section 11175 trash rake - underground utility …dnhiggins.com/docs/606 division 11 -...

Spec. Standard: 03/08/12 11175-1 Revision: 10/31/13

SECTION 11175 TRASH RAKE

PART 1 - GENERAL

1.01 SCOPE:

A. The CONTRACTOR shall furnish all labor, equipment and materials necessary to provide and install a bar screen and debris removal system (“trash rake”) with all required appurtenances for cleaning vegetation and other debris from the canal located upstream of the pump station intake. This specification provides the design and performance requirements for a continuously operated, chain-driven, front-cleaning, front-return trash rake designed to eliminate the need for underwater drive components. The trash rake shall consist of a number of interchangeable units capable of operating independently of each other. Vegetation and debris collected by the trash rake shall be conveyed and discharged to a belt conveyor which shall convey the collected screenings to a trash collection area. The trash rake shall include all auxiliary equipment, accessories and structural modifications to existing facilities necessary for a complete and fully functional debris removal system.

B. The new trash rake shall be a drop-in replacement for an existing trash rake of similar design mounted directly on the trash rake bridge located about 115 feet upstream of the S-13 pump station intake. The existing trash rake consists of six (6) trash rake units. The new trash rake shall consist of eight (8) trash rake units. The submerged end of each existing trash rake unit is supported on a continuous sill plate located about 19 feet upstream of the bridge. The drive end of each existing trash rake unit is supported on a steel beam spanning the concrete pile caps of the bridge. The existing trash rake units are inclined about 46 degrees from the horizontal. The CONTRACTOR shall be responsible for the design, furnishing and installation of the structural steel framework necessary to support the new trash rake system, including the conveyor, on the existing bridge pile caps, without encroaching on the space inboard of the existing guardrail on the upstream (west) side of the bridge deck. The existing sill plate may be reused, at the CONTRACTOR’s discretion.

C. Related Work Specified Elsewhere: 1. SECTION 01300, Submittals 2. SECTION 01630, Product Options and Substitutions 3. SECTION 01665, Equipment Vibration Testing 4. SECTION 03600, Grout 5. SECTION 05100, Structural Steel 6. SECTION 16150, Motors 7. SECTION 16925, Pump Station Instrumentation and Control

1.02 REFERENCES: The edition of the publications of the organizations listed below in effect at the time of the advertisement for bids form a part of this specification to the extent referenced. See the various paragraphs for the specified standard. In the case of a conflict between the requirements of this SECTION and those of the listed document, the requirements of this SECTION shall prevail.

A. American Bearing Manufacturers Association (ABMA): 1. ANSI/ABMA 9, Load Ratings and Fatigue Life for Ball Bearings 2. ANSI/ABMA 7, Shaft and Housing Fits for Radial Ball and Roller Bearings 3. ANSI/ABMA 11, Load Rating and Fatigue Life for Roller Bearings 4. ANSI/AMBA 13, Rolling Bearing Vibration and Noise

B. American Institute of Steel Construction (AISC): 1. Code of Standard Practice for Steel Buildings and Bridges 2. Specification for the Design, Fabrication and Erection of Structural Steel for Buildings, with

Commentary


3. Manual of Steel Construction

C. American National Standards Institute (ANSI)

D. American Society for Testing and Materials (ASTM): 1. ASTM A36, Specifications for Structural Steel 2. ASTM A53, Specification for Pipe, Steel, Black and Hot-Dipped, Zinc Coated, Welded and

Seamless 3. ASTM A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products 4. ASTM A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware 5. ASTM A167, Standard Specification for Stainless and Heat-Resisting Chromium Steel Plate,

Sheet, and Strip 6. ASTM A276, Standard Specification for Stainless Steel Bars and Shapes 7. ASTM A500, Specification for Cold Formed Welded and Seamless Carbon Steel Structural

Tubing in Rounds and Shapes. 8. ASTM A501, Specification for Hot-Formed Welded and Seamless Carbon Steel Structural

Tubing 9. ASTM A572, Specification for High-Strength Low-Alloy Columbium-Vanadium Structural

Steel 10. ASTM A992, Specification for Structural Steel Shapes 11. ASTM F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs 12. ASTM F594, Standard Specification for Stainless Steel Nuts

E. American Welding Society (AWS): 1. AWS D1.1, Structural Welding Code – Steel 2. AWS D1.6, Structural Welding Code – Stainless Steel 3. ANSI/AWS D14.1, Specification for Welding of Industrial and Mill Cranes and Other Material

Handling Equipment

F. Florida Building Code (FBC)

G. National Electrical Manufacturers Association (NEMA): 1. NEMA MG-1, Motors and Generators 2. NEMA MG-2, Safety Standard and Guide for Selection, Installation and Use of Electric Motors

and Generators

H. Conveyor Equipment Manufacturers Association (CEMA)

I. National Fire Protection Association (NFPA)

1.03 SUBMITTALS: Submittal requirements are covered in SECTION 01300. Additional requirements are as follows:

A. MANUFACTURER’s Qualifications: The CONTRACTOR will be required to request and submit to the DISTRICT appropriate documentation certifying that the MANUFACTURER fully complies with the requirements of paragraph 1.04.

B. Technical Data: 1. Design calculations, as well as layout and shop drawings which are dimensioned and scaled,

with complete bill of material including part descriptions, part numbers, material specifications, electrical and control specifications, etc., shall be furnished for the following equipment: a. Bar screens b. Chain driven, front-cleaning, front-return type mechanical trash rake units


c. Belt conveyor unit d. Ancillary equipment and components

2. At a minimum the technical data shall include the following: a. Structural design calculations which clearly indicate the debris loading assumptions, rake

requirements, and hydraulic loading assumptions b. Rake performance data including debris loading assumptions, system capacity, operating

speeds, lift capacity, etc. c. Disposal facility requirements d. Electrical and control system data and schematics e. Structural design calculation and detailed drawings for any required additions and

modifications to the trash rake bridge 3. The shop drawings shall clearly indicate the size, type, material and tolerances for all

mechanical and structural components and members. The shop drawings shall also indicate where the design deviates from the component sizes, types, materials and dimensions shown on the project Drawings. Any proposed deviation from component sizes, types, materials and dimensions shown on the drawings shall be approved, in writing, by the DISTRICT. All shop drawings and design calculations shall be signed and sealed by a licensed Florida professional engineer.

C. The MANUFACTURER’s standard catalog data shall include a description and depiction of each component in sufficient detail to demonstrate full compliance with this specification. If standard catalog data does not contain sufficient detail to verify compliance, then the CONTRACTOR shall submit additional documentation as required. All data submitted shall be on the MANUFACTURER’s letterhead and signed by a company representative or official authorized to make technical representations of its company’s products.

D. Operation and Maintenance Manuals shall include, at a minimum, the following: 1. Installation instructions, including procedures for system startup and shutdown 2. Component catalog information 3. Service sheets for all system components 4. Spare parts list of each equipment component, with a description of each item, manufacturer,

catalog number, serial number and other information required to order an exact replacement 5. Replacement parts data, including serial numbers

E. Operational Field Test Report

F. Installation and Erection Manual

G. MANUFACTURER’s Certification of Compliance with Specifications in accordance with paragraph 1.06.

H. MANUFACTURER’s Certification of Equipment Installation, in accordance with paragraph 3.05

I. MANUFACTURER’s Warranty: The CONTRACTOR shall submit documentation from the trash rake system MANUFACTURER indicating that the equipment warranty fully complies with the requirements of paragraph 1.08.

1.04 MANUFACTURER’S QUALIFICATIONS: The MANUFACTURER of the trash rake system shall have the following minimum qualifications to be considered an acceptable manufacturer to provide, install, and service the equipment specified in this Contract:

A. Experience: The equipment MANUFACTURER supplying the design and fabrication services for the project shall have been in the business of designing and fabricating the specific type of trash rake system specified herein for a minimum of five (5) years from the date of the submittal. The MANUFACTURER shall have completed a minimum of ten (10) similar installations over that time


period all of which are currently in service as constructed. The MANUFACTURER shall provide a minimum of five (5) references of projects that the MANUFACTURER has provided trash rake systems of equal or larger size. These project references shall include the name and telephone number of the owner’s representative who has direct knowledge of the performance of the MANUFACTURER. The reference must indicate an acceptable performance by the MANUFACTURER to be considered by this Contract.

B. Technical Support: The MANUFACTURER shall have an engineering service department to support the project design, perform the required tests, and provide field supervision of the installation.

C. Service: The MANUFACTURER shall have a service department capable of providing immediate response (24 hour notice), to service calls. The MANUFACTURER’s service department shall include skilled technicians and mechanics that can diagnose and repair the equipment supplied by this Contract.

1.05 PRODUCT QUALIFICATION: The rakes and conveyance equipment supplied shall be from a product line that has been used in similar applications and is backed with after-sales service from factory-direct engineering representatives. Spare parts shall be readily available and be “off-the-shelf” from the manufacturer of the equipment. To facilitate this components for the equipment provided shall not be custom fabricated specifically for this project and shall be standard components used as part of the specific equipment product line.

1.06 MANUFACTURER’S CERTIFICATION: The CONTRACTOR shall submit a letter to the DISTRICT from the MANUFACTURER of the trash rake system, signed by an individual with authority to bind the company, and certifying that the MANUFACTURER has read and studied the Contract Documents and agrees to conform and comply with all of the requirements of this specification. All exceptions to the requirements of this specification, including those addressed by compliance submittals, shall be clearly stated in the certification letter.

1.07 INSTALLATION AND ERECTION MANUAL: The CONTRACTOR shall submit, no later than at the time of delivery, the Installation and Erection Manual describing the procedures to be followed in erecting, assembling, installing, and testing the rake and conveyance equipment. The manual shall include such things as alignment procedures, bolt torque values, permissible clearances, permissible shaft misalignment, bearing clearances, etc.

1.08 WARRANTY:

A. The MANUFACTURER shall warrant the EQUIPMENT, MATERIALS and PRODUCTS specified in this SECTION against defective materials and workmanship with the MANUFACTURER’s standard warranty, but for no less than five years from the date of Substantial Completion, and as described in Article 13 of SECTION 00700, General Terms and Conditions. If the MANUFACTURER’s standard warranty is less than the stipulated period, the MANUFACTURER shall provide a special MANUFACTURER’s extended warranty for the stipulated period.

B. The CONTRACTOR shall warranty the WORK against defects for one year from the date of Substantial Completion and as described in Article 13 of SECTION 00700, General Terms and Conditions.

PART 2 - PRODUCTS

2.01 ACCEPTABLE MANUFACTURERS:

A. D&J Machinery

B. Duperon Corporation

C. DISTRICT approved equal


2.02 GENERAL: Design, furnish and install an engineered trash rake system complete with all mechanical, structural, electrical, and monitoring and control components. The trash rake equipment shall remove debris accumulated on the trash rack and convey it to the disposal area as shown on the Contract Drawings. The trash rake system shall be suitable for outdoor service.

A. Single Manufacturer: All rake and conveyance system components shall be furnished by a single MANUFACTURER that meets the requirements of paragraph 1.04. Any other manufacturer proposed by the CONTRACTOR other than those specifically named herein shall demonstrate, to the satisfaction of the DISTRICT, that the quality of its equipment is at least equal to the equipment fabricated by those manufacturers specifically named herein and fully complies with the requirements of this specification.

B. Product Substitutions: The CONTRACTOR is specifically advised that all products provided shall be in strict conformance with this specification and that no exceptions to any of the stated requirements will be permitted. In general, no product substitutions will be approved unless the CONTRACTOR can substantiate complete conformance of the proposed product substitution with all requirements of this specification. All product substitution requests shall be completed in accordance with SECTION 01630.

C. Intake Design: The trash rake system equipment and support structures shall be mounted and secured to the existing trash rake bridge. The equipment shall be positioned on the upstream side of the bridge and shall be limited to the area shown on the Contract Drawings. The minimum clear bridge width between the debris conveyance equipment and other obstructions shall be maintained.

D. Member Sizing: The CONTRACTOR is specifically advised that where structural member sizes have been indicated, the member sizes shall be considered to be the minimum acceptable. The CONTRACTOR shall be solely responsible for ensuring that all members are properly sized for the intended application.

E. Safety: All trash rake system equipment shall comply with the applicable provisions of the Federal Occupational Safety and Health Administration (OSHA) standards. The equipment shall be provided with safety devices such as coupling guards, zero speed switches, emergency shutdown pull string and mushroom push-buttons.

F. Load Limiting Device: The trash rake units shall be supplied with load limiting devices that shut down the rake and signal an alarm condition back to the control panel when the pull force on the rake units exceeds the setting of the load limiting device.

G. Removal and Reinstallation: The trash rake system shall be capable of being removed from service to allow access to the bar screen. The trash rake equipment shall require minimal dismantling to facilitate this maintenance requirement and shall be designed for easy reinstallation. No cutting or welding shall be required to remove and/or reinstall the rake system.

H. Service Life: The trash rake system shall be designed to provide a minimum twenty five (25) years of reliable service under the loading conditions and operation described herein.

2.03 PERFORMANCE: The trash rake shall satisfy the following performance requirements:

A. Head Loss: The trash rake shall prevent a build-up of debris on the rack that will cause a head loss in excess of one (1) foot across the bar screen at the pump station design capacity, for an assumed extreme loading event.

