st. johns county - co.st-johns.fl.us...100 center creek rd., ste 108 hastings lift station upgrades...
TRANSCRIPT
2.
1.
4.
3.
NO. SYMBOLDATEBY
REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
RRP
DRS
12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-3
C-3
603 N MAIN STREET
PROPOSED SITE PLAN
77561
2.
1.
4.
3.
NO. SYMBOLDATEBY
REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
RRP
DRS
12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-4
C-4
603 N MAIN ST.
LIFT STATION SECTION
77561
2.
1.
4.
3.
NO. SYMBOLDATEBY
REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
RRP
DRS
12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-8
C-8
316 PARK AVE
PROPOSED SITE PLAN
77561
2.
1.
4.
3.
NO. SYMBOLDATEBY
REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
RRP
DRS
12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-9
C-9
316 PARK AVE.
LIFT STATION SECTION
77561
2.
1.
4.
3.
NO. SYMBOLDATEBY
REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
RRP
DRS
12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-10
C-10
316 PARK AVE
STANDARD LIFT STATION DETAILS
77561
2.
1.
4.
3.
NO. SYMBOLDATEBY REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
RRP
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12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-12
C-12
115 EAST ESSEX ROAD
DEMOLITION AND BYPASS PLAN
77561
2.
1.
4.
3.
NO. SYMBOLDATEBY
REVISIONS
FLORIDA REGISTRATION NO.
DESIGN ENGINEER
ST AUGUSTINE, FLORIDA 32084-8646
1205 STATE ROAD 16
Phone (904) 209-2700 Fax. (904) 209-2702
5.
6.
ST. JOHNS COUNTY UTILITY DEPARTMENT
ISSUED FOR BID
DESIGNER:
DRAWN BY:
CHECKED BY:
APPROVED BY:
DATE: MAY 2019
PROJECT NO.
FILE NAME
SHEET NO.
HASTINGS LIFT STATION UPGRADES PROJECT
100 CENTER CREEK RD., STE 108ST. AUGUSTINE, FL. 32084PH. 904-562-2185FLORIDACERTIFICATE OF AUTHORIZATION# 9816
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100408.27DAR
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12/19KWS
DAR
PER ADDENDUM NO. 1
DAVID A. RASMUSSEN P.E.
C-13
C-13
115 EAST ESSEX ROAD
PROPOSED SITE PLAN
77561
Project No. 100408.27
11148-1
SECTION 11148
DIESEL ENGINE DRIVEN PUMP
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required, complete and ready for operation and field test, one self-contained, automatic, self-priming centrifugal sewage pump housed in a soundproof enclosure including its respective drives and controls as specified herein.
1.02 SUBMITTALS
A. Submit, in accordance with Section 01330, copies of all materials required to establish compliance with this Section. Submittals shall include the following:
1. Pump
a. Name of manufacturer
b. Type and model
c. Rotative speed
d. Size of discharge and suction pipe
e. Weight of pump
f. Data on shop painting
g. Data on the characteristics and performance of the pump. Data shall include guaranteed performance curves, based on actual shop tests on similar units, which show that they meet the specified requirements for head, capacity, efficiency, NPSHR, and brake horsepower.
2. Engine
a. Name of manufacturer
b. Type and model
c. Size, liters
d. Rated HP @ rpm
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
11148-2
e. Cooling system
f. Electrical:
1) Battery capacity, amp/hr
2) Alternator, rating, amp
3. Weatherproof Enclosure
a. Size, length, width
B. Submit description of factory test plan including test procedures and equipment.
C. Submit for approval results of factory testing and field testing.
D. A list of the manufacturer's recommended spare parts to be supplied with the manufacturer's current price for each item. Include gaskets, packing, etc. on the list. List bearings by the bearing manufacturer's numbers only.
E. Operation and Maintenance Data
1. Complete operating and maintenance instructions shall be furnished for all equipment included under this Section as provided in Section 01730. The instructions shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operation and maintenance personnel unfamiliar with such equipment. The maintenance instructions shall include troubleshooting data and full preventative maintenance schedules and complete spare parts lists with ordering information.
