine driven pump, by a length of time that has been
preselected by the operator.
upon
occurrence
of
5.
The level control system shall utilize alternation to select first
one pump, then the second pump, to run as lead pump for a
pumping cycle. Alternation shall occur at the end of a
pumping cycle, or in the event of excessive run time.
6.
The level control system shall utilize an electronic pressure
switch which shall continuously monitor the wet well level,
permitting the operator to read wet well level at any time.
Upon operator selection of automatic operation, the
electronic pressure switch shall start the motor for one pump
when the liquid level in the wet well rises to the "lead pump
start level". When the liquid is lowered to the "lead pump
stop level", the electronic pressure switch shall stop this
pump. These actions shall constitute one pumping cycle.
Should the wet well level continue to rise, the electronic
pressure switch shall start the second pump when the liquid
reaches the "lag pump start level" so that both pumps are
operating. These levels shall be adjustable as described
below.
a.
City of Wadsworth, Ohio
The electronic pressure switch shall include integral
components to perform all pressure sensing, signal
conditioning, EMI and RFI suppression, DC power
supply and 120 volt outputs. Comparators shall be
Page 35
Lift Station Standards
12/2004
solid state, and shall be integrated with other
components to perform as described below.
b.
The electronic pressure switch shall be capable of
operating on a supply voltage of 12VDC in an ambient
temperature range of -10 degrees C (14 degrees F)
through 55 degrees C (131 degrees F). Control range
shall be 0 to 12.0 feet of water with an overall repeat
accuracy of (plus/minus) 0.1 feet of water. Memory
shall be retained using a non-volatile lithium battery
back-up.
c.
The electronic pressure switch shall consist of the
following integral components: pressure sensor,
display, electronic comparators and output relays.
1)
The internal pressure sensor shall be a
strain gauge transducer and shall receive an
input pressure from the air bubbler system.
The transducer shall convert the input to a
proportional electrical signal for distribution to
the display and electronic comparators. The
transducer output shall be filtered to prevent
control response to level pulsations or surges.
The transducer range shall be 0-15 PSI,
temperature compensated from -40 degrees C
(-40 degrees F) through 85 degrees C (185
degrees F), with a repeat accuracy of
(plus/minus) 0.25% full scale about a fixed
temperature. Transducer overpressure rating
shall be 3 times full scale.
2)
City of Wadsworth, Ohio
The
electronic
pressure
switch
shall
incorporate a digital back lighted LCD panel
display which, upon operator selection, shall
indicate liquid level in the wet well, and the
preset start and stop level for both lead and lag
pump. The display shall include twenty (20),
0.19" high alpha-numeric characters calibrated
to read out directly in feet of water, accurate to
within one-tenth foot (0.1 foot), with a full scale
indication of not less than 12 feet. The display
shall be easily convertible to indicate English or
metric units.
Page 36
Lift Station Standards
12/2004
3)
Level adjustments shall be electronic
comparator set-points to control the levels at
which the lead and lag pumps start and stop.
Each of the level settings shall be easily
adjustable with the use of membrane type
switches, and accessible to the operator
without opening any cover panel on the
electronic pressure switch. Controls shall be
provided to permit the operator to read the
selected levels on the display. Such
adjustments shall not require hard wiring, the
use of electronic test equipment, artificial level
simulation or introduction of pressure to the
electronic pressure switch.
4)
Each output relay in the electronic pressure
switch shall be solid state. Each relay input
shall be optically isolated from its output and
shall incorporate zero crossover switching to
provide high immunity to electrical noise. The
"ON" state of each relay shall be indicated by
illumination of a light emitting diode. The
output of each relay shall be individually fused
providing overload and short circuit protection.
Each output relay shall have an inductive load
rating equivalent to one NEMA size 4
contactor. A pilot relay shall be incorporated for
loads greater than a size 4 contactor.
d.
The electronic pressure switch shall be equipped with
an output board which shall include LED status
indicators and a connector with cable for connection
to the main unit.
e.
