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PART 1 GENERAL
1.01 SUMMARY

A. Section Includes: Factory-built and tested Residential Grinder Pump

Sewage System(s), each consisting of 2 HP centrifugal grinder pump(s)

suitably mounted in a collection tank constructed of linear low-density

polyethylene (LLDPE), pump power cable quick disconnect, tool-free pump

removal system, non-contact solid state level control system, indoor

system monitor, data acquisition system, telemetry system, internal piping

and valve assemblies. For ease of serviceability, all grinder pumps shall be

of like type, impeller and horsepower throughout the system. To ensure

single source responsibility for the equipment, the Residential Grinder

Pump System(s) shall be by the same manufacturer as supplying the

pump, level control and control system.

B. Value Engineering: Components shall be evaluated by function and fit

with packaged residential grinder pump station(s) performance require

ments. Non-metallic components shall be furnished to prevent corrosion.

C. Related Sections

1. Section 02200 - Excavation, Backfilling, and Compacting

2. Section 02700 - Sewerage and Drainage

1.02 NATIONALLY RECOGNIZED TESTING LABORATORIES (NRTL) AND STANDARDS

A. Underwriters Laboratories, Inc. (UL)

1. UL 778, Motor Operated Water Pumps

B. Canadian Standards Agency (CSA)

1. CAN/CSA-C22.2 No. 1010.1-92, Safety Requirements for Electrical

Equipment for Measurement, Control and Laboratory Use, Part 1:

General Requirements

2. CAN/CSA-C22.2 No. 68-92, Standard for Motor-Operated Appliances

(Household and Commercial)

3. CAN/CSA-C22.2 N0. 108-M89, Standard for Liquid Pumps

C. American National Standards Institute ANSI/Instrument Society of America

(ISA)

1. ANSI/ISA S82.01, Safety Requirements for Electrical Equipment for Control Use
   

D. Intertek Testing Services (ITS)


1. ETL Residential Grinder Pump Sewage System Listing

2. ETL-C Residential Grinder Pump Sewage System Listing

1.03 REFERENCES

A. American Association of State Highway and Transportation Officials

(AASHTO)

1. Standard Specifications for Highway Bridges, Fifteenth Edition, 1992.

B. National Electrical Manufacturers Association (NEMA Standard 250-1991)

1. NEMA 4X, Intended for indoor or outdoor use to provide a degree of

protection against windblown dust and rain, splashing water and

hose-directed water (1000 psi)

2. NEMA 6, Intended for indoor or outdoor use to provide a degree of

protection against the entry of liquid during occasional temporary

submergence (1 hour) at a limited depth (6 feet/3 psi)

3. NEMA 6P, Intended for indoor or outdoor use to provide a degree of

protection against the entry of liquid during prolonged submergence

(24 hours) at a limited depth (6 feet/3 psi)

C. Occupational Safety and Health Association (OSHA)

1. 29 CFR 1910.146, Permit Required Confined Space Entry

D. International Electrotechnical Commision (IEC 529)

1. IP 67, Intended for indoor or outdoor use to provide a degree of

protection against the entry of liquid during occasional temporary

submergence (1 hour) at a limited depth (6 feet/3 psi)

2. IP 68, Intended for indoor or outdoor use to provide a degree of

protection against the entry of liquid during prolonged submergence

(24 hour) at a limited depth (265 feet/100 psi)

1.04 SYSTEM PERFORMANCE REQUIREMENTS

A. Grinder Pump: Each two horsepower pump shall be rated 208/230 volts,

single phase, 60 Hertz, and 3450 RPM. Grinder pump shall be capable of

delivering 10 gallons per minute (gpm) against a total dynamic head (TDH)

of 100 feet and 45 gallons per minute (gpm) against a total dynamic head

(TDH) of negative 60 feet without overloading. Manufacturer shall provide

pump characteristics diagrammed graphically on performance curve.

Performance curve shall be established by measuring total dynamic head

in feet of water against discharge flow in gallons per minute and shall

contain at least 5 measured points. Each pump shall be expected to per

form as its curve describes.

