2000 Series Grinder Pump Stations: Typical Specifications

Semi-Positive Displacement Type Grinder Pump Stations

1.0  GENERAL

1.01  GENERAL DESCRIPTION:  The MANUFACTURER shall furnish complete factory-built and tested Grinder Pump Station(s), each consisting of grinder pump(s) suitably mounted in a basin constructed of high density polyethylene (HDPE) for simplex stations and HDPE or Fiberglass Reinforced Polyester Resin for duplex stations, NEMA 6P electrical quick disconnect (EQD), pump removal system, shut-off valve, anti-siphon valve, check valve, each assembled in the basin, electrical alarm panel, and all necessary internal wiring and controls. Component type grinder pump systems that require field assembly will not be acceptable, due to the potential problems that can occur during field assembly. All components and materials shall be in accordance with section 2.0 of this Product Specification. For ease of serviceability, all pump, motor/grinder units shall be of like type and horsepower throughout the system.

1.02  SUBMITTALS:  After receipt of notice to proceed, the MANUFACTURER shall furnish a minimum of six (6) sets of shop drawings detailing the equipment to be furnished including dimensional data and materials of construction. The ENGINEER shall promptly review this data, and return two (2) copies as accepted, or with requested modifications. Upon receipt of accepted shop drawings, the MANUFACTURER shall proceed immediately with fabrication of the equipment.

1.03  MANUFACTURER:  Grinder pump stations, complete with all appurtenances, form an integral system, and as such, shall be supplied by one grinder pump station manufacturer. The CONTRACTOR shall be responsible for the satisfactory operation of the entire system. The equipment specified shall be a product of a company experienced in the design and manufacture of grinder pumps for specific use in low pressure sewage systems. The company shall submit detailed installation and user instructions for its product, submit evidence of an established service program including complete parts and service manuals, and be responsible for maintaining a continuing inventory of grinder pump replacement parts. The MANUFACTURER shall provide a reference and contact list from ten of its largest contiguous grinder pump installations of the type of grinder pumps described within this specification.

The MANUFACTURER of the grinder pump station shall be E/One Corporation (or Proposed Alternate).

Attention is directed to the fact that the drawings and overall system design are based on a particular piece of equipment from a particular manufacturer. These specifications are intended to provide guidelines for standard equipment of a recognized manufacturer who already meets all the requirements of this specification.

1.03a  ALTERNATE EQUIPMENT:  In the event that the CONTRACTOR or another supplier proposes an Alternate to the specified MANUFACTURER, the ENGINEER recognizes that it will be difficult to conform to certain details of this Specification due to different manufacturing techniques or grinder pump station designs. If proposing an Alternate, the CONTRACTOR (supplier) must submit, no less than 15 business days in advance of the bid date, a complete description of any changes that will be necessary to the system design, a complete submittal package as outlined in Section 1.02 SUBMITTALS, a system hydraulic analysis (including pipe sizes, flows, velocities, retention times and number and location of recommended valves and cleanouts, if any) based on the proposed pump, a list of exceptions to this Specification, and demonstration of compliance to Section 1.04 EXPERIENCE CLAUSE of this Specification. This information must be submitted to the ENGINEER for pre-approval of the alternate equipment being proposed and determination of compliance with these Contract Documents. If the equipment differs materially or differs from the dimensions given on the Drawings, the CONTRACTOR (supplier) shall submit complete drawings showing elevations, dimensions, or any necessary changes to the Contract Documents for the proposed equipment and its installation. Pre-approval, if granted, will be provided in writing by the ENGINEER to the CONTRACTOR (supplier) at least five business days in advance of the bid date. If the ENGINEER’S approval is obtained for Alternate Equipment, the CONTRACTOR (supplier) must make any needed changes in the structures, system design, piping or electrical systems necessary to accommodate the proposed equipment at the expense of the CONTRACTOR (supplier).

1.04  EXPERIENCE CLAUSE:  The equipment furnished hereunder shall be the product of a company experienced in the design and manufacture of grinder pumps specifically designed for use in low pressure systems. All manufacturers proposing equipment for this project shall have at least ten (10) years of experience in the design and manufacture of units of identical size(s) and performance to the specified units. All manufacturers proposing equipment for this project must also have not less than five hundred (500) successful installations of low pressure sewer systems utilizing grinder pumps of like type to the grinder pumps specified herein. An installation is defined as a minimum of twenty-five (25) pumps discharging into a common force main which forms a low pressure sewer system. The contractor (supplier) proposing alternate equipment shall also submit, as part of the bid schedule, an installation list with contact person(s), phone number(s) and date(s) of installation of at least ten (10) installations of the type of pump specified herein that have been in operation for at least 10 years.

In lieu of this experience clause, the contractor (supplier) of alternate equipment will be required to submit a five (5) year performance bond for one-hundred (100) percent of the stipulated cost of the equipment as bid and as shown in the Bid Schedule. This performance bond will be used to guarantee the replacement of the equipment in the event that it fails within the bond period.

1.05  OPERATING CONDITIONS:  The pumps shall be capable of delivering 15 GPM against a rated total dynamic head of 0 feet (0 PSIG) and 9 GPM against a rated total dynamic head of 138 feet (60 PSIG). The pump(s) must also be capable of operating at negative total dynamic head without overloading the motor(s). Under no conditions shall in-line piping or valving be allowed to create a false apparent head.

1.06  WARRANTY:  The grinder pump MANUFACTURER shall provide a part(s) and labor warranty on the complete station and accessories, including, but not limited to, panel and redundant check valve, for a period of twenty-four (24) months after notice of OWNER’S acceptance, but no greater than twenty-seven (27) months after receipt of shipment. Any manufacturing defects found during the warranty period will be reported to the MANUFACTURER by the OWNER and will be corrected by the MANUFACTURER at no cost to the OWNER.

1.07  WARRANTY PERFORMANCE CERTIFICATION:  As a bid certification requirement, each bidder shall provide with their bid schedule a Warranty Performance Certification statement executed by the most senior executive officer of the grinder pump MANUFACTURER, which certifies a minimum of a twenty four (24) month warranty. They must further detail any exclusions from the warranty or additional cost items required to maintain the equipment in warrantable condition, including all associated labor and shipping fees, and certify that the MANUFACTURER will bear all costs to correct any original equipment deficiency for the effective period of the warranty. All preventive maintenance type requirements shall be included in this form as exclusions. These requirements include, but are not limited to, unjamming of grinder mechanism, unplugging of lines, periodic motor maintenance, and periodic cleaning of liquid level controls. Should the CONTRACTOR (supplier) elect to submit a performance bond in lieu of the experience clause outlined above, this Warranty Performance Certification shall also be used as a criterion to evaluate the CONTRACTOR’S (supplier’s) performance over the warranty period. A Warranty Performance Certification form is included with the bid schedule and must be completed and submitted as part of the bid package. Bids with incomplete forms or missing forms will be considered nonresponsive.

2.0  PRODUCT

2.01  PUMP:  The pump shall be a custom designed, integral, vertical rotor, motor driven, solids handling pump of the progressing cavity type with a single mechanical seal. The rotor shall be through-hardened, highly polished, precipitation hardened stainless steel. Plating on the rotor will not be acceptable due to its tendency to delaminate. The stator shall be of a specifically compounded ethylene propylene synthetic elastomer. The material shall be suitable for domestic wastewater service. Its physical properties shall include high tear and abrasion resistance, grease resistance, water and detergent resistance, temperature stability, excellent aging properties, and outstanding wear resistance. Buna-N is not acceptable as a stator material because it does not exhibit the properties as outlined above and required for wastewater service.

2.02  GRINDER:  The grinder shall be placed immediately below the pumping elements and shall be direct-driven by a single, one-piece motor shaft. The grinder impeller assembly shall be securely fastened to the pump motor shaft by means of a threaded connection attaching the grinder impeller to the motor shaft. Attachment by means of pins or keys will not be acceptable. The grinder will be of the rotating type with a stationary hardened and ground stainless steel shredding ring spaced in close annular alignment with the driven impeller assembly, which shall carry two hardened type 400 series stainless steel cutter bars.

This assembly shall be dynamically balanced and operate without objectionable noise or vibration over the entire range of recommended operating pressures. The grinder shall be constructed so as to eliminate clogging and jamming under all normal operating conditions including starting. Sufficient vortex action shall be created to scour the tank free of deposits or sludge banks which would impair the operation of the pump. These requirements shall be accomplished by the following, in conjunction with the pump:

a. The grinder shall be positioned in such a way that solids are fed in an upward flow direction.
b. The maximum flow rate through the cutting mechanism must not exceed 4 feet per second. This is a critical design element to prevent jamming and as such must be adhered to.
c. The inlet shroud shall have a diameter of no less than 5 inches. Inlet shrouds that are less than 5 inches in diameter will not be accepted due to their inability to maintain the specified 4 feet per second maximum inlet velocity which by design prevents unnecessary jamming of the cutter mechanism and eliminates blinding of the pump by large objects blocking the inlet shroud.
d. The impeller mechanism must rotate at a nominal speed of no greater than 1800 rpm.

