Section 11309
PROGRESSING CAVITY PUMPS
PART 1 GENERAL
1.1 DESCRIPTION OF WORK
A. The Work of this section includes
all labor, materials, tools and equipment necessary to furnish and
install progressive cavity pumps specifically designed to convey
primary sludge (3-4 percent solids concentrations), Waste Activated
Sludge (WAS) and Trickling Filter Sludge (3 percent solids
concentrations), centrifuge thickened sludge (4-6.5 percent solids
concentrations) and digested sludge (3-4 percent solids
concentrations), active and dilute polymer as specified herein and
shown on the Drawings.
1.2 DESIGN CRITERIA
A. The materials and equipment
covered by this Specification are intended to be standard
materials and equipment of proven ability as manufactured by
reputable companies. Equipment shall be designed and constructed in
accordance with the best practice of the industry and shall be
installed in accordance with the manufacturer's recommendations and
the Contract Documents. The Specifications call attention to
certain features but do not purport to cover all details entering
into the construction of the equipment. All Work shall conform to
the requirements of Section 11210, Pumps, General.
1.3 RELATED SECTIONS
A. The requirements of the following
sections and divisions apply to the Work of this section. Other
sections and divisions of the Specifications, not referenced below,
shall also apply to the extent required for proper performance of
this Work.
1. Division 01, Additional General
Requirements
2. Section 01783, Operation and
Maintenance Manuals
3. Section 01810, Commissioning
4. Section 01820, Training of OCSD
Personnel
5. Section 09800, Protective Coating
6. Section 11210, Pumps and
Equipment, General
7. Section 16220, Electric Motors
8. Section 16418, Variable Frequency
Drives Below 100 HP
9. Section 16419, Variable Frequency
Drives 100 HP and Above
10. Division 16, Electrical, applicable
sections
11. Section 17405, Process
Instrumentation and Control
1.4 REFERENCES
A. Division 11, Section 11210, Pumps,
General, lists the referenced standards’ edition dates unless
otherwise shown.
1.5 SUBMITTALS
A. The CONTRACTOR shall submit complete
shop drawings for acceptance in accordance with Shop Drawing
Submittals of the General Requirements and as specified herein.
B. In addition to the submittal
requirements of Section 11210, Pumps, General, the following shall
be submitted:
1. Shop drawings showing complete
fabrication and construction details, materials, weights,
dimensions, clearances, anchorage locations and bolt detail, piping
and utility requirements, and step-by-step sequence of controls.
2. Pump manufacturer, type and
model, rpm at design point condition, size of suction and discharge
flanges, and maximum bhp requirement at maximum differential
pressure condition.
3. Certified Pump Curves showing
maximum and minimum speeds.
4. For pump control panels, complete
master wiring diagrams, elementary or control schematics, including
required coordination with other electrical control devices
operating in conjunction with the pumping system and acceptable
outline Drawings shall be furnished for acceptance before proceeding
with manufacture. Due to the complexity of the control functions,
it is imperative the above Drawings be clear and carefully prepared
to facilitate interconnections with other equipment. Standard
preprinted sheets or Drawings simply marked to indicate
applicability to this Contract will not be acceptable.
5. Coordination letter stating that
the pump manufacturer has coordinated with the manufacturer of the
Variable Frequency Drives specified in Specification section
16418, Variable Frequency Drives
below 100 Horsepower and 16419, Variable
Frequency Drives 100 Horsepower and
Above for complete compatibility.
6. Bearing Life Calculations.
7. Operation and Maintenance
Manuals.
1.6 DELIVERY, STORAGE, AND
HANDLING
A. All materials and equipment shall
be shipped, stored, handled and installed in such a manner as not to
degrade quality, serviceability or appearance. The equipment shall
be stored in a clean, dry location free from construction dust,
precipitation and excess moisture. If stored for more than two
weeks, the equipment shall receive all maintenance considerations
required by the manufacturer for proper storage of the equipment.
