section 504 pumps rev 00

PROJEK MASS RAPID TRANSIT LEMBAH KELANGJAJARAN SUNGAI BULOH – KAJANG

MATERIALS AND WORKMANSHIPSPECIFICATION

SECTION 504PUMPS

Document Reference No. : KVMRT/PDP/SBK/GEN/OP/PS/ME/3504Revision : 00Date Issued : 25TH JULY 2011

PROJEK MASS RAPID TRANSIT LEMBAH KELANGJajaran Sungai Buloh - Kajang

Materials and Workmanship SpecificationSection 504 – Pumps

KVMRT/PDP/SBK/GEN/OP/PS/ME/3504 Page 1 of 25 Revision: 00

AMENDMENT HISTORY

REVISION NO. DETAILS OF AMENDMENT




TABLE OF CONTENTS

504 PUMPS..............................................................................................................4

504.1 General ..................................................................................................................... 4

504.2 Standards.................................................................................................................. 4

504.3 Technical and Installation Requirements ................................................................. 5

504.4 Controls .................................................................................................................. 19




This Page Left Blank Intentionally




504 PUMPS

504.1 General

This section of specification covered the manufacture and installation of waterpumps.

Pumps shall be provided with duties, quantity and types as shown on the Drawingsand/ or Equipment Schedules.

The pump heads specified on the Drawings and/ or Equipment Schedules are forguidance and information only. The contractor shall carefully checked andcalculate the actual pump head based on the pipe run and the offered equipmentfor each pump before ordering the equipment. The calculation shall be submittedto Employer’s Representatives for approval.

No modification to the piping system shall be allowed without prior approval&consent from Employer’s Representatives. Any additional cost for the modificationof the system (pumps, motors, switchgears, cables, panel boards, switchboards,etc.) necessary to meet the specified duties, spatial conditions and the offeredequipment shall be provided at no extra cost to the Employer.

The testing pressure shall be 1.5 times of the actual working pressure or 1600kPa,whichever is higher.

504.2 Standards

Reference Codes and Standards

BS EN ISO 9906: Rotor dynamic Pumps. Hydraulic performance acceptancetests, Grades 1 and 2.

PD 970: Wrought Steels for Mechanical and Allied EngineeringPurposes

BS EN 1982: Copper and Copper Alloy - Ingots and CastingsBS EN 1561: Grey Cast IronsBS EN 10293: Steel Castings for General Engineering PurposesBS EN 1092: Flanges and their Joints - Circular Flanges for Pipes, Valves,

Fittings and Accessories, PN Designated.BS EN ISO 5198: Centrifugal, Mixed Flow and Axial Pumps - Code for Hydraulic

Performance Tests - Precision Class.

Loss Prevention Council (LPC) – Rules for Automatic Sprinkler Installations for firepump.

Hydraulic Institute Pump Standards

ISO 7919: Mechanical Vibration of Non-reciprocating Machines




ISO 10816: Mechanical Vibration – Evaluation of Machine Vibration byMeasurements on Non-rotating Parts Codes and regulations ofthe jurisdictional authorities.

BS EN 10277 Parts 1 to 5 and BS EN 10278.

Suruhanjaya Perkhidmatan Air Negara (SPAN) guidelines for cold water pump.

504.3 Technical and Installation Requirements

504.3.1 Quality Control

a. Nameplate: Each pump and motor shall have an identification plateshowing the code number and a specification plate showing fulldetails of the pump size, rated speed, rated kW, class of insulation,impeller diameter, lubricants, pump characteristics, flow and anyother pertinent information required by LPC or the Employer’sRepresentatives.

b. For pumps in parallel operation at any particular time, the pumpsselected shall have a steep characteristic. For single pumpoperation at any particular time, the pump selected shall have aflat characteristic. Pumps with curve indicating excessive shut-offhead shall not be used. The maximum speed shall not exceed 1450rpm for chilled water pumps, transfer pumps, booster pumps andjockey pumps and 2900 rpm for firefighting purpose main pumps oras specified in this Specification and/ or on the Drawings.

c. The pump construction shall meet the maximum required workingconditions, liquid temperature, test pressure, and nature of theliquid to be handled as specified.

d. Capacity of each pump and motor shall not be less than thatspecified, and designed for all conditions of parallel operation.Each motor shall be of sufficient capacity to operate over the entirehead capacity range of its respective pump without exceeding thenameplate power rating.

e. Pump characteristic curves shall rise continuously from maximumcapacity to shutoff. Shutoff head shall be approximately 10%greater than design head. Pumps shall operate at or near point ofpeak efficiency and shall permit operation at capacities ofapproximately 25% beyond design capacity without exceedingbreak off point. The diameter of impeller shall not exceed the 90%point of difference between minimum and maximum of impellerdiameters published for respective pump.




