METRO SEWER DISTRCT (MSD), CINCINNATI, OHIO DETAILED PROVISIONS FOR ELECTRICAL PUMP CONTROL PANELS FOR PUMP OR LIFT STATIONS

Transcription

1 METRO SEWER DISTRCT (MSD), CINCINNATI, OHIO DETAILED PROVISIONS FOR ELECTRICAL PUMP CONTROL PANELS FOR PUMP OR LIFT STATIONS PART 1 - GENERAL 1.01 Scope A. The contractor shall furnish all labor, materials, equipment, services and incidentals required to design, build, install and place in satisfactory service, the complete electrical pump control Panels, indoor and outdoor locations, for specified Sewer Pump/Lift Stations including all electrical work as shown in contract drawings and as specified herein Removal of existing Pump Control Panel, Electrical Apparatus and related items A. The contractor shall remove and store or relocate all existing apparatus as shown on the drawings, as specified herein or as necessary for the completion of the installation of the new pump control panel. B. All Interruptions of existing circuit shall be coordinated with the MSD Engineer and the Supervisor of the pump station maintenance group and they shall determine the length of time a circuit may be deenergized in order to maintain the pump station operation in dependable and safe operating condition. C. The circuit shall be deenergized only long enough to disconnect the equipment and terminate the wiring that is to remain. D. All equipment and major length of wiring retired and removed shall remain the property of the MSD unless shown or directed otherwise and shall be placed in storage on MSD site by the Contractor where ordered. E. Any electrical equipment or component damaged during the performance of this contract shall be replaced or repaired with like kind new condition at no cost to MSD. F. All work associated with the design, build, install and test phase of pump control panel at pump/lift stations including earthwork, site improvements, roadways, various materials, sheeting and bracing, removal of existing features, sewers and other piping, manholes and equipment, and painting shall be done in accordance with the latest State of Ohio Department of Transportation, Construction and Materials Specifications, the City of Cincinnati Supplement to the State of Ohio, Department of Transportation, Construction and Material Specifications as well as other applicable MSD Standards, safety, regulatory, and jurisdictional requirements and any amendments and or addenda thereto Temporary Power A. The contractor shall verify and confirm the schedule for temporary power with MSD before installation of new pump control panel and related electrical work. B. The temporary power system shall be installed and maintained at minimize interference with the operation of the pump/lift station. C. Temporary power and lighting shall be the responsibility of MSD. MSD shall provide, control, and operate the required temporary power during the time of this contract Existing Electrical Service, Equipment and Controls for Pump Stations A. Utility power: Annex A. B. Pumps data: Annex A C. Motors data: Annex A S. Saeed, 3/15/2006, Page 1 of 15

2 D. Float switches: Redundant Off, Off, Lead, Lag, and High-level alarm. E. Emergency Generator and a Transfer Switch data. F. Telemetry Panel: 1 Existing Telemetry Status-Alarms for remote monitoring: a. High wet well Terminal #38-39 b. Intrusion alarm-internal Terminal #53-54 c. Loss of CG&E Power Terminal #55-56 d. Emergency run, Terminal #57-58 e. Generator common fault Terminal #69-70 f. Transfer switch in Emergency Terminal #71-72 g. Motor-1 run Terminal #59-60 h. Motor-2 run Terminal #63-64 i. Pump-1 seal fail Terminal #67-68 j. Pump-2 seal fail Terminal # The Contractor shall review and verify all existing status, analog and digital alarm circuits at the pump/lift station. 3 The Contractor shall install wiring and relay contacts for Telemetry alarms in new pump control panels as required, specified, or as shown on the contract drawings. G. Basic Operation 1. The pumps shall be operated automatically or manually as a pump down, lead/lag, common off system. Each pump shall be controlled primarily through a Hand-Off-Auto 3-position maintained selector switch. 2. Position Commands: a. Redundant Off or Low Level Off shuts off all pumps completely. b. In Off position, the applicable pumps will not run under any circumstances. c. In Hand position, the applicable pumps shall run without regard for the level sensing commands and will rely on operator discipline to run and stop. d. In Auto position, both pumps shall be controlled by float switches. These switches will sense the appropriate level in the wet well and initiate start and stop commands to the pumps. All floats shall be interposed with intrinsically safe UL listed relays installed per NEC Article 504, ANSI/ISARP 12.6 and all other applicable codes. H. Float Alarms sequence 1. High Alarm Float: LS-4 float sets High alarm level. 2. Lead Pump Float: Start lead pump; LS-3 turns ON the lead pump when the wet well level reaches preset float level. Lead pump shall alternate at each call. 3. Lag Pump Float: Start lag pump; if the wet well level continues to rise, the LS-2 float turns ON the lag pump. Both pumps running. 4. Pump OFF Float: the lead and/or lag pumps shall continue to run until the low level OFF as indicated by LS-1 is reached. The float LS-1 shall stop all the pumps at this level. 5. Redundant Off Floats: Low wet well level off shuts all pumps completely. A. Standby Generator Controls 1. The Pump Control Panel shall have provision to house wiring and control circuit for standby generator as specified, as shown on the drawings, or as necessary for the completion of the installation of the new pump control panel. B. Power Factor Correction Capacitors 3. The Pump Control Panel shall have provision to house wiring and control circuit for power factor correction capacitors as specified, as shown on the drawings, or as necessary for the completion of the installation of the new pump control panel. S. Saeed, 3/15/2006, Page 2 of 15

