Constant Speed Vertical Turbine Irrigation Pumping Station PART 1 GENERAL 1.

01 SECTION INCLUDES This section of the specification covers the furnishing and installation of a factory assembled pumping station. 1.02 DESCRIPTION The pumping station shall automatically deliver water to the turf irrigation system. It shall include vertical turbine pumps; controls, alarms, sensors, displays, valves, and other devices as specified below; and all interconnecting piping and wiring. All equipment shall be fabricated, mounted on a structural steel base, and, except for the pump assemblies, shipped as a complete unit. The station shall be as manufactured by SyncroFlo, Inc., with model number and design details as shown on the Irrigation Pumping Station Data Sheet. 1.03 REFERENCES American Society for Testing and Materials (ASTM) American National Standards Institute (ANSI) National Electric Code (NEC) Underwriters Laboratories, Inc. (UL) ETL Testing Laboratories, Inc. (ETL) Hydraulic Institute Standard (HIS) American Society of Mechanical Engineering (ASME) 1.04 STATION MANUFACTURER Any reference to a specific manufacturer or model number is for the purpose of establishing a quality or parameter for specification writing and is not to be considered proprietary. A source or item that has superior quality and capabilities may be provided with prior approval. 1.05 SUBMITTAL DATA The submittal data for the pumping station shall include, but not be limited to: pump curves technical data sheet system drawing manufacturer's U.L. and ETL authorization letters SyncroFlo Series Constant Speed Eagle CS- 1 Irrigation Pumping Station

ASME Certification certificate of liability insurance all applicable warranties list of references 1.06 QUALITY ASSURANCE All equipment under this section shall be furnished by a single supplier, who shall be solely responsible for the design and fabrication of the equipment. The supplier shall be regularly engaged in the design and fabrication of such equipment. 1.07 PROVISIONS FOR LOSS PREVENTION A. The complete pump station shall be ETL listed and labeled. The pump station control panel(s) shall be UL listed and labeled. UL listing and labeling of individual electrical components only shall not be acceptable. The station manufacturer shall maintain liability insurance coverage for no less than one million dollars ($1,000,000.00).

B.

PART 2 PRODUCTS 2.01 VERTICAL TURBINE PUMPS A. All pump impellers shall be dynamically balanced. All impellers shall be vertically adjustable by a hex nut located at the top of the pump motor. Pump shafts shall be supported by bearings above and below each impeller. Line shafts shall be supported by bearings no further than 10 feet apart for motors of 1800 rpm or less, and 5 feet apart for motors above 1800 rpm. Line shaft column sections shall be no longer than 10 feet for motors of 2200 rpm or less, and 5 feet apart for motors above 2200 rpm. All column pipe couplings shall be threaded. The diameter of all shafting shall be sized to transmit the maximum horsepower that each pump can draw. All pump shaft couplings shall have left hand threads that tighten during pump operation. Suction strainers shall be of the basket type, and have total inlet areas of at least four times those of the suction bells. Pump heads shall be surface mounted and have 125 class, 200 psig rated, discharge flanges of the same sizes as the pump check valves. The top diameters of the discharge heads shall match the diameters of the motor bases. A 1/4-inch thick neoprene gasket shall be located under each pump head. Each discharge head shall be provided with a drain for the stuffing box wastewater. No wastewater shall be permitted to run onto the skid deck. Each discharge head shall include a stuffing box. A continuous bypass line, from the stuffing box to the wet well, shall be provided on each pump. Each motor shaft shall be removable, and shall couple to the pump head shaft between the bottom of the motor and the packing gland with sufficient clearance to allow removal of the packing assembly without requiring removal of the motor. CS- 2 Irrigation Pumping Station

SyncroFlo Constant Speed-Eagle

B.

Pump bowls, and suction and discharge cases shall be cast iron with enamel lining inside. Pump discharge heads shall be fabricated steel with a complete epoxy coating, or cast iron. Each impeller, suction and discharge case bearing, intermediate bowl bearing, discharge head bearing, column bearing retainer, packing follower, packing bushing, and motor shaft hex nut shall be bronze. Column bearings shall be fluted rubber. Each pump shaft and motor shaft shall be turned, ground, and polished 416 stainless steel. Each line shaft shall be 416 stainless steel. Line shaft couplings and motor shaft couplings shall be 300 stainless steel. Column piping and couplings shall be steel. Packing material shall be graphite impregnated. Water slingers shall be rubber. Pump suction strainers shall be zinc plated.

C.

