part 1 – general - underground utility...

Spec. Standard: 01/11/07 11002-1 Revision: 07/13/2010

SECTION 11002 EQUIPMENT MOUNTING

PART 1 – GENERAL 1.01 DESCRIPTION: A. Scope:

This Section specifies equipment mounting, consisting of equipment bases, supports, anchorage, and accessories.

B. Mounting Requirements:

All supports, anchorage, and mounting of all equipment shall be provided by the MANUFACTURER in accordance with the Standard Building Code (SBC), and industry standards requirements, unless otherwise specified. All elements required to resist the calculated forces described herein or required by the equipment manufacturer shall be provided by the MANUFACTURER. Anchorage for all equipment bases, supports, and foundations shall be designed in accordance with the seismic design criteria in Section 1607 of the SBC. MANUFACTURER shall provide certification that for equipment, 20 horsepower and larger, anchor bolt calculations showing adequacy of bolt sizing and anchor embedment have been performed and signed by a registered structural or civil engineer.

1.02 REFERENCES:

This Section contains references to the following documents. They are a part of this Section as specified and modified. In case of conflict between the requirements of this Section and those of the listed documents, the requirements of this Section shall prevail.

Reference Title

ASCE 7-98 Minimum Design Loads for Buildings and Other Structures.

SBC-99 Standard Building Code.

1.03 SUBMITTALS: The following information shall be provided in accordance with Section 01300:

1. Shop drawings for all equipment bases and anchorage details.

2. Certification of anchor bolt calculations specified in paragraph 11002-1.01 B. 3. A copy of this specification section with addenda updates, and all referenced

sections with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations.

PART 2 – PRODUCTS 2.01 GENERAL:

Unless otherwise specified, equipment and driver shall be rigidly mounted on a common cast iron or fabricated steel base-plate. All equipment located on floor slabs shall be mounted on concrete pads. Bases for equipment shall be hot-dip galvanized after fabrication unless otherwise specified.


2.02 CONCRETE PADS:

Concrete pads for equipment and floor penetrations shall be at least 2 inches larger than the steel or cast base and not less than 6 inches above the finished floor elevation. The concrete pad thickness to support the new engines shall be coordinated with the engine manufacturer so as to match the new engine alignment with the existing gear reducers as noted in the drawings. The new pads shall be shaped to drain away from the base. All conduits, piping connections, drains, etc., shall be enclosed by the concrete base, unless otherwise specified or shown on the drawings.

PART 3 – EXECUTION 3.01 GENERAL:

A. Each piece of equipment shall be anchored to resist a minimum lateral force required either by code or by the manufacturer of the equipment, whichever is greater. This force shall be considered acting at the center of gravity of the piece under consideration. No equipment shall be anchored to vertical structural elements without written approval of the ENGINEER.

B. Equipment which is not mounted on vibration isolators shall be anchored directly to the

supporting floor system. In addition to the anchorage, all such equipment shall be internally designed so that all static and moving parts are anchored to the supporting framework to resist the imposed seismic force. All forces must be transmitted to the base in order to be anchored as required.

C. Piping with flexible connections and/or expansion joints shall be anchored such that the

intended uses of these joints are maintained in the piping system. Conduit and piping for future equipment shall be capped flush with the floor or concrete pad in such a manner to allow future connection.

D. The MANUFACTURER and MANUFACTURER shall coordinate location of electrical

conduit and piping penetrations within the concrete pad and equipment base. All penetrations shall be stub-up on the same side of the equipment as required for connection to the equipment. Equipment drains shall be located as required for drainage from equipment.

3.02 INSTALLATION:

A. All machinery shall be mounted by millwrights. Unless otherwise specified, steel blocks 4 inches square and 1 1/2 inches thick with a hole drilled in the center for the stud shall be placed under the base at every mounting stud. Equipment shall be leveled by using precut stainless steel shims between the base and the steel blocks at the mounting studs. The shims shall be placed so the tabs on the shims are easily accessible. A minimum number of shims per stud shall be used. The total shim thickness at each stud shall be at least 0.015 inches.

B. Leveling nuts shall be used for mounting equipment less than 10 horsepower. Wedges

will not be allowed.

C. Unless otherwise specified, mounting bases for equipment 20 horsepower and larger shall be a minimum of 1 inch thick. Mounting bolt holes in the bases shall be drilled and not burned out and they shall not be open slots. All mounting studs shall be 316 stainless steel and a non-galling compound shall be used on the threads. Mounting studs as furnished and installed as per manufacturer recommended procedures.


D. The equipment manufacturer shall recommend the size of the mounting studs for the equipment and shall also furnish the recommended tightening torque for the nuts; however, the minimum size stud shall be 3/4 inch for 20 to 100 horsepower, 1 inch for over 100 to 300 horsepower and 1-1/4 inch for 300 to 500 horsepower. Over 500 horsepower shall be as recommended by the manufacturer of the equipment and approved by the Construction Manager.

E. Equipment shall be grouted as specified. Non-shrink and nonferrous grout shall be used

and it shall be no less than 7/8 inch and no more than 1-5/8 inches thick.

END OF SECTION


SECTION 11210 SPEED REDUCERS

PART 1 - GENERAL

1.01 SCOPE:

A. Summary of Work: This specification section is for the rehabilitation and installation, including all labor, equipment and materials, of right-angle gear speed reducer to transmit power from a diesel engine to a vertical axial flow pump as shown on the Contract Drawings. The speed reducers shall be rehabilitated / upgraded to “As New” condition and required to meet the specified performance criteria.

B. System Description:

1. EXISTING SYSTEM: Pump Station S-331, has a total of three (3) existing engine-driven main pumping units, each with a design capacity of 387 cubic feet per second. Each vertical axial flow pump is driven by a Detroit Diesel, Model 12V71T, 12-cylinder diesel engine through a Western/Westech make, double reduction, bevel/helical gear assembly.

2. The following are the certified performance data of the existing Gear assembly units:

• Manufacturer: Western Gear Corp., S.O. No. 118-90460

• Unit Model NO. 9716 (Hollow Shaft)

• Number of Units: 3

• Unit Serial Numbers: 3001, 3002, and 3003

• Prime Mover: Diesel

• Driver Equipment: Vertical Pump

• Rated Output Per AGMA 420.05: 329 HP at 1800 GPM Input Speed

• Max Pump HP at Rated Load at 100 RPM: 219 HP

• Service Factor at Rated Output per Max Pump HP 1.50

• Input RPM: 1800

• Output RPM: 100.5

• Ratio: 17.911:1

• Estimated Efficient at Rated Load and Speed: 96.5%

• Heat Rejected by Unit: 22,000/BTU/Hr.

• Fresh Water Supplied to Heat Exchanger: 2.5 GPM at 85oF Max.

• Ambient Air Temperature: 105oC Max.

• Lubricant Required: AGMA No. 4 Turbine Oil, 626-765 SSU at 130o, ASTH-ASLE Grade S-700

• All Bearing Designed for 40,000 Hr. B10 Life

• Low Speed Shaft Design Down Thrust: 31,000 lbs.

• Estimated Weight: 4,900 lbs.

