HEAVY DUTY WASTEWATER PUMPS
SUGGESTED SPECIFICATIONS
PART 1 - GENERAL
1.01 SCOPE
A. Pumps to be supplied under this specification shall be of a non-clog design suitable for use in (wastewater, light slurry, etc.) applications, heavy duty, high efficiency design with a minimum 20 year performance life.
Unit(s) will be of the (vertical / horizontal, dry-pit,) (direct connected, extended shaft) configuration having wet end construction of (cast iron, 3% nickel, 28% chrome iron, ductile iron, 316SS), with 400 series SS wear rings, cast iron bearing frame with high capacity bearings and efficient performance over the pump operating range. All equipment supplied shall be suitable for this application and conform to this specification.
B. The required units shall be Morris Pumps 7100 Series, Type (NC, EC, MF), Model ______, ___Vane, ______(VOS, VPM, HBB) mounting, or a pre-approved equal.
1.02 QUALITY ASSURANCE
A. The equipment covered by this specification is intended to be a standard product of proven reliability as manufactured by Morris Pumps, Aurora, IL or pre-approved equal and having at least twenty (20) years of experience in the production of such equipment. Pumps are to be engineered and manufactured under a written Quality Assurance program certified to the ISO 9001:2000 Quality System Standard. The Quality Assurance program is to have been in effect for at least five (5) years and shall include a written record of periodic internal and external audits to confirm compliance with ISO 9001:2000 requirements. All units specified in this specification shall be supplied by a single pump manufacturer. The pump manufacturer shall supply the required pumps (, and drivers /, and VFDs) and shall be responsible for this equipments' compatibility.
B. Pumps supplied shall conform to this specification and the Hydraulic Institute, Latest Edition. The pump manufacturer shall supply a certificate of conformance at time of shipment, to be included with shipment to confirm that pumps supplied are to these specifications.
C. The pumps shall be tested in accordance with the standards of the Hydraulic Institute, Latest Edition, as required.
1.03 SUBMITTALS
A. With proposal - the pump manufacturer shall submit a typical pump outline drawing, typical cross-sectional drawing, typical price book curve for the required conditions to demonstrate compliance with the referenced specifications.
B. For approval, the pump manufacturer shall submit five prints of the following, after receipt of an order:
1. CERTIFIED PUMP OUTLINE DRAWING.
2. TYPICAL CROSS SECTIONAL DRAWING.
3. SINGLE LINE CHARACTERISTIC CURVE.
4. PUMP OPERATION AND MAINTENANCE MANUAL.
5. CERTIFIED DRIVER OUTLINE DRAWING.
6. DRIVER WIRING DIAGRAM.
7. MAXIMUM FORCES ACTING ON THE PUMP SUPPORT STRUCTURE WITHOUT THE BENEFIT OF CONNECTING PIPES AND 1.5 X SHUT VALVE PRESSURE APPLIED TO THE DISCHARGE FLANGE.
8. TORSIONAL ANALYSIS AND LATERAL CRITICAL CALCULATIONS.
9. MAXIMUM REVERSE RUNAWAY SPEED CALCULATION (Based on maximum system head shown on TABLE 1)
10. PERFORMANCE TEST PROCEDURE.
C. Approved and final data: At, or prior to, shipment, the pump manufacturer shall resubmit five copies of the returned approved data and include all corrections or modifications as required. Five copies of the operating and maintenance manual shall be included with the shipment.
Data referenced in B. and C. shall include customer name, purchase order number, equipment item number, pump manufacturer serial number and pump model as minimum requirements to be listed on the drawings.
ISSUE Date 12/4/12 / PAGE 7100.201SERIES 7100
HEAVY DUTY WASTEWATER PUMPS
SUGGESTED SPECIFICATIONS
1.04 START-UP FIELD SERVICE
A. The pump manufacturer's representative shall include in his proposal two (2) days start-up field service for the purpose of supervising pump start-up and instruction of proper pump operation and maintenance.
SERVICE PROVIDED BY FACTORY REPRESENTATIVE TIME ON SITE
1. INSPECT AND APPROVE INSTALLATION 1/2 DAY
2. SUPERVISE INITIAL ADJUSTMENT 1/2 DAY
3. SUPERVISE FIELD RUN TEST 1/2 DAY
4. INSTRUCT OWNER IN PROPER START-UP AND O&M 1/2 DAY
1.05 SPARE PARTS
A. The pump manufacturer is to include in his proposal recommended spare parts required for normal operation during the first year of operation.
B. Spare parts shall include the following as a minimum:
(1) SET PUMP BEARINGS.
(1) SET WEAR RINGS.
(1) SET PACKING (OR MECHANICAL SEAL), GLAND AND SEAL CAGE.
(1) SHAFT SLEEVE. ("OPTIONAL", RECOMMENDED WITH PACKED BOX DESIGN.)
