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HomeMy WebLinkAboutMONTAVA - PHASE G & IRRIGATION POND - BDR210013 - SUBMITTAL DOCUMENTS - ROUND 5 - STORMWATER-RELATED DOCUMENTSMONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 1 SECTION 33 4413 – STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS, AND APPURTENANCES PART 1 - GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section. B. Additional information concerning subdrainage systems may be found on the civil drawings. In case of conflict between the drawings and the information specified herein, the more stringent requirements shall govern. C. Related Work: 1. Division 03 – Concrete Work 2. Division 22 – Mechanical Systems 3. Division 26 – Electrical Systems 4. Division 31 - Earthwork 5. Division 32 – Exterior Improvements 1.2 SUMMARY A. Work Included: Work consists of furnishing and installing all pumps, equipment, controls and the structures necessary to complete the lift station and force main including dewatering, excavation, backfill and compaction. Contractor is responsible for providing a working system including system start-up, testing, calibration and providing water required for these operations. Pump Schedule: Pump Type Q (gpm) TDH (ft) Configuration 1 Submersible Stormwater 427 35 Duplex 2 Submersible Stormwater 427 35 Duplex 1.3 SUBMITTALS A. Submit product data on pump and control equipment, valves, piping, electrical components, lift station structure, alarm system and all accessories to verify compliance with specifications. B. Submittals shall include the following information from the pump manufacturer: 1. Certified pump outline drawing 2. Typical cross section 3. Single line characteristic curve 4. Pump installation and operations manual 5. Motor driver wiring diagram 6. Control module wiring diagram 7. Performance and test procedure 8. Make available, a full video that completely demonstrates the assembly and dismantling of the proposed pump. C. Documentation: Provide documentation for the complete control system. This documentation MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 2 shall include operating and maintenance manuals and record drawings. 1. Operating and Maintenance Manuals. Provide five complete sets of loose-leaf operating and maintenance manuals. These manuals shall not only include descriptive material, but also drawings and figures bound in appropriate places. The manuals shall include operating and maintenance literature for all components provided in this section. The submitted literature shall be in sufficient detail to facilitate the operation, removal, installation, adjustment, calibration, and maintenance of each component provided under this section. 2. Record Drawings: Provide one set of as-built drawings of the following: a. Instrumentation diagrams. b. Interconnecting Wiring Diagrams: Diagrams shall show all equipment (panels, field elements, etc.) and all terminations provided under this section. Wiring diagrams shall clearly show all terminal block number designations and wire numbers. Diagrams, device designations, and symbols shall be in accordance with NEMA ICS 1-101. D. Product Certificates: For each type of wastewater pump, signed by product manufacturer. E. Shop Drawings: 1. Schematics showing layout of equipment within structures and all piping and control connections. Shop drawings must be accepted prior to purchase. 2. Precast concrete manufacturers shop drawings detailing each precast section and all penetrations. F. Source quality-control test reports G. Field quality-control test reports. 1.4 QUALITY ASSURANCE: A. The equipment covered under this specification shall be a standard product of proven reliability. All units specified in this section shall be supplied by a single pump manufacturer. B. The stormwater pumps shall be tested in accordance with ANSI/HS 11.6: 2012 standards of the Hydraulic Institute’s Pumps Standards, Latest Edition, as required. C. Motor control circuits shall meet the requirements of NEC 430 and 725, and NEMA ICS-1970. D. In the event of a conflict between the text portion of this document and the construction drawings included in this document, the text portion shall govern. E. Unless noted otherwise, the materials used and methods of construction shall conform to the County’s Standard Construction Specifications. F. Pumps and equipment shall be given an operational field test to check pump operation, leaks in piping or seals and correct operation of auxiliary equipment including controls. Contractor is responsible for coordinating pump testing and providing water for testing. G. Piping materials shall bear label, stamp, or other marking of specified testing agency. H. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 820, MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 3 by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. 1.5 DELIVERY, STORAGE, AND HANDLING: A. Preparation for Transport: Prepare valves according to the following: 1. Ensure that valves are dry and internally protected against rust and corrosion. 2. Protect valves against damage to threaded ends and flange faces. 3. Set valves in best position for handling. Set valves closed to prevent rattling. B. During Storage: Use precautions for valves according to the following: 1. Do not remove end protectors unless necessary for inspection, then reinstall for storage. 2. Protect from weather. Store indoors and maintain temperature higher than ambient dew- point temperature. Support off the ground or pavement in watertight enclosures when outdoor storage is necessary. C. Handling: Use sling to handle valves if size requires handling by crane or lift. Rig valves to avoid damage to exposed parts. Do not use hand wheels or stems as lifting or rigging points. D. Deliver piping with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe-end damage and to prevent entrance of dirt, debris, and moisture. E. Protect stored piping from moisture and dirt. Elevate above grade. Do not exceed structural capacity of floor when storing inside. F. Protect flanges, fittings, and specialties form moisture and dirt. G. Store plastic piping protected from direct sunlight. Support to prevent sagging and bending. H. Submersible pumps shall ship fully assembled. I. The skidded pump and related equipment shall be unloaded, stored, and installed in strict accordance with the manufacturer’s Installation and Operating Instructions. The contractor shall review in detail and implement items relating to mounting, lubrication, power requirements, and pump rotation as contained in the manufacturer’s Installation and Operating Instructions to ensure proper warranty. If storage is planned to be longer than three (3) months or in a harsh environment, the manufacturer’s long-term storage instructions must be followed. 