74 PUMPING EQUIPMENT AND CONTROLS
74-1 General
74-1.01 General
74-1.01A Summary
Section 74 -1 includes general specifications for installing pumping equipment and the control systems .
74-1.01B Definitions
Reserved
74-1.01C Submittals
74-1.01C(1) General
If you use the drainage pumps to maintain total pumping capacity before Contract acceptance, submit:
1.Shop drawings for the drainage inlet bulkhead and safeguards
2.Maintenance work plan
74-1.01C(2) Shop Drawings
Plans and detail drawings may be 22 by 34 inches. Submit s hop drawings for the pumping equipment including :
1.System layout
2.Piping connections
3.Appurtenances
4.Other materials required for the equipment installation
5.Mounting details and anchorage details Submit s hop drawings for the electrical equipmen t including :
1.Electrical equipment schematics
2.Control diagrams
3.Wiring diagrams
4.Conductor numbers for control and power conductors Do not use project plan reproductions or the manufacturer's standard printed data for electrical layout drawings. Submit shop drawings for the installation of drainage pump equipment and pumping plant electrical equipment after product data submittals are authorized. If the drainage pump and pumping plant electrical equipment require changes to the pump plan t metal work or other construction details, submit revised shop drawings.
74-1.01C(3) Product Data
Submit at least 5 copies of product data. Each copy must be bound together and include an index stating equipment names, manufacturers, and model numbers. T wo copies will be returned. Product data must include:
1.Catalog cuts including: 1.1. Manufacturer's name 1.2. Catalog or part number 1.3. Size 1.4. Capacity 1.5. Electrical ratings 1.6. Finish 1.7. Maintenance and adjustment requirements 1.8. Identificat ion symbols described 1.9. Installation instructions
2.Performance data SECTION 74 PUMPING EQUIPMENT AND CONTROLS
3.Installation instructions
74-1.01C(4) Samples
The Engineer may request material samples of submitted equipment.
74-1.01C(5) Work Plans
74-1.01C(5)(a) General
Reserved
74-1.01C(5)(b) Performance Testing Plan
Submit a work plan for performance testing of pumping plant equipment. The work plan must include methods for:
1.Blocking pipes at their entrance point into the storage box
2.Removing all debris from the pumping p lant, storage box, debris sump and pump sump before testing
3.Locating and installing bulkheads in the storage boxes, if used
4.Performing an o perational test, including pump controller operation
5.Supplying water
6.Disposing of w ater
74-1.01C(5)(c) Maintenance Plan
Submit a work plan for maintaining the existing pumping plant 's total pumping capacity and maintaining the pumping plant as specified in section 74 -1.03E. The work plan must include:
1.Pumping plant maintenance procedures and schedule.
2.Alternatives for maintaining t otal pumping capacity a s specified in section 74 -1.03E.
3.Description of the p roposed pumping equipment. If using alternative 2 or 3 specified in section 74 - 1.03E, include auxiliary pump curves, equipment ratings, quantity, and power supply.
4.Method for water disposal.
74-1.01C(6) Maintenance and Operation Manual
Submit a maintenance and operations manual before completion of the work. Submit 1 copy of PDF files on a CD or DVD and 2 copies in print format in 3 -ring binder s with tabbed dividers. The manual must include all authorize d action submittals for drainage pump equipment and pumping plant electrical equipment. Organize each binder as follows:
1.Index
2.Part lists
3.Operating instructions
4.Maintenance instructio ns
5.Wiring schematics, with control and power conductor numbers identified
6.Certified pump curves Incomplete or inadequate documents are returned for correction and resubmittal. Submit all paperwork delivered with the pumping plant equipment to the En gineer.
74-1.01D Quality Assurance
74-1.01D(1) General
Notify the Engineer at least 10 days before testing. The pump plant must be complete before testing is performed. Furnish all water and electrical energy necessary for testing. If authorized, you may use the pumping plant discharge system.
74-1.01D(2) Quality Control
74-1.01D(2)(a) General
Reserved SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-1.01D(2)(b) Operational Tests
Perform the operational tests in the Engineer's presence. The Engineer verifies the pump nameplates before testing. Fill the pump sump and storage boxes with water. Fill boxes as required until the operational tests and performance tests are authorized . If authorized, you may add bulkheads in the storage boxes. Perform operational tests of the pumping pl ant to demonstrate:
1.Proper rotation of each pump
2.Manual operation of the pumps separately and combined
3.Automatic operation of the pumps separately and combined
74-1.01D(2)(c) Performance Tests
After acceptance of the operational tests, the Engin eer will run performance tests on the installed pumping plant equipment under section 74 -1.01C(5)(b). Performance tests include two 5 -minute tests for each pump. Performance tests must show that each installed drainage pump complies with at least (1) 97 pe rcent of the factory certified performance curve and (2) the design pump rates shown. Each pump must not load its motor more than the actual full load nameplate amperage, regardless of head. The motor service factor will not be applied. Remove bulkheads an d blocking from pipes after performance testing is complete.
74-1.01D(2)(d) Drainage Pump Final Inspection
If you use the drainage pumps installed under the Contract to maintain the total pumping capacity for the pumping plant drainage area before Contrac t acceptance, remove and disassemble the pumps after your final use of the pumps. Remove and disassemble the pumps before Contract acceptance. The Engineer performs a final inspection of the pumps. Worn, damaged, or otherwise unsatisfactory parts must be r eplaced. Assemble and reinstall the pumps. Test the drainage pumps used before Contract acceptance under section 74 -1.01C(5)(b) after the Engineer's final inspection and before Contract acceptance.
74-1.02 Materials
74-1.02A General
Anchorages must comply with the specifications for concrete anchorage devices in section 75 -3.02C.
74-1.02B Delivery, Storage, and Handling
Deliver products to the job site in an undamaged condition in the manufacturer's original sealed container or other packaging syste m. Packaging must be complete with labels and instructions for handling, storing, unpacking, protecting, and installing. Store and handle products (1) under the manufacturer's written instructions and (2) such that you prevent damage, deterioration, or los s, and maintain warrantee requirements.