3 4. The wiring control circuit for power capacitors shall be as per manufacturer s specifications and instructions where soft start/stop is installed. 5. Power capacitors circuit shall be fused and shall energize or de-energize on line side using bypass or up-to-speed contacts of soft start/stop. C. Existing Schematics and Drawings 1. The existing schematic and drawings are old and may have been modified or corrected. The documents on modifications and records may or may not exist. 2. The contractor shall review existing pump controls for each pump station. 3. The contractor shall use MSD elementary drawings for pump control panels as reference to construct build and install new pump control panels. A. Existing power cables, conduits and wirings 1. The contractor shall verify condition of power cables, conduits, wirings and replace all bad, rusted and weak segments as required, specified and as shown in the drawings Reference Standards A. Electrical material and equipment for Pump Control Panel shall conform in all respect to the latest approved standards of the following: 1. National Electrical manufacturers Association (NEMA) 2. The Institute of Electrical and Electronic Engineers (IEEE) 3. National Electric Codes (NEC) 4. Underwriter laboratories (UL) 1.06 Qualifications A. Motor Controllers, soft-start/stop, microprocessor based or solid-state equipment, when specified and required shall be a product of a manufacturer who has a minimum of ten (10) years experience specializing in the design and manufacturing of Motor Controllers, soft-start/stop, microprocessor based solid-state control devices. B. All equipment shall be installed, inspected, and tested in accordance with the manufacturer s recommendations. C. Provide a field startup report by a qualified factory-trained manufacturer s representative Operation of Lift Station A. The contractor shall perform the electrical work in a manner such that MSD can keep the pump/lift station in operation until the installation or replacement pump control panel is substantially complete and ready for operation. B. The contractor shall keep the MSD Engineer informed of any work, which will interfere with the operation of the pump /lift station. C. All necessary shut down periods shall be scheduled in advance with the Superintendent of Division of Wastewater Treatment, Engineer and Supervisor of the pump station maintenance group, so that the operation of the facility can be maintained in compliance with the applicable regulatory agency requirements. D. Temporary pumping shall be the responsibility of MSD. MSD shall provide, operate, and maintain the required temporary pumping during the time of this contract. E. The contractor shall make every effort to minimize the time that pump/lift station may be out of service. When all equipment, labor and materials that are necessary to begin and complete the work required during the shut down time are ready. MSD shall determine when the shut down period may commence and shall give notice to the Contractor to proceed with the installation of new pump control panel. S. Saeed, 3/15/2006, Page 3 of 15