1.7 DESIGN CONDITIONS
A. The design conditions and other
pertinent requirements for the progressive cavity pumps are listed
in Table 1, at the end of this section. The pumps shall be as
manufactured by Moyno Inc., Springfield, OH, Seepex Inc., Enon, OH,
or NETZSCH Pumps North America, LLC, Or Equal.
B. All chemical feed pumps shall be
manufactured by a single manufacturer. C. All sludge pumps shall be
manufactured by a single manufacturer.
D. Different manufacturers may
provide the sets of chemical feed and sludge pumps. E. Pumps shall
be designed to operate continuously.
1.8 WARRANTY
A. The pumping units shall be
warranted by the manufacturer for a minimum three (3) year period
after Beneficial Occupancy of the Work pursuant to “Use Prior to
Final Completion” of the General Conditions, against defects in
workmanship and materials. Wear items such as seals, bearings,
impellers, motor rotors and stators may be prorated during the three
year period.
1.9 SPECIAL TOOLS
A. If required for pump operation
and maintenance, two sets of special tools required for pump
operation and maintenance shall be provided at the time of pump
deliver.
PART 2 PRODUCTS
2.1 PROGRESSIVE CAVITY PUMPS
A. Pumps shall conform to
applicable provisions listed in Section 11210, Pumps, General.
B. The pumps shall be horizontal,
heavy duty, positive displacement, progressive cavity pumps. The
pump and drive shall be direct coupled and mounted as shown on the
Drawings.
1. Pump Casing:
a. The casing shall be close-grained
cast iron of sufficient strength, weight and metal thickness to
insure long life, accurate alignment and reliable operation. The
volute shall be a symmetrical waterway to provide an
unobstructed discharge flow. Two inspection ports with removable
covers having its interior surfaces matching the volute contour
shall be provided located 180 degrees apart on the casing housing.
The pump shall be mounted to permit the suction port to be rotated
in 90 degree increments perpendicular to the centerline of the pump.
Pump shall be supplied with adequate number of connections for
seal water flushing, stuffing box drainage, pump drainage and gauge
connections.
2. Casing Connections:
a. Suction and discharge
connections shall be ANSI 125 pound flat face flanges.
Suction and discharge flanges shall be provided with 1/2 inch NPT
drilled and tapped holes with threaded plugs.
3. Rotor and Drive Train:
a. The pump rotor shall be machined
from chrome-plated tool steel with a minimum chromium content of
11-13.5 percent, air hardened to a Rockwell "C" hardness
of 57 to 60 and covered with a minimum 0.01 inch thick layer of hard
chrome plating for abrasion resistance. The rotor shall be joined
to the drive shaft by a connecting rod and crown gear type oil or
grease-lubricated, single sealed universal joints of adequate design
to transmit the required thrust and torque while allowing the rotor
to move through its required eccentric path without distortion or
vibration. The universal joint shall be sealed by a Buna-n bellows
clamped positively at both the I.D. and O.D. and protected on the
outer diameter from damage by foreign materials by a thick walled
steel casing on the rotor end and the shaft end.
b. Rotor for polymer pumps
15LPMP-720, -730, -810, -820, and -830; 15MPMP
-831, -840, -910, -920, and -930 shall
be polished 316 stainless steel and shall have no surface coating.
4. Stator:
a. The rotor shall rotate within
a Buna-n rubber stator of approximate 70
Durometer hardness (Shore A)
chemically bonded to high strength steel tube. The stator shall be
attached to the suction housing by four thru-bolts for ease of
assembly and disassembly. The stator end shall be sealed or
gasketed to prevent the material being pumped from contacting the
stator bonding and tube.
b. Stator for polymer pumps
15LPMP-720, -730, -810, -820, and -830; 15MPMP
-831, -840, -910, -920, and -930 shall
be Fluoroelastomer (FPM) material.
5. Shaft:
a. The drive shaft shall be mounted
in two bearings. The connecting rod operating angle shall not
exceed 1 degree off-center (2 degree total operating angle).