• Mass Elastic Drawing: E9716-900-002

• Lubrication System Supplied with: Shaft Mounted Lubrication Pump, Temperature Gage, Pressure Gage, Heat Exchanger, Check Valves, Pressure Relief Valves, Pressure Switch,


Auxiliary Lubrication Pump and Auxiliary Pump Motor 1230 Vac., Single Phase, 60 HZ, 1 HP, 1800 RPM

C. Refurbish and upgrade the existing speed reducers to achieve the performance detailed in this section. The reworked speed 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. Inspection and documentation of condition

2. Furnish and install new components:

a. Spiral bevel ring gear

b. Spiral bevel pinion and input shaft

c. Bearing cartridge and thru cap, output shaft

d. Input shaft bearings

e. Output shaft bearings

f. Gear driven lube oil pump with valves, heat exchanger and other plumbing

g. Electric pre-lube oil pump and motor

h. Lube oil pump bearing

i. Backstop, low speed shaft

3. Rework the following components:

a. Housing

D. Related Work Specified Elsewhere:

1. SECTION 01665 Equipment Vibration Testing

2. SECTION 01670 Equipment Alignment

3. SECTION 09900 Protective Coatings

4. 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 9-1990 (R2000), Load Ratings and Fatigue Life for Ball Bearings

b. ANSI/ABMA 7-1995 (R2001), Shaft and Housing Fits for Radial Ball and Roller Bearings

c. ANSI/ABMA 11-1990 (R1999), Load Rating and Fatigue Life for Roller Bearings

d. ANSI/AMBA 13-1987 (R1999). 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 Society of Mechanical Engineers (ASME)

a. ASME B31.1, Process Piping

4. American Petroleum Institute (API)

a. API 677, General-Purpose Gear Units for Refinery Service, 2nd Edition, 1997

5. 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 (1988), ISO System of Limits and Fits

c. ISO 281 (1990), Rolling Bearings Dynamic Load Ratings and Rating Life

6. National Fire Protection Association (NFPA)

a. ANSI/NFPA T3.10 (1990), Filter Elements

7. Steel Structures Painting Council (SSPC)

a. SSPC-SP2, Hand Tool Cleaning

b. SSPC-SP3, 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-33 45 00.00 10, Speed Reducers for Storm Water Pumps, April 2008

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 speed 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 DIVISION 1.

B. CONTRACTOR’S Manufacturer Selection Proposal: 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 REFURBISHING CONTRACTOR QUALIFICATIONS: The refurbishing Contractor shall have the following minimum qualifications to be considered as an acceptable to provide, install, and service the equipment specified in this Contract:

A. ISO 9001 Certification: The Contractor shall be either the original manufacturer of the equipment or their authorized repair/ refurbishing center with ISO 9001 registered for the design, development, production, installation, and servicing of equipment as required and specified in this Contract.

B. Technical Support: The Contractor 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.

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.

1.06 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 speed 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

B. Product Data: Product data for the proposed speed reducer to be supplied shall include:

1. Speed 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

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 speed 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 speed reducer and its auxiliary units. Include cross-sectional drawings showing the speed 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 pump 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 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 double reduction right-angle speed reducer shall be refurbished to bring the equipment back to “As New” operational status with the overall performance criteria as listed below:

1. Efficiency: The speed 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 existing reduction ratio of 17.911:1 shall be maintained 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 200% of the maximum horsepower rating of the pump (2.0 service factor).


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

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

C. 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.

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

E. Rotation: The existing rotation direction of the input shaft of the speed reducer shall be maintained.

2.02 PERFORMANCE REQUIREMENTS: The speed 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 speed reducers to be refurbished under this specification are double reduction, right-angle spiral-bevel gear assembly. The reducer’s low speed output shaft is of a hollow shaft design. This arrangement permits 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 as shown on the Contract Drawings.

2.03 INSPECTION PROCEDURES:

The CONTRACTOR is responsible to disassemble the gear box assembly units and perform a thorough inspection at their service center as follows:

• Document the “As Received” condition of the gear box with digital photographs

• Disassemble the gear box and remove all external and internal components

• Clean the internal components as required and perform visual inspection and document all damaged areas with photographs

• Dimensional inspection of all critical components such as shafting and gear casing to insure the integrity prior to reuse

• Magnetic particle inspection of all reusable torque transmitting components to determine any sign of operational distress

• Identify additional scope items required based upon the findings and submit to the DISTRICT a report with scope addition, associated cost and delivery impacts

2.04 COMPONENT SPECIFICATIONS FOR BASE SCOPE OF SUPPLY: The Contractor, as a minimum, shall furnish and install following components as part of the refurbishment work.

A. General: The speed reducer shall be of the double reduction, right-angle, spiral-bevel 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 Gear set shall be Klingelnberg cut, carburized,and hard finished with an integral pinion and shaft, and ring gear. The Helical gear set shall be through hardened and cut with an integral pinion and shaft and gear. The gearset shall be produced in accordance with manufacturing tolerances required for AGMA Quality 11 to maximize overall gear mesh performance and minimize sound and vibration levels. The AMGA tooth rating of the gear sets shall provide a service factor greater than 2.0 and shall give significant increase in overall reliability.

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. 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 diametral 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 bearings located in the reducer. The thrust bearings 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).

D. 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 output (low-speed) shaft as an integral part of the transmission unit. Its action shall be instantaneous and without backlash. It shall be of the pin and ramp design and shall be of a capacity adequate to prevent reverse rotation with backflow through the pump equivalent to the maximum driver horsepower. Backstop pins shall be readily accessible for inspection. The backstop ramps shall be manufactured of Ductile Iron, 60-45-10 per ASTM A-339 with a hardness ranging between 140 to 170 BHN. Backstop pins shall be 4140 steel, precision ground. Lubrication and cooling shall be provided by the reducer lube oil system. Torque shall be transmitted directly to the gear housing. Sprag type backstops are not acceptable.

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. Suitable for continuous operation at the engine idle speed.

E. Lubricating System: The speed 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 shall be used for pre-lube start-up and as a backup for the shaft-driven pump. Pump backup operation shall be initiated by a lube oil pressure switch located on the gear unit. Lube oil flow shall be sufficient to keep the gear unit


below a maximum temperature of 140°F with a raw water temperature of 85°F. The oil reservoir 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 Pump: Pumps shall be of the positive displacement type. The gear lube oil pump shall be shaft-driven from the gear and the gear pre-lube oil pump shall be electric motor-driven for pre-lube service prior to normal gear operation and for backup service operation. Both pumps shall be 100 percent capacity units, sized and selected to pump the oil from the gear housing through the gear lube oil heat exchanger, the gear lube oil filters, the gear oil piping, and return the cooled oil to the gear unit. The gear lube oil pump shall have sufficient capacity and pressure to circulate the lubricating and cooling oil required at all gear reducer operating loads and speeds. The gear lube oil pump shall be provided with a pressure relief valve, piping and isolation valves. The gear pre-lube oil pump and its motor shall be mounted on a fabricated steel or cast iron base. The gear reducer shall be pre-lubricated prior to start-up. The pre-lube pump shall utilize zero-leakage check valves to isolate it from the lubrication system during normal operation of the gear reducer. The gear pre-lubrication system shall not require valve operation to execute the pre-lubrication cycle or to return to normal operation. The gear oil pressure switch shall be suitable for lubricating oil applications and shall be resistant to activation by vibration. 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.

2. Oil and Breather Filters:

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.

3. Piping & Fittings: Lube oil lines up to 2-in O.D. shall be seamless steel tubing with 37 degree flare or flareless fittings. Lube oil pipe larger than 2-in O.D. shall be black steel with welded fittings. Water piping shall be copper or copper alloy with brazed or 95-5 soldered joints. All piping, tubing, and fittings shall conform to ASME B31.1 – Process Piping.