74-1.03 Construction
74-1.03A General
Reserved
74-1.03B Painting
Painting metal work must comply with section 59. Paint uncoated drainage pump equipment, including metal work, as machinery under section 59 - 2.01C(4 ). Paint all wood surfaces under section 78 -4.02 before installation . SECTION 74 PUMPING EQUIPMENT AND CONTROLS Paint the pump number on each drainage pump motor and on each discharge pipe 5 feet above every landing. The n umbers must be stenciled and at least 1 -1/2 inches tall. Paint an arrow show ing the direction of the drainage pump rotation on each discharge pipe 4 -1/2 feet above every landing. The arrows must be stenciled and at least 6 inches long. Use 2 applications of commercial -quality white gloss enamel. Paint surfaces before they become unreachable because of assembly operations. Painting must not impair legibility, life expectancy, or function of the following items:
1.Brass surfaces
2.Nameplates
3.Warning plates
4.Push buttons
5.Operating handles
6.Electrical cover plates
7.Plastic parts
8.Locks Repair exposed nongalvanized threads or damaged galvanizing under section 75 -1.02B. Clean, prime, and touch up damaged areas of painted surfaces. Use the same type of primer, paint, and color as the damaged finish. Do not use cold galvanizing aerosol cans for repair or touch -up work.
74-1.03C Care and Cleaning
Do not install pumping plant equipment until the structural portion of the pump sump is substantially complete. You may install anchors and embedded equipment whenever required by the structural work. Protect the installed equipment from damage. Clean equipment, enclosures, galvanized and noncorrodible metal surfaces, and wood surfaces in the pumping plant after installation under section 59 -1.03D. Remove debris from the pump house, pump sump, storage boxes, and premises at Contract acceptance.
74-1.03D Maintenance Instructions
Supply an 11 -by-17 inch fused -laminate copy of:
1.Maintenance instructions in a galvanized sheet -metal frame. Install the frame on an i nterior pump house wall.
2.Control system schematic diagram. Install the diagram on the inside of a motor control center door.
74-1.03E Total Pumping Capacity and Maintenance Requirements
The Department will not issue relief from maintenance and protect ion until Contract acceptance. For existing pumping plants:
1.Stage removal activities such that the total pumping capacity is maintained
2.Provide pumping plant maintenance Upon completion of pumping plants:
1.Maintain total pumping capacity
2.Provid e pumping plant maintenance Furnish electrical energy necessary for maintaining the total pumping capacity and maintenance requirements. Pumping plant maintenance must include:
1.Removing dirt and debris from the storage boxes, entrance bay, pump sump an d drainage inlets SECTION 74 PUMPING EQUIPMENT AND CONTROLS
2.Performing adjustments and repairs for proper operation of drainage pump equipment and pumping plant electrical equipment Keep a pump house logbook of pumping plant maintenance activities. Include the maintenance dates, work performed , and the name of the employee doing the work. Maintain the total pumping capacity at the corresponding dynamic head shown. Use one of the following alternatives to maintain the total pumping capacity:
1.Stage activities such that the entire pumping plant is complete and able to maintain total pumping capacity.
2.Furnish an auxiliary pumping system with a capacity equal to the total pumping capacity. This system must include a power supply, controls, temporary drainage system, sump pumps, and discharge piping.
3.Combination of the above 2 alternatives. Dispose of water. If authorized, you may use the pumping plant discharge system.
74-1.03F Use of Pumps before Contract Acceptance
Section 74 -1.03F applies if you use the drainage pumps installed under the Contract to maintain total pumping capacity before Contract acceptance. The pumping p lant must be complete. Storage boxes, screens, pump sumps, and pumping plant equipment must be authorized before use. Drainage water must be settled before entering the pumping plant. Drainage water must flow through safeguards and drainage inlet bulkheads to remove non -suspended solids. Non -suspended solids include debris, soil, sand, and gravel. Safeguards include stilling ponds, basins, check dams, and weirs. Safeguards must:
1.Intercept the drainage water and effectively stop non -suspended solids by se ttling
2.Deliver settled water to paved surfaces, pipes, or other nonerodible channels leading to the drainage inlets
3.Be maintained such that the safeguards function as intended Construct bulkheads around drainage inlets discharging to the pump sump a nd storage boxes. Drainage inlet bulkheads must consist of burlap sacks filled with pervious material.
74-1.04 Payment
Not Used
74-2 Drainage Pumping Equipment
74-2.01 General
74-2.01A Summary
Section 74 -2 includes specifications for installing drainag e pumping equipment .
74-2.01B Definitions
Reserved
74-2.01C Submittals
74-2.01C(1) General
Reserved
74-2.01C(2) Product Data
Submit product data f or the following items:
1.Drainage pumps
2.Flexible expansion couplings
3.Wall louvers
4.Flap valves SECTION 74 PUMPING EQUIPMENT AND CONTROLS
5.Pressure gauges
6.Pump house doors The d rainage pump data must include:
1.Pump components
2.Representative pump curve showing the motor does not develop more than 95 percent of its nameplate horsepower anywhere on the curve
3.Hp, kVA, kW, power factor, and voltage
4.Starting and running currents
5.Thermal and magnetic trip settings
6.Starter overloads current setting
7.Motor nameplate data , including: 7.1. Full load speed 7.2. Full load current 7.3. Voltage 7.4. Locked rotor kVA per rated horsepower or code letter
74-2.01C(3) Certificates of Compliance
Submit certificates of compliance for factory certified impeller balancing and factory certified drainage pump tests. Certification documents must be in US customary units. Submit the factory original hard copy and 2 copies as PDF files on 2 CDs , DVDs , or another authorized data-storage device . The Department will not accept a facsimile copy. Notify the Engineer of the submittal. Include in the notification the date and contents of the submittal. Factory -certified test documents for each drainage pump must include:
1.Generated pump curve from the cutoff head to the minimum dyna mic head shown. Show on the pump curve: 1.1. Identified test points used to generate the pump curve 1.2. Plot of the design pump rates and dynamic heads shown on the pump curve 1.3. Identified and plotted test point horsepower and efficiencies on the pump curve
2.Data that confirms the pump develops from 97 to 100 percent of the motor nameplate power at the point the pump requires maximum power .
3.Motor rpm .
4.Impeller final diameter .
