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1 / Pre-assembledsewagepumpstation made of Glass fiber reinforcedpolymerequipped with discharge connections, discharge pipes, valves, guide barsand cable holder to assemble 2 submersible waste water pumps.
Inner diameter:1800 mm
For all dimensionsincl. inlet and outlet positions see drawing
……………………………………..
The glass fiber material shall comply with the following standards:.
• Roving of glass fiber acc. ISO 2797
• Chopped strand material acc. ISO 2559.
• Woven roving acc. ISO 2113
The material of the complete station shall be applicable for Municipal and industrial waste water with a PH value from 5,5 to 8,0.
Thebottom part the inlet and the outlet connection pipe shall be laminated to the station cylinder. The cylinder shall be designed and approvedto withstandthe full hydrostatic head from the exterior of the station while the station is completely empty.
The pump station shall be delivered with an anchoring system to protect it from buoyancy over its complete length up to the subsoil level.
The supplier shall give in his installation manual detailed instructions about how to anchor the pump station and shall guaranty that the station is protected from buoyancy.
The pump station bottom shall be self-cleaning by having sloping walls and a reduced floor area which forces all solids typically found in waste water to the suction of the submersible pumps.
The discharge connections shall be mounted on the sloped wall so solids can’t settle below the discharge pipes.
The maximum volume left in the station after the pumps have stopped shall be400 Liters or 150 liter ifthe pumps are connected to an electronic sump cleaning device.
Lifting eyes and anchoring steel bars shall enable a quick and easy installation of the station. The supplier has to provide an installation manual with detailed installation and safety instructions.
The station must be protected against electrical shock according the IEC regulation 611 40.
The pump station shall be furnished with following equipment and ready for operation:
Safety grit divided in 2 parts including safety hook
Material: Stainless steel AISI 304 (not required when access cover is designed for heavy traffic acc. EN 124.
1 Cable holder with for hooks made in Stainless steel AISI 316
2 Discharge connection DN 100/150* made of Cast iron EN-GJL 250 with MULTI/JOINT coupling made in spheroidal graphite cast iron. Screws and bolts made in Stainless steel AISI 304
2 discharge pipes DN* 100/150 with 90° elbow
1 T connection pipe with 1m discharge pipe DN 150 ending with a MULTI/JOINT coupling for pipe PE 100 SDR 11 PN16. DN 125/180*
Pipe material: Stainless steel AISI 304
MULTI/JOINT coupling made in spheroidal graphite cast iron. Screws and bolts made in Stainless steel AISI 304
For each pump 2 guide bars with upper guide bar holder.
Material: Stainless steel 304
Each discharge pipe shall be equipped with a ball check valve and a soft closing gate valve made of cast iron.
Service engineers must be able to close and open the gate valve with a ratchet wrench from the top of the station without entering the pump station or risking his life.
Model: FLYGT 9150.020TOP station 150L or equivalent
Concretebaseplate to fasten the pump station with anchor bolts
Dimensions and weight have to be defined by the supplier to protect the station from buoyancy over its complete length up to the subsoil level.
Concrete quality acc. ENV 206 30/37 or higher.
Access cover in concrete frame for heavy traffic
Lockable, with Slip-proof surface, safety hook and opening hinge.
Design load:400 kN acc.to EN 124
Minimum opening of the access cover755 x 1540mm
Concrete quality acc. LM 1 DIN-FB 101 or higher
Access cover made of cast iron , coated
Access cover*made of Glass fiber reinforcedpolymer
Lockable, with support rod. (Not designed for loads).
Lifting chain with transition links Length = … m
According EN 818-1, 818-5, 818-6. Min. Load: …… Kg
Material: Stainless steel
Chain sling must be CE-marked.
Submersible wastewater pumpfor stationary submerged installation
Single-stage close-coupled submersible centrifugal pump with of semi open multi vane impeller designed to transport wastewater with fibrous materials and heavy sludge.
The impeller blades shall be self-cleaning upon each rotation as they pass across a sharp relief groove in the Insert ring and shall keep the impeller blades clear of debris.
The pump housing shall be prepared for the assembling of a flush valve.
The pump motor shall be induction type with a squirrel cage rotor, housed in an air filled watertight chamber submersible up to 20m according IEC 60034 protection class IP 68. The stator windings and stator leads shall be insulated with moisture resistant Class H insulation rated for 180 degree C (355 degree F). The stator shall be heat-shrink fitted into the stator housing.
The motor shall be sufficiently convection-cooled by the pumped media or by a cooling jacket filled with a Monopropylene glycol/water mixture.
Motor,pump and drive shall be designed and produced by the same manufacturer.
