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PSDR-2020 MSD Pump Station Design Regulations 7/20/2020 Standard Pump Station 1 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 Table of Contents PLAN REVIEW SUBMITTAL REQUIREMENTS................................................ 4 SECTION 1 1.01 GENERAL ................................................................................................................... 4 1.02 PUMP STATION DESIGN REPORT ............................................................................ 4 1.03 FINAL SUBMITTAL ...................................................................................................... 6 PUMP STATION AND FORCE MAIN DESIGN CRITERIA ...............................10 SECTION 2 2.01 GENERAL ..................................................................................................................10 2.02 METHODOLOGY FOR DETERMINING DESIGN FLOWS .........................................10 2.03 PUMP SELECTION DESIGN ......................................................................................11 2.04 DETENTION CHAMBER SIZING ................................................................................13 2.05 BUOYANCY CALCULATIONS....................................................................................14 2.06 FORCE MAIN DESIGN ...............................................................................................14 STRUCTURE REQUIREMENTS ......................................................................15 SECTION 3 3.01 DESIGN CRITERIA ....................................................................................................15 3.02 WET WELL AND VALVE CHAMBER SIZING .............................................................15 3.03 CONDITION MONITORING STRUCTURE .................................................................15 3.04 JOINING CHAMBERS ................................................................................................15 3.05 ACCESS HATCHES ...................................................................................................16 3.06 COMMON WALL ACCESS OPENINGS .....................................................................16 3.07 VALVE CHAMBER FLOOR ........................................................................................17 3.08 PIPE SUPPORTS .......................................................................................................17 3.09 ENTRANCE LADDER AND STEPS ............................................................................17 3.10 DETENTION CHAMBER ............................................................................................18 3.11 CONTROLPANEL PAD ..............................................................................................18 3.12 MISCELLANEOUS ITEMS ..........................................................................................18 PIPING AND VALVES ......................................................................................19 SECTION 4 4.01 GENERAL ..................................................................................................................19 4.02 FORCE MAIN PIPE MATERIAL ..................................................................................19 4.03 FORCE MAIN REQUIREMENTS ................................................................................21 4.04 TRANSITION PIPING .................................................................................................23 4.05 PUMP DISCHARGE RISERS .....................................................................................23 4.06 ISOLATION VALVE ...................................................................................................24 4.07 CHECK VALVES ........................................................................................................25 4.08 VALVE CHAMBER DRAIN VALVE .............................................................................26 4.09 PRESSURE SENSORS ..............................................................................................27 4.10 GRAVITY LINES .........................................................................................................27 Standard Pump Station 2 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 4.11 DETENTION PIPE ......................................................................................................27 SUBMERSIBLE WASTEWATER PUMPS ........................................................28 SECTION 5 5.01 MINIMUM STANDARDS .............................................................................................28 5.02 PUMP SPECIFICATIONS ...........................................................................................28 PUMP STATION APPUTENANCES.................................................................37 SECTION 6 6.01 GUIDE BAR RAILS .....................................................................................................37 6.02 LIFTING CHAIN ..........................................................................................................37 6.03 BOLTS ........................................................................................................................37 6.04 FASTENERS ..............................................................................................................37 6.05 FLOATS AND SETTINGS ...........................................................................................37 6.06 ACCESS HATCHES ...................................................................................................38 6.07 SAFETY POST ...........................................................................................................39 6.08 LOCKING HARDWARE ..............................................................................................39 6.09 PRESSURE SENSOR UNITS ....................................................................................39 6.10 INTRINSIC BARRIERS ...............................................................................................40 6.11 MAGNETIC FLOWMETERS .......................................................................................40 ELECTRICAL ...................................................................................................43 SECTION 7 7.01 PUMP CONTROL PANEL ..........................................................................................43 7.02 THREE PHASE MOTORS ..........................................................................................46 7.03 AmerenUE 3-PHASE SUPPLY CONTROL OPTION ..................................................46 7.04 PHASE CONVERTER OPTION ..................................................................................48 7.05 STATION INTERIOR WIRING ....................................................................................49 7.06 PRESSURE SENSOR WIRING ..................................................................................50 7.07 FIELD WIRING SPECIFICATIONS .............................................................................50 7.08 CONDUIT SPECIFICATIONS .....................................................................................50 7.09 CONTROL PANEL MOUNTING .................................................................................51 ALARM SYSTEM .............................................................................................52 SECTION 8 8.01 SYSTEM REQUIREMENTS .......................................................................................52 8.02 ANTENNA ..................................................................................................................52 8.03 POLE SPECIFICATIONS ............................................................................................52 8.04 POLE SITE LOCATION ..............................................................................................52 8.05 ALARM COAXIAL CABLE ..........................................................................................53 SITE REQUIREMENTS....................................................................................54 SECTION 9 9.01 SITE AND ACCESS ROAD PAVEMENT ....................................................................54 9.02 FENCING ...................................................................................................................55 9.03 SITE MAINTENANCE .................................................................................................56 Standard Pump Station 3 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 9.04 RESTORATION ..........................................................................................................56 INSPECTION AND ACCEPTANCE REQUIREMENTS ....................................57 SECTION 10 10.01 GENERAL ..................................................................................................................57 10.02 PRE-CONSTRUCTION MEETING .............................................................................57 10.03 STAGE ONE: SHOP DRAWING REVIEW ..................................................................57 10.04 STAGE TWO: PRE-STRUCTURE INSPECTION........................................................58 10.05 STAGE THREE: FINAL STRUCTURE INSPECTION/PRE-EQUIPMENT INSTALLATION .....................................................................................................................58 10.06 STAGE FOUR: POST EQUIPMENT INSTALLATION .................................................59 10.07 STAGE FIVE: EQUIPMENT STARTUP ......................................................................59 10.08 STAGE SIX: FINAL COMPLETION INSPECTION ......................................................61 10.09 STAGE SIX A: POST-FINAL COMPLETION INSPECTION (IF REQUIRED) ..............61 10.10 STAGE SEVEN: FINAL ACCEPTANCE/DELIVERABLES ..........................................61 10.11 RE-INSPECTION OF WORK ......................................................................................62 Standard Pump Station 4 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 PLAN REVIEW SUBMITTAL REQUIREMENTS SECTION 1 1.01 GENERAL A. These requirements and specifications apply to all pump station construction projects intended to be dedicated to the District for maintenance. For District contracted projects, these standard specifications may be used by the design engineer for reference and the project specifications shall take precedence over these standard specifications. B. In addition to the requirements set forth in this document, design shall be in accordance with the latest edition of the District’s “Standard Construction Specifications”. C. The following material must be submitted to the Engineering Department for review of any proposed pump station. Material submitted to the District that does not have the required drawings and/or pump station design report data shall be returned to the design engineer with a “request for missing material.” No attempt will be made to review incomplete submittals. D. Upon completion of the review by the appropriate District personnel, the Engineering Department will forward all comments to the designing engineer. After the design engineer has reviewed the comments, a meeting may be arranged with the Engineering Department to clarify any question that may arise. 1.02 PUMP STATION DESIGN REPORT A. A pump station design report shall be in the following format: 1. Title Page a. MSD P number, or MSD Contract number b. Date c. The developer/owner d. Engineering firm preparing plans e. Engineer’s Seal by a professional engineer registered in the State of Missouri 2. Sewer System Information a. Introduction Type, location and size of development. i. Number of and range in size of lots or buildings to be ii. serviced. b. Existing Sewer System Location and type of gravity or pressure system the pump i. station will service (if applicable). Location and type of gravity or pressure system the force ii. main will discharge to. c. Future Sewer Service State whether the proposed development will be serviced by i. a single phase or if several phases will be involved. Indicate when phases are anticipated to be developed. State the number of lots each phase will encompass. ii. State whether other areas outside of the development may be iii. tributary to the pump station. Provide a drainage area map of Standard Pump Station 5 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 the entire pump station service area. 3. Pump Station and Force Main Design Calculations (see Section 2) a. Calculations verifying that the minimum pipe materials specified in Section 4 are adequate. b. Force Main Information: Size i. Material ii. Type or Class iii. Length iv. Velocity at the pump’s operating point v. Force Main Test Pressure - The value is derived from the vi. selected pump manufacturer’s performance curve. It is the maximum pump head or shut-off head, plus 50 PSI. Location of discharge (i.e. existing gravity sewer or force vii. main) 4. Storage Detention Chamber Calculations (See Section 2) a. Calculations verifying that the minimum pipe materials specified in Section 4 are adequate. b. Volume for 24-hour detention or detention volume with generator backup 5. Pump Design Summary (see Section 2) a. For each phase of the proposed development provide the following information: Average Daily Flow i. Peak Daily Flow ii. Static Head iii. Total Dynamic Head, Flow Rate in gallons per minute (GPM) iv. and efficiency at the pump’s operating point Pump Information: v. Model number vi. (a) Type (b) Horsepower (c) RPM (d) Voltage (e) Phase Average Daily Flow Cycle Times: vii. (a) Pump On (b) Pump Off Peak Daily Flow Cycle Times: viii. (a) Pump On (b) Pump Off b. Indicate what phase of development and pump is proposed to be initially installed. 6. Manufacturer’s Specifications, Performance Curves and Cut-Sheets a. The manufacturer’s specifications, performance curves and cut- sheets for the pumps and equipment shall be included in the back of the Pump Station Design Report booklet. b. The manufacturer’s cut sheets shall be marked to identify the applicable items selected. Standard Pump Station 6 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 c. Specifications and performance curves shall be included for each pump proposed by the design engineer. Pump performance curves shall indicate the pump’s Preferred Operating Range (POR) as defined by the Hydraulic Institute Standards and the manufacturer’s Acceptable Operating Range (AOR). d. The pump performance curves shall have the worst case and best case system TDH curves plotted on them. See Section 2 for plotting instructions. 1.03 FINAL SUBMITTAL A. GEOTECHNICAL REPORT 1. A geotechnical analysis of the soil conditions and foundation recommendations in the area of the pump station shall be required. A minimum of two (2) borings are required. A least one (1) of the borings shall be at the proposed location of the wet well with the second being in the area of the detention pipes. The borings shall extend a minimum of five feet (5’) below the invert of the wet well and pipes. 2. Borings along the alignment of the force main shall be required for restrained joint design. 3. Additional borings may be required by the District due to the size of the pump station or detention pipes. B. FLOOD PLAIN STUDY 1. The pump station shall be designed to remain accessible and operational during a 100-year flood. Furthermore, the station shall be protected from damage during a 100-year flood event. A flood plain study shall be completed to determine the flood elevations. C. STRUCTURAL CALCULATIONS 1. Buoyancy calculations (see Section 2) D. DESIGN DRAWINGS 1. The design drawings shall be individual 2' x 3' design plan sheets. Each sheet must indicate the District Project Number in the lower right corner and must be sealed by a professional engineer registered in the State of Missouri. 2. Cover Sheet (when submittal is separate from site improvement plans). 3. General Site Plan (1” = 50’ scale) a. All buildings and/or residences with top of foundation (TF) and basement floor (BF) elevations noted. b. All sanitary sewers and storm sewers with manholes identified. c. All streets. 4. Pump Station Site Plan (1/4” = 1’ scale) a. All grading, access roads, fencing and pavement surrounding the pump station. Provide spot elevations for proposed grading and pavement. b. Location and size of all storm and sanitary sewers. c. Location of all utility lines, including water, gas, electric, etc. running to or through the pump station property and easement. Standard Pump Station 7 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 d. Location of wet well, valve chamber, bypass portal, condition monitoring structure, incoming manhole and detention chamber. e. Location of all pump station appurtenances, such as, control panels, antenna poles, boxes, generators, transfer switches, etc. f. Details on any proposed landscaping affecting the immediate area surrounding the pump station site. g. Property information indicating pump station ingress, egress and sewer easements. h. Adjacent private or common ground property lines. i. Utility easements. 5. Force Main Plan and Profile (1” = 20’ scale horizontal and 1” = 10’ vertical) a. Identify the force main size, pipe material and overall length. b. Locate force main appurtenances, such as, discharge manhole, clean-outs, combination air/vacuum release valves and isolation valves. The distance between each structure shall be indicated. c. Locate mechanically restrained joints at angle points. Also indicate the number of restraining joints required both upstream and downstream from an angle point. d. Show the force main test pressure on each profile sheet. The pressure value shall be clearly indicated on each force main profile sheet as “FORCE MAIN TEST PRESSURE”. e. Show locations of the force main Locator Balls on both the plan and profile sheets. Refer to Section 4 for location requirements. 6. Gravity Sewer Profiles (1” = 20’ scale horizontal and 1” = 10’ vertical) a. Provide a profile of each sanitary sewer reach showing the top and flow line elevations at each manhole. Also indicate the lowest finished floor connected to this sewer system. b. Indicate the pipe size, length and slope of each reach. c. Provide a profile of each detention chamber. 