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HomeMy WebLinkAboutDesign Report LK McLean Associates Recvd 3-12-19 Design Report Vineyard View Southold, NY Sanitary Sewage Pumping Station and Force Main Project W Ix W W W z W z v c c �' JW rock �� 3: Y = W LL conifer zW 3 4��� zco Q tai �a N (: � m D v Ix Q co Qo � � Lo Q� a c4ay as L.K. McLean Associates, P.C�, ° ° ° 0 < W Z LUL zmOJ 00 .° ° Vw m0� O� ~ W0 I[itt A . February 22, 2019 z r4� Vineyard View—Greenport, NY Sewer System Solution Design 1. Description L.K. McLean Associates (LKMA)has been retained by Conifer Reality to prepare a design report for the sanitary infrastructure including a gravity collection system, pumping station, and force main. 2. Site The proposed site for development is the annexation by the Village of Greenport of a 17.2 acre parcel currently located in the Town of Southold adjacent to the northwest border of the Village. The scope of the project consists of developing approximately 7.5 acres of the 17.2 acre site, and preserving close to 4 acres of natural wetlands. The general nature of the project will be to construct a 50-unit affordable housing development modelled after a village square, with community building, communal play& recreation areas, and on-site parking lot while retaining the parcel's characteristic freshwater wetlands and open space. The site is close to the Village of Greenport Sewer District and will be a Sewer District Contractee. marl Park Greenport, BridgeporE 40 Fairfield NY Marwalk io a crhead Z' Hampton Bays naoHa Commack _ rsa Mwwv�ArTM Hicksville Via+ Long Island x ey wcu.s Bay S4xe New York Hempstead rxownrM � Gie°t�U•. Fire Island Lj Figure 1: Location of Village of Greenport on Long Island in Suffolk County, New York Vineyard View—Greenport, NY o - 1 Village of Greenport Water Pollution Control Gravity Line Plant Pumping ' Station 25 Vineyard Force main View Site Force main a Figure 2: Location of Vineyard View Site in relation to Village of Greenport Water Pollution Control Plant 3. Pumping Station The proposed pumping station for the site will be located in the southwest corner of the site and will pump through a force main to the gravity line on CR-48. Entrance to the sanitary pump station manhole will be available through access hatches within the sanitary sewer pumping station(SSPS) limits. Two (2) access hatches will be placed over the wet well with a ladder to allow access to the integral valve vault. Plan drawings of the SSPS are illustrated in Appendix C. Vineyard View—Greenport, NY 4. Wet Well The wet well will be located below grade level and is sized to provide adequate storage of sanitary sewage between pump starts. The surface area of the wet well measures 52.26 ft2 where the area inside one lift is 39.63 ft2 ±and the area of the concrete wall is 12.63 ft2�. This area is adequate to accommodate two (2) submersible alternating duty pumps. According to the Suffolk County Department of Health, the minimum cycle time for pumps is recommended to be between 15 and 30 minutes, or 2 to 4 starts per hour. We will be using a pump cycle time of 22.5 minutes for our location in order to size our wet well appropriately. The depth of sewage in the wet well is 4'-8"±while the finished floor of the wet well is 16.83 ft. below the final grade of the pumping station (as shown in drawings in Appendix Q. Calculations of the wet well volume and operating depths are presented in the design calculations section(Appendix B). 5. Pumps The proposed pumping station will house two (2) submersible wastewater grinder pumps. These pumps are being utilized due to their small size, relatively low cost, and they require little maintenance. The pumps have been sized to meet a peak flow of 42.5 gal/min at a total dynamic head (TDH) of 20.80 feet station(as shown in drawings in Appendix B). One of the pumps will be equipped with a flush valve. Pump performance curves and dimensional drawings are presented in Appendix D. 6. Piping The wet well piping will use 2"o stainless steel schedule 80 discharge pipe and the force main after the wet well will use 2"o DR-11 HDPE. Clean out manholes with ball valves are to be installed periodically throughout the system at distances no greater than 400 feet, as well as at all bends of 45 degrees or greater. Air release manholes are to be installed to remove entrapped air at every high point in the system. Drain manholes are to be installed at every low point in the system. A mixed flush valve is to be installed near the wet well to avoid stagnation in the wet well. Thrust blocks will be placed at every bend to prevent damage due to thrust produced in pipe by fluid velocity and internal pressure. Vineyard View—Greenport, NY At the receiving manhole where the force main ends, a standard weight 8" in diameter SDR-18 PVC gravity line exists which carries flow to a pump station which pumps directly to the Waste Water Treatment Plant. 7. Main Power Supply A 3-phase main power supply will be used. The main switchboard will direct power to operate the pumps, pump controls, lighting, and other electrical equipment. The electrical service will be configured in 208 V grounded Wye. A surge suppressor will be attached to the main breaker panel to prevent overload protection. Large loads such as the pumps will be supplied with 3-phase power from the distribution panel via the Pump Control Panel. All other loads will be supplied via this panel. 8. Emergency Operation If, for some reason, the main power supply should fail, emergency power will be provided by a standby natural gas generator. The generator will have a direct feed to an incoming, metered natural gas line, which will supply as much fuel as necessary. There will be an automatic transfer switch installed that will monitor the status of normal power supply. In the event of a power failure, the natural gas generator will start automatically and will operate both pumps, lighting and KMN04 feed pump & heater. 9. Instrumentation Control MultiTrode MultiSmart Pump Station Manager controller Appendix A Flow Estimation Vineyard View—Greenport, NY Appendix A: Flow Estimation Design Flow Rate 36 Two-Bedroom Units at 225 gpd/unit = 8,100 gpd 14 Three-Bedroom Units at 300 gpd/unit = 4,200 gpd 2,466 Non-medical office space at 0.06 gpd/sf = 148 gpd Total Sanitary Flow = 12,448 gpd Design Sanitary Flow = 12,500 gpd (rounded) 8.68 gpm Population 12,500 gpd-75 gpd/capita — 167 capita p = 167 capita- 1,000 — 0.17 Peak Flow Rate Peak Flow Rate Factor=PF = 1 + [14/ (4+p^0.5)] — 4.18 4.18 x 12,500 gpd — 52,250 gpd — 37 gpm Appendix B Process Design and Pump Selection Vineyard View—Greenport, NY Appendix B: Process Design and Pump Selection Wet Well Sizing The wet well must be of enough size to provide adequate storage of sewage between pump starts. Suffolk County Department of Health recommends minimum cycle times between 15 and 30 minutes. The equation used to determine working flow is as follows: V=TQ 4 Where, V=Working volume between pump starts, gal T=Pump cycle time =22.5 min Q =Pump flow rate, gal/min We have two pumps available for use, but since the pumps alternate, we will use one pump and we will use the total peak flow in this equation which has been derived using the assumption that the minimum cycle time occurs when inflow is one half of the pump flow rate. Therefore, the operating volume is: TQ (22.5 min) x (42.5 gal/min)x(0.134 ft3/gal) V = 4 = 4 = 32.03ft3 The wet well has an inside surface area of 39.63 ft2. Therefore, the operating depth (H), or the height between each pump start and stop is equal to: V 32.03ft.3 H=-- 81 ft. A 39.63 ft.2 An operating depth of 12 in. will be used. Therefore, the pump will start and stop within 12 in. making the pump cycle time approximately 27.8 minutes. There will also be a buffer distance of 0.5 ft. between the starting elevations of the pump as explained in the following sections. Operating Levels The maximum sewage elevation in the wet well is set at the invert elevation of the incoming sewer(11.67 ft.). The minimum elevation of water in the wet well is at 5.93 ft., which is 5.74 ft. below the inlet sewer. This depth will be adequate to accommodate the operation of the pump. Operating levels are set as shown in Table B I. Vineyard View—Greenport, NY Table B1 — Operating Levels in the Wet Well Elevation (ft) Operation 22.76 Top of Wet Well Slab 11.67 8"o Influent Sewer Invert 10.67 Redundant High High Water Alarm(Float) 10.17 High Water Alarm 9.67 Lag Pump On Sensor 9.17 Lead Pump On Sensor 8.50 Pumps Off 8.00 Backup Off Level (Float) 7.50 Low Level Alarm 5.43 Finished Floor of Wet Well 4.76 Bottom Of Wet Well Slab Head Loss Calculations In wastewater applications, centrifugal pumps are typically used due to their unique design, which allows solid particles in sewage to pass through, as well as reducing clogging. Our sanitary sewer pumping station (SSPS)will feature two such pumps (one duty/lead pump and one standby/lag pump). Each of these pumps is sized to handle peak flows individually, as well as handling flows during normal operating conditions. The advantage of having a standby/lag pump is to provide a back-up option if the duty/lead pump were to encounter a problem or malfunction. The back-up pump also allows for servicing to occur without halting operation of the pumping station. Design Parameters The discharge flow rate is set at 42.5 gal/min. This is based on meeting minimum flow velocity in the force main. In addition to the flow rate, the total dynamic head(TDH) is required to size an appropriate pump for our system. TDH consists of the static head and the head due to friction losses in our system. Static head is equal to the vertical difference in elevation between the pumps off elevation in our wet well and the discharge point elevation. Friction losses consist of velocity head and losses due to pipes, valves, and other fittings. Each type of pipe used in a system has a specific friction factor associated with it, depending on the material. In our system, we will be using 2"o DR-I I HDPE with a standard dimension ratio Vineyard View—Greenport, NY of 11. The Hazen-Williams equation, along with the corresponding friction coefficients, is commonly used to calculate head losses in a system. Static Elevation The following elevations were determined using provided survey data: • Ground elevation at the proposed site for pumping station is 22.26 ft. • Highest point of the force main is 31.00 ft. • Elevation at the discharge manhole is 31.00 ft. • Lowest"Pump's Off' elevation (LWL) in the wet well is 8.50 ft. • Invert elevation of the inlet sewer to the wet well is 11.67 ft. We must first determine the static portion of the TDH for the system. To do this, we must look at the two ends of the system that are exposed to atmospheric pressure. These locations correspond to the low water level in the pumping station wet well and the discharge manhole where the force main feeds into the gravity main. The inlet sewer is 3.17 ft. above the low water level (LWL). The LWL is the minimum wet well elevation level where the pump shuts off. Another value, which we will consider when analyzing our pump and system curves is that corresponding to the difference in elevation between the LWL in the pumping station wet well and the highest point in the force main(31.00 ft.). This conservative number is equal to: 31.00— 8.50 =22.5 ft. Hence, the maximum static head is 22.5 ft In summary, our design flow is 42.5 gal/min and the static head is 22.5 ft. Head Losses in Pipe Since our system is entirely new, we need not consider any existing conditions or piping. As stated previously, our system will consist of a 2" (nominal) HDPE pipe. The piping will start at our pumping station and run through the site where it will eventually be discharged to an existing sanitary manhole on North Road(CR-48). This new piping is considered smooth and has a high C-value (Hazen-Williams Coefficient). However, for design purposes, we will be using C = 140 for polyethylene pipe. Head loss for the piping was calculated in feet per foot of length according to the Hazen- Williams formula in U.S. Customary units: Q 11.85 hf=L(0. 432CD2.631 Where, hf Friction head loss in pipe [ft] Q =Volumetric flow rate [ft3/s] Vineyard View—Greenport, NY C =Hazen-Williams friction coefficient [unitless] D =Internal pipe diameter [ft] Consider the new 2" o DR-I1 HDPE force main, the friction losses are as follows: 0.089 cfs hf=(1,045 ft) (0.432(140)(0.16 263)i.s5=(1,045 ft)(0.042928)= 44.86 ft. ft) Head Losses due to Valves and Fittings Friction head losses also occur in valves and fittings throughout the system. These losses are calculated using the following equation: V2 hm=K 2 9 Where, h,,, Friction head loss in pipe due to valve or fitting [ft] v=Fluid velocity [ft/s] *See Calculation Below* K=Valve/fitting resistance coefficient [unitless] g= Gravitational acceleration constant [32.17 ft/s2] Q=v A, Therefore v=Q = (0.020ft2) 0.095 ds =4.75 ft/sec A Where, A Area of HDPE pipe with inside diameter at 1.92" [ft] Although manufacturer's data is preferred, we will be using estimates for the K-values for various fittings and valves. In order to calculate total losses due to these components, we will first need to inventory those being used and determine the losses for each separate component. In order to calculate head loss due to valves and fittings, we have a fluid velocity of 4.75 fps (feet per second), which is the discharge velocity in the force main. Vineyard View—Greenport, NY Item K-Value Unit Head Loss ft Qty Total Head Loss ft Ball Valve 0.05 0.018 14 0.245 Check Valve 1.7 0.596 2 1.192 Gate Valve 0.14 0.049 1 0.049 Plug Valve 0.31 0.109 2 0.217 45° Elbow 0.27 0.095 19 1.799 Total 3.50 Calculations Summary Head Loss (ft) Head Loss, HDPE Force Main 44.86 Fittings and Valves 3.50 Static Head(at LWL) 22.5 Total Dynamic Head 70.86 Appendix C Design Drawings Appendix D Pump Performance Curve, Controls, Equipment, Specifications and Dimensional Drawing 192 REF.LINE 188 (TO FURTHEST POINT) ot2 o Ln 9 516 128 REF.LINE A g4 3" 7 8 I 3/4" GUIDE BARS 2-11/2 NPT V MIN LEVEL Loll ❑ 3 ❑ �N 4 REF.LINE 14 N U Cn 4� BOLT 12(4x) 0Weight (Lbs) VIEW ❑Z — ❑Z Pump Discharge DIMENSION TO ENDS OF GUIDE BARS 120 16 Denomination D�°wn w byeckedW Dote 141201 Dimensional drwg 5c°ie JR ,g MP 3085 1: 1 egn°5399 DRAWING 2" NPT 5384700 9 l � em MP 3085 HT 3- 258 FLYGT Technical specification Head IN 96 92 88 i 84 so-- 72-- 2 722 64 52 48 4 ]Nor 36 32- 8 24Note:Picture night not correspond to the current configuration. 2 General 16 581 3mm Semi-open multi-channel impellers with integral grinder cutter in single 12 volute casing for liquids containing solids and fibres. 8 4 Impeller 0 5 to 15 20 25 30 35 ao a5 50 55 60 65[US g.p.m.] Impeller material Grey cast iron Discharge Flange Diameter 1 9/16 inch Suction Flange Diameter 1 9/16 inch Water,pule Came ISO Impeller diameter 133 mm Number of blades 6 Installation: P-Semi permanent,Wet M otor Motor# M3085.891 15-09-2AL-W 4hp FM Stator variant 12 Frequency 60 Hz Rated voltage 460 V a Number of poles 2 Phases 3- Rated power 4hp Rated current 5.1 A Starting current 30 A Rated speed 3415 rpm Power factor r 1/1 Load 0.91 3/4 Load 0.88 1/2 Load 0.81 Motor efficiency 1/1 Load 80.5% an 3/4 Load 82.5% 1/2 Load 82.5% m u ci4T Configuration o1 � T­ZZ Project Project ID Created by Created on Last update Vineyard View PS Peter Pastore 6/22/2018 6/22/2018 xylem MP 3085 HT 3~ 258 FLYGT Performance curve Pump Motor Discharge Flange Diameter 1 9/16 inch Motor# M3085.891 15-09-2AL-W4hp Power factor Suction Flange Diameter 40 mm 1/1 Load 0.91 Impeller diameter 51/4' Statorva6ant 12 3/4 Load 0.88 Number of blades 6 Frequency 60 Hz 1/2 Load 0.81 Rated voltage 460 V Number of poles 2 Motor efficiency Phases 3– 1/1 Load 80.5% Rated power 4 hp 3/4 Load 82.5% Rated current 5.1 A 1/2 Load 82.5% Starting current 30 A Rated speed 3415 rpm [ft] Head 59085 95- 90- 85 80 75- 70- - 70.3 ft 65 2 00 60 55 50- 45- 40 35- 30- 25 20 15 58 133mm- 10- 5- 0- 33mm1050 Pump Efficiency 28.9% [%] Overall Efficiency 24 20 24% 16 12 8mm 0 aBmm 4 [hpi Power input P1 8 133mm 3.16 hp 3.0 Shaft power P2 8 133mm(P2) 2.5 2.62 hp 2.0- 1.5- 1.0 .01.51.0 0.5 0.0 42.5 US g.p.m. 0 5 10 15 20 25 30 35 40 45 50 55 60 65 [US g.p.m.] Water are Curve ISO 0 Duty pint 10 15 G.Antee 25 30 35 40 45 50 55 60 65 [US g.p.m.] Flow Head 37 US g.p.m. 57.7 ft No Project Project ID Created by Created on Last update Vineyard View PS Peter Pastore 6/22/2018 6/22/2018 xylem MP 3085 HT 3- 258 FX- GT Duty Analysis Head 1 IN- 96- 92 ft]9692 88480 88- 84- 80 76 72- 70. ft 68 2 00 46056 64- 60- 56 52- 48- 44- 40- 36 248444036 32 28 42016 24- 20- 16- L58133mm 12 8 4 0 42.5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 [US g.p.m.] Water,we Curve ISO Curve issue 8 Individual pump Total Pumps running Specific /System Flow Head Shaft power Flow Head Shaft power Pump eff. energy NPSHre 1 42.5 US g.p.m 70.3 ft 2.62 hp 42.5 US g.p.m. 70.3 ft 2.62 hp 28.9% 923kWWUSMG Project Project ID Created by Created on Last update Vineyard View PS Peter Pastore 6/22/2018 6/22/2018 xylem MP 3085 HT 3^' 258 FLYGT Dimensional drawing 1� BEELINE 18 goRm EST Patin o 01 �i 1 F€ LINE 7 7 34' cuoEBARs 2-11 NK o MN LEVEL c fb 3 ❑Z N� 4 FEFUNE 4 x o ' BaT 12(4x) d VIEW 1Z-Z ❑ * DNE1NSCNTOENDBCFa,1D=BA;6 ��� 1W '—w 141201 AUrCCA1) fVPM m° 1:1 ""5399 DRAWING 2'NPT 5381700 9 Project Project ID Created by Created on Last update Vineyard View PS Peter Pastore 6/22/2018 6/22/2018 Oldcastle Precast' PLANNER low- `' h I • e MW Cn CL .r� I r `�`�•tir � ti O i S ETurn-key package or with pre-assembled components including pumps, piping, wiring, and controls _ x Rounded Corner PumpStations with ti Integral ti Product Overview&Advantages ' Advantages to Selecting an Oldcastle Precast Concrete Pump Station Table of The Oldcastle Precast Advantage...................................................... 1 Contents Pump Station Planning 11M Pump Station Layout& Critical Elevations ......................................... 4 CoverLoading .................................................................................... 5 System Design Flows and Site Power ............................................... 5 Station Plan View Dimensions and Station Capacities ...................... 5 Section 3—Components Information &Options Structural Design and Anti-floatation .................................................. 6 Stock& Optional Structural Components ........................................... 7 Joint Treatment/Concrete Additives/Waterproofing ......................... 7 Pipe Penetrations ............................................................................... 8 Access Equipment (hatches and ladders) .......................................... 8 Discharge Piping Size, Supports & Hardware .................................... 9 Discharge Bypass Option ................................................................... 9 Pump Guide Rail Assembly ................................................................ 10 Discharge Gauge Option .................................................................... 10 Standard Valve Details & Options ........................................................ 10 DI Piping/ Fittings Details & Options ........................................................ 11 Wet Well Venting and Options ............................................................ 11 Junction Boxes & Control Panel Placement Options .......................... 11 Level Control Devices and Options .......................................................... 12 Aluminum Trash Basket Option .......................................................... 13 Portable Hoisting Equipment Option .................................................. 14 SectionProduct Transportation/Off-loading/Site Access ............................................ 15 Section 5—The Planner Worksheets Contact and Project Information ......................................................... 16 Pump Station Design and Option Selection Form .............................. 17 Product Overview&Advantages Product Overview The RC509/611 pump station product is designed as a "stockable"structure with a unique oval shape and integral valve vault. It offers standard mechanical equipment, select options, and repeatable design. This product design has proven to be a cost-effective method of providing a high-quality product to the customer with rapid and reliable delivery. ,I I Advantages The RC509/611 pump station, with integral valve vault, is designed and produced specifically to provide the following advantages: • Single structure, with integral valve vault. o Valve vault cast within the structure; in normally unused area. °• ': o Single structure means no differential settlement. o Small footprint for tight sites. • Standard and stockable structural sections; base, shims, valve vault and covers. o Available as standard stock for quick delivery. • Standard structural design (PE stamped), with standard components. o Speedy budget estimates and quotations. o Fast and accurate submittals. : . • Select options to meet a majority of your project needs- see listings to follow in this brochure. • Factory pre-assembled. o All piping, valves, accessories and options are pre- assembled in our factory to ensure all piping, valves, accessories, and options are alignment and fit. Only — vertical piping that crosses precast joints is removed X-PR09F )- E WAL `X PROOF for shipment. 10.5 ELEv 1 1.-G" • Quick site installation and cost savings. 0I PVC VENT 4"BYPASS o One small excavation to a single structural base 4' (FIXED HEIGHT) elevation. o Because of the factory pre-assembly, most INLET-LOCATION 8" 2'-0" structural installations are performed in AS REGURED� (FIXED HEIGHT) only a couple of hours. MIN. F OOR DRAIN (PoTHWT gHIllq SEDTIDNS} 22'-10'MAX 4 HEI o Minimizes excavation open time and costly c IN SHIM SECTIONS) (FIXEDEIGH) de-watering. HHWA(FLOAT, • Proven quality and repeatable design. HIGH WATELIMP AARN LAG PUNP ON 55T GUIDE RAILS (FIXED HEIGHT) o Ready for your project without the need for design LEAD PDA1P ON or re-design. JU311 o Rapid project cycle. BACKUP)CFF p p Y BACKUP CFF FVEI(FLOAT ' (FIXED HEIGHT) o Consistent high level of quality derived from r INY.STRUCT.ELEV. repeatable production. B.D.S.ELEV. E. CPT: iRAN$CUCER • Comparable cost to the conventional 2-structure custom IRreR1oR acavArrov vlsr AE508 x i0'_10^to PS'-f0^ designed and built stations. Product Overview&Advantages 2 Budget Savings Proven Design Means Project Cost Savings When You Oldcastle Precast has designed and refined this Select An standard "stockable" pump station product, with _ integral valve vault, since 2006. We provide a quality pump station solution that is well Oldcastle accepted as a turn-key component for government, municipal, and private projects.. Oldcastle Precast's Precast standard pump station vault has proven to save on design/engineering costs, product submittal/approval Concrete costs, site installation time/costs, as well as product purchase costs. Pump Eliminate Extras During On-site Station Construction Oldcastle Precast provides the RC509/611 package pump station pre-assembled from the factory, to eliminate costly site labor and time-consuming site alterations. The pump station is installed in a matter of hours and backfilling usually occurs the same day. When de-watering is a site issue, this costly and tedious operation can be ' You reduce the project schedule time line. considerably lessened because the excavation open time is reduced. •You prevent scheduling conflicts. •You save cost on product and Site Safety installation. The rapid installation of the pre-assembled RC509/611 package pump station 'You receive a proven quality product also reduces the risk of on site injury by minimizing the amount of time that -You save space on your project site. the hazardous excavation is open, which in most cases is a fraction of a day. •You reduce the time of open In addition, the interior pre-assembled components package eliminates most of the excavation and de-watering. confined space structure entry that would come from site-constructed products. 