Explosion approved acc. EEx dIIB T3 *) (delete if Ex is not required)
Motor sealing
The cable entry shall consist of dual cylindrical elastomer sleeves, flanked by washers, all having a close tolerance fit against the cable and the cable entry. Epoxies, silicones, or other secondary sealing systems shall not be considered acceptable.
The shaft shall be sealed by a tandem mechanical shaft seal system consisting of two seals, each having an independent spring system. The seals shall require neither maintenance nor adjustment and shall be capable of operating in either clockwise or counter clockwise direction of rotation without damage or loss of seal function.
Duty parameters:
Liquid: Wastewater with fibrous solids
Max temperature of pumped liquid: 40° C
Rated flow per pump .….. l/s
Rated head: ……m
Minimum overall efficiency at the operating point: … %
Max. rated speed: ...... rpm
Max. rated Power P2: ...... kW
Operating voltage: ………………………… V
Frequency: ...... Hz
Starting method: direct / soft start*)
Max. Weight: ………..kg
Materials of construction
Pump housing: EN-GJL 250
Impeller: EN-GJL 250 with hardened leading edges
Insert ring: EN-GJL 250
Stator housing: EN-GJL 250
Shaft: 1.4057 or AISI 431
Shaft seal:
- Pump side: - Corrosion resistant Tungsten carbide WCCR
- Motor side: - Corrosion resistant Tungsten carbide WCCR
The motor shall be equipped with 10m submersible and screened cable including 2 leads for the sensors.
Model: FLYGT NP 3102/ 3127/ 3153/ 3171 or equivalent
According performance curve:
Flush Valve
One pump in each pump station shall be equipped with an automatically operating Flush Valve to create an automatic flushing of the sump. The valve shall be assembled on the pump housing and open for approximately 30 seconds when the pump starts. It shall create a powerful jetstream that flushes all solidsinto suspension, ready tobe pumped away. The flushing sequence shall be integral part of the pumping cycle and the valve shall and not require any additional power source.
Model: FLYGT 4901 or equivalent
Monitoring & Control / Pump drive
Each pump shall be equipped with a pump drive unit sized to match the submersible electric motor and designed for a power supply from 230-480V at 50or 60Hz 3 phase.
The pump drive shall provide all level control functionality, hand/auto operation, pump alternation, pump over temperature monitoring, seal leakage monitoring, pump self-cleaning, sump cleaning and pipe cleaning algorithms. The pump drive shall also include capability to monitor station inflow, pump speed and energy consumption in order to automatically operate the pump station at optimal energy efficiency.
One Pump drive per pump should be used to allow full redundancy and alternation.
It shall be tested and approved in accordance with international standards , the European safety directive 98/37/EC, the Low Voltage Directive 2006/95/EC, the EMC Directive 2004/108/EC and in accordance with the European standards:EN 61800-5-1:2003; EN 61800-3; EN 55011:2007;EN60529 and EN 60204-1
The software shall be programmed with all parameters and settings pre-configured for an efficient operation.
It shall be freestanding for wall mounting or cabinet installation construction an equipped with an air ventilated system.
Without any limitation or derating it shall operate in ambient temperature of up to 40°C (104°F) at an altitude up to 1000m.
It shall include provision for external communication to higher-level system. Communication shall be via 2-wire RS-485 connection to the pump drive. Communication shall be available as MODBUS RTU.
Serial communication capabilities shall include, but not be limited to set Start- and stop level, Pump clean interval, speed and ramp times as well as PID control parameters.
The communication telegram shall include process variable feedback like Sump level, power (kW), Output speed/frequency, current (A), % torque, relay outputs, digital inputs and drive status and fault information.
Following function shall be provided by the equipment:
A.High/Low Level Sump Control:
The pump drive shall provide automatic level control via means of a submersible pressure transducer (4-20mADC). User-programmable Start Level shall indicate the point at which the pump will start. Upon activation the pump shall run at maximum speed for a pre-determined period, then ramp down to the energy efficient Optimal speed, calculated by the pump drive. When the water level reaches the Stop Level, the pump shall stop. The Optimal Speed shall either be calculated by the pump drive or manually entered by the user.
In case of high inflow, the pump drive shall increase pump speed until the water level begins to decrease. When the water level reaches the Stop Level, the pump shall stop.
In case of very high inflow, in a duplex installation, when a single pump is unable to overcome the inflow conditions even at maximum speed, additional pumps shall be activated and run at maximum speed until the Stop Level is reached. If water levels continue to rise, a High Level Alarm shall be activated.
The pump drive shall incorporate a Minimum Speed function that prevents the pump from operating at speeds too low to move water based on the pump curve.