Vertical hollowshaft pump motors shall be squirrel cage induction type with WP-1 enclosures and Class F insulation. A thrust bearing, sized to carry the weight of all rotating parts plus the hydraulic thrust of the pump at shutoff shall be incorporated into each motor. All motor bearings shall be rated for at least five years of continuous operation. Pump shaft connections shall be made through a bolted coupling at the top of each motor. All motors shall be coated with the motor manufacturer's original paint only. When called for on the Irrigation Pumping Station Data Sheet, motors shall be equipped with non-reverse ratchets.

2.02 HYDRCUMULATOR TANK Provide a vertically skid mounted, HydroCumulator tank between the pump discharge valve assemblies and the main control valve. It shall be constructed and tested in accordance with ASME code for a 200 psig working pressure. It shall be certified and stamped by the national board (NB) of boiler and pressure vessel inspectors to ensure safety. Tanks without the NB stamp and ASME certification will not be acceptable due to the liability risks they involve. The tank shall contain a replaceable bladder and distribution tube of FDA approved materials. Water shall enter and exit from underneath the tank to provide no less than a 40 percent air capacity for optimum surge control. 2.03 MAIN PUMP CHECK VALVE The main pump discharge check valves shall be of the spring loaded, center guided, silent wafer type. Valve bodies shall be cast iron. Valve internals shall be bronze and stainless steel with buna-n seats. The valves shall have a compound sealing action: metal to metal, and metal to buna-n rubber. Each valve shall mount directly to its pump head's discharge flange. The valves shall be 125 class, 200 psig rated, with 300 psig rated seats. Velocities through main pump check valves shall be limited to 10 fps, and pressure drops shall be limited to 2.5 psig.

SyncroFlo Constant Speed-Eagle

CS- 3

Irrigation Pumping Station

2.04 MAIN CONTROL VALVE A hydraulically operated, pilot controlled, diaphragm-type control valve shall be provided to accurately control the interstage (upstream) pressure and the system (downstream) pressure. The main valve shall be a 125 class flanged, 200 psig rated, angle pattern. It shall be sized for a maximum pressure drop of 8 psig at station capacity. The valve seat shall be rated for at least 300 psig. The main valve body and cover shall be ASTM 48 cast iron, completely coated inside and out with electrostically applied, baked on, fused epoxy. The stationary seat, stem spool, diaphragm washer, and cover bearing shall be bronze. The cover bolts, stem, stem nuts, and spring shall be stainless steel. The diaphragm shall be nylon fiber reinforced buna-n rubber. The resilient seat shall be buna-n rubber. The valve shall be as manufactured by Watts Regulator. 2.05 MAIN CONTROL VALVE PILOT SYSTEM The following adjustable pilot devices shall be included to operate the main control valve: an opening speed control to prevent rapid increases in pressure; a pressure reducing pilot valve to maintain the proper system pressure; a back pressure sustaining pilot valve to maintain a minimum interstage pressure for proper main valve operation and to prevent pump cavitation and overload; and a surge control pilot valve to assist with main valve closure during rapid decreases in demand. Each pilot valve shall have a brass or bronze body, a stainless steel stationary seat, and a buna-n resilient seat. A check feature shall also be included to prevent reverse flow and leaks back through the main valve. The following isolation valves shall be provided with the pilot controls to permit easy setting, servicing, and troubleshooting: at each occupied inlet, outlet, and cover tapping on the main control valve body; around the surge control pilot; and around the outlet side check valve. Flow clean strainers shall be provided to filter all inbound water to the pilot system. Inlet and outlet pressure gauges shall be provided on the main valve to aid in checking and adjusting the pressure settings. The complete pilot assembly shall be constructed so that it may be removed as a complete unit for replacement, repair, or winter storage purposes. 2.06 MAIN PUMP DISCHARGE ISOLATION VALVE A pump discharge isolation valve shall be provided downstream of the check valve in the discharge spool of each main pump. Each isolation valve shall be the same size as the corresponding check valve. Each valve shall be of the butterfly type rated at no less than 200 psig working pressure. Each valve shall have a 10 position, locking, lever handle with open and closed indicators. Each valve body and handle shall be cast iron with a nickel-plated ductile iron disc, a 316 stainless steel shaft, and an EPDM rubber seat. Refer to the Irrigation Pumping Station Data Sheet for specification of lug or Victaulic type valve bodies. 2.07 STATION DISCHARGE ISOLATION VALVE When called for on the Irrigation Pumping Station Data Sheet, a station SyncroFlo Constant Speed-Eagle CS- 4 Irrigation Pumping Station