The electronic pressure switch shall be equipped with
pump start delay(s) preset at a fixed delay time of five
(5) seconds.
f.
Circuit design in which application of power to the lag
pump motor starter is contingent upon completion of
the lead pump circuit shall not be acceptable.
g.
The electronic pressure switch shall be equipped with
a simulator system capable of performing system
cycle testing functions.
City of Wadsworth, Ohio
Page 37
Lift Station Standards
12/2004
h.
The electronic pressure switch shall be capable of
controlling liquid levels in either a pump up or pump
down application.
i.
The electronic pressure switch shall have internal
capability of providing automatic alternation, manual
selection of pump sequence operation, and
alternation in the event of 1-199 hours excessive run
time.
j.
The electronic pressure switch shall be equipped with
a security access code to prevent accidental set-up
changes and provide liquid level set-point lock-out.
k.
The electronic pressure switch shall be equipped with
one (1) 0-33 ft. W.C. input, one (1) scalable analog
input of either 0-5VDC, 0-10VDC, or 4-20mA, and one
(1) 4-20mA scalable output. Output is powered by
10VDC supply. Load resistance for 4-20mA output
shall be 100-400 ohms.
l.
The electronic pressure switch shall include a DC
power supply to convert 120VAC control power to
12VDC EPS power. The power supply shall be 500
mA (6W) minimum and be UL listed Class II power
limited power supply.
m.
The electronic pressure switch shall be equipped with
an electronic comparator and solid state output relay
to alert maintenance personnel to a high liquid level in
the wet well. In the event that the wet well liquid
reaches a preset high water alarm level the alarm
output relay shall energize a signal relay. The signal
relay shall complete a 12 volt DC circuit for an
external alarm device. An indicator, visible on the
front of the control panel, shall indicate that a high wet
well level exists. The alarm signal shall be maintained
until the wet well level has been lowered and the
circuit has been manually reset. High water alarm
shall be furnished with a dry contact wired to terminal
blocks.
n.
The electronic pressure switch shall be equipped with
an electronic comparator and solid state output relay
to start and stop the standby engine in response to
City of Wadsworth, Ohio
Page 38
Lift Station Standards
12/2004
changes in wet well level during a failure of utility
power and during exercise periods.
o.
E.
Pressure Transducer System (AC/DC)
1.
F.
The level control system shall be the pressure transducer
type, Ametek mod 5505B006, 4-20mA, 0-13.8ft pressure
transducer. There shall be a backup DC control for power
interruptions. Operating power for the pressure transducer
shall be provided by the storage battery furnished with the
standby engine.
Alarm Light (External):
1.
G.
An alarm silence pushbutton and relay shall be
provided to permit maintenance personnel to
de-energize the audible alarm device while corrective
actions are under way. After silencing the alarm
device, manual reset of the alarm condition shall clear
the alarm silence relay automatically. The pushbutton
shall be oil tight design with contacts rated NEMA
A300 minimum.
Station manufacturer will supply one 12 VDC alarm light
fixture with vapor-tight shatter resistant red globe, conduit
box, and mounting base. The design must prevent rain water
from collecting in the gasketed area of the fixture, between
the base and globe. The alarm light will be shipped loose for
installation by the contractor.
Engine Control System:
1.
The engine control system shall be designed to accomplish
the following tasks:
a.
Permit the operator to select mode of engine
operation, providing manual start and stop of the
engine to override the level control system and
cranking circuit if required.
b.
Crank the engine upon start command from the level
control system, and stop the engine upon a stop
command.
City of Wadsworth, Ohio
Page 39
Lift Station Standards
12/2004
c.
Stop the cranking sequence if the engine fails to start
after a reasonable number of attempts, and provide
an alarm indication of failure to start.
d.
While the engine is operating, continuously monitor
engine speed, temperature and oil pressure.
e.
Stop the engine for excessive speed, excessive
engine water temperature, or insufficient oil pressure,
and provide an alarm indication of shutdown and its
cause, and shall
f.
Maintain the charge on the engine storage battery.
g.