4 1.08 Identification A. Conduits and pull boxes, Junction boxes, and equipment shall be provided with identification tags. Tags shall be gauge-19, 316-stainless steel, and ½ inch stamped letters and numbers as indicated on the drawings, specified, or required. Tags shall be attached with nylon tie wraps. B. All electrical motors starters disconnect switches, manual starters, push buttons stations, and similar equipment operating components shall be provided with permanently mounted, laminated engraved nameplates. C. All other electrical appurtenances, switches, outlets, fixtures etc., except conduit shall be labeled with appropriate circuit numbers. D. All pilot control switches, indicating lights, and other pilot control devices shall be provided with oversize/jumbo legend plates or laminated engraved nameplates showing each switch position or device function. E. All nameplates, circuit labels, legend plates, and wording on them shall be approved by MSD Engineer. F. Power wires shall be color coded with electrical tape or colored wire jacket: volts, 1-phase, 2-wire: Black, and Neutral as White /240 volts, 3-phase, 3-wire: Black and red, neutral as white volts, 3-phase, 3-wire: Brown, Orange, and Yellow. 4. Ground conductors: Green Submittals and Approvals A. The following preliminary information two (2) copies for each Pump Control Panel shall be submitted to MSD Engineer for review and approval prior to the start of work: 1. Shop drawings, dimensioned outlined drawings, Power and control connection drawings, conduit entry exit locations, cable terminal sizes, wiring diagrams, equipment voltage and horse-power ratings/or continuous current, and product sheets. 2. Preliminary Operation & Maintenance (O&M) Manuals for review and approval. B. The following information shall be submitted two days before the final inspection: 1. Five (5) copies of Final as-built drawings and wiring diagrams. 2. The final as built drawings shall include the same drawings as the construction drawings and shall incorporate all changes made during the manufacturing and installation process. 3. An electronic copy, CD ROM, of Final as-built drawings in Auto Cad - current version. 4. Five (5) copies of equipment Operation and Maintenance (O&M) Manuals shall be provided for all equipment used to build, construct and installation of pump control panel for each pump station. This shall include the following: a. Bill of material (BOM). b. Theory of operation of pump control circuit. c. Manufacturers cut-out sheets. The equipment and devices used shall be clearly marked. d. Technical literature with instruction leaflets and instruction bulletins for the complete assembly of each major component. e. Permits and electrical inspection reports. A. Contractor shall begin work to design, build and install each Pump Control Panel after formal approval of item 1.09A1 & 1.09A2 above Electrical Schematic Diagram A. Furnish a permanently mounted laminated electrical schematic diagram of the pump control circuit including terminal blocks connection on the inside of the enclosure door of each Panel Electrical Inspections and Permits A. Where required or specified, contractor shall obtain permits or complete inspection reports as per inspection Bureau Inc., (IBI). S. Saeed, 3/15/2006, Page 4 of 15

5 B. All required permits and inspection reports shall be provided to MSD Engineer Work Schedule A. Contractor shall follow the order and priority to commence work to design, build and install each Pump Control Panel as set by MSD Engineer. B. Any changes to the work schedule, order or priority to commence work shall require prior approval of MSD Engineer or MSD pump station supervisor. C. The contractor shall provide Gant chart showing the task order and schedule completion of project work with in six (6) month of Notice to Proceed. D. The contractor shall complete each panel installation with in Mon-Fri work week. E. The contractor shall provide Schedule of Values Warranties A. For a twelve (12) month period from date of installation the contractor shall repair or replace product which proves defective due to defective materials or workmanship Inquiries and Clarifications A. Any inquiries or requests for clarifications to this specification shall be addressed to:- Sohail Saeed, PE, Metro Sewer District, 1600 Gest Street, Cincinnati, Oh 45204, (Ph: ). Dennis Edwards, Supervisor of Maintenance, MSD Pump Station Group (Ph: Office, cell). S. Saeed, 3/15/2006, Page 5 of 15

6 PART 2 PRODUCTS 2.01 MATERIALS A. Cable, Wires and Conduits 1. All wires shall be new, comply with NEC, and listed by UL and as shown on the drawings. 2. Sizes of conductors shall conform to the requirements of the NEC, with additional requirements for minimum sizes specified herein: a. THWN, 600Volts, 75 deg. C b. Power: 12 AWG minimum c. Control: 14 AWG minimum d. Cable (4-20 ma): Shielded twisted pair, 16 AWG, 600 Volts 3. Rigid Aluminum conduits and fittings shall be manufactured of 6063-T1 alloy, UL rated, and shall conform to Fed Spec WW-C-540 and ANSI C For PVC-Coated Rigid Steel conduit, the conduit shall be rigid steel and the thickness of the PVC coating shall be at least 40 mils. All fittings and mounting hardware shall be PVC coated. PVC-Coated rigid steel conduit shall be manufactured by Ocal, Perma-Cote, and Robroy or approved equal. 5. Rigid non-metallic (PVC) Conduit shall be heavy wall, Schedule 40; UL labeled for above ground and underground uses, and shall conform to Fed Spec W-C- 1094, Nema TC-2 and UL 651. B. Outlet Boxes, Junction Boxes, Pull Boxes and fittings 1. Cast pull and junction boxes shall be Nema 4X-SS rated, UL listed, and external mounting lugs, drilled and tapped conduit holes, hubs with tapered threads. Bolton junction box covers are not acceptable. Covers must have a hinged door or be clamped-on type. Cast pull and junction boxes shall be manufactured by: a. Hoffman Engineering Company b. Appleton Electric Company 2. Fabricated junction, pull boxes and Terminal boxes shall be type 316 stainless steel code gauge sheet metal with 14 gauge minimum thickness, gasket, external mounting lugs, water tight conduit hubs for all conduit entrances, attached box covers with piano hinge, type 316 stainless steel cover screws, stainless steel overlapping clamp assemblies, UL listed and Nema 4X rated. Shall be manufactured by: a. Hoffman Engineering Company b. Appleton Electric Company C. Main Electrical Disconnect 1. The main service disconnect shall be fused, Nema 4X 300-series stainless steel, lockable handle in ON position, horsepower rated, UL listed, single throw, three pole, front operated, with visible blade. 2. The disconnect switch shall be rated for service entrance equipment and shall utilize quick make, quick break mechanism. 3. Fuses used with disconnect where shown on the drawings, and specified, shall be of current limiting Class J type. 4. Disconnect Switch shall be manufactured by: a. Allen Bradley b. Cutler-Hammer/Eaton D. Circuit Breakers S. Saeed, 3/15/2006, Page 6 of 15

