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Specification (DOC)
1.0 GENERAL: Furnish and install a fully assembled duplex grinder pump package consisting of the grinder pumps, basin assembly, internal discharge piping, check valves, shut-off valves, quick-disconnect guide rail system, lifting cables, four float level controls, level control bracket, junction box, 4” SCH 40 (standard) inlet fitting(s) and control panel. All equipment shall be factory installed except for the grinder pump(s), inlet fitting(s) and externally mounted control panel.
1.1 MANUFACTURER: The manufacturer of the grinder pump station shall be Environment One Corporation.
1.2 SUBMITTALS: After receipt of notice to proceed, the manufacturer shall furnish a minimum of six sets of shop drawings detailing the equipment to be furnished including dimensional data and materials of construction. The Manufacturer shall also submit detailed installation and user instructions for its product and submit evidence of an established service program including complete parts and service manuals. The Engineer shall promptly review this data, and return two copies as accepted, or with requested modifications. Upon the Engineer’s acceptance of the shop drawings and the Manufacturer’s receipt of notice to proceed, the Manufacturer shall begin fabrication of the equipment.
1.3 WARRANTY: The grinder pump manufacturer shall provide a standard limited warranty on complete stations, accessories and control panels for a period of 12 months from the date of installation, or 18 months from the date of shipment, whichever occurs first. Any material or craftsmanship defects not associated with faulty installation, operation or maintenance found during the warranty period will be corrected by the Manufacturer at no cost to the Owner.
2.0 BASIN: Fiberglass Construction. The tank shall consist of a single wall, laminated fiberglass construction. The resin used shall be of a commercial grade suitable for the environment. The reinforcing material shall be a commercial grade of glass fiber capable of bonding with the selected resin. The inner surface shall have a smooth finish and be free of cracks and crazing. The exterior tank surface shall be relatively smooth with no exposed fiber or sharp projections present.
The tank wall and bottom shall be of sufficient thickness and construction to withstand the imposed loading due to saturated soil at the specified burial depth for each available tank height. All station components must function normally when exposed to the external soil and hydrostatic pressures developed at the specified burial depth. The tank bottom shall be reinforced with a fiberglass plate extending beyond the tank walls to support concrete anchoring, as required, to prevent flotation.
2.1 BASIN COVER: A one-piece, aluminum, hatched cover shall be provided with each basin assembly. A cover gasket shall also be provided. Covers shall be bolted to the basin with stainless steel cap screws. Non-corroding stainless steel threaded inserts shall be fully encapsulated in the upper flange of the fiberglass basin.
2.2 LIFT-OUT RAIL ASSEMBLY: The lift-out rail system shall permit easy removal and installation of pumps without the necessity of personnel entering the basin. Each rail assembly shall consist of a ductile iron lift-out base/elbow assembly, stainless steel guide rails and stainless steel guide rail brackets. The lift-out elbow for the base assembly shall contain a dovetailed groove and sealing O-ring on the face to provide a leak-proof seal at all operating pressures. The guide rails are to be of sufficient strength to prevent binding and facilitate easy removal and installation of pumps. The lift-out base elbow incorporates a non-binding stainless steel guide bracket. The guide rail design must be stress-free once the pump is located within the base assembly.
2.3 CHECK VALVE: The check valve shall contain a free flowing sealing method, unobstructive to the flow of liquids and solids within the discharge piping. The valve design shall allow for operation when negative heads up to 5 feet are encountered. The valve shall contain a maintenance access port capable of servicing the valve without disrupting the existing piping. The valve shall be designed to operate at all pressures within the sewer system created by the grinder pumps.
2.4 SHUT-OFF VALVE: PVC, ¼ turn ball type shut-off valves with Teflon seats shall be furnished as an integral part of the internal piping assembly. An extension handle shall be supplied if the discharge depth is greater than 18” from the surface.
2.5 DISCHARGE PIPING: Schedule 80 PVC discharge piping shall connect to the stationary discharge base lift-out assembly and terminate at a 2” stainless steel discharge flange mounted on the basin at the height shown in the plans. The discharge flange shall be manufactured of stainless steel. The discharge flange shall have 2” female NPT threads for attaching external discharge piping.
2.6 INLET FITTING: An inlet fitting for 4,” 6” or 8” SCH 40 or SDR 35 plastic pipe shall be shipped loose for field installation. The fitting shall create a water- and vapor-tight seal without the use of caulking. Consult the contract drawings for the number of, size and type of inlet fittings required.