1.6 PROJECT CONDITIONS A. Existing Utilities: Do not interrupt utilities serving facilities occupied by the Owner or others unless permitted under the following conditions and then only after arranging to provide temporary utility services according to requirements indicated: 1. Notify Owner’s Representative not less than two days in advance of proposed utility interruptions. 2. Do not proceed with utility interruptions without written permission of Owner’s Representative. B. Environmental Requirements: Except by specific written authorization, cease concreting when descending air temperature in shade and away from artificial heat falls below 35° F and there is frost in subgrade. When concreting is permitted during cold weather, temperature of mix shall not be less than 60° F at time of placing. MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 4 C. Immediately pump or bail out water found in excavations, whether rain or seepage. Coordination and use of electric power is the Contractor’s responsibility. Excavations must be kept free from water at all times. D. It shall be the responsibility of the Contractor to take all measures and furnish all equipment and labor necessary to control the flow, drainage, and accumulation of water as required to permit completion of the work under this section to avoid damage to all work at no additional cost to the Owner. E. It shall be the responsibility of the Contractor to take all measures and furnish all material, equipment, and labor necessary to provide adequate backfill material as specified herein. 1.7 PROJECT RECORD DOCUMENTS A. Maintenance of Documents: Store documents apart from drawings used for construction. File submitted documents in accordance with the specification’s section numbers. Maintain documents in a clean, dry, legible condition and in good order. Do not use record documents for construction purposes. B. Recording: Label each document “PROJECT RECORD” in neat, large, printed letters. Record information concurrently with construction progress. Do not cover work until required information is recorded. Marking of project records shall be legible and with a dark pen or pencil. Ink shall not be water based due to easy smearing. Mark drawings to record actual construction including field dimensions, elevations, details, changes made by a modification, details not on original drawings, horizontal and vertical locations of underground utilities and appurtenances referenced to a minimum of two permanent surface improvements, and depths of various elements of work in relation to project datum. All horizontal and vertical information is to be certified by a licensed Professional Land Surveyor. C. Submission: Accompany submittal with transmittal letter in duplicate containing date, project title and number, Contractor’s name, address and telephone number, title and number of each record document, and signature of Contractor or his authorized representative. Contractor shall submit two drawings; substantial deviations shall be surveyed and certified by a licensed Professional Land Surveyor depicting all as-built information to the Engineer. 1.8 PROTECTION A. Barricades and Safety Provisions: Place and maintain until completion of work adequate barricades, construction signs, warning lights and guards to avoid property damage and protect persons from injury. Flares with open flames will not be permitted. Protect by barricades or guards and warning lights all materials, equipment, pipe and earth piles that may serve as hazards to vehicular or pedestrian traffic. B. Shoring: Provide and maintain all sheeting, shoring, and bracing required to safely retain earth banks. Protect adjoining grades and structures from caving, sliding, erosion or other damage, and suitable forms of protection against bodily injury; all in accordance with applicable codes and governing authorities. Do not remove any sheeting unless the pipe strength is sufficient to support the trench loads based on trench width measure to the back of sheeting. Remove sheeting and shoring gradually as excavation backfilling progresses to protect the construction or other structures, utilities or property. Do no attempt removal of sheeting in one operation after backfilling is complete. C. All work must comply with latest OSHA requirements. MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 5 D. Utilities: Protect from damage existing utility lines shown on drawings or locations of which are made known to contractor prior to work and utility lines constructed during construction operations of the project. Hand excavate within six inches of known piping or objects to prevent damage from equipment. Before commencing work, obtain information concerning location, type, and extent of concealed existing utilities on the site and adjacent properties. Repair damage to utilities at no cost to the Owner. E. Granular Fill: Protect existing granular fill adjacent to existing structures from dirt that would impede free drainage. Remove and replace any portions of granular fill that become contaminated with dirt. F. Drainage: Maintain the excavations and site free from water throughout the work. Remove any water encountered in the trench to provide firm subgrade, to permit joints to be made dry at the final grade, and to prevent entrance of water into the pipeline. Accomplish the foregoing by the use of sumps and gravel blankets, well points, or drain lines. Contractor shall obtain all permits associated with dewatering. Rock, gravel, and other appurtenances used to keep trenches free from water or used to add support to installed piping is considered incidental to construction and all costs shall be the responsibility of the Contractor. G. Survey Control Monuments and Range Boxes: Protect existing survey control monuments from damage. Contractor will be responsible for replacement or repair of any monument damaged or destroyed. Replacement of monuments must be performed by a qualified land surveyor. PART 2 - PRODUCTS 2.1 PIPING MATERIALS A. Ductile-Iron Piping and Fittings 1. Mechanical-Joint, Ductile-Iron Pipe: AWWA C151, thickness Class 51 with cement- mortar lining, AWWA C104 with mechanical-joint, and bell- and plain-spigot end. a. Mechanical-Joint, Ductile-Iron Fittings: AWWA C110, pressure rating 250 psig, ductile- or gray-iron standard pattern or AWWA C153, ductile-iron compact pattern. b. Glands, Gaskets, and Bolts: AWWA C111, ductile- or gray-iron glands, rubber gaskets, and high-strength, low alloy steel bolts such as Cor-Ten. Bolts and fasteners located within the wet well shall be stainless steel. c. All fittings cement mortar lined, AWWA C104. d. Bituminous outside coating one mil thick. 