SECTION 33 3200

wastewater utility pumping stations

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[LANL MASTER SPECIFICATION]{.underline}

This template must be edited for each project.  In doing so, specifier
must add job-specific requirements.  Brackets are used in the text to
indicate designer choices or locations where text must be supplied by
the designer.  Once the choice is made or text supplied, remove the
brackets.  The specifications must also be edited to delete
specification requirements for processes, items, or designs that are not
included in the project \-- and specifier's notes such as these.  To
seek a variance from requirements in the specifications that are
applicable, contact the Engineering Standards Manual Civil
[POC](http://engstandards.lanl.gov/engrman/3civ/htmls/civilnew2.htm).
Please contact POC with suggestions for improvement as well.\
\
When assembling a specification package, include applicable
specifications from all Divisions, especially Division 1, General
requirements.\
\
Specification developed for ML-4 projects.  For ML-1, 2, and 3
applications, additional requirements and independent reviews should be
added if increased confidence in procurement or execution is desired;
see ESM Chapter 1 Section Z10 Specifications and Quality sections.

This specification is intended for multiple or large (e.g., Line Item)
buildings. Single GPP-type building should install a small interior
station.

Coordinate this Specification with Civil Standard Drawings ST-G3020-2,
Exterior Sewage Lift Station.

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# GENERAL

## SECTION INCLUDES

A.  Submersible pumps and equipment for sanitary sewer lift station.

## LANL PERFORMED WORK

A.  LANL Utilities will perform acceptance inspection, testing,
    adjusting and tie-in of lift station. See PART 3.

## SUBMITTALS

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The LANL Utilities Group Wastewater Representative shall approve design,
location, and submittals of sewage lift station.

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A.  Submit the following in accordance with Section 01 3300, Submittal
    Procedures:

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1.  Catalog data.

2.  Power and Control Cables.

3.  Pump curves.

4.  Operation and maintenance data.

    a.  Theory of operation.

    b.  Test procedure.

5.  Warranties.

## WARRANTY

A.  Manufacturer\'s printed warranties shall apply to pumps.

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B.  Provide five years or 10,000 elapsed-time hours warranty after
    installation, including parts and labor.

C.  Provide for repairs to be performed at the manufacturer\'s
    authorized warranty repair station located within a 200 mile radius
    of this Project.

## Quality Assurance

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Items available with NRTL label must be NRTL listed. Refer to ESM
Chapter 7, Section D5000, paragraph 5.10 and also LANL Electrical Safety
LIR 402-600-01.3 paragraph 5.9.

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A.  Provide Nationally Recognized Testing Laboratory (NRTL) listed
    material and equipment for the application and environment in which
    installed.

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D.  Install electrical motors, equipment, and wiring in accordance with
    the National Electrical Code.

# PRODUCTS

## Product options and substitutions

A.  Alternate products may be accepted; follow Section 01 2500,
    Substitution Procedures.

## ACCEPTABLE MANUFACTURER

A.  Flygt - No Substitutions.

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E.  Pumps shall be readily removable and replaceable without de-watering
    wet well or disconnecting any piping in wet well.

## PERFORMANCE AND DESIGN REQUIREMENTS

A.  See Schedule in PART 3.

## PUMP MATERIALS

A.  Provide pumps that are NRTL listed to UL 778 *Motor Operated Water
    Pumps*.

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F.  Volute, impeller, motor housing, discharge elbow, and other
    components: Gray cast iron, ANSI Class 30.

G.  Shaft: Stainless steel or carbon steel.

H.  Motor:

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1.  Rotor bars and short circuit rings: Aluminum.

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6.  Windings: Copper.

7.  Stator winding and lead insulation: NEMA Class F.

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I.  Mechanical Seals:

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1.  Lower: Tungsten carbide/tungsten carbide.

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8.  Upper: Tungsten carbide/carbon.

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J.  Wear Ring:

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1.  Case wear ring: Steel with molded nitrile rubber.

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9.  Impeller wear ring: ANSI 304 stainless steel. Provide on pump
    greater than 15 HP.

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K.  Exposed Nuts and Bolts: ANSI 304 stainless steel.

## PUMP CONSTRUCTION

A.  Water Tight Sealings: Nitrile rubber O-rings against machined
    surfaces.

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L.  Cable Entry Design:

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1.  Seal: Torque-free mechanical compression type with strain relief. Do
    not use epoxies, silicones, or other secondary sealing. Submersible
    cable entry shall be field replaceable without replacing cable.