7. Pump Station Structure Sheet (1/2" = 1' scale) a. The purpose of this sheet is to provide an accurate, complete, and uncluttered drawing to aid the pre-cast company to fabricate the structure. Only include measurements and information required for this goal. b. Plan and section view of the wet well and valve chamber to the scale shown above. c. In the section view, show the elevations of the: Top of structure i. Bottom of structure ii. Sanitary sewer inlet flowline iii. Pump discharge pipe iv. d. Detail of the wet well and valve chamber hatch castings with the exact location of hatches and hinges. e. One detailed joint section shall be included. The pre-cast manufacturer shall determine actual joint elevations. f. A sectional view of the chamber tie walls detailing each wall as you are facing it from the pump chamber side and from the valve chamber side. Standard Pump Station 8 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 g. On pre-cast stations, gravity lines must have their angles of entry into the structure included. Also provide a description or detail of the pipe- to-structure joint connection. h. Miscellaneous Details: Corbel i. Valve chamber side wall electric conduit entry ii. Tie wall pump cable opening iii. Tie wall valve chamber drain opening iv. 8. Pump Station Mechanical Sheet (1/2" = 1' scale) a. Plan and Section view of the wet well, valve chamber, incoming manhole, detention chamber and condition monitoring structure the scale shown above. b. In the Section view show the elevations of the: Top of structure i. Bottom of structure ii. Sanitary sewer inlet flowline iii. 12” D.I.P. detention pipe flowline iv. Pump discharge and force main flowlines v. Float elevations: vi. (a) Off Float (b) Lead Pump (c) Lag Pump (d) High Level Alarm (e) Emergency High Level Alarm c. Show the lift station piping and force main piping transition outside the structure. d. Show adjustable cradle jack valve supports. e. Miscellaneous Details: Valve chamber drain i. Wet well pipe support ii. Flow meter iii. Bypass Portal iv. 9. Electrical Plans and Details(1/2" = 1' scale) a. Plan and section view of the wet well and valve chamber to the scale shown above. required for all pump station. b. Electrical plans shall present the following: Electrical routing and equipment locations (Control panel, i. junction boxes, etc.) Conduit and wire sizes ii. One-line schematic iii. Notes referencing documents where detail information is iv. available on each of the major pieces of electrical equipment. c. Miscellaneous Details: Control panel plan and profile i. Antenna ii. Valve chamber junction boxes iii. 10. Miscellaneous Details: a. Provide a sheet that will contain details on items such as: Force main clean-outs i. Combination air/vacuum release valve chamber ii. Standard Pump Station 9 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 Force main taps iii. Fencing iv. Entrance gates v. 11. Pump Station Design Requirements a. The District will provide a computer file of the Standard Pump Station Design Requirements in AutoCAD format upon request. Modifications may be required to this sheet for specific projects. All changes to the Standard Sheet shall be noted in bold. b. Should the design engineer elect not to use the District’s Standard Sheets, all design requirements and specifications in Sections 3 through 10 of this Manual must be included on the sheets prepared by the design engineer. Standard Pump Station 10 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 PUMP STATION AND FORCE MAIN DESIGN CRITERIA SECTION 2 2.01 GENERAL A. In designing all components of the pump station and force main, consideration must be given to the potential need to expand or modify the facility to accommodate future phases of the proposed development and future development of the area tributary to the station. B. If substantial differences exist between initial development phases and ultimate proposed development, consideration may be given for initial pump installation to accommodate initial development phases only. Developer may be responsible for station upgrades as additional development phases are implemented. C. As a minimum the following items should be considered: 1. The ultimate proposed development flow should be considered in sizing the following: a. Wet well b. Valve chamber c. Detention chamber d. Pump selection e. Force main f. Electrical requirements 2. The ultimate future development of the pump station tributary area should be considered in the configuration of the detention chamber to allow for future expansion. Adequate area adjacent to the detention chamber must be provided to allow for this expansion. 2.02 METHODOLOGY FOR DETERMINING DESIGN FLOWS A. The Average Daily Flow (ADF) and Peak Daily Flow (PDF) for each phase of development should be determined. B. Average Daily Flow (ADF): 1. ADF (GPD) = F + I, where a. F = Residential Development Area Flow (FR) + Non-Residential Development Area Flow (FNR) b. I = Infiltration 2. ADF (GPM) = ADF (GPD) / 1440 (min/day) C. Peak Daily Flow (PDF): 1. PDF (GPD) = 2.5 x ADF (GPD) 2. PDF (GPM) = 2.5 x ADF (GPM) a. The use of a peaking factor of 2.5 is a variance from the MoDNR regulations due to the safety factor provided by the twenty-four hour detention requirement. D. Residential Development Area Flow (FR) 1. The average daily flow (excluding infiltration) for residential development areas (FR) shall be based on the following: a. FR = Population Equivalent Flow = Pe x 100 (gal/person/day), where Standard Pump Station 11 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 Pe = Population Equivalent = Nb x Np, where i. (a) Nb = Number of single family residences and other identified types of buildings (b) Np = Number of persons per unit = 3.7 E. Non-Residential Development Area (FNR) 1. The average daily flow (excluding infiltration) for non-residential development areas (FNR) shall be based on one of the following: a. Actual Water Use Records of like facilities. b. The current Rules of the Department of Natural Resources Division 20, Clean Water Commission, Chapter 8. Design Guides (10 CSR 20- 8.021, 1.E.1). c. Industry Standards. F. Infiltration 1. The infiltration flow amount (I) shall be determined by: a. I = Piping diameter (in.) x piping length (miles) x 200 (gal. /in. dia./mi./day) 2. The infiltration flow shall be determined for the following systems: a. Gravity system. b. Detention chamber (including detention pipe(s) and detention manifold). 3. For proposed pump station that will serve areas with existing gravity sewers, the District may require an infiltration rate greater than the 200 gal/dia/mi/day. The design engineer should contact the District prior to submittal to determine if a greater rate will be required. G. Future Development Area 1. Future residential and non-residential development of areas tributary to the pump station should be noted and a drainage area map of the pump station area should be provided. 2.03 PUMP SELECTION DESIGN A. Pumps should be selected that most closely match the pump’s Best Efficiency Point (BEP) when operating at the station’s Average Daily Flow (ADF). Pump selection should be where the system curve intersects the pump curve to the right of the pump’s BEP, but to the left of the maximum limit of the Preferred Operating Range (POR) when operating at full speed. POR shall be as defined by the Hydraulic Institute Standards and shown on the pump’s performance curve. B. The following basic principles shall govern overall pump selection in order of importance: 1. Pumps must be capable of meeting all design operating conditions. 2. Pumps should operate within the POR for the most frequent operating conditions. 3. Pumps must operate within the manufacturer’s Acceptable Operating Range (AOR) even for less frequent operating conditions such as minimum and maximum pumping rates. AOR shall be shown on the pump’s performance curve. Standard Pump Station 12 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 C. The design engineer shall select from the three approved manufacturers (see Section 5). D. Use the following equations and procedures to develop the system curve: 1. Total Dynamic Head (TDH) a. TDH (feet) = Static head plus friction losses in force main and station piping = Hs + Lf + Ls 2. Static Head (Hs) a. Worst case static head: Hsw (feet) = Eh – E1 b. Best case static head: Hsb (feet) = Eh – E2 Eh = Maximum force main elevation i. E1 = Wet well low water elevation (Pump Off) ii. E2 = Wet well absolute highest water elevation (75% iii. Detention Chamber Alarm) 3. Loss (Lf) from friction in force main a. Lf (feet) = Length x Friction Factor/100 Length = Total equivalent length of force main pipe, valves i. and fittings (feet) Friction Factor = Friction head loss (feet) per 100' pipe = ii. 0.2083 x (100/C)^1.85 x Q^1.85/d^4.8655 (Hazen and Williams) C = Hazen and Williams C-Factor (see 5 below) iii. Q = Flow rate (GPM) iv. d = Inside diameter of pipe (inches) v. 4. Loss (Ls) from friction in the station piping a. Ls (feet) = Length x Friction Factor/100’ Length = Total equivalent length of the station piping, valves i. and fittings (feet) 5. The following Hazen and Williams C-Factors shall be used for computation of friction losses: a. The worst-case system design shall be used for determining the pump operating point or Constant Speed Rating (see definition of CSR in B. below): Unlined iron or steel pipe C=100 i. All other pipe (including Plastic and lined DIP) C=120 ii. b. To check the pump motor does not overload after installation, use the best-case system design C-Factor: Plastic pipe C=150 i. All other pipe (including steel and lined DIP) C=140 ii. 6. Plot a worst case TDH curve and a best case TDH curve on a manufacturer’s pump performance curve sheet. a. The worst-case curve begins with the worst-case static head (TDH = Hsw) at Q = 0 and increases with friction losses determined by using the lower C-Factors in 5.a above. b. The best-case curve begins with the best case static head (TDH = Hsb) at Q = 0 and increases with friction losses determined by using the higher C-Factors in 5.b above. c. A minimum of four flow rates shall be used to plot each curve. E. Constant Speed Rating Standard Pump Station 13 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 1. The Constant Speed Rating (CSR) or the pump’s operating point is the point where the worst-case TDH curve and the pump manufacturer’s pump performance curves intersect. F. Pump Motor Overload Check 1. Find where the best-case TDH curve and the pump manufacturer’s pump performance curves intersect and check the pump is not in an overloaded condition. G. Cycle Times – General 1. The volume (Vr) of water required to raise the level in the wet well for the primary pump to turn on: a. Vr (gal.) = E5 x Vpf b. Elevation difference (E5) between primary Pump On elevation (E3) and Pump Off elevation (E4), i.e. E5 (feet) = E3 - E4 Volume (Vpf) of water per vertical foot in the wet well: Vpf (gal. i. /ft.) = A x 7.481 (gal. /cu.ft.) A = the inside area of the wet well (sq. ft.) ii. H. Cycle Time – ADF 1. Time (Tfa) required for volume in wet well to reach Vr (Pump On): a. Tfa (min.) = Vr / ADF (GPM) 2. Time (Tpa) required for pump to return water level to the pump off elevation (Pump Off): a. Tpa (min.) = Vr / (CSR-ADF) 3. Because the pumps alternate in a duplex station, after a pump turns off it remains off until the wet well fills (Tfa), the second pump lowers the wet well level (Tpa), and the wet well fills a second time or Toff (min.) = 2 x Tfa + Tpa. Therefore, the Total Cycle Time Tc for one pump is: a. Pump On for Tpa plus Pump Off (Toff) or Tca (min.) = 2 x (Tfa + Tpa) I. Cycle Time – PDF 1. Tfp (min.) = Vr / PDF (GPM) 2. Tpp (min.) = Vr / (CSR - PDF) 3. Tcp (min.) = 2 x (Tfp + Tpp) 2.04 DETENTION CHAMBER SIZING A. All pump stations will require detention. Standard detention volume requirements are provided below. The District, on a case-by-case basis due to site restrictions or other considerations, may reduce the amount of the detention required. Requests for variance must be submitted in writing with justification provided. 1. Storage Volume Requirements a. 150,000 GPD or Less Average Daily Flow Twenty-four-hour storage will be required for all pump i. stations with average daily flows of less than 150,000 gpd. Generators or alternate power sources will not be considered in lieu of twenty-four-hour detention chambers. b. 150,000 to 250,000 GPD Average Daily Flow For pump stations with 150,000 to 250,000 gpd flows, where i. the District determines that it is impractical to provide 24-hour Standard Pump Station 14 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 detention, only 12-hours of storage will be required, provided an approved secondary power source is also supplied. c. 250,000 GPD or More Average Daily Flow The storage requirements and secondary power requirements i. for pump stations with average daily flows greater than 250,000 gpd shall be determined on a case by case basis by the District. Where detention is not required the pump station design may require the use of a peaking factor greater than 2.5 as determined by MSD. 2. Twenty-Four Hour Storage Volume Requirements: a. The volume of the detention chambers (Vs) is: Vs (gal.) = ADF (GPD) x 1 Day = Cylindrical Volume of detention chamber pipe used. B. The detention chamber shall be sized to handle the entire storage volume requirement. The volume of the incoming gravity lines and wet well shall not be utilized in providing for the required storage volume. C. The lowest development elevation must be above the elevation of the highest point of the detention chamber plus two feet (2’). 2.05 BUOYANCY CALCULATIONS A. The buoyancy potential of the pump station structure and the detention pipe(s) shall be analyzed to ensure that floatation of the structure and detention chambers will not occur. The total weight of the structure (W t) shall be greater than the weight of the displaced water (W s). 1. Wt = W w + We + W f (or weight of detention chambers and backfill overburden) a. W w = Weight of concrete wet well b. We = Weight of earth backfill on footing c. Wf = Weight of concrete bottom slab d. Ws = Weight of displaced water e. Wt > W s 2.06 FORCE MAIN DESIGN A. At design average daily flow, a minimum cleansing velocity of two feet per second (2 fps) shall be maintained with maximum velocity not to exceed eight feet per second (8 fps). Standard Pump Station 15 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 STRUCTURE REQUIREMENTS SECTION 3 3.01 DESIGN CRITERIA A. All reinforced concrete structures shall be designed using the Load and Resistance Factor Design (LRFD). At a minimum this includes the wet well, valve chamber, condition monitoring structure and control panel pad. The structures may be either pre-cast or cast-in-place as approved by the District. 3.02 WET WELL AND VALVE CHAMBER SIZING A. The pump station wet well and valve chamber shall each be sized as determined by the design engineer and as noted on drawings. B. The top elevation shall be one inch (1”) higher than the surrounding ground elevation. 3.03 CONDITION MONITORING STRUCTURE A. A condition monitoring structure shall be provided to house the magnetic flow meter located on the force main. See Section 6 for magnetic flow meter specifications. B. The structure shall be located downstream of the valve chamber and with a minimum of seven feet (7’) and maximum of 15 feet (15’) clearance provided between the valve chamber and the structure. C. The structure shall have a minimum inside diameter of four feet (4’) and be provided with an access hatch. D. The top elevation shall be one inch (1”) higher than the surrounding ground elevation. E. When site restraints do not permit a condition monitoring structure to house the magnetic flow meter, the magnetic flow meter may be placed in the valve chamber with MSD approval. In this instance, the magnetic flow meter would need to meet Class 1 Division 1 requirements per NFPA 70 - National Electric Code. 3.04 JOINING CHAMBERS A. The valve chamber shall rest on a base slab poured integral with the wet well walls. Both chambers shall be tied together with a minimum of two (2) threaded tie bolts. The design engineer shall specify the bolt diameter and material strength. Bolts are to be eighteen inches (18") down from top of structure. For top slab thickness greater than twelve inches (12”), place the bolts down six inches (6") from bottom of top slab. B. One-half inch (½") thick six inch (6") by six inch (6") backing plates shall be used as washers on each end of the tie bolts. Both structure tops shall be at the same elevation separated by a one-inch (1") square flexible rubber mastic sealant placed along the perimeter of the valve chamber where it meets the wet well. The tie bolts and the backing plates shall be stainless steel. Standard Pump Station 16 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 C. To prevent the possibility of the valve chamber pulling the top section of the wet well off of the joint, a poured counter-weight is required to offset the mechanical lever arm tipping force. The counter-weight shall be monolithically poured at the bottom of the upper-most wet well section opposite of the valve chamber tie wall. Size and weight of the counter-weight shall be shown on the plans. 