general requirements and details for … · section 3 drawing number ... terminal vault side view...

City of Vancouver’s General Requirements for Submersible Pump Stations April 2018

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GENERAL REQUIREMENTS AND DETAILS FOR

SANITARY PUMP AND LIFT STATIONS

Prepared By:

PUBLIC WORKS DEPARTMENT ENGINEERING DIVISION

April 2018

Marine Park Engineering Building

4500 SE Columbia Way

P.O. Box 1995

VANCOUVER, WASHINGTON 98668-1995

(360) 487-7130


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TABLE OF CONTENTS

SECTION 1 PAGE NO. SUBMERSIBLE LIFT AND PUMP STATION MINIMUM SPECIFICATIONS 1. GENERAL 5 2. SITE CONDITIONS 5 3. SUBMITTALS 6 4. CAPACITY CALCULATIONS 6 5. PUMPS AND REQUIREMENTS 6 6. WET WELL 7 7. VALVE VAULT 8 8. FORCE MAIN 9

• SIZE 9 • PIPE 9 • HYDROSTATIC TESTING 10 • MARKING TAPE 10 • TONING WIRE 10 • TEST STATIONS 10 • COMBINATION AIR VALVES 10 • CONNECTIONS TO COMMON FORCE MAINS 11 • DISCHARGE MANHOLE 11

9. CHEMICAL FEED STATION 11 10. WATER SERVICE 11 11. ELECTRICAL 12

• ELECTRICAL SERVICE 12 • MOTOR CONTROL CENTER 12 • LIFT STATION EMERGENCY POWER PROVISION 14 • CONTROL SYSTEM 15 • TERMINAL BOX AND VAULT 15 • TELEMETRY 16

12. INSTALLATION AND SERVICE INSTRUCTIONS 17


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TABLE OF CONTENTS

13. START-UP 17 14. AS-BUILTS 17 15. GUARANTEE 17 SECTION 2 PAGE NO. MINIMUM STANDARD SPECIFICATIONS 18-38

ELECTRICAL AND CONTROL - SEWER SECTION 3 DRAWING NUMBER TYPICAL SITE PLAN PS-1.1 SAMPLE ELECTRICAL DRAWING PS-1.2 - PS-1.5 SCADA WIRELESS ANTENNA PS-1.6

ELECTRICAL STRUCTURE PS-1.7A – 1.7C FLOOR PLAN/ ELEVATIONS ELECTRICAL STRUCTURE PS-1.8A – 1.8B DETAILS

TYPICAL WET-WELL LAYOUT PS-1.9A WET-WELL MECHANICAL DETAILS PS-1.9B TERMINAL VAULT LAYOUT DETAILS PS-2.0 TERMINAL VAULT SIDE VIEW DETAIL PS-2.1 TERMINAL STRIP WIRING DETAIL PS-2.2 CONDUIT SCHEMATIC/SCHEDULE PS-2.3 TYPICAL VALVE VAULT LAYOUT PS-2.4 TYPICAL CHEMICAL FEED SYSTEM (ODOR CONTROL) PS-2.6 PRESSURE LEVEL SENSOR DETAIL PS-2.7 TONING WIRE & MARKING TAPE DETAIL PS-2.8


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TABLE OF CONTENTS

SECTION 3 (CONTINUED) DRAWING NUMBER TEST STATION TONING WIRE DETAIL PS-2.9

COMBINATION AIR RELEASE VALVE DETAIL PS-3.0

COMBINATION AIR RELEASE VALVE WITH ODOR CONTROL DETAIL PS-3.1 PUMP STATION BACKFLOW ASSEMBLY DETAIL PS-3.2 YARD HYDRANT BIB & STAND DETAIL PS-3.3 EMERGENCY GENERATOR DETAIL PS-3.4 PRESSURE MAIN DISCHARGE MANHOLE PS-3.5 PRESSURE MAIN ISOLATION VALVE PS-3.6 STANDARD 1 INCH WATER SERVICE W-1


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SECTION 1

1. GENERAL The City of Vancouver has adopted the submersible lift and pump station described herein as its standard pump station design. The Contractor shall contact S&B Inc. for the SCADA System requirements and integration prior to the preconstruction meeting.

• Telephone Number: 425-644-1700 • Fax Number: 425-746-9312 • E-Mail: • General Information is [email protected] • Customer Support is [email protected]

Engineers designing pump stations for developments are required to contact the Engineering Division at the beginning of the process to discuss the preliminary design with the Engineering Division and the Operations Division. The pump supplier shall furnish all mechanical and electrical equipment required for the complete submersible pumping station including two (2) submersible pumps with rails, a third spare pump, internal piping, chemical feed station, MCC (wired for a triplex pump setup, see SCADA requirements), level control system, check valves, SCADA, and standby power. Stations with large flows may require three (3) pumps. Pumps shall be Flygt Pumps supplied with protection relay MiniCas 120 part # 14-40 71 29, or pre approved equal. A preconstruction meeting shall be held prior to beginning construction on any station. Contact the City Construction Manager at (360) 487-7750 to arrange this meeting. 2. SITE CONDITIONS Each pump station shall be placed on a separate lot dedicated to the City of Vancouver. A deed is required to transfer parcel ownership. The lot shall have easy street access and a security fence. Design the pump station site to facilitate access and maintenance. Maintenance vehicles must be able to pull directly to the wet well. A minimum turn radius of 46ft is required to negotiate turns. A turning template is available on the City’s website with the Transportation standards.


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Standard Plan PS-1.1 shows minimum site plan requirements. The engineer shall use the plan as a guide and is required to prepare a site-specific plan. Additional space may be required for maneuvering at stations that access busy streets. Structure and other feature locations may also need to be moved to avoid conflicts. The City will also consider proposed modifications to the standard site layout and the electrical structure for aesthetic reasons. Submit such modifications for review prior to submitting development plans for review. Fencing shall be furnished and installed to WSDOT Type 3 L-20.10-03 standard plan, except as noted herein or shown on the plans. In addition, the fence shall be furnished with galvanized caps and extension arms. All fencing materials shall conform to WSDOT Standard Specifications section 9-16.1. There will be no landscaping within the boundary of the pump station property. Exceptions to fencing, landscaping, and irrigation outside of pump station enclosure requirements may be granted for developments wishing to incorporate these elements into their overall site plan. Developers will be responsible for all landscape and irrigation maintenance. 3. SUBMITTALS The contractor shall submit six sets of complete manufacturer's literature on all items of equipment proposed for use in the station. Submit to the City of Vancouver's Construction Services, 520 SE 155th Ave, (360-487-7750), for review and approval prior to ordering any equipment. Submittals shall include, but are not limited to, the following: pumps, including pump curves showing operating conditions and efficiencies; vaults; covers (hatches); chamber ladder; check valves; gate valves; air valves; solenoid valve; RPBA; Hot Box; chemical feed station; floats; control panel, Motor Control Center (MCC) including all components (SCADA, ultra sonic level control, flow meters, etc.); junction box; transfer switch; generator. 4. CAPACITY CALCULATIONS The engineer shall submit design calculations for the sizing of the pump station. Stations shall be sized for build-out of the basin being served. The criteria used may be that contained in the City of Vancouver’s Sanitary Sewer Master Plan. Use 75gpcd for residential flows and 800gpad for non-residential flows. The peaking factor is based on the following formula: PF = 2.63 - 0.26 ln (Qaverage). Inflow and infiltration allowances are specific to the basin. Contact the City’s Engineering Division for the allowance in the station’s basin. 5. PUMPS AND REQUIREMENTS Each pump in a duplex station shall be capable of delivering the expected peak flow of unscreened raw sewage against the total dynamic head (TDH) including static lift, pipe friction, and station losses. In a triplex station, each pump shall be capable of delivering half of the peak flow. If expected flows are not anticipated to reach peak values for several years, a proposal to initially