Shutdown features shall be wired to the terminal strip
to provide a general alarm indication.
2.
Upon operator selection of automatic operation, when the
standby level control system provides a start command, the
engine control system shall start the engine cranking motor
for a short period of time. If the engine does not start, the
system shall stop the cranking motor for a short period of
time, then resume cranking. Typically, 5 10-second cranking
periods, each followed by a 10-second rest period, should be
considered a reasonable effort to start the engine. When the
engine starts, a sensor on the engine or elsewhere in the
system shall stop the cranking cycle and reset the cranking
circuit for the next start.
3.
If the engine does not start within the preset number of
attempts, the cranking circuit shall be deenergized, a failure
to start indicator on the control panel shall be illuminated,
and an external alarm device shall be energized. Control of
the pump with the standby engine shall be returned to the
AC control system.
4.
Once the engine has started normally, the engine control
system shall monitor engine speed, cylinder head
temperature , and oil pressure. Upon engine failure from
any cause, system shall provide an alarm indication,
illuminate an indicator, and energize and external alarm
device as specified below.
City of Wadsworth, Ohio
Page 40
Lift Station Standards
12/2004
5.
During periods when the DC control system is fully
operative, a battery charger shall continuously charge the
engine storage battery.
6.
Mode of engine operation
a.
b.
7.
Switches or other devices shall be provided and
connected to perform as follows:
1)
When automatic operation is selected, engine
shall start and stop under control of the engine
control system.
2)
When manual
cranking motor
pushbutton or
Once started,
selected.
3)
Operator can stop engine if it is running, and
prevent it from starting during maintenance or
repair.
operation is selected, engine
shall be controlled by a manual
other device on the engine.
engine shall run until off is
Engine failure circuits shall stop the engine, illuminate
a labeled indicator on the control panel, and energize
an external alarm device for each of the following
conditions:
1)
Engine speed exceeds maximum overspeed
setting.
2)
Engine temperature exceeds safe operating
temperature as specified by the engine
manufacturer.
3)
Engine oil pressure falls below engine
manufacturer's specified recommendations.
System must override or bypass this function
during cranking and several seconds after
starting to permit engine to build up oil
pressure.
Engine control system shall be furnished with one battery
charger, designed and connected to operate on 115 volts,
AC 60 hertz to maintain the charge on the 12 volt DC
City of Wadsworth, Ohio
Page 41
Lift Station Standards
12/2004
storage battery supplied with the engine. Battery charger
shall incorporate the following design features:
8.
H.
a.
Automatic charge
adjustment circuit.
sensing
and
charging
b.
Integral current limit circuit to limit charging rate.
c.
Charging rate ammeter.
d.
Fuse for protection of charging circuit.
rate
Operating power for the engine control system, except the
battery charger, shall be provided by the storage battery
furnished with the standby engine.
BACKUP LIQUID LEVEL CONTROL
1.
A backup level control system shall be provided to operate
the pumps, in the event of a failure of the primary solid state
level control system. This backup level control will allow for
a redundant pump off switch to turn the pump motors off in
the event of a primary level control failure.
2.
The backup level control system shall start and stop pump
motors in response to changes in wet well level. It shall be
the mercury float switch type, incorporating intrinsically safe
relays. Rising and falling liquid level in the wet well causes
switches within the floats to open and close, providing start
and stop signals to the remainder of the level control system.
3.
The backup level control system shall start and stop the
pumps in accordance to the wet well level. The pump start
and stop float switches shall be set above and below the
normal pump start and stop level settings utilized for the
primary level control. Upon operator selection of automatic
operation, a float switch shall start one pump motor when
water rises to the “pump start level”. When the water is
lowered to the “pump stop level”, the system shall stop the
pump. These actions shall constitute one pumping cycle.
4.
The backup level control system shall work in conjunction
with an alternator relay to select first one pump, then the
second pump, to run as “Lead” pump. Alternation will occur
at the end of each pumping cycle.
City of Wadsworth, Ohio
Page 42
Lift Station Standards
12/2004
5.