2. Use flanged pipe and flange coupling adapters as indicated on drawings for piping within wet well and valve vault. Pressure rating and thickness class shall be the same as described for the mechanical joint pipe in this specification. B. PVC Pipe and Fittings size 3/4-inches – 12-inches 1. PVC, Schedule 80: solvent welded fittings, ASTM D 1785. ¾ inches – 3 inches a. PVC, Schedule 80 Solvent Weld Fittings: ASTM D 2467. C. PE Pipe and Fittings: High-Density Polyethylene (HDPE) Pipe and Fittings: 1. 4-inch and large HDPE Pipe a. HDPE plastic pipe shall be PE-4710 resin meeting ASTM D3350 cell classification 445574C, DR 17, 125 psig minimum pressure rating and comply dimensionally with AWWA C906 iron pipe size (IPS), compatible with heat fusion. b. Pipe shall be manufactured to the requirements of ASTM F714 for pipe diameters MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 6 of 4” and above. c. HDPE shall be provided in rolls whenever rolls are available in specified pipe size. d. The joining method shall be fusion method and shall be performed in strict accordance with the pipe manufacturer’s recommendations. Butt fusion equipment used in the joining procedures shall be capable of meeting all conditions recommended by the pipe manufacturer, including but not limited to, temperature requirements, alignment, and fusion pressures. Ribbed steel inserts with stainless steel clamps are not approved for HDPE pipe. e. The HDPE pipe shall be Driscoplex 4100 Ultra-Line Pipe as manufactured by Performance Pipe, Plano, TX, 75093, (800) 527-0662, www.performancepipe.com or approved equal. 2. HDPE Fittings a. ASTM D 3350, PE resin material meeting the same dimensions, class and pressure requirements as the pipe. b. Molded fittings shall be ASTM D 3261 manufactured for butt fusing and shall be so marked. c. HDPE fittings shall be molded or fabricated by George Fischer Central Plastics, Shawnee, OK, 74804, (800) 654-3872, www.centralplastics.com or approved equal. 2.2 LIFT STATION STRUCTURE A. Precast Concrete Manholes and Vaults: Meet requirements outlined in “Larimer County Urban Area Street Standards”. Submit certified shop drawings for precast vaults, manhole, base, and top cover with access hatch. B. Wall Penetrations: 1. Wall penetrations in the wet wells and valve vault shall be accomplished by link seal wall sleeve. 2. The gap between the pipe passing through the penetration and the concrete shall be sealed with two (2) Link-Seal units with Type 316 stainless steel hardware. Cover the Link-Seal units with non-shrink grout. Grout shall be installed such that it is smooth with the face of the wall. 3. There shall be a flexible joint outside the wet well within 12” to 18” of the exterior face of the wall with adequate rodding for pressure hammer. C. Discharge Piping: 1. Discharge piping in the wet well shall be made up of flanged sections. 2. All discharge piping shall be DIP pipe, fittings, and appurtenances. 3. The DIP pipe shall have an exterior bituminous coating and a double cement mortar lining. D. Lift Station Steps: No access steps or ladders within wet well. E. Access Hatch: The access door shall be Type TPD as manufactured by U.S.F Fabrication, Inc., with the size being specified on the plans. Door leaves shall be ¼" thick aluminum floor plate reinforced to a 300 PSF live load. The frame shall be an extruded aluminum trough section with an integral anchor flange and door seat on all four sides. The frame shall include an EPDM odor reduction gasket that reduces the amount of odor that escapes from below the door and a 1 ½” threaded drain coupling. The floor access door shall be equipped with a flush lifting handle that does not protrude above the cover and a 316 stainless steel hold open arm with a secondary latching mechanism/release handle that secures the cover in its full upright, open position. The door shall have 316 stainless steel hinges with 316 stainless steel tamper resistant bolts/locknuts. MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 7 A staple for a padlock and a padlock shall be supplied. An adhesive backed vinyl material that protects the product during shipping and installation shall cover the entire top of the frame and cover. Installation shall be in accordance with the manufacturer’s instructions. The door shall be manufactured and assembled in the Unites States. Manufacturer shall guarantee the door against defects in materials and workmanship for a period of ten (10) years. F. Sealant: 1. Joint Sealing Compound: Preformed flexible plastic sealing compound meeting requirements of FS SS-S-210A-75 or latest revision. Ram-Nek, manufactured by K.T. Snyder Company, or approved equal. 2. Primer: As recommended by manufacturer of sealing compound used. G. Mortar: Following proportions by volume: 1/2 part Portland cement, 1 part masonry cement, 3- 1/4 to 4-1/2 parts sand with water as necessary to obtain workable consistency. Sand shall meet requirements of AASHTO M6-81 or latest revision. Use mortar within one hour after mixing. 2.3 PUMP EQUIPMENT A. Operating Conditions: 1. The required units shall be non-clog, inverter-duty rated submersible pumps passing at minimum a 3” spherical solid. 2. The pumps shall have a continuously rising head capacity curve from run-out flow through shutoff. 3. The pump shall be designed to operate continuously for an extended period at any point in the allowable operating range of the curve without cavitation, overheating or excessive vibration. The motor nameplate horsepower rating shall not be greater than specified herein. Performance Data: Number of Units Required 2 Rated Duty Point Condition Capacity (Flow) 427 GPM Total Dynamic Head (TDH) 35 Feet Motor HP 7.5 HP Maximum Pump Operating Speed 3540 RPM Electrical Characteristics Required Voltage 230/460 Volt Phase 3 PH Hertz 60 Hz Rated Current 19.2/10.1 Amps Minimum Shutoff Head 54 Feet Minimum Spherical Diameter Passage Through the Impeller (in) 3 Inches Minimum Suction Size 3 Inches Minimum Discharge Size 3 Inches Pumped Liquid Raw Stormwater Pumping Temperature 68 °F Specific Gravity @ Pumping Temperature 1.0 MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 8 B. Pump Design: 1. Each pump shall have a flanged guide claw attached to the pump discharge flange by an ANSI flange connection. A replaceable Nitrile Butadiene Rubber (NBR) profile seal shall be provided as an integral part of the guide claw to form a leak-proof seal with the base discharge elbow. 