3.05 ACCESS HATCHES A. Access hatches shall be cast in the top slabs of each chamber. The hinged side of the valve and pump chamber hatches shall be located on the wall opposite from each of their respective common tie wall. B. For valve chambers requiring double hatch doors, the hinges shall be placed on the common wall and the wall opposite the common wall. C. See Section 6 for hatch and safety grating specifications. D. Access hatches shall be correspondingly sized to the chosen structure size. VALVE CHAMBER WET WELL Inside Area Hatch Size Inside Area Hatch Size 4' x 4' 30" x 48" 6' x 6' 72" x 72" 6' x 6' 48" x 72" 7’ x 7’ 84" x 84" 7' x 7' 60” x 84” 8' x 8' 84" x 84" 8' x 8' 60" x 84" 3.06 COMMON WALL ACCESS OPENINGS A. Two (2) six-inch (6") holes shall be centered in the valve chamber tie wall, twenty inches (20”) from the structure top. A four-inch (4”) rigid coupler shall be cast in the center of the wet well tie wall and centered on the valve chamber six-inch (6”) hole. After the two (2) chambers have been tied together, a four-inch (4") rigid stub shall be glued in the coupler on the valve chamber side through the six-inch (6") hole. The space between the pipe and the chamber walls shall then be filled and sealed with non-shrink grout. This opening will be used for power and control wire passage between chambers. B. A six-inch (6”) hole shall be centered at the bottom of the valve chamber floor in the tie wall. A four-inch (4") PVC coupler shall be cast in the wet well tie wall and centered with the valve chamber six-inch (6") hole. After the two (2) chambers have been tied together, two (2), four-inch (4") PVC stubs shall be glued into the coupler on each side of the tie wall. These stubs will be used for the valve chamber drain piping. C. Four three quarter inch (3/4") holes shall be placed on the side of the valve chamber sidewalls nearest the control panel, a minimum of eighteen inches (18") from the top of the structure. For a top slab thickness greater than ten inches (10"), place the holes down a minimum of eight inches (8") from the bottom of the top slab. Coordinate depth required with submitted junction boxes dimensions. A three quarter inch (3/4") rigid coupler shall be cast in each hole. Two (2) of the openings shall be used for pump power, One (1) for pump pressures, and One Standard Pump Station 17 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 (1) for intrinsically safe floats. Two (2) additional openings shall be provided for flexibility. The openings not used shall be stubbed and capped. 3.07 VALVE CHAMBER FLOOR A. The valve chamber floor shall be sloped with a three-sided invert towards the four-inch (4") drainpipe using a two-inch (2") fillet. B. Gravity pipes, detention pipes, and electrical conduit may not be run beneath the valve chamber. 3.08 PIPE SUPPORTS A. Valve Chamber piping shall be supported as follows: 1. After discharge piping and valves have been installed in the valve chamber an adjustable pipe cradle jack shall be installed under each valve and tee. Clearance between the floor and valves shall be per manufacturer recommendations, but at least a minimum of ten inches (10") between the floor and valve flanges. The supports shall be firmly bolted to the valve chamber floor. 2. A second adjustable pipe cradle jack shall be placed against the back of the discharge tee and then bolted to the common chamber tie wall to prevent piping thrust movement. The thrust jack shall be shown on the valve chamber plan drawing. B. After discharge piping and flow meter have been installed in the condition monitoring structure, an adjustable pipe cradle jack shall be installed under the flow meter. Clearance between the floor and meter shall be per manufacturer recommendations, but at least a minimum of ten inches (10”) between the floor and meter flanges. The supports shall be firmly bolted to the valve chamber floor. 3.09 ENTRANCE LADDER AND STEPS A. Wet well, valve chamber and conditioning manhole entrance access shall be installed as follows: 1. A safety ladder shall be required when the structure is greater than five feet (5’) deep. The ladder shall be constructed entirely of aluminum, with rungs that flat, slip-resistant rungs. The ladder shall be anchored into the concrete wall of the structure. Anchor bolts shall be Type 316 stainless steel expansion bolts. 2. Entrance steps may be installed when the structure is less than five feet (5’) deep. Entrance steps shall be per the District’s Standard Construction Specifications. 3. Entrance access shall not be placed in front of the incoming gravity line. 4. Entrance access shall not be located under or next to any obstructions. 5. Entrance access should provide clear-in-line unobstructed access from the top of the structure to the bottom of the structure. 6. Entrance access should be placed on the wet well and valve chamber sidewalls closest to the control panel, approximately in the center of the hatch cover. Standard Pump Station 18 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 3.10 DETENTION CHAMBER A. The detention system must be a dedicated system; neither the gravity system nor wet well may be used as part of the detention volume calculations (See Section 2). B. The detention system shall be installed below ground with a twelve inch (12”) diameter pipe (manifold) connecting the detention pipe(s) to the pump station’s incoming manhole. The manifold shall be a minimum of twenty feet (20’) in length. C. An access manhole shall be installed at the downstream and upstream ends of each detention pipe to connect each pipe to the manifold. Manholes shall be per the District’s Standard Construction Specifications. D. A pre-cast bulkhead shall be installed at the upstream end of each detention pipe. E. The detention pipe(s) and manifold shall be laid with a minimum one percent (1%) slope. F. See Section 4 for detention pipe specifications. 3.11 CONTROLPANEL PAD A. The control panel concrete pad shall be a minimum of four inches (4") thick, reinforced with 8-gauge, 6 x 6 welded wire mesh. The concrete shall have a well-compacted four inches (4") thick stone base (minimum) with frost legs to prevent heaving. B. The pad shall be poured next to the pump station, parallel to the length of the station structure and centered between the two (2) chambers. Pad dimensions shall be as required by submitted equipment with minimum six inches (6”) overhang in all directions. 3.12 MISCELLANEOUS ITEMS A. Incoming Manhole Placement: A manhole shall be placed on the incoming gravity line a minimum of twenty feet (20’) and a maximum of twenty-six feet (26’) from the pump station structure. The detention chamber connecting line shall discharge into this manhole. Manhole shall meet the requirements of the District’s Standard Construction Specifications, latest edition. B. Construction Tolerance of Wet Well: The wet well shall be installed so that it is no more than 3 inches per 25 vertical feet out of plumb. C. Exposed Bolts: All bolts located in the structures shall not extend more than two inches (2”) from the wall. D. Connection of Piping through structure walls: All incoming gravity lines and discharge piping shall have a compression fitting cast-in-place where the pipe passes through the walls. 1. The maximum angle of deflection shall follow manufactures recommendations. Standard Pump Station 19 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 2. All piping outside diameters shall be located a minimum of six (6) inches above or below structure joints. PIPING AND VALVES SECTION 4 4.01 GENERAL A. The following specifications shall be used for installation of the pump station piping and valves. Flanged and grooved end piping shall be acceptable means of connecting piping and valving. B. All pipes must enter the structure walls with a six-inches minimum clearance from the outside face of the pipe to the face of the adjoining wall to allow for proper pipe gasket placement. 4.02 FORCE MAIN PIPE MATERIAL A. Ductile Iron Force Main 1. From the individual pump discharge bases through the header tee to a point a minimum of four feet (4’) outside the valve chamber wall or condition monitoring structure (if applicable), the following materials shall be used: a. Four Inch (4”) Diameter and Above: Flange Installation: Ductile iron pipe Class 53 ANSI A-21.51 i. (AWWA C -151). All bolts and nuts for flange connections must be 304 stainless steel (minimum). All flange gaskets must be full face 1/8” thick red rubber. Grooved End Installation: Ductile iron pipe Class 53 ANSI A-ii. 21.51 (AWWA C-151) with rigid radius grooves for end preparation in accordance with AWWA C606. Mechanical couplings shall be of ductile iron conforming to ASTM A-536, Grade S nitrile gasket compounded to conform to ductile iron pipe surfaces with 316 stainless steel nuts and bolts. 2. The following materials shall be used for the force main from four feet (4’) outside the valve chamber wall or condition monitoring structure (if applicable) to the discharge manhole: a. Four-inch (4") Diameter and Above: Ductile iron pipe Class 52 ANSI A-21.51 (AWWA C-151) i. b. Three-inch (3”) Diameter: Ductile iron pipe Class 52 ANSI A-21.51 (AWWA C-151). i. 3. Joints: Push-on joints, mechanical joints, and flanged joints as indicated in the Drawings. Push-on and mechanical joints shall conform to AWWA C111 (ANSI A21.11). Provide gasket composition suitable for exposure to sanitary sewage. Flanged joints shall conform to AWWA C115 (ANSI A21.15). Component flanges shall be rated for a working pressure of 250 psi or greater. 4. Fittings: Ductile iron, manufactured in accordance with AWWA C110 C153 Class 250. Fittings to be designed to accommodate the type of pipe used. Standard Pump Station 20 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 5. Lining: Protecto 401TM for all ductile iron pipe, joints, and fittings in accordance with specifications provided by Protecto 401 Ceramic Epoxy Company. 6. Exterior Coating: Coat exterior of pipe intended for below grade installation with an bituminous material as specified in AWWA C151, approximately one (1) mil thick. 7. Polyethylene Encasement: Install a black polyethylene encasement in accordance with AWWA C105 (ANSI A21.5), on all buried pipe and appurtenances (fittings, valves, etc.). 8. Painting: Ductile iron pipe intended for above grade installation shall be painted as follows: a. Surface Preparation: Remove all dirt, dust, grease, oils, and all other foreign matter from the surface. Clean the surface in accordance with SSPC SP-6 Commercial Blast Cleaning, latest revision. The surface shall be clean and dry prior to painting. b. First Coat: Apply Tnemec Series 66 Hi-Build Epoxoline at 4.0-6.0 dry mils. This coat shall not exceed 3.0 dry mils. Allow coat to dry overnight, minimum 12 hours, to cure. c. Second Coat: Apply Tnemec Series 73 Endura-Shield at 2.0-3.0 dry mils. Color shall be 33GR Gray. Allow coat to dry overnight, minimum of 12 hours. d. Third Coat: Apply Tnemec Series 76 Endura-Clear at 1.5-2.0 dry mils. Allow coat minimum 12 hours to cure. e. Flanges and fittings shall be shop primed with Tnemec Series 66 Epoxoline Primer at 3.0-4.0 dry mils. These surfaces shall then be touched up in the field and receive application of the three coat system listed directly above. B. PVC Force Main 1. From the individual pump discharge bases through the header tee to a point a minimum of four feet (4’) outside the valve chamber wall, the following materials shall be used: a. Three-inch (3") Diameter: Solvent-Weld Installation: ASTM 1785 Schedule 80 PVC. i. Grooved Installation: ASTM 1785 Schedule 80 PVC roll ii. grooved pipe in accordance with C-606. Mechanical couplings shall be of ductile iron conforming to ASTM A-536, Grade T or S nitrile compound gaskets conforming to ASTM D-2000 designation 5BG615A14B24 with stainless steel nuts and bolts. 2. The following materials shall be used for the force main from four feet (4’) outside the valve chamber wall to the discharge manhole: a. Four-inch (4”) Diameter and Above: AWWA C-900 PVC Class 150 i. AWWA C-900 PVCO ii. b. Three-inch (3") Diameter: 3. PVC pipe meeting ASTM D2241 (SDR 21) with integral bell and gasket joint design meeting the requirements of ASTM D3139 and F477, minimum pressure class shall be PC 150.Joints: Join by means of a push on bell joint which is to be an integral part of the barrel in conformance Standard Pump Station 21 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 with AWWA C900. Provide gasket composition suitable for exposure to sanitary sewage. 4. Fittings: For pipe less than four-inch (4”) in diameter, PVC fittings to conform to the material requirements for PVC pipe described herein. For pipe diameters four-inch (4”) or greater, provide mechanical joint fittings. Provide gasket composition suitable for exposure to sanitary sewage 5. Pipe to bear the national Sanitation Foundation Seal of approval. Comply with the requirements of Type I, Grade I of the ASTM resin specification D-1784. Certificates of conformance with the foregoing specifications to be furnished with each lot of pipe supplied. 6. Thermoplastic pipe shall not be used above grade. 4.03 FORCE MAIN REQUIREMENTS A. The following elements shall be included in the force main system design: 1. Air Relief / Vacuum Valves (ARV): Automatic combination vacuum air relief valves shall be placed at high points in the force main as required. a. The valve shall be equipped with all backwash accessories. b. The body of the ARV shall be supported to the wall of the structure by a 1-1/4" x 1-1/4" x 1/8" stainless steel angle bracket. c. For underground installations, provide precast manhole with cover and frame and a concrete valve marker post for each valve location. d. Coat air release manholes and pipes inside air release manholes with Raven 405 Epoxy Coating or approved equal at 120 mils nominal thickness. e. Acceptable Manufacturer: ARI (no substitutions) 2. Connection to Gravity System: Force main shall discharge to the receiving gravity sewer system at a manhole. The point of connection shall be no more than one foot (1’) above the flow line of the receiving manhole. Inside drops will not be permitted. 3. Existing Gravity Manhole Rehabilitation: The sides and bottom of the force main discharge manhole and a minimum of five (5) manholes downstream of the point of connection shall be lined with a solventless, 100% solids, corrosion resistant epoxy coating or a lining have multiple, structural fiberglass layers with a non-porous diaphragm bonded between the layers of fiberglass and molded to the existing structure. a. Acceptable Manufacturer: Raven Lining Systems AquataPoxy A-6, Terre Hill Composites Multiplex Liner THC-610-SL-68 or approved equal. 4. New Manhole Construction: When a new force main discharge manhole is to be constructed at the point of connection to the gravity system, the manhole shall be manufactured with a flexible sheet liner with locking extensions. The bottom of the new manhole and the sides and bottom of the five (5) manholes downstream of the point of connection shall be treated with the epoxy coating specified above. a. Acceptable Manufacturer: Ameron Protective Lining Division, Amer- Plate T-Lock, or approved equal. 5. Connection to Force Main: In limited circumstances, when proposed force main discharges to an existing force main, design engineer shall notify District at the Pump Station Design Report Submittal stage. Upgrades to Standard Pump Station 22 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 existing pump station and force main may be required prior to construction of proposed pump station. 6. Mechanically Restrained Joints: The force main shall be fitted at all angle points with mechanically restrained joints designed to withstand the thrust developed under the test pressure plus 50 psi. The required number of mechanically restrained joints from the angle point shall be determined by the design engineer and shown in plan and profile (see Section 1). 7. By-Pass Portal: A by-pass portal shall be installed within twenty-five feet (25’) downstream of the valve chamber or condition monitoring structure (if applicable). a. The portal shall be the same size as the force main. For force mains larger than four-inch (4”), calculations can be provided to allow for a smaller pumping portal than the force main. All piping within the by- pass assembly shall be meet the requirements of the “Force Main Pipe Material” as described above. b. The connection shall consist of a 90 degree bend with a blind flange connection, with centerline located two and one-half feet (2.5’) above grade. c. The system shall consist of three (3) buried plug valves with associated valve boxes. One (1) valve shall be located on the by- pass portal line. One (1) valve shall be located upstream of the force main/portal connection tee and one (1) valve shall be located downstream of the connection tee. d. Plug valve shall meet the specifications of “Isolation Valves” as described below. e. The connection shall be surrounded by a minimum of four (4) pipe bollards and labeled “For Emergency Bypass Pumping Only”. Pipe bollards shall extend forty-two inches (42”) above grade and be constructed of six inch (6") diameter concrete filled steel or iron pipe. Posts shall be set forty-two inches (42") below grade in an eighteen inch (18") by forty-eight inch (48") poured concrete base. A twelve inch (12”) long, #5 bar shall be installed near bottom of the pipe. f. See standard details for installation details. 8. Clean-Outs: The need for clean-outs on the force main shall be determined during plan review by the District. As a general guide, clean- outs will not be required on force mains less than 1800 feet in length. If clean-outs are required, refer to the District’s Standard Construction Specifications. 9. Locator Marker Rope: Locator marker rope shall be placed on top of the force main for the entire length. The rope shall be laid parallel to the ground surface at a minimum depth of two and one-half feet (2.5’) and a maximum depth of four feet (4’). A minimum six inch (6”) separation shall be maintained between the top of the force main and the rope. Rope shall be 3M Electronic Marking System (EMS) Rope, 7700 Series. 10. Locator Balls: Locator balls shall be placed over the top of the force main during force main installation. The balls shall be installed per manufacturer recommendations. Balls shall be 3M ID Electronic Marking System (EMS) Ball Marker 1424-XR/ID. Balls shall be installed at the following locations: a. Every twenty-five feet (25’) along force main runs. Standard Pump Station 23 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 b. Five feet (5’) from the pavement edge on both sides of a road crossing. c. Fifteen feet (15’) and five feet (5’) back from each side of an angle point and on the angle point itself. d. As directed by the District. 11. Tracer Wire: Tracer wire can be installed on a case-by-case basis where approved by the District. There shall be a connection point to the tracer wire a maximum of 400-feet and at every structure along the alignment. Inspection of the tracer wire shall show that the entire length of the force main is locatable using the tracer wire. Any breaks or faults of the tracer wire will be repaired prior to acceptance, or the installations of locator rope will be required. 