1.03 REFERENCE STANDARDS
A. ASTM International
B. American Gear Manufacturers Association (AGMA)
C. American National Standards Institute (ANSI)
D. American Bearing Manufacturers Association (ABMA)
E. National Electrical Manufacturers Association (NEMA)
F. Hydraulic Institute Standards
G. American Welding Society (AWS)
H. Occupational Safety and Health Administration (OSHA)
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
11148-3
I. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.04 QUALITY ASSURANCE
A. All equipment included in this Section shall be furnished by or through a single manufacturer who shall be responsible for the design, coordination, and the satisfactory performance of all the components, including the pump, engine, enclosure and accessories.
B. The pump offered shall be the manufacturer’s standard production model. It shall have been in continuous use by municipal and industrial owners for a minimum of five years. A list of five user contacts including contact names and telephone numbers shall be provided with the bid submittal. Failure to supply a verifiable users list will be cause for rejection of the bid.
C. All rotating parts shall be accurately machined and shall be in as nearly perfect rotational balance as practicable. Excessive vibration shall be sufficient cause for rejection of the equipment. The mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided.
D. Equipment specified under this Section shall be suitable for outdoor operation.
1.05 DELIVERY, STORAGE AND HANDLING
A. The equipment shall be new at the time of delivery and shall not have been used by the Contractor for any construction operations.
B. Refer to Section 01600 for additional delivery, storage and handling requirements.
1.06 MAINTENANCE
A. A complete set of special tools necessary for operation and maintenance of the equipment shall be provided. All tools shall be premium quality and furnished in labeled heavy-duty tool boxes.
B. Tools and spare parts shall be furnished per manufacturers recommendations.
1.07 MANUFACTURER SERVICES INCLUDING OPERATING INSTRUCTIONS
A. Installation Inspection and Startup:
1. The Contractor shall include in his bid price the services of a Manufacturer’s factory representative who has complete knowledge of proper operation and maintenance shall be provided to instruct representatives of the Owner and the Engineer on proper operation and maintenance. This work may be conducted in conjunction with the
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
11148-4
inspection of the installation and start-up. If there are difficulties in operation of the equipment because of the Manufacturer's design or fabrication, additional service shall be provided at no additional cost to the Owner. The listed service requirements are exclusive of travel time, and shall not limit or relieve the Contractor of the obligation to provide sufficient service necessary to place the equipment in satisfactory and functioning condition. Also refer to requirements in PART 3 of this Section.
2. Installation inspection: Complete review of installation in accordance with Section 01465. Provide written certification that the installation is complete and operable in all respects, and that no conditions exist which may affect the warranty. The Manufacturer shall supply the installation inspection services of an experienced Manufacturer’s factory representative to verify the proper pump installation. Qualified supervisory services, including Manufacturers' Factory representatives, shall be provided to ensure that the installation is done in a manner fully approved by the Manufacturer. The Manufacturer's factory representative shall specifically approve the installation and alignment of the pump with the motor, the grouting, and the alignment of the connecting piping and the installation of the field installed packing or mechanical seal. If there are difficulties in the start-up or operation of the equipment due to the Manufacturer's design or fabrication, additional service shall be provided at no additional cost to the Owner. Services of the Manufacturer’s factory representative and training shall be provided when the pump is started. Field instruction on operation and maintenance of the equipment, including start- up, shut-down troubleshooting, lubrication, maintenance and safety:
a. Minimum time on-site shall be one 8-hour day.
3. Start-Up: Provide written report, summarizing test procedures, tested and measured variables (flow rates, total heads, shaft-speed, vibration measurements, etc.):
a. Minimum time on-site shall be one 4-hour day.
B. The Contractor alone shall be responsible for requesting these services, and shall coordinate these requests with all other relevant trades, to ensure the effectiveness of the Manufacturers' service. In the event that the lack of coordination by the Contractor results in the need to recall the Manufacturer’s factory representative, the lost time shall not be counted against the above days.
1.08 WARRANTY
A. A one (1) year warranty shall be provided for the diesel engine driven pump starting on the date of substantial completion. Running hours shall not be a
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
11148-5
limiting factor for the system warranty.