74-2.01D Quality Assurance
74-2.01D(1) General
Reserved
74-2.01D(2) Regulatory Requirements
Drainage pumps must be factory certified under ANSI/HI 14.6. Each pump certification must be for the actual motor, pump, and trimmed impeller combination delivered to the job site. The im peller balancing must be factory certi fied under ISO 1940 -1, ISO Balance Quality Grade G6.3, at the supplied motor rpm.
74-2.02 Materials
74-2.02A General
Reserved
74-2.02B Drainage Pumps and Pumping Apparatus
74-2.02B(1) General
Reserved SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-2.02B(2) Drainage Pump
Drainage pumps must be submersible, end -suction, single -stage, close -coupled, overhung -impeller, centrifugal wastewater pumps complying with ANSI/HI 1.1 -1.2 and ANSI/HI 1.3. Pumps must be assembled and tested at the factory. Do not use a base elbow mounted pump. Drainage pumps must be coated with the manufacturer's standard finish for the intended use. Drainage pumps must be the rpm and voltage shown and comply with the design pump rates and dynamic heads shown. Drainage pumps must have cast iron:
1.Casings
2.Brackets
3.Volutes with open inlet
4.Horizontal pump discharges Drainage pumps must have a base support engineered to allow design flow into the volute and support the assembled weight of the drainage pump. Base support legs must be bolted to the floor. Drainage pumps must have (1) replaceable bronze wear rings on the impeller and casing, and (2) non - magnetic stainless steel external nuts and bolts. Drainage pump impellers must be:
1.Dynamically balanced.
2.Made from ductile iron or bronze.
3.Nonclog type, open or semi -open design for sludge, and able to handle solids up to 3 inches.
4.Trimmed to develop from 97 to 100 percent of the motor nameplate power at the point of maximum load and still deliver at least the design pump rates and dynamic h eads shown.
5.Keyed and secured to the shaft. The i mpeller balancing must not weaken or deform the impeller. Drainage pumps must have a stainless steel shaft with factory -sealed lubricated roller bearings, tandem double -mechanical seals of tungsten carbi de or silicon carbide with an oil reservoir, and have internal moisture sensors in the oil reservoir. Motors must be a standard efficiency, NEMA code letter "A" through "G", 3 -phase NEMA Design B motor with cable assembly. The cable assembly must include a 4-conductor power cable and a 5 -conductor control cable. The motor with cable assembly must be rated for Class 1, Division 1 locations. Motors must have NEMA Class F insulation, built -in thermal protection, with lifting eyes or lugs. The cables must be li sted for Extra Hard Service for Class 1, Division 2 locations. Each cable must include an equipment grounding conductor with green or green with yellow stripe insulation. The cables must be long enough to be installed from the motor to the enclosure shown without splicing. Install cable connectors for termination in the junction box. Each drainage pump must have a motor nameplate and pump identification nameplate. Attach identical nameplates to the inside of the corresponding starter compartment door on the motor control cabinet.
74-2.02B(3) Pumping Apparatus
Flap valves must have an iron body with pipe flange frame and bronze mating surfaces. Fasteners, expansion anchors, nuts, bolts, and washers must be Type 316 stainless steel. Pressure gauges must be a compound gauge complying with ASME B40.100, Grade A, and must have:
1.4-inch liquid filled dial, with stainless steel case and cover.
2.Reset screw.
3.1/4-inch MPT bottom inlet.
4.Range from 30 inches Hg vacuum to 30 psi .
5.Gauge guard and gauge cock. The g auge guard must be a 1/2 by 1/4 inch, PVC or CPVC body, PTFE or Viton diaphragm, and rated for 0 to 250 psi. The g auge cock must be a 1/2-inch NPT brass ball valve. SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-2.02C Pump House Doors, Louvers, and Fans
74-2.02C(1) General
Fabricate pump house doors and frames under ANSI/SDI A250.8 or ANSI/NAAMM -HMMA 861. Hinges must comply with ANSI/BHMA A156.1. Locksets must comply with ANSI/BHMA A156.2. Door gasketing must comply with ANSI/BHMA A156.22. Thresholds must comply with ANSI/BH MA A156.21. Galvannealed steel sheet must be commercial steel, Type B, complying with ASTM A1008/A1008M with at least an A60 metallic coating complying with ASTM A653/A653M.
74-2.02C(2) Pump House Doors
The pump house door consists of the door, frame, and door hardware. Furnish the factory applied finish coating system for the exterior locations. The pump house doors must be at least 1 -3/4 inches thick, full flush, seamless hollow metal construction. The doors must comply with ANSI/SDI A250.4, physical endurance Level A, and the following:
1.Fabricate face sheets, vertical stiffeners, and top and bottom channels from 0.053 -inch-thick galvannealed steel sheet.
2.Fabricate the steel -stiffened core using ve rtical stiffeners that extend the full-door height. Install stiffeners not more than 6 inches apart and spot weld to both face sheets no more than 5 inches on center. Fill the spaces between the stiffeners with glass -fiber insulation or mineral -fiber insul ation.
3.Top and bottom channels must be continuous and spot welded to both face sheets. The top channel must be flush and the bottom channel must be inverted.
4.Include moisture vents in the bottom channel. The door frames must:
1.Be fabricated from 0 .067-inch-thick galvannealed steel sheet, 5 -1/2 by 2 inches in section
2.Include galvannealed steel sheet grout guards at least 0.016 inches thick
3.Have continuously welded (1) face joints and (2) miter corners that are flush and made smooth
4.Include an integral stop
5.Include a steel channel or angle stiffener head reinforcement at least 0.093 inch thick for openings wider than 48 inches Floor anchors must be welded to the bottom of jambs and mullions with at least 4 spot welds for each anchor. Ther e must be at least 3 jamb anchors on each side. Hinges must be Type A2111 or A5111, heavy weight, stainless steel pin, 5 knuckle, ball bearing, and non-removable pin with set screw. Hinge fasteners must be supplied by the hinge manufacturer. Locksets must be series 4000 bored, operational grade 1, security grade 1, with a nonhanded steel lock chassis and self -aligning trim with concealed through bolts. Locksets must be function F75 with knobs, chromium roses, and a 1/2-inch steel square corner latchbolt. Weatherstripping must have a polyurethane seal. The ov erhead door drips must have a 2 -1/2 inch projection and be full width. The d oor shoe with rain drips must be mill finished aluminum with a neoprene insert, end covers, and formed rain drip. Thresholds mus t be nominal 6 inches wide, mill alumin um with factory non slip finish and span the full width of the opening shown.