'You receive turn-key system responsibility. Schedule Savings • You can count on the quality and g reputation of Oldcastle Precast. The RC509/611 standard pump station product is designed to save schedule time as follows: • standard budget and quote pricing, • standard drawings and cut sheets, • "stockable" structural and mechanical components, and • quicker manufacturing assembly due to product repetition. This Oldcastle Precast product model has proven to save significant scheduling time on projects compared to conventional custom pump stations. In most cases weeks or even months can be saved. Site Constraints and Excavation Savings The RC509/611 pump station has an inherently smaller footprint when tight-site conditions are encountered. The unique single structure design also eliminates added costs for larger and step-elevation excavations. Product Overview&Advantages Turnkey Solution Oldcastle Precast is long-known for its Turnkey solution products. This standard pump station is no exception. When the RC509/611 station is required on your project, you can rest assured that the pump station will be supplied with all of the equipment and services that you have come to depend on from Oldcastle Precast. Industry leading engineering, design assistance, budgeting, factory assembly, site services and product warranty are all part of our turnkey solution. Oldcastle Precast's reputation and company values have been built on a strong foundation, and they will be there for you in the future. Product Warranty Warranty on all components is Standard 1-year warranty from site start-up or 15-months from factory completion, whichever occurs first. Add the Value of Oldcastle Precast Safe and Sure Delivery For over 60 years, Oldcastle Precast To ensure that your Pump Station arrives on schedule, our transportation has provided first-quality, high-per- department carefully reviews each state's weight and dimensional restrictions, formance, cost-effective products along with permit requirements. Each Pump Station also includes and service to the water and waste- cast-in-place lifting points to facilitate off-loading and positioning. water industry. When you choose Oldcastle Precast you can be sure of continuous, dependable service from a global leader. t E a A ---- Oldcastle Precast Pump Station Planner (888) 965-3227 Layout The RC509/611 pump station is very versatile when it comes to inlet and discharge layout. I The inlet(s) can enter the station anywhere around the perimeter of the station. Cored openings, with manhole boots, are typically factory located and Planning installed, unless,the opening spans or opening becomes critically close to the structural joints; in such a case, site coring after erection is required by the site contractor. Your The common discharge location from the valve vault can be selected in: Position#1, #2 or#3. DISCHARGE POSITION #1 Oldcastle Precast INLET-LOCATION ? PumpAS REQUIRED Station :=; O •�• DISCHARGE POSITION #2 O DISCHARGE POSITION #3 Elevations Critical pump station elevations are "Top of Structure" (TOS), grade elevation, inlet invert elevation, floor elevation of structure and discharge elevation. T.O.S ELEV. , GRADE ELEV. TOS is usually set at grade elevation or at least 6" above grade elevation. When TOS is set at grade elevation, the H2O structural loading and hatches w� 1 should be strongly considered, especially if accidental vehicle wheel loading can be foreseen. Typically, when the TOS is set 6" above grade, 300# pedestrian structural loading and hatches are utilized. DISCH. ELEV. qRT The inlet invert elevation is always site-dependent, where elevation is determined with a minimum slope to the pipe for gravity drainage, to the point where it intersects and drains into the pump station. The station inlet is the most critical and determining portion of this process. Elevation above the inlet is considered unusable space. Portions of the station space below the inlet invert are considered to be the "working volume" of the station and, as such, sets the minimum depth of the station. INLET LOCATION AS REQUIRED Floor elevation for the RC509/611 pump station and the station's total eventual INLET INV. ELEV.2�:__ height is determined by the lowest inlet invert elevation, the systems reserve and working volume, and the TOS. Once the inlet invert, reserve andQ HW ALARM working volume is determined, based on volume/ft. values for LEAD PUMP ON the RC509/611, a minimum floor elevation of the pump station can be calculated. �w Z� Compare the distance from the calculated minimum floor elevation to00 3> the TOS, evaluate this distance against the standard heights provided I PUMP(S) OFF with the RC509/611 product line and increase that distance to the next closest available height (10'-10" to 22'-10" standard). The new floor FLOOR ELEV. elevation will be your TOS minus the standard pump station height selected. Discharge elevation from the RC509/611 is usually a minimum of 4' below grade, even when the TOS is set 6" above grade. Should deeper common discharge elevation be required, optional valve vault riser sections (2' & 4') can be added to produce additional earth cover. Optional valve vault riser sections are discussed in structural options. 5 Pump Station Planning Cover Loading It is important to consider hatch loading as it does affect the selection of the structural design for proper support. The pump station cover and hatch loading can be selected as: 300# pedestrian loading or H2O occasional vehicle loading. If the TOS is flush with grade, then H2O occasional vehicle loading should be strongly considered. System Design Flows & On-Site Power Availability Although this brochure does not go into detail about pump section and system controls, it will be important to convey the following information to assist in selecting the proper size station and components: • System design flow rate and TDH. o System design flow rate will determine the interior piping/valve size and force main size. • Available site power (voltage and phase). o This is critical information that is required for pump and control selection. Should you require assistance in sizing your pumps for the system, or determining system controls, please contact Oldcastle Precast or one of our local product distributors in your area. PLAN VIEW DIMENSIONS & STATION CAPACITIES 9.-0. 30"x48"HATCH SUBMERSIBLE WITH SAFETY GRATE 3D"x36" -4'-6 -4'-0" PUMPS OR HATCH DISCHARGE 10'-2" GRINDERS EM.COLLAR POSITION#1 INLET LOCATION Pr AS REQUIRED DISC ARG POSITION#2 O o 2'-D"RAD. DISCHARGE COVER VAULT SECTION POSITION#3 PUMP SECTION RC5O9 PLAN VIEWS 11'-D. INLET LOCATION 5'-9" 4'-9" 13'-10" 36"u 54"HATCH '30"x 35" AS REQUIRED DISCHARGE EXT.COLLAR WITH SAFETY GRATE HATCH POSITION#1 ' DISCHARGE POSITION#2 ] I O \ 2'-0"RAD. SUBMERSIBLE PUMPS OR DISCHARGE GRINDERS POSITION#3 COVER VAULT SECTION PUMP SECTION RC611 PLAN VIEWS Model Interior Interior Min/Max Wall Floor Roof Volume Standard DI Replaces Number Width Length Height** Thickness Thickness Thickness (gal/verticalfoot) Piping& * Conventional Pump (TO.S.to Floor) Discharge Size Stations RC509 5'-0" 9'-0" 101-10"/ '1 Y' 310 gal 4" 6'Diameter& 22'-10" 8'Diameter RC611 6'-0" 11'-0" 101_1011/ 9" or 8" 12" 466 gal 6" 8'Diameter& 22'-10" 10'Diameter *Consult factory for optional pipe size and material available. **Consult Factory for Additional Structure Height Oldcastle Precast Pump Station STRUCTURAL Standard Structural Design Requirements Product • Structural design calculations for the RC509/611 Pump Station with Integral Component Valve Vault will be prepared and stamped by a registered professional engineer in the project state, and will be submitted for approval prior to fabrication or for record purposes as project time allows. Information & • Precast concrete sections will conform to the latest requirements of ACI 350. • The structural design will take into account discontinuities in the structure Options produced by the openings. • The precast pump station with integral valve vault has been designed to support its own weight as well as the minimum superimposed loads tabulated below.All additional equipment will be accounted for in the design of the elements. o Pump Station with Integral Valve Vault. (i) Top Slab, Live Load —AAS HTO HS20, (ii) Floor Slab (valve vault& base), Live Load —200 psf, (iii) Exterior Walls. All exterior walls below finished grade shall be designed for an equivalent fluid pressure of 90 psf per foot of depth caused by saturated earth pressure. The top of the pressure diagram is assumed to originate at finished grade. In addition to the soil pressure, a 2'-0" Live Load Surcharge shall be applied to a depth of 8'-0". 300# Pedestrian or H2O Cover Loading As stated above; although all precast structural covers are designed for AASHTO HS20 Live Loading, hatches and subsequent hatch frame support must be selected for 300# loading or H2O occasional vehicle loading. Buoyancy Footing Sizing The structures have been designed to prevent flotation without requiring surface resistance or the weight of mechanical equipment,when the ground water level is at finished ground surface. The factor of safety against uplift calculated as a ratio of the total resisting force (excluding skin friction and the weight of the equipment)to the total hydrostatic uplift force, shall be at least 1.15. The net uplift force shall be transferred to the anti-buoyancy collar. Component In • • Optionsi Stock Structural Components (standards) COVER (STOCK) Oldcastle Precast has pre-designed and manufactured standard structural components for the RC509/611 product line. The station base, 2' & 4' riser shims, integral valve vault section, and 300#/H20 covers with hatches are all stock components that are inventoried at our facility for ultimate cost savings and reduction in product assembly time. The use of stock structural 2' OR 4' components reduces the time frame required for project submittals. VALVE VAULT RISER SECTION All stock structural components are designed and PE stamped for local (OPTIONAL) final installation. Optional Structural Components (non-stock) Oldcastle Precast offers the following non-stock optional structural components, VALVE VAULT when special circumstances require. The following components, when used in SECTION the package, may increase the product delivery time by 2 to 3 weeks. (STOCK) • 2' &4' Integral valve vault extensions • 3'Wet well shim Joint Treatment and Sealing 2' SHIM (STOCK) The precast components will be fabricated on steel forms, with machined rings to form accurate bell and spigot joint surfaces, to ensure water-tightness. All horizontal joints between precast sections will be sealed with a 3' SHIM vulcanized butyl rubber joint material conforming to AASHTO M-198. The (OPTIONAL) joint material will be "Conseal CS-102" as manufactured by Concrete Sealants. Optional Concrete Additives for Harsh Environments a' SHIM (STOCK) A Crystalline Waterproofing Additive can be supplied when selected as a product option. The system shall cause the concrete to become sealed against the penetration of liquids from any direction and will protect the concrete, surface to surface, from deterioration due to harsh environmental conditions. The Waterproofing Additive offered is Xypex Admix C-100, as manufactured by XYPEX Chemical Corporation, Richmond, B.C., Canada. BASE SECTION (STOCK) (Alternate product suppliers may be used at the manufacturers discretion) Optional Exterior Waterproofing Coating Although the RC509/611 pump station is warranted for water-tightness without exterior coatings or additives, Oldcastle Precast can offer the following damp proofing option (factory installed on all vertical below grade surfaces): Karnak#83AF Fibered Damp proofing asphalt compound,applied at the rate of 25 sf/gal. (Alternate product suppliers may be used at the manufacturers discretions) Oldcastle Precast Pump Station Component InformationOptions • Cored Opening with MH Boots for Pipe Penetrations All pipe penetrations, for the RC509/611 product line, utilize cored openings with flexible manhole boots and stainless strap anchors. Pipe penetrations include: inlet(s), discharge piping from pumps and common discharge, exiting the station and station venting. ACCESS EQUIPMENT Aluminum Access Hatches Pre-determined aluminum hatch sizes have been selected for the RC509/611 product line, and all precast covers with hatch embeds have been structurally designed for these sizes. The sizes have been selected for the maximum equipment expectations, and the factory should be consulted if any clearance questions arise. Hatch loading designations can be ordered for 300# pedestrian loading or H2O for occasional vehicle wheel loading. H2O aluminum hatches offered are not designed for continuous traffic loading. The hatches offered are equipped with the following features: • The wet well side of the pump station is equipped with an angle frame and skit to full precast cover height, tar coated where aluminum comes in contact with precast, slam lock and removable key operator, recessed padlock hasp, lift as- sist, and OSHA safety grate that is permanently attached to the hatchway inner frame, hinged and lockable. Wet well nominal hatch opening sizes are: 0 30"x 48" (RC509) 0 36"x 54" (RC611) • The valve vault side of the pump station is equipped with channel frame and skit to full precast cover height, tar coated where aluminum comes in contact with precast, slam lock and removable key operator, recessed padlock hasp and lift assist. The Valve Vault nominal hatch opening is as follows: 0 30"x 36" (RC509 & RC611) `.1 `�il�• y'.L r" � ��j4' wyY! A i � ., r tIY Aluminum Wall Mounted Valve Vault Access Ladder The valve vault access ladder supplied, with the RC509/611 product line, is aluminum, wall-mounted and is properly sized to meet OSHA Standard 1910.27. • Optional-An aluminum ladder-up,access-assist assembly can be supplied when selected. Component information & Optionsi DISCHARGE PIPING & RELATED OPTIONS Piping and Valves The RC509/611 product allows for a variety of piping, valve sizing and materials. The RC509 product can house piping and valve sizing up to 4 inches and the RC611 product can house piping valve sizing up to 6 inches. Piping, valve sizing and material varieties are as follows: 1 • 2" PVC piping &valves to 2" PVC common force main (FM) discharge. • 3" PVC piping & valves to 3" PVC common FM discharge. • 3" DI discharge piping and valves to 3" DI common FM discharge. • 4" DI discharge piping and valves to 4" DI common FM discharge. • 6" DI discharge piping and valves to 6" DI common FM discharge. (only for RC611) Galvanized Floor-Mounted Adjustable Pipe Supports in Valve Vault Adjustable, floor-mount, galvanized pipe stands are supplied with the RC509/611 product line and will support piping in the middle of the vault. Standard aluminum wall mount support brackets with stainless U-bolts are supplied in 3 locations where piping penetrations enter and exit the vault area. • Optional -Stainless floor mounted supports can be supplied when selected. Stainless Wet Well Pipe Supports Vertical discharge piping, from the pump base elbows, will be additionally supported to the wet well structure in intermediate locations utilizing stainless structural angles and stainless U-bolts where standard station heights exceed 15-10". Flange Gaskets and Stainless Hardware Oldcastle Precast utilizes Toruseal -- ribbed, full faced black rubber flange gaskets for a drip-tight pressurized flange seal. Toruseal gaskets meet the "specially designed" gasket designation found in AWWA sections C110, C11 and C15. All flange bolting hard- ware throughout the pump station and valve vault shall be supplied 18-8 stainless steel. Bypass Piping and Valve Options The bypass piping and valve option can be utilized when it is foreseeable that both pump station submersible pumps may be out of commission at the same time and temporary portable bypass piping equipment would be employed to collect from the pump station working volume area and discharge into the dedicated bypass force main option provided. This scenario, although unlikely, may also be required by the local municipal authority for back-up emergencies. Bypass piping size and material options are as follows: • 2" PVC &3" PVC • 3" &4" DI Note: Bypass piping option not available for 3" DIP in discharge position #2 only Oldcastle Precast Pump Station Component Information&Options 10 Stainless Pump Removal Guide Rail Assembly (standard) All RC509/611 pump stations are supplied with stainless pump removal guide rail systems. The guide rails,appropriately sized forthe pumps(3/4"-2"dia.),extend from the pump base elbows to the stainless upper guide brackets in the hatchway area. The guide 40 50 sd rails will be of the material: 304 stainless, Sch40 and will be supported at intermediate 30 ,'Rr. m locations with stainless brackets, as dictated by the pump manufacturer. 21 p. Its The pump guide rail system is designed to easily allow the submersible pumps to be removed from the pump station via a lifting chain, or cable at grade elevation, and _ allow all pump service to be performed from outside of the station. Discharge Gauge Assembly Option This option can be selected for factory installation of a pressure discharge gauge and related accessories on each pump discharge line as it enters the valve vault (set of 2 gauges total). The discharge pressure gauges will allow the owner to accurately assess down-stream force main pressure conditions and test pumping conditions with select discharge isolation valves. The discharge gauge assembly components consist of: discharge pipe saddle, '/2" brass piping and isolation/ bleed-off ball valves, gauge seal fitting and liquid filled pressure gauge with 0-30, 60, 100psi gauge range readout as best meets pump and system requirements. Standard Cl Flanged Plug Valves- 3", 4" & V Oldcastle Precast stocks and supplies: 3", 4" and 6" pump isolation plug valves with non-lubricated eccentric type plugs and provides a minimum port opening of 80% in order to assure minimum turbulence and minimum pressure drop. Valves are rated for 175psi working pressure and cast of ASTM A126 Class B cast iron. Valve flanges meet ANSI B16.1, Class 125 flange specifications. Valves will have a balanced plug, coated with Buna-N (Neoprene) resilient seating surfaces to mate with the body seat. All plug valves will be supplied with lever operators and shall be epoxy coated,with standard color and materials as supplied by the valve manufacturer. Standard L&W Flanged Check Valves- 3", 4" & V Oldcastle Precast stocks and supplies: 3", 4" and 6" system check valves that are full opening swing type, all iron body, bronze seat and have a resilient disc. The check valve complies with AWWA Standard C-508 latest revision and flanges meet ANSI B16.1, Class 125 flange specifications. The stock check valve is supplied with adjustable outside lever and weight (L&W), and is epoxy coated, with standard color and materials as supplied by the valve manufacturer. • Optional - lever and air cushion check valves with L&W can be supplied when selected. Component InformationOptionsi DI Pipe and Fittings- 3", 4" & V Piping and fittings supplied with the RC509/611 pump station will be ductile iron class 53 of sizes as shown. The standard pipe and fittings will be cement lined to the thickness as specified ANSI A26.51 and ANSI A21.4 and shall be interior/exterior asphalt seal coated by the pipe manufacturer. • Optional—the piping and fittings can be factory Coal-tar epoxy coated when selected. • Optional—the piping and fittings can be factory epoxy Hi-Build Epoxoline (Tnemec N-69)coated when selected (Standard available color determined by owner or engineer). Station Wet Well 4" Passive Vent The RC509/611 product line offers a standard 4 inch passive wet well vent assembly fashioned from Sch80 PVC piping and fittings. The standard vent will end with a goose- neck downward tuning outlet and stainless steel insect screen, approximately 3 feet above the TOS elevation. Standard venting offered will be factory assembled and side mounted to the exterior of the station then removed and shipped loose to the job site for field installation. Should vent piping run underground elsewhere on the site, a cored opening with manhole �c. boot will be supplied below grade for customer use when site-venting is installed by others. Optional—4"Carbon canister with carbon refill con be offered (vs. gooseneck and insect screen)when selected. • Optional—opening and MH boot only below grade (no venting materials supplied), for vent piping by others. Junction Boxes and Control Panel Placement (options) Interior Junction Boxes (when selected): The standard RC509/611 is most often sup- plied with interior junction boxes for the pump power/control cable(s) and the level control float cables (when used). In these cases the control panel is typically remote-mounted elsewhere; adjacent to the station or within a nearby weatherproof structure/facility. The conduits and conductors between the pump control panel and the junction boxes inside the station are to be field supplied and installed by others. The standard pump power/ control cable junction box is Nema 7 explosion-proof,and the float cable box(when used)is Polypropylene (intrinsically safe). Interior: junction boxes, RGS conduit, and stainless supports are supplied with this offering. Final wiring and exterior conduit as and seal fittings by others. When a level transducer is used, the cable is to run uncut to the control panel, and as such no junction box is required. Exterior Junction Box (when selected): The standard RC509/611 can be offered with an exterior Nema 4X junction box with divided interior for power and control voltages. In this case, the junction box is mounted to the exterior of the station approx. 2' above TOS. The conduits and conductors between the pump control panel and the exterior junction box are to be field supplied and installed by others. Exterior: junction box, RGS conduit & seal-offs between j-box and station, and stainless supports are supplied with this offering. Final wiring and filling of conduit seals by others. When level transducer is used, the cable is to run uncut to the control panel, and as such will not be routed through the exterior junction box. Oldcastle Precast Pump Station Planner (888) 965-3227 Component InformationOptions Junction Boxes and Control Panel Placement (options) continued Float Junction Box only (when selected): It may be determined as a matter of preference that pump junction boxes are not required,and pump cables will be run uncut to the control panel, no matter the location of the PCP. In these cases floatj-boxes are usually required alone. Interior:intrinsically safe floatjunction box, RGS conduit, and stainless supports are supplied with this offering. Final wiring and exterior conduit and seal fittings done by others. Control Panel Factory Mounted to Pump Station (when selected): with this option the pump control panel can be mounted to the exterior of the station approx. 