f. Pump alignment work shall be carried out using dial indicator withaccuracy of plus or minus 0.05 mm. It shall be certified in writingthat alignment work has been performed by personnel of theContractor and that the pumps are operating in accordance withthe design requirement.

g. All pumps and motors shall be of minimum vibration and noiselevel during operation so as to meet the respective noise criteria.

h. Additional vibration isolators and sound attenuators shall beprovided as required by the Employer’s Representative at noadditional cost to the Employer if the noise level is found excessiveand not within the requirements.

i. Each pump unit including motor and drive shall be supplied fromthe manufacturer as a completely factory-assembled package. Allguarantees and test certificates shall apply to the entire assembly.

j. All pumps shall be factory painted in accordance with themanufacturer's recommendations. Any damage to finishes shall bemade good in the manner recommended by the manufacturer andto the satisfaction of the Employer’s Representative.

k. Pump casing shall be designed for 1600 kPa working pressure orthe figure specified on the Drawings whichever is the greater,tested and guaranteed to withstand 1.5 times the specified workingpressure. The suction and discharge flanges shall be to BS EN 1092.

l. Pump casing shall be of close-grained, cast iron accuratelymachined and assembled with metal to metal joining.

m. Enclosed impeller shall be statically, dynamically and hydraulicallybalanced, non-overloading and correctly designed for all conditionsof service. Impeller shall be machined to a high degree of surfacefinish and shall be securely fixed to the shaft and protected by shaftsleeves of compatible materials.

n. Wearing rings on both casing and impeller shall be of renewabletype, made of dissimilar bronze metals and of hardness to insuremaximum protection against galling.

o. Renewable shaft sleeves shall be suitable for use with mechanicalseals.




p. Bearings shall be self-aligning, radial thrust type, oil lubricated. Thebearings for chilled water pumps shall be rated at L10 life of notless than 200,000 hours. Bearing housings shall be separated fromthe pump case and bolted and doweled to the pump case. Top halfof bearing housing shall be removable. Bearing housings shallincorporate overflow holes to prevent flooding of bearings. Thebearing shall be packed in the factory with high-quality bearinggrease on lithium-soap base, free of resin and acid, not liable tocrumble or be brittle.

q. Mechanical seals shall be specifically designed for pump workingpressures and shall be of stainless steel construction with stainlesssteel springs and tungsten carbide seats. One extra complete set ofmechanical seal assembly shall be provided for each type of sealfurnished with pump.

r. Pumps and motors shall be assembled on galvanized base plate ofrolled steel and sloping channel type, with tapped drain connectionat pump end. The base plate shall be designed and supplied by thepump manufacturer.

s. Flexible spacer coupling shall be self-aligning, all metal type, ofApproved design, between pump and motor, to enable removal ofimpeller without disturbing the driving motor or its mounting.

t. The casing feet shall be integrally cast with the lower casing and beimmediately adjacent to suction and discharge flanges in order totransmit pipe load to the base and foundation.

u. Material of Construction: The pumps shall be constructed withmaterials specified below or equal unless otherwise specified andshall be submitted for Approval.

504.3.2 Pumps/Motor Coupling

a. A coupling shall be provided between the pump and motor, andshall be semi-flexible, of steel pin/rubber bush type and accuratelyaligned.

b. The coupling shall be provided to reduce shock to the bearings andnot to compensate for misalignment. The pin and bush couplingrequire the same accuracy of alignment as rigid couplings.Demonstrations of correct alignment shall be provided.




c. Pump Set Auxiliary EquipmentEach pump set shall be provided with the following auxiliaryequipment:i. Discharge and suction pressure gauges each complete with

isolating cock.ii. Drains, vents, primary plugs, all necessary water seal

connections and all installation materials including fixing boltsand anti-vibration mountings.

iii. Emergency stop push button for each pump at a locationapproved by the Employer’s Representatives.

iv. Strainers at suction side as shown on the Drawings.v. Thermometers installed at suction and discharge sides as

shown on the Drawings.vi. Pressure gauges tapping at suction and discharge pipework.

504.3.3 Chilled and Condenser Water Pumps

a. Horizontal split casing or vertical-in-line casing shall be used aschilled water pump or condenser water pump as shown on theDrawings.i. Horizontal Split Casing Pump

Horizontal split casing pump shall be single stage, singlevolute, and centrifugal type.

The casing shall be split on the horizontal centre line withthe suction and discharge nozzles and casing feet castintegral with the lower casing half.

The pump volute case shall be cast iron. The interior of the pump shall be easily inspected by

removing the upper half of the casing without disturbingthe pipe connections or pump alignment.

The pump shall have casing wear rings and rated for aminimum 175 psi working pressure.

