PART 1-GENERAL
1.1 Description
A. General
1. Furnish all labor, materials, tools, equipment and services for leachate pumping equipment in accordance with contract documents.
2. Provide all supplementary or miscellaneous items and devices incidental or necessary for a proper and complete installation.
B. Scope of materials and services shall include
1. Supply and installation of a submersible type pumping systems for removal, conveyance, and control of leachate from the landfill operating on electric service.
1.2 Submittals
A. Submittals shall include pump performance data, assembly drawings, electrical schematics, key components cut sheets, fittings installation details, warranty statement, and list any revisions or exceptions to all specifications.
B. Manufacturer’s installation instructions shall be provided with shipment of equipment.
PART 2- PUMP SYSTEM
2.1 Manufacturer
A. Pumping system shall be in compliance to specifications, drawings, and shall not take exceptions.
B. Pumping system shall be a Sidesloper® P2K series as manufactured and supplied by GunnCo Pump & Control, Incorporated, Cumming, Georgia 770-889-7114.
2.2 Pump
A. Pump shall be constructed of 300 series stainless steel including housing, impellers, bowls, check valve disc, shaft, coupling, and strainer. Bearings and seal rings shall be constructed of Teflon material.
B. Pump shall provide a minimum flow of [____] GPM at a discharge pressure of [___] feet of total dynamic head with a second point of [___] GPM at a discharge pressure of [___] of total dynamic head. Shut-off head shall be at [___] feet of total dynamic head.
C. The pump shall be a model [P2K____]
2.3 Motor
A. The motor shall be [___] Horse Power non-overloading and suitable for operation on [1/230] [3/230] [3/460] volt, 60 Hz supply of power.
B. Motor shall be suitable for leachate applications, be permanently lubricated, and constructed of stainless steel wetted parts with stainless steel clad or corrosion resistant end housings.
C. Power cable shall be heavy duty submersible type, jacketed, continuous length, and sized per U.S. NEC standards. A strain relief/riser exit fitting shall be provided. The cable shall be equal to the riser pump length plus 20' minimum.
2.4 Wheeled Carrier
A. Pump and motor shall be mounted in a patented Sidesloper™ wheeled carrier constructed of stainless steel with non-corrosive and self-lubricating wheels. Level sensor holder shall be permanently mounted on carrier as to prevent pump from running dry. The level sensor shall be able to be installed without disassembly or removal of the pump from carrier.
B. Carrier supplied must be in compliance with United States patent laws.
C. Patented removable suction strainer shall be provided to allow for cleaning without removing pump from carrier. Strainer will be reinforced and have round perforations allowing for a minimum of 50% open area.
D. The pump assembly shall be designed for use in an 18” to 24” inch SDR 17 or 11 HDPE riser pipe with a maximum pump riser length of [_____] feet (distance from the pump operating location to the entry of the pipe). The carrier shall allow the pump to travel up and down the riser over welding beads to allow for stable operation of the pump. Wheels shall have a minimum diameter of 6” and shall be constructed of a self-lubricating non-metallic material.
E. The carrier shall be equipped with a welded stainless steel ring with a suitable stainless retrieval cable equal to the total riser pump length. The cable shall be provided with stainless steel U-bolt type clamps, snap hook, and anchor. The cable shall be removable from the pump carrier without removal of cable U-bolt clamps.
F. The carrier shall be equipped with patented skid plate design on both the suction and discharge ends as to allow for easy installation and removal of pump.
G. The carrier shall be equipped with stainless steel cam lock type connection on discharge end as to allow for easy disconnection from discharge piping.
2.5 Discharge Assembly
A. A [___] inch discharge assembly shall be provided. Pipe shall be of suitable material for the application and a minimum working pressure rating 10% over the maximum pump pressure at shut off condition and rated no less than 50 PSI working pressure.
B. Pump discharge shall have stainless steel cam lock connector and positive locking companion fitting to allow for quick connect/disconnect of the pump and discharge piping.
C. Discharge pipe shall be equipped with stainless steel male threaded ends to allow for connection of stainless steel cam lock type connectors.
D. A stainless steel elbow and cam lock fittings shall be provided to allow quick removal of the discharge assembly without tools. A stainless steel gas tight riser side exit fitting shall be provided. Instructions for the installation of the fittings shall be provided.
E. OPTION: A stainless steel flow meter tee fitting (f-npt ends) shall be provided for the installation of the flow meter. Flow tee shall be installed so that the fitting remains full at all times.
1. Insertion paddle wheel flow meter flow tee shall be installed inside the riser with stainless steel cam lock disconnect fittings.