discharge isolation valve shall be provided at the station discharge connection. The discharge valve shall be the same size as the discharge manifold meter run, unless specified otherwise on the data sheet. The valve shall be of the lug body, butterfly type, rated at no less than 200 psig working pressure. The valve shall have either a 10 position locking lever handle with open and closed indications, or a handwheel as specified on the Irrigation Pumping Station Data Sheet. The valve body and handle shall be cast iron with a nickel-plated ductile iron disc, a 316 stainless steel shaft, and an EPDM rubber seat. 2.08 MISCELLANEOUS ISOLATION VALVES Isolation valves shall be provided in the discharge connection of the submersible jockey pump, in the water-side pipe to the air release valve, at each pilot assembly connection on the system relief valve, at the pressure transducer sensing line connection, at the cooling unit feed line connection, and at each drain connection except for the packing gland waste water drains. Each isolation valve shall be a full port ball valve, rated for 200 psig minimum, with a brass body, a chrome plated brass ball, and a Teflon seat. 2.09 PUMP AIR-IN CHECK VALVE A 3/4 inch swing type, 125 class, 200 psig rated, brass or bronze, check valve shall be located on each main pump discharge head. Each check valve shall be mounted vertically to release air from a main pump when it starts, and to slowly allow air to return when it stops. Each check valve shall remain closed when its pump is running. 2.10 DRAINS Drain lines shall be provided from each pump discharge head to carry off packing gland waste water; from the air-in/air-out check valve on each pump, from the exhaust port of the air release valve, and from the cooling unit outlet connection. A drain line shall be located on the discharge manifold near the pumps and another one near the discharge connection of the station. All of these drain connections shall discharge into the wet well. All drain valves shall be 1/2-inch minimum. 2.11 WASHDOWN VALVE A brass hose bib shall be provided at an inlet side tapping of the relief valve. 2.12 PRESSURE GAUGES Provide a system pressure gauge on the inlet connection of the station relief valve pilot assembly. The gauge shall be 2-1/2 inch, glycerin filled, and have an accuracy of ANSI Class B or better 2.13 PIPING AND FITTINGS CS- 5 Irrigation Pumping Station

SyncroFlo Constant Speed-Eagle

All piping 4 through 10-inch nominal size shall be Schedule 40 black steel, ASTM A120 or A53 Grade B, electric resistance welded pipe. All welded flanges shall be ANSI B16.5, 150 class, forged carbon steel, flat faced, weld-neck or slip-on type, ASTM A105 Grade B. All welded fittings shall be seamless, ASTM A234 Grade B. All grooved end fittings shall be rated for a minimum of 350 psig. All piping smaller than 4 inch shall be schedule 40, galvanized steel, ASTM A120 Grade B, continuous welded pipe. All threaded fittings shall be galvanized, malleable iron, 150 class, ASTM A126 Grade B. All pressurized tubing material shall be Impolene polymer. 2.14 SKID BASE The skid base shall be constructed with 6 inch, structural steel channel, cross members, a 3/4-inch solid steel pump mounting plate, and 3/16-inch steel diamond plate. Angle iron shall be used only to support open areas of the deck. The skid base shall completely cover the wet well. A wet well access hatch or flap shall be provided. 2.15 ELECTRICAL CONTROL PANEL ASSEMBLY A. All external or door mounted operating devices shall be dust and weatherproof. All internal components shall be mounted on a removable back panel. All wiring involving internal power and control components shall be completed within this enclosure. No external cable trays or wiring thruways shall be permitted. No water line connections shall be permitted anywhere inside the enclosure. All wiring shall be 600 VAC rated, THW or THWN, stranded copper wire installed according to National Electrical Code standards. All wiring from the control panel to the motors shall be sized according to NEC requirements based on motor full load current. A grounding cable sized to NEC requirements shall be included in the liquid-tight conduit from each motor to the control panel. No splices shall be permitted between the motor starters and the motor connection boxes, except to the submersible jockey pump motor. All control wiring carrying more than 24 volts, shall be 14 gauge with wire numbers at all termination points. The wiring to all devices outside the control panel shall be contained in metal lined, liquidtight conduit. All secondary control components shall be powered with 120 VAC or 24 VDC. Panel face indicating lights shall be transformer type using 6 volt bulbs. All control relays shall be plug in type for easy replacement. Each control relay shall be provided with an integral neon light to indicate when the relay is energized. The complete control panel assembly shall be U.L. Listed as an industrial control panel to ensure operator safety. The pumping station manufacturer's serial numbered U.L. label shall appear inside the enclosure and all applicable components used to construct the assembly shall be U.L. Listed or Recognized. CS- 6 Irrigation Pumping Station

B.