Driveshaft where it passes through the stuffing box shall be hard
chrome plated. Designs which rely on the gear reducer for radial and
axial thrust of the pump are not acceptable except on polymer
service. Bearings must be held in place with solid metal shoulders.
Snap ring designs are not acceptable, except on polymer service.
b. Shaft for polymer pumps
(15LPMP-720, -730, -810, -820, and -830; 15MPMP
-831, -840, -910, -920, and -930)
shall be 316 stainless steel.
6. Bearings:
a. The shaft shall be mounted in two
ball bearings or two tapered roller bearings designed for all radial
and thrust loads encountered in the service conditions. The bearings
shall be pre-lubricated and fully sealed and shall have a minimum
B-10 life of 100,000 hours. Manufacturer shall submit proof that
bearings meet this requirement.
b. Bearings for polymer pumps
(15LPMP-720, -730, -810, -820, and -830;
15MPMP -831, -840, -910, -920, and
-930) shall be 316 stainless steel.
7. Stuffing Box:
a. Stuffing box shall be provided
with tapped connection for seal liquid. The stuffing box shall be
sealed with a split mechanical seal per Section 11210, Pumps and
Equipment, General. Stuffing box shall be sealed with a source of
water external from the pump. A 3/4 inch drain in the stuffing box
shall be provided.
b. All wetted components including
seals metal parts for the polymer pumps
(15LPMP-720, -730, -810, -820, and
-830; 15MPMP -831, -840, -910, -920, and -
930) shall be 316 stainless steel.
8. Baseplate:
a. Each pump and drive unit shall be
mounted on a common baseplate of neat design, with rounded corners.
All exposed seams and contact surfaces of steel plates and shapes
shall be continuously welded and ground smooth. Pipe tapped
openings shall be provided to ensure positive drainage from the
base. At least one drain opening shall be provided for each base. A
½ inch NPT drain connection shall be provided to convey leakage to
the nearest floor drain.
b. Openings shall be provided in the
top of the base to facilitate grouting. An opening shall also be
provided, if necessary, for electrical conduit to the drive unit.
9. Anchor Bolts
a. Anchor bolts shall be accurately
located and centered in pipe sleeves having an inside diameter and
length as shown on the Standard Drawings.
b. Anchor bolts for the polymer
pumps (15LPMP-720, -730, -810, -820, and -
830; 15MPMP -831, -840, -910, -920,
and -930) shall be 316 stainless steel.
2.2 MOTORS AND DRIVES
A. Motors shall conform to the
requirements listed in Table 1. All motors shall be TEFC, with a
Class 1, Division 2 rating, suitable for wet and corrosive
environments, and conform to the requirements specified in
Section 16220, Electric Motors. Motor orientation shall be as
shown on the Drawings.
B. Motor nameplate horsepower shall
be the maximum noted in Table 1 except that the pump motor shall not
be overloaded nor operate within the service factor at any point on
the published pump curve up to the maximum pump speed and the
pressures noted in Table 1.
C. Selection of the motor bearing
sizes shall be based on a B-10 life of 100,000 hours.
D. Motors shall be driven by constant
torque VFD’s and shall be inverter duty rated, compatible with the
variable frequency drive controllers specified under Section 16418
and 16419. Each motor shall be of adequate power for starting
and continuously operating its respective pumping unit under all
specified load conditions without overloading. .
E. The drive unit shall operate the
pump at the speed noted in Table 1.
F. The pumps shall be suitable for
Class 1, Division 2 and wet and corrosive area installation.
2.3 ACCESSORIES
A. Each pump shall be equipped with
suction vacuum switch and discharge pressure switch to protect
against a closed suction or discharge valve situation. Switches
shall be mounted on stainless steel annular pressure sensors mounted
off-line with isolation ball valves mounted above, and below the
pressure sensor ring to allow removal of the unit, or facilitate
sampling. They shall be wired under Division 16, Electrical.