7 1. Circuit breakers shall be thermal-magnetic, molded case, Nema type, UL listed, one or three pole, with each pole of the breaker providing inverse time delay overload protection and instantaneous short-circuit protection by means of a thermal-magnetic element which shall trip at 125% of trip rating. 2. Minimum Interruption ratings of the circuit breakers, protecting pump control electrical circuit, shall be at least equal to the available short circuit at the incoming line terminal. 3. Tripping due to overcurrent or short-circuit shall be clearly indicated by position of handle in mid-way between the manual ON and OFF position. 4. Each motor starter shall have a circuit breaker for short-circuit protection, which shall be properly sized for its motor load as per applicable NEC codes. 5. The circuit breakers shall indicate ON, OFF, and Tripped status. Breakers for 240 VAC shall have interrupting rating not less than 10,000 amperes. 6. Circuit breakers shall be manufactured by: a. Allen Bradley b. Cutler-Hammer/Eaton E. Motor Controllers and Disconnects Single phase 1. Furnish and install single-phase equipment controllers at all 120-volt motors and equipment where shown or specified. Single-phase starters shall be quick make/quick break Toggle operated, non-reversing two poles, horsepower rated, and thermal overload protection with interchangeable heaters. 2. For the controllers rated above 1hp the closure of the contacts shall be blocked while the line terminals are exposed. The operating handle or button shall clearly indicate whether the unit is ON, OFF or TRIPPED. 3. Short circuit protection shall have interrupting rating of at least 10,000 amps at 120 volts. 4. The enclosure when required shall be Nema Type as specified or shown on the contract drawings 5. Furnish and install a local disconnect for Single-phase equipment for all nonmotor, 120-volt equipment. The disconnect switches shall be similar to the controllers described above except without thermal overload protection 6. Manufacturers: a. Allen Bradley b. Cutler Hammer/Eaton F. Motor Starters Electromechanical Three Phase 1. Furnish and install three phase, reversing or non-reversing, magnetic motor starters, when specified and as shown on the drawings. Three-phase motor starter shall be Nema and UL rated with three overload elements. 2. All starters shall be fusible or circuit breaker combination type controller, 120-volt coil and dry type power transformer where required as shown on the drawings and as specified. 3. Fuse sizes, circuit breaker size, overload size and contactor size shall conform to NEC codes. 4. All motor starters shall be full voltage type, single speed, reversing or nonreversing, as shown on the drawings, and as specified. 5. Each motor starter shall include auxiliary contacts as required and specified, plus one spare normally open (NO), and one spare normally closed (NC) contact. 6. Provide AC control power transformer, 120 VAC secondary, not less than 5KVA as specified and as required, or as shown on the drawings. Provide circuit breaker on primary side. The control power transformer shall be sized taking into account connected auxiliary relays, timers, Telemetry signals and other accessories. S. Saeed, 3/15/2006, Page 7 of 15