B. Level Control Sensor: Password protected non-contact level sensor shall be capable of measuring distances between

1 to 16 feet (0.3-5 meter) with a tank resolution of 0.01 feet and with (0.5 percent accuracy of tank span.

1.05 SUBMITTALS

A. Submittals: Manufacturer shall furnish a minimum of four (4) complete

submittals of the proposed equipment for approval by the Engineer prior

to bid. This submittal shall contain, but not be limited to detailed

specifications, pump performance curves, collection tank structural

calculations, collection tank flotation calculations, and drawings of the

major components of the system and complete parts list. Engineer will

return two (2) copies of the accepted submittal to the Manufacturer.

Manufacturer shall include with their bid one (1) copy of the accepted

submittal. Only bids from approved Manufacturers with pre-accepted

submittals will be considered; all other bids will be considered

unresponsive and will be returned.

B. Shop Drawings: After receipt of notice to proceed, the manufacturer shall furnish a minimum of four (4) sets of shop drawings detailing the

equipment to be furnished including dimensional data and materials of

construction. The Engineer will promptly review this data, and return two

(2) copies as accepted shop drawings, the Manufacturer shall proceed

immediately with the fabrication of the equipment.

1.06 MANUFACTURER QUALITY ASSURANCE

A. Qualifications: Manufacturer shall demonstrate experience in the design, manufacture, and assembly of grinder pumps, level control sensors, control systems, piping and valve assemblies, and polyethylene collection tanks for specific use in low pressure sewage systems.

B. Regulatory Requirements: Residential Grinder Pump Sewage System(s) shall be furnished to meet state and local requirements.

C. Certifications: Certified test results shall be supplied by Manufacturer

upon request showing Residential Grinder Pump Sewage System(s)

operation parameters.

1.07 DELIVERY, STORAGE, AND HANDLING

1. Packing, Shipping, Handling, and Unloading: Manufacturer shall provide a complete Residential Grinder Pump Sewage System(s) on skid(s) or pallet(s) ready to install. Do not drop or impact the basin. If basin must be moved, be sure that ground traversed is smooth and free of rocks, debris, etc. When lifting basin, only a pliable strap or rope should contact basin. Do not use chains or steel cables.
   

B. Storage and Protection: Store Residential Grinder Pump Sewage System(s) away from sun and weather exposure until installation.

1.08 PROJECT/SITE CONDITIONS

A. Environmental Requirements: per specific jobsite

B. Existing Conditions: per specific jobsite

1.9 WARRANTY

A. The Manufacturer shall furnish a written warranty for the complete

package grinder pump sewage system against any and all defects in

material and factory workmanship for a period of 2 years from date of

installation, provided product is installed, serviced, and operated under

normal conditions according to Manufacturer�s instruction. Repair or parts

replacement required as a result of such defect will be made free of charge

during this period upon return of defective parts or equipment to

manufacturer.

1.10 OWNER�S INSTRUCTIONS

A. The Manufacturer shall submit two (2) copies of a draft Operations and

Maintenance Manual to the Engineer for review. Upon acceptance by the

Engineer, the Manufacturer shall supply six (6) copies of the final

Operations and Maintenance Manual. Manual shall be neatly bound in

three ring binders. All pages and exhibits shall have reinforcements or be

printed on heavy-duty paper stock to reduce page tear out. The maximum

exhibit size shall be 11 inches by 17 inches.

PART 2 PRODUCTS

2.01 MANUFACTURER

A. Equipment specified shall be produced by qualified company as described in Article 1.06.

2.02 EXISTING PRODUCTS

A. Existing mains shall be of materials specified by Architect/Engineer in

Section 02700 - Sewerage and Drainage. Residential Grinder Pump

Sewage System(s) materials shall be compatible with existing materials to

maintain water tightness.

 

2.03 MATERIALS

A. All components shall be constructed of corrosion resistant materials with proven history in residential sewage service. Painted or galvanized steel components exposed to pumped media shall not be allowed.