The grinder shall be capable of reducing all components in normal domestic sewage, including a reasonable amount of “foreign objects,” such as paper, wood, plastic, glass, rubber and the like, to finely-divided particles which will pass freely through the passages of the pump and the 1-1/4" diameter stainless steel discharge piping.

2.03  ELECTRIC MOTOR:  As a maximum, the motor shall be a 1 HP, 1725 RPM, 240 Volt 60 Hertz, 1 Phase, capacitor start, ball bearing, air-cooled induction type with a low starting current not to exceed 30 amperes and high starting torque of 8.4 foot pounds. Inherent protection against running overloads or locked rotor conditions for the pump motor shall be provided by the use of an automatic-reset, integral thermal overload protector incorporated into the motor. This motor protector combination shall have been specifically investigated and listed by Underwriters Laboratories, Inc., for the application. Non-capacitor start motors or permanent split capacitor motors will not be accepted because of their reduced starting torque and consequent diminished grinding capability. To reduce the potential of environmental concerns, the expense of handling and disposing of oil, and the associated maintenance costs, oil-filled motors will not be accepted.

2.04  MECHANICAL SEAL:  The pump/core shall be provided with a mechanical shaft seal to prevent leakage between the motor and pump. The seal shall have a stationary ceramic seat and carbon rotating surface with faces precision lapped and held in position by a stainless steel spring.

2.05  TANK AND INTEGRAL ACCESSWAY (Model 2010) High Density Polyethylene Construction: The tank shall be made of high density polyethylene, with a melt index of 2.0 grams/10 minutes or lower to assure high environmental stress cracking resistance. Corrugated sections are to be made of a double wall construction with the internal wall being generally smooth to promote scouring. Corrugations of the outside wall are to be of a minimum amplitude of 1 1/2" to provide necessary transverse stiffness. Any incidental sections of a single wall construction are to be a minimum .250 inch thick. All seams created during tank construction are to be thermally welded and factory tested for leak tightness. Tank wall and bottom must withstand the pressure exerted by saturated soil loading at maximum burial depth. All station components must function normally when exposed to 150 percent of the maximum external soil and hydrostatic pressure.
The tank shall be furnished with one EPDM grommet fitting to accept a 4.50" OD DWV or Schedule 40 pipe. Tank capacities shall be as shown on the contract drawings.
The accessway shall be an integral extension of the wet well assembly and include a lockable cover assembly providing low profile mounting and watertight capability. Accessway design and construction shall enable field adjustment of station height in increments of 4" or less without the use of any adhesives or sealants requiring cure time before installation can be completed.
The station shall have all necessary penetrations molded in and factory sealed. To ensure a leak free installation no field penetrations shall be acceptable.
All discharge piping shall be constructed of 304 Series Stainless Steel and terminate outside the accessway bulkhead with a stainless steel, 1 1/4 inch female NPT fitting. The discharge piping shall include a stainless steel ball valve rated for 200 psi WOG; PVC ball valves will not be accepted. The bulkhead penetration shall be factory installed and warranted by the manufacturer to be watertight.
The accessway shall include a single NEMA 6P electrical quick disconnect (EQD) for all power and control functions, factory installed with accessway penetrations warranted by the manufacturer to be watertight. Plug-type connections of the power cable onto the pump housing will not be acceptable due to the potential for leaks and electrical shorts. The accessway shall also include a 2-inch PVC vent to prevent sewage gases from accumulating in the tank.
2.06  TANK & INTEGRAL ACCESSWAY (Models 2012 & 2014) High Density Polyethylene Construction:  The tank shall be made of rotationally molded high density polyethylene, with a melt index of 2.0 grams/10 minutes or lower to assure high environmental stress cracking resistance. The tank shall have a nominal thickness of 1/2". All seams created during tank construction are to be thermally welded and factory tested for leak tightness. Tank wall and bottom must withstand the pressure exerted by saturated soil loading at maximum burial depth. All station components must function normally when exposed to 150 percent of the maximum external soil and hydrostatic pressure.

The tank shall be furnished with one EPDM grommet fitting to accept a 4.50" OD DWV or schedule 40 pipe. Tank capacities shall be as shown on the contract drawings.

The accessway shall be an integral extension of the wet well assembly and include a lockable cover assembly providing low profile mounting and watertight capability. Accessway design and construction shall facilitate field adjustment of station height in increments of 3" without the use of any adhesives or sealants requiring cure time before installation can be completed.

The station shall have all necessary penetrations molded in and factory sealed. To ensure a leak-free installation, no field penetrations shall be acceptable.

All discharge piping shall be constructed of 304 Series Stainless Steel and terminate outside the accessway bulkhead with a stainless steel, 1 1/4 inch female NPT fitting. The discharge piping shall include a stainless steel ball valve rated for 200 psi WOG; PVC ball valve will not be accepted. The bulkhead penetration shall be factory installed and warranted by the manufacturer to be watertight.

The accessway shall include a single NEMA 6P electrical quick disconnect (EQD) for all power and control functions, factory installed with accessway penetrations warranted by the manufacturer to be watertight. Plug-type connections of the power cable onto the pump housing will not be acceptable due to the potential for leaks and electrical shorts. The accessway shall also include a 2 inch PVC vent to prevent sewage gases from accumulating in the tank.

2.07  TANK & INTEGRAL ACCESSWAY (Models 2015 & 2016) Fiberglass-Reinforced Polyester Resin: The tank shall be custom molded of fiberglass reinforced polyester resin. Tank wall and bottom must withstand the pressure exerted by saturated soil loading at maximum burial depth. All station components must function normally when exposed to 150 percent maximum external soil and hydrostatic pressure.

The tank shall be furnished with one EPDM grommet fitting to accept a 4.50" OD DWV or schedule 40 pipe. Tank capacities shall be as shown on the contract drawings.

The accessway shall be an integral extension of the wet well assembly and include a lockable cover assembly providing low profile mounting and watertight capability. Accessway design and construction shall facilitate field adjustment of station height in increments of 3” without the use of any adhesives or sealants requiring cure time before installation can be completed.

The station shall have all necessary penetrations molded in and factory sealed. To ensure a leak-free installation, no field penetrations shall be acceptable.

All discharge piping shall be constructed of 304 Series Stainless Steel and terminate outside the accessway bulkhead with a stainless steel, 1 1/4 inch female NPT fitting. The discharge piping shall include a stainless steel ball valve rated for 200 psi WOG; PVC ball valve will not be accepted. The bulkhead penetration shall be factory installed and warranted by the manufacturer to be watertight.

The accessway shall include a single NEMA 6P electrical quick disconnect (EQD) for all power and control functions, factory installed with accessway penetrations warranted by the manufacturer to be watertight. Plug-type connections of the power cable onto the pump housing will not be acceptable due to the potential for leaks and electrical shorts. The accessway shall also include a 2 inch PVC vent to prevent sewage gases from accumulating in the tank.

2.08  CHECK VALVE:  The pump discharge shall be equipped with a factory installed, gravity operated, flapper-type integral check valve built into the stainless steel discharge piping. The check valve will provide a full-ported passageway when open, and shall introduce a friction loss of less than 6 inches of water at maximum rated flow. Moving parts will be made of a 300 series stainless steel and fabric reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly providing a maximum degree of freedom to assure seating even at a very low back-pressure. The valve body shall be an injection molded part made of glass filled PVC. Ball type check valves are unacceptable due to their limited sealing capacity in slurry applications.

Each grinder pump installation shall also include one separate check valve of the type detailed in Section 2.08 for installation in the 1 1/4" service lateral between the grinder pump station and the sewer main, preferably next to the curb stop. The separate check valve shall be provided as a separate line item in the bid schedule.

2.09  ANTI-SIPHON VALVE:  The pump discharge shall be equipped with a factory-installed, gravity-operated, flapper-type integral anti-siphon valve built into the stainless steel discharge piping. Moving parts will be made of 300 series stainless steel and fabric-reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly, providing a maximum degree of freedom to ensure proper operation even at a very low pressure. The valve body shall be injection-molded from a glass-filled thermoplastic resin. Holes or ports in the discharge piping are not acceptable anti-siphon devices, due to their tendency to clog from the solids in the slurry being pumped.

2.10  CORE UNIT:  The Grinder Pump Station shall have cartridge type, easily removable core assembly consisting of pump, motor, grinder, all motor controls, check valve, anti-siphon valve, level control, electrical quick disconnect and wiring. The watertight integrity of each core unit, shall be established by 100 percent factory test at a minimum of 5 PSIG.

2.11  CONTROLS:  All necessary controls, including motor and level controls, shall be located in the top housing of the core unit. The top housing will be attached with stainless steel fasteners.

