USACE / NAVFAC / AFCESA / NASA UFGS-33 32 13.13 (January 2008) -------------------------------- Preparing Activity: NASA UFGS-33 32 13.13 40 (April 2007) UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated January 2009 SECTION 33 32 13.13 PACKAGED SEWAGE LIFT STATIONS, WET WELL TYPE 01/08 NOTE: This specification covers the requirements for furnishing and installing a package-type underground sewage-lift station of a capacity required by the project. Edit this guide specification for project specific requirements by adding, deleting, or revising text. For bracketed items, choose applicable items(s) or insert appropriate information. Remove information and requirements not required in respective project, whether or not brackets are present. Comments and suggestions on this guide specification are welcome and should be directed to the technical proponent of the specification. A listing of technical proponents, including their organization designation and telephone number, is on the Internet. Recommended changes to a UFGS should be submitted as a Criteria Change Request (CCR). PART 1 GENERAL 1.1 REFERENCES NOTE: This paragraph is used to list the publications cited in the text of the guide specification. The publications are referred to in the text by basic designation only and listed in this paragraph by organization, designation, date, and title. Use the Reference Wizard's Check Reference feature when you add a RID outside of the Section's Reference Article to automatically place the reference in the Reference Article. Also use the Reference Wizard's Check Reference feature to update the issue dates. References not used in the text will automatically be deleted from this section of the project specification when you choose to reconcile references in the publish print process. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)AASHTO M 198(2008) Standard Specification for Joints for Concrete Pipe, Manholes and Precast Box Sections Using Preformed Flexible Joint SealantsAMERICAN WATER WORKS ASSOCIATION (AWWA)AWWA C104/A21.4(2003) Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for WaterAWWA C110/A21.10(2008) Ductile-Iron and Gray-Iron Fittings for WaterAWWA C111/A21.11(2000) Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and FittingsAWWA C115/A21.15(2005) Flanged Ductile-Iron Pipe With Ductile-Iron or Gray-Iron Threaded FlangesAWWA C151/A21.51(2002; Errata 2002) Ductile-Iron Pipe, Centrifugally Cast, for WaterAWWA C207(2007) Standard for Steel Pipe Flanges for Waterworks Service-Sizes 100 mm through 3600 mm 4 in. through 144 in.ASME INTERNATIONAL (ASME)ASME B16.1(2005) Standard for Gray Iron Threaded Fittings; Classes 125 and 250ASME B16.11(2005) Forged Fittings, Socket-Welding and ThreadedASME B16.3(2006) Malleable Iron Threaded Fittings, Classes 150 and 300ASME B31.3(2008) Process PipingASTM INTERNATIONAL (ASTM)ASTM A 105/A 105M(2005) Standard Specification for Carbon Steel Forgings for Piping ApplicationsASTM A 123/A 123M(2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel ProductsASTM A 36/A 36M(2008) Standard Specification for Carbon Structural SteelASTM A 53/A 53M(2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and SeamlessASTM A 536(1984e1; R 2004) Standard Specification for Ductile Iron CastingsASTM A 615/A 615M(2008b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete ReinforcementASTM C 443(2005a) Standard Specification for Joints for Concrete Pipe and Manholes, Using Rubber GasketsASTM C 443M(2007) Standard Specification for Joints for Concrete Pipe and Manholes, Using Rubber Gaskets (Metric)ASTM C 478(2008) Standard Specification for Precast Reinforced Concrete Manhole SectionsASTM C 478M(2008e1) Standard Specification for Precast Reinforced Concrete Manhole Sections (Metric)ASTM C 618(2008a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in ConcreteASTM C 989(2006) Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and MortarsHYDRAULIC INSTITUTE (HI)HI M100(2005) Complete Set of Centrifugal, Reciprocating, Rotary and Vertical Centrifugal/Vertical Pump StandardsINTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)ISO 1940-1(2003; Corrigendum 2005) Mechanical Vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1: Specification and Verification of Balance Tolerance - International RestrictionsISO 2858(1975) End Suction Centrifugal Pump (Rating 16 Bar) Designation Nominal Duty Point and Dimensions - International