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10. Seal junction chamber from motor by terminal board and an elastomer
    compression seal.

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M.  Pump Motor:

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1.  Squirrel cage induction type, housed in air-filled watertight
    chamber.

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11. Dip and bake stator three times in NEMA Class F varnish and heat
    shrink fit into the stator housing. Do not use designs requiring
    penetration of stator housing.

12. Motor cooling system:

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a.  Thermal radiators integrally cast into stator housing, up to 10.5
    HP.

b.  Circulation of pumped media through a cooling jacket for 15 HP and
    larger.

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N.  Pump Shaft Bearings:

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1.  Permanently lubricated ball bearings.

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a.  Upper Bearing: Single row deep groove.

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c.  Lower Bearing: Two-row angular contact.

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13. Sealed completely from pump liquid.

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O.  Minimum B10 Bearing Life: 20,000 elapsed-time hours at any point on
    head-capacity curve.

P.  Mechanical Seals: Tandem independent and run in a standard motor oil
    reservoir.

Q.  Impeller: Dynamically balanced, double shrouded, non-clog, single
    vane capable of handling 3 inch diameter solids, unless otherwise
    scheduled.

R.  Equip each pump with stainless steel lifting chain and submersible
    pump cable.

S.  Provide sliding guide bar bracket unit to guide on at least two
    rails which is an integral part of pump unit. Do not permit any
    portion of the pump or guidance system to bear on sump floor. Do not
    use guide cables.

T.  Provide metal-to-metal discharge pump/elbow connection seal. Do not
    use diaphragm or O-ring type seals.

## PERFORMANCE

A.  Pump motor:

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1.  3 phase motor.

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14. Non-overloading throughout pump curve.

15. Capable of 15 evenly spaced starts per hour.

16. Capable of running dry indefinitely without damage.

17. Motor shall be rated for the site elevation.

## PROTECTIVE COATING

A.  Pump Exterior: PVC epoxy primer and chloric rubber paint finish.

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U.  Impeller: PVC epoxy or Rislan.

## ACCESSORIES

A.  Pump accessories supplied by pump manufacturer.

B.  Provide pump accessories required for proper installation and/or as
    recommended by manufacturer, including the following.

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1.  Upper and intermediate guide bar brackets with stainless steel nuts
    and bolts.

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18. Stainless steel guide rails and brackets with stainless steel nuts
    and bolts.

19. Stainless steel lift chain.

20. Safety chain hook.

21. Cable holder for pump cable and float cable.

22. Cable support grip.

23. Anchorage.

24. Cable rack for high level float.

25. Self-weighted float switch, Flygt Model ENH‑10.

26. Check valve, flanged ends, line size, Flygt Model HDL 5087.

27. Plug valve, eccentric, flanged ends, line size, BUNA packing,
    neoprene plug facings, lever handle, DeZuric series 100, Fig. No.
    118.

28. Standard discharge connection.

29. Wet Well: Aluminum access frame and cover, single door with spring
    assist, 48 inches x 36 inches, with stainless steel hinges and
    accessories, locking mechanism to accept a Best brand government
    padlock, and hinged safety grating built-in.

30. Dry Well: Aluminum access frame and cover, single door, 36 inches x
    36 inches, with stainless steel hinges and accessories, and locking
    mechanism to accept a Best brand government padlock.

    15\. Transducer Containment Fittings:

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a.  8 x 6 inch PVC Schedule 40 reducer coupling.

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d.  8 inch PVC Schedule 40 cap.

e.  8 inch Schedule 40 pipe.

    C. Controls:

    1.  RACO Verbatim -- No substitute, including the following.

        a.  Enclosure -- NEMA 4X.

        b.  Environmental -- Heater.

        c.  Local alarm relay output.

    2.  Milltronics Hydro-Ranger 200, Part No. 7ML1034 - 1AA1 with
        Echomax XPS-10 transducer, Part No. 7ML1115 - 0CA31.

    3.  NEMA 4X enclosure box for mounting of RACO Verbatim outside of,
        but attached to, motor control center. Provide connections in
        motor control center for RACO Verbatim unit.

        4\. Telephone line grounding/terminator box, Hoffman No.
        A-1086CHQRFG, with 1/2 inch plywood backing plate mounted
        inside. Mount box beside and connect to the RACO Verbatim box
        with 3/4 inch conduit nipple.

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    5.  RACO Verbatim enclosure and backplate, Hoffman No. A-201608LP
        and No. A-20P16.

