NORTHEAST WRF IMPROVEMENTS PROJECT - 19-0029-UT - BOOK 2Book 2
Northeast WRF Improvements
Project 19-0029-UT
Contract Documents &
Specifications
Section IVb
Subsection 03350 through
Subsection 16775
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 03350
2
3 CONCRETE FINISHES
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and finish
10 cast -in-place concrete surfaces as shown on the Drawings and as specified
11 herein.
12
13 1.02 RELATED WORK
14
15 A. Concrete Formwork is included in Section 03100.
16
17 B. Cast -In -Place Concrete is included in Section 03300.
18
19 C. Grout is included in Section 03600.
20
21 D. Painting, toppings and special surfaces are included in Division 9.
22
23 1.03 SUBMITTALS
24
25 A. Submit to the Engineer, in accordance with Sections 01300 and 01340, shop
26 drawings and product data showing materials of construction and details of
27 installation for:
28
29 1. Concrete sealer. Confirmation that the sealer is compatible with
30 additionally applied coatings shall also be submitted.
31
32 1.04 REFERENCE STANDARDS
33
34 A. American Society for Testing and Materials (ASTM)
35
36 1. ASTM C33 - Standard Specification for Concrete Aggregates.
37
38 B. Where reference is made to one of the above standards, the revision in effect
39 at the time of bid opening shall apply.
40
41 1.05 QUALITY ASSURANCE
42
43 A. Finishes
44
45 1. For concrete which will receive additional applied finishes or materials,
46 the surface finish specified is required for the proper application of the
CONCRETE FINISHES
03350-1 03/22/2019
1 specified manufacturer's products. Where alternate products are
2 approved for use, determine if changes in finishes are required and
3 provide the proper finishes to receive these products.
4
5 2. Changes in finishes made to accommodate products different from
6 those specified shall be performed at no additional cost to the Owner.
7 Submit the proposed new finishes and their construction methods to the
8 Engineer for approval.
9
10 B. Services of Manufacturer's Representative
11
12 1. Make available at no extra cost to the Owner, upon 72 hours
13 notification, the services of a qualified field representative of the
14 manufacturer of curing compound, sealer or hardener to instruct the
15 user on the proper application of the product under prevailing job
16 conditions.
17
18 PART 2 - PRODUCTS
19
20 2.01 MATERIALS
21
22 A. Chemical hardener shall be Lapidolith by Sonneborn; Hornolith by A.C. Horn;
23 Penalith by W.R. Meadows or equal fluosilicate base material.
24
25 B. Concrete sealer shall be "Kure -N -Seal", by Sonneborn, Minneapolis, MN or
26 equal.
27
28 PART 3 - EXECUTION
29
30 3.01 FORMED SURFACES
31
32 A. Forms shall not be removed before the requirements of Section 03300, have
33 been satisfied.
34
35 B. Exercise care to prevent damaging edges or obliterating the lines of chamfers,
36 rustications or corners when removing the forms or performing any other work
37 adjacent thereto.
38
39 C. Clean all exposed concrete surfaces and adjoining work stained by leakage of
40 concrete.
41
42 D. Rough -Form Finish
43
44 1. Immediately after stripping forms and before concrete has changed
45 color, carefully remove all fins and projections.
46
CONCRETE FINISHES
03350-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 2. Promptly fill holes left by tie cones and defects as specified in Section
2 03300.
3
4 E. Rubbed Finish
5
6 1. Immediately upon stripping forms and before concrete has changed
7 color, carefully remove all fins. While the wall is still damp apply a thin
8 coat of medium consistency neat cement slurry by means of bristle
9 brushes to provide a bonding coat within all pits, air holes or blemishes
10 in the parent concrete. Avoid coating large areas with the slurry at one
11 time.
12
13 2. Before the slurry has dried or changed color, apply a dry (almost
14 crumbly) grout proportioned by volume and consisting of 1 part cement
15 to 1-1/2 parts of clean masonry sand having a fineness modulus of
16 approximately 2.3 and complying with the gradation requirements of
17 ASTM C33 for such a material. Grout shall be uniformly applied by
18 means of damp pads of coarse burlap approximately 6 -in square used
19 as a float. Scrub grout into the pits and air holes to provide a dense
20 mortar in all imperfections.
21
22 3. AIIow the mortar to partially harden for 1 or 2 hours depending upon the
23 weather. If the air is hot and dry, keep the wall damp during this period
24 using a fine, fog spray. When the grout has hardened sufficiently so it
25 can be scraped from the surface with the edge of a steel trowel without
26 damaging the grout in the small pits or holes, cut off all that can be
27 removed with a trowel. (Note: Grout allowed to remain on the wall too
28 long will harden and will be difficult to remove.)
29
30 4. AIIow the surface to dry thoroughly and rub it vigorously with clean dry
31 burlap to completely remove any dried grout. No visible film of grout
32 shall remain after this rubbing. The entire cleaning operation for any
33 area must be completed the day it is started. Do not leave grout on
34 surfaces overnight. AIIow sufficient time for grout to dry after it has
35 been cutoff with the trowel so it can be wiped off clean with the burlap.
36
37 5. On the day following the repair of pits, air holes and blemishes, the
38 walls shall again be wiped off clean with dry, used pieces of burlap
39 containing old hardened mortar which will act as a mild abrasive. After
40 this treatment, there shall be no built-up film remaining on the parent
41 surface. If, however, such a film is present, a fine abrasive stone shall
42 be used to remove all such material without breaking through the
43 surface film of the original concrete. Such scrubbing shall be Tight and
44 sufficient only to remove excess material without changing the texture
45 of the concrete.
46
CONCRETE FINISHES
03350-3 03/22/2019
1 6. A thorough wash -down with stiff bristle brushes shall follow the final
2 bagging or stoning operation. No extraneous materials shall remain on
3 the surface of the wall. The wall shall be sprayed with a fine fog spray
4 periodically to maintain a continually damp condition for at least 3 days
5 after the application of the repair grout.
6
7 7. It is the intent of this finish to provide a surface that is uniform in
8 appearance with no blemishes, imperfections, discolorations, etc.
9
10 F. Abrasive Blast Finish
11
12 1. Coordinate with Rubbed Finish application. Do not begin until Rubbed
13 Finish operation is complete or before concrete has reached minimum
14 7 -day strength. The Rubbed Finish application may be deleted by the
15 Engineer if the unfinished concrete surface is of superior quality. Apply
16 the abrasive blast finish only where indicated on Drawings.
17
18 2. Prepare a sample area of minimum 4 -ft high by 16 -ft wide Blast Finish
19 as directed by Engineer on a portion of new wall construction which will
20 not be exposed in the final work. Sample area shall contain a variety of
21 finishes obtained with different nozzles, nozzle pressures, grit materials
22 and blasting techniques for selection by Engineer. Final accepted
23 sample shall remain exposed until completion of all Blast Finish
24 operations.
25
26 3. Blast finish operation shall meet all regulatory agency requirements.
27 Blast Finish contractor shall be responsible for obtaining all required
28 permits and/or licenses.
29
30 4. Perform abrasive blast finishing in as continuous an operation as
31 possible, utilizing the same work crew to maintain continuity of finish on
32 each surface or area of work. Maintain patterns or variances in depths
33 of blast as present on the accepted sample.
34
35 5. Use an abrasive grit of proper type and gradation as well as equipment
36 and technique to expose aggregate and surrounding matrix surfaces as
37 follows:
38
39 a. Medium: Generally expose coarse aggregate - 1/4 -in to 3/8 -in
40 reveal.
41
42 6. Abrasive blast corners and edge of patterns carefully, using back-up
43 boards, to maintain uniform corner or edge line. Determine type of
44 nozzle, nozzle pressure and blasting techniques required to match
45 Architect's samples.
46
CONCRETE FINISHES
03350-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 7 Upon completion of the Blast Finish operation, thoroughly flush finished
2 surfaces with clean clear water to remove residual dust and grit. Allow
3 to air dry until curing of concrete is complete.
4
5 8. After the concrete has cured for a minimum of 28 days, apply a clear
6 acrylic sealer as directed by manufacturer.
7
8 3.02 FLOORS AND SLABS
9
10 A. Floated Finish
11
12 1. Machine Floating
13
14 a. Screed floors and slabs with straightedges to the established
15 grades shown on the Drawings. Immediately after final
16 screeding, a dry cement/sand shake in the proportion of two
17 sacks of portland cement to 350 lbs of coarse natural concrete
18 sand shall be sprinkled evenly over the surface at the rate of
19 approximately 500 lbs /1,000 sq ft of floor. Do not sprinkle neat,
20 dry cement on the surface.
21
22 b. The application of the cement/sand shake may be eliminated at
23 the discretion of the Engineer if the base slab concrete exhibits
24 adequate fattiness and homogeneity and the need is not
25 indicated. When the concrete has hardened sufficiently to
26 support the weight of a power float without its digging into or
27 disrupting the level surface, thoroughly float the shake into the
28 surface with a heavy revolving disc type power compacting
29 machine capable of providing a 200 Ib compaction force
30 distributed over a 24 -in diameter disc.
31
32 c. Start floating along walls and around columns and then move
33 systematically across the surface leaving a matte finish.
34
35 d. The compacting machine shall be the "Kelly Power Float with
36 Compaction Control" as manufactured by Kelley Industries of
37 SSP Construction Equipment Inc., Pomona, CA or equal.
38 Troweling machines equipped with float (shoe) blades that are
39 slipped over the trowel blades may be used for floating. Floating
40 with a troweling machine equipped with normal trowel blades will
41 not be permitted. The use of any floating or troweling machine
42 which has a water attachment for wetting the concrete surface
43 during finishing will not be permitted.
44
45 2. Hand Floating
46
CONCRETE FINISHES
03350-5 03/22/2019
1 a. In lieu of power floating, small areas may be compacted by hand
2 floating. The dry cement/sand shake previously specified shall
3 be used unless specifically eliminated by the Engineer. Screed
4 the floors and slabs with straightedges to the established grades
5 shown on the Drawings. While the concrete is still green, but
6 sufficiently hardened to support a finisher and kneeboards with
7 no more than 1/4 -in indentation, wood float to a true, even plane
8 with no coarse aggregate visible. Use sufficient pressure on the
9 wood floats to bring moisture to the surface.
10
11 3. Finishing Tolerances
12
13 a. Level floors and slabs to a tolerance of plus or minus 1/8 -in when
14 checked with a 10 -ft straightedge placed anywhere on the slab in
15 any direction. Where drains occur, pitch floors to drains such
16 that there are no low spots left undrained. Failure to meet either
17 of the above requirements shall be cause for removal, grinding,
18 or other correction as directed by the Engineer.
19
20 B. Broom Finish
21
22 1. Screed slabs with straightedges to the established grades indicated on
23 the Drawings. When the concrete has stiffened sufficiently to maintain
24 small surface indentations, draw a stiff bristle broom lightly across the
25 surface in the direction of drainage, or, in the case of walks and stairs,
26 perpendicular to the direction of traffic to provide a non -slip surface.
27
28 C. Steel Trowel Finish
29
30 1. Finish concrete as specified in Paragraph 3.04. Then, hand steel trowel
31 to a perfectly smooth hard even finish free from high or low spots or
32 other defects.
33
34 D. Concrete Sealer
35
36 1. Prepare and seal surfaces indicated on the room finish schedule to
37 receive a sealer as follows:
38
39 a. Finish concrete as specified in the preceding paragraphs and in
40 accordance with the Schedule in Paragraph 3.05 below.
41
42 b. Newly Placed Concrete: Surface must be sound and properly
43 finished. Surface is application -ready when it is damp but not
44 wet and can no longer be marred by walking workmen.
45
CONCRETE FINISHES
03350-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 c. Newly -Cured Bare Concrete: Level any spots gouged out by
2 trades. Remove all dirt, dust, droppage, oil, grease, asphalt and
3 foreign matter. Cleanse with caustics and detergents as
4 required. Rinse thoroughly and allow to dry so that surface is no
5 more than damp, and not wet.
6 d. Aged Concrete: Restore surface soundness by patching,
7 grouting, filling cracks and holes, etc. Surface must also be free
8 of any dust, dirt and other foreign matter. Use power tools
9 and/or strippers to remove any incompatible sealers or coatings.
10 Cleanse as required, following the procedure indicated under
11 cured concrete.
12
13 e. Methods: Apply sealer so as to form a continuous, uniform film
14 by spray, soft -bristle pushbroom, long -nap roller or lambswool
15 applicator. Ordinary garden -type sprayers, using neoprene
16 hose, are recommended for best results.
17
18 f. Applications: For curing only, apply first coat evenly and
19 uniformly as soon as possible after final finishing at the rate of
20 200 to 400 sq ft per gallon. Apply second coat when all trades
21 are completed and structure is ready for occupancy at the rate of
22 400 to 600 sq ft per gallon.
23
24 g. To meet guarantee and to seal and dustproof, two coats are
25 required. For sealing new concrete, both coats shall be applied
26 full-strength. On aged concrete, when renovating, dustproofing
27 and sealing, the first coat should be thinned 10 to 15 percent
28 with reducer per manufacturer's directions.
29
30 3.03 CONCRETE RECEIVING CHEMICAL HARDENER
31
32 A. After 28 days, minimum, concrete cure, apply chemical hardener in three
33 applications to a minimum total coverage of the undiluted chemical of 100 sq ft
34 per gallon and in accordance with manufacturer's recommendations as
35 reviewed.
36
37 3.04 APPROVAL OF FINISHES
38
39 A. All concrete surfaces, when finished, will be inspected by the Engineer.
40
41 B. Surfaces which, in the opinion of the Engineer, are unsatisfactory shall be
42 refinished or reworked.
43
44 C. After finishing horizontal surfaces, regardless of the finishing procedure
45 specified, the concrete shall be cured in compliance with Section 03300 unless
46 otherwise directed by the Engineer.
CONCRETE FINISHES
03350-7 03/22/2019
1
2 3.05 SCHEDULE OF FINISHES
3
4 A. Concrete shall be finished as specified either to remain as natural concrete to
5 receive an additional applied finish or material under another section.
6
7 B. Concrete for the following conditions shall be finished as noted on the
8 Drawings and as further specified herein:
9
10 1. Concrete to Receive Dampproofing: Rough -form finish. See
11 Paragraph 3.01 D above.
12
13 2. Concrete Not Exposed to View and Not Scheduled to Receive an
14 Additional Applied Finish or Material: Rough -form finish. See
15 Paragraph 3.01D above.
16
17 3. Exterior Vertical Concrete Above Grade Exposed to View: Rubbed
18 finish. See Paragraph 3.01E above.
19
20 4. Interior Vertical Concrete Exposed to View Except in Water
21 Containment Areas: Rubbed finish. See Paragraph 3.01E above.
22
23 5. Vertical Concrete in Water Containment Areas. Rubbed finish on
24 exposed surfaces and extending to two feet below normal operating
25 water level: Rough -form finish on remainder of submerged areas. See
26 Paragraphs 3.01E and 3.01D above.
27
28 6. Interior and Exterior Underside of Concrete Exposed to View: Rubbed
29 finish. See Paragraph 3.01E above.
30
31 7 Exterior surfaces exposed to view and indicated to have an abrasive
32 blast finish. See Paragraph 3.01 F above.
33
34 8. Interior or Exterior Horizontal Concrete not Requiring Floor Hardener or
35 Sealer: Floated finish. See Paragraph 3.02A above.
36
37 9. Concrete for Exterior Walks, Interior and Exterior Stairs: Broomed
38 finish perpendicular to direction of traffic. See Paragraph 3.02B above.
39
40 10. Concrete Slabs On Which Process Liquids Flow or In Contact with
41 Sludge: Steel trowel finish. See Paragraph 3.02C above.
42
43 11. Concrete to Receive Hardener: See Paragraph 3.02D above.
44
45 12. Concrete to Receive Floor Sealer: See Paragraph 3.02E above.
46
CONCRETE FINISHES
03350-8 03/22/2019
13. Concrete tank bottoms to be covered with grout: See Section 03600.
END OF SECTION
CONCRETE FINISHES
03350-9 03/22/2019
1 THIS PAGE INTENTIONALLY LEFT BLANK
2
CONCRETE FINISHES
03350-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 03600
2
3 GROUT
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and install grout
10 complete as shown on the Drawings and as specified herein.
11
12 1.02 RELATED WORK
13
14 A. Formwork is included in Section 03100.
15
16 B. Concrete Reinforcement is included in Section 03200.
17
18 C. Concrete Joints and Joint Accessories are included in Section 03250.
19
20 D. Cast -in -Place Concrete is included in Section 03300.
21
22 E. Miscellaneous Metals are included in Section 05500.
23
24 1.03 SUBMITTALS
25
26 A. Submit to the Engineer, in accordance with Sections 01300 and 01340, shop
27 drawings and product data showing materials of construction and details of
28 installation for:
29
30 1. Commercially manufactured nonshrink cementitious grout. The
31 submittal shall include catalog cuts, technical data, storage
32 requirements, product life, working time after mixing, temperature
33 considerations, conformity to required ASTM standards and Material
34 Safety Data Sheet.
35
36 2. Commercially manufactured nonshrink epoxy grout. The submittal shall
37 include catalog cuts, technical data, storage requirements, product life,
38 working time after mixing, temperature considerations, conformity to
39 required ASTM standards and Material Safety Data Sheet.
40
41 3. Cement grout. The submittal shall include the type and brand of the
42 cement, the gradation of the fine aggregate, product data on any
43 proposed admixtures and the proposed mix of the grout.
44
45 4. Concrete grout. The submittal shall include data as required for concrete
46 as delineated in Section 03300 and for fiber reinforcement as delineated
GROUT
03600-1
03/22/2019
1 in Section 03200. This includes the mix design, constituent quantities
2 per cubic yard and the water/cement ratio.
3
4 B. Laboratory Test Reports
5
6 1. Submit laboratory test data as required under Section 03300 for concrete
7 to be used as concrete grout.
8
9 C. Certifications
10
11 1. Certify that commercially manufactured grout products and concrete
12 grout admixtures are suitable for use in contact with potable water after
13 30 days curing.
14
15 D. Qualifications
16
17 1. Grout manufacturers shall submit documentation that they have at least
18 10 years' experience in the production and use of the proposed grouts
19 which they will supply.
20
21 1.04 REFERENCE STANDARDS
22
23 A. American Society for Testing and Materials (ASTM)
24
25 1. ASTM C531 - Standard Test Method for Linear Shrinkage and Coefficient
26 of Thermal Expansion of Chemical Resistant Mortars, Grouts and
27 Monolithic Surfacings and Polymer Concretes
28
29 2. ASTM C579 - Standard Test Method for Compressive Strength of
30 Chemical Resistant Mortars, Grouts and Monolithic Surfacings and
31 Polymer Concretes
32
33 3. ASTM C827 - Standard Test Method for Change in Height at Early Ages
34 of Cylindrical Specimens from Cementitious Mixtures
35
36 4. ASTM C1107 - Standard Specification for Packaged Dry,
37 Hydraulic -Cement Grout (Nonshrink)
38
39 B. U.S. Army Corps of Engineers Standard (CRD)
40
41 1. CRD C-621 - Corps of Engineers Specification for Nonshrink Grout
42
43 C. Where reference is made to one of the above standards, the revision in effect
44 at the time of bid opening shall apply.
45
46 1.05 QUALITY ASSURANCE
GROUT
03600-2
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Qualifications
2
3 1. Grout manufacturer shall have a minimum of 10 years' experience in the
4 production and use of the type of grout proposed for the work.
5
6 B. Pre -installation Conference
7
8 1. Well in advance of grouting, hold a pre -installation meeting to review the
9 requirements for surface preparation, mixing, placing and curing
10 procedures for each product proposed for use. Parties concerned with
11 grouting shall be notified of the meeting at least 10 days prior to its
12 scheduled date.
13
14 C. Services of Manufacturer's Representative
15
16 1. A qualified field technician of the nonshrink grout manufacturer,
17 specifically trained in the installation of the products, shall attend the
18 pre -installation conference and shall be present for the initial installation
19 of each type of nonshrink grout. Additional services shall also be
20 provided, as required, to correct installation problems.
21
22 D. Field Testing
23
24 1. All field testing and inspection services required shall be provided by the
25 Owner. The Contractor shall assist in the sampling of materials and shall
26 provide any ladders, platforms, etc, for access to the work. The methods
27 of testing shall comply in detail with the applicable ASTM Standards.
28
29 2. The field testing of Concrete Grout shall be as specified for concrete in
30 Section 03300.
31
32 1.06 DELIVERY, STORAGE AND HANDLING
33
34 A. Deliver materials to the jobsite in original, unopened packages, clearly labeled
35 with the manufacturer's name, product identification, batch numbers and printed
36 instructions.
37
38 B. Store materials in full compliance with the manufacturer's recommendations.
39 Total storage time from date of manufacture to date of installation shall be
40 limited to 6 months or the manufacturer's recommended storage time,
41 whichever is less.
42
43 C. Material which becomes damp or otherwise unacceptable shall be immediately
44 removed from the site and replaced with acceptable material at no additional
45 expense to the Owner.
46
GROUT
03600-3
03/22/2019
1 D. Nonshrink cement -based grouts shall be delivered as preblended, prepackaged
2 mixes requiring only the addition of water.
3
4 E. Nonshrink epoxy grouts shall be delivered as premeasured, prepackaged, three
5 component systems requiring only blending as directed by the manufacturer.
6
7 1.07 DEFINITIONS
8
9 A. Nonshrink Grout: A commercially manufactured product that does not shrink in
10 either the plastic or hardened state, is dimensionally stable in the hardened state
11 and bonds to a clean base plate.
12
13 PART 2 - PRODUCTS
14
15 2.01 GENERAL
16
17 A. The use of a manufacturer's name and product or catalog number is for the
18 purpose of establishing the standard of quality desired.
19
20 B. Like materials shall be the products of one manufacturer or supplier in order to
21 provide standardization of appearance.
22
23 2.02 MATERIALS
24
25 A. Nonshrink Cementitious Grout
26
27 1. Nonshrink cementitious grouts shall meet or exceed the requirements of
28 ASTM C1107, Grades B or C and CRD C-621. Grouts shall be portland
29 cement based, contain a pre -proportioned blend of selected aggregates
30 and shrinkage compensating agents and shall require only the addition
31 of water. Nonshrink cementitious grouts shall not contain expansive
32 cement or metallic particles. The grouts shall exhibit no shrinkage when
33 tested in conformity with ASTM C827.
34
35 a. General purpose nonshrink cementitious grout shall conform to
36 the standards stated above and shall be SikaGrout 212 by Sika
37 Corp.; Set Grout by Master Builders, Inc.; Gilco Construction
38 Grout by Gifford Hill & Co.; Euco NS by The Euclid Chemical Co.;
39 NBEC Grout by U. S. Grout Corp. or equal.
40 b. Flowable (Precision) nonshrink cementitious grout shall conform
41 to the standards stated above and shall be Masterflow 928 by
42 Master Builders, Inc.; Hi -Flow Grout by the Euclid Chemical Co.;
43 SikaGrout 212 by Sika Corp.; Supreme Grout by Gifford Hill & Co.;
44 Five Star Grout by U. S. Grout Corp. or equal.
45
46 B. Nonshrink Epoxy Grout
GROUT
03600-4
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 1. Nonshrink epoxy -based grout shall be a pre -proportioned, three
3 component, 100 percent solids system consisting of epoxy resin,
4 hardener, and blended aggregate. It shall have a compressive strength
5 of 14,000 psi in 7 days when tested in conformity with ASTM D695 and
6 have a maximum thermal expansion of 30 x 10-6 when tested in
7 conformity with ASTM C531. The grout shall be Masterflow 648 by
8 Master Builders Inc.; Five Star Epoxy Grout by U.S. Grout Corp.; Sikadur
9 42 Grout -Pak by Sika Corp.; High Strength Epoxy Grout by the Euclid
10 Chemical Co. or equal.
11
12 C. Cement Grout
13
14 1. Cement grouts shall be a mixture of one part portland cement conforming
15 to ASTM C150, Types I, II, or III and 1 to 2 parts sand conforming to
16 ASTM C33 with sufficient water to place the grout. The water content
17 shall be sufficient to impart workability to the grout but not to the degree
18 that it will allow the grout to flow.
19
20 D. Concrete Grout
21
22 1. Concrete grout shall conform to the requirements of Section 03300
23 except as specified herein. It shall be proportioned with cement,
24 [pozzalan,] coarse and fine aggregates, water, water reducer and air
25 entraining agent to produce a mix having an average strength of 2900
26 psi at 28 days, or 2500 psi nominal strength. Coarse aggregate size shall
27 be [3/8] [1/2] -in maximum. Slump should not exceed 5 -in and should be
28 as low as practical yet still retain sufficient workability.
29
30 2. Synthetic reinforcing fibers as specified in Section 03200 shall be added
31 to the concrete grout mix at the rate of 1.5 lbs of fibers per cubic yard of
32 grout. Fibers shall be added from the manufacturer's premeasured bags
33 and according to the manufacturer's recommendations in a manner
34 which will ensure complete dispersion of the fiber bundles as single
35 monofilaments within the concrete grout.
36
37 E. Water
38
39 1. Potable water, free from injurious amounts of oil, acid, alkali, organic
40 matter, or other deleterious substances.
41
42 PART 3 - EXECUTION
43
44 3.01 PREPARATION
45
GROUT
03600-5
03/22/2019
1 A. Grout shall be placed over cured concrete which has attained its full design
2 strength unless otherwise approved by the Engineer.
3
4 B. Concrete surfaces to receive grout shall be clean and sound; free of ice, frost,
5 dirt, grease, oil, curing compounds, Iaitance and paints and free of all loose
6 material or foreign matter which may effect the bond or performance of the
7 grout.
8
9 C. Roughen concrete surfaces by chipping, sandblasting, or other mechanical
10 means to ensure bond of the grout to the concrete. Remove loose or broken
11 concrete. Irregular voids or projecting coarse aggregate need not be removed
12 if they are sound, free of Iaitance and firmly embedded into the parent concrete.
13
14 1. Air compressors used to clean surfaces in contact with grout shall be the
15 oilless type or equipped with an oil trap in the air line to prevent oil from
16 being blown onto the surface.
17
18 D. Remove all loose rust, oil or other deleterious substances from metal
19 embedments or bottom of baseplates prior to the installation of the grout.
20
21 E. Concrete surfaces shall be washed clean and then kept moist for at least 24
22 hours prior to the placement of cementitious or cement grout. Saturation may
23 be achieved by covering the concrete with saturated burlap bags, use of a
24 soaker hose, flooding the surface, or other method acceptable to the Engineer.
25 Upon completion of the 24 hour period, visible water shall be removed from the
26 surface prior to grouting. The use of an adhesive bonding agent in lieu of
27 surface saturation shall only be used when approved by the Engineer for each
28 specific location of grout installation.
29
30 F. Epoxy -based grouts do not require the saturation of the concrete substrate.
31 Surfaces in contact with epoxy grout shall be completely dry before grouting.
32
33 G. Construct grout forms or other leakproof containment as required. Forms shall
34 be Tined or coated with release agents recommended by the grout manufacturer.
35 Forms shall be of adequate strength, securely anchored in place and shored to
36 resist the forces imposed by the grout and its placement.
37
38 1. Forms for epoxy grout shall be designed to allow the formation of a
39 hydraulic head and shall have chamfer strips built into forms.
40
41 H. Level and align the structural or equipment bearing plates in accordance with
42 the structural requirements and the recommendations of the equipment
43 manufacturer.
44
45 1 Equipment shall be supported during alignment and installation of grout by
46 shims, wedges, blocks or other approved means. The shims, wedges and
GROUT
03600-6
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 blocking devices shall be prevented from bonding to the grout by appropriate
2 bond breaking coatings and removed after grouting unless otherwise approved
3 by the Engineer.
4
5 3.02 INSTALLATION - GENERAL
6
7 A. Mix, apply and cure products in strict compliance with the manufacturer's
8 recommendations and this Section.
9
10 B. Have sufficient manpower and equipment available for rapid and continuous
11 mixing and placing. Keep all necessary tools and materials ready and close at
12 hand.
13
14 C. Maintain temperatures of the foundation plate, supporting concrete, and grout
15 between 40 and 90 degrees F during grouting and for at least 24 hours
16 thereafter or as recommended by the grout manufacturer, whichever is longer.
17 Take precautions to minimize differential heating or cooling of baseplates and
18 grout during the curing period.
19
20 D. Take special precautions for hot weather or cold weather grouting as
21 recommended by the manufacturer when ambient temperatures and/or the
22 temperature of the materials in contact with the grout are outside of the 60 and
23 90 degrees F range.
24
25 E. Install grout in a manner which will preserve the isolation between the elements
26 on either side of the joint where grout is placed in the vicinity of an expansion or
27 control joint.
28
29 F. Reflect all existing underlying expansion, control and construction joints through
30 the grout.
31
32 3.03 INSTALLATION - CEMENT GROUTS AND NONSHRINK CEMENTITIOUS GROUTS
33
34 A. Mix in accordance with manufacturer's recommendations. Do not add cement,
35 sand, pea gravel or admixtures without prior approval by the Engineer.
36
37 B. Avoid mixing by hand. Mixing in a mortar mixer (with moving blades) is
38 recommended. Pre -wet the mixer and empty excess water. Add premeasured
39 amount of water for mixing, followed by the grout. Begin with the minimum
40 amount of water recommended by the manufacturer and then add the minimum
41 additional water required to obtain workability. Do not exceed the
42 manufacturer's maximum recommended water content.
43
44 C. Placements greater than 3 -inches in depth shall include the addition of clean,
45 washed pea gravel to the grout mix when approved by the manufacturer.
GROUT
03600-7
03/22/2019
1 Comply with the manufacturer's recommendations for the size and amount of
2 aggregate to be added.
3
4 D. Place grout into the designated areas in a manner which will avoid segregation
5 or entrapment of air. Do not vibrate grout to release air or to consolidate the
6 material. Placement should proceed in a manner which will ensure the filling of
7 all spaces and provide full contact between the grout and adjoining surfaces.
8 Provide grout holes as necessary.
9
10 E. Place grout rapidly and continuously to avoid cold joints. Do not place cement
11 grouts in layers. Do not add additional water to the mix (retemper) after initial
12 stiffening.
13
14 F Just before the grout reaches its final set, cut back the grout to the substrate at
15 a 45 degree angle from the lower edge of bearing plate unless otherwise
16 approved by the Engineer. Finish this surface with a wood float (brush) finish.
17
18 G. Begin curing immediately after form removal, cutback, and finishing. Keep grout
19 moist and within its recommended placement temperature range for at least 24
20 hours after placement or longer if recommended by the manufacturer. Saturate
21 the grout surface by use of wet burlap, soaker hoses, ponding or other approved
22 means. Provide sunshades as necessary. If drying winds inhibit the ability of a
23 given curing method to keep grout moist, erect wind breaks until wind is no
24 longer a problem or curing is finished.
25
26 3.04 INSTALLATION - NONSHRINK EPDXY GROUTS
27
28 A. Mix in accordance with the procedures recommended by the manufacturer. Do
29 not vary the ratio of components or add solvent to change the consistency of
30 the grout mix. Do not overmix. Mix full batches only to maintain proper
31 proportions of resin, hardener and aggregate.
32
33 B. Monitor ambient weather conditions and contact the grout manufacturer for
34 special placement procedures to be used for temperatures below 60 or above
35 90 degrees F.
36
37 C. Place grout into the designated areas in a manner which will avoid trapping air.
38 Placement methods shall ensure the filling of all spaces and provide full contact
39 between the grout and adjoining surfaces. Provide grout holes as necessary.
40
41 D. Minimize "shoulder" length (extension of grout horizontally beyond base plate).
42 In no case shall the shoulder length of the grout be greater than the grout
43 thickness.
44
GROUT
03600-8
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 E. Finish grout by puddling to cover all aggregate and provide a smooth finish.
2 Break bubbles and smooth the top surface of the grout in conformity with the
3 manufacturer's recommendations.
4
5 F. Epoxy grouts are self -curing and do not require the application of water.
6 Maintain the formed grout within its recommended placement temperature
7 range for at least 24 hours after placing, or longer if recommended by the
8 manufacturer.
9
10 3.05 INSTALLATION - CONCRETE GROUT
11
12 A. Screed underlying concrete to the grade shown on the Drawings. Provide the
13 surface with a broomed finish, aligned to drain. Protect and keep the surface
14 clean until placement of concrete grout.
15
16 B. Remove the debris and clean the surface by sweeping and vacuuming of all dirt
17 and other foreign materials. Wash the tank slab using a strong jet of water.
18 Flushing of debris into tank drain lines will not be permitted.
19
20 C. Saturate the concrete surface for at least 24 hours prior to placement of the
21 concrete grout. Saturation may be maintained by ponding, by the use or soaker
22 hoses, or by other methods acceptable to the Engineer. Remove excess water
23 just prior to placement of the concrete grout. Place a cement slurry immediately
24 ahead of the concrete grout so that the slurry is moist when the grout is placed.
25 Work the slurry over the surface with a broom until it is coated with
26 approximately 1/16 to 1/8 -in thick cement paste. [(A bonding grout composed
27 of 1 part portland cement, 1.5 parts fine sand, an approved bonding admixture
28 and water, mixed to achieve the consistency of thick paint, may be substituted
29 for the cement slurry.)]
30
31 D. Place concrete grout to final grade using the scraper mechanism as a guide for
32 surface elevation and to ensure high and low spots are eliminated where
33 application is at clarifier bottom. Unless specifically approved by the equipment
34 manufacturer, mechanical scraper mechanisms shall not be used as a finishing
35 machine or screed.
36
37 E. Provide synthetic reinforcing fibers in all applications unless steel reinforcement
38 is indicated in the Drawings.
39
40 F. Provide grout control joints as indicated on the Drawings.
41
42 G. Finish and cure the concrete grout as specified for cast -in-place concrete.
43
44 3.06 SCHEDULE
45
46 A. The following list indicates where the particular types of grout are to be used:
GROUT
03600-9
03/22/2019
1
2 1. General purpose nonshrink cementitious grout: Use at all locations
3 where non shrink grout is called for on the plans except for base plates
4 greater in area than 3 -ft wide by 3 -ft long and except for the setting of
5 anchor rods, anchor bolts or reinforcing steel in concrete.
6
7 2. Flowable nonshrink cementitious grout: Use under all base plates
8 greater in area than 3 -ft by 3 -ft. Use at all locations indicated to receive
9 flowable nonshrink grout by the Drawings. The Contractor, at his/her
10 option and convenience, may also substitute flowable nonshrink grout for
11 general purpose nonshrink cementitious grout.
12
13 3. Nonshrink epoxy grout: Use for the setting of anchor rods, anchor bolts
14 and reinforcing steel in concrete and for all locations specifically indicated
15 to receive epoxy grout.
16
17 4. Cement grout: Cement grout may be used for grouting of incidental base
18 plates for structural and miscellaneous steel such as post base plates for
19 platforms, base plates for beams, etc. It shall not be used when
20 nonshrink grout is specifically called for on the Drawings or for grouting
21 of primary structural steel members such as columns and girders.
22
23 5. Concrete grout: Use for overlaying the base concrete under scraper
24 mechanisms of clarifiers to allow more control in placing the surface
25 grade. Use at grout fillets or grout pours greater than 4" thick.
26
27 END OF SECTION
GROUT
03600-10
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 03740
2
3 MODIFICATIONS AND REPAIR TO CONCRETE
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and cut,
10 remove, repair or otherwise modify parts of existing concrete structures or
11 appurtenances as shown on the Drawings and as specified herein. Work under
12 this Section shall also include bonding new concrete to existing concrete.
13
14 1.02 RELATED WORK
15
16 A. Concrete Formwork is included in Section 03100.
17
18 B. Concrete Reinforcement is included in Section 03200.
19
20 C. Concrete Joints and Accessories are included in Section 03250.
21
22 D. Cast -in -Place Concrete is included in Section 03300.
23
24 E. Grout is included in Section 03600.
25
26 F. Miscellaneous Metals are included in Section 05500.
27
28 1.03 SUBMITTALS
29
30 A. If applicable, submit to the Engineer, a Schedule of Demolition and the detailed
31 methods of demolition to be used at each location.
32
33 B. Submit manufacturer's technical literature on all product brands proposed for
34 use, to the Engineer for review. The submittal shall include the manufacturer's
35 installation and/or application instructions.
36
37 C. When substitutions for acceptable brands of materials specified herein are
38 proposed, submit brochures and technical data of the proposed substitutions to
39 the Engineer for approval before delivery to the project.
40
41 1.04 REFERENCE STANDARDS
42
43 A. American Society for Testing and Materials (ASTM)
44
45 1. ASTM C881 - Standard Specification for Epoxy -Resin -Base Bonding
46 Systems for Concrete.
MODIFICATIONS AND REPAIR TO CONCRETE
03740-1 03/22/2019
1
1 1
2 2. ASTM C882 - Standard Test Method for Bond Strength of Epoxy -Resin
3 Systems Used with Concrete by Slant Sheer. I 4
5 3. ASTM C883 - Standard Test Method for Effective Shrinkage of
6 Epoxy -Resin Systems Used with Concrete.
7
8 4. ASTM D570 - Standard Test Method for Water Absorption of Plastics.
9
10 5. ASTM D638 - Standard Test Method for Tensile Properties of Plastics.
11
12 6. ASTM D695 - Standard Test Method for Compressive Properties of Rigid
13 Plastics.
14
15 7. ASTM D732 - Standard Test Method for Shear Strength of Plastics by
I
16 Punch Tool.
17
18 8. ASTM D790 - Standard Test Methods for Flexural Properties of
I
19 Unreinforced and Reinforced Plastics and Electrical Insulating Materials.
20
21 B. Where reference is made to one of the above standards, the revision in effect 1
22 at the time of bid opening shall apply.
23
24 1.05 QUALITY ASSURANCE
1
25
26 A. No existing structure or concrete shall be shifted, cut, removed, or otherwise
27 altered until authorization is given by the Engineer.
1
28
29 B. When removing materials or portions of existing structures and when making
30 openings in existing structures, all precautions shall be taken and all necessary1
31 barriers, shoring and bracing and other protective devices shall be erected to
32 prevent damage to the structures beyond the limits necessary for the new work,
33 protect personnel, control dust and to prevent damage to the structures or
I
34 contents by falling or flying debris. Unless otherwise permitted, shown or
35 specified, line drilling will be required in cutting existing concrete.
36
I
37 C. Manufacturer Qualifications: The manufacturer of the specified products shall
38 have a minimum of 10 years' experience in the manufacture of such products
39 and shall have an ongoing program of training, certifying and technically 1
40 supporting the Contractor's personnel.
41
42 1.06 DELIVERY, STORAGE AND HANDLING r
43
44 A. Deliver the specified products in original, unopened containers with the
45 manufacturer's name, labels, product identification and batch numbers. I
46
MODIFICATIONS AND REPAIR TO CONCRETE
1
03740-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. Store and condition the specified product as recommended by the
2 manufacturer.
3
4 PART 2 - PRODUCTS
5
6 2.01 MATERIALS
7
8 A. General
9
10 1. Materials shall comply with this Section and any state or local
11 regulations.
12
13 B. Epoxy Bonding Agent
14
15 1. General
16
17 a. The epoxy bonding agent shall be a two -component, solvent -free,
18 asbestos -free moisture insensitive epoxy resin material used to
19 bond plastic concrete to hardened concrete complying with the
20 requirements of ASTM C881, Type II and the additional
21 requirements specified herein.
22
23 2. Material
24
25 a. Properties of the cured material:
26
27 1) Compressive Strength (ASTM D695): 8500 psi minimum at
28 28 days.
29
30 2) Tensile Strength (ASTM D638): 4000 psi minimum at 14
31 days.
32
33 3) Flexural Strength (ASTM D790 - Modulus of Rupture):
34 6,300 psi minimum at 14 days.
35
36 4) Shear Strength (ASTM D732): 5000 psi minimum at 14
37 days.
38
39 5) Water Absorption (ASTM D570 - 2 hour boil): One percent
40 maximum at 14 days.
41
42 6) Bond Strength (ASTM C882) Hardened to Plastic: 1500
43 psi minimum at 14 days moist cure.
44
45 7) Effective Shrinkage (ASTM C883): Passes Test.
46
MODIFICATIONS AND REPAIR TO CONCRETE
03740-3 03/22/2019
1 8) Color: Gray.
2
3 3. Approved manufacturers: Sika Corporation, Lyndhurst, NJ - Sikadur 32,
4 Hi -Mod; Master Builder's, Cleveland, OH - Concresive Liquid (LPL) or
5 equal.
6
7 C. Epoxy Paste
8
9 1. General
10
11 a. Epoxy Paste shall be a two -component, solvent -free, asbestos
12 free, moisture insensitive epoxy resin material used to bond
13 dissimilar materials to concrete such as setting railing posts,
14 dowels, anchor bolts and all -threads into hardened concrete and
15 shall comply with the requirements of ASTM C881, Type I, Grade
16 3 and the additional requirements specified herein. It may also be
17 used to patch existing surfaces where the glue line is 1/8 -in or
18 less.
19
20 2. Material
21
22 a. Properties of the cured material:
23
24 1) Compressive Properties (ASTM D695): 10,000 psi
25 minimum at 28 days.
26
27 2) Tensile Strength (ASTM D638): 3,000 psi minimum at 14
28 days. Elongation at Break - 0.3 percent minimum.
29
30 3) Flexural Strength (ASTM D790 - Modulus of Rupture):
31 3,700 psi minimum at 14 days.
32
33 4) Shear Strength (ASTM D732): 2,800 psi minimum at 14
34 days.
35 5) Water Absorption (ASTM D570): 1.0 percent maximum at
36 7 days.
37
38 6) Bond Strength (ASTM C882): 2,000 psi at 14 days moist
39 cure.
40
41 7) Color: Concrete grey.
42
43 3. Approved manufacturers:
44
MODIFICATIONS AND REPAIR TO CONCRETE
03740-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 a. Overhead applications: Sika Corporation, Lyndhurst, NJ - Sikadur
2 Hi -mod LV 31; Master Builders, Inc., Cleveland, OH - Concresive
3 1438 or equal.
4
5 b. Sika Corporation, Lyndhurst, N.J. - Sikadur Hi -mod LV 32; Master
6 Builders, Inc., Cleveland, OH - Concresive 1438 or equal.
7
8 D. Non -Shrink Precision Cement Grout, Non -Shrink Cement Grout, Non -Shrink
9 Epoxy Grout and Polymer Modified mortar are included in Section 03600
10 GROUT.
11
12 E. Adhesive Capsule type anchor system shall be equal to the HIT-HY 200
13 adhesive Anchoring System by Hilti Fastening Systems, Tulsa, OK. The
14 capsule shall consist of a sealed glass capsule containing premeasured
15 amounts of polyester or vinylester resin, quartz sand aggregate and a hardener
16 contained in a separate vial within the capsule. Where the adhesive anchor is
17 under sustained tensile loading (i.e. vertically installed anchors) the anchor
18 system shall be Hilti HIT RE -500 SD by Hilti Fastening Systems, Tulsa, OK. All
19 steel reinforcement shall be anchored using the Hilti HIT RE -500 SD adhesive
20 anchoring system.
21
22 F. Acrylic Latex Bonding Agent
23
24 G. Crack Repair Epoxy Adhesive
25
26 1. General
27
28 a. Crack Repair Epoxy Adhesive shall be a two -component,
29 solvent -free, moisture insensitive epoxy resin material suitable for
30 crack grouting by injection or gravity feed. It shall be formulated
31 for the specific size of opening or crack being injected.
32
33 b. All concrete surfaces containing potable water or water to be
34 treated for potable use that are repaired by the epoxy adhesive
35 injection system shall be coated with an acceptable epoxy coating
36 approved by the FDA for use in contact with potable water.
37
38 2. Material
39
40 a. Properties of the cured material
41
42 1) Compressive Properties (ASTM D695): 10,000 psi
43 minimum at 28 days.
44
45 2) Tensile Strength (ASTM D638): 5,300 psi minimum at 14
46 days. Elongation at Break - 2 to 5 percent.
MODIFICATIONS AND REPAIR TO CONCRETE
03740-5 03/22/2019
1
2 3) Flexural Strength (ASTM D790 - Modulus of Rupture):
3 12,000 psi minimum at 14 days (gravity); 4,600 psi
4 minimum at 14 days (injection)
5
6 4) Shear Strength (ASTM D732): 3,700 psi minimum at 14
7 days.
8
9 5) Water Absorption (ASTM D570 - 2 hour boil): 1.5 percent
10 maximum at 7 days.
11
12 6) Bond Strength (ASTM C882): 2,400 psi at 2 days dry;
13 2,000 psi at 14 days dry plus 12 days moist.
14
15 7) Effective Shrinkage (ASTM 883): Passes Test.
16
17 3. Approved manufacturers:
18
19 a. For standard applications: Sika Corporation, Lyndhurst,
20 NJ - Sikadur Hi -Mod; Master Builders Inc., Cleveland,
21 OH - Concressive 1380 or equal.
22
23 b. For very thin applications: Sika Corporation, Lyndhurst,
24 NJ - Sikadur Hi -Mod LV; Master Builders Inc., Cleveland,
25 OH - Concressive 1468 or equal.
26
27 PART 3 - EXECUTION
28
29 3.01 GENERAL
30
31 A. Cut, repair, reuse, demolish, excavate or otherwise modify parts of the existing
32 structures or appurtenances, as indicated on the Drawings, specified herein, or
33 necessary to permit completion of the Work. Finishes, joints, reinforcements,
34 sealants, etc., are specified in respective Sections. All work shall comply with
35 other requirements of this of Section and as shown on the Drawings.
36
37 B. All commercial products specified in this Section shall be stored, mixed and
38 applied in strict compliance with the manufacturer's recommendations.
39
40 C. In all cases where concrete is repaired in the vicinity of an expansion joint or
41 control joint the repairs shall be made to preserve the isolation between
42 components on either side of the joint.
43
44 D. When drilling holes for dowels/bolts at new or existing concrete, drilling shall
45 stop if rebar is encountered. As approved by the Engineer, the hole location
46 shall be relocated to avoid rebar. Rebar shall not be cut without prior approval
MODIFICATIONS AND REPAIR TO CONCRETE
03740-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 by the Engineer. Where possible, rebar locations shall be identified prior to
2 drilling using "rebar locators" so that drilled hole locations may be adjusted to
3 avoid rebar interference.
4
5 3.02 CONCRETE REMOVAL
6
7 A. Concrete designated to be removed to specific limits as shown on the Drawings
8 or directed by the Engineer, shall be done by line drilling at limits followed by
9 chipping or jack -hammering as appropriate in areas where concrete is to be
10 taken out. Remove concrete in such a manner that surrounding concrete or
11 existing reinforcing to be left in place and existing in place equipment is not
12 damaged. Sawcutting at limits of concrete to be removed shall only be done if
13 indicated on the Drawings, or after obtaining written approval from the Engineer.
14
15 B. Where existing reinforcing is exposed due to saw cutting/core drilling and no
16 new material is to be placed on the sawcut surface, a coating or surface
17 treatment of epoxy paste shall be applied to the entire cut surface to a thickness
18 of 1/4 -in.
19
20 C. In all cases where the joint between new concrete or grout and existing concrete
21 will be exposed in the finished work, except as otherwise shown or specified,
22 the edge of concrete removal shall be a 1 -in deep saw cut on each exposed
23 surface of the existing concrete.
24
25 D. Concrete specified to be left in place which is damaged shall be repaired by
26 approved means to the satisfaction of the Engineer.
27
28 E. The Engineer may from time to time direct the Contractor to make additional
29 repairs to existing concrete. These repairs shall be made as specified or by
30 such other methods as may be appropriate.
31
32 3.03 CONNECTION SURFACE PREPARATION
33
34 A. Connection surfaces shall be prepared as specified below for concrete areas
35 requiring patching, repairs or modifications as shown on the Drawings, specified
36 herein, or as directed by the Engineer.
37
38 B. Remove all deteriorated materials, dirt, oil, grease, and all other bond inhibiting
39 materials from the surface by dry mechanical means, i.e. - sandblasting,
40 grinding, etc, as approved by the Engineer. Be sure the areas are not less than
41 1/2 -in in depth. Irregular voids or surface stones need not be removed if they
42 are sound, free of Iaitance, and firmly embedded into parent concrete, subject
43 to the Engineer's final inspection.
44
45 C. If reinforcing steel is exposed, it must be mechanically cleaned to remove all
46 contaminants, rust, etc, as approved by the Engineer. If half of the diameter of
MODIFICATIONS AND REPAIR TO CONCRETE
03740-7 03/22/2019
1 the reinforcing steel is exposed, chip out behind the steel. The distance chipped
2 behind the steel shall be a minimum of 1/2 -in. Reinforcing to be saved shall not
3 be damaged during the demolition operation.
4
5 D. Reinforcing from existing demolished concrete which is shown to be
6 incorporated in new concrete shall be cleaned by mechanical means to remove
7 all loose material and products of corrosion before proceeding with the repair.
8 It shall be cut, bent or lapped to new reinforcing as shown on the Drawings and
9 provided with 1 -in minimum cover all around.
10
11 E. The following are specific concrete surface preparation "methods" to be used
12 where called for on the Drawings, specified herein or as directed by the
13 Engineer.
14
15 1. Method A: After the existing concrete surface at connection has been
16 roughened and cleaned, thoroughly moisten the existing surface with
17 water. Brush on a 1/16 -in layer of cement and water mixed to the
18 consistency of a heavy paste. Immediately after application of cement
19 paste, place new concrete or grout mixture as detailed on the Drawings.
20
21 2. Method B: After the existing concrete surface has been roughened and
22 cleaned, apply epoxy bonding agent at connection surface. The field
23 preparation and application of the epoxy bonding agent shall comply
24 strictly with the manufacturer's recommendations. Place new concrete
25 or grout mixture to limits shown on the Drawings within time constraints
26 recommended by the manufacturer to ensure bond.
27
28 3. Method C: Drill a hole 1/4 -in larger than the diameter of the dowel. The
29 hole shall be blown clear of loose particles and dust just prior to installing
30 epoxy. The drilled hole shall first be filled with epoxy paste, then
31 dowels/bolts shall be buttered with paste then inserted by tapping.
32 Unless otherwise shown on the Drawings, deformed bars shall be drilled
33 and set to a depth of ten bar diameters and smooth bars shall be drilled
34 and set to a depth of fifteen bar diameters. If not noted on the Drawings,
35 the Engineer will provide details regarding the size and spacing of
36 dowels.
37
38 4. Method D: Combination of Method B and C.
39
40 5. Method E: Capsule anchor system shall be set in existing concrete by
41 drilling holes to the required depth to develop the full tensile and shear
42 strengths of the anchor material being used. The anchor bolts system
43 shall be installed per the manufacturer's recommendation in holes sized
44 as required. The anchor stud bolt, rebar or other embedment item shall
45 be tipped with a double 45 degree chamfered point, securely fastened
46 into the chuck of all rotary percussion hammer drill and drilled into the
MODIFICATIONS AND REPAIR TO CONCRETE
03740-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 capsule filled hole. The anchor may be installed in horizontal, vertical
2 and overhead positions.
3
4 3.04 GROUTING
5
6 A. Grouting shall be as specified in Section 03600.
7
8 3.05 CRACK REPAIR
9
10 A. Cracks on horizontal surfaces shall be repaired by gravity feeding crack sealant
11 into cracks per manufacturer's recommendations. If cracks are less than 1/16 -in
12 in thickness they shall be pressure injected.
13
14 B. Cracks on vertical surfaces shall be repaired by pressure injecting crack sealant
15 through valves sealed to surface with crack repair epoxy adhesive per
16 manufacturer's recommendations.
17
18 C. Cracks shall be repaired according to the following generalized procedure:
19
20 1. Remove any efflorescence, dirt, oil, etc. off the surfaces in the vicinity of
21 the observed seepage. Where loose cementitious surfacer/slurry is
22 encountered it shall be removed to reveal the original concrete surface.
23 Removal shall be performed using mechanical methods chemical
24 solutions provided they are approved by other product manufactures
25 which are to be use (i.e. paint).
26
27 2. Apply adequate surface seal to crack to prevent leakage of epoxy.
28
29 3. Establish injection points at a distance along crack not less than
30 thickness of cracked member.
31
32 4. Crack injection sequence:
33
34 5. Ensure that tank is full of water.
35
36 6. Inject epoxy into crack from exterior at first port with sufficient pressure
37 to advance epoxy to adjacent port.
38
39 7. Seal original port and shift injection to port where epoxy appears.
40
41 8. Continue port -to -port injection until crack has been injected for its entire
42 length.
43
44 9. For small amounts of epoxy, or where excessive pressure developed by
45 injection pump might further damage structure, premixed epoxy and use
46 hand caulking gun to inject epoxy if acceptable to the Engineer.
MODIFICATIONS AND REPAIR TO CONCRETE
03740-9 03/22/2019
1
2
3 10. Seal ports, including adjacent locations where epoxy seepage occurs, as
4 necessary to prevent drips or run out.
5
6 11. The crack is considered to be sealed once no moisture is transferred
7 from the concrete to a dry hand for a minimum of 24 hours after
8 injections. Continue injection procedures if the crack does not meet this
9 condition.
10
11 12. After epoxy injection is complete, remove surface seal material and
12 refinish concrete in area where epoxy was injected to match existing
13 concrete including applying new surfacer patch material to match existing
14 in thickness, texture, etc. All materials used for patching or repairs shall
15 be coordinated with other products to be used such as paint to ensure
16 conformance and applicability.
17
18
19 END OF SECTION
20
MODIFICATIONS AND REPAIR TO CONCRETE
03740-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 03750
2
3 FLOW CHANNEL COATING SYSTEM
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Description:
10
11 This section covers all workmanship, materials safety and quality requirements
12 for concrete flow channel resurfacing and coating work. Provide and apply
13 repair materials as specified herein to the limits directed by the Engineer
14 and/or as indicated on drawings.
15
16 B. A general description of the work to be performed is listed below:
17
18 • Power wash the interior surface of the channels to remove grease and
19 contaminants.
20 • Sand blast the interior surface of the channels to obtain the correct surface
21 profile and surface mechanical grip properties.
22 • Power rinse the interior surface of the channels to remove sand blasting
23 debris, dust, and particles.
24 • Apply Xypex Megamix II with BIO SAN
25
26 C. Cracks and joints that require additional materials shall be injected with
27 hydrophilic polyurethane grout.
28
29 1.02 RELATED WORK:
30
31 Division 1 - General Requirements
32
33 1.03 REFERENCES:
34
35 A. This section contains references to the documents listed below. They are a
36 part of this section as specified and modified. In case of conflict between the
37 requirements of this section and those of the listed documents, the more
38 stringent of the requirements shall prevail.
39
40 B. Unless otherwise specified, references to documents shall mean the
41 documents in effect at the time of receipt of Bids.
42
43 C. Referenced publications found within this specification shall be the latest
44 revision unless otherwise specified; and applicable parts of the referenced
45 publications shall become a part of this specification as if fully included.