4.04 TRANSITION PIPING A. When PVC pipe (See Section 4) is used for force main outside the structural walls, a transition in pipe material must be made. B. When a condition monitoring structure is used, a transition pipe must be used to make the transition between the flow meter inside the condition monitoring structure and the force main outside the structure. A flanged DIP stub shall be bolted to the flow meter then passed through the gasket installed in the condition monitoring structure wall. The PVC force main shall be attached to the DIP stub outside the structure by a long pattern sleeve mechanical joint with Mega-Lug retainer glands. C. When no condition monitoring structure is used, a transition pipe must be used to make the transition between the header tee inside the valve chamber and the force main outside the structure. The following methods shall be used: 1. Four Inch (4") Diameter and Larger: Both pump discharge lines shall be joined to a flanged cast iron tee. A flanged DIP stub shall be bolted to the tee then passed through the gasket installed in the valve chamber discharge wall. The PVC force main shall be attached to the DIP stub outside of the valve chamber by a long pattern sleeve mechanical joint with Mega-Lug retainer glands. 2. Three Inch (3") Diameter: Both pump discharge lines shall be joined to a Schedule 80 PVC socket tee. From the tee, a Schedule 80 PVC stub shall pass through the gasket installed in the valve chamber discharge wall. Transition the stub to the SDR-21 PVC force main with a PVC coupling outside of the valve chamber. 4.05 PUMP DISCHARGE RISERS A. When the pump discharge riser exceeds twelve feet (12’) in length, a stainless steel support brace must be installed between the riser and wet well wall. The brace shall be placed approximately in the middle of the riser but kept above the normal operating level of the well. A minimum of two (2) braces will be needed on lengths in excess of twenty feet (20’). B. Pump discharge riser pipes shall be installed straight and plumb. Standard Pump Station 24 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 4.06 ISOLATION VALVE A. One (1) non-buried isolation valve shall be placed on the discharge line of each pump, downstream of the check valve. Valves shall be located so that each pump may be isolated from the common discharge header. No pump discharge valves shall be vertically mounted or located in the wet well area. B. Three (3) buried isolation valves shall be provided on the by-pass portal system. Valves shall be located so that by-pass pumping can occur along with isolation of the force main and pump station. C. All valves shall be rated so as to withstand normal working pressure plus allowances for water hammer. D. Isolation valves shall be plug type valves. 1. Materials a. Valve bodies and covers shall be constructed of ASTM A126 Class B cast iron for working pressures up to 175 psig and ASTM A536 Grade 65-45-12 for working pressures up to 250 psig. b. The words “SEAT END” shall be cast on the exterior of the body seat end. c. Plugs shall be of one-piece construction and made of ASTM A126 Class B cast iron or ASTM A536 Grade 65-45-12 ductile iron and fully encapsulated with resilient facing per ASTM D2000-BG and ANSI/AWWA C517 requirements. d. Plug valves shall have radial shaft bearings constructed of self- lubricating Type 316 stainless steel. The top thrust bearing shall be Teflon. The bottom thrust bearing shall be self-lubricating Type 316 stainless steel. Cover bolts shall be corrosion resistance with zinc plating. e. Plug valves shall have a valve seat that is a welded overlay of 95% pure nickel applied directly to the body on a pre-machined, cast seating surface and machined to a smooth finish. f. Permanently lubricated, radial shaft bearings shall be supplied in the upper and lower bearing journals. Thrust bearings shall be provided in the upper and lower journal areas, except for threaded type which only have upper thrust bearings. g. Threaded and all other valves under four inch (4”) shall have port areas of not less than 100% of pipe area. Port areas on other sizes are 85% on sixteen inch (16”) and smaller, 80% on eighteen inch (18”) to twenty-four inch (24”) and 75% on thirty inch (30”) and larger. h. The exterior of the valve for non-buried service shall be coated with a universal alkyd primer. Valve exterior for buried service shall be coated with an epoxy coating. i. Manufacturer shall demonstrate a minimum of ten (10) years’ experience in the manufacture of plug valves. The manufacturer shall provide test certificates, dimensional drawings, parts list drawings and operations and maintenance manuals. 2. Connection Types a. Non-buried application Flange valves shall be in accordance with ANSI B16.1 Class i. Standard Pump Station 25 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 125 standards. Grooved end valves shall have end-to-end dimensions in ii. conformance with AWWA C-509 with the grooved ends conforming to AWWA C-606 rigid grooving dimensions. b. Buried application: Mechanical Joint 3. Valve Operators a. Six-inch (6”) and smaller valves shall be provided with a two-inch (2”) square operating nut and wrench head for direct quarter turn operation. The packing gland shall include a friction collar and an open position memory stop. The friction collar shall include a nylon sleeve to provide friction without exerting pressure on the valve packing. b. Valves larger than six inch (6”) shall be provided with a Manual Gear Operator sized so that the maximum rim pull required is not more than 80 pounds. c. When specified, valves four inch (4”) and larger shall include a totally enclosed and sealed worm gear actuator with position indicator (non- buried service only) and externally adjustable open and closed stops. The worm segment gear shall be ASTM A536 Grade 65-45-12 ductile iron with a precision bore and keyway for connection to the valve shaft. Bronze radial bearings shall be provided for the segment gear and worm shaft. Alloy steel roller thrust bearings shall be provided for the hardened worm. 4. Valve Box and Extension Stem a. For buried valve applications, valve boxes shall be provided. The valve box shall extend to the elevation as shown on the drawings. b. All buried valves shall have a hot dipped galvanized steel extension stem keyed to the valve and the operating nut brought to within six inches (6”) of the top of valve box. 5. Acceptable Manufacturer: Valves are to be Milliken, fig. #601-N, Victaulic Series 365, Val-Matic Valve and Mfg. Corporation Series 5800 or 5900, or approved equal. 4.07 CHECK VALVES A. A check valve shall be placed on the discharge line of each pump. The check valve shall be located between the shut-off valve and the pump. All valves shall be rated so as to withstand normal working pressure plus allowances for water hammer. No pump discharge valves shall be vertically mounted or located in the wet well area. B. Check valves shall be of the swing check type with iron body and bronze trim. Check valves shall be outside spring, lever, weighted arms, or flexible disc type. 1. Materials a. The valve body and cover shall be constructed of ASTM A536 Grade 65-45-12 ductile iron. b. The top access port shall be full size, allowing removal of the disc without removing the valve from the line. The access cover shall be domed in shape to provide flushing action over the disc for operating in lines containing high solids content. 2. Connection Types Standard Pump Station 26 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 a. Flange valves shall be in accordance with ANSI B16.1 Class 125 standards. b. Grooved end valves shall have end-to-end dimensions in conformance with AWWA C-509 with the grooved ends conforming to AWWA C-606 rigid grooving dimensions. 3. Disc Types a. Flexible Disc - The seating surface shall be on a 45-degree angle to minimize disc travel. A threaded port with pipe plug shall be provided on the bottom of the valve to allow for field installation of a backflow actuator or oil cushion device without special tools or removing the valve from the line. A threaded port with pipe plug shall be provided in the access cover to allow for field installation of a mechanical, disc position indicator. The disc shall be of one-piece construction, precision molded with an integral O-ring type sealing surface and reinforced with alloy steel. The flex portion of the disc contains nylon reinforcement and shall be warranted for twenty-five years. Non-Slam closing characteristics shall be provided through a short 35-degree disc stroke and a memory disc return action to provide a cracking pressure of 0.25 psig. The valve disc shall be cycle tested 1,000,000 times in accordance with ANSI/AWWA C508 and show no signs of wear, cracking, or distortion to the valve disc or seat and shall remain drop tight at both high and low pressures. The disc shall be precision molded Buna-N (NBR) ASTM D2000-BG. b. Metal Disc - The valve body shall be full flow equal to nominal pipe diameter area at all points through the valve and shall be equipped with a threaded adjustable open stop. The body seat shall be O-ring sealed and field replaceable without removing the valve from the line. The disc shall be of one-piece construction and connected to the shaft with a disc arm and two pivot pins to provide pivot action to allow self- adjusting seating at all pressures. 14” and larger discs shall be convex shape for lift, stabilization and strength. The disc seat shall be resilient with integral O-ring type sealing surface for drop tight shut-off at high and low pressures and for easy replacement in the field without removing the valve from the line. The shaft seals shall consist of V-type packing in a fixed gland with an adjustable follower designed to prevent over compression of the packing and to meet design parameter of the packing manufacturer. Removable, slotted shims shall be provided under the follower flanges to provide for adjustment and prevent over loading of the packing. The valve shall be factory equipped with a lever and weight assembly. The lever shall be equipped with three holes for adjusting the bolted weight assembly. When the valve is closed, the lever and weight shall be located 30 degrees below horizontal. 4. Acceptable Manufacturer: Check Valves shall be Clow Style 1106SL, Victaulic Series 317, or Val-Matic Series 7800 Swing Check, or MSD approved equivalent. 4.08 VALVE CHAMBER DRAIN VALVE A. A backwater check valve shall be installed on the valve chamber drain line. The valve shall be installed as follows: Standard Pump Station 27 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 1. A four inch (4”) diameter PVC stub shall be glued into the four inch (4”) diameter coupler cast into the wet well wall at the valve chamber floor line (See Section 3). A 90-degree elbow shall be glued to this stub and directed toward the wet well floor. A four inch (4”) by three feet (3’) long PVC pipe shall be glued into the other end of the elbow. The check valve shall be installed on the pipe end and attached with two (2) stainless steel clamps to be supplied by the vendor. 2. Acceptable Manufacturer: The valve shall be a four inch (4”) slip on check valve, "Tide-Flex" series TF-2 by Red Valve Co. or EVR Type CPO-4", or MSD approved equivalent. 4.09 PRESSURE SENSORS A. Each installed pump shall have an in-line full ported pressure sensor installed on the pump side of the discharge line. The sensor shall be located in the valve chamber between the pump and check valve. Sensor specifications are provided in Section 5. 4.10 GRAVITY LINES A. Ductile iron pipe shall be used: 1. Between the incoming manhole (last manhole preceding the station) up to the wet well. 2. The twelve inch (12”) diameter pipe (manifold) connecting the detention chamber and incoming manhole. B. Concrete or PVC pipes in these areas will not be acceptable. C. Gravity pipes shall be per the District’s Standard Construction Specifications, latest edition. 4.11 DETENTION PIPE A. Detention pipe(s) shall be selected from current approved materials for large diameter sanitary sewers, and installed under current MSD construction specifications. Pipe materials shall be labeled on the plans, and notes added for installation requirements. B. The detention pipe ends shall be bulk headed with a gasket installed in the outfall side. C. Buoyancy calculations shall be submitted as part of the pump station design report. Measures to restrain the pipe from floatation shall be shown on the plans. Standard Pump Station 28 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 SUBMERSIBLE WASTEWATER PUMPS SECTION 5 5.01 MINIMUM STANDARDS A. Pump selection shall be based on the following minimum standards: 1. Type a. Submersible, non-clog pumps are preferred. b. Grinder pumps and vertical lift pumps may be approved by the District upon receipt of a written request for variance and acceptable justification. 2. Electrical a. Three-phase pumps are preferred. b. Pumps less than three horsepower (3 Hp) are not acceptable. 3. All pumps, with the exception of grinder pumps, shall be capable of passing spheres of at least three inches (3”) in diameter. 4. Pump suction and discharge piping shall be at least three inches (3”) in diameter. 5.02 PUMP SPECIFICATIONS A. The pump shall be non-clog solids handling submersible capable of handling raw, unscreened sewage. B. The discharge connection elbow shall be permanently installed in the wet well along with the discharge piping. C. The pump shall automatically connect to the discharge connection elbow when lowered into place and shall be easily removed for inspection or service. There shall be no need for personnel to enter the wet well. A simple linear downward motion of the pump shall accomplish sealing of the pumping unit to the discharge connection elbow. D. A sliding guide bracket shall be an integral part of the pump unit. No portion of the pump shall bear directly on the floor of the sump. E. The pump, with its appurtenances and cable, shall be capable of continuous submergence underwater without loss of watertight integrity to a depth of 65 feet. 1. Major Components a. Major pump components shall be of gray cast iron, ASTM A-48, Class 35B with smooth surfaces devoid of blowholes and other irregularities. Where watertight sealing is required, O-rings made of nitrile rubber shall be used. All exposed nuts and bolts shall be of AISI type 316 stainless steel. b. The pump shall be equipped with an open lifting hoop suitable for attachment of standard chain fittings, or for hooking from the wet well surface. The hoop shall be stainless steel, 1.4401 (AISI 316), and shall be rated to lift a minimum of four (4) times the pump weight. 2. Watertight Seals a. All mating surfaces where watertight sealing is required shall be machined and fitted with nitrile O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between machined Standard Pump Station 29 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 surfaces. This will result in controlled compression of nitrile rubber O- rings without requirement of a specific torque limit. No secondary sealing compounds, rectangular gaskets, elliptical O-rings, grease or other devices shall be used. 3. Cooling System a. Each unit shall be provided with an adequately designed cooling system. When thermal radiators (cooling fins) are used, they shall be i. integral to the stator housing and shall be adequate to provide the cooling required by the motor. When water jackets are used, the water jacket shall encircle ii. the stator housing. The water jacket shall be provided with a separate, self-contained liquid cooling system. b. Regardless of the cooling system used, the motor must be capable of pumping under full load continuously with the water level only to the top of the volute. c. Motors with intermittent full load ratings or motors requiring oil for cooling will not be allowed. 4. Impellers a. Semi Open with Adjustable Bottom Plates Impeller: The impeller shall be of gray cast iron, ASTM A-48, i. Class 35B. The impeller shall be of the semi-open, non- clogging, single vane design, and shall be capable of passing solids as are commonly found in wastewater. The impeller shall be highly clog resistant by virtue of its single or dual vane semi open design. The impeller shall have a slip fit onto the motor shaft and drive key and shall be securely fastened to the shaft by a stainless steel bolt which is mechanically prevented from loosening by a positively engaged ratcheting washer assembly. The head of the impeller bolt shall be effectively recessed within the impeller bore to prevent disruption of the flow stream and loss of hydraulic efficiency. The impeller shall be dynamically balanced to the ISO 10816 standard to provide smooth vibration-free operation. Self-Cleaning Wear Plate: The wear plate shall be ii. constructed from gray cast iron ASTM A-48, Class 35 B. The wear plate shall be designed with an inlet incorporating strategically placed cutting grooves and an outward spiral V- shaped groove on the side facing the impeller, to shred and force stringy solids outward from the impeller and through the pump discharge. The wear plate shall be mounted to the volute with four stainless steel securing screws and four stainless steel adjusting screws to permit close tolerance adjustment between the wear plate and impeller for maximum pump efficiency. Adjustment to allow for wear and restore peak pumping performance shall be accomplished using standard tools, and without requiring disassembly of the pump. The use of fixed or non-adjustable wear plates or rings, or systems that require disassembly of the pump or shimming of the impeller to facilitate adjustment shall not be Standard Pump Station 30 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 considered equal. The suction flange shall be integrated into the wear plate and its bolt holes shall be drilled and threaded to accept standard 4-inch ANSI Class 125 flanged fittings. b. Vortex The Vortex impeller shall be of gray cast iron, EN-GJL-250 i. (ASTM A-48, Class 35B). The impeller shall be an open vane design, capable of passing a minimum of 3-inch diameter spherical solids as are commonly found in wastewater. The impeller shall have a slip fit onto the motor shaft and drive key and shall be securely fastened to the shaft by a stainless steel bolt which is mechanically prevented from loosening by a positively engaged ratcheting washer assembly. The head of the impeller bolt shall be effectively recessed within the impeller bore to prevent disruption of the flow stream and loss of hydraulic efficiency. The impeller shall be dynamically balanced to the ISO 10816 standard to provide smooth vibration-free operation. The pump volute shall be single piece gray cast iron, ASTM ii. A-48, Class 