B. Debris Loading: Under normal operation the debris will consist of floating and submerged aquatic and wetland vegetation. This vegetation may vary from tall grasses, reeds and other aquatic plants such as hydrilla, to floating leafy plants such as water hyacinth. The rate of loading will vary seasonally as well as with discharge conditions. During a flood event there is the possibility of larger objects and materials included with the debris load. This debris could be upland vegetation, including small trees and brush, as well as man-made items such as lumber, tires, containers, etc. It is recommended that representatives from the MANUFACTURER visit the project site to evaluate the service condition requirements and determine the adequacy of the proposed debris rake and conveyance equipment.


C. Handling Capacity: The rake and its conveyance equipment shall be capable of collecting and conveying the debris described above in a cycle time that will result in a head loss across the bar screen that does not exceed the maximum allowed. Because of debris loading rate variability, the cycle time shall be capable of adjustment to optimize the rake’s performance. The maximum debris volume (loose) shall be assumed to be 0.1% of the pump station design capacity. The density of the collected debris screenings shall be assumed to be 35 pounds per cubic foot (pcf) dry and 65 pcf wet.

D. Lift Capacity: Each trash rake unit shall be designed for a minimum continuous lift capacity of 6,000 pounds of debris on the bar screen.

E. Wind Loading: Wind loads on the trash rake system equipment and support structures shall be determined in accordance with the 2010 Florida Building Code for Buildings, including Section 1620, using ASCE 7-10, Minimum Design Loads for Buildings and Other Structures, except as noted herein. The velocity pressure (qz or qh) shall be calculated using ASCE 7-10 and modified as noted below for critical facilities. 1. The ultimate design wind speed shall be obtained from Figure 26.5-1B, Basic Wind Speeds for

Risk Category III and IV Buildings and Other Structures (ASCE 7-10). The calculated velocity pressure (qz or qh) shall be multiplied by 1.13 to increase the nominal mean recurrence interval (MRI) to 200 years.

2. The design for wind loading shall be based on Exposure Category C. 3. The debris rake and conveyance equipment shall also be designed to operate without loss of

effectiveness during periods with sustained winds of up to 70 mph. 4. The MANUFACTURER shall provide a written certification from a Florida licensed

Professional Engineer that the system proposed for use is capable of satisfying the wind load requirements specified herein.

5. Design wind pressures (psf) for components and cladding shall be shown on the contract documents for both ultimate design wind speed (Vult) and nominal design wind speed (Vasd).

2.04 BAR SCREENS:

A. General: Design, furnish and install custom-engineered bar screens complete with all structural support and anchorage. The bar screens shall be supplied by the MANUFACTURER of the trash rake system to ensure complete compatibility.

B. Bar Spacing: The clear spacing of the bars shall not be less than two (2) inches and not more than four (4) inches. The maximum flow velocity through the bar screens shall be two (2) feet per second when calculated at the design flow of the pump station.

C. Head Loss: The design head loss through a clean bar screen shall not exceed two (2) inches at the pump station’s rated capacity. In addition, the hydraulic design of the trash rake system shall assume a 50% blocked screen with a maximum of eight (8) inches head loss across the trash rack at the pump station’s rated capacity.

D. Inclination: The bar screens shall be inclined 46 to 60 degrees from the horizontal plane.

E. Elevations and Dimensions: 1. The nominal width of each bar screen shall be ten (10) feet. The screens shall be identical and

interchangeable. 2. The bar screens shall span the entire width of the trash rake bridge and the full height from the

existing sill plate to the bridge anchorage points. The top of the existing sill plate is at elevation -9.6 ft. Trash rake bridge elevations on the east side are as follows:

Bridge End Top of Pile Cap Bridge Deck

North 5.97 ft 7.23 ft

South 5.88 ft 7.09 ft


a. All elevations are referenced to NAVD 88. b. The CONTRACTOR shall field verify all elevations and dimensions.

F. Removal and Reinstallation: Each bar screen shall be capable of being removed to allow for maintenance, refurbishment or replacement. Anchorage of the screen shall be at the service bridge, with the toe of the screen resting on the sill plate as indicated on the Contract Drawings. Each bar screen shall be designed for two lift points. The screen anchorage shall be readily accessible with adequate tolerance to facilitate easy reinstallation. All fasteners shall be equipped with a locking device such as a lock nut and locking washer.

G. Fabrication: Each bar screen shall be a rigid frame of all-welded construction, consisting of vertical parallel flat bars with regularly spaced horizontal cross braces for stability. The toe of the rack shall have a flat plate for added stiffness. The nose of the vertical bars shall be rounded. All welding shall be in accordance with ANSI/AWS D1.6 and AWS D14.1.

H. Structural Design: The structural design of all components shall be in accordance with the AISC Manual of Steel Construction and AWS 14.1. 1. Design Loads: The design shall address all live and dead loads with a minimum 25% increase

in live loads to address impact loads caused by the operation of the trash rake system. The bar screen shall be designed for a minimum hydrostatic loading corresponding to a five (5) foot differential head across the screen where the low water elevation is equal to the pump’s low water shut off elevation (-1.1). The force due to this head differential shall be applied across the full width of the screen. Each lifting lug shall be designed to withstand a load of no less than three (3) times the dead weight of the bar screen.

2. Bar Screen Deflection: The maximum allowable deflection of the screen shall be L/360. 3. Intermediate Support: No intermediate supports may be used. 4. Minimum Bar and Component Size: All structural members shall have a minimum thickness of

0.375 inches. The vertical collection bars shall have a minimum depth of four (4) inches. 5. Allowable Stresses: Allowable stress for the bar screen’s structural elements shall not exceed

those stated in AISC Manual of Steel Construction and shall also not be higher than the following percentages of the minimum yield strength of the materials used: a. Tension (on net section at holes): 40% b. Bending (tension and compression on extreme fibers of members): 55% c. Shear (on gross section of member) : 35% d. Bearing on contact area of machine surfaces: 70% e. Stress concentration factors shall be used where applicable.

I. Flow Induced Vibration: The bar screen shall be designed to prevent resonant vibrations induced by flow through the screen. The laterally unsupported lengths of the vertical bars and other members shall limit the natural frequency of the screen when submerged and subject to flow to not less than 2.5 times the vortex shedding frequency. Fixed supports shall be assumed for the calculation of the natural frequency of the screen. The average net flow velocity through the screen shall be increased 50% to account for flow concentration. The Strouhal number shall be NS = 0.14 + 0.01(d/t), where d = bar depth and t = bar thickness.

2.05 TRASH RAKES:

A. The trash rake system shall be capable of cleaning vegetation and other debris across the entire width of the canal. Each rake unit shall be designed to deposit collected screenings onto a common horizontal belt conveyor located on the service bridge. The trash rake system shall be designed to clean continuously from bottom to top for the entire width of trash rack.

B. The rake units shall be shall be inclined 46 to 60 degrees from the horizontal plane to match the proposed inclination angle of the bar screens. The nominal width of each mechanical rake unit shall be ten (10) feet.


C. All parts of the mechanism shall be amply proportioned for all stresses that may occur during erection, fabrication, and intermittent or continuous operation.

D. The mechanical rake assembly shall be a chain and drag mechanism utilizing slats mounted at a predetermined spacing on the drive chains. The slats shall be 3/4-inch thick UHMW polypropylene strips with a machined profile matching the bar screen spacing. The slats shall be backed with stainless steel channels or other stainless steel sections for additional strength. Each slat shall be designed to accommodate a uniform debris load equivalent to 1200 pounds while limiting deflection to no more than L/360. The distance between slats shall be as recommended by the MANUFACTURER to ensure adequate screenings removal.

E. The mounting system of the slats shall allow for the slats to be removed and reseated, and shall allow for additional slats to be inserted to change the slat spacing.

F. The rake shall have head sprockets only, with no sprockets, bearings, or similar drive components permanently installed underwater. The head sprockets shall positively engage the chains.

G. The chain linkage for the drive shall be such that it bends in one direction only, which allows it to become its own lower sprocket and frame. The chain shall also have the ability to deflect around large objects such as tires, logs, etc. to avoid shutting down the unit.

H. The driveshaft shall be mounted in adjustable plates or on blocks that can be adjusted with jack bolts to align the chains.

I. A stripper or cutter assembly shall be installed on the raking device, as recommended by the MANUFACTURER, to assist in removing debris from the scrapers.

J. Each rake unit shall be equipped with a speed reducer to provide the required output speed.

K. Bearings shall be anti-friction-type, self-aligning and manually lubricated, with a radial load rating as required for the intended service. Underwater bearings of any kind are not acceptable. The layout of the mechanical rake equipment shall allow for easy access to all the major operating parts of the mechanism for maintenance, cleaning and repair. All lubrication fittings that are not easily accessible shall be modified and equipped with tubing to extend the grease fittings to the nearest accessible location for ease of maintenance. All stainless steel tubing and grease fitting shall be rigidly secured with fasteners and clips as required.

L. All bolted connections in the mounting and support frame for the mechanical rake drive assembly shall be made with a minimum of two bolts.

M. Each rake unit shall operate independently with its own drive unit and controls.

N. Each rake shall be driven with an electrically operated gear motor sized for the intended loads. The electric gear motor shall be 1/8 to 1/2 hp, three-phase, 60 cycle, 120 VAC, Sumitomo integral gear motor (or approved equal) capable of operating the scrapers and chain at approximately 28+/- inches per minute. All electric motors shall be totally enclosed, fan cooled, type, suitable for outdoor service and shall be driven by variable frequency drives. All gearboxes shall have a service factor of 2.0.

O. A reversing starter that is properly sized for the required loading shall be provided for each drive motor. The starter shall be mounted within the trash rake main control panel. Sufficient starter contacts shall be provided to open all motor leads when the motor is de-energized. The starter shall be interlocked electrically and mechanically to prevent energizing forward and reverse contactors simultaneously.

P. Each rake in the system shall be controlled from a single central main control panel, either manually or automatically, located inside the trash rake control building, and from local push button stations located at the rake structure. Local push-button stations for controlling rake mechanism shall be mounted in a NEMA 4X enclosures. The main control panel enclosure shall be rated NEMA 12 for indoor use.


2.06 BELT CONVEYOR:

A. General: The belt conveyor shall transport the debris from the trash rake units to the disposal area shown on the Contract Drawings. The conveyor model shall be fully compatible with the trash rake, shall work together with the trash rake as a unit and shall have similar safety and shutdown safeguards with all controls interlocked with the trash rake. The conveyor design shall be the responsibility of the trash rake MANUFACTURER to ensure complete compatibility with the trash rake units. The belt conveyor shall be capable of operating automatically or manually. All safety features shall be enabled when operating in the manual mode.

B. Conveyor Bed: The conveyor shall be a flat roller bed belt conveyor with integrated side walls designed to handle wet loose material that can be expected from the debris collection operation at the intake side of the pump station. The rake and conveyor shall be designed to withstand, without any damage, the free fall of a 1,000-pound object from a free fall discharge height of five (5) feet. Side rails or guides shall be provided to ensure the debris is contained in the conveyor until discharged at the end. The side rails and guides (side panels) shall be a minimum of 24 inches high and shall be pitched as required to receive collected screenings from the rake units. The rails and guides shall be designed and fabricated to prevent screening material from becoming jammed, wedged or bound between the conveyor belt and the frame and/or idlers and pulleys. Conveyor designs that fail to include provisions to account for these potential issues are not acceptable.

C. Conveyor Belt: The conveyor belt shall be minimum of 30 inches wide (maximum 36 inches wide) and be constructed of uniform ply and covering. The conveyor belt shall have an adequate number of plies (minimum two) and be of sufficient weight so that the maximum belt tension does not exceed 75% of the belt manufacturer’s allowable tension recommendation. Belt shall be designed to withstand maximum operating and starting tensions when fully loaded and to bend properly over the idlers and drive pulleys without overstressing the belt covering, carcass or splice. Covers shall be oil resistant, with minimum 1/4-inch cover on the carrying side and minimum 1/8-inch cover on the bottom side. The conveyor belt profile on the carrying side shall be provided with either cleats or a chevron patterned cover. The layout and size of the cleats or pattern shall be determined by the MANUFACTURER and shall be as required to prevent material roll back when traversing the incline section of the unit. Conveyor belt ends shall be spliced using a stainless steel mechanical splice. The splice shall have a minimum efficiency of 100% of the belt manufacturer’s allowable tension recommendations. The belt shall be as manufactured by Goodyear, Georgia Duck, or approved equal.

D. Idlers: Idlers shall be CEMA Class C, non-metallic rollers. Idler bearings shall be tapered roller type with a minimum B-10 life of 60,000 hours. Each bearing shall be sealed using double seals using a contact seal to exclude dirt and triple-labyrinth seal to retain lubricant. The idlers shall be self-lubricating and require no grease fittings. Idlers shall be of rigid shaft, single-roller type. Idler rollers shall be provided with a minimum 1/8-inch thick urethane covers. Carrying idlers shall be spaced by the MANUFACTURER as required to convey the screenings material but shall not exceed two (2) feet at belt loading locations and no more than three (3) feet at all other locations. Return idler spacing shall be spaced by the MANUFACTURER but shall not exceed five (5) feet. Idlers shall also be provided as required at the point where the belt conveyor transitions from a horizontal profile to an incline profile as required to minimize belt stress. The calculated belt sag across all idlers shall not exceed 2% of the idler spacing under fully loaded conditions.