Impellers shall be precision cast, dynamically balances andshall be of the enclosed type, non-leaking brass and keyedto the shaft. The impeller shall have annular pressurereducing clearance with impeller holes to reduce axialthrust.

Spacer coupling shall be provided between the motor andpump.

The pump shall have stainless steel mechanical seal withstainless steel springs, tungsten carbide seats and sealwater flush line.

Motor shall be high efficiency, NEMA rated and TEFC type.The motor shall be non-overloading throughout the entiretyof the pump performance curve.




The pump shall be factory hydrostatically test as perHydraulic Institute Pump Standards.

ii. Vertical In-Line Pump Vertical in-line pump shall be high efficiency close-coupled

design, single volute, single stage and centrifugal type. The pump shall be of the pullout designs and capable of

being services without disturbing piping connections. The pump volute case shall be cast iron. The pump shall have casing wear rings and rated for a

minimum 175 psi working pressure. Casing shall have taped holes on the suction and discharge

to accommodate gauges, fittings and drain ports. Impellers shall be precision cast, dynamically balances and

shall be of the enclosed type, non-leaking brass and keyedto the shaft. The impeller shall have annular pressurereducing clearance with impeller holes to reduce axialthrust.

The pump shall have a replaceable bronze or stainless steelshaft sleeve and shall cover the liquid area under seal.

The pump shall have stainless steel mechanical seal withstainless steel springs, tungsten carbide seats and sealwater flush line.

Motor shall be high efficiency, NEMA rated and TEFC type.The motor shall be non-overloading throughout the entiretyof the pump performance curve.

The pump shall be factory hydrostatically test as perHydraulic Institute Pump Standards.

504.3.4 Fire System Pumps

a. Horizontal end suction, single volute, back-pull out type completewith spacer coupler, centrifugal type shall be used for all firesystem pumps except drencher pumps, jockey pumps and transferpumps.

b. Vertical multi-stage centrifugal type shall be used for transferpumps and jockey pumps.

c. The jockey pumps shall be a packaged unit comprising pump,electric motor and common base plate of galvanized ironconstruction.

d. Each electric motor driven fire pump shall be a packaged unitcomprising pump, electric motor and common base platefabricated from galvanized steel construction.




e. High/low level float switches shall be provided at each of the fireservice water tanks for the control of the respective pumps.Indicator lights and buzzers shall be provided on the automatic andmanual fire alarm control panel to indicate water level of the tanks.The switches shall be submersible, maintenance free bulb type.

f. Diesel fire pump

i. The diesel engine for the fire pump shall be a four stroke, directinjection, industrial machine constructed to BS 5514. It shall befitted with renewable wet cylinder liners and shall be directcoupled to the Standby Fire Pump with both units mounted ona common rigid steel bedplate.

ii. The engine shall be complete with cooling fan drive, lubricatingoil filters, air cleaners, starter motor/exciter, battery charging,regulator, fuel injector, fuel control solenoid, fuel lift pump,engine speed adjustment, other standard/operationalaccessories and protective devices.

iii. The engine shall be cooled by means of a water jacket, heavyduty air blast radiator with integral radiator header tank,circulating pump and engine driven pusher type fan

iv. The starting system shall comprise a 24 V heavy duty lead acidbattery and electric starting motor. The battery shall be sizedto give not less than six consecutive starts of the engine at 0C.An engine driven alternator and charging system shall beprovided plus a mains powered battery charger.

v. Instrumentation shall be provided mounted on the generatorset to monitor the following: oil pressure, oil temperature andwater temperature

vi. A service fuel tank shall be provided; its capacity shall notexceed that stipulated in the local fire regulations.

vii. A bulk fuel storage tank manufactured in 6mm mild steel inaccordance with BS 2594 shall be provided adjacent to each firepump building. All required automatic fuel transfer facilities fortransferring fuel from the bulk storage tank to the service tankshall be provided.

504.3.5 Pneumatic Cold Water Booster Pump Sets

a. The pump sets shall comprise duplicated pumps, complete withpressure vessel, motor starter panel and control unit.

b. Pump sets shall be of package type, being designed andmanufactured by manufacturers normally supplying this type ofequipment, and who can show evidence of having furnished suchequipment that has been in successful operation for at least fiveyears. Locally assembled pump sets will not be accepted.




c. The pumps shall be vertically mounted, directly driven by motors.The pumps shall be of multi-stage construction with eachstage/section to be renewable.

d. The pump casings shall be of close-grained cast iron accuratelymachined and assembled with metal-to-metal joints.

e. The impellers shall be of gunmetal or bronze mechanicallybalanced and keyed to shaft. Renewable guide rings shall beprovided in the casting, keyed to prevent rotation.