35B non-concentric design with centerline discharge. Passages shall be smooth and large enough to pass any solids which may enter the impeller. Discharge size shall be three inch (3”) minimum. The discharge flange design shall permit attachment to standard ANSI or metric flanges/appurtenances. The discharge flange shall be slotted to accept both three inch (3”) ANSI Class 125 (rotated 22.5 degrees) and metric CN80 (PN10) flanged fittings. Proprietary or nonstandard flange dimensions shall not be considered acceptable. The minimum working pressure of the volute and pump assembly shall be 10 bar (145 psi). c. Enclosed Impeller An enclosed or channel impeller shall be of gray cast iron i. ASTM A-48, Class 35B. The impeller shall be of the double shrouded, non-clogging, two vane design, meeting the Ten States Standards requirement for minimum solids passage size of three inches (3”). The impeller shall have a slip fit onto the motor shaft and ii. drive key and shall be securely fastened to the shaft by a stainless steel bolt which is mechanically prevented from loosening by a positively engaged ratcheting washer assembly. The head of the impeller bolt shall be effectively recessed within the impeller bore or supporting washer to prevent disruption of the flow stream and loss of hydraulic efficiency. The impeller shall be dynamically balanced to the ISO 10816 standard to provide smooth vibration-free operation. Impeller designs which do not meet the Ten States Standards requirement for three inch (3”) solids passage size, those that rely on retractable impeller designs to pass three inch (3”) solids, or those that rely on fins or pins protruding into the suction path to assist in the handling of fibrous material shall not be considered equal. A replaceable wear ring of cast iron ASTM A-48, Class 40 or iii. Standard Pump Station 31 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 AISI 318 shall be securely fitted into the pump casing (volute). The optional impeller wear ring shall be stainless steel AISI 316Ti. d. Chopper/Cutter Type Impeller: Shall be semi-open type with pump out vanes to i. reduce seal area pressure. Chopping/maceration of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter bar of 0.010” to 0.015”. Impeller shall be cast steel heat treated to minimum Rockwell C 60 and dynamically balanced. The impeller shall be keyed to the shaft and shall have no axial adjustments or set screws required. Cutter Bar Plate: Shall be recessed into the pump bowl and ii. shall contain at least 2 shear bars extending diametrically across the intake opening to within 0.010-0.015” of the rotating cutter nut tooth, for the purpose of preventing intake opening blockage and wrapping of debris at the shaft area. Chopper pumps utilizing individually mounted shear bars shall not be acceptable. Cutter bar shall be T1 plate steel heat- treated to minimum Rockwell C 60. Cutter Nut: The impeller shall be secured to the shaft using a iii. special cutter nut, designed to cut stringy materials and prevent binding. The cutter nut shall be ASTM A148 cast alloy steel heat treated to minimum Rockwell C 60. Upper Cutter: Shall be threaded into the back pull-out iv. adapter plate above the impeller, designed to cut against the pump-out vanes and the impeller hub, reducing and removing stringy materials from the mechanical seal area. Upper cutter shall be cast steel heat treated to minimum Rockwell C 60. 5. Volute a. The pump volute shall be single piece gray cast iron ASTM A-48, Class 35B non-concentric design with centerline discharge. Passages shall be smooth and large enough to pass any solids which may enter the impeller. Discharge size shall be as specified on the pump performance curve. The discharge flange design shall permit attachment to standard ANSI or metric flanges/appurtenances. The discharge flange shall be drilled to accept both ANSI Class 125 and metric flanged fittings. Proprietary or non-standard flange dimensions shall not be considered acceptable. The minimum working pressure of the volute and pump assembly shall be 10 bar (145 psi). 6. Pump Motor a. The Premium Efficiency motor shall meet efficiency standards in accordance with IEC 60034-30, level IE3 and NEMA Premium. Motor rating tests shall be conducted in accordance with IEC 60034-2-1 requirements and shall be certified accurate and correct by a third party certifying agency. A certificate shall be available upon request. IE3 and NEMA Premium efficiency levels are equivalent, i. however the NEMA Premium standard is intended to cover dry installed motors only, not integrated submersible motors. Standard Pump Station 32 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 b. The Premium Efficiency motor shall be housed in a water tight gray cast iron, EN-GJL-250 (ASTM A-48, Class 35B) enclosure capable of continuous submerged operation underwater to a depth of 20 meters (65 feet) and shall have an IP68 protection rating. The motor shall be of the squirrel-cage induction design, NEMA type B, Premium Efficiency. The copper stator windings shall be insulated with moisture i. resistant Class H insulation materials, rated for 180°C (356°F). The stator shall be press fitted into the stator housing. ii. The use of bolts, pins or other fastening devices requiring iii. penetration of the stator housing is unacceptable. The rotor bars and short circuit rings shall be made of cast iv. aluminum. c. The motor shall be designed for continuous duty. The maximum continuous temperature of the pumped liquid shall be 40°C (104°F), and intermittently up to 50°C (122°F). The motor shall be capable of handling up to 10 evenly spaced starts per hour without overheating. The service factor (as defined by the NEMA MG1 standard) shall be 1.15 minimum. The motor shall have a voltage tolerance of +/- 10% from nominal, and a phase to phase voltage imbalance tolerance of 1%. The motor shall be FM and CSA approved for use in NEC Class I, Division I, Groups C & D hazardous locations. The surface temperature rating shall be T3C. The motor shall meet the requirements of NEMA MG1 Part 30 and 31 for operation on PWM type Variable Frequency Drives. 7. The motor shall be capable of operating, completely submerged, partially submerged, or unsubmerged. For submerged (wet pit) applications, the motor shall be self-cooling via the process fluid surrounding the motor. For unsubmerged (dry pit) applications an integrated oil cooling system shall be utilized to enhance heat transfer and allow the motor to operate at full rated power continuously without the need for de-rating or reduced duty cycle. No external coolant supply or external cooling jacket shall be required for dry pit applications. The motor shall have a NEMA Class A temperature rise for submerged service, and class B rise for dry pit service, providing cool operation under all operating conditions. 8. Thermal Sensors a. Each phase of the motor shall contain a normally closed bi-metallic temperature monitor switch imbedded in the motor windings. These thermal switches shall be connected in series and set to open at 140°C +/- 5°C (284°F). They shall be connected to the control panel, and used in conjunction with, and supplemental to, external motor overload protection. 9. Pump Shaft a. Each pump shall be provided with an oil chamber for the shaft sealing system. The drain and inspection plug, with positive anti-leak seal, shall be accessible from the outside. b. Shaft: The pump shaft and motor shaft shall be an integral, one-i. piece unit adequately designed to meet the maximum torque Standard Pump Station 33 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 required at any normal start-up condition or operating point in the system. The shaft shall have a full shutoff head design safety factor of ii. 1.7, and the maximum shaft deflection shall not exceed 0.05 mm (0.002 inch) at the lower seal during normal pump operation. Each shaft shall be stainless steel 1.4021 (AISI 420) material iii. and shall have a polished finish with accurately machined shoulders to accommodate bearings, seals and impeller. Carbon steel, chrome plated, or multi piece welded shafts shall not be considered adequate or equal. c. Bearings: Each pump shaft shall rotate on two (2) high quality i. permanently lubricated, greased bearings. The upper bearing shall be a single row deep grooved ball ii. bearing and the lower bearings shall be a heavy duty double row angular contact ball bearing. Bearings shall be of sufficient size and properly spaced to iii. transfer all radial and axial loads to the pump housing and minimize shaft deflection. L-10 bearing life shall be a minimum of 50,000 hours at flows iv. ranging from ½ of BEP flow to 1 ½ times BEP flow (BEP is best efficiency point). The bearings shall be manufactured by a major internationally v. known manufacturer of high quality bearings and shall be stamped with the manufacturer’s name and size designation on the race. Generic or unbranded bearings from other than major bearing manufacturers shall not be considered acceptable. 10. Mechanical Seal a. Each pump shall be equipped with a tandem mechanical shaft seal system consisting of two totally independent seal assemblies. The seals shall operate in a lubricant reservoir that hydro-dynamically lubricates the lapped seal faces at a constant rate. The lower, primary seal unit, located between the pump and the lubricant chamber, shall contain one stationary industrial duty silicon-carbide seal ring and one rotating industrial duty silicon-carbide seal ring. The stationary ring of the primary seal shall be installed in a seal holding plate of gray cast iron EN-GSL-250 (ASTM A-48, Class 35B). The seal holding plate shall be equipped with swirl disruption ribs to prevent abrasive material from prematurely wearing the seal plate. The upper, secondary seal unit, located between the lubricant chamber and motor housing, shall contain one stationary industrial duty silicon-carbide seal ring, and one rotating industrial duty silicon-carbide seal ring. Each seal interface shall be held in contact by its own spring system. The seals shall not require routine maintenance, or adjustment, and shall not be dependent on the direction of rotation for proper sealing. Each pump shall be provided with a lubricant chamber for the shaft sealing system which shall provide superior heat transfer and maximum seal cooling. The Standard Pump Station 34 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 lubricant chamber shall be designed to prevent overfilling, and to provide lubricant expansion capacity. The drain and inspection plug shall have a positive anti-leak seal, and shall be easily accessible from the outside of the pump. The seal system shall not rely upon the pumped media for lubrication and shall not be damaged when the pump is run dry. Lubricant in the chamber shall be environmentally safe non toxic material. b. The following seal types shall not be considered equal: Seals of proprietary design, or seals manufactured by other than major independent seal manufacturing companies. Seals requiring set screws, pins, or other mechanical locking devices to hold the seal in place, conventional double mechanical seals containing either a common single or double spring acting between the upper and lower seal faces, any system requiring a pressure differential to seat the seal and ensure sealing. c. Mechanical Seal Protection System: The primary mechanical seal shall be protected from interference by particles in the wastewater, including fibrous materials, by an active Seal Protection System integrated into the impeller. The back side of the impeller shall be equipped with a sinusoidal cutting ring, forming a close clearance cutting system with the lower submersible motor housing or seal plate. This sinusoidal cutting ring shall spin with the pump impeller providing a minimum of 75 shearing actions per pump revolution. Large particles or fibrous material which attempt to lodge behind the impeller, or wrap around the mechanical seal shall be effectively sheared by the active cutting system into particles small enough to prevent interference with the mechanical seal. The Seal Protection System shall operate whenever the pump operates, and shall not require adjustment or maintenance in order to function. Submersible pump designs which do not incorporate an active cutting system to protect the primary mechanical seal shall not be considered acceptable for wastewater service. d. Seal Failure Early Warning System: The integrity of the mechanical seal system shall be continuously monitored during pump operation and standby time. An electrical probe shall be provided in a sensing chamber positioned between the primary and secondary mechanical seals for detecting the presence of water contamination within the chamber. The sensing chamber shall be filled with environmentally safe non-toxic oil. A solid-state relay mounted in the pump control panel or in a separate enclosure shall send a low voltage, low amperage signal to the probe, continuously monitoring the conductivity of the liquid in the sensing chamber. If sufficient water enters the sensing chamber through the primary mechanical seal, the probe shall sense the increase in conductivity and signal the solid state relay in the control panel. The relay shall then energize a warning light on the control panel, or optionally, cause the pump to shut down. This system shall provide an early warning of mechanical seal leakage, thereby preventing damage to the submersible pump, and allowing scheduled rather than emergency maintenance. Systems utilizing float switches or any other monitoring devices located in the stator housing rather than in a sensing chamber Standard Pump Station 35 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 between the mechanical seals are not considered to be early warning systems, and shall not be considered equal. 11. Power Cable a. The power cables shall be sized according to NEC and CSA standards and shall be of sufficient length to reach the junction box without requiring splices. The outer jacket of the cable shall be oil and water resistant, and shall be capable of continuous submerged operation underwater to a depth of 65 feet. 12. Cable Entry System a. Plug Assembly: The cable entry system shall consist of submersible plug i. assembly which allows the cable to be easily disconnected from the pump for service or replacement. Cable sealing shall be accomplished by a Nitrile compression ii. grommet with both cylindrical and conical sealing surfaces, flanked by a stainless steel washer and an integrated strain relief. A brass (C3604) compression nut shall be threaded into the iii. cast iron EN-GJL-250 (ASTM A-48, Class 35B) cable plug housing, compressing the grommet ID to the cable while the grommet OD seals against the bore of the cable entry housing. Cable conductors shall be terminated in copper pin iv. connectors which are separated and retained by a circular pin retainer fabricated form high dielectric strength Polyamid (30% GF). Each pin shall pass through its own hole in the pin retainer, maintaining the perfect alignment with the mating pins in the motor body. The corresponding motor body pin assembly shall be manufactured from high dielectric strength Polyamid (30% GF), with copper connector pins. The pin assembly shall be sealed with an O-ring to prevent water entry into the motor, and retained in the motor housing bore via a retaining ring. Attachment of the plug assembly to the motor shall engage the corresponding copper pins, creating a complete circuit between the motor cable. The plug assembly shall be fastened with stainless steel v. fasteners, and shall be sealed by an O-ring. The cable plug and sealed entry system as part of the motor vi. shall be FM and CSA approved for use in NEC Class I, Division I, Groups C & D hazardous locations. The system shall be anti wicking by design, and shall prevent any water that enters the cable through damage to the jacket from entering the motor. Cable entry designs which utilize potting compounds to provide a water tight seal, or those which do not allow the cable to be easily changed in the field shall not be considered equal. b. Cable Entry/Junction Chamber: The cable entry design shall not require a specific torque to i. ensure a watertight seal. The cable entry shall consist of cylindrical elastomer ii. Standard Pump Station 36 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 grommets, flanked by stainless steel washers. A cable cap incorporating a strain relief and bend radius iii. limiter shall mount to the cable entry boss, compressing the grommet ID to the cable while the grommet OD seals against the bore of the cable entry. The junction chamber shall be isolated and sealed from the motor by means of sealing glands. Electrical connections between the power cables and motor iv. leads shall be made via a compression or post type terminal board, allowing for easy disconnection and maintenance. c. Acceptable Manufacturer: Flygt i. Sulzer ii. KSB iii. Vaughan (Chopper/cutter type only) iv. No other manufacturers shall be acceptable v. Standard Pump Station 37 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 PUMP STATION APPURTENANCES SECTION 6 6.01 GUIDE BAR RAILS A. Two (2) guide bar rails shall be installed for each pump to facilitate pump removal. Rails shall be made of Type 316 Schedule 40 stainless steel pipe, installed and sized per manufacturer's recommendations. The rails shall be firmly braced to the wet well wall with stainless steel support brackets. Maximum spacing between brackets shall be per pump manufacturer’s recommendations. Rails shall be sparkless design suitable for use in Class 1, Division 1, Group D hazardous location as defined in NFPA 70 – National Electric Code (NEC). 6.02 LIFTING CHAIN A. Pump lifting chain, clevises and shackles shall be made of Type 316 stainless steel and provided by the pump manufacturer. The chain shall be sized to accommodate the installed pump weight but shall not be sized smaller than 3/16" stainless steel diameter links. 6.03 BOLTS A. All field-installed bolts, nuts, and washers used inside either the wet well or valve chamber shall be made of Type 316 stainless steel. 6.04 FASTENERS A. All concrete fasteners used for installation of braces, brackets or boxes shall be stainless steel wedge type stud anchors. Anchor holes shall be drilled to the manufacturer's recommended depth. Pump base anchor studs shall be sized per manufacturer recommendations, with the following minimums: 1. 