E. Pulleys: Pulleys shall be of the welded-steel-drum-type with grooved lagging. The lagging shall be minimum 1/2-inch thick, with 1/4-inch deep herringbone grooves, and shall be a minimum 60 durometer hardness, vulcanized rubber. Pulley shafts shall be ANSI C1045 steel. Pulleys shall be keyed to the shafts. Pulley shafts shall be supported by roller-bearing pillow blocks which are in turn secured to the belt conveyor structural frame. Bearings shall be self-aligning rollers with a minimum B-10 life of 60,000 hours. Bearing adjustment screws shall be provided on each end of the bearing base to aid in alignment. Pulley shaft bearings shall be lubricated from a single grease fitting located on the access bridge side of the pulley. All grease fittings shall be zerk type. The tail pulley shall be equipped with a take-up assembly with a minimum adjustment of 18 inches. The take-up assembly shall be a screw-type which is capable of tensioning and loosening the belt through the turning of


capture nuts located on either side of the supporting frame. The take up assembly shall be capable of being adjusted while the conveyor belt is fully loaded.

F. Conveyor Frame and Floor Supports: The conveyor bed shall be supported on a stainless steel frame. All structural members shall be at least 5/16-inch thick. Side closeouts shall be minimum 1/8-inch thick. The framing shall include adequate support for head and tail section machinery as well as all supports required for the idlers. The frame shall be provided with frame support legs spaced at an interval to be determined by the MANUFACTURER. The support legs shall be equipped with base plates to facilitate anchoring the conveyor to the steel beams or other structural framing spanning the trash rake concrete piles. Each base plate shall be anchored using stainless steel bolts. All bolted connections shall be made with a minimum of two bolts.

G. The belt conveyor shall be driven with an electrically operated gear motor sized for the intended loads. The electric gear motor shall be 3 hp, three-phase, 60 cycle, 120 VAC, Sumitomo integral gear motor (or approved equal) capable of operating the conveyor at a minimum speed of 60 feet per minute and/or a maximum speed of 90 feet per minute. The electric motor shall be totally enclosed, fan cooled, type, suitable for outdoor service and shall be driven by a constant speed drive.

H. Safety Guards: Safety guards shall be provided for all exposed gears, chains, sprockets and flexible couplings. Guards shall be painted safety orange. Guards shall be rigidly supported and shall be properly secured using stainless steel hardware. Guards shall be removable to facilitate any required maintenance. The conveyor equipment shall comply with the applicable provisions of the Federal OSHA standards.

I. Safety Devices: The conveyor shall be equipped with the following safety devices: 1. Emergency trip cord running on the side of the conveyor which is accessible from the trash rake

bridge. Trip cabling shall be minimum 3/16-inch, stainless steel cable with orange color nylon sheathing. Cabling shall be supported by stainless steel eyebolts spaced every ten (10) feet maximum. Wired clamps shall be stainless steel.

2. Two (2) safety stop switches that meet the applicable OSHA standards. The safety stop switches shall be located at each end of the conveyor. The safety switches shall be housed in a 316 stainless steel NEMA 4X enclosure mounted directly to the conveyor frame.

3. A zero speed switch shall be directly connected to the tail pulley. The switch shall be housed in a 316 stainless steel NEMA 4X enclosure mounted directly to the conveyor frame.

2.07 TRASH RAKE SUPPORT FRAMING:

A. General: The CONTRACTOR shall be responsible for designing, furnishing, fabricating and installing new structural steel framing on the existing trash rake bridge for the support of the bar screens, trash rakes and that portion of the belt conveyor that runs along the bridge. The framework shall consist of beams and/or trusses spanning the existing trash rake bridge pile caps outboard of the guardrail on the upstream (west) side of the bridge deck. Structural steel framing shall be designed and fabricated in accordance with SECTION 05100.

B. Materials and Galvanizing: Structural steel framing shall be fabricated of carbon steel plate and structural shapes. The main structural frame shall be fabricated from structural grade channel or wide flange sections. All steel shall be hot-dipped galvanized following fabrication. All holes required for assembly and/or connection of the conveyor components shall be pre-drilled or punched prior to the galvanizing process. Field drilling and/or punching of any galvanized steel component will not be permitted.

C. Base Plates and Anchors: The structural steel framing shall be equipped with base plates to facilitate anchoring to the bridge pile caps. Each base plate shall be anchored to the bridge using stainless steel adhesive anchor bolts. The number of anchor bolts, size, orientation and embedment depth shall be determined by the CONTRACTOR to meet the requirements of the Florida Building Code. All bolted connections shall be made with a minimum of two bolts.


2.08 MATERIALS OF CONSTRUCTION: The trash rake, auxiliary equipment and all accessories shall be of all-stainless-steel construction except where otherwise specified below. All materials shall conform to the latest ASTM specification or other listed commercial specifications covering the class or kind of material to be used.

Component Material

Bar screen 316L stainless steel, ASTM A167 or A276

Trash rake mounting and support frame 316L stainless steel, ASTM A167

Trash rake slats Ultra-high molecular weight (UHMW) polypropylene

Trash rake slat reinforcing members 316 stainless steel, ASTM A167

Chain links 316 stainless steel, ASTM A276

Chain pins 303 stainless steel, ASTM A276

Chain guides UHMW polypropylene

Drive shaft 416 stainless steel, ASTM A276

Sprockets and sprocket pins 316 stainless steel, ASTM A276

Bolts, anchors, fasteners 316 stainless steel, ASTM F593

Nuts 316 stainless steel, ASTM F594

Gear reduction unit housing Cast iron

Bearing housings Stainless steel

Conveyor bed, rollers, idlers, side rails and guides, safety guards

316 stainless steel, ASTM A276

Conveyor drive components, pulley take-up assembly

316 stainless steel, ASTM A276

Conveyor frame and floor supports 316 stainless steel, ASTM A276

Conveyor belt Nitrile impregnated belt

Tubing, clips, fasteners 316 stainless steel

Structural steel framing for support of bar screens, trash rakes and conveyor

Carbon steel, hot-dip galvanized, as specified in SECTION 05100

2.09 DEBRIS REMOVAL SYSTEM CONTROLS:

A. Operational Control: The operation of the rake and conveyance equipment shall be determined by the position of an “Auto-Off-Manual” selector switch located on the Control Panel. “Auto” mode shall interlock the rake and conveyance equipment with the operation of the pump station pumps and require no operator interface for proper operation of the system. “Manual” mode shall allow operation of the system, or any of the system components, by an operator while maintaining all safety features and interlocks.


B. Electrical Controls: The electrical control panel for the rake/conveyance equipment shall be mounted on the inside of the trash rake control building, as indicated on the Contract Drawings, with local controls, disconnects, etc. as required located adjacent to rake equipment on the trash rake bridge. The control panel enclosure shall be rated NEMA type 12. Local disconnects, enclosures for local controls, etc. shall be rated NEMA type 4X. All components of the control system, control schematics and other electrical components shall be submitted to the DISTRICT for approval in accordance with paragraph 1.03. The controls for the trash rake system shall be integrated into a single control panel. All equipment shall be interlocked as required to sequence the operation of the individual components and to ensure that the system safety features are continuously enabled. Refer to the Contract Drawings and SECTION 16925.

2.10 SPARE PARTS: All spare parts shall be duplicates of the original parts furnished and shall be interchangeable. Spare parts shall be packed in crates. The CONTRACTOR shall furnish one set of replacement parts for all of the wear components of the rake and conveyance equipment. Wear components are defined as those structural, mechanical and electrical components that are subject to replacement due to wear for a cycle time less than the twenty five year service life of the debris removal system, excluding motors, drive units and/or consumables.

2.11 SPECIAL TOOLS: The CONTRACTOR shall furnish one set of “special tools” required for complete assembly, disassembly, or maintenance of the rake and conveyance equipment. Special tools are defined as oversized or specially dimensioned tools, special attachments or fixtures, or any similar items.

2.12 SUMMARY: A summary of the pump station design information is provided below:

*CONTRACTOR to verify

PART 3 - EXECUTION

3.01 FACTORY TESTS: The equipment MANUFACTURER shall conduct all necessary factory performance tests to insure that the mechanical and electrical operation of the equipment to be supplied is in accordance with the specifications and free of defects prior to shipment. The factory test shall include testing of all functional and control interlocks as well as all safety interlocks. All such tests shall be documented by the MANUFACTURER and supplied to the DISTRICT upon request.

3.02 FACTORY INSPECTIONS: The DISTRICT may make periodic visits to the MANUFACTURER’s plant to inspect the fabrication and assembly of the equipment. The MANUFACTURER shall have detailed fabrication and assembly drawings available for review upon request. Drawing details shall include all dimensions, tolerances, shaft clearances and bearings. The MANUFACTURER shall also have available at the time of the inspections purchase orders, mill orders or shop orders including certified material test reports

Overall trash rake width, ft* 84

Number of trash rake units 8

Rated capacity of pump station/gated spillway, cubic feet per second (cfs)

540

Minimum continuous lift capacity (each trash rake unit), lbs 6000

Maximum bar screen clear spacing, inches 4

Maximum water surface elevation, upstream, ft 0.9

Minimum water surface elevation, upstream, ft -0.6

Maximum differential head across bar screen at rated pump station capacity, 50% blocked, inches

8


that indicate components and/or materials to be used in the equipment’s manufacture. The DISTRICT will review these records, drawing details and the unit for compliance with the specifications as well as standard industry practice. The DISTRICT will provide a written report to the CONTRACTOR of the inspection that will include those items observed to be in non-compliance with the specifications. It shall be the CONTRACTOR’S responsibility to ensure that all items are corrected by the MANUFACTURER. Re-inspection of the items in non-compliance may be requested by the DISTRICT.

3.03 FACTORY ASSEMBLY: All equipment shall be completely shop-assembled and aligned prior to shipping. Tolerances shall not exceed those specified or shown in the MANUFACTURER’s drawings. Rotating elements shall be checked for binding. The DISTRICT will witness the shop assembly unless otherwise stated. After completion of the specified factory tests, equipment shall be prepared for shipment with the minimum amount of disassembly. Any components removed for shipping shall be match-marked prior to removal and shipment.

3.04 STORAGE: All equipment placed in storage shall be stored indoors, protected from the weather, humidity and temperature variations, dirt, dust and other contaminants. The CONTRACTOR shall locate and procure all off-site storage that may be required throughout the life of the Contract. All on-site and off-site storage provisions are subject to approval by the DISTRICT.

3.05 INSTALLATION: Installation, start-up and testing of all equipment and associated construction shall conform to the MANUFACTURER's recommendations, and the installation and erection manual. The MANUFACTURER's field representative shall meet with CONTRACTOR to provide all necessary guidelines and specifications for installation and testing of equipment supplied. The MANUFACTURER’s field representative shall also inspect all equipment after installation and prior to start-up. Upon completion of the installation the equipment MANUFACTURER shall certify in writing to the DISTRICT that the equipment has been installed in accordance with the MANUFACTURER’s installation and erection manual.

A. Equipment Leveling: The rake/conveyance equipment shall be installed and leveled by millwrights experienced in setting and leveling heavy equipment. The CONTRACTOR shall level the base plates against the anchor bolt nuts using steel leveling blocks and shims at every bolt location to a maximum tolerance of 0.005 in/ft unless otherwise recommended by the MANUFACTURER. Leveling equipment shall be precision surveying equipment. The void space below equipment base plates shall be filled with non-shrink grout conforming to the requirements of specification SECTION 03600. The grout shall be placed in one continuous operation and in a manner to avoid air entrapment. After the grout has attained the required compressive strength, remove the leveling blocks and shims and torque the anchor bolts to the clamping force required by the equipment MANUFACTURER. Torque bolts in increments of not more than 25 percent of the final value in an alternating pattern to avoid stress concentration on the grout surface. Void spaces created by the removal of the leveling blocks and shims shall be filled with grout after the anchor bolts have been tightened to their final value.

B. Equipment Alignment: All equipment shall be aligned in accordance with the MANUFACTURER’s installation and erection manual.

3.06 FIELD OPERATING TEST:

A. General: All field operating and equipment tests shall be performed by the CONTRACTOR and in the presence of the DISTRICT. The MANUFACTURER's field representative shall be present during all operating tests. The CONTRACTOR’S instrumentation and controls subcontractor and/or electrical subcontractor shall also be present during all operating tests. The CONTRACTOR shall be responsible for the coordination of the various trades and responsible parties for the successful performance of all field tests. Should the tests reveal a design deficiency or a manufacturing error, the problem shall be promptly corrected by, and at the expense of, the CONTRACTOR.

B. Operating Tests: Conduct operational tests as necessary to determine that the performance of equipment and controls is as specified. Tests shall consist of placing all equipment in operation and performing functional tests and check-out of all system components.

C. Make all necessary equipment adjustments and corrective work indicated by tests.


D. Submit a written test report of all tests performed and their results to the DISTRICT.

3.07 POST CONSTRUCTION INSPECTIONS:

A. Sixty (60) Day Check: Recheck equipment for alignment in accordance with specification SECTION 01670, after the equipment has been placed in operation for approximately 60 days. All alignment checks shall be performed by an independent qualified testing consultant with all costs borne by the DISTRICT. If the alignment variation exceeds the allowable limits as indicated in the referenced SECTION, the CONTRACTOR shall investigate the cause of the problem and, if it is determined to be a defect with the equipment or its installation, the CONTRACTOR shall take all necessary action to correct the problem.