2. Insertion magmeter flow tee shall be installed outside the riser with stainless steel cam lock disconnect fittings.
F. OPTION: A stainless steel swing check and ball valve shall be provided and installed outside the riser.
2.6 Controls
A. The control panel shall provide automatic pump operation, protection, and level indication for a single pump operating in sump. Panel shall be a Sidesloper™ GC101 Series Control Panel. Enclosure shall be rated [NEMA 4 Steel] [NEMA 4X Stainless Steel]. Enclosure size shall be minimum dimensions of 30” X 36” and shall include a 17” X 11” outer door viewing window which allows view of indicators. Door shall open and close using a three point latch system with stainless steel exterior handle and no perimeter clips or latches shall be required to properly close. The handle shall be equipped with a lock hasp for use with customer’s pad lock.
B. The panel shall be equipped with a properly sized main disconnect circuit breaker (thermal magnetic permanent trip Square D type HDL) with inner door interlocked operator handle. Additional breakers shall include Motor Breaker (Square D type HDL), Control Circuit Breaker (Square D QOU), and Receptacle/Accessories Circuit Breakers (Square D type QOU) where applicable. All breakers shall be selected for the required trip characteristics of the components protected and shall be back-plate mounted. Fuses for voltage/phase monitor shall be provided.
C. The motor starter shall be a heavy duty NEMA rated Square D 8536 with properly selected thermal overloads with alarm auxiliary contacts for overload condition.
D. An indicating controller with digital level read out to 1/10th of an inch shall be installed for each pump. Range shall be 0-138.6” and display shall be with ½” high back lit LCD digits. The controller shall be adjustable for pump and alarm set and reset points using only a screwdriver. Level and ON and OFF set points require only turning a 5 position selector knob. No punch and scroll techniques shall be required to check or adjust set points. Controller shall have plug in type terminals for all input and output connections to allow simple should replacement be required. Display shall flash during a high level condition. A plug in type auxiliary relay shall be provided for operation of the motor starter contactor to maximize life of controller pump contacts.
E. The unit shall include a primary power surge protection device, control circuit surge suppressor (plug-in module with indicator light), and an instrument signal surge suppressor. The level system shall be intrinsically safe using a dual barrier fused intrinsically safe barrier. A plug-in type indicating voltage/phase monitor shall be provided to protect against phase or voltage fault conditions.
F. Interior door operator controls and indicators shall include RUN light, OVERLOAD light, and a PHASE LOSS/VOLTAGE FAULT light shall be provided. Lights shall be 30mm transformer type with 6.3V lamps. H-O-A switch and overload reset push button shall be 30mm. An electro-mechanical elapsed run time meter to 1/10th hour shall be provided. Interior door shall allow access to all breaker resets at surface level.
G. A heater with adjustable thermostat shall be provided to reduce moisture inside of the panel.
H. Terminal strip shall be provided for connection of level sensor and flow meter (if applicable) which shall be mounted for easy access.
I. All components shall be labeled and all wires shall be numbered. Schematic drawing shall include wire and terminal numbers for each component.
J. A transformer shall be provided where required or specified with a rating of 250VA. Transformer shall be properly fused and control circuit shall be equipped with a control circuit breaker.
K. An overload reset shall be provided. Reset shall be a through the door push button with spring return.
L. OPTION: A top mounted RED high level alarm light shall be provided in addition to the flashing level indicator display feature. Alarm light shall be [LED Flashing] [Lexan lens with 40 watt bulb with flasher] [Strobe].
M. OPTION: A digital flow meter with LCD display allowing for simultaneous display of flow rate and gallons total (to 99,999,999) shall be provided. Unit shall be potted into an aluminum frame housing and mounted in the interior door of the enclosure. Unit shall be a pulse input type operating a 24vdc power supply. Total gallons pumped must be re-settable and lockable for non-reset operation. A power supply rated for 24vdc 100mA minimum output shall be provided. An LED on the power supply shall provide operation indication.
N. OPTION: A motor monitoring device shall detect a dry run/“dead head” (undercurrent) condition shall be installed. In addition the device shall be capable of providing redundant motor protection for overload, high and low voltage, short cycle, and undercurrent. Three phase units shall also provide phase and amperage unbalance detection. Unit shall provide a digital code of any fault or status and be selectable for display of voltage or amperage for each leg and average. Display shall provide amperage or voltage. Unit shall be fully programmable for actual amperage/voltage selection using the digital display and shall be capable of programming delay periods and number of restarts after a detected fault condition. Unit shall be back-plate mounted with an interior door cut out to allow viewing and adjustment without opening panel interior door.
O. OPTION: A remote lockout circuit with indicating light shall be provided. Circuit shall include a 24vdc relay and lockout/tank full indicating light. Primary lock out panels shall additionally be equipped with a 24vdc power supply suitable for application.