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install smaller pumps or impellers will be considered. However, all piping and electrical components shall be sized for ultimate use. Each pump shall have a maximum allowable speed of 1,750 rpm. Each motor shall have the appropriate horsepower as indicated by the pump manufacturer. Motors shall be 3-phase. All openings and passages shall be large enough to permit passage of a 3-inch diameter sphere and any trash or stringy material which can pass through a 4-inch collection system. Service shall be 480 volts when ever possible. Confirm availability with Clark Public Utilities. A third “spare” pump will be required for all duplex stations. This spare pump will include the motor, power cable, volute, and impeller. Submit pump curves for the proposed pumps including the Model Number, Series Number, Type, and impeller size. 6. WET WELL The engineer shall design an appropriate wet well. Arrange a single gravity inlet entering perpendicular to a line drawn through the pumps. The minimum wet well diameter for a duplex station (with pumps smaller than 13.5HP) is 8ft. Wet wells serving triplex stations or duplex stations with large motors shall be a minimum diameter of 10ft. all metal components shall be 316L stainless steel. The contractor shall furnish and install the wet well according to the project plans and the City’s General Requirements and Details. See Standard Plan PS-1.9A & PS-1.9B. Prepare and include plan and profile views. Show and note all components. Show and note wet well wall and base thicknesses. Prepare and include flotation calculations if the wet well is to be placed in an area of high groundwater. The wet well shall be sized to accommodate the ultimate flows to be pumped. The wet well capacity shall be adequate to allow the pump motors to cycle at or above the minimum cycle times required by the given motor. This is dependent on the motor type, motor speed, motor horsepower, the shaft load, and the motor starter. NEMA guidelines can be found in the Energy Management Guide for Selection and Use of Single-Phase Motors, NEMA MG 11-1977 (R1997, R2001, R2007), http://www.nema.org/stds/mg11.cfm#download . The engineer is referred to the Wastewater Pump Station Design Manual prepared by the Bureau of Environmental Services of the City of Portland, and to Chapter 26, Pumping Station Design Second Edition, Editor-in-Chief, Robert Sanks, for more detailed discussions of wet well sizing for constant speed pumps. Calculate and submit for review the detention time provided by the wet well and piping system in the event of a power outage. All pump stations will require the developer to provide a site built emergency generator. Install lifting lugs on the wet well cover. No steps are required. Provide modular mechanical seals, Link-Seal or equal, at the discharge pipe penetrations. The wet well shall be completely cast with Ameron "T" Lock PVC or approved equal including joint and weld strips to construct a continuous liner. As an alternate, the wet well may be lined with Raven 405 if approved by City Engineering.


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Provide an H-20 rated double door cover, 6ft by 6ft minimum (sized for pumps and size of wet well), frame size per pump manufacturer, with hasp for locking with City of Vancouver padlocks. The wet well hatch opening shall be surrounded by a 316 stainless steel handrail system powder coated yellow with a gate opening on one end (See Standard Plan No. PS-1.9B). Northwest Access Products @ 360-980-1288, manufactures the hand railing required. Cast a 3-inch diameter vent hole into the lid and install an approved flush stainless steel grate in the wet well cover. Locate it where it will not hamper access to the wet well. Mount individual hooks with type 316L stainless steel anchors, equally spaced, along the length of the pump access hatch opposite the rails to hang the floats and power leads from. Also mount three additional hooks for the stainless steel lift cables, one in each of the remaining corners next to the rails. Kellum grips shall be stainless steel. Galvanized is not acceptable. 7. VALVE VAULT Include in the plans top and side views of the valve vault showing all of the components. Draw the plan to scale and show how the piping and valves will fit in the vault. Show dimensions for all valves, pipe spools, fittings, air relief valve, flow meter, etc.

Standard Plan No. PS-2.4 shows a typical plan view for a valve vault, illustrating the detail required on the plans. Precast concrete vault for valves shall be sized for the pipe size and layout, minimum 5ft-6-inches by 7ft, inside dimensions, with a depth of less than 4ft. Triplex stations and stations with piping larger than 4-inch will require a larger vault. If the vault selected has a standard depth of 4ft or more, paver blocks may be used to reduce the depth to less than four feet. The vault cover shall include a double door, H-20 rated, and a heavy duty hasp sized for City of Vancouver padlocks. Provide a 2-inch PVC drain line from a sump in the floor of the vault to the wet well with a P-trap and a check valve. The P-Trap shall be primed by water introduced from a waterline plumbed into the vault. Locate the check valve where it can be accessed for maintenance. Minimum slope shall be 2 percent. Provide a chamber ladder for access. The ladder shall be permanently secured to the base and cover of the vault and have a removable three foot long extension with hooks to hang it from the top ladder rung when not in use. The pressure gauge in the valve vault shall be a mechanical bourdon tube type with analog dial, a minimum 4-inch diameter face, and a liquid filled case (glycerin or mineral oil). The supplied gauge shall have an operating range so that the predicted operating head at the gauge is between 50% and 75% of the gauge range. The gauge bourdon tube shall be made of phosphor bronze, 316L stainless steel, monel, or inconel. The gauge diaphragm seal shall be rated for the operating pressure range of the gauge, with a diaphragm and body made of materials such as; the same materials as the bourdon tube, PTFE, other stainless steels, or materials documented to be inert and corrosion resistant to wastewater. The pressure gauge case shall be corrosion resistant, or factory painted with corrosion resistant paint. The gauge shall be accurate to +/- 2% of the gauge scale, mid-range. The gauge shall be mounted to the pressure main using ¼” NPT 316L stainless steel pipe and fittings.


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Resilient-seated gate valves shall be used. Resilient-seated gate valves shall conform to AWWA C509 or C515 and shall be epoxy coated on the inside. Units shall be fully gasketed and grease packed. Valves shall be installed with the operator hand wheel on the top side of the pipe. There shall be adequate clearance to operate and maintain the gate valve. Plug valves are not acceptable. A resilient-seated gate valve shall be required downstream of the valve vault for quick access for isolation of the pump station. See Standard Plan No. PS-3.6 Check valves shall be cast iron swing check type, Mueller Resilient Seat, or approved equal with external lever and weight. Air relief valve shall be as noted on plans. Exhaust from the air relief valve will be plumbed back into the wet well. Provide a bypass connection downstream of the gate valves inside the valve vault, unless the discharge manhole is adjacent to the pump station. Install a four inch Kamlock, male, connector with a cap. 8. FORCE MAIN Size: The minimum force main size shall be 4-inch in diameter. The minimum depth of the force main shall be 3ft. The minimum velocity shall be 3 fps to prevent solids from dropping out. A velocity of 5 fps is preferred to ensure proper operation of the swing check valves. Design velocities should not exceed 10 fps. Pipe: Approved Material Specifications

Wet-well to Valve Vault

Ductile Iron Pipe (DIP) Class 52 ANSI A21.51 or AWWA C151

Force Main

Polyvinyl Chloride (PVC) AWWA C900 (Blue Brute)

High Density Polyethylene (HDPE)

ASTM F-714, ASTM D-3350, PE: 34534C & ASTM D-1248, type III, Class C, Category 5, grade P34, AWWA C906

The force main shall contain no elbows or bends greater than 45 degrees, downstream of the valve vault. Restrained mechanical joints for pipe joints, where noted on the plans shall be U.S. Iron Pipe "TR Flex". Restrained mechanical joints for fitting joints, where noted on the plans, shall be EBAA Iron "Megalug" series 1100, or equal.