B Each pump shall be supplied with
a three (3) inch minimum diameter pressure relief valve with an
integral limit switch. The pressure relief valve shall be
constructed with a cast iron body and ductile iron cover, to
withstand severe shock conditions. The body shape shall be 90°
angle pattern to permit side or downward discharge. The cover shall
provide an air gap between the surge valve and the hydraulic
cylinder. The valve stem shall be connected to the hydraulic
cylinder by means of a self aligning universal connector to
provide smooth positive opening, without binding. The hydraulic
cylinder shall be removable from the valve without dismantling or
removing the valve from the line. The closing speed shall be
externally adjustable by means of a coded micrometer control valve.
The valve disc shall be normally closed against the system operating
pressure by means of a spring or springs. When the system pressure
exceeds the factory setting of 90 psig the surge relief valve shall
open immediately to relieve the pressure surge and close slowly as
the system pressure returns to normal. The hydraulic cylinder shall
be capped on both ends (totally enclosed) to prevent dirt or dust
from fouling up the cylinder operation. It shall be fitted with an
atmospheric oil reservoir. The relief pressure shall be set at the
factory. The valve shall be field adjustable by increasing or
decreasing the tension on the externally adjustable springs. The
surge relief valve shall be constructed of the following materials:
1. Body shall be Cast Iron ASTM A126
Grade B
2. Body Seat Ring shall be Aluminum
Bronze ASTM B148
3. Cover shall be Ductile Iron ASTM
A536
4. Disc Seat shall be Buna-N
5. Disc shall be Steel ASTM A36
C. Each polymer pump (15LPMP-720,
-730, -810, -820, and -830; 15MPMP -831, -840,
-910, -920, and -930) shall be
supplied with 1 1/2-inch diameter pressure relief valve. Valve body,
top, spring and all wetted components shall be 316 stainless steel.
Diaphragm shall be Teflon/Viton or 316 stainless steel disc. Seals
and/or O-rings shall be Teflon or Teflon encapsulated Viton. Valve
shall be adjustable in the range of 10 to 250 pounds per inch. Valve
shall be rated for pressure of 400 pounds per inch. Valve shall have
flanged connections. Pressure relief valve shall be manufactured by,
Or Equal:
1. Tyco/Kunkle Valve Model 171S
2. Griffco Valve, Model G-Series
D. The couplings shall be effectively
covered by means of protective metal guards, conforming to OSHA
standards.
E. The pump, motor, speed reducer
and couplings shall all be accurately aligned and mounted on a
fabricated structural steel base.
F. A seal water system shall be
provided for each pump as shown on the Drawings. G. Provide rotor
locking to prevent reverse rotation.
PART 3 EXECUTION
3.1 INSTALLATION
A. All materials and equipment shall
be installed in a neat, workmanlike manner.
B. All wiring of the equipment shall
be as specified under Division 16, Electrical, of these
Specifications.
C. All equipment specified
herein shall be installed in accordance with the
manufacturer's recommendations and the Drawings.
D. Where anchor bolts and other parts
to be embedded in concrete are required, such parts shall be
furnished to the site in advance of the equipment along with
templates and instructions for their installation.
E. Such installation shall be done
under Division 3, Concrete.
3.2 PAINTING
A. Shop painting and the surface
preparation is a part of the Work specified in this section and
shall be as specified in Section 09800, Protective Coatings.
Stainless steel shall not be painted.
3.3 CLEAN-UP
A. Prior to start-up and field
testing, all foreign matter shall be removed from the pumps,
interconnecting piping, and spillage of lubricants used in servicing
the equipment shall be cleaned from pumps, piping and concrete
surfaces.
3.4 LUBRICATION REQUIREMENTS
A. All lubricants required for the
first year of operation shall be provided for the system.
3.5 MAINTENANCE OF INSTALLED
EQUIPMENT
A. Maintain the operability and
functionality of all installed equipment between the time of
installation and the commissioning period. See Specification
section 01660 for requirements.