B.Run Time Averaging
The pump drive shall provide capability to balance run times for even wear. This shall be an internal function of the drive and not require external devices, such as an alternating relay. The function shall operate by determining a “random” start level based on the Start Level setting. Each drive shall determine its own random start level independent of each other. New random start levels will be determined after each pump cycle. The pump with the lowest random start level shall be first to start on any given pump cycle. The second pump shall remain in Standby capacity in case the lead pump shall not be able to lower the water level as described in the section above. By recalculating the random start levels every pump cycle, balanced run times are accomplished.
C.Pump Cleaning Function:
The Pump drive shall incorporate a “self-cleaning” function to remove debris from the impeller. The cleaning shall be triggered by following circumstances:
- Soft Clogging: When motor current is increasing over a certain period of time defined by the pump supplier.
- Hard Clogging: When motor current is increase drastically and pump stops.
D.Sump Cleaning Function:
The pump drive shall incorporate a sump cleaning function to ensure surface solids and grease is regularly removed from the sump. The sump cleaning function shall perform regularly when enabled by the operator. Sump cleaning shall consist of the following functions:
- Sump cleaning is triggered when internal timer expires and during a normal pump down cycle
- Pump is automatically ramped to maximum speed
- Pump runs at maximum speed for designated time or until the pump are snoring."
- When Sump Cleaning is over, the pump is shut off and resumes normal operation.
The pump drive shall incorporate a pipe cleaning function to avoid discharge pipe sedimentation and clogging due to reduced pump speed. This shall be an automatic feature that initiates with every pump cycle. Upon reaching Pump Start Level, the drive shall operate the pump at 100% speed for a determined time before ramping down to the most energy efficient speed for the duration of the cycle.
F.Energy efficient speed finder:
The pump drive shall provide a function that automatically calculates the most energy efficient speed for the pump based on station inflow characteristics. The speed shall be constantly adjusted to account for changes of the inflow without requiring operator adjustment.
This function shallalso prevent the drive from running off of the system curve and ensure the maximum hydraulic efficiency.
G.Alarms & Monitoring:
The pump drive shall provide alarms and monitoring for the drive, pump and sump. Alarms shall be presented on the LCD display, via a Summary Alarm relay and via Modbus registers. All alarms, when occurring, shall remain active until reset.
Alarms shall have a built-in 4 second delay to prevent nuisance tripping. Alarms shall be as follows:
- Motormonitoring:
- Motor Temperature too high
- Leakage in stator housing
- Sump monitoring:
- High sump Level (via float switch or transducer)
- transducer sensor error (connection failure, faulty values)
- Pump drive monitoring:
- overcurrent or overload trip
- over- or under voltage
- ambient or drive temperature too high
- ambient temperature too low.
- input phase loss
- max torque exceeded
The pump drive shall incorporate an (OLED) LCD screen to display drive operating status, alarms, liquid level and parameters.
The pump drive shall include 7 pushbuttons with the following functions: Pump Start, Pump Stop, Hand (Manual) Operation, Auto Operation, Menu Access, Increase Value, and Decrease Value.
Pump Start Level, Operating Parameter Adjustment and Alarm History shall be accessed via menu structure. Menu shall have at least 2 levels of security, limiting access to qualified personnel only.
The LCD screen shall display status information in 4 modes: Off, standby, active auto and active Manual.
The information shown shall be as follows:
OFF:Firmware name, Status (“STOP”), Rating (kW/hp)
STANDBY:Status and Name, Operating Mode, Sump Level
Auto/Manual: Status and Name, Operating Mode, Motor Freq.
Power, Sump Level, Current
Model: FLYGT SmartRun™ SRC 300or equivalent
Level regulator for High Level Sump Control.
Approved acc.LVD EN61058 and CSA
EX approved acc. IECEx ia IIC T4 Ga: -20°C<Ta<60°C.
Material of casing: Polypropylene.
Degree of protection: IP 68
Applicable for liquids with a Density of 0.95 – 1.10g/cm3.
Including 6m submersible cable and cable holder.
Model: FLYGT ENM 10 or equivalent
Level transmitter unit for 2 pumps
Approved acc. EN 61000-6-2, EN 61000-6-3, EN 61326-1
output 4–20 mA direct current, proportional to the measured level
Low supply voltage 8–30 V DC – or battery operation.
Insulation > 100 MΩ at 500 V DC
Load impedance: RΩ = (Usupply - 8 V)/0.02 A
Material of sensor body:Stainless steel, 1.4404 AISI 316L
Degree of protection: IP 68
Including 10m submersible cable and cable holder.
Model: FLYGT LTU 401 or equivalent
Telemetry unit with HMI
To enable the operator to control the pump station as a substation of a pump station system it shall be equipped with telemetry unit.Thehardware and software ofthis unitshall beastandardproduct from the supplier, specially designed for pumpingapplications.
