QCS Section 9 Part 4 Sump Pumps Page 1

4. SUMP PUMPS ...............................................................................................2

4.1 GENERAL ......................................................................................................2

4.1.1 Scope 2
4.1.2 References 2
4.1.3 Submittals 2
4.2 PRODUCTS ...................................................................................................2
4.2.1 General 2
4.2.2 Design Conditions 3
4.2.3 Materials 3
4.2.4 Accessories 3
4.2.5 Fabrication 4
4.2.6 Factory Inspection and Testing 4
4.2.7 Spare Parts and Tools 5
4.3 INSTALLATION AND COMMISSIONING.......................................................5
4.3.1 Installation 5
4.3.2 Site Inspection and Testing 5
QCS Section 9 Part 4 Sump Pumps Page 2

4. SUMP PUMPS
4.1 GENERAL

4.1.1 Scope

1 This Part includes specifies the requirements for the design, manufacture, construction,
installation, testing and commissioning of electro submersible sump pumps up to and
including 5 kW, unless specified otherwise.

2 Related Sections and Parts are as follows:

This Section
Part 1, General
Section 1, General
Section 8, Sewerage
Section 10, Instrumentation, Control and Automation
Section 13, Masonry
Section 21, Electrical Works
4.1.2 References

1 The following standards are referred to in this Part:

BS 970 (ISO 683) Wrought steels for mechanical and allied engineering purposes
BS 1400, Copper alloy ingots and copper alloy and high conductivity copper coatings
BS 1452 (ISO 185) Flake graphite cast iron
BS 3468 (ISO 2892) Austenitic cast iron
BS 4504, Circular flanges for pipes, valves and fittings
BS 5512 (ISO 281) Methods of calculating dynamic load ratings and rating life of rolling
bearings
BS 6007 (IEC 245) Rubber insulated cables for electric power and lighting
BS 6105 (ISO 3506) Corrosion-resistant stainless steel fasteners
BS 6861 (ISO 1940) Balance quality of requirements of rigid rotors
4.1.3 Submittals

1 In addition to the requirements of Part 1 of this Section the Contractor shall provide
submittals as described in the following paragraphs

2 Design Data
(a) the Contractor shall provide manufacturer’s published pump curves, and the
necessary hydraulic calculations to justify the sizes of any pumps selected.
3 Shop Drawings
(a) the Contractor shall provide the following:
(i) impeller diameter
(ii) velocity of liquid in pump at duty point
(iii) the materials of construction shall be specified in detail and itemised against a
sectional drawing of the pump proposed.
(b) after approval of the pump type the Contractor shall submit the test data as required
under factory inspection and testing
4.2 PRODUCTS

4.2.1 General

1 Submersible sump pumps shall be as follows:

(a) bottom suction, side or top discharge type
QCS Section 9 Part 4 Sump Pumps Page 3

(b) threaded discharge connection shall not exceed 50 mm diameter; all larger discharge
connections shall be flanged to BS 4504 NP16
(c) flexible hose connections for discharge shall be provided for pumps less than 15 kg.
For pumps greater than 15 kg guide rails and couplings shall be provided.
2 If explosion-proof motor or electrical system construction is required, this will be specified in
the particular Project Specification.

4.2.2 Design Conditions

1 Pumps shall be designed and constructed to satisfactorily meet the designated design
conditions and the requirements specified in this Part.

2 Castings, fabrications, machined parts and drives shall conform to industry standards for
strength and durability and shall be rated for continuous duty over the entire operating
range.

3 Bearings shall be of the anti-friction type designed for BS 5512 L10 life of 10,000 h.

4.2.3 Materials

1 Pumps and appurtenances shall be manufactured of the following materials:

(a) the pump case and motor housing shall be cast iron BS 1452, Grade 220 or 260, or
nickel iron, BS 3468, depending on the characteristics of sewage or fluid pumped.
(b) impellers shall be cast iron, BS 1452, Grade 220, or nickel iron, BS 3468
(c) shafts shall be stainless steel, BS 970 Part 1
(d) all fasteners shall be stainless steel, BS 970 Part 1 type 304 S 15
(e) lifting chains shall be stainless steel, BS 970 Part 1 type316 S 31
(f) bends shall be cast iron, BS 1452 grade 250
(g) fasteners shall be stainless steel, BS 6105 and BS 970 304 S 15
2 The lifting system (pumps over 15 kg) shall be a guide rail system, stainless steel, BS 970
Type 316 S 31.

3 Additional or other requirements for materials of construction may be specified in the

particular project specification.