PART 2 PRODUCTS
2.01 GENERAL
A. This Section is intended to give a general description of what is required, but does not cover all details which will vary in accordance with the requirements of the equipment as offered. It is, however intended to cover all materials, equipment and appurtenances for the complete pumping units as herein specified, whether specifically mentioned in this Section or not.
B. Pumping units shall be provided with a pump, flanged connections, discharge check valve, engine mounted on a skid and inside of a weatherproof enclosure with all other appurtenances specified or otherwise required for proper operation.
1. Parts and components not specifically mentioned in this Section, but which are required to provide a complete pumping unit, shall be included as a part of the equipment to be furnished.
C. Pump shall be supplied with an integral flap check valve mounted on the discharge of the pump, allowing unrestricted flow from the impeller. The check valve shall prevent in-line return of flow when the pump is shut off. Non-return valve elastomers shall be Nitrile rubber and shall be field replaceable.
D. Pump suction and discharge flanges shall be cast iron ANSI (B16.1) Class 150, raised faced. Pump gaskets shall be compressed fiber and/or Teflon. Pump O-rings shall be Buna-N.
E. Pump castings shall be cast iron. Pump design shall incorporate a direct suction flow path that is in axial alignment with the impeller eye. There shall be no turns, chambers, or valves between the suction flange and the impeller eye.
F. The pump impeller shall be cast steel, open, three-bladed, non-clog type with pump-out vanes on the back shroud.
G. Wear plates shall be fully adjustable and replaceable, fabricated of cast iron. Wear plate clearances shall have no relationship to the ability of the pump to achieve a prime.
H. Pump shall be fitted with a bearing bracket to contain the shaft and bearings. Bearings shall be tapered roller bearings of adequate size to withstand imposed loads for sustained pumping at maximum duty points. Minimum ISO L10 bearing life to be 100,000 hours. Impeller shafts shall be fabricated of 1.5% chromium alloy.
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
11148-6
I. Seal shall be high pressure, mechanical self-adjusting type with silicon carbide faces capable of withstanding suction pressures to 87 psi. The mechanical seal shall be cooled and lubricated in an liquid bath reservoir, requiring no maintenance or adjustment. Pump shall be capable of running dry, with no damage, for periods up to twenty-four hours. All metal parts shall be of stainless steel. Elastomers shall be Viton.
J. Pump shall be fitted with a fully automatic priming system incorporating a twin-cylinder compressor and air ejector assembly. The compressor shall be installed on the engine auxiliary drive and shall be gear driven, lubricated and cooled from the engine. The priming system shall require no fail-safe protection float gear or any adjusting at high or low suction lifts. Pumps with self-priming chambers modified with vacuum priming systems shall not be accepted as equal. The pump must be capable of running totally dry for periods up to 24 hours, then re- priming and returning to normal pumping volumes. Pump and priming system is capable of priming the pump from a completely dry pump casing. The pump shall be capable of static suction lifts to 28 vertical feet, at sea level. It shall also be capable of operation using extended suction lines. Equipment acceptance shall be contingent upon the pump’s ability to run continuously at full speed in a completely dry condition. The engineer may require a demonstration.
K. The pump shall be an engine-drive, self-priming centrifugal pump, Model 4JSCM-DYS-3TNVF-DC, size 4-inches by 4-inches, as manufactured and assembled by Thompson Pumps or equal by Godwin, Xylem Inc.
L. Stainless steel nameplates giving the name of manufacturer, the rated capacity, head, speed and all other pertinent data shall be attached to each pump.
M. The pumps and drives shall conform to the noise limitations specified in Section 01170.
2.02 DIESEL ENGINE
A. The drive unit shall be a diesel water-cooled engine. The engine shall drive the pump by use of direct-connected intermediate drive plate. Starter shall be twelve-volt electric. Low oil pressure safety shutdown, high temperature shutdown, tachometer, and hour-meter shall be integrated into engine control panel. Battery shall have 180-amp hour rating. Drive unit shall be a Yanmar 3TNV88F, rated at 24HP (continuous) at 2200RPM. A certified continuous duty engine curve shall be supplied to the Owner and Engineer.