46
47
48
FLOW CHANNEL COATING SYSTEM
03750-1 02/25/2020
1 Reference Title
2
3 ASTM (American Society of Testing and Materials)
4 ASTM C 920 Specification for Elastomeric Joint Sealants
5 ASTM D 3960 Practice for Determining Volatile Organic Compound (VOC)
6 Content of Paints and Related Coatings
7 ASTM D 4259 Practice for Abrading Concrete
8 ASTM E 337 Standard Practice Test Method for Measuring Humidity with a
9 Psychrometer
10
11 Federal Standard Colors
12 F 595 B Federal Standard Colors
13 Guideline No. 03732 Selecting and Specifying Concrete Surface Preparation
14 for Sealers, Coatings, and Polymer Overlays
15
16 ICRI (International Concrete Restoration Institute)
17 Guideline No. 03732 Selecting and Specifying Concrete Surface Preparation
18 for Sealers, Coatings, and Polymer Overlays
19
20 NACE (National Association of Corrosion Engineers)
21 Publication 6D-173 "A Manual for Painter Safety"
22 Publication 6G-164 "Surface Preparation Abrasives for Industrial Maintenance
23 Painting"
24 Publication TPC2 Coatings and Linings for Immersion Service:
25 Chapter 1 Safety
26 Chapter 2 Surface Preparation
27 Chapter 3 Curing
28 Chapter 4 Inspection
29 Publication 6F-163 "Surface Preparation of Steel or Concrete Tank Interiors."
30 RP0892-92 Standard Recommended Practice, Lining over Concrete in
31 Immersion Service
32 RP0288-88 Standard Recommended Practice, Inspection of Linings on Steel
33 and Concrete
34
35 SSPC (Steel Structures Painting Council)
36 SSPC-SP 12 Surface Preparation and Cleaning of Steel and Other Hard
37 Materials by High and Ultrahigh Pressure Water Jetting Prior to
38 Recoating
39 SSPC-SP 13 Surface Preparation of Concrete
40 SSPC-PA-3 "A Guide to Safety in Paint Application"
41 SSPC-Guide 12 Guide for Illumination of Industrial Painting Project
42
43 OSHA (Occupational Safety and Health Administration)
44 1915.35 Standards – 29 CFR – Painting
45
46
47 ANSI (American National Standards Institute)
48 ANSI/ASC 29.4 Abrasive Blasting Operations — Ventilation and Safe Practice
FLOW CHANNEL COATING SYSTEM
03750-2
02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 1.04 QUALITY ASSURANCE
3
4 A. The manufacturer and/or applicator of the coating system shall be a company
5 that specializes in the design, manufacture or installation of corrosion
6 protection systems for wet wells. The applicator shall be completely trained in
7 leak repair, surface preparation and corrosion materials application in wet
8 wells.
9
10 B. The applicator shall be trained and certified by the manufacturer for the
11 handling, mixing, application and inspection of the liner system as described
12 herein.
13
14 C. To ensure total unit responsibility, all materials and installation thereof shall be
15 furnished and coordinated with/by one supplier/applicator.
16
17 D. Requirements:
18
19 1. Do not use or retain contaminated, outdated, or diluted materials for
20 resurfacing. Do not use materials from previously opened containers.
21 2. Use only products of the approved Manufacturer(s). Use products of
22 one manufacturer with compatible materials. Provide same material
23 product for touch-up as for original material.
24 3. If any requirements of this specification conflict with a referenced
25 standard, the more stringent requirement shall apply.
26 4. Make all locations and phases of the work available for access by the
27 Engineer. The Contractor shall provide ventilation and egress to safely
28 access the coating work areas for construction and inspection.
29 5. Conduct work so that the resurfacing system is installed as specified
30 herein. Inspect work continually to ensure that the resurfacing system
31 is installed as specified herein. The Contractor shall inspect the work to
32 determine conformance with the specifications and referenced
33 documents. The Contractor shall inform the Engineer of the progress
34 and the quality of the work through daily reports as specified below.
35 Any nonconforming coating system work shall be corrected as specified
36 herein or as recommended by the Manufacturer.
37 6. Summarize test data, work progress, areas covered, ambient
38 conditions, quality control inspection test findings, and other information
39 pertinent to the resurfacing system installation in daily reports to be
40 submitted to the Engineer.
41 7. The methods of construction shall be in accordance with all
42 requirements of this specification.
43 8. Employ only trades people who have at least five years of experience
44 performing resurfacing work of similar size and complexity as the work
45 specified in this Section. Submittals to verify these qualifications are to
46 be made within thirty (30) days of the Notice -to -Proceed and are
47 subject to approval by the Engineer.
48
FLOW CHANNEL COATING SYSTEM
03750-3 02/25/2020
1 1.05 SUBMITTALS
2
3 A. Submit the following prior to commencing with any phase of the work covered
4 by this Section:
5
6 1. Manufacturer's current printed recommendations and product data
7 sheets for all coating system products supplied under this section
8 including performance criteria, surface preparation and applications,
9 volatile organic compound (V.O.C.) data, and safety requirements.
10 2. Material Safety Data Sheets (MSDS) for any materials brought on-site
11 including all resurfacing system materials, solvents, and abrasive blast
12 media.
13 3. Storage requirements including temperature, humidity, and ventilation
14 for resurfacing system materials.
15 4. Manufacturer's requirements, including application procedures for
16 resurfacing materials shall be in writing and shall be followed in detail.
17 All safety precautions recommended by the Manufacturer shall be
18 strictly adhered to at all times when work is in progress.
19 5. Color samples for all surfaces to be resurfaced that have been field -
20 matched to existing colors.
21 6. Submit applicators' certification that resurfacing materials comply with
22 Federal, State, and Local regulations for VOC (Volatile Organic
23 Compounds).
24 7 Submit daily reports that contain the following information: Substrate
25 conditions, ambient conditions, application procedures, work completed
26 and location thereof. Mark-up drawings that show location of work.
27 8. Submit letter(s) with associated product data signed by Manufacturer
28 certifying that submitted products are suitable for application on the
29 surfaces to be resurfaced and for the service conditions.
30
31 1.06 WARRANTIES
32
33 A. All patch or filler concrete used below the lining coating shall be warranted for
34 the same length of times as the lining coating.
35
36 B. The Contractor shall warrant the lining coating for a period of 5 years. A
37 coating failure will have occurred if the lining fails to prevent damage or
38 corrosion to the structure, bubbles out from wall or metal, or fails to adhere to
39 concrete or metal. Failure does not include mechanical or chemical abuse. If
40 coatings are deemed to have failed, the Contractor shall at his expense
41 completely repair the damaged area including an expanded area of a
42 minimum of 6 -inches in any direction.
43
44 1.07 DELIVERIES AND STORAGE
45
46 A. Materials shall be stored in accordance with Manufacturer's recommendations
47 in enclosed structures and shall be protected from weather and adverse
48 temperature conditions. Flammable materials shall be stored in accordance
FLOW CHANNEL COATING SYSTEM
03750-4 02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 with state and local codes. Materials exceeding storage life recommended by
2 the manufacturer shall be removed from the site.
3
4 B. Store all materials only in area or areas designated by the Engineer solely for
5 this purpose. Confine mixing, thinning, clean-up and associated operations,
6 and storage of materials -related debris before authorized disposal, to these
7 areas. All materials are to be stored on pallets or similar storage/handling
8 skids off the ground in sheltered areas in which the temperature is maintained
9 between 70°F and 90°F.
10
11 C. Mix all resurfacing materials in a mixing area supplied by the Contractor. This
12 enclosed area must protect the mixing operation and materials from direct
13 sunlight, inclement weather, freezing, or other means of damage or
14 contamination. Protect all other concrete and metallic surfaces and finishes
15 from any spillage of material(s) within the mixing area.
16
17 D. Do not use floor drains, dikes or storm drains for disposal of resurfacing
18 systems materials.
19
20 E. The Contractor shall take all precautions and implement all measures
21 necessary to avert potential hazards associated with the resurfacing system
22 materials as described on the pertinent Material Safety Data Sheets or
23 container labels.
24
25 F Deliver all materials to the job site in their original, unopened containers. Each
26 container shall bear the Manufacturer's name and label.
27
28 1. Labels on all material containers must show the following information:
29
30 a. Name or title of product.
31 b. Federal Specification Number if applicable.
32 c. Manufacturer's batch number and date of manufacture.
33 d. Manufacturer s name.
34 e. Generic type of material.
35 f. Application and mixing instructions.
36 g. Hazardous material identification label.
37 h. Shelf life date.
38 i. Storage requirements.
39
40 G. All containers shall be clearly marked indicating any personnel safety hazards
41 associated with the use of or exposure to the materials.
42
43 H. All materials shall be handled and stored to prevent damage or loss of label.
44
45 I. The Contractor shall provide resurfacing material storage and mixing areas.
46
47 J. Do not use or retain contaminated, outdated, prematurely opened, diluted
48 materials, or materials which have exceeded their shelf life.
FLOW CHANNEL COATING SYSTEM
03750-5 02/25/2020
1
2 1.08 COORDINATION OF WORK
3
4 A. Work Areas:
5
6 The work areas on the job site will be limited to the flow channels as
7 designated by the Owner. The Contractor's personnel shall not be permitted
8 in any area other than those expressly designated by the Owner.
9
10 B. Coordination:
11
12 The Contractor shall coordinate with the Engineer and Owner regarding
13 availability of work areas, completion times, safety, access and other factors,
14 which can impact plant operations.
15
16 1.09 SAFETY
17
18 A. The work may be inside a confined space. The Contractor's work forces shall
19 comply with all applicable documentation and safety requirements related to
20 confined spaces and all safety requirements referenced in Section 1.03.
21
22 B. The Contractor shall provide personnel with all safety equipment necessary to
23 protect them during any phase of the work. This shall include, but not be
24 limited to safety glasses, goggles, earplugs, hard hats, steel toed work shoes,
25 appropriate personal protective clothing, gloves, and plant approved escape
26 respirators (where required).
27
28 C. Keep any flammable materials such as cleaning solvents, thinners, or
29 resurfacing materials away from open flames, sparks or temperatures higher
30 than 150°F. Drums containing flammable materials will be grounded. No
31 solvent in any quantity shall be allowed inside containment enclosures or
32 permitted confined spaces at any time during resurfacing work.
33
34 D. Power tools are to be in good working order to avoid open sparking. No spark
35 producing tools shall be utilized in restricted areas as indicated herein.
36
37 E. The Contractor shall fireproof all work areas by maintaining a clean work area
38 and having Underwriter's Laboratories approved fire extinguishers on -hand.
39 The Contractor shall furnish these fire extinguishers.
40
41 F Workers doing abrasive blasting operations shall wear a fresh air supplied
42 protective helmet and hood and personal protective clothing acceptable to
43 industry standards and all government regulations.
44
45 G. Dispose of rags used for wiping up resurfacing materials, solvents, and
46 thinners by drenching them with water and placing in a metal container with a
47 tight fitting metal cover. Complete this disposal process at the end of each
48 day. Final disposal of these materials is the Contractor's responsibility.
FLOW CHANNEL COATING SYSTEM
03750-6 02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 H. Matches, smoking, flames, or sparks resulting from any source including
3 welding, must be remote from the work area during coating work. Smoking is
4 permitted only in designated areas of the plant.
5
6 PART 2 — PRODUCTS
7
8 2.01 MANUFACTURERS
9
10 A. Materials specified are those that have been evaluated for the specific service.
11 Equivalent materials by other manufacturers may be submitted upon written
12 approval of the Engineer. As part of the proof of equality, the Contractor shall
13 submit certified test reports from a nationally known, reputable and
14 independent testing laboratory conducting comparative tests between the
15 product specified and the requested substitution.
16
17 B. Requests for substitution shall include manufacturer's literature for each
18 product giving name, product number, generic type, descriptive information,
19 solids by volume, recommended dry film thickness and certified lab test
20 reports showing results to equal the performance criteria of the products
21 specified herein. In addition, a list of five projects shall be submitted in which
22 each product has been used and rendered satisfactory service.
23
24 C. All requests for product substitution shall be made at least 10 days prior to the
25 bid opening date.
26
27 D. Any material savings shall be passed to the Owner in the form of a contract
28 dollar reduction.
29
30 E. Approved manufacturers for this project include products of Xypex Chemical
31 Corporation, the Sika Corporation, or equal.
32
33 2.02 MATERIALS
34
35 Specific Products are listed below to establish a quality benchmark.
36
37 A. Structural Repair Mortar (XYPEX Megamix 11 with BIO -SAN)
38
39 1. Structural repair mortar shall have low shrinkage, high strength, and
40 durability against corrosion.
41
42 2. Shall not contain volatile organic carbons (VOC).
43
44
45 3. Typical Properties (@ 28 days unless otherwise specified):
46
47 a. Compressive Strength: 7700 psi
48 b. Flexural Strength: 1190 psi
FLOW CHANNEL COATING SYSTEM
03750-7 02/25/2020
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45 PART 3 - EXECUTION
46
47 3.01 GENERAL
c.
d.
e.
f.
g.
h.
i.
J.
k.
Splitting Tensile Strength:
Direct Tensile Bond to Concrete:
Elastic Modulus:
Rapid Chloride Permeability:
Carbonation Depth @ 49 days:
Scaling Resistance @ 50 cycles:
Acid Resistance @ 84 days:
Initial Set:
Final Set
603 psi
330 psi
20.4 GPa
572 C
no measurable depth
no scaling
negligible mass loss
3:25 hrs:min
5:00 hrs:min
4. The structural repair mortar shall be placeable in 3/8" to 2" lifts.
5. The materials shall be resistant to corrosion.
B. Hydrophilic Polyurethane Grout (SikaFix HH Hydrophilic)
1. Nonflammable hydrophilic polyurethane resin.
2. Cures to from a flexible adhesive closed cell foam.
3. The material shall not contain volatile solvents.
4. Performance Criteria
a. Properties of the uncured resin grout.
• Shelf Life : 1 Year @ 73° F
• Solids (ASTM D 2369 B) 83%
• Viscosity (ASTM D 2196 A) 650-800 csp
• Density (ASTM D 3574-95) 8.7-9.2 lbs/gal
• Flashpoint F (ASTM D-92) 225
• Reaction Time 1:1 with Water 20 sec @ 68 F
b.
Properties of the cured resin grout.
• Tensile Strength (ASTM D 3575-95) 380 psi
• Bond Strength
• Elongation (ASTM D 3574-95)
• Shrinkage (ASTM D 1042)
2.03 ABRASIVE BLAST MEDIA
250-300 psi
400%
less than 10%
A. Provide the material, size, gradation, and quality necessary to produce the
degree of cleanliness and surface profile required herein.
FLOW CHANNEL COATING SYSTEM
03750-8 02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 A. Hoisting, Scaffolding, Staging, and Planking:
3
4 Provide, set-up, and maintain all required hoists, scaffolds, and staging and
5 planking, and perform all access related hoisting work required to complete
6 the work of this section as indicated and specified. Scaffolds shall have solid
7 backs and floors to prevent dropping materials from there to the floors or
8 ground below.
9
10 B. Environmental Requirements:
11
12 Comply with the Manufacturer's recommendations as to environmental
13 conditions under which resurfacing system materials can be applied. Do not
14 apply resurfacing system materials when dust is in work site. The Contractor
15 shall provide all temporary lighting during the work.
16
17 C. Protection:
18
19 Cover or otherwise protect finish work or other surfaces not being resurfaced.
20 Erect and maintain protective tarps, enclosures and/or maskings to contain
21 debris (such as dust or airborne particles resulting from surface preparation)
22 generated during any and all work activities. This includes but is not limited to
23 the use of dust/debris collection apparatus as required.
24
25 D. Initial Inspection Of Surfaces To Be Coated:
26
27 It is the responsibility of the Contractor to inspect and report unacceptable
28 concrete substrate surface conditions to the Engineer prior to the
29 commencement of surface preparation activities. Unacceptable surface
30 conditions are defined as the presence of cracked surfaces or concrete
31 deteriorated to a depth of greater than 1 -inch or otherwise unable to withstand
32 surface preparation as specified herein.
33
34 E. Thinners and Solvents:
35
36 The Contractor shall use only solvents and thinners as recommended by the
37 Manufacturer.
38
39 3.02 PREPARATION OF EXISTING SURFACES
40
41 A. Surface preparation shall produce a cleaned, abraded and sound surface with
42 no evidence of laitance, loose dust, dirt, concrete, brick or mortar,
43 contaminants or debris, and shall display a surface profile suitable for
44 application of liner system
45
46 B. Prior to abrasive media blasting, loose materials, acid constituents, grease, oil,
47 and other contaminants shall be removed with a 2500-5000 psi power wash
48 using potable water and an alkaline -based emulsifying detergent as
FLOW CHANNEL COATING SYSTEM
03750-9
02/25/2020
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
recommended by the resurfacing material manufacture.
C. Prepare the surface to be coated per the coating manufacturers'
recommendations.
D. Where reinforcing steel with active corrosion is encountered, sandblast the
steel to a white metal finish to remove all contaminants and rust. Where
corrosion has occurred due to the presence of chlorides, the steel shall be
high pressure washed after mechanical cleaning. Prime steel with 2 coats of
Sika Armatec 110 EpoCem as per the technical data sheet. (See Spec
Component SC -201-0699)
E. Abrasive Blast Cleaning
1. Sand blasting media shall be washed, graded and free of contaminants
that might interfere with the adhesion of the resurfacing materials.
Used or spent blast abrasive shall not be reused on work covered by
this section.
2. The compressed air used for blast cleaning will be filtered free of
condensed water or oil. Moisture traps will be cleaned at least once
every four hours or more frequently as is appropriate.
3. Oil separators shall be installed just downstream of compressor
discharge valves and at the discharge of the blast pot discharges. Oil
separators shall be cleaned at least once every four hours or more
frequently as is appropriate.
4. A paper blotter test shall be performed by the Contractor when
requested by the Engineer or the Engineer's representative to
determine if the air is sufficiently free of oil and moisture.
5. Regulators, gauges, filters, and separators will be in good working order
for all of the compressor air lines to blasting nozzles at all times during
this work.
6. An air dryer or drying unit shall be installed which dries the compressed
air prior to blast connections. This dryer shall be used and maintained
for the duration of surface preparation work.
7. The quality, volume, and velocity of life support and ventilation air used
during surface preparation shall be in accordance with applicable safety
standards and as required to ensure adequate visibility and proper
dissipation of volatiles without impacting the prepared surface or the
health of the public or personnel working for the Contractor,
Subcontractors, Engineer, Engineer's Representatives, or anyone who
may be affected by on-site maintenance coating work activities.
8. The abrasive blast nozzles used shall be the venturi or other high
velocity type supplied with a minimum of 100-psig air pressure and the
necessary volume to obtain the required blast cleaning production rates
and specified degree of cleanliness.
9. The Contractor must provide adequate ventilation for airborne
particulate evacuation and lighting (meeting all pertinent safety
standards) to optimize visibility for both blast cleaning and observation
FLOW CHANNEL COATING SYSTEM
03750-10 02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 of the substrate during surface preparation work.
2
3 F After abrasive blasting, the interior surface shall be power rinsed with potable
4 water to remove all loose materials and other contaminants.
5
6 3.03 APPLICATION REQUIREMENTS RESURFACING MORTAR
7
8 A. Application of the resurfacing material shall be in accordance with the
9 manufacturers' recommendations.
10
11 3.04 APPLICATION REQUIREMENTS HYDROPHILIC POLYURETHANE GROUT
12
13 A. Prepare materials per Manufacturer's recommendations.
14
15 B. Drill injection ports at a 45° degree angle to intersect the crack at
16 approximately 1/2 the depth of the structure. Spacing of the injection ports
17 depends on crack width, but normal spacing varies from 6" to 24". It is
18 necessary to flush the drilled holes with water to remove drill dust from the
19 holes and cracks, and insure that the crack is wet enough to react with the
20 grout when introduced to the crack. On structures open on both sides, provide
21 ports on opposite sides at staggered elevations. Install the injection ports in
22 the holes.
23
24 C. Inject first port with clean water at 250 -psi minimum until air and water begin to
25 flow out of the crack and the other ports. Complete this step for every port.
26
27 D. Limitation times and related temperature range restrictions between
28 successive lifts for all products specified herein per Manufacturer's stated
29 requirements.
30
31 E. Inject the prepared cracks with a minimum of 250 psi in order to achieve
32 maximum filling and penetration without the inclusion of air pockets or voids in
33 the polyurethane chemical grout. Begin the pressure injection at the lowest
34 packer and continue until there is the appearance of the polyurethane
35 chemical grout at an adjacent packer, thus indicating travel. When travel is
36 indicated, a decision to discontinue or continue the pressure injection from that
37 packer should be made by the contractor, based on his experience, with the
38 approval of the engineer. Continue the procedure until all applicable cracks
39 have been filled.
40
41 F Pump polyurethane chemical grout for 45 seconds and then pause to allow the
42 material to flow into all of the cracks and crevices. Watch for material flow and
43 water movement to appear on the surface. When movement stops, begin
44 injection into the next packer. When sealing vertical cracks, begin injecting at
45 the bottom of the crack and work vertically. If site temperature are extremely
46 low, heat bands or heated water baths may be used on the pails, before and
47 during use to maintain the products temperature. Re-inject to assure that all
48 voids are properly sealed off.
FLOW CHANNEL COATING SYSTEM
03750-11 02/25/2020
1
1 1
2 G. If penetration of any cracks is impossible, consult the engineer before
3 discontinuing the injection procedure. If modification of the proposed I 4 procedure is required to fill the cracks, submit said modification in writing to
5 the engineer for acceptance prior to proceeding.
6
I
7 H. Adhere to all limitations and cautions for the polyurethane chemical grout as
8 stated in the manufacturer's current printed literature.
9
10 I Caution: Expanding chemical grout is exerting outward high pressures and
11 review of drawings of the area to be repaired is recommended.
12
I
13 J. All equipment and procedures used for polyurethane resin injection system
14 application shall be as recommended by the Manufacturer. Unless specified
15 elsewhere herein, the Contractor shall comply with the Manufacturer's most
I
16 recent written instructions.
17
18
I
19 3.06 FIELD QUALITY CONTROL INSPECTION AND TESTING
20
21 A. Inspection by the Engineer or others does not limit the Contractor's
1
22 responsibilities for quality control inspection and testing as specified herein or
23 as required by the Manufacturer's instructions.
24
1
25 B. Perform the quality control procedures listed below in conjunction with the
26 requirements of this Section.
27
1
28 1. Inspect all materials upon receipt to ensure that all are supplied by the
29 Manufacturer.
30 1
31 2. Provide specified storage conditions for the resurfacing system
32 materials, solvents, and abrasives.
33
1
34 3. The pH of the concrete substrate will be measured using pH -indicating
35 papers. pH testing is to be performed once every 50 sq. ft. Acceptable
36 pH values shall be between 9.0 and 11.0 as measured by a full range 1
37 (1-12) color indicating pH paper with readable color calibrations and a
38 scale at whole numbers (minimum). Use Hydrion Insta-Check Jumbo I 39 0-13 or 1-12 or equal. The paper shall be touched to the surface once
40 using moderate gloved finger pressure. The surface shall not be wiped
41 or moved laterally to disturb the surface during pH testing. Following I 42 the one touch, lift the paper vertically to not "wipe" the surface.
43 Compare the color indicated with the scale provided and record the pH.
44
45 4. Inspect and record substrate profile (anchor pattern). Surfaces shall be 1
46 abraded, as a minimum, equal to the roughness of 40 grit sand paper.
47
48 5. Measure and record ambient air temperature once every two hours of
FLOW CHANNEL COATING SYSTEM
03750-12 02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 each shift using a thermometer and measure and record substrate
2 temperature once every two hours using a surface thermometer.
3
4 6. Measure and record relative humidity every two hours of each shift
5 using a sling psychrometer in accordance with ASTM E337.
6
7 C. Provide correct mixing of resurfacing materials in accordance with the
8 Manufacturer's instructions.
9
10 D. Inspect and record that the "pot life" of resurfacing materials are not exceeded
11 during installation.
12
13 E. Verify curing of the resurfacing materials in accordance with the
14 Manufacturer's instructions.
15
16 F
17
18 G. Upon completion of the lining system installation, the lined area shall be
19 cleaned and prepared to permit close visual inspection by the Engineer or the
20 Engineer's Representative. Any and all deficiencies or defective work (not in
21 compliance with this section or related sections) will be marked for repair or
22 removal/replacement by the Contractor at no additional cost to the Owner.
23
24 3.07 ACCEPTANCE CRITERIA
25
26 A. Acceptance Criteria for Surface Preparation Work: All surfaces shall be
27 prepared in accordance with the specification and referenced standards
28 herein.
29
30 B. Acceptance Criteria for Coating System Application Work: Acceptable coating
31 work will be based upon the following:
32 1. No pockmarks, trowel marks, depressions, unconsolidated areas,
33 waviness or ridges, pinholes or holidays in either size or frequency.
34 2. No inter -coat bond failures between lifts.
35 3. Proper curing of coatings.
36
37 C. Resurfaced areas shall pitch to drains. There shall be no areas that puddle
38 when flood tested.
39
40 D. The Engineer or Engineer's Representative shall, at their discretion, inspect
41 the following:
42
43 1. Profile and degree of cleanliness of substrate.
44 2. Thickness of materials/coverage rate confirmation.
45 3. Ambient temperature and humidity requirements, and substrate
46 temperature.
47 4. Curing and recoat times.
48 5. Proper curing of the resurfacing materials.
FLOW CHANNEL COATING SYSTEM
03750-13 02/25/2020
1
2 E. Rework required on any holidays or any other inadequacies found by the
3 Engineer or the Engineer's representative in the quality of the coating work
4 should be marked. Such areas shall be recleaned and reworked by the
5 Contractor according to these specifications and the manufacturer's
6 recommendations at no additional cost to the Owner.
7
8 F The Contractor is responsible for keeping the Engineer informed of all
9 progress so that inspection for quality can be achieved.
10
11 G. The Contractor is ultimately responsible for the quality performance of the
12 applied materials and workmanship. Inspections by the Engineer or the
13 Engineer's Representative do not limit this responsibility.
14
15 3.08 FINAL INSPECTION
16
17 A. Perform a final inspection to determine whether the resurfacing system work
18 meets the requirements of the specifications. The Engineer and the
19 Engineer's Representative will conduct final inspection with the Contractor.
20
21
22 END OF SECTION
23
FLOW CHANNEL COATING SYSTEM
03750-14 02/25/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 03800
2
3 LEAKAGE TESTING OF WATER RETAINING STRUCTURES
4
5
6 PART 1 - GENERAL
7
8 1.01 SCOPE OF WORK
9
10 A. Water tightness testing of reinforced concrete water retaining structures.
11
12 1.02 REFERENCE STANDARDS
13
14 A. American Concrete Institute (ACI)
15
16 1. ACI 350.1-01 — Tightness Testing of Environmental Engineering
17 Concrete Structures.
18
19 PART 2 - PRODUCTS
20
21 2.01 GENERAL
22
23 A. Provide potable or reclaimed water, piping, and equipment required to test
24 concrete structures for leakage.
25
26 PART 3 - EXECUTION
27
28 3.01 GENERAL
29
30 A. Hydrostatically test reinforced concrete structures that will contain water in
31 accordance with the requirements specified below, and assure structures are
32 free of detectable leaks.
33
34 B. Do not start leak testing or cleaning of surfaces until concrete is cured and
35 joint sealants have set and cured a minimum of 14 days.
36
37 C. Conduct testing before backfill is placed against walls and prior to installing
38 interior lining systems, if applicable.
39
40 D. Prior to testing, clean exposed surfaces by thorough hosing, and remove
41 surface laitance and loose matter from walls and slabs. Remove wash water
42 and debris by means other than washing through plant piping.
43
44 3.02 TEST PROCEDURE
LEAKAGE TESTING OF WATER RETAINING STRUCTURES
03800-1 03/22/2019
1
2 A. Fill structure to be tested to the normal operating liquid level. Filling rate shall
3 not exceed 4 feet of water per hour, and shall be at continuous uniform rate
4 with continuous monitoring.
5
6 B. The exterior surface of the tank shall be monitored for flowing Teaks. Repair
7 any flowing leaks that occur before continuing filling.
8
9 C. The water shall be kept at the test level for at least three days prior to the
10 actual test.
11
12 D. Measure the vertical distance to the water surface from a fixed point on the
13 tank above the water surface. Record measurements at 24-hour intervals.
14
15 E. A drop of the water surface exceeding 1/20 of 1% of the normal volume of
16 contained liquid is considered a failing leakage test.
17
18 F. The structure also fails the leakage test if flowing or seeping water is
19 observed, or if moisture can be transferred to a dry hand from the exterior
20 surface.
21
22 G. Independently measure change in water volume due to evaporation and
23 precipitation using a 24 inch deep white, watertight container not less than 10
24 square feet of surface area. Position the container to experience
25 environmental conditions similar to the structure being tested. The volume
26 change of the structure shall be corrected based on the water volume change
27 in the sample container.
28
29 H. Failing tanks that exhibit no visible signs of leaking or seepage may be
30 permitted to be immediately retested.
31
32 I. Failing tanks shall be drained, repaired, and retested until the tank has met the
33 test requirements.
34
35 3.03 REPAIR METHODS
36
37 A. Methods for repairing concrete are described in section 03740.
38
39
40 END OF SECTION
41
LEAKAGE TESTING OF WATER RETAINING STRUCTURES
03800-2 03/22/2019
1
1 1 SECTION 05500
2
I 3
4 MISCELLANEOUS METAL
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and install
10 miscellaneous metals as shown on the Drawings and as specified herein. The
11 miscellaneous metal items include but are not limited to the following:
I12
13 1. All metal frames, ladders, stair rails, floor opening frames including
14 gratings and supports.
I15
16 2. Prefabricated access hatches and frames.
17
I
18 3. Anchors and anchor bolts except those specified to be furnished with all
19 equipment.
20
I
21
22 4. Railings, posts and supports both interior and exterior.
23 5. Cast iron frames, covers, grates, drain leaders and drains.
1 24
25 6. Stair nosings, steel plates, overhead steel door frames, angle frames,
26 plates and channels.
I27
28 7. Guardrails and bollards.
' 29
30 1.02 COORDINATION
31
• 32 A. The work in this section shall be completely coordinated with the work of other
I 33 Sections. Verify at the site both the dimensions and work of other trades
34 adjoining items of work in this Section before fabrication and installation of items
I
35 herein specified.
36
37 B. Furnish to the pertinent trades all items included under this Section that are to
1 38 be built into the work of all other Sections.
39
40 1.03 SHOP DRAWINGS AND SAMPLES
I41
42 A. Detail Drawings, as provided for in the General Conditions, showing sizes of
43 members, method of assembly, anchorage, and connection to other members
I44 shall be submitted to the Engineer for approval before fabrication.
45
46 B. For each fabricated item include drawings, elevations, and details. Show the
47 following:
1
MISCELLANEOUS METAL
05500-1 12/17/20
1
2 1 Details of Sections
3
4 2. Jointing and Connections
5
6 3. Indicate welded connections using standard AWS symbols; indicate net
7 weld length.
8
9 4. Reinforcing
10
11 5. Fasteners and Anchors
12
13 6. Accessories
14
15 7. Location of each finish
16
17 C. Manufacturer's specifications, details and installation instructions. Submit for:
18
19 1. All manufactured products used in fabrications.
20
21 D. Samples shall be submitted at the request of the Engineer for concurrent review
22 with shop drawings.
23
24 1.04 JOB CONDITIONS
25
26 A. Field measurements shall be taken at the site to verify or supplement indicated
27 dimensions and to insure proper fitting of all items.
28
29 B. Where fabricated items or their anchors are to be embedded into concrete and
30 masonry work, deliver such items to those performing the installation, together
31 with all coordination Drawings and installation instructions required. Provide
32 temporary bracing or anchors in formwork where required for installation in new
33 concrete or other adjacent work.
34
35 1.05 REFERENCE SPECIFICATIONS
36
37 A. Design, manufacturing and assembly of elements of the materials herein
38 specified shall be in accordance with the standards of the below listed
39 organizations, except as otherwise shown or specified. Where reference is
40 made to a standard of one of these or other organizations the version of the
41 standard in effect at the time of bid opening shall apply.
42
43 1. Welded and Seamless Steel Pipe ASTM A53
44 2. Gray Iron Castings ASTM A48 (Class 30)
45 3. Galvanizing, general ASTM A123
46 4. Galvanizing, hardware ASTM A153
47 5. Galvanizing, assemblies ASTM A386
MISCELLANEOUS METAL
05500-2 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 6. Stainless Steel Bolts, Fasteners - AISI, Type 316
2 7. Stainless Steel Plate and Sheet Wire - AISI, Type 316
3 8. Welding Rods for Steel -- AWS Spec. for Arc Welding
4 9. ANSI/AWS D1.1-88 -- Structural Welding Code -- Steel
5 10. ANSI/AWS D1.3-81 -- Structural Welding Code -- Sheet Steel
6 11. ASTM A 36/A 36M -88d -- Standard Specification for Structural Steel
7 12. ASTM A 307-88a -- Standard Specification for Carbon Steel Bolts and
8 Studs, 60,000 PSI Tensile Strength
9 13. ASTM A 501-88 -- Standard Specification for Hot -Formed Welded and
10 Seamless Carbon Steel Structural Tubing
11 14. ASTM A 563-88a -- Standard Specification for Carbon and Alloy Steel
12 Nuts
13 15. ASTM B 221-85a -- Standard Specification for Aluminum and Alumi-num-
14 Alloy Extruded Bars, Rods, Wire, Shapes and Tubes
15 16. FS FF -S -92B -- Screw, Machine: Slotted, Cross -Recessed or Hexagon
16 Head
17 17. FS FF -W -84A -- Washers, Lock (Spring)
18 18. FS FF -W -92B -- Washer, Flat (Plain)
19 19. SSPC-PA 1 -- Shop, Field, and Maintenance Painting; Steel Structures
20 Painting Council
21 20. SSPC-Paint 12 -- Cold -Applied Asphalt Mastic (Extra Thick Film); Steel
22 Structures Painting Council
23 21. SSPC-Paint 13 -- Red or Brown One -Coat Shop Paint; Steel Structures
24 Painting Council
25 22. SSPC-SP 1 -- Solvent Cleaning; Steel Structures Painting Council
26 23. SSPC-SP 3 -- Power Tool Cleaning; Steel Structures Painting Council
27 24. SSPC-SP 5 -- White Metal Blast Cleaning; Steel Structures Painting
28 Council
29 25. SSPC-SP 6 -- Commercial Blast Cleaning; Steel Structures Painting
30 Council
31 26. SSPC-SP 8 -- Pickling; Steel Structures Painting Council
32 27. SSPC-SP 10 -- Near -White Blast Cleaning; Steel Structures Painting
33 Council
34 28. 2010 Florida Building Code (FBC)
35
36 PART 2 - PRODUCTS
37
38 2.01 MATERIALS
39
40 A. Unless otherwise noted, materials for miscellaneous metals shall conform to the
41 following standards:
42
43 1. Structural Steel
44 a. W Shapes: ASTM A992, Gr.50
45 b. M Shapes: ASTM A36
46 c. S, C and MC Shapes: ASTM A36
47 d. L Shapes: ASTM A36
MISCELLANEOUS METAL
05500-3 12/17/20
1 e. Plates, rods and Bars: ASTM A36
2
3 2. HSS Rectangular Shapes: ASTM A500, Grade B, 42 ksi
4
5 3. HSS Round Shapes ASTM A500, Grade B, 35 ksi
6
7 4. Welded and Seamless Steel Pipe ASTM A501 or ASTM A53, Type E
8 or S, Grade B Schedule 40. Use
9 standard malleable iron fittings,
10 galvanized for exterior work
11
12 5. Steel Sheets ASTM A366
13
14 6. Gray Iron Castings ASTM A48, Class 35
15
16 7. Ductile Iron Castings ASTM A536, Grade 65-45-12
17
18 8. Aluminum Extruded Pipe ASTM B429, Alloy 6063 T6
19
20 9. Aluminum Extruded Shapes ASTM B221, AIIoy 6061 T6
21
22 10. Aluminum Sheet and Plate ASTM B209, AIIoy 6061 T6
23
24 11. Stainless Steel Plates, Sheets, and Structural Shapes
25
26 a. Exterior, Submerged or Industrial Use ASTM A240, Type 316 (Type
27 316L for welded)
28
29 b. Interior and Architectural Use ASTM A240, Type 304
30
31 12. Stainless Steel Bolts, Nuts, and Washers ASTM A276, Type 316
32
33 13. Carbon Steel Bolts and Studs ASTM A307, Grade A or ASTM
34 F1154, Gr.36 (galvanized unless
35 noted otherwise)
36
37 14. High Strength Steel Bolts, Nuts and washers ASTM A325 (mechanically
38 galvanized per ASTM B695, Class
39 50, where noted)
40
41 a. Elevated Temperature Exposure Type I
42
43 b. General Application Type I or Type II
44
45 15. Galvanizing ASTM A123, Zn w/0.5 percent
46 minimum Ni
47
MISCELLANEOUS METAL
05500-4 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 16. Galvanizing, hardware ASTM A153, Zn w/0.5 percent
2 minimum Ni
3
4 2.02 ANCHORS, BOLTS, AND FASTENING DEVICES
5
6 A. Furnish anchors, bolts, fasteners, etc., as necessary for installation of the work
7 of this section or as specified for securing the work of other sections.
8
9 B. Type 316 stainless steel, wedge type anchors shall be used where they will be
10 submerged or exposed to the weather, when used with aluminum shapes or
11 where stainless steel wedge type anchors are required. When the length or
12 embedment of the bolt is not noted on the Drawings, provide length sufficient to
13 place the wedge and expansion sleeve portion of the bolt at least 1 -in behind
14 the concrete reinforcing steel. Expansion anchors shall be Hilti, Kwik -bolt III;
15 ITW Ramset; Redhead trubolt, or equal.
16
17 C. Unless otherwise noted, adhesive anchors shall be a two -component chemical
18 resin anchoring system. Capsules shall be self-contained, exactly premeasured
19 amounts of polyester or vinyl ester resin, aggregate and hardener. Stud
20 assemblies shall consist of a stainless steel type 316 all -thread anchor rod with
21 nut and washer. Provide manufacturer's recommended installation tools for
22 installing anchor components. Install anchors in full compliance with the
23 manufacturer's recommendations. Adhesive anchor system shall be Hilti, HIT -
24 RE 500 -SD; Simpson Strong Tie, SET -XP Epoxy -Tie or Acrylic Tie; or approved
25 equal.
26
27 D. Machine bolts and nuts shall conform to Federal Specification FF -B -575C. Bolts
28 and nuts shall be hexagon type. Bolts, nuts, screws, washers and related
29 appurtenances shall be Type 316 stainless steel.
30
31 2.03 ALUMINUM ITEMS
32
33 A. Aluminum gratings shall be of serrated I -Bar Aluminum Alloy 6063-T6, and shall
34 be Thompson Fabricating Company, Aluminum I -Bar Grating; or equal. Bearing
35 bars shall be 1-1/2 inch minimum. Grating shall be of sufficient strength to carry
36 a uniformly distributed live load of not less than 200 pounds per square foot with
37 maximum deflection of 1/4" of the span length. Provide bearing angles,
38 anchors, and bolts constructed of aluminum or stainless steel and as detailed.
39 Grating shall be removable type with standard removable fasteners. Aluminum
40 surfaces in contact with concrete surfaces shall be protected with a special
41 protective lacquer or bituminous coating or other approved coating in order to
42 keep stains to a minimum. Top surface of all bars shall be flush; ends of gratings
43 shall be provided with binding strips of same depth and thickness as the main
44 bars welded thereto. All openings 2 inches and greater in diameter shall be
45 banded with a bar of the same depth and thickness as the main bearing bars of
46 the grating, or furnished with continuous cross bridges. Each cut bar shall be
47 welded to the band if banding is utilized. The ends of all grating sections shall
MISCELLANEOUS METAL
05500-5 12/17/20
1 be likewise banded. Clamps and bolts used for attaching grating to supporting
2 members shall be stainless steel. All grating shall be clamped unless noted
3 otherwise. Clamps shall be as recommended by the manufacturer.
4
5 B. Metal frames and supports for grating or hatches/access covers shall be of the
6 same material as the grating or hatches/access covers unless otherwise shown
7 on the Drawings. Where aluminum supports are used, they shall be fabricated
8 from aluminum alloy 6061-T6.
9
10 C. Stair treads shall be as specified above for grating and shall have abrasive
11 nonslip nosing.
12
13 D. Aluminum nosing at concrete stairs shall be an extrusion of 4 -inch minimum
14 width with abrasive filled and shall be Wooster Products, Inc., Alumogrit Treads,
15 Type 116; equal by Barry Pattern and Foundry Co.; Andco; or equal. Embedded
16 anchors shall be furnished with a minimum of three anchors per tread.
17
18 E. Aluminum ladders shall be fabricated to the dimensions and details and installed
19 as shown on the Construction Drawings.
20
21 F Aluminum Handrails, Mechanically Fastened Type:
22
23 1. All aluminum mechanically fastened type pipe handrails and guardrails
24 shall be clear anodized aluminum finish and installed as specified herein
25 and indicated on the Construction Drawings. Handrails shall be made of
26 nominal 1-1/2 inches inside diameter pipe (schedule 40 for rails,
27 schedule 80 for posts) fabricated of seamless 6105-T5 or 6061-T6 alloy,
28 ASTM B-429 or ASTM B-221. The supplier of the handrail system shall
29 supply all necessary fittings, rackets, transition, corner and connector
30 pieces, toe boards, protective gaskets, etc., for a complete job at the
31 locations indicated on the Construction Drawings. All mounting hardware
32 including bolts, studs, nuts, etc., shall be stainless steel Type 316. Bends
33 shall be smooth and accurate to the details shown. The handrail systems
34 shall comply with all OSHA codes and the Florida Building Code. Railing
35 systems incorporating pop -rivets or glued fittings shall no be allowed.
36
37 2. Handrail and components shall be as manufactured by Thompson
38 Fabricating Company, Birmingham, Alabama, or approved equal.
39
40 3. Handrails and stair rails shall be designed to withstand a 200 Ib
41 concentrated load applied in any direction at any point on the top rail.
42 Handrails and stair rails shall also be designed to withstand a load of 50
43 Ib/ft. applied horizontally to the top rail. The 200 Ib load will not be applied
44 simultaneously with the 50 lb/ft. load. In addition, the handrails shall be
45 designed to withstand a load of 100 Ib/ft. applied vertically downward to
46 the top rail and simultaneously with the 50 Ib/ft. horizontal load. The 100
47 Ib/ft. vertical load does not apply to stair rails.
MISCELLANEOUS METAL
05500-6 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 4. Spacing of posts where posts are required shall be as noted on shop
3 drawings, but in all cases shall be uniform and shall not exceed the
4 requirements of OSHA and the Florida Building Code. Shorter spacing
5 may be used where required to maintain the maximum spacing. The
6 fabricator of the aluminum handrail and guardrail system shall be
7 responsible for the design and preparation of shop drawings and design
8 calculations (signed and sealed by Registered Engineer) to meet OSHA
9 requirements and the Florida Building Code.
10
11 5. All railings shall be erected in line and plumb. Field splicing and
12 expansion compensation shall be accomplished using internal splice
13 sleeves. Make provisions for removable railing sections, as detailed and
14 where shown on the Construction Drawings.
15
16 6. Where handrail or guardrail posts are set in concrete, as per the
17 manufacturer's requirements, the posts shall be set into aluminum
18 sleeves cast in the concrete and firmly cemented with 1651 epoxy resin
19 by E -Bond Epoxies, Oakland Park, Florida, or Moulded Reinforced
20 Plastics, Inc., Fort Lauderdale, Florida or equal. Collars shall be placed
21 on the posts and fastened in place, as shown and as detailed on
22 approved shop drawings.
23
24 7. Where handrail is supported from structural members, it shall be done by
25 the use of approved sockets, flanges, brackets, or other approved
26 means, which will provide neat and substantial support for the pipe
27 railing.
28
29 8. All railing shall be properly protected by paper, plastic or by an approved
30 coating or by both against scratching, splashes or mortar, paint, or other
31 defacements during transportation and erection and until adjacent work
32 by other trades has been completed.
33
34 G. Toe Boards:
35
36 1. Contractor shall furnish and install aluminum toe boards conforming to
37 latest OSHA requirements on all railings and other locations where
38 indicated on the Drawings.
39
40 2. Toe boards shall consist of an extruded 6063-T6 aluminum shape bolted
41 by means of a pipe clamp to the railing posts without requiring any drilling
42 or welding of the toeboard to the railing posts as manufactured by
43 Thompson Fabricating Company, or approved equal. Toe boards shall
44 have pitched top and tear drop bottom to prevent accumulation of dirt, or
45 other material.
46
MISCELLANEOUS METAL
05500-7 12/17/20
1 3. Toe boards shall be aluminum alloy 6063-T6. All fastening hardware
2 shall be Type 316 stainless steel.
3
4 H. Kick plates, if required, shall be fabricated and installed as shown on the
5 Construction Drawings.
6
7 1 Prefabricated checkerplate aluminum floor hatches/access covers shall be as
8 noted on the drawings and shall be Type "S -S" as manufactured by Halliday
9 Products or type "APD" as manufactured by USF Fabrication or equal, sized as
10 shown. The access covers shall have integrally mounted hinged safety gratings
11 for fall protection. Hatches with either dimension over 3 feet -6 inches shall be
12 double leaf type. Hatches and gratings shall be designed for a live load of 300
13 pounds per square foot. The access frames and covers shall have a 1/4" (7mm)
14 thick one-piece, mill finish, extruded aluminum frame, incorporating a
15 continuous concrete anchor, of otherwise suitable for mounting as shown on the
16 drawings. A bituminous coating shall be applied to the frame exterior where it
17 will come in contact with concrete. Door panel shall be 1/4" (7mm) aluminum
18 diamond plate, reinforced to withstand a live load of 300 lbs. psf (1464 kg. psm).
19 Uniform live load shall sustain a maximum allowable deflection of 1/150 of the
20 span. Doors shall open to 90 degrees and automatically lock with a T-316
21 stainless steel hold open arm with aluminum release handle. For ease of
22 operation, the hold open arm shall incorporate an enclosed stainless steel
23 compression spring assist. Doors shall close flush with the frame and rest on a
24 built-in neoprene cushion/gasket. Hinges and all fastening hardware shall be
25 T-316 stainless steel. Unit shall lock with a T-316 stainless steel slam lock with
26 removable key and have a non -corrosive handle. Unit shall carry a lifetime
27 guarantee against defects in material and/or workmanship.
28
29 The protective grating panel shall be 1 inch (25 kg.) aluminum "I" bar grating
30 with Safety Orange powder -coated finish. Grating shall be hinged with tamper
31 proof stainless steel bolts, and shall be supplied with a positive latch to maintain
32 unit in an upright position. Grating shall have a 6 -in. (152mm) viewing area on
33 each lateral unhinged side for visual observation and limited maintenance.
34 Grating support ledges on 300 lbs. psf (1464 kg. per sq. meter) loaded access
35 covers shall incorporate nut rail with a minimum of four (4) stainless steel spring
36 nuts. A padlock hasp for owner -supplied padlock shall be provided.
37
38 J. Ship ladders shall be of all aluminum construction as detailed. Treads shall
39 have abrasive nosing as manufactured by Thompson Fabricating Company,
40 Birmingham, Alabama.
41
42 K. Checkplate aluminum cover plates shall be fabricated to the details shown and
43 installed at the locations shown.
44
45 L. Structural aluminum angle and channel door frames shall be provided as shown
46 on the Construction Drawings and shall be anodized. Frames shall be
47 fabricated with not less than three anchors on each jamb.
MISCELLANEOUS METAL
05500-8 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 M. Miscellaneous aluminum shapes and plates shall be fabricated as shown.
3 Angle frames for hatches, beams, grates, etc., shall be furnished complete with
4 welded strap anchors attached. Furnish all miscellaneous aluminum shown but
5 not otherwise detailed. Structural shapes and extruded items shall conform to
6 the detail dimensions or the Shop Drawings within the tolerances published by
7 the American Aluminum Association.
8
9 2.04 STEEL ITEMS
10
11 A. Sleeves shall be steel or cast iron pipe in walls and floors with end joints as
12 shown on the Construction Drawings. All pipe sleeves shall have center anchor
13 around circumference as shown.
14
15 B. Miscellaneous steel pipe for sleeves and lifting attachments and other uses as
16 required shall be Schedule 40 pipe fabricated according to the details as shown
17 on the Construction Drawings.
18
19 C. Miscellaneous steel shall be fabricated and installed in accordance with the
20 Drawings and shall include: beams, angles, support brackets, closure angles
21 in roof at edge of T -beam; base plates to support ends of T -beams; door frames;
22 splice plates, anchor bolts (except for Equipment furnished in Divisions 11, 13,
23 14 and 15); lintels and any other miscellaneous steel called for on the
24 Construction Drawings and not otherwise specified.
25
26 D. Guardrails shall be of a standard FDOT W -Beam design with reflectors. All
27 mounting hardware including bolts, washers, and nuts shall be galvanized.
28
29 2.05 CAST IRON ITEMS
30
31 A. Outside pipe clean-out frames and covers, when and where shown on the
32 Construction Drawings, shall be heavy duty, R -6013-R-6099 series as
33 manufactured by Neenah Foundry Co., or equal. All outside pipe clean -outs
34 shall be 6 -inch diameter.
35
36 B. Frames, covers and grates for manholes, catch basins and inlets shall be of a
37 good quality, strong, tough even grained cast iron and capable of supporting an
38 H-20 loading. Castings shall be as manufactured by the U.S. Foundry, Neenah
39 Foundry, Mechanics Iron Foundry or equal. Sizes shall be as shown on the
40 Drawings. Covers to have letters "WATER", "SEWER" or "DRAIN", as
41 applicable, embossed on top.
42
43 C. Electric and telephone manhole frames and covers, when and where shown on
44 the Construction Drawings, shall be ductile iron castings conforming to all
45 requirements of ASTM A536. The covers shall be watertight and shall have the
46 letters "HIGH VOLTAGE," "LOW VOLTAGE," "SIGNAL," "TELEPHONE," as
MISCELLANEOUS METAL
05500-9 12/17/20
1 applicable, embossed on top in letters 2 inches high. The clear opening shall
2 be 36 -inches.
3
4 2.06 STAINLESS STEEL ITEMS
5
6 A. Stainless steel plates and shapes, when and where shown on the Drawings,
7 shall be manufactured using 316 S.S.
8
9 2.07 MATERIALS - MISCELLANEOUS
10
11 A. Use fasteners of suitable size and length for the materials being fastened and
12 for the type of connection required.
13
14 1. For concealed interior and exterior use or built into exterior walls:
15 Nonferrous stainless steel and zinc coated.
16
17 2. For embedded anchor that will be protected from the elements, use
18 fasteners of the same material as the miscellaneous stem being
19 fastened.
20
21 2.08 PRE-ENGINEERED ALUMINUM CANOPY
22
23 A. Basis of Design: As manufactured by Mitchell Metals, LLC or equal. The
24 manufacturer shall be responsible for the engineering, structural design,
25 construction, and detailing of a nominal 20' x 10' x 12' tall free-standing canopy
26 to meet the requirements of the project. The canopy to provide shelter for the
27 air compressors and air receiver tank located adjacent to the electrical building
28 for the equalization tank. Drawings and the following dimensions indicate
29 minimum requirements of the canopy construction.
30
31 B. Columns: 6" x 6" x'/4" thick.
32
33 C. Beams: Open top aluminum extrusion. Minimum beam size shall be 6" x 8" x
34 1/4" thick.
35
36 D. Support Rods: Support rods shall be fabricated from minimum 1" diameter
37 round galvanized steel rod with eye bolt welded to each end to emulate a
38 turnbuckle design.
39
40 E. Decking: Decking shall be of extruded, rigid roll -locked design that is self -
41 flashing and utilizes interlocking sections sufficiently sized for spending distance
42 required.
43
44 F. Gutter: Gutter shall be radius cornered aluminum extrusion. Minimum size shall
45 be 4" x 6" at 0.093" thick. Downspouts shall be installed on the south side and
46 the roof shall be sloped to the south appropriately.
47
MISCELLANEOUS METAL
05500-10 12/17/20
1
1 1 G. False Fascia: False Fascia shall be aluminum extrusion. Minimum size shall
2 be 1" x 8" at 0.070" thick.
1 3
4 H. Flashing: Flashing shall be made of aluminum sheet to match color of the
5 canopy. Minimum flashing thickness shall be 0.040" thick.
I6
7 I. Fasteners: Fasteners shall be stainless steel with neoprene washers, and rivets
8 are 3/16". Isolate dissimilar metals.
I9
10 J. Finishes: Factory applied baked enamel to comply with AAMA 2603. Color to
11 be white.
I12
13 K. Provide signed and sealed drawings and calculations performed by a State of
14 Florida registered professional engineer for the canopy design which ensures
I
15 that that the structure meets or exceeds all applicable loading conditions in
16 accordance with the applicable Florida Building Code and can withstand the
17 wind loading as indicated on sheet S1.00.
I18
19 L. The Contractor for General Construction shall provide all necessary parts,
20 accessories and reinforcing that may not be included in the standard offerings
I
21 of the manufacturer to complete the installation of the canopies.
22
23
24 PART 3 - EXECUTION
25
26 3.01 FABRICATION
1 27
28 A. All miscellaneous metal work shall be formed true to detail, with clean, straight,
• 29 sharply defined profiles and smooth surfaces of uniform color and texture and
I 30 free from defects impairing strength or durability.
31
I
32 B. Connections and accessories shall be of sufficient strength to safely withstand
33 stresses and strains to which they will be subjected. Steel accessories and
34 connections to steel or cast iron shall be steel, unless otherwise specified.
35 Threaded connections shall be made so that the threads are concealed by
I36 fitting.
37 C. Welded joints shall be rigid and continuously welded or spot welded as specified
I
39
38 or shown. The face of welds shall be dressed flush and smooth. Exposed joints
shall be close fitting and jointed where least conspicuous.
40
I
41
42 D. Welding of parts shall be in accordance with the Standard Code for Arc and Gas
Welding in Building Construction of the AWS and shall only be done where
43 shown, specified, or permitted by the Engineer. All welding shall be done only
I
44
45 by welders certified as to their ability to perform welding in accordance with the
requirements of the AWS Code. Component parts of built-up members to be
46 welded shall be adequately supported and clamped or held by other adequate
I47 means to hold the parts in proper relation for welding.
MISCELLANEOUS METAL
05500-11 12/17/20
1
1
2 E. Welding of aluminum work shall be on the unexposed side as much as possible
3 in order to prevent pitting or discoloration.
4
5 F. All aluminum finish exposed surfaces, except as specified below, shall have
6 manufacturer's standard mill finish. Aluminum handrails shall be given an
7 anodic oxide treatment in accordance with the Aluminum Association
8 Specification AA -C22 -A41. A coating of methacrylate lacquer shall be applied
9 to all aluminum before shipment from the factory.