2'-6" above TOS. The connecting RGS conduit, external seal-off fittings and stainless unistrut framework support between the control panel and the pump station are all included. With this option selected, the following equipment and tasks shall be clarified: o After factory mounting and conduit work; the control panel/supports and conduit shall be disassembled at the conduit unions and at the support-mounting locations to allow control panel to be shipped separately (due to trucking height restrictions). Minimal reassembly effort will be required on site by others. o Final wiring and filling of conduit seals: pumps to control panel & level devices to control panel by others. o All interior junction boxes, RGS conduit, seal-offs and supports are not required or offered with this option. Level Control Devices (supplied with pump control panel) The pump control panel will be supplied with floats,or submersible transducer,or a combination of both. The level control devices and operation is usually dictated by the owner/engineer or the local municipality. When multiple floats for primary operation are required (4-5 floats), Oldcastle Precast will provide a stainless chain tree and weight assembly for standard float positioning.The stainless chain and weight assemblywith attached floatswill hang from a support in the hatchway for easy access and removal for adjustment outside ofthe station. When a transducer is required (primary control), with only 2 floats for emergency conditions; then the transducer cable and each float cable are suspended individually from supports inside the hatchway for easy access. • Standard —4 or 5 float primary operation with stainless chain tree and weight assembly • Optional — Primary level transducer with 2 float emergency back-up • Optional - Primary level transducer with 4 or 5 float secondary operation (or visa-versa) o Note: floats and transducers are supplied with the pump control panel, and as such; site mounting and wiring is expected to be performed by others, unless specifically arranged otherwise. 13 Component In • • Optionsi Removable Aluminum Trash Basket and Rail Assembly — Option The RC509/611 pump station can be supplied with a trash basket straining system mounted on an aluminum rail guide system for easy extraction from grade elevation; similar to the pumps. Because the wet well hatch is set in size and location,there should be circumstances to considerwith this option: 1. The inlet pipe to the station should come in the end-wall, perpendicular and in the center; this will position the interior basket centralized to the wet well hatch above. 2. It should be noted that based on the pumping equipment size, the basket sitting above the pumps may interfere with the pump removal when required, and as such the basket may have to be removed first, prior to any pump removal. • Basket construction:the trash basket can be offered with a low-flow, light-weight,thinner profile and perforated holes, or with higher flow, larger profile, heavy-duty bar screen construction. • Optional—Stainless construction. The trash basket and rail system can be offered with stainless steel materials when selected. . o 0 Q a INLET LOCATION END WALL 00 00 0 00 0 00 0 00 0 00 0 00 0 00 .._.4 TRASH BASKET ' TRASH BASKET OPTION & RAIL SYSTEM ELEVATION PLAN Oldcastle Precast Pump Station Component InformationOptions Portable Hoisting Equipment for Pump Removal — Optional The RC509/611 pump station can be supplied with portable hoisting equipment for pump and trash basket removal. The hoisting equipment will utilize exterior wall mounted sockets which are permanently mounted to the pump station structure. The hoist and wall mounts are constructed of 304 stainless steel. The winch is hand operated and the hoist reach is adjustable from 24"—36". When a portable hoist option is selected; dedicated lifting cables will be provided for each pump and trash basket option (if selected). The dedicated lifting cable is designed to mesh with the winching equipment provided and is expected to be coiled and stored in the hatchway when not in use. Hoisting capacity options are: • 300#lifting capacity • 1000# lifting capacity a PORTABLE HOIST OPTION WALL—MOUNT IIIIIII II a o_ HOIST SOCKETPRIMP-111M I I111111 —=I o - o - 0 o - SOCKET DETAIL ELEVATION Product 1. Transportation Delivery The RC509/611 pump stations have been designed with narrow dimensions to transport them, without the need for wide load permits. Devoid of permit Before You Begin restrictions; site delivery schedules can usually be met without compromise. Once the station is complete and ready for shipment, an Oldcastle Precast repre- Three issues must be addressed to sentative will contact the site contractor with specific questions and details to make ensure the successful, cost effec- tive delivery of your prefabricated delivery and site access as seamless as possible. In most cases Oldcastle Precast pump Station. trucking can be scheduled for early morning delivery times, and must be coordi- nated with the setting crane equipment through the site contractor. 1. Transportation All RC509/611 factory installed equipment,unless otherwise noted,will remain in the 2. Off-loading precast sections for transport to the site. All Oldcastle Precast transportation equip- 3. Site Access mentand operatorsfully complywith insurance institute and on-site safety guidelines. Maximum standard transportation width is 8'-8"W, and maximum transportation height (on the trailer) is 11'-3"H. 2. Off-loading By design, Oldcastle Precast RC509/611 pump stations feature a four-point lifting configuration which utilizes (4) 8 ton Burke clamshell lifting toggles. Oldcastle Precast will provide the lifting toggles with the Oldcastle Precast truck driver,who is responsible to return the loaned lifting equipmenttothe Oldcastle Precast facility after the final piece is setthat day. The setting equipment company(as arranged bythe site contractor)is responsible for providing (1)4 hook lifting cable x 20'long, rated for a minimum picking weight of 17 tons. Oldcastle Precast pump station structural weights will range from 17 tons (base or vault/cover sections) to 2.5 tons (smallest station riser section). It is anticipated that the pump station sections will be off-loaded from the delivery truck and into the final excavation. Specialty lifting equipment cannot be left on site for future product placement, unless prior arrangements are made with Oldcastle Precast. 3. Site Access To ensure a successful delivery, attention must be given to narrow roads, bridge restrictions,small site entries,inadequate turnarounds,steep inclines,soft surfaces, overhead obstructions (cables, trees, bridges), and crane accessibility. The Planner Worksheet Please Read About Your Company Before You Begin Company Name: Complete the information on this Street Address: page about your company, the site(s)for which you are planning a Pump Station installation, and the indi- City, State, Zip Code: viduals who should be contacted if additional technical information is Your Name: Title: required.Then, starting with Item 1 (Structural Options)on page 7, fill in the quantity for each item you Business Telephone: ( ) Fax: ( ) need in your Pump Station design. Re- fer to Product Information Section 3 Cell Phone Number: ( ) E-mail: for product descriptions. Technical Contact for Your Company: For a firm quotation, send digital copies of your completed worksheets About the End User (if applicable) and sketch to: Customer Name: e-mail to: ken.pasco@oldcastle.com Project Name: If you need assistance, call our product line staff at:(888)965-3227 Application: (sewage,drainage,water) or visit :www.oldcastleprecast.com/ Site Street Address: pumpstations/ City, State, Zip Code: Business Telephone: ( ) Fax: ( ) Now You're Ready Cell Phone Number: ( ) E-mail: To Begin Project Stage & Timeline -i Planning -i Design ❑ Emergency Replacement Approximate Design Deadline: Month/Year: Approximate Bidding Date: Month/Year: Aproximate Installation Date: Month /Year: Oldcastle Precast Pump Station The Planner Worksheet 17 Description Planner F• • • Pumping System Design Form Top of pump station structure elevation (TOS): Ft Grade elevation: Ft Inlet invert elevation(s): Ft, Inlet size(s): Inch Pump station discharge invert elevation (if critical) Ft (standard 4' below grade min) • (Known Pumping Requirements) Required pump performance (if known): GPM @_ Ft TDH Pump power requirements (volts, phase) • (Pump Sizing Information Requirements) Average daily flow GPD (ex: 200 Homes * 3.5 people/home * 100 gal per person per day = 70,000 gal per day) Storage capacity (if required) gal (i.e. volume required between working volume and lowest inlet invert) Force main length from pump station discharge to outflow Ft Force main difference in elevation from pump station discharge to outflow Ft Force main pipe: Size inch, Material (Cl, DI, PVC Sch_, SDR_) Force main outflow pressure(s) psi, psi, psi (ex: 0-psi if outflow drop in gravity MH) Pump power requirements (volts, phase) Oldcastle Precast Pump Station The Planner Worksheet 18 Description Planner F• • • Pump Station Design and Option Selection Form Select Standard Pump Station Size - RC509 -! RC611 Select Standard Pump Station Height (stock components) ❑ 10'-10" (base, valve vault section and cover) ❑ 12'-10" ❑ 13'-10" ❑ 14'-10" ❑ 15'-10" ❑ 16'-10" ❑ 17'-10" ❑ 18'-10" ❑ 19'-10" ❑ 20'-10" ❑ 21'-10" ❑ 22'-10" ( Maximum Structural Height) Optional Structural Components ❑ 2' valve vault riser (non-stock) - overall interior VV height 6'-8" ❑ 4' valve vault riser (non-stock) - overall interior VV height 8'-8" ❑ 3'wet well riser (non-stock) Optional Concrete Treatments -i Concrete admixture for Hydrogen Sulfide protection Exterior dampproofing treatment (vertical below grade surfaces) Hatch Load Rating 300# (pedestrian) H2O (occasional vehicle wheel load) Optional Access Equipment -i Aluminum ladder-up 19 The Planner Worksheet Description Planner F• • • Discharge Piping Material and Orientation ❑ Discharge position #1 Discharge position #2 Discharge position #3 ❑ 2" PVC piping & valves ❑ 3" PVC piping & valves ❑ 3" DI piping and CI valves ❑ 4" DI piping and CI valves ❑ 6" DI piping and CI valves (only in RC611 structure) DI Pipe & Fitting Coatings (PVC not coated) ❑ Asphalt coated — manufacture supplied (standard) ❑ Coal-tar epoxy finish coat ❑ Tnemec N69 Hi-Build Epoxoline finish coat Optional Check Valve Selection —i Check valve — air cushion (optional) Floor Stand Pipe Supports in Valve Vault Galvanized (standard) Stainless (optional) Optional Bypass Connection (piping, isolation valve & quick connect) ❑ 2" PVC Bypass ❑ 3" PVC Bypass ❑ 3" DI Bypass (not available with Position #2 discharge) ❑ 4" DI Bypass (Offered on 4" and 6" DIP) Optional Discharge Pressure Gauges —i None required ❑ 0-15 psi —i 0-30 psi — 0- 60psi —i 0- 100psi —i Unknown Guide Rail Sizing for Pumps (if known) —i 2" 1 '/2" —i 1" —i 3/4" Unknown size Passive Station Venting ❑ 4" PVC Gooseneck with stainless insect screen attached to station (standard) ❑ 4" PVC with carbon odor control canister attached to station (optional) ❑ Opening with manhole boot for site venting by others (optional) Oldcastle Precast Pump Station The Planner Worksheet 1 Description Planner • • • Control Panel Placement I Shipped loose (standard) 7 Mounted to station (optional) Junction Box Location (pumps and intrinsically safe float cable j-boxes) All interior (X-proof Nema 7 pump j-boxes) - All exterior Nema 4X Int. float j-box only None (PCP mounted to station or otherwise) Level Control Floats (standard) -1 Transducer w/emerg. Floats Transducer w/back-up floats Trash Basket Option -i Perforated screen -i Bar rack Materials: -i Aluminum -i Stainless steel Stainless Portable Hoist Option 300# (optional) 1000# (optional) ©2012 Oldcastle Precast, Inc. P B_Pum pStation_09_2012_bjb_v01 u � IV lop— PF CL Oldcastle Precast Oldcastle Precast is the leading manufacturer of precast concrete, polymer concrete, and plastic products in the United States. With a nationwide network of facilities, our products are always close at hand. Our employees are committed to upholding core values of reliability, quality, and service in revolutionary ways. Our attention to detail O exceeds the expectations of customers from some of the largest companies in the U.S.,across a spectrum of industries. Sales & Service 888-9 Oldcastle y (888-965-3227) old castle precast/pumpstation All designs, specifications and availabilities of products and services presented in this bulletin are subject to change without notice. ©2012 Oldcastle Precast,Inc. PB_RC509611 PumpStationPlanner_v03 MP3085 SPECIFICATION GRINDER PUMP Each grinder pump shall be a heavy duty pump modified to be used as a grinder. Each grinder pump shall contain special cutters to reduce sewage to a fine slurry. The stationary cutter shall consist of hardened 316 "L" stainless steel and the rotary cutter shall consist of chrome alloyed cast iron. The cutter materials shall provide maximum corrosion and abrasion resistance. The remaining portion of the grinder pumps, with the exception of seal materials and wet end, shall be similar to the heavy duty pumps used in larger pump stations for daily operation. All equipment shall be warrantied for a period of two years from the date of acceptance by the regulatory agency. REQUIREMENTS _ Furnish and install 2 submersible wastewater grinder pump(s). Each pump shall be ecuuipped with a 4 HP, submersible electric motor connected for operation on 480 volts, 3 phase, 60 hertz, 3 wire service, with 15 feet of submersible cable (SUBCAB) suitable for submersible pump applications. The power cable shall be sized according to NEC and ICEA standards and also meet with P-MSHA Approval. The pump shall be supplied with a mating cast iron 2 inch discharge connection and be capable of delivering 42.5 GPM at TDH. An additional point on the same curve shall be 37 GPM at 70 feet total head. Shut off head shall be 95 feet (minimum). Each pump shall be fitted with 20 feet of lifting chain or stainless steel cable. The working load of the lifting system shall be 50% greater than the pump unit weight. PUMP DESIGN The MP Grinder pump(s) shall be automatically and firmly connected to the discharge connection, guided by no less than two guide bars extending from the top of the station to the discharge connection. There shall be no need for personnel to enter the wet-well. Sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal to metal watertight contact. Sealing of the discharge interface with a diaphragm, O-ring or profile gasket will not be acceptable. No portion of the pump shall bear directly on the sump floor. PUMP CONSTRUCTION Major pump components shall be of grey cast iron, ASTM A-48, Class 35B, with smooth surfaces devoid of blow holes or other irregularities. The lifting handle shall be of stainless steel. All exposed nuts or bolts shall be AISI type 316 stainless steel construction. All metal surfaces coming into contact with the pumpage, other than stainless steel or brass, shall be protected by a factory applied spray coating of acrylic dispersion zinc phosphate primer with a polyester resin paint finish on the exterior of the pump. Sealing design shall incorporate metal-to-metal contact between machined surfaces. Critical mating surfaces where watertight sealing is required shall be machined and fitted with Nitrile rubber 0-rings. Fittings will be the result of controlled compression of rubber 0-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. No secondary sealing compounds, elliptical 0-rings, grease or other devices shall be used. COOLING SYSTEM Motors are sufficiently cooled by the surrounding environment or pumped media. A water jacket is not required. CABLE ENTRY SEAL The cable entry seal design shall preclude specific torque requirements to insure a watertight and submersible seal. The cable entry shall consist of a single cylindrical elastomer grommet, flanked by washers, all having a close tolerance fit against the cable outside diameter and the entry inside diameter and compressed by the body containing a strain relief function, separate from the function of sealing the cable. The assembly shall provide ease of changing the cable when necessary using the same entry seal. Epoxies, silicones, or other secondary sealing systems shall not be considered acceptable. MOTOR The pump motor shall be a NEMA B design, induction type with a squirrel cage rotor, shell type design, housed in an air filled, watertight chamber. The stator windings shall be insulated with moisture resistant Class H insulation rated for 180°C (356°F). The stator shall be insulated by the trickle impregnation method using Class H monomer-free polyester resin resulting in a winding fill factor of at least 95%. The motor shall be inverter duty rated in accordance with NEMA MG1, Part 31.The stator shall be heat-shrink fitted into the cast iron stator housing. The use of multiple step dip and bake-type stator insulation process is not acceptable. 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 40°C (104°F) and capable of no less than 30 evenly spaced starts per hour. The rotor bars and short circuit rings shall be made of cast aluminum. Thermal switches set to open at 125°C (260°F) shall be embedded in the stator end coils to monitor the temperature of each phase winding. These thermal switches shall be used in conjunction with and supplemental to external motor overload protection and shall be connected to the control panel. The motor and pump shall be designed and manufactured by the same source. The combined service factor (combined effect of voltage, frequency and specific gravity) shall be a minimum of 1.15. The motor shall have a voltage tolerance of plus or minus 10%. The motor shall be designed for operation up to 40°C (104°F) ambient and with a temperature rise not to exceed 80°C. A performance chart shall be provided upon request showing curves for torque, current, power factor, input/output kW and efficiency. This chart shall also include data on starting and no-load characteristics. The pump system including the pump, motor and power cable shall be approved for use in areas classified as hazardous locations in accordance with the NEC Class I, Div. 1, Group C and D service as determined and approved by a U.S. nationally recognized testing laboratory (U.L., FM, CSA) at the time of the bidding of the project. As required by Factory Mutual (FM) the motor shall be capable of operating in pumped media up to 104 DEGREES F. Motor thermal switches shall monitor and protect the motor from excessive temperature. An internal Float Switch shall be available, as an option, in the motor chamber. Service of explosion-proof submersible units shall be performed by qualified FM experienced personnel. The pump manufacturer must provide training schools to qualify personnel in the proper service and repair of explosionproof pumps. The power cable shall be sized according to the NEC and ICEA standards and shall be of sufficient length to reach the junction box without the need of any splices. The outer jacket of the cable shall be oil resistant chlorinated polyethylene rubber. The motor and cable shall be capable of continuous submergence underwater without loss of watertight integrity to a depth of 65 feet or greater. 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. BEARINGS The pump shaft shall rotate on two bearings. Motor bearings shall be permanently grease lubricated. The upper bearing shall be a single deep groove ball bearing. The lower bearing shall be a two row angular contact bearing to compensate for axial thrust and radial forces. Sleeve or single row lower bearings are not acceptable. The minimum 1_10 bearing life shall be 50,000 hours at any usable portion of the pump curve. MECHANICAL SEAL Each pump shall be provided with a tandem mechanical shaft seal system consisting of two totally independent seal assemblies. The seals shall operate in a lubricant reservoir that hydro- dynamically lubricates the lapped seal faces at a constant rate. The lower, primary seal unit, located between the pump and the lubricant chamber, shall contain one stationary and one positively driven rotating, corrosion and abrasion resistant tungsten-carbide ring. The upper, secondary seal unit, located between the lubricant chamber and the motor housing, shall contain one stationary and one positively driven rotating, corrosion and abrasion resistant tungsten- carbide seal ring. Each seal interface shall be held in contact by its own spring system. The seals shall require neither maintenance nor adjustment nor depend on direction of rotation for sealing. The position of both mechanical seals shall depend on the shaft. Mounting of the lower mechanical seal on the impeller hub will not be acceptable. For special applications, other seal face materials shall be available. The following seal types shall not be considered acceptable or equal to the dual independent seal specified: shaft seals without positively driven rotating members, or conventional double mechanical seals containing either a common single or double spring acting between the upper and lower seal faces. No system requiring a pressure differential to offset pressure and to effect sealing shall be used. Each pump shall be provided with a lubricant chamber for the shaft sealing system. The lubricant chamber shall be designed to prevent overfilling and to provide lubricant expansion capacity. The drain and inspection plug, with positive anti-leak seal shall be easily accessible from the outside. The seal system shall not rely upon the pumped media for lubrication. The motor shall be able to operate dry without damage while pumping under load. Where a seal cavity is present in the seal chamber, the area about the exterior of the lower mechanical seal in the cast iron housing shall have cast in an integral concentric spiral groove. This groove shall protect the seals by causing abrasive particulate entering the seal cavity to be forced out away from the seal due to centrifugal action. Seal lubricant shall be non-hazardous. PUMP SHAFT Pump and motor shaft shall be the same unit. The pump shaft is an extension of the motor shaft. Couplings shall not be acceptable. The shaft shall be stainless steel —ASTM A479 S43100-T. If a shaft material of lower quality than stainless steel—ASTM A479 S43100-T is used, a shaft sleeve of stainless steel —ASTM A479 S431 00-T is used to protect the shaft material. However, shaft sleeves only protect the shaft around the lower mechanical seal. No protection is provided in the oil housing and above. Therefore, the use of stainless steel sleeves will not be considered equal to stainless steel shafts. IMPELLER The impeller(s) shall be of grey cast iron, Class 35B, dynamically balanced, single shrouded design having a long throughlet without acute turns. The impellers shall be capable of handling fine slurry from the special cutters. Impeller(s) shall be taper collet fitted and retained with an Allen head bolt. All impellers shall be coated with an acrylic dispersion zinc phosphate primer. VOLUTE Pump volute(s) shall be single-piece grey cast iron, Class 35B, non-concentric design with smooth passages large enough to pass any media that may enter the impeller. Minimum inlet and discharge size shall be as specified. PROTECTION All stators shall incorporate thermal switches in series to monitor the temperature of each phase winding. At 125°C (260°F) the thermal switches shall open, stop the motor and activate an alarm. A leakage sensor shall be available as an option to detect water in the stator chamber. The Float Leakage Sensor(FLS) is a small float switch used to detect the presence of water in the stator chamber. When activated, the FLS will send an alarm and, if desired, stop the motor. USE OF VOLTAGE SENSITIVE SOLID STATE SENSORS AND TRIP TEMPERATURE ABOVE 125°C (260°F) SHALL NOT BE ALLOWED. The thermal switches and FLS shall be connected to a Mini CAS (Control and Status) monitoring unit. The Mini CAS is designed to be mounted in any control panel. SECTION 33 32 13.13 SPECIFICATIONS FOR PACKAGED SEWAGE LIFT STATIONS, WET WELL TYPE PART 1 GENERAL 1.1 SECTION INCLUDES A. Sewage/Non-Potable Water 1. Pump Stations i. Extent of packaged pump station work required by this Section is indicated on Drawings and Schedules and by requirements of this Section. 