8 7. Provide AC control power transformer, 24volt, not less than 50VA and as required, or as shown on the drawings for all wet-well alarm circuits. 8. Furnish a three-phase ambient-compensated bimetallic thermal overload relay with manual or automatic reset. Electrically isolated normally open (NO) and normally closed (NC) contacts shall be provided with the relay. Visual trip indication shall be standard. Each motor starter overload shall be sized for its motor load as per applicable NEC codes. 9. Solid State overload relay when specified or shown shall have the following features: Self powered, class 10 or 20 fixed tripping, UL listed, manual or automatic reset, phase loss protection, visible trip indication, one normally (NO) and one normally closed (NC) isolated contacts, ambient temperature compensated, have ground fault and motor jam and motor stall protection. 10. Three-phase motor starters shall be manufactured by: a. Rockwell-Allen Bradley b. Cutler Hammer/Eaton G. Reduced Voltage Motor Control - Solid State 1. Furnish and install a solid state UL listed soft start/stop when specified and as shown on the contract drawings. 2. The reduced voltage starter shall be integrated unit with power SCRs logic board, parallel bypass contactor, and adjustable electronic overload relay enclosed in a single molded housing. The SCR based power section shall consist of six (6) back-to-back SCRs. 3. SCR and diode combination or triacs shall not be acceptable. 4. The reduced voltage starter shall include electronic overload protection as standard, and based on inverse time-current algorithm. The overload shall have motor full load adjustment from 30 to 100% of maximum continuous rating of the starter. The overload selectable class setting shall be 5, 10, 20 or 30 and capable of electronic or mechanical reset after fault. The overtemperature protection (on heat sink) shall be standard. 5. The starter shall provide protection against a motor stall and motor jam condition as standard. These features can be disabled when not required. 6. The reduced voltage starter shall provide protection against phase loss or unbalance condition, and motor jam condition. 7. The reduced voltage starter shall have a Form C normally open (NO) and (NC) contact for READY and FAULT status that shall change state when fault condition exists. Contacts shall be rated 60 VA resistive and 20 VA inductive. The LED display shall indicate type of fault, i.e., over-temperature, phase loss, jam, stall, phase reversal and overload. 8. The reduced voltage starter shall have minimum of one normally open (NO) auxiliary contact and a provision to add additional normally open (NO) auxiliary contacts. 9. The reduced voltage starter shall have the following control functions adjustments and features on the device: a. Selectable torque ramp start or current limit start. b. Adjustable kick-start torque time: 0-2 seconds. c. Adjustable kick start torque 0-85%, ramp start time seconds, initial starting ramp torque 0-85%, and smooth stop ramp time 0-60 seconds. 10. Maximum continuous operation shall be at 115% of continuous ampere rating. 11. The control power-supply shall be provided as per manufacturer s specification for 120 volt AC or 24 V dc as specified and as shown on the drawings. 12. Resistor and Capacitor snubber networks shall be used to prevent false firing of SCRs due to dv/dt effects. Noise suppression diode for DC control relay or noise suppressor (filter) for AC control relay shall be provided with each starter S. Saeed, 3/15/2006, Page 8 of 15

9 13. Furnish and install one MOV with each controller as required per manufacturer s specifications. 14. The solid state reduced voltage starter shall be manufactured by: a. Rockwell-Allen Bradley b. Cutler Hammer/Eaton H. Pump Control Panel Enclosure 1. A Control Panel Enclosure shall be furnished as specified, and as shown in drawings. The enclosure size shall be large enough to hold all the specified and required components to be installed, Nema 3R or 4X-300-series SS rated, UL 508 listed, with white baked enamel painted steel back panel. 2. Back back-panel shall mount main circuit breaker, motor circuit breakers, motor starters, overloads, and fuses, Transformer(s), relays, timers, alternator, ground lugs and terminal blocks. Duplex GFI receptacle, indicator lights, H-O-A selector and push button switches and time elapsed meter shall be mounted on the front door. 3. The control panel enclosure shall have a heat exchanger or a thermal management unit. 4. The enclosure shall be designed specifically for municipal wastewater applications. The panel manufacturer shall have a minimum of 5 years experience manufacturing systems specifically for wastewater applications. 5. The electrical enclosure shall have three point locking system, a hasp and padlock, and anchor bolts for outdoor units to anchor to concrete slab all made of 300-series stainless steel. 6. The electrical enclosures shall have enough space to house alternate or secondary electrical power system wirings and controls as required, as specified or as shown in the drawings. 7. The dimensions of electrical enclosure for underground lift station shall be based on the existing panel size and the manhole diameter of the lift station. 8. The enclosure shall be manufactured by: a. Saginaw Control & Engineering b. Smith & Loveless (S&L) I. Pilot Control Devices 1. Pushbuttons, Selector Switches (H-O-A), and Indicator Lights shall be provided and installed as shown in the drawing, and as specified: a. Type: Shall be round heavy-duty water tight, corrosion resistant, UL listed and Nema rated equal to or better than the enclosure onto which they are installed, maintaining the integrity of the enclosure Nema rating. b. Operator legend plates: Jumbo size, custom lettered as designated on the drawings, black lettering on white background. c. Contact blocks: Heavy-duty type, Nema A600 Contact rating. d. Shall have screw terminals for wire connection. e. Indicator lights shall be push-to-test type, with each lamp having its own 120/6V AC transformer and low voltage (6 volt No 755) bulb. f. Lens color as shown on the drawings. g. H-O-A switches for each motor shall be UL rated, heavy duty, 600VAC, and oil-tight switches. Hand position not to override motor overload shut down. h. Provide pilot lights for motor run and stop, over temperature, motor failure, seal fail, for each pump motor, and as shown on the drawing, and as specified. i. Manufacturers: 1) Cutler Hammer/Eaton 2) Allen Bradley S. Saeed, 3/15/2006, Page 9 of 15