F. Cooling System:

1. Heat Exchanger: The oil cooler shall be a shell-and-tube 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. The exchanger shall withstand a test pressure of 150 percent of the design pressure for a period of 4 hours during which time the exchanger will be checked for leaks. Any leakage shall be cause for rejection. The oil cooler shall be designed to use the existing once thru raw water cooling system and shall have a thermo-mechanical control valve to adjust flow rate through the cooler to maintain a minimum oil temperature of 120°F in the housing sump.

G. 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 –Pump Station Instrumentation and Control for additional details of the control and monitoring systems. The gear reducer shall have the following devices, as a minimum:

1. High Oil Temperature: An oil temperature sensor RTD shall be provided to monitor oil temperature in the housing sump. The alarm and shutdown shall be inputs to the control and monitoring system. Alarm and shutdown settings shall be as follows (lower settings shall be used if recommended by reducer manufacturer):

a. Alarm at 180°F


b. Shut down at 200°F

2. Oil Pressure: Provide a gauge after the oil pump to monitor oil pressure. The gauge shall be oil or glycerin filled and shall include an isolation valve. Low oil pressure alarm and shutdown threshold levels shall be input to the control and monitoring system. Threshold levels shall be as specified by the manufacturer.

3. Temperature Gauges: Provide thermometers in the sump, in the oil line after the lube oil cooler, and in the backstop.

4. Oil Level Sight Gauge: Provide an oil level sight gauge to monitor oil level in the housing sump.

5. Vibration Switch: Provide a vibration switch with alarm and shutdown inputs to the control and monitoring system. The vibration alarm shall be set at 0.5 in/sec or at a baseline level recommended by the reducer manufacturer.

H. Housing: Clean, sandblast and paint the housing in accordance with requirements specified under Paragraph 2.06 – Protective Coating of this Section.

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.

2.05 COMPONENT SPECIFICATIONS FOR OPTIONAL SCOPE OF SUPPLY (TO BE DETERMINED AND APPROVED BY THE DISTRICT BASED UPON THE INSPECTION REPORT):

A. Shafts, Seals and Couplings

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 locked in position to prevent movement. The high speed pinion shaft shall be supported in a straddle mounted bearing assembly, which utilizes a support bearing on both sides of the pinion mesh to maximize stability.

1. Couplings: The speed reducer-to-pump coupling shall be of the rigid design and of the same material as the shaft. The speed 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.

2. 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.

2.06 PROTECTIVE COATINGS:

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

B. Field Painting: 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 at no load, to check for contact patterns, noise levels, lubrication and cooling, and all other operational characteristics. 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. Speed Reducer:

1. General: 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. All equipment that is to be anchored shall be properly aligned and shall be carefully grouted in place.

2. Servicing: Prior to operation 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 speed reducer with the connecting shafts of the pump and driver shall be performed in accordance with SECTION 01670 Equipment Alignment 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:

A. Supervision: The CONTRACTOR shall be responsible for supervising, checking and testing the driver, speed reducer, pump and all associated auxiliaries to insure the assemblies are installed in accordance with the manufacturer’s recommendations. The gear manufacturer shall also furnish a qualified factory representative to supervise, check and test the speed 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.

B. Field Test shall be performed concurrent with the operating test specified in SECTION 11211 Diesel Engines and Auxiliaries and in accordance with the requirements specified in Section 01660 Equipment and System Performance and Operational Testing.

C. 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 flow rate

3. Leakage from reducer and lubrication cooling system

D. Vibration Test: Vibration testing and allowable vibration limits shall be in accordance with Section 01665 Equipment Vibration Testing and the reducer manufacturer’s recommendations.

E. Field Test Report: The field report shall document all data collected including, oil temperature and flow rate, 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 - OWNER FURNISHED EQUIPMENT (ISSUED FOR INFORMATION ONLY)

PART 1 - GENERAL

1.01 SCOPE:

A. Summary of Work: This section covers furnishing and delivering diesel engine as the prime driver to the existing vertical axial flow pumps through a right angle speed reducer in accordance with the provisions of these specifications. All engines shall be furnished complete with the necessary auxiliaries and all other parts and accessories indicated, specified, or required for proper installation, operation, and maintenance.

B. Three (3) Engines and auxiliaries shall be furnished complete as specified below in the Section 11211 with no exceptions. These engines will be installed and coupled with the existing speed reducers by the DISTRICT’S construction contractor to drive the existing vertical axial flow pumps at the Pumping Station S-331.

C. A fourth engine with HPTO shall be supplied. The fourth engine shall be stored and used as a spare engine by the District as and when required for the Pumping station S-331. This engine shall be furnished and delivered in full conformance with the requirements of this section and with following exceptions.

1. Heat Exchanger and all interconnecting piping within the skid as specified in paragraph 2.05 (B) is not required under the scope of supply

2. Disc brake assembly as specified in paragraph 2.10 of this Section is not required under the scope of supply

3. Flexible Coupling as specified in paragraph 2.11 (B) is not required under the scope of supply

4. Battery and battery chargers as specified in paragraph 2.08 B and 2.08 C of this Section are not required under the scope of supply

5. Exhaust system as specified in paragraph 2.03 is not required to be furnished under the scope of supply.

6. The engine is not required to be supplied on the skid as specified in this section. However, it shall be supplied on a mounting suitable for long term storage and suitable for handling with fork lift.

D. Related Work Specified Elsewhere:

1. Section 01664 Training

2. Section 01300 Submittals

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.

1. American National Standards Institute (ANSI)

2. American Society for Testing and Materials (ASTM)

3. Standard Specification for Fuel Oils (ASTM D396)

4. Diesel Fuel Oils (ASTM D975)


5. Standard Specification for Chromium and Chromium Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and General Applications (ASTM A240)

6. Calcium Silicate Block and Pipe Thermal Insulation (ASTM C533)

7. Pipe, Steel, Black, and Hot-Dipped, Zinc-Coated, Welded and Seamless (ASTM A53)

8. Standard Specification for Seamless Carbon Steel Pipe for High Temperature Service (ASTM A106)

9. Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service (ASTM A234)

10. Standard Specification for Carbon Steel Forgings, for General Purpose Piping (ASTM A181)

11. Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength (ASTM A307)

12. Standard Specification for Carbon and Alloy Steel Nuts (ASTM A563)

13. Diesel Engine Manufacturers Association (DEMA)

14. Occupational Safety and Health Administration (OSHA)

15. CFR 1910.212 General Requirements for all Machines

16. National Fire Protection Association (NFPA)

17. Flammable and Combustible Liquids Code (NFPA 30 (1996; Errata: TIA 96-2)

18. Installation and Use of Stationary Combustion Engines and Gas Turbines (NFPA 37 (1998)

19. Society of Automotive Engineers (SAE)

20. Marine Propulsion Engines and Systems, Power Measurement and Declaration (SAE J1228/ISO 8665 (1994)

21. Engine Power Test Code - Spark Ignition and Compression Ignition - Gross Power Rating (SAE J1995 (1990; R 1995)

22. DC Starter-Generator, Engine (SAE ARP 892 (1965; R 1994)

23. Storage Batteries (SAE J537 (1996)

24. Electronic Data Interchange (SAE J1587)

25. Recommended Practice for a Serial Control and Communications Vehicle Network (SAE J1939)

26. Underwriter Laboratory (UL)

27. Battery Charges for Charging Engine-Starter Batteries (UL 1236 (1994; Rev thru Mar 1999)

28. International Organization for Standardization (ISO)

29. Reciprocating Internal Combustion Engines - Performance Part 1 - Declaration of Power, Fuel and Lubricating Oil Consumption and Test Methods (ISO 3046 (2002)

30. Manufacturers Standardization Society (MSS)

31. Pipe Hangers and Supports – Materials, Design, and Manufacture (MSS SP-58 (1993)

32. Pipe Hangers and Supports- Selection and Application (MSS SP-69 (1996)

33. Bronze Gate, Globe, Angle and Check Valves (MSS SP-80 (1997)

34. American Society of Mechanical Engineers (ASME)

35. Boiler and pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic Coverage (ASME BPV VIII (1998)


36. Forged Fittings, Socket-Welding and Threaded (ANSI/ASME B16.11 (1996)

37. Malleable Iron Threaded Fittings (ANSI/ASME B16.3 (1998)

38. Pipe Flanges and Flanged Fittings NPS 1/2 thru NPS 24 (ANSI/ASME B16.5 (1996; B16.5a)

39. Power Piping (ANSI/ASME B31.1 (1998)

40. Welded and Seamless Wrought Steel Pipe (ANSI/ASME B36.10 (1996)

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 applications.