1. Under this Section the Contractor shall furnish and install one (1) pre- packaged, pre—assembled pump station complete with submersible pumps, precast concrete pump chamber with integral valve vault structure, slide rail pump removal system, discharge piping with required supports and fittings, discharge check and plug valves, access hatches, valve vault access ladder, liquid level controls, duplex pump control panel, internal wiring and other required appurtenances. 2. The pre-packaged pump station shall be manufactured and pre- assembled off site to ensure product quality and consistency. The pre-package pump station manufacturer or their distributors shall provide sole-source responsibility to the owner through the warranty period. 1.2 REFERENCES Where applicable, the latest editions of the following standards shall form a part of this specification to the extent referenced. The publications are referenced to in the text of this guide specification by the basic designation only. AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO) ACI INTERNATIONAL (ACI) 034100-1 ACI 211.1 Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete ACI 211.2 Standard Practice for Selecting Proportions for Structural Lightweight Concrete ACI 304R Guide for Measuring, Mixing, Transporting, and Placing Concrete ACI 305R Hot Weather Concreting ACI 306R Cold Weather Concreting ACI 309R Consolidation of Concrete ACI 318 Building Code Requirements for Structural Concrete ACI 350 Code Requirements for Environmental Engineering Concrete Structures and Commentary ACI 517.2R Accelerated Curing of Concrete at Atmospheric Pressure AMERICAN NATIONAL STANDARDS INSTITUTE (ASTM) ASTM A 36 Specification for Carbon Structural Steel ASTM A 82 Specification for Steel Wire, Plain, for Concrete Reinforcement ASTM A 615 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement ASTM C 31 Standard Practice for Making and Curing Concrete Test Specimens in the Field ASTM C 33 Specification for Concrete Aggregates ASTM C 39 Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C 40 Test Method for Organic Impurities in Fine Aggregates for Concrete ASTM C 70 Standard Test Method for Surface Moisture in Fine Aggregate ASTM C 117 Standard Test Method for Materials Finer than 75- pm (No. 200) Sieve in Mineral Aggregates by Washing ASTM C 123 Standard Test Method for Lightweight Particles in Aggregate 034100-2 ASTM C 136 Test Method for Sieve Analysis of Fine and Coarse Aggregates ASTM C 138 Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete ASTM C 150 Specifications for Portland Cement ASTM C 172 Standard Practice for Sampling Freshly Mixed Concrete ASTM C 192 Practice for Making and Curing Concrete Test Specimens in the Laboratory ASTM C 231 Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method ASTM C 260 Specification for Air-Entraining Admixtures for Concrete ASTM C 494 Standard Specification for Chemical Admixtures for Concrete ASTM C 566 Test Method for Total Evaporable Moisture content of Aggregate by Drying ASTM C 595 Specification for Blended Hydraulic Cements ASTM C 617 Standard Practice for Capping Cylindrical Concrete Specimens ASTM C 618 Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete ASTM C 805 Test Method for Rebound Number of Hardened Concrete ASTM C 857 Practice for Minimum Structural Design Loading for Underground Precast Concrete Utility Structures ASTM C 858 Specification for Underground Precast Concrete Utility Structures ASTM C 890 Practice for Minimum Structural Design Loading for Monolithic or Sectional Precast Concrete Water and Wastewater Structures ASTM C 891 Practice for Installation of Underground Precast Concrete Utility Structures ASTM C 913 Specification for Precast Concrete Water and Wastewater Structures ASTM C 920 Specification for Elastomeric Joint Sealants 034100-3 ASTM C 990 Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint Sealants ASTM C 1037 Practice for Inspection of Underground Precast Concrete Utility Structures ASTM C 1064 Standard Test Method for Temperature of Freshly Mixed Concrete ASTM C 1107 Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink) Standard Practice for Use of Unbonded Caps in ASTM C 1231 Determination of Compressive Strength of Hardened Concrete Cylinders ASTM C 1240 Standard Specification for Use of Silica Fume for Use as a Mineral Admixture in Hydraulic-Cement Concrete, Mortar, and Grout ASTM C 1260 Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method) ASTM C 1293 Standard Test Method for Determination of Length Change of Concrete due to Alkali-Silica Reaction ASTM C 1602 Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete ASTM C 1611 Standard Test Method for Slump Flow of Self- Consolidating Concrete CONCRETE REINFORCING STEEL INSTITUTE (CRSI) Manual of Standard Practice Placing Reinforcing Bars NATIONAL PRECAST CONCRETE ASSOCIATION (NPCA) NPCA QC Manual Quality Control Manual for Precast Concrete Plants 1.3 GENERAL REQUIREMENTS Precast concrete units shall be designed and fabricated by an experienced and acceptable precast concrete manufacturer. The manufacturer shall have been regularly and continuously engaged in the manufacture of precast concrete units similar to that indicated in the project specifications or drawings for at least 10 years with annual sales of more than $40 million. In addition, the manufacturer shall employ a professional engineer registered in the state where the product is to be installed. 1.4 SUBMITTALS 034100-4 The following items shall be submitted unless specified otherwise herein. A. Preconstruction Submittals 1. Upon request by the customer, submit quality control procedures established by the precast manufacturer's Quality Control Manual B. General 1. Submit Four (4)copies of complete project submittals for the Engineer's review and Approval. The submittal shall be assembled in a permanent binder, complete with index and cover, clearly identifying the Project Title, Customer, Project Engineer and submittal date. The submittal shall be compiled in a logical and organized manner. 2. Partial or incomplete submittals will not be reviewed, but instead will be returned as "Incomplete- Revise and Resubmit". 3. Product Data: Submit manufacturer's specific technical product data, including installation and start up instructions, furnished specialties and accessories, and pump characteristic performance curves with selection points clearly indicated. Provide structural calculations stamped by a Professional Engineer registered in the State the project is being installed. C. Drawings 1. Submit manufacturer's assembly-type shop drawings indicating dimensions, mechanical &electrical components, complete bill of materials, structural layout& reinforcing per calculations and structural weights. Structural reinforcing drawings shall be stamped by a Professional Engineer registered in the State the project is being installed. 2. The drawings for precast concrete units shall be furnished by the precast concrete producer for approval. These drawings shall show the design loads and standards have been met. Installation and construction information shall be included on shop drawings upon request. It is the responsibility of the project's engineer-of-record to verify that the design assumptions are suitable for the proposed application. 3. For custom made precast concrete units, in addition to the requirements in B.1, the drawing for submittal shall show locations and dimensions to all penetrations and special embed items. Product dimensions and thicknesses shall be shown, and the drawing shall be to a common architectural scale with the precast producer's information in the title block. D. Precast Concrete Unit Data 1. Anchorage, Lifting Inserts and Devices i. For anchors, lifting inserts and other devices, the precast concrete producer shall provide product data sheets and proper installation instructions upon request. 2. Accessory Items i. For items including, but not limited to sealants, gaskets, pipe entry connectors, steps, racks, and other items installed before or after delivery, the precast concrete producer shall include proper installation instructions and relevant product data upon request. E. Design Data 1. The precast concrete producer shall supply submittals showing design loading and material specifications for supplied products. At a minimum, the following shall be shown on the submittals: i.Live load used in design ii.Vertical and lateral earth loads used in design 034100-5 iii.Depth of soil fill on the structure iv.Water table depth used in calculations 2. Upon request, the precast concrete producer shall supply precast concrete unit design calculations and concrete mix design proportions and appropriate mix design test data. Structural design calculations shall be sealed by a licensed professional engineer in the state of this project. F. Test Reports 1. Upon request, the precast concrete producer shall supply copies of material certifications and/or laboratory test reports, including mill tests and all other test data, for Portland cement, blended cement, pozzolans, ground granulated blast-furnace slag, silica fume, aggregate, admixtures, and curing compound proposed for use on this project 2. Upon request, the precast concrete producer shall submit copies of test reports showing that the mix has been successfully tested to produce concrete with the properties specified and will be suitable for the project conditions. Such tests may include compressive strength, plastic air content, temperature of freshly mixed concrete, and slump of freshly mixed concrete. Special tests for precast concrete items shall be clearly detailed in the specifications 3. Upon request, the precast concrete producer shall supply copies of in-plant QA/QC inspection reports. 1.5 DESIGN All components of the pre-package submersible pump station with integral valve vault shall be designed for all stresses that may occur during continuous operation, and for any additional stresses that may occur during fabrication or erection. Workmanship shall be high quality in all respects. All equipment shall be constructed of materials that will maintain their functional integrity during continuous handling, and in contact with the liquids and atmosphere, likely to be encountered in this application. The following items shall be accounted for in the precast unit design. A. Precast Concrete Unit Design 1. Design standard precast concrete units to withstand design load conditions in accordance with ACI 350. Design must also consider stresses induced during handling, shipping, and installation in order to avoid product cracking or other handling damage. Design loads for precast concrete units shall be indicated on the shop drawings, and designed by a licensed professional engineer. 2. The structural design shall take into account discontinuities in the structure produced by openings. 3. The Precast Pump Station with Integral Valve vault shall be designed to support its own weight as well as the minimum superimposed loads tabulated below. All additional equipment shall be accounted for in the design of the elements. i.Pump Station with Integral Valve Vault 1. Top Slab 2. Live Load & Impact Load—AASHTO HS20 3. Floor Slab (valve vault& base) 4. Live Load —200 psf 034100-6 5. Exterior Walls 6. All exterior walls below finished grade shall be designed for an equivalent fluid pressure of 81.6 psf caused by saturated earth pressure. The top of the pressure diagram is assumed to originate at finished grade. In addition to the soil pressure, a Live Load Traffic Surcharge shall be applied according to the AASHTO Specification. 4. The structures shall be designed to prevent floatation without the benefit of skin friction and the weight of mechanical equipment when the ground water level is at finished ground surface. The factor of safety against uplift calculated as a ratio of the total resisting force (excluding skin friction and the weight of the equipment)to the total hydrostatic uplift force shall be at least 1.15. The net uplift force shall be transferred to the anti-buoyancy collar. B. Joints and Sealants 1. Joints and sealants between adjacent units shall be of the type and configuration indicated on the shop drawings meeting specified design and performance requirements. C. Concrete Mix Design 1. Concrete type i. For non machine cast products, the concrete shall be self-consolidating concrete which produces minimal bugholes and does not segregate. 2. Concrete Proportions i. Selection of proportions for concrete shall be based on current self- consolidating concrete mix design techniques. At a minimum, ACI 211.1 shall be used. ii. Upon request the precast concrete producer shall submit a mix design for each strength and type of concrete that will be used. Submitted mix designs shall include the quantity, type, brand and applicable data sheets for all design constituents as well as documentation indicating conformance with applicable reference specifications. 3. Durability and Performance Requirements i.Concrete Compressive Strength 1. Precast concrete units shall have a 28-day compressive strength of 5000 psi for SCC. ii.Water-Cementitious Ratio 1. Concrete that will be exposed to freezing and thawing shall contain air and shall have a water-cementitious ratio of 0.45 or less. Concrete which will not be exposed to freezing, but which is required to be leak resistant, shall have a water-cementitious ratio of 0.48 or less. For corrosion protection, reinforced concrete exposed to deicer salts, brackish water or seawater shall have a water-cementitious ratio of 0.40 or less. iii.Air Content 1. The air content of concrete that will be exposed to freezing conditions shall be within the limits given below Nominal Maximum Air Content % 034100-7 Aggregate size (in) Severe Exposure Moderate Exposure 3/8 6.0 to 9.0 4.5 to 7.5 1/2 5.5 to 8.5 4.0 to 7.0 3/4 4.5 to 7.5 3.5 to 6.5 1 4.5 to 7.5 3.0 to 6.0 1-1/2 4.5 to 7.0 3.0 to 6.0 * For specified compressive strengths greater than 5000 psi, air content may be reduced 1% 1.6 QUALITY ASSURANCE The precast concrete producer shall demonstrate adherence to the standards set forth in the plant Quality Control Manual. The precast concrete producer shall meet the requirements written in subparagraph 1.7.A. The Precast Concrete Pump Station Manufacturer shall have a minimum of ten (10)years successful experience in the design and the assembly of factory-built, prefabricated, pre-assembled Pump Stations. In addition, the Manufacturer shall have made no less than ten (10) Pump Stations similar to the one on this project. Evidence shall be submitted to verify these requirements are met prior to being deemed an acceptable manufacturer. A. Qualifications, Quality Control and Inspection 1. The precast producer shall maintain a permanent quality control department. 2. The precast concrete producer shall have a quality control program which is audited for compliance annually by persons outside that plant's employee structure. 3. Upon request, the precast concrete producer shall supply a copy of their quality control manual. B. Quality Control 1. The precast concrete producer shall show that the following quality control tests are performed as required and in accordance with the ASTM International standards indicated i. Concrete Testing 1. Slump: A slump test shall be performed at least once per day per mix design used. Slump tests shall be performed in accordance with ASTM C 1611 for self-consolidating concrete. 2. Temperature: The temperature of fresh concrete shall be measured each time a slump, air content, or compressive strength tests are made. Temperature shall be measured in accordance with ASTM C 1064. 3. Compressive Strength: At least four compressive strength specimens shall be made each day for each mix design unless otherwise specified. In accordance with ASTM C 31, C 39, C 192. 4. Air Content: Tests for air content shall be performed if the mix design specifies air entrainment. The air content will be measured in accordance with ASTM C 231. The Air Content shall be measured 034100-8 once per day per mix design. 5. Density (Unit Weight): Tests for Density (Unit Weight) shall be performed monthly for each mix design used at a minimum. Tests shall be in accordance with ASTM C 138 ii. Aggregate Testing 1. A full set of aggregate tests shall be performed on each aggregate at least annually by an independent testing agency or an in house test lab. These tests will include gradations (ASTM C136), Soundness (ASTM C 88), Organic Impurities (ASTM C 40), Sand Equivalent for fine aggregates only (ASTM D 2419) 2. Potential reactivity shall be performed once per each aggregate source, and when aggregate sources change (ASTM C 1260 or C 1293) 3. Monthly, at a minimum, gradations shall be performed per ASTM C 33. 4. Aggregate Moisture tests: Moisture tests on aggregates shall be performed in accordance with ASTM C 70 or ASTM C 566. Fine aggregate moisture content tests shall be performed at least once per day if there are no moisture meters, otherwise it shall be performed once per month. Alternatively the speedy moisture test is acceptable (ASTM D 4944). iii.Preplacement Check 1. All products shall be inspected for accuracy prior to placing concrete. Checks shall include, but not be limited to, form condition and cleanliness, form dimensions,joints, release agent, blockouts, inserts and locations, lifting devices, reinforcing steel size, spacing, clearances and proper placement. 2. Preplacement checks shall be documented and initialed by the inspector. A drawing with verifications of the above criteria can be used as documentation. iv.Postplacement Check 1. All products shall be inspected for accuracy after the concrete forms have been removed. Checks shall include, but not be limited to, dimensional checks, finishing, insert locations, squareness, honeycombing, cracking, marking, coatings, racking, hole size and location. Postplacement checks may require a corrective action report. 2. Postplacement checks shall be documented and initialed by the inspector. A drawing with verifications of the above criteria can be used as documentation. 2. Copies of the test results and Inspections above shall be available upon request. C. Outside Inspection 1. The customer or customer's agent (specifier) may place an inspector in the plant when the units covered by this specification are being manufactured. The precast concrete producer shall give notice of 3 days prior to the time the precast concrete units will be available for plant inspection D. All equipment and materials furnished in the pump station shall be new and free of defects. All equipment shall be the manufacturer's latest and proven design. 034100-9 E. All electrical materials, devices, and equipment shall be UL listed wherever applicable. F. All equipment and installations shall meet the National Electric Code. 1.7 DELIVERY, STORAGE, AND HANDLING A. Handling 1. Precast concrete units shall be handled and transported in a manner to minimize damage. Lifting devices or holes shall be consistent with industry standards. Lifting shall be accomplished with methods or devices intended for this purpose as indicated on the shop drawings. Upon request, the precast concrete producer shall provide documentation on acceptable handling methods for the product. B. Storage 1. Precast concrete units shall be stored in a manner that will minimize potential damage. C. Delivery 1. Precast concrete units shall be delivered to the site in accordance with the delivery schedule. Upon delivery to the jobsite, all precast concrete units shall be inspected by the customer's agent for quality and final acceptance. D. Final Acceptance 1. Upon final acceptance, the customer's agent acknowledges and understands the appropriate methods for handling the accepted precast concrete unit(s). Upon acceptance by the customer or customer's agent, the precast concrete manufacturer is not responsible for replacing damaged product resulting from improper handling practices on the job site. 1.8 PLANT CONDITIONS Any plant producing precast concrete units for this specification shall have a written, implemented, comprehensive safety and environmental program. Upon request, documentation shall be provided to show the safety program meets the following minimum requirements. A. Safety Program Requirements The safety program shall include the following written and documented parts as a minimum. 1. Housekeeping 2. Lock-Out Tag-Out 3. Machine Guarding 4. Risk Assessment 5. Personal Protective Equipment 6. Contractor and Visitor Safety 7. Cranes and Lifting Equipment Safety 034100-10 8. Ergonomics and handling Safety 9. Fall Protection B. Health and Safety Management System Requirements The health and safety management system shall be used to manage the safety program and all measureable aspects. C. Environmental Management System Requirements The Environmental Management System shall encompass the following: 1. Air Pollution Control 2. Water and Wastewater Management D. Recordable rate 1. The recordable rate shall be below the industry average. If the industry average is not readily available, assume a value of 6 recordable injuries per 200,000 hours worked as the industry average. 1.9 Single Source Responsibility A. To ensure that all equipment required for the installation of the pre-package pump station is properly coordinated and will function as a unit in accordance with the intent of these specifications, the Contractor shall obtain all the equipment specified under this section, from a single supplier with whom the responsibility for the proper function of all equipment, regardless of manufacturer, as an integrated and coordinated system shall be vested. This requirement is to establish unit responsibility for all the equipment with the equipment supplier. The use of the word responsibility relating to the equipment supplier is in no way intended to relieve the Contractor's ultimate responsibility for equipment coordination, installation, operation, and guarantee. B. Factory pre-assembly: During fabrication and before shipment, all equipment shall be fully factory installed to verify all proper clearances. All installed equipment, unless crossing structural joints, shall remain in the precast structure during travel to the jobsite and final re- assembly. C. When contracted to do so, the manufacturer can furnish the services of an experienced service technician to check the installation, and provide with the Owner, a certificate indicating that the pre-packaged submersible pump station has been installed in accordance with the manufacturer's recommendations. PART 2 PRODUCTS 2.1 MANUFACTURERS A. Acceptable Manufacturer: Oldcastle Precast Inc. 1. This specification is based on the precast concrete OneLiftTM pump station product line manufactured and pre-assembled by Oldcastle Precast of Avon, CT (OneLift Model RC509). The OneLiftTM is chosen as the basis of design for; quality manufacturing, compact size, single structure differential settlement elimination, ease 034100-11 and speed of installation, and overall project timeline savings. 