15445 Sewage Pumps

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PROJECT STANDARD SPECIFICATION

SECTION 15445 - SEWAGE PUMPS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes sewage pumps for the building sanitary drainage systems.

B. Related Sections include the following:

1. Division 15 Section "Motors" for sewage pump motors.

1.3 PUMP SELECTION

A. Where parallel pump operation is indicated, pumps shall be selected with characteristics specifically suited for the service without unstable operation.

B. Pumps shall be selected for service within 4 percent of maximum efficiency for a given casing and impeller series.

C. Pumps having impeller diameter larger than 90 percent of the published maximum diameter of the casing or less than 15 percent larger than the published minimum diameter of the casing will be rejected.

D. Pump duty conditions shall be as indicated. A pump unit shall deliver, at rated speed, not less than the specified flow against the specified or indicated discharge head while the liquid level is not more than 300 mm above the datum elevation of the pump. Datum elevation shall be taken as the level of the entrance eye of the impeller.

E. Discharge head, specified or indicated, shall include the friction head of the system piping external to the pump unit and the static head measured from a point of reference on the sump to the highest point in the system.

F. Ratings shall be based on pumping clear, fresh water at a temperature of 50 deg. C (122 deg. F).

1.4 SUBMITTALS

A. Product Data: Manufacturer catalog shall show:

1. Performance data including performance curves and indicating brake horsepower, head, flow and NPSH.

2. Equipment foundation data.3. Furnished specialties, and accessories for each type and size of pump indicated.

SEWAGE PUMPS 15445 - Page 1/12STD-SPC-DCA(A)-ME-DCA REV A

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B. Shop Drawings: Show layout and connections for pumps. Include setting drawings with templates, directions for installing foundation and anchor bolts, and other anchorages. The following shall be submitted:

1. Connection Diagrams: Connection diagrams shall show details of connection of cables and pump motors.

2. Control Diagrams: Control diagrams shall show motor starters, relays, or any other component necessary for safe operation.

3. Fabrication Drawings: Fabrication drawings shall indicate size, type, and efficiency rating.

4. Installation Drawings: Installation drawings shall be in accordance with the manufacturer's recommended instructions.

5. Wiring Diagrams: Wiring diagrams shall show detail wiring for power, signal, and control systems and differentiate between manufacturer-installed and field-installed wiring.

C. Test Reports: Test reports shall be submitted for the following tests:

1. Hydrostatic leak.2. Static heads.3. Pump flow capacity.

D. Certificates: Listing of product installations for similar items shall identify at least 5 installed units similar to those proposed for use, that have been in successful service for a minimum of 5 years. List shall include purchaser, address of installation, service organization, and date of installation. Certificates shall be submitted for the each equipment and accessories showing conformance with the referenced standards contained in this Section.

E. Manufacturer's Instructions: The following shall be submitted:

1. Manufacturer's installation instructions2. Vibration specifications.

F. Maintenance Data: For each type and size of pump specified to include in maintenance manuals specified in Division 1.

1.5 QUALITY ASSURANCE

A. Product Options: Drawings indicate size, profiles, connections, and dimensional requirements of pumps and are based on specific manufacturer types and models selected. Other manufacturers' pumps with equal performance characteristics may be considered. Refer to Division 1 Section "Product Requirements."

B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in latest and relevant IEC standard, by a testing agency acceptable to the Engineer.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Retain shipping flange protective covers and protective coatings during storage.

B. Protect bearings and couplings against damage.


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C. Comply with pump manufacturer's rigging instructions for handling.

1.7 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed, are packaged with protective covering for storage, and are identified with labels clearly describing contents.