4" pumps and smaller = 5/8" minimum 2. 6" and 8" pumps = 1" minimum 3. Pumps larger than 8" shall be installed with stainless steel anchors sized per the pump manufacturer instructions. 6.05 FLOATS AND SETTINGS A. General 1. Floats shall be located near the flow of the incoming sanitary lines. All floats shall be located away from the turbulence of the incoming flow. Sewage shall not rise to the level of the incoming gravity lines or the detention pipes during normal pump operation. All floats shall be utilized in intrinsically safe applications. B. Float Levels 1. The following levels shall guide the setting of float levels: Off Float The Entire Pump Shall be Covered at the Off Level Lead Pump No Less than 1-1/2 Feet above Top Of Pump Standard Pump Station 38 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 Motor Lag Pump No Less than 2 Feet above Top of Pump Motor High Level Alarm No Less than 2-1/2 Feet above Top of Pump Motor and No More than 1-Inch Below the 12-Inch Pipe to the Twenty-Four-Hour Detention Tank Emergency High Level Alarm Set to a Level Equivalent to 75% of the Detention Chamber Capacity C. Float Leads 1. Float leads shall be hung with stainless steel kellum grips from a stainless steel bracket, Series J by Halliday. The bracket shall be attached to the wet well hatch cover or firmly bolted to the concrete immediately below the hatch cover. D. Float Wires 1. Float wires shall be neatly routed from the wet well to the valve through the access sleeve (see Section 3), without excessive wire strain or pull. Wire length on all float wires shall be such that each float may be adjusted to the bottom of the station wet well. E. Acceptable Manufacturer: a. Flygt model ENM-10 b. Anchor Scientific type eco-float. c. MSD approved equivalent. 6.06 ACCESS HATCHES A. The access hatches shall be aluminum, rated for a 300 lbs/sf live load. Door size and orientation shall be as described in Section 3. The access frame and cover shall be flush with the top of the concrete, complete with hinged and flush locking mechanism, upper guide holder and level sensor cable holder. Frame shall be securely placed. Hatches shall be equipped with form skirts, sized for the top slab thickness. Doors shall be provided with padlock lugs. B. Safety grating shall be factory installed on all hatches and rated for a 300 lbs/sf live load. Grating shall be aluminum “I” bar grating with powder coated finish. Grating shall be hinged to open in same direction as aluminum hatch and supplied with positive latch to maintain unit in upright position. A viewing area shall be provided on each lateral unhinged side of panel for visual observation and limited maintenance procedures. All hardware and fasteners shall be stainless steel. C. All access hatch construction materials and appurtenances shall be manufactured from stainless steel, aluminum or brass. D. Acceptable Manufacturer: 1. Halliday Model S1S or S2S Standard Pump Station 39 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 2. Approved equal 6.07 SAFETY POST A. A stainless steel or aluminum safety extension post shall be provided on the top two steps under the access. When entrance steps are utilized (depth less than 5 feet), the safety extension post shall be anchored into the concrete wall of the structure using a manufacturer-provided bracket. When access ladders are installed (depth greater than 5 feet), the safety post shall be connected to the access ladder itself. All bolts and hardware shall be stainless steel. Contractor shall verify required spacing. B. Acceptable Manufacturer: 1. Halliday L1E Ladder Extension 2. Approved equal. 6.08 LOCKING HARDWARE A. All equipment enclosures, access hatches, entrance gates and service disconnect arms shall be provided with stainless steel locks. Locks shall have two inch (2") high shackles with 5/16" diameter shanks. Temporary construction cores and keys will be provided by the manufacturer until such time as the facility is inspected and accepted for maintenance by the District. All temporary keys and cores will be turned over to the District at acceptance. B. Acceptable Manufacturer: 1. Best Access Systems. Best Stock #21B772-L with stainless steel body. 6.09 PRESSURE SENSOR UNITS A. Pressure sensors shall be of the full flange design with through boltholes or one- piece wafer style with carbon steel flanges. Sensors shall clamp between standard ANSI pipeline flanges. All exposed surfaces shall be epoxy painted or of a non-corrosive material. Sensor shall be flow through design with flexible Buna-N elastomer sensing ring around the full circumference. B. Sensors shall be provided to the installer, assembled complete, from the supplier. The units shall be filled with a 50/50 ethylene glycol and water mixture and have no entrapped air in the system. The supplier shall pre-test the unit at the minimum operable sensing level of the switch prior to delivery to the installer. C. Pressure sensors units shall include loop powered pressure instrumentation for both analog and discrete pressure signals. Instrument shall have NEMA-7 Housings with two programmable set point fail-safe solid state relays. Switches shall be wired normally closed, with adjustable pressure settings. The pressure range shall be specified for each specific installation. Pressure sensor shall also include manual gauge. D. Acceptable Manufacturers: 1. Gauges: SPAN Model LFS 210 with 1/4" connection and 2-1/2” dial. 2. Instrumentation: United Electric “One Series” 1XTXSW 3. Pressure sensors: “ONYX VALVE” wafer pressure sensor type PSW. Standard Pump Station 40 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 4. Accessory piping: 1/2" or 1/4" Parker Hex stainless steel with reducing fittings where necessary to connect instruments. 6.10 INTRINSIC BARRIERS A. The interior of the wet well and the valve chamber is a Class 1, Division 1, Group D hazardous location as defined in NFPA 820 - Standard for Fire Protection in Wastewater Treatment and Collection Facilities. Therefore, intrinsic barriers shall be installed for all intrinsically safe instruments such as floats per NFPA 70 – National Electric Code. B. Acceptable Manufacturer: 1. MTL 5016 dual channel 2. Approved equal. 6.11 MAGNETIC FLOWMETERS A. Flow Tube 1. The flowmeter shall be of the electromagnetic type, utilizing pulsed DC excitation with microprocessor-based converter/transmitter. The flowmeter shall measure flow throughout the cross-sectional area. Single or multi-point measurement devices are not acceptable. 2. Unless otherwise specified, all magmeter applications shall utilize full-pipe measurement and will always flow full. 3. The flowmeter accuracy shall be better than ±0.5% of measured value or better in both forward and reverse flows. 4. As a minimum, the magmeter shall be capable of operating at specified accuracy with flow velocity between three feet per second (3 fps) and thirty feet per second (30 fps). 5. The repeatability shall be ±0.1% of reading or better. 6. Magnetic flowmeters shall operate with process streams having conductivity of 20 µS/cm. 7. The meter shall offer a stable zero and shall not require routine zeroing. The meter shall automatically indicate zero under empty sensor conditions. 8. Once installed in process pipeline, the magmeter and converter/transmitter shall be capable of digital set-up and commissioning in order to verify the integrity of sensor, cabling and transmitter. The testing technique shall provide verification of the complete flow system, i.e., sensor and transmitter in-situ, without removal of, or access to, the sensor. A verification certificate shall be provided. Upon request, references indicating successful installations with over two years operation shall be provided. 9. The flowmeter shall be designed and manufactured in an ISO 9001 certified manufacturing facility. 10. The wetted materials shall be compatible with the process stream. 11. Unless otherwise specified, the liner material shall be either neoprene or hard-rubber. Magmeter electrodes shall be compatible with raw, unscreened sewage. Standard Pump Station 41 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 12. The magmeter body (flow-tube) shall be rated to NEMA 6P (IP68) and suitable for indefinite (continuous) submergence in water to a depth of 30 feet. 13. Magmeter Bodies shall be suitable for installation in a NEC Class 1, Division 2, Group D Hazardous Location. The metering tube shall be constructed of Type 304 stainless steel with 150# ANSI carbon steel flanges. Meter body shall be fully welded no bolt on “clam shell” type meters. Coil will be located behind the measurement tube. Tube coils imbedded in the liner or not located behind the measurement tube will not be acceptable. Meter liner shall be recessed into the flange face on meters over twenty-four inches (24”) and supplied with AWWA flanges to maintain the integrity of the Flat Faced Flanges. 14. All conduit entrances shall be either ½” or ¾” NPT. 15. All magmeters shall be furnished with one of the following, grounding electrodes, a pair of compatible grounding rings or Virtual Grounding. Where ground rings are furnished, install per all manufacturer’s requirements. All grounding and bonding per manufacturer’s requirements are considered incidental to this section. 16. Flow meter shall be installed per manufacturer recommendations, including minimum required length of pipe upstream and downstream of flow meter. B. Remote Flow Converter 1. Converter shall provide separate isolated outputs for analog transmitter (4-20mA) and pulse outputs (volt free). The working flow range shall be fully configurable in the field by the end user. 2. Instrument power shall be 120 VAC, 60 Hz. 3. Magmeter Converter/Transmitter housing shall be rated NEMA 4X (IP65), non-hazardous unless specified as a hazardous classified area. All conduit entrances shall be either ½” or ¾” NPT. 4. The input impedance shall be 1015 Ohms or greater so that the electrode fouling does not affect signal and electrode seal integrity. 5. The converter/transmitter display shall be capable of indicating flowrate and totalization simultaneously in user selectable engineering units. The totalizer shall be nine (9) digits minimum. Display shall also be capable of indicating alarm status, percentage of span, and velocity along with measuring bidirectional flow. Display shall be mounted in Pump Control Panel. 6. The transmitter shall be configurable by use of a keypad located on the front face of the transmitter. 7. Magmeter cables between magmeter body and remotely mounted Flow Converter/Totalizer shall be furnished by the manufacturer in sufficient length to permit field installation without splicing. Cables installed without meeting this requirement will be rejected and shall be replaced at Contractor’s expense. C. Manufacturers Standard Pump Station 42 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 1. Siemens – Sitrans F M Mag 5100W with Sitrans F M Mag 5000 transmitter (Base Bid) 2. Toshiba – Mount Anywhere Sanitary LF494 with LF622F transmitter 3. Krohne – Optiflux 2000 with IFC 100 transmitter Standard Pump Station 43 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 ELECTRICAL SECTION 7 7.01 PUMP CONTROL PANEL A. The General Contractor shall be directly responsible for all panel fabrication and component installations. The pump control panel shall meet the following specifications. Any deviations from the standards specified below shall be approved prior to manufacture or installation. B. General Contractor shall submit shop drawings that include detailed panel drawings, component cut sheets, etc. Use of provided drawings is not sufficient to meet these requirements. The District will provide the programming. Contractor and panel fabricator shall be responsible for testing IO for proper operation. C. Panel Configuration 1. The pump controls shall be housed within a NEMA-3R, floor mount enclosure, constructed from 12-gauge 304 stainless steel, with a #4 finish. Enclosure shall be two door construction with three-point latching and pad-lockable stainless steel handles. One side shall be designed to contain Line Voltage (480, 240, 208VAC) and the other side shall contain controls (120VAC, 24VDC, Intrinsically Safe Circuits). Panel shall be designed with removable center post for easy panel installation and maintenance. Panel shall include Heavy Duty Lifting Eyes. Eyes shall be stainless steel or removed after installation and replaced with gasketed stainless steel bolts. 2. No operators shall be mounted on exterior of enclosure doors. Control Panel shall include door in door construction with all operators mounted on inner doors with continuous hinge swing out kits that allow the operator to interface with controls without being exposed to live and energized components. During maintenance inner doors may be opened by quarter turn latches which allow access to subpanel components. Inner doors shall be set back to allow room for circuit breaker handles, pilot lights, displays, etc. All control switches, hour and event meters, GFI receptacles, indicator lights and circuit breaker toggles, shall be mounted on the hinged inner door. 3. All compartment exterior doors shall be mounted to the enclosure with stainless steel full-length continuous hinges. Hinges shall be welded to the enclosure. 4. Full sub-panels shall be mounted within each door interior. The sub- panels shall be formed from mild steel. Panel edges shall be turned down to form a 3/4" lip. All panels shall be painted white and mounted on 3/8"-16 standoff studs per NEC and UL 508 5. All hardware on the panel exterior shall be stainless steel. 6. The control section shall be used for installation of the Supervisory Control and Data Acquisition (SCADA) system. The primary element of this system is a combination radio and remote terminal unit (RTU) manufactured by Motorola. The unit’s name is ACE3600. This system will be referred to as ACE3600 throughout the remainder of this Standard Pump Station 44 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 document. Additional space shall be provided for future cellular communications. Open space shall be of 18” x 18” dimensions. 7. Distribution Equipment for incoming service and backup power generation shall be installed via stainless steel strut mounted on the back of the Control panel. Panel enclosure shall be modified to support equipment without compromising NEMA rating. D. Thermal Magnetic Breakers 1. Individual thermal magnetic circuit breakers shall be provided for branch disconnecting service and short circuit protection of all motor and auxiliary circuits. Combination circuit breaker and overload mechanism shall not be allowed. Motor circuit protectors may be magnetic only. E. Float Switches 1. Five floats shall be provided with sufficient length cord to extend uninterrupted to the valve chamber control junction box. The five float levels shall be: pump off, lead pump on, lag pump on, wet well high-water alarm, and detention tank high level alarm. An additional float shall be provided in the valve chamber for high water alarm. All floats shall be connected to an intrinsic safety barrier powered by ACE3600 and located in the pump control panel. F. Forced Entry Limit Switch 1. A forced entry limit switch shall be wired directly to the ACE3600. The limit switch shall alarm the opening of the control panel outer doors. Multiple switches shall be wired to single input. 2. Acceptable Manufacturer: Micro Switch Model 1AC2 or MSD approved equal. G. LED Work Light 1. A minimum 12-inch LED work light shall be mounted at each enclosure door inside the top of the control panel without penetrating the panel outer skin with screws or fasteners. The light shall be operated with an on/off switch mounted on the inner door. H. Panel Heater 1. Low wattage strip heaters shall be installed on inner compartment doors to prevent the accumulation of condensation. Heaters shall be sized per submitted enclosure dimensions. I. Enclosure Fans 1. Enclosures shall include fans to provide adequate cooling for included components where required. Fans/Vents shall be located to allow airflow across the panel without short circuiting. Supply and exhaust many not be installed on the same side of the control panel enclosure. Fans shall maintain NEMA3R or highest rating of the panel. J. Wiring 1. All wires in the pump control panel shall be numbered with either clip sleeve or heat shrink type markers. Wrap on or adhesive type wire markers shall not be allowed. Approved Control panel schematic shall Standard Pump Station 45 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 show wire and terminal numbers. A physically separated terminal section shall be dedicated for the ACE3600 and control wiring. This terminal section shall consist of a minimum of 80 terminal points and shall be separated from 120-volt terminals by a minimum of 4". A final 11" x 17" as-built schematic shall be laminated to the inside of the control panel exterior door. K. Surge Protection Device (SPD) 1. A type 1 SPD shall protect the pump station and integrated into the incoming power or within the service disconnecting means. The arrestor shall be sized for the incoming power service voltage and shall be provided in addition to the ACE3600 control surge arrestor. L. Service Disconnect 1. All stations shall be supplied with service disconnecting means. Fused disconnect shall be 304 stainless steel minimum NEMA 3R rating rated minimum 200A. Service Disconnect shall be installed on back of pump control panel via stainless steels strut and hardware integral to control panel. 2. Acceptable Manufacturer: Square D, Cutler Hammer, or ABB M. Utility Meter 1. Contractor shall coordinate utility requirements with servicing utility. Contractor shall procure and install all equipment, accessories, and appurtenances required by utility. Equipment shall be minimum NEMA 3R and installed on back of pump control panel via stainless steel strut and hardware integral to control panel. N. Manual Transfer Switch 1. All stations shall be supplied with Double Throw Manual Transfer Switch. Transfer Switch shall be 304 stainless steel minimum NEMA 3R rating rated minimum 200A. Transfer Switch shall be installed on back of pump control panel via stainless steel strut and hardware integral to control panel. 