10
11 G. Castings shall be of good quality, strong, tough, even -grained, smooth, free
12 from scale, lumps, blisters, sand holes, and defects of any kind which render
13 them unfit for the service for which they are intended. Castings shall be
14 thoroughly cleaned and will be subjected to a hammer inspection in the field by
15 the Engineer. All finished surfaces shown on the Drawings and/or specified
16 shall be machined to a true plane surface and shall be true and seat at all points
17 without rocking. Allowances shall be made in the patterns so that the thickness
18 specified or shown shall not be reduced in obtaining finished surfaces. Castings
19 will not be acceptable if the actual weight is less than 95 percent of the
20 theoretical weight computed from the dimensions shown. The Contractor, if
21 requested by the Owner or Engineer, shall provide facilities for weighing
22 castings in the presence of the Owner or Engineer showing true weights,
23 certified by the supplier.
24
25 H. All steel finish work shall be thoroughly cleaned, by effective means, of all loose
26 mill scale, rust, and foreign matter before shipment and shall be given one shop
27 coat of primer compatible with finish coats specified in Painting Section after
28 fabrication but before shipping. Paint shall be applied to dry surfaces and shall
29 be thoroughly and evenly spread and well worked into joints and other open
30 spaces. Abrasions in the field shall be touched up with primer immediately after
31 erection. Final painting is specified in Painting Section 09900.
32
33 I. Galvanizing, where required, shall be the hot -dip zinc process after fabrication.
34 Following all manufacturing operations, all items to be galvanized shall be
35 thoroughly cleaned, pickled, fluxed, and completely immersed in a bath of
36 molten zinc. The resulting coating shall be adherent and shall be the normal
37 coating to be obtained by immersing the items in a bath of molten zinc and
38 allowing them to remain in the bath until their temperature becomes the same
39 as the bath. Coating shall be not less than 2 oz. per sq. ft. of surface.
40
41 J. Provide for anchorage of type indicated; use anchors of same material and finish
42 as item except where specifically indicated otherwise.
43
44 K. Fabricate to prevent water intrusion or migration.
45
46 3.02 INSTALLATION
47
MISCELLANEOUS METAL
05500-12 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Install all items furnished except items to be imbedded in concrete or other
2 masonry which shall be installed under Division 03. Items to be attached to
3 concrete or masonry after such work is completed shall be installed in
4 accordance with the details shown. Fastening to wood plugs in masonry will
5 not be permitted. All dimensions shall be verified at the site before fabrication
6 is started.
7
8 B. All steel surfaces to come in contact with exposed concrete or masonry shall
9 receive a protective coating of an approved heavy bitumastic troweling mastic
10 applied in accordance with the Manufacturer's instructions prior to installation.
11
12 C. Where aluminum is embedded in concrete, apply a heavy coat of approved
13 bitumastic troweling mastic in accordance with the Manufacturer's instructions
14 prior to installation.
15
16 D. Where aluminum contacts masonry or concrete, provide a 1/32 -inch neoprene
17 gasket between the aluminum and the concrete or masonry.
18
19 E. Where aluminum contacts a dissimilar metal, apply a heavy brush coat of
20 zinc -chromate primer and provide a 1/32 -inch neoprene gasket between the
21 aluminum and the dissimilar metal.
22
23 F. Where aluminum contacts wood, apply two coats of aluminum metal and
24 masonry paint to the wood.
25
26 G. Anchor metal fabrications to substrata indicated; set all fasteners required.
27
28 H. Cut, drill and fit items as required for installation.
29
30 1. Fit exposed connection together accurately to form tight hairline joints.
31
32 2. Weld joints as indicated.
33
34 a. Comply with AWS code for welding procedures, for appearance
35 and quality of welds, and for corrective methods.
36 b. Grind exposed joints smooth.
37
38 I. Set items accurately in location, alignment and elevation; level, true and free of
39 rack, measured from established lines and levels.
40
41 J. Provide temporary bracing as required.
42
43 3.03 CLEANING AND TOUCH-UP
44
45 A. Touch up shop paint immediately after erection.
46
47 1. Clean field welds, bolted connections and abraded surfaces.
MISCELLANEOUS METAL
05500-13 12/17/20
1
2 2. Paint with same material used for shop painting, minimum 2 mils dry film
3 thickness.
4
5
6
7 END OF SECTION
8
MISCELLANEOUS METAL
05500-14 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 06600
2
3 FIBERGLASS REINFORCED PLASTIC FABRICATIONS
4
5 PART 1 - GENERAL
6
7 1.01 SUMMARY
8
9 A. This section includes all Fiberglass Reinforced Plastic (FRP) Products and
10 Fabrications, including but not limited to:
11
12 1. Molded Grating and Stair Treads
13 2. Grating Embedment Angle Frames
14 3. Structural Fabrications
15 4. Stairs
16 5. Handrail
17 6. Ladders and Cages
18 7. Troughs
19 8. Weir Plates
20 9. Scum Baffles
21
22 1.02 SCOPE OF WORK
23
24 A. The Contractor shall furnish all labor, materials, equipment, and incidentals as
25 required for the provision and proper installation of all of the FRP Products as
26 shown on the Drawings and specified herein. All anchor bolts, gaskets,
27 sealants, and other accessories and appurtenances, required for a complete
28 and operating installations shall be included whether specifically mentioned or
29 not.
30
31 1.03 REFERENCES
32
33 A. ANSI/NSF 61 — Drinking Water System Components — Health Effects.
34
35 B. ANSI/AWWA F101 — Contact -Molded, Fiberglass -Reinforced Plastic Wash
36 Troughs and Launders
37
38 C. ASTM D 638 — Standard Test Method for Tensile Properties of Plastics.
39
40 D. ASTM D 695 — Standard Test Method for Compressive Properties of Rigid
41 Plastics
42
43 E. ASTM D 790 — Standard Test Methods for Flexural Properties of Unreinforced
44 and Reinforced Plastics and Electrical Insulating Materials.
45
46 1.04 QUALITY ASSURANCE
47
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-1 03/22/2019
1 A. All FRP Products and Fabrications shall be supplied by an experienced firm
2 who has continually engaged in the manufacture and/or fabrication of
3 fiberglass reinforced plastics. Firms not listed in this specification must clearly
4 document a minimum of five years' experience with similar projects of equal
5 scope or design.
6
7 B. The Contractor shall assure that all field dimensions are taken accurately and
8 communicated properly to the FRP Fabricator, that other trades will not affect
9 a proper installation of the FRP, and that all manufacturer's instructions and
10 recommendations are followed.
11
12 1.05 DESIGN REQUIREMENTS
13
14 A. All fabrication shall comply with OSHA — 29 CFR as it pertains to worker safety
15 and walking -working surfaces for stairs, ladders, handrail, and platforms.
16
17 1.06 SUBMITTALS
18
19 A. Submit complete shop drawings and product data for all FRP materials and
20 fabrications as required by this scope of work in accordance with Sections
21 01300 and 01340.
22
23 B. Product data:
24
25 1. Manufacturers catalog data with Toad and deflection charts for all FRP
26 Gratings.
27
28 2. Manufacturers catalog data for all FRP Structural Shapes.
29
30 3. Manufacturer's 6 -inch square samples of FRP laminate of the same
31 construction, thickness, and color as the structural item.
32
33 4. Test results of FRP laminate.
34
35 5. Installation instructions and manufacturer certification that materials
36 comply with specified requirements and are suitable for the intended
37 application.
38
39 C. Shop drawings:
40
41 1. Shop drawings shall show all FRP materials as required and include all
42 dimensions, connections, fasteners, structural supports, adjustments,
43 openings, anchors, tolerances, assembly and installation details as
44 required.
45
46 PART 2 - PRODUCTS
47
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 2.01 GENERAL
2
3 A. All FRP materials shall be manufactured with Vinylester, with chemical
4 formulations as necessary to provide the corrosion resistance, strength and
5 other physical properties as required.
6
7 B. All structural shapes shall be constructed of continuous strand roving,
8 continuous transverse mat, and synthetic surface veil, and shall include
9 ultraviolet (UV) inhibitors.
10
11 C. All structural grating & shapes shall be flame retardant per ASTM E-84 Class 1
12 Flame Spread equal to or less than 25.
13
14 D. After fabrication of FRP, all cuts, holes, and abrasion shall be sealed
15 according to MANUFACTURER'S instructions to prevent corrosion.
16
17 2.02 FRP GRATING AND STAIR TREADS
18
19 A. FRP grating to be molded fiberglass grating made with vinlyester.
20
21 B. Grating to be 1 -5/8 -inch thick with a grid pattern of 1 -1/2 -inch x 1 -1/2 -inch.
22
23 C. Color shall be dark grey.
24
25 D. FRP grating shall designed to support 100 lbs. per square foot uniform load.
26 Deflection shall not exceed 0.25 inch.
27
28 E. All molded grating shall have ultraviolet (UV) inhibitors.
29
30 F Grating and stair treads shall have integral embedded grit to a nominal depth
31 of 3/16 -inch for slip resistance.
32
33 G. The tops and bottoms of the bearing bars and cross bars of the grating shall
34 be in the same plane.
35
36 H. Stair treads shall have 1 %-inch wide by 3/8 -inch thick contrasting color
37 integral bull nosing. The load -carrying bearing bars shall be on 1 'A -inch
38 centers.
39
40 I. All platform grating shall be attached with type 316 stainless steel grating clips.
41 Minimum of four clips per piece.
42
43 J. Grating shall be manufactured by Fibergrate, Seasafe or approved equal.
44
45 2.03 FRP GRATING EMBEDMENT ANGLE FRAMES
46
47 A. All FRP grating set in concrete openings shall have a FRP embedment angle
48 frame.
49
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-3 03/22/2019
1 B. Embedment angle frame to be EBA-10, EBA-15, or EBA-20 as required for the
2 thickness of grating specified above.
3
4 C. Embedment angle shall have a continuous integral anchor.
5
6 D. FRP embedment angle frames shall be vinylester resin.
7
8 E. FRP angle frames shall be manufactured by Fibergrate, Seasafe, or approved
9 equal.
10
11 2.04 FRP STRUCTURAL FABRICATIONS
12
13
14
15
16
17
18
19
20
21
22
23
A. FRP structural shapes shall be Vinylester pultruded fiberglass shapes. All
shapes shall meet ASTM E-84 Class 1 Flame Spread equal to or less than 25
and ASTM D-635 self -extinguishing.
B. The minimum physical properties shall be:
Property
ASTM
Longitudinal
Direction
Transverse Direction
Tensile Stress
D-638
30,000 psi
7,000 psi
Tensile Modulus
D-638
2.5 x 106 psi
0.8 x 106 psi
Compressive Stress
D-695
30,000 psi
15,000 psi
Compressive Modulus
D-695
2.5 x 106 psi
1.0 x 106 psi
Flexural Stress
D-790
30,000 psi
10,000 psi
Flexural Modulus
D-790
1.8 x 106 psi
0.8 x 106 psi
Modulus of Elasticity,
E
Full Section
2.8 x 106 psi
C.
All structural shapes shall be fabricated per the drawings with commercial
workmanship, closely fitted joints, and finished true to line and in accurate
position to permit installation and proper joining of parts in the field.
24 D. Use type 316 stainless steel bolts and washers.
25
26 E. All joint surfaces to be bonded shall be abraded to remove surface gloss and
27 be free of burrs and other foreign materials that would prevent proper
28 adhesion.
29
30 F Use high-strength epoxy adhesives designed for FRP use and mechanical
31 fasteners.
32
33 G. All pieces to have easily identified part numbers or pieces marks.
34
35 H. Shop assemble pieces into the largest practical assembly suitable for
36 shipping.
37
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 I. FRP structural fabrications shall be manufactured by Fibergrate, Seasafe or
2 approved equal.
3
4 2.05 FRP STAIRS
5
6 A. Fabricate structural support from FRP structural shapes as noted in section
7 2.04.
8
9 B. Use OSHA standards for rise and run.
10
11 C. Use Stair Treads as specified in section 2.02.
12
13 D. Use FRP handrail as specified in section 2.06.
14
15 E. Use type 316 stainless steel hardware throughout.
16
17 F. FRP stairs shall be manufactured by Fibergrate, Seasafe or approved equal.
18
19 2.06 FRP HANDRAIL
20
21 A. The handrail system shall be made from vinylester.
22
23 B. All handrail components shall be flame retardant per ASTM E-84 Class 1.
24
25 C. Handrail posts and rail shall be 2 -inch x 2 -inch x 1/4 -inch square tube. All posts
26 and rails shall use the same tube size. All tubing for handrail to have a
27 minimum 1/4 -inch wall thickness.
28
29 D. All handrail to be safety yellow.
30
31 E. All post to rail connections to be fully bonded with an epoxy adhesive and shall
32 have a 1 '/z -inch square solid internal connection plug for added strength and
33 durability. All connections to have a smooth transition between post and rail.
34
35 F FRP handrail to be standard two -rail design with kickplate unless otherwise
36 noted.
37
38 G. FRP handrail shall be manufactured by Fibergrate, Seasafe or approved
39 equal.
40
41 2.07 FRP LADDERS AND CAGES
42
43 A. Ladders and cages shall be made from vinylester.
44
45 B. All ladder and cage components shall be flame retardant per ASTM E-84
46 Class 1.
47
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-5 03/22/2019
1 C. Ladder rails shall be 2 -inch x 2 -inch x 1A -inch square tube. Ladder rungs shall
2 be 1 -inch diameter solid round.
3
4 D. Ladders and cages are to be safety yellow.
5
6 E. Ladder rungs are to penetrate inside wall of ladder rail tube and be
7 countersunk into outside wall of ladder rail tube, providing support for the
8 ladder rung in four places. This connection is to be fully bonded and with
9 epoxy adhesives and pinned to prevent rung rotation.
10
11 F. Ladder rungs to have slip -resistant quartz epoxy grit surface.
12
13 G. Ladder stand-off brackets are to be FRP and are to be installed at a maximum
14 of 6'-0 on center. Ladder base mount brackets are to be FRP. All hardware is
15 to be type 316 stainless steel.
16
17 H. Ladder cages, if required per OSHA, shall be fabricated from FRP Hoops and
18 Straps. FRP Hoops are to be 3 -inch x 1/4 -inch preformed FRP. Hoop spacing
19 shall be a max. of 4'-0" on center. FRP Straps are to be 2 -inch x'/4 -inch FRP
20 and are to be spaced at 9 -inch on center. Hoops and Straps are to be bonded
21 with epoxy adhesives and riveted with type 316 stainless steel rivets.
22
23 I. FRP ladders and cages shall be manufactured by Fibergrate, Seasafe or
24 approved equal.
25
26 2.08 MOLDED COVERED FRP GRATING
27
28 A. Manufacture: Grating shall be of a one piece molded construction with tops
29 and bottoms of bearing bars and cross bars in the same plane. Grating shall
30 have a square mesh pattern. Grating shall be reinforced with continuous
31 rovings of equal number of layers in each direction. The top layer of
32 reinforcement in the grating panel shall be no more than 3/16 -inch below the
33 top surface of the grating so as to provide maximum stiffness and prevent
34 resin chipping of unreinforced surfaces. Percentage of glass (by weight) shall
35 not exceed 35% so as to achieve maximum corrosion resistance, and as
36 required to maintain the structural requirements.
37
38 B. After molding, no dry glass fibers shall be visible on any surface of bearing
39 bars or cross bars. All bars shall be smooth and uniform with no evidence of
40 fiber orientation irregularities, resin rich or resin starved areas.
41
42 C. The grating cover plate shall be attached to the completed panel of grating by
43 chemical means to ensure integral action of the panel and plate. The panel
44 and grating shall be uniformly clamped together to ensure that all contact
45 surface remain in contact throughout the curing process.
46
47 D. Non -slip surfacing: Covered grating shall have a gritted surface.
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 E. Grating bar intersections shall be filleted to a minimum radius of 1/16 -inch to
3 eliminate local stress concentrations and the possibility of resin cracking at
4 these locations.
5
6 F. Fire rating: Grating shall be fire retardant with a tested flame spread rating of
7 25 or less when tested in accordance with ASTM E 84. Certifications shall be
8 dated within the past two years and test data performed only on the resin shall
9 not be acceptable.
10
11 G. The resin system used in the manufacture of the grating shall be vinylester.
12 Manufacturer may be required to submit corrosion data from tests performed
13 on actual grating products in standard chemical environments. Corrosion
14 resistance data of the base resin from the manufacturer is not a true indicator
15 of grating product corrosion resistance and shall not be accepted.
16
17 H. Color shall be dark grey.
18
19 I. Depth: 2 1/8 -inch with a tolerance of plus or minus 1/16 -inch.
20
21 J. Mesh Configuration of grating: 2 -inch x 2 -inch with a tolerance of plus or
22 minus 1/16 -inch centerline to centerline
23
24 K. Covered grating load/deflection requirements at the required span (shown
25 below) shall be less than manufacturers published maximum recommended
26 loads. Maximum recommended loads shall be determined by acoustic
27 emission testing. Grating shall be designed for a uniform load of 100 psf or
28 concentrated load of 300 Ib. Deflection is not to exceed 0.375 -inch or L/D =
29 120, whichever is less.
30
31 L. Covered FRP grating shall be manufactured by Fibergrate, Seasafe, or
32 approved equal.
33
34 2.09 FRP TROUGHS
35
36 A. Fiberglass reinforced polyester resin contact -molded composite laminate, with
37 1/4 -inch minimum nominal thickness. Inside surface shall have a smooth gel -
38 coat resin finish. Outside surface shall have gel -coat finish or resin sealed
39 with no exposed glass fibers. Edges shall be seal cut with polyester resin.
40
41 B. Color shall be white unless otherwise noted or chosen by Engineer or Owner
42 and shall be molded -in with ultraviolet inhibitor.
43
44 C. Fiberglass Reinforced Plastic (FRP) Laminate Physical Properties:
45
46 1. Tensile Strength, ASTM D 638: 12,000 psi.
47 2. Flexural Strength, ASTM D 790: 19,000 psi.
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-7
03/22/2019
1 3. Flexural Modulus, ASTM D 790: 900,000 psi.
2
3 D. Construction shall comply with all requirements of ANSI/AWWA/NSF
4 standards listed above, and manufacturer shall provide proof of such
5 certification.
6
7 E. The design shall support all applied downward vertical or gravity loadings
8 associated with a water -filled trough in the layout and configuration as shown
9 on the drawings. The design shall resist deflection under full buoyant and
10 gravity water loads with maximum upward and downward deflection less than
11 or equal to L/1000 where L equals the unsupported trough length; maximum
12 deflection at midpoint shall not be greater than 1/8 inch.
13
14 F The trough bottom shall be round, square, or V-shaped as indicated on the
15 drawings, with vertical sides. The top edge shall be straight with a maximum
16 of 1/8 inch deviation from true plane over 10 feet.
17
18 G. Longitudinal steel stiffening ribs shall be integrally molded on the outside of
19 troughs to prevent deflection. One -inch diameter 316 stainless steel spacer
20 rods shall be provided to maintain uniform width over the length of trough.
21
22 H. A 2 -inch wide, 1/2 -inch thick wall, grouting rib molded to outside of each trough
23 at the gullet end to act as a water stop when trough is grouted in place.
24
25 I. Slotted holes in closed end of trough shall be provided to allow a minimum
26 vertical level adjustment of 1 inch.
27
28
29
30
31 K. All wall anchors and flat bars shall be 316 stainless steel.
32
33
34
35
36 M. Troughs shall be installed in accordance with the manufacturer's instructions
37 plumb, level, square, in true and proper alignment, free of warp or twist, within
38 tolerances specified by the manufacturer and indicated herein.
39
40 N. Manufacturer is responsible for providing troughs of proper length for mounting
41 to walls and for grouting water -stop. Lengths listed nominal and shall be
42 verified by the Contractor.
43
44 O. Troughs shall be as manufactured by Warminster Fiberglass, or approved
J. The saddle at the closed end of the trough shall be integrally molded -in at 1.5
times the thickness of the trough body.
L. Adjustable weir plates shall be fiberglass reinforced plastic as specified herein,
and shall be straight -edge as indicated on the drawings.
45 equal.
46
47 2.10 FRP WEIR PLATES
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-8
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 A. Except for bolts and hardware specified herein scum baffles and supports
3 shall be polyester plastic resin, reinforced with glass fiber. All weir plates, weir
4 washers, weir splice plates, and support brackets shall be fiberglass reinforced
5 plastic molded to produce uniform smooth surfaces.
6
7 B. The glass content of the finished laminate shall not be less than 30% and not
8 more than 32% using Type E silane glass with chrome or silane finish. Final
9 laminate thickness shall be within 10% of nominal specified thickness.
10
11 C. The surface shall be resin rich, free of voids and porosity, without dry spots,
12 crazes or unreinforced areas and shall provide for increased corrosion
13 resistance and UV protection. All machines or cut edges shall be sealed with
14 resin. The weirs shall be green or white in color.
15
16 D. Ultraviolet resistance is required in all laminates. Surfacing veil is required on
17 all surfaces to increase chemical resistance and provide additional UV
18 absorption.
19
20 E. The weir plates, splice plates and weir washers shall be 1/4 -inch thick plastic
21 laminate. Oversized mounting holes in the weir plates shall be provided for
22 vertical and horizontal alignment of at least 2 -inches with 5 -inch diameter FRP
23 weir washers to cover the holes. The weirs shall be mounted with 1/2 -inch
24 stainless steel expansion anchors 24 -inch on center. Cut ends of non-standard
25 lengths shall be sealed with resin.
26
27 F. Expansion anchors, nuts, bolts, washers and other hardware shall be Type
28 316 stainless steel.
29
30 G. Fiberglass Reinforced Plastic (FRP) Laminate Physical Properties:
31
32 Method Test Min. Value
33 ASTM D-638 Tensile Strength 24,000 psi
34 ASTM D-790 Flexural Strength 25,000 psi
35 ASTM D-790 Flexural Modulus 1.4 x 106 psi
36 ASTM D-2583 Barcol Hardness 40
37 ASTM D-570 Water Absorption 0.2%
38
39 H. Construction shall comply with all requirements of ANSI/AWWA/NSF
40 standards listed above, and manufacturer shall provide proof of such
41 certification.
42
43 I. Straight weirs shall be cut from a flat sheet. Curvilinear weirs (clarifier) cut
44 from a flat sheet will not be acceptable.
45
46 J. Weir notch configuration and dimensions shall be as shown on the drawings.
47
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-9 03/22/2019
1 K. Weirs intended for attachment to FRP collection troughs shall be flat -crested
2 and shall be a single section extending the full length of the trough, wall -to -
3 wall. Clarifier weirs shall be V -notch as shown on the drawings. All other
4 weirs shall be flat -crested.
5
6 L. Mounting to trough: 1/2 -inch diameter by 1 -1/2 -inch 316 stainless steel bolt,
7 nut, and 2 washers including 5 -inch diameter fiberglass reinforced plastic
8 washer.
9
10 M. Weir plates shall be as manufactured by Nefco Inc., Warminster Fiberglass, or
11 approved equal.
12
13 2.11 FRP SCUM BAFFLES
14
15 A. Except for bolts and hardware specified herein, scum baffles and supports
16 shall be polyester plastic resin, reinforced with glass fiber. All scum baffle
17 panels, scum baffle splice plates and support brackets shall be fiberglass
18 reinforced plastic molded to produce uniform smooth surfaces.
19
20 B. The glass content of the finished laminate shall not be less than 30% and not
21 more than 32% using Type E silane glass with chrome or silane finish. Final
22 laminate thickness shall be within 10% of nominal specified thickness.
23
24 C. The surface shall be resin rich, free of voids and porosity, without dry spots,
25 crazes or unreinforced areas and shall provide for increased corrosion
26 resistance and UV protection. All machines or cut edges shall be sealed with
27 resin. The weirs and scum baffles shall be green or white in color.
28
29 D. Ultraviolet resistance is required in all laminates. Surfacing veil is required on
30 all surfaces to increase chemical resistance and provide additional uv
31 absorption.
32
33 E. Scum baffle panels and splice plates shall be 1/4 -inch thick plastic laminate.
34 The scum baffle panels shall be 12 -inch high and shall not exceed 12' in
35 length unless otherwise noted. Splice plates shall be 6 -inch x 12 -inch. The
36 scum baffle brackets shall be 7 -inch x 10 -inch x 1/4 -inch FRP with gussets on
37 both sides and slotted holes to provide horizontal, vertical and radial
38 adjustment of the baffle. The brackets shall be installed a maximum of 4' on
39 center or as shown on the drawings. Fastening holes in the scum baffle panel
40 shall be countersunk to accommodate 3/8 -inch flat head fasteners. Cut ends
41 of non-standard lengths shall be sealed with resin.
42
43 F Expansion anchors, nuts, bolts, washers and other hardware shall be Type
44 316 stainless steel.
45
46 G. Fiberglass Reinforced Plastic (FRP) Laminate Physical Properties:
47
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Method Test Min. Value
ASTM D-638 Tensile Strength 24,000 psi
ASTM D-790 Flexural Strength 25,000 psi
ASTM D-790 Flexural Modulus 1.4 x 106 psi
ASTM D-2583 Barcol Hardness 40
ASTM D-570 Water Absorption 0.2%
3 H. Construction shall comply with all requirements of ANSI/AWWA/NSF
4 standards listed above, and manufacturer shall provide proof of such
5 certification.
6
7 I. Mounting holes shall allow 3 inches vertical adjustment, and shall be spaced
8 as recommended by the manufacturer.
9
10 J. Splice Plates are required to secure ends and to allow for horizontal
11 expansion. Nominal thickness and color shall be the same as the weir.
12
13 K. Scum baffle plates shall be as manufactured by Nefco Inc., Warminster
14 Fiberglass, or approved equal.
15
16 PART 3 - EXECUTION
17
18 3.01 INSPECTION
19
20 A. Upon receipt of material at job site, the Contractor shall inspect all materials
21 for shipping damage. Any damage is to be noted on the shipping receipt /
22 packing list and reported promptly to the shipper.
23
24 3.02 HANDLING AND STORAGE
25
26 A. Handle all FRP materials with reasonable care to prevent damage. Use
27 shipping pallets to move material. Do not drag FRP materials.
28
29 B. If FRP materials are not to be installed immediately, then store to prevent
30 twisting, bending, breaking, or damage of any kind.
31
32 3.03 INSTALLATION
33
34 A. Installing contractor to coordinate and verify that other construction trades and
35 materials have been installed per the contract drawings, and, that they are
36 accurate in location, alignment, elevation, and are plumb and level
37
38 B. Install FRP materials in accordance with the installation drawings and
39 instructions supplied by the FRP Supplier.
40
41 C. Install materials accurately in location and elevation, level, and plumb. Field
42 fabricate as necessary for accurate fit.
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-11 03/22/2019
1
2 D. Troughs shall also be installed square, in true and proper alignment without
3 warp or twist, within the tolerances specified by the manufacturer and as
4 indicated herein. Troughs shall be set with weir edges to the elevations
5 indicated on the drawings. Grout in place after leveling, and adjust lengths of
6 plates as necessary under direction of manufacturer and Engineer.
7
8 E. All field cuts, holes or abrasions must be sealed with Manufacturer's sealing
9 resin according to Manufacturer's instructions to prevent corrosion.
10
11 F. If the scope of work requires the contractor to perform additional tasks, which
12 may damage the installed FRP materials, the contractor is responsible for
13 covering the grating with plywood, or other suitable protective material.
14
15
16 END OF SECTION
17
FIBERGLASS REINFORCED PLASTIC FABRICATIONS
06600-12 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 09865
2
3 SURFACE PREPARATION AND SHOP PRIME PAINTING
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required for the surface
10 preparation and application of shop primers on ferrous metals, excluding
11 stainless steels, and concrete as specified herein.
12
13 1.02 SUBMITTALS
14
15 A. Submit to the Engineer for review, shop drawings, manufacturer's specifications
16 and data on the proposed primers and detailed surface preparation, application
17 procedures and dry mil thickness.
18
19 B. Submit representative physical samples of the proposed primers, if required by
20 the Engineer.
21
22 PART 2 - PRODUCTS
23
24 2.01 MATERIALS
25
26 A. Submerged Services:
27
28 1. Shop primer for ferrous metals that will be submerged or that are subject to
29 splash action or that are specified to be considered submerged service shall
30 be sprayed with one coat of Tnemec Series 66 at 3.0-5.0 mils (D.F.T.), PPG
31 Pitt -Guard Epoxy Coating 97-145 at 4.0-6.0 mils (D.F.T.), or approved equal.
32
33 2. Voids and bugholes in concrete surfaces must be filled with Tnemec Series
34 218 (up to 1/4" deep) or Tnemec Series 219 (1/4" to 11/2" deep) or approved
35 equal recommended by manufacturer of approved paint system.
36
37 B. Non -submerged Services:
38
39 1. Shop primer for ferrous metals other than those covered by Paragraph 2.01A
40 shall be sprayed with one coat of Tnemec Series 66 Epoxy Fast Dry Primer
41 94-109 (3.0-5.0 mils D.F.T.) or approved equal.
42
43 C. Non -primed Surfaces:
44
45 1. Gears, bearings surfaces, and other similar surfaces obviously not to be
46 painted shall be given a heavy shop coat of grease or other suitable
SURFACE PREPARATION AND SHOP PRIME PAINTING
09865-1 03/22/2019
1 rust -resistant coating. This coating shall be maintained as necessary to
2 prevent corrosion during all periods of storage and erection and shall be
3 satisfactory to the Engineer up to the time of the final acceptance test.
4
5 D. Compatibility of Coating Systems:
6
7 1. Shop priming shall be done with primers that are guaranteed by the
8 manufacturer to be compatible with their corresponding primers and finish
9 coats specified in Section 09900 for use in the field and which are
10 recommended for use together.
11
12 PART 3 - EXECUTION
13
14 3.01 APPLICATION
15
16 A. Surface Preparation and Priming:
17
18 1. Non -submerged components scheduled for priming, as defined above, shall
19 be sandblasted clean in accordance with SSPC-SP-6, Commercial Grade,
20 immediately prior to priming. Submerged components scheduled for
21 priming, as defined above, shall be sandblasted clean in accordance with
22 SSPC-SP-10, Near White, immediately prior to priming.
23
24 2. Surfaces shall be dry and free of dust, oil, grease, dirt, rust, loose mill scale,
25 and other foreign material before priming. Concrete surfaces shall be
26 prepared in accordance with ICRI CSP 4-6.
27
28 3. Shop prime in accordance with approved paint manufacturer's
29 recommendations.
30
31 4. Priming shall follow sandblasting before any evidence of corrosion has
32 occurred and within 24 hours.
33
34 5. Allow all new concrete to cure for a minimum of 28 days. Test for moisture
35 by plastic film tape down test (ASTM D4263).
36
37
38 END OF SECTION
SURFACE PREPARATION AND SHOP PRIME PAINTING
09865-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 09900
2
3 PAINTING
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. The work of this section consists of furnishing all materials, labor, equipment
10 and incidentals required and performing all the painting necessary to complete
11 this Contract in its entirety.
12
13 B. It is the intent of these Specifications to paint all concrete where scheduled,
14 exposed miscellaneous metal, pipe, fittings, supports, valves, equipment and all
15 other work obviously required to be painted unless otherwise specified. Minor
16 items omitted in the schedule of work shall be included in the work of this
17 Section where they come within the general intent of the Specifications as stated
18 herein.
19
20 C. The following surfaces or items are not required to be painted:
21
22 1. Portions of metal, other than aluminum, embedded in concrete. This
23 does not apply to the back face of items mounted to concrete or masonry
24 surfaces which shall be painted before erection. Aluminum to be
25 embedded in or in contact with concrete or masonry shall be coated to
26 prevent electrolysis.
27
28 2. Stainless steel.
29
30 3. Fencing
31
32 4. Concealed surfaces of pipe or crawl spaces.
33
34 5. Acoustical ceilings.
35
36 6. Tile.
37
38 7. Fiberglass other than piping.
39
40 8. Packing glands and other adjustable parts and nameplates of
41 mechanical equipment.
42
43 9. Electrical switchgear, motor control centers, lighting and power panels,
44 and control panels.
45
46 10. Polyethylene chemical storage tanks.
PAINTING
09900-1 03/22/2019
1
1 1
2 1.02 REFERENCES
3
4 A. Steel Structures Painting Council (SSPC)
5
6 1. SSPC-SP-1 through SSPC-SP-10 Surface Preparation Specifications '
7
8 B. International Concrete Repair Institute (ICRI)
9
I
10 1. ICRI CSP — 3 through ICRI CSP — 6 Concrete Surface Preparation
11 Standards.
12
I
13 1.03 SUBMITTALS
14
15 A. Submit to the Engineer for review in accordance with the General Conditions,
I
16 shop drawings, working drawings and product data including manufacturer's
17 specifications and data on the proposed paint systems and detailed surface
18 preparation, application procedures and dry film thickness.
I
19
20 B. Submit to the Engineer for review in accordance with the General Conditions,
21 color cards, including standard and special colors, for initial color selections.
1
22
23 C. Schedule of Painting Operations: Submit to the Engineer for review a complete
24 Schedule of Painting Operations within 90 days after the Notice to Proceed.
I
25 This Schedule is imperative so that the various fabricators may be notified of
26 the proper shop prime coat to apply. Properly notify and coordinate the
27 fabricators' surface preparation and painting operations with these
I
28 Specifications. This Schedule shall include for each surface to be painted, the
29 brand name, the percent volume of solids, the coverage and the number of
30 coats the Contractor proposes to use in order to achieve the specified dry film
I
31 thickness, and color charts. When the Schedule has been approved, apply all
32 material in strict accordance with the approved Schedule and the
33 manufacturer's instructions. Wet and dry paint film gages shall be made
I
34 available to the Engineer to verify the proper application while work is in
35 progress.
36
1
37 1.04 SPARE MATERIAL
38
39 A. Furnish one unopened gallon can of each type and each color of paint used. I
40
41 1.05 CONTRACTOR QUALIFICATIONS
42
I
43 A. Contractor shall submit a list of projects successfully completed during the past
44 3 years of similar projects. Contractor shall also supply record of Certificates of
45 Approval from Manufacturers to show they have completed technical product 1
PAINTING
09900-2
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 and application training. Contractors shall submit a list of surface preparation
2 and application equipment sufficient to mix and apply the products specified.
3
4 PART 2 - PRODUCTS
5
6 2.01 MATERIALS
7
8 A. All painting materials shall be fully equal to those manufactured by the Tnemec
9 Company Inc., Carboline, and PPG/Porter Coatings. The painting schedule has
10 been prepared on the basis of these products and recommendations for
11 applications. No brand other than those named will be considered for approval,
12 unless the brand and type of paint proposed for each item in the following
13 schedule, together with sufficient data substantiated by certified tests conducted
14 at no expense to the Owner, to demonstrate its equality to the paint(s) named,
15 is submitted in writing to the Engineer for approval within 30 days after the
16 signing of the Notice to Proceed. The type and number of tests performed shall
17 be subject to the Engineer's approval.
18
19 B. All painting materials shall be delivered to the mixing room in unbroken
20 containers, bearing the manufacturer's brand, date of manufacturer, batch
21 number, and name. They shall be used without adulteration and mixed, thinned,
22 and applied in strict accordance with manufacturer's directions for the applicable
23 materials and surface and with the Engineer's approval before using.
24
25 C. Shop priming shall be done with primers that are guaranteed by the
26 manufacturer to be compatible with the finish paints to be used.
27
28 D. No paint containing lead will be allowed. Oil shall be pure boiled linseed oil.
29
30 E. Work areas will be designated by the Engineer for storage and mixing of all
31 painting materials. Materials shall be in full compliance with the requirements of
32 pertinent codes and fire regulations. Proper containers outside of the buildings
33 shall be provided and used for painting wastes, and no plumbing fixture shall be
34 used for this purpose.
35
36 F. All recommendations of the paint manufacturer in regard to the health and safety
37 of workmen shall be followed.
38
39 2.02 PAINTING SYSTEMS
40
41 A. Colors for pipe shall match that of existing connected piping. Colors for
42 structural steel shall match that of existing connected structural steel.
43
44 B. The following surfaces shall have the types of paint scheduled below applied at
45 the dry film thickness (D.F.T.) in mils per coat noted. Some of the painting
PAINTING
09900-3
03/22/2019
1 systems listed below may not be used in this project. Some colors will require
2 an additional coat from what is listed to get the proper color coverage.
3
4 1. Non -submerged concrete and precast concrete walls and ceilings:
5
6 a. Tnemec
7 1st Coat: Tnemec Series 66 (3.0 - 5.0 mils D.F.T.)
8 2nd Coat: Tnemec Series 66 (4.0 - 6.0 mils D.F.T.)
9
10 b. Carboline
11 1st Coat : Carboguard 890 (4.0-6.0 mils D.F.T.)
12 2nd Coat : Carboguard 890 (4.0-6.0 mils D.F.T.)
13
14 c. PPG/HPC
15 1st Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
16 D.F.T.)
17 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
18 D.F.T.)
19
20 2. Submerged Concrete (except for where a lining system is specified)
21
22 a. Tnemec
23 1st Coat: Tnemec Series N69 (3.0 - 5.0 mils D.F.T.)
24 2nd Coat: Tnemec Series N69 (4.0 - 6.0 mils D.F.T.)
25
26 b. Carboline
27 1 Coat: Carboguard 691 (10.0-14.0 mils D.F.T.)
28
29 c. PPG/HPC
30 2 Coats: Pitt -Guard All Weather D -T -R Epoxy Coating 97-946/949
31 Series. (5.0-7.0 mils D.F.T. per coat)
32
33 3. Interior Exposed Masonry (above grade and interior partitions)
34
35 a. Tnemec
36 1st Coat: Tnemec Series 54-660- (80-100 sq. ft. per gal.)
37 2nd Coat: Tnemec Series 66 (4.0 - 6.0 mils D.F.T.)
38 3rd Coat: Tnemec Series 66 (4.0 - 6.0 mils D.F.T.)
39
40 b. Carboline
41 1 Coat: Sanitile 600/600TG (60-80 sq. ft. per gal.)
42 2 Coats: Sanitile 655 (4.0-6.0 mils D.F.T. per coat)
43
44 c. PPG/HPC
45 1 Coat: Aquapon Polyamide Epoxy Block Filler 97-685/686 (40 to
46 80 sq. ft. per gal @ 12.0-24.0 mils D.F.T.)
47 2 Coats: Aquapon High Build Semi -Gloss Polyamide Epoxy
48 Coating
PAINTING
09900-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 97-130 Series. (4.0-6.0 mils D.F.T. per coat)
2
3 4. Interior and Exterior Exposed Masonry (Unpainted)
4
5 a. Tnemec
6 Regular CMU
7 2 Coats: Prime a Pell 200 @ 75-100 SF/gallon/coat
8 Split face CMU
9 2 Coats: Prime a Pell Plus @ 65-80 SF/gallon/coat
10
11 b. Carboline
12 CMU
13 1 Coat: Carbocrete Sealer WB @ 60-80 SF/gallon
14 Split Face CMU
15 2 Coats: Carbocrete Sealer WB, 1st coat @ 40-60 SF/gallon &
16 2nd coat @ 80-120 SF/gallon
17
18 c. PPG/HPC
19 2 Coats: PPG/HPC Canyon Tone Stain Clear at 100 to 150 SF
20 per gallon.
21
22
23
24 a. Tnemec
25 1st Coat: Tnemec Series 180 smooth (4.0 — 6.0 mils D.F.T.)
26 2nd Coat: Tnemec Series 180 smooth (4.0 —6.0 mils D.F.T.)
27
28 b. Carboline
29 1st Coat: Sanitile 100 (10.0-12.0 mils D.F.T.)
30 2nd Coat: Sanitile 155 (2.0-3.0 mils DFT)
31 3rd Coat: Sanitile 155 (2.0-3.0 mils D.F.T.) - OPTIONAL
32
33 c. PPG/HPC
34 1st Coat Pitt -Flex Elastomeric Coating 4-110 (5.5-7.3 mils D.F.T.)
35 2nd Coat Pitt -Flex Elastomeric Coating 4-110 (5.5-7.3 mils
36 D.F.T.)
37
38 6. Ferrous metals submerged or subject to splashing
39
40 a. Tnemec
41 1st Coat: Tnemec Series 104-1211 High Solids Catalyzed Epoxy
42 Coating (3.0-5.0 mils D.F.T.)
43 2nd Coat: Tnemec Series 104 -Color High Solids Catalyzed Epoxy
44 Coating (8.0 — 10.0 mils D.F.T.)
45
46 b. Carboline
47 1 Coat: Carboguard 691 (10.0-14.0 mils D.F.T.)
48
5. Exterior Exposed Stuccoed Walls
PAINTING
09900-5
03/22/2019
1 c. PPG/HPC
2 1 Coat: Pitt -Guard All Weather D -T -R Epoxy Coating 97-946/949
3 Series. (5.0-7.0 mils D.F.T per coat)
4 1 Coat: Pitt -Guard All Weather D -T -R Epoxy Coating 97-946/949
5 Series. (5.0-7.0 mils D.F.T per coat)
6
7 7 Exterior non -submerged ferrous metals:
8
9 a. Tnemec
10 1st Coat: Tnemec Series 66 (3.0 - 5.0 mils D.F.T.)
11 2nd Coat: Tnemec Series 66 (4.0 - 6.0 mils D.F.T.)
12 3rd Coat: Tnemec Series 1074 (2.5 - 4.5 mils D.F.T.)
13
14 b. Carboline
15 1st Coat : Carboguard 893SG (3.0-5.0 mils D.F.T.)
16 2nd Coat : Carboguard 893SG (3.0-5.0 mils D.F.T.)
17 3rd Coat : Carbothane 133HB (3.0-4.0 mils D.F.T.)
18
19 c. PPG/HPC
20 1st Coat: Epoxy Fast Dry Primer 94-109 (4.0-6.0 mils D.F.T.)
21 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
22 D.F.T.)
23 3rd Coat: Pitthane HB Semi -Gloss Urethane 95-8800 (2.0-6.0 mils
24 D.F.T.)
25
26 8. Interior non -submerged ferrous metals:
27
28 a. Tnemec
29 1st Coat: Tnemec Series 66 Color (3.0 - 5.0 mils D.F.T.)
30 2nd Coat: Tnemec Series 66 Color (4.0 - 6.0 mils D.F.T.)
31
32 b. Carboline
33 1st Coat : Carboguard 893SG (3.0-5.0 mils D.F.T.)
34 2nd Coat : Carboguard 893SG (3.0-5.0 mils D.F.T.)
35
36 c. PPG/HPC
37 1st Coat: Epoxy Fast Dry Primer 94-109 (4.0-6.0 mils D.F.T.)
38 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
39 D.F.T.)
40
41 9. Exterior galvanized and non-ferrous metal:
42
43 a. Tnemec
44 1st Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
45 2nd Coat: Tnemec Series 1074 (2.5 - 3.5 mils D.F.T.)
46
47 b. Carboline:
48 1st Coat : Carboguard 893SG (3.0-4.0 mils D.F.T.)
PAINTING
09900-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 2nd Coat : Carbothane 133HB (3.0-4.0 mils D.F.T.)
2
3
4 c. PPG/HPC
5 1st Coat: Epoxy Fast Dry Primer 94-109 (4.0-6.0 mils D.F.T.)
6 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
7 D.F.T.)
8 3rd Coat: Pitthane HB Semi -Gloss Urethane 95-8800 (2.0-6.0
9 mils D.F.T.)
10
11 10. Interior galvanized and non-ferrous metals:
12
13 a. Tnemec
14 1st Coat: Tnemec Series 66 Color (2.5 - 3.5 mils D.F.T.)
15 2nd Coat: Tnemec Series 66 Color (3.0 - 5.0 mils D.F.T.)
16
17 b. Carboline:
18 1st Coat : Carboguard 893SG (3.0-4.0 mils D.F.T.)
19 2nd Coat : Carboguard 893SG (3.0-5.0 mils D.F.T.)
20
21 c. PPG/HPC
22 1st Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
23 D.F.T.)
24 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
25 D.F.T.)
26
27 11. Galvanized and non-ferrous metal submerged or subject to splashing:
28
29 a. Tnemec
30 1st Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
31 2nd Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
32
33 b. Carboline
34 1 Coat: Carboguard 691 (10.0-14.0 mils D.F.T.)
35
36 c. PPG/HPC
37 1st Coat: PPG Pitt -Guard All Weather D -T -R Epoxy Coating 97-
38 946/949 Series. (5.0-7.0 mils D.F.T per coat)
39 2nd Coat: PPG Pitt -Guard All Weather D -T -R Epoxy Coating 97-
40 946/949 Series. (5.0-7.0 mils D.F.T per coat)
41 3rd Coat: PPG Pitt -Guard All Weather D -T -R Epoxy Coating 97-
42 946/949 Series. (5.0-7.0 mils D.F.T per coat)
43
44 12. Metal surfaces exposed to temperatures above 250°F:
45
46 a. Tnemec
47 1st Coat: Tnemec Series 39-1261(0.7 - 1.5 mils D.F.T.)
48 2nd Coat: Tnemec Series 39-1261(0.7 - 1.5 mils D.F.T.)
PAINTING
09900-7 03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
b. Carboline
1 Coat: Thermaline 450, up to 450°F (8.0-10.0 mils D.F.T.)
or
1st Coat: Carbozinc 11 or 11 HS (2.0-3.0 mils D.F.T.)
2nd Coat: Thermaline 4700, 400-1000°F (2.0 mils D.F.T.)
c. PPG/HPC
2 Coats: Speedhide Int/Ext Aluminum Paint 6-230. (1.0 -1.3 mils
D.F.T. per coat)
13. Insulated Pipe:
a. Tnemec
1st Coat: Tnemec Series 6 (2.0 - 3.0 mils D.F.T.)
2nd Coat: Tnemec Series 6 (2.0 - 3.0 mils D.F.T.)
b. Carboline
2 Coats: Sanitile 155 (2.0-3.0 mils D.F.T. per coat)
c. PPG/HPC
2 Coats: PITT -TECH Interior/Exterior Satin DTM Industrial
Enamels 90-474 Series.(2.0-3.0 mils D.F.T. per coat)
14. Aluminum in contact with dissimilar metals:
a. Tnemec
1st Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
2nd Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
c. Carboline
1st Coat : Carboguard 893SG (3.0-4.0 mils D.F.T.)
2nd Coat : Carboguard 893SG (3.0-4.0 mils D.F.T.)
c. PPG/HPC
1st Coat: Epoxy Fast Dry Primer 94-109 (4.0-6.0 mils D.F.T.)
2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
D.F.T.)
15. Plastic Piping - Interior:
a. Tnemec
1st Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
2nd Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
b. Carboline
1st Coat : Carbocrylic 120 (1.0-2.0 mils D.F.T.)
2 Coats : Carboguard 893SG (3.0-4.0 mils D.F.T. per coat)
PAINTING
09900-8 03/22/2019
1
11
2 c. PPG/HPC
I 3 1st Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
4 D.F.T.)
5 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
I6 D.F.T.)
7
8 16. Plastic Piping - Exterior
I9
10 a. Tnemec
11 1st Coat: Tnemec Series 73 (2.5 - 3.5 mils D.F.T.)
I12
13 2nd Coat: Tnemec Series 73 (2.5 - 3.5 mils D.F.T.)
14 b. Carboline
I15 1st Coat : Carbocrylic 120 (1.0-2.0 mils D.F.T.)
16 2 Coats : Carbothane 133HB (3.0-4.0 mils D.F.T. per coat)
17
I18 c. PPG/HPC
19 1st Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
20 D.F.T.)
I
21 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
22 D.F.T.)
23 3rd Coat: Pitthane HB Semi -Gloss Urethane 95-8800 (2.0-6.0
I
24
25 mils D.F.T.)
26 17. Interior Drywall and Plaster -Industrial Areas
I27
28 a. Tnemec
29 1st Coat: Tnemec Series 51-792 (1.0 - 1.5 mils D.F.T.)
I30 2nd Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
31 3rd Coat: Tnemec Series 66 (2.5 - 3.5 mils D.F.T.)
32
I33 b. Carboline
34 1st Coat : Carbocrylic 120 (1.0-2.0 mils D.F.T.)
35 2nd Coat : Sanitile 655 (4.0-5.0 mils DFT)
I
36
37 3rd Coat : Sanitile 655 (4.0-5.0 mils D.F.T.)
38 c. PPG/HPC
1 39 1st Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
40 D.F.T.)
41 2nd Coat: Aquapon HB Semi -Gloss Epoxy 97-130 (4.0-6.0 mils
I42
43 D.F.T.)
• 44 18. Interior Drywall and Plaster -Office Areas
45
46 a. Tnemec
• 47 1st Coat: Tnemec Series 51-792 (1.0 - 1.5 mils D.F.T.)
PAINTING
09900-9 03/22/2019
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
2nd Coat: Tnemec Series 6 (2.0 — 3.0 mils D.F.T.)
3rd Coat: Tnemec Series 6 (2.0 — 3.0 mils D.F.T.)
b. Carboline
1st Coat : Carbocrylic 120 (1.0-2.0 mils D.F.T.)
2 Coats: Sanitile 155 (2.0-3.0 mils D.F.T. per coat)
c. PPG/HPC
1st Coat: Speedhide Interior Latex Primer/Sealer 6-2 (1 mil DFT)
2 Coats: Speedhide Int Latex Eggshell 6-411 (2 mils D.F.T. per
coat)
19. Interior Concrete Floors
a. Tnemec
1st Coat: Tnemec Series 201 (5.0 — 7.0 mils D.F.T>)
2nd Coat: Tnemec Series 280 (8.0 — 10.0 mils D.F.T.)
Note: Apply 50 — 70 mesh silica sand at 5 lbs. per 150 sq. ft.
between
1st and 2nd coat to provide non -slip surface.
b. Carboline
1st Coat: Carboguard 1340 (1.0-2.0 mils D.F.T.)
2 Coats: Carboguard 890 (4.0-6.0 mils D.F.T. per coat)
Note: Utilize 40-60 mesh silica sand to provide non -slip surface.
Consult with Carboline for application details.
c. PPG/HPC
1st Coat: Megaseal High Solids Primer 99-6639 (5.0 — 7.0 mils
D.F.T)
2nd Coat: Megaseal Self -Leveling Epoxy 99-6680 (10.0-12.0 mils
D.F.T.)
20. Concrete in highly Corrosive Environment Special Coating
a. Tnemec
1st Coat: Tnemec Series 434 Perma-Shield H2S (125 mils D.F.T.)
2nd Coat: Tnemec Series 435 Perma-Glaze (12.0-15.0 mils
D.F.T.)
b. Carboline
1st Coat: Plasite 5371 (125 mils)
2nd Coat: Plasite 4500S (12.0-15.0 mils D.F.T.)
c. PPG/HPC/Polyspec (Concrete Headworks)
1st Coat: 300EX Epoxy Primer
2nd Coat: TuffRez 240 Chemical Resistant Epoxy Liner (100 mils)
PAINTING
09900-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 3rd Coat: TuffRez 240 Chemical Resistant Epoxy Liner (100 mils)
2
3 PPG/HPC/Polyspec (Manholes/Lift Stations -Force & Gravity
4 Mains)
5 1st Coat: 300EX Epoxy Primer
6 2nd Coat: TuffRez 240 Chemical Resistant Epoxy Liner (100 mils)
7 3rd Coat: TuffRez 240 Chemical Resistant Epoxy Liner (100 mils)
8
9 PPG/HPC/Enviroline (Concrete Headworks)
10 1st Coat #54 High Solids Epoxy Primer (3-5 mils DFT)
11 2nd Coat #224 100% Solids Epoxy Novolac (20-40 mils DFT)
12 3rd Coat #224 100% Solids Epoxy Novolac (20-40 mils DFT)
13
14 PPG/HPC/Enviroline (Manholes/Lift Stations -Force & Gravity
15 Mains)
16 1st Coat #54 High Solids Epoxy Primer (3-5 mils DFT)
17 2nd Coat #224 100% Solids Epoxy Novolac (20-40 mils DFT)
18 3rd Coat #224 100% Solids Epoxy Novolac (20-40 mils DFT)
19
20 21. Metals submerged or subject to splashing in highly corrosive
21 environment - Special coating
22
23 a. Tnemec
24 1st Coat: Tnemec Series 435 Perma-Shield H2S (30 mils D.F.T.)
25
26 b. Carboline
27 1 Coat: Plasite 4500S (35.0-40.0 mils D.F.T.)
28
29 c. PPG/HPC/Polyspec
30 1st Coat:
31 2nd Coat:
32
33 22. Secondary Containment Concrete 12.5% Sodium Hypochlorite
34
35 a. Tnemec
36 1st Coat: Tnemec Series 61-5002 Tenemeliner (8.0-10.0 mils
37 D.F.T.)
38 2nd Coat: Tnemec Series 61-5001 Tenemeliner (8.0-10.0 mils
39 D.F.T.)
40
41 b. Carboline
42 1st Coat: Semstone 800 primer
43 Finish Coats: Semstone 870
44 (reference Semstone 870 application spec for installation details)
45 c. PPG/HPC/Polyspec
46 1st Coat:
47
PAINTING
09900-11
03/22/2019
1 23. Buried Pipe Appurtenances (Coal Tar Epoxy / Bitumastic Coating)
2
3 a. Tnemec
4 1st Coat Tnemec Series 46H-413 Tneme-Tar (14.0-20.0 mils
5 D.F.T)
6 2nd Coat Tnemec Series 46H-413 Tneme-Tar (14.0-20.0 mils
7 D.F.T)
8
9 b. Carboline
10 1st Coat Carboline Bitumastic 300M (14.0-20.0 mils D.F.T)
11 2nd Coat Carboline Bitumastic 300M (14.0-20.0 mils D.F.T)
12
13 C. Any surfaces not specifically named in the Schedule and not specifically
14 excepted shall be prepared, primed and painted in the manner and with
15 materials consistent with these Specifications. The Engineer shall select which
16 of the manufacturer's products, whether the type is indicated herein or not, shall
17 be used for such unnamed surfaces. No extra payment shall be made for this
18 painting.
19
20 2.03 COLOR CODING FOR PIPES AND EQUIPMENT
21
22 A. Color coding shall consist of color code painting and identification of all exposed
23 conduits, trough items and pipelines for the transport of gases, liquid and semi -
24 liquids including all accessories such as valves, insulated pipe coverings,
25 fittings, junction boxes, bus bars, connectors and all operating accessories
26 which are integral to be whole functional mechanical pipe and electrical conduit
27 system. Colors shall be as noted in the Paint and Color Coding Schedules
28 attached at the end of this Section.
29
30 B. All hangers and pipe support floor stands shall be painted the same color and
31 with the same paint as the pipe it supports. The system shall be painted up to,
32 but not including, the flanges attached to the mechanical equipment nor the
33 flexible conduit connected to electrical motors. When more than one pipe
34 system is supported on the same bracket, the bracket shall be painted the same
35 color as the adjacent wall or ceiling. Colors shall be as noted in the Paint and
36 Color Coding Schedule.
37
38 C. All systems which are an integral part of the equipment, that is originating from
39 the equipment and returning to the same piece of equipment, shall be painted
40 between and up to, but not including, the fixed flanges or connections on the
41 equipment.
42
43 2.04 LETTERING OF TITLES
44
45 A. Each pipe system shall be labeled with the name of the materials in each
46 pipeline and alongside this an arrow indicating the direction of flow of liquids.