Two (2) float switches shall be supplied for installation by the
contractor. Each float shall contain a mercury switch sealed
in a polypropylene housing, with 50 feet of power cord, and
polypropylene mounting hardware. A PVC chain with weight
shall be furnished to secure the switches in the wet well.
6.
Two intrinsically safe relays shall be supplied in a separate
level control enclosure. Relays must be recognized and
listed as intrinsically safe by a nationally recognized testing
laboratory. Installing contractor shall make connections from
relays to motor controls.
3.
PART - EXECUTION
3.1.
EXAMINATION
A.
3.2.
Contractor shall off-load equipment at installation site using
equipment of sufficient size and design to prevent injury or damage.
Station manufacture shall provide written instruction for proper
handling. Immediately after off-loading, contractor shall inspect
complete pump station and appurtenances for shipping damage or
missing parts. Any damage or discrepancy shall be noted in written
claim with shipper prior to accepting delivery. Validate all station
serial numbers and parts lists with shipping documentation. Notify
the manufacturers representative of any unacceptable conditions
noted with shipper.
INSTALLATION
A.
Install, level, align, and lubricate pump station as indicated on
project drawings. Installation must be in accordance with written
instructions supplied by the manufacture at time of delivery.
B.
Suction pipe connections are vacuum tight. Fasteners at all pipe
connections must be tight. Install pipe with supports and thrust
blocks to prevent strain and vibration on pump station piping. Install
and secure all service lines (level control, air release valve or pump
drain lines) as required in wet well.
C.
Check motor and control data plates for compatibility to site
voltage. Install and test the station ground prior to connecting line
voltage to station control panel.
D.
Prior to applying electrical power to any motors or control
equipment, check all wiring for tight connection. Verify that
protective devices (fuses and circuit breakers) conform to project
City of Wadsworth, Ohio
Page 43
Lift Station Standards
12/2004
design documents. Manually operate circuit breakers and switches
to ensure operation without binding. Open all circuit breakers and
disconnects before connecting utility power. Verify line voltage,
phase sequence and ground before actual start-up.
3.3.
FIELD QUALITY CONTROL
A.
B.
Operational Test
1.
Prior to acceptance by owner, an operational test of all
pumps, drives, and control systems shall be conducted to
determine if the installed equipment meets the purpose and
intent of the specifications. Tests shall demonstrate that all
equipment is electrically, mechanically, structurally, and
otherwise acceptable; it is safe and in optimum working
condition; and conforms to the specified operating
characteristics.
2.
After construction debris and foreign material has been
removed form the wet well, contractor shall supply clear
water volume adequate to operate station through several
pumping cycles. Observe and record operation of pumps,
suction and discharge gage readings, ampere draw, pump
controls, and liquid level controls. Check calibration of all
instrumentation equipment, test manual control devices, and
automatic control systems. Be alert to any undue noise,
vibration or other operational problems.
Manufacturers Start-up Services
1.
3.4.
CLEANING
A.
3.5.
Co-ordinate station start-up with manufactures technical
representative. The representative or factory service
technician will inspect the completed installation.
He will calibrate and adjust instrumentation, correct or
supervise
correction
of
defects or malfunctions, and instruct operating personnel in
proper operation and maintenance procedures.
Prior to acceptance, inspect interior and exterior of pump station for
dirt, splashed material or damaged paint. Clean or repair
accordingly. Remove from the job site all tools, surplus materials,
scrap and debris.
PROTECTION
City of Wadsworth, Ohio
Page 44
Lift Station Standards
12/2004
A.
The pump station should be placed into service immediately. If
operation is delayed. Station is to be stored and maintained per
manufacturers written instructions.
City of Wadsworth, Ohio
Page 45
Lift Station Standards
12/2004
SEWAGE FLOW METER:
The pump station manufacturer shall furnish a Polysonics SX40 Doppler flow
meter with the pump station. The flowmeter shall be factory mounted and wired
within the above ground building. A 15 amp circuit breaker shall be provided and
1/60/120 volt pump supply shall be connected to the flowmeter. The Doppler
transducer sensors shall be field installed on the discharge piping within the
building, at the time of station startup.
