SECTION 11303 SANITARY SEWAGE PUMP STATIONS PART 1 GENERAL 1.1 DESCRIPTION: This work shall include the construction of a sewage pumping station complete with all pumping and electrical equipment, all piping and valves within the structure, electrical service for the pumping station, and all miscellaneous work and appurtenances required to complete and test the pumping station. PART 2 PRODUCTS 2.1 LIFT STATION STRUCTURE: The precast reinforced concrete structure as specified shall conform to the SECTION 02601 PRECAST MANHOLES. All joints shall be watertight and shall be sealed with preformed flexible joint sealant. A watertight seal is required at openings through the wall for entrance and exit piping. The exterior surface of the precast reinforced concrete basin below the finish ground line shall be treated with an application of hot liquid asphalt in accordance with the SECTION 02601 PRECAST MANHOLES. 2.2 PUMPS AND ACCESSORIES: The principal items of equipment shall include: two submersible sewage pumps, piping with valves, electrical control panel with control circuit and motor starters, automatic pump control floats, and all internal wiring, flashing light high water alarm, audible high water alarm horn, pump guide rail system, vent piping, hinged access doors, and incidental accessories as required and shown on the Plans to provide a complete and functioning system. 2.2.1 PUMPS AND MOTORS: Pumps and motors shall be as specified in Section 11214, SUBMERSIBLE PUMP AND ACCESSORIES. 2.2.2 AUTOMATIC DISCHARGE CONNECTION: Each pump shall be furnished with a submersible discharge connection system to permit removal and installation of the pump without the necessity of an operator entering the wet well. The design must insure an automatic and firm connection of the pump to the discharge piping when lowered into place. A gray iron cast base with integral guide rail pilots shall be provided along with all hardware and anchor bolts required for permanent installation to the wet well floor. The base shall be designed with an integral 90 degree elbow, or adapt to a commercially available elbow for connection to the vertical discharge piping utilizing standard ANSI 125 lbs. flanges. The base shall be coated with coal tar epoxy for corrosion resistance. The manufacturer shall provide all necessary drawings to insure proper installation and alignment of baseplate within the sump. 2.2.3 CRANE AND LIFTING CABLE: The lift station lid will include a Thern 5124 davit crane with a M2 worm gear hand winch. The crane will be powder coated with 20 feet of stainless steel wire rope. Pump access components inside the lift station will include the Flygt Pump Lift Grip Eye and Chain Sling units rated for a 540 lbs load, or approved equivalent. 2.2.4 VALVES AND PIPING: Each pump shall be equipped with a full flow type check valve, capable of passing a 3" spherical solid, with flanged ends and be fitted with an external lever, weight, and spring. The valve seat shall be constructed of stainless steel and shall be replaceable. The valve body shall be cast iron and incorporate a 3" cleanout port. 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 Section 11303 - Page 1
brass bushings, sealing bushing shall have double o-rings. O-rings shall be easily replaceable without requiring access to interior of valve body. 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. Each discharge line shall be equipped with a 2-way plug valve to permit isolation of the pumps from the common discharge header. The plug valve shall as specified in Section 02641. 2.3 WET WELL ACCESS: The wet well access shall be a Halliday S2R4848 with a Series X Retro Gate, or approved equal. 2.4 ELECTRICAL EQUIPMENT: 2.4.1 GENERAL: Pump control and monitoring equipment shall be Multitrode, Inc. 2.4.2 CONTROL PANEL: The duplex control panel shall be mounted in a NEMA 4X enclosure. The NEMA 4X enclosure shall have a separate inside hinged door to provide for mounting control switches, lights and overload reset buttons. The outer door on the NEMA 4X enclosure shall have a hasp for padlock. 2.4.3 CIRCUIT BREAKERS: A three-pole main circuit breaker for each pump shall be mounted with the operating handles through the inside door and shall have a lock arrangement that prevents the door from being opened when the breakers are in the "ON" position. When the breakers are off, all power shall be killed to the control elements. 