1. One set of manufacturer recommended spare parts for each type and size of pump.

PART 2 - PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

A. Materials and equipment shall be standard products of a manufacturer regularly engaged in the manufacturing of such products, which are of a similar material, design and workmanship. The standard products shall have been in satisfactory commercial or industrial use for 5-years prior to bid opening. The 5-year use shall include applications of equipment and materials under similar circumstances and of similar size. The 5-years experience shall be satisfactorily completed by a product that has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a 5-year field service record shall not be acceptable. Products shall be supported by a service organization. System components shall be environmentally suitable for the indicated locations.

2.2 SEWAGE PUMPS, GENERAL

A. Description: Factory-assembled and -tested, single-stage, centrifugal, end-suction sewage pump units complying with UL 778 or equivalent European or BS Standard. Include motor, operating controls, and construction for permanent installation.

B. Discharge Pipe End Connections DN50 and Smaller: Threaded. Pumps available only with flanged-end discharge pipe may be furnished with threaded companion flanges.

C. Discharge Pipe End Connections DN65 and Larger: Flanged.

D. Motors: Motor shall be manufacturer's standard construction for the service and shall be permanently sealed, oil-filled, and watertight. Motor space shall be fitted with watertight expansion provisions to accommodate temperature normal to specified duty. Motor seals shall remain watertight under any pressure developed in the volute and under a sump-level static head of not less than 9100 mm of water; Shop Drawings shall so certify. Motors shall be single speed, with grease-lubricated ball bearings, and non-overloading through full range of pump performance curves. Power cord shall be of suitable length, waterproof, internally grounded, oil-resistant, Type SO chloroprene, with 3 prong plug.

E. Bolts, nuts and washers shall be stainless steel, AISI Type 316.

F. Pump shaft shall be constructed of ground and polished AISI Type 304 or 316 corrosion-resistant steel with hardened wearing surfaces at intermediate shaft-bearing locations. Hardened surfaces may be overlays of 500 Brinell Stellite, Wall Colmonoy, or similar proprietary metals, or plasma-spray-applied ceramic materials of not less than 900 Brinell hardness. Mechanical properties and diameter of the shaft shall ensure that whip, deflection,


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or vibration will not be of sufficient magnitude to impose greater than design loads on the specified shaft bearings under normal operating conditions. Means shall be provided for external adjustment of the clearance between the impeller and the inner surfaces of the volute section.

G. Bearings and Lubrication: One or more antifriction ball- or roller-bearings shall be furnished in the motor and bearing support housing above the cover-plate surface, with full provision for the mechanical and hydraulic radial and thrust loads imposed. Bearings shall be sealed and grease-lubricated and shall have an L-10 rating of not less than 200,000 hours. Shop Drawings shall bear the manufacturer's certification of bearing life. Bearings shall be manufactured from vacuum-processed or degassed-alloy steels. Bearings shall be furnished with grease and pressure-relief fittings at bottom or opposite side the bearing where discharge may be viewed.

H. Intermediate shaft bearings shall be of the sleeve type. Center distance between any 2 bearings on the shaft shall not exceed 1370 mm or 1520 mm for pumps operating at 1,200 rpm or less. Sleeve-bearing length shall be not less than 2 times the shaft diameter. A sleeve bearing located near the lower extremity of the shaft shall be provided.

I. Flexible Couplings: Pump shaft shall be connected to the motor shaft through a flexible coupling. Flexible member shall be a tire shape or a solid-mass serrated-edge disk shape made of chloroprene material and retained by fixed flanges. Flexible coupling shall act as a dielectric connector, shall not transmit vibration or end thrust, and shall permit up to 4-degree misalignment under normal duty.

J. Support Pipe: A wrought-iron or steel support pipe concentric with the pump shaft shall connect the pump to the sump coverplate. Support-pipe flanges shall be machined and doweled to ensure proper alignment of the pump and shaft whenever the pipe is disassembled and reassembled in the field.

K. Liquid-Level Control: Simplex unit shall have a float mechanism to provide automatic operation of the pump unit when the liquid in the sump rises to a predetermined level. A means of adjustment, such as float-rod stops, shall be provided to allow for variation in the start and stop level-control points. Float and stem shall be AISI Type 304 or 316 corrosion-resistant steel, and all other parts of the fluid-level-sensing mechanism below the coverplate shall be bronze, brass, or material of equivalent resistance to the corrosive effects of sewage.