(1) SET GASKETS AND "O" RINGS.
PART 2 - PRODUCT SELECTION
2.01 OPERATING SELECTION
The pump shall be designed for continuous operation and operate at/or below vibration levels listed in the Hydraulic Institute standards, Latest Edition.
The pump operating and service conditions shall be as listed on the attached TABLE 1 - PERFORMANCE DATA. The Rated Condition as listed in TABLE 1 - PERFORMANCE DATA shall be the rated condition as defined by the Hydraulic Institute Standards. This condition will be used for any performance evaluation. Other Rated Conditions, must be within 5% of the values and are furnished to describe the full range of the operating requirements.
The number of pump starts for a 24 hour period shall not exceed that as required by the driver manufacturer.
PART 3 - PRODUCT DESIGN
3.01 The pump shall have a continuously rising head capacity curve from runout flow through shutoff.
3.02 The pump shall be designed to operate continuously for an extended period of time at any point in the specified operating range of the curve without cavitation, overheating or excessive vibration. The motor nameplate horsepower rating shall not be exceeded by the pump brake horsepower required.
ISSUE PAGE 7100.202 / Date 12/4/12/ SERIES 7100
HEAVY DUTY WASTEWATER PUMPS
PART 4 - MATERIALS OF CONSTRUCTION
4.01 The (vertical, horizontal) non-clog pump shall conform to the materials of construction as listed for this design.
4.02 MATERIALS
PUMP COMPONENT STANDARD MATERIAL OPTIONAL
Casing Cast Iron (ASTM A48,Class 35) 1,2,3,4,12
Impeller Cast Iron (ASTM A48, Class 35) 1,2,3,4,12
Wear Rings 420SS Castings (ASTM A743, CA-40, 12
Min. 450 Brinell)
Suction/Stuffing Cast Iron (ASTM A48, Class 35) 1,2,3,4,12
Box Covers
Shaft SAE 1045 Steel (AISI 1045 H.R.) 5,6,7,8
Shaft Sleeve 420SS Castings (ASTM A743, CA-40, 9,10
Min. 450 Brinell)
Bearing Frame Cast Iron (ASTM A48, Class 25)
Gland Bronze-40 (ASTM B584- C83600) 4
Lantern Ring Bronze-40 (ASTM B584- C83600) 4,11
OPTIONAL MATERIALS: 1. 3% Nickel (ASTM A48, CLASS 35/3% Ni)
2. 28% Chrome Iron (ASTM A532, Class 3, Type A, Min. 325 Brinell
3. Ductile Iron (ASTM A536, 80-55-06)
4. 316 Stainless Steel (ASTM A743, CF-8M)
5. 304 Stainless Steel (AISI 304)
6. 316 Stainless Steel (AISI 316)
7. 4140 Steel (AISI 4140 H.R.A.)
8. 1141 Steel (AISI 1141 H.R.)
9. Ceramic Coated (Al-Ox/416) (Colmonoy 304)
10. 440 Stainless Steel (AISI 440-C) Min. 550 Brinell
11. Teflon - 15% Filler
12. Other (Contact Factory)
4.03 CASING CONSTRUCTION
A. The pump casing shall be designed for the type service herein specified and shall be of sufficient strength and metal thickness to insure long life, accurate alignment and reliable operation. The volute of the pump casing shall have smooth fluid passages large enough at all points to pass any size solid which can pass through the impeller and provide smooth unobstructed flow. The casing shall have a separate and removable suction cover and stuffing box cover.
The casing shall be designed to permit rear pump rotating assembly removal without disturbing either the suction or discharge piping. The casing shall have connections for vents and drains, gauges, and have a minimum nominal thickness of _____ inches.
B. A handhole shall be provided in the casing to give convenient access to the impeller and interior parts of the pump. The inner contours of the handhole cover shall match the contours of the casing.
C. The discharge flange shall conform to ANSI B16.1, Class 125 lb., flat face, of standard size with drilled holes. The discharge flange shall be drilled and tapped for gauge connections.
D. No stationary guides will be permitted on either the suction or discharge sides of the casing.
ISSUE Date 12/4/12 / PAGE 7100.203SERIES 7100
HEAVY DUTY WASTEWATER PUMPS
SUGGESTED SPECIFICATIONS
4.04 IMPELLER CONSTRUCTION
A. The pump impeller shall be of the single suction enclosed type of the non-clogging design. The impeller shall be designed with smooth water passages to prevent clogging by large chunks, splinters or fibrous material and shall be capable of passing solids having a maximum sphere size as listed in TABLE 1 - PERFORMANCE DATA.
B. The impeller shall be dynamically balanced to ISO standards G6.2 to insure that the specified vibration limits are met.