B. Integral skid fuel tank capacity shall be sufficient to provide at least twenty-four hours of operating time at full load. The engine shall be capable of operating satisfactorily on a commercial grade of distilled No. 2 fuel oil.
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
11148-7
2.03 DESIGN REQUIREMENTS
A. The pumping unit shall be designed for the following operating conditions and requirements:
1. Design Capacity
a. Flow (gpm) 500
b. Total dynamic head, (ft) 49
c. Maximum NPSHr, (ft) 5
2. Run-out Capacity
a. Flow (gpm) 800
b. Total dynamic head, (ft) 36
c. Maximum NPSHr, (ft) 10
3. Operating Speed (Maximum, rpm) 1,600
4. Maximum Solids Handling (in) 3
5. Suction Size (in) 4
6. Discharge Size (in) 4
7. Suction Pipe Entrance Elevation 8.10 ft
8. Suction Pipe Min Submergence Elevation -9.00 ft
9. Diesel Pump Float Elevations:
a. Diesel Pump “ON”: -2.90 ft
b. Diesel Pump “OFF”:-8.25 ft
2.04 ENGINE STARTING AND CONTROL PANEL
A. Governor shall be a mechanical type. Engine speed shall be adjustable to operate the pump between maximum and minimum design operation speeds in manual mode.
B. The engine shall be equipped with a factory installed microprocessor-based controller designed to start/stop the engine at a signal supplied by high and low level floats or a 4-20 mA transducer.
C. The engine shall be started, stopped, and controlled by a high performance state
DIESEL ENGINE DRIVEN PUMP
Project No. 100408.27
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of the art digital controller. The controller shall be weather proof enclosed, and contain an external weatherproof 12-position keypad accessible without the need to remove or open any protective cover or enclosure. It shall be designed to start/stop the engine at a signal supplied by high and low level floats or a 4-20 mA transducer. The controller shall provide the following functions without modification, factory recalibration, or change of chips or boards, by simply accessing the keypad.
D. The keypad shall be a capacitive touch sensing system. No mechanical switches will be acceptable. The keypad shall operate in extreme temperatures, with gloves, through ice, snow, mud, grease, etc. and maintain complete weather-tight sealing of the controller.
E. In automatic mode, the unit shall conserve energy and go to “sleep” (115 mA parasitic battery draw).
F. The controller shall function interchangeably from float switches, pressure switch, or transducer, as well as manual start/stop by selection at the keypad. No other equipment or hardware changes are required.
G. The controller can be programmed to start and stop the pumpset up to three times daily or three times a week (i.e. a start, exercise cycle on three separate times for a varying length of time all via the keypad).
H. In Manual Mode, manual “Start” button starts engine and runs until “Stop” button is depressed or an emergency shutdown occurs.
I. In Automatic Mode, start/stop sequencing is initiated by either one (1) high-level N/O and (1) one low-level N/C narrow angler float switches, pressure switch, pressure or level transducer, or a signal from a digital input.
J. The controller shall integrate the engine safety shut-off for low and high oil temperature, and provide over-speed protection.
K. The controller shall have only one circuit board with eight built-in relays. Five (5) of the relays shall be programmable to output desired parameter on display and to be used as dry-contacts for communication with the County SCADA system, all via the keypad without changing relays, chips, printed circuits, or any hardware or software.
L. Standard components shall consist of (6) digital inputs, (8) analog inputs, (1) magnetic pick-up input, (6) 10-amp form “C” relays, (2) 20-amp form “C” relays, (1) RS485 port, (1) J1939 port, and (1) 320x240 pixel full graphic LCD display with backlight, (1) 12 position keypad, LCD lamps for visual indication of shutdown (red), warning (amber) and power (green).
M. The industrially-hardened Controller shall withstand Vibration of 3 g, 3 axis, frequency swept 10-1000 Hz, in an operating temperature Range of 4° to 176°F
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(-20° to 80°C) and an operating humidity range of 0-95% Non-Condensing.