3.6 MANUFACTURER’S FIELD
SERVICES
A. Furnish the services of
authorized technical representatives of the Manufacturer to
assist/inspect the installed equipment and to certify that the
equipment has been properly installed and is ready to operate, train
OCSD personnel, conduct pre-operational mechanical checkout of the
equipment, place equipment into operation, optimize the performances
of the equipment and perform the field performance testing.
B. Conduct multiple separate site
visits as follows:
1. Inspection of equipment
installation – four trips
a. Trickling Filter Sludge Pumps –
two trips (4 hours minimum, each)
b. Polymer Pumps (8 hours minimum)
c. Centrifuge Feed Pumps (8 hours
minimum)
2. Training of OCSD Personnel. See
Specification section 01820 for requirements.
3. Commissioning. See Specification
section 01810 for requirements. Number of trips and hours shall be
as required to meet all testing and commissioning requirements, but
shall not be less than 60 hours.
3.7 SPARE PARTS
A. Spare parts shall be provided for
the equipment furnished as outlined in Table 1.
3.8 PUMP TESTS
A. Pump tests shall be performed for
all equipment supplied under this section as outlined in Section
11210, Pumps and Equipment and Section 01810, Commissioning.
SEE FOLLOWING TABLE 1
TABLE 1
SPECIFIC CONDITIONS AND REQUIREMENTS
PROGRESSING CAVITY PUMPS
A. Design Conditions:
|
|
|
|
Fluid
Conveyed |
Design Flow Condition (gpm) |
|
|
|
Maximum Pump Speed (rpm) |
Motor
(hp) |
Type of Seal
Mfg No./ Or Equal |
|
|
15LPMP110,
210, 310 |
|
|
0.5-3.5 percent
WAS/Primary
Sludge |
|
|
|
|
|
|
Single Seal
Chesterton 442
Split Seal w/ Flushing |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor with VFD |
|
15LPMP510,
520,540,
550,570,580 |
Co-Thickened
Sludge Transfer Pumps |
|
4-6.5 percent
Centrifuge Thickened Sludge |
|
|
|
|
|
|
Single Seal
Chesterton 442
Split Seal w/ Flushing |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor with VFD |
|
15LPMP720,
730 |
|
|
|
|
|
|
|
|
|
Double Seal
Chesterton Model 280 w/ silicon carbide faces |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor Constant Speed |
|
15LPMP810,
820,830 |
|
|
|
|
|
|
|
|
|
Double Seal
Chesterton Model 280 w/ silicon carbide faces |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor with VFD |
|
15MPMP100,
200,300 |
|
|
|
|
|
|
|
|
|
Single Seal
Chesterton 442
Split Seal w/ Flushing |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor with VFD |
|
15MPMP831
840 |
|
|
|
|
|
|
|
|
|
Double Seal
Chesterton Model 280 w/ silicon carbide faces |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor Constant Speed |
PROGRESSING CAVITY PUMPS
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
11309-8
February 2012
|
|
|
|
Fluid
Conveyed |
Design Flow Condition (gpm) |
|
|
|
Maximum Pump Speed (rpm) |
Motor
(hp) |
|
|
|
15MPMP910
920,930 |
|
|
|
|
|
|
|
|
|
Double Seal
Chesterton Model 280 w/ silicon carbide faces |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor with VFD |
|
12BPMP100,
110 |
Trickling Filter
Sludge Pumps |
Trickling
Filter Sludge/ Scum Pump Station |
|
|
|
|
|
|
|
Single Seal
Chesterton 442
Split Seal w/ Flushing |
480 V, 3 PH, 60
HZ, Class 1, Division 2 motor with VFD |
B. Manufacturers’ field services
shall be as specified in Section 01810, Commissioning.
C. Manufacturers’ training of OCSD
personnel shall be as specified in Section 01820, Training of OCSD
Personnel. D. The following spare parts shall be furnished, one set
for each system:
1. Rotor
2. Stator
3. Shaft sleeve
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