1. The flow meter shall utilize ultrasonic, Dual Frequency Doppler (DFD)
technology, which will transmit a minimum of two independent frequencies
through the flow stream, to provide indication, totalization, data logging
and signal transmission of liquid rate in full pipes.
2. The flowmeter will measure flow rates of solids bearing and/or aerated
fluids over a velocity span of 0.2 to 32 ft/s (0.06 to 10 m/s). The two Dual
Frequency transducers will be supplied with the instrument and shall be
suitable for pipe sizes from 0.5 to 200 inches (12 to 5000 mm).
3. The instrument will provide a +- 1% total error ban under reference
conditions.
4. Configuration will be via a front panel 19 key flat membrane keypad with
tactile feedback. Input parameters will be password protected. The
nonvolatile memory shall retain totalizer and user parameters for up to five
years. Flowmeter diagnostics shall be accessible via the keypad.
5. A 90,000 point data logger, programmable in 30 second, 1, 5, 15, 30, and
50 minute intervals will be included as standard in the flowmeter.
HydraLink data retrieval software will be supplied with the instrument.
6. The analog output shall be an opto isolated, 12 bit, 4-40mA DC signal
proportional to flow. Output current limited circuitry will be incorporated in
the flow meter electronics. An RS232 serial interface will be provided.
7. The flowmeter shall be suitable for either (1)90-132 VAC, 190-250 VAC,
50/60 Hz, switch selectable.
8. The transducers will be encased in stainless steel shrouds and will be
suitable for submersion and operation from -70°F to +250°F (-40°C to
+122°C).
9. The transducers will attach to the outside of the pipe by means of
stainless steel straps. The standard transducer cable length will be 20 feet
(6m).
10. The flowmeter electronics shall be designed to operate at temperatures
between -5°F to +140°F (-20°C to +60°C). All electronic circuits are to be
interchangeable with other flow meters having the same model number.
All circuit boards will be conformal coated with an antifungus compound.
11. The display will be a backlit, 240 x 640 dot, high resolutions graphics
display.
12. The electronics enclosure will be environmentally protected to NEMA 4X
(IP65).
City of Wadsworth, Ohio
Page 46
Lift Station Standards
12/2004
13. For additional security, the enclosure will provide a facility for the
attachment of a padlock to prevent unauthorized access to the display and
front panel.
14. The manufacture shall provide a full NIST traceable flow calibration
certificate.
15. The instrument shall be manufacture in the USA at an ISO 9001 certified
facility.
16. The dual frequency Doppler flow meter will be the Polysonics Hydra SX40
model manufacture by Polysonics, Inc., 10335 Lansbury, Suite 300,
Houston, Texas 77099-3407, (281) 879-3700.
City of Wadsworth, Ohio
Page 47
Lift Station Standards
12/2004
CONDUIT:
A. Conduit requirements are as follows:
1. All conduit and fittings shall be UL Listed
2. Liquid tight flexible metal conduit shall be constructed of a smooth,
flexible galvanized steel core with smooth abrasion resistant, liquid
tight, polyvinyl chloride cover.
3. Conduit shall be supported in accordance with articles 346, 347, and
350 of the national electric code.
4. Conduit shall be sized according to the national electric code.
B. Grounding
1. The pump station manufacturer shall ground all electrical equipment to
the enclosure back panel. The mounting surface of all ground connections
shall have any paint removed before making final connections.
2. The contractor shall provide an earth driven ground connection to the
control panel at the main ground lug in accordance with the national
electric code (nec).
City of Wadsworth, Ohio
Page 48
Lift Station Standards
12/2004
TELEMETRY SYSTEM
The lift station supplier shall supply an integrated pump control package with its
standard offering, complete with the following signals available for incorporation
into the Wadsworth Water Treatment SCADA System:
Pump status (on/off)
High level switch (on/off)
Backup High level switch (on/off)
Lift station water level (4-20 ma signal from level transmitter)
The integrated pump control package supplier shall also provide complete
electrical schematics showing all components integrated into its pump control
system.