The unit shall supply multiple protocolsincludingAquaCom, ModBus andComli.
All measured values, commands andoperating datashall be able to read and modified locally or remotely.
The hardware shall include
- Power supply 24 VDC +/-20 %; 400 mA max.
-12 DigitalInputs(DI), separatelyisolated
-8 DigitalOutputs(DO)(6relayoutputs and 2transistor outputs)
-3 AnalogInput(AI), separate isolated
-Fieldbusconnectionfor connectingexternalflowmeter
- USB connector
-Wi-Fi access
- IntegratedGSM / GPRS modem
TheHMIinterface hardwaremusthave at leastthe following properties:
-Screen size7.4 " 800 x 480 Pixel
- TFT-LCD Touch Display
-Applicationtemperaturerange-20 /+50C
- 1xCAN Busports forRS 485
- 1xserial port
- 1xEthernetconnection
- 1xUSB port and USB Mini
- 1xSD cardreader
- 1xAudio Output
- In a radius up to 20m it shallbe possible to connect a computervia aWi-Fi to the telemetry unit.
The outer casing of the telemetry unit shall be made of aluminum and be isolated according protection class IP 66 and Nema 4.
The supplier shall offer an APP free of charge forAndroidorIOSsystem.
Model: FLYGT My connect HMI or equivalent
Electromagnetic Flow Meter DN 150 PN 16
Flanges drilled according EN 1092-2 Tab. 9
Power supply: 230/115/24 VAC or 10-30VDC
The electromagnetic flow measurement system shall consist of a Flow Sensor which uses Faradays law of electromagnetic induction along with a microprocessor based Flow Converter and Display.
It shall be capable to measure the flow of wastewater with a temperature between - 10 and + 80 °C in a velocity range between 0,2-10m/s with an accuracy of 0.25% of the actual flow in both directions.
The net flow for both directions shall be able to be totalized.
A simple menu selection shall be available to determine the normal flow direction.
The flow meter including its display and the connection box shall withstand an ambient temperature of - 20 to + 60 °C and be enclosed according IP 68.
Material of construction:
Housing: carbon steel
Sensor lining material: hard rubber.
Electrodes: DIN 1.4571 or AISI 316 TI.
Automatic electrode cleaning shall be standard and always active.
The flow meter shall supply following output data:
Analog:
1 Active 4 - 20 mA, isolated, 12 bit resolution,
Min. range = 0 - 0,2 m/s, Max. range = 0 - 10 m/s
Digital:
1 Voltage-free electromechanical relay
1 Optically isolated MOSFET relay
Programmable for: Totalizer counter, batch counter, high/low flow, system error, empty pipe and flow direction.
Display interface shall be supported by:
1 RS-485 Modbus® RTU-mode,
1 USB 1,1 type mini B, female, 1 pcs. for Communication module
Converter communication: MODBUS® RTU-mode, 9600 baud, 2-wire RS 485, slave-mode
The Flow Sensor shall be registered to an integrally or remotely mounted signal converter using a unique coded six-digit serial number technique. It shall set calibration data, the nominal diameter and the sensor configuration – making the system ready to measure immediately. Unlimited interchanging of converters and Flow Sensors shall be allowed.
All programming shall be accomplished through an integral keypad and all programming shall be protected by a user-defined password.
The data Logger shall be able to hold min 160.000 logs.
Data (CSV) shall be able to be displayed graphically, but also be able to be exported to a PC via the USB port on the Display Unit. The exported data shall be able to be imported to Excel.
The Display shall show data and graphs of up to 4 sensors simultaneously for the following:
-Indication of flow
-Flow direction,
-Volume
-totalizers
-Pop-Up and alarm messages
-Configuration
Model: FLYGT MagFlux EMF 801 or equivalent
Cabinet for 2 pump drives and telemetry unit.
The Monitoring & Control and the telemetry unit shall be assembled in a cabinet.
The cabinet shall be made of Reinforced plastic or stainless steel and it shall be prepared for an installation on a concrete floor.
It shall be isolated according protection class IP 44.
Beside the Monitoring & Control and the telemetry unit it shall include
- Power switch, which can be locked in the off position by a padlock.
- 1 light group with socket
- 1 backup battery for the telemetry unit.
- 1 installation log for a flow meter converter unit with Display.
The inner dimension of the cabinet shall reserve at least 10% space for future adjustments and 20 cm space for the cables.
All components on the front of the machine should be provided with function plate.
Supply of equipment specified in item 1-5 above according DAP incoterm to …………………………..
Installation of equipment specified in item 1-5
Under the condition that that the pump station is accessible with a truck and that lifting gear is available.
Place of installation …………………………….. / 0,-
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+ VAT.
*) Delete text which is not applicable