1. US Army Corps of Engineers Guide Specification UFGS-41 65 10.00.10 - Diesel/Natural Gas Fueled Engine Pump drives, May 2009.

1.03 DEFINITIONS: The following definitions apply to this specification.

A. Pump Input Power: The pump input power (brake horsepower), is the power needed to drive the complete pump rotating assembly including the propeller-bowl assembly input power, line shaft power loss, stuffing box loss and thrust bearing loss. With pumps that rely on the driver thrust bearing, the thrust bearing loss shall be added to the power delivered to the pump shaft.

B. Driver Input Power: The mechanical power delivered by the diesel engine driver (horsepower) to the transmission, (pump input power, divided by the speed reducer efficiency).

C. Engine Output Power: The mechanical power (horsepower) of the diesel engine measured at the flywheel at the rated engine speed and standard environmental conditions as per ISO 3046.

1.04 UNIT RESPONSIBILITY

Equipment and services specified in this Contract including the Diesel Engines shall be provided by the diesel engine manufacturer (MANUFACTURER), who shall be fully qualified under the requirements set forth in below paragraph 11211.1.05. The MANUFACTURER shall be responsible for the design, selection and operation of all systems and components provided therewith and shall be the original equipment manufacturer of the diesel engine furnished under this Contract. The engine MANUFACTURER shall provide a certificate of Unit Responsibility confirming that the engineering, design, and selection of all systems and components conducted by the respective manufacturers are fully compatible and will be free from operational defects.

Additionally, the MANUFACTURER shall cause the responsible equipment manufacturers to supply qualified installation specialists to supervise the unloading, specified under this Section. The MANUFACTURER shall furnish an affidavit, signed and notarized as above, attesting that the equipment has been properly unloaded, placed, installed, adjusted, tested, and started in accordance with the MANUFACTURERS’ requirements for proper operation and acceptable service life. Nothing in these provisions, however, shall be construed as relieving the MANUFACTURER of responsibility for the overall quality and completeness of the work.

1.05 MANUFACTURERS QUALIFICATIONS: The MANUFACTURER shall have the following minimum qualifications to be considered as an acceptable MANUFACTURER to provide 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.

B. Experience: The engine manufacturer shall be regularly engaged in the production of the products to be furnished under this Contract and shall comply with the Diesel Engine Manufacturer's Association (DEMA) standard practices for stationary diesel engines.


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.

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 engines shall be from the product line of stationary diesel engines that have been use in similar applications and backed with after sales service from direct factory engineering representatives.

1.07 SUBMITTALS:

A. General:

The material listed below shall be submitted in accordance with the requirements of Section 01300. The material listed in paragraph 1.07 B. below shall be submitted with the Proposal. The material listed under paragraph 1.07 C. below shall be submitted within 40 days from the date of Effective Date of Contract of this Contract. Insofar as possible, the material shall be submitted as a single, coordinated submission. Exceptions will be allowed only on presentation of reasonable explanation for omission and an absolute date when the required information will be furnished to the ENGINEER. Submittal material shall include the following:

B. To Be Submitted With The Proposal:

The following information on the proposed diesel engine shall be submitted with the proposal to illustrate the compliance with the performance requirements of the specification.

Diesel Engine:

1. Engine make and model, performance data including power rating

2. Engine bore and stroke, number of cylinders, and stroke per cylinder

3. Performance history of engine model proposed for use

4. Allowable operating limits for pressure and temperature for cooling water, fuel, and lubrication oil

5. Overall engine dimensional layout drawing

6. Certification by the MANUFACTURER of the engine speed, horsepower, and duty rating

7. Description and data for the engine’s electronic control and monitoring system

8. Layout drawings showing plan and elevation views of all major items of equipment, including engines and other auxiliary system to be furnished under this Contract. Layout drawings shall show recommended clearances and clearances required for assembly and disassembly of all equipment.

9. Performance characteristic curves of the proposed engines including torque vs. speed, BHP vs speed and specific fuel consumption vs. speed curves for the specified conditions.

10. Expected weight and sizes of major subassemblies for the engines.

11. Heat rejection data for engine. Heat rejection data for the engines shall be disaggregated by ambient, exhaust, jacket water, intercooler, and return oil coolers.


12. Interconnection diagrams showing relative location of electrical and instrumentation connections at individual machines. A termination identification system shall be developed and a schedule of termination requirements shall be furnished.

13. Manufacturer’s Certifications including (a) Agreement with requirements of this specification, (b) Compliance with Federal, State, and local emission requirements and (c) Pressure vessel certification for the heat exchangers and expansion tanks.

C. To Be Submitted Within Forty Days (40) After The Effective Date Of The Contract:

Engines:

Drawings: 1. Dimensional plan and sectional drawings showing the skid layout including all major items of

equipment the MANUFACTURER proposes to furnish. The items shown shall include the diesel engine, Heat Exchanger, PTO assembly, Brake assembly, drive shaft and coupling.

2. Plan, elevation and sectional views of engine support foundation and anchorage details.

System Information:

3. Data on the air intake system components proposed for use

4. Data on the water cooling system components proposed for use

5. Data on the engine starting system components proposed for use

6. Data on the engine control module (ECM)

7. Data on the engine exhaust system

8. Emission data of the engine at different load conditions and certificate of compliance with Tier-3/Stage IIIA EPA emission standards.

9. Alignment procedures and allowable tolerances for the speed reducer, engine, and drive shaft

10. Manufacturer and performance data on power take-off (PTO) proposed for use

11. Manufacturer and performance data on forward brake assembly proposed for use

1.08 OPERATION AND MAINTENANCE MANUAL: The MANUFACTURER shall submit operation and maintenance manuals in accordance with Section 01300 for the engine and its auxiliaries containing complete information on settings and adjustments, lubrication, alignment procedures, routine and special maintenance, disassembly, repair, re-assembly, and trouble diagnosis. In addition to the engine, include information on the starting system equipment including the battery starter, clutch assembly and brake assembly.

1.09 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 (5) years from the date of delivery to the Project site and/or to the designated location upon receipt of notice from the DISTRICT/ construction contractor.

B. If the MANUFACTURER’S standard warranty is less than the periods stipulated above for the particular engine application, the MANUFACTURER shall provide a special MANUFACTURER’S extended warranty for the stipulated period to extend the MANUFACTURER’S warranty period for the stipulated period.


C. The DISTRICT shall maintain the engine and its auxiliaries in accordance with the approved Operation and Maintenance Manuals, or shall execute a maintenance contract for a time period equaling the extent of the warranty period.