These signals will be incorporated into a stand-alone, networked Lift Station
SCADA panel using an Allen-Bradley Micrologix 1200 programmable logic
controller with Ethernet connectivity allowing this control panel to send its data
over the city of Wadsworth's fiber optic backbone to the Wadsworth Water
Treatment Plant SCADA System. The SCADA system located at the Wadsworth
Water Treatment Plant shall provide the following information to the Water
Treatment plant operator from each lift station:
Communication active
Communication failure alarm
Call for pump
Pump running
Pump run hours
Level
High-level alarm
Backup high level switch alarm
Level transmitter fault
The Lift Station SCADA Panel will contain the following devices:
Allen-Bradley MicroLogix 1200 Programmable Logic Controller
Allen-Bradley 4 Channel Analog Input Module
Allen-Bradley ENI Serial to Ethernet Converter
Serial to ENI Network Cable
24V DC Power Supply
Current Switch
Terminal Blocks
The City of Wadsworth will supply the cable connection to its fiber optic
backbone and cable modem. The city will be responsible for network addressing
and routers required to facilitate data communication. Once networking is
City of Wadsworth, Ohio
Page 49
Lift Station Standards
12/2004
implemented and data is available to the Water Treatment Plant, operator
graphics will be provided by the operations staff at the Water Treatment Plant.
City of Wadsworth, Ohio
Page 50
Lift Station Standards
12/2004
WET WELL
A. Construction
1. Wet wells shall be constructed of reinforced, precast concrete sections
having a 4,000-psi, 28-day compressive strength, and shall conform to
ODOT 511, Class “C” concrete. Precast, concrete sections shall conform
to ASTM C478, with “O” ring joints per ASTM C443. Walls shall be sized
to adequately function for the intended purpose and shall withstand all
loadings when full or empty. All walls and joints shall be watertight. The
entire wet well shall be coated inside and out with coal tar epoxy or
approved equal, and all joints shall be sealed with a butyl sealant sheet
around the outside perimeter of the joint, extending 9” on either side of the
joint.
2. All reinforcing steel used in wet well construction shall conform to
ODOT item 509 and ACI 301-84. All reinforcing bars shall be epoxy
coated and have a yield stress of Fy = 60,000 psi. All reinforcing fabric
shall be epoxy coated and shall conform to ASTM A 185.
B. Floor Slope: The wet well floor shall have a minimum slope of 1:1 from the
walls to the hopper bottom. The horizontal area of the hopper bottom shall
be not greater than that necessary for proper installation and function of
the suction pipe inlets.
C. Standard manhole steps shall be installed as indicated on the drawings
and shall meet applicable OSHA and D.O.E.S. standards. Steps shall be
plastic coated type per M.A. Industries, Inc., PS-1-PF or approved equal.
D. Top Slab and Access:
The top slab of the pump station wet well shall be designed to support the
personnel and equipment needed for maintenance and equipment
removal and shall be reinforced concrete, 8” thick minimum. The slab shall
be provided with a minimum 36” square wet well access hatch. Access
hatch frame and cover shall be aluminum with 300 series stainless steel
hinges and hardware. The frame and cover shall be flush with the slab top
when closed, have a slip resistant, diamond pattern texture, and be
designed for heavy-duty service. The cover shall be provided with a lifting
handle and safety latch to hold the cover in an open position, shall have
safety grating for fall protection when the doors are open, and shall have
recessed padlock hasps with hinged covers. Contractor shall provide two
(2) padlocks. Access hatch shall be Bilco Type KD or approved equal.
E. Size:
City of Wadsworth, Ohio
Page 51
Lift Station Standards
12/2004
The wet well size (volume) and control settings for pumps shall be
appropriate to avoid excessive on/off cycles and shall also avoid septic
conditions due to excessive detention time. As much as is practical, wet
well size and pumping rates shall be designed to deliver as uniform a flow
as possible. The effective volume of the wet well shall be based on design
average flow and filling time not to exceed 30 minutes. In no case shall the
well diameter be less than five (5) feet.