10 3) Or approved equal 2. Relays: a. All relays shall be sized for the load condition, UL listed and plug-in type. b. Coil voltage shall be 120 VAC unless shown otherwise on the drawings. c. Light Duty Relays: 1) Shall be used for control circuits and similar duty, 10 amps rated DPDT or 3PDT contacts with built-in pilot light ON/OFF indicator. 2) General-purpose plug-in pin terminals type mounted on heavy-duty octal sockets with barrier protected screw terminals. 3) Light duty relays shall be manufactured by: a) Potter Brumfield b) Cutler Hammer/Eaton c) Or approved equal 3. Heavy Duty Relays: a. Shall be used by small motors (single phase, 120/240 VAC) and any contact loading above 5 amperes. b. Shall have 10 ampere rated convertible contact cartridges. c. Heavy duty relays shall be manufactured by: 1) Cutler Hammer/Eaton 2) Or approved equal 4. Timers a. Description: 1) Field adjustable with range and initial setting as shown on the drawings or specified. 2) On delay, off delay or repeat cycle, solid state timing. 3) Power Input 120 VAC, unless shown otherwise on drawings, compatible contact rating with current of devices simultaneously operated by contact. 4) Plug in type mounted on heavy-duty octal sockets with barrier protected screw terminals. Timers to be UL listed. b. The timers shall be manufactured by: 1) Automatic Timing and Control Company (ATC). 2) Diversified Electronics 3) Or approved equal 5. Alternators a. Contractor shall provide an alternating relay, with LED indication, and H-O-A switch for manual operation. A built in time delay shall prevent the simultaneous energization of both pumps. Contacts shall be N.O. SPDT, rated 10 A resistive, 345 VA inductive at 120 VAC. b. Include three-position switch to override automatic alternator and provide manual selection of either Pump-1 or Pump-2 as the lead pump. c. The alternator shall be manufactured by: 1) Diversified Electronics 2) Or approved equal 6. Elapsed Time Meters a. Elapse time meter shall be Nema rated, UL listed, non-resettable and utilize 120 VAC, 60 cycles, permanent magnet motor that is accurate within plus or minus 50 milli-seconds per start or stop. b. Operate at 100 percent when running at normal frequency with a range of 0 to 99,999.9 hours and temperature range of 0 degrees to 140 degrees F. c. The elapsed time meter shall be manufactured by: 1) Cramer Model 635K S. Saeed, 3/15/2006, Page 10 of 15

11 2) Or approved equal 7. Phase Monitor Relays a. The phase Loss, under voltage and phase sequence plug in type relays shall be provided to monitor power and phase loss. The phase monitor shall have appropriate fuses installed for short circuit protection. b. The phase monitor Relays shall be manufactured by: 1) Diversified Electronics 2) Or approved equal J. Power Blocks and Fuse Holders 1. Power distribution blocks shall be aluminum; tin-plated and must be compatible with copper conductors. Each block shall be sized appropriately for the size and number of wires being terminated and shall be based on NEC ampacity tables using 75 0 Celsius wire. 2. Fuse holders shall be 600V, 30 amp high impact thermoplastic with copper alloy plated clips. 3. Manufacturers: a. Marathon b. Or approved equal S. Saeed, 3/15/2006, Page 11 of 15