END OF SECTION


SECTION 11210 RIGHT-ANGLE GEAR SPEED REDUCERS

PART 1 - GENERAL

1.01 SCOPE:

A. Summary of Work: This specification SECTION is for the furnishing and installation, including all labor, equipment and materials, of right-angle gear speed reducers to transmit power from diesel engines to vertical axial flow pumps as shown in the Contract Drawings. The gear reducer shall be furnished complete with couplings, shafts, bearings, seals, lubrication system, cooling system, housing, anchor bolts, a complete set of special tools and all other parts and accessories indicated, specified, or required for proper installation, operation and maintenance.

B. System Description: 1. EXISTING SYSTEM: The station has three (3) engine-driven main pumping units, each with a

design capacity of 180 cubic feet per second at 4.0 ft static head. Each Fairbanks Morse 60-in vertical axial flow pump is driven by a Detroit Diesel V-71 diesel engine connected to the pump through a Brad Foote Model 2RV1200 right-angle gear speed reducer rated for 225 horsepower (hp) at 1800 rpm input speed, with 1.5 service factor, and 191 rpm output speed (9.42 to 1 ratio). The engine driveshaft is coupled to the gear reducer input shaft with a Spicer SL 1710 flexible driveshaft. Each gear reducer is water-cooled using the engine jacket water keel cooling system, which supplies 6 gallons per minute of 90⁰F water.

2. PROPOSED SYSTEM: Each existing pump shall be driven by a new Caterpillar C9.3 diesel engine through a new, drop-in replacement, spiral-bevel gear speed reducer rated for 225 hp at 1800 rpm input speed, with a minimum 1.8 service factor, and 191 rpm output speed (9.42 to 1 ratio). The new gear reducer shall be water cooled via the new engine’s aftercooler keel cooling water circuit, supplying 6 gallons per minute of 90⁰F water. a. The new gear reducer shall be mounted on the existing pedestal welded to the top of the

vertical axial pump base plate. b. The lubrication system shall be upgraded to include an electric-motor-driven prelube

pump and oil filter/water separator. c. The new gear reducer shall be fully instrumented to allow automatic as well as manual

operation. The instrumentation and electrical conduit and wiring, as necessary, shall be wired to a new, dedicated junction box mounted near the gear reducer.

C. Alternative Work Scope: Refurbish and upgrade the existing gear reducer to achieve the performance and design characteristics referenced under PROPOSED SYSTEM and detailed in this SECTION. The reworked gear reducer shall be subject to all the same technical requirements and quality provisions, including warranty, as the drop-in replacement unit that is the basis for this SECTION. The work scope shall include, as a minimum, the following items: 1. Manufacture new, upgraded components:

a. Low speed pinion and gear b. High speed bevel gear set c. All shafts except output shaft (to be reused) d. Backstop e. Bearings, seals, shims and gaskets f. Shaft driven lube pump

2. Rework reusable components: a. Gear housing – inspect, clean, sandblast and paint b. Inspect and rework output (pump) shaft and coupling

3. Upgrade the gear lubrication system: a. Add electric motor driven pre-lube pump


b. New oil cooler c. New oil filter/water separator d. New oil piping and supports

4. Replace and upgrade instrumentation: a. Low and low-low pressure switches b. High and high-high temperature switches c. Differential pressure indicator/switch (oil filter/separator) d. Level indicator/switch e. Vibration switch f. Speed switch on input shaft g. Pressure gauge h. Thermometer

5. Wire all instrumentation and electrical wiring to a dedicated junction box.

D. Related Work Specified Elsewhere: 1. SECTION 01300, Submittals 2. SECTION 01665, Equipment Vibration Testing 3. SECTION 01670, Equipment Alignment 4. SECTION 09900, Protective Coatings 5. SECTION 11211, Diesel Engines and Auxiliaries 6. SECTION 16925, Pump Station Instrumentation and Control

1.02 APPLICABLE PUBLICATIONS:

A. Standards or Codes: The edition of the publications of the organizations listed below in effect at the time of the advertisement for bids form a part of this specification to the extent referenced. See the various paragraphs for the specified standard. In the case of a conflict between the requirements of this SECTION and those of the listed document, the requirements of this SECTION shall prevail. 1. American Bearing Manufacturers Association (ABMA):

a. ANSI/ABMA 9, Load Ratings and Fatigue Life for Ball Bearings b. ANSI/ABMA 7, Shaft and Housing Fits for Radial Ball and Roller Bearings c. ANSI/ABMA 11, Load Rating and Fatigue Life for Roller Bearings d. ANSI/AMBA 13, Rolling Bearing Vibration and Noise

2. American Gear Manufacturers Association (AGMA): a. ANSI/AGMA 1012-F90, Gear Nomenclature, Definitions of Terms with Symbols b. ANSI/AGMA 2009-B01, Bevel Gear Classification Tolerances and Measuring Methods c. ANSI/AGMA 2005-C96, Design Manual for Bevel Gears d. ANSI/AGMA 6010-F97, Standard for Spur, Helical, Herringbone, and Bevel Enclosed

Drives e. ANSI/AGMA 6025-D98, Sound for Enclosed Helical, Herringbone and Spiral Bevel

Gear Drives f. ANSI/AGMA 6000-B66, Measurement of Linear Vibration of Gear Limits

3. American National Standards Institute (ANSI) 4. American Society of Mechanical Engineers (ASME):

a. ASME B31.1, Power Piping 5. Hydraulic Institute (HI):

a. ANSI/HI 9.6.4, Centrifugal and Vertical Pumps for Vibration Measurement and Allowable Values


6. International Organization for Standardization (ISO): a. ISO 9001, Quality Systems – Model for Quality Assurance in Design, Development,

Production, Installation, and Servicing b. ISO 286-1, ISO System of Limits and Fits c. ISO 281 (1990), Rolling Bearings Dynamic Load Ratings and Rating Life

7. National Fire Protection Association (NFPA): a. ANSI/NFPA T3.10, Filter Elements

8. Society for Protective Coatings (SSPC): a. SSPC-SP 2, Hand Tool Cleaning b. SSPC-SP 3, Power Tool Cleaning

B. References: The reference listed below was used in the preparation of this specification. The content of this specification may vary from that of the reference due to the specific requirements of the application. 1. US Army Corps of Engineers Guide Specification UFGS-15005A, Speed Reducers for Storm

Water Pumps, December 2001

1.03 DEFINITIONS: Definitions shall be as defined and set forth by the American Gear Manufacturer's Association, ANSI/AGMA 1012 -F90. The following definitions apply to the job:

A. EFFICIENCY: The gear reducer efficiency shall be calculated as follows:

η = Poutput (shaft output power) / Pinput (shaft input power) x 100%

B. REDUCTION RATIO: Input shaft rotary speed (rpm) / Output shaft rotary speed (pump rated speed, rpm)

C. RATING AND SERVICE FACTOR: The reducer shall be rated in accordance with AGMA 6010-F97.

1.04 SUBMITTALS:

A. Submit as specified in SECTION 01300.

B. CONTRACTOR’s MANUFACTURER Selection Proposal: The CONTRACTOR’s proposal of the MANUFACTURER, see paragraph 1.11 (“PAYMENT”). 1. Product Qualifications 2. MANUFACTURER’s Qualifications 3. MANUFACTURER’s Certification

C. Tests Reports: 1. Factory test report 2. Field test report

D. Erection and Installation Manual

E. Operation and Maintenance Manual (including alignment requirements)

F. Overhaul Manual

G. Warranty

1.05 MANUFACTURER’S QUALIFICATIONS: The MANUFACTURER shall have the following minimum qualifications to be considered as an acceptable MANUFACTURER to provide, install, and service the equipment specified in this Contract:

A. ISO 9001 Certification: The MANUFACTURER shall be ISO 9001 registered for the design, development, production, installation, and servicing of equipment as required and specified in this Contract, and shall provide a copy of this certification.


B. Experience: The MANUFACTURER shall have experience within the last five (5) years (from the date of the submittal) with the design and manufacture of gear reducers for pumping systems as specified herein. The CONTRACTOR shall provide a minimum of five (5) references of projects that the MANUFACTURER has provided gear reducers for pump stations of a similar design and mechanical capacity to that required by this Contract. These project references shall include the name and telephone number of the owner’s representative who has direct knowledge of the performance of the manufacturer. The reference must indicate an acceptable performance by the MANUFACTURER to be considered by this Contract.

C. Technical Support: The MANUFACTURER shall have an engineering service department to support the project design, perform the required tests, and provide field supervision of the installation. The service department shall include registered professional engineers on staff. The MANUFACTURER shall provide a current copy of their staffed registered professional engineer’s certificate.

D. Service: The MANUFACTURER shall have a service department capable of providing immediate response (24-hour notice) to service calls. The MANUFACTURER’s service department shall include skilled technicians and mechanics that can diagnose and repair the equipment supplied by this Contract.

1.06 PRODUCT QUALIFICATION: The reduction gear shall be from a product line that has been used in similar applications and backed with after sales service from direct factory engineering representatives. The following technical data of the proposed equipment shall be submitted to the DISTRICT for approval prior to placement of an order:

A. Shop Drawings: Shop drawings of the proposed gear reducer to be supplied shall include: 1. Equipment dimensions and layout 2. Cross sectional views illustrating the design of the reducer 3. Support, anchorage and alignment details 4. Shaft and coupling details 5. Detailed piping plan and elevations

B. Product Data: Product data for the proposed gear reducer to be supplied shall include: 1. Gear reducer: Unit’s manufacturer, model, characteristics, type, weight, performance data,

component descriptions, construction materials 2. Thrust Bearings: Manufacturer, model, type, rating 3. Lubrication System: Description, materials 4. Backstop Device: Manufacturer, type, capacity, service factor 5. Instrumentation: Equipment descriptions, models, ratings 6. Gear mesh frequencies and/or tooth counts for vibration analysis

C. Operating conditions as per Paragraph 2.02

1.07 MANUFACTURER’S CERTIFICATION: A letter shall be submitted to the DISTRICT by the reduction gear manufacturer, signed by a senior executive officer, certifying that the MANUFACTURER’s representative has read and studied the Contract Documents and agree to the requirements of this SECTION. All exceptions to the requirements of this specification including those addressed by compliance submittals shall be stated in the letter.

1.08 ERECTION AND INSTALLATION MANUAL: The CONTRACTOR shall submit, no later than at the time of delivery, an erection and installation manual describing procedures to be followed in erecting, assembling, installing and testing the gear reducer.

1.09 OPERATION AND MAINTENANCE MANUAL: The CONTRACTOR shall submit operation and maintenance manuals containing complete information on operation, lubrication, adjustment, routine and special maintenance, disassembly, repair, re-assembly, and trouble diagnosis of the gear reducer and its auxiliary units. Include cross-sectional drawings showing the gear reducer with the complete list of parts.


1.10 PAYMENT:

A. Payment for work performed under this Contract shall be in accordance with SECTION 01020 and the General Terms & Conditions.

B. CONTRACTOR’s MANUFACTURER Selection Proposal: The CONTRACTOR shall select the manufacturer who best satisfies the requirements of this specification at an economical price. The CONTRACTOR shall submit a proposal to the DISTRICT for approval. The proposal shall include the required compliance submittals, detailed cost breakdown, delivery schedule, and any other information that has importance in the selection of the manufacturer for this Contract. The DISTRICT may request alternative proposals from manufacturers to compare costs and insure the DISTRICT is receiving a fair and reasonable offer.

1.11 WARRANTY:

A. The MANUFACTURER shall warrant the EQUIPMENT, MATERIALS, and PRODUCTS specified in this SECTION against defective materials and workmanship with the MANUFACTURER’s standard warranty, but for no less than five years from the date of Substantial Completion, and as described in Article 13 of SECTION 00700, General Terms and Conditions. If the MANUFACTURER’s standard warranty is less than the stipulated period, the MANUFACTURER shall provide a special MANUFACTURER’s extended warranty for the stipulated period, or a Maintenance Bond, to extend the MANUFACTURER’s warranty period for the stipulated period.

B. The CONTRACTOR shall warranty the WORK against defects for one year from the date of Substantial Completion and as described in Article 13 of SECTION 00700, General Terms and Conditions.

PART 2 - PRODUCTS

2.01 GENERAL DESIGN REQUIREMENTS: Each right-angle gear reducer shall be designed to reduce the speed and redirect the power of the driver to rotate the shaft of the vertical axial flow pump as shown on the Contract Drawings. Each reducer and auxiliaries to be furnished shall be complete in every respect.

A. Standard Products: The items of equipment shall be standard products of manufacturers regularly engaged in the production of such equipment.

B. Standard Practices: Standard practices shall be as defined and set forth by the American Gear Manufacturer's Association. The procedures outlined in AGMA 2005-C96 and AGMA 6010-F97 shall be followed unless otherwise specified. The design and manufacture of the reducer shall conform to AGMA standards. The furnished unit shall display the AGMA insignia as evidence of conformance to these standards.

C. Dynamic Analysis: 1. Lateral Critical Speed: The MANUFACTURER shall determine the lateral (dry) critical speed

of the pump rotor using static deflection calculations as described in ANSI/HI 9.6.4.2.1 or approved alternate method. A critical speed shall not occur within 25 percent above or below the operating speeds of the pump.

2. Torsional Critical Speed: The MANUFACTURER shall determine the torsional critical speed of the pump rotor using manual calculation methods as described in ANSI/HI 9.6.4.2.3 or approved alternate method. A critical speed shall not occur within 25 percent above or below the rated operating speed of the pump.