f. The shafts shall be stainless steel to BS EN 10095 grade 316.Gunmetal sleeves shall be provided to protect the shaft in thewater space and through the sealing glands. The sleeves shall bekeyed to prevent rotation and secured against axial movement.

g. The bearings shall be of ball or roller type protected against ingressof water, dirt and other matter.

h. Stuffing boxes shall be of ample length with bronze lined gland andneck bush, fitted with Approved packing and lantern ring water sealwith piping. Alternatively, a stainless steel mechanical seal may beoffered.

i. The pump sets shall be complete with inter-connecting pipework,isolating and check valves, and flexible connectors and with flangedconnection ready for connection to the pipework system.

j. One or more pressure vessels shall be provided and installed on thesame mounting. The vessels shall be of adequate capacity toaccommodate a considerable fluctuation in water demand by thesystem and shall minimize the start/stop cycles of the pumps.

k. The vessels shall be constructed of steel plate built to ASMEStandards for Unfired Pressure Vessels. All ancillary internal partsshall be made of copper or bronze.

l. A rubber diaphragm shall be provided in the pressure vesselsseparating the water and the gas therein. The diaphragm shall becorrosion resistant. The design life of the diaphragm shall be atleast 15 years.

m. The vessels shall be pre-charged with nitrogen at the factory at apressure to suit the systems. The recharge pressure shall beadjustable and a charging port with non-return device shall beprovided in each vessel.




n. The unit shall be complete with a local motor control panel and allaccessory controls, including starters, isolators, overload relay,selector switch, low level cut-out for pumps and pressure switches.The complete local motor control panel shall also be mounted onthe common bed plate fabricated from galvanized steel.

o. The operation of the duty pumps shall be initiated by the pressuresensors/ switches in sequence. If the pressure in the system dropsto the predetermined level, the duty pumps shall cut inautomatically. Pump start/ stop frequency shall not be more than6 times per hour at the rated output.

504.3.6 Pneumatic Flushing Water Booster Pump Sets

a. The pump sets shall comprise duplicated pumps, complete withpressure vessel, motor starter panel and control unit. Pump setsshall be of package type, being designed and manufactured bymanufacturers normally supplying this type of equipment, and whocan show evidence of having furnished such equipment that hasbeen in successful operation for at least five years. Locallyassembled pump sets will not be accepted.

b. The pumps shall be vertically mounted, directly driven by motors.The pumps shall be of multi-stage construction with each stage/section to be renewable.

c. The pump shall be of centrifugal type, arranged with shaft vertical.

d. The pump casing shall be of close-grained cast iron, accuratelymachined and assembled with metal-to-metal joints.

e. The impellers shall be of zinc-free bronze material mechanicallybalanced and keyed to the shaft. Renewable guide rings are to beprovided in the casing, keyed to prevent rotation.

f. The shaft shall be of stainless steel to BS EN 10095 grade 316. Zinc-free bronze sleeves shall be provided to protect the shaft in thewater space and through the sealing glands. The sleeves shall bekeyed to prevent rotation and secured against axial movement.

g. The bearings shall be of ball or roller type protected against ingressof water, dirt and other matter.

h. Stuffing boxes shall be of ample length with bronze lined gland andneck bush, fitted with Approved packing and lantern ring water sealwith piping. Alternatively, a stainless steel mechanical seal may beoffered.




i. The pump sets shall be complete with inter-connecting pipework,isolating and check valves, flexible connectors and with flangedconnection ready for connection to the pipework system.

j. One or more pressure vessels shall be provided and installed on thesame mounting. The vessels shall be of adequate capacity toaccommodate a considerable fluctuation in water demand by thesystem and shall minimize the start/stop cycles of the pumps.

k. The vessels shall be constructed of steel plate built to ASMEStandards for Unfired Pressure Vessels. All ancillary internal partsshall be made of copper or bronze.

l. A rubber diaphragm shall be provided in the pressure vesselseparating the water and the gas therein. The diaphragm shall becorrosion resistant. The design life of the diaphragm shall be atleast 15 years.

m. The vessels shall be pre-charged with nitrogen at the factory at apressure to suit the systems. The pre-charge pressure shall beadjustable and a charging port with non-return device shall beprovided in each vessel.

n. The unit shall be complete with a local motor control panel and allaccessory controls, including starters, isolators, overload relay,selector switch, low level cut-out for pumps and pressure switches.The complete local motor control panel shall also be mounted onthe common bed plate fabricated from galvanized steel.

o. The operation of the duty pumps shall be initiated by the pressuresensors/switches in sequence. If the pressure in the system dropsto the predetermined level, the duty pumps shall cut inautomatically. Pump start/ stop frequency shall not be more than6 times per hour at the rate output.