RestrictionsISO 5199(2002) Technical Specifications for Centrifugal Pumps, Class IIISO 7005-2(1988) Metallic Flanges Part 2: Cast Iron FlangesMANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)MSS SP-70(2006) Standard for Cast Iron Gate Valves, Flanged and Threaded EndsMSS SP-86(2002) Guidelines for Metric Data in Standards for Valves, Flanges, Fittings and ActuatorsNATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA 250(2003) Enclosures for Electrical Equipment (1000 Volts Maximum)1.2 SUBMITTALS NOTE: Review Submittal Description (SD) definitions in Section 01 33 00 SUBMITTAL PROCEDURES and edit the following list to reflect only the submittals required for the project. Submittals should be kept to the minimum required for adequate quality control. A “G” following a submittal item indicates that the submittal requires Government approval. Some submittals are already marked with a “G”. Only delete an existing “G” if the submittal item is not complex and can be reviewed through the Contractor’s Quality Control system. Only add a “G” if the submittal is sufficiently important or complex in context of the project. For submittals requiring Government approval on Army projects, a code of up to three characters within the submittal tags may be used following the "G" designation to indicate the approving authority. Codes for Army projects using the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO" for District Office (Engineering Division or other organization in the District Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project Office. Codes following the "G" typically are not used for Navy, Air Force, and NASA projects. Choose the first bracketed item for Navy, Air Force and NASA projects, or choose the second bracketed item for Army projects. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES: _{SD-01 Preconstruction Submittals} Submit _{Material, Equipment, and Fixtures List} in accordance with paragraph entitled, "General Requirements," of this section. _{SD-02 Shop Drawings} Submit the following in accordance with paragraph entitled, "Design Requirements," of this section. _{Fabrication Drawings Erection/Installation Drawings SD-03 Product Data} Submit manufacturer's catalog data and equipment and performance data for the following items: Submit _{Spare Parts Data} also for the following in accordance with paragraph entitled, "General Requirements," of this section. _{Man Hole Chambers EPA-CPG Compliance Entrance Covers Sump Pumps Sewage Pumps Pump Controls Impellers Couplings Bearings Stuffing Boxes Valves Piping Blowers Dehumidifier Electric Motors SD-05 Design Data} Submit _{Design Data} of _Motor/Pumps with Manufacturer part number following: _{Rotor Bars Stator Slots Speed of Rotation Cooling Fan Blades Bearing Manufacturer Bearing Style Bearing Type Balls/Elements Commutator Bars Commutator Brushes SCR Firing Frequencies} (for variable speed motors) _{Pump Impellers SD-07 Certificates} Submit the following in accordance with paragraph entitled, "General Requirements," of this section. _{Listing of Product Installations Safety Considerations} Submit Certificates for the following items in accordance with the applicable reference standards and description of this section. _{Man Hole Chambers Entrance Covers Sump Pumps Sewage Pumps Bearings Pump Controls Impellers Couplings Stuffing Boxes Valves Piping Blowers Dehumidifier Electric Motors SD-08 Manufacturer's Instructions} Submit manufacturer's instructions including special provisions required to install equipment components and system packages for the following items. Submit operating instructions, including standard operating procedures with startup, shutdown, and emergency operation for _{Package Lift Station}, and the following: _{Man Hole Chambers Entrance Covers Sump Pumps Sewage Pumps Pump Controls Impellers Couplings Stuffing Boxes Valves Piping Blowers Dehumidifier Electric Motors} Submit the following in accordance with paragraph entitled, "General," of this section. _{Preventative Maintenance and Inspection Special Tools Posted Instructions SD-10 Operation and Maintenance Data} Submit _{Operation and Maintenance Manuals} for package lift stations including the following in accordance with paragraph entitled, "Operation and Maintenance," of this section. _{Equipment Description Assembly and Installation Procedures Adjustment and Alignment Checkout Procedures Procedures of