2.4.4 PUMP CONTROL EQUIPMENT (PRIMARY CONTROLLER) A. Pump Control and Monitoring Equipment shall be Multitrode, Inc. B. Include line-voltage surge protection in all control equipment. Comply with UL 1449 and ANSI C62.41 Standards. C. Description: Microprocessor based, intelligent pump controller with pre-configured pump control logic and fault handling. The Pump Control Equipment shall be Multitrode MultiSmart Model MSU3PC. F. User Interface: The field hardware shall include a user interface for operations and configuration. The display shall provide status of the pump station, control of pumps, resetting of faults and configuration of parameters. 2.4.5 HAZARDOUS LOCATION PROTECTIVE DEVICE (INTRINSICALLY SAFE BARRIER): A. Equipment Description: The Hazardous Area Protective Device is intended to protect equipment and personnel in areas where hazardous conditions may be present. The Hazardous Area Protective Device shall be Multitrode Model MTISB, or approved equal. The intrinsically safe device shall be supplied according to the following specifications: 1. The intrinsically safe barrier shall be 5 or 10 channels (project specific). The device shall be panel mounted and designed to protect a multi-sensored conductive probe. The barrier shall be certified intrinsically safe for use with Multitrode equipment in installations up to and including Class 1 Zone O. 2. The intrinsically safe barrier shall have screw terminals for wire connections. Section 11303 - Page 2
3. The intrinsically safe barrier shall be protected and current limited according to the requirements of UL Class I (Groups A, B, C & D), Class II (Groups E, F, & G) and Class III certification. 4. The intrinsically safe barrier shall allow for a maximum short circuit current of 10 ma. B. Mounting and Installation: The intrinsically safe barrier shall be surface mounted using the attached mounting flanges on either side of the unit assembly. The unit shall be fastened with approved screws or bolts in accordance with NEC requirements. 2.4.6 CONTROL PANEL CONSTRUCTION & ASSEMBLY A. General Requirements: 1. Control Panels shall be manufactured in accordance with ISO 9000-2001 specifications and shall be so constructed for the application of a UL Listing Label by an approved UL Control Panel Assembly Facility. 2. Control Panel wiring shall be installed and arranged in an organized, efficient manner. All control panel wiring shall be inspected for safety and verified by performing a point to point test. 3. All electrical connections shall be properly inspected and torqued in compliance with ISO specifications. External connections to the control panel shall be by way of numbered terminal blocks. 4. Control Panels shall be properly checked and load tested with power applied. A control panel assembly and test log shall be supplied with the panel in order to indicate the scope and the extent of the final control panel test. The assembly and test log shall include all of the appropriate detail to demonstrate compliance with UL Labelling and ISO construction standards. 5. Control Panels shall be dispatched from the UL approved control panel assembly facility with all of the necessary or required UL Labels, Warning Labels, etc. properly attached. D. Control Panel Enclosure Specific Construction Requirements: 1. Enclosure shall be sized according to physical and functional device requirements. 2. Enclosure seams shall be continuously welded and ground smooth. 3. Enclosure door opening flange trough shall exclude liquids and contaminants. 4. Enclosure shall include an integral body grounding stud and sub-panel mounting studs. 5. Enclosure shall be wall mounted, unless otherwise specified. 6. Enclosure door shall have hidden hinges for a clean, aesthetic appearance. 7. Enclosure door opening angle shall be standard, full access, 135 degree opening radius. 8. Enclosure door shall be interchangeable and easily removable by pulling captive hinge pins. 9. Enclosure door shall have a high-impact thermoplastic data pocket mounted on the inner side of the enclosure door. 10. Enclosure door shall have a seamless, foam-in-place, one-piece gasket to provide an oiltight, dust-tight seal against contaminants. 11. Enclosure shall have a three-point latching system with a zinc die-cast handle that is painted with black textured polyester powder paint. 12. Enclosure handles shall be capable of being padlocked. Section 11303 - Page 3