Non-fouling wastewater level controls for controlling pump operation shall be accomplished by monitoring the pressure changes in an integral air column connected to a pressure switch. The level detection device shall have no moving parts in direct contact with the wastewater. High-level sensing will be accomplished in the manner detailed above by a separate air-bell sensor and pressure switch of the same type. Closure of the high-level sensing device will energize an alarm circuit as well as a redundant pump-on circuit. For increased reliability, pump ON/OFF and High-level alarm functions shall not be controlled by the same switch. Float switches of any kind, including float trees, will not be accepted due to the periodic need to maintain (rinsing, cleaning) such devices.

To assure reliable operation of the pressure switches, each core shall be equipped with a breather assembly, complete with a suitable means to prevent accidental entry of water into the motor compartment. The grinder pump will be furnished with a 6 conductor 14 gauge, type SJOW cable, pre-wired and watertight to meet UL requirements with a FACTORY INSTALLED NEMA 6P EQD half attached to it.

2.12  ALARM PANEL:  Each grinder pump station shall include a NEMA 4X, UL listed ALARM PANEL suitable for wall mounting. The NEMA 4X enclosure shall be manufactured of thermoplastic to assure corrosion resistance. The enclosure shall include a hinged, lockable cover, padlock, and secured dead front. The enclosure shall not exceed 11.38"W x13.5"H x 5.63"D.

For each core, the panel shall contain one (1) 15 amp, double pole circuit breaker for the power circuit and one (1) 15 amp single pole circuit breaker for the alarm circuit. The panel shall contain terminal blocks, integral power bus, push to run feature and a complete alarm circuit.

The Alarm Panel shall include the following features: audio & visual alarm, push-to-run switch, and high level (redundant) pump starting control. The alarm sequence is to be as follows:

a. When liquid level in the sewage wet-well rises above the alarm level, visual and audio alarms will be activated. The contacts on the alarm pressure switch will close. The redundant pump starting system will be energized.
b. The audio alarm may be silenced by means of the externally mounted, push-to-silence button.
c. Visual alarm remains illuminated until the sewage level in the wet-well drops below the "off" setting of the alarm pressure switch.

The visual alarm lamp shall be inside a red fluted lens at least 2 5/8" in diameter and 1 11/16" in height. Visual alarm shall be mounted to the top of the enclosure in such a manner as to maintain NEMA 4X rating. For duplex units, in addition to the above, two high level indicator lights shall be mounted behind the access cover.

During a high level alarm condition on a duplex station, the appropriate light will illuminate to indicate which pump core requires servicing. The audio alarm shall be a printed circuit board in conjunction with an 86 dB buzzer with quick mounting terminal strip mounted in the interior of the enclosure. The audio alarm shall be capable of being deactivated by depressing a push-type switch which is encapsulated in a weatherproof silicone boot and mounted on the bottom of the enclosure.

The entire Alarm Panel as manufactured, shall be listed by Underwriters Laboratories, Inc.

2.13  SERVICEABILITY:  The grinder pump core unit shall have two lifting hooks complete with nylon lift-out harness connected to its top housing to facilitate easy core removal when necessary. All mechanical and electrical connections must provide easy disconnect capability for core unit removal and installation. A push-to-run feature will be provided for field trouble shooting. All motor control components shall be mounted on a readily replaceable bracket for ease of field service.

2.14  OSHA CONFINED SPACE:  All maintenance tasks for the grinder pump station must be possible without entry into the grinder pump station (as per OSHA 1910.146 Permit-required confined spaces). “Entry means the action by which a person passes through an opening into a permit-required confined space. Entry includes ensuing work activities in that space and is considered to have occurred as soon as any part of the entrant’s body breaks the plane of an opening into the space.”

2.15  SAFETY:  The Grinder Pump shall be free from electrical and fire hazards as required in a residential environment. As evidence of compliance with this requirement, the completely assembled and wired Grinder Pump Station shall be listed by Underwriters Laboratories, Inc., to be safe and appropriate for the intended use. UL listing of components of the station, or third-party testing to UL standard will not be acceptable.

The grinder pump shall meet accepted standards for plumbing equipment for use in or near residences, shall be free from noise, odor, or health hazards, and shall have been tested by an independent laboratory to certify its capability to perform as specified in either individual or low pressure sewer system applications. As evidence of compliance with this requirement, the grinder pump shall bear the seal of NSF International. Third-party testing to NSF standard will not be acceptable.

3.0  EXECUTION

3.01  FACTORY TEST:  Each grinder pump shall be submerged and operated for 5 minutes (minimum). Included in this procedure will be the testing of all ancillary components such as, the anti-siphon valve, check valve, discharge assembly and each unit’s dedicated level controls and motor controls. All factory tests shall incorporate each of the above listed items. Actual appurtenances and controls which will be installed in the field, shall be particular to the tested pump only. A common set of appurtenances and controls for all pumps will not be acceptable. Certified test results shall be available upon request showing the operation of each grinder pump at two (2) different points on its curve, with the maximum pressure no less than 60 psi. The ENGINEER reserves the right to inspect such testing procedures with representatives of the OWNER, at the GRINDER PUMP MANUFACTURER’S facility.

All completed stations shall be factory leak tested to assure the integrity of all joints, seams and penetrations. All necessary penetrations such as inlets, discharge fittings and cable connectors shall be included in this test along with their respective sealing means (grommets, gaskets etc.).

3.02  DELIVERY:  All Grinder Pump units will be delivered to the job site 100 percent completely assembled, including testing, ready for installation. Grinder pump units will be individually mounted on wooden pallets.

3.03  INSTALLATION:  Earth excavation and backfill are specified under SITE WORK, but are also to be done as a part of the work under this section, including any necessary sheeting and bracing.

The CONTRACTOR shall be responsible for handling ground water to provide a firm, dry subgrade for the structure, and shall guard against flotation or other damage resulting from general water or flooding.

The Grinder Pump Stations shall not be set into the excavation until the installation procedures and excavation have been approved by the ENGINEER.

Remove packing material. Users instructions MUST be given to the OWNER. Hardware supplied with the unit, if required, will be used at installation. The basin will be supplied with a standard 4" inlet grommet (4.50" OD) for connecting the incoming sewer line. Appropriate inlet piping must be used. The basin may not be dropped, rolled or laid on its side for any reason.

Installation shall be accomplished so that 1" to 4" of accessway, below the bottom of the lid, extends above the finished grade line. The finished grade shall slope away from the unit. The diameter of the excavated hole must be large enough to allow for the concrete anchor.

A 6" inch (minimum) layer of naturally rounded aggregate, clean and free flowing, with particle size of not less than 1/8" or more than 3/4" shall be used as bedding material under each unit.

A concrete anti-flotation collar, as detailed on the drawings, and sized according to the manufacturer’s instructions, shall be required and shall be pre-cast to the grinder pump or poured in place. Each Grinder Pump Station with its pre-cast anti-flotation collar shall have a minimum of three (3) lifting eyes for loading and unloading purposes.

If the concrete is poured in place, the unit shall be levelled, and filled with water, to the bottom of the inlet, to help prevent the unit from shifting while the concrete is being poured. The concrete must be manually vibrated to ensure there are no voids. If it is necessary to pour the concrete to a level higher than the inlet piping, an 8" sleeve is required over the inlet prior to the concrete being poured.

The CONTRACTOR will provide and install a four (4) foot piece of four inch SCH 40 PVC pipe with water tight cap, to stub-out the inlet for the property owners’ installation contractor, as depicted on the contract drawings.

The electrical enclosure shall be furnished, installed and wired to the Grinder Pump Station by the CONTRACTOR. An alarm device is required on every installation, there shall be NO EXCEPTIONS. It will be the responsibility of the CONTRACTOR and the ENGINEER to coordinate with the individual property owner(s) to determine the optimum location for the Alarm Panel.

The CONTRACTOR shall mount the alarm device in a conspicuous location, as per national and local codes. The Alarm Panel will be connected to the Grinder Pump Station by a length of six (6) conductor 12 gauge type TC cable as shown on the contract drawings. The power and alarm circuits must be on separate power circuits. The grinder pump stations will be provided with a minimum of 32’, 25’ of useable electrical supply cable outside the station, to connect to the alarm panel. This cable shall be supplied with a FACTORY INSTALLED EQD half to connect to the mating EQD half on the core.

3.04  BACKFILL REQUIREMENTS:  Proper backfill is essential to the long-term reliability of any underground structure. Several methods of backfill are available to produce favorable results with different native soil conditions. The most highly recommended method of backfilling is to surround the unit to grade using Class I or Class II backfill material as defined in ASTM 2321. Class 1A and Class 1B are recommended where frost heave is a concern, Class 1B is a better choice when the native soil is sand or if a high, fluctuating water table is expected. Class 1, angular crushed stone offers an added benefit in that it doesn’t need to be compacted.

Class II, naturally rounded stone, may require more compactive effort, or tamping, to achieve the proper density. If the native soil condition consists of clean compactible soil, with less than 12 percent fines, free of ice, rocks, roots and organic material, it may be an acceptable backfill. Soil must be compacted in lifts not to exceed one foot to reach a final Proctor Density of between 85 percent and 90 percent. Heavy, non-compactible clays and silts are not suitable backfill for this or any underground structure such as inlet or discharge lines.