L. Liquid-Level Control: Duplex pump unit shall be furnished with the electrical and mechanical devices required to provide automatic operation of the pump unit when the liquid in the sump rises to a predetermined level. Controls shall automatically transfer the operating cycle from one pump to the other and shall operate both pumps simultaneously whenever the inflow to the sump exceeds the capacity of the operating pump. A means of adjustment such as float-rod stops shall be provided to allow for variations in the start and stop level-control points. Float and rod shall be AISI Type 304 or 316 corrosion-resistant steel, and all other parts of the fluid-level sensing mechanism below the cover shall be bronze, brass, or material of equivalent resistance to the corrosive effects of sewage.

M. Finish: Manufacturer's standard paint applied to factory-assembled and -tested units before shipping.

N. Manufacturer's Preparation for Shipping: Clean flanges and exposed machined metal surfaces and treat with anticorrosion compound after assembling and testing. Protect flanges, pipe openings, and nozzles with wooden flange covers or with screwed-in plugs.


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2.3 WET-PIT-MOUNTED, VERTICAL SEWAGE PUMPS

A. Description: Vertical, separately coupled, suspended sewage pump complying with HI 1.1-1.5 for wet-pit-volute sewage pumps.

1. Pump Arrangement: Duplex.2. Casing: Cast iron, with open inlet.3. Impeller: ASTM A 48, Class No. 25 A or higher cast iron; statically and dynamically

balanced, open or semiopen nonclog design, overhung, single suction, keyed to shaft, and secured by locking cap screw.

4. Impeller: ASTM B 584, cast bronze; statically and dynamically balanced, open or semiopen nonclog design, overhung, single suction, keyed to shaft, and secured by locking cap screw.

5. Impeller: ASTM A 532/A 532M, abrasion-resistant cast iron; statically and dynamically balanced, open or semiopen nonclog design, overhung, single suction, keyed to shaft, and secured by locking cap screw.

6. Pump Shaft and Sleeve Bearings: Stainless-steel shaft with bronze sleeve bearings. Include oil-lubricated, intermediate sleeve bearings at 1200 mm maximum intervals if basin depth is greater than 1200 mm, and grease-lubricated, ball-type thrust bearings.

7. Pump and Motor Shaft Coupling: Flexible, capable of absorbing torsional vibration and shaft misalignment.

8. Pump Discharge Piping: GRP.9. Basin Cover: Multiple sections, steel, and suitable for supporting pumps, motors, and

controls. Refer to "Sewage Pump Basins" Article for other requirements.10. Cover Shaft Seal: Stuffing box, with graphite-impregnated braided-yarn rings and

bronze packing gland.11. Motor: Mounted vertically on cast-iron pedestal.

a. Thermal Overload Protection: Built into pump motors or starters, as appropriate, according to size.

12. Controls: IP20 to IEC 60529, pedestal-mounted float switch; with floats, float rods, and rod buttons. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.

13. Float-Guide Pipe: Stainless Steel Guide pipe or other restraint for floats and rods in basins of depth greater than 1500 mm.

14. High-Water Alarm: Cover-mounted, compression-probe alarm, with electric bell; 230 V ac, with transformer and contacts for remote alarm bell, unless battery operation is indicated.

2.4 QUICK-DISCONNECT-SYSTEM, SUBMERSIBLE SEWAGE PUMPS

A. Description: Submersible, direct-connected sewage pump complying with HI 1.1-1.5 for submersible sewage pumps. Include quick-disconnect system.

1. Pump Arrangement: Duplex.2. Casing: Cast iron, with cast-iron legs that elevate pump to permit flow into impeller,

and discharge companion flange arranged to connect to quick-disconnect-system discharge-elbow fitting.