C.

D.

SyncroFlo Constant Speed-Eagle

2.16 CONTROL FEATURES A. A control power indicating light, a light to indicate when the control valve is closed to indicate no flow, and help with setting the limit switch shall be included. This light shall flash and signal an alarm if any pump is running in the automatic mode too long while the control valve is closed. A pressure start time delay for the lead pump flow start time delay for each pump with 2 jumper selectable settings shall be provided. Pressure start time delays for each lag pump with 2 jumper selectable settings and On/Off flow sequencing set points shall be provided for each pump. A minimum run time for each pump with automatic and manual time out and a stop time delay shall be provided for each pump. A non-resettable, weatherproof, elapsed run time meter for each motor with a 99999.9-hour range and a.1 hour resolution shall be provided. Double Successive automatic alternation of equal capacity pumps which prevents short cycling while limiting equal wear shall be provided. Time delayed automatic sequence shifting which ensures that all operating pumps will sequence properly when one or more of them have been disabled due to motor overload, a single blown motor fuse, or a manual shutdown shall be provided. A low system pressure shutdown alarm with an illuminated START-RUN selector switch, time delay, and manual reset shall be provided. While start mode is engaged, the low system pressure light will flash and the pressure light will flash and the alarm will not be able to shut down the pumps. A low wet well level shutdown alarm with indicating light, time delay, and manual reset. The low level alarm light shall flash to indicate when normal level is restored after a shutdown. An irregular power shutdown alarm with indicating light, shutdown time delay, automatic time delay and manual reset of the pumps, and a manual reset for the light shall be provided. The alarm light shall flash when normal power has been restored after shutdown. This alarm protects the motors from running under irregular phase or low voltage conditions. Indication of which alarm condition still exists after a reset is attempted shall be provided. CS- 7 Irrigation Pumping Station

B. C.

D. E. F. G.

H.

I.

J.

K.

SyncroFlo Constant Speed-Eagle

L.

An alarm shutdown of each pump in either the HAND or AUTO mode shall be provided.

M.

A single dry contact for remote monitoring that indicates any one of the 13 fault conditions including any alarm, a motor overload, a pump turned off, a power failure, or a controller failure shall be provided. Magnetic starters for each motor with 120 VAC coils shall be provided. Adjustable, ambient temperature compensated bimetallic, inverse time, thermal overload relays for each motor shall be provided. The overload relays shall provide phase loss and phase unbalance protection as well as U.L. class 10 overload protection. An external overload reset button for each starter shall be provided. A control power transformer with primary and secondary fusses mounted in puller equipped fuse holders shall be provided. Internal storage of critical settings to ensure they are always correct and properly coordinated shall be provided.

N O.

P. Q. R.

2.17 PROGRAMMABLE CONTROLLER Provide a programmable controller to control all functions of the station. Relays may be used for interface purposes only. The programmable controller shall include a non-volatile memory (no battery needed) that prevents loss of program or field adjustable settings during power failures; an EEPROM cartridge that allows program changes via cartridge replacement; a protected data area that retains field adjustable settings while the program cartridge is changed; POWER, RUN, ERROR, and I/O status lights; rack mounted modules with quick release latches and safe disconnecting terminal strips that permit them to be changed within 30 seconds; availability of rack mounted RS-422 or RS-232C communications modules; dry contact, 2 amp rated, outputs (Triac outputs shall not be accepted.); a dedicated fault output contact on the CPU module; and a duty-rated design for locations where electro-magnetic noise, voltage spikes, high temperature, humidity, and mechanical shock exist. 2.18 MAIN DISCONNECT When called for on the Irrigation Pumping Station Data Sheet, a main disconnect switch shall be provided. The disconnect shall have be NEMA 4 rated. Refer to the data sheet for fuse type and ratings. 2.19 MOTOR FUSES SyncroFlo Constant Speed-Eagle CS- 8 Irrigation Pumping Station