If you are unsure of the consistency of the native soil, it is recommended that a geotechnical evaluation of the material is obtained before specifying backfill.

Another option is the use of a flowable fill (i.e., low slump concrete). This is particularly attractive when installing grinder pump stations in augured holes where tight clearances make it difficult to assure proper backfilling and compaction with dry materials. Flowable fills should not be dropped more than four feet from the discharge to the bottom of the hole to avoid separation of the constituent materials.

Backfill of clean native earth, free of rocks, roots, and foreign objects shall be thoroughly compacted in lifts not exceeding 12" to a final Proctor Density of not less than 85 percent. Improper backfilling may result in damaged accessways. The Grinder Pump Station shall be installed at a minimum depth from grade to the top of the 1 1/4" discharge line, to assure maximum frost protection. The finish grade line shall be 1" to 4" below the bottom of the lid, and final grade shall slope away from the Grinder Pump Station.

All restoration will be the responsibility of the CONTRACTOR. Per unit costs for this item shall be included in the CONTRACTOR’S bid price for the individual Grinder Pump Stations. The properties shall be restored to their original condition in all respects, including, but not limited to, curb and sidewalk replacement, landscaping, loaming and seeding, and restoration of the traveled ways, as directed by the ENGINEER.

3.05  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 as specified herein, and instruct the OWNER’S personnel in the operation and maintenance of the equipment before the stations are accepted by the OWNER.

All equipment and materials necessary to perform testing shall be the responsibility of the INSTALLING CONTRACTOR. This will include, as a minimum, a portable generator (if temporary power is required) and water in each basin.

The services of a trained factory-authorized technician shall be provided at a rate of two days for every 200 grinder pump stations supplied. Each day shall be ten (10) person hours in duration.

Upon completion of the installation, the authorized factory technician(s) will perform the following test on each station:

a. Make certain the discharge shut-off valve is fully open. This valve must not be closed when the pump is operating. In some installations, there may be a valve(s) at the street main that must also be open.
b. Turn ON the alarm power circuit.
c. Fill the wet well with water to a depth sufficient to verify the high level alarm is operating. Shut off water.
d. Turn ON pump power circuit. Initiate pump operation to verify automatic "on/off" controls are operative. Pump should immediately turn ON. Within one (1 ) minute alarm light will turn OFF. Within three (3) minutes the pump will turn OFF.

Upon completion of the start-up and testing, the MANUFACTURER shall submit to the ENGINEER the start-up authorization form describing the results of the tests performed for each Grinder Pump Station. Final acceptance of the system will not occur until authorization forms have been received for each pump station installed and any installation deficiencies corrected.

4.0  OPERATION AND MAINTENANCE

4.01  SPARE CORE:  The MANUFACTURER will supply one (1) spare grinder pump core for every 50 grinder pump stations installed, complete with all operational controls, level sensors, check valve, anti-siphon valve, pump/motor unit, and grinder.

4.02  MANUALS:  The MANUFACTURER shall supply four (4) copies of Operation and Maintenance Manuals to the OWNER, and one (1) copy of the same to the ENGINEER.

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Indoor Grinder Pump Stations

1.0  GENERAL

1.01  GENERAL DESCRIPTION:  The MANUFACTURER shall furnish complete factory-built and tested Grinder Pump Station(s), each consisting of grinder pump(s) suitably mounted in a basin constructed of high density polyethylene (HDPE) for simplex stations and HDPE or Fiberglass Reinforced Polyester Resin for duplex stations, pump removal system, shut-off valve, anti-siphon valve, check valve assembled within the basin, electrical alarm panel, and all necessary internal wiring and controls. Component type grinder pump systems that require field assembly will not be acceptable, due to the potential problems that can occur during field assembly. All components and materials shall be in accordance with section 2.0 of this Product Specification. For ease of serviceability, all pump, motor/grinder units shall be of like type and horsepower throughout the system.

1.02  SUBMITTALS:  After receipt of notice to proceed, the MANUFACTURER shall furnish a minimum of six (6) sets of shop drawings detailing the equipment to be furnished including dimensional data and materials of construction. The ENGINEER shall promptly review this data, and return two (2) copies as accepted, or with requested modifications. Upon receipt of accepted shop drawings, the MANUFACTURER shall proceed immediately with fabrication of the equipment.

1.03  MANUFACTURER:  Grinder pump stations, complete with all appurtenances, form an integral system, and as such, shall be supplied by one grinder pump station manufacturer. The CONTRACTOR shall be responsible for the satisfactory operation of the entire system. The equipment specified shall be a product of a company experienced in the design and manufacture of grinder pumps for specific use in low pressure sewage systems. The company shall submit detailed installation and user instructions for its product, submit evidence of an established service program including complete parts and service manuals, and be responsible for maintaining a continuing inventory of grinder pump replacement parts. The MANUFACTURER shall provide a reference and contact list from ten of its largest contiguous grinder pump installations of the type of grinder pumps described within this specification.

The MANUFACTURER of the grinder pump station shall be E/One Corporation or Proposed Alternate.

Attention is directed to the fact that the drawings and overall system design are based on a particular piece of equipment from a particular manufacturer. These specifications are intended to provide guidelines for standard equipment of a recognized manufacturer who already meets all the requirements of this specification.

1.03a  ALTERNATE EQUIPMENT:  In the event that the CONTRACTOR or another supplier proposes an Alternate to the specified MANUFACTURER, the ENGINEER recognizes that it will be difficult to conform to certain details of this Specification due to different manufacturing techniques or grinder pump station designs. If proposing an Alternate, the CONTRACTOR (supplier) must submit, no less than 15 business days in advance of the bid date, a complete description of any changes that will be necessary to the system design, a complete submittal package as outlined in Section 1.02 SUBMITTALS, a system hydraulic analysis (including pipe sizes, flows, velocities, retention times and number and location of recommended valves and cleanouts, if any) based on the proposed pump, a list of exceptions to this Specification, and demonstration of compliance to Section 1.04 EXPERIENCE CLAUSE of this Specification. This information must be submitted to the ENGINEER for pre-approval of the alternate equipment being proposed and determination of compliance with these Contract Documents. If the equipment differs materially or differs from the dimensions given on the Drawings, the CONTRACTOR (supplier) shall submit complete drawings showing elevations, dimensions, or any necessary changes to the Contract Documents for the proposed equipment and its installation. Pre-approval, if granted, will be provided in writing by the ENGINEER to the CONTRACTOR (supplier) at least five business days in advance of the bid date. If the ENGINEER’S approval is obtained for Alternate Equipment, the CONTRACTOR (supplier) must make any needed changes in the structures, system design, piping or electrical systems necessary to accommodate the proposed equipment at the expense of the CONTRACTOR (supplier).

1.04  EXPERIENCE CLAUSE:  The equipment furnished hereunder shall be the product of a company experienced in the design and manufacture of grinder pumps specifically designed for use in low pressure systems. All manufacturers proposing equipment for this project shall have at least ten (10) years of experience in the design and manufacture of units of identical size(s) and performance to the specified units. All manufacturers proposing equipment for this project must also have not less than five hundred (500) successful installations of low pressure sewer systems utilizing grinder pumps of like type to the grinder pumps specified herein. An installation is defined as a minimum of twenty-five (25) pumps discharging into a common force main which forms a low pressure sewer system. The CONTRACTOR (supplier) proposing alternate equipment shall also submit, as part of the bid schedule, an installation list with contact person(s), phone number(s) and date(s) of installation of at least ten (10) installations of the type of pump specified herein that have been operating for at least 10 years.

In lieu of this experience clause, the contractor (supplier) of alternate equipment will be required to submit a five (5) year performance bond for one-hundred (100) percent of the stipulated cost of the equipment as bid and as shown in the Bid Schedule. This performance bond will be used to guarantee the replacement of the equipment in the event that it fails within the bond period.

1.05  OPERATING CONDITIONS:  The pumps shall be capable of delivering 15 GPM against a rated total dynamic head of 0 feet (0 PSIG) and 9 GPM against a rated total dynamic head of 138 feet (60 PSIG). The pump(s) must also be capable of operating at negative total dynamic head without overloading the motor(s). Under no conditions shall in-line piping or valving be allowed to create a false apparent head.

1.06  WARRANTY:  The grinder pump MANUFACTURER shall provide a part(s) and labor warranty on the complete station and accessories, including, but not limited to, panel and redundant check valve, for a period of sixty (60) months after notice of OWNER’S acceptance, but no greater than sixty-three (63) months after receipt of shipment. Any manufacturing defects found during the warranty period will be reported to the MANUFACTURER by the OWNER and will be corrected by the MANUFACTURER at no cost to the OWNER.