3. Submit the complete dynamic analysis report for C(1) and C(2) above, as required, to the DISTRICT prior to start of fabrication.

D. Balancing: Before assembly, each gear and shaft assembly shall be dynamically balanced in accordance with ANSI/AGMA 2005-C96.

E. Rotation: The rotation of the input shaft of the gear reducer shall match the typical rotation of the driver.


2.02 PERFORMANCE REQUIREMENTS: The gear reducer shall be used to transmit the power from the diesel engine driver to the vertical axial flow pump as indicated on the Contract Drawings and specified herein. The reducer shall be designed and rated to provide a reliable, efficient, smooth and quiet running gear drive under all operating conditions of the pumping system. The reducer, shafts and couplings shall be furnished and installed complete in every respect, with all items of equipment ready for operation. The reducer shall conform to the requirements of AGMA 6010-F97 or AGMA 6025-D98 as applicable.

A. Arrangement: The gear reducers to be furnished under this specification shall be identical and shall be a double reduction, right-angle spiral-bevel gear assembly. The reducer’s low speed output shaft shall be a hollow shaft design. This arrangement shall permit the pump head shaft to pass concentrically through the reducer shaft for vertical adjustment of the pump propeller. The reducer’s high speed input shaft shall be connected to the diesel engine driver by a flexible coupling furnished by the diesel engine supplier as shown on the Drawings.

B. Performance Requirements: The CONTRACTOR, in coordination with the driving and driven equipment manufacturers, shall determine the unit’s performance requirements to transmit the necessary torque from the approved driver to the pump shaft for the entire operating range of the system. The reducer shall have a thrust bearing to carry the up-thrust and down-thrust hydraulic loads of the pump. The reducer shall satisfy the following minimum requirements: 1. Efficiency: The gear reducer shall have a minimum efficiency of 96%. 2. Reduction Ratio: The reducer’s shaft output speed shall equal the pump rotary speed at the

rated condition. The overall reduction ratio shall properly match the driver speed with the pump rpm at the rated condition.

3. Rating and Service Factor: The gear reducer shall have a continuous mechanical horsepower rating of not less than 1.8 (service factor) × 225 hp (service rating) = 405 hp. The reducer shall be designed with sufficient capacity to stall the driver without injury to the reducer at any load condition contemplated by this Contract, assuming the engine driver is rated for a maximum output power of 300 hp at 1800 rpm.

4. Vibration Velocity Limits: Unless otherwise specified, the equipment shall not exceed the allowable vibration limits as indicated in SECTION 01665.

C. Operating Conditions: 1. Maximum input power: 225 hp (service rating) × 1.8 (service factor) = 405 hp 2. Driver speed at rated condition: 1800 rpm 3. Gear reducer ratio: 9.42 to 1 4. Low speed shaft downward thrust including weight: 20,000 pounds 5. Low speed shaft upward thrust during start-up or shut-down: Not applicable to axial flow

pumps 6. High speed shaft direction of rotation: Clockwise* 7. Low speed shaft speed direction of rotation: Counter-clockwise* 8. Maximum engine overload torque transmitted through the clutch: 1009 ft-lb (@ 1400 rpm)* 9. Reverse torque load on backstop: 886.3 ft-lb (405 hp @ 1800 rpm)* 10. Minimum input shaft rpm: 1200 rpm (idle)

*CONTRACTOR to verify

2.03 COMPONENT SPECIFICATIONS:

A. General: The gear reducer shall be of the double reduction, right-angle, spiral-bevel (high speed) and single helical (low speed) type and shall be capable of operating continuously the vertical main pump when driven via the horizontal high-speed shaft by the diesel engine driver. Definitions and standard practices shall be as defined and set forth by the AGMA. Gears shall be rated and designed to meet or exceed AGMA 6010.


B. Gearing: Gearing shall conform to AGMA Quality Level 11 or better, and shall be designed in accordance with AGMA formulas. Spiral Bevel Gears shall be Klingelnberg Hard Finished or Gleason ground type, produced in accordance with manufacturing tolerances required for AGMA Quality 11 to maximize overall gear mesh performance and minimize sound and vibration levels. Magnetic particle inspection shall be performed to verify the surface integrity of ground gears. In addition to rating the gears according to ANSI/AGMA 6010-F97 and ANSI/AGMA 2005-C96, gear stresses shall not exceed 80 percent of yield strength for any overload condition. Gears shall have a surface finish of 10-16 microns RMS and a surface hardness of 58 Rockwell C. Errors in tooth spacing-involute form, spiral angle and run-out shall be within the rigid tolerances established for gearing of this AGMA Quality Class. All gears and pinions shall have interference fits and keys, or shall be integral with the shaft, and shall be supported on anti-friction bearings.

C. Shafts: Each shaft shall be heat treated stainless steel. Welded shafts are not acceptable. Individual shafts and gearing shall be statically and dynamically balanced along the axial and radial axes to an amplitude of less than 0.001 inch. Input shaft size and configuration shall be compatible with the driver. The reducer output shaft shall accommodate the pump head shaft. Sufficient thread length shall be provided at the top of the output shaft to permit at least one (1) inch adjustment, up or down, of the pump shaft. The adjusting nut shall be designed to support the total axial load and thrust of the pump and be lockable in position to prevent movement. 1. Motor shaft: The existing motor shaft, which is a hollow shaft design, may be reused. 2. Couplings: The existing gear reducer-to-pump coupling, which is a rigid design, may be reused.

If replaced, the coupling shall of the same material as the shaft. The gear reducer half of the coupling shall be keyed and have the proper shrinkage fit on the hollow output shaft. The coupling shall have a service factor of 2.0 based on the maximum rated load. In addition, the stresses shall not exceed 80% of the yield strength at the maximum rated load condition. The coupling shall be dynamically balanced to AGMA balance classification of 7 or better.

3. Seals: The down output shaft shall have a drywell design seal. The input shaft shall have a lip seal to prevent leakage of the oil and exclude dirt. Lip seals shall utilize hardened steel wear sleeves to preclude shaft repair or replacement.

D. Rolling Bearings: Rolling bearing elements shall be located on the shaft using shoulders, collars, or other positive locating devices and shall be retained on the shaft with an interference fit and fitted into the housing with a diametrical clearance, both in accordance with the recommendations of ISO 286 (ANSI/ABMA 7-1995). The rolling element bearing life shall have a basic rating of L10 per ISO 281 (ANSI/ABMA 11-1990) of at least 100,000 hours with continuous operation at the rated condition, and at least 16,000 hours at maximum radial and axial loads and rated speed. 1. Thrust Bearings: The entire weight of the rotating element of the pump and hydraulic thrust,

(up-thrust and down-thrust), imposed by the propeller and any radial loads created by the reduction gear shall be carried by the thrust bearing located in the reducer. The thrust bearing shall be sized for continuous operation under all specified conditions and shall provide full load capabilities if the pump’s normal direction is reversed. The thrust bearing shall be a steep angle tapered bearing type. Misalignment of the outer and inner bearing rings shall be limited to 0.001 radian for cylindrical and tapered-roller bearings and 0.0087 radian for spherical ball bearings. Bearings shall be mounted directly on the shaft; bearing carriers are not acceptable.

2. Radial Loads: Radial load shall be addressed by the thrust bearing(s) or separate rolling element bearings shall be provided.

E. Backstop Device: A self-actuated backstop device to prevent reverse rotation of the pump due to loss of power, or drive failure, shall be installed on the intermediate or output (low-speed) shaft as an integral part of the transmission unit. Its action shall be instantaneous and without backlash. Lubrication and cooling shall be provided by the reducer lube oil system. Torque shall be transmitted directly to the gear housing. 1. Service Factor: A service factor of 2.0 shall be applied to the MANUFACTURER's published

rating.


2. Backstop Maximum Operating Temperature: The backstop shall operate at a temperature of less than 140°F under all operating conditions.

3. Ambient Temperature: The maximum ambient temperature shall be 105°F. 4. The backstop shall be suitable for continuous operation at the engine idle speed.

F. Lubrication System: The gear reducer shall be furnished with its own self-contained oil lubrication system. A positive flow of pressurized lubricating oil shall be provided by a shaft-driven gear pump to lubricate the gears, bearings and backstop. An electric motor-driven gear pump (“pre-lube pump”) shall be used to pre-lubricate the gear reducer prior to start-up and as a backup for the shaft-driven pump during normal, automatic operation. Lube oil flow shall be sufficient to keep the gear unit below a maximum temperature of 140°F with a cooling water temperature of 90°F. The oil reservoir (“sump”) shall be located within the gear housing and shall be equipped with a filler pipe with quick disconnect fitting to pump oil in and out of the unit. 1. Gear Lube Oil Pumps: Pumps shall be of the positive displacement type. Both the shaft-driven

pump and the motor-driven pre-lube pump shall be 100 percent capacity units, sized and selected to pump the oil from the oil reservoir through the gear lube oil heat exchanger, the gear lube oil filter/water separator and the gear oil piping, returning the oil to the oil reservoir. Each pump shall have sufficient capacity and pressure to circulate the lubricating oil required at all gear reducer operating loads and speeds. Each pump shall be provided with a pressure relief valve, piping and zero-leakage check valves.

2. Pre-lube Pump: The pre-lube pump and its motor shall be mounted on a fabricated steel or cast iron base. While in the automatic control mode, which is the default mode, backup operation shall be initiated by a signal from an external PLC, triggered by falling pressure in the oil pump discharge piping. While in the manual operating mode, prelube pump operation must be manually initiated. The gear pre-lubrication system shall not require valve operation to execute the pre-lubrication cycle or to return to normal operation. Electric motors shall comply with the applicable requirements of NEMA MG-1 and shall be rated for continuous duty operation and for full voltage starting.

3. Lubricating Oil: The recommended lubricating oil shall be AGMA mineral oil or a synthetic hydrocarbon, as recommended in ANSI/AGMA 6010-F97 for an ambient temperature range of 15°F to 125°F. The lubrication system shall be designed and components selected such that the gear unit will not require more than a single viscosity oil for year-round operation. Lube oil that is required or recommended to be changed twice each year is not acceptable. Lubricant additives shall be used as recommended by the gear MANUFACTURER. Lubricating oil shall also be suitable for use with the backstop device.

4. Oil and Breather Filters: The lubricating system shall have an oil filter/water separator in the pump discharge piping. The filter shall incorporate an differential pressure indicator/switch to show the pressure drop across the filter and initiate a high differential pressure alarm in the external automatic control/monitoring system. The filter shall be sized for a clean element pressure drop of 4.0 psi maximum. The filter shall have a bypass setting of 40 to 60 psi. Element collapse rating shall not be less than 150 psi. a. Oil Particle Filter: The Beta rating shall be B6 > 75 at 60 psi differential per ANSI/NFPA

T3.10 1990 Filter Elements, or an approved alternative. The filter shall be sized to avoid bypass at a start-up oil temperature of 80°F.

b. Oil/Water Filter: The filter shall maintain the water content in the oil of no greater than 200 ppm.

c. Breather Filter: The breather filter shall have a Beta rating of B6 > 75 and a desiccant chamber to remove water.

5. Piping & Fittings: Lube oil piping shall be black steel with welded fittings. Tubing shall be seamless steel with 37 degree flare or flareless fittings. All piping, tubing, and fittings shall conform to ASME B31.1.

G. Cooling System: Provide a water cooled system that utilizes an oil-to-water heat exchanger (“oil cooler”) to limit the lube oil sump temperature at rated speed and load to 140°F or less. The cooling


system shall be sized to dissipate the full mechanical losses in the drive system, with adequate capacity to prevent the lubricating oil from exceeding allowable temperature limits with an entering raw water temperature of 90°F. 1. Oil Cooler: The oil cooler shall be designed and manufactured by the manufacturer for the

proposed application and equipment. The oil cooler shall be either a shell-and-tube type or plate type. Heat exchanger tubes shall be 90-10 copper-nickel alloy and plates shall be 316 stainless steel. The minimum wall thickness of the tubes shall be 16 gauge and shall be adequate for the pressure rating. Cooling water shall be circulated through the tubes and plates and the design shall be such that the tubes and plates can be cleaned. The exchanger shall withstand a test pressure by the MANUFACTURER of 150 percent of the design pressure for a period of four (4) hours during which time the exchanger shall be checked for leaks. Any leakage shall be cause for rejection.

H. Instrumentation: The instrumentation supplied with the reducer shall be a complete working package that has been coordinated with the other major equipment supplied. See Contract Drawings and SECTION 16925 for additional details of the control and monitoring systems. The gear reducer shall have, as a minimum, the following devices: 1. Oil Temperature Switches: Oil temperature sensors and switches shall be provided to monitor

oil temperature after the oil cooler. The switches shall provide inputs to the external control and monitoring system. Alarm (“high”) and shutdown (“high-high”) set-points shall be set by the manufacturer. Products: Ashcroft G-Series, or equal.

2. Oil Pressure Switches: Oil pressure sensors and switches shall be provided to monitor oil pressure after the oil pump. The switches shall provide inputs to the external control and monitoring system. Alarm (“low”) and shutdown (“low-low”) set-points shall be set by the manufacturer. Products: Ashcroft A-Series, or equal.

3. Oil Pressure Gauge: Provide a gauge after the oil pump to monitor oil pressure. The gauge shall include an isolation valve. Products: Ashcroft Type 1122KE, or equal.