13. Steel sub-panel shall be white. 14. When enclosure cut-outs for instruments and other devices are required, holes shall be cut, punched, or drilled and finished with rounded edges. 15. A door stiffener shall be used where applicable to prevent door deflection under instrument loading or operation. E. Instrument Location Requirements: 1. Instruments or control devices designated for sub-panel (back) mounting shall be located in a manner that will allow for maintenance and adjustment. 2. Instrument mounting height shall not exceed 6-6 to the top of the instrument and shall not be lower than 3-0 to the bottom of the instrument (unless otherwise specified). O. Power Supply 1. The 12 Volt DC Power Supply shall be rated for 120VAC Input and 12VDC Regulated Output according to the following specifications: a. 85-265 VAC Input Range b. High Efficiency (70%) or Better c. Short Circuit Protection d. Over Voltage Protection e. EMI Input Filter f. DIN Rail Mountable 2. The Power Supply shall be Astrodyne Model AD55-A/DRL. P. Backup Battery 1. The 12 Volt DC Backup Batttery shall be sealed lead acid type. 2. The battery shall be rated for a minimum of 12 Amp Hours. 3. The battery shall be Powersonic Model PS-12120, or approved equal. Q. GFCI Convenience Recepatcle 1. There shall be a 120VAC, 15 Amp GFCI rated convenience receptacle mounted on the dead front swing door of the control panel. 2. The receptacle shall be Pass & Seymour Model #1594-W or approved equal. R. Enclosure Heater 1. There shall be a 120VAC, 50 watt enclosure heater inside the control panel. 2. The heater shall be a silicone rubber, insulated strip type enclosure heater. 3. The heater shall be Chromalox Model #SL-B-2-5-55P, or approved equal. 2.4.7 MOTOR STARTERS: 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 "O", "OO", or fractional size shall not be acceptable. Power contacts shall Section 11303 - Page 4
be double-break and made of cadmium oxide silver. Coils shall be epoxy molded for protection from moisture and corrosive atmospheres. The starter assembly shall be equipped with a metal mounting plate for durability. All motor starters shall be equipped to provide under-voltage release and overload protection on all three phases. Motor starter contacts and coils shall be easily replaceable without removing the motor starter from its mounted position. 2.4.8 OVERLOAD RELAYS: Overload relays shall be of block type utilizing melting alloy type spindles, and shall have visual trip indication with trip free operation. Pressing the overload reset lever shall not actuate the control contact until such time as the overload spindle has reset. Resetting of the overload reset lever will cause a snap-action control contact to reset, thus re-establishing a control circuit. Overload relays shall be of manual reset only and not convertible to automatic reset. Trip settings shall be determined by the heater element only and not by adjustable settings. Heater elements shall provide NEMA class 10 trip times and shall be selected in accordance with the actual motor nameplate data. An overload reset pushbutton 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. Alternate styles of overload relays may be used only with explicit approval of the Engineer. 2.4.9 PUMP ALTERNATOR: A pump alternator equal to Furnas Electric Alternator, Catalogue No. 47AB10AF, or an approved equal, shall be supplied to alternate pumps on each successive cycle. 2.4.10 H-O-A SELECTOR SWITCHES: H-O-A selector switches shall be industrial, oiltight switches equivalent to General Electric CR104B with black knob and bright metallic ring. Factory engraved metallic nameplates shall be provided with the marking HAND-OFF-AUTO. H-O-A switches, alarm switch, run lights, seal leak lights and overload reset buttons shall be mounted on the inside door. 2.4.11 ALARM LIGHT: A weatherproof alarm light shall be mounted on the outside of the NEMA 4X enclosures. 2.4.12 AUDIBLE HORN: A weatherproof audible horn shall be mounted on the outside of the NEMA 4X enclosures. 2.4.13 LEVEL CONTROLS: A 10-point Level Sensing Device designed to detect liquid level at specified intervals in tanks or sumps and interface with an electronic controller for pump control and liquid level display. Probe length shall be determined by the operating range of the pumps as specified in the station drawing and supplied with 100 of cable. The Level Sensing Equipment shall be Multitrode (Level Sensing Probe). Mounting connections shall be stainless steel. The mounting assembly for probes shall include a device available to maintenance personnel to clean the level sensing probe at desired maintenance intervals. 2.4.14 PUMP RUN INDICATORS: Control panel shall be equipped with one oil-tight pilot light for each pump motor. Light shall be wired in parallel with the related pump motor starter to indicate that the motor is on or should be running. Run lights shall be equipped with lamps providing a minimum of 15,000 hours. 2.4.15 ELAPSED TIME INDICATORS: Six digit elapsed time indicators (non-reset type) shall be connected to each motor starter to indicate the total running time of each pump in "hours" and "tenth of hours". 2.4.16 TELEMETRY: The Control Panel shall include a telemetry system conforming to SECTION 11320 LIFT STATION TELEMETRY SYSTEM, and shall be installed by the pre-approved system integrator. The Section 11303 - Page 5