Operation Troubleshooting} 1.3 DESIGN REQUIREMENTS Actual range in capacities may vary from that stipulated if the minimum and maximum capacities specified are included. Provide each station with two pumps with controls capable of operating the pumps either simultaneously or individually, depending on the load conditions. Furnish and install each lift station as a complete unit with necessary appurtenances factory installed within a pump chamber and a vertical entrance tube cover and access ladder, all designed for the following: NOTE: Pump capacity, head, and service life must be as required by the project. Service life - [15] [_____] years Pump capacity - [475] [125] [_____] liter gallons per minute (gpm) Total head - [35] [115] [_____] meter feet Submit _{Fabrication Drawings} after receiving tentative approval of the equipment and the materials list but before installation, Contractor to submit drawings covering necessary or recommended changes to accommodate the equipment offered. Show clearly on the drawings the design of the chamber, with dimensions, types, and thicknesses of materials, and elevation levels with reference to those elevations indicated. Submit _{Erection/Installation Drawings} for the manhole chamber with the required equipment and accessories that are inclusive. Precast reinforced concrete manhole sections must conform to ASTM C 478M ASTM C 478, and AASHTO M 198 . Show clearly on the drawings the design of the chamber, with dimensions, types, and thicknesses of materials, and elevation levels with reference to those elevations indicated. Provide the following _{motor/pumps design data} provided prior to final turnover - number of motor _{rotor bars} and _{stator slots}; number of _{cooling fan blades}; RPM of motor; _bearings, _{bearing manufacturer}, _{bearing type}, _{bearing style} and number of _{balls/elements}; number of _{commutator bars} and _{commutator brushes}; _{SCR firing frequencies}; and number of _{pump impellers}. 1.4 PROTECTION FROM MOVING PARTS Locate and guard belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts in accordance with applicable OSHA standards and so that personnel are properly protected from injury. 1.5 NAMEPLATES Provide4 the manufacturer's name or trademark on a corrosion-resistant identification plate or cast integrally, on each item of equipment, stamped, or otherwise permanently marked in a conspicuous place. Include on the pump identification plate the pump capacity in liter per minute gpm, pump head in meter, feet, and _{speed of rotation} . Cast on the body of the pump the direction of rotation On the identification plate indicate all necessary information to complete identification such as the manufacturer. 1.6 FIELD REPRESENTATIVE A representative of the lift station manufacturer must direct the startup of the station and instruct representatives of the Government in startup and operation procedures. 1.7 GENERAL REQUIREMENTS Submit _{Material, Equipment, and Fixtures List} of all major components including manufacturer's catalog numbers, specification and drawing reference number, warranty information, and fabrication site. Submit _{Listing of Product Installations} similar to the package lift station the Contractor is installing. Submit _{Safety Considerations} including information relating to load limits, speed of operation, environmental criteria (temperature and pressure limitations), and personnel hazards and equipment safety precautions for the package lift station. Submit _{Spare Parts Data}, including a complete list of parts and supplies with current unit prices and source of supply. List parts and supplies that are either normally furnished at no extra cost with the purchase of equipment, or specified to be furnished as a part of the contract, and list additional items recommended by the manufacturer to ensure an efficient operation for a period of one year. PART 2 PRODUCTS Verify conformance of materials and equipment for _{package lift station} to the referenced publications or as specified Verify manufacturers regularly engaged in the manufacture of such products. 