3. Impeller: ASTM A 48, Class No. 25 A or higher cast iron; statically and dynamically balanced, open or semiopen nonclog design, overhung, single suction, keyed to shaft, and secured by locking cap screw.


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6. Pump and Motor Shaft: Stainless-steel, with factory-sealed, grease-lubricated ball bearings.

7. Seals: Double mechanical seals.8. Motor: Hermetically sealed, capacitor-start type; with built-in overload protection;

lifting eye or lug; and three-conductor waterproof power cable of length required, with grounding plug and cable-sealing assembly for connection at pump.

9. Moisture-Sensing Probe: Internal moisture sensor, moisture alarm, and waterproof cable of length required, with cable-sealing assembly for connection at pump.

10. Pump Discharge Piping: GRP.11. Basin Cover: Multiple sections, steel, and suitable for supporting controls. Refer to

"Sewage Pump Basins" Article for other requirements.12. Quick-Disconnect System: Include the following:

a. Guide Rails: 2 stainless-steel vertical pipes, attached to baseplate and basin sidewall or cover.

b. Baseplate: Corrosion-resistant metal plate, attached to basin floor, supporting guide rails and stationary elbow.

c. Pump Yokes: Pump-motor-mounted or casing-mounted yokes or other attachments for aligning pump during connection of flanges.

d. Movable Elbow: Pump discharge-elbow fitting with flange, seal, and positioning device.

e. Stationary Elbow: Fixed discharge-elbow fitting with flange that mates to movable-elbow flange and support attached to baseplate.

f. Lifting Chain: Stainless-steel type AISI 316 chain attached to pump and basin cover at manhole.

13. Controls: IP20 to IEC 60529 enclosure, pedestal mounted, unless wall mounting is indicated; with 3 micropressure switches in IP67 to IEC 60529 enclosures; mounting rod; and electric cables. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.

14. Controls: IP20 to IEC 60529 enclosure, pedestal mounted, unless wall mounting is indicated; with 3 mercury-float switches in IP67 to IEC 60529 enclosures; mounting rod; and electric cables. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.

15. Controls: IP20 to IEC 60529 enclosure, pedestal-mounted float switch; with floats, float rods, and rod buttons. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.

16. Float-Guide Pipe: Guide pipe or other restraint for floats and rods in basins of depth greater than 1500 mm.


18. High-Water Alarm: Rod-mounted, IP67 to IEC 60529 enclosure with micropressure-switch alarm matching control and electric bell; 230 V ac, with transformer and contacts for remote alarm bell, unless battery operation is indicated.

19. High-Water Alarm: Rod-mounted, IP67 to IEC 60529 enclosure with mercury-float-switch alarm matching control and electric bell; 230 V ac, with transformer and contacts for remote alarm bell, unless battery operation is indicated.


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2.5 STATIONARY, SUBMERSIBLE SEWAGE PUMPS

A. Description: Submersible, direct-connected sewage pump complying with HI 1.1-1.5 for submersible sewage pumps.


and discharge companion flange arranged for vertical discharge.3. Impeller: ASTM A 48, Class No. 25 A or higher cast iron; statically and dynamically

balanced, open or semiopen nonclog design, overhung, single suction, keyed to shaft, and secured by locking cap screw.



6. Pump and Motor Shaft: Stainless-steel, with factory-sealed, grease-lubricated ball bearings.

7. Seals: Double mechanical seals.8. Motor: Hermetically sealed, capacitor-start type; with built-in overload protection;

and three-conductor waterproof power cable of length required, with grounding plug and cable-sealing assembly for connection at pump.


10. Pump Discharge Piping: GRP pipe.11. Basin Cover: Multiple sections, steel, and suitable for supporting controls. Refer to

"Sewage Pump Basins" Article for other requirements.12. Controls: IP20 to IEC 60529 enclosure, pedestal mounted, unless wall mounting is

indicated; with 3 micropressure switches in IP67 to IEC 60529 enclosures; mounting rod; and electric cables. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.