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Hydrostatic Testing: All sizes of pipe shall be tested hydrostatically as per the requirements of section 7-9.3(23) in the most current version of the WSDOT Standard Specifications, or at 150 psi for 15 minutes with no pressure drop. Marking Tape: The installation shall include furnishing and installing plastic marking tape continuously along the center line of the pipe, 18-inches above the force main. The marking tape shall be green, inert polyethylene, impervious to known alkalis, acids, chemical reagents, and solvents likely to be encountered in soil. The tape shall be a minimum of 4 mils thick Identifying lettering shall be a minimum of 1-inch high in permanent black lettering imprinted continuously over the entire length. Tape shall be Reef Industries, Terra Tape; Allen, Markline; or equal. See Standard Plan No. PS-2.8. Toning Wire: Toning wire shall be installed on all force mains. The wire shall be installed in such a manner as to be able to properly trace the force main without loss or deterioration of signal or without the transmitted signal migrating off the toning wire. The toning wire shall be laid flat and securely affixed to the top of the force main at 6 foot intervals. The toning wire shall be protected from damage during all phases of construction. No breaks or cuts in the toning wire or the toning wire insulation shall be permitted Toning wire system shall be tested for functionality by the City of Vancouver’s Waste Water Crew only after the Contractor has confirmed and demonstrated that the entire toning wire system is installed and functioning properly. All spliced or repaired wire connections in the toning wire system shall be made by soldering. The buried service wire repair closure shall be a Raychem GHFC-2-90 H-Frame Gel Closure or approved equivalent. Spliced connections shall only be allowed at intersections of common force mains and test stations. The splices for common force mains shall be located above the convergence of the force mains. Test stations shall be required at all toning wire convergences. See Standard Plan No. PS-2.8. Test Stations: The first test station shall be at the valve vault (beginning of the force main) and the last test station shall be adjacent to the discharge manhole. If the distance between the first and last test stations is more than 500ft, additional test stations shall be required. Test stations shall be shown and detailed on the engineering plans. See Standard Plan No. PS-2.9. Combination Air Release Valves: Design the force main to minimize the number of high points along the profile. However, topographic considerations and the desire to minimize the depth of the force main may not always make this practical. Install a Sewage Combination Air Release Valve, manufacturer and model noted on the plans, at each high point. Valves shall be installed in vaults


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with flushing facilities and an odor control canister, when required by Sewer Engineering as per Standard Plan No. PS-3.1. Connections to Common Force Mains: Wyes, not tees, shall be used to connect a branch line to a common force main. Install a gate valve and a check valve in combination on the branch line and on the upstream side of the common force main. Install each combination of valves in a vault with one foot clearance all around for maintenance access. When possible, the vault should be less than four feet deep. Discharge Manhole: See Standard Plan No. PS-3.5. the discharge manhole shall be lined with Strong-Seal Systems Strong-Seal High Performance Mix, or with Raven 405. Strong-Seal High Performance Mix is an acid resistant calcium aluminate cementitious liner product. Minimum thickness shall be ½-inch. Raven 405 is an ultra-high build, 100% solids based, epoxy coating. Minimum thickness shall be 80 mils. For either type of liner, equipment, preparation, application, and curing shall be performed as recommended by the manufacturer. 9. CHEMICAL FEED STATION (ODOR CONTROL) Furnish and install a Furrow Pumps Inc. calcium nitrate Feed System (or approved equal). The minimum system, required at most stations, consists of a 1000 gallon cylindrical, vertical, double walled, cross-linked polyethylene storage tank, Control Panel with timer, 15 amp breaker, GFI outlet, and fan; one Metering Pump; one tank parts kit; and all necessary pipe, valves, fittings, conduit, electrical fittings, and wire to install the station as recommended by the manufacturer. Install a 2-inch PVC, Schedule 80, vent pipe on top of the tank. The feed line shall be ¾-inch PVC, Schedule 80, with flexible piping used at the pump which is located in the control cabinet. Discharge line shall be ½-inch flexible piping from the pump to PVC underground. Install a filter in the flex piping. The minimum system is illustrated in Standard Plan No. PS-2.6. Contact the Engineering Division for a determination if a larger system is required. In locations where vandalism is more likely, the bioxide system will be required to be placed in a vault. Furnish and install a 120 volt, 15 amp, electrical circuit dedicated for power supply to the calcium nitrate feed system. The circuit shall constitute a bolt-to-bus breaker with no other control device in series. 10. WATER SERVICE A 1-inch diameter copper water service and 5/8”x3/4” water meter shall be provided to the pump station as shown on the plans. The water service, meter box, and installation shall be in conformance with City of Vancouver Standard Plan No. W-1. All water piping past the meter set shall be seamless type K soft annealed copper. Back Flow Assembly: The reduced pressure backflow assembly shall meet the requirements of City of Vancouver’s General Requirements and Details. It and the other components of the water system downstream of the meter shall be installed inside of the electrical panel building. The


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components shall be installed per standard detail PS-3.2. Install ¾-inch conduit from electrical panel to the backflow with 2-#12 and 1-#12 ground for heat tape, and 2-#14 for the solenoid valve. Install "FD" device box with 15A GFCI receptacle and weatherproof duplex receptacle snap cover, Crouse-Hinds "WLDR". 11. ELECTRICAL Electrical and Control systems shall be furnished and installed as specified herein and on the drawings and as per the City of Vancouver's "Minimum Standard Specifications / Electrical & Control - Sewer" (latest revision). The contractor shall submit Electrical Drawings (including PLC/relay interface) for approval prior to construction of the electrical control panel. Drawings shall be similar to the sample electrical drawing shown on Standard Plan No. PS-1.2 through Standard Plan No. PS-1.5. A shelter shall be provided by the contractor for the electrical panels as per Standard Plan No. PS-1.6, 1.7A through 1.7C and Standard Plan No. PS-1.8A & 1.8B. The City will consider alternate shelter designs made for aesthetic reasons. Submit such designs for review prior to submitting development plans for review. For pump stations in remote locations, install a motion sensitive or light sensitive (photo cell) flood light as directed by the city on one end of the shelter. This is required to prevent vandalism at the pump station. Provide an override switch (off-motion/light-on) inside the electrical building. Install an on-site emergency generator with an automatic transfer switch as per Standard Plan No. PS-2.3 & PS-3.4 Generator sizing will be based on location, pumping rate, and detention (storage) time. Electrical Service: The contractor shall make all arrangements with Clark Public Utilities to obtain electrical service (power) for the pump station. The electrical service shall be mounted as shown on the electrical structure plans. Motor Control Center: Motor Control Centers (MCC) as specified and as shown on Standard Plan No. PS-1.4, shall be furnished by the Control System Integrator and installed by the contractor. The manufacturer, its designated field service group, or the Control System Integrator shall program, test, commission and certify operation of the MCC equipment. The Motor Control Center shall be the TIAstar model by Siemens without exception. It shall be a NEMA 1A rated enclosure in an ANSI Grey finish. The MCC shall include a main circuit breaker, surge protection device, transformer, panelboard, motor starters, and feeder breakers. All PROFINET enabled devices will be network connected from the MCC to the PLC using 600VAC rated cable – Siemens model 6XV18402AH10 or equal. Remote Telemetry Unit (RTU): See Standard Plan No. PS-1.4. The telemetry controls shall be mounted in a control panel which shall be a NEMA 12 type fabricated painted steel enclosure. The RTU will include breakers, fuses, relays, power supplies, Programmable Logic Control (PLC), communication modules, and terminal blocks. Wiring raceway shall be neatly arranged on a removable steel back plate. A touch control panel shall be door mounted on the RTU for


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local operator control of the station. The RTU shall be manufactured by S&B Inc, without exception. ISR Control Panel: All Intrinsically Safe devices shall be placed in a NEMA 12 type fabricated, painted steel enclosure, pre-attached to the RTU. Inside shall be intrinsically safe relays and barriers, desiccant vent filters for level transducers, and terminal blocks. The ISR control panel shall be manufactured by S&B Inc, without exception. PLC: The PLC shall be a Siemens S7-1500 series processor, without exception. All input, output, and communication cards will utilize the ET200SP series form factor. The CPU memory card shall be 4MB minimum. The touch panel shall be a Siemens Comfort Series, 9” minimum. PROFINET communication will be used to connect the PLC to all PROFINET enabled devices in the Siemens MCC, other PLC equipment, and touch panel. Programming: All control system programming shall be performed by the City’s Control System Integrator, S&B Inc, without exception. This includes motor starters inside the MCC, PLC, touch panel, and Master Telemetry Unit (MTU) updates. The communication between the MTU and RTU will be configured and validated by S&B Inc. FIELD DEVICES: “Floats: Direct acting float switches shall be supplied to control the operation of the sewage pumps at levels outside of SCADA parameters. Emergency High Wet Well Start, and Low Wet Well Emergency Off. The float switches shall be polyurethane foam resin bodies encapsulating mercury tube switches that are the “Normally Open” type. The float switches shall be Anchor Scientific Inc., Roto-Float, Type S - Suspended, model S40N0, UL listed for pilot duty and industrial control equipment, or equal. Cable shall be PVC type STO #18 conductors, rated 600 volts. Provide intrinsically safe relays.” “Submersible Level Transducer: Level monitoring shall be done by a Mercoid PBLTX-5-400-11.54' W.C. Level Probe. Provide and install a Desiccant Vent Filter, model A-297, in the ISR termination junction box.” “Flow Meter: Flow Monitoring shall be done by Siemens Mag 5100W meter and Siemens Mag5000 Transmitter Head (24VDC), model 7ME6910-1AA10-1AA0. The Transmitter head is to be remote mounted using wall mount kit model FDK: 085U1053. Provide a submergence kit for the meter body, model FDK: 085U0220. Provide adequate cable lengths of Siemens Standard and Special electrode cables for the remote mounting application. ” The RTU panel shall be mounted with clear line of sight to the wet-well, unless otherwise approved by Sewer Engineering. The electrical service meter, automatic transfer switch, and a Hubbel duplex receptacle shall be mounted separate from the exterior enclosure as shown on Standard Plan No. PS-1.7B. the duplex receptacle shall be weatherproof 115V GFCI, 20 amp breaker with #12 wire. Install a second