2. The guide claw shall direct the pump down by two vertical guide rails to the discharge connection in a simple linear movement without tilting the pump side wards. There shall be no need for any personnel to enter the wet well in order to remove the pumps. No portion of the pump shall be supported directly on the bottom of the wet well, guide rails or lifting chain. A cast iron or fabricated steel base plate with integral guide rail holders shall be provided. The base plate shall be designed with an integral 90° elbow. C. Pump Construction: 1. Major pump components including casing, impellers, motor frame shall be of at minimum Class 40B cast iron with smooth surfaces devoid of blowholes or other irregularities. 2. All exposed nuts or bolts shall be 304 stainless steel. All metal surfaces coming into contact with the pumped media, other than stainless steel, shall be protected by a factory applied, impact-resistant powder coating finish on the exterior of the pump. 3. Critical mating surfaces where watertight sealing is required shall be machined and fitted with NBR O-rings. Joint sealing will be the result of controlled compression of rubber O- rings in two planes and O-ring contact of four sides without the requirement of a specific torque limit. Rectangular cross-sectioned gaskets requiring specific torque limits to achieve compression shall not be considered as adequate or equal. 4. Pump and motor shall be the same unit. The pump shaft is an extension of the motor shaft. Motor shaft shall be 316 stainless steel. Pump and motor shall be shipped from the factory as a finished product. Pumps that are assembled outside of the manufacturer’s facility are not allowed. 5. Pump housing and motor housing shall be fastened together by a 316 stainless steel clamp in lieu of bolts for easy serviceability. D. Cable and Cable Entry Seal: 1. The power cable shall be sized in accordance with NEC and ICEA standards and shall be of sufficient length to reach the junction box without need of splices. The outer jackets of the cable shall be composed of oil resistant chloroprene rubber. 2. The pump shall be equipped with leak-proof stainless steel cable plug where the unscreened conductors of the cable are cast into the plug by means of a two-component sealant to prevent moisture from entering the motor via the cable core. 3. The pump cable end (plug) shall incorporate in its design the ability to quick disconnect the power cable from the pump without the need to enter the pump. This cable plug shall allow the same plug to be utilized for 208/230/460-volt applications without the need to enter the pump. E. Pump Motor: 1. The pump motor shall be an induction type, IE3 component design with a squirrel cage rotor, shell type design, housed in an air-filled, watertight chamber according to IEC class IP 68 and NEMA MG1, part 31. Oil-filled motors shall not be considered acceptable or equal. Stator housing to be ASTM A-48 Class 40. 2. The motor shall be explosion proof and inverter duty rated approved for use in Class 1, Division 1, Group C & D hazardous areas. The stator winding and stator leads shall be insulated with moisture resistant Class H insulation rated for 356° F (180° C). 3. The stator shall be trickle impregnated and heat shrunk fitted into the cast iron stator MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 9 housing. The use of bolts, pins or other fastening devices requiring penetration of the stator housing is not acceptable. The motor shall be designed for continuous duty handling pumped media of 104° F (40° C) and capable of up to 20 spaced starts per hour. 4. The motor shall have voltage tolerance of plus or minus 10%. The motor shall be designed for operation up to 104° F (40° C) ambient temperature, with a temperature rise of Class A not to exceed 176° F (80° C). 5. The motor horsepower shall be adequate so that the pump is non-overloading throughout the entire pump performance curve from shut-off through run-out. Service factor shall be 1.15. F. Cooling System: Pump shall be submersible design cooled by ambient fluids with no additional cooling system required. G. Bearings: The pump shaft shall rotate on two bearings. Motor bearings shall be grease lubricated for the lift of the bearing. The upper motor bearing shall be a single roller bearing, and the lower bearings shall compensate for axial thrust and radial forces and shall consist of a roller bearing and two angular contact ball bearing. H. Mechanical Seals: 1. Mechanical seal shall be a cartridge style encased with a 316 stainless steel housing. 2. Primary seal faces shall be silicon carbide/silicon carbide, and secondary seal faces shall be carbon/ceramic. I. Pump Shaft: Pump shaft must be a short overhung and dynamically balanced to eliminate shaft deflection. Motor shaft shall be 316 stainless steel. J. Impeller: The S-tube impeller shall be of cast iron ASTM A48 Class 250B. Impellers to be balanced to ISO scale G 6.3. K. Volute: The pump volute shall be single piece cast iron, ASTM A48, Class 40B with smooth passages large enough to pass any solids that may enter the suction. Minimum through let shall be 3”. Pump housing and motor housing shall be fastened together by a 316 stainless steel clamp in lieu of bolts for easy serviceability. L. Lifting Bail: Lifting bail shall be cast 316 stainless steel bolted to the top of the pump. Bail shall be constructed so that the pump is in proper position to connect to elbow. M. Auto Coupling System: 1. Pumps shall be equipped with a complete auto coupling system to include factory upper guide rail brackets, base elbow, guide claw. Fabricated, non-factory components will not be accepted. 2. Upper guide rail bracket shall be 316 stainless steel. 3. Base elbow shall have a smooth interior to allow for specific solids passage. Base elbow shall be gray cast iron, ASTM A-48, Class 35 or better, with smooth surfaces devoid of blowholes or other irregularities. Base elbows shall have a factory-applied spray coating. 