2.1 CHAMBER Fabricate [Chamber, including base, walls, and entrance tube with 35 Megapascal 5000 psi precast concrete designed to form an integral unit. [Fabricate wet well as an integral part of the unit with a separate manhole entrance.] Ladder, pipe supports, brackets, and other miscellaneous components of steel conforming to ASTM A 36/A 36M,ASME B16.3 ,ASME B16.11 and hot-dipped galvanized in accordance with ASTM A 123/A 123M.] Fly ash is required as an admixture and must conform to ASTM C 618, Class C or F. Fly ash replacement of cement must not exceed 20 percent (maximum one part fly ash to four parts cement) by weight. NOTE: Ground granulated blast furnace slag and fly ash are materials listed in the EPA's Comprehensive Procurement Guidelines (CPG) (http://www.epa.gov/cpg/). If the Architect/Engineer determines that use of certain materials meeting the CPG content standards and guidelines would result in inadequate competition, do not meet quality/performance specifications, are available at an unreasonable price or are not available within a reasonable time frame, the Architect/Engineer may submit written justification and supporting documentation for not procuring designated items containing recovered material. Written justification may be submitted on a Request for Waiver Form to the NASA Environmental Program Manager for approval. The Request for Waiver Form is located in the NASA Procedures and Guidelines (NPG 8830.1) (http://nodis3.gsfc.nasa.gov ). Ground granulated blast furnace slag [is required] [used] as an admixture [and] must conform to ASTM C 989, Grade [120] with between 25 to 50 percent maximum cement replacement by weight. Submit certificate to verify _{EPA-CPG compliance} Submit _{Man hole chambers}, including base, entrance tube, air ducts, and similar structural parts, with [steel conforming to ASTM A 36/A 36M,ASTM A 615/A 615M] [reinforced fiberglass]. Protect steel from corrosion by means of hot-dip galvanizing conforming to ASTM A 123/A 123M epoxy-resin coatings. 2.2 _{ENTRANCE COVERS} Fabricate entrance-tube cover with reinforced fiberglass or steel. Secure steel covers with bolts to the shaft flanges. 2.3 _{SUMP PUMPS} NOTE: Capacity in liter gallons and the discharge head must be as required by the project. Provide a submersible, direct-motor-driven unit with a capacity of 3800 liter 1,000 gallons per hour at a 12.2 meter 40-foot discharge head. Enclose sump and pump in 6 millimeter 1/4-inch mesh of corrosion-resistant metal. 2.4 _{SEWAGE PUMPS} NOTE: Pump capacity must be as required by the project. Provide pumps of the nonclogging, centrifugal type designed to pump unscreened sewage. Each pump must have a rated capacity as specified and be capable of passing 75 millimeter 3-inch solids. Conform to the requirements of ISO 2858 and ISO 5199 HI M100. [Pump speed must not exceed 1,800 revolutions per minute.] 2.5 _{PUMP CONTROLS} Provide automatic type pump operating controls recommended by the pump station manufacturer, including necessary switches, relays, and appurtenances, complete. Mount controls on a control panel. Make equipment subject to contact with sewage of corrosion-resistant metal. Provide Controls with a high-level switch for remote monitoring. Provide at each station a three-wire receptacle for a portable generator in case there is an external power outage. Provide at each station a double-throw switch in an enclosure conforming to NEMA 250, Type 3R. 2.6 PUMP CONSTRUCTION Fabricate castings in cast iron or steel free from injurious defects. Design castings to permit easy replacement of parts. Joints must be gasketed and must not leak under a test pressure equal to 50 percent more than the pump discharge pressure or total dynamic head, whichever is greater. Design and install passageways to permit the smooth flow of sewage and free from sharp turns and projections. Provide pump castings with cleanout plates in the suction line and drain plugs. 2.7 _IMPELLERS Fabricate Impellers in of cast iron, cast steel, or an alloy suitable for the service required. Impellers must be free flowing and permit objects in the sewage that enter the pump to pass into the discharge pipe. Each impeller must be keyed, splined, or threaded on the shaft and locked in such manner that lateral movement will be prevented and reverse rotation will not cause loosening. 2.8 _COUPLINGS Couplings must be the heavy-duty flexible type, keyed to the shaft. Provide universal type couplings for vertical pumps. 2.9 SHAFT SLEEVES Protect the shaft from the liquid being pumped, points in contact with the stuffing boxes, and other wearing parts with sleeves designed in bronze or a suitable alloy. 