PAINTING
09900-12 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 Titles shall read as shown in the attached schedule or as directed by the
2 Engineer. Titles shall not be located more than twenty (20) linear feet apart and
3 shall also appear directly adjacent to each side of any wall the pipeline
4 breaches, adjacent to each side of the valve regulator, check, strainer clean -
5 out, and all pieces of equipment.
6
7 B. Titles shall identify the contents by complete name. Identification title locations
8 shall be determined by the Engineer but, in general, they shall be placed where
9 the view is unobstructed and on the two lower quarters of pipe or covering where
10 they are overhead. Title should be clearly visible from operating positions
11 especially those adjacent to control valves.
12
13 C. Titles on equipment shall be applied at eye level on machines, where possible,
14 or at the uppermost broad vertical surface of low equipment. Where more than
15 one piece of the equipment item to be titled exists, the items shall be numbered
16 consecutively, as indicated on the mechanical drawings, or as directed by the
17 Engineer; for example Pump No. 1, Pump No. 2, etc. Titles shall be composed
18 and justified on the left hand side as follows: Pump No. 1.
19
20 D. Application of titles.
21
22 1. The color of the titles shall be black or white, as approved, to best
23 contrast with the color of the pipes and equipment and shall be stencil
24 applied.
25
26 2. Stencil text is to be in ALL CAPS worded exactly as shown in the
27 Schedule or as directed. Titles are to be printed in a single line.
28
29 3. Letter sizes.
30
31 Outside Diameter
32 of Pipe or Size of Legend
33 Covering (inches) Letters (inches)
34
35 3/4 to 1-1/4 1/2
36 1-1/2 to 2 3/4
37 2-1/2to6 1-1/4
38 8 to 10 2-1/2
39 More than 10 3-1/2
40
41 Equipment titles are to be two inches high.
42
43 4. Arrow sizes. Where "a" is equal to 3/4 of outside diameter of pipe or
44 covering, the arrow shaft shall be 2 "a" long by 3/8 "a" wide. The arrow
45 head shall be an equilateral triangle with sides equal to "a." Maximum
46 "a" dimension shall be 6 inches.
PAINTING
09900-13
03/22/2019
1
2 5. When using direction arrows, point arrowhead away from pipe markers
3 and in direction of flow. If flow can be in both directions, use a
4 double -headed directional flow.
5
6 2.05 FABRICATED EQUIPMENT
7
8 A. Unless otherwise indicated, all fabricated equipment shall be shop primed and
9 shop or field finished.
10
11 B. All items to be shop primed shall be thoroughly cleaned of all loose material
12 prior to priming. If, in the opinion of the Engineer, any prime coating shall have
13 been improperly applied or if material contrary to these Specifications shall have
14 been used, that coating shall be removed by sandblasting to white metal and
15 re -primed in accordance with these Specifications.
16
17 C. All shop prime coats shall be of the correct materials and applied in accordance
18 with these Specifications. Remove any prime coats not in accordance with these
19 Specifications by sandblasting and apply the specified prime coat at no
20 additional cost to the Owner.
21
22 D. Shop primed surfaces shall be cleaned thoroughly and damaged or bare spots
23 retouched with the specified primer before the application of successive paint
24 coats in the field.
25
26 E. Be responsible for and take whatever steps are necessary to properly protect
27 the shop prime and finish coats against damage from weather or any other
28 cause.
29
30 F. A shop finish coat shall be equal in appearance and protection quality to a field
31 applied finish coat. If, in the opinion of the Engineer, a shop finish coat does
32 not give the appearance and protection quality of other work of similar nature,
33 prepare the surfaces and apply the coat or coats of paint, as directed by the
34 Engineer, to accomplish the desired appearance and protection quality. Submit
35 to the Engineer substantial evidence that the standard finish is compatible with
36 the specified finish coat.
37
38 G. Wherever fabricated equipment is required to be sandblasted, protect all
39 motors, drives, bearings, gears, etc., from the entry of grit. Any equipment found
40 to contain grit shall be promptly and thoroughly cleaned.
41
42 PART 3 - EXECUTION
43
44 3.01 PREPARATION OF SURFACES
45
PAINTING
09900-14
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. All surfaces to be painted shall be prepared, as specified herein or in Section
2 09865, and shall be dry and clean before painting. Special care shall be given
3 to thoroughly clean interior concrete and concrete block surfaces of all marks
4 before application of finish.
5
6 B. All metal welds, blisters, etc., shall be ground and sanded smooth in accordance
7 with SSPC-SP-3 or in difficult and otherwise inaccessible areas by hand
8 cleaning in accordance with SSPC-SP-2. All pits and dents shall be filled and
9 all imperfections shall be corrected so as to provide a smooth surface for
10 painting. All rust, loose scale, oil, grease and dirt shall be removed by use of
11 approved solvents, wire brushing or sanding.
12
13 C. Concrete surfaces shall have been finished, as specified in Division 3. Report
14 unsatisfactory surfaces to the Engineer. Concrete shall be free of dust, oil,
15 curing compounds, and other foreign matter. Concrete surfaces should have
16 any laitance or weak layers removed prior to install of coatings or linings using
17 captive shot blasting systems. Concrete shall have a minimum surface tensile
18 strength of at least 300 PSI per ASTM D-4541 standard. Testing is required to
19 confirm this strength using ASTM D-4541 standard and methods. Surface
20 profile shall be CSP -3 to CSP -6 meeting ICRI (International Concrete Repair
21 Institute) standard guideline #03732 for Coating, Concrete, producing an anchor
22 profile equal to 60 -grit sandpaper or coarser. Prepare concrete surfaces by
23 mechanical (captive shot blast) means to achieve this desired profile. Moisture
24 Vapor Transmission should be 3 pounds or less per 1,000 square feet over 24
25 hour timeframe as confirmed through a calcium chloride test as per ASTM E-
26 1907. Quantitative relative humidity (RH) testing, ASTM F-2170, should confirm
27 concrete RH results < 75%. Application of coatings and linings should be made
28 when out gassing of concrete is declining during periods when surface
29 temperatures of the concrete is falling. Use of a surface thermometer to
30 determine when surface temperatures are falling is required. When in doubt,
31 double priming may be required. All surface irregularities, cracks, expansion
32 joints and control joints should be properly addressed prior to application of
33 coatings and linings. Remove all contaminates and contaminated surface
34 layers prior to application of coatings and linings.
35
36 D. Concrete block surface shall be smooth and cleaned of all dust, efflorescence,
37 chalk, loose mortar, dirt, grease, oil, tar and other foreign matter.
38
39 E. All plastic pipe surfaces shall be lightly sanded before painting.
40
41 F Wood surfaces shall be dry. Sand to obtain a smooth surface. All encrustations
42 shall be removed.
43
44 G. Exposed Pipe: Bituminous coated pipe shall not be used in exposed locations.
45 Pipe which shall be exposed after project completion shall be primed in
46 accordance with the requirements herein. Any bituminous coated pipe which is
PAINTING
09900-15 03/22/2019
1 inadvertently installed in exposed locations shall be sandblasted clean before
2 priming and painting. After installation all exterior, exposed flanged joints shall
3 have the gap between adjoining flanges sealed with a single component
4 polysulfide sealant to prevent rust stains.
5
6 H. Primed or Previously Painted Surfaces and Nonferrous Surfaces: All coated
7 surfaces shall be cleaned prior to application of successive coats. All
8 nonferrous metals not to be coated shall be cleaned. This cleaning shall be done
9 in accordance with SSPC-SP-1, Solvent Cleaning.
10
11 I. Shop -Finished Surfaces: All shop -coated surfaces shall be protected from
12 damage and corrosion before and after installation by treating damaged areas
13 immediately upon detection. Abraded or corroded spots on shop -coated
14 surfaces shall be "Hand Cleaned" and then touched up with the same materials
15 as the shop coat. All shop coated surfaces which are faded, discolored, or
16 which require more than minor touch-up, in the opinion of the Engineer, shall
17 receive new surface preparation before being repainted. Cut edges of
18 galvanized sheets and exposed threads, and cut ends of galvanized piping,
19 electrical conduit and metal pipe sleeves, that are not to be finished painted,
20 shall be "Solvent Cleaned" and primed with zinc dust -zinc oxide metal primer.
21
22 J Galvanized and Zinc -Copper Alloy Surfaces: These surfaces to be painted shall
23 be "Solvent Cleaned" and treated as hereinafter specified. Such surfaces not
24 to be painted shall be "Solvent Cleaned." (Carboline recommends brush off
25 blasting per SSPC-SP7 of galvanized surfaces to insure optimum coating
26 adhesion).
27
28 K. Aluminum embedded or in contact with concrete must be painted with one shop
29 coat of zinc chromate followed by one heavy coat of aluminum pigmented
30 asphalt paint. (Carboline recommends brush off blasting per SSPC-SP7 of
31 galvanized surfaces to insure optimum coating adhesion).
32
33 3.02 WORKMANSHIP
34
35 A. General:
36
37 1. Primer (spot) and paint used for a particular surface shall, in general, be
38 as scheduled for that type of new surface. Confirm with the paint
39 manufacturer that the paint proposed for a particular repaint condition will
40 be compatible with the existing painted surface. Sample repainted areas
41 on the actual site will be required to insure this compatibility. Finished
42 repainted areas shall be covered by the same guarantee specified for
43 remainder of work.
44
45 2. At the request of the Engineer, samples of the finished work prepared in
46 strict accordance with these Specifications shall be furnished and all
PAINTING
09900-16 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 painting shall be equal in quality to the approved samples. Finished
2 areas shall be adequate for the purpose of determining the quality of
3 workmanship. Experimentation with color tints shall be furnished to the
4 satisfaction of the Engineer where standard chart colors are not
5 satisfactory.
6
7 3. Protection of furniture and other movable objects, equipment, fittings and
8 accessories shall be provided throughout the painting operations.
9 Canopies of lighting fixtures shall be loosened and removed from contact
10 with surface, covered and protected and reset upon completion. Remove
11 all electric plates, surface hardware, etc., before painting, protect and
12 replace when completed. Mask all machinery name plates and all
13 machined parts not receiving a paint finish. Dripped or spattered paint
14 shall be promptly removed. Lay drop cloths in all areas where painting
15 is being done to adequately protect flooring and other work from all
16 damage during the operation and until the finished job is accepted.
17
18 4. On metal surfaces apply each coat of paint at the rate specified by the
19 manufacturer to achieve the minimum dry mil thickness required. If
20 material has thickened or must be diluted for application by spray gun,
21 the coating shall be built up to the same film thickness achieved with
22 undiluted material. One gallon of paint as originally furnished by the
23 manufacturer shall not cover a greater area when applied by spray gun
24 than when applied unthinned by brush. Deficiencies in film thickness
25 shall be corrected by the application of an additional coat(s). On
26 masonry, application rates will vary according to surface texture,
27 however, in no case shall the manufacturer's stated coverage rate be
28 exceeded. On porous surfaces, it shall be the painter's responsibility to
29 achieve a protective and decorative finish either by decreasing the
30 coverage rate or by applying additional coats of paint.
31
32 5. Paints shall be mixed in proper containers of adequate capacity. All
33 paints shall be thoroughly stirred before use and shall be kept stirred
34 while using. No unauthorized thinners or other materials shall be added
35 to any paint.
36
37 6. Only skilled painters shall be used on the work and specialists shall be
38 employed where required.
39
40 B. Field Priming:
41
42 1. Steel members, metal castings, mechanical and electrical equipment and
43 other metals which are shop primed before delivery at the site will not
44 require a prime coat on the job. All piping and other bare metals to be
45 painted shall receive one coat of primer before exposure to the weather,
PAINTING
09900-17
03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
and this prime coat shall be the first coat as specified in the painting
schedule.
2. Equipment which is customarily shipped with a baked -on enamel finish
or with a standard factory finish shall normally be field painted unless the
prefinished equipment is specifically color selected and unless the finish
has not been damaged in transit or during installation. Surfaces that
have been shop painted and have been damaged, or where the shop
coats or coats of paint have deteriorated, shall be properly cleaned and
retouched before any successive painting is done on them in the field.
All such field painting shall match as nearly as possible the original finish.
C. Field Painting:
1. All painting at the site shall be designated as Field Painting.
2. All paint shall be at room temperature before applying, and no painting
shall be done when the temperature is below 50°F, in dust -laden air,
when rain or snow is falling, or until all traces of moisture have completely
disappeared from the surface to be painted.
3. Successive coats of paint shall be tinted so as to make each coat easily
distinguishable from each other with the final undercoat tinted to the
approximate shade of the finished coat.
4. Finish surfaces shall not show brush marks or other irregularities.
Undercoats shall be thoroughly and uniformly sanded with No. 00
sandpaper or equal to remove defects and provide a smooth even
surface. Top and bottom edges of doors shall be painted and all exterior
trim shall be back -primed before installation.
5. Painting shall be continuous and shall be accomplished in an orderly
manner so as to facilitate inspection. All exterior concrete and masonry
paint shall be performed at one continuous manner structure by
structure. Materials subject to weathering shall be prime coated as
quickly as possible. Surfaces of exposed members that will be
inaccessible after erection shall be cleaned and painted before erection.
6. All materials shall be brush painted unless spray painting is specifically
approved by the Engineer. The Contractor shall be responsible for all
damage caused by overspray or drifting.
7. All surfaces to be painted, as well as the atmosphere in which painting is
to be done, shall be kept warm and dry by heating and ventilation, if
necessary, until each coat of paint has hardened. Any defective paint
PAINTING
09900-18
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 shall be scraped off and repainted in accordance with the Engineer's
2 directions.
3
4 8. Before final acceptance of the work, all damaged surfaces of paint shall
5 be cleaned and repainted as directed by the Engineer.
6
7 9. Any pipe scheduled to be painted and having received a coating of a tar
8 or asphalt -compound shall be painted with two coats of PPG/HPC PITT -
9 GUARD® Epoxy Penetrating Sealer 95-2328 or equal before successive
10 coats are applied per the schedule. Tnemec recommends using 66
11 Hi -Build Epoxoline over tar, but a test patch must be run initially to test
12 the paint's compatibility with the tar. Carboline does not recommend
13 application of their coatings over tar. Instead, Carboline recommends
14 removal of the tar followed by the application of suitable coatings based
15 on the substrate and intended service application.
16
17 3.03 CLEANUP
18
19 A. The premises shall at all times be kept free from accumulation of waste material
20 and rubbish caused by employees or work. At the completion of the painting
21 remove all tools, scaffolding, surplus materials, and all rubbish from and about
22 the buildings and leave work "broom clean" unless more exactly specified.
23
24 B. Upon completion, remove all paint where it has been spilled, splashed or
25 splattered on all surfaces, including floors, fixtures, equipment, furniture, etc.,
26 leaving the work ready for inspection.
27
28 C. All cloths and waste that might constitute a fire hazard shall be placed in closed
29 metal containers or destroyed at the end of each day. Upon completion of the
30 work, the entire job left clean and acceptable to the Engineer.
31
32 3.04 INSPECTION, TESTING EQUIPMENT & PROCEDURES
33
34 A. Inspection
35
36 1. All phases of the work are subject to inspection by the Engineer to assure
37 proper performance and compliance with the specifications.
38
39 2. The Engineer shall be advised of the proper time to inspect surface
40 preparation, prime coat and each succeeding coat. The Contractor shall
41 apply additional coats only after the previous coat has been approved by
42 the Engineer or owner's representative.
43
44 B. Testing
45 1. The Contractor shall have on the project site the following testing
46 equipment. Equipment shall be in calibration and proper working order.
PAINTING
09900-19 03/22/2019
1 Equipment shall be used in accordance with the manufacturers'
2 instructions or as directed by the Engineer.
3
4 A. Sling Psychrometer: Relative humidity and dew point readings
5 shall be taken at intervals throughout each work day. Readings
6 shall be taken at the start of the mornings work, mid-day and
7 afternoon. Should environmental conditions change, additional
8 reading shall be taken to assure that coatings are being applied
9 under the conditions as outlined by the coatings manufacturer.
10
11 B. Surface Temperature Thermometer: Surface temperatures shall
12 be taken in areas where work is being performed. Surface
13 temperature shall be that as specified by the coatings
14 manufacturer.
15
16 C. Replica Tape & Micrometer: Testex X -Course Replica Tape shall
17 be employed to determine the surface profile of blasted surfaces.
18 Surface profile shall be as specified.
19
20 D. Dry Film Thickness Measurements: Dry film thickness reading
21 shall be taken with a properly calibrated (per the manufacturer's
22 instructions) Type 1 (magnetic) or Type 2 (electromagnetic)
23 instrument. Dry film thickness reading will be taken and recorded
24 in the in a frequency and manner as dictated by the Engineer.
25
26 E. Holiday Detection: After completion of immersion coating systems
27 on steel surfaces, all surfaces shall be holiday detected in
28 accordance with ASTM G 62 low voltage holiday detection.
29 Holiday detector shall be a Tinker & Rasor Model M-1 or equal.
30 Areas found to have holidays shall be marked and repaired in
31 accordance with the paint manufacturer's instructions. The
32 Engineer shall be notified of time of testing so that he might be
33 present to witness testing. The Contractor shall provide ladders,
34 rigging, etc. as necessary to allow the Engineer to spot check
35 paint thickness of each coat.
36 3.05 PAINT
37
38 A. General Notes & Guidelines:
39
40 1. All color numbers and names herein refer to master color card. Colors
41 of specified equal manufacturers may be substituted with approval of the
42 Engineer.
43 2. Pipe lines, equipment, or other items which are not listed here shall be
44 assigned a color by the Engineer and shall be treated as an integral part
45 of the Contract.
46
PAINTING
09900-20
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 3. When color coding is specified or directed by the Engineer, it shall consist
2 of color code painting and identification of all exposed conduits, through
3 lines and pipelines for the transport of gases, liquids or semi -liquids,
4 including all accessories such as valves, insulated pipe coverings,
5 fittings, junction boxes, bus bars, connectors and any operating
6 accessories which are integral to a whole functional mechanical pipe and
7 electrical conduit systems.
8
9 4. The colors of the Finish Schedule shall be interpreted as follows:
10
11 COLORS TNEMEC # COLORS TNEMEC #
12 White 11 WH Tank Blue 25BL
13 Ivory 01 BR Blue 11 SF
14 Red 06SF D. Blue 78BL
15 L. Green 52GN L. Blue 26BL
16 Green 09SF Aqua 10GN
17 D. Green 08SF
18
19 COLORS TNEMEC # COLORS TNEMEC #
20 L. Brown 06BR Inter. Orange 05SF
21 Brown 84BR Orange 04SF
22 Bronze 86BR Tan 04BR
23 L. Gray 31 GR Yellow 03SF
24 M. Gray 33GR Safety Yellow 02SF
25 D. Gray 34GR
26
27 5. All moving parts, drive assemblies, and covers for moving parts that are
28 potential hazards, shall be Safety Orange 04SF
29
30 6. All safety equipment shall be painted in accordance with OSHA
31 standards.
32
33 7. All in line equipment and appurtenances not assigned another color shall
34 be painted the same base color as the piping. The pipe system shall be
35 painted with the pipe color up to, but not including, the flanges attached
36 to pumps and mechanical equipment assigned another color. Tanks
37 shall be painted the color of the piping system that they serve, unless the
38 tank is fiberglass or polyethylene.
39
40 8. All conduit shall be painted to match its background surface.
41
42 9. Building surface colors shall be painted, as scheduled in the Finish
43 Schedule, or as selected by the Engineer.
44
45 10. Control panels shall be factory finished.
46
PAINTING
09900-21
03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
3.06 GUARANTEE AND ANNIVERSARY INSPECTION
A. All work shall be warranted for a period of one year from date of acceptance of
the project.
B. The Owner will notify the Contractor at least 30 days prior to the anniversary
date and shall establish a date for the inspection. Any defects in the coating
system shall be repaired by the Contractor at no additional cost to the Owner.
Should a failure occur to 25% of the painted surface, either interior or exterior,
the entire surface shall be cleaned and painted in accordance with these
specifications.
3.07 PAINT AND COLOR CODING SCHEDULE
Piping and Legend
Backwash Waste
Blower Air
Coagulant
Compressed Air
Drains
Fuel
Potable Water
Process Sample
Reclaimed Effluent
Return Activated Sludge
Sodium Hypochlorite
Sprinkler
Thickened Sludge
Wastewater
Waste Activated Sludge
Color
Light Brown
Green
Aqua
Dark Green Red
Black
Red
Dark Blue
Light Grey Red
Pantone Purple 522C
Brown
Yellow
Red
Dark Brown
Dark Gray
White
Bands
Orange
White
Equipment and Building
Exterior Equipment, Valves, Gates, Fans
Interior Equipment and Pumps
Structural Steel (Interior)
Ceiling
Cranes and Hoists
Ductwork
Interior Air Handling and Ventilation Equipment
Valve and Gate Operators
Electrical Conduit and Junction Boxes
Submerged Concrete
PAINTING
09900-22
Orange
Color
Match System
Match System
White
White
Yellow
Match Surface
Match Surface
Match System
Match Surface
Black
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 3.08 PAINT SCHEDULE
2
3 The following areas of the plant shall be coated. Those areas without a special note
4 shall be coated in accordance with the standard coating systems specified above.
5
6 1. All above ground ductile iron piping systems
7 2. Miscellaneous Steel
8 3. Stainless Steel, PVC, and galvanized steel shall not be painted
9 4. Aluminum shall not be painted except where it is contact with concrete.
10 5. All ductile iron pipe in the headworks building shall be considered metals
11 submerged or subject to splashing in highly Corrosive Environment and shall
12 use a Special Coating per Section 2.02 B. 21.
13 6. All other above ground ductile iron piping shall be considered subject to
14 splashing and shall be coated in accordance with Section 2.02 B. 6. Ferrous
15 metals submerged or subject to splashing.
16
17
18 END OF SECTION
19
PAINTING
09900-23
03/22/2019
1 THIS PAGE INTENTIONALLY LEFT BLANK
PAINTING
09900-24
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11203
2
3 WATER CONTROL GATES
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required to install all
10 water control slide gates, weir gates and appurtenances as shown on the
11 Drawings or as specified herein.
12
13 B. These Specifications are intended to give a general description of what is
14 required, but do not cover all details, which will vary in accordance with the
15 requirements of the equipment as offered. It is, however, intended to cover the
16 furnishing, the shop testing, the delivery and complete installation and field
17 testing, of all materials, equipment and appurtenances for the unit as herein
18 specified, whether specifically mentioned in these Specifications or not.
19
20 C. For these units, there shall be furnished and installed all specified and
21 necessary equipment and appurtenances for a complete and fully functional
22 installation in accordance with these plans and specifications, including field
23 testing of the entire installation and instructing the regular operating personnel
24 in the care, operation and maintenance of all equipment.
25
26 1.02 QUALIFICATIONS
27
28 A. The gates specified under this Section shall be furnished by a manufacturer,
29 who is fully experienced, reputable, and qualified in the manufacture of the
30 equipment furnished. The gates and all related equipment shall be designed,
31 constructed and installed with the best practices and methods.
32
33 B. Manufacturer shall have installations functioning for at least ten (10) years.
34
35 C. Gates, weir gates, and stop logs shall be as manufactured by Ashbrook Simon
36 Hartley, Rodney Hunt, Fontaine, or approved equal.
37
38 1.03 SUBMITTALS
39
40 A. Materials and Shop Drawings:
41
42 1. Copies of all materials required to establish compliance with the
43 specifications shall be submitted to the Engineer. Submittals shall
44 include the following:
45
46 a. Certified shop and erection drawings and data regarding slide
47 gates.
WATER CONTROL GATES
11203-1 03/22/2019
1 b. Literature on drawings describing the equipment and showing all
2 important details of construction and dimensions.
3
4 c. Manufacturers recommended method for anchoring gates.
5
6
7 B. The Manufacturer shall provide installation instructions. The installation and
8 adjustment of gates, operators and all accessories shall be in full accordance
9 with these instructions. All gates shall be installed by the best practices and
10 methods.
11
12 C. Manufacturer shall submit drawings and comprehensive design criteria to
13 substantiate that the required deflection figure for each gate has been achieved.
14 Comprehensive safety factor calculations shall include bending moments,
15 buckling stress, and bonding stress with thermal expansion factors suitable for
16 reference in NASA CR -1457, "Manual for Plates and Shells," et al. Safety
17 factors shall be calculated for the disc under maximum head, and shear at the
18 disc/seal interface.
19
20 D. Manufacturer shall submit affidavit of compliance that gates meet Standard
21 AWWA C 563 or C 561 of the latest revision.
22
23 E. Manufacturer shall submit contact information for ten facilities with a similar or
24 identical product to the project site.
25
26 F Operating and maintenance instructions shall be furnished to the Engineer in
27 accordance with Section 01730.
28
29 1.04 TOOLS AND SPARE PARTS
30
31 A. Special tools, if required for normal operation and maintenance, shall be
32 furnished with the equipment by the manufacturer.
33
34 1.05 PATENTS AND LICENSES
35
36 A. The equipment Manufacturer shall be responsible for all patents or licenses that
37 exist because of the equipment that may be provided.
38
39 B. The Manufacturer shall assume all costs of patent fees or licenses for the
40 equipment or process, and shall safeguard and save harmless the Owner from
41 all damages, judgments, claims and expenses arising from license fees, or
42 claimed infringement of any letters, patent or patent rights, or fees for the use
43 of any equipment or process, structural feature or arrangement of any of the
44 component parts of the installation, and the price bid shall be deemed to include
45 payment of all such patent fees, licenses or other costs pertaining thereto.
46
47 1.06 WARRANTY AND GUARANTEE
WATER CONTROL GATES
11203-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 A. The Manufacturer shall guarantee the gates, when installed and operated as
3 recommended by the Manufacturer with a documented maintenance program,
4 trouble-free operation for a period of ten (10) years. The Manufacturer shall
5 guarantee the following:
6
7 1. Leakage shall be no more than that allowed by the AWWA C561 or C563
8 Standards.
9
10 2. Door (disc) shall be free of sticking or binding (move freely via operator
11 provided) and frame members will not deflect with 2.0 times the
12 recommended force on the operating mechanism. Gate operators shall
13 be warranted by the operator manufacturer.
14
15 1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING:
16
17 A. All equipment shall be delivered in suitable packaging, cases, or crates and
18 stored or placed in an appropriate manner to prevent damage to gate and
19 appurtenances. Each package shall have an identifying mark and a complete
20 list showing contents.
21
22 PART 2 — PRODUCTS
23
24 2.01 SLIDE GATES AND WEIR GATES
25
26 A. The slide gates shall be furnished at the locations shown on the Drawings with
27 sizes, as specified in the Gate Schedule and as shown on the Drawings. All
28 gates shall have a pipe cover with position markings over every operating stem.
29 Stem guides shall be 316 or 316L stainless steel located as required by the
30 manufacturer.
31
32 B. The frames shall be 316 or 316L stainless steel. The frames shall be of ample
33 length to completely support the disc in the open position. All frames shall have
34 a member across the top for support that shall not deflect at 2.0 times the
35 recommended force on the operating mechanism. Mounting angles are to be
36 continuous along the length of the frame; mounting tabs will not be acceptable.
37
38 C. The sealing arrangement shall be comprised of sealing faces and side guides
39 constructed of ultrahigh molecular weight polyolefin having an extremely low
40 coefficient of friction with backing constructed of highly resilient expanded
41 neoprene or EPDM. Guides and seating of the gate shall be easily adjustable
42 (min. 5/8 -inch). All moving contact surfaces shall be incompatible to each other
43 in order to minimize sticking / jamming, facilitating operation.
44
45 D. Slide (Disc) shall be constructed of reinforced rigid composite plastic material
46 or 316 stainless steel, having a minimum thickness of 1/8 -inch. Slide (disc) shall
47 have an internal matrix of carbon steel of suitable strength for the specified
WATER CONTROL GATES
11203-3 03/22/2019
1 service. The slide (disc) outer surface skins shall be a homogeneous plastic
2 material having extremely high tensile and impact strength, be nontoxic and
3 shall be stabilized against ultraviolet Tight. The composite material shall be an
4 Aramid fiber from the KEVLAR family of fibers, and shall have the following
5 minimum properties and shall be designed to limit the deflection to a maximum
6 of 1/1000 of the span under design head conditions based upon horizontal
7 support members only. Manufacturer shall submit drawings and
8 comprehensive design criteria to substantiate that the required deflection figure
9 for each door has been achieved. Comprehensive safety factor calculations
10 shall include bending moments, buckling stress, and bonding stress with
11 thermal expansion factors suitable for reference in NASA CR -1457, "Manual for
12 Plates and Shells", et al. Safety factors shall be calculated for the disc under
13 maximum head, and shear at the disc/seal interface. No substitute of fiber type
14 will be acceptable. Glass fiber is not acceptable.
15
16 E. The stems shall be manufactured from stainless steel Type 304 with a minimum
17 diameter of 1 1/4".Stems shall be of ample gross section to prevent distortion
18 and shall have stub acme threads. Stems shall be designed to withstand tensile
19 and comprehensive loads that occur under maximum operating conditions.
20 Design for compressive loading shall meet AISC code where K-1 with a
21 minimum safety factor of 2 to 1. The stems shall not deflect at 2.0 times the
22 recommended force on the operating mechanism. Stems shall be cold rolled
23 with a double start stub acme thread with a finish of 32 mic or less. Stem shall
24 be fixed to the disc by a threaded and keyed assembly into a lifting nut, attached
25 to the disc in a lifting bracket that is bolted to the disc.
26
27 F. At the design seating head and under normal conditions, the leakage rate of the
28 gates shall not exceed 0.1 gallons per minute per foot of seating perimeter. At
29 the design unseating head and under normal conditions, the leakage rate of the
30 gates shall not exceed 0.2 gallons per minute per foot of seating perimeter.
31
32 G. Stem Covers
33
34 Rising stem gates shall be provided with clear plastic stem covers to facilitate
35 indication of gate position, permit inspection of the stem threads, and to protect
36 the stem from contamination. Vent holes shall be provided to prevent
37 condensation.
38
39 H. Operator
40
41 The benchstand hoists shall be sized to permit operation of the gate under the
42 full operating head with a maximum effort of 40 pounds on the crank or
43 handwheel. The hoist nut shall be manganese bronze conforming to ASTM
44 B584 C86500. The hoist nut shall be supported on roller bearings. A lubrication
45 fitting shall be provided for lubrication of hoist bearings without disassembly of
46 the hoist. Suitable seals shall be provided to prevent entry of foreign matter.
47 The direction of handwheel or crank rotation to open the gate shall be clearly
48 and permanently marked on the hoist.
WATER CONTROL GATES
11203-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 I. Motor -Operated Actuators
3
4 1. Motor -Operated actuators shall include the electric motor, reduction
5 gearing, valve stem drive nut/bushing, position sensor, overload torque
6 sensor, ductile iron gear case, automatic declutchable handwheel, local
7 control & mechanical position indication, and remote control & position
8 indication. All actuators shall be designed for severe duty use in a
9 corrosive environment contaminated with ammonia and hydrogen sulfide
10 gas.
11
12 2. Motors shall be totally enclosed, non -ventilated 480 volt, 3 phase and
13 specifically designed for high torque, low inertia duty and for a corrosive
14 atmosphere. Motors for actuators shall also be specifically designed and
15 rated for 15 -minute duty operation at 104°F (40°C). Output capacity shall
16 be sufficient to open or close the valve against the maximum differential
17 pressure when the voltage is 10% above or below normal at the specified
18 service conditions. Motors shall have Class F insulation. Motors must be
19 protected by 3 thermal contacts, which are embedded in the motor
20 windings. The actuator shall be suitable for up to 60 starts per hour for
21 open/close service and 1200 starts per hour for modulating service.
22
23 3. The actuators shall be suitable for use on nominal 3 phase power supply
24 and must include motor, integral reversing starters, local controls and
25 terminals for remote control and indication housed within a self -
26 contained, sealed enclosure. The actuator gearing shall be totally
27 enclosed in a lubricant filled cast iron gearcase suitable for operation in
28 any orientation. Non-metallic gearing is not acceptable. For rising stem
29 valves the output shaft shall be hollow to accept a rising stem, and
30 incorporate thrust bearings of the roller type at the base of the actuator.
31 All gearing and bearings shall be oil or grease lubricated and suitable for
32 year-round service based on prevailing ambient temperature conditions.
33
34 4. The actuator shall be furnished with a handwheel with a maximum rim
35 pull requirement of 40 pounds for valve travel loads. An external manual
36 declutch lever shall be included to place actuator in the manual mode.
37 The lever shall not require more than 10 pounds of force to engage even
38 when the valve has been tightly seated. The lever is to be padlockable
39 in either handwheel or motor mode. Operation by motor shall not cause
40 the handwheel to rotate, or operation of the handwheel shall not cause
41 the motor to rotate. Handwheel shall operate in the clockwise direction
42 to close.
43
44 5. Two nameplates, made of stainless steel, shall be attached to each
45 actuator; one on the motor housing, showing all relevant motor data, one
46 on the actuator housing showing all relevant actuator data. Special
47 information, such as the valve tag no., shall be shown if required. The
WATER CONTROL GATES
11203-5 03/22/2019
1 nameplates shall be securely fixed to the actuator and motor, so that they
2 cannot be removed or scratched off during shipment, installation,
3 operation or maintenance.
4
5 6. The rated output torque of the motor actuator shall be at least 1.5 times
6 the maximum torque required to open or close the valve at any position
7 including seating and unseating conditions when subjected to the most
8 severe operating condition including any mechanical friction and/or other
9 restrictive conditions that are inherent in the valve assembly. Do not
10 include hammer -blow effect in sizing the actuator to comply with this
11 torque requirement. Valve manufacturer is responsible to assure that the
12 motor actuator stall torque output does not exceed the torque limits of
13 the valve operating stem or shaft. Maximum torque shall include seating
14 or unseating torque, bearing torque, dynamic torque, and hydrostatic
15 torque. Assume that the differential pressure across the valve is equal to
16 the pressure or head rating of the valve.
17
18 7 Actuator housings, supports, and connections to the valve shall have a
19 minimum safety factor of five based on the ultimate strength or three
20 based on the yield strength of the material used. Actuators shall be 0-
21 ring sealed, watertight to NEMA 4/6 (6 feet for 30 minutes). All external
22 fasteners shall be of stainless steel. Gear case shall be cast iron.
23
24 8. Torque switch bypass to be provided for the torque sensing system to
25 inhibit torque switch trip during unseating or during starting in mid -travel
26 against high inertia loads. Manual operation shall be by handwheel.
27 Manual operation shall be via power gearing to minimize required rimpull
28 and facilitate easy changeover from motor to manual operation when the
29 actuator is under load. A seized or inoperable motor shall not prevent
30 manual operation.
31
32 9. Test each actuator prior to shipment in accordance with AWWA C540.
33 The application torque shall be the maximum torque required to open or
34 close the valve at any position including seating and unseating
35 conditions.
36
37 10. For all actuators that are installed greater than five (5) feet above the
38 finished floor surface, the actuator manufacturer shall furnish for
39 installation by the Contractor a remote control unit, such that the operator
40 is able to manually control the actuator while standing on floor grade.
41 The remote control unit shall be hardwired to the actuator and be
42 equipped with all the controls/functionality as on the face of the actuator.
43 Remote controllers shall be mounted between 3 feet and 5 feet from the
44 nearest operator accessible floor surface.
45
46 11. The operator face plate shall include as a minimum:
47
WATER CONTROL GATES
11203-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 Buttons for OPEN - STOP — CLOSE — RESET.
2 Backlit LCD display showing the actuator status in plain English text.
3 Lockable selector switch with LOCAL - OFF - REMOTE function.
4 Indication lights for CLOSED, OPEN, RUNNING, and FAULT.
5
6 12. The terminal compartment shall provide sufficient space to
7 accommodate the possible maximum number of incoming wires. A
8 minimum of three cable entries must be provided. Each cable entry shall
9 be properly sealed by cable glands during site installation. The cable
10 glands size shall be chosen by the Contractor, responsible for wiring
11 during the commissioning phase.
12
13 13. Liquid Crystal Display (LCD) — back -lit for setting menu showing status
14 indication and diagnostic information. The actuator shall include a digital
15 position indicator with a display from fully open to fully closed in 1%
16 increments. For all actuators that utilize a battery, the actuator
17 manufacturer shall furnish one (1) spare battery for each actuator
18 furnished.
19
20 14. Setting of all actuator parameters including the torque levels, position
21 limits, configuration of the indication contacts, and positioner functionality
22 shall be accomplished without removing covers from the actuator control
23 assemblies or housing.
24
25 15. Actuators shall be suitable for indoor and outdoor use. The actuator shall
26 be capable of functioning in an ambient temperature ranging from -20 °F
27 to +140°F, up to 100% relative humidity. In order to prevent
28 condensation, a space heater shall be installed inside the actuator,
29 suitable for continuous operation. The actuator shall be stored according
30 to the Manufacturer's instructions. If the Contractor voids the actuator
31 warrantee in any way, he shall replace the actuator at no cost to the
32 Owner.
33
34 16. Actuators are to receive remote input commands for OPEN, CLOSE, and
35 POSITION (as required). Actuators are to provide remote indication as
36 listed above.
37
38 17. Contractor is to provide startup, inspection, and instruction services from
39 the Manufacturer's authorized technical representative. Startup and
40 inspection shall not be less than five (5) days. One (1) day shall be
41 provided for training of plant personnel in operation and maintenance of
42 electric operators.
43
44 18. All electric actuators for this project shall be provided by one
45 Manufacturer. Contractor shall coordinate installation on valves and
46 gates with valve and gate manufacturers. Electric actuators shall be as
47 manufactured by EIM Tec 2000, Auma Matic, Rotork IQ, Limitorque or
WATER CONTROL GATES
11203-7 03/22/2019
1 approved equal.
2
3 19. Each actuator shall be warranted for a minimum of 24 months from the
4 date of system acceptance by the Owner.
5
6 J. Valve/Gate Limit Switches:
7
8 1. Type: Mechanical cam gear for remote operation, indication, and other
9 control; compatible with associated operation and suitable for service
10 intended; for valves/gates specified and indicated on the Drawings; with
11 racks, gears, cam, linkages mountings, and accessories.
12
13 2. Mechanical Limit Switches: 2 -pole, 3 -pole, or 4 -pole, gang -mounted in
14 required multiples, and with necessary mechanical linkage.
15
16 3. Contact Ratings: 120 volt alternating current, 20 amperes at 75 to 100
17 percent power factor, and 24 volt direct current, 5 amperes minimum.
18
19 4. Enclosures: Watertight and oil tight for normal service, Class 1, Division
20 1, Group D for gates located in hazardous locations.
21
22 5. Valve box: Large enough to contain and to allow easy adjustment of limit
23 switch without switch's removal.
24
25 K. Provide a handwheel for manual operation of the motor operator unit. The
26 handwheel shall be integral to the unit and require less than 60 ft -pounds of
27 torque to rotate either open or closed. The handwheel shall be a non -corrosive
28 metal and have arrows to indicate "open" rotation. The stem and the gate frame
29 shall not deflect if 80 ft -pounds or less is applied to the handwheel.
30
31 L. All mounting brackets and mounting hardware shall be stainless steel if exposed
32 to the elements. All operator and motor assembly hardware shall be stainless
33 steel if exposed to the elements.
34
35 M. All necessary attaching bolts and anchor bolts shall be 316 stainless steel and
36 shall be furnished by the slide gate manufacturer.
37
38
39
40
41
42
43
44
WATER CONTROL GATES
11203-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 2.02 GATE SCHEDULE
2
3
4
5
6
7
8
9
10
11
12 Note 2:
13 • Top Concrete Channel = Elev. 67.5
14 • Top of Weir — Up Position = Elev. 67.0 (no flow over weir)
15 • Maximum Upstream Water Elevation = Elev. 67.0
16 • Minimum Upstream Water Elevation = Elev. 62.75
17 • Top of Weir — Down Position = Elev. 62.5
18 • Maximum Downstream Water Elevation = Elev. 67.0
19 • Invert Splitter Box = Elev. 56.17
20
21 PART 3 — EXECUTION
22
23 3.01 INSTALLATION
24
25 A. It shall be the responsibility of the Contractor to handle, store and install the
26 equipment specified in this Section in strict accordance with the Manufacturer's
27 drawings and recommendations. Frames and guides shall be installed in a true
28 vertical plane with 90 -degree corners.
29
30 B. Frames and guides shall be set in place using non -shrink grout as listed in
31 Section 03600 of the Specifications. Gates shall be protected and cleaned from
32 over spray and grout splatter. Contractor shall replace or repair without cost to
Actuator
Type
Width
Height
Frame
Mounting
Operator
Mounting
Num
Req'd
Seating —
Unseating
Static Head
LOCATION
Manual
Slide
Gate
6 ft
6 ft
Channel
Mounted
Frame
Raise to allow
water through
2
6/0 ft
Headworks
Building
Downstream
of Screens
Electric
Weir
Gate
8 ft
Note 1
Channel
Mounted
Frame
Raise to allow
water through
1
4/4 ft
Headworks
Building
Downstream
of Screens
Manual
Weir
Gate
2 ft
Note 2
Face Mounted
Frame Lower
to allow water
to overflow
1
4/0 ft
Scum Well
for Primary
Bldg.
Manually
Install or
Remove
Gate
Stop
Gate
4 ft
Field
Verify
10'-9"
Field
Verify
No Frame -
Existing Slots
Formed with
Aluminum
Angle
Embedded in
Concrete
No Operator -
Fabricate
Gate with 2
Reinforced
Lifting Eyes
1
0/10 ft
Second
Anoxic Tank
Diversion
Box
Note 1:
• Top Concrete Channel = Elev. 71.25
• Top of Weir — Up Position = Elev. 69.5 (no flow over weir)
• Maximum Upstream Water Elevation = Elev. 69.25
• Top of Weir — Down Position = Elev. 68.5 (12 in. flow over weir)
• Maximum Downstream Water Elevation = Elev. 68.0
• Invert Concrete Channel = Elev. 65.25
WATER CONTROL GATES
11203-9 03/22/2019
1 Owner any damaged gate as instructed by the Engineer. Repairs shall be done
2 by Manufacturer or Manufacturer's approved representative.
3
4 C. Prior to initial start-up, the Contractor shall provide to the owner written
5 certification from the manufacturer that the equipment has been installed and
6 tested in accordance with the Manufacturer's approved methods, and that the
7 equipment is ready for permanent operation.
8
9 3.02 SERVICES
10
11 A. The Contractor shall provide the services of each gate Manufacturer's field service
12 technician for a period of not less than one (1) day to inspect the installed
13 equipment and instruct operating personnel.
14
15 B. At least one half of a day of the one (1) day period shall be allocated solely to the
16 instruction of operating personnel on the proper operations and maintenance of
17 the equipment. This inspection and instruction shall be scheduled at least ten (10)
18 days in advance with the Owner and shall take place prior to start-up and
19 acceptance by the Owner.
20
21
22 END OF SECTION
23
WATER CONTROL GATES
11203-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11306
2
3 SUMP PUMP
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE OF WORK
8
9 Furnish and install four pairs (8 total) sump pumps, each with swing check valves
10 installed in a horizontal run of piping, discharge piping, discharge pipe supports, self -
11 contained on-off controls, and auxiliary equipment as shown in the drawings and
12 specified herein. The pumps will installed as pairs. Each pair will be installed in the
13 same sump but at slightly at different elevations.
14
15 1.02 DESCRIPTION OF THE SYSTEM
16
17 A. The proposed equipment is intended to pump seal water drainage and liquids
18 from pump cleanout events that may accumulate on the Equalization Basin
19 pump slab, the Macerator slab, and the Moving Belt Filter slab. The pump at
20 the EQ basin discharge pipe will be up into the Equalization Basin. The
21 discharge for the other sump pumps is into the existing splitter box. Each pair
22 of pumps shall be identical and shall be single phase units with integral controls.
23
24 B. Two (2) of the eight (8) pumps shall be installed in the existing sump on the
25 lower level of the headworks building. These pumps are also intended to pump
26 seal water drainage and other liquids from pump cleanout events that may
27 accumulate in the sump.
28
29 1.03 SUBMITTALS
30
31 A. Shop drawings shall be submitted to the Engineer for review in accordance
32 Sections 01300 and 01340.
33
34 B. Product technical data including:
35
36 1. Certification that the product submitted meets the requirements of
37 standards referenced.
38
39 2. Manufacturer's installation instructions.
40
41 3. Manufacturers cut sheet including a dimensioned drawing, power
42 requirements, and discharge pipe connection.
43
44 4. Pump curve showing flow and total dynamic head relationships.
45
46 1.04 WARRANTY
47
SUMP PUMP
11306-1 06/25/2019
1 A. The equipment shall be warranted to be free from defects in workmanship,
2 design and materials. If any part of the equipment should fail during the
3 warranty period, it shall be replaced in the machine(s) and the unit(s) restored
4 to service at no expense to the Owner.
5
6 B. The manufacturer and the Contractor shall warrant the equipment against
7 defects in workmanship and materials for a period of one (1) year under normal
8 use, operation and service, commencing at the time of final system acceptance
9 by the Owner.
10
11 PART 2 - PRODUCTS
12
13 2.01 EXTERIOR SUBMERSIBLE SUMP PUMPS
14
15 A. The Contractor shall furnish and install 115 Volt, single phase, submersible
16 sump pumps with a minimum 1/2 HP motors. Each pump shall pump a
17 minimum 15 gallons per minute at a minimum 29.5 feet of total dynamic head.
18
19 B. The curve submitted for approval shall state head and capacity performance of
20 the pump.
21
22 C. Pumps shall be able to operate dry for extended periods without damage to
23 motor and/or seals.
24
25 D. Pump shall be easily removable for inspection or service, requiring no bolts,
26 nuts or other fasteners to be disconnected other than the discharge piping, or
27 the need for personnel to enter the sump. The motor and pump shall be
28 designed, manufactured and assembled by the same manufacturer.
29
30 E. Materials of construction:
31
32 1. The pump shall be constructed with single row upper and lower ball
33 bearings.
34
35 2. The pump volute, motor, and seal housing shall be 304 stainless steel or
36 high quality cast iron, ASTM A48, Class 30, with smooth surfaces devoid
37 of blow holes or other casting irregularities.
38
39 3. Impeller shall be cast stainless steel, cast iron or ductile iron, ASTM
40 A536, Class 40.
41
42 4. The motor shaft shall be 304 Stainless Steel
43
44 5. All external mating parts shall be machined and sealed with Buna N 0-
45 Rings.
46
47 6. All exposed bolts and nuts shall be 316 stainless steel.
SUMP PUMP
11306-2 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 7. All power cords shall be water resistant UL or CSA approved, with double
3 insulation and sized as a function of amperage draw. Sufficient cord
4 length shall be provided to connect to weatherproof receptacles.
5
6 F. Provide a minimum 2- inch threaded NPT discharge connection with a steel
7 handle for lifting the pump out of the sump.
8
9 G. The pumps shall be supplied with mechanical seals that have carbon/ceramic
10 faces, a stainless steel body and spring, and a Buna-N bellows.
11
12 H. The pumps shall be manufactured by Aurora Pumps, Hydromatic, Flygt, Weil,
13 BJM or approved equal.
14
15 I. The pumps shall be supplied with an integral on-off float control system. No
16 other controls are required.
17
18 2.02 HEADWORKS BUILDING SUMP PUMPS
19
20 A. The Contractor shall furnish and install (two) 230V, single phase, submersible
21 sump pumps with 1.5 HP motors. The capacity of each pump shall be nominally
22 100 gallons per minute at a minimum of 20 feet of total dynamic head. Each
23 pump shall operate at 1750 RPM and be capable of passing a 2 -inch diameter
24 sphere. The pumps shall be Series 3MW manufactured by Pentair Myers or
25 approved equal.
26
27 B. The curve submitted for approval shall state head and capacity performance of
28 the pump.
29
30 C. Pumps shall be able to operate dry for extended periods without damage to
31 motor and/or seals.
32
33 D. Pump shall be easily removable for inspection or service, requiring no bolts,
34 nuts or other fasteners to be disconnected other than the discharge piping, or
35 the need for personnel to enter the sump. Provide a quick disconnect in the
36 discharge piping, upstream of the discharge check valve, to allow the pump to
37 be removed by grasping the piping. The motor and pump shall be designed,
38 manufactured and assembled by the same manufacturer.
39
40 E. Materials of Construction:
41
42 1. The pump shall be constructed with two ball bearings to support the shaft
43 and take radial and thrust loads.
44
45 2. The pump volute, motor, and seal housing shall be 304 stainless steel or
46 cast iron, ASTM A48, Class 30, with smooth surface devoid of blow holes
47 or other casting irregularities.
SUMP PUMP
11306-3 06/25/2019
1
2 3. Impeller shall be cast stainless steel, cast iron or ductile iron, ASTM
3 A536, Class 40.
4 4. The motor shaft shall be 304 Stainless Steel.
5
6 5. All external mating parts shall be machined and sealed with Buna N 0-
7 Rings.
8
9 6. All exposed bolts and nuts shall be 316 stainless steel.
10
11
12 7. All power cords shall be water resistant UL or CSA approved, with double
13 insulation and sized as a function of amperage draw. Sufficient cord
14 length shall be provided to connect to weatherproof receptacles.
15
16 F. Provide a minimum 2 -inch threaded NPT galvanized steel discharge connection
17 with a steel handle for lifting the pump out of the sump.
18
19 G. The pumps shall be supplied with dual mechanical seals that have
20 carbon/ceramic faces, a stainless-steel body and spring, and a Buna-N bellows.
21
22 H. The pump manufacturer's typical duplex control panel shall be provided and
23 installed. The control panel shall be equipped with on/off manual switches for
24 each pump, a pump alternator, and audible and visual alarms. Four (4) floats
25 shall be provided and installed to provide on/off, override, and high-level alarm
26 signals to the control panel. No backup battery power supply or SCADA
27 connection is required for this control panel.
28
29 PART 3 — EXECUTION
30
31 3.01 INSTALLATION
32
33 A. Install pumping equipment in accordance with the manufacturer's written
34 recommendations.
35
36 3.02 INSPECTION AND TESTING
37
38 A. The pump shall be individually tested to include the following:
39
40 1. Verify proper alignment and freedom from binding, scraping, or other
41 defects.
42
43 2. Ensure that the equipment is secure in position and neat in appearance.
44
45 3. The pump and power cord shall be visually inspected for imperfections,
46 cuts or nicks.
47
SUMP PUMP
11306-4 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 4. Pump shall be allowed to run dry to check for proper rotation.
2
3 B. Provide a written statement that manufacturer's equipment has been installed
4 properly, started up and is ready for operation by Owner's personnel.
5
6 END OF SECTION
7
SUMP PUMP
11306-5
06/25/2019
1
2 THIS PAGE INTENTIONALLY LEFT BLANK
SUMP PUMP
11306-6 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11310
2
3 END SUCTION PUMPS
4
5 PART 1 — GENERAL
6
7 1.01 DESCRIPTION
8
9 A. This specification covers non -clog, end suction, back pullout centrifugal pumps
10 designed specifically to pump raw wastewater in municipal wastewater
11 treatment plants.
12
13 1.02 RELATED WORK SPECIFIED ELSEWHERE
14
15 A. Painting
16
17 B. Basic Mechanical Requirements
18
19 1.03 QUALITY ASSURANCE
20
21 A. Pumps shall be in accordance with applicable Hydraulic Institute Standards,
22 including the default pump acceptance test grades specified in ANSI/HI 14.6.
23
24 B. Motors shall conform to all applicable NEMA Standards.
25
26 C. All of the equipment specified under this Section shall be furnished by a single
27 Manufacturer, who shall be fully experienced, reputable and qualified in the
28 manufacture of the equipment furnished.
29
30 D. The pumps and all related equipment shall be designed, constructed and
31 installed in accordance with the best practices and methods. The pumps shall
32 be suitable for satisfactory operation with the operating levels shown on the
33 Drawings or specified herein.
34
35 E. Requests for substitution shall include manufacturer's literature for each product
36 giving name, product number, type, descriptive information, and independent
37 lab test reports showing results to equal the performance criteria of the
38 equipment specified herein. In addition, a list of five projects shall be submitted
39 in which identical equipment has been used and rendered satisfactory service.
40
41 F. Should equipment that differs from these Specifications be offered and
42 determined to be the approved equal of that specified, such equipment will be
43 acceptable only on the basis that any revisions in the design and/or construction
44 of the structures, piping, appurtenant equipment, electrical work, etc., required
45 to accommodate such a substitution, shall be made at no additional cost to the
46 Owner and be as approved by the Engineer.
47
END SUCTION PUMPS
11310-1 04/22/2019
1 G. The pump supplier shall guarantee the performance of each pump. The pumps
2 shall be as manufactured by Xylem A -C NSY Series, or equal.
3
4 1.04 SUBMITTALS
5
6 A. Pump submittals shall be in accordance with Section 01300 and 01340 and
7 shall include installation and start up instructions.
8
9 B. Submit dimensional drawings showing weights and materials of construction by
10 ASTM reference and grade. Show pump surface preparation and coatings.
11
12 C. Submit pump performance curves showing the specified operating points,
13 including the pump head, efficiency, brake horsepower and NPSH required at
14 full speed; the impeller diameter and pump sphere size capability; the reduced
15 speed head, efficiency and brake horsepower curves for all specified reduced
16 speed operating points and speeds with a minimum of two additional speeds
17 (85 and 70% if not otherwise specified) in addition to the full speed curve.
18
19 D. Submit motor data for approval including manufacturer, model or type, and
20 dimensional drawing. Show horsepower, service factor, full load speed, NEMA
21 design, frame size, weight, enclosure, winding insulation class and treatment,
22 rated ambient temperature, voltage, phase, frequency, full load current and
23 locked rotor current. Also show the guaranteed efficiency and power factor at
24 full, 3/4, and 1/2 loads. Provide a statement from the pump manufacturer that the
25 motors are compatible with the VFDs to be furnished.
26
27 E. Furnish wiring diagrams and elementary or control schematics as requested.
28
29 F. Submit manufacturer's short commercial motor test data prior to shipment.
30
31 G. Submit Operation and Maintenance manuals and Training manuals in
32 accordance with Section 01730 and Section 01820, respectively, for approval
33 prior to start-up. These manuals shall include all of the approved and corrected
34 submittal data, installation, operation and maintenance requirements and test
35 data on all equipment furnished by the pump supplier. If test data has not been
36 completed at the time these manuals are prepared, this test data may be
37 furnished later.
38
39 H. The weight of the equipment components, including the weights of the larger
40 components.
41
42 I. A complete bill of materials for all equipment and a listing of the
43 manufacturer's recommended spare parts.
44
45 J. Provide exploded views of all assemblies with all parts and materials of
46 construction identified.
47
END SUCTION PUMPS
11310-2 04/22/2019
1
1
1
2
1 4
35
6
7
8
I9
10
11
1 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
1
1
1
1
1
1
1
1
1
1
1
1
1
1.05 WARRANTY
A.
Provide the Manufacturer's equipment warranty in accordance with Section
01740 of these Specifications.