4. Minimum guide rail diameter shall be 2” of 4” – 6” discharge and 1.5” for 2.5” – 3” discharge. Guide rails to be 316 stainless steel with minimum thickness of 0.15” (schedule 40). N. Pump Protection: 1. Each pump shall incorporate three thermal switches, on per stator phase wind and be MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 10 connected in series, to monitor the temperature of the motor. Should the thermal switches open, the motor shall be stopped, and an alarm indication shall be activated. Pump should also include thermistor to current stator temperature while pump is operating. 2. Pumps shall have normally closed moisture switches. The moisture switches shall be incorporated into the pump to sense moisture in the bottom of the stator housing. The switch shall be wired in series so that if a switch opens, the motor is de-energized, and the pump is stopped. 3. A water leakage sensor shall be installed in the seal chamber to monitor the condition of the primary seal. The sensor shall measure the water content in the oil and convert the value into an analog current signal. The sensor shall measure the water content in the oil chamber from 0% - 20% and send a continuous 4 – 20 mA signal to a factory-supplied, seal fail module to allow for seal fail monitoring. This shall allow for constant trending of seal leakage without the need to remove the pump from the wet well. The sensor shall be fitted in a stainless steel tube for mechanical protection. Seal fail sensor in pump shall be FM-approved. O. Control Module: 1. Control module shall be supplied by pump manufacturer and to be mounted within the control panel. Module shall mount on a din rail and shall be UL 61010 approved. 2. Signals from the pump shall be received by the module via a control cable. While pump is running, the module shall monitor real time stator temperature, thermal sensor failure, moisture switches status, and the water leakage sensor signaling the real time quantity of water in the oil chamber. 3. A warning signal and alarm signal shall be delivered by the control module. Both the warning and alarm levels shall be adjustable for the water leakage sensor and stator temperature sensors. 4. Module shall incorporate Modbus output to communicate with a PLC, dedicated controller, SCADA, or remote monitor system. All monitored signals shall be real-time viewable via this Modbus connection. 2.4 CABLE HOLDER A. Furnish and install 316 stainless steel cable holder to suspend liquid level floats. 2.5 CONTROL EQUIPMENT A. Equipment: Furnish and install one (1) Grundfos Model LC 241 Duplex automatic pump control center in a NEMA 4X enclosure. Inner door shall be provided. The control center shall be designed and manufactured for submersible pump applications and supplied by the pump manufacturer to insure compatibility and proper protection. B. The control system shall be compatible with the Owner’s equipment. The station control panel shall provide for all aspects of operation and control for the stormwater pumping units. 1. The panel shall be capable of serving the duplex pumps at their ultimate horsepower for each pump for which each lift station is designed. 2. The control system shall be of the float switch type incorporating a liquid level indicator/controller as the level sensing and signal control device. 3. The factory assembled system shall include: a. Liquid level indicator/controller. b. Microprocessor controller. c. Alarms and sensors as specified herein. MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 11 4. The panel shall be equipped with the following Electrical capacity: a. Main Frequency: 60 Hz b. Rated Voltage: 3 x 208-460 V c. Rated Current: 8 – 32 A d. Start Method: Direct-on-line (DOL) e. Enclosure class (IEC 34-5): IP56 f. Back-up Fuse Required: 100 A 5. All wires in the control panel shall be color-coded by voltage. Power supply wires shall be isolated from the control wires. Control wiring is to be run in wire channels and not simply tied together. 6. A schematic diagram shall be supplied with every control panel. C. Primary control system shall include the following: 1. PLC units with custom software are not acceptable. 2. Pumps shall operate in alternating lead-lag configuration. 3. H-O-A selector switches for each pump. 4. High water level, low water level, power failure, seal failure, or motor over-temperature shall initiate alarm signals. 5. In case of lockout of motor starters, in case of phase loss, phase reversal, or low voltage; alarm signals shall be initiated. D. A secondary control system, consisting of four (4) float switches, shall be provided. 1. Intrinsically safe relays shall be used to isolate the float switch. 2. High level float shall cause all pumps to start. 3. Secondary control system to be capable of operation even when primary control system is disabled. 4. Secondary system to be automatically activated when high level float switch is activated. 5. High wet well level alarm signal shall be sent to telemetry system when float switch is activated. 6. Control to be automatically returned to primary system on next pumping cycle after alarm condition has been resolved. E. Panel enclosure shall be NEMA 4X. Inner door shall be provided. The enclosure shall be fabricated from thermoplastic. It shall be completely removable and held closed by at least two (2) ¼ turn fasteners. It shall be capable of being locked shut by either an integral lock or pad lock. Supply the lock and two (2) keys. Locks shall be keyed per Owner’s requirements. F. Control circuit wiring shall be 16 gauge minimum, Type MTW or THW rated for 300 volts. Power wiring shall be rated for 600 volts. G. All labeling both within the enclosure and external shall be laser-screened, laminated Mylar. H. I. Motor and control circuit breakers shall be molded case. Minimum interrupting rating 18,000 AMPs RMS SYM at 208 volts. Acceptable manufacturers are: 1. Cutler Hammer 2. General Electric 3. Westinghouse 4. Square D I. Motor starters shall be full-voltage, non-reversing NEMA HP rated and equipped with a minimum of one n.o. auxiliary contact for customer’s use. Acceptable manufacturers are: MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 12 1. Cutler Hammer 2. General Electric 3. Allen Bradley 4. Square D J. Provide ambient compensated overload relays of the bimetallic type. Overload relays to have electrically isolated n.o./n.c. contact to annunciate motor overload