1.07  WARRANTY PERFORMANCE CERTIFICATION:  As a bid certification requirement, each bidder shall provide with their bid schedule a Warranty Performance Certification statement executed by the most senior executive officer of the grinder pump MANUFACTURER, which certifies a minimum of a twenty-four (24) month warranty. They must further detail any exclusions from the warranty or additional cost items required to maintain the equipment in warrantable condition, including all associated labor and shipping fees, and certify that the MANUFACTURER will bear all costs to correct any original equipment deficiency for the effective period of the warranty. All preventive maintenance type requirements shall be included in this form as exclusions. These requirements include, but are not limited to, unjamming of grinder mechanism, unplugging of lines, periodic motor maintenance, and periodic cleaning of liquid level controls. Should the CONTRACTOR (supplier) elect to submit a performance bond in lieu of the experience clause outlined above, this Warranty Performance Certification shall also be used as a criterion to evaluate the CONTRACTOR’S (supplier’s) performance over the warranty period. A Warranty Performance Certification form is included with the bid schedule and must be completed and submitted as part of the bid package. Bids with incomplete forms or missing forms will be considered nonresponsive.

2.0  PRODUCT

2.01  PUMP:  The pump shall be a custom designed, integral, vertical rotor, motor driven, solids handling pump of the progressing cavity type with a single mechanical seal. The rotor shall be through-hardened, highly polished, precipitation hardened stainless steel. Plating on the rotor will not be acceptable due to its tendency to delaminate. The stator shall be of a specifically compounded ethylene propylene synthetic elastomer. The material shall be suitable for domestic wastewater service. Its physical properties shall include high tear and abrasion resistance, grease resistance, water and detergent resistance, temperature stability, excellent aging properties, and outstanding wear resistance. Buna-N is not acceptable as a stator material because it does not exhibit the properties as outlined above and required for wastewater service.

2.02  GRINDER:  The grinder shall be placed immediately below the pumping elements and shall be direct-driven by a single, one-piece motor shaft. The grinder impeller assembly shall be securely fastened to the pump motor shaft by means of a threaded connection attaching the grinder impeller to the motor shaft. Attachment by means of pins or keys will not be acceptable. The grinder will be of the rotating type with a stationary hardened and ground stainless steel shredding ring spaced in close annular alignment with the driven impeller assembly, which shall carry two hardened type 400 series stainless steel cutter bars.

This assembly shall be dynamically balanced and operate without objectionable noise or vibration over the entire range of recommended operating pressures. The grinder shall be constructed so as to eliminate clogging and jamming under all normal operating conditions including starting. Sufficient vortex action shall be created to scour the tank free of deposits or sludge banks which would impair the operation of the pump. These requirements shall be accomplished by the following, in conjunction with the pump:

1. The grinder shall be positioned in such a way that solids are fed in an upward flow direction.
2. The maximum flow rate through the cutting mechanism must not exceed 4 feet per second. This is a critical design element to prevent jamming and as such must be adhered to.
3. The inlet shroud shall have a diameter of no less than 5 inches. Inlet shrouds that are less than 5 inches in diameter will not be accepted due to their inability to maintain the specified 4 feet per second maximum inlet velocity which by design prevents unnecessary jamming of the cutter mechanism and eliminates blinding of the pump by large objects blocking the inlet shroud.
4. The impeller mechanism must rotate at a nominal speed of no greater than 1800 rpm.

The grinder shall be capable of reducing all components in normal domestic sewage, including a reasonable amount of “foreign objects”, such as paper, wood, plastic, glass, rubber and the like, to finely-divided particles which will pass freely through the passages of the pump and the 1-1/4" diameter stainless steel discharge piping.

2.03  ELECTRIC MOTOR:  As a maximum, the motor shall be a 1 HP, 1725 RPM, 240 Volt 60 Hertz, 1 Phase, capacitor start, ball bearing, air-cooled induction type with a low starting current not to exceed 30 amperes and high starting torque of 8.4 foot pounds. Inherent protection against running overloads or locked rotor conditions for the pump motor shall be provided by the use of an automatic-reset, integral thermal overload protector incorporated into the motor. This motor protector combination shall have been specifically investigated and listed by Underwriters Laboratories, Inc., for the application. Non-capacitor start motors or permanent split capacitor motors will not be accepted because of their reduced starting torque and consequent diminished grinding capability. To reduce the potential of environmental concerns, the expense of handling and disposing of oil, and the associated maintenance costs, oil-filled motors will not be accepted.

2.04  MECHANICAL SEAL:  The core shall be provided with a mechanical shaft seal to prevent leakage between the motor and pump. The seal shall have a stationary ceramic seat and carbon rotating surface with faces precision lapped and held in position by a stainless steel spring.

2.05  TANK:  The tank shall be made of rotationally molded high density polyethylene, with a melt index of 2.0 grams/10 minutes or lower to assure high environmental stress cracking resistance. The tank shall have a nominal thickness of 0.50".

The tank shall be furnished with one 4” inlet valve for connection to PVC building sewer (4.650 OD). Tank capacity shall be 91 gallons. The tank must be capable of withstanding static heads of 10 feet without leaking or causing permanent structural damage.

An aesthetically pleasing, rotationally molded cover shall be supplied with the tank to protect and conceal the pump core, discharge valve and diagnostic control center.

The station shall have all necessary penetrations molded in and factory sealed. No field penetrations shall be acceptable.

All discharge piping shall be constructed of 304 Series Stainless Steel or PVC and terminate with a 1 1/4” female NPT fitting. The discharge piping shall include a PVC ball valve rated for 200 psi WOG.

The tank shall also include a 2” PVC vent to prevent sewage gases from accumulating in the tank.

2.06  CHECK VALVE:  The pump discharge shall be equipped with a factory installed, gravity operated, flapper-type integral check valve built into the stainless steel discharge pipe. The check valve will provide a full-ported passageway when open, and shall introduce a friction loss of less than 6 inches of water at maximum rated flow. Working parts will be made of a 300 series stainless steel and fabric reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly providing a maximum degree of freedom to assure seating even at a very low back pressure. The valve body shall be an injection molded part made of glass filled PVC. Ball type check valves are unacceptable due to their limited sealing capacity in slurry applications.

2.07  ANTI-SIPHON VALVE:  The pump discharge shall be equipped with a factory-installed, gravity-operated, flapper-type integral anti-siphon valve built into the stainless steel discharge piping. Moving parts will be made of 300 series stainless steel and fabric-reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly, providing a maximum degree of freedom to ensure proper operation even at a very low pressure. The valve body shall be injection-molded from a glass-filled thermoplastic resin. Holes or ports in the discharge piping are not acceptable anti-siphon devices, due to their tendency to clog from the solids in the slurry being pumped.

2.08  CORE UNIT:  The Grinder Pump Station shall have cartridge type easily removable core assemblies containing pump, motor, grinder, all motor controls, pump diagnostics center, check valve, anti-siphon valve, and wiring. The watertight integrity of each core unit, shall be established by 100 percent factory test at a minimum of 5 PSIG.

2.09  CONTROLS:  All necessary controls shall be located in the top housing of the core unit. The top housing will be attached with stainless steel fasteners.

Non-fouling waste water level controls for controlling pump operation shall be accomplished by monitoring the pressure changes in an integral air column connected to a pressure switch. The level detection device shall have no moving parts in direct contact with the wastewater. High-level sensing will be accomplished in the manner detailed above by a separate air-bell sensor and pressure switch of the same type. Closure of the high-level sensing device will energize an alarm circuit as well as a redundant pump-on circuit. For increased reliability, pump ON/OFF and High-level alarm functions shall not be controlled by the same switch. Float switches of any kind, including float trees, will not be accepted due to the periodic need to maintain (rinsing, cleaning) such devices.

2.10  DIAGNOSTICS CENTER:  Each 2010-IDU shall include a 4 7/8” H x 4 1/2” W diagnostics center that displays the present operating condition of the grinder pump station. This display shall be located on the top of the grinder pump core and shall be readily visible when the 2010-IDU grinder pump station cover is removed. The diagnostic center shall consist of (5) circular light emitting diode (LED) displays measuring 0.15” in diameter each. One 0.50” diameter circular touch pad shall also be included in this display.

The Diagnostics Center shall visually and audibly indicate the present operating condition of the 2010-IDU as described below.

The Diagnostics Center shall visually and audibly indicate the present operating condition of the 2010-IDU as described below.

1. POWER — A solid green LED indicates that the proper electrical supply voltage is present at the grinder pump station. A blinking green LED indicates that the electrical supply voltage being supplied to the station is to low.
2. PUMP RUN — A solid green LED illuminates when the grinder pump is running.
3. HIGH WATER ALARM — If the sewage level in the 2010-IDU reaches 20" from the bottom of the tank basin a blinking red LED is illuminated. Two minutes after this condition has been reached a 75 dB buzzer will be energized. If the power to the station is interrupted, the blinking LED and 75 dB buzzer will operate without delay via an 9.0 volt lithium or alkaline battery.
4. NO POWER ALARM — If the power to the pump is interrupted a red LED will blink and a 75 dB buzzer will be energized.
5. LOW BATTERY — If the battery voltage is low a blinking yellow LED will be illuminated and a 75 dB buzzer will be energized with short beeps.
6. SILENCE/PTR — Pressing the silence/PTR button will silence all high water level alarms. It will not silence the low supply or battery voltage alarms. Pressing this button and holding it compressed for 5 seconds or more will manually start and run the pump until the button is released.