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Hubbel duplex receptacle, weatherproof 115V GFCI near the reduced pressure backflow device located within electrical structure. For each pump install a current transformer on one of the three line side motor branch circuit conductors in front of each VFD’s. Each motor shall have a running digital ammeter with 1inch characters. Scale the full running amps to as close to fifty percent resolution on each ammeter as possible. All external wiring shall be in PVC coated rigid steel conduit, OCAL BLUE, Robroy Plastibond Red, or approved equal. Lift Station Emergency Power Provision: Site Built Generators: The City of Vancouver has established standards for site built emergency power generator requirements. See Standard Plan No. PS-3.4 Provide a permanent standby power generator sized specifically for the pump station. The system shall be complete with engine, alternator, electrical and control systems, cooling and exhaust systems, transfer switch, fuel tanks sound dampening enclosure, etc. The generator may be required to be housed inside a building. Install the system and provide a warranty. The system shall be provided by

Cummins Northwest, LLC Oregon Power Generation

4711 N Basin Avenue Portland OR 97217-3557

503-289-0900 www.cumminsnorthwest.com

Switch: Install a UL service-rated, three-pole, double-throw, fusible, horsepower rated, manual transfer switch in a NEMA 3R enclosure immediately adjacent to the electrical utility meter. Provide fuse rejection clips and BUSSMANN fuses as specified in section E.23.2. The switch shall disconnect each ungrounded phase conductor completely from one source before connecting any conductor to the second supply source. The switch shall incorporate a cover interlock and provide means to padlock the operating handle in the up, neutral and bottom positions. With the switch handle in the raised/up position, the station shall be connected to "NORMAL"/CPU power. With the switch handle in the down position, the station shall be connected to emergency power. Provide metal, engraved nameplates on the face of the transfer switch to indicate switch status (NORMAL, OFF, STANDBY). The contractor shall provide a solid-neutral to connect the utility service neutral and the standby source's grounded conductor. The neutral conductor shall not be disconnected by the operation of the transfer switch (per Clark Public Utility, June 1995). Minimum transfer switch rating shall be 60-amps at 240-volt AC, 3-phase, 4-wire. Approved Manufacturers: Switch shall be ITE #FR322DTK enclosed switch with neutral kit #DT100NK, CUTLER-HAMMER #DT322FRK with #DT100NK neutral kit, or approved equal. (These catalog numbers are for 60-amp, 3-phase, 4-wire, 240-volt AC. For other system voltages or ampacities, catalog numbers will need to be verified.)


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Control System:

Pump Panel: The electrical controls shall be mounted in the pump panel which shall be a NEMA 12 type fabricated, painted steel enclosure. All equipment including breakers, variable speed drives, relays, timers, and wiring raceway shall be neatly arranged on a removable steel back plate. All fusible switch handles, HOA switches, VFD reset buttons, running time meters, ammeters, and indicating lights shall be mounted on, or extended through die cut openings in the front of the panel door. All units shall be identified by plastic engraved labels, attached with stainless steel fasteners. A suitable type latching device shall be provided on the door. It shall not be necessary to open this enclosure except for adjustment of controls. The circuit breakers in the pump panel shall include those for the exterior enclosure heater and the duplex receptacles. Hour meters shall be Reddington #772-004 elapsed time meter, round case, 120v-60Hz non-resettable, or approved equal, to fit a nominal two-inch round knock out. Thermal magnetic circuit breakers shall be provided for branch circuit protection and over-current protection of all control, and auxiliary circuits. Install a wired in branch panel surge protection (Hubbel model HBL3W100) to protect all control and auxiliary circuits. Properly sized, NEMA rated, and under voltage release for operation and protection of the pump motors. Breakers shall be GE, or Square D. Ground fault and short circuit protection of the motors shall be by dual element fuses manufactured by Bussmann. Control Panel shall be Usemco, or preapproved equal. Obtain City approval prior to manufacture. Level monitoring shall be done by a Mercoid PBLTX-5-400-11.54' W.C. Level Probe Note: Wet Well depths greater than 30ft, contact Sewer Engineering at (360) 487-7130. Flow Monitoring shall be done by Siemens Magflo Mag 5100W and Siemens 7ME6910-1AA10-1AA0 Magflo Mag5000 Transmitter/Converter. Terminal Box and Vault: The Contractor shall furnish and install a padlock-able vault to house the pump and float terminal boxes. See Standard Plan No. PS-2.0. The vault shall have minimum interior dimensions of 4ft by 4ft in length and width and 4ft in depth. Installation and construction of the vault and box shall include installation of a 2-inch PVC drain line from the terminal vault to the wet well with a self priming P-trap and check valve. The float terminal box shall be Hoffman model CSD20168W (stainless steel) and Back Panel model CP 1616 (painted steel). Circuits to be intrinsically safe. The pump terminal box shall be an explosion proof rated Eaton Crouse-Hinds model EJB120804 (stainless steel). Circuits to be intrinsically safe.


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Pump motor wiring and float wiring (intrinsically safe) shall terminate on Allen-Bradley #1492-CA1, or #1492-CA2, terminal blocks, or approved equal. Terminal blocks shall have a rating of 55 amps, minimum, and a wire range of #22 to #8 AWG and be mounted on a DIN rail that is mounted on the interior back panel mounting plate.

Terminal blocks shall have heavy-duty end anchors, Allen-Bradley #1492-N23, or approved equal. End anchors shall rely on at least two set screws to assure positive placement. A minimum of two inches shall separate power wiring and terminals from any intrinsically safe wiring within the terminal box, per NEC Article 504-30. “The terminal box vault shall have a Gems #01901 LS-1900 Series Level Switch, Thomas Products model 4600, or approved equal, to indicate a flooding condition within the terminal box vault.” PVC coated, rigid, steel conduit shall be used from the exterior control panel to the pump/float terminal box and from the vault to the wet well. Each cable shall be installed in a separate conduit from the wet well to the vault. Each stub inside the vault shall be fitted with an insulator bushing and cord/cable fitting with gland nut and bushing, Crouse-Hinds CGB-SG, or equal. These assemblies shall also be installed on each opening on the wet well side of the junction box. Each cable requires a separate opening. PVC coated conduit and fittings shall be OCAL BLUE or ROBROY Plastibond Red, or approved equal. PVC coated conduit shall have a minimum 40-mil exterior PVC coating and a nominal 2-mil urethane interior coating. All factory threads shall be galvanized. Installation of all PVC coated conduit shall be per the appropriate manufacturer's recommendations. Refer to See Standard Plan No. PS-2.3 for a conduit schedule. Telemetry: Supervisory Control And Data Acquisition: The SCADA system shall be provided by

S & B Inc. Phone 425-644-1700 Fax 425-746-9312 [email protected]

[email protected] The communication modem used for connecting the RTU to the MTU shall be placed inside the RTU enclosure. The Contractor will be responsible for coordinating with the City of Vancouver IT Department for acquisition of all communication lines. The Contractor shall also be responsible for any and all fees related to the purchase of the communication and all fees shall be paid for prior to start-up of the pump station.