2.04 MANUFACTURED UNIT

A. Manufacturer shall provide factory built and tested Residential Grinder Pump Sewage System(s) completely assembled with grinder pump suspended in a polyethylene collection tank, tool-free pump removal system, shut-off valve with integral extension handle, non-contact ultrasonic level control sensor, and check valve assemblies within collection tank, remote system monitor panel, and all necessary internal wiring, piping, and controls. Collection tank shall include shallow dry well so that service to controls or changes to control settings may be

performed outside wet well.

2.05 MODULAR CONSTRUCTION

A. Modules: Residential Grinder Pump Sewage System(s) shall have easily removable pump, level sensor and control modules. The pump module shall contain all mechanical components including pump, motor, grinder, ball check valve, electrical quick disconnect and sealing flange. The non-contact level sensor shall contain only solid state components. The control module shall include motor contactor, terminal blocks and supplementary circuit breaker. Each module must be serviceable or repairable without special tools.

2.06 COMPONENTS

                   for specific tank height. Coils of extra cable inside wet well shall not

B. Collection Tank and Integral Shallow Drywell: The collection tank shall be

made of linear low-density polyethylene (LLDPE) of a grade selected for

tank applications, corrosion resistance to domestic sewage and

environmental stress cracking resistance. LLDPE shall be stabilized against UV degradation to UV-8 protection level

(ASTM D-2565). The collection tank wall shall be a minimum of 0.250 inches thick. Only one (1) seam shall be allowed

in collection tank. Seam shall be thermally welded and factory tested for leak tightness. The grinder pump station(s) shall

have all necessary penetrations molded-in and factory sealed. Under no conditions shall mechanical joints or fasteners

penetrating tank exterior be allowed. Collection tank wall and bottom must withstand the pressure exerted by saturated

soil loading at maximum burial depth and not allow a center deflection of more than 3/8 of an inch. All grinder pump station(s)

components must function normally when exposed to maximum external

soil and hydrostatic pressure.

1. Comprehensive Design Basis: Structural calculations using short

term physical properties shall be de-rated with 20 year design

coefficient. Lateral backfill and hydrostatic pressure shall be

calculated as 120 pounds per cubic foot and 62.4 pounds per cubic

foot, respectively.

2. Anti-Flotation Flange: Collection tank shall incorporate integral anti- floatation flange. Flanges attached with glue or welding shall not be acceptable.

3. Cover Attachment: Six (6) 3/8 inch 300 series stainless steel cover fasteners shall be molded-in basin.

4. Integral Shallow Dry Well: To meet safety provisions in Article 1.03 C, collection tanks shall incorporate shallow dry

well for access to pump disconnect, isolation valve handle and level control. It shall be built 7 inches deep, contain all

control equipment including integral junction box, and not be considered a confined space by OSHA 1910.146 definition.

5. Minimum Wet Well Capacities:

a. Working volume, calculated from collection tank bottom to

inlet invert, shall be 90 gallons.

b. Standing volume, calculated from collection tank bottom to

pump off level, shall not exceed 27 gallons.

c. Operating volume, calculated from pump off to pump on level

shall be 25 gallons.

d. Reserve volume, calculated from high alarm level to inlet

invert shall be 20 gallons.

.

C. Collection Tank Cover:

                     Cover shall withstand 2500 pound live wheel and impact load per AASHTO specifications. Cover shall be gas and watertight. Cover                       
                     surface shall have low profile silhouette and non-skid surface. Manufacturer shall provide test data supporting load rating upon                        
                      request. Covers without load ratings shall not be considered acceptable.

D. Piping and Valves:

1. Internal Discharge Piping: Collection tank shall be equipped with

series 300 stainless steel and/or engineered thermoplastic discharge

piping joined by tapered pipe threads or solvent cement.

2. External Discharge Piping: 48 inches of Braid-reinforced medium

density polyethylene (MDPE) piping shall be installed to discharge

connection to reduce the possibility of shearing from downward

backfill settlement.