12 PART 3 EXECUTION 3.01 INSTALLATION A. Cables 1. Except as otherwise specified or indicated on the drawings, cable shall be installed according to the following procedures, taking care to protect the cable and to avoid kinking the conductors, cutting or puncturing the jacket, contamination by oil or grease, or any other damage. 2. Stranded conductor cable shall be terminated by lugs or pressure type connectors. Wrapping stranded cables around screws type terminals is not acceptable. Stranded conductor cable shall be spliced by crimp type connectors. The splice may be made only at readily accessible locations. 3. Cable shall not be pulled tight against bushings nor pressed heavily against enclosures. Spare cable ends shall be taped, coiled, and identified. Cable shall not be bent to a radius less than the minimum recommended by the manufacturer. B. Conduit 1. All conduit required to complete the electrical work, as shown on the drawings and as specified herein, shall be rigid galvanized and coated with plastic when underground or in concrete. 2. All exposed conduits shall be rigid aluminum or galvanized. When running a conduit through any precast concrete structure, seal both ends and gaps with a rubber link seal with stainless steel fasteners. 3. Terminations and connections of conduits shall be taper threaded. Conduits shall be reamed free of burrs and shall be terminated with conduit bushing. 4. Exposed conduits shall be installed either parallel or perpendicular to structural members and surfaces. All conduits that enter enclosures shall be terminated with acceptable fittings that will not affect the Nema rating of the enclosure. Hub fittings shall be Meyer Scru tight or equal. 5. Existing conduits may be reused subject to concurrence of MSD Engineer and compliance with the following requirement: 6. A wire brush shall be pulled through the conduit to remove any loose debris. 7. A mandrel shall be pulled through the conduit to remove sharp edges and burrs. C. Disconnect Switches 1. Mount equipment so that sufficient access and working space is provided for ready and safe operation and maintenance. 2. All mounting hardware shall be Type 316 stainless steel. Securely fasten equipment to walls or other structural surfaces on which they are mounted. Provide independent Type 304 stainless steel supports where no wall or other vertical surface exists. 3. All boxes installed against concrete or masonry shall be installed with a ¼-inch space between the box and the mounting surface. Spacers shall be Type 316 stainless steel, PVC, or nylon. D. Circuit Breakers 1. Install circuit breakers in the pump control panel as shown on the drawings. 2. Mount equipment so that sufficient access and working space is provided for ready and safe operation and maintenance 3. Where indicated on the drawings, install individual circuit breakers in a NEMA 4X stainless steel enclosure. E. Equipment Controllers and Disconnects Single (1) Phase 1. Install all equipment in conformance with NEC codes. S. Saeed, 3/15/2006, Page 12 of 15

13 2. Install controlling and disconnecting devices on all single-phase equipment including motors, fans, compressors, flow meters, and miscellaneous equipment unless such devices are specified with equipment with other items. 3. When the controller is located with in sight of the equipment, the controller shall also function as the disconnection device. 4. When the controller is not located with in sight of the equipment, an individual disconnect switch similar to the controllers, except without overload protection shall be provided at the equipment. 5. Engraved laminated nameplates describing equipment function shall be installed on all controller and disconnect switches. Nameplates shall comply with section Securely fasten equipment to surfaces to which they are mounted. a. Do not mount enclosure or box directly on brick, masonry or concrete walls. Provide suitable ¼-inch spacers made of Type 316 stainless steel, PVC or nylon. b. Provide independent Type 304 stainless steel supports where no wall or other surface exists. c. Use Type 316 stainless steel material for miscellaneous and mounting hardware. 7. Select overload size from actual motor nameplate data or from manufacturer s equipment protection requirements information whichever is applicable. F. Motor Controllers Three (3) Phase 1. Install all equipment in conformance with NEC codes. 2. Securely fasten equipment to surfaces to which they are mounted. a. Do not mount enclosure or box directly on brick, masonry or concrete walls. Provide suitable ¼-inch spacers made of Type 316 stainless steel, PVC or nylon. b. Provide independent Type 304 stainless steel supports where no wall or other surface exists. c. Use Type 316 stainless steel material for miscellaneous and mounting hardware. 3. Size overloads from actual motor nameplate data, corrected for actual power factor correction capacitor value if installed. G. Control Stations 1. Install all equipment in conformance with NEC codes. 2. Securely fasten equipment to surfaces to which they are mounted. a. Do not mount enclosure or box directly on brick, masonry or concrete walls. Provide suitable ¼-inch spacers made of Type 316 stainless steel, PVC or nylon. b. Provide independent Type 304 stainless steel supports where no wall or other surface exists. c. Use Type 316 stainless steel material for miscellaneous and mounting hardware. 3. Mount equipment so that sufficient access and working space is provided for ready and safe operation and maintenance. H. Pilot Control Devices 1. Mount pilot control devices in enclosure as required under other Sections and as shown on the drawings. 2. Install each item in complete accordance with the manufacturer s instructions. 3. Conform to all applicable provisions of NEMA Standards and NEC when installing wiring and pilot control devices. 4. Where the pilot control devices are installed in separate enclosure, the enclosure shall be water tight, dust-tight and corrosion resistant NEMA 4X stainless steel. S. Saeed, 3/15/2006, Page 13 of 15