74-2.02C(3) Wall Louvers
Wall louvers must be continuous channel frame with nonvision, inverted Y blades. Wall louvers must:
1.Have a frame fabricated from 18 gauge electro -galvanized steel
2.Have dual 12 gauge security grilles with through bolted screws on the inside
3.Have a bronze insect and bird screen in a removable frame fastened on the inside
4.Be factory primed and finished with enamel or powder coated epoxy
74-2.02C(4) Fans
Reserved SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-2.02D Pipe, Joints, and Fittings
74-2.02D(1) General
Reserved
74-2.02D(2) Steel Pipe
Galvanized steel pipe must be standard weight complying with ASTM A53/A53M. Threaded fittings must be galvanized steel or galvanized malleable iron. Welded steel pipe must comply with section 70 -3, except that electrically insulated connections must not be used. Coat pipe under section 70 -3.02B(3). Steel pipe must be flanged. Flanges may be a factory threa ded or welded type. Flange dimensions must comply with ASME B16.5, Class 150. Threaded flanges must be ductile iron complying with ANSI/AWWA C115/A21.15 . Welded flanges must be steel hub slip -on type complying with ANSI/AWWA C207, Class D. Galvanize welded flange pipe sections under section 75 -1.02B. Gaskets must be a full face SBR rubber flange type complying with ASME B16.5, Class 150. Steel flange bolts, washers, and nuts must be nonmagnetic stainless steel.
74-2.02D(3) Ductile Iron Pipe
Ductile iron pi pe must comply with ANSI/AWWA C151/A21.51. Pipe and fitting joints must be a gasketed mechanical joint type complying with ANSI/AWWA C111/A21.11 . Pipe fittings must comply with ANSI/AWWA C110/A 21.10 and ASME B16.1, Class 125. Pipe and fittings must have a n asphaltic coating complying with ANSI/AWWA C151/A21.51, and an epoxy lining complying with ANSI/AWWA C116/A21.16.
74-2.02D(4) Flexible Expansion Couplings
Flexible expansion couplings must be gasketed short -sleeve type having:
1.Mild steel middle ring with pipe stop
2.2 rubber -compounded wedge -section ring gaskets
3.2 mild steel follower rings
4.Mild steel bolts to compress the gaskets Galvanize all ferrous parts after fabrication. Assemble couplings such that a permanent watertight joint is obtaine d.
74-2.02E Bracing and Hardware
Brace drainage pumps and other equipment to prev ent movement during operation. The b racing method must comply with California Seismic Hazard Zone requirements in the CBC. Slots for bolt and U -bolt holes in bracing and clips must be 2 bolt diameters wi de. The s lot holes must be parallel to the axis of the member. Install cut washers under bolt heads and nuts for slotted hole locations. Galvanize braces, frames, and other metal hardware under section 75 -1.02B. Pumping pla nt metal work must comply with section 75 -4.
74-2.02F Storage Cabinets
Storage cabinets must:
1.Be wall mounted, steel, and bolted or welded construction
2.Have double doors with a single locking handle or magnet catch, and padlock staples
3.Have 2 adj ustable shelves
4.Be from 24 to 28 inches wide, 10 to 12 inches deep, and 30 to 33 inches tall SECTION 74 PUMPING EQUIPMENT AND CONTROLS
5.Be factory primed and finish painted
74-2.03 Construction
74-2.03A General
Install pressure gauges with gauge guards and gauge cocks. Mount the gauges ver tically. Furnish specialty tools required for the assembly or adjustment of equipment. Mount the tools in the storage cabinet. Install tools too large for the cabinet on adjacent brackets.
74-2.03B Pump House Doors
Install pump house doors under ANSI/BHMA A156.115. Check door frames for square ness , alignment, twist, and plumb ness before and after installation and adjust if necessary. The t olerances are ±1/16 inch. Check the door frame as follows:
1.Squareness at the door rabbet on a line 90 degrees from the jamb perpendicular to frame head
2.Alignment at jambs on a horizontal line parallel to the plane of the wall
3.Twist at opposite face corners of jambs on parallel lines and perpendicular to the plane of the wall
4.Plumbness at jambs on a perpendicular line from head to floor Fill the space between the door frame and wall with grout. The grout slump must not exceed 4 inches. Do not deform or damage frames during grouting. Remove grout and other bonding materials from exposed surfaces of doors and frames immediately after grout work. If grout contains an antifreezing agent, field apply a bituminous coating to the backside of frames. Fit the door in the frame and shim as necessary. Install weatherstripping on the top and sides of the frame. Install a door shoe on the door. Install an overhead door drip over the door. Use weatherproof silicone sealant and adhesive as the threshold bedding sealant. Furnish a padlock for the pump house door until Contract acceptance. The Department furnishes padlocks after Contract acceptance.
74-2.04 Payment
Not Used
74-3 Pumping Plant Electrical Equipment
74-3.01 General
74-3.01A Summary
Section 74 -3 includes specificat ions for installing pumping plant electrical equipment .
74-3.01B Definitions
Reser ved
74-3.01C Submittals
74-3.01C(1) General
Submit the toll-free telephone number of the designated service organization for manufacturer's field services as an informational submittal.
74-3.01C(2) Product Data
Submit product data for:
1.Power and mete ring equipment
2.Pump control
3.Conduit
4.Conductors and cables
5.Nameplates and warning plates
6.Miscellaneous materials SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-3.01D Quality Assurance
74-3.01D(1) General
Reserved
74-3.01D(2) Regulatory Requirements
Electrical equipm ent must comply with section 86 and be NRTL certified. Materials and workmanship must comply with section 86 and the following:
1.8 CA Code of Regs § 3200 et seq.
2.19 CA Code of Regs § 1.00 et seq.
3.NFPA 820, "Standard for Fire Protection in Wastewater Treatme nt and Collection Facilities"
74-3.01D(3) Manufacturer's Field Services
At Contract acceptance, provide 12 months of full maintenance for the pump controller by qualified employees of the pump controller manufacturer's designated service organization. Ma intenance must include the manufacturer's routine preventive maintenance, adjustments for proper operation, and all required parts and supplies.