3. Check Valve: Pump discharge shall be equipped with a factory

installed, gravity operated, self-cleaning, injection molded PVC ball

check valve to prevent drainage back into the collection tank. Check

valve shall provide a full-port passageway and an access port for

visual and physical inspection without disassembling the discharge

piping. All working parts shall be non-metallic to ensure corrosion

resistance.

4. Isolation Valve with Integral Extension Handle: Discharge piping

shall be equipped with a PVC single union 1/4 turn ball valve rated at

235 PSI at 73(F (23(C). Ball valve shall be equipped with an integral

handle extending into the shallow drywell.

5. Compression Piping Seals: All pipe penetrations shall be sealed with

compression pipe grommets injection molded from DuPont Alcryn�

thermoplastic. The use of mechanical fasteners or other

thermoplastic materials shall not be acceptable.

E. Level Control:
                    Non-fouling sewage level detection for controlling pump

operation shall be accomplished by non-contact, solid state, continuous

ultrasonic level measurement. To assure reliable level control there shall

be no mechanical parts or breather assemblies in the level control. Level

control sensor shall meet NEMA 6P/IP68 for electrical enclosures and

connectors for operation inside wet well. Level control sensor shall be

equipped with quick disconnect. Electrical maintenance and changes to

level settings shall be done at surface level without exposure to wet well.

F.  Control Panel:
               Each grinder pump sewage system shall include a NEMA 4X & 6 UL listed controls enclosure integrally mounted in the shallow drywell.                  The enclosure shall be manufactured of thermoplastic to ensure corrosion resistance. The enclosure shall include a clear cover to allow                  visual confirmation of control status without removal of cover. The control panel shall include the following features: visual alarm and                  system status LED�s, push-to-run switch, pump run LED, high level (redundant) pump starting control. For each grinder pump, the                  control panel shall contain one (1) 20 amp, double pole circuit breaker with accidental actuation protection, one (1) low voltage                  (24VDC) control and alarm circuit with catastrophic over-voltage and over-current protection. The control panel shall contain motor                  contactor, terminal blocks and complete multi-alarm circuitry.

G. Indoor System Monitor:

Each Residential Grinder Pump Sewage System shall include a system monitor for interior wall mounting. System monitor shall be equipped with remote alarm and data display. System Monitor shall indicate the following conditions visually and audibly: system OK, high sewage level in basin, level control sensor failure, pump power failure, preventive maintenance and telemetry system fault.

H.  Pump Removal System:

The grinder pump(s) shall be automaticallyconnected to and suspended from the discharge connection guided by a C-channel. C-Channel shall be a one-piece extrusion of corrosion resistant, temperature modified and impact modified PVC. C-Channel shall extend from discharge connection to top of station. Each grinder pump shall be outfitted with a vinyl coated stainless steel lifting cable. The working load of the lift cable system shall be 50% greater than the grinder pump unit weight. Sealing of the grinder pump(s) to the discharge connection shall be accomplished by a hydraulic sealing flange. No part of the grinder pump shall bear on the bottom of the collection tank. Sealing of the pump/discharge interface with a metal-to-metal, O-ring or profile gasket shall not be acceptable. Systems utilizing painted steel or galvanized materials shall not be acceptable. Systems requiring tools to secure thegrinder pump/discharge interface shall be acceptable.

2.07 SYSTEM OPERATION

A. Pump Operation: The pump control system shall provide the following

routines for pump operation:

1. Level Settings: Pump ON, pump OFF and high level alarm settings levels shall be programmable to nearest 0.01 feet via a laptop computer interface without the need to for access or be exposed to the wet well.

2. Grease Ring Reduction Operation: The control system shall

incorporate a routine which will stagger the pump ON level by

0.14 ft. over a 0.5 foot range each pump cycle to reduce grease ring buildup.

3. Clog-Fault Operation: The control system will be capable of

detecting a clog in the pump. The method for detecting a clog shall

be via monitoring pump voltage, current draw and tank level

movement. In the event a clog is detected, the control system shall

jog the pump ON and OFF to remove the clog. The controls shall

then energize the pump continuously and check to see if the clog is

removed. This control routine will repeat three times. If after the

third cycle, the clog is not removed, an alarm shall be triggered.