4. Temperature Gauge: Provide thermometers to indicate oil temperature at the oil cooler outlet and in the sump. Products: Ashcroft CI Series with 3” dial.

5. Oil Level Indicator/Switch: Provide an oil level indicator/switch for visual indication of oil sump level and to provide “low” and “low-low” level inputs to the control and monitoring system. Products: Murphy Lube Level “Swichgage,” Model L129, or equal.

6. Oil Filter Differential Pressure Indicator/Switch: The oil filter shall have a differential pressure indicator/switch for visual indication and to provide a “high” differential pressure input to the control and monitoring system. Products: Murphy Model 25DPE, or equal.

7. Vibration Switch: Provide a vibration switch with alarm and shutdown inputs to the control and monitoring system. The MANUFACTURER shall be responsible for determining proper settings for the vibration switch to provide equipment protection while avoiding spurious trips due to normal initial and running vibrations. The vibration alarm shall be set at 0.5 in/sec or at a baseline level recommended by the reducer MANUFACTURER. Products: Murphy Model VS94, or equal.

8. Speed Switch: A bracket-mounted speed switch including non-contacting sensor, magnetic target and speed switch in NEMA 4 enclosure shall be provided to monitor high speed (input) shaft speed, with an input to the control and monitoring system. Products: Maxigard A1000, or equal.

I. Nameplate: A nameplate shall be mounted in a conspicuous place on each unit. The plate shall be brass or bronze alloy and include the make, type, service rating, service factor and gear ratio.

J. Housing: The reducer housing shall be cast iron or cast or fabricated steel, stress relieved prior to machining, and reinforced to carry all applied loads and maintain gear alignment. Where housings are supplied of cast iron, the minimum housing wall thickness shall be 0.75 inch or greater. The housing shall have not less than 8 vertical internal stiffener ribs with cross sections not less than the housing wall thickness and shall extend the entire length of the internal housing walls. The housing mounting feet shall be 2.5 inches thick or greater. The unit shall be made in two sections for service and


assembly, with the joint between the lower and upper halves aligned with the centerline of the input shaft. The housing shall be so constructed as to provide stability and maintain precise alignment of the gears and shafts. All joints shall be finish-machined and oil tight. 1. Inspection Openings: Inspection openings with cover plates shall be provided over each set of

gears. All inspection, access, service and other type openings shall be provided with suitable metal covers that are vented, screened and easily removable.

2. Lifting Lugs: The housing shall be provided with eye bolts or lifting lugs for installation and removal.

2.04 MAINTENANCE: The following items shall be provided when the first engine under this contract is put into service.

A. Spare Parts: The following minimum spare parts shall be furnished: 1. Four (4) refills for all lubricating oil filters for each gear reducer

B. Tools: The manufacturer shall furnish all special tools required to completely assemble, disassemble and maintain the reducer, couplings and spacer shaft. "Special tools” denotes any grossly oversize or specially dimensioned tools of any kind, any special attachments or fixtures, or any other similar items.

2.05 PROTECTIVE COATINGS:

A. Shop Painting: The exterior of the reducer housing shall have a shop-applied protective coating system as specified in SECTION 09900, System S-3.

B. Field Painting: The CONTRACTOR shall touch up coatings damaged during shipment or installation.

PART 3 - EXECUTION

3.01 FACTORY TESTS: Shop tests on each unit shall include the reducer MANUFACTURER's standard running-in and/or load test. In addition, if not part of the MANUFACTURER’s normal shop test, the reducer shall be tested at the rated speed with no load, to check for contact patterns, noise levels, lubrication and cooling, and all other operational characteristics. The CONTRACTOR’s bid price shall include the cost of travel, lodging, and car rental for two (2) District representatives to travel to the site of each factory test required. The District reserves the right to substitute alternative visits for gear reducer inspections, not to exceed the total number of factory test trips. The report of the factory test shall be submitted to the DISTRICT prior to delivery.

A. Gear Contact Patterns: The reducer shall be operated a sufficient duration to develop verifiable gear contact patterns. The gear contact patterns shall be inspected and the results submitted to the DISTRICT. The spiral bevel gears shall have a central toe contact pattern with a contact of 50 percent of the face width at full load. The gear contact patterns shall be photographed and included in the field test report.

B. Noise Measurement: The sound pressure level of the reducer and the prime mover used to test the unit shall not exceed 90 dBA measured 3 feet from the equipment. The sound shall be measured in accordance with AGMA 6025-D98.

C. Factory Test Report: The factory report shall document all the data collected, including oil temperature and flow rate, ambient temperature, noise measurements, gear contact patterns, speed and load measurements, as well as all other data required to show compliance with the specifications.

3.02 PREPARATION FOR SHIPMENT: A weatherproof cover shall be provided to protect each entire unit during shipment. Any eye bolts, special slings, strong backs or devices used in loading shall be furnished for unloading and handling at the destination. All openings in all items furnished under this SECTION shall be adequately sealed before shipment to prevent the entrance of dirt or foreign material.

3.03 STORAGE: All equipment placed in storage shall be stored indoors, protected from the weather, humidity and temperature variations, dirt, dust and other contaminants. The CONTRACTOR is responsible for


locating and procuring all off-site storage that may be required throughout the life of the contract. All on-site and off-site storage provisions are subject to approval.

3.04 INSTALLATION: The CONTRACTOR shall furnish competent supervisors to direct the installation of the equipment with all work done by mechanics, skilled in the particular trade. The installation shall be in accordance with the MANUFACTURER’s recommendations and the approved installation manual. Moving parts shall be carefully and accurately aligned, tested for operation and adjusted so that all parts move freely and function properly in accordance with the MANUFACTURER’s recommendations. All changes or adjustments required to ensure satisfactory operations shall be made by and at the expense of the CONTRACTOR.

A. Gear Reducer: 1. General: If a new gear reducer is furnished, the new unit shall be a drop-in replacement for the

existing reducer and shall be bolted to the existing steel pedestal. Special care shall be taken to locate and align all parts to insure that each part or member is in alignment to the equipment with which it will operate as specified by the MANUFACTURER.

2. Servicing: Prior to operating the lubricating oil system, external piping and related auxiliaries shall be thoroughly flushed by a solvent flushing oil or lubricating oil, as required by the MANUFACTURER, and circulated through the system at an approved capacity and pressure, after which the filters and strainers shall be opened and cleaned of contaminants. All special solvents or special flushing oil required shall be furnished by the CONTRACTOR and disposed of by the CONTRACTOR upon completion of the flushing operations. Lubricating oil shall also be furnished by the CONTRACTOR. After each machine is installed and ready to operate, it shall be serviced and prepared for a running-in test. The servicing shall consist of thoroughly cleaning, lubricating and adjusting all parts of machine requiring the same.

3. Alignment: Alignment of the gear reducer with the connecting shafts of the pump and driver shall be performed in accordance with SECTION 01670 and in accordance with the specific requirements of the MANUFACTURER. Alignment requirements shall be included in the operation and maintenance manual.

B. Pipe, Valves and Fittings: All pipe, valves, fittings and supports required shall be furnished and installed complete and ready for operation. Install all pipe and fittings in accordance with recognized industry practice as necessary to achieve a permanent, leak-proof piping system, capable of performing each indicated service without piping failure.

3.05 FIELD TEST: The CONTRACTOR shall be responsible for supervising, checking and testing the gear reducer and all associated auxiliaries and shall ensure the unit is installed in accordance with the MANUFACTURER’s recommendations. The MANUFACTURER shall also furnish a qualified factory representative to supervise, check and test the gear reducer and support systems. Startup and other tests of the systems and equipment furnished shall begin only after the installation is complete and the DISTRICT has been notified in writing by the factory service representative that the installation is in accordance with MANUFACTURER's recommendations.

3.06 FIELD OPERATING TEST:

A. General: All field operating and equipment tests shall be performed by the CONTRACTOR and in the presence of the DISTRICT. The MANUFACTURER’s field representative shall be present during all operating tests. The CONTRACTOR’s monitoring and control subcontractor and/or electrical subcontractor shall also be present during all operating tests. The CONTRACTOR shall be responsible for the coordination of the various trades and responsible parties for the successful performance of all field tests. Should the tests reveal a design deficiency or a manufacturing error; the problem shall be promptly corrected by and at the expense of the CONTRACTOR.

B. Wet Operating Tests: Conduct wet operational tests as necessary to determine that the performance of equipment and controls is as specified. Tests shall consist of placing all pump equipment in operation under the pump’s preferred operating region for a period of four (4) hours. If the water conditions are not suitable at the time of the test, the test shall be postponed until conditions are acceptable.


1. Gear Reducer Vibration Measurements: 2. Vibration testing and allowable vibration limits shall be in accordance with SECTION 01665

and the reducer MANUFACTURER’s recommendations. a. The DISTRICT will provide a qualified vibration specialist to verify compliance with

vibration limits 3. Monitoring and Control Systems Check: See SECTION 16925

C. Make all necessary equipment adjustments and corrective work indicated by tests.

D. Submit a written test report of all tests performed and their results to the DISTRICT.

E. Monitoring and Control Systems Check: The gear reducer shall be checked for proper operation, including testing of the monitoring, alarm, and shut-down control instrumentation. The following specific operating parameters of the reducer shall be checked to insure they are within the recommended operating range: 1. Lube oil temperature 2. Lube oil pressure 3. Leakage from reducer and lubrication cooling system

F. Field Test Report: The field report shall document all data collected including oil temperature and pressure, ambient temperature, water conditions, speed and load measurements, as well as all other data required to show compliance with the specifications.

END OF SECTION


SECTION 11211 DIESEL ENGINES AND AUXILIARIES

PART 1 - GENERAL

1.01 SCOPE:

A. Summary of Work: This SECTION covers furnishing all labor, equipment and material to install Owner-furnished diesel engines and the necessary support systems for driving vertical axial flow pumps through right-angle gear speed reducers as shown on the Contract Drawings and in accordance with the provisions of these specifications. All engines will be furnished complete with the necessary auxiliaries as indicated herein. All other materials, parts and accessories required for proper installation and maintenance that are not expressly itemized herein as Owner-furnished shall be the responsibility of the CONTRACTOR.

B. Related Work Specified Elsewhere: 1. SECTION 01045, Cutting and Patching 2. SECTION 05070, Bolted Fasteners 3. SECTION 01641, Start-up/Check Out/Manufacturer's Field Services for Owner Furnished

Equipment 4. SECTION 01665, Equipment Vibration Testing and Laser Alignment 5. SECTION 01670, Equipment Alignment 6. SECTION 15010, Piping 7. SECTION 15607, Fuel System for Diesel Engine Drivers

PART 2 - PRODUCTS

2.01 GENERAL DESIGN REQUIREMENTS:

A. General Equipment Description: The Owner-furnished diesel engine package to be installed will be used to drive a vertical shaft, axial flow, single-stage propeller pump through a speed reducing gear transmission. Each engine shall be installed complete and fully functional by the CONTRACTOR, with all necessary ancillary equipment including, but not limited to: air filtration; starting system; fuel system; cooling system; instrumentation; and engine exhaust and after-treatment system. The engine shall be electric-started and water-cooled. A hydraulic power take-off and flexible driveshaft coupling will be provided for each engine. Approved safety guards shall be provided for all exposed moving parts that might be hazardous to operating personnel.

B. Owner-Furnished Scope of Supply: Caterpillar C9.3 DITA industrial diesel engine rated for 300 hp at 1800 rpm continuous, EPA/CARB Tier 4I EU Stage IIIB, with the following equipment: 1. Structural steel base for engine, power take-off and engine auxiliaries (dual base design to allow

for leveling/anchoring/grouting of lower base and 3-plane alignment of upper base to gear reducer)

2. Power take-off, including SAE flywheel housing, flywheel and hydraulically actuated clutch (Twin Disc 244)

3. Keyed output shaft 4. Flexible coupling (Frontline), for connection to gear reducer input shaft 5. Air inlet system, including in-line silencer, air cleaner, turbocharger, crankcase ventilation

system 6. Jacket water coolant system, including expansion tank, pump and thermostat, with supply and

return piped and terminated at a common location on engine skid 7. Aftercooler coolant system, including aftercooler, expansion tank, pump and thermostat, with

supply and return piped and terminated at a common location on engine skid, plus separate supply connection for oil cooler on gear reducer

8. Dedicated, packaged keel coolers for the jacket water and aftercooler coolant systems


9. Flexible hose connections for jacket water and aftercooler supply and return piping (4 total) 10. Exhaust and after-treatment system, including diesel oxidation catalyst and diesel particulate

filter, piped to an exhaust piping connection (butt weld end) 11. Flexible exhaust connections, metal bellows (2 total) 12. Exhaust silencer, hospital grade 13. Rain cap, hinged 14. Primary fuel filter/water separator on engine skid 15. Fuel cooler, mounted on engine skid, piped to fuel return piping connection 16. Flexible hose connections for fuel supply and return connections (2 total) 17. Lubricating system, including oil cooler, pump and crankcase breather 18. Starting system, including electric start motor, charging alternator, Ni-Cad batteries, battery

charger and elevated battery rack 19. Control system, including engine protection and control sensors mounted and prewired to a

skid-mounted junction box 20. Spare parts (filter refills) 21. Maintenance tools (engine turning tool, oil sampling pump, etc.) 22. Diagnostic equipment (process meter, RTD calibrator, pneumatic test pump, loop calibrator,

laptop with pre-installed software)

C. Contractor-Furnished Materials: All other items, materials, piping, valves, insulation, electrical, etc., as required to install and test each diesel engine, including but not limited to the following, shall be provided by the CONTRACTOR. 1. Removable, expanded metal guard for output shaft/coupling/gear reducer input shaft 2. Anchors, shims, grout, etc., as required to mount engine base to operating floor and perform

rough alignment of engine 3. Pipe, fittings, flanges, valves, supports, insulation (as applicable), etc., for all piping external to

the diesel engine package 4. Wiring, conduit, supports, etc., for all electrical and controls external to the diesel engine

package (see DIVISION 16 specifications) 5. Instruments, gauges, piping, valves, etc., including special equipment, as required to perform

equipment alignment, field operation tests and vibration test

PART 3 - EXECUTION

3.01 EQUIPMENT STORAGE: All equipment placed in storage shall be stored indoors, protected from the weather, humidity and temperature variations, dirt, dust and other contaminants. The MANUFACTURER is responsible for locating and procuring all off-site storage that may be required throughout the life of the CONTRACT. All on-site and off-site storage provisions are subject to approval.