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12. INSTALLATION AND SERVICE INSTRUCTIONS Installation of the pump station shall be in accordance with the approved plans and the written instructions furnished by the manufacturers. The contractor shall keep one set of approved plans and submittals available on site during construction. The contractor shall furnish four (4) complete and bound detailed operation and maintenance manuals each with an electronic copy available on electronic media. Provide one factory original manual and three neat and legible copies. This manual shall cover the initial startup, operating procedures, and maintenance and servicing procedures on the major component parts provided in the pump station. One (1) manual shall be shipped with the station, the remainder shall be sent to the Engineering Division at the City of Vancouver. 13. STARTUP Provide final as-built electrical, construction and mechanical record drawings to the City at least ten (10) working days prior to startup (to enable PLC program verification prior to station startup). Provide 72 hours advance notice to the City’s Construction Inspectors and the Operations Waste Water Supervisors (360-487-8177) prior to startup. This notice will be in addition to any notice given when the record drawings are turned in. The communication line shall be operational prior to startup. The manufacturer shall provide the services of a factory trained representative for a minimum period of one (1) day to perform the initial startup of the pump station. The representative shall instruct operating personnel on required maintenance and service procedures. The representative shall also operate the station for a second day if necessary to fully test the components and train City crews. Each station component shall be operated, tested and demonstrated during startup. This includes filling the wet well, activating each set point and float, triggering and observing alarms, pump starting, pump drawdown tests, etc. 14. AS-BUILTS The station’s design engineer shall prepare asbuilt record drawings. Follow City of Vancouver General Requirements Section 1-4. Clearly indicate all modifications to plan features and elements. Show all electrical, communications, piping, and conduits. Mark the drawings as As-Built/Record Drawings and include an acknowledgement by the preparing engineer. 15. GUARANTEE The manufacturer shall guarantee the pump station for workmanship and to be free from defects for a period of two years from date of final Civil Project acceptance. The contractor is responsible for the complete and satisfactory operation and function of all equipment and materials, regardless of the manufacturer's guarantee on any item furnished. It is the


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contractor's responsibility to place all equipment in operation, furnish all lubrication, packing and other accessories necessary for initial operation, and ensure proper operating and maintenance instructions are prepared before final acceptance.

SECTION 2

CITY OF VANCOUVER Submersible

Lift and Pump Station Minimum Specifications

ELECTRICAL & CONTROL

MINIMUM STANDARD SPECIFICATIONS

E.1 GENERAL E.2 CODES, RULES, REGULATIONS E.4 ELECTRICAL SERVICE E.13 INSPECTION AND TESTS E.14 MOTORS, MOTOR CIRCUITS 14.1 MOTOR TESTING 14.2 MOTOR TERMINATIONS E.15 CONDUITS AND RACEWAYS


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15.1 RIGID METAL CONDUIT (GRC) 15.2 LIQUIDTIGHT FLEXIBLE METALLIC CONDUIT 15.3 PVC COATED GRC CONDUIT 15.4 ELECTRICAL METALLIC TUBING (EMT) 15.5 ROUTING 15.6 MATERIALS 15.7 SIZE 15.8 INSTALLATION 15.9 CONDUIT GROUNDING

E.16 FITTINGS 16.1 UNIONS/CLASSIFIED LOCATIONS 16.2 SEALS/HAZARDOUS LOCATIONS 16.3 LOCKNUTS 16.4 BUSHINGS 16.5 GROUNDING BUSHINGS 16.6 HUBS 16.7 CONDUIT FITTINGS 16.8 LIQUIDTIGHT METALLIC FLEX CONNECTORS

16.9 FLEXIBLE CONDUIT FITTINGS, EMT FITTINGS 16.10 PORTABLE CORD AND CABLE FITTINGS

E.17 CONDUCTORS 17.1 MATERIAL AND SIZE 17.2 INSULATION 17.3 WIRE CONNECTORS 17.4 INSTALLATION 17.5 CONDUCTOR IDENTIFICATION 17.6 COLOR CODE 17.7 MISCELLANEOUS E.18 BOXES 18.1 DEVICE BOXES 18.2 PULL BOXES .2.1 INTERIOR APPLICATION .2.2 EXTERIOR AND BELOW GRADE APPLICATIONS 18.3 TERMINAL BOXES 18.4 DEVICES E.19 CONDUIT SUPPORTS 19.1 CONDUIT CLAMPS 19.2 HANGER ROD 19.3 CHANNELS, FITTINGS, HANGERS, CLAMPS AND ACCESSORIES


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E.21 GROUNDING E.23 MOTOR CONTROL CENTER 23.1 GENERAL REQUIREMENTS 23.2 MOTOR STARTERS 23.3 NETWORK 23.4 PROGRAMMING 23.5 INSTALLATION

E.25 DISTRIBUTION 25.1 PANEL BOARDS AND LOAD CENTERS .1.1 CIRCUIT BREAKERS .1.2 BUSSBARS ************************************************************************* E.1 GENERAL These electrical specifications are "typical" for City of Vancouver Sewer installations. Not

all sections may be applicable to this specific project. E.2 CODES, RULES, REGULATIONS All work shall comply with the current NEC and current local codes. Where the drawings or

specifications exceed code standards, the drawings and specifications shall take precedence. All work shall be installed as per NFPA 70 article 110-12 “workmanlike manner” E.4 ELECTRICAL SERVICE Electrical service shall be as shown on drawings: ___ Amp, ________-volt, 3-phase, 4-wire. Install a UL service-rated, three-pole, double-throw, fusible, horsepower rated, manual

transfer switch. Provide fuse rejection clips and BUSSMANN fuses. Provide means to padlock the operating handle. Refer to City of Vancouver "Submersible Lift and Pump Station Minimum Specifications" for additional requirements.

E.13 INSPECTION AND TESTS All electrical work shall be inspected before concealment. After installation and prior to the energizing of any cables or equipment, megger all service

entrance conductors, power cables, motor feeders, lighting feeders, switchgear busses, and MCC busses. Readings shall be taken between pairs of phases and between each phase and


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ground. Equipment and cable operating at 600 volts or less shall be tested with a 500 volt megger per Biddle test recommendations.

Test all service entrance equipment and branch circuits for shorts and grounds prior to

energizing. Provide written megger test report on each item tested to the City Utility inspector, listing: circuit tested, test voltage, test duration, test result, ambient

temperature, weather conditions, and tester's initials. E.14 MOTORS, MOTOR CIRCUITS E.14.1 Motor Testing Tests shall be made prior to starting motors, and submit 2 copies of the results to the

City of Vancouver’s Sewer Engineering Dept. Test report shall include the motor being tested (motor/pump number, location, voltage, phase, horsepower), temperature and weather conditions (for outdoor location only).

Megger all motor windings from load side of starter after terminations are made. If

resistance is low, dry out and re-test. Megger readings shall be in accordance with NEMA standards but in no case less than 25 M-ohm.

E.14.2 Motor Terminations Motors shall be terminated using one-hole crimp terminals applied with hand tools

through size #8, and hydraulic applied terminals, Thomas and Betts Color-Keyed, or equal, for wire sizes #6 and larger. Terminals shall be bolted together with minimum of #10-32 bolted connections.

Wire nuts and split bolts are specifically prohibited for motor connections. Bolted connections shall be over wrapped first with one layer of Scotch 2520

varnished cambric tape, followed by one layer half-lapped, Scotch "Scotchfil" or 130C tape and top-wrapped with one layer, half-lapper Scotch Super 33-plus or Scotch Super-88 tape. Motor conductors shall be color coded at motor starter termination, each splice point (if applicable), and at motor terminal box as per color code in section E.17.6.

E.15 CONDUITS AND RACEWAYS E.15.1 Rigid Metal Conduit (GRC)


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Rigid steel, hot dipped galvanized inside and outside after threading. Republic, National or equal. Acceptable for applications inside "dry well" not defined as liquid tight flexible metallic conduit. Not acceptable for direct burial.

E.15.2 Liquidtight Flexible Metallic Conduit These shall contain a separate grounding conductor. Liquid tight, neoprene or vinyl

jacket, Anaconda Sealtite, type 'UA' or equal. Use to connect electrical apparatus subject to vibration such as motors, heaters,

solenoids, limit switches, etc. Flex shall not be used for connection to panel boards, motor control centers, motor starters or load centers except for specific prevention of noise transmission.

Limit lengths to 36" except at motor connections where the maximum may be increased to 60".