The 9.0 volt lithium or alkaline bat tery shall be located on the top of the grinder pump core so that it may be easily replaced. All alarms energized by the battery shall operate for at least 24 hours.

Unit shall be capable of accepting the Remote Sentry as defined in Section 2.11 below.

2.11  REMOTE SENTRY:  The grinder pump manufacturer shall supply a remote, indoor mounted, high level alarm module with each grinder pump station. This module shall incorporate a visual and audible (70 Db) high level alarm, a membrane covered push to silence audible alarm button, and a membrane covered push to test visual and audible alarm button all housed in a low profile, neutral-colored case to be placed in a conspicuous location within the residence by the installing contractor. The maximum dimension of the case shall be 5 1⁄2” W x 3 3⁄4” H x 1 1⁄4” D. This module shall be connected to the Indoor Grinder Pump Diagnostic Center and will indicate a high-level alarm with or without AC power at the grinder pump. The indoor alarm unit shall have a renewable Lithium battery power source enabling its continued operation without AC power. The visual and audible alarm shall be automatically reset when the high level alarm condition is corrected. If the battery voltage is low the LED will blink and the buzzer will be energized with short beeps. The push-to-silence will not change this condition until the batteries are replaced.

2.12  SERVICABILITY:  The grinder pump core unit shall have two hand holds to facilitate easy core removal when necessary. All mechanical and electrical connections must provide easy disconnect accessibility for core unit removal and installation. A push to run feature will be provided for field trouble shooting. All motor control components shall be mounted on a readily replaceable bracket for ease of field service.

2.13  SAFETY:  The Grinder Pump shall be free from electrical and fire hazards as required in a residential environment. As evidence of compliance with this requirement, the completely assembled and wired Grinder Pump Station shall be listed by Underwriters Laboratories, Inc., to be safe and appropriate for the intended use. UL listing of components of the station, or third-party testing to UL standard will not be acceptable.

The grinder pump shall meet accepted standards for plumbing equipment for use in or near residences, shall be free from noise, odor, or health hazards, and shall have been tested by an independent laboratory to certify its capability to perform as specified in either individual or low pressure sewer system applications. As evidence of compliance with this requirement, the grinder pump shall bear the seal of NSF International. Third-party testing to NSF standard will not be acceptable.

3.0  EXECUTION

3.01  FACTORY TEST:  Each grinder pump shall be submerged and operated for 5 minutes (minimum). Included in this procedure will be the testing of all ancillary components such as, the anti-siphon valve, check valve, discharge assembly and each unit’s dedicated level controls and motor controls. All factory tests shall incorporate each of the above listed items. Actual appurtenances and controls which will be installed in the field, shall be particular to the tested pump only. A common set of appurtenances and controls for all pumps will not be acceptable. Certified test results shall be available upon request showing the operation of each grinder pump at two (2) different points on its curve, with the maximum pressure no less than 60 psi. The ENGINEER reserves the right to inspect such testing procedures with representatives of the OWNER, at the GRINDER PUMP MANUFACTURER’S facility.

All completed stations shall be factory leak tested to assure the integrity of all joints, seams and penetrations. All necessary penetrations such as inlets, discharge fittings and cable connectors shall be included in this test along with their respective sealing means (grommets, gaskets etc.).

3.02  DELIVERY:  All Grinder Pump units will be delivered to the job site, 100 percent completely assembled, including testing, ready for installation. Grinder pump units will be individually mounted on wooden pallets.

3.03  INSTALLATION:  Shall be per all manufacturer’s installation instructions. User instructions shall be given to the homeowner.

3.04 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 as specified herein, and instruct the OWNER’S personnel in the operation and maintenance of the equipment before the stations are accepted by the OWNER.

All equipment and materials necessary to perform testing shall be the responsibility of the INSTALLING CONTRACTOR. This will include, as a minimum, a portable generator (if temporary power is required) and water in each basin.

The services of a trained factory-authorized technician shall be provided at a rate of two days for every 200 grinder pump stations supplied. Each day shall be ten (10) person hours in duration.

Upon completion of the installation, the authorized factory technician(s) will perform the following test on each station:

1. Turn off circuit breaker that supplies power to station.
2. Remove station cover. Open battery compartment and install battery according to Diagnostics Center instructions.
3. Close battery compartment. After approximately 15 seconds, the No Power Alarm should activate with a light and chirp, and will repeat every 15 seconds.
4. Ensure gate valve and ball valve are open.
5. Fill with water until “High Water Alarm” activates (approximately 70 gallons).
6. Plug in AC power cord and turn on circuit breaker. A louder audible alarm will sound; push the “Silence/PTR” button. The “Run” and “Power” LED’s will illuminate.
7. After a few minutes the “High Water Alarm” LED will stop flashing; the pump will turn off after a minute.
8. Push and hold the “Silence/PTR” button for 5 to 10 seconds. The pump should activate after 5 seconds and deactivate when the button is released. IMPORTANT! Release the button as soon as the pump turns on. This step is only to test the “PTR” feature.
9. Replace the station cover. The unit is ready for normal use.
Upon completion of the start-up and testing, the MANUFACTURER shall submit to the ENGINEER the start-up authorization form describing the results of the tests performed for each Grinder Pump Station. Final acceptance of the system will not occur until authorization forms have been received for each pump station installed and any installation deficiencies corrected.

4.0  OPERATION AND MAINTENANCE

4.01  SPARE CORE:  The MANUFACTURER will supply one (1) spare grinder pump core for every 50 grinder pump stations installed, complete with all operational controls, level sensors, check valve, anti-siphon valve, pump/motor unit, and grinder.

4.02  MANUALS:  The MANUFACTURER shall supply four (4) copies of Operation and Maintenance Manuals to the OWNER, and one (1) copy of the same to the ENGINEER.

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After Market Grinder Pump

1.0  GENERAL 1.01  GENERAL DESCRIPTION:  The MANUFACTURER shall furnish complete factory-built and tested Grinder Pump Unit(s), each consisting of a grinder pump core suitably mounted on an integral stand of stainless steel, electrical quick disconnect (NEMA 6P), pump removal harness, discharge hose and shut- off valve, anti-siphon valve and check valve assembly, electrical alarm assembly, and all necessary internal wiring and controls. For ease of serviceability, all pump motor/grinder units shall be of like type and horsepower throughout the system.

1.02  SUBMITTALS:  After receipt of notice to proceed, the MANUFACTURER shall furnish a minimum of six (6) sets of shop drawings detailing the equipment to be furnished including dimensional data and materials of construction. The ENGINEER shall promptly review this data, and return two (2) copies as accepted, or with requested modifications. Upon receipt of accepted shop drawings, the MANUFACTURER shall proceed immediately with fabrication of the equipment.

1.03  MANUFACTURER:  Grinder pump stations, complete with all appurtenances, form an integral system, and as such, shall be supplied by one grinder pump station manufacturer. The CONTRACTOR shall be responsible for the satisfactory operation of the entire system. The equipment specified shall be a product of a company experienced in the design and manufacture of grinder pumps for specific use in low pressure sewage systems. The company shall submit detailed installation and user instructions for its product, submit evidence of an established service program including complete parts and service manuals, and be responsible for maintaining a continuing inventory of grinder pump replacement parts. The MANUFACTURER shall provide a reference and contact list from ten of its largest contiguous grinder pump installations of the type of grinder pumps described within this specification.

The MANUFACTURER of the grinder pump station shall be E/One Corporation (or Proposed Alternate).

Attention is directed to the fact that the drawings and overall system design are based on a particular piece of equipment from a particular manufacturer. These specifications are intended to provide guidelines for standard equipment of a recognized manufacturer who already meets all the requirements of this specification.

1.03a  ALTERNATE EQUIPMENT:  In the event that the CONTRACTOR or another supplier proposes an Alternate to the specified MANUFACTURER, the ENGINEER recognizes that it will be difficult to conform to certain details of this Specification due to different manufacturing techniques or grinder pump station designs. If proposing an Alternate, the CONTRACTOR (supplier) must submit, no less than 15 business days in advance of the bid date, a complete description of any changes that will be necessary to the system design, a complete submittal package as outlined in Section 1.02 SUBMITTALS, a system hydraulic analysis (including pipe sizes, flows, velocities, retention times and number and location of recommended valves and cleanouts, if any) based on the proposed pump, a list of exceptions to this Specification, and demonstration of compliance to Section 1.04 EXPERIENCE CLAUSE of this Specification. This information must be submitted to the ENGINEER for pre-approval of the alternate equipment being proposed and determination of compliance with these Contract Documents. If the equipment differs materially or differs from the dimensions given on the Drawings, the CONTRACTOR (supplier) shall submit complete drawings showing elevations, dimensions, or any necessary changes to the Contract Documents for the proposed equipment and its installation. Pre-approval, if granted, will be provided in writing by the ENGINEER to the CONTRACTOR (supplier) at least five business days in advance of the bid date. If the ENGINEER’S approval is obtained for Alternate Equipment, the CONTRACTOR (supplier) must make any needed changes in the structures, system design, piping or electrical systems necessary to accommodate the proposed equipment at the expense of the CONTRACTOR (supplier).