2. Substitutions: Not permitted. 1. Alternative systems based upon a built-in-place, field erected pump station utilizing separate precast structures, or cast-in-place concrete shall not be accepted. 2.2 PRODUCTS A. Precast Concrete Pump Station Sections with Valve Vault 1. The Pump Station with Integral Valve Vault shall be composed of precast reinforced concrete units, rectangular in shape with rounded corners. The precast structures shall be monolithically cast, and have minimum interior dimensions of 5' wide by 9' long with 2.5' radius corners (RC509) , or 6' wide by 11' long with 2' radius corners (RC611). The precast base section will be supplied with an extended buoyancy collar to withstand upward buoyant forces with ground water at grade. Overall structure heights shall be as shown on the contract drawings, and range from 10'-10"to 24'-10", in product-standard 2', 3' &4' increments. 2. Exterior Walls shall be a minimum of 6 inches thick, integral valve vault common wall and floor shall be a minimum or 4 inches thick, station floor and buoyancy footing shall be a minimum of 8 inches thick, and the roof slab with hatches shall be a minimum of 12 inches thick. 3. The Integral Valve Vault shall be located in the pump station structure as shown on the contract drawing, to conserve site space and to eliminate the possibility of differential settlement. Conventional means, utilizing two (2) separate structures for the pump station and the valve vault will not be accepted as an equal. 4. The Precast Structures shall be comprised of product-standard: base, riser sections, integral valve vault, optional vault riser shims as required, and station cover. 5. The Pump Station Manufacturer shall have a production facility in which all work associated with structural fabrication, mechanical/electrical pre-assembling and product final inspection of the pump station will be performed. The building shall keep the pump station components protected from the elements and kept at an ambient temperature of at least 45 degrees Fahrenheit. No concrete shall be batched and placed when the ambient temperature is below 50 degrees Fahrenheit. 6. All wall penetrations shall be formed utilizing hole-formers or cored drilled holes for manhole boots, and galvanized threaded couplings with waterstops for electrical connection. 7. All cast wall openings for ductile iron, PVC or galvanized steel pipe shall incorporate adjustable rubber manhole boots for a watertight seal. 8. All Precast components shall be fabricated on steel forms with machined rings to form accurate bell and spigot joint surfaces to ensure watertight joints. 9. The Horizontal joints between precast sections shall be sealed with a vulcanized butyl rubber joint material conforming to AASHTO M-198. The joint material shall be "Conseal CS-102" as manufactured by Concrete Sealants, or approved equal. 10. All surfaces of the precast structures shall be smooth, even, and free from roughness, irregularities and other defects. The surfaces shall be suitable for receiving exterior treatments as specified elsewhere herein. 034100-12 11. (optional)An antimicrobial concrete additive shall be used to protect the structure against deterioration from harsh H2S environments. The product shall be an EPA- registered liquid, integral concrete admixture for the prevention of microbial-induced corrosion (MIC)typically found in concrete tanks, pipes, manholes, and other structures/elements in sewage and drainage systems. The admixture shall molecularly bond to cement hydration products and ruptures the cell membrane of harmful bacteria and other microorganisms on contact through an electro-physical mechanism. The admixture shall create a concrete surface that is not conducive to the growth of harmful microorganisms. Dose rate of additive shall be per manufacturers' recommendations, but should not be less than 1-gallon per cubic yard of concrete mix. All concrete used for the structural components and non-structural components (including fill concrete, common interior wall and floor of integral valve vault) shall include the admixture as described above. i.The "Integral Antimicrobial Admixture" shall be MasterLife AMA 100, as manufactured by BASF Corporation, Cleveland, OH, or engineer-approved equal. 12. (optional)A Crystalline Waterproofing Additive shall be used. The system shall cause the concrete to become sealed against the penetration of liquids from any direction, and shall protect the concrete, surface to surface, from deterioration due to acidic environmental conditions. i.Dose rate of additive shall be per manufacturers' recommendations. All concrete used for the structural components and non-structural components (including fill concrete, common interior wall and floor of integral valve vault) shall attain a minimum 28-day compressive strength of 5,000 psi. ii.The Waterproofing Additive shall be Xypex Admix C-500, as manufactured by XYPEX Chemical Corporation, Richmond, B.C., Canada, or approved equal. 13. (optional)An exterior damp-proofing coating shall be factory applied to the below grade vertical surfaces of the structure. Damp-proofing material shall be cold-applied solvent based asphalt mastic brush or roller applied at a rate of 1-gal per 25SF. Damp-proofing material shall meet ASTM# D-4471 Type 1 and Federal Spec#SS-A- 694d(AF). Damp-proofing shall be Karnak 83AF or approved equal. B. Pump Removal Rail System 1. The pump station shall be supplied with a stainless steel guide rail pump removal system, to facilitate emergency and routine maintenance in removing and re-installing the submersible pumps from the top of the station. The guide rail system will include lower guide brackets incorporated in the pump base elbow, 316-stainless upper guide brackets, 316-stainless intermediate guide brackets as may be required per the pump manufacture, and 304stainless steel Sch40 guide rails of size and quantity as dictated by the select pump manufacturer and model. 2. Guide rail components shall be assembled and installed plumb to the pump station structure, and shall allow for pump removal and re-installation without interfering with the access hatch or frame. All assembly hardware shall be 316-stainless steel. C. Hazardous Location Compliance 1. The wet well and the area within 2 feet of the wet well has been classified as a Class 1, Division 1, A Hazardous Location as defined by the National Electrical Code. All electric wiring and motors located within the subject area shall be in strict compliance with these standards. The shop drawings carry the manufacturer's certification that all equipment located in the subject area meets the requirements of NEC Class 1, Division 1 Criteria and the Underwriter's Laboratory (UL). D. Pump Station Access Frame and Cover 034100-13 1. Furnish and install (1) aluminum pump access hatch, 30" x 48 nominal interior dimension, flush with precast cover, 300psf, H2O AASHTO load rating with 316- stainless steel hardware. Cover will be minimum '/4" diamond plate with stainless steel slam lock and weather plug, lift handle which sits flush with cover, recessed pad lock clip (pad lock by others), hold open arm to lock cover in 90-degree position, heavy duty stainless hinges. Frame to be angle style with continuous 1 '/2" anchor flange and full slab-height skirt to show no exposed concrete when hatch is open, exterior surfaces in contact with concrete to receive one coat bituminous paint. 2. Pump access hatch to be supplied with integral safety grating system. The safety grate shall be made of 6061-T6 aluminum and designed per the "Specifications for Aluminum Structures". The grating shall be designed to withstand 300psf, H2O AASHTO loading. Each grate shall be supplied with a heavy duty, stainless steel pneu-spring for ease of operation when opening. Each grate shall be provided with a permanent hinging system; which will lock the grate in the 90-degree position once opened. Grate shall be coated with an OSHA type safety orange color, base coat is a thermosetting epoxy powder coat finish with a minimum thickness of 2-4 mils. The top coat is a mar-resistant, TGIC polyester powder coating with a minimum thickness of 2- 4 mils. Each coat shall be baked at 350-375 degrees F until cured. 3. Access hatches to be manufactured by EJ, East Jordan, MI, or approved equal. E. Valve Vault Access Frame and Cover 1. Furnish and install (1) aluminum valve vault access hatch, 30" x 36" nominal interior dimension single door, flush with precast cover, 300psf, H2O AASHTO load rating with 316 stainless steel hardware. Cover will be minimum '/4" diamond plate with stainless steel slam lock and weather plug, lift handle which sits flush with cover, recessed pad lock clip (pad lock by others), hold open arm to lock cover in 90-degree position, heavy duty stainless hinges. Frame to be channel style with 1 '/2" NPT drain port in the bottom of the channel, continuous 1 '/2" anchor flange and full slab-height skirt to show no exposed concrete when hatch is open, exterior surfaces in contact with concrete to receive one coat bituminous paint. Hatch will be supplied with a heavy duty, stainless steel pneu-spring, for ease of operation when opening cover. 2. Access hatches to be manufactured by EJ, East Jordan, MI, or approved equal. F. Aluminum Vault Ladder 1. The valve vault shall be supplied with an aluminum (6061-T6)wall-mount access ladder. The ladder shall be fastened to the concrete with 316 stainless expansion bolts and shall meet OSHA standard 1910.27 requirements. 2. The ladder rails & supports shall be all welded aluminum construction. Rails and wall supports shall be solid 3/8" x 2 '/2"flat stock, and rungs shall have a 1-1/4" diameter with serrated surface extruded into the rung for slip resistance. The minimum design live load shall be a single concentrated load of 200 lbs. 3. Rung spacing shall be uniform and not exceed 12", the minimum clear length of rungs shall be 15-1/4", and the distance from the center line of the rung to the nearest permanent object shall not be less than 7". 4. The aluminum ladder shall be manufactured by EJ, East Jordan, MI, or approved equal. G. Ladder Extension (Optional) 1. The ladder extension assembly shall be constructed of aluminum and stainless steel. The aluminum housing shall mount to the ladder by means of grade 316 stainless steel channel clamps secured to the ladder rungs with grade 316 stainless steel "U" bolts. The aluminum telescoping post shall extend 42" above the top of the housing and lock into position with a grade 316 stainless steel pin. 034100-14 2. The safety extension post shall be manufactured by EJ, East Jordan, MI, or approved equal. H. Polyvinyl Chloride (PVC) Piping and Fittings 1. All PVC pressure piping and fittings for water and wastewater treatment are to be Sch80. Corrosion resistant pressure pipe, IPS sizes, for use at temperatures up to and including 140°F. Pressure rating (120 psi to 1230 psi)varies with schedule, pipe size, and temperature. 2. The material used in the manufacture of the pipe and fittings shall be domestically produced rigid polyvinyl chloride (PVC) compound, Type 1 Grade 1, with a Cell Classification of 12454 as defined in ASTM D1784, trade name designation H707 PVC. This compound shall be gray in color, and shall be approved by NSF International for use with potable and non-potable water(NSF Std 61). All sizes of PVC Schedule 80 pipe &fittings shall be manufactured in strict accordance to the requirements of ASTM D1785 for physical dimensions and tolerances, and all performance test requirements of ASTM D1785. I. Polyvinyl Chloride (PVC) Ball Valves (Standard 2" & 3" PVC) 1. All ball valves shall be of the flanged model with one-piece capsule and shall open counterclockwise. The valves shall be rated for 250psi at 73 degrees F. 2. The ball valve shall be of full-port design to minimize flow restriction to the lowest possible pressure drop. Full flange face gaskets having a 50to 70 durometer A hardness shall be used. 3. Ball valve bodies shall be constructed of PVC, with Teflon seats and Viton seals. 4. PVC ball valves shall be manufactured by Haward, Nibco Inc., or approved equal. J. Polyvinyl Chloride (PVC) Check Valves (Standard 2" & 3" PVC) 1. All check valves shall be of the flanged model with one-piece capsule. The valves shall be rated for 150psi at 73 degrees F. 2. Free oscillation of ball in guide ribs facilitates full port flow with minimum of turbulence and chatter. Full flange face gaskets having a 50to 70 durometer A hardness shall be used. 3. Check valve bodies and ball shall be constructed of PVC, with EPDM seals. 4. PVC check valves shall be manufactured by Hayward, Nibco Inc., or approved equal. K. Ductile Iron Pipe and Fittings 1. All ductile iron pipe shall be designed in accordance with ANSI A21.50, and shall be manufactured in accordance with ANSI A21.51. Pipe for use with grooved end couplings shall have grooved ends in accordance with AWWA C606. 2. Pipe thickness class shall be Class 53 for use with threaded flanges, unless specified otherwise on the product drawings. 3. Flanged joints shall conform with ANSI A21.15, utilizing long-hub flanges which shall be screwed on tight by the foundry before they are faced and drilled. 4. Fittings shall conform to the requirements or ANSI A21.10 and shall be of a pressure classification at least equal to that of the pipe with which they are used. Flanged fittings shall be faced and drilled in accordance with ANSI A21.10. 5. All ductile iron piping and fittings shall be double-thick cement mortar lining and bituminous seal coat (black) on the inside and a bituminous seal coat on the outside, all in accordance with ANSI/AWWA A21.4/C104. 034100-15 L. DI Pipe & Fitting Coating - Coal Tar Epoxy Black Exterior Coating (Optional) 1. All ductile iron piping and fittings shall be double-thick cement mortar lining and bituminous seal coat on the inside accordance with ANSI/AWWA A21.4/C104. Exterior pipe and fitting surfaces shall receive a compatible prime coating for coal tar epoxy top coat. Exterior top coat shall be Polyamide Epoxy coal tar high-build application which conforms to AWWA C210 performance requirements. Application rate shall be sufficient for 16DMT. 2. Coal tar epoxy coating shall be Tnemec Series 46H-413, of approved equal. M. DI Pipe & Fitting Coating - Epoxy Exterior Coating—Select Color(Optional) 1. All ductile iron piping and fittings shall be double-thick cement mortar lining and bituminous seal coat on the inside accordance with ANSI/AWWA A21.4/C104. Exterior pipe and fitting surfaces shall receive a compatible prime coating for select 2- part epoxy top coat. Exterior top coat shall be Polyamidoamine Epoxy high-build application, applied at a rate sufficient for 6DMT per coat, and 2-coats required. Color shall be selected from manufacturer's standard color chart. 2. Epoxy exterior top coat shall be Tnemec Series N69, of approved equal. N. Flange Type Couplings 1. Flange couplings shall be mounted on each pump base elbows to ensure proper pressure seal while providing a minimum of assembly flexibility. The flange couplings shall be fusion bond epoxy coated and supplied with 304-stainless assembly and mounting hardware for harsh &wet environments. The pipe gasket and O -ring seal shall be Nitrile (Bung N) NFS 61 Listed. 2. To ensure correct fitting of pipe and couplings, all flange couplings shall be furnished by the pipe supplier and shall be of the pressure rating of at least that of the pipeline in which they are to be installed. 3. The flange couplings shall be Smith-Blair Inc., model 912 or approved equal. O. Grooved Couplings 1. Grooved couplings shall be supplied where shown on the product drawings and shall conform to AWWA C606. The couplings are designed for use on radius cut grooved pipe with minimum wall thickness of ANSI/AWWA C1 51/A21.51, Class 53 DIP, or a transition coupling may be required for connection of grooved end IPS steel pipe to grooved end AWWA ductile iron pipe. 2. The housing coating shall be coal tar epoxy, the gasket shall be Nitrile (red color code), and bolting hardware of 304-stainless steel. 3. The grooved coupling shall be Victaulic style 31/307, or approved equal. P. Pipe supports 1. Piping shall be supported in the valve vault by means of adjustable stainless steel floor supports stands which cradles the pipe/valve flanges. The support stands shall be floor mounted with 316-stainless expansion bolting hardware. Where piping enters and exits the vault structure; aluminum wall supports angles with 304-stainless U-bolts and 316-stainless expansion bolt wall-mounting hardware shall be utilized in (3) locations. 2. Piping shall be supported in the pump station by means of a common 304-stainless fabricated angle brace spanning the width of the station and mounted with wall brackets and 316-stainless hardware. Both vertical discharge pipes shall be supported from the brace by means of individual 316-stainless U-bolts and bolting hardware. 034100-16 i.(1) Common pipe support assembly at mid length shall be required when the vertical discharge pipe lengths exceed 10'-0". ii.(2) Common pipe support assemblies at equal spacing shall be required when the vertical discharge pipe lengths exceed 14'-0". Q. Wall Penetrations 1. Where wall penetrations are called for on the plans; mechanical piping shall utilize cast or cored openings with flexible manhole boots. Flexible rubber boots shall consist of EPDM polymer compounds meeting ASTM C923 material performance requirements. Expansion banding and strap shall be 304-stainless material and the connection between boot and structure shall utilize an expansion wedge system with 304-stainless wedge and hardware components. 2. Electrical conduit penetrations will utilize galvanized electrical couplings assemblies with 2"wide minimum waterstop embedded in the structure at casting, or cored openings with mechanical rubber seals to fill the annular spacing between electrical conduit and precast wall structure. Mechanical seals shall be Link Seal by Thunderline Corp. or approved equal and shall utilize 304-stainless assembly hardware. Mechanical seals shall be employed when pump control panel or exterior junction box option is factory mounted to the station. R. Check Valves Outside L&W (Standard) 1. The check valve shall have a heavy-duty body of ASTM A126 Class B cast iron with integral flanges faced and drilled to ANSI B16.1 Class 125 for horizontal installation as listed in the schedule or shown on plans. Valve clapper shall swing completely clear of the waterway when valve is full open, permitting a full flow through the valve equal to the nominal pipe diameter. Check valves shall comply with AWWA Standard C-508 latest revision. The valve shall have a bolted and gasketed cover to allow for clapper access without removing the flanged valve from line. 2. Pressure ratings: Class 125 flanged valve body shall be rated for a shell pressure of 250 PSI. 3. The check valve shall be supplied with adjustable outside lever and weight. 4. Manufacturer-paint all interior& exterior ferrous surfaces with fusion bonded epoxy coating, AWWA C550 Manufacturer standard color only applies. 5. Manufactured valve shall be Matco-Norco, mod. 120WC or approved equal. S. Air-Cushioned Swing Check Valve (Optional) 1. The valve shall have a heavy-duty body of ASTM A126 Class B cast iron with integral flanges faced and drilled to ANSI B16.1 Class 125 for horizontal installation as listed in the schedule or shown on plans. Valve body shall be full waterway type, designed to provide a net flow area of not less than the nominal pipe size area when swung open no more than 25 degrees. Valve shall have a replaceable bronze body seat. 2. Pressure ratings: Class 125 flanged valve body shall be rated for a shell pressure of 250 PSI. 3. Valve disc shall be faced with a renewable, resilient seat ring retained by a stainless steel screws 4. Disc arm shall be high strength ASTM A536 ductile iron or steel, suspended from and keyed to an 18-8 stainless steel shaft which is completely above the waterway and supported at each end by heavy bronze bushings. Shaft shall rotate freely without the need for external lubrication. 5. Shaft shall be sealed where it passes through the body by means of a stuffing box and adjustable packing gland. O-ring type shaft seals are not acceptable. 034100-17 6. Valve shall be supplied with an outside lever and adjustable counterweight to initiate valve closure. Final closure shall be dampened by means of a single, external, bronze air-cushion chamber directly mounted to the valve body on machined pads. The amount of air-cushioning shall be easily adjustable. Pre-charged air chambers and/or commercial air cylinders which pivot or are attached with fabricated brackets, are not acceptable. 7. Manufacturer-paint all exterior ferrous surfaces with (1) coat of 2-part epoxy primer and (1)finish coat of 2-part epoxy, or(2) coats of self-priming 2-part epoxy. Manufacturer standard color only applies. 8. Manufactured valve shall be GA Industries Figure 250-D or approved equal. T. Plug Valve (Standard) 1. Plug valves shall be of the non-lubricated, quarter-turn, eccentric type with flanged ends and lever operated, in full conformance with the latest revision of the AWWA C517 Standard. 2. Valves sizes 3" to 6" shall have a minimum 175 PSI pressure rating. Plug Valves shall be round ported for reduced pumping costs and improved flow characteristics. The valves shall have the following minimum full open flow coefficients (Cv): 3"=569, 4"=982, 6"=1997. 3. Flange diameter, thickness, and drilling shall conform to ANSI B16.1 Class 125. 4. Valve shaft seals shall be of the self-adjusting U-cup design for reduced maintenance and replaceable without removing the cover from the valve. 5. Valves shall have bodies and covers of ductile iron per ASTM A536 for superior strength. Valve sizes 3" and larger shall have body seats of 95%welded nickel applied directly to the body and machined to a smooth finish. Sprayed, plated or removable seats are not acceptable. Valves shall have plugs made from ductile iron per ASTM A536 with a vulcanized synthetic rubber seat facing tested per ASTM D429 for all sizes. 6. Valves shall be provided with stainless steel thrust bearings on the upper and lower plug shaft to eliminate plug-to-body contact and ensure long lasting plug-to-seat alignment. Grit seals shall be provided on the upper and lower bearing journals to minimize the entrance of grit into the shaft seal and bearing areas. 7. Valves shall be coated internally and externally with 6-8 mils NSF approved two part epoxy paint for corrosion protection. 8. Valves shall be Golden Anderson Figure 517 "ECO-Centric" or approved equal. U. Air/Vacuum Release Valve (Optional) 1. Air/Vacuum release valve shall be 2" and installed at high points in the main line or as directed by the design engineer. The valves shall be fully automatic float operated, designed to exhaust large quantities of air during the filling of a piping system and close upon liquid entry. The valve shall re-open during draining or if a negative pressure occurs. Combination Air Valves for both air release and air/vacuum functions. 2. Valves shall be manufactured and tested in accordance with American Water Works Association (AWWA) Standard C512. 3. Valve sizes 2 in. and smaller shall have full size NPT inlets and outlets equal to the nominal valve size. The body inlet connection shall be hexagonal for a wrench connection and be supplied with brass gate vale for system isolation. The valve body shall have cleanout and drain connections on the side of the casting. 