F. Ventilitation:
Air displacement shall be accomplished using an inverted “j” tube or other
means. Ventilation for maintenance safety purposes shall provide at least
12 complete air changes per hour if continuous, or 30 complete air
changes per hour if intermittent. Air shall be forced into the wet well by
mechanical means. Switches for operation of ventilation equipment shall
be marked and located conveniently and/or automatic controls installed for
intermittent usage.
G. Piping:
All piping in wet wells shall be ductile iron pipe, Class 53, per
ANSI/AWWA C151/A21.51 with flanged or mechanical joints, and of the
size shown on the drawings.
H. Testing:
Wet wells shall be vacuum tested in accordance with the City of
Wadsworth, Engineering Construction Standards.
City of Wadsworth, Ohio
Page 52
Lift Station Standards
12/2004
MANUFACTURER'S RESPONSIBILITIES:
A. OPERATIONAL TEST
The pumps, motors, and controls shall be given an operational test in
accordance with the standards of the hydraulic institute. Recordings of
the test shall substantiate the correct performance of the equipment at
the design head, capacity, suction lift, speed and horsepower as
herein specified.
Upon request from the engineer, the engineer or his representative
shall be invited to witness the operational test at the manufacturer's
facility or other location designated by the manufacturer.
B. SUBMITTALS
The manufacturer of the pump station shall be responsible for delivery to
the engineer of (4) copies of the support literature required herein.
C. INSTALLATION INSTRUCTIONS
Installation of the pump station and related appurtenances shall be
performed in accordance with written instructions by the manufacturer.
D. OPERATION AND MAINTENANCE INSTRUCTIONS
1. The pump station manufacturer shall be responsible for supplying
written instructions, which shall be sufficiently comprehensive to enable
the operator to operate and maintain the pump station and all equipment
supplied by the station manufacturer. Said instructions shall assume that
the operator is familiar with pumps, motors, piping, and valves, but that he
has not previously operated and/or maintained the exact equipment
supplied.
2. The instructions shall include, but not limited to, the following:
a. Descriptions of, and operating instructions for, each major
component of the pump station as supplied.
b. Instructions for operation of the pump station in all intended
modes of operation.
c. Instruction for all adjustments that must be performed at initial
start-up of the pump station, adjustments that must be performed
after the replacement of the level control system components, and
adjustments that must be performed in the course of preventative
maintenance as specified by the manufacturer.
d. Service instructions for major components not manufactured by
the pump station manufacturer but which are supplied by him in
City of Wadsworth, Ohio
Page 53
Lift Station Standards
12/2004
accordance with these specifications. The incorporation of literature
produced by the actual component manufacturer shall be
acceptable.
e. Electrical schematic diagram of the pump station as supplied,
prepared in accordance with NMTBA and JIC standards.
Schematics shall show, to the extent of authorized repair, pump
motor branch, control, and alarm system circuits, and
interconnections among these circuits. Wire numbers shall be
shown on the schematic. Schematic diagrams for individual
components, the detail parts of which are not normally repairable
by the station by the station operator, need not be included, and
shall
not
be
substituted
for
an
overall
schematic diagram. Partial schematics, block diagrams, and
simplified schematics shall not be provided in lieu of overall
schematic diagram.
f. Layout drawing of the pump station as supplied, prepared in
accordance with good commercial practice, showing the locations
of all pumps, motors, valves, and piping.
3. Operation and maintenance instructions which are limited to a collection
of component manufacturer literature without overall pump station
instructions shall not be acceptable.
4. Operation and maintenance instructions shall be specific to the
equipment supplied in accordance with these specifications. Instruction
manuals applicable to many different configurations and pump stations,
and which require the operator to selectively read portions of the
instructions shall not be acceptable.
MANUFACTURER'S ABILITIES:
A. DELIVERY
Upon request from the engineer, the pump station manufacturer shall
demonstrate proof of financial responsibility with respect to performance
and delivery date.