1.04  EXPERIENCE CLAUSE:  The equipment furnished hereunder shall be the product of a company experienced in the design and manufacture of grinder pumps specifically designed for use in low pressure systems. All manufacturers proposing equipment for this project shall have at least ten (10) years of experience in the design and manufacture of units of identical size(s) and performance to the specified units. All manufacturers proposing equipment for this project must also have not less than five hundred (500) successful installations of low pressure sewer systems utilizing grinder pumps of like type to the grinder pumps specified herein. An installation is defined as a minimum of twenty-five (25) pumps discharging into a common force main which forms a low pressure sewer system. The contractor (supplier) proposing alternate equipment shall also submit, as part of the bid schedule, an installation list with contact person(s), phone number(s) and date(s) of installation of at least ten (10) installations of the type of pump specified herein that have been in operation for at least 10 years.

In lieu of this experience clause, the contractor (supplier) of alternate equipment will be required to submit a five (5) year performance bond for one-hundred (100) percent of the stipulated cost of the equipment as bid and as shown in the Bid Schedule. This performance bond will be used to guarantee the replacement of the equipment in the event that it fails within the bond period.

1.05  OPERATING CONDITIONS:   The pumps shall be capable of delivering 15 GPM against a rated total dynamic head of 0 feet (0 PSIG) and 9 GPM against a rated total dynamic head of 138 feet (60 PSIG). The pump(s) must also be capable of operating at negative total dynamic head without overloading the motor(s). Under no conditions shall in-line piping or valving be allowed to create a false apparent head.

1.06  WARRANTY:  The grinder pump MANUFACTURER shall provide a part(s) and labor warranty on the complete station and accessories, including, but not limited to, panel and redundant check valve, for a period of twenty-four (24) months after notice of OWNER'S acceptance, but no greater than twenty-seven (27) months after receipt of shipment. Any manufacturing defects found during the warranty period will be reported to the MANUFACTURER by the OWNER and will be corrected by the MANUFACTURER at no cost to the OWNER.

1.07  WARRANTY PERFORMANCE CERTIFICATION:  As a bid certification requirement, each bidder shall provide with their bid schedule a Warranty Performance Certification statement executed by the most senior executive officer of the grinder pump MANUFACTURER, which certifies a minimum of a twenty four (24) month warranty. They must further detail any exclusions from the warranty or additional cost items required to maintain the equipment in warrantable condition, including all associated labor and shipping fees, and certify that the MANUFACTURER will bear all costs to correct any original equipment deficiency for the effective period of the warranty. All preventive maintenance type requirements shall be included in this form as exclusions. These requirements include, but are not limited to, unjamming of grinder mechanism, unplugging of lines, periodic motor maintenance, and periodic cleaning of liquid level controls. Should the CONTRACTOR (supplier) elect to submit a performance bond in lieu of the experience clause outlined above, this Warranty Performance Certification shall also be used as a criterion to evaluate the CONTRACTOR'S (supplier's) performance over the warranty period. A Warranty Performance Certification form is included with the bid schedule and must be completed and submitted as part of the bid package. Bids with incomplete forms or missing forms will be considered nonresponsive.

2.0  PRODUCT

2.01  PUMP:  The pump shall be a custom designed, integral, vertical rotor, motor driven, solids handling pump of the progressing cavity type with a single mechanical seal. The rotor shall be through-hardened, highly polished, precipitation hardened stainless steel. Plating on the rotor will not be acceptable due to its tendency to delaminate. The stator shall be of a specifically compounded ethylene propylene synthetic elastomer. The material shall be suitable for domestic wastewater service. Its physical properties shall include high tear and abrasion resistance, grease resistance, water and detergent resistance, temperature stability, excellent aging properties, and outstanding wear resistance. Buna-N is not acceptable as a stator material because it does not exhibit the properties as outlined above and required for wastewater service.

2.02  GRINDER:   The grinder shall be placed immediately below the pumping elements and shall be direct-driven by a single, one-piece motor shaft. The grinder impeller assembly shall be securely fastened to the pump motor shaft by means of a threaded connection attaching the grinder impeller to the motor shaft. Attachment by means of pins or keys will not be acceptable. The grinder will be of the rotating type with a stationary hardened and ground stainless steel shredding ring spaced in close annular alignment with the driven impeller assembly, which shall carry two hardened type 400 series stainless steel cutter bars.

This assembly shall be dynamically balanced and operate without objectionable noise or vibration over the entire range of recommended operating pressures. The grinder shall be constructed so as to eliminate clogging and jamming under all normal operating conditions including starting. Sufficient vortex action shall be created to scour the tank free of deposits or sludge banks which would impair the operation of the pump. These requirements shall be accomplished by the following, in conjunction with the pump:

1. The grinder shall be positioned in such a way that solids are fed in an upward flow direction.
2. The maximum flow rate through the cutting mechanism must not exceed 4 feet per second. This is a critical design element to prevent jamming and as such must be adhered to.
3. The inlet shroud shall have a diameter of no less than 5 inches. Inlet shrouds that are less than 5 inches in diameter will not be accepted due to their inability to maintain the specified 4 feet per second maximum inlet velocity which by design prevents unnecessary jamming of the cutter mechanism and eliminates blinding of the pump by large objects blocking the inlet shroud.
4. The impeller mechanism must rotate at a nominal speed of no greater than 1800 rpm.

The grinder shall be capable of reducing all components in normal domestic sewage, including a reasonable amount of "foreign objects," such as paper, wood, plastic, glass, rubber and the like, to finely-divided particles which will pass freely through the passages of the pump and the 1-1/4" diameter discharge.

2.03  ELECTRIC MOTOR:  As a maximum, the motor shall be a 1 HP, 1725 RPM, 240 Volt 60 Hertz, 1 Phase, capacitor start, ball bearing, air-cooled induction type with a low starting current not to exceed 30 amperes and high starting torque of 8.4 foot pounds. Inherent protection against running overloads or locked rotor conditions for the pump motor shall be provided by the use of an automatic-reset, integral thermal overload protector incorporated into the motor. This motor protector combination shall have been specifically investigated and listed by Underwriters Laboratories, Inc., for the application. Non-capacitor start motors or permanent split capacitor motors will not be accepted because of their reduced starting torque and consequent diminished grinding capability. To reduce the potential of environmental concerns, the expense of handling and disposing of oil, and the associated maintenance costs, oil-filled motors will not be accepted.

2.04  MECHANICAL SEAL:  The pump/core shall be provided with a mechanical shaft seal to prevent leakage between the motor and pump. The seal shall have a stationary ceramic seat and carbon rotating surface with faces precision lapped and held in position by a stainless steel spring.

2.05  DISCHARGE HOSE AND SLIDE FACE DISCONNECT/VALVE:  All discharge fittings and piping shall be constructed of 304 series stainless steel, polypropylene, EPDM or PVC. The discharge hose assembly shall include a shut-off valve rated for 200 psi WOG and a quick disconnect feature to simplify installation and pump removal.

2.06  ELECTRICAL QUICK DISCONNECT:  The grinder pump unit shall include a single NEMA 6P electrical quick disconnect for all power and control functions. An integral tube shall allow venting of the control compartment to assure proper operation of the pressure switch level system. The grinder pump will be furnished with a length of 6 conductor, 14 gauge, type SJOW cable, pre-wired and watertight to meet UL requirements.

2.07  CHECK VALVE:  The pump discharge shall be equipped with a factory-installed, gravity-operated, flapper-type integral check valve built into the pump discharge. The check valve will provide a full-ported passageway when open, and shall introduce a friction loss of less than 6 inches of water at maximum rated flow. Moving parts will be made of a 300 series stainless steel and fabric-reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly providing a maximum degree of freedom to assure seating even at a very low back pressure. The valve body shall be an injection molded part made of glass filled PVC. Ball-type check valves are unacceptable due to their limited sealing capacity in slurry applications.

Each grinder pump installation shall also include one separate check valve of the type detailed in this section for installation in the 1 1/4" service lateral between the grinder pump station and the sewer main, preferably next to the curb stop. The separate check valve shall be provided as a separate line item in the bid schedule.

2.08  ANTI-SIPHON VALVE:  The pump discharge shall be equipped with a factory-installed, gravity-operated, flapper-type integral anti-siphon valve built into the stainless steel discharge piping. Moving parts will be made of 300 series stainless steel and fabric-reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly, providing a maximum degree of freedom to ensure proper operation even at a very low pressure. The valve body shall be injection-molded from a glass-filled thermoplastic resin. Holes or ports in the discharge piping are not acceptable anti-siphon devices, due to their tendency to clog from the solids in the slurry being pumped.