74-3.01D(4) Field Quality Control
A factory -authorized service representative must inspect, test, and adjust t he pump controller for proper installation, operation, components, and connections.
74-3.01D(5) Training
Train 6 Department personnel in the programming, connection, operation, troubleshooting, and maintenance of the pump controller. T he training must be for at least 4 hours at the job site. The training instructor must be a factory -authorized representative of the pump controller manufacturer. The training must include :
1.Books , manuals, and other training material for Department personnel
2.Equipmen t required for the pump controller training
3.Hands -on experience in programming techniques and operation
74-3.02 Materials
74-3.02A General
All magnetic coils of relays, starters, and other electrical equipment must be wound for an operating range hav ing a mean equal to the voltage applied.
74-3.02B Power and Metering Equipment
74-3.02B(1) General
Reserved
74-3.02B(2) Service Pedestal Equipment
Reserved
74-3.02B(3) Motor Control Center Equipment
Panelboards must be a factory -assembled panelboard interior with metal cover, single -phase, 3 -wire, 120/240 V(ac), and must have:
1.2-pole, 50 A main circuit breaker and molded case branch circuit breakers
2.Phase, neutral, and ground buses that are hard-drawn copper, 98 perc ent conductivity
3.Separate, isolated neutral bus
4.Ground bus bonded to the cabinet
5.Directory frame mounted on the inside of the door Current switches must be self -powered, solid state, alternating current sensing switches having the following: SECTION 74 PUMPING EQUIPMENT AND CONTROLS
1.Single -pole, normally open contact rated 1 -ampere at 240 V(ac)
2.1/2-inch-diameter through -hole
3.Low range current sensing level from 1 to 15 A
4.High-range current sensing level from 15 to 300 A Time meters must be 120 V(ac) and non -resettable from 0 to 99,999.9 hours. Selector switches must:
1.Be single -pole, 2 -position -maintained, 10 A, 120 V(ac) rotary types
2.Have contacts rated at 120 V(ac) and 35 percent power factor
3.Have an inductive pilot duty rating of: 3.1. 60 A make 3.2. 6 A break 3.3. 10 A continuous Pilot lights must be panel mounted, 120 V(ac), high -visibility LEDs with a colored plastic lens and screw cap. Control relays must be 120 V(ac), 3 -pole, double -throw general purpose relays with a clear plastic case and 11 -pin plug base wit h 10 A contacts. Control relays must include a matching barrier type, 11 -contact relay socket with 10 A contacts and screw terminals. Time delay relays must:
1.Be 120 V(ac), electronic on -delay types
2.Have double -pole, double -throw, double -break 10 A contacts, having a range from 0.6 to 60 seconds
3.Have time delays set for: 3.1. TDR1: 5 seconds 3.2. TDR2: 20 seconds Intrinsically safe relays must be:
1.Solid -state, completely self -contained, latching types
2.NRTL approved for use with Class I, Division 2 location sensors
3.120 V(ac) with single -pole, double -throw, 0.3 A contact with: 3.1. Maximum turn -on time of 5 milliseconds 3.2. Maximum output current of 100 mA at 28 V(dc) Push buttons must:
1.Be heavy duty, general purpose types
2.Have 1 normally open, momentary contact rated at 120 V(ac) and 35 percent power factor
3.Have an inductive pilot duty rating of: 3.1. 60 A make 3.2. 6 A break 3.3. 10 A continuous Terminal blocks must comply with NEMA ICS 4 and be:
1.DIN rail m ounted or attached to the enclosure
2.Rated for 30 A at 600 V(ac)
3.Made from molded plastic
4.Equipped with: 4.1. High-pressure clamp connectors 4.2. Nameplates screwed to each block or a computer printed plastic label attached with adhesive 4.3. Identified conductor numbers SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-3.02C Pump Control
74-3.02C(1) General
The automatic operation of the drainage pump must be controlled by the water level monitoring system and pump controller.
74-3.02C(2) Water Level Monitoring System
The water level monitoring system must be a trapped air level monitoring type that calculates the water depth using air pressure that is converted to an electrical signal. The system must include an air compressor, 3 -way solenoid valve, pressure transducer , polyethylene air tube, and a compression bell. The system must:
1.Operate from 0 to 32 feet of water head
2.Be accurate to ±0.1 feet for ambient conditions ranging from 0 to 200 degrees F
3.Isolate the pressure transducer during the purge cycle of the air column The air compressor must:
1.Have a 120 V(ac), ±1/20 hp shaded pole motor with integral overload protection
2.Include an aluminum piston with polytetrafluoroethylene -sleeved cylinder
3.Have a capacity of at least 0.65 cu ft/min at 50 psi
4.Be capable of initializing against a 250 psi head The solenoid valve must be a 120 V(ac), direct acting, three -way type having a NEMA Type 1 plastic body and compression connections. The pressure transducer must output a 4 to 20 -mA signal. The p olyethylene air tube must be a 0.04-inch-thick wall type complying with ASTM D1248, Class A.
74-3.02C(3) Pump Controller
The pump controller must (1) control the pumps based on the output signal of the water l evel monitoring system, (2) interface with the monitoring system, and (3) generate alarms. The controller must be 120 V(ac), solid state, industrial grade with softwar e stored in nonvolatile memory. The controller must process the 4 to 20 mA signal from th e water level monitoring system and operate the pumps as follows:
1.Alternate pumps for each lead pump operation .
2.Energize the lead pump at the water level shown .
3.Energize the lag pump at the water level shown .
4.De-energize the lead pump at the water level shown .
5.De-energize the lag pump at the water level shown .