B. EXPERIENCE
Upon request from the engineer, the pump station manufacturer shall
demonstrate proof or evidence of facilities, equipment, and skills required
to produce the equipment specified herein.
C. MANUFACTURER'S QUALIFICATIONS
The Manufacturer of Equipment of this Section shall have five years
minimum proven experience in such Equipment and shall have
City of Wadsworth, Ohio
Page 54
Lift Station Standards
12/2004
satisfactorily completed three jobs of similar size and type within the last
year.
D. MANUFACTURER'S FIELD REPRESENTATIVE
1. The Manufacturer of the Equipment of this Section shall provide a
qualified field representative at the Site.
2. Such Manufacturer's field representative shall instruct the Owner's
personnel in the proper handling, installation, start-up, and operation of
the equipment.
3. Such Manufacturer's field representative shall instruct the Owner's
personnel in the proper start-up, operation, and maintenance of the
equipment. The instruction period shall be a minimum of eight hours.
E. RESPONSIBILITY
It shall be the responsibility of the Manufacturer of the pumps specified in
this Section to provide the pumps/motors, level control systems, complete
motor control center and all ancillary equipment for the correct operation
and performance of each pump. The pump manufacturer shall test the
pumps and controls as a system at the factory.
MANUFACTURER'S WARRANTY:
A. MATERIAL AND WORKMANSHIP
The manufacturer of the pump station shall warrant it to be of quality
construction, free from defects in material and workmanship. This
warranty shall include specific details described below.
OVERALL PUMP STATION:
A. EQUIPMENT WARRANTY
1. The contractor shall furnish a Maintenance and Guaranty Bond to the
City upon completion of the pump station and force main. The equipment,
apparatus, and parts furnished shall be warranted for a period of one (1)
year, excepting only those items that are normally consumed in service,
such as light bulbs, oil, grease, packing, gaskets, o-rings, etc. The
contractor shall be solely responsible for the warranty of the station and all
components.
2. Components failing to perform as specified by the engineers, or as
represented by the manufacturer, or as proven defective in service during
City of Wadsworth, Ohio
Page 55
Lift Station Standards
12/2004
the warranty period, shall be replaced, repaired, or satisfactorily modified
by the manufacturer without cost of parts or labor to the owner.
EFFECTIVE DATE:
A. INITIAL DATE
1. The warranty shall become effective upon the acceptance by the City of
Wadsworth of the entire pumping system. Acceptance shall be made only
after all testing is complete and passed, all punch list items addressed by
the contractor and/or manufacturer, and all equipment functioning as
designed.
PERMITS AND APPROVALS:
A. The contractor shall obtain and pay for any and all permits and inspections
required for the execution of this work. Permits, approvals and other
requirements included in this work shall be as follows.
1. Electrical Service
a. Contractor shall pay initial installation charges as well as monthly
charges until the pump station is accepted by the City of
Wadsworth.
2. Natural Gas Service (If Required)
a. Contractor shall pay initial installation charges as well as monthly
charges until the pump station is accepted by the City of
Wadsworth.
3. Ohio Environmental Protection Agency
a. Contractor shall pay all plan review fees and other associated
fees.
b. Contractor shall submit a copy of the EPA Plan Approval Letter
to the City.
4. Building Department
a. Contractor shall pay all plan review fees and other associated
fees.
5. Planning Department
City of Wadsworth, Ohio
Page 56
Lift Station Standards
12/2004
a. Contractor shall pay all plan review fees and other associated
fees.
6. Engineering Department
a. Contractor shall pay for any inspection fees associated with the
work.
b. Contractor shall pay a Pump Station Installation Fee to cover the
cost of programming and telemetry system coordination at the
Water Pollution Control Plant, which shall be the actual cost of such
work, but not to exceed $1500.00. The full $1500 shall be paid up
front as a deposit, and any unused portion refunded to the
contractor following successful pump station start-up.
City of Wadsworth, Ohio
Page 57
Lift Station Standards
12/2004