PART 2 — PRODUCTS
2.01
GENERAL
A. All equipment for the pumps, including motors and bases, shall be furnished as
a complete unit by the pump supplier. The Pump Data Table included at the
end of this section shows the minimum pump requirements.
B. The pumps and motors shall be rated for continuous duty and shall be capable
of pumping the specified flow range without cavitation or excessive vibration.
The pumps and drives shall not infringe upon the motor service factor at any
point on the pump's full speed curve.
C. The amplitude of vibration shall not exceed the limits set forth in the latest edition
of the Hydraulic Institute Standards.
D. Corrosion resistant nameplates with the name of the manufacturer and the
serial number shall be attached to each pump shall be permanently affixed to
the pump.
E. Corrosion resistant nameplates with the name of the manufacturer, serial
number, horsepower, speed, voltage and amperes shall be attached to each
motor.
2.02 MATERIALS
Part:
Casing
Suction Cover
Suction Cover Wear Plate
Impeller
Impeller Nut & Set Screw
Impeller Wear Ring
Stuffing Box
Bearing Frame
Shaft
Shaft Sleeve
Base
2.03 PUMP CONSTRUCTION
Material:
Cast Iron
Cast Iron
Stainless
Cast Iron
Stainless Steel
Stainless Steel
Cast Iron
Cast Iron
Stainless Steel
Stainless Steel
Stainless Steel
Designation:
ASTM A48, Class 30
ASTM A48, Class 30
AISI 410 SS
2-3% Nickel Cast Iron
18-8
AISI 410
ASTM A48, Class 30
ASTM A48, Class 30
AISI 4140
316
304
END SUCTION PUMPS
11310-3 04/22/2019
1 A. Casing - The pump casing shall be of sufficient strength, weight and metal
2 thickness to insure long life, accurate alignment and reliable operation. The
3 volute shall have smooth fluid passages large enough at all points to pass any
4 size solid that can pass through the impeller and provide smooth, unobstructed
5 flow. A large clean out opening with removable cover, having its interior
6 surfaces match the volute contour, shall be located on the casing at the impeller
7 centerline to allow access to the interior of the impeller. The casing shall be
8 split perpendicular to the shaft with removable suction cover and stuffing box
9 cover. Machined fits for these parts shall be accurately aligned and identical so
10 that the casing may be installed for either clockwise or counterclockwise
11 direction of rotation. The casing shall be arranged so that the impeller may be
12 removed without disturbing either suction or discharge piping. The discharge
13 flange shall be ANSI 125# flat face. All flange bolt holes shall be slotted for
14 ease of assembly and disassembly. The discharge flange shall be drilled and
15 tapped for a pressure gauge connection. Furnish pressure gauges for each
16 pump as specified elsewhere.
17
18 B. Suction Cover - The suction cover shall be removable to allow for access to the
19 impeller.
20
21 C. Suction Cover Wear Plate - A suction cover wear plate shall be furnished. It
22 shall provide 1A -inch minimum wear and shall be installed with its wear surface
23 parallel to the end of the impeller inlet.
24
25 D. Impeller - The impeller shall be of the enclosed type and shall be keyed and
26 secured to the shaft by a lock nut and set screw. The impeller shall have a
27 tapered bore and be readily removable without the use of special tools. The
28 impeller clearance adjustment shall be made through the use of shims placed
29 between the frame and the outboard bearing housing. Pump impellers shall be
30 dynamically balanced.
31
32 E. Impeller Wear Ring - A replaceable "L" shaped wear ring shall be mounted on
33 the impeller to provide a renewable surface opposite the suction cover wear
34 plate.
35
36 F. Stuffing Box - The stuffing box cover shall be made with an integral stuffing box
37 and shall be designed to accept either packing or a mechanical seal. Drilled
38 and tapped sealing liquid connection and drain ports shall be provided.
39
40 1. Pumps shall be supplied with John Crane Type 3740 split mechanical
41 seals.
42
43 G. Bearing Frame - The pump bearing frame shall be a one-piece rigid frame with
44 a cast iron bearing housing mounted at the outboard end and a cast iron end
45 cover mounted at the inboard end. Both ends of the frame shall be provided
46 with lip type grease seals and labyrinth type deflectors to prevent the entrance
47 of contaminants. The frame shall be provided with a 3/ -inch tapped hole,
END SUCTION PUMPS
11310-4 04/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 located as low as possible, to drain the leakage from the packing gland.
2
3 1. Pump bearings shall be designed for a minimum 50,000 hours life at the
4 worst-case design point specified. Inboard bearings shall be the radial
5 type and outboard bearings shall be the radial and axial type suitable for
6 thrust loads in two directions. Bearings shall be grease lubricated with
7 provisions for the addition and relief of grease. The outboard bearing
8 shall be locked to the shaft with a nut and lock washer. The lock washer
9 shall have a key seat tab on its inside diameter to prevent it from turning
10 and a set of tabs on its outside diameter, one of which will align with a
11 notch in the nut, to prevent it from turning.
12
13 H. Shaft - The pump shall be fully and accurately machined, tapered at the impeller
14 end and of sufficient size to transmit the full driver output.
15
16 I. Shaft Sleeve - A renewable 316 SS shaft sleeve shall be provided that extends
17 through the stuffing box and under the gland. An 0 -ring seal shall be provided
18 between the sleeve and shaft.
19
20 J. Couplings - The pump shall utilize the manufacturer's recommended flexible
21 coupling. Coupling halves shall be secured to the driver and driven shafts by a
22 set screw located over the key. Couplings shall be suitable for the speed range
23 specified or required. Coupling guards shall be the expanded metal type and
24 shall meet OSHA standards.
25
26 K. Hardware - All machine bolts, nuts and cap screws shall be of the hex head
27 type. Hardware or parts requiring special tools shall not be used.
28
29 L. Cleanout Handhole - The pumps be provided with separate suction and
30 discharge cleanout handholes. The handholes shall have a removable cast iron
31 cover. The handhole shall have a minimum diameter of 4 inches and shall have
32 its inner surface match the contour of the pump.
33
34 M. Baseplate and Pedestal - The pumps shall have a 304 SS drip rim baseplate
35 with a tapped hole at one end for drain piping connection.
36
37 2.04 TOOLS AND SPARE PARTS
38
39 A. Furnish the Manufacturer's recommended spare parts for each pump. Furnish
40 lubricants as required for all scheduled maintenance for a period of one (1) year
41 following Substantial Completion.
42
43 B. Furnish one set of all special tools required for normal operation and
44 maintenance.
45
46 C. The following spare parts shall be provided, if not furnished with the
47 Manufacturer's recommended spare parts:
END SUCTION PUMPS
11310-5 04/22/2019
1
2 1. One mechanical seal for each pump.
3 2. One set of gaskets for each pump.
4 3. One impeller wear ring for each pump.
5 4. One casing wear ring for each pump.
6 5. Enough lubricants as required for a period of one (1) year.
7
8 2.05 MOTORS
9
10 A. Pump motors shall be in accordance with Division 16 requirements. The motors
11 shall be 3 phase, 60 hertz and 460 volts and shall be sized so that the service
12 factor is not infringed upon throughout the full speed performance curve of the
13 pumps. At minimum, motors shall have Class B insulation and a 1.15 service
14 factor. Motors shall have re-greaseable or oil lubricated bearings. Variable
15 speed motors shall be rated for inverter duty per NEMA MG -1, Part 31.
16
17 B. The motors shall be driven by variable frequency drives.
18
19 2.06 FACTORY TESTS
20
21 A. Each motor shall be given a non -witnessed short commercial test to determine
22 that the motor is free from electrical and mechanical defects and to provide
23 assurance that it meets the specifications. Testing shall be in accordance with
24 NEMA standards and shall consist of no load current, locked rotor current,
25 winding resistance, high potential and bearing inspection.
26
27 B. Each pumping unit, with a calibrated factory test motor, shall be given a factory
28 performance test to provide assurance that the unit meets the specifications.
29 Tests shall be performed in accordance with Hydraulic Institute Standards
30 ANSI/HI 14.6. Variable speed pumps shall be tested at full speed and at 85%
31 and 70% speed. . Copies of the test reports shall be provided to the Engineer.
32
33 2.07 FACTORY PAINTING
34
35 A. The pumps shall be cleaned and blasted to SSPC-SP10 and shall be given one
36 coat of rust inhibitive primer to a minimum of 4-6 mils DFT and one coat of epoxy
37 finish to 4-8 mils DFT.
38
39 2.08 ROTATION
40
41 A. The rotation shall be marked on the pump casing and the pumps shall be
42 clocked as shown on the Drawings.
43
44 PART 3 — EXECUTION
45
46 3.01 INSTALLATION
47
END SUCTION PUMPS
11310-6 04/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Pumps, drivers and bases shall be precisely leveled and aligned, accurately
2 anchored into position and grouted by the Contractor. Installation shall be in
3 strict accordance with the manufacturer's instructions and recognized industry
4 practices. The Contractor shall furnish the anchor bolts and the required
5 lubricants for initial operation. The existing concrete maintenance pads shall be
6 removed and new bases shall be installed.
7
8 B. Pressure gauge assemblies shall be furnished and installed by the Contractor
9 on the suction and discharge of each pump. The gauges shall have a 2.5 inch
10 dial and be installed with a pressure snubber, isolation valve, brass tee handle
11 and a seal with a 316 SS diaphragm. The gauge calibration ranges shall be as
12 small as is practical so that that full range is utilized, but safely within maximum
13 conditions.
14
15 C. The Contractor shall connect the new seal water system to each pump as shown
16 on the drawings such that seal water is automatically supplied to the inlet port
17 of the stuffing box when the pump is started and in operation.
18
19 3.02 JOBSITE PAINTING
20
21 A. The Contractor shall field paint the pumping equipment in accordance with
22 Section 09900.
23
24 3.03 INSPECTION AND TESTING
25
26 A. General - Furnish the services of a factory representative in accordance with
27 Specification Section 01820 to inspect the final installation, supervise a test run
28 of the equipment, and provide operator training. The factory representative
29 shall provide a written certification that the pumps are installed in accordance
30 with the manufacturer's recommendations.
31
32 B. Motors - The Contractor shall check all motors for correct clearances and
33 alignment, and for correct lubrication in accordance with the manufacturer's
34 instructions. The Contractor shall verify the proper rotation of all motors.
35
36 C. Pumps - After the pumps have been completely installed and inspected by a
37 factory representative, field tests shall be conducted on each unit in the
38 presence of the Engineer to show conformance with the specifications. The
39 Contractor shall supply all labor, equipment and incidentals required to
40 complete these tests. The factory representative shall provide a complete
41 startup report for each pump, documenting the pump operating conditions at
42 startup. This report shall be made part of the operation and maintenance
43 manual. Pumps that cannot be made to comply with the specifications shall be
44 removed and replaced with pumps that satisfy the conditions specified.
45
46 3.04 PUMP DATA TABLE
47
END SUCTION PUMPS
11310-7 04/22/2019
1
2
3
4
5
Service
EQ Tank Supply
EQ Tank Return
Salsnes Filter
Feed
Quantity
2
2
3
Location
Outdoors
Outdoors
Indoors
Position/Orientation
Horizontal
Drive
480-V 3 phase A/C Variable Speed (VFD)
Gauges
Discharge
Design Point - Full Speed
Flow, gpm
TDH, feet
Min. Efficiency, %
972
29
71.5
1632
28
74
1700
12.4
78
Runout Point - Full Speed
Max Flow, gpm
TDH, feet
NPSH Required, feet
1425
18
11
2950
17
18
2300
9
12
Max. Solids Sphere Size, In
3.63
3.75
3.75
Min. Casing Thickness
0.5
0.5
0.5
Nominal Shaft Diameter, In.
2.75
2.50
2.50
Max. Motor Speed, RPM
1170
875
695
Max, Motor HP
15
20
10
Min. Shutoff Head, feet
48
39
20.3
Suction x Discharge, inch
8 X 6
10 X 10
10 X 10
Min. Weight, lbs. (w/o motor
or base)
750 ± 10%
1,600 ± 10%
1,600 ± 10%
Basis of Design
Xylem A -C Series
1
1
1
1
1
1
1
1
1
1
1
1
6 ENDOF SECTION
7 1
END SUCTION PUMPS
11310-8 04/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11317
2
3 PROGRESSING CAVITY PUMPS
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and install,
10 place in operation, and field test three (3) horizontal variable speed
11 progressing cavity pumps and motors with bases and appurtenances,
12 designed specifically to pump primary sludge with 4%-6% solids content;
13 complete with motors, control systems, and seal water systems at the
14 Salsnes Filters area as hereinafter specified to perform the intended
15 function and achieve a fully integrated and operational system.
16
17 B. Furnish all labor, materials, equipment and incidentals required and install,
18 place in operation, and field test one (1) horizontal constant speed
19 progressing cavity pump and motor with base and appurtenances,
20 designed specifically to pump primary scum with 0.25%-2% solids content;
21 complete with motor, control system, and seal water system in the
22 Salsnes Filters Feed Pump Building as hereinafter specified to perform the
23 intended function and achieve a fully integrated and operational system.
24
25 C. These Specifications are intended to give a general description of what is
26 required, but do not cover all details which will vary in accordance with the
27 requirements of the equipment application. It is, however, intended to
28 cover the furnishing, the shop testing, the delivery and complete
29 installation and field testing, of all materials, equipment and all
30 appurtenances for the complete pumping system as herein specified,
31 whether specifically mentioned in these Specifications or not.
32
33 1.02 DESCRIPTION OF THE SYSTEM
34
35 Sizing and Performance Criteria: Provide pumps with the following design
36 criteria:
37
38 Salsnes Filters Primary Sludge Pumps
39 Number of Pumps 3
40 Maximum Pump Speed (rpm) 140
41 Design Capacity (gpm) 15
42 TDH at Design Capacity (psi) 60
43 Pump Inlet Open Throat with Screw Auger Feed
44 Pump Outlet 3 -inch Flanged
45 Maximum Motor Horsepower 5
46 Configuration Variable Speed Motor with Gear Box
PROGRESSING CAVITY PUMP
11317-1 03/22/2019
1 Fabricated Base Material 304 Stainless Steel
2 Dry Solids Content of Primary Sludge 4%-6%
3
4 Primary Scum Pump
5 Number of Pumps 1
6 Maximum Pump Speed (rpm) 275
7 Design Capacity (gpm) 90
8 TDH at Design Capacity (psi) 65
9 Pump Inlet 6 -inch Flanged
10 Pump Outlet 6 -inch Flanged
11 Maximum Motor Horsepower 10
12 Configuration Constant Speed Motor with Gear Box
13 Fabricated Base Material 304 Stainless Steel
14 Dry Solids Content of Primary Scum 0.25%-1.0%
15
16 1.03 REFERENCE STANDARDS
17
18 A. Design, manufacturing and assembly of elements of the equipment herein
19 specified shall be in accordance with the standards of the below listed
20 organizations. Where reference is made to a standard of any
21 organization, the version of the standard in effect at the time of bid
22 opening shall apply.
23
24 1. American Iron and Steel Institute (AISI)
25 2. American Society of Mechanical Engineers (ASME)
26 3. American National Standards Institute (ANSI)
27 4. American Society for Testing Materials (ASTM)
28 5. American Water Works Association (AWWA)
29 6. Hydraulic Institute Standards
30 7. National Electrical Manufacturers Association (NEMA)
31 8. Underwriters Laboratories, Inc. (UL)
32 9. Anti -Friction Bearing Manufacturers Association (AFBMA)
33 10. American Gear Manufacturers Association (AGMA)
34 11. Occupational Safety and Health Administration (OSHA)
35
36 1.04 QUALITY ASSURANCE
37
38 A. To ensure a consistently high standard of quality, the manufacturer of this
39 pumping equipment shall comply with the requirements of the ISO 9001
40 Quality System, and such compliance shall be verified by an independent
41 certification agency approved by the International Organization for
42 Standardization. Documentation shall be submitted for approval showing
43 compliance with this requirement, and the equipment will not be released
44 for shipment until approved.
45
46 B. Motors shall be in accordance with NEMA Standards.
PROGRESSING CAVITY PUMP
11317-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 C. All of the equipment specified under this Section shall be furnished by a
3 single Manufacturer, who is fully experienced, reputable and qualified in
4 the manufacture of the equipment furnished. The pumps shall be suitable
5 for satisfactory operation with the normal operating levels shown on the
6 Drawings. The Contractor shall assume full responsibility for the
7 satisfactory installation and operation of the entire pumping system as
8 specified.
9
10 D. The pumps and all related equipment shall be designed, constructed and
11 installed in accordance with the best practices and methods.
12
13 E. Requests for substitution shall include manufacturer's literature for each
14 product giving name, product number, type, descriptive information, and
15 independent lab test reports showing results to equal the performance
16 criteria of the equipment specified herein. In addition, a list of five projects
17 shall be submitted in which identical equipment has been used and
18 rendered satisfactory service.
19
20 F. The pump manufacturer shall be fully responsible for the design,
21 arrangement and operation of all connected and rotating components of
22 the assembled pumping units to ensure that neither harmful nor damaging
23 vibrations occur at any speed within the specified operating range.
24
25 G. Should equipment which differs from these Specifications be offered and
26 determined to be the approved equal of that specified, such equipment will
27 be acceptable only on the basis that any revisions in the design and/or
28 construction of the structures, piping, appurtenant equipment, electrical
29 work, etc., required to accommodate such a substitution, shall be made at
30 no additional cost to the Owner and be as approved by the Engineer.
31
32 H. The pump supplier shall guarantee the performance of each pump. The
33 pumps shall be as manufactured by Moyno and shall be the EZ -Strip
34 Models or approved equals.
35
36 1.05 SUBMITTALS
37
38 A. Submit to the Engineer, in accordance with Sections 01300 and 01340,
39 copies of all materials required to establish compliance with this Section.
40 Submittals shall include at least the following:
41
42 1. Certified shop drawings, erection drawings, and installation
43 instructions showing all important details of construction,
44 dimensions and anchor bolt locations. Provide exploded views of
45 all pump assemblies with all parts and materials of construction
46 identified.
PROGRESSING CAVITY PUMP
11317-3 03/22/2019
1
2 2. Descriptive literature, bulletins and/or catalogs of the equipment.
3
4 3. Data on the characteristics and performance of the pumps. The
5 data shall include performance curves, based on actual shop tests
6 of like pumping units, which show that they meet the specified
7 requirements for head, capacity and horsepower. Curves shall be
8 submitted on 8 -1/2 -in by 11 -in sheets.
9
10 4. Submit motor data for approval including manufacturer, model or
11 type, and dimensional drawing. Show horsepower, service factor,
12 full load speed, NEMA design, frame size, weight, enclosure,
13 winding insulation class and treatment, rated ambient temperature,
14 voltage, phase, frequency, full load current and locked rotor current.
15 Also show the guaranteed efficiency and power factor at full, %,
16 and 1/2 loads. Provide a statement from the pump manufacturer
17 that the motors are compatible with the VFDs to be furnished.
18
19 5. Furnish wiring diagrams and elementary or control schematics as
20 requested.
21
22 6. Submit complete data on pump drive including gearbox.
23
24 7 The weight of the equipment components, including the weights of
25 the larger components.
26
27 8. A complete bill of materials for all equipment.
28
29 9. Complete description of surface preparation and shop prime
30 painting.
31
32 B. In the event that it is impossible to conform to certain details of this
33 Section due to different manufacturing techniques, describe completely all
34 nonconforming aspects.
35
36 C. Operating and Maintenance Data and Training
37
38 1. Operating and maintenance instructions shall be furnished to the
39 Engineer as provided for in Section 01730. The instructions shall
40 be prepared specifically for this installation and shall include all
41 cuts, drawings, equipment lists, and descriptions that are required
42 to instruct operating and maintenance personnel unfamiliar with
43 such equipment.
44
45 2. A factory representative who has complete knowledge of proper
46 operation and maintenance of the pumps shall be provided in
PROGRESSING CAVITY PUMP
11317-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 accordance with Specification Section 01820 to provide
2 training/instruction to operations and maintenance personnel on
3 proper operation and maintenance. The work may be conducted in
4 conjunction with the inspection of the installation and test run as
5 provided. If there are difficulties in operation of the equipment due
6 to the manufacturer's design or fabrication, additional service shall
7 be provided at no additional cost to the Owner.
8
9 1.06 TOOLS AND SPARE PARTS
10
11 A. Furnish the Manufacturer's recommended spare parts for each pump.
12 Furnish lubricants as required for all scheduled maintenance for a period
13 of one (1) year following Substantial Completion.
14
15 B. Furnish one set of all special tools required for normal operation and
16 maintenance.
17
18 C. At minimum the following spare parts shall be provided.
19
20 1. One mechanical seal for each pump.
21 2. One complete set of gaskets for each pump.
22 3. One complete set of O -rings for each pump.
23 4. One complete set of seals for each pump.
24 3. One stator and rotor assembly for each pump.
25 4. One set of bearings for each pump. List the bearings by the
26 bearing manufacturer's numbers only.
27 5. One set of the split coupling rods for each pump.
28 6. One set of coupling rod bushings for each pump.
29 7. One set of coupling rod pins for each pump.
30 8. Enough lubricants as required for a period of one (1) year
31
32 1.07 PRODUCT HANDLING
33
34 A. All parts shall be properly protected so that no damage or deterioration will
35 occur during a prolonged delay from the time of shipment until installation
36 is completed and the units and equipment are ready for operation.
37
38 B. All equipment and parts must be properly protected against any damage
39 during a prolonged period at the site.
40
41 C. Factory assembled parts and components shall not be dismantled for
42 shipment unless permission is received in writing from the Engineer.
43
44 D. Finished surfaces of all exposed openings shall be protected by wooden
45 blanks, strongly built and securely bolted thereto.
46
PROGRESSING CAVITY PUMP
11317-5 03/22/2019
1 E. Finished iron or steel surfaces not painted shall be properly protected to
2 prevent rust and corrosion.
3
4 F After hydrostatic or other tests, all entrapped water shall be drained prior
5 to shipment and proper care shall be taken to protect parts from the
6 entrance of water during shipment, storage and handling.
7
8 G. Each box or package shall be properly marked to show its net weight in
9 addition to its contents.
10
11 1.08 WARRANTY
12
13 A. In order to assure proper performance and compatibility, all equipment
14 supplied within this Specification shall be warranted by the same supplier.
15
16 B. The equipment shall be warranted to be free from defects in workmanship,
17 design and materials. If any part of the equipment should fail during the
18 warranty period, it shall be replaced in the machine(s) and the unit(s)
19 restored to service at no expense to the Owner.
20
21 C. The pump manufacturer and the Contractor shall warrant the pumps
22 against defects in workmanship and materials in accordance with Section
23 01740 of these Specifications.
24
25 1.09 MANUFACTURER'S REPRESENTATIVE
26
27 A. Provide the services of a qualified factory certified representative for a
28 minimum of (1) day for each pump for equipment installation inspection,
29 certification, start-up, training, and corrective adjustments.
30
31 PART 2 - PRODUCTS
32
33 2.01 MATERIALS AND EQUIPMENT
34
35 A. General
36
37 1. The equipment specified herein is intended to be standard pumping
38 equipment of proven ability as manufactured by a reputable firm
39 having long experience in the production of such equipment. The
40 equipment furnished shall be designed and constructed in
41 accordance with the best practices and methods and the same
42 model and pump performance currently in use at the plant.
43
44 2. All parts shall be so designed and proportioned as to have liberal
45 strength and stiffness and to be especially adapted for the work to
46 be done. Ample room and facilities shall be provided for inspection,
PROGRESSING CAVITY PUMP
11317-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 repairs and adjustment.
2
3 3. All necessary foundation bolts, plates, nuts and washers shall be of
4 Type 316 stainless steel.
5
6 4. Brass or stainless steel nameplates giving the name of the
7 manufacturer, pump model and serial number shall be attached to
8 each pump and motor.
9
10 5. The nameplate rating of the motors and drives shall not be
11 exceeded, nor shall the motor design service factor be reduced
12 when its pump is operating at the maximum design performance.
13
14 2.02 PUMP
15
16 A. Pump shall be heavy duty, positive displacement, and progressing cavity
17 type. The pump body shall be of thick-walled cast iron and shall
18 incorporate two inspection ports 180 degrees apart. The pump shall be
19 mounted to permit the suction port to be rotated to any angle
20 perpendicular to the centerline of the pump. Discharge connections shall
21 be 125 Ib ANSI cast iron flanged. The suction port shall be rectangular
22 shaped open throat design with a screw auger on the three sludge pumps
23 and a flanged pipe connection on the scum pump. All wetted internal
24 components shall be alloy steel unless otherwise described in this
25 specification.
26
27 B. The pump rotor shall be one-piece alloy steel conforming to BS970 grade
28 708M40T/709M40T (ASTM A322 grade 4140/4145) or equivalent. The
29 rotor shall be machined and coated with a hard chrome plate to a nominal
30 thickness of 0.10 inches at the scroll peaks. The chrome plate shall be
31 hardened to a Rockwell "C" value of 57 to 60 and polished to a minimum
32 of Ra value of 1.6 um.
33
34 C. The rotor shall rotate relative to a one-piece, medium-high acrylonitrile
35 Buna "N" rubber stator of approximate 70 Durometer hardness (Shore A)
36 securely bonded to its steel tube housing. The stator shall be arranged to
37 prevent the pumped material from contacting the bonding or the tube.
38
39 D. The rotor shall be joined to the drive shaft by a 2 -piece connecting rod and
40 pin type connection with 2 pins and 2 bushings as the wear components.
41 The 2 -piece connecting rod allows the rotor and stator to be removed
42 without disturbing or dismantling the pump pin -joint drive connections.
43
44 E. The rotor, stator, connecting rod, main drive shaft, and gland seal shall be
45 capable of being removed and replaced without disturbing or removing the
46 pump suction or discharge connections.
PROGRESSING CAVITY PUMP
11317-7 03/22/2019
1
2 F. The suction chamber area shall have unrestricted 360 degree access.
3
4 G. The pump stuffing box shall be equipped with a John Crane Bellows Type
5 mechanical seal with SilCar/SilCar/Fluoroelastomer and 316 SS
6 components.
7
8 H. The pumps shall fit in the available space provided without encroaching on
9 adjacent pump access space or working space. To this end, the
10 Contractor shall, with 30 days from the Notice to Proceed, submit
11 installation drawings (scaled and dimensioned) of any pump whose
12 dimensions differ more than 2 -inches from the specified pump. The
13 Engineer will review the installation drawings and advise the Contractor
14 whether the proposed pump is acceptable. The Engineer shall be the sole
15 judge of the acceptability of pumps other than that specified.
16
17 2.04 MOTORS
18
19 A. Pump motors shall be in accordance with Division 16 requirements. The
20 motors shall be 3 phase, 60 hertz and 460 volts and shall be sized so that
21 the service factor is not infringed upon throughout the full speed
22 performance curve of the pumps. At minimum, motors shall have Class B
23 insulation and a 1.15 service factor. Motors shall have re-greaseable or
24 oil lubricated bearings. Variable speed motors shall be rated for inverter
25 duty per NEMA MG -1, Part 31.
26
27 B. The motor shall be mounted in-line with the pump to a gearbox as shown
28 on the drawings and directly drive the gearbox. The motor shall be rated
29 for outdoor use.
30
31 C. The pump shaft shall be connected to the drive with a close -coupled,
32 flange -mounted gear motor with a cross drilled shaft.
33
34 D. The motors shall be driven by variable frequency drives on the three
35 sludge pumps and be constant speed on the scum pump.
36
37 2.05 BASE
38
39 A. The motor and pump shall be mounted in-line on a fabricated/bent 304
40 stainless steel base. The base shall be fitted with lifting lugs and grout
41 holes for grouting to the concrete maintenance pad.
42
43 2.06 TEMPERATURE AND PRESSURE SWITCH
44
45 A. The pump manufacturer shall furnish for each pump a temperature and
46 pressure switch with all suitable accessories for outdoor installation and
PROGRESSING CAVITY PUMP
11317-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 connection to the pump. The switches shall be wired to deactivate the
2 pump motor if the temperature or pressure exceed the manufacturer's
I
3
4 recommended settings.
5 2.07 SURFACE PREPARATION AND SHOP PRIME PAINTING
II 6
7 A. All surfaces shall be prepared and shop primed as part of the work under
8 this Section. Surface preparation and shop priming shall be as specified
I
9 in Section 09900.
10
11 PART 3 - EXECUTION
I12
13 3.01 INSTALLATION
14
I
15 A. Installation shall be in strict accordance with the manufacturer's
16 instructions and recommendations at the locations shown on the
17 Drawings. Installation shall include furnishing the required oil and grease
I
18 for initial operation. The grades of oil and grease shall be in accordance
19 with the manufacturer's recommendations. Anchor bolts shall be set in
20 accordance with the manufacturer's recommendations.
U
21
22 B. The base shall be set on a concrete pad and grouted in place after proper
23 leveling with an approved non -shrink grout.
I
24
25 3.02 INSPECTION AND TESTING
26
1 27 A. Furnish the services of a factory representative in accordance with
28 specification 01820 who has complete knowledge of proper operation and
29 maintenance to inspect the final installation and supervise a test run of the
30 equipment.
31
I32 B. The Contractor shall fabricate and connect a seal water supply system to
33 the pump such that seal water is automatically supplied to the inlet port of
34 the stuffing box when the pump is started and in operation. The seal
I35 water system shall start and stop with the pump motor and shall provide
36 pressure above the pump discharge pressure.
37
I
38
39 C. After all pumps have been completely installed under the direction of the
manufacturer's factory representative the Contractor shall conduct, in the
40 presence of the Engineer, such tests as are necessary to ensure that the
I
41
42 pumps conform to the requirements specified herein. Field tests shall be
performed on all pumps included under this Section. Pumps shall be
43 operated for at least 24 hours run time prior to acceptance.
I44
45 D. If the pump performance does not meet the specified requirements,
46 corrective measures shall be taken, or pumps shall be removed and
1
1
PROGRESSING CAVITY PUMP
11317-9 03/22/2019
1 replaced with pumps that satisfy the conditions specified.
2
3 E. The factory representative shall provide written certification that the pump
4 is installed in accordance with the manufacturer's recommendations.
5
6
7
8 END OF SECTION
9
PROGRESSING CAVITY PUMP
11317-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11320
2
3 RECESSED IMPELLER PUMPS
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and install,
10 place in operation, and field test four (4) horizontal vortex -type recessed
11 impeller pumps designed specifically to pump wastewater containing a grit
12 slurry in municipal wastewater treatment plants with motors, bases, control
13 systems, and seal water systems at the Headworks area as hereinafter
14 specified to perform the intended function and achieve a fully integrated and
15 operational system.
16
17 B. These Specifications are intended to give a general description of what is
18 required, but do not cover all details, which will vary in accordance with the
19 requirements of the equipment application. It is, however, intended to cover
20 the furnishing, the shop testing, the delivery and complete installation and field
21 testing, of all materials, equipment and all appurtenances for the complete
22 pumping system as herein specified, whether specifically mentioned in these
23 Specifications or not.
24
25 1.02 DESCRIPTION OF THE SYSTEM
26
27 Sizing and Performance Criteria: Provide pumps with the following design criteria:
28
29 Number of Pumps 4
30 Maximum Pump Speed (rpm) 1,100
31 Design Capacity (gpm) 150
32 TDH at Design Capacity (ft) 50.9
33 TDH at Shutoff (ft) 8.5
34 Pump Inlet/Outlet 4-inch/3-inch flanged
35 Maximum Horsepower 15
36 Minimum Efficiency % 25
37 Configuration Constant Speed Belt Driven
38
39 1.03 REFERENCE STANDARDS
40
41 A. Design, manufacturing and assembly of elements of the equipment herein
42 specified shall be in accordance with the standards of the below listed
43 organizations. Where reference is made to a standard of any organization, the
44 version of the standard in effect at the time of bid opening shall apply.
45
46 1. American Iron and Steel Institute (AISI)
47 2. American Society of Mechanical Engineers (ASME)
RECESSED IMPELLER PUMPS
11320-1
03/22/2019
1 3. American National Standards Institute (ANSI)
2 4. American Society for Testing Materials (ASTM)
3 5. American Water Works Association (AWWA)
4 6. Hydraulic Institute Standards
5 7. National Electrical Manufacturers Association (NEMA)
6 8. Underwriters Laboratories, Inc. (UL)
7
8 1.04 QUALITY ASSURANCE
9
10 A. Pumps shall be in accordance with applicable Hydraulic Institute Standards.
11 To ensure a consistently high standard of quality, the manufacturer of this
12 pumping equipment shall comply with the requirements of the ISO 9001
13 Quality System, and such compliance shall be verified by an independent
14 certification agency approved by the International Organization for
15 Standardization. Documentation shall be submitted for approval showing
16 compliance with this requirement, and the equipment will not be released for
17 shipment until approved.
18
19 B. Motors shall be in accordance with NEMA Standards.
20
21 C. All of the equipment specified under this Section shall be furnished by a single
22 Manufacturer, who is fully experienced, reputable and qualified in the
23 manufacture of the equipment furnished. The pumps shall be suitable for
24 satisfactory operation with the normal operating levels shown on the Drawings.
25 The Contractor shall assume full responsibility for the satisfactory installation
26 and operation of the entire pumping system as specified.
27
28 D. The pumps and all related equipment shall be designed, constructed and
29 installed in accordance with the best practices and methods.
30
31 E. All requests for equipment substitution shall be made at least 10 days prior to
32 the bid opening date.
33
34 F. Requests for substitution shall include manufacturer's literature for each
35 product giving name, product number, type, descriptive information, and
36 independent lab test reports showing results to equal the performance criteria
37 of the equipment specified herein. In addition, a list of five projects shall be
38 submitted in which identical equipment has been used and rendered
39 satisfactory service.
40
41 G. The pump manufacturer shall be fully responsible for the design, arrangement
42 and operation of all connected rotating components of the assembled pumping
43 units to ensure that neither harmful nor damaging vibrations occur at any
44 speed within the specified operating range.
45
46 H. Should equipment which differs from these Specifications be offered and
47 determined to be the approved equal of that specified, such equipment will be
RECESSED IMPELLER PUMPS
11320-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 acceptable only on the basis that any revisions in the design and/or
2 construction of the structures, piping, appurtenant equipment, electrical work,
3 etc., required to accommodate such a substitution, shall be made at no
4 additional cost to the Owner and be as approved by the Engineer.
5
6 I. The pump supplier shall guarantee the performance of each pump. The
7 pumps shall be as manufactured by WEMCO Model C, Hayward Gordon
8 Torus XR, or equal.
9
10 1.05 SUBMITTALS
11
12 A. Submit to the Engineer for review in accordance with Section 01340 and 01730
13 complete installation drawings, shop drawings, working drawings, O&M
14 Manuals and product data for all materials and equipment furnished under this
15 Section. Submittals shall include at least the following:
16
17 1. Certified shop drawings, erection drawings and installation instructions
18 showing all important details of construction, dimensions and anchor
19 bolt locations.
20
21 2. Descriptive literature, bulletins and/or catalogs of the equipment.
22
23 3. Data on the characteristics and performance of each pump. Data shall
24 include guaranteed performance curves, based on actual shop tests of
25 similar units, which show that they meet the specified requirements for
26 head, capacity, efficiency, NPSHR and horsepower. Curves shall be
27 submitted on 8-1/2" x 11" sheets, at as Targe a scale as is practical.
28 Curves shall be plotted from no flow at shut off head to pump capacity
29 at minimum specified total head. Catalog sheets showing a family of
30 curves will not be acceptable.
31
32 4. Complete master wiring diagrams, elementary or control schematics,
33 including coordination with other electrical control devices such as the
34 pump control system and suitable outline drawings shall be furnished
35 for approval before proceeding with manufacture. Provide suitable
36 outline drawings showing such details as are necessary to locate
37 conduit stub -ups and field wiring. Due to the complexity of the system,
38 it is imperative the above drawings be clear and carefully prepared to
39 facilitate interconnections with other equipment. Standard pre-printed
40 sheets or drawings simply marked to indicate applicability to this
41 contract will not be acceptable.
42
43 5. A complete total bill of materials of all equipment (may be furnished with
44 Operation and Maintenance manuals specified herein).
45
46 6. A list of the manufacturers recommended spare parts to be supplied in
47 addition to those specified, with the manufacturer's current price for
RECESSED IMPELLER PUMPS
11320-3 03/22/2019
1 each item. Include gaskets, packing, etc. on the list. List bearings by
2 the bearing manufacturer's numbers only.
3
4 7 Complete motor data.
5
6 8. The weight of the pump assembly not including the base, the motor, or
7 the coupling.
8
9 B. Test Reports to be Submitted
10
11 9. Description of factory testing procedures and equipment.
12
13 10. Copies of all test results, as specified in Parts 2 and 3 of this Section.
14
15 11. Copies of all start-up test reports which show compliance with these
16 Specifications.
17
18 C. The submittal data shall be prepared, in its entirety, by the equipment
19 manufacturer. Shop drawings prepared by the manufacturer's sales
20 representative, fabrication shops, or other than the listed manufacturers will
21 not be acceptable. No additions or modifications to the manufacturer's
22 submittal will be accepted, with the sole exception of a cover sheet provided
23 by the manufacturer's local Representative and the Contractor.
24
25 D. The operating and maintenance information shall include lubrication
26 instructions, troubleshooting data, full preventative maintenance schedules,
27 complete spare parts lists with ordering information, and exploded views of all
28 components and equipment with part numbers and the materials of
29 construction identified.
30
31 E. In the event that is impossible to conform to certain details of the
32 Specifications due to different manufacturing techniques, describe completely
33 all non -conforming aspects.
34
35 1.06 TOOLS AND SPARE PARTS
36
37 A. Furnish one (1) set of all special tools required for normal operation and
38 maintenance.
39
40 B. Furnish and package for storage all of the manufacturer's recommended spare
41 parts to assure normal running and maintenance for a period of two (2) years
42 assuming all units are in in continuous operation.
43
44 C. Furnish and package for storage a quantity of the recommended lubrication to
45 meet the manufacturers' recommended lubrication change intervals for 1 year
46 assuming all units are in continuous operation. Lubricants shall include summer
47 and winter grades with alternate reference to equal products of other
RECESSED IMPELLER PUMPS
11320-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 manufacturers, and shall include all lubricant specification such as viscosity,
2 AGMA numbers, etc.
3
4 E. All spare parts shall be furnished in containers clearly identified with indelible
5 markings as to contents. Each container shall be packed with its contents
6 protected for prolonged storage.
7
8 F In addition to items A-E, the following spare parts shall be supplied with the
9 equipment:
10
11 Four (4) sets of drive belts
12 One (1) completely assembled motor
13 One (1) completely assembled bare shaft pump
14 Four (4) complete sets of wear plates or wear elements as applicable
15 Four (4) mechanical seals
16 Four (4) sets of pump gaskets
17 Enough lubricants as required for a period of one (1) year
18
19 1.07 PRODUCT HANDLING
20
21 A. All parts shall be properly protected so that no damage or deterioration will
22 occur during a prolonged delay from the time of shipment until installation is
23 completed and the units and equipment are ready for operation.
24
25 B. All equipment and parts must be properly protected against any damage
26 during a prolonged period at the site.
27
28 C. Factory assembled parts and components shall not be dismantled for
29 shipment unless permission is received in writing from the Engineer.
30
31 D. Finished surfaces of all exposed openings shall be protected by wooden
32 blanks, strongly built and securely bolted thereto.
33
34 E. Finished iron or steel surfaces not painted shall be properly protected to
35 prevent rust and corrosion.
36
37 F. After hydrostatic or other tests, all entrapped water shall be drained prior to
38 shipment and proper care shall be taken to protect parts from the entrance of
39 water during shipment, storage and handling.
40
41 G. Each box or package shall be properly marked to show its net weight in
42 addition to its contents.
43
44 1.08 WARRANTY
45
46 A. In order to assure proper performance and compatibility, all equipment
47 supplied within this Specification shall be warranted by the same supplier.
RECESSED IMPELLER PUMPS
11320-5 03/22/2019
1
2 B. The equipment shall be warranted to be free from defects in workmanship,
3 design and materials. If any part of the equipment should fail during the
4 warranty period, it shall be replaced in the machine(s) and the unit(s) restored
5 to service at no expense to the Owner.
6
7 C. The pump manufacturer and the Contractor shall warrant the pumps against
8 defects in workmanship and materials in accordance with Section 01740 of
9 these Specifications.
10
11 1.09 MANUFACTURER'S REPRESENTATIVE
12
13 A. Provide the services of a qualified factory certified representative for a
14 minimum of (2) days for each machine for equipment installation inspection,
15 certification, start-up, training, and corrective adjustments.
16
17 1.10 PERFORMANCE TESTING
18
19 A. Factory and performance testing shall be conducted by the Contractor on each
20 pump as described in Part 3 of this specification.
21
22 PART 2 - PRODUCTS
23
24 2.01 GENERAL
25
26 A. All equipment for the pumps, including motors and bases, shall be furnished
27 as a complete unit by the pump supplier. The Pump Data Sheet included at
28 the end of this section shows the minimum pump requirements.
29
30 B. The pumps and motors shall be rated for continuous duty and shall be capable
31 of pumping the specified flow range without cavitation or excessive vibration.
32 The pumps and drives shall not infringe upon the motor service factor at any
33 point on the pump full speed curve.
34
35 C. The amplitude of vibration shall not exceed the limits set forth in the latest
36 edition of the Hydraulic Institute Standards.
37
38 D. The pumping units required under this Section shall be complete including,
39 where required, proper alignment and balancing of the individual units. All
40 parts shall be so designed and proportioned as to have liberal strength,
41 stability and stiffness and to be especially adapted for the service to be
42 performed. Ample room for inspection, repairs and adjustment shall be
43 provided.
44
45 E. Corrosion resistant nameplates with the name of the manufacturer and the
46 serial number shall be attached to each pump.
47
RECESSED IMPELLER PUMPS
11320-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
2
3
4
5
6
7
8
19
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
1
1
1
1
1
1
1
1
1
1
1
1
1
F. Corrosion resistant nameplates with the name of the manufacturer, serial
number, horsepower, speed, voltage and amperes shall be attached to each
motor.
G. The pumping equipment shall be WEMCO Model C, Hayward Gordon
XR, or approved equal, meeting the design requirements herein.
2.02 MATERIALS
Part: Material: Designation:
Casing
Suction Cover
Wear Plate
Impeller
Impeller Nut & Set Screw
Stuffing Box
Bearing Frame
See 2.03 Below
See 2.03 Below
See 2.03 Below
See 2.03 Below
Stainless
Cast Iron
Cast Iron
Shaft Stainless Steel
Shaft Sleeve
Base
2.03 PUMP CONSTRUCTION
Stainless
Stainless
Torus
18-8 SS
ASTM A48, Class 30
ASTM A48, Class 25 or
Class 30
ASTM A108 or
AISI Grade 1045 or
4140
ASTM A582 Type 416
or Type 410
304 SS
A. The parts exposed to abrasive wear - casing, removable suction cover, wear
plate, and the impeller, shall be of Ni -Hard, ASTM A532 Class I Type A or Hi -
Chrome Iron ASTM A532, Class III, Type A material, and be a minimum of 650
Brinell hardness for maximum wear resistance.
B. The pump(s) shall be of a fully recessed, slurry type design, with the impeller
mounted completely out of the flow path between the pump inlet and
discharge connection, so that solids are not required to flow through the
impeller. All flow path clearances within the pump shall be equal to or greater
than the discharge diameter, so that all solids which will pass through the
discharge will pass through the pump.
C. The casing shall be a minimum of 3/4 -inch thickness. The pump casing shall be
of sufficient strength, weight and metal thickness to ensure long life, accurate
alignment and reliable operation. The volute 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.
1. For pumps with cup -type impeller: The casing shall be split
RECESSED IMPELLER PUMPS
11320-7
03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
perpendicular to the shaft with removable suction cover and stuffing box
cover. Machined fits for these parts shall be accurately aligned and
identical so that the casing may be installed for either clockwise or
counterclockwise direction of rotation. The casing shall be arranged so
that the impeller may be removed without disturbing either suction or
discharge piping. The discharge flange shall be ANSI 125# flat face.
All flange bolt holes shall be slotted for ease of assembly and
disassembly. The discharge piping immediately downstream of the
discharge flange shall be drilled and tapped for a gauge connection.
2. For pumps with radial -vane impeller: The casing shall consist of a one
piece casting with integral suction and discharge nozzles plus a back
plate with integral wear element. The casing will have cast on feet,
which will fully support the volute, to allow removal of the complete
rotating assembly, without disturbing suction or discharge piping.
D. Suction Cover (if required) - The suction cover shall be removable to allow for
access to the impeller. The suction flange shall be 125# flat face with slotted
bolt holes. The suction piping immediately upstream of the suction flange
shall be drilled and tapped for a gauge connection. Special case slots shall be
cast in to retain bolts and to fasten the case to the bearing housing and to the
intake for easy case removal.
E. Impeller — The impeller shall be specifically designed and constructed to
maintain hydraulic pumping performance as wear occurs.
1. Cup Type Impellers:
a. The impeller shall be of cup design such that the deepest portion
of the vane is not located at the vane tips and the tips are
surrounded by a thick -sectioned rim of at least 1 inch
b. The hydraulic design shall be such that the length of the impeller
vane increases as wear occurs to the rim, allowing as -new or
better pumping performance throughout the wear cycle of the
impeller
c. The hydraulic design of the impeller shall preferentially direct
flow to a sacrificial, independently replaceable suction piece.
The suction piece shall be easily accessible and replaceable,
without the need to disassemble any other component of the
pump.
d. Pump -out vanes on the rear shroud of cup type impellers are not
acceptable.
2. Radial Vane Impellers
RECESSED IMPELLER PUMPS
11320-8
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 a. Impellers shall be fitted with full back pump out vanes to restrict
3 flow behind the impellers and shall be keyed to the shaft and
4 secured by a shrouded securing bolt and lock washer.
5
6 b. Minimum thickness at the front edge of the impeller vane shall be
7 1/ "
2
8
9 F Impeller Wear Plate:
10
11 1. For Cup Type Impellers: A replaceable wear plate shall be mounted in
12 the back of the impeller to provide a renewable surface. The wear plate
13 shall be designed to direct flow from behind the impeller to the center of
14 the volute for maximum protection to the casing.
15
16 2. For Radial Vane Impellers: Pumps with radial vane impellers shall be
17 fitted with a rear casing wear plate and integral radial wear element,
18 which will protect the area behind and at the periphery of the impeller
19 from brunt of abrasive wear. The radial wear element will be of a
20 tapered design to promote flow of solid out of the impeller recess.
21
22 G. Stuffing Box - The stuffing box shall be designed to accept either packing or a
23 mechanical seal. 3A" NPT drilled and tapped sealing liquid connection and
24 drain ports shall be provided. The pumps shall be supplied with John Crane
25 Type 3740 split mechanical seal or Chesterton 442.
26
27 H. Bearings - Bearings shall be oil bath lubricated. The oil reservoir shall be
28 sealed at both ends to prevent entrance of foreign matter. The thrust bearings
29 shall consist of three angular contact ball bearings for maximum protection
30 from all thrust loads. The bearing housing will be equipped with a pressure
31 venting device and oil fill and drain taps. A built-in sight glass shall be
32 furnished to check proper oil level. Alternatively, bearings shall be grease
33 lubricated with deep groove ball bearing and 2 angular contact bearing. The
34 bearings shall be rated for a minimum B-10 life of 100,000 hours.
35
36 1 Shaft - The shaft shall be protected throughout the packing area by a
37 removable, hardened stainless steel shaft sleeve.
38
39 J. Shaft Sleeve - A renewable shaft sleeve shall be provided that extends
40 through the stuffing box and under the gland. An 0 -ring seal shall be provided
41 between the sleeve and shaft.
42
43 K. Hardware - All machine bolts, nuts and cap screws shall be of the hex head
44 type and made of 316 stainless steel. Hardware or parts requiring special
45 tools shall not be used.
46
47 L Belts - The pump manufacturer shall furnish and install belts and sheaves to
RECESSED IMPELLER PUMPS
11320-9 03/22/2019
1 drive the pump at the speed necessary to meet the design conditions.
2
3 M. Baseplate and Pedestal - The pump and motor shall be mounted on a
4 common base constructed of a minimum 3/8" thick 304 stainless steel, suitably
5 reinforced to support the full weight of the motor and pump. The pump
6 manufacturer shall furnish and mount a separate, adjustable motor base
7 constructed of 304 stainless steel so that the motor can be easily moved for V-
8 belt tensioning and adjustment.
9
10 2.04 MOTORS
11
12 A. Pump motors shall be in accordance with Section 16480 and shall be TEFC
13 type, 3 Phase, 460 Volt with a maximum speed 1,750 RPM and shall conform
14 to NEMA standards and specifications. The motor supplied with the pump
15 shall be suitable for constant speed use.
16
17 B. All motors shall be built in accordance with latest NEMA, IEEE, ANSI and
18 standards, where applicable.
19
20 C. Motor manufacturers shall be GE, US Motors, Reliance, or Baldor or WEG.
21
22 D. The motors shall be sized such that the service factor is not infringed upon
23 throughout the full speed performance curve of the pumps. At minimum,
24 motors shall have Class B insulation and a 1.15 service factor. Motors shall
25 have re-greaseable or oil lube bearings.
26
27 E. The motors shall be connected to the pump by the drive method specified. All
28 motors shall be of nationally known manufacture and shall conform to NEMA
29 standards and specifications
30
31 2.05 CONTROLS
32
33 A. Furnish and install controls for the grit pumps as described in Section 13640.
34
35 2.06 SHOP PAINTING
36
37 A. Before exposure to weather and prior to shop painting, all surfaces shall be
38 thoroughly cleaned and blasted to SSPC-SP10, dry and free from all mill -
39 scale, rust, grease, dirt and other foreign matter.
40
41 B. All exposed portions of the pumps and motors shall be shop primed, with rust
42 inhibitive primer to a minimum of 4-6 mils FDT and one coat of epoxy finish to
43 4-8 mils DFT. Primer and epoxy must be compatible with field painting as
44 specified in Division 9.
45
46 C. All nameplates shall be properly protected during painting.
47
RECESSED IMPELLER PUMPS
11320-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 D. Gears, bearing surfaces and other similar surfaces obviously not to be painted
2 shall be given a heavy shop coat of grease or other suitable rust resistant
3 coating. This coating shall be maintained as necessary to prevent corrosion
4 during periods of storage and erection and shall be satisfactory to the
5 Engineer up to the time of the final acceptance test.
6
7 E. Stainless steel components shall not be painted.
8
9 2.07 ROTATION
10
11 A. The rotation direction shall be marked on the casing and the pump clocked to
12 the discharge position as shown on the Drawings.
13
14 PART 3 - EXECUTION
15
16 3.01 INSTALLATION
17
18 A. Pumps, drivers and bases shall be precisely leveled and aligned, accurately
19 anchored into position and grouted by the Contractor. Installation shall be in
20 strict accordance with the manufacturer's instructions and recognized industry
21 practices. The Contractor shall furnish and install anchor bolts and the
22 required lubricants for initial operation. The grades of oil and grease shall be in
23 accordance with the manufacturer's recommendations. Anchor bolts shall be
24 304 stainless steel set in accordance with the manufacture's
25 recommendations. The existing concrete maintenance pads shall be modified
26 or removed and replaced as necessary to accommodate the new base plates.
27
28 B. Pressure gauge assemblies shall be furnished and installed on the suction
29 side and the discharge side of each pump by the Contractor. The gauge
30 assemblies shall be per the seal water detail in the drawings. The gauge
31 calibration ranges shall be as small as is practical so that that full range is
32 utilized, but safely within maximum conditions.
33
34 C. The Contractor shall connect the new seal water system to each pump as
35 shown on the drawings such that seal water is automatically supplied to the
36 mechanical seal when the pump is started and in operation.
37
38 D. Prior to initial start-up, the pump manufacturer's representative shall provide
39 written certification to the Owner that the equipment has been installed, tested
40 in accordance with the Manufacturer's approved method, and testing
41 requirements specified herein and shall certify that the equipment is ready for
42 permanent operation.
43
44 3.02 FIELD PAINTING
45
46 A. Field painting is specified under Section 09900 - Painting. The primer and
47 paint used in the shop shall be products of the same manufacturer as the field
RECESSED IMPELLER PUMPS
11320-11 03/22/2019
1 paint to assure compatibility.
2
3 B. All nameplates shall be properly protected during painting.
4
5 3.03 FACTORY TESTS
6
7 A. Each motor shall be given a non -witnessed short commercial test to determine
8 that the motor is free from electrical and mechanical defects and to provide
9 assurance that it meets the specifications. Testing shall be in accordance with
10 NEMA standards and shall consist of no load current, locked rotor current,
11 winding resistance, high potential and bearing inspection.
12
13 B. Each pumping unit, with a calibrated factory test motor, shall be given a
14 factory performance test to provide assurance that the unit meets the
15 specifications. Tests shall be performed in accordance with Hydraulic Institute
16 Standards. Variable speed pumps shall be tested at full speed and all
17 specified reduced speeds with a minimum of two reduced speeds. Copies of
18 the test reports shall be provided to the Engineer.
19
20 C. If any pump tested fails to meet any Specification requirement it shall be
21 modified until it meets all Specification requirements. If any pump tested fails
22 to meet the efficiency requirements at any of the specified flow or head
23 conditions, and all reasonable attempts to correct the inefficiency are
24 unsuccessful, the pump(s) shall be replaced with unit(s) that meet the
25 specified requirements.
26
27 D. Hardness Testing
28
29 1. Before final shipment, a Brinell hardness test shall be conducted
30 showing compliance to ASTM A532 and shall be submitted for
31 approval. Each individual casting shall be Brinell tested at the
32 manufacturer's plant to ASTM Method E-10. Each casting shall be
33 checked in a minimum of two places, in an area that is representative of
34 casting thickness.
35
36 2. Results of the Brinell tests shall be certified by a Registered
37 Professional Engineer and submitted for approval before final shipment.
38
39 3. Hardness tests may be witnessed by a representative of the Owner if
40 so desired.
41
42 E. Performance Testing
43
44 1. A certified shop test shall be performed on each pumping unit in
45 accordance with the test code of the Hydraulic Institute Section 14.6,
46 Level 2B. Tests shall be sufficient to determine the curves of head,
47 input horsepower, and efficiency for capacity from shutoff to runout. A
RECESSED IMPELLER PUMPS
11320-12 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1 minimum of six points, including shutoff, shall be taken for each test
2 run. At least one point of the six shall be taken as near as possible to
3 each specified condition.
4
5 2. Results of the performance tests shall be certified by a Registered
6 Professional Engineer and submitted for approval before final shipment.
7
8 3.04 FIELD INSPECTION AND TESTING
9
10 A. General - Furnish the services of a factory representative in accordance with
11 Specification Section 01820 to inspect the final installation, supervise a test
12 run of the equipment, and provide operator training. The factory
13 representative shall provide a written certification that the pumps are installed
14 in accordance with the manufacturer's recommendations.
15
16 B. The final copies of Operation and Maintenance manuals specified in Section
17 01730 must be delivered to the Engineer prior to scheduling the instruction
18 period with the Owner.