2.09  CORE UNIT:  The Grinder Pump Station shall have an easily removable core assembly containing pump, motor, grinder, all motor controls, check valve, anti-siphon valve, electrical quick disconnect and wiring. The watertight integrity of the core unit, shall be established by 100 percent factory test at a minimum of 5 PSIG.

2.10  CONTROLS:  All necessary controls, including motor and level controls, shall be located in the top housing of the core unit. The top housing will be attached with stainless steel fasteners.

Non-fouling waste water level controls for controlling pump operation shall be accomplished by monitoring the pressure changes in an integral air column connected to a pressure switch. The level detection device shall have no moving parts in direct contact with the wastewater. High-level sensing will be accomplished in the manner detailed above by a separate air-bell sensor and pressure switch of the same type. Closure of the high-level sensing device will energize an alarm circuit as well as a redundant pump-on circuit. For increased reliability, pump ON/OFF and High-level alarm functions shall not be controlled by the same switch. Float switches of any kind, including float trees, will not be accepted due to the periodic need to maintain (rinsing, cleaning) such devices.

To assure reliable operation of the differential pressure switches each core shall be equipped with a pressure equalization chamber. The equalization chamber shall continuously calibrate the level sensing pressure switches to fluctuations in barometric pressure & prevent fluid from entering the control compartment during high water level conditions. The equalization chamber shall be constructed from EPDM, High Impact Polystyrene and stainless steel and measure 12" in diameter by 6" high. The chamber shall be assembled by the core manufacturer & factory tested at the point of assembly to verify proper operation.

The grinder pump will be furnished with 6 conductor 14 gauge, type SJOW cable, pre-wired and watertight to meet UL requirements with a FACTORY INSTALLED NEMA 6P EQD half attached to it.

2.11  ALARM PANEL:  Each grinder pump station shall include a NEMA 4X, UL listed ALARM PANEL suitable for wall mounting. The NEMA 4X enclosure shall be manufactured of thermoplastic to assure corrosion resistance. The enclosure shall include a hinged, lockable cover, padlock, and secured dead front. The enclosure shall not exceed 11.38"W x13.5"H x 5.63"D.

For each core, the panel shall contain one (1) - 15 amp, double pole circuit breaker for the power circuit and one (1) 15 amp single pole circuit breaker for the alarm circuit. The panel shall contain terminal blocks, integral power bus, push to run feature and a complete alarm circuit.

The Alarm Panel shall include the following features: audio & visual alarm, push-to-run switch, and high level (redundant) pump starting control. The alarm sequence is to be as follows:

1. When liquid level in the sewage wet-well rises above the alarm level, visual and audio alarms will be activated. The contacts on the alarm pressure switch will close. The redundant pump starting system will be energized.
1. The audio alarm may be silenced by means of the externally mounted, push-to-silence button.
1. Visual alarm remains illuminated until the sewage level in the wet-well drops below the "off" setting of the alarm pressure switch.

The visual alarm lamp shall be inside a red fluted lens at least 2 5/8" in diameter and 1 11/16" in height. Visual alarm shall be mounted to the top of the enclosure in such a manner as to maintain NEMA 4X rating. For duplex units, in addition to the above, two high level indicator lights shall be mounted behind the access cover.

During a high level alarm condition on a duplex station, the appropriate light will illuminate to indicate which pump core requires servicing. The audio alarm shall be a printed circuit board in conjunction with an 86 dB buzzer with quick mounting terminal strip mounted in the interior of the enclosure. The audio alarm shall be capable of being deactivated by depressing a push-type switch which is encapsulated in a weatherproof silicone boot and mounted on the bottom of the enclosure.

The entire Alarm Panel as manufactured, shall be listed by Underwriters Laboratories, Inc.

2.12  SERVICEABILITY:  The grinder pump core unit shall have two lifting hooks complete with polypropylene lift-out harness connected to its top housing to facilitate easy core removal when necessary. All mechanical and electrical connections must provide easy disconnect capability for core unit removal and installation. A push to run feature will be provided for field trouble shooting. All motor control components shall be mounted on a readily replaceable bracket for ease of field service.

2.13  CORROSION PROTECTION:  All materials exposed to waste water shall have inherent corrosion protection. Acceptable corrosion protection includes epoxy powder coat, cast iron, fiberglass, stainless steel, PVC.

2.14  SAFETY:  The Grinder Pump shall be free from electrical and fire hazards as required in a residential environment. As evidence of compliance with this requirement, the completely assembled and wired Grinder Pump Station shall be listed by Underwriters Laboratories, Inc., to be safe and appropriate for the intended use. UL listing of components of the station, or third-party testing to UL standard will not be acceptable.

The grinder pump shall meet accepted standards for plumbing equipment for use in or near residences, shall be free from noise, odor, or health hazards, and shall have been tested by an independent laboratory to certify its capability to perform as specified in either individual or low pressure sewer system applications. As evidence of compliance with this requirement, the grinder pump shall bear the seal of NSF International. Third-party testing to NSF standard will not be acceptable.

3.0 EXECUTION

3.01  FACTORY TEST:  Each grinder pump shall be submerged and operated for 5 minutes (minimum). Included in this procedure will be the testing of all ancillary components such as, the anti-siphon valve, check valve, discharge assembly and each unit's dedicated level and motor controls. All factory tests shall incorporate each of the above listed items. Actual appurtenances and controls which will be installed in the field, shall be particular to the tested pump only. A common set of appurtenances and controls for all pumps will not be acceptable. Certified test results shall be available upon request showing the operation of each grinder pump at two (2) different points on its curve, with the maximum pressure no less than 60 psi. The ENGINEER reserves the right to inspect such testing procedures with representatives of the OWNER, at the GRINDER PUMP MANUFACTURER'S facility.

3.02  DELIVERY:  All Grinder Pump units will be delivered to the job site, 100 percent completely assembled, including testing, ready for installation.

3.03  INSTALLATION:  Earth excavation and backfill are specified under SITE WORK, but are also to be done as a part of the work under this section, including any necessary sheeting and bracing.

The CONTRACTOR shall be responsible for handling ground water to provide a firm, dry subgrade for the structure, and shall guard against flotation or other damage resulting from general water or flooding.

The Grinder Pump Stations shall not be set into the excavation until the installation procedures and excavation have been approved by the ENGINEER.

Remove packing material. Users instructions MUST be given to the OWNER. Hardware supplied with the unit, if required, will be used at installation.

The electrical enclosure shall be furnished, installed and wired to the Grinder Pump Station by the CONTRACTOR. An alarm device is required on every installation, there shall be NO EXCEPTIONS. It will be the responsibility of the CONTRACTOR and the ENGINEER to coordinate with the individual property owner(s) to determine the optimum location for the Alarm Panel.

The CONTRACTOR shall mount the alarm device in a conspicuous location, as per national and local codes. The Alarm Panel will be connected to the Grinder Pump Station by a length of six (6) conductor 12 gauge TC type cable as shown on the contract drawings. The power and alarm circuits must be on separate power circuits. The grinder pumps station will be provided with a minimum of 32', 25' of useable electrical supply cable outside the station, to connect to the alarm panel. This cable shall be provided with a FACTORY INSTALLED EQD half to connect to the mating EQD half on the core.

3.04  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 as specified herein, and instruct the OWNER'S personnel in the operation and maintenance of the equipment before the stations are accepted by the OWNER.

All equipment and materials necessary to perform testing shall be the responsibility of the INSTALLING CONTRACTOR. This will include, as a minimum, a portable generator (if temporary power is required) and water in each basin.

The services of a trained factory-authorized technician shall be provided at a rate of 2 days for each 200 grinder pump stations supplied. Each day shall be ten (10) person hours in duration.

Upon completion of the installation, the authorized factory technicians will perform the following test on each station:

1. Make certain the discharge shut-off valve is fully open. This valve must not be closed when the pump is operating. In some installations, there may be a valve(s) at the street main that must also be open.
1. Turn ON the alarm power circuit.
1. Fill the wet well with water to a depth sufficient to verify the high level alarm is operating. Shut off water.
1. Turn ON pump power circuit. Initiate pump operation to verify automatic "on/off" controls are operative. Pump should immediately turn ON. Within one (1) minute alarm light will turn OFF. Within three (3) minutes the pump will turn OFF.

Upon completion of the start-up and testing, the MANUFACTURER shall submit to the ENGINEER the start-up authorization form describing the results of the tests performed for each Grinder Pump Station. Final acceptance of the system will not occur until authorization forms have been received for each pump station installed and any installation deficiencies corrected.

4.0 OPERATION AND MAINTENANCE

4.01  SPARE CORE:  The MANUFACTURER will supply one (1) spare grinder pump core for every 50 grinder pump stations installed, complete with all operational controls, level sensors, check valve, anti-siphon valve, pump/motor unit, and grinder.

4.02  MANUALS:   The MANUFACTURER shall supply four (4) copies of Operation and Maintenance Manuals to the OWNER, and one (1) copy of the same to the ENGINEER.

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