2.10 _{STUFFING BOXES} Grease-seal stuffing boxes with a seal ring, designed to ensure tight packing without excessive wear or friction on the shafts, and prevent the leakage of air or water. Provide split type glands which can be easily removed for repacking. 2.11 BALANCE Balance rotating parts of the equipment mechanically and hydraulically to operate throughout the required range without excessive end thrust, vibration, and noise. Comply allowable vibration limits with ISO 1940-1, Table 1. Existence of defects that cannot be eliminated by adjustment will be sufficient cause for rejection of the equipment. 2.12 SHAFTS Provide high-grade steel shafts of a size and strength to perform the work required. NOTE: Specify sealed bearings on motors. Properly installed sealed bearings with warranty for minimal maintenance requirements. 2.13 _BEARINGS Provide ball or roller type main bearings to withstand radial and end thrust. Pumps dependent upon hydraulic balance are prohibited.. 2.14 LUBRICATION Provide [grease type lubrication with fittings for a grease gun and, if not easily accessible, with grease tubing extending to convenient locations. Grease fittings must be the pump manufacturer's standard type .] [self lubricating, permanently sealed] bearings. 2.15 PIPING CONNECTIONS Provide pump suction and discharge with flanged connections of the proper size for the pump type and capacity. Conform pipe flanges to [AWWA C104/A21.4, AWWA C110/A21.10, AWWA C111/A21.11, AWWA C115/A21.15, AWWA C151/A21.51 ,ASTM A 53/A 53M, ASTM A 536 for ductile iron or gray-iron threaded flanges and piping] ASTM A 105/A 105M, MSS SP-86 , ISO 7005-2 ASME B16.1 or AWWA C207. Piping must conform to the requirements of ASME B31.3. 2.16 SUMP PUMP CONTROL NOTE: Insert head differential size. Automatically actuated sump pump by a built-in float responsive to a [_____][_____] mm pascal inchhead differential. 2.17 _VALVES Conform gate valves to MSS SP-70. Provide +horizontal, swing check type check valves. Provide valves permit a free flow of sewage forward and a positive check against backflow. Provide iron body valves with a removable cover for inspection and removal of the gate assembly. Provide bronze gate, gate seats, shaft, studs, and nuts. 2.18 _PIPING Terminate discharge lines 1.5 meter 5-feet outside the lift station in flanged connections. Include the pipe from the wet well manhole in the suction line. External connection joints for pipe using rubber gaskets must comply with the standards ofASTM C 443M ASTM C 443. 2.19 VENTILATING BLOWER _Blowers must maintain one air change every [3] [_____] minutes. Mount A manual and automatic switch on the side of the entrance tube for operation of the blower. Provide vent to atmosphere with covers and screens to prevent the entrance of rain, insects, and rodents. Automatically actuated blower upon opening the entrance tube cover, unless overridden by the manual control. 2.20 _DEHUMIDIFIER Furnish and install a packaged dehumidifier in accordance with lift station manufacturer's recommendations. Include in controls a humidistat and low-temperature cutout /discharge condensate to the wet well. 2.21 EMERGENCY OVERFLOW Provide a gravity-overflow line from the wet well. Terminate overflow line with a headwell and flap valve. 2.22 _{ELECTRIC MOTORS} Motors must be 60-hertz, 3-phase. 2.23 PAINT Treat and paint equipment in accordance with the manufacturer's standard practice for sewage resistance. PART 3 EXECUTION 3.1 GENERAL Install lift station as indicated, in accordance with drawings and the manufacturer's instructions. Submit _{Preventative Maintenance and Inspection} procedure for package lift stations. Procedures should include frequency of preventative maintenance, inspection, adjustment, lubrication, and cleaning necessary to minimize corrective maintenance and repair. Submit _{Special Tools} that are required for maintenance and testing of the package lift stations. Submit _{Posted Instructions} to be posted consisting of labels, signs, and templates of operating instructions that are required to be mounted or installed on or near the package lift stations. 3.2 TESTS Perform Tests, including hydrostatic leak checking of piping and operation of equipment. 3.3 OPERATION AND MAINTENANCE Submit _{Operation and Maintenance Manuals} for package lift stations, including _{Equipment Description}, _{Assembly and Installation Procedures}, _{Adjustment and Alignment}, _{Checkout Procedures}, _{Procedures of Operation} and _{Troubleshooting} .