504.3.7 Variable Speed Drive Booster Pump System

a. General

i. Variable Speed booster pump system shall be compactpackaged type. The system shall consist of 2 (1 duty/1 standby)horizontal multi-stage centrifugal pumps, pre-pressurisedbladder pneumatic tank, a control panel incorporating anelectronic pump controller and manifolds with isolating andnon-return valves. All booster system components shall comefrom a single manufacturer to ensure proper system integration




b. Pump

i. The pump shall be of vertical/horizontal multi-stage centrifugaltype with a direct-coupled design complete with a variablespeed electrical motor. The stage intermediate chambers,impeller and shaft shall be made of stainless steel 316. Themechanical shaft seal shall be of carbon/ceramic sealingsurfaces for long maintenance-free and resistance to wear.

c. Electric Motor

i. The motor shall be fitted with frequency converter for speedcontrol. The motor shall be of totally enclosed fan-cooledsquirrel cage type. The enclosure shall be IP55 and insulationshall be of Class F. The motor shall be suitable for three (3)phase 415V, 50Hz power supply.

ii. Motor power up to 2.2kw shall be suitable for D.O.L. starting.Above 2.2kw, it shall be suitable for star-delta starting.

iii. The motor shall be of non-overloading design regardless of theactual duty points. Speed of the motor shall be 2900 RM.

iv. The pump and electric motor shall be from a singlemanufacturer.

d. Pre-pressurized Tank

i. The tank shall have a volume of minimum 18 litres or as shownon the drawings and shall be equipped with heavy duty butylbladder. It shall be approved by Jabatan Keselamatan DanKesihatan Pekerjaan (JKKP).

e. Starter Panel and Controls

i. The control panel shall be of Direct-On-Line/Star Delta typesuitable for 3ph/415v/50HZ operation. The starter panel shallconsist of standard high quality electrical components and shallbe incorporated with an electronic based pump controller tomonitor and regulate the performance of the pumps. Thecontroller shall continuously monitor the discharge and shallregulate the operation of the pumps to maintain a constantpressure in the system. In addition, the controller shall havethe following features:-




Flexibility and simplicity in allowing the necessaryprogramming of the system pre-set delivery pressure tooperate the pump within the specified maximum andminimum delivery pressure range.

Easy pressure setting through turning of a potentiometerknob in the control panel.

Built-in 10% programmable friction loss compensation(through the setting of DIP switches) which shallautomatically increase the delivery pressure setting inresponse to the increase in flow demand. This shall be ableto minimize the system pressure differences and provide amore constant pressure along the supply line.

Automatic change over of the pump after each start/stop ofthe system operation.

When the system is not operated for more than 24 hours, itshall automatically start the pumps for a few seconds/dayunder the test mode. This shall ensure its readiness at alltimes.

The standby pump shall automatically be activated uponfailure of the duty pump.

Built-in automatic programme to limit the maximumnumber of pump start/stop per hour.

The control panel shall be able to provide LED alarms forany faults in the system.

The system shall be tripped when the maximum workingpressure has been exceeded and an alarm shall be triggered.The system shall resume on its own when the systempressure falls below the set maximum pressure.

In case of low water level in the suction tank, the systemshall automatically cut off to protect itself against ‘dryrunning’ and an alarm shall be indicated on the controlpanel. The system shall resume operation automaticallywhen the water level is raised. The ‘dry running’ protectionshall be by means of level electrodes in each tank. Manualoverride shall be provided for each electrode control suchthat the required control shall not be affected if one of thetanks is drained empty for maintenance purpose.

504.3.8 Drainage Sump Pumps and Sewage Ejector Pumps

a. Drainage sump pumps shall be of the centrifugal submersible type.The pump shall be so designed that it can be removed from thesump without the need to drain the sump or enter the sump todisconnect the pipework. For sewage ejectors, pumps shall beinstalled in pump room or dry pit.




b. Fixed facilities (except the I-beam) shall be provided for raising andlowering the pump, and the discharge pipe connection shall beautomatic.

c. Pump casing shall be of cast iron/ stainless steel, with an impellerof zinc-free bronze or other Approved materials. Shaft and shaftsleeves shall be stainless steel to BS EN 10095 grade 316.

d. Coupling between the pump and motor shall be by means ofdouble mechanical seals. The seal should be enclosed in an oil fillchamber for dissipation of heat.

e. Pump impeller and water chute shall be of non-clog type and be sodesigned that it can pump out soil or waste water containing solidup to 32mm diameter and high viscosity sludge.