4. The valve shall be supplied back flushing attachments so that the interior body can be 034100-18 flushed periodically for proper operation. 5. A bolted cover with alloy screws and flat gasket shall be provided to allow for maintenance and repair. The resilient seat shall provide drop tight shut off to the full valve pressure rating. The seat shall be a minimum of.5in. thick on 2 in. and larger valves and secured in such a manner as to prevent distortion. 6. The valve body, cover, and baffle shall be constructed of ASTM A126 Class B cast iron. The float and guide shafts shall be constructed of Type 316-stainless steel. Resilient seats shall be Buna-N 7. The exterior of the valve shall be coated with a universal alkyd primer& paint. 8. The manufacturer shall demonstrate a minimum of five (5)years experience in the manufacture of water/wastewater air valves. Air/Vacuum Valves shall be manufactured by G.A. Ind., Crispin Valve, Val-Matic Valve or approved equal. A. Gaskets, Bolts, Nuts 1. For flange joints, gaskets shall be a minimum of 1/8" thick full faced gaskets. Gaskets shall be of composition suitable for exposure to fluids within the pipe. Gaskets shall meet AWWA C110, C111, and C115 performance standards. 2. Flange joints shall be bolt-assemble utilizing the full faced gasket. Bolting hardware, number& size, shall conform to the same ANSI standards as the flange. Bolts and nuts shall be 316-stainless steel, heavy hex Grade B conforming to ASTM A493/494. B. Station Vent 1. A passive station vent shall be supplied using 4" Sch80 PVC piping & fittings, and a stainless insect screen. The vent will be factory assembled and mounted to the exterior of the station, where the venting will rise above the station, and turn downward (gooseneck), and end with insect screen minimum 3' above finish grade. 2. (optional carbon canister)A passive station vent shall be supplied using 4" Sch80 PVC piping &fittings, and a top mounting carbon canister unit. The vent will be factory assembled and mounted to the exterior of the station, where the venting will rise above the station a minimum 3' above finish grade, and end with a top mounted carbon canister unit with rain shield. The canister housing shall be aluminum with 4" mounting flange, rain shield, with power coat finish. The replaceable canister shall contain a minimum of 12 pounds of activated carbon, and shall be safe for recyclable disposal. i.The carbon canister assembly shall be Purafil PV40 Vent Scrubber or approved equal. C. Interior Junction Boxes for Pumps and Level Control Devices 1. The pump station shall be supplied with interior junction boxes for pump power/control and float conductor connections. The pump power/control junction boxes shall be rated NEMA 7 explosion-proof, and shall require one junction box for each pump. The float junction box shall be rated NEMA 4X and constructed of durable polypropylene for intrinsically safe float operation, where barrier relays are supplied in the pump control panel. The interior junction boxes shall be positioned together and accessible from the hatchway at grade. Interior conduits and fittings shall be utilized for passage of pump power/control and level control conductors to the junction boxes. 2. Pump and level control SJO jacketed cables shall be properly supported within the pump station via stainless strain reliefs (Kellums Grip) or other methods, so that cable weight is not transferred to the junction boxes. 3. Interior conduits and fittings between the wall-embedded electrical couplings and the interior junction boxes will be RGS construction and will be factory mounted. Interior 034100-19 conduit support assembly shall be a fabricated type 304 stainless steel Unistrut frame with all type 316 stainless steel fasteners. All final conductor connection in the junction boxes and final float positioning shall be completed on site by the site electrician. 4. Where submersible or ultrasonic type level control transducer device is used instead of, or in conjunction with, level control/emergency floats, the transduce cable shall have a dedicated conduit entrance to the station with dedicated conduit and cord bushing. The transducer shall run un-cut to the pump control panel and not require an interior junction box. The weight of the SJO jacketed cable and transducer shall be supported within the pump station via stainless strain relief(Kellums Grip) or other methods, so that cable weight is not transferred to conduit bushing. All final transducer positioning and connection to pump control panel shall be completed on site by the site electrician. 5. Conduit seal fittings shall be supplied outside of the pump station and prior to the control panel on site by site electrician. D. Interior Pump Cable Support and Float Junction Box (Optional) 1. The SJO jacketed pump power/control cables shall run un-cut from the submersible pumps to the pump control panel and not require any interior junction boxes. The weight of the pump cables shall be supported within the pump station via stainless strain relief(Kellums Grip), so that cable weight is not transferred to the associated conduit bushings. 2. An interior float junction box shall be required and rated NEMA 4X, and constructed of durable polypropylene for intrinsically safe float operation, where barrier relays are supplied in the pump control panel. The interior junction box shall be positioned to be accessible from the hatchway at grade. Interior conduit and fittings between the wall- embedded electrical coupling and the interior float junction box will be RGS construction, and will be factory mounted. Interior conduit support assembly shall be a fabricated type 304 stainless steel Unistrut frame with all type 316 stainless steel fasteners. All final conductor connection in the junction box and final float positioning shall be completed on site by the site electrician. 3. Where submersible or ultrasonic type level control transducer device is used instead of, or in conjunction with, level control/emergency floats, the transduce cable shall have a dedicated conduit entrance to the station with dedicated conduit and cord bushing. All final transducer positioning and connection to pump control panel shall be completed on site by the site electrician. 4. Conduit seal fittings shall be supplied outside of the pump station and prior to the control panel on site by site electrician. E. Exterior Termination Cabinet (Optional) 1. A NEMA 4X, stainless steel, weather-tight pump station exterior termination cabinet shall be factory furnished and mounted to the exterior of the pump station with a minimum of 2' clearance between the bottom of the cabinet and the top surface of the pump station. The cabinet will house divided areas for both power/control and low voltage level control. The termination cabinet shall be 304 stainless steel with back plate, interior area dividers, power/control/low voltage terminals, continuous door hinge, quarter-turn latch hardware and pad locking hardware. The cabinet size will be 16"H x 16"W x 6"D minimum. 2. The pump power, pump control and float switch conductors shall be connected to suitable power and terminal blocks inside the cabinet. Pump and level control SJO jacketed cables shall be properly supported within the pump station via stainless strain reliefs (Kellums Grip) or other methods, so that cable weight is not transferred to the terminal strips. 034100-20 3. The exterior termination cabinet shall be mounted to the pump station with a fabricated type 304 stainless steel Unistrut frame with all type 316 stainless steel fasteners. 4. Conduits, fittings and seal between the termination cabinet and pump station will be RGS construction and will be factory mounted. Conduits, fittings and seals between the termination cabinet and pump control panel shall be supplied and installed by the site electrician. All final conductor termination and filling of seal fittings, shall be completed on site by the site electrician. 5. The complete factory mounted termination cabinet may be removed from the station (via station mounting bolts) and shipped separately to the jobsite due to shipping height restrictions, for field reattachment by site electrician. F. Station-Mounting of Pump Control Panel (Optional) 1. The duplex pump control panel shall be factory mounted to the exterior of the pump station with a minimum of 2'-6" clearance between the bottom of the control cabinet and the top surface of the pump station. Exterior conduit, fittings and seals shall be utilized for passage of pump and control cables from the pump station to the pump control panel. The control panel shall be mounted to the pump station with a fabricated type 304 stainless steel Unistrut frame with all type 316 stainless steel fasteners. 2. The pump power, pump control and float switch conductors shall be connected to suitable power and terminal blocks inside the control panel. Pump and level control SJO jacketed cables shall be properly supported within the pump station via stainless strain reliefs (Kellums Grip) or equal methods, so that cable weight is not transferred to the terminal strips. 3. Conduits, fittings and seal between the control panel and pump station will be RGS construction and will be factory mounted. Incoming control panel power supply& communication conduits, fittings and seals to the pump control panel shall be supplied and installed by the site electrician. All final conductor termination and filling of seal fittings, shall be completed on site by the site electrician. 4. The complete factory mounted pump control panel shall be removed from the station (via station mounting bolts) and shipped separately to the jobsite due to shipping height restrictions, for field reattachment by site electrician. G. Perforated Trash Basket (Optional) 1. The trash basket shall be of the perforated screen style basket, having 2" (2mm) holes on 3" (77mm) centers. The basket shall be of .080" (2mm) stainless steel), with tracking angles as part of the basket frame. The guide rails shall be stainless steel pipe rail sized to facilitate easy operation of the basket. A basket stop shall be supplied loose for site installation at the exact location, once the inlet pipe is installed. 2. The basket and rail system shall be wall mounted with adequate leg-length to facilitate removal without hatch interference. The basket system shall be supplied with 1/4" (7mm) T-304 stainless steel lifting cable with stainless safety hook of adequate length, so that an additional 10' of cable will be coiled and hung from a dedicate stainless hook in the access hatchway. i.(The B1A series aluminum trash basket system shall be manufactured by Halliday Products, Inc. or approved equal. ii.The B4A series T304 stainless trash basket system shall be manufactured by Halliday Products, Inc. or approved equal.) H. Bar Screen Trash Basket (Optional) 1. The trash basket shall be of the bar screen style basket, having 2" (51 mm) clear 034100-21 opening between 1/4" (7mm)thick bars and solid sides. The basket shall be constructed of stainless steel), with (4) 2 '/2" solid wheels and 1/2" stainless steel axles. The heavy duty guide rail system shall be of 3" (77mm) stainless steel structural channel, sized to facilitate easy operation of the basket. A basket stop shall be supplied loose for site installation at the exact location, once the inlet pipe is installed. 2. The basket and rail system shall be wall mounted with adequate leg-length to facilitate removal without hatch interference. The basket system shall be supplied with 1/4" (7mm) T-304 stainless steel lifting cable with stainless safety hook of adequate length, so that an additional 10' of cable will be coiled and hung from a dedicate stainless hook in the access hatchway. i.(The B1 B series aluminum bar screen system shall be manufactured by Halliday Products, Inc. or approved equal. ii.The 13413 series T304 stainless bar screen system shall be manufactured by Halliday Products, Inc. or approved equal.) I. Portable Stainless Hoist (Optional) 1. The pump station will be supplied with a permanent stainless hoist to facilitate equipment removal and placement for periodic and emergency maintenance. The hoisting equipment shall be sized for 1,330lbs max load rating and will include stainless wall socket(s), factory mounted to the pump station exterior wall(s)to adequately reach required equipment. 2. The portable hoist shall be all Type 316 stainless steel construction with marine grade brake winch and 1/4"T-316 stainless steel lifting cable with stainless safety hook. The davit arm shall adjust in 1" increments from 24" to 36" and the overall unit height shall be 60". The winch-end of the cable shall be supplied with a swedge-ball end for easy removal from the winch, and shall be supplied with an additional 10' of cable from the top of station elevation, to be coiled and hung from a dedicate stainless hook in the access hatchway. Each pump and/or trash basket as required shall have a dedicated lifting cable assembly. 3. The portable hoist shall be series DB as manufactured by Halliday Products, Inc. or approved equal. J. Gauge Assembly (Optional) 1. A discharge gauge assembly shall be supplied on each pump discharge pipe line as they enter the valve vault for monitoring system performance. The assembly shall be equipped with a '/2" process connection, '/2" isolation ball valve, stainless diaphragm seal, 4 '/2" pressure gauge and an aluminum wall support with stainless connection hardware. Discharge pressure range shall be, 0-100psi. 2. All gauge and diaphragm seal assemblies shall be of a 1 piece welded design with a full scale accuracy of±1.0%. The gauge shall have a P.E.T. resin case, 4.5" diameter, glycerin fill fluid, with a 316 stainless steel movement, bourdon tube and connection welded to a 1 pc 316ss diaphragm seal. The fill fluid shall be DC200 silicone. Threaded connections between the gauge and the diaphragm seal will not be accepted. The diaphragm seal shall be all 316 stainless steel including diaphragm and have a '/2" NPT male 316ss lower connection. The assembly shall be factory assembled and calibrated. 3. The gauge assembly shall be connected to each discharge line by means of dedicated welded and threaded boss, or by means of pipe saddle with '/2" outlet. Drilling and tapping discharge piping; utilizing only the pipe wall thickness for threading, will not be acceptable. 4. The gauge & seal assembly shall be XR-81 by Ametek, PTR50 by Winters, or approved equal. 034100-22 2.3 MATERIALS Except as otherwise specified, material shall conform to the following section. A. Materials Cement ASTM C 150 (Type I, II, III, or V) ASTM C 595 (for Blended Cements) Silica Fume ASTM C 1240 Fly Ash and Pozzolans ASTM C 618 Ground Granulated Blast-Furnace Slag ASTM C 989 Water ASTM C 1602 (the use of reclaimed/recycled water shall be permitted) Aggregates ASTM C 33 (and aggregate specifications) Air Entraining Admixtures ASTM C 260 Accelerating, Retarding, Water Reducing ASTM C 494 Admixtures Corrosion Inhibitors ASTM C 1582 Reinforcing Bars ASTM A 615 or ASTM A 706 Plain, Welded Wire Reinforcement ASTM A 185 Deformed, Welded Wire Reinforcement ASTM A 497 Epoxy Coated Reinforcing Bars ASTM A 775 Epoxy Coated Welded Wire Reinforcement ASTM A 884 Hot-Dipped Galvanizing for Inserts ASTM A 152 Rubber Gaskets for Circular Pipe ASTM C 443 External Sealing Bands for Pipe ASTM C 877 Preformed Flexible Joint Sealants for Concrete ASTM C 990 Pipe, Manholes, and Manufactured Box Sections Elastomeric Joint Sealants ASTM C 920 Pipe Entry Connectors ASTM C 923, ASTM C 1478 Nonshrink Grout ASTM C 1107 034100-23 2.4 MANUFACTURE Manufacture shall conform to the producer's acceptable quality control manual A. Forms 1. Forms for manufacturing precast concrete units shall be of the type and design consistent with industry standards and practices. They should be capable of consistently providing uniform products and dimensions. Forms shall be constructed so that the forces and vibrations to which the forms will be subjected cause no damage to the precast concrete unit. 2. Forms shall be cleaned of concrete build-up after each use. 3. Form release agents shall be applied according to the manufacturer's recommendations and shall not be allowed to build up on the form casting surface. B. Reinforcement 1. Cages of reinforcement shall be fabricated by tying the bars, wires or welded wire reinforcement. The tolerances for concrete cover shall be 3/8 in. or as specified in the design. Welding shall be allowed only for ASTM A 706 rebar. 2. Positive means shall be taken to assure that the reinforcement does not move significantly during the casting operations C. Embedded Items 1. Embedded items shall be positioned at locations specified in the design documents. Inserts and other embeds shall be held rigidly in place so that they do not move significantly during casting operations. D. Concrete 1. Concrete Mixing i.Mixing operations shall produce batch-to-batch uniformity of strength, consistency and appearance ii.Batching weight and volume measurement devices shall be annually calibrated by an independent testing laboratory or more frequently if batching irregularities or concrete inconsistencies are observed 2. Concrete placing i. Concrete shall be placed in a manner in which it flows and consolidates without segregation or air entrapment. The freefall of concrete shall be kept to a minimum. ii.Cold Weather Concreting 1. Recommendations for cold weather concreting are given in detail in ACI 306 R. Adequate equipment shall be provided for heating concrete materials and protecting concrete during freezing or near- freezing temperatures. All concrete materials, reinforcement, and forms shall be free from frost. In cold weather, the temperature of the concrete at the time of placement shall not be below 45 degrees F. Concrete that freezes before it reaches a compressive strength of 500 psi shall be discarded. iii. Hot Weather Concreting 1. Recommendations for hot weather concreting are given in detail in 034100-24 ACI 305 R. During hot weather excessive concrete temperatures and water evaporation shall be minimized. The temperature of concrete at the time of placing shall not exceed 95 degrees F. 3. Concrete Curing i. Curing operations shall commence immediately following the initial set of the concrete and completion of surface finishing. ii.Curing by moisture retention 1. Precast products shall be protected from drafts and wind to prevent plastic shrinkage cracking. 2. Moisture shall be prevented from excessively evaporating from exposed surfaces until adequate strength for stripping the precast concrete unit from the form is reached. iii.Curing with Heat and Moisture 1. Concrete shall not be subjected to steam or hot air until after the concrete has attained its initial set. If hot air is used, precautions shall be taken to prevent moisture loss from the concrete. The temperature of the concrete shall not be permitted to exceed 150 degrees F. The temperature gain shall not exceed 40 degrees F per hour. 4. Surface Finish i.The surface finish shall be as specified on the contract documents and/or approved shop drawings. 5. Stripping Precast Concrete Units from Forms Precast concrete units shall not be removed from the forms until the concrete reaches the compressive strength for stripping required by design. Stripping strengths shall be routinely measured to ensure product has attained sufficient strength for safe handling. 6. Patching and Repair i. Repairing Minor Defects 1. Defects that will not impair the functional use or expected life of the precast concrete unit may be repaired by any method that does not impair the product ii. Repairing Honeycombed Areas 1. When honeycombed areas are to be repaired, all loose material shall be removed and the areas cut back into essentially horizontal or vertical planes to a depth at which coarse aggregate particles break under chipping rather than being dislodged. Proprietary repair materials shall be used in accordance with the manufacturer's instructions. Otherwise, the area shall be saturated with water. Immediately prior to repair, the area should be damp, but free of excess water. A cement-sand grout or an approved bonding agent shall be applied to the chipped surfaces, followed immediately by consolidating an appropriate repair material into the cavity. iii. Repairing Major Defects 1. Defects in precast concrete products which impair the functional use or the expected life of products shall be evaluated by qualified personnel to determine if repairs are feasible and, if so, to establish the repair procedure. 034100-25 7. Shipping Precast Concrete Units i.Precast concrete units shall not be shipped until they have reached at least 70% of their specified 28-day design strength, unless damage will not result, impairing the performance of the product. 2.5 WARRANTY A. The manufacturer of the lift station shall guarantee for one (2) years from the date of approval by the regulatory agency, that the structure and all equipment will be free from defects in design, material and workmanship. B. Warranties and guarantees by the suppliers of various components in lieu of a single source responsibility by the manufacturer will not be accepted. The manufacturer shall be solely responsible for the warranty of the station and all components. C. In the event a component fails to perform as specified or is proved defective in service during the warranty period, the manufacturer shall provide a replacement part without cost to the Owner. The Contractor shall further provide, without cost to the Owner such labor as may be required to replace, repair or modify major components such as the station structure, pumps, pump motors sewage piping manifold, etc. PART 3 EXECUTION 3.1 SURVEY D. The installation area shall be surveyed using the work print and a checklist to identify the work to be done and to determine that the plans are correct E. All underground facilities and structures such as gas, water, sewer, power, telephone cable, and so forth shall be located and identified. Location markings shall be placed by the affected utilities before construction F. The survey shall identify and obstacles such as overhead wires, building structures that will interfere with crane operations, work progress, or create a safety hazard. G. The survey shall give consideration to the soil structure so that proper shoring, sloping, or both may be planned in advance of the excavation work 3.2 PLANNING A. Permits required to do work in accordance with the detail plans shall be secured before starting the job. All permits or a record of the permits shall be retained on the job for immediate reference B. All utilities and owners of surface and subsurface facilities and structures in the area shall be given advance notification of proposed excavation. Every effort shall be made to avoid damage to the facilities of others. If any damage occurs, the owner of the damaged facility shall be notified immediately. C. Planning shall include the coordination of all responsible parties to ensure that arrangements for removal of excess and damaged material have been made. D. Should it appear that a structure location will interfere with traffic, review the situation with the engineer and notify appropriate authorities. E. Provide for access to call boxes, fire hydrants, etc. 034100-26 3.3 SAFETY REQUIREMENTS A. Safety requirements for construction shall be in accordance with all federal, state, and local regulations. 