6.Energize the lead pump first and then energize the lag pump 10 seconds later if the pump controller energizes both pumps simultaneously . The controller must output a 120 V(ac) sig nal when the high or low alarms are energized. The controller must energize the trapped air level monitoring system air compressor to purge the air system. The purge interval must be adjustable from 1 to 8 hours. The compressor run time must be adjustable from 5 to 30 seconds. The controller must have (1) an LED display with 1/2 -inch-high letters that computes to 1 decimal place and (2) use faceplate -mounted, gold contact switches for programming. Do not use software for programming control levels. The cont roller must have:
1.At least 6 output relays with 120 V(ac), 10 A rated contacts
2.LED indicators mounted on plug -in bases
3.Test push button and potentiometer for system testing System testing must bypass the pressure transducer input to allow manual adjustment of the signal. SECTION 74 PUMPING EQUIPMENT AND CONTROLS The controller must have at least 6 programmable levels each programmable from 0 to 32 feet. The controller must be capable of programming the following levels for the elevations shown:
1.High alarm
2.Low alarm
3.Lead pump on
4.Lead pump off
5.Lag pump on
6.Lag pump off The pump controller must include an internal power supply with:
1.120 V(ac) input with V(dc) and current outputs to suit the equipment
2.Panel or channel mounting capability
3.Convection cooling
4.Wiring that is completely enclosed
5.Adjustment range of at least ±5 percent
6.Operational temperature range from 32 to 120 degrees F
74-3.02D Conduit
Conduit and fittings must be Type 1 comply ing with section 86. Flexible conduit and fittings must be Type 4 comply ing with section 86.
74-3.02E Conductors and Cable
74-3.02E(1) General
Do not rewire manufacturer's stock items specified in section 74 -3.01C(2).
74-3.02E(2) Conductors
Conductors must comply with section 86, except conductors must be stranded copper and comply with the following:
1.In enclosures, install Type MTW
2.In wet, underground, or outdoor locations, install Type XHHW -2
3.For all other locations, install Type THHN
74-3.02E(3) Conductor and Cable Identification
Identify conductors by number. Use one of the following methods:
1.Clear, heat -shrinkable tubing sealed over adhesive -backed paper or cloth wrap -around markers
2.Preprinted, white, heat -shrinkable tubing
74-3.02F Nameplates and Warning Plates
74-3.02F(1) General
Nameplate and warning plates must be predrilled, multilayer, multicolor, plastic labels with mechanically engraved inscriptions. Secure plates to equipment using screws or rivets. Do not use adhesives except on the insi de face of enclosure doors. If authorized, you may secure nameplates to an adjacent surface.
74-3.02F(2) Nameplate and Warning Plate Identification
Nameplate and warning plate inscriptions must be as shown. Nameplate letters must be white, upper case Helv etica, and 1/4 inch in height. Leave at least a 3/8 -inch black background on all 4 sides. Equipment control switch nameplate letters must be white, upper case Helvetica, and 1/8 inch in height. Leave at least a 3/8 -inch black background on all 4 sides. Sec ure the nameplate to the equipment directly beneath the switch. SECTION 74 PUMPING EQUIPMENT AND CONTROLS Warning plate letters must be white, upper case Helvetica, and 1/4 inch in height. Leave at least a 3/8 - inch red background on all 4 sides.
74-3.02G Miscellaneous Materials
Enclosures must be minimum NEMA Type 1. Floor coverings must comply with ASTM D178 and be rated for at least 20,000 volts dielectric strength, when tested under ASTM D149. Floor covering must be at least 1/4 inch thick. Float switches must:
1.Be 120 V(ac) , 8 A, single pole, double throw, mechanically -activated, wide -angle types
2.Have an inert synthetic leak -proof, shockproof, and corrosion -resistant casing
3.Have a 16 -gauge, 2 -conductor, SJOW sealed cable Room lights must:
1.Be NRTL listed for damp lo cations
2.Be ceiling mounted, heavy duty, industrial type fixtures
3.Have a fiber -reinforced polymer housing with steel wireway
4.Have a hinged acrylic lens with closed -cell gasket and ABS or stainless steel latches
5.Include 2 T8 lamps with an electro nic, instant -start ballast
6.Include the manufacturer's emergency battery pack Sump lights must:
1.Be NRTL listed and labeled for Class 1, Division 2 locations
2.Be wall mounted, nonmetallic type fixtures
3.Have a fiber -reinforced polymer housing
4.Have a hinged polycarbonate or acrylic lens with nonmetallic latches
5.Have nonmetallic lampholders
6.Include 2 T8 lamps with an electronic, instant -start ballast Entry lights must be outdoor, wall -mounted metal -halide luminaire type having a die -cast fr ame with hinged door and 1 -piece front and bottom prismatic -glass lens. Indicator lights must:
1.Be UL listed for wet locations
2.Have a vapor -tight, cast -metal base with pin socket
3.Have a n impact and heat resistant colored polycarbonate threaded globe with neoprene gasket
4.Have a threaded, die -cast-aluminum guard
5.Include a twin tube, 18 W, 120 V(ac), compact fluorescent lamp with integral ballast Light switches must:
1.Be NRTL listed , specification grade
2.Have 20 A, 120/277 V(ac), silver alloy contacts
3.Be suitable for stranded conductor wiring
4.Be ivory color Duplex plug receptacles must be NEMA Type 5 -20R, specification grade, ivory color, and suitable for stranded conductor wiring. Junction and outlet boxes must comply with NEMA FB 1. Boxes must be cast iron with threaded hubs, have cast iron covers with gaskets, and be at least 4 by 4 by 1 -7/8 inches. For weatherproof device boxes, use covers with gasketed, hinged flaps. Sump light switches at remote pump station must:
1.Be single -pole, 2 -position maintained, 10 A, 120 V(ac) rotary switches
2.Have contacts rated at 120 V(ac) and 35 percent power factor SECTION 74 PUMPING EQUIPMENT AND CONTROLS
3.Have an inductive pilot duty rating of: 3.1. 60 A make 3.2. 6 A break 3.3. 10 A continuous Remote pump stations must be deadfront NEMA Type 4X enclosures having the following:
1.Hinged interior door and mounting panel on the back
2.Push buttons, duplex plug receptacle, nameplates, and sump light switch on the hinged inte rior door
3.Terminal blocks on the mounting panel
4.Hasp for a padlock Seal failure relays must be (1) compatible with the drainage pump and (2) be a factory assembled unit having 1 normally open and 1 normally closed contact, each rated at 120 V(ac) . Seal failure relays must have individual pump leak -indicator lights. Pull boxes must comply with secti on 86 . Supporting devices must be corrosion resistant. Concrete anchorage devices must be Type 316 stainless steel.