504.3.9 Installation

a. Pumps and accessories shall be fitted to the space provided andmake readily serviceable.

b. Hot-dipped galvanized steel framework, hangers, anchor bolts andvibration isolators shall be provided for pumps except verticalmulti-stage pumps where heavy duty neoprene pad shall beprovided for vibration mounting purposes. Vertical split casingpumps shall be directly mounted on concrete. Unless otherwisespecified, inertia blocks with mass concrete shall be provided bythe Civil Contractor.

c. Horizontal mounted pumps shall be installed with the pump andcomplete motor drive assembly located on a common hot-dippedgalvanized iron base plate which shall be machine-finished andaccurately aligned.

d. Pump bases mounted on the inertia blocks shall be fixed on theconcrete plinths by means of the Approved spring isolators.

e. Flanges and flexible pipe connectors shall be provided to thesuction and discharge connections of pumps.

f. Supports to both sides of the flexible connection shall be providedto prevent undue strain on pumps. Such support shall be mountedso as not to transmit vibration to the structure.




g. Each pump shall be fitted with air cocks, drain plugs and a pressuregauge on both suction and discharge sides of the pump. Thepressure gauges shall be mounted on a hardwood gauge board onthe wall or elsewhere as Approved. Suitable permanent labels inMalay and English shall be affixed for each pressure gauge toindicate its function.

h. Except in the case of glandless pumps, provision shall be made forcollecting gland leakage via a copper drain pipe fitted from thepump to the nearest gully or drain point. A copper collector shall beused to collect the drips at the gland packing.

i. Galvanized angle iron wire mesh guards shall be provided to allexposed shafts, couplings and moving parts. The guard shall bestoutly constructed with lifting lugs for easy removal.

j. Pump installations shall be complete with adequate facilities formaintenance and future replacement of plant. Lifting eyes shall beprovided for pumps and motors. Details of any requirements foroverhead run-ways and hoists shall be provided to the Employer’sRepresentatives.

k. Pipe connections to the pump should not impose any load on thepump which is liable to disturb shaft and bearing alignment. Thepump/ pipework connection ends shall be of final closure joints,and thus ensuring the pipework is independently supported.

l. Demonstration of free pump rotation before and after pipeconnection shall be provided.

m. All necessary steps shall be taken to ensure that noise and vibrationare not transmitted from any part of the installation to any part ofthe structure at an acceptable level.

n. Equipment shall be selected for minimum noise and vibration, androtating machinery shall be fully statically and dynamicallybalanced.

o. Pumps shall be isolated from their associated pipework by means offlexible pipework vibration isolators, of suitable stiffness, and mountedwith the isolator axis at right angles to the direction of maximumvibration amplitude. These isolators shall be mounted as close as possibleto the pump, and as such may be used as the final closure joint. However,the isolators should not be used to compensate for misaligned pipework.

p. Automatic priming equipment shall be included where necessary toensure that the pumps are primed at all times.




q. Long radius reducing elbows or reducers at the locations wherepipe size decreases shall be provided. Provide Support to pipeworkadjacent to pumps shall be provided such that no weight is carriedon pump casings. Supports shall be provided under elbows onpump suction and discharge line of 100mm diameter and over.

r. The straight pipe length for the suction side shall be a minimumlength of 5 times the diameters of the suction pipework size.

s. Motor starter for all pumps shall be provided as specified.

t. Shaft Coupling Alignment

i. Shafts of all machinery shall be carefully and accurately aligned,utilizing shaft couplings between drivers and speed reducersand the equipment. The direction of rotation of the driver shallbe tested before final shaft coupling connection is made.

ii. All necessary corrections to eliminate both types of shaft mis-alignment defined as below shall be made at no extra cost tothe Employer.

iii. Angular Mis-alignment - Shafts having axis concentric but notparallel.

iv. Parallel Mis-alignment - Shafts having axis parallel but notconcentric

u. Pumps and appurtenances shall be installed in the space providedand made readily serviceable.

v. Foundations, platforms, and vibration isolators shall be provided asdescribed in relevant section of this Specification and as requiredfor the proper installation of equipment.

w. Drains shall be provided for bases and stuffing boxes piped to anddischarging into floor drains and drain funnels.

x. Air cock and drain connection shall be provided on pump casing.

y. Reduction in line size shall be by utilizing long radius reducingelbows or reducers. Support piping shall be provided adjacent topumps such that no weight is carried on pump casings. Supportsshall be provided under elbows on pump suction and discharge linesizes of 100mm and over.

z. Base mounted pumps shall be checked, aligned and certified priorto start-up




504.4 Controls

504.4.1 Wet Riser System/Pressurised Hydrant System

Pump starter panel should be complete with indicator lights as perBOMBA guideline. Ventilation slots should be provided with insectscreen to prevent entry of vermin. Power supply cables to the panelshould be of fire rated type routed within the same room as the firepumps it controls.