2.7 LEVEL CONTROLS: Pump on, off and alarm levels shall be controlled by four mechanical floats. Switches shall be sealed in a corrosion-resistant polypropylene housing and shall use a minimum of 18 gauge, 2-wire, SJOW/A jacketed cable. The level controls shall be suspended by an externally weighted cord from a stainless steel bracket so that adjustment or replacement may be done without entering the basin and without the use of any specialized tools. Level controls shall be UL/CSA listed.
2.8 JUNCTION BOX: The NEMA 6 junction box shall be constructed of structural plastic for corrosion resistance and of adequate thickness to provide stability and mechanical strength. The junction box shall have a fully gasketed cover that is held in place by four captive stainless steel screws with heads of adequate size so that they may be easily installed and removed without the use of special tools. An adequate number of sealing-type cord grips shall be supplied for incoming pump and level control cords. The cord grips shall be made of a non-corrosive material, such as PVC or nylon, and shall make an effective seal around the wire jacket. The cord grips shall seal to the junction box with an O-ring or gasket.
The junction box shall have a PVC solvent weld socket type conduit hub of adequate size to accommodate the number of wires required for the pump and level control operation. The incoming wires shall be sealed by an external EY type seal-off (supplied by others) so condensation from the conduit or groundwater will not enter the enclosure. The interior of the enclosure shall be of adequate size to accommodate the wires and connections for pump and level control operation. The wires running between the control panel and the junction box shall be color-coded and fastened to the pump and level controls by means of adequately sized and insulated twist lock or crimp connectors.
2.9 CONTROL PANEL, 4 FLOAT: (Separate from basin assembly). A NEMA 4X fiberglass control panel shall be furnished with each basin package. The control panel shall be molded of glass reinforced polyester resins that are chemically resistant to corrosive atmospheres. The resin system shall be pigmented to impart a gray color to the enclosure and be resistant to ultraviolet light. The resin system shall include a flame retardant to obtain flammability rating that meets UL 94V-O. Heat distortion temperature shall be 350 degrees Fahrenheit. The enclosure shall be hinged with a heavy-duty, corrosion-resistant, stainless steel piano hinge. Two stainless steel lockable clasps shall be incorporated in the enclosure. The complete control box assembly shall conform to UL 508 standards.
The enclosure shall be of one piece with smooth, rounded corners and shall be constructed to have a smooth exterior and interior. The enclosure shall be fitted with a closed cell neoprene gasket cover. The enclosure shall have back panel mounting provisions. The enclosure shall be provided with external mounting feet on the top and bottom of the enclosure. These mounting feet shall be of fiberglass and molded as an integral part of the enclosure. The back panel shall be a minimum of .080” aluminum and held in place by four #10 screws, which will mate to four threaded standoffs, which are molded into the enclosure.
The panel shall include: main disconnect circuit breakers; alarm circuit breaker; two IEC-rated motor contactors; two sets of start and run capacitors (single-phase only); two plug-in control relays; alternator relay; two pump hand-off-auto switches; red alarm light; audible alarm; alarm silence switch; enclosed wire way; terminal blocks; ground lug; and all necessary wiring. Terminal strips must have a minimum 3” clearance to the inside wall of the enclosure for ease of wiring.
The control panel shall be fitted with a red lexan alarm light. The light shall remain solidly illuminated for moisture detection in the lower seal chamber of the pump. The alarm light shall flash, indicating a high water alarm condition in the basin. The light shall be approximately 3” high by 2” diameter, mounted on the top surface of the enclosure, visible from 360 degrees. The bulb shall be 40-watt minimum, high intensity, medium base type. The bulb or lens shall be easily replaced by removing a threaded setscrew and locking washer on the interior of the panel. The lens shall be mounted on top of the enclosure with a neoprene gasket and must maintain the NEMA 4X rating.
The alarm condition will produce a bright glowing alarm light and audible buzzer. The audible buzzer can be silenced by means of the silence switch inside the front panel. The red indicator light will remain illuminated as long as the alarm condition persists. Both flashing alarm light and audible buzzer will stop when the water level drops to normal operating conditions.