4. Recovery Operation: The control system will be capable, through

pump current/voltage and tank level monitoring, to detect large-scale

collection system recovery conditions. An example of such a

ondition can occur after an extended power outage when a large

number of individual pumps turn on at the same time causing shut

off head pressures in the mains. In the event a recovery condition is

detected, the control system shall incorporate a random delay into

the pump cycle (provided that the tank level has not reached the

high level point) to reduce the pressure in the network mains and

speed the collection system recovery.

5. Sensor Fault Operation: If for any reason the system level sensor

fails, the control system shall enter a timed pump cycle. The pump

shall be activated once every 15 min. and will pump down the tank

until empty. The controls will determine when the tank is empty by

monitoring pump voltage and current draw.

6. Locked Rotor Fault Operation: The control system shall detect pump

locked rotor condition and will shut the pump down before the

pump circuit breaker blows. The system will attempt to unlock the

rotor by jogging the pump ON three (3) seconds and and OFF three

(3) seconds five (5) times.

7. System Alarms: The control system shall support the following alarms.

a. Pump Power Failure � Triggered by power failure to the pump.

b. System Failure � Triggered by a sensor failure, contactor

failure or communication failure between the System Monitor

and collection tank controls.

c. High Level � Triggered by high water level in the collection

tank.

d. Modem Failure � Triggered by a failure of the modem to

ommunicate with the central station.

e. Preventive Maintenance � Triggered if the control system

sensors detect a degradation of pump performance beyond

reasonable levels.

B. Data Acquisition: The control system shall log system performance data and automatically download the data (via modem) to the central station on a monthly basis. This performance data can be used to schedule routine maintenance. Data logged will include:

1. Number of pump cycles

2. Average runtime, seconds

3. Shortest runtime, seconds

4. Longest runtime, seconds

5. Average flowrate, gpm

6. Slowest flowrate, gpm

7. Fastest flowrate, gpm

8. Average supply voltage, volts

9. Lowest supply voltage, volts

10. Highest supply voltage, volts

11. Average current draw, amps

12. Lowest current draw, amps

13. Highest current draw, amps

14. Average time to speed, seconds

15. Slowest time to speed, seconds

16. Fastest time to speed, seconds

17. Number of Clog-Faults

18. Number of Recovery operations

C. Modem Operation: The System Monitor shall provide an interface for a 2400 baud modem card. The modem will connect to the pre-existing house phone line and the system will detect when the line is not in use. The modem shall allow the system to call a central monitoring station and

convey alarm status and system performance information. Via computer

interface at the central station, an operator shall be able to remotely

control the pump, change system settings and monitor tank level and

pump parameters in real time.

2.08 SAFETY

A. Confined Space: All preventive maintenance tasks for Residential Grinder Pump Sewage System(s) shall be accomplished outside wet well,

eliminating confined space entry as described in 29 CFR 1910.146. The

Occupational Safety and Health Administration defines in 1910.146

confined space to be one large enough and shaped in a way that allows

workers to enter and perform assigned work. Confined space has limited

or restricted means for egress, has poor natural ventilation, and is not

designed for continuous occupancy. Permits are required to enter con

fined spaces if they contain chemical or mechanical hazards.

B. Biological Hazards: All preventive maintenance tasks shall be performable with minimum contact with residential sewage.

C. Electrical Equipment: Grinder pump, level sensor and controls shall meet accepted standards for equipment for use in or near residences, and shall have been tested by a nationally recognized testing laboratory (NRTL) to certify its capability as a system to perform as specified.

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3.01 ACCEPTABLE INSTALLERS

A. List of acceptable installers or installer qualifications

3.02 EXAMINATION

A. Site Verification of Conditions: actions required to physically determine

that conditions are acceptable to receive packaged station. Including

verifying absence of defects.

3.03 PREPARATION

A. Actions required to physically prepare surface. Describe removal of

existing assemblies.

B. Protection: Erosion controls, hi-vis fencing, etc.

3.04 INSTALLATION