19
20 C. Motors - The Contractor shall check all motors for correct clearances and
21 alignment, and for correct lubrication in accordance with the manufacturer's
22 instructions. The Contractor shall check the direction of rotation of all motors
23 and reverse if necessary.
24
25 D. Pumps - After the pumps have been completely installed and inspected by a
26 factory representative, field tests shall be conducted on each unit in the
27 presence of the Engineer to show conformance with the specifications. The
28 Contractor shall supply all labor, equipment and incidentals required to
29 complete these tests.
30
31 E. The factory representative shall include certification of proper installation and
32 provide a complete startup report for each pump, documenting the pump
33 operating conditions at startup. This report shall be made part of the operation
34 and maintenance manual. Pumps that cannot be made to comply with the
35 specifications shall be removed and replaced with pumps that satisfy the
36 conditions specified.
37
38
' 39 END OF SECTION
1
1
1
1
40
RECESSED IMPELLER PUMPS
11320-13 03/22/2019
1 THIS PAGE INTENTIONALLY LEFT BLANK
2
RECESSED IMPELLER PUMPS
11320-14 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11321
2
I3 STACKED TRAY GRIT CONCENTRATORS
4
5 PART 1 — GENERAL
I 6
7 1.01 SCOPE OF WORK
8
I
9 A. Furnish and install all labor, equipment, materials, tools and incidentals required
10 for a complete and operable installation as necessary to provide complete and
11 operational stacked tray grit concentrators as shown on the drawings and
I12 specified herein. The equipment shall be of the latest design and shall be
13 fabricated of materials and in a fashion that will fully perform the functions
14 described below. An approved Manufacturer shall supply the equipment and
I 15 the Contractor shall install the equipment.
16
17 B. The grit concentrators shall consist of but not be limited to the following:
I18
19 1. Four (4) independent stacked tray grit removal units
20 2. Each stacked tray grit concentrator shall consist of three trays and a
1
21 collector
22 3. Each tray shall be 12 -foot in diameter.
23
1
24 C. The concentrators shall be installed as shown on the plans, as recommended
25 by the manufacturer, and in compliance with all OSHA, local, state, and federal
26 codes and regulations.
I27
28 D. All metal components shall be 316 stainless steel. Metal components that will
29 be fully submerged at all times shall be 304 stainless steel. All components shall
I30 be furnished by one manufacturer who shall be responsible for the design,
31 coordination and proper operation of the entire system.
32
I
33 E. These Specifications are intended to give a general description of the system
34 required, but do not cover all details; which will vary in accordance with the
I
36
35 requirements of the equipment as offered. They are, however, intended to cover
the furnishing, shop testing, delivery and complete installation and field testing
37 of all materials, equipment and appurtenances for the complete unit as herein
I38 specified, whether specifically mentioned in these Specifications or not. The
39 scope of work includes providing a manufacturer's authorized representative to
40 perform start-up of the equipment, and to instruct the Owner's personnel in the
I
41
42 care, operation and maintenance of all equipment provided under this section.
43 1.02 SUBMITTALS
I44
45 A. Provide shop drawings and product data as specified in Division 1 for the
46 equipment being furnished. The submittal information shall at minimum include
I47 the following:
STACKED TRAY GRIT REMOVAL SYSTEM
11321-1 03/22/2019
1
1
2
3 1. Certified shop drawings showing all details of construction, dimensions
4 and anchor bolt requirements.
5 2. Descriptive product literature and catalog cuts.
6 3. Complete exploded view of parts and materials of construction identified
7 and bill of materials lists for the equipment.
8 4. Manufacturer's installation drawings and instructions
9 5. Operation and Maintenance Data as specified in Division 1.
10 6. Manufacturer's Certificate of Compliance certifying compliance with the
11 referenced Specification and standards
12 7. Certified copies of reports of factory tests specified in this Section and
13 required by the referenced standards.
14 8. Equipment weights and lifting points.
15 9. Recommendations for unloading, handling, short and long term storage,
16 including procedures and equipment to be used for removal of the
17 existing roof, equipment rigging and equipment placement.
18 10. A copy of the manufacturer's warranty.
19 11. Installation reference list.
20
21 B. Furnish Operation and Maintenance Manuals in accordance with Section
22 01730. At minimum, the manuals shall include equipment descriptions,
23 operating instructions, drawings, exploded views, parts listings, troubleshooting
24 techniques, a recommended maintenance schedule and the recommended
25 lubricants
26
27 C. Failure to include all drawings applicable to the equipment specified in this
28 section will result in rejection of the entire submittal with no further review.
29
30 D. A copy of documents proving certification of the Manufacturer's Quality
31 Management System according to ISO 9001 and Environmental Protection
32 Management System according to ISO 14001.
33
34 1.03 REFERENCE STANDARDS
35
36 A. Codes, Specifications and Standards referred by number or title shall form a
37 part of this Specification to the extent required by the references thereto. Latest
38 revisions as of the date of bid opening shall apply, unless otherwise shown or
39 specified.
40
41 1. American Iron and Steel Institute (AISI).
42 2. American National Standards Institute (ANSI).
43 3. American Society for Testing and Materials (ASTM).
44 4. American Bearing Manufacturers Association (ABMA).
45 5. American Gear Manufacturers Association (AGMA).
46 6 National Electrical Manufacturers Association (NEMA).
47 7. National Fire Protection Association (NFPA).
STACKED TRAY GRIT REMOVAL SYSTEM
11321-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 8. Underwriters Laboratory (UL).
2
3 1.04 QUALITY ASSURANCE
4
5 A. The grit concentrators shall be Manufacturer's standard product and only
6 modified as necessary to comply with the drawings, specifications, and
7 specified service conditions. All equipment covered by these specifications
8 shall be manufactured and provided by one manufacturer, and shall be
9 complete including all appurtenances.
10
11 B. Certificate of Compliance
12
13 1. The manufacturer shall certify in writing that the stacked tray grit
14 concentrators shall be manufactured in strict compliance with the
15 Contract Specifications and that all quality and quality control standards
16 are met. The manufacturer shall submit the written certification along
17 with the Shop Drawing submittal.
18
19 C. The Manufacturer shall completely shop assemble and adjust the equipment
20 prior to shipment. The Owner shall be notified 30 days in advance of the
21 expected assembly date and again two weeks prior to when the assembled
22 components are available for inspection prior to shipment.
23
24 D. Should equipment which differs from these Specifications be offered and
25 determined to be the approved equal of that specified, such equipment will be
26 acceptable only on the basis that any revisions in the design and/or construction
27 of the structures, piping, appurtenant equipment, electrical work, etc., required
28 to accommodate such a substitution, shall be made at no additional cost to the
29 Owner and the Engineer and be as approved by the Engineer.
30
31 1.05 PRODUCT DELIVERY, STORAGE AND HANDLING
32
33 A. The Contractor shall be responsible for the delivery, proper storage and
34 handling of products in accordance with the manufacturer recommendations.
35
36 B. The Contractor shall be responsible for promptly removing damaged products
37 from the job site and replacing damaged products with undamaged products
38
39 C. Thoroughly clean all equipment and subassemblies of all water, sand, grit, weld
40 splatter, grease, oil and other foreign materials before preparation for shipment.
41 Protect all machined surfaces against physical damage and exposure to the
42 elements during shipment, handling, storage and installation.
43
44 D. Pack equipment to provide ample protection from damage during shipment,
45 handling and storage. Cap and seal all openings.
46
STACKED TRAY GRIT REMOVAL SYSTEM
11321-3 03/22/2019
1 E. The equipment and material shall be shipped complete except where partial
2 disassembly is required by transportation regulations or for protection of
3 components.
4
5 F. In order to install the concentrators, the Contractor shall remove the existing
6 double -tee roof over the existing screens in order to provide access for the
7 equipment. After moving the concentrator equipment into the building, the roof
8 shall be re-installed/re-constructed. The Contractor shall submit a detailed
9 procedure and schedule for installing the concentrators that shall minimize the
10 time that the roof is open. The procedure and schedule shall be subject to
11 review by the Engineer and approval of the Owner.
12
13 1.06 MANUFACTURER QUALIFICATIONS
14
15 A. The grit concentrators shall be supplied by a single manufacturer in order to
16 provide standardization for appearance, operation, maintenance, spare parts
17 and manufacturer's service.
18
19 B. The manufacturer shall be have been regularly engaged in the production of
20 equipment for the specified use for a minimum of 10 years. The Contractor and
21 the manufacturer shall have the responsibility for the proper functioning of the
22 equipment furnished.
23
24 C. Subject to compliance with the requirements of the specification, the acceptable
25 manufactures and products shall be the Head Cell grit concentrator as
26 manufactured and supplied by Hydro, International or approved equal.
27
28 1.07 WARRANTY
29
30 A. The equipment shall be warranted in accordance with Section 01740. Any
31 product or part that proves defective in material, workmanship, or design within
32 twelve (12) months from the date of substantial completion shall be repaired,
33 modified, or replaced, at no expense to the Owner.
34
35 1.08 DESIGN CRITERIA
36
37 A. The grit concentrator design shall be based on surface area and flow. The
38 design requirements of the grit concentrator are listed below. All grit removal
39 components shall be sized for a peak flow rate of 27 mgd.
40
41 Number of grit concentrators 4
42 Number of trays in each grit concentrator 3
43 Diameter of each tray 12 -feet
44 Peak process flow to each grit concentrator 6.25 mgd
45 Peak hydraulic flow to each grit concentrator 6.75 mgd
46 Maximum headloss at 27 mgd with all 4 units in service 8 -inches
47 Fluidizing water requirements for each concentrator 20 gpm @ 50 psi
STACKED TRAY GRIT REMOVAL SYSTEM
11321-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 1.09 PERFORMANCE GUARANTEE
3
4 A. The grit concentrator Manufacturer shall provide a performance guarantee as
5 outlined below using the design criteria in the previous Section:
6
7 1. Minimum capture efficiency at flows < 6.25 mgd with specific gravity 2.65 or
8 greater shall be 95% by weight for all grit > 106 microns.
9
10 2. Minimum capture efficiency at flows > 6.25 mgd and < 6.75 mgd with specific
11 gravity 2.65 or greater shall be 95% by weight for all grit > 125 microns.
12
13 PART 2 — PRODUCTS
14
15 2.01 MATERIALS AND FINISHES
16
17 A. MATERIALS
18
19 1. All stainless steel used for the fabrication of the equipment shall conform
20 to the following standards:
21
22 a. Plate and Sheet: ASTM A 167; ASTM A 240
23 b. Bar: ASTM A 276; ASTM A 479
24 c. Tube: ASTM A 312
25
26 B. EXTERIOR SURFACES FINISHES
27
28 1. All surfaces shall be free of sharp edges, weld spatter and residue. All
29 welds shall be ground smooth.
30
31 2. All stainless steel surfaces shall be acid washed.
32
33 2.02 GRIT CONCENTRATOR
34
35 A. The grit concentrator design shall be a stacked tray type with cone shaped trays
36 and a cone shaped bottom. Grit concentrator shall be placed in a concrete tank
37 to receive the incoming screened flow. Grit concentrators shall provide
38 sufficient surface area to remove the specified grit particles from the specified
39 peak flow and concentrate the grit in a sump at the bottom of the unit. The de -
40 gritted effluent from the grit concentrators shall discharge over a weir as shown
41 on the drawings.
42
43 B. The grit concentrator inlet manifold shall be 316 stainless steel and function as
44 a flow splitter to direct and equally divide the flow between each of the trays.
45
STACKED TRAY GRIT REMOVAL SYSTEM
11321-5 03/22/2019
1 C. The grit concentrators shall be all -hydraulic, self -activating and shall not require
2 internal moving parts. The underflow connection shall be as required by the
3 manufacturer.
4
5 D. Construction
6
7 1. The grit concentrator trays shall be 12 -feet diameter and constructed with
8 a minimum 1/4 inch thick PE.
9
10 2. The trays shall fit securely into a 304 stainless steel support frame
11 provided by the manufacturer.
12
13 3. All structural members of the stainless steel support frame shall be 1/4"
14 thick minimum.
15
16 4. The support frame shall fit inside and be secured to the bottom of a
17 concrete support structure.
18
19 5. The concrete support structure shall also serve as a tank and shall
20 incorporate an effluent overflow weir as shown on the drawings.
21
22 6. A stainless steel underflow grit collector shall be provided by the
23 manufacturer for collection and removal of settled solids. The grit
24 collector shall be installed at the bottom of the concrete tank and at the
25 tip of the concentrator cone and incorporate flanged underflow and
26 threaded fluidizing pipe connections.
27
28 7. All pipe flanges shall conform to ANSI B16.1 bolt patterns.
29
30 E. Accessories
31
32 1. Each grit concentrator unit shall be supplied with a brass throttling valve,
33 a brass shut off valve, and a stainless steel and acrylic in-line flow meter
34 for the fluidizing water system.
35
36 2.03 GRIT PUMP
37
38 A. Grit pump requirements are specified in Section 11320.
39
40 2.04 OPERATION DESCRIPTION
41
42 A. Screened raw wastewater shall be gravity fed into the individual grit
43 concentrators through a manually controlled gate.
44
45 B. Grit Slurry Pumps
46
STACKED TRAY GRIT REMOVAL SYSTEM
11321-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. Slurry from the grit concentrators shall be pumped continuously or
2 intermittently at the plant operator's discretion. If intermittent operation
3 is desired, the system shall be capable of starting and stopping
4 automatically based on an adjustable time interval.
5
6 2. Control and operation of the grit pumps are described in Section 13640
7 of the Specifications.
8
9 2.05 UTILITY REQUIREMENTS
10
11 A. WATER
12
13 1. Each grit concentrator shall be furnished with a connection at the
14 collector section for 20 gpm of non -potable water at a minimum 50 psig
15 for fluidizing the deposited grit.
16
17 2.06 MODIFICATIONS TO EXISTING WASTEWATER SCREENS
18
19 A. The Contractor shall coordinate with the manufacturer (Huber) of the existing
20 screens to provide a qualified factory technician to re -program and start-up the
21 screen differential set point based on the higher downstream water level.
22
23 PART 3 — EXECUTION
24
25 3.01 INSTALLATION
26
27 A. Install equipment in accordance with the approved shop drawings and the
28 manufacturer's installation instructions.
29
30 B. Prior to initial start-up, the Manufacturer's representative shall provide written
31 certification to the Owner that the equipment has been installed, tested in
32 accordance with the Manufacturer's approved method, and testing
33 requirements specified herein and shall certify that the equipment is ready for
34 permanent operation.
35
36 3.02 FIELD QUALITY CONTROL
37
38 A. The Manufacturer shall provide an authorized field technician to perform the
39 following services.
40
41 1. Inspect the completed installation and note any deficiencies and provide
42 an installation report.
43
44 2. Provide equipment startup and provide a startup report.
45
46 3. Conduct performance verification testing and provide a performance
47 verification report along with a certificate of proper installation.
STACKED TRAY GRIT REMOVAL SYSTEM
11321-7 03/22/2019
1
2 4. Instruct plant personnel in the operation and maintenance of the
3 equipment.
4
5 a. Training sessions shall include, but not be limited to, a classroom
6 session and a hands-on session. The training shall be provided
7 for a minimum of one (1) day.
8
9 3.04 STARTUP AND PERFORMANCE TESTING
10
11 A. The Manufacturer shall submit to the Engineer through the Contractor a proven
12 test procedure that can be conducted following startup that will demonstrate the
13 specified performance criteria has been met, including removal efficiencies,
14 solids loading parameters, and solids concentration criteria as previously
15 described.
16
17 B. The Manufacturer shall conduct the performance testing in accordance with the
18 approved test procedure and provide a report on the results of the testing.
19
20 C. Should the results of the performance testing indicate that specified
21 performance criteria is not met, the Contractor shall make those modifications
22 necessary to achieve compliance with the criteria and shall re -perform the test
23 at no additional cost to the Owner.
24
25
26 END SECTION
27
STACKED TRAY GRIT REMOVAL SYSTEM
11321-8 03/22/2019
1
1
1 SECTION 11323
I 2
3 GRIT SEPARATION EQUIPMENT
4
II5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
I 8
9 A. Furnish and install grit separation and removal equipment consisting of one (1)
10 10 -inch diameter cyclonic separator and one (1) 12 -inch diameter full flared 316
I11 stainless steel screw-type dewatering classifier, including 316 stainless steel
12 supports for this equipment. The classifier shall be fitted with a grit discharge
13 chute, which shall connect the classifier and direct grit by gravity to a new
I 14 opening in the floor as shown on the drawings.
15
16 B. In addition, the Contractor shall furnish replacement parts and refurbish two
17 (2) existing cyclonic separators and one (1) existing classifier as described in
18 Part 3 herein.
19
I
20 1.02 DESCRIPTION OF THE SYSTEM
21
22 A. The cyclonic separator (cyclone) shall receive flow from the grit pumps and
I
23 separate the inlet feed into two streams: overflow and underflow. The
24 overflow shall include the majority of the liquid along with lighter organic
25 materials. The underflow shall consist of concentrated grit slurry that shall
I26 flow by gravity into the grit classifier. The grit classifier shall further remove
27 organic material and shall separate the grit for discharge into a grit disposal
129 28 system.
30 B. The cyclone shall be sized for an inlet feed rate of 300 gpm at an inlet
31 pressure of 10 psi and an underflow of 16 gpm. At those conditions, the
I32 cyclone shall be capable of removing 95 percent of 106 micron grit entering
33 the inlet feed with a specific gravity of 2.65 or greater.
I
34
35 C. The classifier shall be capable of the same removal rates for the 16 gpm
36 entering the classifier from the cyclone underflow. The classifier shall be 316
I
38
37 stainless steel construction and shall be an inclined screw with a pooling
section at the lower end with an adjustable weir.
39
I40 1.03 REFERENCE STANDARDS
41
42 A. Design, manufacturing and assembly of elements of the equipment herein
I43 specified shall be in accordance with the standards of the below listed
44 organizations. Where reference is made to a standard of any organization, the
45 version of the standard in effect at the time of bid opening shall apply.
GRIT SEPARATION EQUIPMENT
11323-1 12/18/20
1
1
1
2 1. American Iron and Steel Institute (AISI)
3 2. American Society of Mechanical Engineers (ASME)
4 3. American National Standards Institute (ANSI)
5 4. American Society for Testing Materials (ASTM)
6 5. American Water Works Association (AWWA)
7 6. Hydraulic Institute Standards (HI)
8 7. National Electrical Manufacturers Association (NEMA)
9 8. Underwriters Laboratories, Inc. (UL)
10
11 1.04 QUALITY ASSURANCE
12
13 A. All grit separation, classification and removal equipment furnished under this
14 Section shall be of a design and manufacture that has been used in similar
15 applications and it shall be demonstrated to the satisfaction of the Owner that
16 the quality is equal to equipment made by that manufacturer specifically
17 named herein. Manufacturers shall provide evidence of at least five (5)
18 installations in which identically sized equipment has provided satisfactory
19 performance for a minimum of ten (10) years in a similar application. No
20 consideration will be given to individually sized equipment that has not been
21 commercially available for at least ten (10) years.
22
23 B. To ensure a consistently high standard of quality, the manufacturer of this
24 equipment shall comply with the requirements of the ISO 9001 Quality
25 System, and such compliance shall be verified by an independent certification
26 agency approved by the International Organization for Standardization.
27 Documentation shall be submitted for approval showing compliance with this
28 requirement, and the equipment will not be released for shipment until
29 approved.
30
31 C. The cyclone, classifier, and appurtenant equipment shall be a complete
32 system and shall be furnished by, and be the product of, one manufacturer
33 who is fully experienced, reputable and qualified in the manufacture of the
34 equipment furnished. The grit concentration and removal equipment shall be
35 suitable for satisfactory operation with the normal operating levels shown on
36 the Drawings and described herein. The Contractor shall assume full
37 responsibility for the satisfactory installation and operation of the entire grit
38 separation, classification and removal system as specified.
39
40 D. Motors shall be in accordance with NEMA Standards.
41
42 E. The cyclone and classifier and all related equipment shall be designed,
43 constructed and installed in accordance with the best practices and methods.
44
45 F Requests for substitution shall include manufacturer's literature for each
GRIT SEPARATION EQUIPMENT
11323-2 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 product giving name, product number, type, descriptive information, and
2 independent lab test reports showing results to equal the performance criteria
3 of the equipment specified herein. In addition, a list of five projects shall be
4 submitted in which identical equipment has been used and rendered
5 satisfactory service.
6
7 G. The cyclone and classifier manufacturer shall be fully responsible for the
8 design, arrangement and operation of all connected rotating components of
9 the assembled pumping units to ensure that neither harmful nor damaging
10 vibrations occur at any speed within the specified operating range.
11
12 H. Should equipment which differs from these Specifications be offered and
13 determined to be the approved equal of that specified, such equipment will be
14 acceptable only on the basis that any revisions in the design and/or
15 construction of the structures, piping, appurtenant equipment, electrical work,
16 etc., required to accommodate such a substitution, shall be made at no
17 additional cost to the Owner and be as approved by the Engineer.
18
19 1 The cyclone and classifier operating parameters, i.e., cyclone feed rate,
20 pressure and underflow and classifier pool area, weir length, screw speed,
21 submergence, and slope, shall be designed to avoid build-up of fine grit in the
22 classifier tank, which would cause grit of the desired size to be lost. Changes
23 in any of these parameters will not be acceptable unless a detailed submittal
24 showing calculations and operating data provides evidence that any such
25 change will not affect the ability of the system to perform as specified.
26
27 K. The equipment manufacturer shall guarantee the performance of each
28 component. The cyclones and classifier shall be as manufactured by WEMCO
29 and be a WEMCLONE Model 1000C and a WEMCO 12 -inch Full Flare
30 Classifier or equal.
31
32 1.05 SUBMITTALS
33
34 A. Copies of all materials required to establish compliance with the Specifications
35 shall be submitted. The submittal format shall be in the form of a booklet,
36 suitably tabbed and divided to cover at least the areas noted below for each
37 major equipment item. The submittal booklet shall include adequate detail and
38 sufficient information for the Engineer to determine that all of the equipment
39 proposed meets the detailed requirements of the Specifications. Incomplete
40 or partial submittals will not be reviewed. Submittals shall include at least the
41 following:
42
43 B. Certified shop and erection drawings showing all important details of
44 construction, dimensions and anchor bolt locations and in accordance with
45 provisions of Section 01300.
GRIT SEPARATION EQUIPMENT
11323-3 12/18/20
1
2 C. Descriptive literature, bulletins and/or catalogs of the equipment.
3
4 D. A complete total bill of materials of all equipment (may be furnished with
5 Operation and Maintenance manuals specified herein).
6
7 E. A list of the manufacturer's recommended spare parts to be supplied in addition
8 to those specified herein. Include gaskets, packing, etc. on the list. List bearings
9 by the bearing manufacturer's numbers only. Provide an exploded view showing
10 part numbers and materials of construction for all components.
11
12 F Complete motor data.
13
14 G. Test Reports to be Submitted
15
16 Data on the characteristics and performance of each component. Data shall
17 include guaranteed removal rates based on actual shop tests of similar units,
18 which show that they meet the specified requirements for removal efficiency.
19
20 1. Description of factory testing procedures and equipment.
21
22 2. Copies of all test results, as specified in Parts 2 and 3 of this Section.
23
24 3. Copies of all start-up test reports showing compliance with these
25 Specifications.
26
27 H. In the event that is impossible to conform to certain details of the
28 Specifications due to different manufacturing techniques, completely describe
29 all non -conforming aspects.
30
31 I. Submit manufacturer's installation instructions under provisions of Division 1.
32
33 J. The submittal data shall be prepared, in its entirety, by the equipment
34 manufacturer. Shop drawings prepared by the manufacturer's sales
35 representative, fabrication shops, or other than the listed manufacturers will
36 not be acceptable. No additions or modifications to the manufacturer's
37 submittal will be accepted, with the sole exception of a cover sheet provided
38 by the manufacturer's local Representative.
39
40 1.06 OPERATION AND MAINTENANCE DATA
41
42 A. Complete operating and maintenance instructions in accordance with
43 Specification 01730 shall be furnished for all equipment included under these
44 Specifications. The maintenance instructions shall include installation
45 instructions, lubrication instructions, troubleshooting data, full preventative
GRIT SEPARATION EQUIPMENT
11323-4 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 maintenance schedules, complete spare parts lists with ordering information,
2 and exploded views of all equipment with part numbers identified.
3
4 1.07 TOOLS AND SPARE PARTS
5
6 A. Furnish one (1) set of all special tools required for normal operation and
7 maintenance.
8
9 B. Furnish and package for storage all of the manufacturer's recommended spare
10 parts to assure normal running and maintenance for a period of two (2) years
11 assuming all units are in in continuous operation.
12
13 C. Furnish and package for storage a quantity of the recommended lubrication to
14 meet the manufacturers' recommended lubrication change intervals for 1 year
15 assuming all units are in continuous operation. Lubricants shall include summer
16 and winter grades with alternate reference to equal products of other
17 manufacturers, and shall include all lubricant specification such as viscosity,
18 AGMA numbers, etc.
19
20 D. All spare parts shall be furnished in containers clearly identified with indelible
21 markings as to contents. Each container shall be packed with its contents
22 protected for prolonged storage.
23
24 E. In addition to items A -D, the following spare parts shall be supplied with the
25 equipment:
26
27 One (1) set of drive belts (or coupling) for the new classifier
28 One (1) set of drive belts for the existing classifier
29 One (1) complete set of molded replaceable liners for each of the three
30 cyclones
31 Two (2) complete sets of feed box liners as applicable for each
32 classifier
33 One (1) set of UHMW or ARS wearing shoes for the new classifier
34 One (1) set of UHMW or ARS wearing shoes for the existing classifier
35 One (1) complete lower bearing assembly for the new classifier
36 One (1) complete lower bearing assembly for the existing classifier
37 Ten (10) lower bearing rubber toric seals for the existing classifier
38 One (1) lower bearing seal tool for the new classifier
39 One (1) lower bearing seal tool for the existing classifier (if different)
40 Six (6) lower bearing O -Rings for each classifier
41
42 1.08 DELIVERY, STORAGE AND HANDLING
43
44 A. The equipment and material shall be shipped complete except where partial
45 disassembly is required by transportation regulations or for protection of
GRIT SEPARATION EQUIPMENT
11323-5 12/18/20
1 components.
2
3 B. All parts shall be properly protected so that no damage or deterioration will
4 occur during a prolonged delay from the time of shipment until installation is
5 completed and the units and equipment are ready for operation.
6
7 C. All equipment and parts must be properly protected against any damage
8 during a prolonged period at the site.
9
10 D. Factory assembled parts and components shall not be dismantled for
11 shipment unless permission is received in writing from the Engineer.
12
13 E. Finished surfaces of all exposed openings shall be protected by wooden
14 blanks, strongly built and securely bolted thereto.
15
16 F. Finished iron or steel surfaces not painted shall be properly protected to
17 prevent rust and corrosion.
18
19 G. After hydrostatic or other tests, all entrapped water shall be drained prior to
20 shipment and proper care shall be taken to protect parts from the entrance of
21 water during shipment, storage and handling.
22
23 H. Each box or package shall be properly marked to show its net weight in
24 addition to its contents.
25
26 1.09 WARRANTY
27
28 A. In order to assure the proper performance and compatibility of all equipment
29 supplied within the intent of this Specification shall be warranted by the same
30 supplier.
31
32 B. The equipment shall be warranted to be free from defects in workmanship,
33 design and materials. If any part of the equipment should fail during the
34 warranty period, it shall be replaced in the machine(s) and the unit(s) restored
35 to service at no expense to the Owner.
36
37 C. The manufacturer and the Contractor shall warrant the equipment against
38 defects in workmanship and materials for a period of one (1) year under
39 normal use, operation and service, commencing at the date of substantial
40 completion.
41
42 1.10 SERVICES OF MANUFACTURER
43
44 A. Provide the services of a qualified factory certified representative for a total of
45 four (4) days for equipment installation inspection, certification, start-up,
GRIT SEPARATION EQUIPMENT
11323-6 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 training, and corrective adjustments for the new equipment and existing
2 equipment
3
4 PART2- PRODUCTS
5
6 2.01 CYCLONE
7
8 A. Each cyclone shall consist of a heavy-duty cast iron volute feed chamber with
9 one fabricated stainless steel cylindrical section with 2 conical sections and
10 two apex sections of aluminum to minimize overhung weight.
11
12 B. Each interior section of the cyclone shall be individually Tined and protected from
13 the high velocity grit by a replaceable rubber or neoprene liner. The cyclone
14 shall be constructed so that any section of the liner can be replaced
15 independently.
16
17 C. A quick disconnect clamp shall be provided between the apex assembly and
18 lower cone section to allow removal of material which may clog the apex, without
19 disconnecting any piping on the cyclone itself.
20
21 D. The inlet feed to the cyclone shall be 4 -inch, the overflow 6 -inch, with Victaulic
22 connections furnished by the cyclone manufacturer. Cast iron adaptor pieces
23 will be provided with ANSI 125 Ib. flat face flanges. The adaptor piece will be
24 fitted with a cast iron elbow on the overflow so that the flange face will mate up
25 with horizontal piping.
26
27 E. Each cyclone shall be supplied complete with a 2 -inch apex.
28
29 F. The cyclone vortex finder shall be 4 -inch diameter and made of Ni -Hard with a
30 minimum hardness of 500 Brinnell.
31
32 G. Each cyclone inlet feed shall be tapped for a 1" NPT gauge connection and a
33 diaphragm -protected pressure gauge assembly shall be provided by the cyclone
34 manufacturer.
35
36 H. The cyclone underflow shall feed into the classifier for washing and dewatering,
37 and be sized so that the proper hydraulic loading is provided to the classifier.
38
39 I. The cyclone overflow will connect to piping furnished by the Contractor, which
40 must be properly and adequately vented to prevent siphoning.
41
42 J. The cyclone manufacturer shall supply a fabricated 316 stainless steel mounting
43 plate that connects to the cyclone support structure. The mounting plate shall
44 be minimum 3/8 inch thick and properly oriented such that the cyclone underflow
45 is directed into the classifier at the appropriate location.
GRIT SEPARATION EQUIPMENT
11323-7
12/18/20
1
2 2.02 CLASSIFIER
3
4 A. Each classifier shall consist of a full flare fabricated 316 stainless steel grit
5 settling tank with a screw-type grit conveyor.
6
7 B. Each classifier shall have a minimum pool area at maximum water level of 8.3
8 square feet, a minimum weir length of 28.3 inches, and a screw speed of 12
9 RPM maximum.
10
11 C. The classifier pool depth and weir height shall be adjustable by removable weir
12 bars.
13
14 D. The grit settling tank shall be constructed of 1/4" 316 stainless steel plate,
15 suitably reinforced and mounted on 316 stainless steel supports at a slope of not
16 more than 3-1/2 inches per foot. The tank shall be designed to provide a settling
17 compartment where grit separation takes place, with a minimum full water depth
18 of 150% of the screw diameter.
19
20 E. The weir overflow shall discharge into a launder box equipped with a screwed
21 pipe nozzle or Victaulic fitting for connection to 2 1/2 inch drain connection.
22
23 F. The classifier tank shall be provided with a welded bar, running from the top of
24 the tank to below the water level to provide a sluice channel, in order to prevent
25 the buildup of grit opposite the raked material, to aid in drainage.
26
27 G. The manufacturer shall supply and install a valve cock with a 3/8 -inch NPT
28 nipple for the spiral sluice water. A 115 volt, single phase solenoid valve, which
29 is compatible with the motor enclosure, shall also be supplied and installed by
30 the manufacturer for the sluice water line and connected by the electrical
31 contractor to open when the Classifier motor is activated.
32
33 H. Each classifier tank shall be fitted with a grit discharge opening, located such
34 that accumulated grit at the top (dry) end of the screw conveyor shall exit the
35 tank in a vertical down direction through the grit discharge opening.
36
37 I. Each classifier tank shall be fabricated to accept the underflow from the
38 cyclone. The flow receiving area shall function as a splash guard and be fitted
39 with a wear protector and a cover allowing inspection of the cyclone apex
40 without disturbing the cyclone piping or alignment.
41
42 J. The flow receiving area shall be designed and located by the manufacturer to
43 minimize short-circuiting to the overflow weir of the classifier, and to handle
44 maximum cyclone underflow discharge.
45
GRIT SEPARATION EQUIPMENT
11323-8 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 K. The classifier manufacturer shall be responsible for ensuring that the flow
2 receiving area is designed to dissipate energy generated from the cyclone
3 underflow, to minimize disruption of the classifier pool.
4
5 L. The grit shall be removed from the bottom of the settling compartment and
6 discharged by means of a 50% pitch, 12 -inch diameter screw-type conveyor.
7
8 M. The screw shall be made from pre -formed heavy 316 stainless steel flight
9 sections welded to a 316 stainless steel shaft and fitted with replaceable wearing
10 shoes.
11
12 N. The shaft of the conveyor shall be a minimum of 3 -inch diameter, Schedule 80
13 stainless steel pipe, and shall be designed with a maximum stress of 3000 psi,
14 and a fatigue at 98% reliability of 20 years minimum.
15
16 O. The screw conveyor shall be rigidly supported at both the upper and lower ends,
17 so that the screw conveyor is mounted above, and does not contact, the
18 classifier tank. This mounting shall provide for a clearance between the screw
19 conveyor and the tank bottom, so that a buildup of sand or grit will provide a bed
20 for the screw, eliminating tank wear, and providing a drainage area for the
21 conveyed grit.
22
23 P. The flights shall be a minimum thickness of 12 gage 316 stainless steel, welded
24 to the pipe shaft. The flights shall be a minimum height of 4-1/8 inches, as
25 measured along the face of the flight. The flights shall travel above the structure
26 and therefore no wear to the walls or the bottom of the structure shall occur.
27
28 Q. Wearing shoes shall be abrasion resistant and mounted on the flights by
29 means of hardened flat head screws and nuts. The abrasion resistant wearing
30 shoes shall be made of UHMW or ARS and shall be a minimum of 10 gage
31 thickness by 4 inches high.
32
33 R. The screw shall have the capacity to remove 3/4 ton(s) per hour of grit from the
34 grit settling tank.
35
36 S. The upper end of the screw conveyor shall be connected to a direct drive or v-
37 belt speed reducer drive unit. The drive unit shall be fitted with a stainless steel
38 guard.
39
40 T The lower end of the screw shall be supported by a submerged bearing, housed
41 in a water -tight cast iron housing, suitable for completely submerged operation in
42 grit service. The bearing shall be designed to accept radial and axial loads from
43 the spiral screw conveyor. The cast iron housing shall be provided with stainless
44 steel cap screws, and fill and drain plugs. The lower bearing shall utilize a
45 sealed bronze sleeve -type bearing, running completely submerged in oil, and
GRIT SEPARATION EQUIPMENT
11323-9 12/18/20
1 shall require only yearly inspection and oil change. The bearing shall be
2 provided with permanent stellite seals to prevent the leakage of oil and infiltration
3 of grit and other foreign particles into the housing. The seal shall be of the self -
4 compensating type, consisting of two mating hardened steel alloy rings, each
5 held in place by a rubber toric. The wearing surfaces of the rings shall be
6 precision lapped to form an initial sealing band of approximately 1/32 inch in
7 width. The seal shall be designed such that as seal rings wear through normal
8 operation, the pressure from the rubber torics shall push the rings further against
9 each other to form a broadened contact band.
10
11 U. An alternative lower bearing design may be acceptable upon approval by the
12 owner.
13
14 V. The complete drive assembly, screw conveyor, and lower bearing assembly
15 shall be designed so that the screw can be raised for inspection without the
16 need to disassemble any components, or to drain the classifier tank.
17
18 X. The complete drive assembly shall be pivoted at the shaft centerline so that the
19 screw assembly can be raised for periodic inspection.
20
21 Y The lower end of the assembly shall be attached to a manually operated lifting
22 device designed to allow the entire assembly to be lifted above the maximum
23 water level.
24
25 Z. The classifier shall be fitted with an OSHA approved cover to enclose the
26 entire settling tank during normal operation. The cover shall be designed to
27 prevent objects from coming into contact with moving parts while the classifier
28 is in operation. The cover shall be provided in two pieces and clamped to the
29 classifier tank, to allow for removal, regular maintenance, and inspection. The
30 clamps shall be designed so that they cannot be removed without the use of
31 tools. The cover shall be made of the same material as tank with stainless
32 steel expanded metal viewing windows to allow for inspection of the settling
33 pool and upper portion of the spiral.
34
35 AA. All submerged metal pieces shall be 316 stainless steel or other non -corrosive
36 metal.
37
38 AB. Stainless steel parts shall receive a cosmetic blast with to remove all weld stain
39 markings and give the surface a uniform appearance. Stainless steel parts will
40 not be coated.
41
42 AC. The drive assembly shall be fitted with mechanical type torque limiter affixed to
43 the drive or an over -current device connected to the motor circuit. Either device
44 shall stop the screw from turning before any mechanical or electrical damage
45 occurs.
GRIT SEPARATION EQUIPMENT
11323-10 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 1. The torque limiter shall be adjustable and shall be set to disengage when
3 the torque on the spiral exceeds the operating limit of the drive.
4
5 2. Upon disengaging, the torque limiter will open the motor control circuit
6 and disconnect power to the motor.
7
8 AD. Classifier safety stop switches: Each classifier, one new and one existing, shall
9 be fitted with an emergency stop system.
10
11 1. The tank will be fitted with a vinyl coated wire rope running the periphery
12 of the classifier tank and connected to the safety stop switch.
13
14 2. When the wire rope is pulled, it will actuate a safety stop switch that will
15 open the motor control circuit and disconnect power to the motor.
16
17 3. The safety stop switch shall be fitted with a raised flag for positive
18 identification of when the switch has been actuated. The switch shall be
19 reset by raising the flag arms to their original position.
20
21 2.03 CONTROLS
22
23 A. Furnish and install controls for the grit separation equipment as described in
24 Section 13640.
25
26 B. Furnish a zero -speed switch mounted to the classifier input shaft of each
27 classifier, one new and one existing, to provide an output signal the PLC.
28
29
30 PART 3 - EXECUTION
31
32 3.01 INSTALLATION
33
34 A. Install the new grit equipment in accordance with the manufacturer's
35 instructions and as shown on the drawings.
36
37 B. Lubricate the equipment before start-up.
38
39 3.02 FIELD INSPECTION AND TESTING
40
41 A. General - Furnish the services of a factory representative in accordance with
42 Specification Section 01820 to inspect the final installation, supervise a test
43 run of the equipment, and provide operator training. The factory
44 representative shall provide a written certification that the grit separation
45 equipment is installed in accordance with the manufacturer's
GRIT SEPARATION EQUIPMENT
11323-11 12/18/20
1 recommendations.
2
3 B. The final copies of Operation and Maintenance manuals specified in Section
4 01730 must be delivered to the Engineer prior to scheduling the instruction
5 period with the Owner.
6
7 C. Motors - The Contractor shall check all motors for correct clearances and
8 alignment, and for correct lubrication in accordance with the manufacturer's
9 instructions. The Contractor shall check the direction of rotation of all motors
10 and reverse if necessary.
11
12 D. After the grit separation equipment has been completely installed and
13 inspected by a factory representative, startup testing shall be conducted by
14 the Contractor in accordance with specification 01625. The Contractor shall
15 supply all labor, equipment and incidentals required to complete the startup
16 activities. The factory representative shall provide a complete startup report
17 documenting the operating conditions at startup. This report shall be made
18 part of the operation and maintenance manual. Equipment that cannot be
19 made to comply with the specifications shall be removed and replaced with
20 equipment that satisfy the conditions specified.
21
22 3.03 REHABILITATE EXISTING CYLONES
23
24 A. Rehabilitate each existing cyclone by furnishing and replacing all wear items,
25 seals, and gaskets including but not limited to a complete set of liners.
26
27 B. Replacement items shall be sourced from the original equipment manufacturer
28 to ensure proper fit and function.
29
30 C. Clean and paint the exterior in accordance with Section 09900, including all
31 carbon steel supports.
32
33 D. One existing cyclone shall remain in service at all times.
34
35 3.04 REHABILITATE THE EXISTING GRIT CLASSIFIER
36
37 A. Rehabilitate the existing classifier by furnishing and replacing the upper
38 bearing, the lower bearing, the screw, the wearing shoes and hardware
39 mounted to the screw, all seals, gaskets, zero speed switch, water solenoid,
40 emergency stop switch, and all other typical wear items. Furnish all new
41 conduit and wiring required for retrofitting the existing grit classifier with an e-
42 stop and a zero -speed switch as are specified or shown on the drawings for
43 the new classifier.
44
45 B. Replacement items shall be sourced from the original equipment manufacturer
GRIT SEPARATION EQUIPMENT
11323-12 12/18/20
to ensure proper fit and function.
C. The existing classifier shall be rehabilitated after the new classifier has been
installed and placed in service.
END OF SECTION
GRIT SEPARATION EQUIPMENT
11323-13 12/18/20
1 THIS PAGE INTENTIONALLY LEFT BLANK
GRIT SEPARATION EQUIPMENT
11323-14 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11324
2
3 MACERATOR
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and install,
10 place in operation, and field test one (1) horizontal in-line type sludge macerator
11 designed specifically for primary thickened sludge applications in municipal
12 wastewater treatment plants complete with motor, base and controls at the
13 location shown on the drawings and as hereinafter specified to perform the
14 intended function and achieve a fully integrated and operational system.
15
16 B. These Specifications are intended to give a general description of what is
17 required, but do not cover all details, which will vary in accordance with the
18 requirements of the equipment application. It is, however, intended to cover the
19 furnishing, the shop testing, the delivery and complete installation and field
20 testing, of all materials, equipment and all appurtenances for the complete
21 pumping system as herein specified, whether specifically mentioned in these
22 Specifications or not.
23
24 1.02 DESCRIPTION OF THE SYSTEM
25
26 A. Sizing and Performance Criteria: Provide macerator with the following design
27 criteria:
28
29 Number of Macerators 1
30 Maximum Primary Sludge Flow Rate (gpm) 60
31 Maximum Line Pressure (psi) 60
32 Primary Sludge Pipe Size 6 -inch flanged
33 Thickened Primary Sludge Solids Content 4% - 6%
34 Motor 460 -volt Constant Speed with Controls
35 Minimum Peak Shaft Torque 4,700 Ib -in / hp
36 Minimum Peak Force at Cutter Tip 2,000 Ib / hp
37
38
39 1.03 REFERENCE STANDARDS
40
41 A. Design, manufacturing and assembly of elements of the equipment herein
42 specified shall be in accordance with the standards of the below listed
43 organizations. Where reference is made to a standard of any organization, the
44 version of the standard in effect at the time of bid opening shall apply.
45
46 1. American Iron and Steel Institute (AISI)
47 2. American Society of Mechanical Engineers (ASME)
MACERATOR
11324-1 03/20/2020
1 3. American National Standards Institute (ANSI)
2 4. American Society for Testing Materials (ASTM)
3 5. American Water Works Association (AWWA)
4 6. Hydraulic Institute Standards
5 7. National Electrical Manufacturers Association (NEMA)
6 8. Underwriters Laboratories, Inc. (UL)
7 9. Society of Automotive Engineers (SAE)
8 10. National Electric Manufacturers' Association (NEMA)
9 11. National Electric Code (NEC)
10 12. International Electro -technical Commission (IEC)
11
12 1.04 QUALITY ASSURANCE
13
14 A. The Macerator shall be in accordance with applicable requirements of the ISO
15 9001 Quality System, and such compliance shall be verified by an independent
16 certification agency approved by the International Organization for
17 Standardization. Documentation shall be submitted for approval showing
18 compliance with this requirement, and the equipment will not be released for
19 shipment until approved.
20
21 B. Motors and Controls shall be in accordance with NEMA Standards and shall be
22 UL certified.
23
24 C. The equipment furnished under this Section shall be supplied by a single
25 Manufacturer, who is fully experienced, reputable and qualified in the
26 manufacture of the equipment furnished. The equipment shall be suitable for
27 operation with the normal operating levels shown on the Drawings. The
28 Contractor shall assume full responsibility for the satisfactory installation and
29 operation of the entire system as specified.
30
31 D. The macerator and all related equipment shall be designed, constructed and
32 installed in accordance with the best practices and methods.
33
34 E. Requests for substitution shall include manufacturer's literature for each product
35 giving name, product number, type, descriptive information, and independent
36 lab test reports showing results to equal the performance criteria of the
37 equipment specified herein. In addition, a list of five projects shall be submitted
38 in which identical equipment has been used and rendered satisfactory service.
39
40 F The macerator manufacturer shall be fully responsible for the design,
41 arrangement and operation of all connected rotating components of the
42 assembled units to ensure that neither harmful nor damaging vibrations occur
43 at any speed within the specified operating range.
44
45 G. Should equipment which differs from these Specifications be offered and
46 determined to be the approved equal of that specified, such equipment will be
47 acceptable only on the basis that any revisions in the design and/or construction
MACERATOR
11324-2 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 of the structures, piping, appurtenant equipment, electrical work, etc., required
2 to accommodate such a substitution, shall be made at no additional cost to the
3 Owner and be as approved by the Engineer.
4
5 H. The macerator manufacturer and supplier shall guarantee the performance of
6 each unit. The macerator shall be a Muffin Monster In -Line Electric Grinder type
7 as manufactured by JWC Environmental, similar by Franklin Miller, or equal.
8
9 1.05 SUBMITTALS
10
11 A. Submit to the Engineer for review in accordance with Section 01340 and 01730
12 complete installation drawings, shop drawings, working drawings, O&M Manuals
13 and product data for all materials and equipment furnished under this Section.
14 Submittals shall include at least the following:
15
16 1. Certified shop drawings, erection drawings and installation instructions
17 showing all important details of construction, dimensions and anchor bolt
18 locations.
19
20 2. Descriptive literature, bulletins and/or catalogs of the equipment.
21
22 3. Data on the characteristics and performance of each unit. Data shall
23 include guaranteed performance, based on actual shop tests of similar
24 units, which show that they meet the specified.
25
26 4. Complete master wiring diagrams and control schematics, including
27 coordination with other electrical control devices such as the pump
28 control system and suitable outline drawings shall be furnished for
29 approval before proceeding with manufacture. Provide suitable outline
30 drawings showing such details as are necessary to locate conduit stub -
31 ups and field wiring. Due to the complexity of the system, it is imperative
32 the above drawings be clear and carefully prepared to facilitate
33 interconnections with other equipment. Standard pre-printed sheets or
34 drawings simply marked to indicate applicability to this contract will not
35 be acceptable.
36
37 5. Refer to Specification 13640 Control Strategy for specific information on
38 how this unit is controlled.
39
40 6. A complete total bill of materials of all equipment (may be furnished with
41 Operation and Maintenance manuals specified herein).
42
43 7. A list of the manufacturers recommended spare parts to be supplied in
44 addition to those specified, with the manufacturer's current price for each
45 item. Include gaskets, packing, etc. on the list. List bearings by the
46 bearing manufacturer's numbers only.
47
MACERATOR
11324-3
03/20/2020
1 8. Complete motor data.
2
3 9. The weight of the entire assembly including the motor.
4
5 B. Test Reports to be submitted
6
7 1. Description of factory testing procedures and equipment.
8
9 2. Copies of all test results, as specified in Parts 2 and 3 of this Section.
10
11 3. Copies of all start-up test reports which show compliance with these
12 Specifications.
13
14 C. The submittal data shall be prepared, in its entirety, by the equipment
15 manufacturer. Shop drawings prepared by the manufacturer's sales
16 representative, fabrication shops, or other than the listed manufacturers will not
17 be acceptable. No additions or modifications to the manufacturer's submittal
18 will be accepted, with the sole exception of a cover sheet provided by the
19 manufacturer's local Representative and the Contractor.
20
21 D. The operating and maintenance information shall include lubrication
22 instructions, troubleshooting data, full preventative maintenance schedules,
23 complete spare parts lists with ordering information, and exploded views of all
24 components and equipment with part numbers and the materials of construction
25 identified.
26
27 E. In the event that is impossible to conform to certain details of the Specifications
28 due to different manufacturing techniques, describe completely all non -
29 conforming aspects.
30
31 1.06 TOOLS AND SPARE PARTS
32
33 A. Furnish one (1) set of all special tools required for normal operation and
34 maintenance as recommended by the manufacturer.
35
36 B. Furnish and package for storage of the manufacturer's recommended spare parts
37 to assure normal running and maintenance for a period of two (2) years assuming
38 all units are in in continuous operation.
39
40 C. Furnish and package for storage a quantity of the recommended lubrication to
41 meet the manufacturers' recommended lubrication change intervals for 1 year
42 assuming all units are in continuous operation. Lubricants shall include summer
43 and winter grades with alternate reference to equal products of other
44 manufacturers, and shall include all lubricant specification such as viscosity,
45 AGMA numbers, etc.
46
47 E. All spare parts shall be furnished in containers clearly identified with indelible
MACERATOR
11324-4 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 markings as to contents. Each container shall be packed with its contents
2 protected for prolonged storage.
3
4 F. Furnish one complete sludge macerator cartridge to be used as a spare.
5
6 1.07 PRODUCT HANDLING
7
8 A. All parts shall be properly protected so that no damage or deterioration will occur
9 during a prolonged delay from the time of shipment until installation is completed
10 and the units and equipment are ready for operation.
11
12 B. All equipment and parts must be properly protected against any damage during
13 a prolonged period at the site.
14
15 C. Factory assembled parts and components shall not be dismantled for shipment
16 unless permission is received in writing from the Engineer.
17
18 D. Finished surfaces of all exposed openings shall be protected by wooden blanks,
19 strongly built and securely bolted thereto.
20
21 E. Finished iron or steel surfaces not painted shall be properly protected to prevent
22 rust and corrosion.
23
24 F After all factory testing or other tests, all entrapped water shall be drained prior
25 to shipment and proper care shall be taken to protect parts from the entrance of
26 water during shipment, storage and handling.
27
28 G. Each box or package shall be properly marked to show its net weight in addition
29 to its contents.
30
31 1.08 WARRANTY
32
33 A. In order to assure proper performance and compatibility, all equipment supplied
34 within this Specification shall be warranted by the same supplier.
35
36 B. The equipment shall be warranted to be free from defects in workmanship,
37 design and materials. If any part of the equipment should fail during the
38 warranty period, it shall be replaced in the machine(s) and the unit(s) restored
39 to service at no expense to the Owner.
40
41 C. The unit manufacturer and the Contractor shall warrant the macerator against
42 defects in workmanship and materials in accordance with Section 01740 of
43 these Specifications.
44
45 1.09 MANUFACTURER'S REPRESENTATIVE
46
47 A. Provide the services of a qualified factory certified representative for a minimum
MACERATOR
11324-5 03/20/2020
1 of (2) days for equipment installation inspection, certification, start-up, training,
2 and corrective adjustments.
3
4 1.10 PERFORMANCE TESTING
5
6 A. Factory and performance testing shall be conducted by the Contractor on the
7 macerator as described in Part 3 of this specification.
8
9 PART 2 - PRODUCTS
10
11 2.01 GENERAL
12
13 A. All equipment for the unit, including the motor and base, shall be furnished as a
14 complete unit by the supplier.
15
16 B. The macerator and motor shall be rated for continuous duty and shall be
17 capable of processing the specified flow range without cavitation or excessive
18 vibration. The macerator and drive shall not infringe upon the motor service
19 factor.
20
21 D. The specified macerator shall be complete including, proper alignment and
22 balancing of the individual units. All parts shall be so designed and proportioned
23 as to have liberal strength, stability and stiffness and to be especially adapted
24 for the service to be performed. Ample room for inspection, repairs and
25 adjustment shall be provided.
26
27 E. Corrosion resistant nameplate with the name of the manufacturer and the serial
28 number shall be attached to each macerator.
29
30 F Corrosion resistant nameplate with the name of the manufacturer, serial
31 number, horsepower, speed, voltage and amperes shall be attached to each
32 motor.
33
34 2.02 MATERIALS
35
36 Part: Material: Designation:
37
38 Housing and Covers Ductile Iron ASTM A536-84
39 Cutters and Spaces Alloy Steel AISI 4130
40 Shafts Alloy Steel ASTM A4140
41 Intermediate Shaft Supports Stainless Steel ASTM A743, AISI 17-4
42 Intermediate Shaft Bearings Bronze SAE 660
43
44 2.03 MACERATOR CONSTRUCTION
45
46 A. The Macerator shall reduce or shred sludge solids and all material captured by
47 the moving belt filters for protection of downstream equipment. The Macerator
MACERATOR
11324-6 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 shall be two shafted design consisting of individual cutters and spacers with a
2 single piece main body housing consisting of pipe flanges and inspection ports.
3 The cutter cartridge shall be removable from the main body without removing
4 the main body from the pipeline. The Macerator shall have a motor and a speed
5 reducer that drives the cutter shafts.
6
7 B. Cutters and Spacers
8
9 a. Cutting stack shall be a nominal height of 12 inches (203.2mm).
10
11 b. Cutter shall be an individual disk constructed of AISI 4130 alloy steel surface
12 ground to thickness of .215 -inches +.000/-.001.
13
14 c. Cutters shall be heat treated to produce a hardness of 45-50 Rockwell C.
15
16 d. Cutters shall have 13 cam shaped teeth. Tooth height shall not be greater
17 than 1/2 -inch (13 mm) above the root diameter of the cutter. OD shall be 4.71-
18 inches (120 mm).
19
20 e. Spacers shall be an individual disk constructed of AISI 4130 alloy steel
21 surface ground to a thickness of .223 -inches +.001/-.000.
22
23 f. Spacers shall have a hardness of 34-38 Rockwell C.
24
25 g. Spacers shall have a smooth outside diameter with no tooth profiles.
26
27 C. Shafts
28
29 a. Shafts shall be ASTM 4140 alloy steel with a minimum tensile strength of
30 149,000 PSI (1,027 kPA).
31
32 b. Shafts shall measure nominal 2 -inches (51 mm) across flats of hex.
33
34 c. Shafts shall be hardened to 38-42 Rockwell C.
35
36 D. Intermediate Shaft Supports
37
38 a. Intermediate shaft supports shall be ASTM A743 stainless steel, AISI 17-4
39 stainless steel and SAE 660 bearing bronze.
40
41 b. Shaft supports shall be lubricated with high temperature marine grade
42 grease at the factory.
43
44 c. Intermediate shaft supports shall provide additional support to the shafts
45 during severe grinding demands.
46
47 d. Intermediate shaft supports shall be provided only for cutter stacks of 24
MACERATOR
11324-7 03/20/2020
1 inches (610 mm).
2
3 E. Seal Cartridges
4
5 a. Seal cartridges shall be rated to a maximum of 90 PSI (620 kPA).
6
7 b. Seal cartridges shall not require flushing.
8
9 c. Dynamic and rotating seal faces shall be tungsten carbide with 6% nickel
10 binder.
11
12 d. O -rings shall be Buna-N (Nitrile).
13
14 e. Radial and axial loads shall be borne by sealed, oversized, deep -groove ball
15 bearings.
16
17 F. Housings and Covers
18
19 a. Main body, gear, base, and end housings shall be ASTM A536-84 ductile
20 iron.