Minimum size shall be 1/2". E.15.3 PVC Coated GRC Conduit OCAL "Blue", Robroy Plastibond Red, or approved equal. Use for all raceways on

exterior of "dry well" whether exposed or direct burial. Also acceptable for applications inside "dry well" not defined as liquid tight flexible metallic conduit. Conduit shall be rigid steel with a 40 mil PVC exterior coating, minimum, and a nominal 2 mil urethane interior coating.

Underground installation shall comply with section E.15.7-13. E.15.4 Electrical Metallic Tubing (EMT) Steel, galvanized, Allied tubing or equal. Use inside "dry well" only. All fittings

shall be steel compression type, water tight, RACO, or approved equal. Connectors shall have factory installed throats, RACO, or approved equal.

E.15.5 Routing

Exposed conduits shall be installed vertically on wall and horizontal runs shall be installed square with building lines.

E.15.6 Materials


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All interior conduits shall be rigid galvanized steel, EMT, or PVC coated GRC. Exterior or underground raceways shall be PVC coated GRC and comply with section 15.8.13

E.15.7 Size Minimum size conduit shall be 3/4 inch, except 1/2 inch for switch legs. Control conduit shall be 3/4 inch minimum. E.15.8 Installation 1. Cut end of all conduits square and ream. Fittings shall be compatible with

conduit used, secured wrench-tight, and form a smooth transition from conduit to fittings. Make all bends with an approved conduit bender. All bends in metallic conduit must be made while the conduit is "cold". Conduits shall not be flattened or wrinkled.

2. Conduits encased in concrete shall be securely attached and anchored to prevent movement during pouring, tamping and vibration of the concrete. Ends shall be sealed with factory seals. Replace conduits containing concrete as directed by Engineer. 3 Empty conduits shall be swabbed out clean and dry, and nylon pull cords

installed. Spare conduits 2-inch and larger shall have 1/4-inch pull line installed. Spare conduits shall be capped using caps made for the purpose (tape, rags or similar methods will not be recognized), and locations clearly marked with a monument or other permanent marker. See also section e.15.8.13 E-F.

4. Run conduit in neat rows with smooth concentric bends. Support multiple

runs from Unistrut or Kindorf hangers in all exposed areas and maintaining 3/4-inch minimum spacing between conduits. Diagonal, crossed or haphazard, non-supported runs will not be allowed.

5. Install insulated grounding bushings on the ends of all rigid steel conduit, except where conduits terminate in threaded hubs on cast boxes or cabinets, in which case insert manufacturer's

standard insulating sleeves and grounding terminal(s). 6. Provide suitable expansion fittings for raceways crossing expansion joints in

concrete slabs, or provide other suitable means to compensate for building expansion and contraction. Comply with section E.16.6A.

7. Wooden plugs inserted in concrete or masonry are not acceptable as base for

raceway fastenings. Use only approved concrete expansion anchors for fastening to concrete. In exposed area, "permanent"


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concrete fasteners, such as Zamac type, shall not be used. The intention is to allow future adjustment or relocation of raceways. 8. Raceways or pipe straps shall not be welded to steel structures. Unistrut or

channel may be clamped or bolted to steel structure, and conduit and clamps bolted to the channel.

9. Conduits shall emerge from concrete at right angles and shall have none of

curved portion of bend exposed. 10. Conduit shall be of the greatest practical single length between joints, and all

joints shall be made up with approved conductive jointing compound, T&B, KOPR-SHIELD, or approved equal. Conduits shall not be bent through more than 90 degrees. Not more than the equivalent of three 90 degree bends (270 degrees total) shall be installed between pull points.

11. Do not use nails to fasten boxes or conduits. Do not use wire to support conduit. 12. Dry pack with non-shrink grout around conduits that penetrate finished

concrete or masonry walls, floors, or ceilings. E.15.8, 13. UNDERGROUND RACEWAYS A) Separate parallel runs of two or more conduits in single trench with

spacers designed for purpose. Install spacers at intervals not greater than those specified in the NEC for support of type conduit used. Support conduits installed in fill areas suitably to prevent accidental bending until backfilling is complete.

B) Do not backfill underground conduit until it has been inspected by

Electrical Inspector and Engineer or his representative/City Electrician. Ensure that ends are capped per part F, this section, prior to inspection.

C) Mark with buried 6" wide, Red, warning tape inscribed "Electric Line" as

per NEC’s current standard. A single warning tape shall be installed in trenches up to 24" in width, an additional tape shall be installed for each additional 18" of trench width, or fraction thereof. (Example: 30" trench would require two tapes.)

D) Minimum cover for conduits shall be 24-inches to the top of raceway.

marked with warning tape. E) Make up conduit installed underground water tight and sealed. Conduit

containing water shall be pumped dry and swabbed. If water is infiltrating


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and cannot be removed, then re-route conduits as directed without additional charge.

F) During construction, all installed conduits shall be plugged temporarily

with duct tape or by other adequate means to prevent the entrance of dirt, trash or other foreign material. Any conduit which may become clogged through neglect of the contractor to protect them, shall be replaced by the contractor without additional cost to the customer.

G) Submit as-built drawings to the City utility inspector, minimum of two

copies, showing the location of all underground raceways with dimensions. A dimension shall be given from building corners where raceways leave building lines and then at least 100' thereafter. The intermediate dimensions shall reference to at least two permanent structures per location.

14. Final connection to motors and to other equipment shall be made with 18-inch minimum lengths of liquid-tight, polyvinyl chloride jacketed, flexible steel conduit where the required conduit size is 3-inches or less. Where conduit size is greater that 3-inches, rigid steel conduit shall be continued to the motor terminal box. 15. Running thread shall be limited to lengths not to exceed 6 inches. exposed portions of running thread shall be treated with a "cold- galv" finish such as CRC "Zinc Re-Nu". E.15.9 Conduit Grounding All conduit runs shall have a minimum of one #10 AWG 600 volt, stranded copper,

green colored, insulated ground wire unless specifically noted otherwise on drawings.

E.16 FITTINGS E.16.1 Unions/Classified locations Type UNF or UNY suitable for hazardous locations, cast ferrous alloy, electroplated or hot dipped galvanized. E.16.2 Seals/Hazardous Locations


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Hot dipped galvanized cast ferrous alloy, sealing compound of same manufacture, UL listed for class 1 areas. Crouse-Hinds EYSX Expanded Fill Sealing Fittings shall be used. E.16.3 Locknuts Two inches and smaller, heavy galvanized steel. Larger than two inches, malleable iron, galvanized. E.16.4 Bushings Electro galvanized steel or malleable iron with molded phenolic or nylon insulating collar. E.16.5 Grounding Bushings Malleable iron, galvanized, with molded nylon insulating collar, grounding lug.

Grounding wedges or grounding locknuts shall not be used. E.16.6 Hubs Hubs shall provide watertight conduit connection to sheet metal boxes in exterior or

below grade applications. Zinc, galvanized steel or galvanized malleable iron, with nylon insulated throats, T&B "BULLET" HUB or approved equal. Hubs shall be used for top, side, rear or front conduit entries. "Sealing-type" lock nuts may be used for bottom entry.

E.16.7 Conduit Fittings A) In exposed conduit runs, expansion fittings shall be weatherproof with

external bonding jumper, 4 inches longitudinal movement, bushed conduit ends. In concealed conduit runs, expansion fittings shall be

watertight, internal bonding jumper, neoprene construction and allow 3/4" movement in any direction. Refer to section E.15.7-8.


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B) Exposed conduit fittings shall be cast, threaded type, Crouse-Hinds Form-7, or approved equal, with cast covers and neoprene gaskets. Condulets in conduit runs 1 1/2" or larger shall be "Mogul" type.

C) GRC couplings shall be factory threaded, or T&B "Erickson" type or equal.

Threadless fittings are specifically prohibited, except by special permission in limited locations.