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D.  Standby Generator Connections:

1\. Furnish means to connect the lift station motor control panel to a
portable standby generator; meet the requirements of National Electrical
Code Article 702.

2\. Provide a double-throw fusible safety switch that will serve as a
manual transfer switch to connect the lift station to either utility
power or a standby generator.

> a\. Switch shall be rated 100 amperes, 480 volts and shall include two
> mechanically interlocked fusible switches in a NEMA 3R enclosure.
> Rating shall be equal to or greater than the circuit feeder.
>
> b\. Provide switch with an external operating handle that can be
> padlocked in either position.
>
> c\. Switch must be NRTL-listed to UL 98 *Enclosed and Dead Front
> Switches* and NRTL-listed for use as service entrance equipment.
>
> d\. Manufacturer: Square D, Cutler-Hammer, Westinghouse

e.  Provide six Class R 100 ampere dual-element time-delay fuses and six
    spare fuses.

    f\. Switch shall be installed on the circuit feeder before the
    controller and connected to the input terminal lugs.

3\. Provide watertight pin and sleeve power inlet device and matching
connector body for connecting the generator to the double-throw safety
switch.

> a\. Devices must be NRTL-listed to International Standards IEC 309-1
> and 309-2.
>
> b\. Provide devices rated for 100 amperes, 480 Vac, 3-phase, 4-wire;
> the fourth wire is the equipment grounding conductor.
>
> c\. Provide closure caps for inlet device and connector body.
>
> d\. Provide metallic angle back box for the inlet device.
>
> e\. Manufacturer: Hubbell HBL4100B7W inlet, HBL4100C7W connector,
> BB1002W back box, PC100 closure caps.

## MOTOR CONTROL CENTER

A.  Provide motor center panel that is NRTL listed to UL 508 Industrial
    Control Equipment. Where directly connected to electrical utility
    service, provide motor control panel that is NRTL-labeled for
    service entrance use.

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V.  Duplex pump control panel supplied by pump supplier.

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1.  Manufacturer: E.G. Pumps Controls.

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W.  Provide duplex pump controls required for proper installation and/or
    as recommended by manufacturer including the following:

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1.  If MCC is required provide it with separate cubicle to accommodate
    Milltronics unit with glass view port on door.

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31. Two pump Circuit Breakers: UL interrupting rating not less than
    14,000 amperes RMS symmetrical at 480 volts or 22,000 amperes RMS
    symmetrical at 240 volts.

32. Two NEMA rated, full voltage non-reversing motor starters.

33. Duplex Logic Chassis (an anodized aluminum sub-assembly) with Logic
    Panel Including:

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a.  Two Hand-Off-Auto selector switches.

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f.  Two run pilot lights (red).

g.  Two off pilot lights (green).

h.  Level alarm pilot light.

i.  Alarm silence pushbutton.

j.  Motor over temperature sensor -- shut pump down.

k.  LED status indication pilot lights for each relay function.

l.  GFCI duplex convenience receptacle. Mount inside on front plate.

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34. Space heater to prevent condensation within the enclosure.

35. Ground lugs for pump and service connections.

36. Enclosure NEMA 3R.

37. Additional control breaker - 15 amp, 1 pole.

38. Control power transformer - 2 KVA, 16.7 amps.

39. Phase Monitor Relay, 200-240 volt or 440-480 volt, 3-phase as
    required; capable of detecting loss of a single phase,
    under-voltage, over voltage, and voltage unbalance. Alarm will be
    sent to the RACO Verbatim unit.

40. Lightning surge arrestor.

41. Elapsed time meter for each pump.

42. Lag pump time delay relay.

43. Seal failure relay, Flygt, with pilot light.

44. Audible Alarm horn, 93 dB at 20 feet.

45. Alarm beacon with flasher.

46. Alarm memory circuit to maintain alarm beacon until manually reset.

47. Alarm and control enclosure.

48. Additional isolated dry contacts.

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a.  Motor over-temperature (2) - contact type form \"C\".

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m.  Motor overload trip (2) - contact type normally open.

n.  Seal failure (2) - contact type form \"C\".

o.  Power failure - contact type form \"C\".

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49. High-level float status light.

50. High-level float test switch.

51. Local control panel disconnect. Mount beside, but exterior to, the
    control panel.

52. Main breaker.

53. Operating voltage sign and station name.

54. pH enclosure, Hoffman No. U-U504030.