3.4 EXCAVATING A. If unforeseen facilities or obstructions are encountered, stop excavation operations immediately. Expose the obstruction with wood handled digging tools and investigate them with caution. If there is any doubt as to the type of obstruction exposed, request positive identification from those suspected of owning the facility and then proceed as circumstances dictate. B. Inspect excavations after every rainstorm or other hazard-increasing occurrence, and increase the protection against slides and cave-ins, if necessary C. In dewatering excavations, make certain that the discharge is carried to a suitable runoff point. Also verify that the design accounts for the level of groundwater encountered. D. Excavation size shall be large enough to allow access around the structure after it is installed. E. All excavating shall be under the full guidelines for on-site OSHA regulations, and shall be under the supervision of an OSHA-certified safety coordinator. 3.5 SHORING A. Shoring for construction shall be in accordance with all federal, state, and local regulations 3.6 INSTALLATION A. General Installation of the pump chamber sections and related equipment shall be done in accordance with written instructions supplied by the manufacturer. Installation oversight service (1-day)can be provided by the pump station manufacture (as may be required by the owner), when specifically stated as necessary site service. Additional days for factory technicians shall be paid for at the standard daily rate. B. Assembly 1. The pump station shall be factory assembled and shipped to the job site as follows: i.Wet well precast base assembly with interior fillet and extended base. Pump base elbow& slide couplings will be factory mounted. ii.Precast concrete riser shims as required, shall include holes and factory installed rubber boots as required. iii. Integral valve pit assembly shall include factory installed: piping, valves, supports, gauges, bypass, ladder, hatch drain to pump station—as required. Valve pit assembly my incorporate riser sections of 2' &4' as may be required. iv.Precast pump station top slab shall include aluminum access covers (300#or 034100-27 HS20 loading as required). v.Miscellaneous items provided and field installed shall include: pumps, control panel, floats, vertical discharge piping, dresser couplings, and pump guide rails. C. Site Access The general contractor shall be responsible for providing adequate access to the site to facilitate hauling, storage, and proper handling of the precast concrete units. D. Subgrade Bedding Materials and compaction The installation contractor shall be responsible for ensuring that the subgrade is compacted to 95% of ASTM D558 density. The subgrade shall be a minimum of 6" in depth. A granular material shall be used to create a level surface for placing the precast concrete unit. E. Installation Precast concrete units shall be installed: to the lines and grades shown on the contract documents or otherwise specified; be lifted by suitable lifting devices at points provided by the precast concrete producer; in accordance with applicable industry standards. Upon request, the precast concrete producer shall provide installation instructions Field modifications to the product shall relieve the precast producer of liability and warranty regardless if such modifications result in the failure of the precast concrete unit. F. Leak Resistance Where leak resistance is a necessary performance characteristic of the precast concrete unit's end use,joint sealant, pipe-entry connectors and other penetrations shall be sealed according to manufacturers requirements to ensure the integrity of the system. 3.7 BACKFILLING AND RESTORATION A. Do the backfilling as soon as possible after the structure has been placed. B. Backfill material shall be granular and free from large stones, rocks, and pavement. Expansive soil material shall not be used as backfill around the structure. C. Backfilling shall be achieved by lifts (layers)to the required compaction. D. Follow up inspections for settlements are required. Should settlement occur, the contractor shall be responsible for all necessary repairs. 3.8 FIELD QUALITY CONTROL A. Inspection 1. Final field elevations and compaction properties shall be verified and documented. 3.9 SPARE PARTS A. Spare parts shall be provided in accordance with manufacturer's standard package, and shall be optional for the pump station. 034100-28 3.10 O&M MANUALS A. Four(4) sets of Operation and Maintenance Manuals shall be furnished for the pump station. The manuals shall contain instructions that are comprehensive, and sufficiently detailed for the intended use. B. The Operation and Maintenance Manuals shall be assembled in a permanent binder, complete with index and cover clearly identifying the pump station name. The manuals shall be compiled in a logical and organized manner. C. The Manuals shall contain specific pump station instructions which will enable personnel to operate and maintain the pump station and all equipment associated with each individual system installed within the station. D. Manuals that are a compilation of generalized manufacturer's literature that are not solely applicable to the particular pumping station will not be accepted. E. The Manuals shall contain, but not be limited to: F. Pump service and maintenance instructions, as detailed in the pump specification section G. Duplex pump control panel programing and maintenance instruction and wiring diagrams, as detailed in the control panel specification section H. All pump station equipment service and maintenance instructions for equipment supplied in the package pump station product. I. AS-BUILT fabrication and assembly drawings. J. Start-up& training reports K. Product warranties L. Product contact information and project reference information. END OF SECTION 034100-29 Instrumentation and Control System Specification Pump Controller & Control Panel PART 1 - GENERAL 1.1 Related Documents 1. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section. 1.2 Summary 1. It is the intent of this specification to provide a pump control and monitoring system for a pump station. All components specified or required for a complete, operable system shall be included. 1.3 Related Sections 1. Division 16 Section "Basic Electrical Materials and Methods" for general component identification and support requirements. 1.4 Definitions 1. LCD: Liquid Crystal Display 2. LED: Light Emitting Diode 3. COM: Communications 4. LAN: Local Area Network 5. PVC: Poly Vinyl Chloride 6. CMF: Central Monitoring Facility 1.5 Submittals 1. General: Submit items in this article according to the conditions of the contract and in compliance with Division 1 of the project specification. 2. Product Data for monitoring and control equipment shall include physical dimensions and data on features, components, ratings, and performance. Include wiring diagram and elevation views of the front display panel/keypad where applicable. 3. Shop Drawings detailing dimensions, components, location and identification of field connections, arrangement of components and operational characteristics. 4. Wiring Diagrams detailing the installation of the equipment and differentiating between factory- installed and field-installed wiring. 1.6 Quality Assurance 1.Electrical Component Standard: Provide components that comply with NFPA 70 and that are listed and labelled by UL, CE or CSA where required by local authorities. 21isting and Labelling: Provide products specified in this Section that are listed and labelled. a. The Terms "Listed" and "Labelled": As defined in the "National Electrical Code", Article 100. b. Listing and Labelling Agency Qualifications: A"Nationally Recognized Testing Laboratory" (NRTL) as defined in OSHA Regulation 1910.7. 1.7 Warranty 1.General Warranty: The special warranty specified in this Article shall not deprive the Owner of other rights the Owner may have under other provisions of the Contract Documents and shall be in addition to, and run concurrent with other warranties made by the Contractor under requirements of the Contract Documents. 2.Warranty Period: Two (2)Years from the date of approval by the regulatory agency unless otherwise indicated in other sections of this specification. PART 2 - PRODUCTS 2.1 Manufacturers Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to the following: 1. Pump Control Equipment: a. Flygt b. Xylem The pump controller shall be Flygt Multismart Model MSU3MP2. 2.2 Pump Control Equipment (Primary Control System) The pump controller shall provide automatic control of pumps with an HMI display interface. The minimum features available in the pump controller shall include: 1. Pump control of up to 6 pumps; including pump grouping and pump alternation. 2. Intelligent Hand-Off-Auto Control for each pump from the main display keypad as follows: a. Hand mode (semi-automatic, non-maintained manual mode), the pump switches off at the deactivation set point and then resets to Auto mode for the next pump run cycle. b. Hand mode (fully manual, maintained mode). To pump beyond the off (deactivation) set point, the Hand-Off-Auto button must be held down by the user for failsafe control. 3. Level set point adjustment for pump activation, deactivation and station level alarms. 4. Level device inputs shall include: 4-20mA analog signals, conductive probes or floats. 5. Redundant level device inputs with automatic fault control (input device switching). 6. Selectable charge (fill) or discharge (empty) modes. 7. Pre-configured station optimization features shall include: a. Maximum pumps to run b. Maximum starts per hour c. Maximum pump run time d. Pump maintenance run function e. Blocked pump detection f. Well mixer control capability g. Well clean out control capability h. High inflow mitigation i. Function to minimize buildup of fat or grease deposits 8. Pump alternation modes shall include: a. Standard alternation of pumps b. Fixed sequence pump control c. User defined alternation using a (N:1) or (N:M) ratio d. Alternation based on the most efficient pump e. Alternation by the number of hours run f. Alternation by the number of starts within a specified time period 9. Pump decommissioning mode to allow one or more pumps to be fully decommissioned. 10. Up to (6) unique user defined profiles of set points shall be available to control pumps during specific site conditions or events. Features shall include: a. Automatic profile change based on date and time b. Profile selection option from SCADA (remote control), digital input, logic tag or local keypad 11. Locked level alarm function to indicate a level device fault. 12. Analog input signal watcher function to monitor analog input values for control and alarm uses. 13. Level simulation function for pump station commissioning and general testing. 14. A datalogger for user-defined faults and events shall include: a. Recording of up to 50,000 events to internal flash memory b. Download capability up to 10,000,000 events in the form of a (csv), comma delimited file 15. Three phase supply voltage monitoring and supply fault management for the following conditions: a. Under-voltage b. Over-voltage c. Phase fail d. Phase rotation 16. Monitoring of do power supply, battery voltage, and internal controller temperature. 17. Energy, power and pump efficiency monitoring: a. kW, kVA, power factor, kWHr, KVAH calculation for each pump b. Pump efficiency calculation (gallons per KWHr) for each pump c. Power supply data (voltage, frequency and phase angle information) 18. Motor fault protection features: a. 3-phase current monitoring for each pump b. Over current fault detection c. Under current fault detection d. Ground fault detection e. Current phase imbalance fault f. Motor insulation resistance failure detection 19. Flow measurement: (when enabled by software key) a. Calculated flow by liquid level draw down method b. Flow monitoring by inputs from a flow meter (analog input and pulsed signal input) c. Flow alarms for pump(s) and total station flow 20. VFD speed control function (when enabled by software key) 21. Fault handling functions: a. Pump hold out function b. Automatic reset function after fault condition is no longer present c. Manual reset of fault (if user intervention of fault reset is required) 22. Remote control functions via remote telemetry: (when enabled with software key) a. Change the operating mode of pump(s) (hand/off/auto operations) b. Reset of pump faults and station faults c. Change pump and alarm set point values d. Change the operational profile of the pump(s) 23. Security a. User defined password management for access to programming areas in the controller b. Automatic data logging of personnel who have entered the programming areas c. Automatic logging of all unsuccessful login attempts with a date and time stamp d. Digital input option for controlled access to programming areas 24. SD and USB media access ports shall be available for the following operations: a. Firmware upgrades b. Saving or loading pump controller configuration information c. Exporting or importing MODBUS and DNP3 points list information d. Downloading data logs 25. Advanced programming functions: (when enabled by software key) a. The pump controller shall have the ability to be used with IEC61131-3 and IEC61499 compliant PLC programming languages to enhance or modify existing functionality. b. IsaGraf software programming and Logic Engine scripting language shall be supported. User interface The pump controller shall include a separate user interface (HMI display) keypad for configuration settings, control operations, and advanced programming. 26. Status indication The following parameters shall be displayed on the main screen: a. Liquid level in percent, meters, feet, inches or other custom defined units b. Set points for pump control and level alarms c. Pump status (running, stopped or next to run) d. Pump availability indication e. Pump fault indication f. (3) user configurable lines of information to display pump station status and data 27. Pump Station Information The main screen shall include an INFO button to view the following pump station information: a. Hours Run counter for each pump and the pump station to include: • minutes run for last pump cycle • total minutes (hourly) • total hours today, total hours yesterday • total hours this week, total hours last week • total accumulated hours b. Pump Start counter for each pump and the pump station including: • pump starts this hour, pump starts last hour • pump starts today, pump starts yesterday • pump starts this week, pump starts last week • total accumulated pump starts c. Flow values (when enabled by software key) • station inflow rate • pump flow rate • total station volume • overflow data (including overflow start time, duration, estimated volume) d. Power and Efficiency • pump efficiency in gallons or litres per KWHr - or KVAh • power in kW, KVA • power factor • energy accumulators per pump in KWHr and KVAH e. Insulation resistance value for each pump motor in (Ohms) f. 1/0 Status • Digital 1/0 status and accumulated values • Analog 1/0 status with a value in (mA) and a scaled value • 3-phase voltage, frequency, phase angle, power factor g. Database viewer function to review statistics and tag data information in real time h. Communications information and statistics 28. Pump Station Fault Information The main screen shall include a FAULT button to view fault information as follows: a. The fault screen will provide fault details along with a date/time stamp for each fault b. A fault reset option shall be presented to the user when alarms are allowed to be reset 29. Pump Station Historical Information The main screen shall include a HISTORY button to browse history information as follows: a. View all recorded pump station events along with a date/time stamp for each event b. The history log shall be capable of being filtered to display individual events 30. Pump Station Settings The main screen shall include a SETTINGS button to configure the pump controller as follows: a. Set point programming of pump activation/deactivation values and level alarm values b. Enable/Disable level alarms, faults and historical data recording c. Configuration of Inputs and Outputs d. Setup parameters for each type of fault available in the pump controller e. Set alternation mode for pumps f. Configure station optimization parameters g. Configure voltage supply monitoring parameters h. Configure motor monitoring parameters i. Configure communications parameters j. Configure data logging parameters k. Enable level simulation session I. Create or restore backup copies of the pump controller configuration settings m. Restart the pump controller 31. Hardware Specifications a. The pump controller inputs and outputs shall be modular and shall be expandable. b. Available 1/0 types shall include: 1. Digital Inputs (discrete, voltage free input) 2. Digital Outputs (dry contact type, rated at 240VAC/DC, 5A resistive) 3. Analog Inputs (1 Obit) 4. Analog Outputs (10bit) c. Digital Inputs shall be configurable based on specific input requirements as follows: 1. Pump sensor inputs: Flygt FLS circuit, Conductive Seal, PTC Thermistor (overtemp) 2. Conductive probe sensing (for liquid level monitoring) 3. (2) High speed counter inputs d. The pump controller shall include the following data communication ports: 1. (2) Ethernet ports (10Mbit/s) 2. (2) RS232 ports (115kBit/s) 3. (2) RS485 ports (115kBit/s) 4. (1) USB device port 5. (1) SD card port 32. Communication Architecture a. The pump controller shall support the following communication types: 1. TCP/IP Ethernet 2. UDP 3. RS232 Serial Data 4. RS485 Serial Data 5. Private radio over RS232 6. PSTN (Dial-up) 7. Wireless LAN 8. Cellular Communications b. The pump controller shall support the following communication protocols: (when enabled) 1. DNP3 (master & slave, level 2 compliant) 2. Modbus (master & slave) as follows: Modbus TCP, Modbus RTU, Modbus ASCII 33. Performance and Evironmental Specifications a. Central Processing Unit Speed: 566MHz b. Central Processing Unit RAM Size: 256MByte c. Central Processing Unit Flash Memory Size: 64MByte d. Real Time Clock (with battery backup) e. Working temperature -10°C to +60°C f. Storage temperature -40°C to +90°C g. Humidity 5% to 95% (non-condensing) h. IP Ratings: Controller Base Unit (IP20, NEMA 1), Display Keypad (IP65, NEMA 4) 34. Warranty (Multismart Pump Controller) a. The pump controller shall have a (5) year limited manufacturer's warranty. 2.3 Pump Control Equipment (Backup Control System): 1. The backup control system shall be Flygt Model (MTR, MTRA or SAFE-TL relays) or equal. 2. The backup control equipment shall be supplied with the following specifications: a. The control relay shall accept 2 or 3 level inputs from a conductive level probe or ball floats b. The following settings shall be dip switch programmable from the front panel: • Conductive probe sensitivity adjustment. • Activation Delays. • Charge/Discharge selection. (MTR Relay) • Level Alarm Output (MTRA and SAFE-TL Relay) • Overtemp and Seal Condition Detection (SAFE-TL Relay) c. Output Contact Rating: 250VAC, 5 Amps Resistive, 2 Amps Inductive d. Mounting and Installation: DIN Rail or 2 x#6 screws Base Mount 2.4 Level Sensing Equipment (Conductive Probe): 1. Description: A Multi-Stage Level Sensing Device designed to detect liquid level at specified intervals for pump control and liquid level display. 2. Construction: Each sensor unit within the probe assembly shall be PVC injected to seal the unit and prevent any moisture from entering any of the sensor units. Each sensor on the probe shall be rotated 90 degrees horizontally from the previous sensor along the probe length to eliminate tracking between sensors. Level sensing probes shall be pressure injected with an epoxy resin at final assembly to encapsulate all internal components and connections, thereby creating a rigid, sealed, homogeneous unit. 3. Cable: The flexible cable used for the Level Sensing Probe shall be comprised of PVC/PVC multi-conductor construction with a common oversheath that is water and oil resistant. The multi-conductor cable shall be identified with numbering and text along the entire length of the outer sheath at required intervals. Cables shall be secured to the top of probe bodies by synthetic rubber compression fittings for strain relief. The cable shall be rated to physically support the combined weight of the level sensing probe and the suspended cable connected to the probe. 4. Mounting and Installation: Mounting connections shall be by stainless steel hardware. The mounting bracket assembly for probe(s) shall include a wiper device that allows maintenance personnel to clean the level sensing probe when necessary. 5. Failsafe Functionality: Two wires shall be included within the length of the probe. The two wires shall be connected to each other at the bottom of the probe. When the wires are connected to a MultiSmart Pump Controller, the connection of these wires to the controller shall provide fail-safe monitoring of the probe cable and the probe assembly. 6. The Level Sensing Equipment shall be a Flygt Level Probe or equal. 2.5 Hazardous Location Protective Device (Intrinsically Safe Barrier): 1. Description: The Hazardous Area Protective Device is intended to protect equipment and personnel in areas where hazardous conditions may be present. 2. The Hazardous Area Protective Device shall be Flygt Model MTISB series, or approved equal. 3. The intrinsically safe device shall be supplied according to the following specifications: a. The intrinsically safe barrier shall be panel mounted and designed to protect a multi-sensor conductive probe or ball float inputs. The barrier shall be certified intrinsically safe for use with equipment in installations up to and including Class 1 Zone O. b. The intrinsically safe barrier shall have screw terminals for wire connections. c. The intrinsically safe barrier shall be protected and current limited according to the requirements of UL Class I (Groups A, B, C & D), Class II (Groups E, F, & G) and Class III certification. The device shall also be CE and CSA listed for applicable locations. d. The intrinsically safe barrier shall allow for a maximum short circuit current of 10 ma. 4. Mounting and Installation: The intrinsically safe barrier shall be surface mounted using the mounting flanges on either side of the unit assembly. The unit shall be fastened with approved screws or bolts in accordance with UL requirements. 2.6 Control Panel Construction & Assembly 1. Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to the following: a. Flygt (Xylem) 2. General Requirements: a. Control Panels shall be manufactured in accordance with ISO 9000-2001 specifications and shall be so constructed for the application of a UL Listing Label by an approved UL Control Panel Assembly Facility. b. All electrical connections shall be properly inspected and torqued in compliance with ISO specifications. External connections to the control panel shall be by way of numbered terminal blocks. c. Control Panels shall be properly checked and load tested with power applied. A control panel test log shall be supplied with the control panel. d. Control Panels shall be supplied from a UL approved control panel assembly facility with all of the required labels properly attached. 3. Control Panel Enclosure Environmental Rating: a. Control Panel Enclosure rating shall be specified in accordance with the project requirements or the contract drawings as either NEMA 3R, 12, 4 (Painted Steel) or 4X (Stainless Steel). 