P. Option: An event counter shall be provided to display the number of starts of the pump.
Q. Option: A level simulator circuit shall be provided to allow for push button testing of level indication system.
2.7 Instrumentation
A. Each pump shall be equipped with a submersible pressure transducer of stainless steel construction compatible with control panel and with a static accurate of no more than 1% of range shall be provided. Range shall be 0-5 PSI and the unit shall provide a 4-20mA signal and be equipped with an integral surge suppressor.
B. The transducer shall be equipped with a shielded cable suitable for the application and of continuous length with a heavy outer jacket. A strain relief/riser exit fitting shall be provided. Cable shall be equal to pump power cable length.
C. The transducer shall be equipped with a desiccant type disposable drier tube for shipment and a permanent bellow breather located in the control panel for operation.
D. Transducer shall have an oversized sensing face with Teflon coated diaphragm.
E. OPTION: A flow meter sensor shall be provided.
1. Device shall be an insertion paddle wheel type of stainless steel construction with jewel bearings to resist wear and clogging. A 15’ cable shall be provided.
2. Device shall be an insertion magmeter type of stainless steel construction. A 15’ cable shall be provided.
F. OPTION: A wireless remote lockout system shall be provided with the capability of receiving signal from radio transmitter to initiate lockout condition and disabling pump from pumping. Associated sending unit to be located at tank or sump. Requires option “O” in control panel (2.6.O)
G. OPTION: A cellular based monitoring system shall be provided allowing for web based monitoring, SMS notification, and email notification of system status. System shall include 12 months of cellular service plan included.
2.8 Junction Boxes
A. The pump supplier shall provide junction boxes for use with the cables for the riser side exit arrangement. Junction boxes shall be selected and designed for easy recovery and replacement of the pump and transducer cables while providing a complete seal of moisture and gases between the riser and control panel.
B. All boxes shall be NEMA 4X rated [non-metallic] [stainless steel] with hinged door and locking hasp. All exterior latching screws shall be self-retaining.
C. The power cable junction box shall be size 10” X 8” X 4” minimum and provided with a steel back plate, properly sized terminal strips, ground lug, and properly sized non-metallic cable compression fitting.
D. The transducer level sensor/flow meter cable junction box shall be size 10 X 8” X 4” minimum and provided with a steel back plate, terminal strips, a properly sized bellows breather device, and properly sized non-metallic cable compression fitting.
E. Riser pipe cable fittings for the power and sensor cables shall be nylon construction non-corrosive strain liquid tight straight strain relief type properly sized for the power and sensor cables provided. Fittings shall be provided for both the riser and associated conduit or junction boxes. A sufficient quantity shall be provided for each application. Cable fittings shall be installed in correctly sized tapped holes as per pump provider’s instructions.
2.9 Junction Box Mounting Rack
A. Uprights and Cross supports shall be galvanized unistrut type material.
B. All Hardware shall be corrosion resistant and unistrut type. Nuts shall be used at each connection.
C. All ends of unistrut shall be finished and capped with vinyl covers.
D. Bottom of boxes shall be a minimum of 24” above grade and secured with concrete or mounted on wall with appropriate stainless steel fasteners.
E. Conduit Seals shall be provided for use under control panel for pump power and instrument cables to provide a gas seal between panel and junction boxes. Proper conduit fittings shall be provided for proper installation.
2.10 Control Panel Mounting Rack
A. The pump supplier shall provide a mounting support for use with the control panel provided.
B. Uprights shall be minimum 2” sch 40 galvanized steel pipe with threaded ends.
C. Uprights shall be capped with thread on galvanized caps.
D. Cross supports shall be galvanized unistrut type material.
E. All hardware shall be corrosion resistant and unistrut type. Nuts shall be used at each connection.
F. All ends of unistrut shall be finished and capped with vinyl covers.
G. Bottom of panel shall be a minimum of 30” above grade and secured with concrete.
PART 3-EXECUTION
3.1 Installation
A. Equipment shall be properly installed by the manufacturer based upon the contract documents and manufacturer’s instructions.
B. Control panel shall be installed on suitable mounting rack to resist damaged caused by wind, corrosion, and/or rot. All electrical routing between the control panel and equipment shall allow for recovery and installation necessary for service and prevent moisture or gas fumes from entering control panel from the riser pipes.
C. Flow meter sensor fitting shall be installed per manufacturer’s instructions and shall ensure that the sensor tee fitting remains full at all time for proper recording of flow totals.
D. All piping outside the riser (pipe, pipe supports, required pipe fittings, check valves, and isolation valves) shall be supplied and installed by the contractor.