## POWER and control cables

A. Provide for all cables to connect between motor control center,
motors, control devices, and electrical devices. Cables shall be based
on the pump manufacturer's products and requirements.

# EXECUTION

## iNSTALLATION

A.  Wet well and dry well shall be fabricated and installed by the LANL
    Standard Exterior Lift Station Drawings ST-G3020-2 and per LANL
    Master Spec Section 33 0513, Manholes and Structures.

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1.  Wet well bottom and walls shall be coated with a two-part, high
    build epoxy lining. Material shall have chemical resistance and
    designed as a structural lining for manholes and vessels in
    wastewater facilities.

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55. Verify that surfaces and substrate conditions are ready to receive
    work as instructed by the product manufacturer before applying
    lining.

56. Apply products in accordance with manufacturer's instructions.

57. Material will be 100% solids by volume.

58. Manufacturer: Raven Lining Systems.

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B.  Install pumps and equipment in accordance with manufacturer\'s
    instructions, Subcontract Drawings and LANL Standard Drawings
    ST-G3020-2.

C.  Install pumps level, plumb, accurately aligned, with leak-proof pump
    connection, and easily removed without entering wet well.

D.  Provide vehicle accessible, level, all-weather surface adjacent to
    control panel that is suitable for positioning a trailer-mounted
    engine-generator.

E.  Install all electrical equipment and electrical boxes outside of
    lift station pit except for the transducer that is installed by LANL
    Utilities.

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1.  Install Millitronics Hydro-Ranger in electrical motor control
    center.

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59. Adjust settings as directed by LANL Utilities.

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F.  Make no splices in cable.

G.  Furnish and install all power connections to and from the control
    box in accordance with provisions of Division 26.

H.  Provide communications link between the lift station
    monitoring/controls and the TA-46 Wastewater Plant PLC system.
    System shall be installed and available for testing during the
    Acceptance Inspection.

## HIGH LEVEL FLOAT

A.  Suspend on bracket as shown on Drawings.

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X.  Make no splices in cable.

Y.  Adjust float level as directed by LANL Utilities.

## MANUFACTURER\'S ON-SITE SERVICE

A.  Arrange for a factory trained service engineer to be present to
    check installation and operation.

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Z.  Arrange for a factory trained service engineer to provide a minimum
    of 4 hours per pump station of training to operating personnel on
    operation and maintenance of pumping equipment.

A.  Provide a report by the service engineer certifying that equipment
    has been installed and is operating correctly.

## LANL ACCEPTANCE INSPECTION, TESTING, ADJUSTING, AND TIE-IN

A.  LANL Subcontract Technical Representative (STR) will contact LANL's
    Utility Group Wastewater Representative at least 10 working days in
    advance to have LANL's Support Services Subcontractor (Utilities)
    perform the following:

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1.  Video inspection of gravity and force main sewer lines.

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60. Inspection, testing, and adjusting of alarms and controls on lift
    station.

61. Inspection of lift station for compliance with drawings and
    specifications.

62. Tie-ins to existing sanitary sewer system.

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B.  LANL STR will ensure that an approved WPF (Waste Profile Form) for
    all anticipated wastewater from all drains or buildings connected to
    the sanitary wastewater system has been completed by LANL STR and on
    file before scheduling tie-ins. Documentation shall be submitted to
    the LANL Utility Group wastewater representative prior to utility
    tie-in. <http://enterprise.lanl.gov/forms/1346.pdf>

C.  Schedule electrical inspection by the LANL Electrical Authority
    Having Jurisdiction (AHJ). Do not connect equipment to electrical
    service until the work has been inspected and approved by the AHJ.

## Identification

A.  Install component identification, voltage warning labels, and
    arc-flash warning labels on motor control center \[and manual
    transfer switch\].

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D.  Install placard at generator power inlet indicating phase rotation.

E.  Refer to Section 26 0553 Identification for Electrical Systems.

## EQUIPMENT SCHEDULE

A.  Flygt Model \[ \] with Impeller Model \[ \].

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1.  GPM/TDH (feet): \[ \]

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63. HP: \[ \]

64. Discharge Pipe (inches): \[ \]

65. RPM: \[ \]

66. Volts/Phase: \[ \]

67. Max motor Input at design point (KW):\[ \]

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F.  Site elevation: 7500 feet.

END OF SECTION

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Do not delete the following reference information:

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FOR LANL USE ONLY

This project specification is based on LANL Master Specification 33 3200
Rev. 2, dated July 14, 2008.