4.2.4 Accessories

1 The following accessories shall be provided for the pumps:

(a) power and control cables: power and control cables shall be sized in accordance with
MEW regulations, and shall be suitable for submersible applications in wastewater.
They shall be EPR insulated, niplas sheathed, flexible 450/750 volts grade with tinned
annealed copper conductors in accordance with BS 6007. The cable shall be of
sufficient length to be terminated in an IP67 junction box adjacent to the pump.
(b) motor control panels
(i) local control panels (LCP) shall be provided as Section 21 to control sump
pumps, if provision is not made in the main motor control centre.
(ii) pumps shall operate automatically from float switches, with manual override by
means of a hand-off-automatic selector switch
(iii) pumps shall operate on rising level as follows, start 1st pump, start 2nd pump
(if required), and high level alarm, with a common pump stop.
(c) float switches: float switches shall be of the pendant type with change-over contacts
sealed in a hypalon case. The height of the floats shall be adjustable
(d) lifting equipment: where designated, manually operated, chain blocks
capable of lifting the pumps for each location shall be provided.. They shall
be provided with a fabricated steel support frame and have a minimum capacity of
1.5 times pump weight. The cable end shall be fitted with a grab hook to properly link
up with the lifting chain or lifting bar, as applicable
QCS Section 9 Part 4 Sump Pumps Page 4

(e) for pumps less than 15 kg, the initial 2 m of delivery pipework from the pump shall be
in armoured flexible PVC, to enable the pump to be removed from its sump for
cleaning, and the connection to the pipework shall be by stainless steel or plastic
unions to facilitate easy removal
(f) for pumps greater than 15 kg a duckfoot bend with sliding bracket guide rails and
discharge connection shall be provided
(g) if check valves are not provided in the external pipework, the pumps shall be
provided with intergral uPVC check valves.
4.2.5 Fabrication

1 General. All castings shall be produced in accordance with the pump manufacturer’s
specifications under the manufacturer’s direct supervision.

2 Impellers
(a) semi-open type
(b) multi-vane design keyed to shaft, with ejector vanes on backside (if recommended by
pump manufacturer) for further protection of seal chamber
(c) capable of passing 25 mm minimum diameter spheres

3 Shafts.
(a) shall have a double mechanical seal and a tungsten-carbide ring with stainless
steel parts. Oil filled chambers shall be provided to lubricate running faces
4 Motors
(a) squirrel cage motors shall be in accordance with Section 21
(b) rotors and pump shafts shall be integral
(iii) motors shall be capable of startup and operation in the event of a completely
flooded wet well
(iv) stator winding thermal protection shall be provided
(iv) cooling ribs or forced cooling by pumped liquid shall be provided
5 Coatings
(a) any steel parts shall be fusion bonded epoxy, minimum thickness 300 microns
(b) any other coatings shall be in accordance with Part 1 of this Section; alternative
recommendations of the pump manufacturer will be considered if information is
provided in pump submittals for the Engineer’s approval
6 Bearing
(a) bearings shall comprise progressed rolling elements
7 Strainers
(a) spring loaded strainers for pump suctions shall be provided.
8 Discharge Connection and Guide Rails. Where required, sliding guide bracket and
discharge connections shall be provided which, when bolted to the floor of the sump and to
the discharge line, will receive the pump discharge connecting flange without need of
adjustment, fasteners, clamp, or similar devices. The guide rails shall not support any
portion of the weight of the pump. The pump discharge connections shall incorporate a
sealing face and connection yoke to allow for automatic coupling to fixed discharge
connection pipework.

4.2.6 Factory Inspection and Testing

1 Pumps shall be factory type tested by the manufacturer.

2 The Contractor shall secure from the pump manufacturer certification that the following
inspections and tests have been conducted on each pump at the factory and submit to the
Engineer prior to shipment:
QCS Section 9 Part 4 Sump Pumps Page 5

(a) impeller, motor rating and electrical connections checked for compliance with the
designated requirements
(b) motor and cable insulation tested for moisture content or insulation defects
(c) submergence, that the pump has been run dry to establish correct rotation and
mechanical integrity
(d) the pump has been run for 30 min submerged under a minimum of 2 m of water
(e) after the operational test of item (d) that the insulation test of item (b) has been
performed again.
3 One pump of each service category shall be factory tested.

4 The Contractor shall submit to the Engineer before shipment:

(a) certified copies of the curves and reports generated by the tests described above
(b) foundry composition certificates for all major casting (pump case, impeller, motor
housing) showing exact material composition and test conducted to ensure
compliance with the pump manufacturer material’s specifications.
4.2.7 Spare Parts and Tools

1 The pump manufacturer shall provide all spares required during the commissioning and
maintenance periods and as required below.

2 In addition to the above, the following spare parts for each size and type of sump pump
shall be furnished to the Employer:
(a) three sets of complete bearings
(b) three sets of wear rings
(c) three sets of gaskets/’O’rings complete
(d) three sets of mecahnical seals
(e) three sets of cable entry seals
4.3 INSTALLATION AND COMMISSIONING

4.3.1 Installation

1 The equipment delivered to the site shall be examined to determine that it is in good
condition and in conformance with the approved shop drawings.

2 All equipment shall be installed in strict conformance with Part 1 of this Section and the
manufacturer’s instructions.

4.3.2 Site Inspection and Testing

1 The Contractor shall operate each pumping unit for 24 hours over the entire specified range.
The operation over the entire specified range shall be free of vibration, noise, and
cavitation.

2 Draw down tests shall be carried out to test the capacity of the pump.

END OF PART