2. Acceptable Manufacturer: Square D, Cutler Hammer, or ABB O. Generator Tap Box 1. All stations with Manual Transfer Switch shall be provided with Generator Tap Box. Box shall be 304 stainless steel minimum NEMA 3R rating. Generator tap box shall be a junction box with power distribution blocks for phase, neutral and ground connections to be used with portable generators. Junction box shall be secured by quarter turn latches with white subpanel for equipment installation. Contractor shall install 1 x 4” PVC coated aluminum conduit nipples with cap for temporary connection of generator cables out the bottom of the generator tap box. Generator Tab Box shall be mounted approximately 5’-0” above finished grade to allow easy connection during emergency operations. P. Phase Sequence and Loss Monitor Standard Pump Station 46 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 1. All stations shall be protected by a phase sequence and loss monitor. This monitor/relay shall be a plug-in-type with automatic reset. The relay shall interrupt the control circuit immediately after the control fuse. 2. Acceptable Manufacturer: The relay shall be a Diversified Electronics VBA or SLA as appropriate for utility source. Q. Relays 1. All control and time delay relays shall be at a minimum DPDT 8 or 11 pin octal base D.I.N. rail mounted. 2. Acceptable Manufacturer: a. Control Relays: IDEC RH4B-ULand DIN-rail socket or MSD approved equal b. Time Delay Relays: IDEC RTE-P2D12 and DIN-rail socket with additional control relay, or IDEC GT5Y-4SN3D12 and DIN-rail socket or MSD approved equal. R. Main Terminal Strip 1. The main terminal strip at the lowest portion of the sub panel shall have a minimum clearance of six inches. S. Control Power 1. The control power shall be 120 volts. If 120-volt, single phase is not available, a minimum 5 KVA transformer shall be supplied with primary and secondary protection. Individual 120-volt circuit breakers shall be provided for each separate power requirement. The ACE3600 shall be powered from a separate dedicated 5-amp circuit breaker, fed from the control circuit. A 15-ampere Ground Fault Interrupter receptacle shall be mounted on the inner door of the control panel. T. Control Panel Name Plate 1. All pump control panels shall have a 4" x 6" phenolic name plate firmly fastened to the lower right front side of the cabinet inner door. The nameplate shall include the following: a. Manufacturer's job number b. Manufacturer's name, location, phone number c. Site name d. Pump model, pump serial numbers, horsepower, voltage, amperage 7.02 THREE PHASE MOTORS A. All pumps will operate using three phase power. Pumps may either be 208VAC, 240VAC or 480VAC. B. Any station may use the single phase power source with converter option upon District approval. Allowance of such a system will depend on the cost analysis presented by the designer/owner. Allowance will be determined on a case –by- case basis. Three phase power is the preferred option. 7.03 AMERENUE 3-PHASE SUPPLY CONTROL OPTION A. MSD will provide generic electrical drawings and the ACE3600 control program. All 3-phase installations shall meet the following requirements: Standard Pump Station 47 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 1. Magnetic Motor Starters (NEMA) a. Magnetic across the line horsepower rated motor starters shall be supplied for each pump under 20 horsepower. Pumps 20 horsepower and larger shall be supplied with soft starters with bypass contactors. b. Acceptable Manufacturer: Cutler Hammer ,Square D, ABB or MSD approved equal. 2. Soft Starters a. The solid state reduced voltage starter shall be UL and CSA listed and consist of a silicon controlled rectifier (SCR) based power section, logic board and paralleling bypass contactor. b. The SCR based power section shall consist of six (6) back-to-back SCR’s and shall be rated for a minimum peak inverse voltage rating of 1,500 peak inverse voltage (PIV). Units using triacs or SCR/diode combinations shall not be acceptable. c. Resistor/capacitor snubber networks shall be used to prevent false firing of SCRs due to dv/dt characteristics of the electrical system. d. The logic board shall be mounted for ease of testing, service and replacement. It shall have quick disconnect plug-in connectors for current transformer inputs, line and load voltage inputs and SCR gate firing output circuits. The logic board shall be identical through all ampere ratings and voltage classes and shall be conformally coated to protect from environmental conditions. e. The paralleling bypass contactor shall energize when the motor reaches full speed and close/open under 1 x motor current. The contactor shall be fully rated for across-the-line starting duty should this be desired. The contactor shall utilize an energy balanced contact closure to limit contact bounce and an intelligent coil controller which optimizes coil voltage during varying system conditions. The coil shall have a lifetime warranty. f. The overload protection shall be electronic and be based on an inverse time/current algorithm. Overload protection shall be adjustable, and Class 10/20 shall be selectable. Units using bimetal overload relays are not acceptable. Over temperature protection (on heat sink) shall be standard. g. The solid-state logic shall be phase sensitive and shall inhibit starting on incorrect rotation. Improper phase rotation shall be indicated on the starter. h. Starters shall protect against a phase loss/unbalance condition shutting down if a 35% current differential between any two phases is encountered. i. A normally open (NO) contact shall annunciate fault conditions, with contact ratings of 60 VA resistive load and 20 VA inductive load. In addition, an LED display shall indicate type of fault (current trip, phase loss, phase rotation). j. The following adjustments are required: Ramp time: 1-45 seconds i. Initial torque: 100-200% current ii. Current limit: 100-500% current iii. FLA of motor: 4-1 range of starter iv. Standard Pump Station 48 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 k. Smooth stopping shall be available to provide a linear voltage deceleration. It is to be adjustable from 1-45 seconds. l. Acceptable Manufacturers: Cutler Hammer Square D or ABB 3. Pump Control Circuits and Indicator Lights a. Individual pump control circuits shall be provided with 30mm Nema 4 H-O-A switches, elapsed time meters and re-settable event counters for monitoring pump cycles. Provide green pump running lights, white control power available light and individual red indicator lights for faults and amber indicator lights for warnings. Indicator lights shall be 30 mm full-voltage LED push to test type (white with colored lenses) or MSD approved equal. The above switches, lights, meters and counters shall be mounted on the inner door of the control section of the panel. b. Momentary Contact NEMA 4 30mm pushbuttons shall be installed to test float operations. 4. Starter Control and Back Up Control a. The starters shall be controlled by ACE3600 and the District will provide a standard control program to operate the station. All floats, auxiliary starter contacts and pressure switches shall be wired to the ACE3600 as digital inputs as shown in the generic electric drawings. A Pump Run digital output shall switch 120 VAC to the starter coil via an interposing relay and the pump’s H-O-A switch. A normally closed contact of another interposing relay shall interrupt the starter coil when a Pump thermal or starter overload is activated. Pump Failures shall be reset by switching the H-O-A switch to the off position. The contact ratings of the interposing relays shall be 10 amperes minimum. b. As a backup control, the high-level float will latch a relay that will start the two pumps at the station and that relay will release when the wet well water level falls below the stop float. The backup start command will be wired in parallel with the ACE3600 Pump Run relay contact. 5. Device Identification a. All devices mounted flush on the inner cabinet door shall be identified with phenolic legend plates. All switches, pumps, lights, breakers, relays, and auxiliary devices mounted to the sub-panels shall be identified with engraved phenolic legend plates. 7.04 PHASE CONVERTER OPTION A. Because of the higher probability of electrical failure from using a phase converter, this type of system shall only be considered after investigating the feasibility of having three phase power brought onto the job site. Three phase power shall be used unless installation costs justify the installation cost of a converter. All phase converter installations shall meet the following requirements, any deviations shall be approved by MSD prior to manufacture and installation: 1. Converter a. The converter shall be a variable frequency drive unit set up to run at 100% speed. The converter shall be de-rated to account for the single-phase power supplied to the unit. Converter shall have EMI/RFI filtering built in to the front end to inhibit harmonic Standard Pump Station 49 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 interference. It shall be programmed and controlled from a keypad/display unit. The following functions will be available: Local/Remote with Start/Stop keypad pushbuttons. i. Keypad and hardwired reset functions. ii. Hardwired input for external failure points (high pump iii. temperature and seal failure) Hardwired remote start/stop through a single contact iv. (ACE3600 or high-level alarm relay) Ramp up, ramp down settable 0-30 second v. Status display vi. Under-voltage protection. vii. Over-current protection. viii. Ground fault protection. ix. Failure log. x. Hardwired run and failure output contacts. xi. 2. Converter Control and Back Up Control: a. Converters will be controlled by the ACE3600. All floats, run and failure feedback, and pressure switches will be wired to the ACE3600 as digital inputs. The digital outputs will be wired to start/stop and reset inputs on the converters. The District will provide a standard control program to operate the station. As a backup control, the high- level float will latch a relay that will start the two pumps at the station and that relay will release when the when the wet well water level falls below the stop float. This start command will be wired in parallel with the ACE3600 run command. b. The converters shall be mounted in the line voltage section of the control panel. Cooling ventilation with fan and filter will be provided and sized to ensure no failures due to over temperature of the converter unit. AC units shall be stainless steel with minimum NEMA 3R rating. c. Acceptable Manufacturer: Cutler Hammer, Square D, ABB or MSD approved equal. 7.05 STATION INTERIOR WIRING A. The interior of the wet well and valve chamber are Class 1, Division 1, Group D hazardous locations. All electrical installations within these areas shall be explosionproof in accordance with minimum requirements set forth by NFPA 70 – National Electrical Code (NEC). B. Wet well level control float leads shall be hung with stainless steel kellum grips from a series J Halliday stainless steel cable holder. The holder shall be bolted to the inside of the wet well hatch, immediately below the hatch cover and shall be located to not interfere with the wet well entrance steps. The pump power cables shall be hung with stainless steel kellum grips from the upper pump guide rail brackets. Power and control wiring shall be routed with adequate separation. All excess wires shall be rolled up inside the valve chamber. C. Passage of the pump and float wires from the pump chamber to the valve chamber shall be made through two (2) open ended lengths of four inch (4”) PVC coated aluminum conduit installed between the valve and pump chamber. A Standard Pump Station 50 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 minimum of twelve inch (12”) separation should be maintained between the control and power wiring. D. There shall be no electrical connections made in the pump chamber. All wiring shall run unbroken from the pump chamber to the valve chamber through the four inch (4”) PVC coated aluminum conduits and terminated at a properly sized terminal boards inside a NEMA 7 junction box. Intrinsically safe conductors may be spliced in NEMA 4X 304 stainless steel junction box. Power and control conductors shall be spliced in separate junction boxes. Conduits leaving the junction box shall include Class 1, Division 1, Group D conduit seals. Conduits and seals shall be PVC coated aluminum conduit as manufactured by Calbond or MSD approved equal. E. Valve chamber junction box connections are to be made with Class 1, Division 1 Group D cord connectors. F. All wiring in the valve chamber shall be routed and fastened securely along the chamber walls with non-corrosive stainless steel wire straps and fasteners. 7.06 PRESSURE SENSOR WIRING A. Each pump shall include a discharge pressure sensor. Wiring from the pressure sensors shall be in accordance with NEC minimum requirements for classified locations. Wiring may be in conduit with flexible connection at instrument or by use of type MC-HL cable with listed fittings. 7.07 FIELD WIRING SPECIFICATIONS A. Control panel wiring shall be as follows: 1. All wiring installed on the line and load side of the electric meter shall be THHN copper wire. 2. Electric service to the station shall be sized to provide the maximum total station amperage with all installed pumps running under a fully loaded condition. 3. All pump station control panels shall be provided with a minimum 100- amp service. 7.08 CONDUIT SPECIFICATIONS A. The following conduit sizes are to be used on any combination of pumps with a total station HP of less than 60 HP. For larger HP stations, contact MSD Pump Station Division for specific conduit sizes. 1. All above grade and exposed conduits shall be PVC coated aluminum. Conduits installed below grade may be schedule 80 PVC with minimum 2 foot burial depth. Install line marking tape 6 inches above conduit. Transition from PVC to PVC coated aluminum conduit below grade. 2. A 2-1/2" conduit shall be used to run from AmerenUE supply source to the electric meter mounted on the control panel. The meter disconnect switch, manual transfer switch and generator tap box are to be connected together with PVC coated aluminum. A 2-1/2" conduit shall be used to run all power wires from the control panel, to the power junction box in the valve chamber. Conduit to include conduit seal. Standard Pump Station 51 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 3. A 2-1/2" conduit shall be used to run all control wires from the control panel, to the control junction box in the valve chamber. Conduit to include conduit seal. 4. A 2-1/2" conduit shall be used to run the antenna coax from beneath the antenna pole to the control panel. 5. PVC coated aluminum conduit shall be used below grade for pump power conduits, including all fittings and transition points, when a converter is used with single phase utility supply. 7.09 CONTROL PANEL MOUNTING A. The station pump control panel shall incorporate the pump controls, alarm system and power distribution into one stainless steel structure. The panel shall be placed as follows: 1. The control structure shall be set on a 4-inch concrete pad (see Section 3). 2. Conduits shall be run into the control panel from beneath the structure per the detail drawing. 3. The panel shall be centered on the concrete pad and set a minimum of 4- inches in from the rear edge of the pad. 4. Prior to setting and securing the panel to the concrete mounting pad, a strip of 2”x1/4” solid rubber gasket material shall be placed against the bottom frame to create a seal between the concrete mounting pad and the panel bottom. 5. The control panel shall be firmly anchored to the concrete mounting pad with six, 3/8-inch stainless steel Wej-It type stud anchors. Anchor holes in the concrete pad shall be drilled to the manufacturer’s recommended depth. B. Acceptable Manufacturer: Anchors shall be Hilti Quick Bolt Two or MSD approved equal. Standard Pump Station 52 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 ALARM SYSTEM SECTION 8 8.01 SYSTEM REQUIREMENTS A. Each pump station shall have a ACE3600 RTU conforming to the District's existing system. B. The District's system operates on 173.39625 MHZ utilizing a Motorola ACE3600 Central Station Transceiver for interrogation and acknowledgment of alarms. C. The RTU shall be provided by MSD for contractor installation. Contractor shall install and terminate the RTU per the construction drawings. The RTU shall not be energized until MSD personnel are present for program download and startup. D. Additional space shall be provided for future cellular equipment. A clear space of 18” x 18” shall be provided. 8.02 ANTENNA A. The minimum acceptable transmission strength shall be determined as +20 db. above the threshold of the closest satellite receiver. B. The antenna azimuth shall be in the direction of the nearest satellite receiver +/- 15 degrees. C. The actual working antenna height is to be determined by contractor to ensure direct communications with SCADA Central. The minimum height allowable per MSD is 20' above finished grade. If topography requires the antenna to be located higher than 20', contact the Pump Station Division for additional pole specifications. D. Acceptable Manufacturer: Antenna - Decibel Model #DB230-L or Comtelco or equal 8.03 POLE SPECIFICATIONS A. The antenna shall be mounted a minimum of 20' from finished grade on a minimum 24' long fiberglass street light type pole. The pole base shall be set 4' below ground with 4-1/2' deep and 1-1/2' round concrete base poured around it. The pole must be installed so that it is vertical +/- 1 degree. The top of the pole shall be sealed against water penetration with a cover cap. A grounding rod installed at the base of the tower must protect all antennas. Grounding rod length shall follow national electric code requirements. B. Acceptable Manufacturer: Fiberglass Pole - Whatley #E3029-01-59-S or MSD approved equal. 8.04 POLE SITE LOCATION A. Antenna poles shall be installed behind the control panel as indicated on the control panel drawings or as approved in the field by MSD personnel. Standard Pump Station 53 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 8.05 ALARM COAXIAL CABLE A. The alarm coaxial cable shall be installed as follows: 1. The coaxial cable is to be run in one continuous length with no splices. The coax shall be terminated at the antenna connector on one end and a lightning arrestor on the other end. Another cable shall be connected from the lightning arrestor to the connector on the outside of the radio cabinet (to be installed per drawing). 