PART 2 - PRODUCTS

2.01 GENERAL DESIGN REQUIREMENTS:

A. General Equipment Description: Each diesel engine to be furnished will be installed to drive a vertical shaft, axial flow single stage propeller pump through a speed reducing gear transmission. Each engine shall be provided and installed complete and totally functional, with all necessary ancillary equipment including, but not limited to: air filtration; starting system; fuel system; cooling system; instrumentation; and engine exhaust system. The engine shall be electric starting and shall be water cooled. The engine shall operate with the existing elevated day tank arrangement. A power take-off / clutch assembly and brake assembly shall be provided for each engine. Suitably designed flexible coupling shall be provided between each engine output shaft and the associated speed reducer. For items furnished under the section, approved safety guards shall be provided for all exposed moving parts that might be hazardous to operating personnel.

B. Operation: The engine shall be remotely monitored and operated via the DISTRICT’S telemetry system to be furnished under a separate construction contract. The engine mounted electronic control module shall output engine parameters and functions via a data-link to a logic controller.

2.02 INDUSTRIAL DIESEL ENGINE:

A. Standard Model: The engine model proposed shall be a unit with a satisfactory service record of not less than 36 months of operating 1200 hr/yr under similar or more severe conditions of duty. The available models of drivers shall be matched to the pumping system requirements.

B. Engine Description: The engine shall be a compression-ignition type, four cycle, diesel engine for stationary applications and shall be turbocharged-after cooled. The engine shall be a vertical in-line type with solid cast block. The engine shall have no less than six cylinders. Engines shall be current models of a type in regular production with all devices specified or normally furnished with the engine.

C. Service: The engine service shall be “Continuous Duty” intended for continuous use for load application requiring uninterrupted service at full power.

D. Engine Rating: The standard reference conditions, methods of declaring the power, fuel consumption, lubricating oil consumption, and test methods for the proposed engine shall be in accordance with applicable sections of ISO 3046 for the conditions listed below. The basis for gross engine power rating, methods for correcting observed power to reference conditions and the method for determining gross full load engine power with a dynamometer shall conform to SAE J1995.

1. Project Site Conditions:

Maximum Ambient Temperature: 105 deg F

Minimum Air Temperature: 35 deg F

Maximum Raw Water Temperature: 90 deg F

Minimum Raw Water temperature: 60 deg F

Elevation: Sea Level

Relative Humidity: 80%

2. Engine Output Power: The output power (continuous) to be delivered by the engine shall be minimum 325 HP at 1800 RPM and shall generate minimum engine torque of 947 lb-ft at the


rated speed. The proposed engine ratings including other performance characteristics calculations shall be submitted to the DISTRICT for approval. It should be noted the engine power ratings are based on the total power output capability at the flywheel. The required engine output shall include the horsepower requirements of the engine auxiliaries.

Start-up: The engine will generally be started with the pump disengaged. The engine manufacturer shall also ensure there are no damaging overload conditions during the engine’s warm-up period.

Manufacturer’s Certification: The engine manufacturer shall certify in writing the proposed engine model has sufficient output power to satisfy the pump and transmission input power requirements as specified.

E. Engine Speed at Rated Condition: 1800 rpm.

F. Fuel Requirements: The engine shall be operated on Ultra Low Sulfur Diesel fuel Oil as defined in ASTM D975.

G. Fuel Consumption: The standard reference conditions and methods of declaring fuel consumption shall be in accordance with applicable sections of ISO 3046. The fuel consumption rate shall not exceed 0.37 lb. per bhp-hour between 75% and 100% of rated full load for the SAE J1995 conditions:

H. Emissions Requirements: The proposed engine shall comply with EPA Tier 3, Stage IIIA emissions requirements. A letter shall be submitted to the DISTRICT by the engine manufacturer, certifying that the furnished system satisfies all emissions regulations. The use of Catalytic Converter on the diesel engine exhaust to reduce emissions is not acceptable. Exhaust emissions levels must be maintained at the diesel engine’s continuous duty design loading conditions without manual engine adjustments.

I. The heat rejection rate to the ambient shall not exceed 3200 BTU/min under specified rated operating conditions.

J. Engine Electronics: The engine’s electronic control module shall provide monitoring of vital engine parameters and control of engine operation. The system shall regulate emissions and optimize fuel economy and provide condition monitoring to prevent engine damage. The electronic control system shall have programmable speed control. The electronic package shall also provide standard data-link to a logic controller for manual and remote monitoring and operation via the DISTRICT’S telemetry facilities. A standard factory supplied engine control and monitoring panel shall be provided for manual operation.

K. Rotation: The rotation of the engine shall be the SAE standard rotation with the speed reducer and pump to match this rotation. It is intended that the engine deliver power in one direction only and an anti-reverse rotation device will be provided integral to the Gear Speed Reducers.

L. Engine Mounting: All engines with accessories except the one engine that will be used as “Spare Engine” shall be skid mounted. Refer to the requirements in the Paragraph 1.01C. Complete equipment foundation plates, sole plates, mounting straps, brackets or structural bases with suitable anchor bolts, nuts, sleeves, washers and shims or wedge plates and vibration dampers or isolation blocks shall be furnished as required. Anchor bolts shall be designed to fully restrain the engine and its motion under acceleration induced forces and torque reactions.

M. The overall dimension of the engine including the skid and other specified auxiliary system shall not exceed 75”L X 70”W X 78”H.

N. The proposed engine shall be Type C-11 ACERT as manufactured by Caterpillar or approved equal.


2.03 EXHAUST SYSTEM: A complete exhaust system including following items shall be provided for each engine.

A. Exhaust Silencer: The exhaust silencer shall be a hospital grade chamber type exhaust muffler to be mounted on the exterior of the pump station building. The exhaust silencer and miscellaneous fasteners shall be ASTM A276 type 304 stainless steel. The MANUFACTURER shall select the silencer that will provide the most effective system considering; noise levels generated, pressure drop and physical size of the silencer. The allowable Noise Level taken three (3) feet from the silencer shall not exceed 86 dBA.

2.04 AIR INTAKE SYSTEM: A complete and separate air intake system shall be provided for each engine. The MANUFACTURER shall be responsible for the design and installation of the air intake system in accordance with the proposed engine requirements.

A. Air Intake Filter: The air intake filter for each engine shall consist of high-efficiency, washable paper elements packaged in a low restriction waterproof housing. The filter shall be provided in a location convenient for servicing.

B. Inline Silencer: For turbo-charged engines, an inline silencer shall be provided on the air intake. The silencer shall be of the high frequency filter type. A combined filter silencer unit meeting the requirements for the separate filter and silencer items may be provided.

2.05 ENGINE COOLING SYSTEM: A complete integral water cooling system with all associated piping , valves and other accessories as specified below, factory piped suitable for field connection to the existing cooling water pipe, shall be provided for each engine. The limit of the cooling water piping to be furnished by the MANUFACTURER shall be the edge of the engine skid.

A. General Description: The Engine shall be designed to use the existing once-through raw water cooling system. The cooling water source is the canal water. The engine driven jacket water pump shall force water through the engine cooling passages, the heat exchanger, expansion tank, and back to the pump. The pump shall be the MANUFACTURER’S standard centrifugal type pump properly sized for the intended purpose.