control panel and telemetry system shall be capable of providing the status of the pump station including at a minimum the following conditions: PUMP 1: ON / OFF and TOTAL RUN TIME PUMP 2: ON / OFF and TOTAL RUN TIME LAG PUMP (BOTH PUMPS CALLED): ON / OFF HIGH WATER ALARM: ON / OFF POWER FAILURE ALARM: ON / OFF BACKUP GENERATOR: ON / OFF The telemetry system shall be integrated into the existing telemetry system and shall send text alerts to maintenance personnel for all alarm conditions. PART 3 EXECUTION 3.1 EXCAVATION AND BACKFILL: Excavating, backfilling, filling and grading for the lift station structure shall conform to the applicable requirements of the SECTION 02220 EXCAVATION FOR STRUCTURES. The Contractor shall remove all materials encountered within the required limits of excavation for the structure regardless of the nature of the materials. 3.2 ELECTRICAL CONSTRUCTION REQUIREMENTS: All electrical work shall conform to the 1990 National Electrical Code (or most current revision), local city codes and local utility company requirements as well as applicable state statutes and federal regulations. If two codes pertain to the same work, the more stringent requirement shall apply. The basic general electrical specification requirements for the sewage pump station and the related equipment shall conform to the requirements as set forth in the technical specifications found in Division 16 Electrical. 3.3 TESTS AND INSPECTION: The Contractor shall provide labor, material and test equipment, except as noted to the contrary herein, to test all wiring and equipment for continuity, proper polarity, proper phase relation, dielectric strength, operation and alignment after installation. Test equipment and methods shall meet the Engineer's approval. The Engineer shall be notified at least two working days prior to tests. The Engineer reserves the right to witness any and all such tests and shall interpret test results and determine on the acceptability. The Contractor-supplied work which does not test to the Engineer's satisfaction shall be corrected and retested as required without additional cost to the Owner. The Engineer reserves the right to perform any test on any phase of the installation utilizing Contractor's personnel and test equipment. All wiring installed shall be megger tested. Insulation resistance shall not be less than one megohm. Where such tests indicate the possibility of faulty insulation, the Contractor shall locate the point of such faulty insulation and shall replace the conductor and shall retest the insulation. 3.4 FACTORY TEST: All components of the lift stations shall be given an operational test of all equipment at the factory to check for excessive vibration, for leaks in all piping or seals, and for correct operation of the control system and all auxiliary equipment. 3.5 INSTALLATION AND OPERATING INSTRUCTIONS: Installation of the pumping units shall be done in accordance with the written instructions provided by the manufacturer. Six (6) copies of an operation and maintenance manual shall be provided for the Owner's use. Section 11303 - Page 6
3.6 DRAWINGS AND DATA: Complete assembly and installation drawings, together with detailed specifications and data covering material used, parts, devices, and other accessories forming a part of the equipment furnished, shall be submitted. The data and specifications for each unit shall include, but shall not be limited to, the following: A. Submersible Pumps: Name of Manufacturer. Type and model. Rotative speed. Size of discharge. Type of bearings. Net weight of submersible pump. Complete performance curves showing capacity, head, and bhp requirements. Rated size of motor (hp). Temperature rating. Full load rotative speed. Full load current. Locked rotor current. 3.6 SEWER LIFT STATION TESTING: The Contractor will be required to test the submersible pumps' rated pump capacity, plus all the other equipment within the lift station. The water required to test the submersible pumps shall be furnished by the Contractor at his own expense. END OF SECTION Section 11303 - Page 7