condition. K. Relays shall be plug-in design with transparent polycarbonate dust cover. All relays to have 3 PDT contacts and molded nylon coil rated for continuous duty. Coil voltage to be 24 VAC or 120 VAC. Relay contacts shall be rated for 10 AMPs at 300 VAC. L. Provide phase monitor relay to monitor loss of phase, phase reversal and under voltage. Unit shall stop pump motors after detention of fault. Unit shall automatically reset after fault is cleared. M. Provide a running time meter for each pump, non-resetable, reading in hours and tenths up to 99999.9. N. Provide a lightning arrestor/surge capacitor at the panel service entrance. Solid state type. Capable of clamping in 5 nanoseconds and absorb 25KA peak surge current. Life expectancy of 10,000 occurrences at 200 AMPs. O. Provide a duplex GFCI convenience receptacle on a dedicated 20 AMP 120 VAC branch circuit within the panel. P. The panel manufacturer shall be U/L certified as a U/L 508 manufacturing facility and certified to install a serialized label for quality control and insurance liability considerations. Panel shall meet the following standards as a minimum: 1. Institute of Electrical and Electronic Engineers 2. National Electric Code 3. National Electrical Manufacturers Association 4. American National Standards Institute 5. Underwriters Laboratories 508 Q. In the event that a motor over-temperature switch is activated, the pump shall shut down until the switch is automatically reset. 2.6 PROCESS VALVES AND OPERATORS A. General: 1. Valves shall include operator, actuator, hand wheel, chain wheel, extension stem, floor stand, worm and gear operator, operating nut, chain, wrench, and accessories for complete operation. 2. Valve shall be suitable for wastewater service. Renewable parts not to be of a lower quality than specified. 3. Valve shall be the same size as adjoining pipe. 4. Valve ends shall suit adjacent piping. 5. Size operator to operate valve for the full range of pressures and velocities. 6. Valve to open by turning counterclockwise. 7. Factory mount operator, actuator, and accessories. B. Schedule: MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 13 1. Requirement relative to this section for certain type of actuated or process valves are shown on the Valve Schedules attached as a Supplement at the end of this Section. C. Materials: 1. Unless otherwise noted, valve bodies shall be construction of ductile iron, ASTM A536, Grade 65-45-12. 2. Brass and bronze valve components and accessories that have surfaces in contact with water to be alloys containing less than 16% zinc and 2% aluminum. 3. Approved alloys are the following ASTM designations: a. B61, B62, B98 (Alloy UNC No. C65100, C65500, or C66100), B139 (Alloy UNS No. C51000), B584 (Alloy UNS No. C90300 or C94700), B164, B194, and B127. 4. Stainless steel, AISI Type 316 may be substituted for bronze. D. Factory Finishing: 1. Epoxy Lining and Coating: a. In accordance with AWWA C550 unless otherwise specified. b. Either two-part liquid material or heat-activated (fusion) material except only heat- activated material if specified as “fusion” or “fusion-bonded” epoxy. c. Minimum 7-mil dry film thickness except where limited by valve, operating tolerances. 2. Exposed Valves: a. Match adjacent piping system. E. Valves: 1. Plug Valves: a. Eccentric Plug Valve 3” through 12”: 1) Non-lubricated type rated 175 psig CWP, drip-tight shutoff with pressure from either direction, ductile iron body, with flanged ends or grooved ends in accordance with AWWA C606 for rigid joints, mechanical joint ends for buried valve. 2) Follow valve box and lid requirements as indicated on the drawings. 3) Plug cast iron with round port of no less than 100% of connecting pipe area and coated with Buna-N or Hycar, seats nickel, stem bearing self-lubricating stainless steel, stem seal multiple V-rings or V-cups of nitrile rubber, girt seals on stem. 4) Valve 3 – 4” with wrench lever manual operator, and valve 6 – 12” with totally enclosed, geared, manual operator with hand wheel, 2” nut, or chain wheel. 5) Manufacturers and Products: DeZuirk Series 100, Victaulic Vic-Plug, Pratt Ballcentric, Val-Matic Valve. 2. Check Valves: a. Ball Check Valve 2” through 36”. 1) The valve shall consist of three components: body, cover and ball (one moving part). 2) The design of the valve shall be such that it keeps solids, stringy material, grit, rags, etc., moving without the need for back flushing. In the operating mode, the ball shall not significantly impede flow through the valve and shall provide full flow equal to the nominal size of the valve. 3) The ball shall clear the water way, providing "full flow" equal to the nominal MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 14 size. It shall be non-clog. 4) There shall not be outside levers, weights, springs, dash pots or other accessories required for a swing (clapper type check valve). The ball shall be hollow steel with an exterior of nitrile rubber; it shall be resistant to grease, petroleum products, animal and vegetable fats, diluted concentrations of acids and alkalines (pH 4-10), tearing and abrasion. 5) The body and cover shall be of ductile iron, ASTM A536, Grade 65-45-12. Flange drilling shall be according to AISI B16.1 Class 125. F. Operators: 1. Manual Operator: a. General: 1) Operator force not to exceed 40 pounds under any operating condition, including initial breakaway, and gear reduction operator when force exceeds 40 pounds. 2) Operator self-locking type or equipped with self-locking device. 3) Position indicator on quarter-turn valves. 4) Worm and gear operators, one-piece design worm-gears of gear bronze material. Worm hardened alloy steel with thread ground and polished. Traveling nut type operators, threaded-steel reach rods with internally threaded bronze or ductile iron nut. b. Exposed Operator: 1) Galvanized and painted hand wheels. 2) Lever operators allowed on quarter-turn valves 8” and smaller. 3) Cranks on gear type operators. 4) Chain wheel operator with tiebacks, extension stem, floor stands, and other accessories to permit operation from normal operation level. 