B. Heat Exchanger: An engine package mounted, single wall, dual circuit type, frame plate type cooling water heat exchanger shall be furnished. Shell and tube type heat exchangers are not acceptable. The heat exchanger shall be ASME rated, with a design pressure of 150 PSIG, and sized to maintain safe engine operation at full load in a maximum ambient temperature of 125 degrees F and with a cooling water supply of 30 GPM at 90 Degrees F, maximum of 25 PSI. The exchanger shall be constructed and suitable for use with facility furnished reuse cooling water supply. The exchanger’s design and construction shall also allow for future adjustment in cooling water supply system parameters by the field removal or addition of exchanger plates without having to remove the entire exchanger from the engine mounting.

The heat exchanger shall be complete dual type, single wall and gasket design. Heat exchanger plate material shall be 316 stainless steel. The heat exchanger shall as manufactured by Alfa Laval Thermal, Inc., or approved equal. The heat exchanger and associated accessories shall be mounted within the engine skid.

The heat exchanger supply shall include a 24V DC actuated cooling water supply inlet solenoid valve to automatically open any time the engine is operated and to close any time the engine is shut off as controlled and operated by the engine controls. Furnish and install within the engine skid, cooling water supply Y-strainer, a manual isolation shutoff valve for the cooling water inlet supply, a manual isolation valve for the cooling water return, and a manual shutoff valve for purposes of solenoid valve bypass in the event of solenoid valve failure. The Y- strainer shall be equipped with a gate type blow down valve which shall be connected to the existing nearby equipment or floor drain. The cooling water supply strainer, supply and return manual isolation valves, solenoid valve, manual bypass valve, and cooling water flexible connectors shall be


coordinated with the existing piping and shall be designed to minimize cooling system restriction with the cooling water supply system. The engine-skid mounted cooling water piping and valves required to be furnished by the MANUFACTURER shall conform to the following requirements.

C. Pipe & Fittings: All piping shall comply with ASTM A53 steel pipe. Pipes smaller than 2 inch. in diameter shall be schedule 80. Pipes of 2 inch. in diameter or larger shall be schedule 40.

1. Flanges and Flanged Fittings: Flanges shall comply with ASTM A234, Grade WPB or WPC, Class 150 or ASME B16.11, 3000 lbs.

2. Threaded Fittings: Threaded fitting shall be in accordance with ASME B16.3, Class 150.

3. Valves: Valves shall be in accordance with MSS SP-80, Class 150.

D. Thermostatic Control Valve: Each engine cooling system shall include one thermostatically controlled proportioning valve of appropriate size and temperature rating installed at the bypass line. The valve shall be complete with automatic control element so that the temperature of the jacket water may be regulated.

E. Temperature and Level Sensors: Each engine shall be equipped with a coolant temperature sensor and coolant level sensor. The temperature sensors shall provide signals for coolant temperature indication and high coolant temperature alarms.

F. Expansion Tank: A jacket water expansion tank and a separate aftercooler cooling loop expansion tank shall be furnished for each engine. The tanks shall be of welded steel construction and shall be hot dipped galvanized inside and out after fabrication. The tanks shall be designed with adequate capacity for the intended application and shall be suitable for an operating temperature of 250 deg F and a working pressure of 125 psig. The tanks shall be tested and stamped in accordance with ASME BPV VIII Div 1 and registered with the National Board of Boiler and Pressure Vessel Inspectors. Each tank shall be properly fitted for vent, overflow, expansion, and make-up lines and mounted so the bottom of the tank is above the top of the engine. A brass water gage with valves shall be provided on each tank. The MANUFACTURER shall submit the details of the tanks support for approval.

2.06 LUBRICATING OIL SYSTEM:

A. General Description: The engine lubricating oil system shall include electrically operated pre-lube pump and shall be of the MANUFACTURER's standard design for the model engine proposed. The lubricating system shall be monitored and controlled by the engine’s electronic control system to insure proper lubrication for the application proposed. The system shall be readily accessible for service such as draining and refilling. Each system shall permit addition of oil and have oil-level indication. All items of equipment shall be furnished and installed as complete units ready for operation.

B. Lube Oil Sensors: Each engine shall be equipped with lube-oil temperature and pressure sensors. The temperature sensors shall provide signals for high lube-oil temperature indication and alarm. Provide low lube-oil pressure indication and alarm.

C. Lubricating Oil Filter: Each engine lubricating oil system shall include a suitable lubricating oil full-flow, duplex (80) micron filter of the throw away cartridge type. The filter medium shall be absorbent type as recommended for use with the type of oil used in the engine. The filter shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. The filter shall have the inlet and outlet connections plainly marked.

D. Each engine shall be furnished with electrically operated pre-lube pump of MANUFACTURER’s standard design. The pumps shall be fed from the station power as indicated on the drawings.

2.07 FUEL SYSTEM:


A. The MANUFACTURER shall confirm the suitability of the proposed engine with the existing elevated day tank arrangement and the fuel piping distance. Each engine shall be provided with a high pressure diesel fuel injection system suitable for direct fuel injection and precise injection timing with the specified diesel fuel. The fuel system for the engine shall conform to requirements of NFPA 30 and NFPA 37.

B. Fuel Injection Valves: Each engine shall have an individual injection valve for each cylinder, any one of which may be removed and replaced from parts in stock. Injection valves shall be of a type that does not require adjustment in service and shall be of a design allowing quick replacement by ordinary mechanics without special diesel experience.

C. Fuel Pump: Each engine shall be equipped with an engine-driven, positive displacement fuel pump.

D. Fuel Filters: Each engine shall be equipped with both primary and secondary diesel fuel filters having replaceable elements which are easily removable for inspection and replacement. Fuel oil filters shall be arranged so that diesel fuel is filtered or strained before it reaches the fuel injection pump and once again before reaching the fuel injectors. All fuel oil filters shall be conveniently located in one accessible housing. Filters shall have carbon steel housings and stainless steel elements. Both fuel oil filter assemblies shall be serviceable without breaking fuel line connections or disturbing any part of the engine. The primary filter shall be capable of filtering out particles down to 125-micron size. The secondary filter shall be capable of filtering out particles down to 25-micron size. An indicating differential pressure switch to signal a clogged filter condition shall be provided across each filter.

E. Bypass Valve: A safety bypass valve shall be provided next to the pump isolation valve to prevent the buildup of excessive pressure if the discharge line or fuel pump filter becomes clogged. This bypass shall protect the fuel piping from overpressure. The bypass relief line shall return the fuel to the main fuel storage tanks.

F. Shutoff Valves: The engines shall be provided with fast-acting diesel fuel supply and return shutoff valves with electric actuators in accordance with NFPA 37 requirements. Each fuel shutoff valve shall be provided with a manual bypass ball valve. An indicating low flow switch shall be provided downstream of the fuel supply shutoff valve to signal a low flow condition. The fuel shutoff valves shall be direct-acting type solenoid valves. The valves shall be listed by Underwriters Laboratories in accordance with UL 429 and UL 1002. Solenoid valves shall be rated for continuous duty at 24 volts DC and have fully encapsulated Class H coils. The valves shall have combination NEMA 7C, 7D and 4 enclosures. The valves shall be threaded for sizes 2-inch and smaller.

2.08 STARTING SYSTEM:

A. General: The electric starting system shall consist of a 24 VDC battery starting system. The engine D.C. starting system shall be mounted separate from the engine skid. The system shall have sufficient capacity to start the engine with the pump engaged. Starting motors shall be in accordance with SAE ARP 892.

B. Battery System: A starting battery system shall be provided, one system for each engine, which includes batteries, battery charger with over-current protection, battery rack, inter-cell connectors, spacers, metering and relays as indicated on the Contract Drawings. The batteries shall be in accordance with SAE J537 and shall be a lead acid type, with sufficient capacity to provide the minimum cranking cycle consisting of no fewer than three cranking periods of up to 8 seconds per period with 8 second intervals between crank periods.