3.2 Contractors Responsibilities
A. Contractor shall ensure that all collection piping and the riser pipe should be free of shavings, debris, sand, silt, and/or mud at the time of pump installation.
B. Contractor shall ensure there is sufficient liquid in the risers at the time of start-up and testing.
C. Contractor shall ensure an accurate “AS BUILT” sketch is recorded of the riser pipe fabrication and dimensions at the time of installation of the pumps.
D. Contractor shall ensure a record of the total lengths of materials “AS INSTALLED” used in each riser pipe is recorded and provided to the manufacturer at the time of start-up along with a copy of the original “AS BUILT” sketch.
E. OPTION: Contractor shall install the system package per the manufacturer’s instructions including but not limited to the pump, discharge piping, control panel, junction boxes, wiring between junction boxes and control panel, and seal-offs.
3.3 Start-Up
A. After installation the manufacturer shall provide system start-up services including the following services:
1. Inspect installation and adjust or set all necessary adjustments for proper service.
2. Test and record pump and control operating characteristics including flow rates, amperage, and level readings and cycles at start and completion of testing.
3. Confirm that the installation is correct and advise contractor of any revisions necessary for proper maintenance or operation.
4. A final start-up report shall be furnished which shall include the “AS BUILT” of pump system and of discharge piping.
B. Operations and Maintenance Manuals shall be provided and shall include troubleshooting guide, system controls operator instructions, pump assembly and service guide, pump operating characteristics, electrical AS BUILT schematic, bill of materials of electrical control panel, warranty statement, contact statement, and additional information as necessary for normal operation and maintenance of the system.
3.4 Semi-Annual Preventative Maintenance Service
A. A semi-annual preventative maintenance service agreement for maintaining compliance shall be included with system sale to provide inspection of performance, operation, and to evaluate the pumping system to ensure proper operation. Inspection shall include but not be limited to: test panel operation, test level and alarm settings and adjust if needed, check lights, fuses, and surge suppressors/arrestors, record pump run hours, check cycle times to ensure pump is not short cycling, inspect all electrical connections for signs of corrosion caused by gas, check and record operating voltages and amperages, inspect exit fitting and discharge piping for leaks, provide an inspection report with evaluations to operator.
3.5 Warranty
A. Sidesloper™ packages sold as specified and complete systems (pump, panel, and level sensor) shall be covered by a 12-month warranty. The warranty period begins upon the date of shipment and covers all components against failure to function due to workmanship, component failure, or materials compatibility for the application as recommended and sold and paid for within quoted terms.
B. Claims under the warranty can be made by obtaining a return authorization number from GunnCo during the warranty period and returning the defective component(s), freight pre-paid to GunnCo or the proper service location as directed by GunnCo. Details of the problem should be included with the returned item along with the return authorization number. The defective component must be returned within 30 days of the authorization date. The option to repair, replace components shall be that of GunnCo. Costs associated with troubleshooting, removal or replacement of components, rental equipment, rush premium charges, and freight is not included under warranty unless stated.
C. Warranty does not cover normal wear, damage due to accident or physical damage (during shipment, installation, or storage), acts of nature (lightning, flooding, etc.) (Blown fuses, surge suppressors, or voltage monitors), misuse, abuse, improper storage, improper/defective electrical service (low or high voltage or surges), improper installation, improper selection by others, operation outside design performance, or improper or unauthorized service or modifications.
D. Warranty applies only to system as operated under the conditions at the time of installation and per design parameters and conditions as specified pumping “clean” leachate free of excessive debris, solids, and sludge. Damage due to abrasives, solids, sludge, sand, silt, and scale causing damage and wear in pump/motor/carrier and transducer is not considered warranty issue unless specifically stated in proposal.
E. Option: Field Warranty for all GunnCo installed systems.
1. Pump systems sold as an installed system project package are covered for a 12-month service period after installation by GunnCo or its representative. The warranty does not cover physical damage, abuse, misuse, freezing, lightning and surge damage, improper operation, or damage due to unauthorized design revisions or operating parameters. Materials failures may be subject to the original manufacturer terms and conditions of warranty.
2. The service warranty procedure shall include confirmation of nature of problem to GunnCo and may require local electrician or site personnel to confirm scope of problem.
3. Repairs by others should be authorized by GunnCo. No invoices or back charges will be accepted without prior approval by GunnCo. Charges should be customary and include a written description of the problem and solution. Damaged components must be returned to GunnCo for warranty consideration.
4. When applicable, GunnCo requests site personnel replace a damaged component (such as plug-in parts) or check status lights and troubleshoot to determine nature and scope of problem.
5. Service visits determined to be non-warranty related are subject to normal GunnCo service charges, per diem rates, and travel time charges.