Wet Riser/Pressurised Hydrant pumps as shown on the Drawings and/ orEquipment Schedules shall be controlled by the following:

a. It shall be able to manually operate on the motor control panel(MCP).

b. There shall be one pump in operation at any time.

c. Automatic change-over facility shall be provided, the standby pumpshall automatically start if the duty pump fails to operate.

d. Manual selection switch of the duty and standby pump shall beprovided.

e. Once the pump has started, it can only be stopped manually.

f. Pump operation status shall be provided inside the Station ControlRoom and Fire Control Panel Room.

g. Usually three pressure switches are provided with the followingsuggested pressure setting:-

i. starting the duty pumpset set at 80% of the system pressure;ii. starting the standby pumpset set at 60% of the system pressure;

andiii. starting and stopping the jockey pumpset set at 90% and 110%

of the system pressure respectively.

h. The pressure switches are normally installed in the test and drainline on the pump discharge side.

i. The pressure settings should be clearly labeled on tags attached toeach pressure switch.




504.4.2 Hose reel System

Pump starter panel should be complete with indicator lights as perBOMBA guideline. Ventilation slots should be provided with insectscreen to prevent entry of vermin.

Hose Reel pumps as shown on the Drawings and/ or EquipmentSchedules shall be controlled by the following:


b. It shall be automatically started by actuation of any break glassunits.

c. There shall be one pump in operation at any time.

d. Automatic change-over facility shall be provided, the standby pumpshall automatically start if the duty pump fails to operate.

e. Manual selection switch of the duty and standby pump shall beprovided.

f. Once the pump has started, it can only be stopped manually.

g. Pump operation status shall be provided inside the Station ControlRoom and Fire Control Panel Room.

h. Usually two pressure switches are provided with the followingsuggested pressure setting:-

i. Starting and stopping the duty pumpset set at 80% and 100% ofthe system pressure respectively;

ii. Starting and stopping the standby pumpset set at 60% and 100%of the system pressure respectively.

i. The pressure switches are normally installed in the test and drainline on the pump discharge side.

j. The pressure settings should be clearly labeled on tags attached toeach pressure switch.




504.4.3 Automatic Sprinkler System

Pump starter panel should be compartmented for each of the duty,standby and jockey pumps and complete with indicator lights as perJBPM requirements. Ventilation slots should be provided with insectscreen to prevent entry of vermin. Power supply cables to the panelshould be of fire rated type routed within the same room as the firepumps it controls.

Electrical interlocks should be provided so that the sprinkler pumps ateach installation should not operate in parallel simultaneously. A buzzershould be sounded should the isolator be in the off or manual position.

Sprinkler pumps as shown on the Drawings and/or Equipment Schedulesshall be controlled by the following:


b. The sprinkler pumps shall be controlled by the pressure switchinstalled on the discharge side of each pump as shown on theDrawings. The duty pump and standby pump shall cut inautomatically when the water pressure drops to 80% and 60% ofthe designed system pressure respectively.

c. There shall be only one pump in operation at any one time.

d. Automatic change-over facility shall be provided and the standbypump shall automatically start if the duty pump fails to start.

e. Manual selection switch of the duty and standby pump shall beprovided.

f. Once the pump has started, it can only be stopped manually.

g. Pump operation status shall be indicated on the fire alarm panel &repeater fire alarm panel provided inside the Station Control Roomand Fire Control Panel Room.

h. Usually three pressure switches are provided with the followingsuggested pressure setting:-

i. Starting the duty pumpset set at 80% of the system pressure;ii. Starting the standby pumpset set at 60% of the system pressure;

andiii. Starting and stopping the jockey pumpset set at 90% and 110%

of the system pressure respectively.




i. The pressure switches are normally installed in the test and drainline on the pump discharge side.

j. The pressure settings should be clearly labeled on tags attached toeach pressure switch.

504.4.4 Water Transfer Pump/Suction Pump

Transfer pumps as shown on the Drawings and/ or Equipment Schedulesshall be controlled by the following:

a. When the water level in the water storage tank is drawn to belowthe full storage levels, the duty pump shall be started to operateand continue to draw the water from the suction tank to thestorage tanks until the water level reaches 25mm below the invertof the overflow pipe, at which the water storage tank is of fullstorage capacity.

b. An overriding float switch of differential type shall be provided inthe suction tank to cut off the pumps operation when the suctiontank has been emptied.

c. Automatic change-over facility shall be provided and the standbypump shall automatically start if the duty pump fails to start.

d. Automatic change-over facility shall be provided for the controlcircuit. After one pump has finished its operation, the other pumpshall stand as the duty pump for the next cycle.

e. Auto/manual selectors shall be provided.

f. It shall be manually operated from the motor control panel (MCP)and the remote ON/ OFF inside the suction pump rooms.

504.4.5 Chilled and Condenser Water System

Chilled and condensing water pumps as shown on the Drawings and/orEquipment Schedules shall be controlled by the following:

a. Automatic started by the Station BMS.

b. Automatic change-over facility shall be provided for the chilled andcondensing water pump sets.

c. Pump operation status shall be provided inside the Motor ControlCentre and the Station BMS.