C. Battery Charger: A current limiting battery charger, conforming to UL 1236 (1994; Rev thru Mar 1999) Battery Charges for Charging Engine-Starter Batteries, shall be provided to automatically recharge the batteries. The charger shall be capable of providing both automatic float charging and equalize charging of the battery installation. The charger shall be capable of maintaining the batteries in a fully charged condition when under full load from the typical equipment described above and shall also provide a float charge to maintain the batteries in a fully charged condition


when there is no load. The charger shall be capable of carrying the load with the battery disconnected. An ammeter and voltmeter shall be provided on the charger to indicate charging rate and voltage. The charger shall include an alarm system providing indication of charger and battery status by LED displays. Separate contacts for “Low Battery Voltage” and “Battery Charger AC Failure” shall be provided. An LED shall indicate input power on. The input power to the charger shall be 120 VAC. Transient voltage filtering conforming to UL 1449 shall be provided at the 120 VAC input to protect the charger from surges caused by lightning. The charger shall conform to the following specifications:

1. Ambient conditions: 32 to 122 degrees F; Humidity 5 percent to 95 percent non-condensing

2. Input frequency: 60 Hz, ± 5 percent

3. Voltage range: 120 volt, ±10%. Input protection shall consist of a circuit breaker. A proven surge suppression device shall be included.

4. Output current: 20 amps

5. Output voltage: 24 volts nominal. The charger shall incorporate automatic current limiting with a rectangular current limit characteristic, and shall be capable of operating into a short circuit or dead battery indefinitely without damage or overheating. The charger shall be equipped with output circuit breaker.

2.09 HYDRAULIC POWER TAKE-OFF (HPTO) ASSEMBLY:

A. A power take-off and clutch assembly shall be provided for each engine. The clutch shall be an oil filled, multiple disc, self adjusting and hydraulically actuated type. Each HPTO unit shall be designed to allow the engine shaft to be engaged/disengaged by remote/automatic operation. The existing operating procedure requires the engine/pump to be started with clutch disengaged. Engaging the clutch typically occurs after engine is run for a predetermined time period and with the jacket temperature reaching a preset value as recommended by the Engine MANUFACTURER. Each Unit shall be equipped with internally mounted oil pump, oil cooler and hydraulic control valve with 24 Volt DC solenoid for remote operation and shall be equipped with manual override to enable manual operation of the clutch. The torque rating shall be coordinated with the engine performance characteristics.

B. Each unit shall be furnished with the necessary field instrument devices for remote monitoring and control of the following parameters.

1. Clutch Hydraulic Oil Temperature Sensors (RTD-100 Ohm Platinum

2. Clutch Hydraulic Oil Pressure (pressure transmitter)

3. Clutch Hydraulic Oil Level Switch (Low and High level)

4. Clutch Engaged/Disengaged Status Sensor

C. The HPTO and clutch assembly shall be model HPTO 244 as manufactured by Twin Disc or approved equal.

2.10 DISC BRAKE ASSEMBLY:

A. Provide pneumatically operated disc brake assembly to restrain the engine from forward rotation during the siphoning operation and when the Engine is not running. The brake assembly shall be mounted between the PTO output shaft and the drive shaft coupling assembly. Note that brake assembly is engaged when the engine is not in operation and the disengaging the brake occurs prior to the engaging the clutch assembly. The brake assembly shall be designed for the existing compressed air system available to each engine and shall be provided with integral 24V DC solenoid operated control valve and other accessories to allow for remote operation.


2.11 DRIVE SHAFT AND COUPLING ASSEMBLY:

A. The engine shall be equipped with appropriately sized drive shaft and flexible coupling. The drive shaft shall be a single section out of solid, forged and heat treated alloy steel conforming to SAE 4140 or DISTRICT approved equal. The drive shaft shall also comply with the ANSI B106.1M Standrads.

B. Flexible Coupling: The drive shaft shall be coupled to the existing right-angle gear input shaft with a flexible type coupling of a non-lubricated design. The coupling shall be based on a minimum 2.5 service factor. The maximum potential unbalance allowable shall be per the requirements of API 671. The coupling shall have a drop-out center ring, such that the coupling can be serviced without disturbing the hubs and/or the equipment. Material of construction shall be 303 or 316 stainless steel. The coupling shall be capable of accommodating the following shaft misalignments:

1. Angular: 4 degrees

2. Parallel: 70 mils

3. Axial: 250 mils

C. The coupling shall be Type WA 21 as manufactured by Rexnord/Falk products.

2.12 GUARDS AND COVERS: In accordance with CFR 1910.212, General Requirements for all Machines (OSHA), machine guards and/or covers shall be provided wherever necessary to protect the operators from accidental contact with moving parts. Guards and covers shall be sheet steel or expanded metal and shall be removable

2.13 SPARE PARTS: The following minimum spare parts shall be furnished if applicable to the type of engine proposed:

A. (4) Refills for all lubricating oil filters for each engine

B. (4) Refills for all fuel oil filters for each main engine.

C. (4) Refills for inlet air filter for each engine

D. Tools: One complete set of diesel engine and engine accessory maintenance tools shall be provided, including engine timing tools, socket sets and combination end wrenches and miscellaneous tools, for each size nut and bolt and each engine auxiliary item. Tools shall be provided in a pad-lockable, all-metal chest with casters and with multiple drawers on nylon wheeled captive guides. Tools too large to fit in the chest shall be tagged and boxed separately. Maintenance tools shall be chrome plated high strength steel, as manufactured by Proto, Snap-On, or equal.

2.14 INSTRUMENTATION & CONTROL:

A. Engine Control Module (ECM):

The engine mounted ECM shall provide the following data in SAE-J1939 protocol to be linked to the PLC installed in the Engine Control Panel (furnished under a separate contract) through a converter.

1. Diagnostic Codes

2. Percent Load

3. Oil Pressure

4. Battery Voltage

5. Boost Pressure


6. Coolant Temperature

7. Fuel Pressure

8. Fuel Temperature

9. Fuel Rate

10. Engine Speed

11. Inlet Manifold Temperature

B. Engine Instrumentation Panel:

Provide standard factory instrumentation panel mounted on engine. This panel shall be used for manual mode of operation of the engine. The monitoring and control features shall include:

1. Engine Oil Pressure Gage

2. Engine Oil Temperature Gage

3. Jacket Water Inlet Temperature Gage

4. Jacket Water Outlet Temperature Gage

5. Hour-meter

6. Emergency Stop Button

7. Digital Tachometer

8. Keyed On/Off Switch

9. Speed Control Switch

10. Fuel Pressure Gage

11. Gear Oil Pressure Gage

12. Gear Oil Temperature Gage

13. Hydraulic Clutch Oil Temperature

C. Vibration Isolation:

All electronic apparatus (engine control module, transmitters, etc.) mounted on the engine shall incorporate resilient vibration isolators designed specifically for the protection of electronic devices.

2.15 NAMEPLATES: The engine shall have the MANUFACTURER’s name, address, type or style, model, and serial number on a plate secured to the equipment.

2.16 PROTECTIVE COATINGS: Unless otherwise approved, the engines and engine support shall be cleaned, primed and finish coated in accordance with the MANUFACTURER's standard practice, at the MANUFACTURER's plant. Surfaces shall preferably be finished by spray method. The exhaust silencer and piping and all other piping and equipment furnished under this Contract shall be cleaned and finish coated in accordance with SECTION 09900-Protective Coatings. Any painted surface damaged by the MANUFACTURER'S operations shall be cleaned, primed and finish coated with the same paint as existing.