C. The impeller shall be taper bored and keyed and securely held in place to the shaft by a locking plate and secured to the shaft by no less than three high-strength socket head cap screws threaded into the pump shaft. This arrangement shall provide positive locking of the impeller to the shaft, so that the impeller cannot be loosened by torque from either forward to reverse rotation.
4.06a WEAR RING - SUCTION COVER
A replaceable suction cover wear ring providing 1/8" minimum wear shall be installed with its wear surface parallel to the suction end of the pump impeller. The wear ring shall be installed with recessed stainless steel screws for attachment to the suction cover.
4.06b WEAR RING - IMPELLER
A replaceable impeller wear ring providing 1/8" minimum wear shall be mounted on the impeller to provide a renewable surface opposite the suction cover wear ring. The wear ring shall be secured to the impeller with recessed stainless steel screws.
4.07 SUCTION/STUFFING BOX COVERS
A. The pump casing shall be provided with suction and stuffing box covers of the same material as the material used in the casing, cast separately from the casing and shall be built to allow for complete removal of the pump rotating assembly by unbolting the stuffing box cover. The suction cover and the stuffing box backplate shall be a machined register fit to the casing to assure accurate alignment.
B. The suction cover flange shall conform to ANSI B16.1, Class 125 lb., flat face, of standard size with drilled holes and shall be designed to assure equal distribution of the liquid to all parts of the impeller suction eye. Drilled gauge connection shall be provided.
4.08 SHAFT
A. The pump shaft shall be made from a high-strength alloy steel, accurately machined over its entire length and of sufficient size to transmit the full driver horsepower with a liberal safety factor and free from any harmful or damaging vibrations. The pump shaft shall include an accurately machined tapered end for impeller mounting to assure positive alignment. Shaft deflection shall not exceed .002 inch at the stuffing box at ± 40% of the best efficiency point of the impeller performance curve furnished.
B. The shaft shall be sized such that the maximum bending stress is less than 15,000 psi at any shaft section when the pump is operating at maximum speed with the maximum published impeller diameter at pump shut-off head (zero flow).
C. The pump shaft shall be protected from the pumped liquid by a shaft sleeve extending from the impeller hub through the area of adjustment of the gland follower.
4.09 SHAFT SLEEVE
A. A renewable, shaft sleeve extending from the hub of the impeller through the stuffing box packing and of sufficient length to cover the complete area of adjustment of the gland follower shall be provided. The shaft sleeve shall utilize a system of sealing between the shaft and shaft sleeve which will not allow leakage of the liquid being pumped between them or allow air to enter the pump casing. Shaft sleeve wall thickness shall be a minimum of (.25) inches.
B. The shaft sleeve shall be positively secured to the shaft by a set screw to prevent slip between sleeve and shaft.
ISSUE PAGE 7100.204 / Date 12/4/12/ SERIES 7100
HEAVY DUTY WASTEWATER PUMPS
4.10 BEARING FRAME
A. The pump bearing frame shall be a one-piece rigid cast iron construction, providing a self-centering and self-indexing fit with the stuffing box cover of the pump to assure proper alignment. The bearing frame shall be provided with retainer covers for the outboard and inboard ends of the housing. Both of the retainer covers shall be equipped with lip-type grease seals and deflectors to prevent the entrance of contaminants. The bearing assembly shall be designed to allow the removal of the complete rotating assembly from the casing without disconnecting suction or discharge piping.
B. The pump bearing frame shall be equipped with a three bearing system designed to provide a separate bearing for the thrust load imposed by the pump impeller and two separate bearings to accept the radial load. The radial bearing shall be of the roller or spherical roller type suitable for all loads encountered in the specified service conditions. The thrust bearings shall be angular contact ball or spherical roller type suitable for all thrust loads. All bearings shall be designed for a minimum of 100,000 hours B-10 life for any point within the pump operating range specified. Certified calculations shall be provided to demonstrate compliance.
C. All bearings shall be able to be relubricated while the pump is in operation. The bearings shall be grease lubricated. Greased bearings shall be provided with a pressure relief system so that excessive temperature and/or pressure will not damage the bearings. (Oil lubricated bearings on vertical pumps shall be provided with an electrically driven oil pump and interconnected flow/pressure switch to insure positive flow of oil to the bearings. Horizontal pumps shall have a clear glass indicator for visually checking oil level.)
D. The bearing frame assembly shall be designed to withstand the loads from frequent running against a closed control valve on the pump discharge for minimum periods of three minutes during pump start-up and stop cycles.
E. The bearing frame shall have provisions for adjustment of the axial clearance between the impeller wear ring and the suction cover wear ring. This adjustment shall be accomplished through the use of metal shims placed between the mounting flange of the bearing frame and the mounting flange on the stuffing box cover. A cylindrical sliding fit between the bearing frame and stuffing box cover shall assure positive bearing alignment.