2. All R.F. cable connectors outside of the radio cabinet shall be properly terminated and sealed with 3M Cold Shrink. B. Acceptable Manufacturers: 1. Coax: Beldon #8267 2. Lightning Arrestor: Polyphasor: # IS-50NX-C2 3. RF connector: Amphenol - Male: #82-202, Female: #82-63 4. Cold Shrink: 3M P/N (8425-7 and 8426-9) Standard Pump Station 54 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 SITE REQUIREMENTS SECTION 9 9.01 SITE AND ACCESS ROAD PAVEMENT A. Pavement will be required at the pumping station as follows: 1. Station Area a. The wet well, valve chamber, and condition monitoring structure shall have a minimum six feet (6') paved apron installed around the structures. The pavement shall be sloped so as to permit surface water to drain away from the station. b. When fencing is required around the station area, the entire area within the fence shall be paved, with the pavement extending an additional one foot (1’) beyond the fencing perimeter. 2. Station Access Road a. The access road shall: Be a minimum of twelve feet (12’) wide. i. Be designed to limit the access road grade to a 10% ii. maximum. If the road grade must exceed a 10% slope, a combination of step type sloping and protection barriers will be required. Have a turn around area at the station end of the access road iii. large enough to accommodate the turning radius of a sixteen feet (16’) service van. b. The centerline of the entrance road shall bisect the station gate entrance, security fence, and the valve chamber and wet well structures. If this type entry is not feasible for a particular site, the closest structure to the gate and road shall be the wet well. 3. Pavement Specifications: a. Asphaltic Concrete The access road and area surrounding the station shall be i. paved with two inches (2") of type "C" asphaltic concrete laid over six inches (6") of type "X" asphaltic concrete. All subgrade shall consist of six inches (6") of well-compacted crushed limestone. b. Poured Concrete Concrete pavement shall be Class A six inch (6") thick, six (6) i. sack mix with a four inch (4") slump. Pavement shall be reinforced with 8 gauge, 6 x 6 welded wire mesh. The concrete shall be laid over a well-compacted four inch (4") stone base. 4. Entrance Road Barriers a. Stations requiring entrance roads shall have thirty-six inch (36”) high barrier posts installed at the road entrance. Post shall be constructed of six inch (6") concrete filled steel or iron pipe, or six inch (6”) by six inch (6”) cedar posts. Posts shall be set thirty inches (30") below grade in an eighteen inch (18") by thirty-six inch (36") poured concrete base. A 5/16" diameter galvanized chain locked on one end and firmly fastened to the other, shall be run between the poles. For safety purposes, a four inch (4") by twelve inch (12") reflective plate reading “NO PARKING” shall be attached to the chain at the span center. Standard Pump Station 55 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 9.02 FENCING A. Fencing shall be required around all pump station sites unless it can be satisfactorily shown by the design engineer that no safety hazard or vandalism threat would exist by the absence of fencing. Fencing limits must be included on the pump station site plan. Elimination or alterations to the approved fencing plan shall only be considered for compliance with municipal requirements. B. Fencing Specifications 1. Chainlink Fence a. Wire fabric for the fence shall be brown or green vinyl clad six feet (6') high chain link fabric. Wire shall be No. 11 gauge woven in a two inch (2") mesh. Top and bottom salvages shall be barbed. b. All posts and other appurtenances used in the construction of the fence shall be brown vinyl clad schedule 40 pipe. All posts shall be equipped with tops. Fiberglass fencing components will not be acceptable. c. A twelve feet (12') wide entrance gate shall be provided for access to the station grounds. d. Posts shall be sized and set as follows: TYPE SIZE PULL Top Rails & Brace 1-14” Nominal (1.66” O.D.) 2.27 lbs./ft. Line Post & Gate Frame 1-1/2” Nominal (1.9” O.D.) 2.72 lbs./ft. End Corner or Pull Post 2” Nominal (2.375 O.D.) 5.79 lbs./ft. Gate Post 3-1/2” Nominal (4” O.D.) 9.11 lbs./ft. e. Posts shall be set in the concrete bases so that the pole bottom rests six inches (6") higher than the concrete base bottom. f. Horizontal support bars shall be installed half way between the top rail and the ground. g. A #7 tension wire shall be installed at the bottom of the fencing fabric and stretched taught enough so as to not allow the bottom of the fencing fabric to be lifted away from the fencing poles and/or ground. 2. Wrought Iron Fence a. Fencing shall be Heavy Industrial Steel Ornamental Fence System – Fusion Welded. b. The system shall include all posts, panels, and mounting accessories. c. Grade: Industrial d. Standard Style: 3-3/4 inch air space between pickets Invincible Style: Pressed pointed pickets extended above the i. top rail, curving outward. e. Steel (ASTM A924/A924M): Steel for tubular pickets, rails and posts have minimum yield strength of 45,000 psi (310 MPa). f. Galvanizing (ASTM A653/A653M): Prior to forming, hot dip galvanized with minimum zinc coating weight of 0.90 oz/ft2, Coating Designation G-90. g. Rails: Steel channel, 1.75 inches x 1.75 inches i. Standard Picket Spacing: Picket holes shall be spaced at ii. 4.715 inches o.c. Standard Pump Station 56 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 h. Pickets: 1 inch square x 14 gauge tubing. i. Racking/Biasability (Ability of Panels to Follow Grades): able to follow varying grade changes to a maximum of 48 inches rise in an 8 foot run. j. Posts: Size: 2.5 inches by 2.5 inches by 12 gauge with standard post i. cap Size: 3 inches by 3 inches by 12 gauge with standard post ii. cap Size: 4 inches by 4 inches by 11 gauge with standard post iii. cap k. Acceptable Manufacturer: Montage II, Invincible design by Ameristar Fence Products, i. Inc., or approved equal. 3. Fencing Placement: a. Fencing shall be located so that: There is a four-foot (4') space between all auxiliary pump i. station equipment, panels, antenna poles, generators, etc. and the fence perimeter. The access gate shall be located so that hoisting or cleaning ii. equipment can easily access the valve and wet well chambers. 9.03 SITE MAINTENANCE A. Temporary erosion control shall be provided in accordance with state and local requirements. B. Surface water must be directed away from the pump station structures and paved areas to prevent debris from washing over the paved area or ponding of water at the pump station site. Ground shall be sloped at a minimum two percent (2%) grade away from the pump station. Spot elevations should be included on approved plans prior to Construction. 9.04 RESTORATION A. Restoration shall be in accordance with the District’s Standard Construction Specifications, latest edition. Final acceptance of the station shall be withheld until the site is restored to the District’s satisfaction. Standard Pump Station 57 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 INSPECTION AND ACCEPTANCE REQUIREMENTS SECTION 10 10.01 GENERAL A. In addition to the ongoing construction inspection by District Engineering Construction Inspectors, District Operations/Pump Station personnel shall make inspections of the constructed work at specific stages of the pump station construction. Any inspection of the work by the MSD Construction Inspectors or Pump Station personnel shall not relieve the Contractor of its responsibility to comply with the plans and specifications and to perform all work in a good and workmanlike manner in accordance with the approved plans and specifications and the contract documents. The Contractor responsible for constructing the pump station shall notify the District Construction Development Inspection Division when the facility is ready for each inspection. Failure to have the inspection performed at the proper time during the construction process could result in the District requiring the removal and reconstruction of the completed work. 10.02 PRE-CONSTRUCTION MEETING A. Contractor will schedule a pre-construction meeting through the MSD Division/Resident Inspector. MSD Operations will be involved in this meeting as well. This meeting will cover construction phase requirements and inspections, as detailed below. 10.03 STAGE ONE: SHOP DRAWING REVIEW A. Purpose 1. Verify Contractor’s proposed pump station components, including structures, piping and equipment, meet the approved construction specifications and plans prior to ordering material. 2. All Shop drawings shall be reviewed by Design Engineer and stamped prior to submittal to MSD. 3. Submittals shall be made using Accela. B. Suggested Shop Drawings 1. Construction schedule 2. Pre-cast structures a. Manholes b. Wet well (if applicable) c. Valve chamber (if applicable) d. Detention chamber (if applicable) 3. Cast-in-place structures a. Concrete mix design b. Concrete reinforcing 4. Piping a. Influent sewer b. Pump discharge piping c. Pump forcemain d. Pipe supports e. Detention chamber (if applicable) Standard Pump Station 58 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 f. Bypass portal 5. Equipment a. Submersible pumps and appurtenances b. Pump station control panel (Contractor to request radio from MSD upon shop drawing approval). c. Pump station appurtenances d. Valves e. Floats or level measurement f. Flow meter g. Hatches h. Antenna i. Pressure sensor j. Pressure transducer k. Miscellaneous electrical l. Gate (if applicable) m. Hoists or davit cranes (if applicable) n. Generator (if applicable) 10.04 STAGE TWO: PRE-STRUCTURE INSPECTION A. Purpose 1. Verify excavation and subgrade placement for the pump station. 2. Verify any fillets and that the site has proper drainage. 3. Verify contractor is not encroaching on adjacent property, is minimizing disturbance to the extent practical. 4. If pre-cast structures are approved, verify structures match approved shop drawings, prior to installation. Also check condition of precast and ensure no damage is evident. Check mastic sealant, and that it meets the specifications. Ensure that the precast exterior is waterproofed with bitumastic/asphaltic material. If piping penetrations are cast in, verify the number of holes and that their location generally matches the drawings. This could include wet well, valve chamber, manholes, detention chamber, etc. 5. If cast-in-place structures are approved, verify rebar on site matches approved shop drawings, prior to installation. Ensure the rebar is adequately supported, and measure to verify the thickness of the base slab matches the drawings. 6. Verify any piping and equipment that is on-site matches approved shop drawings B. Timing 1. Following excavation and backfilling of subgrade, prior to installation and/or construction of any structures. C. Suggested Certifications/Reports received prior to inspection 1. Subgrade compaction testing (if required) 2. Geotechnical boring logs (if required) 10.05 STAGE THREE: FINAL STRUCTURE INSPECTION/PRE-EQUIPMENT INSTALLATION Standard Pump Station 59 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 A. Purpose 1. All structures shall be cleaned and acceptable for manned entrance for inspection. 2. Verify all pump station structures have been installed/constructed correctly 3. Verify influent sewer and associated manholes have been installed correctly. 4. Locate forcemain and verify it was installed correctly. 5. Verify detention chamber and associated manholes have been installed correctly. 6. Inspect control panel prior to install. B. Timing 1. Following Stage 2, after installation/construction of all structures, influent sewer and detention basin, but prior to backfilling. C. Certifications/Reports received prior to inspection 1. Wet well hydrostatic test (if required) 2. Influent sewer pressure test (if required) 3. Detention chamber hydrostatic test (if required) 4. Concrete testing reports (if required) 10.06 STAGE FOUR: POST EQUIPMENT INSTALLATION A. Purpose 1. Verify pumps, control panel, and radio have been installed correctly. 2. Verify remaining equipment and associated ancillary items are per specifications and have been installed correctly. 3. Inspect yard piping and electrical conduit installation. 4. Verify Grounding Electrode System is installed at service disconnect. 5. Inspect trench excavation and pipe bedding. 6. Verify thrust restraint is installed at all pressure fittings. 7. Pipe supports for vertical forcemain piping in wet well. 8. Correct configuration of piping and appurtenances in valve chamber. 9. Measure distance upstream of magnetic flowmeter to tee or fitting. 10. All pipe supports in valve chamber are secure. 11. Pipe penetrations through structures and method of sealing. 12. Pressure testing of gravity sewer, isolation valves, and cleanouts. B. Timing 1. Following Stage 3, after installation of all piping, valves and fittings, prior to trench backfill. 10.07 STAGE FIVE: EQUIPMENT STARTUP A. Purpose 1. Pull pumps from the pump station for inspection. Standard Pump Station 60 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 2. Verify each manufacturer has field-verified their specific devices. 3. Demonstrate that all equipment is installed and operates as an integrated system. 4. Complete startup testing. B. Timing 1. Following Stage 4, after installation of pumps and all electrical and controls systems. C. Suggested Certifications/Reports 1. Submersible pump equipment start-up report and certification (includes pumps, control panel, and related appurtenances). 2. Standby generator start-up report and certification (if required). D. Testing 1. Performance Acceptance Test (by Contractor) a. In the presence of the District Operation/Pump Station personnel, the Contractor shall subject the pump equipment to such operating tests as may be required by the District to demonstrate that the equipment performs in accordance with the design requirements. At a minimum, the following two (2) tests shall be performed: The insulation resistance of the pump’s windings and cables i. shall be tested. The installed pumps shall not register less than 100 meg-ohms resistance per winding on a meg-ohm meter. The pumps shall be subjected to start-up tests with the ii. voltage, current and other significant parameters being recorded on the standard forms provided by the manufacturer. The contractor shall arrange for an adequate supply of water for the tests. The minimum quantity of water to be provided shall be equivalent to 1.5 minutes of continuous pumping at the rated pump capacity for each pump operating alone. Each pump shall be tested a minimum of two (2) times. In addition to the water required for the Contractor’s test, the Contractor shall supply an adequate water supply for all of MSD’s pump startup described below. 2. Pump Startup (by MSD) a. Drawdown test b. Check for leaks in pump mating surface and discharge piping c. Test alarms d. Pump station testing for full flush of the forcemain. Testing will include single pump operation and multiple pump operation. e. Check pump guiderails 3. Flowmeter Startup (by MSD) a. Verify flowmeter installation and check accuracy 4. Instrumentation/Control Panel Startup (by MSD) a. PLC Program test b. Communication test 5. Generator Startup (by MSD) Standard Pump Station 61 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 a. Load test for station operation b. Test automatic switchover cycle c. Validate manual transfer switch (if applicable) 10.08 STAGE SIX: FINAL COMPLETION INSPECTION A. Purpose 1. Verify sitework, including grading and pavement, has been completed per approved construction plans and specifications. 2. Verify fencing has been installed correctly. 3. Verify Conduit Seals have been poured. B. Timing 1. Following Stage 5, after installation and construction of all sitework, including grading, paving, fencing, etc. 10.09 STAGE SIX A: POST-FINAL COMPLETION INSPECTION (IF REQUIRED) A. Purpose 1. Verify final punch list items have been completed as required B. Timing 1. Following Stage 6, after notice by contractor that punch list items have been corrected. 10.10 STAGE SEVEN: FINAL ACCEPTANCE/DELIVERABLES A. A Reliability Acceptance Test shall occur for the first thirty (30) days of the pump station being in service. If the pump station operates as intended for the entirety of this period, the pump station will be ready for acceptance by the District. B. Prior to District Operations/Pump Station Division accepting this facility, the following submittals must be provided thru Accela: 1. Four (4) sets of as-built electrical schematics. 2. Four (4) sets of as-built prints of the pump station site, prepared by an engineer or land surveyor registered in the Missouri, certifying that all structures, sewers, roads and other pavement were built in accordance with the approved plans and located within existing easements. 3. A complete set of the as-built drawing computer files (including structural and mechanical details) in AutoCAD Lt format (jump drive). 4. Pump manufacturer’s start-up test procedures; the recorded factory test readings for voltage, current and other significant parameters documented on standard forms; and blank forms for the field test. 5. Letter of completion from paving contractor, guaranteeing that all pavement and pavement subsurface have been installed per the approved plans and specifications. 6. Control panel schematics, 11”x17” in size, laminated to the inside of the control panel exterior door. 7. Operating manuals and specification literature (both hardcopy and digital copy). 8. Equipment Warranties (both hardcopy and digital copy). Standard Pump Station 62 Metropolitan Saint Louis Sewer District Design and Construction Requirements July 2020 9. Copy of electric, gas and water bills to facilitate the transfer of these accounts to the District at the time of dedication. 10.11 RE-INSPECTION OF WORK A. The District will perform one (1) inspection and one (1) re-inspection at each stage of the construction at no charge to the contractor. The contractor will be responsible for all additional costs associated with the District’s re-inspections due to the failure of the contractor to satisfactorily correct the identified deficiencies.