14. Controls: IP20 to IEC 60529 enclosure, pedestal-mounted float switch; with floats, float rods, and rod buttons. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.

15. Float-Guide Pipe: Guide pipe or other restraint for floats and rods in basins of depth greater than 1500 mm.


17. High-Water Alarm: Rod-mounted, IP67 to IEC 60529 enclosure with micropressure-switch alarm matching control and electric bell; 230 V ac, with transformer and contacts for remote alarm bell, unless battery operation is indicated.


2.6 SUBMERSIBLE, GRINDER SEWAGE PUMPS


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1. Pump Arrangement: Duplex.2. Impeller: Bronze or stainless-steel impeller, with stainless-steel grinder assembly.3. Pump and Motor Shaft: Stainless-steel, with factory-sealed, grease-lubricated ball

bearings.4. Seals: Double mechanical seals.5. Motor: Hermetically sealed, capacitor-start type; with built-in overload protection;

and three-conductor waterproof power cable of length required, with grounding plug and cable-sealing assembly for connection at pump.


7. Pump Discharge Piping: Factory or field fabricated, ASTM A 53, Schedule 40, galvanized-steel pipe, bronze pipe, or copper tube.

8. Basin Cover: Multiple sections, steel, and suitable for supporting controls. Refer to "Sewage Pump Basins" Article for other requirements.

9. Quick-Disconnect System: Include the following:

a. Guide Rails: 2 Stainless-steel vertical pipes, attached to baseplate and basin sidewall or cover.





f. Lifting Cable: Stainless-steel grade SS316 cable attached to pump and basin cover at manhole.

10. Controls: IP20 to IEC 60529 enclosure, pedestal mounted, unless wall mounting is indicated; with three mercury-float switches in IP67 to IEC 60529 enclosures; mounting rod; and electric cables. Include automatic alternator to alternate operation of pump units on successive cycles and to operate both units if one pump cannot handle load.


2.7 SUBMERSIBLE, CUTTER SEWAGE PUMPS



and discharge companion flange arranged to connect to quick-disconnect-system discharge-elbow fitting.

3. Impeller: Bronze or stainless-steel impeller, with stainless-steel cutter assembly.4. Pump and Motor Shaft: Stainless-steel, with factory-sealed, grease-lubricated ball

bearings.5. Seals: Double mechanical seals.


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6. Motor: Hermetically sealed, capacitor-start type; with built-in overload protection; and three-conductor waterproof power cable of length required, with grounding plug and cable-sealing assembly for connection at pump.


8. Pump Discharge Piping: GRP pipe.9. Basin Cover: Multiple sections, steel, and suitable for supporting controls. Refer to

"Sewage Pump Basins" Article for other requirements.10. Quick-Disconnect System: Include the following:

a. Guide Rails: 2 Stainless-steel vertical pipes, attached to baseplate and basin sidewall or cover.





f. Lifting Cable: Stainless-steel grade SS316 cable attached to pump and basin cover at manhole.



2.8 SEWAGE PUMP, REVERSE-FLOW ATTACHMENT

A. Description: Factory-fabricated, reverse-flow pump attachment for factory or field installation in sewage pump basin.

B. Inlet Fitting: 1 combination inlet-overflow strainer fitting.

C. Valves: 2 shutoff valves and 2 check valves.

D. Strainers: 2 strainer housings with reverse-flow, self-flushing strainers.

E. Pipe and Fittings: Size and configuration required to connect to sewage pumps and piping.

2.9 SEWAGE PUMP BASINS

A. Description: Factory fabricated with sump, pipe connections, and separate cover.

B. Basin Sump: Fabricate watertight, with sidewall openings for pipe connections.

1. Material: Fiberglass or cast iron.2. Reinforcement: Mounting plates for pumps, fittings, rail systems, and accessories.3. Anchor Flange: Same material as or compatible with basin sump, cast in or attached

to sump, in location and of size required to anchor basin in concrete slab.