3.02 INSTALLATION:

A. General: All work of installation shall be performed by mechanics, skilled in the particular trade and in accordance with the installation methods and practices established by the manufacturer. Both the CONTRACTOR and engine MANUFACTURER shall furnish competent supervisors to direct the installation and testing of the equipment. All moving parts of the mechanical equipment and machinery shall be carefully and accurately installed, tested for operation and adjusted so that all parts move freely and function properly to secure satisfactory operation, as determined by the CONTRACTOR. Any changes or adjustments required to secure satisfactory operations shall be made by and at the expense of the CONTRACTOR.

B. Engine Mounting: The CONTRACTOR shall anchor-bolt and grout the engine base as follows: 1. Demolition: The concrete pedestals for the existing engines shall be removed by cutting them

flush with the floor. Rebar sticking out of the floor shall be cut back 1/2 inch to 3/4 inch below


the surface and the holes patched (see SECTION 01045), leaving a smooth-finished surface on which to mount the new engine skid.

2. Anchors: Stainless steel epoxy anchor bolts of the appropriate diameter and length, and in accordance with SECTION 05070, shall be located and installed in the concrete floor.

3. Rough Alignment: The engine shall be rough-aligned to the gear reducer. The engine base shall be leveled and co-planar to within 2 mils using jacking bolts.

4. Resin Chock: Non-shrink resin chock shall be poured between the engine base and the floor, in accordance with the manufacturer’s recommendations. Resin chock shall be Chockfast “Orange” (PR-610TCF), or equal; it shall be suitable for depths of 1/2” to 4” and have a compressive strength of 19,000 psi. Resin chock shall be poured the full length of the engine base rails in a continuous pour. Foam rubber strips shall be used to form the dams for pouring the resin chock. Resin chock shall not be poured inboard of the engine base rails. Sealing material (Armaflex tubing insulation, or equal) shall be wrapped around the anchor bolts below the base rails to prevent the resin chock from filling the bolt holes in the base rails.

C. Alignment: Special care shall be taken to locate and align all parts to insure that each part or member is in alignment to the equipment with which it will operate. The CONTRACTOR shall use a laser alignment system to align each engine. Jack bolts shall be used for horizontal and vertical moves and shims shall be precision precut stainless steel. Use of hammers and crowbars to move the machines shall be avoided. Alignment shall be done such that the engine and gear reducer are within both the engine and gear manufacturers’ allowable alignment tolerances under actual operating conditions. Thermal growth and any other potential movement shall be taken into consideration. Alignment shall be checked both before and after the machines have reached their operating temperatures. Records of alignment readings for the engines shall be submitted to the District for future reference. Alignment shall be in accordance with SECTION 01670.

D. Servicing: After each machine is installed and ready to operate, it shall be serviced and prepared for a running-in test in accordance with the MANUFACTURER’s recommendations and the approved operation and maintenance manual. The servicing shall consist of visually inspecting and checking engine mounting bolts for proper application and torque; thoroughly cleaning, lubricating and adjusting all parts of engine; and the filling the oil lubrication and cooling water systems with the manufacturer’s specified fluids.

E. Pipe, Valves and Fittings: The CONTRACTOR shall furnish and install all piping external to the engine package. Piping shall be furnished, installed, inspected and tested in accordance with SECTION 15010, SECTION 15607 and the Contract Drawings.

3.03 FIELD OPERATING TESTS:

A. General: The CONTRACTOR shall perform field operating tests as described herein on each engine unit with all necessary station auxiliaries. The MANUFACTURER’s supervisor shall be present during all tests. In addition to the testing protocol specified herein, the CONTRACTOR shall perform the operating tests recommended by the manufacturer, required by the codes and additional tests deemed necessary by the DISTRICT to ensure proper operation and function of the equipment furnished and to certify that the furnished equipment meets the performance specified. Startup and other tests of the systems and equipment furnished shall begin only after the installation is complete and the DISTRICT has been notified in writing by the MANUFACTURER’s representative that the installation is in accordance with manufacturer's recommendations. MANUFACTURER-recommended after-starting checks and inspections shall be performed after a reasonable warm-up period.

B. CONTRACTOR Responsibilities: The CONTRACTOR shall be responsible for conducting startup, operating and performance tests in a safe and orderly manner with qualified trained personnel; obtaining all necessary approvals, acceptances and permits; furnishing electrical power, water, fuel and operating personnel; furnishing all instruments and gauges required for testing; and correcting all deficiencies found during the tests. If the accuracy or completeness of installed instrumentation is not sufficient, the CONTRACTOR shall provide additional instrumentation.


C. Interim Operation of Rejected Equipment: In the event of failure of any equipment or systems specified in this Contract to operate and perform as specified, or if the equipment fails to meet the performance guarantees provided for in this CONTRACT, the DISTRICT shall have the right to operate the system or equipment until such defects have been remedied by the CONTRACTOR or MANUFACTURER, and the guarantees complied with. In the event that defects necessitate the rejection of the system or equipment the DISTRICT shall have the right to operate the equipment without additional cost until such time as new equipment is provided to replace the rejected equipment. Replacement of the equipment shall be coordinated and scheduled with the DISTRICT. The DISTRICT shall not bear any cost associated with replacement of rejected equipment.

D. Testing Protocol: The following test runs shall be performed. Data taken during runs shall be recorded at 30-minute intervals and shall include all available pressure and temperature data that is monitored by the instrumentation furnished under this CONTRACT. 1. The engine shall be started in the Manual mode, the starting time recorded and all of the engine

manufacturer’s recommended checks and inspections performed following a reasonable warm-up period.

2. The engine shall be operated for at least two (2) hours at rated speed. 3. The engine shall be re-started in the Automatic mode by activating the Auto Start pushbutton

and the same sequence of inspections and checks performed in the Manual test shall be repeated, except that the engine and pumping system shall be shut down by activating the Auto Stop pushbutton.

4. The manual Emergency Stop pushbutton shall be activated and the time to stop the engine recorded.

E. Testing Guidelines: 1. Proper operation of all controls shall be verified. Protective devices shall be inspected, adjusted,

tested and calibrated in accordance with the manufacturer’s instructions. Device ratings, settings and other operational data shall be documented.

2. Proper operation and setpoints of all gages and instruments shall be verified. Setpoints shall be recorded.

3. The pumping system, consisting of the engine, gear reducer and pump, shall be free of harmful torsional vibrations per SECTION 01665.

4. Proper operation of all ancillary equipment shall be verified.

F. Sound Level Test: The engine shall be run for at least 15 min at 100 percent of rated speed. The maximum sound level in each frequency band at a distance of 75 ft from the end of the exhaust piping shall be recorded.

G. Field Test Report: After the field test data and results have been gathered, the CONTRACTOR shall prepare a field test report for review by the DISTRICT. The CONTRACTOR’s construction schedule shall allot a period of at least one (1) week for this review.

H. The CONTRACTOR shall comply with the requirements of Section 01641 for field testing and other field services performed under this CONTRACT.

3.04 FINAL INSPECTION: For a final inspection, the engine shall be inspected and all engine mounting bolts checked for tightness and visible damage. The lube oil filter shall be removed and both the oil and filter examined by the engine manufacturer for excessive metal, abrasive foreign particles and other indications of engine distress. Any corrective actions shall be verified for effectiveness by running the engine for eight (8) hours at full rated speed, then re-examining the oil and the filter.

END OF SECTION


SECTION 11215 PUMP RECONDITIONING AND UPGRADE

PART 1 - GENERAL

1.01 SUMMARY:

A. CONTRACTOR shall provide all labor, materials and equipment necessary to recondition and upgrade the vertical axial flow propeller pumps as specified herein. The WORK shall include, but not be limited to, the following tasks: 1. Remove, inspect and recondition the following pump components:

a. Suction bell b. Propeller c. Discharge bowl (add a stainless steel wear ring) d. Pump column and elbow

2. Replace the existing, grease-lubricated packing in the pump stuffing box with new, water-lubricated packing. Modify the gland/stuffing box as necessary to properly seal the shaft. Modify existing pump base plate to allow filtered raw water piping access to stuffing box.

3. Provide a new shaft enclosure tube to supply filtered raw water to flush, lubricate and cool the upper and lower discharge bowl bearings.

4. Modify suction bowl to allow filtered raw water to flush suction bowl bearing. 5. Remove and replace the following pump components:

a. Pump bearings (replace with water-lubricated elastomeric type) b. Top drive shaft, pump shaft and shaft couplings (upgrade to stainless steel)

6. Replace existing Siphon vent valve and actuator.

B. Related Work Specified Elsewhere: 1. SECTION 01665, Equipment Vibration Testing and Laser Alignment 2. SECTION 09900, Protective Coatings 3. SECTION 11301, Siphon Vent Valve

1.02 SYSTEM DESCRIPTION:

A. Main pumps are Fairbanks Morse model 60-6310 vertical axial pumps with overall shaft length of approximately 22ft. Pump flow capacity is 180 cubic feet per second at a design static head of 5.2 feet. Nominal pump rotational speed is 190 rpm.

B. The bearing data listed below are estimates only, pending acquisition of manufacturer’s shop drawings or, if necessary, measurements of actual components after pump disassembly. All dimensions and data shall be field verified by CONTRACTOR.

Service Shaft

Dia. (in) Bearing Sleeve

Thk. (in) Bearing Thk. (in)

Bearing Length (in)

Top Bearing

4 3/16 7/16 10

Upper Bowl Bearing

5 1/4 1 8

Lower Bowl Bearing

5 1/4 1 8

Suction Bowl Bearing

5 1/4 1 6


1.03 PERFORMANCE REQUIREMENTS: Water-lubricated bearings shall be capable of running dry for at least two (2) minute without damage or undue wear.

1.04 MANUFACTURER’S QUALIFICATIONS: In addition to having a full-service pump repair shop, equipped with facilities for welding, heat treating, machining, sandblasting, painting, etc., the manufacturer shall have the following minimum qualifications to be considered as an acceptable manufacturer to perform the work specified in this Contract:

A. ISO 9001 Certification: The manufacturer shall be ISO 9001 registered for the design, development, production, installation, and servicing of equipment as required and specified in this Contract, and shall provide a copy of this certification.

B. Experience: The manufacturer shall have experience within the last five (5) years (from the date of the submittal) providing reconditioning and rebuilding services for axial flow pumps of capacities 125 cubic feet per second (cfs) or greater. The CONTRACTOR shall provide a minimum of five (5) references of projects in which the manufacturer has performed pump rebuilds of a similar nature as those required by this Contract. These project references shall include the name and telephone number of the owner’s representative who has direct knowledge of the performance of the speed reducer manufacturer. The reference must indicate an acceptable performance by the manufacturer to be considered by this Contract.

C. Technical Support: The manufacturer shall have an engineering service department to support the project design and provide field supervision of the installation. The service department shall include at least one registered professional engineer on staff. The manufacturer shall provide a current copy of their staffed registered professional engineer’s certificate.

1.05 WARRANTY:

A. The MANUFACTURER shall warrant the EQUIPMENT, MATERIALS, and PRODUCTS specified in this section against defective materials and workmanship with the MANUFACTURER’s standard warranty, but for no less than five years from the date of Substantial Completion, and as described in Article 13 of SECTION 00700, General Terms and Conditions. If the MANUFACTURER’s standard warranty is less than the stipulated period, the MANUFACTURER shall provide a special MANUFACTURER’s extended warranty for the stipulated period, or a Maintenance Bond in the form attached herein, to extend the MANUFACTURER’s warranty period for the stipulated period.

B. The CONTRACTOR shall warrant the WORK against defects for one year from the date of Substantial Completion and as described in Article 13 of SECTION 00700, General Terms and Conditions.

1.06 SUBMITTALS:

A. Submit as specified in SECTION 01300.

B. Subcontractor’s Qualifications, in accordance with Paragraph 1.04 1. ISO 9001 Certification 2. References 3. Manufacturer certifications

C. Mechanical details including: 1. Bearing manufacturer, performance data, material composition, and sizing calculations 2. Shaft size, material, and design calculations 3. Suction bell and discharge bowl manufacturing details 4. Coating system data

a. Description b. Manufacturer c. Applicator d. Experience


e. Bond strength f. Surface preparation requirements g. Application procedure h. Test procedure

D. Pump teardown inspection report

E. Test Reports and Procedures: 1. Factory Test:

a. Factory test setup and test procedure b. Component balance procedures and acceptance criteria c. Factory test report

2. Field Operating Test: a. Field test procedure including vibration test and operation test b. Field test report

F. Warranty

PART 2 - PRODUCTS

2.01 WATER-LUBRICATED BEARINGS:

A. Replacement bearings shall be water-lubricated, elastomeric type Thordon SXL grade (Bill Coppedge, Coppedge Marine & Industrial, 904-398-9586), or DISTRICT approved equal. Bearings shall be one-piece and shall have water grooves.