21
22 b. Top cover and inspection port covers shall be ASTM A536-84 ductile iron.
23
24 c. Main body housing shall have inlet and outlet flanges with bolt pattern
25 machined to 8 -inch pipe flange size.
26
27 d. Main body housing shall have integral side wall deflectors to direct solids
28 into cutters.
29
30 e. Inspection port covers shall be on both inlet and outlet sides of main body
31 housing.
32
33 f. End housing shall have integral bushing deflectors to guide solids away from
34 seal cartridges.
35
36 G. Speed Reducer
37
38 a. Reducer shall be manufactured by Sumitomo Machinery Corporation of
39 America.
40
41 b. Reducer shall be internal planetary mechanism with trochoidal curved tooth
42 profile.
43
44 c. Reducer shall be a vertically mounted with 29:1 single reduction.
45
46 d. Reducer shall be grease lubricated.
47
MACERATOR
11324-8
03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 2.04 CONTROLS
2
3 A. See Specification 13630 and 13640 for the Control Strategy, the Controls, and
4 the Control Panel requirement for this equipment.
5
6 2.05 SHOP PAINTING
7
8 A. Before exposure to weather and prior to shop painting, all surfaces shall be
9 thoroughly cleaned and blasted to SSPC-SP10, dry and free from all mill -scale,
10 rust, grease, dirt and other foreign matter.
11
12 B. All exposed portions of the casing and motor shall be shop primed, with rust
13 inhibitive primer to a minimum of 4-6 mils FDT and one coat of epoxy finish to
14 4-8 mils DFT. Primer and epoxy must be compatible with field painting as
15 specified in Division 9.
16
17 C. All nameplates shall be properly protected during painting.
18
19 D. Gears, bearing surfaces and other similar surfaces obviously not to be painted
20 shall be given a heavy shop coat of grease or other suitable rust resistant
21 coating. This coating shall be maintained as necessary to prevent corrosion
22 during periods of storage and erection and shall be satisfactory to the Engineer
23 up to the time of the final acceptance test.
24
25 E. Stainless steel components shall not be painted.
26
27 2.06 ROTATION
28
29 A. The rotation direction shall be permanently marked on the casing and the unit
30 clocked to the discharge position as shown on the Drawings.
31
32 PART 3 - EXECUTION
33
34 3.01 INSTALLATION
35
36 A. Drivers and bases shall be precisely leveled and aligned, accurately anchored
37 into position and grouted by the Contractor. Installation shall be in strict
38 accordance with the manufacturer's instructions and recognized industry
39 practices. The Contractor shall furnish and install anchor bolts and the required
40 lubricants for initial operation. The grades of oil and grease shall be in
41 accordance with the manufacturer's recommendations. Anchor bolts shall be
42 304 stainless steel installed in accordance with the manufacture's
43 recommendations.
44
45 B. The Contractor shall furnish and install pressure gauge assemblies on the
46 suction side and the discharge side of each unit. The gauge assemblies shall
47 be per the seal water detail in the drawings. The gauge calibration ranges shall
MACERATOR
11324-9 03/20/2020
1 be as small as is practical so that that full range is utilized, but safely within
2 maximum conditions.
3
4 C. The Contractor shall connect the controls such that in the automatic mode, the
5 macerator is in operation when any of the moving belt filter sludge pumps is in
6 operation.
7
8 D. Prior to initial start-up, the pump manufacturer's representative shall provide
9 written certification to the Owner that the equipment has been installed, tested
10 in accordance with the Manufacturer's approved method, and testing
11 requirements specified herein and shall certify that the equipment is ready for
12 permanent operation.
13
14 3.02 FIELD PAINTING
15
16 A. Field painting is specified under Section 09900 - Painting. The primer and paint
17 used in the shop shall be products of the same manufacturer as the field paint
18 to assure compatibility.
19
20 B. All nameplates shall be properly protected during painting.
21
22 3.03 FACTORY TESTS
23
24 A. Each motor shall be given a non -witnessed short commercial test to determine
25 that the motor is free from electrical and mechanical defects and to provide
26 assurance that it meets the specifications. Testing shall be in accordance with
27 NEMA standards and shall consist of no load current, locked rotor current,
28 winding resistance, high potential and bearing inspection.
29
30 B. If any unit tested fails to meet any Specification requirement it shall be modified
31 until it meets all Specification requirements.
32
33 C. Hardness Testing
34
35 1. Before final shipment, a Rockwell hardness test shall be conducted
36 showing compliance to the specifications. Each individual and applicable
37 component shall be tested at the manufacturer's plant to ASTM Method
38 E-18. Each casting shall be checked in a minimum of two places, in an
39 area that is representative of casting thickness.
40
41 2. Results of the testing hall be certified by a Registered Professional
42 Engineer and submitted for approval before final shipment.
43
44 3. Hardness tests may be witnessed by a representative of the Owner if so
45 desired.
46
47 3.04 FIELD INSPECTION AND TESTING
MACERATOR
11324-10
03/20/2020
1
1 1
2 A. General - Furnish the services of a factory representative in accordance with
I 3 Specification Section 01820 to inspect the final installation, supervise a test run
4 of the equipment, and provide operator training. The factory representative
5 shall provide a written certification that the macerator is installed in accordance
I 6 with the manufacturer's recommendations.
7
8 B. The final copies of Operation and Maintenance manuals specified in Section
1 9 01730 must be delivered to the Engineer prior to scheduling the instruction
10 period with the Owner.
11
I 12 C. Motors - The Contractor shall check all motors for correct clearances and
13 alignment, and for correct lubrication in accordance with the manufacturer's
14 instructions. The Contractor shall check the direction of rotation of all motors
I 15 and reverse if necessary.
16
17 D. After the Macerator has been completely installed and inspected by a factory
1 18 representative, field tests shall be conducted on each unit in the presence of the
19 Engineer to show conformance with the specifications. The Contractor shall
20 supply all labor, equipment and incidentals required to complete these tests.
I
21
22 E. The factory representative shall include certification of proper installation and
23 provide a complete startup report for each unit, documenting the operating
24 conditions at startup. This report shall be made part of the operation and
25 maintenance manual. Macerators that cannot be made to comply with the
26 specifications shall be removed and replaced with units that satisfy the
1 27 conditions specified.
28
29
1 30 END OF SECTION
1
1
1
1
1
1
1
31
MACERATOR
11324-11
03/20/2020
1 THIS PAGE INTENTIONALLY LEFT BLANK
2
MACERATOR
11324-12
03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11335
2
3 FIBERGLASS REINFORCED PLASTIC TANK
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
19 A. The Contractor shall furnish all labor, materials, equipment and incidentals required
10 and shall install, complete and ready for operation, and field test one (1) vertical
11 fiberglass reinforced plastic (FRP) tank as shown on the Contract Drawings and
112 specified herein.
13
14 1.02 DESCRIPTION OF SYSTEMS
115
16 A. The tank shall serve as a collection chamber for screened and degritted wastewater
17 pumped from the equalization tank and simultaneously allow this water to flow by
118 gravity to downstream treatment processes through a piping connection at the
19 bottom of the tank. Under normal conditions, the hydraulic grade line in the tank will
20 be at a constant depth of 6- to 7 -feet, due to a weir located downstream of the tank,
21 however, the tank shall be designed to hold water to its full depth. The pitched
22 bottom, open top FRP tank shall be nominal 48 -inch diameter, 24 -feet tall, and
23 furnished complete with all reinforcement, flanged nozzles where shown on the
124 drawings, gaskets, lifting lugs, supporting legs and anchor bolts to properly anchor
25 the tank to a concrete pad.
26
1 27 1.03 QUALIFICATIONS
28
29 A. All of the equipment specified under this Section shall be furnished by a single
I30 manufacturer, fully experienced, reputable and qualified in the manufacture of the
31 equipment furnished. The fiberglass tank and all related equipment shall be
32 designed, constructed and installed in accordance with the best practices and
I33 methods. All equipment furnished under these Specifications shall be new and
34 unused and shall be the standard product of a manufacturer having a successful
35 record of manufacturing and servicing the equipment specified herein for a minimum
1 36 of five (5) years.
37
I38 B. Should equipment that differs from these Specifications be offered and determined
39 to be the approved equal of that specified, such equipment will be acceptable only
40 on the basis that any revisions in the design and/or construction of the structures,
41 piping, appurtenant equipment, electrical work, etc., required to accommodate such
I421 a substitution, shall be made at no additional cost to the Owner and be as approved
43 by the Engineer.
I44
45 C. The tank fabricator shall hold a current ASME RTP -1 "Certificate of Authorization"
46 and the tank shall bear an ASME RTP -1 label.
1 47
1
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS
11335-1 03/22/19
1 1.04 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
2
3 A. Design, manufacturing and assembly of elements of the equipment herein specified
4 shall be in accordance with the standards listed below, except as otherwise shown
5 or specified. Where reference is made to a standard of one of these, or other
6 organizations the version of the standard in effect at the time of bid opening shall
7 apply.
8
9 1. AWWA D120-09 Thermosetting Fiberglass —Reinforced Plastic Tanks
10
11 2. ASME RTP -1 Reinforced Thermoset Plastic Corrosion Resistant Equipment
12
13 3. ASTM D2563 Classifying Visual Defects in Glass Reinforced Plastic
14 Laminate Parts
15
16 4. ASTM D2583 Test Method for Indentation Hardness of Rigid plastics by
17 Means of a Barcol Impresser
18
19 5. ASTM D3299 Filament -Wound Glass -Fiber -Reinforced Thermoset Resin
20 Chemical -Resistant Tanks
21
22 105 SUBMITTALS
23
24 A. Copies of all materials required to establish compliance with the specifications shall
25 be submitted in accordance with the provisions of Sections 01300 and 01340.
26 Submittals shall include at least the following:
27
28 1. Certified shop and erection drawings showing all important details of
29 construction, dimensions and anchor bolt locations.
30
31 2. Descriptive literature, bulletins and/or catalogs of the equipment.
32
33 3. A complete, total bill of materials for all equipment with the O&M manual.
34
35 4. A list of the manufacturer's recommended spare parts with the
36 manufacturer's current price for each item.
37
38 5. Certifications as required by ASME RTP -1
39
40 1.06 OPERATING AND MAINTENANCE MANUALS
41
42 A. Complete copies of the Operating and Maintenance manuals shall be furnished in
43 accordance with Specification 01730. The manuals shall be prepared specifically
44 for this installation and shall include all required cuts, drawings, equipment lists,
45 descriptions, etc. that are required to instruct operating and maintenance personnel
46 unfamiliar with such equipment.
47
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS
11335-2 03/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1.07 TOOLS AND SPARE PARTS
2
I
3 A. Furnish one (1) set of all special tools required for normal operation and
4 maintenance.
5
I6 B. Furnish one (1) set of manufacturer's recommended spare parts. All spare parts
7 shall be properly protected for prolonged periods of storage and packed in suitable
8 containers that are clearly identified with indelible markings as to contents.
9
10 1.08 WARRANTY
11
112 A. The equipment manufacturer shall provide a twelve (12) month warranty
13 commencing at the time of substantial completion and acceptance by the Owner as
14 outlined in Specification 01740. The equipment manufacturer shall guarantee that
115 the equipment furnished is suitable for the purpose intended and free from defects
16 of design, material and workmanship. In the event the equipment fails to perform as
17 specified, the equipment manufacturer shall promptly repair or replace the defective
118 equipment without any cost to the Owner (including handling and shipment costs).
19
20 PART 2 - PRODUCTS
121
22 2.01 GENERAL
23
1 24 A. These Specifications are intended to give a general description of what is required,
25 but do not cover details that may vary in accordance with the exact requirements of
26 the equipment as offered. They are, however, intended to cover the furnishing,
1 27 delivery, installation and field testing of all materials, equipment and apparatus, as
28 required. Any additional auxiliary equipment necessary for the proper operation of
29 the proposed installation not mentioned in these Specifications, or shown on the
I30 Drawings shall be furnished and installed.
31
32 B. The material covered by these Specifications is intended to be standard equipment
I33 of proven ability and as manufactured by reputable concerns having experience in
34 the production of such equipment. The equipment furnished shall be designed,
35 constructed and installed in accordance with best practice and methods and shall
I36 operate satisfactorily when installed as shown on the Drawings.
37
38 C. Stainless steel nameplates giving the name of the manufacturer, model number,
I39 serial number, capacity, and any other pertinent data shall be attached to each tank.
40
▪ 41 D. All hardware such as bolts, nuts and washers shall be AISI 316 stainless steel
I 42 furnished in accordance with ASTM A193/A194.
43
• 44 E. All tanks shall be designed and furnished with all mounting hardware required to
I 45 securely fasten the tank to a concrete pad and shall withstand 130 mph sustained
46 winds.
47
1
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS
11335-3 03/22/19
1 F The fiberglass tanks shall be as manufactured by Augusta Fiberglass, Design
2 Tanks, or approved equal.
3
4 2.02 TANK SHELL AND JOINTS
5
6 A. The tank shall be manufactured using the filament wound or contact molded process
7 with the following physical properties as a minimum:
8
9 Min. Tensile Strength (psi) 29,000
10
11 Min. Flexural Strength (psi) 30,000
12
13
14 B. The shell thickness design shall be determined based on a full tank of wastewater.
15 Liners and corrosion barriers shall not be considered as contributing structural
16 strength to the laminate.
17
18 C. All tanks subject to hydrostatic heads shall have minimum wall thickness of'/ -inch.
19 The equipment manufacturer shall be responsible for properly sizing the tank wall
20 thickness to provide a structurally sound tank when completely full.
21
22 D. Stiffener ribs or other means shall be used to provide structural rigidity.
23
24 E. The knuckle radius shall be 1 -1/2 -inch minimum. The knuckle area shall be
25 reinforced in accordance with ASTM D-3299-00.
26
27 F. All cut edges shall be coated with resin such that no glass fibers are exposed and all
28 voids shall be filled. All exterior surfaces shall be relatively smooth with no exposed
29 fibers or sharp projections.
30
31 2.03 LAMINATE
32
33 A. The laminate shall consist of an inner surface, an interior layer, and an exterior layer
34 or structural laminate.
35
36 B. An ultraviolet outdoor stabilizer shall be incorporated in the final coat of resin to
37 improve weather resistance. Resins may contain pigments provided their
38 concentration does not prevent detection of visual defects. Manufacturer shall
39 submit color chart of available pigments of the exterior of the tank for selection by
40 the Owner.
41
42 C. A corrosion barrier made of an isophthalic polyester surfacing mat (veil) shall be
43 Type C glass, 10 mils thick, with a silane finish and a binder compatible with the
44 resin.
45
46 D. The inner surface shall be free of cracks and crazing with a smooth finish and with a
47 maximum of 10 pits per square foot. All pits shall be less than 1/8 inch diameter and
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS
11335-4
03/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
' 1 Tess than 1/32 inch deep. All pits shall be covered with sufficient resin to avoid
2 exposure of inner surface fabric. A minimum of 7-20 mils of reinforced, resin -rich
I3 surface shall be provided. The surface shall be reinforced with a glass surfacing veil
4 or a synthetic fiber veil.
5
I6 E. A minimum of 90 mil of laminate is required in the corrosion barrier and shall be
7 reinforced with not less than 27 percent by weight of non -continuous glass strands
8 having fibers lengths from 0.5 and 2.0 inches.
9
10 F. Where separate layers such as mat is used, all layers shall be lapped a minimum of
11 one inch. Laps shall be staggered as much as possible. The exterior surface shall
112 be relatively smooth with no exposed fibers or sharp projections.
13
14 G. The structural wall glass content of filament wound laminate shall be a minimum
115 of 50% by weight.
16
17 2.04 TANK CONNECTIONS AND APPURTENANCES
118
19 A. All connections for equipment shall be FRP conically-gusseted flanges located as
20 shown on the Drawings. Flanges for pipe connections shall be drilled in accordance
121 with ANSI B-16.5 for 150# bolting configuration.
22
23 B. All flanges shall be furnished with a 1/8 -inch EPDM full face gasket with a minimum
24 durometer of 50 and 316 SS bolting hardware.
25
26 C. Tank shall be furnished with a 24 -inch side access manway with a blind flange,
' 27 EPDM gasket and 316 SS bolts.
28
29 D. All tanks shall be furnished with 316 stainless steel support ring/legs, bolting pads,
1 30 anchor bolts and all other necessary hardware required to securely fasten the tank
31 to a concrete pad.
I32 33 E. All tanks shall be furnished with mold -in stainless steel clips for mounting electrical
34 and instrumentation conduit and piping as required.
I35
36 PART 3 - EXECUTION
37
38 3.01 INSTALLATION
t39
40 A. Each unit shall be installed in accordance with the manufacturer's instructions and
41 accurately aligned in orientation with related equipment in order to insure proper
I42 operation.
43
44 B. The Contractor shall supply all necessary anchor bolts, washers, nuts, temporary
45 lifting equipment, power, labor and all other requirements for satisfactory installation.
46
47 3.02 MANUFACTURER'S SERVICES
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS
11335-5 03/22/19
1
1
2 A. Prior to initial start-up, the manufacturer's representative shall provide written
3 certification to the Owner that the equipment has been properly installed, tested in
4 accordance with the Manufacturer's approved method and the testing requirements
5 specified herein and shall certify that the equipment is ready for permanent
6 operation.
7
8 B. The manufacturer shall provide an affidavit that the materials comply with the
9 applicable requirements of this specification.
10
11 3.03 PAINTING
12
13 A. All exposed metal surfaces, other than aluminum, galvanized steel and stainless
14 steel, shall be shop primed and painted.
15
16 B. Surface preparation and shop prime painting shall be as specified in Section 09865.
17
18 C. Field painting shall be as specified in Section 09900.
19
20 3.04 TESTING
21
22 A. Upon completion of installation, the Contractor shall in the presence of the Engineer
23 and a qualified manufacturer's representative, perform a preliminary test on the tank
24 to insure no leaks are detected. The Contractor shall furnish all labor, materials,
25 supplies, test equipment, water and power required to perform each test. Tests
26 shall verify proper alignment, proper connection and satisfactory performance of the
27 FRP tank.
28
29 B. The Contractor shall furnish the services of a factory representative who has
30 complete knowledge of proper operating and maintenance to inspect the final
31 installation and supervise a test run of the equipment.
32
33 C. In the event of improper installation, the Contractor and the manufacturer shall be
34 responsible for supervising the correction of the work and subsequent test runs until
35 the defects are corrected without any additional cost to the Owner.
36
37
38 END OF SECTION
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS
11335-6 03/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
19
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
1
1
1
1
1
1
1
1
1
1
SECTION 11350
CONTINUOUS LOOP MOVING BELT FILTER
PART 1 - GENERAL
1.01 SCOPE
A. Provide all labor, materials, equipment and appurtenances required to furnish,
install, and startup three complete continuous loop moving belt filters for
wastewater solids separation (belt filter). Equipment, ancillaries and services
shall be fully functional and automated and shall be suitable for raw domestic
wastewater. The overall scope of supply shall be for factory assembled and
tested units incorporating a continuous loop moving mesh screen (filter belt), a
belt cleaning system, a discharge sludge chute, blowers, and system control
panels for automatic operation. The basis for design is the Salsnes Filter and
shall be capable of meeting the minimum criteria standards listed in this section.
B. Alternate equipment manufacturers shall not be allowed. Only equipment from
the approved manufacturer shall be considered.
C. Prior to ordering equipment the Contractor shall coordinate with the
manufacturer and conduct sieve testing and column testing and particle size
distribution testing at a representative location in the process to confirm the
machine and belt pore size. The sieve and column testing and reporting shall
be similar to preliminary testing conducted on April 14, 2016. The particle size
and distribution analysis shall use a procedure based on Standard Methods or
other industy-accepted standard. The belt filter unit manufacturer shall provide
the method for review prior to conducting the testing. The testing shall
indicate the percentage of particles larger than 350 microns. All testing and
analyses shall be supervised by a NELAC certified laboratory and all results
shall be submitted to the Engineer.
D. The Contractor shall furnish and install the Inlet, outlet, overflow, vent, drain,
cold water, hot water, bottom bearing flush water, and air piping associated with
each each belt filter unit.
1.02 DESCRIPTION OF THE SYSTEM
A.
Sizing and Performance Criteria: Provide equipment that will process raw
wastewater without the use of a coagulant and with the following characteristics:
1. Number of Belt Filter Units:
2. Each Belt Filter Flow Capacity:
3. Influent Solids Concentration (TSS):
4. Minimum TSS Removal Required:
5. Influent BOD:
3
1736 GPM
178 mg/L (average)
47% (average)
220 mg/L (average)
CONTINUOUS LOOP MOVING BELT FILTER
11350-1 04/22/19
1 6. Minimum Primary Sludge Solids Content 5% (average by weight)
2 7. Typical Influent Solids Concentration (TSS) Range : 140 to 240 mg/L
3 (monthly average)
4 8. Typical Influent Biological Oxygen Demand (BOD) Range: 160 to 250
5 mg/L (monthly average)
6 9. Typical Particle Size Distribution (PSD): At least 47% of particles
7 greater than 350 micron.
8
9 B. Provide complete and operational Belt Filters consisting of self-cleaning filter
10 belts and dedicated appurtenant equipment. Each Belt Filter unit shall be
11 equipped with an inclined continuous loop filter belt, compartment access
12 covers, belt cleaning provisions, a blower, and control panel and a level
13 transmitter for monitoring and belt speed control.
14
15 C. The system shall be sized for continuous operation (24-hour/day, 365-
16 days/year).
17
18 1.03 SUBMITTALS
19
20 A. Manufacturer shall submit, to the Owner or Engineer, Shop Drawings for review
21 and to establish compliance with the specifications. Shop Drawings shall
22 include the following:
23
24 1. Complete description in sufficient detail to permit an item comparison
25 with the specification.
26 2. Drawings showing plan and elevation views of the Belt Filter and
27 requirements for any external piping and utilities
28 3. Electrical schematics and layouts
29 4. Installation requirements
30 5. Descriptive literature, bulletins and catalogue cuts of the major system
31 components;
32 6. Statement of warranty.
33 7. Exploded views indentifying all part numbers and materials of
34 construction
35
36 B. Manufacturer shall submit, upon system delivery, complete Operations and
37 Maintenance manuals in accordance with Section 01730.
38
39 1.04 QUALITY ASSURANCE
40
41 A. Motors shall be in accordance with NEMA Standards.
42
43 B. All of the equipment specified under this Section shall be furnished by a single
44 Manufacturer, who is fully experienced, reputable and qualified in the
45 manufacture of the equipment furnished. The equipment shall be suitable for
46 satisfactory operation with the normal operating levels shown on the Drawings.
47 The Contractor shall assume full responsibility for the satisfactory installation
CONTINUOUS LOOP MOVING BELT FILTER
11350-2 04/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 and operation of the entire system as specified.
2
3 C. The belt filter units and all related equipment shall be designed, constructed and
4 installed in accordance with the best practices and methods.
5
6 D. The manufacturer shall be fully responsible for the design, arrangement and
7 operation of all connected rotating components of the assembled filter units to
8 ensure that neither harmful nor damaging vibrations occur at any speed within
9 the specified operating range.
10
11 E. The equipment manufacturer shall guarantee the performance of each belt filter.
12
13 1.05 TOOLS AND SPARE PARTS
14
15 A. Furnish one (1) set of all special tools required for normal operation and
16 maintenance.
17
18 B. Furnish and package for storage all of the manufacturer's recommended spare
19 parts to assure normal running and maintenance for a period of two (2) years
20 assuming all three filter screens are in in continuous operation.
21
22 C. Furnish and package for storage a quantity of the recommended lubrication to
23 meet the manufacturers' recommended lubrication change intervals for 1 year
24 assuming all three filter screens are in continuous operation. Lubricants shall
25 include summer and winter grades with alternate reference to equal products of
26 other manufacturers, and shall include all lubricant specification such as viscosity,
27 AGMA numbers, etc.
28
29 D. Furnish and package for storage one continuous loop belt filter cartridge
30 assembly including all rollers, bearings, seals, etc., less the motors and gear
31 boxes and identical to those installed on the complete machines. Furnish a
32 portable stand fabricated of 316 stainless steel to support the cartridge assembly
33 12 -inches above the stand mounting elevation.
34
35 E. All spare parts shall be furnished in containers clearly identified with indelible
36 markings as to contents. Each container shall be packed with its contents
37 protected for prolonged storage.
38
39 F. In addition to items A-E, the following spare parts shall be supplied with the
40 equipment:
41
42 1. Two (2) additional filter belts and lacings
43 2. Three (3) belt drive motors
44 3. Three (3) belt drive gear boxes
45 4. Three (3) sets of drive bearings
46 5. Three (3) sets of lower bearings
47 6. Three HMI units for the Northeast WRF belt filter units
CONTINUOUS LOOP MOVING BELT FILTER
11350-3 04/22/19
1
2 1.06 WARRANTY
3
4 A. All equipment supplied under this Specification except the knife gate valve and
5 the acutuator for the bottom roller bearing flush system shall be warranted to
6 perform as specified for a period of eighteen (18) months from the date of
7 shipment or one (1) year from when placed in continuous operation, whichever
8 comes first. The knife gate valve and the actuator for the the bottom roller
9 bearing flush system shall be warranted for 5 years parts. One (1) complete
10 spare valve with actuator and set of bearings shall be furnished for each filter.
11
12 B. If any part of the equipment supplied under this Specification should fail during
13 the warranty period, it shall be covered by the terms of the Manufacturer's
14 standard warranty.
15
16 1.07 PRODUCT HANDLING
17
18 A. All parts shall be properly protected so that no damage or deterioration will occur
19 during a prolonged delay from the time of shipment until installation is completed
20 and the units and equipment are ready for operation.
21
22 B. All equipment and parts must be properly protected against any damage during
23 a prolonged period at the site.
24
25 C. Factory assembled parts and components shall not be dismantled for shipment
26 unless permission is received in writing from the Engineer.
27
28 D. Finished surfaces of all exposed openings shall be protected by wooden blanks,
29 strongly built and securely bolted thereto.
30
31 E. Finished iron or steel surfaces not painted shall be properly protected to prevent
32 rust and corrosion.
33
34 F. After hydrostatic or other tests, all entrapped water shall be drained prior to
35 shipment and proper care shall be taken to protect parts from the entrance of
36 water during shipment, storage and handling.
37
38 G. Each box or package shall be properly marked to show its net weight in addition
39 to its contents.
40
41 1.08 MANUFACTURER'S REPRESENTATIVE
42
43 A. Provide the services of a qualified factory certified representative for a minimum
44 of (2) days for each machine for equipment installation inspection, certification,
45 start-up, training, and corrective adjustments.
46
47 1.09 PERFORMANCE TESTING
CONTINUOUS LOOP MOVING BELT FILTER
11350-4 04/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 A. Performance testing shall be conducted by the Contractor on each belt filter unit
3 as described in Part 3 of this specification. Sample collection and analysis
4 shall be supervised or performed by a NELAC certified laboratory.
5
6
7 PART 2 - PRODUCTS
8
9 2.01 MANUFACTURER
10
11 The physical layout of the system shown on the drawings and the equipment specified
12 herein is based on the Filter System Model SF6000 as manufactured by Salsnes Filter
13 / Trojan Technologies, London Ontario, Canada.
14
15 2.02 DESIGN, CONSTRUCTION AND MATERIALS
16
17 A. Filter Unit General
18
19 1. Each Belt Filter unit shall be freestanding, designed for installation on a
20 concrete slab or concrete pedestals.
21 2. Each Belt Filter's weight, including water, shall not exceed 5732 lbs.
22 3. Each Belt Filter shall contain one (1) rotating filter belt with horizontal
23 gravity thickening stage, air knife belt cleaning system, hot water spray
24 system, fresh water flush system, water level transmitter, and an
25 integrated sludge collection chute.
26 4. Each Belt Filter shall be supplied with the following connections:
27 a) One 16 -inch inlet flange located at the front of the machine
28 b) One 16 -inch outlet flange — side discharge only — can be either left
29 or right discharge
30 c) One 16 -inch overflow flange side discharge only — can be either
31 left or right discharge
32 d) One 1/2 -inch NPT connection for cold water (EFW) and one 1/2"
33 NPT hot water (Potable) connection
34 e) One 4 -inch NPT connection for filter drain.
35 f) One 3 -inch flanged connection for the air supply
36
37 5. Each Belt Filter and all welded metal components in contact with effluent
38 shall be constructed of 355 or 316L stainless steel. No other materials of
39 construction shall be acceptable.
40
41 B. Belt Filter Internals
42
43 1. The filter belt mesh screen shall be contained in the filter compartment.
44 The filter mesh screen shall be constructed of polyethylene with Kevlar-
45 reinforced drive ends. The mesh screen porosity (opening size) shall be
46 initially sized at 350 microns. Prior to ordering the equipment the pore
47 size shall be confirmed by testing as outlined in Section 101 C. of this
CONTINUOUS LOOP MOVING BELT FILTER
11350-5 04/22/19
1 specification.
2
3 2. A level monitor and transmitter device for monitoring the water level in
4 the influent compartment shall be provided. The equipment shall be
5 specifically designed for use in raw wastewater applications. Level
6 transmitter shall utilize a ceramic sensing element resistant to sludge
7 build up, ASTM A -316L stainless steel housing, and a vented
8 polyurethane insulated cable.
9
10 3. An air knife and blower suitable for continuous operation shall be
11 provided for removal of solids from the surface of the filter belt. The air
12 knife shall be fabricated of ASTM A -316L stainless steel and HDPE.
13 The device shall be piped to the exterior of the filter compartment for
14 supply air connection.
15
16 4. Filter mesh cleaning is to be performed by pressurized air and periodic
17 hot water.
18
19 5. Each unit shall include a horizontal gravity thickening zone to facilitate
20 removal of water and increase the dry solids content of the sludge.
21
22 6. Hot water spray nozzles shall be provided for cleaning the filter belt and
23 in the dewatering chamber. Spray nozzles and manifolds shall be
24 constructed of stainless steel. A 2 -way solenoid valve shall be provided
25 for automated control. Manifolds for hot water supply connection shall
26 combine and terminate at a strainer on the exterior of the filter
27 compartment. Hot water shall be potable water.
28
29 7 A reclaimed water flush manifold shall be provided for automated
30 cleaning of the lower belt roller compartment. The reclaimed water flush
31 shall be controlled with a 2 -way solenoid valve provided wity the unit.
32 The reclaimed water manifold connection shall terminate at a strainer on
33 the exterior of the unit. The flush water shall exit the unit through a 3-
34 way solenoid valve. Energizing the 3 -way solenoid valve shall open a
35 drain vavle for the compartment allowing flush water to exit the unit.
36
37 8. All internal Filter components shall be installed by the Manufacturer prior
38 to the Filter Unit being shipped to the job site.
39
40 9. Electrical drive motors shall be UL approved and/or for a Class 1 Div 1
41 hazardous location if applicable. Filter instrumentation and solenoid
42 valves shall be intrinsically safe or UL approved for a Class 1 Div 1
43 hazardous location if applicable.
44
45 C. Filter Fittings and Connections
46
47 1. Flange drilling and bolting for all flange connections shall be in
CONTINUOUS LOOP MOVING BELT FILTER
11350-6 04/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 accordance with ANSI/ASME B-16.5 class 150.
2
3 2. All threaded connectors to the Salsnes Filter Unit(s) shall be NPT.
4
5 3. For all plain end pipe terminations, flexible sewer connectors (Fernco or
6 equal) shall be provided by the Contractor.
7
8 D. System Piping and Ducting
9
10 All Filter System piping including small diameter hot and cold water piping shall
11 be ASTM A316L stainless steel or specified hose. Hot and cold small diameter
12 water piping shall use threaded connections and fittings with the appropriate
13 pressure ratings.
14
15 2.03 SYSTEM CONTROLS- See Control Strategy Specification 13640
16
17 2.04 BLOWER PACKAGES
18
19 A. The manufacturer of the Belt Filter shall provide three rotary lobe positive
20 displacement blower packages, with each package dedicated to a single belt
21 filter unit and sized to meet the required conditions of airflow and pressure to
22 each unit. The Contractor shall install these units.
23
24 B. The blowers shall be positive displacement rotary lobe type with sound
25 attenuation enclosure as manufactured by Kaeser - BB Compact series or
26 equal. The sound enclosure shall be fabricated with non -corrosive material.
27
28 C. Each blower package shall include an inlet filter with removal efficiency of 90
29 percent or better on particles 10 microns and larger.
30
31 D. Intake and discharge silencers of heavy duty, all welded, carbon steel sheet and
32 plate construction featuring treated inlets and outlets for pulse control shall be
33 provided.
34
35 E. Provide flexible expansion joint connectors as recommended by the blower
36 manufacturer to connect the inlet and discharge silencers of each blower to the
37 piping. Connectors shall be designed for temperatures 50 degrees F above the
38 discharge temperature of the blower air and 25 psi. Connector size and end
39 connections shall be the same as the inlet and discharge silencer connections.
40
41 F. Pressure relief valves shall be a weight type or spring loaded valve properly sized
42 for the application. The size shall be as recommended by the blower
43 manufacturer. Each relief valve shall have the capacity of relieving the entire
44 blower flow. Set point pressure shall be at the blower's maximum pressure rating.
45 Inlet and outlet shall be standard threaded connections. The design of the valve
46 shall permit the discharge of the relief valve to be piped away.
47
CONTINUOUS LOOP MOVING BELT FILTER
11350-7 04/22/19
1
1 G. Each blower shall be provided with a stem mounted stainless steel liquid filled I
2 discharge pressure gauge assembly with a 2.5 inch casing, a 270 degree 0-25 psi
3 scale and accurate to 2% of the full scale. The gauge assembly shall be I 4 equipped with an isolation valve such that the gauge can be replaces while the
5 blower is running.
6 I 7 H. Provide each blower with a Dwyer type inlet pressure gauge to accurately
8 measure pressure Toss through the inlet filter.
9
10 I.Each blower shall be mounted on specially vibration pads as recommend by the
11 blower manufacture.
12 I 13 J. Furnish and package for storage all of the blower manufacturer's recommended
14 spare parts to assure normal running and maintenance for a period of two (2)
15 years assuming all three blowers are in in continuous operation.
I 16
17 2.05 BLOWER SOUND REDUCTION ENCLOSURE
18
19 A.Each blower assembly shall be furnished with a weather tight, self -ventilating
20 sound attenuating enclosure. The enclosure shall be manufactured of 16 gauge
21
22 aluminum and lined with acoustical foam and perforated stainless steel sufficient
I
to meet 75 dba noise level at 3 feet from any exterior surface of the enclosure.
23 The enclosure shall have removable side panels which shall allow full access to
24 the assembly for maintenance or repair. No part of the sound enclusre or sound
25 enclusre hardware shall be carbon steel.
26
27 B. An air ventilation fan shall be mounted in/on the enclosure and sized as necessary
1
28 to keep the assembly ventilated at a temperature to maintain proper operation as
29 recommended by the assembly manufacturer. The fan motor shall be powered
30 by the blower control panel. 1
31
32 C. Pipe and conduit penetrations shall be sized to allow for passage of flanges and
33 fittings. All penetrations shall have flash rings installed to seal around the pipe.
34
35 D. The enclosure and the blower shall be free standing and not attached or mounted
36 to the blower package frame or base plate in any way. The enclosure shall be
I
37 supplied and shipped from the manufacturer as one unit completely assembled
38 and painted and shall not require field assembly at the site.
39
I
40 2.06 HOT WATER HEATER See Electric Water Heater Specification 15480
41
42 2.07 SLUDGE DISCHARGE CHUTE
I
43
44 A. A sludge discharge chute shall be furnished with each filter. Chutes shall be
45 fabricated of 316 stainless steel, with integral SS supports for mounting to the I
46 concrete slab and the structural steel members supporting the moving belt
47 filters. The Chutes shall be furnished with flanges for connecting to the filter
I
CONTINUOUS LOOP MOVING BELT FILTER
11350-8 04/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 and to the pump via flanged flexible couplings as shown on the drawings.
2 Chutes shall have an access opening at the top, adjacent to the filter discharge,
3 for mounting a level sensor. The chute shall also have a 3h -inch SS nipple with
4 SS ball valve for a hose connection and a 4 -inch SS cam-lok connection with
5 cap properly arranged to flush the chute. The chute shall be so designed and
6 properly reinforced and supported to prevent any loads from being transferred
7 through the flexible connector to the connected equipment (pump and filter)
8 when completely filled with sludge. In addition, the members od the chute shall
9 not bulge or distort when filled completely with sludge.
10
11 PART 3 — EXECUTION
12
13 3.01 SITE AND UTILITIES
14
15 The belt filters shall be located and installed as shown on the drawings. Site
16 preparation, utility service and installation are the responsibility of the Contractor.
17
18 A. Hot and cold water supply lines for each belt filter shall be provided and installed
19 by the Contractor. The cold water supply to each belt filter will be reclaimed
20 water. The hot water supply will be potable water from the water heating
21 system located in the feed pump building. The hot water piping downstream of
22 the hot water heater shall be insulated.
23
24 B. Water temperature at the belt filter shall be at least 160°F and shall not exceed
25 195°F.
26
27 C. The sizing of the electrical service and belt filter interconnecting piping shall be
28 in accordance with the Manufacturer's recommendations.
29
30 D. Electric: 460 -volt, 3-phase electrical service shall be supplied and installed by
31 the Contractor.
32
33 E. Air piping from each blower to the dedicated to the belt filter shall be supplied
34 and installed by the Contractor. The piping will be 3 -inch Schedule 10s stainless
35 steel ASTM A312 and the fittings shall be schedule 40 ASTM A774 or ASTM
36 A403. No threaded connections shall be used on the blower piping.
37
38 F. Drain piping from the flush valves (filter and chute) shall be provided and
39 installed by the Contractor as shown on the drawings.
40
41 3.02 INSTALLATION
42
43 A. The Contractor shall install the Salsnes Filter system in accordance with
44 instructions provided by the Manufacturer. Contractor's installation personnel
45 shall be qualified in the areas of plumbing, electrical work, and instrumentation
46 as required to properly complete the installation.
47
CONTINUOUS LOOP MOVING BELT FILTER
11350-9 04/22/19
1 B. The Contractor shall provide protection for all equipment so that no damage or
2 deterioration will occur from the time of delivery until installation is completed
3 and the units and equipment are ready for operation.
4
5 C. Finished surfaces of all exposed equipment openings shall be protected.
6 Finished iron or steel surfaces not painted or coated shall be properly protected
7 to prevent rust and corrosion.
8
9 D. Contractor shall be responsible for connecting all plumbing, ducting and
10 electrical interconnections to the belt filter system as detailed in the
11 Manufacturer's installation instructions.
12
13 3.03 INSPECTION, START UP AND TRAINING
14
15 A. The Contractor shall provide the services of a trained and certified technical
16 service representative from the Manufacturer to be on-site and inspect the final
17 installation, perform start-up, and train the WWTP Operations personnel.
18 Training of plant personnel shall be required only on the first trip and will require
19 two sessions on one day.
20
21 B. Startup of two machines at the same time may be permitted if influent flow is
22 sufficient. Startup of three machines at the same time shall not be permitted.
23
24 C. Following proper start-up of each machine, the manufacturer's field service
25 representative through the Contractor shall provide a certificate of proper
26 installation (COPI) stating that the equipment has been properly installed and is
27 ready to be placed in service.
28
29 3.04 FIELD PERFORMANCE TESTING
30
31 A. After the COPI has been received for a particular machine, three 12 -hour
32 performance tests shall be conducted on that particular machine on three
33 consecutive days by the Contractor to demonstrate conformance with the
34 criteria outlined in Section 1.02. The machine shall be operated by the
35 Contractor in accordance with the equipment O&M Manual at 1730 gpm (± 10%)
36 for 12 consecutive hours on three consecutive days and provide 47% (or higher)
37 TSS removal and produce primary sludge cake with a dry solids content with an
38 average value not less than 5% by weight.
39
40 B. The performance testing shall be performed on each machine individually.
41 Performance testing shall not be conducted on multiple machines at the same
42 time.
43
44 C. The Contractor shall provide verification of the performance by sampling and
45 analyzing the influent and effluent TSS values, influent particle size distribution,
46 and primary sludge moisture content. All four of these parameters shall be
47 sampled (grab) and analyzed every half hour for the 12 hour duration (24
CONTINUOUS LOOP MOVING BELT FILTER
11350-10 04/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 samples).
2
3 D. The arithmetic average of the 24 samples for each day shall be used as the
4 pass/fail yardstick for each day. The system shall be considered to have
5 passed that day's performance test if the average TSS percent removal is 47%
6 or higher for the 12 hour test period. Three consecutive days of passing results
7 are required for the machine to pass the performance test.
8
9 E. A sampling and testing protocol to comply with A, B, and C above shall be
10 provided by the Contractor and submitted for review. The testing and analyses
11 shall be supervised and conducted by a NELAC Certified Laboratory using
12 Standard Methods as described in the Northeast Wastewater Treatment Plant
13 FDEP Operating Permit.
14
15 F. Each machine shall be subject to the performance testing.
16
17 G. Plant influent TSS, BOD, and particle size distribution parameters must be
18 within typical ranges for those parameters for the testing to be considered valid.
19 Daily influent TSS and BOD values for the previous 12 -month period will be
20 made available by the City. It is the Contractor's responsibility to determine
21 and verify influent water quality, if the Contractor elects to do so. The
22 Contractor is not required to conduct influent sampling and testing. However,
23 it will be assumed that the influent TSS, BOD, and particle size distribution
24 values are within typical ranges unless proven otherwise by the Contractor.
25
26 H. The Contractor shall furnish the results of all testing to the Owner and the
27 Engineer. The Contractor shall submit records of flow and all laboratory
28 analyses conducted as part of the performance testing on each machine.
29
30 I. The Contractor shall notify the Engineer when the performance testing has been
31 completed and passed for each machine.
32
33 J. Should any daily average of TSS removal or daily average primary sludge solids
34 connected not meet the performance requirement, the Contractor shall perform
35 a Particle Size Distribution Analysis as described previously of the filter influent
36 flow. Should the percentage of particles larger than 350 microns be within 10%
37 of the previously measured value, then the Contractor shall modify the belt filter
38 and re -conduct the performance test until the belt filter TSS removal and primary
39 sludge solids content meets the performance requirements.
40
41 K. If the belt filter fails the performance test under influent conditions within
42 specification, the Manufacturer, at the Owner's request, shall correct any
43 system deficiencies and re -test at the Manufacturer's expense.
44
45 L. Exclusive Remedy
46
CONTINUOUS LOOP MOVING BELT FILTER
11350-11 04/22/19
1 In the event the any belt filter fails to meet the Process Performance
2 Requirements, the Contractor's sole remedy shall be to replace the filtration
3 system to enable the process to meet such Performance Requirements, at no
4 additional cost to the Owner.
5
6 3.05 PARTIAL SUBSTANTIAL COMPLETION
7
8 A. At the Contractor's discretion, after the moving belt filters and all related
9 subsystems, including inlet and sludge pump systems, piping systems,
10 mechanical systems, water systems, electrical systems and instrumentation
11 and controls have been installed and successfully tested to the satisfaction of
12 the Engineer and Owner, the Contractor may request partial substantial
13 completion and the City will assume responsibility fo the moving belt filter
14 system.
15
16
17
18
19
20 END OF SECTION
CONTINUOUS LOOP MOVING BELT FILTER
11350-12 04/22/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 11560
2
3 COMPRESSED GAS MIXING SYSTEM
4
5
6 PART 1 — GENERAL
7
8 1.01 SCOPE OF WORK
9
10 A. This section covers the furnishing of a compressed gas mixing system for
11 the Equalization Tank including air compressors, compressed air receiver,
12 master control panel, valve panel, header supply piping, nozzle headers,
13 nozzles, auxiliary equipment and accessories as specified herein.
14
15 1.02 DESCRIPTION OF THE SYSTEM
16
17 A. The system shall intermittently and sequentially inject compressed air
18 through fixed nozzles located on the basin floor to create large bubbles
19 which effectively mix the basin contents with negligible oxygen transfer from
20 the mixing system to the bulk liquid.
21
22 1.03 REFERENCES
23
24 A. ASTM International (ASTM)
25
26 1. A240/A240M, Standard Specification for Chromium and Chromium -
27 Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and
28 General Applications.
29
30 2. A276, Standard Specification for Stainless Steel Bars and Shapes.
31
32 3. A312, Standard Specification for Seamless, Welded, and Heavily Cold
33 Worked Austenitic Stainless Steel Pipe
34
35 4. A380, Standard Practice for Cleaning, Descaling, and Passivation of
36 Stainless Steel Parts, Equipment, and Systems
37
38 1.04 DEFINITIONS
39
40 A. Basin: The structure within which mixing occurs; i.e., Anoxic/Swing Zones.
41
42 B. Header Supply Pipe: Piping between a valve panel and respective nozzle
43 headers.
44
45 C. Nozzle Header: Continuous (i.e., not branched) horizontal piping with
46 nozzle offsets, with single inlet connection to header supply pipe and outlet
47 offset connections to nozzles.
48
COMPRESSED GAS MIXING SYSTEM
11560-1 06/25/2019
1
2 D. Nozzle Offset: Piping branching off nozzle header trunk piping and which
3 connects to nozzles either at a 90 degree angle or vertically.
4
5 E. Nozzle: Floor -anchored, large bubble -emitting device.
6
7 F Standard Cubic Feet per Minute (scfm): Air at 68° F, 14.7 psia, and
8 0 percent relative humidity as defined by the Compressed Air & Gas
9 Institute.
10
11 G. Actual Cubic Feet per Minute (acfm): Terminology to quantify volume of air
12 at the standardized reference condition (ISO 1217) delivered to the terminal
13 point of the compressor package.
14
15 H. Valve Panel (VP): Control panel that controls the firing of solenoid -actuated
16 air control valves, which intermittently emit compressed air bursts to the
17 respective header supply pipes.
18
19 I. Master Control Panel (MCP): Single control panel that controls the firing of
20 solenoid -actuated air control valves in one or more remote VPs.
21
22 1.05 SUBMITTALS
23
24 A. Submit to the Engineer for review in accordance with Section 01340 and
25 01730 complete installation drawings, shop drawings, working drawings,
26 O&M Manuals and product data for all materials and equipment furnished
27 under this Section. Submittals shall include at least the following:
28
29 1. Certified shop and erection drawings showing all important details of
30 construction, dimensions and anchor bolt locations.
31
32 2. Descriptive literature, bulletins and/or catalogs of the equipment.
33
34 3. Data on the characteristics and performance of each diffuser including
35 pressure drop across each diffuser
36
37 4. A complete total bill of materials of all equipment (may be furnished with
38 Operation and Maintenance manuals specified herein).
39
40 B. The submittal data shall be prepared, in its entirety, by the equipment
41 manufacturer. Shop drawings prepared by the manufacturer's sales
42 representative, fabrication shops, or other than the listed manufacturers will
43 not be acceptable. No additions or modifications to the manufacturer's
44 submittal will be accepted, with the sole exception of a cover sheet provided
45 by the manufacturer's local Representative and the Contractor.
46
47 C. Complete operating and maintenance instructions in accordance with
48 Specification 01730 shall be furnished for all equipment included under
COMPRESSED GAS MIXING SYSTEM
11560-2 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 these Specifications. The maintenance instructions shall include
2 installation instructions, lubrication instructions, troubleshooting data, full
3 preventative maintenance schedules, complete spare parts lists with
4 ordering information, and exploded views of all equipment with part
5 numbers identified.
6
7 D. In the event that is impossible to conform to certain details of the
8 Specifications due to different manufacturing techniques, describe
9 completely all non -conforming aspects.
10
11 1.06 TOOLS AND SPARE PARTS
12
13 A. Furnish one (1) set of all special tools required for normal operation and
14 maintenance.
15
16 B. Furnish and package for storage all of the manufacturer's recommended
17 spare parts to assure normal running and maintenance for a period of two (2)
18 years assuming all units are in continuous operation.
19
20 C. All spare parts shall be furnished in containers clearly identified with indelible
21 markings as to contents. Each container shall be packed with its contents
22 protected for prolonged storage.
23
24 D. In addition to items A -C, the following spare parts shall be supplied with
25 the equipment:
26 1. Six (6) Air Control Valve (ACV) rebuild kits
27 2. One (1) pilot air filter assemby
28 3. One (1) solenoid
29 4. One (1) valve plug and cable assembly
30 5. One (1) relay
31 6. One (1) 5 -micron pilot air filter
32 7. One (1) compressor intake air filter element per compressor
33 provided
34 8. One (1) compressor oil filter element per compressor provided
35 9. One (1) each compressor separator element per compressor
36 provided
37 Any other standard parts recommended by the Manufacturer.
38
39 1.07 WARRANTY
40
41 A. In accordance with Section 01740 the Compressed Gas Mixing
42 Manufacturer and the Contractor shall warrant the compressed gas mixing
43 system against defects in workmanship and materials for a period of one
44 (1) year under normal use, operation and service, commencing at the time
45 of final system acceptance by the Owner.
46
47 B. All equipment supplied within this Specification shall be warranted by the
48 same manufacturer.
49
COMPRESSED GAS MIXING SYSTEM
11560-3 06/25/2019
1 C. The equipment shall be warranted to be free from defects in workmanship,
2 design and materials. If any part of the equipment should fail during the
3 warranty period, it shall be replaced in the machine(s) and the unit(s)
4 restored to service at no expense to the Owner.
5
6 1.08 DELIVERY, STORAGE, AND HANDLING
7
8 A. All parts shall be properly protected so that no damage or deterioration will
9 occur during a prolonged delay from the time of shipment until installation
10 is completed and the units and equipment are ready for operation.
11
12 B. All equipment and parts must be properly protected against any damage
13 during a prolonged period at the site.
14
15 C. Equipment shall be protected from exposure to the elements and kept dry
16 at all times. Handle and store equipment on site to prevent damage and in
17 accordance with manufacturer's recommendations
18
19 D. Factory assembled parts and components shall not be dismantled for
20 shipment unless permission is received in writing from the Engineer.
21
22 E. Finished surfaces of all exposed openings shall be protected by wooden
23 blanks, strongly built and securely bolted thereto.
24
25 F Finished iron or steel surfaces not painted shall be properly protected to
26 prevent rust and corrosion.
27
28 G. Each box or package shall be properly marked to show its net weight in
29 addition to its contents.
30
31 H. Equipment damaged by handling and storage shall be repaired or replaced
32 by the Contractor as directed by the Engineer.
33
34 1.09 MANUFACTURER'S REPRESENTATIVE
35
36 A. Provide the services of a qualified factory certified representative for a
37 minimum of (4) days for final equipment installation inspection, certification,
38 start-up, training, and corrective adjustments.
39
40 1.10 QUALITY ASSURANCE
41
42 A. All equipment furnished under this Section shall be of a design and
43 manufacture that has been used in similar applications and it shall be
44 demonstrated to the satisfaction of the Owner that the quality is equal to
45 equipment made by that manufacturer specifically named herein. Alternate
46 manufacturers shall provide evidence of at least five (5) installations in
47 which identically sized equipment has provided satisfactory performance for
48 a minimum of five (5) years in a similar application. No consideration will
COMPRESSED GAS MIXING SYSTEM
11560-4 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 be given to individually sized equipment that has not been commercially
2 available for at least five (5) years.
3
4 B. All equipment shall be supplied by the same system supplier who is fully
5 experienced, reputable and qualified in the manufacture of the equipment
6 furnished and the process. The Contractor shall assume full responsibility
7 for the satisfactory installation and operation of the system as specified.
8
9 C. Motors shall be in accordance with NEMA Standards.
10
11 D. All equipment shall be designed, constructed and installed in accordance
12 with the best practices and methods.
13
14 E. Requests for substitution shall include manufacturer's literature for each
15 product giving name, product number, type, descriptive information, and
16 independent lab test reports showing results to equal the performance
17 criteria of the equipment specified herein. In addition, a list of five projects
18 shall be submitted in which identical equipment has been used and
19 rendered satisfactory service.
20
21 G. The system supplier shall be fully responsible for the design, arrangement
22 and operation of all components to ensure that neither harmful nor
23 damaging vibrations occur at any speed within the specified operating
24 range.
25
26 H. Should equipment which differs from these Specifications be offered and
27 determined to be the approved equal of that specified, such equipment will
28 be acceptable only on the basis that any revisions in the design and/or
29 construction of the structures, piping, appurtenant equipment, electrical
30 work, etc., required to accommodate such a substitution, shall be made at
31 no additional cost to the Owner and be as approved by the Engineer.
32
33 I. Changes in the number of nozzles, valves, or compressors will not be
34 acceptable unless a detailed submittal showing calculations and operating
35 data provides evidence that any such change will not affect the ability of the
36 system to perform as specified.
37
38 J. The equipment manufacturer shall guarantee the performance of each
39 component. The compressed gas mixing system shall be as manufactured
40 and provided by EnviroMix in Charleston South Carolina.
41
42 PART 2 — PRODUCTS
43
44 2.01 PERFORMANCE AND DESIGN REQUIREMENTS
45
46 A. Provide a compressed gas mixing system for mixing the Equalization Tank.
47 The system shall intermittently and sequentially inject compressed air
48 through nozzles located on the basin bottom to create large bubbles that
COMPRESSED GAS MIXING SYSTEM
11560-5 06/25/2019
1 will completely mix the basin with no moving parts located within the basin.
2
3 1. Basin mixing shall be uniform throughout the basin with effective mixing
4 confirmed through a Field Performance Test as specified.
5
6 B. Air distribution and balancing shall be sufficient to maintain suspended
7 solids in a state of suspension over entire basin. The operator interface shall
8 allow control of firing parameters (sequence, duration, and frequency) to
9 achieve basin mixing.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28 2.02 MATERIALS
29
30 A.
31
32
33
34
C. Firing flow rate shall be adjustable via the throttling valve. The compressed
gas mixing system equipment and piping shall be sized to thoroughly mix
the contents of the basins for which the systems are designed.
D. Treatment Process
Basin
Equalization
Basin Diameter (ft.)
120
Side Water Depth (ft.)
24
Number of Basins
1
Number of VPs per Basin
1
Number of ACVs per VP
13
Number of Nozzle Headers
Varies
Number of Nozzles
143
Nozzle Density (ft2 basin area / # nozzles)
79
Minimum Header Supply Pipe Dia. (in.)
2.0
Number and size of air compressors
2 -Rotary Screw
30 HP
Air Receiver Size
400 gallon
E. Performance Requirements Refer to section 3.03 of this specification.
F. The compressed gas mixing system Manufacturer shall be responsible for
sizing and selecting all system components to meet the requirements of the
field mixing performance test specified herein. The compressor size,
number of nozzles and piping size specified herein and shown on the
Drawing are minimum. Any increase in the number and size of system
components required in order to meet the performance and testing criteria
shall be supplied and installed at no additional cost to the Owner.
Header Supply Piping
1. Provide threaded connections only where required.
2. Sch 5S, stainless steel Press technology system (Viega, or equal),
COMPRESSED GAS MIXING SYSTEM
11560-6 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 comprised of stainless steel Press technology fittings, couplings, and
2 pipe, unless specified otherwise.