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C. Basin Cover: Fabricate with openings with gaskets, seals, and bushings, for access, pumps, pump shafts, control rods, discharge piping, vent connections, and power cables.

1. Material: Steel, with bitumastic coating.2. Reinforcement: Steel reinforcement capable of supporting foot traffic for basins

installed in foot-traffic areas.

2.10 GENERAL-DUTY VALVES

A. Refer to Division 15 Section "Valves" for general-duty gate, ball, butterfly, globe, and check valves. Use valves specified for domestic water, unless otherwise indicated. Include features and devices indicated.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine roughing-in of plumbing piping systems to verify actual locations of piping connections before pump installation.

3.2 EARTHWORK

A. Excavating, trenching, and backfilling are specified in Division 2 Section "Earthwork."

3.3 CONCRETE

A. Install concrete bases of dimensions indicated, or otherwise required, for sewage pumps. Refer to Division 3 Section "Cast-in-Place Concrete" and Division 15 Section "Basic Mechanical Materials and Methods."

3.4 INSTALLATION

A. Install pumps according to manufacturer's written instructions.

B. Install pumps and arrange to provide access for maintenance, including removal of motors, impellers, couplings, and accessories.

C. Support piping so weight of piping is not supported by pumps.

D. Wet-Pit-Mounted, Vertical Sewage Pumps: Suspend pumps from basin covers. Make direct connections to sanitary drainage piping.

E. Submersible Sewage Pumps: Set pumps on basin floor. Make direct connections to sanitary drainage piping.

1. Anchor quick-disconnect systems to bottom of basins and basin sidewalls or covers. Install pumps so pump and discharge pipe disconnecting flanges make positive seals when pumps are dropped into place.


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F. Sewage Pump Basins: Install basins and connect to drainage and vent piping. Brace interior of basins according to manufacturer's written instructions to prevent distortion or collapse during concrete placement. Set basin cover and fasten to basin top flange. Install cover so top surface is flush with finished floor.

G. Packaged Pump Units: Install and make direct connections to drainage and vent piping.

3.5 CONNECTIONS

A. Sanitary drainage and vent piping installation requirements are specified in Division 15 Section "Drainage and Vent Piping." Drawings indicate general arrangement of piping and specialties. The following are specific connection requirements:

1. Install discharge pipe sizes equal to or greater than diameter of pump nozzles, and connect to sanitary drainage piping.

2. Install non-slam, swing check valve and gate or ball valve on each sewage pump discharge. Include spring-loaded or weighted-lever check valves for piping DN65 and larger.

B. Install electrical connections for power, controls, and devices.

C. Electrical power and control components, wiring, and connections are specified in Division 16 Sections.

D. Ground equipment.

1. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B.

3.6 ADJUSTING

A. Pump Controls: Set pump controls for automatic start, stop, and alarm operation as required for system application.

3.7 COMMISSIONING

A. Final Checks before Starting: Perform the following preventive maintenance operations:

1. Lubricate bearings.2. Disconnect couplings and check motors for proper direction of rotation.3. Verify that each pump is free to rotate by hand. Do not operate pump if it is bound or

drags, until cause of trouble is determined and corrected.4. Verify that pump controls are correct for required application.

B. Starting procedure for pumps with shutoff power not exceeding safe motor power is as follows:

1. Start motors.2. Open discharge valves slowly.3. Check general mechanical operation of pumps and motors.


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3.8 DEMONSTRATION

A. Engage a factory-authorized service representative to train the Employer's maintenance personnel to adjust, operate, and maintain sewage pump units. Refer to Division 1 Section "[Demonstration and Training] [Closeout Procedures]."

1. Schedule at least four (4) hours of training.

END OF SECTION 15445


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15445 Sewage Pumps