74-3.03 Construction
74-3.03A General
Do not install electrical equipment on unpainted wood panels.
74-3.03B Installation
74-3.03B(1) General
Reserved
74-3.03B(2) Conduit, Conductors, and Cable
Do not install conduits behind ladders or within 15 inches of the ladder -rung vertical ce nterline. Install flexible conduit with approximately 6 inches of slack between terminations. Flexible conduits and their fittings are considered a discontinuity and must be shunted by bonding jumpers. Install bonding jumpers inside the flexible conduit. D o not use the flexible conduit as the ground. Install conductors and cable s under section 87 and as follows :
1.Pull conductors to prevent damage to the sheath or insulation.
2.Install conductors and cables entering equipment and boxes with drip loops to prevent water reaching the current -carrying parts or other conduits.
3.Remove insulation without damaging the conductor.
4.Identify conductors by number at each termination. Feeder and branch circuit conductors that are ungrounded must have continuously color -coded insulation. Conductors no. 6 AWG or larger may use colored tape. If used, apply tape at each connection and where accessible. Ungrounded conductor color -coding must be as shown in the following table: Ungrounded Conductor Color -Coding System Color code 120/240 V(ac) -Single phase Black, blue 120/240 V(ac) -Three phase Black, orange, blue 120/208 V(ac) -Three phase Black, red, blue 480/277 V(ac) -Three phase Brown, purple, yellow
74-3.03B(3) Motor Control Center
Use concrete anchorage devices to anchor the motor control center sections to the concrete slab. Shim each section to make the motor control center level. SECTION 74 PUMPING EQUIPMENT AND CONTROLS The motor control center sections must fit through the pump house doorway or roof access opening. Any modification s required for installation must be pre -approved by the manufacturer and must not change performance. Install current switches in the starter compartments. Loop power conductors around the sensing coil multiple times.
74-3.03B(4) Panel LP
The panelboard d irectory must list the equipment controlled and the area designation. The directory must be printed using Times New Roman font and at least 12 -point font size. Place the directory in the panelboard door frame with a transparent protective cover.
74-3.03B(5) Miscellaneous Materials
Secure hangers, brackets, supports, and electrical equipment to surfaces using:
1.Concrete anchorage devices into concrete or solid masonry surfaces
2.Machine screws or bolts into metal surfaces
3.Wood screws into wood constru ction surfaces
74-3.03C Conductor Splices
Do not splice the drainage pump cables between the pumps and the enclosure shown. Conductor splices must be made only in (1) fixtures, (2) junction boxes, and (3) gutters. Splices must be made using either pressu re connectors listed by a NRTL or soldered joints made by soldering irons. Do not use open flame soldering. Insulate splices using the following sequence:
1.Apply 2 half -lapped layers of self -fusing, oil and flame -resistant, synthetic rubber tape covered by 2 half-lapped layers of pressure -sensitive, adhesive, PVC electrical tape at least 7 mils thick.
2.After taping the splice, apply an electrical insulating coating. The coating must be (1) fast drying, (2) resistant to oil, acids, alkalis, and corrosive atmospheric conditions, and (3) compatible with the tape.
74-3.04 Payment
Not Used
74-4 Booster Pump S
74-4.01 General
74-4.01A Summary
74-4.01B Definitions
Reserved
74-4.01C Submittals
74-4.01C(1) General
Reserved
74-4.01C(2) Shop Drawings
Submit shop drawings for each booster pump.
74-4.01C(3) Product Data
Submit product data for the booster pump, including the following components:
1.Pump, including pump curve and motor information
2.Valves
3.Pump controller
4.Booster pump enclosure
5.Pressure gauge SECTION 74 PUMPING EQUIPMENT AND CONTROLS
6.Appurtenances
74-4.01C(4) Closeout Submittals
Submit closeout submittals as a Maintenance and Operations Manual before completion of the work. Submit 2 copies as PDF files on CDs or DVDs. Submit 1 copy as fused -laminate prints in a 3 ring binder with tabbed dividers. Organize each manual as follows:
1.Index
2.Parts list
3.Opera ting instructions
4.Maintenance instructions
5.Pump curve
74-4.01D Quality Assurance
The requirements of section 74 -1.01D do not apply to the booster pump. Notify the Engineer 5 business days before testing the booster pump. Test the booster pump in th e Engineer's presence after connecting the booster pump to the irrigation system. The d ischarge water from testing must not cause erosion, damage to equipment or plantings, or interfere with ongoing work. The pump must not load the motor to more than the product of the nameplate (1) amperage and (2) service factor. The flow rate must not vary from the pump curve by more than 5 percent at 100 percent motor speed. Test each booster pump at the following test points:
1.Zero flow rate (cutoff head)
2.Maximum flow rate
3.Design heads shown
4.Steady -state flow for each irrigation controller station Record the following for each test point:
1.Motor rpm
2.Motor voltage
3.Motor amperage
4.Suction pressure of the pump
5.Discharge pressure of the pump After testing, run the booster pump through 3 successful, complete irrigation controller cycles. If the booster pump fails testing, adjust system components as necessary and retest.
74-4.02 Materials
74-4.02A General
The concrete for the foundation and pa d of the booster pump must be minor concrete.
74-4.02B Manufactured Units
74-4.02B(1) General
The booster pump must consist of a factory assembled and tested skid -mounted system with the following components: pump, pump controller, booster pump enclosure, manifold, inlet and outlet valves, sensors, fittings, and appurtenances. The system working pressure must be at least 150 ps i. The booster pump must be listed and labeled by a NRTL. SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-4.02B(2) Components
74-4.02B(2)a General
Reserved
74-4.02B(2)(b) Pumps
Pumps must consist of a close -coupled pump and motor. Pumps must be (1) end suction, centrifugal type with mechanical seals, (2) coated with the manufacturer's standard finish for exterior use, and (3) single or multiple stage. Booster pumps must have a horizontal or vertical configuration. For horizontal pumps:
1.Casing must be close -grained cast iron with a replaceable bronze wearing ring
2.Impeller must be (1) dynamically balanced, (2) made from bronze, and ( 3) keyed and secured to the shaft by a stainless steel washer and cap screw
3.Impeller shaft must be either steel with a bronze sleeve or stainless steel with no sleeve For vertical pumps:
1.Casing must be close -grained cast iron with replaceable stainl ess steel wearing ring
2.Motor pedestal must be close -grained cast iron
3.Impeller must be (1) dynamically balanced, (2) made from stainless steel, and (3) keyed and secured to the shaft by a stainless steel washer and cap screw
3.The impeller shaft mus t be stainless steel Motors must be standard efficiency, NEMA code letter "G" or smaller, open drip proof, and NEMA Design B.