14 I. Pump Control Panel 1. All control panel components must be labeled and all components on the enclosure door must have engraved labels. Voltage identification labels and comprehensive warning labels shall be provided. Provide plastic wire way for placing wires in neat bundles. All wires shall have numbered labels for identification in the field 2. Disconnect Operator shall allow external operation of main and /or pump disconnect switches. Handles are interlocked with door to prevent opening while disconnect is in ON position, and are pad lockable in the OFF position 3. Overload reset buttons shall be mounted through enclosure door to allow manual reset of tripped starter overloads without opening the enclosure door. The pump control system(s) shall be fully tested by the factory prior to shipment and installation. It shall include testing of both power and control devices as well as all control functions. The pump control panel and related accessories must insure compatibility and matching controls to all the pumps. 4. All electrical equipment for pump controls shall be mounted inside the pump control panel enclosure unless specified otherwise. A horizontal latching rod shall hold both outer doors in the open position. 5. All items shall be mounted on a interior swing out type door and back mounted panel. 6. The Main Electrical Disconnect Switch shall be mounted on the side of the above ground control cabinet/enclosure or on a stainless steel pole adjacent to the control cabinet. 7. The contractor shall verify and confirm the location of main disconnect for the underground stations when specified and as shown on the drawings. The location for new disconnect shall be same as of the existing/old disconnect switch that is to be removed. 8. The new electrical panel shall be installed at or near the existing/old pump control panel as specified, and as shown on drawings. 9. The power cable, conduit and wiring connecting new electrical pump control panel shall be replaced as specified, required and shown on the drawings. J. Alternator 1. Alternator shall alternate the lead pump on successive pumping cycles and provide for energization of the lag pump. Three (3) normally open float switches (Off, lead, and lag) shall be wired using intrinsically safe inputs to the alternator. High-level normally closed float shall be wired for high-level alarm only. 2. The alternator shall contain logic for the detection of malfunctioning float switches and shall adjust the mode of operation so that both pumps may continue to be duplexed. Operation of the duplexor shall revert to normal operation automatically upon detection of proper float switch function. K. Pump Mode Select 1. Method of operation shall be a 3-position green illuminated maintained Hand- Off-Auto selector switch for each pump, which shall provide for mode selection and run indication. L. Pump Thermal Trip and Seal Leak Detection One Temperature monitoring relay shall be supplied for each pump. The relay shall monitor the stator temperature of the pump motor. Over temperature shall be detected by NC low temperature switch mounted on the stator. An over temperature will cause immediate shut down and pumps shall remain locked-out until manually reset. The over temperature function shall incorporate a bistable relay that retains its position during power failures. Pilot lights located on the pump control panel shall indicate thermal trip. S. Saeed, 3/15/2006, Page 14 of 15

15 Seal leak shall be provided for all pumps. Detection of a seal leak occurring within the motor chamber shall not shut down or lockout the pump. Pilot light located on the pump control panel shall indicate a seal leak condition. M. Pump Start Delay 1. A 10 seconds time delay shall be set on time delay relay to start the lead pump and a 20 second time delay shall be set to start the lag pump. N. Convenience Outlet 1. A 20A GFI duplex outlet shall be provided. It shall be mounted on the outer door. A dedicated 20A circuit breaker shall be provided for this outlet. O. Equipment Grounding 1. Ground all electrical equipment in compliance with the NEC codes, local codes that apply, and as specified. 2. Equipment grounding conductors shall be installed in all conduits and shall be at least equal in size to the largest phase wire in the conduit, unless shown otherwise, and shall not be smaller than #12 AWG. 3. All conduit systems shall be electrically continuous from the service equipment. 4. Connect grounding conductors to equipment by means of lug compressed on cable end. 5. Bolt lug to equipment frame using holes or terminals provided on equipment specifically for grounding. 6. Do not use equipment or cover plate hold-down bolts. 7. Where grounding provisions are not included, drill suitable locations approved by the Engineer. 8. The resistive value of the main grounding conductor measured between the main disconnect and a good earth ground shall not exceed five (5) ohms. 9. Equipment ground Conductors shall be copper, THHN/THWN insulated green in color unless shown or specified otherwise. 10. Ground cable splices and joints, ground rod connections, and equipment bonding connections shall meet the requirement of IEEE 837, and shall be exothermic weld connections or irreversible high compression connections. P. Training 1. Motor Controllers, Soft-Starts and related Pump Control Circuits: F. Total of eight (8) hours of training equally divided in two sessions shall be provided; one session with in one month of the equipment installation/startup and the second session with in three to six months of equipment commissioning. G. The training shall be conducted by the manufacturer s qualified representative. 2. The training program shall consist of the following: a. Instruction on the proper maintenance of the equipment. b. The training shall be application specific. +++END+++ S. Saeed, 3/15/2006, Page 15 of 15