2.05 WEATHERPROOF ENCLOSURE, NON-WALK-IN TYPE
A. The engine and pump shall be completely enclosed with fourteen-gauge sheet metal panels backed with one inch and two-inch layers of polydamp acoustical sound-deadening material. The acoustical enclosure shall reduce pump and engine noise to sixty-eight dBA or less at a distance of thirty feet. The enclosure shall be removable for easy access to the engine / pump for maintenance and repair. The enclosure doors shall all be equipped with latches that are keyed alike. For maintenance and service needs, the enclosure sides shall have hinged doors for quick access to the engine oil fill, fuel fill port, oil dipstick, and filters.
2.06 EXHAUST AND MUFFLER
A. Exhaust system shall include a hospital grade muffler housed in a separate chamber within the enclosure. All exhaust piping and manifolds shall be encased in fitted acoustic blankets. They shall be constructed of high-density fiberglass material with waterproof jacketing.
2.07 UL LISTED SKID BASE
A. The pump base tank shall be a UL-142 approved double wall design constructed in accordance with Flammable and Combustible Liquids Code, NFPA 30; The Standard for Installation and use of Stationary Combustible Engine and Gas Turbines, NFPA 37; and The Standard for Emergency and Standby Power Systems, NFPA 110.
B. The tank design shall be a Closed Top Dike Pump Base Tank. It shall be of double wall construction having a primary tank to contain the diesel fuel, held within another tank or dike, which is intended to collect and contain any accidental leakage from the primary fuel tank. The completed base tank assembly is to incorporate pump mounting locations and must be able to support four times the rated load.
C. The primary tank shall be designed to withstand normal and emergency internal pressures and external loads. It shall be capable of withstanding internal air pressures of 3 to 5 psig without showing signs of excessive or permanent distortion and 25 psig hydrostatic pressure without evidence of rupture or leakage.
D. The primary and secondary tanks or dike shall have venting provisions to prevent the development of vacuum or pressure capable of distorting them as a result of the atmospheric temperature changes or while emptying or filling. The vent shall also permit the relief of internal pressures caused by exposure to fires. The vent size shall be determined by using the calculated wetted surface area in square feet (the top is excluded) in conjunction with venting capacity table 10.1of UL-142. The tank’s vent shall also be equipped with a coupling
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device and shall be located to facilitate connection to a vent piping system. The dike’s vent may be an opening for venting directly to the atmosphere and protection from the entrance of natural elements or debris shall be provided.
E. Both primary and secondary tanks shall be fitted with the proper welded pipe fittings to accommodate the requirements for the fill port and normal and emergency venting.
F. Manufacturing and testing of this system shall be performed within the scope of Underwriters Laboratories, Inc. “Standard for Safety UL 142.” A UL label shall be permanently attached to the tank system showing the following information:
1. The registered UL mark and the name: Underwriters Laboratories, Inc.
2. A control number and the word “listed”
3. The product’s name as identified by Underwriters Laboratories Inc.
4. The serial number assigned by Underwriters Laboratories, Inc.
5. Other manufacturer’s information may also be included.
2.08 SURFACE PREPARATION AND PAINTING
A. Pump, engine, and base shall be shop primed and finish painted at the place of manufacturer. Materials and dry film thickness for priming and finish paint shall be as specified herein.
B. Ferrous metal surfaces of castings and welded steel shall be cleaned to remove all casting projections, weld flux, or splatter. Sharp projections of cut or sheared edges shall be ground to a radius to improve paint adherence. The use of chipping tools in a manner that produces cuts, burrs, or other excessive roughness will not be accepted. Exposed seams shall be filled with a metal filler, finished smooth, and cleaned as required to provide a smooth uniform base for painting.
C. All ferrous metal surfaces, except stainless steel, shall be blast cleaned in the shop in accordance with the paint manufacturer's recommendations. All mill scale, rust, and contaminants shall be completely removed before shop primer is applied.
D. All ferrous metal surfaces and engines shall be shop primed, then given two shop coats of high solids enamel paint. Paint shall have rust inhibitors suitable for outdoor service. The shop coating, including the primer, shall have a minimum dry film thickness of 0.25 mm.
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PART 3 EXECUTION
3.01 FIELD QUALITY CONTROL
A. The pumping unit shall be set up, inspected, and field tested in the presence of the Engineer to demonstrate its compliance with the Contract Documents.