504.4.6 Pneumatic Booster Pump Sets

There shall be duplicated pump sets in the system, one duty and onestandby. The pumps shall be automatically controlled to maintain thewater pressure in the system as indicated on the Drawings.

The pump control shall have the following features:-

a. The duty pump shall cut in and cut out automatically by thepressure switch installed on the pressure vessel. The cut in and outpressure range shall be adjustable.

b. An overriding float switch of differential type shall be provided inthe water tank to cut off the pumps operation when the tank hasbeen exhausted.

c. Automatic change-over facility shall be provided. The standbypump shall automatically start on the failure of the duty pump.

d. Lead/ lag selection and automatic alternation shall be provided forthe control circuit. After one pump has finished one operation, theother pump shall stand as the duty pump for the next cycle.

e. Duty/standby and auto/ off/ manual selectors shall be provided.

504.4.7 Sump Pumps Control

For the two-pump arrangement, one pump shall act as duty and theother one as standby. The pumps shall be automatically controlled totransfer the soil and/or waste water to the manhole or the nearestdrainage pipe connections.

Automatic controls shall be of float-type mercury switches suitable foruse with soil or waste water. Each pit shall be fitted with four switches atdifferent levels to correspond with the required depths of water and toinitiate the relevant controls to operate the pump and/ or raise thealarm suitably.

The pump control operation shall be:-

a. When the water level in the sump pit reaches the first pre-determined high level, the duty pump shall be started and continueto run until the water level falls back to the low level.

b. For duplicated pump sets, if the water level continues to rise to thesecond pre-determined level, the second pump shall also be calledto operate in parallel with the first pump. The pumps shall only bestopped when the water level drops back to the low level.




Automatic and manual change-over facilities shall be provided for thepumps.

A lead/ lag selection and an automatic alternation facility shall beprovided. After one pump has finished one operation, the second pumpshall act as duty pump for the next cycle.

An extra high level alarm shall be provided at the vicinity of the pit andthe control panels, when the water raises up to the extra high level, anaudible and visual alarm shall be raised.

Remote monitoring and control shall be required as follows:-

a. Run/ stop status of the sump pumps such as sewage pumpsandwaste sump pumps.

b. Overload alarm for the above pumps.

c. High water level for the sump pits.

d. Power supply failures for the pumps.

e. Auto/ manual mode status of the pumps.

f. Run/ stop control of the pumps.

504.4.8 Float Switches

Float switches required for pump control and alarm system shall beprovided. (The high/ low level alarm)

All cables and conduits shall be provided between the float switches inthe water tanks and sump pits and the local motor control panels.

All the alarms of the sump pits shall be wired back to the associatedlocal motor control panels in the pump rooms or at the vicinity of the pitrespectively. Should any one of these alarms be actuated an audible anda visual alarm shall be indicated on the pump control panel andtransmitted to the Station BMS Controller.

504.4.9 Maintenance Facilities

Pump installations shall be complete with adequate facilities formaintenance and future replacement of plant. Lifting eyes shall beprovided for pumps and motors. Details of any requirements foroverhead runways and hoists shall be submitted for Approval.




Each pump shall have a pressure gauge installed to indicate dischargepressures. The gauge shall be mounted on a hardwood gauge board onthe wall adjacent to the pumps. Gauges shall be 100mm dial calibratedto read directly in kPa of range to match the respective pump duties.

504.4.10 Site Testing

Pumps shall be tested in actual operating conditions to verifycompliance with this Specification. All wirings shall be checked forconnection and continuity. Performance of all relays and logic shall betested.

All excessive vibration, noise, rattles or other objectionable factors shallbe corrected promptly or all defective items shall be replaced and thesystem shall be subsequently retested to the satisfaction of theEmployer’s Representatives.

Controls shall be checked and all necessary adjustments to secureproper control shall be carried out in the presence of the controlmanufacturer's authorized representative.

504.4.11 Testing at Manufacturer's Works

Pumps shall be tested over the full range of their capacities. The rangeshall be from closed valve condition to a point corresponding to adischarge of 15% in excess of the maximum discharge in the specifiedrange of duties. Testing shall determine the output, power consumedand mechanical efficiency. Copies of the NPSH design curve shall also beprovided.

Head/ quantity curves, pump efficiency/ quantity curves, overallefficiency/ quantity and power/ quantity curves shall be drawn. Thecurves produced shall be used to demonstrate that the pump will becapable of meeting the full range of operating conditions at Site.

All pump components subject to pressure shall be hydraulically tested toa pressure of 1.5 times the sum of the closed valve head plus themaximum suction pressure for 5 minutes.

section 504 pumps rev 00

Documents