D) Conduit "chase" nipples shall have nylon, pre-insulated throats. E.16.8 Liquidtight Metallic Flex Connectors Heavy cadmium plated malleable iron with grounding insert and pre- insulated throat. E.16.9 Flexible Conduit Fittings, EMT Fittings All steel compression type, pre-insulated, rain tight. Fittings with die cast aluminum or pot metal components are not acceptable. E.16.10 Cord and Cable Fittings, CGB Portable cable connectors shall form secure connections to prevent moisture and gasses from passing through. They shall be rated for Class 1, Division 2, Group A,B,C,D. They shall be steel-zinc electroplate with chromate finish coat and include a neoprene bushing sized for proper cord and cable diameter. Crouse-Hinds, or equal. E.17 CONDUCTORS E.17.1 Material and Size All conductors shall be stranded copper. No aluminum or solid conductor shall be

used. Conductor sizes shall not be less than shown. Conductors shall be not smaller than

No. 12 AWG for lighting or power circuits, or No. 14 AWG for control circuits, unless otherwise indicated.

E.17.2 Insulation General use: Type "XHHW" above or below grade. Type "THHN"/"THWN" permitted for dry locations in sizes #6 AWG and below. E.17.3 Wire Connectors


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Lighting circuit conductors up to #8, spring compression type Scotchlok connectors

or equal may be used as per UL Listing. All other conductors shall be terminated using one-hole crimp terminals applied with hand tools through size #8; and hydraulic compression terminals, Thomas and Betts Color-Keyed, or equal, for wire sizes #6 and larger. Terminals shall be bolted together with minimum of #10-32 bolted connections.

Bolted connections shall be over wrapped first with one layer of Scotch 2520

varnished cambric tape, followed by one layer half-lapped Scotch "Scotchfil" or 130C top-wrapped with one layer, half-lapper Scotch Super 33-plus or Scotch Super-88 tape.

Where control wire terminations are not provided mechanical clamp connection,

control wire shall be terminated with nylon insulated, compression terminals, Thomas and Betts "Stak-on", or approved equal. No more than two conductors shall be placed at each termination unless terminal is specifically identified for such use.

E.17.4 Installation All wire shall be continuous from outlet to outlet. Splices, where required, may be

made in outlet, pull and terminal boxes only. Terminals or connectors shall be approved for type of conductor materials used.

Arrange wiring in cabinets, panels, motor control centers, and neatly cut to proper length, and remove surplus wire.

Apply Stake-on connectors to control wiring for connection to screw terminals, and

bridle and secure in approved manner. Refer to section E.17.3.

E.17.5 Conductor Identification All wiring shall be identified at all terminations and splice points including pull,

device, terminal and junction boxes where a break in the wiring occurs. List all circuits emanating from panel boards and load centers by function on directory card. Lighting circuits may be excluded from this requirement unless in proximity of other conductors requiring marking.

Control wiring shall be identified with approved wire markers bearing designation

shown on contract drawings. All wiring of #10 AWG and smaller shall be tagged with type-written, heat-shrink wire markers, such as Brady "SCN" type, or approved equal. Adhesive backed, wrap around wire markers are specifically prohibited.


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Identification shall either be the circuit number if a lighting or convenience circuit, or the control number from wiring schematics. It is the intention of this section to provide a unique wire number to each wire in the control scheme at each station.

Pull wire with adequate pig tails left in the junction box for make up. E.17.6 Color Code Power feeders using all black insulated wiring shall have phases identified with

colored vinyl tape at all terminations and splices (this includes motor starter terminations and at the motor terminal box). Conductors of sizes #8 and smaller shall be color coded by the manufacturer along the entire conductor length, field re-identification will not be permitted.

Color code wire to conform to code requirements or as indicated below: 1) 240/120 or 208/120 volt A-phase Black B-phase Red C-phase Blue Neutral White 2) 480/277 or 480/3ph A-phase Brown B-phase Orange C-phase Yellow Neutral Grey (or white with tracer)

E.17.7 Miscellaneous Use pulling compounds as recommended by the wire manufacturer. Do not exceed recommended pulling tensions. All wire contained in the same raceways shall have an insulation value to match the highest voltage between conductors of all circuits contained therein. E.18 BOXES E.18.1 Device Boxes


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Exposed switch and receptacle boxes shall be cast ferrous alloy, hot dipped or electro galvanized with integrally cast hubs for all conduit entrances, with all drilling and threading done before galvanizing. Manufacturer shall be Crouse-Hinds type 'FD" or equal. Type 'FS" boxes are not acceptable. Concealed boxes may be stamped or welded steel construction, 2" minimum depth with stainless steel or cast cover plates.

Weatherproof cover and device plates shall be of the same material, neoprene

gaskets, with stainless steel screws, Crouse-Hinds "WLRD" or equal. Interior cover plates shall be stainless steel, or stamped steel Crouse-Hinds type "DS" or equal. Plastic cover plates are specifically excluded.

E.18.2 Pull Boxes .2.1 Interior Application Enclosures for indoor use shall be NEMA Type 12, with hinged door, gasket. Larger enclosures shall be Hoffman Bulletin A-12, or approved equal. Smaller enclosures shall be Hoffman Bulletin A-51, or approved equal. Enclosures in chemical rooms or wet wells shall be English or Carlon non-metallic,

NEMA 4 or stainless steel NEMA 4X, and except for device boxes, shall have full back plates where terminations are required.

.2.2 Exterior and Below Grade Applications Enclosures use shall be NEMA Type 4 or 4X, with hinged door, gasketed,

watertight, and except for device boxes, shall have full back panel. Enclosures in wet wells shall be English or Carlon non-metallic, NEMA 4 or stainless steel NEMA 4X.

Larger enclosures shall be Hoffman Bulletin A-4, or approved equal. Smaller enclosures shall be Hoffman Bulletin A-51, or approved equal. E.18.3 Terminal Boxes Boxes and terminals shall comply with the requirements of other sections of these

specifications.


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All control wiring shall be spliced on approved terminals housed in an enclosure

sized for the components. Provide terminal junction boxes where required for splices whether specifically shown or not.

Provide terminal boxes with full back panels where shown on the drawings. Terminal Junction Boxes may also be required where called out on the drawings for

splicing power conductors. Refer to detail for wiring in pull vault adjacent to wet well.

E.18.4 Devices Devices shall be as indicated (or approved equal): Duplex receptacles HUBBELL CR120I Single pole switches HUBBELL CS115-I Three-way switches HUBBELL CS315-I GFCI receptacles HUBBELL GF5252-I E.19 CONDUIT SUPPORTS E.19.1 Conduit Clamps One hole, cadmium plated or galvanized heavy gauge steel, or galvanized malleable

clamps iron with clamp-back spacers shall be used in all exposed locations that Kindorf channel is not used. Acceptable: RACO 1300 Series clamps with Series 1340 clamp backs or equal. Stamped steel one-hole or two-hole straps are specifically prohibited except in concealed locations.

E.19.2 Hanger Rod Galvanized steel or electro galvanized and zinc chromate coated steel, 3/8" minimum. Approved manufacturers, Midland Ross "Kindorf", Unistrut. E.19.3 Channels, Fittings, Hangers, Clamps and Accessories Hot dipped galvanized, or electro galvanized and zinc chromate coated steel. Channels shall be 14 gauge minimum, 13/16" or 1-5/8" deep by 1-5/8" wide minimum. Approved manufacturers, MIdland Ross "Kindorf", Unistrut. E.21 GROUNDING Provide a complete grounding system as shown and as required by the NEC and the


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local enforcing authority with common grounding point at the main motor control center or switchboard. All equipment grounding conductors shall be copper, Type THW or THHN insulation,

green in color, sizes as noted on the drawings, or as required by NEC. #10 stranded shall be the minimum size unless specifically noted otherwise.

All grounding terminations to bus and/or equipment shall be with 1-hole compression type lugs. All grounding conductors’ splices shall be made with compression sleeves. Connection of grounding electrode conductors to ground rods, re-enforcing steel and building steel shall be made with "Cadweld" exothermic welds or approved equal. Provide grounding conductors, other than grounded neutral conductors, where shown on the drawings to provide an effective ground path or a silent ground. All boxes and raceways shall be grounded by use of lugs and the raceway shall not be used as the equipment ground conductor. E.23 Motor Control Centers

E23.1 General Requirements: A. Standards

1. The Motor Control Center shall be manufactured and tested according to the latest applicable standards of the following agencies:

a. UL 845 – Motor Control Centers

b. NEMA ICS 18-2001 – Motor Control Centers

c. NEMA ICS 1-2001 – Industrial Control and Systems: General Requirements

d. NEMA ICS 2.3-2008 – Industrial Control and Systems: Instructions for the Handling, Installation, Operation, and Maintenance of Motor Control Centers

B. Quality Assurance

1. Manufacturer: For equipment required for the work of this section, provide products which are the responsibility of one manufacturer.