5) Valve handles to take a padlock and wheels or a chain and padlock. c. Buried Operator: 1) Buried service operators on valves larger than 2-1/2” shall have a 2” AWWA operating nut. Buried operators on valves 2” and smaller shall have cross handle for operation by forked key. Enclose moving parts of valve and operator in housing to prevent contact with the soil. 2) Design buried service operators for quarter-turn valves to withstand 450 foot-pounds of input torque at the FULLY OPEN or FULLY CLOSED positions, grease packed and gasketed to withstand a submersion in water to 10 psi. 3) Buried valves shall have extension stems, bonnets, and valve boxes. G. Accessories 1. T-Handled Operating Wrench: a. 2 each galvanized operating wrenches, 4 feet long. b. Manufacturers and Products: 1) Mueller No. A24610 2) Clow No. F-2520 c. 2 each galvanized operating keys for cross-handled valves. d. Extension Bonnet for Valve Operator: 1) Complete with stem and accessories for valve and operator. e. Manufacturers and Products: 1) Metallic Valves 2) Pratt 3) Allis-Chalmers 4) Plastic Valves 5) ASAHI/America MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 15 2. Floor Stand and Extension Stem: a. Non-rising, indicating type. b. Complete with stem, coupling, hand wheel, stem guide brackets, and yoke attachment. c. Stem Guide: Space such that stem UR ratio does not exceed 200. d. Anchor Bolts: Type 304 Stainless Steel e. Manufacturers and Products: 1) Neenah Foundry R 7506 2) Clow No. F5690 3. Chain Wheel and Guide: a. Hand wheel, direct-mount type. b. Complete with chain. c. Galvanized or cadmium-plated. d. Manufacturers and Products: 1) Clow Figure F-5680 2) Walworth Co. Figure 804 3) DeZurik Corp. Series W or LWG 4. Cast Iron Valve Box: a. Design for traffic loads, sliding type, with minimum of 6” ID shaft. b. Box: Cast iron with minimum depth of 9” c. Lid: Cast iron, minimum depth 3”, marked for the appropriate service. d. Extensions: Cast iron. PART 3 - EXECUTION 3.1 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. B. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. C. Protection of Equipment: Equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. 3.2 EXAMINATION A. Examine substrates and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance. B. Examine roughing-in of stormwater piping systems to verify actual locations of piping connections before storm sewer lift station installation. C. Proceed with installation only after unsatisfactory conditions have been corrected. 3.3 EARTH MOVING A. Refer to Division 31 Earthwork for excavating, trenching, and backfilling. B. Exploratory Excavation: It shall be the Contractor’s responsibility to excavate and locate all MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 16 existing utilities which may affect construction of the storm sewer facilities. All exploratory excavations shall occur far enough in advance to permit any necessary relocation to be made with minimum delay and to verify existing vertical and horizontal location to determine alignment for the proposed force main. All costs incurred by the Contractor in making exploratory excavation shall be considered to be included in the unit price bid for constructing the lift station, force main, or the associated structures. C. Unstable Trench Bottom: Where trench does not have sufficient strength to support pipe and bedding, or stream crossing are encountered, use one of the following methods to repair trench bottom as approved by Engineer. A minimum depth of repair is 2 feet. 1. Embankment: Clear and strip existing surface of all unacceptable material. Place embankment material as discussed and agreed to in writing by Engineer, compact to 95% AASHTO T99. 2. Aggregate Trench Bottom, percent by weight passing square mesh sieves: 1-1/2”, 90- 100; ¾”, 50-90; No. 4, 30-50; No. 200, 3-12. 3.4 INSTALLATION A. Install storm sewer lift station components where indicated, according to specific equipment and piping arrangement indicated. B. Install control panel and materials as detailed in the manufacturer’s installation manual and as detailed on the project drawing set. C. Coordinate layout and installation of control panel with other construction including conduit, piping, equipment, and adjacent surface. Maintain required workspace clearances and operational clearances, i.e. heat dissipation, for equipment and its access doors and panels. D. Coordinate features, accessories, and functions of each control panel component and characteristics of supply circuit, motor, required control sequence, and duty cycle of motor and load. E. All power wiring shall be installed by the electrical contractor. F. Install electromagnetic flow meter according to the manufacturer’s recommendations. G. Valve Flange Ends: 1. Flanged valve bolt holes shall straddle vertical centerline of pipe. 2. Clean flanged faces, insert gasket and bolts, and tighten nuts progressively and uniformly. H. Valve Orientation: 1. Install operating stem vertical when valve is installed in horizontal runs of pipe having centerline elevation 4’ – 6” or less above finished floor, unless otherwise shown. 2. Install operating stem horizontal in horizontal runs of pipe having centerline elevations between 4’ – 6” and 6’ – 9” above finish floor, unless otherwise shown. 3. If no plug valve seat position is shown, locate as follows: a. Horizontal Flow: The flow shall produce an “unseating” pressure, and the plug shall open into the top half of valve. b. Vertical Flow: Install seat in the highest portion of the valve. 4. Locate valve to provide accessibility for control and maintenance. Install access doors in MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 17 finished walls and plaster ceilings for valve access. I. Extension Stem for Valve Operator: Where the depth of the valve is such that its centerline is more than 3 feet below grade, exclude valves located within an accessible vault. Furnish an operating extension stem with 2” operating nut to bring the operating nut to a point 6” below the surface of the ground and/or box cover. 3.5 CONNECTIONS A. Coordinate piping installations and specialty arrangement with schematics on Drawings and with requirements specified. B. Ground equipment according to Division 26 Specifications. C. Connect wiring according to Division 26 Specifications. 3.6 PIPING APPLICATIONS A. General: Use pipe, fittings, and joining methods for piping systems according to the following applications. B. Transition coupling and special fittings with pressure rating at least equal to piping pressure rating may be used in application below, unless otherwise indicated. C. Do not use flanges, unions, or keyed coupling for underground piping, excluding those located within an accessible vault. D. Flanges, unions, keyed couplings, and special fittings may be used, instead of joints indicated, on aboveground piping and piping in vaults. 