PART 3 - EXECUTION

3.01 FACTORY TESTS:


Each diesel engine including the spare engine shall be given the MANUFACTURER’s standard factory test and quality control checks to ensure the proper operation of the engine and its auxiliaries. Test data shall be recorded on the MANUFACTURER's standard test data sheets. Certified records of all test data including adjustments, results, graphs, diagrams showing engine and accessory test arrangement, with complete narrative of test procedure shall be submitted to the DISTRICT as soon as practical after completion of the tests.

3.02 EQUIPMENT STORAGE:

The MANUFACTURER shall be responsible for the storage of all engines and related sub assemblies until they are shipped to the Project site subsequent to the receipt of notice from the DISTRICT that construction contractor is ready to receive the equipment at the site or at the location designated by the DISTRICT for the spare engine.

All equipment placed in storage shall be stored indoors, protected from the weather, humidity and temperature variations, dirt, dust and other contaminants. The MANUFACTURER shall be responsible to locate and procure all off-site storage that may be required till the engines are shipped to the Project site. All on-site and off-site storage provisions are subject to approval of the DISTRICT.

3.03 SHIPMENT:

The engines shall be mounted on skids of ample size to facilitate unloading and handling at the destination. 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.

When engines and auxiliaries are delivered to the project site (Pumping station S-331) or to the other designated location for the spare engine, the DISTRICT or its construction contractor will be responsible for unloading the equipment and place them securely. The MANUFACTURER shall provide an erection engineer to witness the construction contractor in the unloading and storage process.

3.04 FIELD SERVICES:

A. The MANUFACTURER shall provide field services for the entire duration of installation, field testing, start-up, commissioning and training of equipment provided under this Contract.

The MANUFACTURER shall be prepared to make the required specialists available at the project site within fifteen calendar days from the date notification by the DISTRICT that the services are required and these services shall be coordinated with the DISTRICT construction contractor.

B. Services during Installation, Start-Up and Testing:

Installation of the equipment will be performed by the DISTRICT’s construction contractor in accordance with the MANUFACTURER’s specific instructions. The MANUFACTURER shall furnish installation specialists to supervise the DISTRICT’s construction contractor in the installation of the equipment furnished under this Section.

The MANUFACTURER shall provide the services of an experienced erection engineer(s) to provide technical assistance and furnish written acceptance to the DISTRICT that the installation of each key element of the diesel engine has been installed in accordance with MANUFACTURER’s requirements and the MANUFACTURER accepts contractor’s work as satisfying MANUFACTURER’s tolerances for his equipment. The MANUFACTURER shall be required to furnish certificates, attesting that the installation process has been performed satisfactorily.

Field Testing and commissioning of the equipment furnished under this Section will be performed in accordance with the applicable requirements of Section 01660 (furnished in this Contract for information only) by the DISTRICT’s construction contractor. The MANUFACTURER shall


provide required services to the DISTRICT’s construction contractor in testing and commissioning of the engines.

Field acceptance tests shall include field operational test. All tests will be performed only after completion of the test work described in paragraph. Field acceptance test shall include but not limited to the following specific tests for each engine.

• Engine exhaust emissions testing:

• Sound level test :

C. Services For Training:

The Manufacturer shall provide necessary services during the training on the operation and maintenance of the engines in accordance with the requirements of Section 01664. The services for training shall be coordinated with the DISTRICT construction contractor and the duration shall consist of the following:

Training, Duration:

Theory 8 Hrs

Operation 12 Hrs

Troubleshooting 8 Hrs

Maintenance 16 Hrs

END OF SECTION


SECTION 11216 CONVERSION OF PUMP PACKED SEAL TO MECHANICAL SPLIT-FACE SEAL

PART 1 - GENERAL

1.01 SUMMARY:

A. Contractor shall provide all labor, materials and equipment necessary to inspect, recondition and replace the existing S-331 Pump Station main pumps’ packed seals with split-face mechanical seals 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. Pump stuffing box and pump shaft

2. Remove and replace the following pump components:

a. Pump packing; replace with a split-case mechanical seal, active throat bushing and all necessary appurtenances.

B. Related Work Specified Elsewhere:

1. None.

1.02 SYSTEM DESCRIPTION:

A. Main Pumps No. 1, 2 and 3 are Allis-Chalmers 108-inch, axial-flow pumps, Model 15000, manufactured in May 1979. Pump flow capacity is 387 cubic feet per second (cfs) at a design head of 3 feet per pump. Nominal pump rotational speed is 100 rpm.

B. The manufacturer of the existing packed stuffing box is unknown. The pump shaft is 8-inches in diameter. The Contractor shall attempt to obtain manufacturer’s shop drawings or, if necessary, measurements of actual components. All dimensions and data shall be field verified by Contractor.

C. The station operates in both pumping and siphoning modes at various times of the year.

D. The vacuum priming system is utilized to prime the main pumps.

1.03 PERFORMANCE REQUIREMENTS: The new split-face mechanical seals must be hydraulically balanced and capable of handling from 25 Hg vacuum to 400 psi PV (pressure/velocity) sensitive. All components shall be split requiring no disassembly of the pump for installation. Upon inspection of the stuffing box and pump shaft by the Contractor and mechanical seal manufacturer technical representative, the Contractor shall perform the necessary rehabilitation to the stuffing box and pump shaft such that the installation of the new mechanical seal assemblies will perform successfully and as designed by the manufacturer. No new piped sources of flush water will be constructed to accommodate the new mechanical seal. Seal manufacturer shall furnish the seal water requirements (gpm and pressure), if any, and new flow controller.

PART 2 - PRODUCTS

2.01 SPLIT MECHANICAL SEAL: Chesterton 442 or Crane 37FS, RSC (reaction bonded silicon carbide) faces, ball and socket type o-rings (no glue is acceptable), universal design with adjustable bolting tabs, constructed with two flush/by-pass ports tapped into the gland. The rotary holder shall be held together with two set screws as well as three set screws that set to the shaft/sleeve to assure that no axial slippage is allowed. The set screws to the shaft shall have o-rings installed to eliminate leakage. All hardware, rotary holder and gland shall be 316 stainless steel.


2.02 ACTIVE THROAT BUSHING: EnviroSeal SpiralTrac, Version D, Type A, manufactured of STR material for environmental control of temperature, pressure and any fluids inside the stuffing box.

2.03 SPARE SEAL REPAIR KIT: One (1) manufacturer-supplied spare seal repair kit.

PART 3 - EXECUTION

3.01 GENERAL:

A. Remove, as a minimum, the main pump stuffing box.

B. Inspect pump shaft and stuffing box for cleanliness and wear. Replace worn parts and clean stuffing box as necessary. Inspect all parts and complete as-found report.

C. If, after inspection, the pump shaft has significant wear as determined by seal manufacturer such that the new mechanical seal cannot be properly function, using the pump shaft as template, fabricate and machine new, stainless steel shaft.

D. Remove, clean, inspect, blast, and coat the existing stuffing boxes’ exterior with a water resistant epoxy.

E. The Contractor shall follow API Plan 13 (suction recirculation) for seal flush.

F. Make additional modifications as recommended by mechanical seal manufacturer to ensure adequate installation of new mechanical seal.

G. Prior to start-up the Contractor must ensure air is vented from the seal area.

END OF SECTION