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2. Manufacturer shall have had produced similar electrical equipment for a minimum of 5 years.

3. Manufacturer shall be ISO 9001; 2008 certified

C. Manufacturers

1. The Motor Control Center shall be a TiaStar model by Siemens. No Exception.

D. Structures

1. The enclosure shall be NEMA Type 1A with gasketed doors. Vertical sections shall be constructed with steel divider sheet assemblies formed or otherwise fabricated to eliminate open framework between adjacent sections or full-length bolted-on side sheet assemblies at the ends of the MCC(s).

2. Vertical sections shall be 90” high excluding mounting sills, 20” wide and 20” deep for front mounting of units.

3. Each standard 20” and 24” wide structure shall be supplied with a vertical wire way

4. MCC’s shall be assembled in such a manner that it is not necessary to have rear accessibility to remove any internal devices or components.

5. All MCC structures shall be supplied with 1-1/8” high X 3” wide base channel sills that are continuous for the entire length of the shipping split. The base channel sills shall be fabricated of 7 gauge steel and shall be suitable for grouting the base channel sills in place, welding to leveling plates or securing to the floor with 1/2” anchor bolts. MCC structures shall be supplied with reversible bottom end cover plates to cover the bottom horizontal wireway and ends of the base channel sills. The bottom end cover plates shall be factory installed to cover the ends of the base channel sills to prevent entrance of dirt and rodents into the MCC when installed flush on the floor and shall be removable to expose the ends of the base channel sills if they are to be grouted into the floor.

6. A removable, full length lifting angle shall be provided for each shipping split of each MCC. The lifting angle shall be bolted to each side sheet or divider sheet of the shipping split to evenly distribute the weight of the MCC during lifting

7. Maximum shipping split is 40” wide.

E. Manufacturer Seismic Qualification:


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1. The low voltage motor control center(s) shall meet and be certified to seismic requirements specified in the IBC 2012 International Building Code.

2. The low voltage motor control center(s) shall be complaint with IBC 2012 parameters:

a. Building Occupancy Category (as defined in Table 1.1 from ASCE 2010): IV

b. Seismic Design Category: D

c. Site Class: C – Very dense soil and soft rock as defined in IBC 2006 Table 1613.5.2 Site Class Definitions

d. Ip – Importance Factor: 1.5 – Components must function after an earthquake for life safety purposes (Building Occupancy Code IV)

e. Ss: Mapped Spectral Accelerations for Short Periods at 0.2 seconds – 1.4g

f. Sds – 5% Damped Design Spectral Response Accelerations for Short Periods at 0.2 seconds – 0.93g

g. z/h – Height factor ratio: 0.083. Note: Ratio is a calculated value equal to the floor the gear is installed on divided by 12. A 6th floor installation is a 0.5 value. A basement or ground floor installation is a 0.0 value.

F. Bussing

1. The main horizontal bus shall be Tin plated copper rated at 600 amperes with a conductivity rating of 100% IACS. The horizontal bus bars shall be fully sized to carry 100% of the rated current the entire length of the MCC. It shall be isolated from the top horizontal wireway by a clear, flexible, polycarbonate, barrier.

2. The vertical bus shall be Tin plated copper rated at 300 amperes with a conductivity rating of 100% IACS. It shall be isolated from the unit mounting space by means of a full height steel barrier.

3. The horizontal ground bus shall be rated 300 amperes copper.

4. The neutral bus connection shall be rated 600 amperes copper

5. All power bus shall be braced to withstand a fault current of 42,000 RMS symmetrical amperes.

G. Units


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1. Plug-in units shall connect to the vertical bus by means of self-aligning, tin plated copper stab-on connectors.

2. All plug-in units will include a racking mechanism to assure full engagement with the stab-on connectors with the vertical bus

3. Plug-in units shall be provided with interference mechanism type draw-out to prevent complete removal of the plug-in unit from the structure in one motion. The interference mechanism shall also provide clear indication when the plug-in unit has been withdrawn to the “TEST” position.

4. A mechanical interlock shall be supplied on all plug-in units to prevent insertion or removal of a unit from the structure when the unit operator handle is in the ON position. This interlock may not be defeated.

5. Unit Disconnects shall be Thermal Magnetic type Circuit Breakers

6. All CPTs must be sized with an Extra 100VA

7. When pilot lights, push buttons or sector switches are specified. The devices shall be mounted in a formed metal device panel that is removable from the door, and capable of accepting four (4) such devices in any combination.

8. Pilot Devices shall be heavy duty, oil tight 30mm devices. All Pilot Lights shall use an LED Bulb and be Push-To-Test type.

9. Unit identification nameplate shall be provided for each unit, and mounted with screw connections. Nameplates shall be black with white lettering.

H. Wiring

1. The wiring shall be NEMA Class 1.

2. All internal wiring shall be labeled using heat shrink type material.

3. Control Wiring shall be 16AWG

4. Terminal Blocks shall be Pull-Apart type

I. Feeders

1. Feeder disconnects shall be Siemens thermal-magnetic circuit breaker.

E23.2 Motor Starters

Variable Frequency Drive (VFD) Motor Starters 1. Siemens model G120 without exception.


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2. Must communicate via PROFINET

3. Provide a Door Mounted Intelligent Operator Panel for each motor starter.

4. Use of passive harmonic filters, line reactors, or load reactors where shown on drawings

Full Voltage Non-Reversing (FVNR) Motor Starters 1. Combination Motor Starters shall be rated equal to or greater than the AIC rating

of the Motor Control Center.

2. The Overload protection shall be a SIMOCODE ProV solid state overload relay with Class 5-40 protection multifunctional, electronic full motor protection. It will monitor Current/Voltage. Detailed operating, service, and diagnostics will be transmitted to the PLC via PROFINET communication.

3. Each starter unit shall be provided with an encapsulated control power transformer (CPT) of sufficient size to accommodate the contactor coil burden plus all specified auxiliary devices. ALL CPTs must be size with an extra 100VA.

Reverse Voltage Solid State (RVSS) Motor Starters 1. Siemens model 3RW44 without exception. Must include PROFINET

communication module with each starter. Detailed operating, service, and diagnostics will be transmitted to the PLC via PROFINET communication.

E23.3 Network 1. The Motor Control Center shall be connected to the control system via the

PROFINET switch located in the PLC enclosure.

2. Motor Control Center shall be supplied with PROFINET. The network cabling shall be installed at the factory to provide code compliancy on the complete system.

E23.4 Programming 1. All Motor Starters shall be programmed by the Control System Integrator.

E23.5 Installation 1. The Motor Control Center shall not be placed in hazardous locations. The

location shall be well ventilated and free from humidity, dust, and dirt. The temperature shall be no less than 32°F and no greater than 104°F. Protection shall be provided to prevent moisture from entering the enclosure.

2. Installation shall be per the manufacturer’s recommendations, written instructions, final shop drawings, and contract documents. Installation shall be coordinated


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with adjacent work to ensure proper sequence of construction, clearances and support.

3. The System Integrator shall provide review and coordination of the MCC equipment with the PLC based control system.


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E.25 DISTRIBUTION E.25.1 Panel Boards and Load Centers Acceptable manufacturers are Siemens, General Electric and Square D. Panelboards inside a Motor Control Center (MCC) shall be of the same manufacturer as the MCC. 1.1 Circuit Breakers Circuit breakers shall be rated for the voltage and amperage with a minimum AIC of

10,000 Amps. Circuit breakers shall be bolt-to-buss type, Siemens BL/BLH, GE THQB or Square D QOB type for 240 volt or less application. Circuit breakers shall be manually operable with instantaneous and thermal magnetic tripping mechanisms. Breakers shall be trip-free in all positions. Each circuit breaker shall be distinctly numbered and identified on a directory card. Circuit numbers shall comply with drawings.

1.2 Bussbars Bussbars shall be of copper construction. Aluminum is specifically prohibited.


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Section 3

Standard Details

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