3.7 IDENTIFICATION A. Install identifying labels permanently attached to equipment. B. Label circuit breakers on panel. C. Install continuous underground detectable warning tape and tracer wire during backfilling of trench or horizontal directional drilling for underground storm sewer force main. Locate warning tape below finished grade, directly over piping. Tape tracer wire directly to the pipe. See Division 31 Earthwork for underground warning tapes and tracer wire. 3.8 FIELD QUALITY CONTROL A. Testing Agency: Contractor may utilize a Manufacturer’s Representative or a qualified testing agency to perform field tests and inspections and prepare test reports. B. Contractor shall notify Engineer and Owner’s Representative a minimum of 48 hours before conducting any testing. C. Manufacturer’s Field Service: Engage a factory-authorized service representative to inspect, test, and adjust components, assemblies, and equipment installations, including connections. Report results in writing. All hydraulic, mechanical, and electrical tests shall be run to ensure the proper installation, operation and maintenance of the pumps. The pump manufacturer’s representative shall include in bid at minimum one (1) days start-up field service for the purpose MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 18 of supervising pump start-up and instruction of proper pump operation and maintenance. D. Control Panel Acceptance Testing: Upon completion of physical installation, the contractor shall configure and start up the lift station using the provided control panel, if certified by the manufacturer to perform the start-up service. The contractor shall perform all necessary configuration, calibration, and perform a test of all required operation check to ensure that the control panel is function in full accordance with these specifications. This service and any replacement costs or additional labor as a result of these services shall be provided at no additional cost to Owner and shall be considered in the unit pricing of the bid. E. Tests and Inspections: 1. All factory testing shall be in accordance with the standards of the Hydraulic Institute, ANSI/HI 11.6:2012, 3B. All testing is to be performed at the pump manufacturer’s facility. 2. After installing storm sewer lift station and after electrical circuitry has been energized, test for compliance with requirements. Contractor shall furnish water required for pump tests. 3. Hydrostatic Test: After installation, fill wet-well and emergency overflow vault with water, hold for a minimum of 90 minutes, and test for leaks. Repair leaks and retest until no leaks exist. 4. Operational Test: After electrical circuitry has been energized, start units to confirm proper rotation and unit operation. During the tests, observation shall be made of head, capacity, and motor input to detect any defects in the equipment. Observe and confirm design flow rate with each pump running individually and both pumps running together. All defects or defective equipment revealed by or noted during the test shall be corrected or replaced promptly at the expense of the Contractor, and if necessary, the test shall be repeated until satisfactory results are obtained. In case the Contractor is unable to demonstrate to the satisfaction of the Owner that the units will satisfactorily perform the service required and that they will operate free from vibration and heating, the unit may be rejected. The Contractor shall then remove and replace the equipment at no additional expense to the Owner. 5. Hydrostatic Testing HDPE Pipe: a. Hydrostatic testing shall be performed in accordance with ASTM F2164-13, Standard Practice for Field Leak Testing of Polyethylene Pipe. b. Hydrostatic leak testing may be conducted on the full system or in sections. The test liquid shall be potable water. c. Maximum permissible test pressure is measured at the lowest elevation in the test section. d. Maximum permissible test pressure is the lower of: 1) 150% of the system design operating pressure provided that all components in the test section are rated for the test pressure, or 2) The pressure rating of the lowest pressure rated component in the test section. e. Test pressure must be reduced in elevated temperatures (above 90° F) as per manufacturer’s recommendations. f. Gradually pressurize the test section to test pressure of 150% of the system design pressure and maintain test pressure for three (3) hours during initial expansion phase while PE pipe expands. g. Test Method: Immediately following the initial expansion phase, reduce test pressure by 10 psi, and stop adding test liquid. If test pressure remains steady (with 5% of the target value) for one (1) hour, no leakage is indicated. h. Prepare reports of testing activities and submit to Engineer and Owner’s Representative within three (3) days of completion of testing. 6. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. MONTAVA Basis of Design Report April 11, 2023 STORMWATER UTILITY PUMPING STATIONS, FORCE MAINS AND APPURTENENCES 334413 - 19 7. Valves may be either tested while testing pipelines or as a separate step. 8. Test to confirm that valves open and close smoothly with operating pressure on one side and atmospheric pressure on the other, in both directions for two-way valve applications. 9. Inspect combination air valves as pipe is being filled to verify venting and seating is fully functional. 10. Count and record number of turns to open and close valve. Account for any discrepancies with Manufacturer’s data. F. Remove and replace any components that do not pass tests and inspections, and retest as specified above. 3.9 SERVICE FACILITY An authorized factory maintenance and parts facility shall be located within a 45-mile radius of the pumping installation. This facility shall routinely stock complete sets of spare parts (wear ring, upper mechanical seal, lower mechanical seal, upper bearing, lower bearing, 50 feet of power cable, O- rings, terminal board) for each size of pump supplied for this project. No exception will be allowed. The service facility shall have at least two qualified and nationally recognized testing agency (U.L. or F.M.) certified mechanics to service these pumps. 3.10 WARRANTY A. Pumps shall be warranted for a period of 2 years from defects in material and/or workmanship in accordance with the manufacturer’s normal warranty statement. END OF SECTION 33 4413