All internal wiring shall be neatly assembled within an enclosed wire way. Each wire shall be a different color or stripe (except for ground), and all incoming wires shall terminate in the terminal block. All wires shall be 14GA. Type TEW rated for 105 degrees Celsius.
A schematic diagram shall be permanently fastened to the inside of the enclosure.
The control panel shall be UL listable as an assembly.
The control circuitry shall include thermal overload protection, automatically stopping pump operation if overheating is sensed inside the motor housing of the pump. Pump operation will automatically resume once overheating conditions have passed.
2.10 GRINDER PUMP MODEL: The pumps shall incorporate an integrally built-in grinder unit and submersible type motor. The grinder unit shall be capable of macerating all material in normal domestic and commercial sewage, including reasonable amounts of foreign objects such as sanitary napkins, disposable diapers, thin rubber, small wood, plastic and the like to a fine slurry that easily pass through the pump and 2” discharge pipe. Pump discharges shall be standard 2.5” / 3”, 150 lbs ANSI horizontal flange.
2.11 OPERATING CONDITIONS: The pump shall have a capacity of _______ GPM at a total head of _______ feet, and shall use a motor rated at ______ HP and 3450 RPM.
2.12 PUMP IMPELLER: Ductile iron and threaded on a stainless steel shaft. The impeller shall be of the recessed vortex type to provide an unobstructed passage through the volute for the ground solids.
2.13 GRINDER CONSTRUCTION: Both grinder impellers and shredding ring shall be of 440C stainless steel hardened to 56-60 Rockwell C. The grinder assembly shall consist of a grinder impeller and shredding ring mounted directly below the volute passage. The grinder impeller is threaded to a stainless steel shaft, locked with a screw and washer. The shredding ring shall be pressed into an iron holding flange for easy removal. The flange shall be provided with tapped back-off holes so screws can be used to push the shredding ring from the housing. All grinding of solids shall be from the action of the grinder impeller against the shredding ring. There shall be 17,250 cuts / second (High Flow) or 12,400 cuts/second (High Head).
2.14 SEALS: Type 21, dual mechanical seal construction mounted in tandem, shall protect the motor. Primary seal shall be silicon carbide. Secondary seal shall be silicon carbide. The seal face shall be lapped to a flatness of one light band. A double electrode shall be mounted in the seal chamber to detect water entering the chamber through the lower seal. Water in the chamber shall cause a red light to turn on at the control box. This signal shall not stop the motor, but shall act as a warning only, indicating service is required.
2.15 MOTOR: The pump motor shall be of the submersible type, rated at _____ HP and 3450 RPM. The motor shall be for 60 Hz, _______volt, single phase (capacitor start/capacitor run), or three-phase operation. Major operating temperature must not exceed Class B ratings. The stator winding shall be of the open type with Class F insulation. Motor shall be oil-filled and shall transfer heat efficiently. Continuous lubrication shall be provided to bearings. An upper motor bearing cap shall be a separate casting for easy mounting and replacement. The motor shall have two heavy-duty ball bearings to support the pump shaft, taking radial and thrust loadings. A sleeve guide bushing is mounted directly above the lower seal to take radial load and act as a flame path for the seal chamber. Ball bearings shall be designed for a minimum 50,000 hours B-10 life. The stator shall be pressed into the motor housing. The common motor pump and grinder shaft shall be of 416 SST, threaded to take the pump and grinder impeller.
Motors shall have a heat sensor thermostat attached to the top end of the motor windings to stop the motor if the winding temperature reaches 200 degrees F. The high temperature shut-off will cause the pump to cease operation. The thermostat shall automatically reset when the motor cools to a safe operating temperature.
2.16 POWER CORD / CONTROL CORD: Each motor power cord shall be 10 Gauge, SOW/SOWA or SOOW. The control cord shall be 40 feet in length, 18 Gauge SJOW/SOW. Both cable jackets shall be sealed at the motor entrance by means of a rubber compression washer and compression nut. An epoxy filled cord cap shall seal the outer cable jackets and individual leads to prevent water from entering the motor housing. Individual conductor strands shall be soldered within the epoxy seal. Cords shall withstand a pull of 300 pounds.
3.0 START-UP AND FIELD TESTING: The manufacturer shall provide the services of qualified, factory-trained technician(s) who shall inspect the placement and wiring of each station, perform field tests and instruct the owner’s personnel in the operation and maintenance of the equipment before the stations are accepted by the owner.