When called for on the Irrigation Pumping Station Data Sheet, motor fuses shall be provided in each motor circuit for fault protection and motor isolation. Motor fuses shall be dual element, time delay, class R rejection type. Fuses shall be provided for each motor circuit for fault protection. The fuses shall be installed in fuse holders equipped with rejection type clips. 2.20 FLOW SENSOR A flow sensor shall be located in the meter run of the discharge manifold. It shall be rated for a minimum of 200 psig, and be capable of accurately reading all velocities within the operating range of the station. 2.21 LEVEL SENSORS The wet well level probes shall be 316 stainless steel, 12 VAC conductance type. Float type or high voltage conductance type probes shall not be accepted. The probes shall be held straight with insulated guide rings. The low level alarm probe will end above the minimum submergence level for the pumps, and the reset probe will end at least one-half foot above the low level alarm probe. The level relay shall be a 120 VAC to 12 VAC, differential type level relay with a light to indicate normal high level operation. The probe holder shall be a threaded, cast iron and epoxy coated aluminum, watertight enclosure. 2.22 POWER MONITOR The main power supply in the pumping station shall be equipped with a 3-phase power monitor. It shall detect phase loss, reversal, shift, or improper sequence. It shall also detect abnormally low voltage. A voltage adjustment, normal status light, and line side fuses mounted in puller equipped fuse holders, shall be provided. 2.23 LIGHTNING ARRESTOR The main power supply in the pumping station shall be equipped with a 3 phase, 600 volt rated, watertight, silicon oxide varistor type, lightning arrestor. It shall have a current rating of no less than 100,000 amps, a sparkover voltage rating of 1000, and a clamping voltage of 2,400 volts at 20,000 amps (NEMA standard 8x20 USEC. wave). It shall be mounted inside the control panel enclosure. 2.24 ASSEMBLY All of the station components shall be mounted on the skid in a professional manner. Prefabrication shall include all work except for the installation of components that extend into the wet well. The station shall be structurally sound to prevent excessive noise during operation. No PCB, asbestos, or other environmentally unsafe materials shall be used in the construction of the station. All bolts shall be zinc plated for corrosion resistance. 2.25 FINISHES SyncroFlo Constant Speed-Eagle CS- 9 Irrigation Pumping Station

The entire station, with the exception of the control panel, motors, and the underside of the skid base, shall be sand blasted, cleaned and painted with a multipart coating system having a total dry-film thickness of not less than 6 mils. One coat of a modified alkyd, rust inhibiting, industrial enamel primer shall be applied to a dry film thickness of not less than 2 mils. Two coats of a two part, semigloss, acrylic, aliphatic, urethane, enamel finish shall be applied to a dry-film thickness of not less than 4 mils. A 1 quart can of the finish paint shall be shipped with the station for job site touch up. The underside of the skid shall be coated with an epoxy based, coal tar lining, not less than 10 mils thick. The control panel and the motors shall retain their manufacturer's original coatings. 2.26 FACTORY TESTING On completion of assembly, the pumping station shall be hydro-statically tested at not less than 300 PSIG. Before shipment, the assembled pumping station shall be completely electrically tested, including motor operation, at the appropriate line voltage. 2.27 PUMPING STATION INSTALLATION A factory-trained technician shall supervise the installation of the pumping station assembly, pumps, motors, relief valve diffuser assembly, level probes, and any other components requiring field installation. The pumping station manufacturer shall provide written instructions for the contractor to use when installing the station. All labor, equipment, and miscellaneous materials required to install the pumping station shall be provided by the contractor as specified in the appropriate section of the specification. 2.28 PUMPING STATION START UP A factory-trained technician shall supervise the start-up of the pumping station. All manufacturing or design defects shall be corrected, and adjustments made at the expense of the pumping station manufacturer. All tests shall be repeated until satisfactory results are obtained. The technician shall train the owner's representative. One 8-hour day shall be provided for start up supervision. 2.27 WARRANTY The pumps shall be guaranteed for one year from date of shipment against defective materials and workmanship; the pumping station as a whole shall be guaranteed for a period of eighteen months from date of shipment or one year from date of first use against defects in design, materials, or construction. The manufacturer shall be solely responsible for the warranty of the pumping station and all station components: pass-through warranties from the suppliers of individual components shall not be accepted. PART 3 EXECUTION SyncroFlo Constant Speed-Eagle CS- 10 Irrigation Pumping Station

3.1

INSTALLATION A. The pumping station shall be connected to mains power by the installing contractor, and all labor, materials, equipment, et al. shall be provided as given elsewhere in this specification.

3.2

NOTIFICATION OF START-UP A minimum of two weeks notice shall be given to the pumping station manufacturer prior to the scheduled start up date, and the start up date shall not be scheduled earlier than the completion of installation and electrical inspection.

SyncroFlo Constant Speed-Eagle

CS- 11

Irrigation Pumping Station