3.02 INSTALLATION
A. Installation shall be in strict accordance with the Manufacturer’s instructions and recommendations in the locations shown on the Drawings. The Contractor shall furnish all required oil and grease for initial operation, if required, in accordance with the Manufacturer's recommendations. Anchor bolts shall be set in accordance with the Manufacturer's recommendations.
B. Upon completion of each pump installation, the Manufacturer shall inspect the unit and submit a certificate stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and care of each unit.
3.03 INSPECTION AND TESTING
A. General
1. The Engineer shall be notified in writing prior to initial shipment and/or testing, in ample time so that arrangements can be made for inspection by the Engineer.
2. Field tests shall not be conducted until such time that the pumping system, including controls, is complete and ready for testing.
B. Factory Pump Test
1. All pumps shall receive a non-witness factory test.
2. The Manufacturer shall factory test all pumps prior to shipment in accordance with the Hydraulic Institute standards, latest version. Flow rate, total head and Input KW shall be tested and recorded for at least five points on the pump performance curve. Test shall be performed to demonstrate that the pumps meet ANSI/HI 14.6 acceptance grade 1U for all specified points. The five points shall include the points specified in pump performance table in Paragraph 2.03.
3. The Manufacturer shall perform hydrostatic test on the pressure-containing parts in accordance with ANSI/HI 14.6. Test shall be conducted on each pump prior to final coating and shipment.
4. The Manufacturer shall perform the following test on each pump
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prior to shipment from factory:
a. Megger motor and pump for insulation breaks or moisture.
b. The pump shall be run dry and checked for correct rotation.
c. A written certification test report regarding the above tests shall be submitted for approval prior to shipment.
C. Field Pump Test
1. As specified in Paragraph 1.07, the Manufacturer shall furnish the services of a representative who shall have complete knowledge of proper operation and maintenance to inspect the final installation and supervise the test run of the equipment. The Manufacturer shall include in his price, a minimum of eight hours of a representative's time for the above tests.
2. Written test procedures shall be submitted to the Engineer for approval 30 days prior to testing.
3. The Contractor shall furnish all water, fuel, power, facilities, labor, materials, supplies and test instruments required to conduct the field testing.
4. The Final Acceptance Test shall demonstrate that all items of these Specifications have been met by the equipment as installed and shall include, but not be limited to, the following tests:
a. That all units have been properly installed and are in correct alignment.
b. The Contractor shall check for correct lubrication in accordance with manufacturer's instructions. The Contractor shall check direction of rotation of all motors and reverse connections, if necessary.
c. That the units operate without overheating or overloading any parts and without objectionable vibration.
d. That there are no mechanical defects in any of the parts.
e. That the pumps can deliver the specified total head and flow rate to demonstrate that the pumps generally meet the requirements specified (factory performance test is the basis of pump acceptance).
f. That the pump sensors and controls perform satisfactorily as to sequence control, correct start and stop pressures, and
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proper alarm functions.
5. If the pump performance does not meet the specifications, corrective measures shall be taken or pumps shall be removed and replaced with pumps which satisfy the conditions specified.
6. A five-day continuous operating period of the pumps will be required before acceptance. If pumping system fails during the test period, the test shall be restarted (including reset of time to zero) after repair (or replacement) has been completed.
D. Field Vibration Testing
1. After installation and as soon as conditions permit full speed operation, and in the presence of the Engineer, have the vibration tests performed on each unit by a minimum level III qualified vibration technician as defined by Vibration Institute or equivalent to (a) establish compliance with a maximum vibration level of 0.35 inches per second RMS, and (b) prove that there are no field installed resonant conditions due to misalignment, the foundation, or the connection piping and its supports, when operating at any speed within the specified operating range.
a. At a minimum, if pump system is furnished with vibration and temperature monitoring system, the motor lower vibration sensors may be used for acceptance testing. Alternatively, temporary surface mounted sensors mounted in the vicinity of the installed sensors are preferred to additionally establish the accuracy of the permanently installed system.
2. If required, take corrective action and the units shall be retested to ensure full compliance with this Section. All costs associated with the field tests or any required corrective action shall be borne by the Contractor.
END OF SECTION