4. Control Panel Enclosure Requirements: a. Enclosure shall be sized according to physical and functional device requirements. b. Enclosure seams shall be continuously welded and ground smooth. c. Enclosure door opening flange trough shall exclude liquids and contaminants. d. Enclosure shall include an integral body grounding stud and sub-panel mounting studs. e. Enclosure shall be wall mounted, unless otherwise specified. f. Enclosure door shall have hidden hinges for a clean, aesthetic appearance. g. Enclosure door opening angle shall be standard, full access, 135 degree opening radius. h. Enclosure door shall be interchangeable and removable by pulling a captive hinge pin. i. Enclosure door shall have a high-impact thermoplastic data pocket mounted on the inner side of the enclosure door. j. Enclosure door shall have a seamless, foam-in-place, one-piece gasket to provide an oil-tight, dust-tight seal against contaminants. k. Enclosure shall have a three-point latching system with a zinc die-cast handle that is painted with black textured polyester powder paint. I. Enclosure handles shall be capable of being padlocked. m. Steel sub-panel shall be white. n. When enclosure cut-outs for instruments and other devices are required, holes shall be cut, punched, or drilled and finished with rounded edges. o. A door stiffener shall be used where applicable to prevent door deflection under instrument loading or operation. 5. Instrument Location Requirements: a. Instruments or control devices designated for sub-panel (back) mounting shall be located in a manner that will allow for maintenance and adjustment. b. Instrument mounting height shall not exceed 6'-6" to the top of the instrument and shall not be lower than 3'-0" to the bottom of the instrument (unless otherwise specified). 6. Wiring Requirements: a. Wiring for AC and DC control circuits shall be Type SIS or Type MTW stranded copper and shall be sized for the applied voltage and current. Unless otherwise noted, control circuit wiring shall not be smaller than No. 16 AWG. b. Cable wiring for analog signal circuits shall be twisted, shielded pairs of stranded copper conductors that shall not be smaller than No. 20 AWG. c. Wiring for special signalling equipment such as communications, digital data, and multiplexed signals shall be provided by the equipment supplier. d. Wiring shall be numbered and marked at each termination point. e. Terminal blocks for internal or external wiring shall be DIN rail mounted, individual screw compression type terminals with machine printed labels. 7. Nameplate Requirements: a. Nameplates are defined as inscribed, plastic plates mounted above or near a panel face mounted component. Unless otherwise noted, nameplates shall be engraved, rigid, laminated plastic with an adhesive back. Nameplate color shall be blue with white letters. b. Component Labels are defined as printed, vinyl labels mounted above, below or near a sub-panel (back) mounted component for identification. Printed vinyl labels shall be white in color with black letters and an adhesive back. 8. Grounding: a. Control Panel enclosure shall be properly grounded in accordance with the National Electrical Code and local code requirements. b. Each analog signal loop shall only have it's shield wire connected to ground at a single point for the loop. Shields shall be grounded at control panels where signals are input to the receiving device and not at the source of the transmitting device. 9. Electrical Transient (Surge) Protection: a. All electrical and electronic components of the Control Panel shall be protected against damage due to electrical transients induced in interconnecting lines from lightning discharges and surges in nearby electrical systems. b. The transient surge protector shall be rated for 25kA per phase or larger. 10. Circuit Breakers: a. Power Circuit Breakers shall be thermal magnetic type designed for AC current with a minimum interrupting capacity of 15,000 amperes. b. Control Circuit Breakers shall be in accordance with section UL 489 with a minimum interrupting capacity of 10,000 amperes. 11. Control Power Transformers: a. Control Power Transformers required to provide control system and accessory power shall be machine tool type control transformers with epoxy encapsulated coils or resin impregnated coils, high quality silicon steel laminations, copper magnet wire, moulded terminals and 55° C rise (Class 10 insulation system). 12. Supply Voltage/Phase Monitor: a. The voltage-phase monitor shall continually measure the voltage of each of the three phases of the incoming power to the equipment and provide protection for three phase motors and sensitive electronics. b. The phase monitor shall sense the following conditions: under- and over-voltage, voltage unbalance, phase loss and phase reversal. 13. Control Relays: a. Control relays shall be square base type with coil voltage (120VAC,12VDC or 24VDC). b. Control relays shall be 4PDT (4 Pole, Double Throw)with normally closed/normally open contacts rated at 120VAC, 5 amps minimum. c. Control relays shall include an integrated test button and relay energized flag indicator. 14. Full Voltage Magnetic Motor Controller: a. The motor controller shall be a NEMA rated, full voltage, non-reversing, across the line contactor and overload relay combination. b. The motor overload relay shall be an ambient compensated type with inverse-time- current characteristic and shall be provided with heaters or sensors in each phase matched to nameplate full load current of the specific motor to which it connects . 15. GFCI Convenience Receptacle: a. There shall be a 120VAC, 15 Amp GFCI rated convenience receptacle mounted on the dead front swing door of the control panel. Receptacle circuit shall be protected by a thermal magnetic circuit breaker. 16. Enclosure Condensation Heater: a. There shall be a 120VAC, 50 watt enclosure heater inside the control panel. b. The heater shall be a silicone rubber, insulated strip type enclosure heater. c. The heater shall be Chromalox Model #SL-B-2-5-55P, or approved equal. 17. Local Alarm (Flashing Light): a. There shall be a Flashing Alarm Light mounted on top of the control panel enclosure for local alarm indication. The flashing alarm light shall be supplied according to the following specifications: • UL Recognized for use with UL NEMA Type 3R, 4, 4X, 12 & 13 Enclosures. • Shatter Resistant Lexan globe, U.V. Stabilized and Flame Retardant. b. The Flashing Alarm Light shall be by Ingram Products, or approved equal. PART 3 - EXECUTION 3.1 Installation 1. Install equipment according to manufacturers written instructions. 2. Mount control equipment according to manufacturers instructions and Division 16 Section "Basic Electrical Materials and Methods". 3. Install wiring between control devices as specified in Division 16 Section "Wires and Cables". Bundle, train and support wiring in enclosures. 4. Identify components along with power and control wiring according to Division 16 Section "Electrical Identification". END OF SECTION KOHLER. Model: 30CCL 208-600 V Gas a9001 EPA-Certified for Stationary Standard Features 4 KOHLER. Emergency Applications • Kohler Co. provides one-source responsibility for the NATIONALLY REGISTERED generating system and accessories. Ratings Range • The generator set and its components are prototype-tested,factory-built, and production-tested. 60 Hz Standby: kW 30 • The generator set accepts rated load in one step. WA 30-38 • A five-year/2000 hour limited warranty covers all generator set systems and components. A five-year r extended comprehensive limited warranty is also e available. • Engine Features c Powerful and reliable 2.2 L turbocharged liquid- cooled engine 1_ = o Electronic engine management system. c Simple field conversion between natural gas and LPG fuels while maintaining emission certification. • Innovative Cooling System �« = KOHLER o Electronically controlled fan speeds minimize generator set sound signature. • Alternator features: o Kohler's wound field excitation system with its unique PowerBoost" design delivers great voltage The Kohler® Advantage response and short-circuit capability. o The unique Fast-Responses X excitation system • High Quality Power delivers excellent voltage response and Kohler generators provide advanced voltage and frequency short-circuit capability using a rare-earth, regulation along with ultra-low levels of harmonic distortion for permanent magnet (PM)-excited alternator. excellent generator power quality to protect your valuable o The brushless, rotating-field alternator has electronics. broadrange reconnectability. • Extraordinary Reliability Kohler is known for extraordinary reliability and performance and • Kohler designed controller for one-source system backs that up with a premium five-year or 2000 hour limited integration and remote communication. See warranty. Controller on page 3. • All-Aluminum Sound Enclosure • Certifications Durable aluminum sound-attenuating enclosure. o The generator set engine is certified by the Environmental Protection Agency (EPA)to Generator Set Ratings conform to the New Source Performance Standard g NSPS for stationa soark-icinited emissions. Natural Gas LP Gas o UL 2200/cUL listing is available. 130°C Rise 130°C Rise c The generator set meets NFPA 110, Level 1,when Standby Rating Standby Rating equipped with the necessary accessories and Alternator Voltage Ph Hz kW/kVA Amps kW/kVA Amps installed per NFPA standards. 120/208 3 60 30/38 106 30/38 106 P 127/220 3 60 30/38 100 30/38 100 o CSA certification Is available. 120/240 3 60 30/38 92 30/38 92 c Accepted by the Massachusetts Board of 4D8.3 120/240 1 60 30/30 125 30/30 125 Registration of Plumbers and Gas Fitters. 139/240 3 60 30/38 92 30/38 92 • Approved for stationary standby applications in 220/380 3 60 30/38 58 30/38 58 locations served by a reliable utility source. 277/480 3 60 30/38 46 30/38 46 347/600 3 60 30/38 37 30/38 37 120/208 3 60 30/38 106 30/38 106 127/220 3 60 30/38 100 30/38 100 120/240 3 60 30/38 92 30/38 92 4P7BX 120/240 1 60 30/30 125 30/30 125 139/240 3 60 30/38 92 30/38 92 220/380 3 60 30/38 58 30/38 58 277/480 3 60 30/38 46 30/38 46 4E8.3 160$U/3u12b $U/0U 120 4Q7BX 120/240 1 60 30/30 125 30/30 125 RATINGS: All three-phase units are rated at 0.8 power factor. All single-phase units are rated at 1.0 power factor. Standby Ratings: The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this rating. Ratings are in accordance with ISO-8528-1 and ISO-3046-1. Obtain technical information bulletin(f1B-101)for ratings guidelines,complete ratings definitions,and site condition derates. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. G4-275 (30CCL) 7/18 Alternator Specifications Specifications Alternator • NEMA MG1, IEEE, and ANSI standards compliance for Manufacturer Kohler temperature rise and motor starting. Exciter type Brushless,Wound-Field • Sustained short-circuit current enabling downstream circuit Leads:quantity,type breakers to trip without collapsing the alternator field. 4D 12, Reconnectable 4E 4, 110-120/220-240 V • Self-ventilated and dripproof construction. 4PX 12, Reconnectable • Windings are vacuum-impregnated with epoxy varnish for 4QX 4, 110-120/220-240 V dependability and long life. Voltage regulator Solid State,Volts/Hz Insulation: NEMA MG1 • Superior voltage waveform from a two-thirds pitch stator and Material Class H skewed rotor. Temperature rise 130°C,Standby Bearing:quantity,type 1, Sealed Coupling Flexible Disc Amortisseur windings Full Voltage regulation, no-load to full-load Controller Dependent One-step load acceptance 100%of Rating Unbalanced load capability 100%of Rated Standby Current Peak motor starting kVA: (35%dip for voltages below) 480 V 4D8.3(12 lead) 120 240 V 4E8.3(4 lead) 74 480 V 4P7BX(12 lead) 180 240 V 4Q7BX(4 lead) 113 Application Data Engine Exhaust Engine Specifications Exhaust System Manufacturer Kohler Exhaust manifold type Dry Engine:model,type KG2204T,2.2 L,4-Cycle Exhaust temperature at rated kW,dry Turbocharged exhaust, °C(°F) 610(1130) Cylinder arrangement In-line 4 Maximum allowable back pressure, Displacement, L(cu.in.) 2.2(134.25) kPa(in. Hg) 7.5(2.2) Bore and stroke,mm(in.) 91 x 86(3.5 x 3.4) Compression ratio 10.5:1 Fuel Piston speed, m/min. (ft./min.) 340(1016) Fuel System Main bearings: quantity,type 5,plain alloy steel Fuel type Natural Gas o LPG Rated rpm 1800 Max power at rated RPM,kW(HP) Fuel supply line inlet 1 NPTF LPG 47.8(64.1) Natural gas fuel supply pressure,kPa Natural Gas 47.6(63.9) in. H O 1.24-2.74 5-11 Cylinder head material Cast Iron LPG vapor withdrawal fuel supply Piston type and material High Silicon Aluminum pressure,kPa(in.H2O) 1.24-2.74(5-11) Crankshaft material Nodular Iron Fuel Composition Limits Nat.Gas LP Gas Valve(exhaust)material Forged Steel Methane,%by volume 90 min. — Governor type Electronic Ethane,%by volume 4.0 max. — Frequency regulation,no-load to full-load Isochronous Propane,%by volume 1.0 max. 85 min. Frequency regulation,steady state X1.0% Propene,%by volume 0.1 max. 5.0 max. Frequency Fixed C4 and higher,%by volume 0.3 max. 2.5 max. Air cleaner type,all models Dry Sulfur, ppm mass 25 max. Lower heating value, Engine Electrical MJ/m3(Btu/ft3),min. 33.2(890) 84.2(2260) Engine Electrical System * Fuels with other compositions may be acceptable. If your fuel is Ignition system Electronic outside the listed specifications,contact your local distributor for Battery charging alternator: further analysis and advice. Ground (negative/positive) Negative Volts(DC) 14 Ampere rating 90 Starter motor rated voltage(DC) 12 Battery,recommended cold cranking amps(CCA): Qty.,rating for-18°C(0°F) One,630 Battery voltage(DC) 12 Battery group size 24 G4-275 (30CCL) 7/18 Application Data Lubrication Controller Lubricating System Type Full Pressure 1Q Oil pan capacity, L(qt.) § 4.2(4.4) Oil added during oil change(on C9(0 O O average), L(qt.)§ 3.3(3.5) Oil pan capacity with filter, L(qt.) § 8.5(9.0) Oil filter:quantity,type§ 1,Cartridge § Kohler recommends the use of Kohler Genuine oil and filters. APM402 Controller Provides advanced control,system monitoring,and system diagnostics Cooling for optimum performance and compatibility. • Digital display and menu control provide easy local data access Radiator System • Measurements are selectable in metric or English units Ambient temperature, °C(°F) 50(122) • Remote communication thru a PC via network or Engine jacket water capacity, L(gal.) 2.65(0.7) serial configuration Radiator system capacity, including • Controller supports Modbus®protocol engine, L(gal.) 13.2(3.5) • Integrated hybrid voltage regulator with X0.5%regulation Engine jacket water flow, Lpm(gpm) 62(16.4) • Built-in alternator thermal overload protection Heat rejected to cooling water at rated • NFPA 110 Level 1 capability kW,dry exhaust, kW(Btu/min.) 22.5(1280) Refer to G6-161 for additional controller features and accessories. Water pump type Centrifugal Fan diameter,including blades,mm(in.) qty.3 @ 406(16) Modbus�is a registered trademark of Schneider Electric. Fan power requirements(powered by engine battery charging alternator) 12 VDC, 18 amps each Sound Enclosure Operation Requirements • Durable aluminum,sound-attenuating enclosure with quiet operation of 57 dB(A)log average @ 7 m(23 ft.)at no load. Air Requirements • Internally mounted silencer. Radiator-cooled cooling air, • Fade-,scratch,and corrosion-resistant Kohler®Power Armor' M3/Min. (scfm)$ 51 (1800) automotive-grade textured finish. Combustion air,m3/min. (cfm) 1.6(57) Air over engine m3/min. (cfm) 25(883) • Acoustic insulation that meets UL 94 HF1 flammability classification # Air density=1.20 kg/m3(0.075 Ibm/ft3) and repels moisture absorption. Fuel Consumption$ Natural Gas,nrl(cfh)at%load Standby Ratings 100% 11.9 (421) 75% 10.0 (355) 50% 8.2 (289) 25% 6.3 (223) 0% 4.5 (158) LP Gas,nrl(cfh)at%load Standby Ratings 100% 4.6 (164) 0 0.1 klol) 50% 2.8 (99) 25% 1.9 (66) 0% 1.0 (34) $ Nominal fuel rating: Natural gas,37 MJ/m3(1000 Btu/ft.3) LP vapor,93 MJ/m3(2500 Btu/ft.3) LP vapor conversion factors: 8.58 ft.3= 1 Ib. 0.535 m3= 1 kg. 36.39 ft.3= 1 gal. G4-275 (30CCL) 7/18 KOHL KrQHLER® Phone 9 CO., Kohler,Wisconsin 9-164 USA Phone 920-457-4441, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada,phone 1-800-544-2444 KOHLERPower.com Standard Features Miscellaneous • Alternator Protection a-Air Cleaner Restriction Indicator • Aluminum Sound Enclosure with Enclosed Silencer Fer Certified Test Report • Battery Rack and Cables 4�]r Engine Fluids Added • Flexible Fuel Line ❑ Maintenance Kit(filters,spark plugs,oil) • Gas Fuel System(includes fuel mixer,electronic secondary gas Rated Power Factor Testing regulator,gas solenoid valve,and flexible fuel line between the engine and the skid-mounted fuel system components) Literature �' • Integral Vibration Isolation General Maintenance ❑ NFPA 110 • Local Emergency Stop Switch ❑ Overhaul • Low Fuel Pressure Switch(with NFPA fuel module) Production • Oil Drain Extension • Operation and Installation Literature Warranty • Standard 5-Year Limited Warranty Ja'Optional Extended 5-Year/2000 Hour Comprehensive Limited Warranty Available Options Other Options Approvals and Listings ❑ ❑ CSA Certified UL2200 Listing ❑ Controller ❑ ❑ 15-Relay Dry Contact Board ❑ ❑ Communication Products ❑ ❑ Input/Output Module(2 inputs,5 outputs) ❑ ❑ Lockable Emergency Stop(lockout/tagout) ❑ Manual Key Switch ❑ Manual Speed Adjust Remote Annunciator Panel ❑ Remote Emergency Stop J2- Run Relay Enclosure Accessories Enclosure Doors for 291 kph (181 mph)Wind Load Starting Aids* JLC Block Heater, 110-120 V Dimensions and Weights ❑ Block Heater,220-240 V Overall Size, L x W x H, mm(in.): 2280 x 830 x 1182 Oil Pan Heater* (89.8 x 32.7 x 46.5) Oil Pan Heater, 110-120 V Weight,with engine fluids,kg(lb.): 635(1432) ❑ Oil Pan Heater, 190-240 V * One block heater or oil pan heater is required for ambient temperatures below 0°C(32°F). At temperatures below-18°C(0°F) installation of both heaters is required. Electrical System H ❑ Alternator Strip Heater Battery [�] Battery Charger, 6 Amp ❑ Battery Charger, 10 Amp w/Alarms ❑ Battery Heater W—►I L ❑ Temperature Compensation for 10 Amp Battery Charger NOTE:This drawing is provided for reference only and should not be used for planning. Contact your local distributor for more detailed information. DISTRIBUTED BY: Cooper Power Systems A.J. Enos aj.enos@cooper-electric.com 603-505-7737 ©2018 by Kohler Co. All rights reserved. G4-275 (30CCL) 7/18 Appendix E Vendors Vineyard View—Greenport, NY Appendix F: List of Vendors Equipment Equipment Information Manufacturer Contact Info/Supplier Submersible Model No.: MP 3085 HT-3— 258 ITT Water and G.A. Fleet Associates, Inc. Wastewater Impeller Diameter: 133 mm Wastewater 55 Calvert Street Pump Rated Speed: 3415 rpm (Flygt-A Xylem Harrison, NY 10528 Rated Power: 4 hp Brand) Phone: 914-835-4000 Electrical: 460 V, 3 phase, 60 Hz Fax: 914-835-1331 www.gafleet.com Mix Flush Valve Model No.: 4901 ITT Water and G.A. Fleet Associates, Inc. Wastewater 55 Calvert Street (Flygt-A Xylem Harrison, NY 10528 Brand) Phone: 914-835-4000 Fax: 914-835-1331 www.gafleet.com Flygt MultiSmart See specifications in Appendix D MultiTrode, Inc. G.A. Fleet Associates, Inc. Pump Station 55 Calvert Street Manager Harrison, NY 10528 Phone: 914-835-4000 Fax: 914-835-1331 www.gafleet.com MultiTrode Probe Model Code 0.5/3-10 MultiTrode, Inc. G.A. Fleet Associates, Inc. (Level Monitor) Probe Length: 16 in 55 Calvert Street Sensor Separation: 6 in Harrison, NY 10528 Cable Length: 33 ft Phone: 914-835-4000 Number of Sensors: 3 Fax: 914-835-1331 www.gafleet.com Natural Gas Model No.: 30CCL(60 Hz Natural Kohler Power, Cooper Electric Standby Gas Model) Inc. Distributor, KOHLER Power Generator Power Rating: 30 kW Systems Voltage: 208/600 V New York Cooper Power Engine: General Motors Systems Industrial Powertrain 29 West 38th St, NY 10018 5.7 L, 4-Cycle Phone: 631-392-2212 Natural Aspiration www.power.kohItr.com Alternator: Kohler Controller: Decision-Maker® 3000 Controller Vineyard View—Greenport, NY Equipment Equipment Information Manufacturer Contact Info/Supplier Portable Pump Halliday Hoist Products Access Doors Halliday Products Precast Concrete Onel-ift RC509 Pump Station Oldcastle Oldcastle Precast Items (Wet Well Precast 114 Rocky Point Rd and Integral Middle Island, NY Valve Vault) Phone: 631-924-7400 www.oldcastleprecast.com Appendix F Buoyancy Calculations ldCiaSlPI'E'.CSt 7921 5outhpark Plaza Suite 200 • Littleton,CO 80120 f www.oldca5tlepre€ast.com Phone: (888)965-3227 0flelivering Rekabffity Fax: (303)794-4297 Structure Weights Weights assuming 150 pcf reinforced concrete unit weight: WIN:= 50001bf Wvve:= 76001bf Wvvewall := 10151bf Wvv:= 123501bf W2ftriser:= 37661bf I W3ftriser:= 57001bf W4ftriser:= 76001bf Wbase:= 218001bf Weights assuming 145 pcf unit weight(for Buoyancy Calculations) ^yc:= 150pcf 'Yb:= 145pcf 'Yb 'Yb Wlid.b := WIN'— = 4833• Ibf W2ftriser.b:= W2ftriser'— = 3640• Ibf ,�c ^YC Wvve.b:= Wvve' b = 7347• Ibf W3ftriser.b:= W3ftriser' b = 5510• Ibf IC 'YC 'Yb 'Yb Wvvewall.b:= Wvvewall ' — = 981 • Ibf W4ftriser.b:= W4ftriser'— = 7347• Ibf 1'c ^Yc Wvv.b:= Wvv' b = 11938• Ibf Wbase.b:= Wbase' b = 21073• Ibf '1c 1'c Copyright Oldcastle Precast 08/24/17 Page 4 of 72 7921 Southpark Plaza Suite 200 D Littleton,C080120 Oldcastle Precast www.oldcasdeprecast.com Phone: {888}965-3227 0 ivef ng RefiabiW Fax: {303)794-4297 Buoyancy Check Given: ^ys:= 120pcf Ainside 39.635ft2 Area Inside One Lift ^yam,:= 62.4pcf Arim 12.639ft2 Cross Sectional Area of the Wall Aapron 26.23ft2 Area of the Buoyancy Collar Ataper 4.5625ft2 Cross Sectional Area of the Sloped Walls Atotal Ainside+ Arim + Aapron + Ataper= 83.07 ft Total Area not used 12'- ° 1'-4' Y-0° 1'-4' LALreaInside39.635 fF Rim=12.639 fl Area Apron = 26.23 ft` Worst Case Bouyancy Calculation: Volume:= (Ainside+ Arim) - 25.5ft+ Ataper' 5.5ft+ Aapron-8in = 1376• ft Concrete Volume FB:= Volume•-yw= 85835 lbf Buoyancy Force BOXDL Wlid.b + Wvv.b + 3W4ftriser.b+ W2ftriser.b+ Wbase.b = 63525 Ibf Total weight Of structure SOilDL•= Aapron' (25.5ft- 8in) • (7s- -Yw) = 37519lbf Weight of soil above apron Check FB:= NG" if (BOxDL+ SOilDL) < 1.15FB = "OK" Minimum SF=1.15 "OK" otherwise (BOXDL+ SOilDL) SF:_ = 1.18 Actual Safety Factor FB *See project specific safety factor calc on next sheet* Copyright Oldcastle Precast 08/24/17 Page 5 of 72 7921 Southpark Plaza Suite 200 • Littleton,CO 80120 Oldastle Precast u � www.oldcastleprecast.com Phone: (888)965-3227 DeGvefing Reliability 81K��wK = Devi S.ahs Fax: (303)794-4297 Bouancy Summary for all Heights: Factor ofUplift Downward RC509 Safety Force Self Weight �ForceonApronl 10'-10" 1.35 40169 37845 16368 12'-10" 1.30 46693 41485 19389 13'-10" 1.29 49955 43355 20900 14'-10" 1.27 53216 45192 22411 15-10" 1.26 56478 46995 23922 16'-10" 1.24 W59740 (Z)48865 3 25433 17'-10" 1.23 63002 50702 26943 18'-10" 1.22 66264 52538 28454 19'-10" 1.21 69526 54342 29965 20'-10" 1.20 72788 56179 31476 21'-10" 1.20 76050 58048 32987 22'-10" 1.19 79312 59885 34498 23'-10" 1.18 82574 61689 36009 24'-10" 1.18 85835 63525 37519 &65ej worst LAS& Bouyqy%cy LO►jc,AlcAn: (•,*se& SWcl Wow VuC ►�,e: �A;�sae� � ' 4.38-f,� !� 1 ' �f.3$ f+ A q�t'v,,)• 266. 51 f43 {��ar rg; VoLme ' �, = 266. 51 f� 3. 62,q pJ = 1630.22 16f --� Bkoya,��y/ I;F� Forces a, (D4% G5 )b� x> -ToW v,-65hf of siY,a,4,e/jplf tVP-iOk - * Sa-Ie VA424K Sp l qtr' f�aP' 17 5 f�' -�S �'r) C2G.23 f+Z�` i6.$3 f+) C� Pcf — 62.11. P�f) =�2 2 542-/.57 16f --3 W6154 of Soi)Oka ro S f' V i oW weight of St,dxte, +LV4,,j t of 5Li I cibae, apr,),,) _ d 4$q6514+25427.5719 duo y�h��r�UpJift �vrce�) r 1663p,2Z ibf 5r 4. 49 ;s (�Y`P.-k+- +ktv, 4& M;n;n,,,i�np� 1.Jr 5,kfp—,-y Aprrox, Lkish'I 514ri�t& e)ev.=)7.15 AX �f h� i.( V ->� ,ti.�, 3i Uawb wuer ' M,Or encouwkrea S ba10 , q w e �hah dt a.iS �cse S�HiiJn �/_ us Pen- .�+-ojo4��es(-p;� lop r _ w Copyright Oldcastle Precast 08/24/17 Page 6 of 72