B. Bearings shall be machined on the OD and semi-finished on the ID to suit the bearing housing ID and length and the shaft sleeve OD. CONTRACTOR shall do the final machining of the IDs.

C. Bearings shall be secured in their respective housings by an interference fit. In addition, bearings shall be retained axially. This shall be done by leaving a shoulder or stop at one end of the housing, if boring is required. The shoulder or stop should be 1/4” smaller overall than the nominal bearing OD. Secure a keeper ring at the other end of the bearing with set screws. If the housing does not have to be bored, then the bearings shall be retained axially by drilling and tapping two set screws at each end of the housing, through the installed bearings and approximately 1/8” into the bearing wall.

D. Final Machining: The bearing IDs shall be machined to Marine clearances, for example, 0.025” clearance over the shaft for a 4” diameter bearing. Use shaft clearance guidelines recommended by the bearing manufacturer. Bearing bores shall be shaft journal plus clearance, with bore tolerance of +0.005” −0.000”.

E. Modify packing gland/stuffing box as necessary to provide seal around new shaft and bearing.

2.02 PUMP SHAFTING:

A. Shafting shall be machined from high tensile strength, solid 416 stainless steel bar stock. The pump shafting shall be turned, ground and polished its entire length. The pump refurbishment contractor shall verify that the replacement shaft meets the following design requirements: 1. The shaft shall be designed and manufactured to transmit the maximum torque from the driver

to the propeller and support the maximum thrust load with the proper factor of safety. In accordance with ASME B106.1M, the shafts shall be designed for two cases: a) safety factor of 5.0 based on the ultimate tensile strength of the shaft material and the rated horsepower of the engine; b) 75 percent of the yield strength of the shaft material and the maximum horsepower of the driver.

2. Torsional and Combined Shaft Stress: All shafts shall be designed to carry the steady state and transient loads suitable for the unlimited number of load applications, in accordance with ASME


B106.1M. The maximum torsional stress shall not exceed the shear endurance limit of the shaft after application of the safety factor of 2.0.

PART 3 - EXECUTION

3.01 GENERAL: Work scope includes but is not limited to the following:

A. Pumps shall be removed from pump station by lifting through removable roof hatches and transported to pump repair shop.

B. Remove, as a minimum, the following pump components: Intake bell, propeller, propeller housing, pump shaft, intermediate shaft, shaft sleeves and bearing housings.

C. Inspect all parts. Provide a written report supplemented by pictures detailing the as-found condition, measurements taken and recommendations for rework, repair or replacement.

D. Weld repair and resurface all parts, inside and out, as necessary. See following sections for propeller reconditioning procedure and cast iron weld repair. Use pump shaft as template to fabricate and machine new, stainless steel shaft.

E. Clean, blast and paint all surfaces.

F. Replace existing bearings.

G. Install new shaft enclosure tube.

H. Replace other parts as specified in 1.01 A.

I. Reassemble pump with new stainless steel bolts, nuts, and fasteners.

J. Make additional modifications as recommended by pump and bearing manufacturers to ensure adequate flushing water flow through all bearing passages. Provide a drainage tube through the pump mounting plate for drainage of excess cooling water from the gear stand into the pump bay.

3.02 PROPELLER: Remove propeller and recondition using the following procedure:

A. Clean propeller and do the following: 1. Check pitch and diameter. 2. Check track and angular spacing at the 0.5, 0.7, and 0.9 radii. 3. Non-destructively test the hub, fillets, blade tips, and leading and trailing edges. 4. Complete as-found report.

B. After consulting with DISTRICT, proceed with the following repairs: 1. Straighten any bent blades. 2. Repair any missing or cavitated areas using weld procedures approved by the American Bureau

of Shipping (ABS). a. Use approved preheat and interpass temperatures. Verify temperatures with infrared gun

or other approved method. b. Welder shall be qualified by ABS or AWS (American Welding Society).

3. Upon completion of weld repairs, grind smooth and non-destructively test. a. Non-destructive testing (NDT) shall utilize MT (magna flux). b. Use Level II inspector to interpret and Level I inspector to apply (applies to all NDT).

4. Re-pitch and track blades as necessary. 5. Stress-relieve the propeller. 6. Make a blade pattern and ensure all blades are the same and in correct angular spacing. 7. Rough polish the propeller and non-destructively test. 8. Polish propeller to a 63 RMS finish. 9. Balance the propeller. Static imbalance should be no more than 1.0 lb at propeller tip.


10. Machine bore as necessary to match pump shaft. 11. Perform the final stress relief. 12. Perform final inspection to verify pitch, track, and angular spacing at the 0.5, 0.7, and 0.9 radii. 13. Complete as-released inspection report.

3.03 CAST IRON WELD REPAIR: All cast iron weld repairs shall comply with the following requirements:

A. Preparation: Remove all surface contaminations with solvents, commercial cleaners or paint removers. Blind cracks and pits shall be completely dressed out to sound metal by mechanical means such as grinding, chipping, rotary filling or shot blasting. Cracks shall be excavated to their full length and depth. Excavate spongy areas and pinholes.

B. Preheating: If preheating is used, heat the entire piece. Preheat to 500-1200 degrees F. Preheating shall be done slowly and uniformly.

C. Welding: Use a nickel-type electrode (Lincoln Softweld, Aufhauser NickelRod, or equal). Weld using a low current. Welds should be restricted to small, approximately 1-inch-long segments to prevent residual stress buildup. Peen each weld with a blunt tool immediately after welding.

D. Cooling: Wrap the piece in an insulating blanket, or bury it in dry sand, to slow the cooling rate.

3.04 PAINTING: All exposed ferrous metal surfaces of the disassembled pump parts, both inside and outside, shall be coated with a minimum of 16 mils, dry film thickness, of coal tar enamel. See SECTION 09900, coating system S-4. All other steel surfaces shall be coated in accordance with system S-2 of SECTION 09900. Use lead paint mitigation procedures if lead paint is found to be present.

3.05 BEARINGS:

A. Factory representatives of the water-lubricated bearing manufacturer shall be present during the installation of their products. All dimensions and tolerances shall be verified in the field by CONTRACTOR prior to ordering materials.

B. Final Machining: The bearing ID’s shall be machined to the correct tolerances as recommended by the pump and bearing manufacturers. Minimum tolerances, subject to manufacturers’ approval, are shaft diameter + 0.025” (+0.005” –0.00” machining tolerance).

3.06 WATER FLUSH SYSTEM:

A. The water flush system shall be pressure controlled and started by any of the three PSCCs and consist of (2) 100% capacity, self-priming, centrifugal pumps (1 service, 1 backup), piping, valves, filters and controls as necessary to supply an adequate supply of filtered raw water to all pump bearings and packing. See the CONTRACT drawings for additional information and design details.

B. The lube water pumps shall draw raw water from the canal using dedicated 3” diameter suction lines with bell-type inlets. The pumps shall discharge into a common 2 1/2” diameter line. The 2 1/2” line will split the flow through a tee, 40 gpm will recirculate back to the canal with the remaining 70 gpm flowing through a 2” diameter pipe into two (2) 100% auto self-cleaning filters located in the trash rake building. The filtered water will then flow to the pump station and split off from the 2“main through 1” lines at each pump bay and into the pump station through the exterior wall. Inside the flow will split and travel through a series of flow meters and control valves and then to the water lube bearings and stuffing box through water lube piping. All water lube bearing piping will have a flexible connection at the pump so that pump vibration is not transferred to piping.

C. Lube water pump suction pipe and fittings shall receive the S-4 coating system (steel, severe exposure, immersed) in accordance with Section 09900.

3.07 SHOP TESTING:

A. Upon completion of the reconditioning and bearing installation work, the CONTRACTOR shall notify the DISTRICT, and prepare for operational testing in the shop.


B. The DISTRICT shall be provided with a minimum of five (5) days’ notice in advance of testing.

C. The testing shall be witnessed by the DISTRICT, and shall consist of: 1. Connection of a water source for bearing lubrication; 2. Uninterrupted, continuous operation of the pump for a period not less than two (2) hours under

full flow at pump rated condition.

D. CONTRACTOR’s bid price shall include the cost of travel, lodging, and car rental for two (2) DISTRICT representatives to travel to the site of each factory test required. The DISTRICT reserves the right to substitute alternative diesel engine inspection visits, not to exceed the total number of factory test trips.

E. In the event that the testing is interrupted at any time prior to the completion of two (2) continuous hours of operation, the testing shall be started over.

F. At the completion of the testing, the pump shall be removed and disassembled. The propeller clearances shall be checked, and the bearing and discharge liner surfaces shall be inspected.

G. If there is any evidence of wear or other problems, the DISTRICT and a representative of the bearing manufacturer shall be consulted for resolution.

H. If any rework to the pump or bearing is required, the pump shall be operationally retested for a minimum of two (2) continuous hours.

3.08 OPERATIONAL TESTING:

A. General: All field operating and equipment tests shall be performed by the CONTRACTOR and in the presence of the DISTRICT. The manufacturer's field representative shall be present during all operating tests. The CONTRACTOR’s monitoring and control subcontractor and/or electrical subcontractor shall also be present during all operating tests. The CONTRACTOR shall be responsible for the coordination of the various trades and responsible parties for the successful performance of all field tests. Should the tests reveal a design deficiency or a manufacturing error, the problem shall be promptly corrected by and at the expense of the CONTRACTOR.

B. Wet Operating Tests: Conduct wet operational tests as necessary to determine that the performance of equipment and controls is as specified. Tests shall consist of placing all pump equipment in operation under the pumps’ preferred operating region for a period of 4 hours. If the water conditions are not suitable at the time of the test, the test shall be postponed until conditions are acceptable. 1. Pump Vibration Measurements:

a. Vibration testing shall be in accordance with SECTION 01665. b. Allowable field vibration level of vibration of the assembled pumping units shall be in

accordance with SECTION 01665. 2. Monitoring and Control Systems Check: CONTRACTOR shall verify satisfactory operation of

pump system monitoring and control systems.

C. CONTRACTOR shall make all necessary equipment adjustments and corrective work indicated by tests.

D. CONTRACTOR shall submit a written test report of all tests performed and their results to the DISTRICT.

END OF SECTION


SECTION 11301 SIPHON VENT VALVES

PART 1 - GENERAL

1.01 SCOPE: This section specifies requirements for electrically-actuated siphon vent valves.

1.02 EQUIPMENT LIST: Equipment furnished under this section shall include as a minimum the following for each of the five main pumps:

A. Siphon vent valve with electric actuator and accessories

B. Valve stem extension

C. Valve floor stand, if required

D. Pipe and fittings, as required

1.03 PERFORMANCE REQUIREMENTS: Siphon vent valves shall be special butterfly valves rated for vacuum services down to 2 x 10-2 Torr. Valves shall be suitable for on-off operation and shall provide tight shutoff in either direction.

1.04 DESIGN REQUIREMENTS: Valves, actuators and accessories shall be furnished and installed complete and ready for operation. Each valve and its associated controls shall be wired to its respective engine control cabinet for remote actuation and monitoring.

1.05 WARRANTY:

A. The MANUFACTURER shall warrant the EQUIPMENT, MATERIALS and PRODUCTS specified in this section against defective materials and workmanship with the MANUFACTURER’S standard warranty, but for no less than one year from the date of Substantial Completion, and as described in Article 13 of Section 00700 - General Terms and Conditions.

B. The CONTRACTOR shall warrant the WORK against defects for one year from the date of Substantial Completion and as described in Article 13 of Section 00700 - General Terms and Conditions.

PART 2 - PRODUCTS

2.01 GENERAL: Valves shall be Jamesbury Wafer-Sphere high-performance butterfly valves for vacuum service (contact: Dean Hall, Wacco Inc., 813-621-6441), or DISTRICT approved equal. Electric actuators shall be El-O-Matic EL Series rotary valve actuators, or DISTRICT approved equal.

2.02 MATERIALS: Valve materials of construction shall be as follows:

A. Body - Ductile iron

B. Disc - Ductile iron

C. Shaft - 316 stainless steel

D. Seat/Seal - TFE

2.03 ACTUATOR: Valves shall be equipped with reversible, weatherproof electric actuators with enclosures per NEMA 4X. Each actuator shall incorporate field-adjustable limit switches to indicate full open and closed valve positions, mechanical travel stops and dome position indicator. Actuator shall have built-in, 115 VDC motor with auto reset, thermal overload protection and ball bearings. Manual override shall be smooth rim handwheel that engages with a pull, disengages automatically upon release.


PART 3 - EXECUTION

Existing 3 inch siphon vent valves and accessories shall be removed. The CONTRACTOR shall add spacers or otherwise modify the vent pipe as necessary to center and install the new valves under the existing floor penetrations. The existing valve floor stands and/or valve stem extensions may be re-used if feasible; otherwise the CONTRACTOR shall furnish new floor stands, stem extensions and other parts as necessary to achieve a fully functional system.

END OF SECTION