74-4.02B(2)(c) Ball Valves
Ball valves must have a 2 -piece bronze body with full size port, chrome -plated or brass ball, and be rated for at least 400 psi.
74-4.02B(2)(d) Butterfly Valves
Butterfly valves must have a ductile iron body with molded seat liner made from EPDM or PTFE, bi - directional stainless steel stem, locking lever with extended neck, and be rated for at least 250 psi.
74-4.02B(2)(e) Pump Controller
The pump controller must consist of an enclosure, VFD, main disconnect, circuit breakers, motor starter, motor protector, and a pressure transducer. The pump controller must keep the pump r unning when the flow of water fluctuates between the changing of the irrigation controller stations. The pump controller must have a potentiometer or keypad for adjusting the motor speed. The enclosure must be a NEMA Type 12 enclosure and rated for the hor sepower, voltage, and phase shown. The ground bus must be bonded to the enclosure. The circuit breaker must be rated as shown. The following equipment must be on the front of the enclosure:
1.2-way switch for automatic mode or manual mode.
2.Main disconn ect. You may use the main breaker as the main disconnect if it is accessible on the front of the enclosure.
3.High-visibility pilot lights rated for 120 V(ac), with a colored plastic lens and screw caps. Include pilot lights for the following conditions: 3.1. Power on 3.2. Run 3.3. No flow The VFD must:
1.Be listed and labeled by a NRTL
2.Have 5 percent input impedance at the rated motor horsepower SECTION 74 PUMPING EQUIPMENT AND CONTROLS
3.Be mounted in the enclosure
4.Have a LCD screen with operator interface
5.Process the analog input si gnal from the pressure transducer and: 5.1. Determine water pressure 5.2. Set the pump motor speed 5.3. Determine "no -flow" conditions When the pressure transducer signal indicates a "no flow" condition in the manifold, the VFD must stop the pump regardle ss of demand. The VFD must have an adjustable time delay for the "no flow" condition. Upon resumption of flow in the manifold, it must reset and resume automatic mode. The VFD and the 2 -way switch must operate the booster pump as follows:
1.Automatic mode must start and stop the pump based on digital input signals from multiple irrigation controllers .
2.Manual mode must start the pump regardless of the input signal . Pressure transducer must be stainless steel, rated for at least 300 psi working pressure and send a 4 to 20 mA output signal to the VFD.
74-4.02B(2)(f) Booster Pump Enclosures
The booster pump enclosure and lid must be fabricated from stainless steel or marine grade aluminum. The lid must have a continuous hinge, gas springs or equivalent lid supports, and a hasp for padlocking. Gas springs must use their entire stroke without forcing the lid beyond its fully opened position. Side louvers must have internal bronze insect screens and be mounted on each end. The enclosure must include at least 1 thermostatically controlled exhaust fan with bronze insect screens.
74-4.02B(2)(g) Pressure Gauges
Pressure gauges must:
1.Comply with ASME B40.100, Grade B
2.Include a 2 -1/2-inch glycerin filled dial, stainless steel case and cover, reset screw, and 1 /4-inch NPT bottom inlet
3.Read from 0 to 200 psi
74-4.02B(2)(h) Appurtenances
Manifolds must be steel pipe or copper pipe. Steel pipe must comply with ASTM A53, Grade B. Copper pipe must comply with ASTM B88, Type K. The skid must be (1) either steel or aluminum channel with risers as necessary, and (2) all welded construction. Welding must comply with AWS D1.1 for steel construction or AWS D1.2 for aluminum construction. Fasteners, expansion anchors, nuts, bolts, and washers must be Type 316 sta inless steel. Nameplates must comply with section 74 -3.02F.
74-4.02B(3) Fabrication
Fabricate the booster pump as follows:
1.Install the inlet and outlet valves inside the booster pump enclosure.
2.Use threaded or flanged fittings on the pump inlet and outlet connections.
3.Fabricate th e pump so that it is removable without disassembling the manifolds.
4.Install pressure gauges in the manifolds on the suction and discharge sides of the pump.
5.Install the pressure transducer in the manifold.
6.Mount the pump controller inside the enclosure.
7.Attach the enclosure to the skid. SECTION 74 PUMPING EQUIPMENT AND CONTROLS
74-4.03 Construction
74-4.03A General
Support the connected water piping outside the enclosure. Do not use the booster pump to support the connected piping. Install a padlock after installing the booster pump. The Department furnishes a padlock at Contract acceptance. Place the maintenance and operations manual binder inside the enclosure.
74-4.03B Foundation and Pad
Pour a concrete foundation and pad where the booster pump is shown. The foundation must be at least 3 inches wider than the skid on all 4 sides. Place the pad against the foundation on the door side of the enclosure. The pad must be the same width as the foundation and at least 36 inches long. Conduit risers must be located inside the skid footprint.
74-4.03C Skid Installation
Use concrete anchorage devices to mount the booster pump skid on the foundation. Use at least 4 sets of tapered steel leveling wedges to level the skid. Use 2 wedges placed taper -to-taper at each point of support. The steel wedges must remain in place in the completed work. After suction and discharge piping has been installed and tightened in place, level the skid and tighten the concrete anchor hex nuts against the base. Fill the voids under the base with mortar complying with section 51 -1.02F. Retighten the mounting bolts after the voids have been filled.
74-4.03D Nameplates
Install nameplates under section 74 -3.02F. Install nameplates on:
1.Pump
2.Pump controller
3.Switches
4.Main disconnect
5.Circuit breakers
6.Panel lights
74-4.04 Payment
Not Used
74-5 74-10 Reserved
Source: California Standard Specifications, 2024 Edition. Pages 1059–1080 of 1,372.