3
4 3. Maximum working pressure of 150 psi.
5
6 4. Couplings and fittings: Press technology products formed of Type
7 304/304L stainless steel tubing including a self-contained o -ring seal(s)
8 molded of synthetic FKM rubber.
9
10 5. Pipe: Type 304/304L ASTM A312 stainless steel.
11
12 B. Nozzle Headers
13
14 1. Sch 10S, 304/304L stainless steel with 1" Sch 40S, stainless steel
15 nozzle offsets.
16
17 2. Nozzle couplings: 1" NPT, 150 Ib, 304/304L stainless steel.
18
19 3. Delivered from the Manufacturer pre -assembled to the extent
20 practicable to minimize field assembly error and installation time.
21
22 4. Pipe: Type 304/304L ASTM A312 stainless steel.
23
24 5. Provide nozzle headers in maximum 20 -ft segments with two bolt
25 304/304L stainless steel flexible gasketed coupling connections.
26 Flexible couplings shall be rated for a maximum working pressure of 150
27 psi.
28
29 6. Provide nozzle headers with removable end caps to facilitate clean-out.
30
31 C. Nozzles
32
33 1. Top plate fabricated from 1/8" stainless steel plate, ASTM A240/A240M,
34 Type 304/304L with a 2D finish.
35
36 2. Bottom plate fabricated from HDPE and gasketed to prevent air from
37 leaking between the top plate and the bottom plate.
38
39 3. Top and bottom nozzle plates shall be joined together using Type
40 304/304L stainless steel hardware. Nozzles shall come pre -assembled.
41
42 4. Nozzles shall be designed with adequate strength to withstand vertical
43 thrust of mixing air.
44
45 5. Threaded Rod Anchors: Use Hilti HIT -RE 500 adhesive or equal to be
46 provided by the Contractor. A minimum of two threaded rods shall be
47 installed per nozzle for flat floor installations, one each on opposite
48 diagonal corners. Three threaded rods shall be installed per nozzle for
COMPRESSED GAS MIXING SYSTEM
11560-7 06/25/2019
1 slope floor installations.
2
3 6. Nozzles shall be installed in the locations as shown on the Drawings.
4
5 D. Appurtenances
6
7
8
9
10
11
12 2.03 FABRICATION
13
14 A. The piping used for the air mixing system shall be Type 304/304L stainless
15 steel unless otherwise noted.
16
17 B. Shop fabricate welded metal parts and assemblies from stainless steel,
18 ASTM A240/A240M, Type 3041304L with a 2D finish.
19
20 C. Shop fabricate non -welded parts and pieces from sheets and plates of
21 stainless steel, ASTM A240/A240M, Type 304 or from bars of stainless
22 steel ASTM A276, Type 304, unless specified otherwise.
23
24 D. Welds and Welding Procedure
25
26
27
28
29
30 2. Provide full penetration welds to interior surface with gas shielding to
31 interior and exterior of joint.
32
33 3. Provide smooth, evenly distributed interior weld beads with an interior
34 projection not exceeding 1/16 inch beyond inner diameter of nozzle
35 header or fittings.
36
37 4. Field welding is not permitted.
38
39 5. Clean all welded stainless steel surfaces and welds after fabrication to
40 remove weld splatter and finish clean all exterior welds, carbon deposits
41 and contaminants by passivation per ASTM A380 Section 6.2.11.
42
43 2.04 CONTROLS
44
45 A. Master Control Panel (MCP) Enclosure
46
47
48
49
1. Miscellaneous: Nuts, bolts, washers, threaded rod, and other non -
welded parts shall be stainless steel, ASTM A240/A240M, Type 304.
Threaded assemblies shall be chemically treated or lubricated prior to
assembling to prevent galling.
1. Shop weld with filler wire using MIG, TIG or shield -arc, or plasma -arc
welding inert gas processes. Provide a cross-section equal to or greater
than parent metal.
1. MCP shall have UL -rated NEMA 12 painted steel enclosure. The MCP
shall be sized to provide heat dissipation such that, at 80 degrees F
ambient temperature, the operating temperature rating of the Iowest-
COMPRESSED GAS MIXING SYSTEM
11560-8 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 rated component in the panel is not exceeded. The MCP shall meet the
2 requirements of Section 13630, including the requirement to furnish and
3 install a managed switch and a UPS in the MCP.
4
5 B. Valve Panel (VP) Enclosure
6
7 1. VP shall have UL -rated NEMA 4X 304 stainless steel enclosures.
8 Control panels shall be sized to provide heat dissipation such that, at a
9 110 degree F ambient temperature, the operating temperature rating of
10 the lowest -rated component in the panel is not exceeded.
11
12 C. Power Connection
13
14 1. All panels shall accept a single source 120 VAC power connection.
15 Lightning and surge protection shall be provided on the incoming line
16 power. Lightning and surge protection shall be as specified in Section
17 13630, 2.10.
18
19 D. MCP Operator Interface Terminal (OIT)
20
21 1. The MCP shall have an OIT to make operating parameter changes and
22 acknowledge alarms. The OIT shall be an Allen Bradley Panel View
23 color touchscreen or equal. The OIT shall have flash memory capacity,
24 USB port, and Ethernet communication.
25
26 E. Controller
27
28 1. The master control panel shall be equipped with an Allen Bradley
29 Compact Logix controller which controls the sequence, duration, and
30 frequency of ACV openings, or equal. The controller shall also provide
31 alarming functionality and network communication capabilities via
32 Ethernet TCP/IP protocols.
33
34
35 F Air Control Valves (ACVs)
36
37 1. The air control valves shall be, mounted to a common manifold. The
38 valves shall have a life expectancy of 15,000,000 cycles. Valves shall
39 vent to the outside of the panel.
40
41 G. Throttling Valve
42
43 1. Each VP shall be equipped with a throttling valve to adjust the volume
44 of air released to the ACVs and corresponding header supply piping.
45 The throttling valve shall be pre -plumbed into the VP.
46
47 H. Control Air Filter
48
COMPRESSED GAS MIXING SYSTEM
11560-9 06/25/2019
1 1. Each VP shall include a pre -plumbed 5 -micron filter with a drain to
2 remove fine particles, water vapor, and oil from the air supply. The filter
3 shall be Watts F603D or approved equal.
4
5 I. Heater
6
7 1. Each control panel located outdoors shall be provided with a 120 VAC
8 heater designed to maintain 40° F in an ambient outside temperature of
9 20° F. The heater shall be equipped with a thermostat to turn the heater
10 off at temperatures above 40° F.
11
12 J. Nameplate
13
14 1. A stainless steel nameplate shall be provided on the control panel. The
15 nameplate shall be securely fastened in a conspicuous place and clearly
16 inscribed with the Manufacturer's name, year of manufacture, and serial
17 number.
18
19 2.
20
21 2.05 CONTROL AND OPERATION
22
23 A. All control features shall be adjustable from the Operator Interface Terminal
24 (OIT) provided by the mixing system Manufacturer. Control features shall
25 be adjustable at any time during the operation of the system. Control
26 features shall be initially set according to Manufacturer recommendations.
27
28 B. Mixing Parameters
29
30 1. The operator shall be able to enable/disable mixing operation, select the
31 firing sequence, the firing duration and the frequency of firing. Minimum
32 control features selected through the OIT shall include the following:
33
34 a. Enable / Disable
35 1) ACV firing can be started and stopped at any point during
36 operation without powering down the system.
37
38 b. Firing Sequence
39 1) Order and operation in which ACVs are fired, e.g.
40 1,2,3,..8 1,1,2,2,3,..8 8,1,7,2,..1.
41
42 c. Firing Duration
43 1) Length of time an individual ACV is open during a firing
44 event. The duration shall be operator adjustable within
45 programmed limits and configurable for each ACV individually.
46
47 d. Firing Frequency
48 1) Length of time to complete the firing sequence. Frequency shall
49 be operator adjustable within programmed limits.
COMPRESSED GAS MIXING SYSTEM
11560-10 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 e. Valve Isolation
3 1) Individual ACVs or specific groups of ACVs may be added and/or
4 removed from the firing sequence at any point during operation.
5
6 C. Startup Modes
7
8 1. The Controller shall enable startup modes that utilize the Manufacturer
9 default settings, firing parameters set during the preceding mixing
10 system operation, as well as new settings entered through the OIT.
11
12 D. Alarms
13
14 1. Each VP shall come equipped with a pressure transducer plumbed to
15 the valve manifold. The pressure transducer shall transmit pressure
16 anomalies to the controller. The controller shall interpret the pressures
17 transmitted to provide a low system pressure alarm and monitor ACV
18 position.
19
20 E. Alarm Indication
21
22 1. When either the low system pressure or Valve Fail to Open, Valve Fail
23 to Close alarms occur, a red general alarm light shall be illuminated on
24 the VP. The specific alarm shall be indicated on the alarm shall remain
25 until the fault is corrected or the system is turned off.
26
27 F. Heartbeat Function
28
29 1. The controller shall have a register with a bit that toggles at a regular
30 interval to act as a heartbeat for confirmation of continued controller
31 operation and network communication.
32
33 G. The controller shall communicate the following through Ethernet.
34 1. System pressure
35 2. Firing sequence
36 3. Firing frequency
37 4. Firing duration (each valve)
38 5. System running (enabled)
39 6. Low pressure
40 7. Valve fail to open (each valve)
41 8. General alarm
42 9. Heartbeat
43 10. Compressor fault (each compressor)
44
45 H. The controller shall accept the following parameters through Ethernet:
46 1. Enable Mixing
47 2. Firing sequence (up to 16 firing events)
48 3. Firing frequency
COMPRESSED GAS MIXING SYSTEM
11560-11 06/25/2019
1 4. Firing duration (each valve)
2
3 2.06 AIR COMPRESSORS
4
5 A. Two (2) air compressors shall be supplied. Each unit shall include an inlet air filter,
6 compressor with an AC motor, air/oil separator reservoir, air cooled oil cooler,
7 cooling fan, separator pressure relief valve, discharge check valve, air dryer,
8 moisture separator, particulate and coalescing filters, controls, control panel, base,
9 and unloading system.
10
11 B. Each compressor module shall be completely factory assembled requiring only
12 field connection of electrical power, and air and condensate drain piping.
13
14 C. Each compressor shall be of the single stage, positive displacement, oil -flooded,
15 rotary screw type. The compressor shall be provided with an integral skid or lifting
16 lugs for unloading and placement.
17
18 D. Each compressor rotors shall be asymmetrical, steel or high strength ductile iron
19 integral shafts, and dynamically balanced. Housings shall be cast iron. Rotors
20 and housings shall be precision machined for accurate bearing positioning and
21 running clearances. The drive arrangement shall be a gear driven design.
22
23 E. Positive pressure lubrication shall be provided by an inherent pressure differential
24 system. Lubricant shall be provided as recommended by the Manufacturer. A
25 lubricant filter shall have a high-capacity 10 micron rating.
26
27 F. An air/oil separator reservoir shall be provided for each compressor. The reservoir
28 shall be designed and constructed in accordance with the ASME Code for Unfired
29 Pressure Vessels and shall bear the code stamp. The reservoir shall include two -
30 stage filtration to remove oil from air stream. Oil carry-over downstream of
31 compressor modules shall not exceed 3 mg/m3.
32
33 G. Each air compressor module shall have automatic controls integral to the unit
34 which open (loaded condition) and close (unloaded condition) the inlet valve to the
35 air end to deliver appropriate volume to meet demand and maintain system target
36 pressure. On sensing a low demand, the motor will keep running but the air end
37 inlet valve will close, resulting in a decreased "idling" power draw on the motor.
38 The valve shall reopen when system pressure drops below the set point.
39
40 H. Each baseplate shall be constructed of one-piece folded mild -steel with structural
41 members and shall be designed for no measurable deflection with the equipment
42 mounted thereon and the baseplate supported around its perimeter. Each base
43 shall be designed so that all equipment bolted to it can be removed without access
44 to the underside of the plate and with a flat top surface for ease of cleaning.
45 Structural stiffeners shall be located under the compressors at the compressor
46 anchor points.
47
48 I. Valves and piping within the enclosure shall be the compressor Manufacturer's
49 standard. Relief valves shall be provided for equipment protection on the air and
50 coolant systems as required
51
52 J. Each compressor shall be provided with an integral, dry -type intake filter. Intake
53 filters shall have replaceable filter element(s). Particle arrestance shall be not less
COMPRESSED GAS MIXING SYSTEM
11560-12 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 than 99.9% efficient at 10 microns and above.
2
3 K. Each compressor shall be supplied in a sound attenuated enclosure. The
4 enclosure shall reduce the measured sound to a maximum of 85 decibels, as
5 measured by ISO 8571, while the compressor is operating and the sound level is
6 measured a distance of three feet from the enclosure.
7
8 L. Each compressor electrical control cabinet shall be a NEMA 3R rated enclosure.
9
10 M. A high air/fluid temperature shutdown system shall be provided. The unit must
11 have safety devices mounted and wired. Safety devices shall include motor
12 thermal overload and high compressor discharge temperature shut -down. These
13 systems must be designed to prevent the compressor from running in an over
14 temperature situation or motor from running in an overload condition.
15
16 N. The two compressors shall each feature controls capable of operating at two
17 pressure settings, selected by a panel mounted switch on the compressor's control
18 panel. The controller shall allow one of two different pressure control settings to
19 be chosen for each compressor. If the demand is greater than one unit's capacity
20 (the lead compressor), the second compressor (the lag compressor) will
21 automatically turn itself on until the excess demand has been satisfied. The lag
22 compressor's motor will shut down after a set period of time in which it is not loaded
23 as described in paragraph above. The lead/lag circuits shall be fully incorporated
24 inside the compressor's control panel. No additional separate control sequence
25 panels shall be required.
26
27 O. The compressors shall be as manufactured by Atlas Copco, Model GA22+ or
28 equal.
29
30 P. Refrigerated Dryers
31
32 1. A cycling refrigerated air dryer shall be provided for each compressor.
33 The dryers shall produce an ISO Class 4, 7°C dew point at the dryer exit
34 when operating continuously at the rating conditions of 2°C and RH of
35 60%.
36
37 2. The dryers shall be capable of continuously drying the maximum
38 discharge capacity of the air compressor.
39
40 3. The dryers shall be integral or separately mounted to the compressor
41 package.
42
43 2.07 FREE STANDING AIR RECEIVER
44
45 A. One (1) air receiver shall be provided. The receivers shall be designed and
46 constructed in accordance with the ASME Code of Unfired Pressure Vessels and
47 shall bear the code stamp.
48
49 B. Receivers shall be factory powder coated. One quart touch-up paint shall be
50 provided.
51
52 C. Each receiver shall be provided with mounting feet, safety relief valve and pressure
COMPRESSED GAS MIXING SYSTEM
11560-13 06/25/2019
1 gauge.
2
3 D. Each receiver shall be provided with a 24 VDC motor-operated'/2" FNPT stainless
4 steel ball valve powered and controlled out of an adjacent VP or MCP.
5
6
7 2.08 COMPRESSOR SYSTEM PARTICULAR AND COALESCING OIL FILTERS
8
9 A. Replaceable -cartridge primary particulate and secondary high -efficiency oil -
10 removal filters shall be provided for the compressor package. Following both
11 filters, the maximum particulate size removal shall be to 1 micron and coolant
12 removal shall be to 0.1 mg/m3 at 21°C.
13
14 B. The filters shall be rated for the maximum discharge capacity of the air
15 compressor.
16
17 2.09 COMPRESSOR SYSTEM ELECTRICAL
18
19 A. All electrical and control equipment for the air compressor module shall be
20 furnished as required for a complete installation, requiring only field connection of
21 480 VAC, three phase power supply.
22
23 B. The compressor electric motor shall be rated 480 volts, 60 Hz, three phase.
24
25 2.10 COMPRESSOR SYSTEM CONTROL PANEL
26
27 A. An enclosure -integrated control panel mounted on the compressor module shall
28 include:
29
30 1. Full voltage, non -reversing, motor starters sized as required by the
31 Manufacturer.
32
33 2. Control power transformers shall have both primary leads fused, one
34 secondary lead fused, and one secondary lead grounded.
35
36 3. Terminal blocks for all system wiring. Internal panel wiring shall be
37 neatly bundled and tied and shall be identified with suitable wire markers
38
39 4. Controller shall be provided to indicate the following conditions;
40 Differential pressure across fluid filter, discharge pressure, compressor
41 discharge temperature, power on, hours of operation, operating mode,
42 differential separator, percent capacity, air filter.
43
44 5. A contact which closes under alarm conditions shall be provided for the
45 compressor for remote "FAIL" alarm. The contact shall close when any
46 alarm occurs for the compressor.
47
48 6. Remote mounted fusible disconnects with time delay fuses shall be
49 provided by Contractor.
50
COMPRESSED GAS MIXING SYSTEM
11560-14 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 2.11 COMPRESSOR SHOP PAINTING
2
3 A. All components of the compressed air equipment system shall be shop primed and
4 finish painted with the Manufacturer's standard paint system prior to shipment to
5 the site.
6
7 2.12 COMPRESSOR SYSTEM PERFORMANCE AND DESIGN REQUIREMENTS
8
9 A. The compressed air equipment shall be designed for the following operating
10 conditions:
11
12
13
Ambient Conditions
Max Air temperature, F
100
Min Air temperature, F
35
Relative humidity, percent
100
Barometric pressure, psia
14.7
Compressors
Number required
2
Maximum discharge pressure, psig
100
Capacity at operating target pressure, acfm
140
Motor size, hp
30
Max motor shaft speed, rpm
3600
Max free field noise ±3 dB(A) when measured in
free field conditions at a distance of 1 meter
according to IS01217
70
Receivers
Number required
1
Design pressure, psig
200
Nominal volume, gal
400
Filters
Type
Particulate and Oil
Removal
Number required
1 each/compressor
Refrigerated Air Dryer
Type
Cycling
Number required
1
Target Pressure Dew Point (°C)
1 — 3
14
15
16 2.13 COMPRESSOR PRESSURE TRANSDUCER
17
18 A. Each compressor shall be equipped with a pressure transducer plumbed to the
19 discharge piping to monitor the common discharge pressure from the
20 compressors.
21
COMPRESSED GAS MIXING SYSTEM
11560-15 06/25/2019
1 PART 3 — EXECUTION
2
3 3.01 INSTALLATION
4
5 A. Install items in accordance with approved shop drawings, Manufacturer's
6 printed instructions and as indicated.
7
8 B. All nozzles on respective nozzle header shall be level within 'A -inch of a
9 common horizontal plane.
10
11 3.02 MANUFACTURER'S FIELD SERVICES
12
13 A. General - Furnish the services of a factory representative to inspect the
14 installation, supervise a test run of the system, conduct the performance
15 testing, and provide training for the Owner's operations and maintenance
16 staff in proper operation and maintenance of the equipment. The factory
17 representative shall provide a written certification that the system is installed
18 in accordance with the manufacturer's recommendations.
19
20 B. The final copies of Operation and Maintenance manuals specified in Section
21 01730 must be delivered to the Engineer prior to scheduling the instruction
22 period with the Owner.
23
24 C. A minimum of 4 -on-site days shall be scheduled by the Manufacturer's
25 technical representative to provide the services described.
26
27 3.03 FIELD PERFORMANCE TESTING AND GUARANTEE
28
29 A. All mixer piping and components shall be field tested with 2 -feet nominal of
30 submergence initial for leaks. All leaks shall be repaired as required.
31
32 B. After initial leak testing has been conducted and all leaks repaired, the
33 Contractor shall fill the tank with reclaimed water to the invert of the tank
34 overflow pipe. All mixer piping and components shall be field tested with a
35 full tank of reclaimed water and repairs made as required.
36
37 C. Exposed, non -submerged air piping shall be tested by Contractor for leaks
38 using soapy water on all joints and applying 100 psi test pressure. Buried
39 air piping shall be tested using this method before the trench is filled.
40
41 D. The Contractor shall operate the mixing system with reclaimed water at the
42 maximum water surface elevation in the basins for a continuous period of
43 not less than 72 hours. The Contractor shall correct and resolve all
44 operating problems, deficiencies, etc., determined as a result of the tests.
45
46 E. After the above testing is complete, field mixing performance testing of the
47 installed compressed gas mixing system shall be performed by the
48 Manufacturer as described below.
COMPRESSED GAS MIXING SYSTEM
11560-16 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 1. Mixing performance testing shall be conducted in the Equalization Tank.
3
4 2. All personnel and equipment necessary to conduct and supervise all
5 testing shall be provided by the compressed gas mixing system
6 Manufacturer. Engineer/Owner shall be notified of the test to witness at
7 their option and expense.
8
9 3. The tank shall be filled with typical influent wastewater with TSS in
10 typical operating range of 150 — 350 mg/L. No flow shall enter or exit
11 the respective basin for two hours prior to and during the test.
12
13 4. The compressed gas mixing system Manufacturer shall conduct total
14 suspended solids (TSS) testing using a Cerlic TSS probe, or equal,
15 suspended solids analyzer.
16
17 5. Testing Procedure:
18
19 a. In the mixing test, the compressed gas mixing system shall have
20 been in normal operating mode for at least two days prior to testing
21 and must have TSS in the typical operating range indicated above.
22
23 b. Four horizontal -plane sample sites to be tested shall be selected by
24 the Engineer. At each sample site, three vertical samples shall be
25 collected as follows: 24 -inches from the surface, tank sidewall mid -
26 point and 24 -inches above the tank sidewall bottom. Each sample
27 site must be a minimum of 4 ft away from any structure within the
28 tank. The samples for each location shall be analyzed as described
29 above.
30
31 c. The Coefficient of Variation (Cv) shall be determined for the sample
32 set, excluding the maximum and minimum samples. The Cv shall be
33 calculated by taking the resultant set of ten (10) samples as follows:
34 Cv = (100 x Standard Deviation of Ten Samples)/(Mean Value of Ten
35 Samples)."
36
37 d. If the Cv is less than or equal to 10% then the mixer performance
38 shall be acceptable for that location.
39
40 e. If the Cv is greater than 10%, then the mixer performance shall be
41 unacceptable for that location and the Contractor and/or
42 Manufacturer shall make all necessary improvements (at no
43 additional cost to the Owner) and repeat the testing procedure at no
44 additional cost to the Owner until the Cv is less than or equal to 10%
45 for that location.
46
47 END OF SECTION
48
COMPRESSED GAS MIXING SYSTEM
11560-17 06/25/2019
1 THIS PAGE INTENTIONALLY LEFT BLANK
COMPRESSED GAS MIXING SYSTEM
11560-18 06/25/2019
1
1
1
1
1
1
1
1
1
1
1
1
t
1
1
1
1
1
1 SECTION 13210
2
3 BOLTED STEEL WATER STORAGE TANK
4
5 PART1 GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish and erect one (1) glass -fused -to -steel bolted water storage tank including
10 foundation, tank structure, and tank appurtenances as shown on the contract
11 drawings and described herein.
12
13 B. All required labor, materials and equipment shall be included.
14
15 1.02 SUBMITTALS
16
17 A. Construction shall be governed drawings and Specifications showing general
18 dimensions and construction details, after review by the Engineer of detailed
19 erection drawings prepared by the tank manufacturer. There shall be no deviation
20 from the drawings and specifications, except upon written order from the Engineer.
21
22 B. The Contractor shall furnish six (6) sets of shop drawings in accordance with
23 Section 01300 and 01340. A complete set of structural calculations shall be
24 provided for the tank structure and foundation. All such submissions shall be
25 stamped by a Registered Professional Engineer licensed in the State of Florida,
26 as well as, by a Registered Professional Engineer employed on the tank
27 manufacturer's engineering staff.
28
29 C. The tank manufacturer's standard published warranty shall be included with
30 submittal information. Submit detailed design drawings sealed by a professional
31 engineer registered in the State of Florida.
32
33 D. Submit design calculations sealed by a professional engineer registered in the
34 State of Florida.
35
36 E. Submit mix designs for floor slab and footing concrete mixes.
37
38 1.03 QUALIFICATIONS OF TANK SUPPLIER
39
40 A. The Engineer's selection of factory applied glass -fused -to -steel bolt together tank
41 construction for this facility has been predicated upon the design criteria,
42 construction methods specified, and optimum coating for resistance to internal and
43 external tank surface corrosion. Deviations from the specified design,
44 construction, or coating details, will not be permitted.
45
46 B. The Contractor shall furnish a new tank structure as supplied from a
47 manufacturer/erector specializing in the design, fabrication and erection of factory
BOLTED STEEL WATER STORAGE TANK
13210-1 12/17/20
1 applied glass -fused -to -steel, bolt together tank systems. The
2 manufacturer/erector shall employ a staff of full time engineers, and shall own and
3 operate its production plant, fabricate and glass coat the tank at one location.
4
5 C. The tank shall be a glass coated, rolled tapered panel (RTP) bolted tank as
6 manufactured by CST Storage of DeKalb, Illinois; Tank Connection of Parsons,
7 Kansas; or equal.
8
9 D. Alternate glass -fused -to -steel tank products, as provided by other manufacturers,
10 will be considered for prior approval by the Engineer. Manufacturers lacking the
11 experience requirement will not be considered.
12
13 E. Strict adherence to the standards of design; fabrication; erection; product quality;
14 and long term performance, established in this Specification will be required by the
15 Owner and Engineer.
16
17 F. Tank substitutions that cause engineering and contract changes - the tank
18 installation as shown on the plans and specified herein, is based on the equipment
19 furnished by one manufacturer. A tank that is offered as a substitute to the specific
20 requirements of these Specifications and that differs in detail and arrangement
21 from that shown may require changes in design and construction. All costs
22 resulting from such changes in design and construction are to be borne entirely
23 and unconditionally by the Contractor; said costs to include but not be limited to
24 structural, piping, mechanical and electrical changes and all engineering costs
25 incurred as a result of the substitution, in the revision of Plans and Specifications,
26 review of design changes by others, preparation of change orders, and any other
27 costs directly resulting from said substitution.
28
29 1.04 TANK DESIGN CRITERIA
30
31 A. Tank Design Standards
32
33 a. The materials, fabrication, and erection of the bolt together tank shall conform
34 to the AWWA Standard for "Factory Coated Bolted Steel Tanks For Water
35 Storage" - ANSI/AWWA D103, latest revision (potable water applications) or
36 AISC for wastewater tank applications.
37 b. Florida Building Code 2017.
38 c. The tank coating system shall conform solely to Section 12.4 of ANSI/AWWA
39 D103. NOTE: Baked -on epoxy painted or galvanized bolt -together tanks are
40 not considered equal.
41 d. The glass coating on the tank, bolt head encapsulation material, and joint
42 sealant shall have been approved for listing under ANSI/NSF Standard 61 for
43 Indirect Additives.
44 e. The tank manufacturer shall be ISO -9001 certified to assure product quality.
45
46 B. Tank Size: The factory -coated glass -fused -to -steel, bolt together tank shall have a
47 nominal diameter of 120 feet, with a nominal sidewall height of 25 feet.
BOLTED STEEL WATER STORAGE TANK
13210-2 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 C. Tank Capacity: Tank effective capacity shall be 2,021,000 gallons (nominal, U.S.
3 gallons) with 24" freeboard.
4
5 D. Floor Elevation: Finished floor elevations shall be as shown on the Drawings.
6
7 E. Design Loads:
8 a. Specific Gravity 1.0 (Min. design shall be 1.0)
9 b. Wind Velocity 160 mph (ASCE 7-05 Design)
10 c. Wind Default: AWWA D103-09
11 d. Allowable Soil Bearing Capacity: Per Geotechnical Report in the Appendix
12 e. Roof Snow Load: N/A
13 f. Seismic Design: AWWA D103-09
14 g. Seismic Site Class D
15 h. Seismic Importance Factor (le): 1.5; Seismic TL: 8
16
17 F Tank Design will include provisions for a future domed cover with an eight (8)
18 foot vertical skirt.
19
20 PART 2 PRODUCTS
21
22 2.01 PLATES AND SHEETS
23
24 A. Plates and sheets used in the construction of the tank shell, tank floor and tank
25 roof, shall comply with the minimum standards of AWWA D103, Section 4.4.
26
27 B. Design requirements for high strength steel shall be per AWWA D103.
28
29 C. The annealing effect created from the glass coated firing process shall be
30 considered in determining ultimate steel strength. In no event shall a yield strength
31 greater than 50,000 psi be utilized for calculations as detailed in AWWA D103,
32 Sections 5.4 and 5.5.
33
34 D. Sheet edge protection: each full size steel sheet, all rectangular floor sheets (if
35 glass/steel floor is designed) and all foundation/starter sheets will have a
36 mechanically rounded edge (bullnose profile) to specific radii per Porcelain Enamel
37 Institute PEI -101. The sheets shall be glass coated with a minimum of 5 mil
38 thickness along the rounded edges. Edge coating shall provide full encapsulation
39 of the sheet edges.
40
41 E. Concrete materials shall meet the requirements of ACI 301. Cement shall be
42 Portland Type I or II. Up to 25% of cement may be replaced by fly ash. The design
43 mix shall have a minimum compressive strength of 4,000 psi.
44
45 2.02 ROLLED STRUCTURAL SHAPES
46
47 A. Material shall conform to minimum standards of ASTM A36 or AISI 1010.
BOLTED STEEL WATER STORAGE TANK
13210-3 12/17/20
1
2 2.03 HORIZONTAL WIND STIFFENERS
3
4 A. Design requirements for intermediate horizontal wind stiffeners shall be of the "web
5 truss" design with extended tail to create multiple layers of stiffeners, permitting
6 wind load to be distributed around the tank.
7
8 B. Web truss stiffeners shall be of steel with hot dipped galvanized coating.
9
10 C. Rolled steel angle stiffeners are not permitted for use as intermediate stiffeners.
11
12 2.04 BOLT FASTENERS
13
14 A. Bolts used in tank lap joints shall be 1/2 - 13 UNC -2A rolled thread, and shall meet
15 the minimum requirements of AWWA D103, Section 2.
16
17 B. Bolt Material — SAE J429 Grade 8
18
19 C. Bolt Finish — JS1000 or mechanically deposited finish
20
21 D. Bolt Head Encapsulation
22
23 1. High impact polypropylene copolymer encapsulation of entire bolt head.
24
25 2. Resin shall be stabilized with an ultraviolet light resistant material such that
26 the color shall appear black. The bolt head encapsulation shall be certified
27 to meet the ANSI/NSF Standard 61 for indirect additives.
28
29 E. All bolts on the vertical tank wall shall be installed such that the head portion is
30 located inside the tank, and the washer and nut are on the exterior.
31
32 F All lap joint bolts shall be properly selected such that threaded portions will not be
33 exposed in the "shear plane" between tank sheets.
34
35 G. Bolt lengths shall be sized to achieve a neat and uniform appearance. Excessive
36 threads extending beyond the nut after torqueing will not be permitted.
37
38 H. All lap joint bolts shall include a minimum of four (4) splines on the underside of
39 the bolt head at the shank in order to resist rotation during torqueing.
40
41 I. Polyethylene co -polymer "bolt caps" and sealant shall be used to cover the bolts,
42 nuts, and washers exposed on the outside of the tank sidewall.
43
44 2.05 SEALANTS
45
46 A. The lap joint sealant shall be a one component, moisture cured, polyurethane
47 compound. The sealant shall be suitable for contact with potable water and meet
BOLTED STEEL WATER STORAGE TANK
13210-4 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 applicable FDA Title 21 regulations, as well as, ANSI/NSF Additives Standard 61.
2
3 B. The sealant shall be used to seal lap joints and bolt connections. The sealer shall
4 not be used as a coating except for minimal exposed panel edges for the
5 embedded starter ring, notches of sidewall panels, and edges exposed for nozzle
6 connections. The sidewall panel edges shall be protected by the fused glass
7 coating (spray or brush on coatings are not acceptable). The sealant shall cure to
8 a rubber like consistency, have excellent adhesion to the glass coating, have low
9 shrinkage, and be suitable for interior and exterior exposure.
10
11 C. Sealant curing rate at 73° F and 50% RH
12 1. Tack -free time: 6 to 8 hours.
13 2. Final cure time: 10 to 12 days.
14
15 D. Neoprene gaskets and tape type sealer shall not be used.
16
17 2.06 GLASS PROCESS
18
19 A. Surface Preparation: The tank sheets shall be steel grit -blasted on both sides to
20 the equivalent of SSPC-10 (near white blast cleaning). Sand blasting and chemical
21 pickling of steel sheets is not acceptable. The surface anchor pattern shall be not
22 less than 1.0 mil. These sheets shall be evenly oiled on both sides to protect them
23 from corrosion during fabrication.
24
25 B. Cleaning: After fabrication and prior to application of the coating system, all sheets
26 shall be thoroughly cleaned by a caustic wash and hot rinse process followed
27 immediately by hot air drying. Inspection of the sheets shall be made for traces of
28 foreign matter, soil particles, grease, or rust. Any such sheets shall be re -cleaned
29 or grit -blasted to an acceptable level of quality.
30
31 C. Coating:
32
33 1. A base coat of glass frit containing nickel oxide shall be applied to both sides
34 of the sheet.
35 2. A second coat of milled cobalt blue glass shall be applied to both sides of the
36 sheet.
37 3. A third coat of glass shall be applied to all interior sidewall and floor sheet
38 surfaces which must be a titanium dioxide reinforced mixture, white color. The
39 specified coating shall be AQUA AGT 2020 or Aquastore Vitrium. An
40 acceptable alternate three coat system must be submitted for approval at least
41 three weeks prior to the bid.
42 4. The same glass coating as applied to the exterior sheet surfaces shall be
43 applied to the exposed edges.
44 5. The sheets shall then be fired at a minimum temperature of 1500 degrees F in
45 strict accordance with the manufacturer's ISO 9001 quality control procedures,
46 including firing time, furnace humidity, temperature control, etc.
BOLTED STEEL WATER STORAGE TANK
13210-5 12/17/20
1
2
3
4
5
6
7
8
9
10
11
12
6. The interior coating process for sidewall sheets and floor must be a 3 coat
process. The interior color shall be white. The exterior color shall be cobalt
blue.
7. Dry film interior coating thickness shall be 10.0 -18.0 mils (0.010 to 0.018
inches) minimum.
8. Dry film exterior coating thickness shall be 7.0 — 15.0 mils (0.007 to 0.015
inches) minimum.
9. The finished exterior color shall be the manufacturer's standard cobalt blue.
D. Factory Inspection: The manufacturer's quality system shall be ISO 9001 certified
and refer to ISO (International Organization for Standardization) for the following
testing and procedures.
13 1. Chemical Resistance of Glass Coating: Frits shall be individually tested in
14 accordance with pertinent sections of ISO 28706-1:2008.
15
16 2. Measurement of Glass Thickness: Glass thickness shall be measured using an
17 electronic dry film thickness gage (magnetic induction type). The thickness
18 gage shall have a valid calibration record.
19
20 a. The thickness of the glass shall be between 10.0 and 18.0 mils (0.010 and
21 0.018 inches).
22
23 3. Measurement of Color: The exterior color of the sheets shall be measured
24 using a colorimeter. The colorimeter shall have a valid calibration record. The
25 color must fall within the tolerances specified by the tank manufacturer, else
26 the panel shall be rejected.
27
28 4. Factory Holiday Test: A dry volt test using a minimum of 1100 volts is required.
29 Frequency of the test shall be every sheet. Any sheet registering a discontinuity
30 on the interior surface or floor shall be rejected.
31
32 5. Fishscale test: The glass coating shall be tested in-house for fishscale by
33 placing the full size production sheets in an oven at 400° F for one hour. The
34 sheets shall then be examined for signs of fishscale. Any sheet exhibiting
35 fishscale shall be rejected and all sheets from the gage lot will be similarly
36 tested.
37
38 6. Impact Adherence Test: The adherence of the glass coating to the steel shall
39 be tested in accordance with ISO standards. Any sheet that has poor
40 adherence shall be rejected.
41
42 2.07 PACKAGING
43
44 A. All approved sheets shall be protected from damage prior to packing for shipment.
45
46 B. Heavy paper or plastic foam sheets shall be placed between each panel to
47 eliminate sheet -to -sheet abrasion during shipment.
BOLTED STEEL WATER STORAGE TANK
13210-6 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 C. Individual stacks of panels will be wrapped in heavy mil black plastic and steel
3 banded to special wood pallets built to maintain the roll -radius of the tank panels
4 and minimize contact or movement of finished panels during shipment.
5
6 D. Shipment from the factory to the job site will be by truck, hauling the tank
7 components exclusively. No common carrier, drop, or transfer shipments.
8
9 2.08 ROOF
10
11 A. The tank shall be designed to accept the addition of a tank roof at a later date (a
12 clear -span, aluminum geodesic dome) along with an 8 -foot tall structural aluminum
13 skirt enclosure 360 degrees around the top of the tank sidewall. The aluminum
14 dome cover shall be constructed of non -corrugated triangular aluminum panels,
15 which are sealed and firmly clamped in an interlocking manner to a fully
16 triangulated aluminum space truss system of wide flange extrusions, thus forming
17 a spherical dome structure.
18
19 B. The aluminum dome shall be clear -span and designed to be self-supporting from
20 the periphery structure with primary horizontal thrust contained by an integral
21 tension ring. The dome dead weight shall not exceed 3 pounds per square foot of
22 surface area.
23
24 C. The actual dome and skirt are not part of this project.
25
26 2.09 APPURTENANCES
27
28 A. Pipe Connections: Where pipe connections are shown to pass through tank
29 panels, they may be factory located prior to glass coating, or field located, saw cut,
30 (acetylene torch cutting or welding is not permitted), and utilize an interior and
31 exterior flange assembly. For field located openings, a single component urethane
32 sealer shall be applied on any cut panel edges or bolt connections.
33
34 B. The tank manufacturer shall coordinate with the contractor and supply all required
35 pipe and conduit supports and hardware that attach to the tank. All supports and
36 hardware shall be 316 stainless steel.
37
38 C. Sidewall Access Manway: One sidewall access manway shall be provided as
39 shown on the Drawings in accordance with AWWA D-103. Such manway shall be
40 a minimum of 30 -inches in diameter and shall include a properly designed
41 reinforcing frame and cover plate. A davit to hold the cover plate, when opened,
42 shall be furnished and installed.
43
44 D. Identification Plate: A manufacturer's nameplate shall list the tank serial number,
45 tank diameter and height, and maximum design capacity. The nameplate shall be
46 affixed to the tank exterior sidewall at a location approximately five (5') feet from
47 grade elevation in a position of unobstructed view.
BOLTED STEEL WATER STORAGE TANK
13210-7 12/17/20
1
2 E. Cathodic Protection: The manufacturer shall design and supply a passive,
3 sacrificial anode catholic protecting system. The anodes shall be floor mounted.
4 The cathodic protection system shall be designed for protection of uncoated steel
5 surfaces in the product zone, including rebar within the uncoated concrete tank
6 floor.
7
8 PART 3 EXECUTION
9
10 3.01 FOUNDATION
11
12 A. The tank foundation is a part of the tank manufacturer's contract and shall be
13 installed by the tank manufacturer/erector per the tank manufactures' drawings.
14
15 B. The tank foundation shall be designed by the manufacturer to safely sustain the
16 structure and its live loads.
17
18 C. Tank stem wall design shall be based on the soil bearing capacity given in the
19 geotechnical report located in the Appendix.
20
21 D. The tank manufacturer shall notify the Engineer of any soil bearing strengths less
22 than that required.
23
24 E Embedded starter ring shall be 19 -inch minimum or as determined by the
25 manufacturer.
26
27 F Slot mount concrete footing is not acceptable. The floor shall be reinforced
28 concrete construction and shall be designed as a membrane slab in accord with
29 AWWA D-110.
30
31 3.02 TANK FLOOR
32
33 A. The floor shall be of reinforced concrete with an embedded glass fused to steel
34 starter sheet per the manufacturer's design, and is an integral element of the tank
35 assembly; therefore, the tank floor slab with embedded starter sheet shall be
36 constructed by the tank manufacturer/erector using manufacturer -trained
37 personnel regularly engaged in this type of tank construction. Floor shall be sloped
38 to the sump as shown on the drawings. The tank floor slab shall have a minimum
39 thickness of 6 -inches and shall have a minimum reinforcement ratio (ratio of gross
40 concrete area to reinforcement area) of 0.005.
41
42 B. Leveling of the starter ring shall be required and the maximum differential elevation
43 within the ring shall not exceed one-eighth (1/8) inch, nor exceed one -sixteenth
44 (1/16) inch within any ten (10) feet of length.
45
46 C. A leveling plate assembly, consisting of two 18 -inch anchor rods (3/4 -inch dia.) and
47 a slotted plate (3 1/2" X 11" X 3/8" thick) shall be used to secure the starter ring,
BOLTED STEEL WATER STORAGE TANK
13210-8 12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 prior to encasement in concrete. Installation of the starter ring on concrete blocks
2 or bricks, using shims for adjustment, is not permitted.
3
4 D. Two water stop seals made of a butyl rubber elastomer special for this application
5 shall be placed on the inside surface of the starter ring below the concrete floor
6 line. These materials shall be installed as specified by the tank
7 manufacturer/erector.
8
9 3.03 SIDEWALL STRUCTURE
10
11 A. Field erection of the Glass Fused to Steel, bolted -steel tank shall be in strict
12 accordance with the procedures outlined in the manufacturer's erection manual,
13 and performed by an authorized dealer of the tank manufacturer, regularly
14 engaged in erection of these tanks. Dealer's field supervisor shall be certified by
15 the manufacturer as having undergone factory training in proper tank erection
16 techniques.
17
18 B. Specialized erection jacks and building equipment developed and manufactured
19 by the tank manufacturer shall be used to erect the tanks.
20
21 C. Particular care shall be taken in handling and bolting of the tank panels and
22 members to avoid abrasion of the coating system. Prior to liquid test, all surface
23 areas shall be visually inspected by the Engineer.
24
25 D. An electrical leak test shall be performed during erection using a nine (9) volt leak
26 detection device. All electrical leak points found on the inside surface shall be
27 repaired in accordance with manufacturer's published touch up procedure.
28
29 E. The placement of sealant on each panel may be inspected prior to placement of
30 adjacent panels. However, the Engineer's inspection shall not relieve the
31 manufacturer/erector from his responsibility for liquid tightness.
32
33 F. No backfill shall be placed against the tank sidewall without prior written approval
34 and design review of the tank manufacturer. Any backfill shall be placed according
35 to the strict instructions of the tank manufacturer.
36
37 3.04 TESTING
38
39 A. Hydrostatic Testing: Following completion of erection and cleaning of the tank, the
40 structure shall be tested for liquid tightness by filling tank to its overflow elevation
41 with reclaimed water. Any leaks disclosed by this test shall be corrected by the
42 erector in accordance with the manufacturer's recommendations. Water required
43 for testing shall be furnished by the owner at the time of tank erection completion,
44 and at no charge to the tank erector. Disposal of test water shall be the
45 responsibility of the Contractor.
46
47 3.05 WARRANTY
BOLTED STEEL WATER STORAGE TANK
13210-9 12/17/20
1
2 A. Tank Manufacturer's Warranty: The tank manufacturer shall include a warranty for
3 the tank materials and coating. As a minimum, this warranty shall provide
4 assurance against defects in material or workmanship of the glass -coated surface
5 for the minimum period specified. The tank manufacturer shall warrant the liquid
6 storage tank shall be free from any defect in material or workmanship under normal
7 and proper use, maintenance and operation, during the period expiring on the
8 earlier of five (5) years after liquid is first introduced into the tank or 62 months
9 after the substantial portion of the tank sheets is delivered to the site where the
10 tank is erected.
11
12 B. Tank Erector's Warranty: The tank erector shall warrant the tank
13 erection/installation to be free from defects in workmanship and materials during
14 the period expiring on the earlier of one (1) year after liquid is first introduced into
15 the tank or 14 months after notice of substantial completion of the tank erection.
16 In addition, any defect to be corrected under the tank manufacturer's warranty shall
17 be corrected by the Tank manufacturer/erector at no cost to the Owner.
18
19
20
21 END OF SECTION
BOLTED STEEL WATER STORAGE TANK
13210-10
12/17/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13300
2
3 FRP COVER SYSTEM
4
5 PART 1 - GENERAL
6
7 1.01 DESCRIPTION OF WORK
8
9 A. Furnish all labor materials, equipment and hardware required to place in
10 satisfactory service fiberglass reinforced plastic flat covers over the four grit
11 removal tanks as shown on the drawings and specified herein. The FRP
12 covers shall include all support beams and composite panels, anchor bolts,
13 fasteners and gaskets required for a complete installation. Loose pieces,
14 such as closure strips or seals and other such items shall not be allowed.
15
16 1.02 QUALITY ASSURANCE
17
18 A. Quality assurance shall be as required in other Sections of the specifications
19 and the following requirements:
20
21 1. Manufacturer and erector shall demonstrate experience of a minimum
22 of five (5) years in Industrial Construction and FRP erection.
23
24 B. A system of quality control is required of the manufacturer of the panels to
25 assure and to document that the panels are manufactured to the following
26 standards and conditions where applicable:
27
28 ASTM D638 - Tensile Properties of Plastics
29 ASTM D790 - Flexural Properties of Plastics
30 ASTM D2538 - Indentation Hardness of Plastics (barcol)
31 National Bureau of Standard, PS 15-69
32
33 C. FRP Covers shall be flat covers as manufactured by Midwestern Fabricators,
34 or approved equal.
35
36 1.03 SUBMITTALS
37
38 A. General arrangement drawings showing complete structure, fasteners, other
39 such items and erection procedures for a complete assembly.
40
41 B. Shop drawings showing detail of all components including installation
42 instructions.
43
44 C. Design calculations sealed by a registered professional engineer in the state
45 of Florida.
46
FRP COVER SYSTEM
13300-1 03/22/2019
1 D. Certification that manufacturer has been actually engaged in the manufacture
2 of fiberglass flat panel covers for a minimum of five years.
3
4 E. Color samples for approval.
5
6 F. Operation and maintenance manuals to include:
7
8 1. Installation instructions, operation and maintenance
9 instructions, copies of all approved drawings, material
10 specifications of resin used, procedures, and repair procedures
11 for fiberglass.
12
13 PART 2 - PRODUCTS
14
15 2.01 DESIGN
16
17 A. Flat covers shall be designed to provide a minimum safety factor of three to
18 one against maximum calculated stresses and ultimate physical properties of
19 the laminate.
20
21 B. The panels shall be designed to withstand a combined live load of 2 -inch
22 water column vacuum, 150 PSF live load and 5 psf dead load with a
23 maximum deflection of L/120.
24
25 C. All panels shall be completely sealed and any access holes, or other
26 penetrations that pass through the panels shall be completely sealed.
27
28 D. Each tank covers shall be furnished with four (4) 30 -inch by 30 -inch access
29 hatches to allow inspection of the equipment below. Coordinate the location
30 of the hatches with the stacked tray grit removal equipment supplier.
31
32 D. Panels shall be designed to support a 250 Ib. point load on an area 1 ft. x 2
33 ft. anywhere on the cover.
34
35 E. Any connections, such as ducting or vents that fasten to the panels, shall be
36 provided with molded -in nut plates or molded -in studs in the panels so that
37 bolting shall be from the exterior of the cover.
38
39
40 2.02 MATERIALS
41
42 A. FRP covers shall be specifically designed, constructed and installed for the
43 service intended. The materials shall provide a minimum of three to one
44 factor of safety against the maximum calculated stresses.
45
46 B.
47
Resin shall be suitable for Fiberglass reinforcement shall consist of a
combination of chopped strand matt and woven roving suitably treated with a
FRP COVER SYSTEM
13300-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 finish compatible with the resin system. Glass content shall not be less than
2 25 percent.
3
4 C. Panels shall be manufactured using sandwich type construction but the effect
5 of the core material will not be allowed in calculating the bending, tensile,
6 rigidity or buckling stresses of the fiberglass skins and panel, i.e., the
7 fiberglass shell shall support all of the Toads as though the core material was
8 not present.
9
10 D. Each panel will be manufactured with overlapping seams. These seams
11 shall contain molded -in Type 304 S.S. nut plates for fastening the panels
12 together with stainless steel bolts from the exterior of cover.
13
14 E. Gaskets shall be supplied and installed between the seams and along the
15 outside edge of all panels. The gaskets shall be suitable for service over raw
16 municipal wastewater grit removal tanks with high levels of hydrogen sulfide
17 gas, other organic sulfide gases, and ammonia gas.
18
19 F. The panels shall rest on the concrete slab, curb wall or be supported from
20 above and held in place by 304 SS anchor bolts with suitable SS washers.
21
22 G. The top of the panels shall be peaked, to allow for drainage, with a non-skid
23 surface. The panels shall be 3 -inches high in the center and slope towards
24 the ends, at approximately'/4-inch per foot. Any structure needed for support
25 of the panels shall be placed to the topside of the panels. All structural
26 beams shall be box beam fabricated using the filament winding method.
27
28 H. The exterior surface of the fiberglass panels shall contain ultra -violet
29 stabilizers for protection against sunlight. The color of the cover system to be
30 selected by owner/engineer.
31
32 I. The interior of the panels shall be lined with a corrosion resistant liner.
33
34 PART 3 - EXECUTION
35
36 3.01 INSPECTION
37
38 A. Owner shall be allowed access to the manufacturing area for the purpose of
39 inspection.
40
41 B. The manufacturer shall include in its submittal, complete quality assurance
42 procedures and inspection forms. The manufacture shall provide at the time
43 of delivery complete inspection forms.
44
45 3.02 ERECTION
46
FRP COVER SYSTEM
13300-3 03/22/2019
1 A. Erection shall proceed in strict accordance with the manufacturer's written
2 instructions, according with sequences as shown on the shop drawings and
3 in the installation instructions.
4
5 B. Shim FRP framing only with approved shims. The use of scrap, off -fall or
6 other building materials as shims is not allowed.
7
8 C. Install FRP framing members on location, as shown on the approved
9 submittals. Field modifications (cuts, copes, holes, etc.) other than work
10 shown on the drawings are not allowed without the manufacturer's written
11 consent.
12
13 D. Place FRP deck units on supporting members and install fastening systems.
14
15 E. Cut and trim FRP deck units as shown on the shop drawings. Adjust into
16 final position with proper bearing and alignment at joints, laps and supports.
17
18 F Fasten FRP panels to the FRP supports as shown on the shop drawings.
19 Refer to the manufacturer's installation instructions for proper fastener
20 selection and installation techniques.
21
22 G. Place and fasten FRP hatches as shown on approved shop drawings.
23
24 3.03 MATERIAL HANDLING AND STORAGE
25
26 A. At the time of delivery, all material be inspected for shipping and handling
27 damage. The Contractor shall notify the freight company and the
28 manufacturer immediately of any damage.
29
30 B. Protect the surface of FRP covers from cuts, scratches, gouges, abrasions,
31 and impacts. Do not use wire slings unless material is fully protected. Use
32 spreader bars when lifting these materials. Do not drag panels or flashing
33 across one another unless separated by a non -scratching spacer.
34
35 C. Store all FRP panels on edges, do not store flat. Keep all FRP materials
36 covered - do not stack or store other building materials on top of unprotected
37 units. Store materials in a dry location, off the ground, for ventilation.
38
39 3.04 DAMAGED MATERIAL
40
41 A. Replace or repair all damaged material to the satisfaction of the Engineer.
42
43 B. Contact the FRP cover manufacturer for instructions regarding the proper
44 materials and procedures for the repair of FRP products before commencing
45 repair.
46
47 END OF SECTION
FRP COVER SYSTEM
13300-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13525
2
3 WET TAP SYSTEM
4
5 PART 1 — GENERAL
6
7 1.01 DESCRIPTION
8
9 A. The Contractor shall furnish and install two (2) permanent wet taps in the
10 existing 48 -inch diameter primary treatment effluent piping while maintaining the
11 upstream and downstream portions of the primary effluent piping system in
12 service. The wet taps sizes are 48" x 30" as shown on the drawings.
13
14 B. The existing primary effluent piping system is approximately 30 years old,
15 potentially corroded and, as such, subject to failure. The Contractor shall take
16 every precaution necessary to protect the existing pipelines and assure their
17 continued availability and functionality.
18
19 C. The existing primary effluent pipe is called out on the drawings provided by the
20 City as 48 -inch ductile iron. It is the Contractor's responsibility to verify the
21 material, and outside diameter of the existing pipe before ordering the wet tap
22 equipment.
23
24 D. The wet tap installation fittings and valves shall be subject to the same
25 standards and testing as other pipe fittings and shall provide a leak free
26 connection to the host pipe.
27
28 E. The wet tap system shall include, but not be limited to, a tapping sleeve fitting
29 with flanged connection, a gate valve that bolts to the flanged connection, and
30 a drilling machine that bolts to the gate valve. The wet tap sleeve and valve shall
31 provide a leak free sealed connection between the existing and proposed
32 piping.
33
34 F All work, materials, and incidentals necessary for the construction and testing
35 of the wet tap system including scaffolding, excavation, excavation support
36 systems, shoring, dewatering, hauling, removal, and disposal of excess and
37 unsuitable material, test pit to locate the pipe section where the wet tap sleeve
38 will be installed, providing and installing the sleeve on the existing pipe,
39 protection of the existing piping systems, suitable backfill material, backfilling,
40 compaction, furnishing all materials, cutting and removal of existing pipe,
41 testing, protection of existing surface features and utilities, all miscellaneous
42 materials, labor, equipment, tools, and incidentals necessary to complete the
43 work per the requirements of the Specifications, except as may be modified
44 herein.
45
46 G. The wet tap systems shall be as provided by Rangeline Tapping Services., TDW
47 Services Inc., or approved equal.
WET TAP SYSTEM
13525 -1 04/23/2019
1
2 1.02 SUBMITTALS
3
4 A. Submit complete information on the subcontractor that will install the permanent
5 wet tap system. The subcontractor shall have a minimum of 5 years of
6 experience in the installation of wet taps on existing pipelines. The submittal
7 shall include a client contact list that includes wet taps which have been installed
8 on ductile iron pipe of the same diameter. The client list shall include the names
9 and telephone numbers of a minimum of 20 client contacts.
10
11 B. The Contractor shall make all submittals in accordance with Sections 01300 and
12 01340 of these Specifications.
13
14 C. Shop Drawings shall be submitted for the wet tap sleeve, tapping valve, and
15 drilling machine and shall include a statement that the wet tap will perform
16 properly under the existing service conditions.
17
18 1.03 QUALITY ASSURANCE
19
20 A. Quality control shall be in accordance with Section 01640 of these
21 Specifications.
22
23 1.04 EXISTING UTILITIES
24
25 A. Existing utilities are as indicated on the Drawings based on the best available
26 information. The Contractor shall excavate test pits as required and verify the
27 horizontal and vertical location of the piping systems (primary effluent piping)
28 and all existing and known conflicting utilities prior to construction. Existing
29 utilities and services shall be carefully investigated and protected by the
30 Contractor. Damage to existing utilities caused by the Contractor or the
31 Contractor's work shall be immediately reported to the Owner and the Engineer.
32 The Contractor shall be responsible for repairing the damage as directed by the
33 Owner of the utility.
34
35 B. The Contractor shall verify all materials of construction, pipe wall thicknesses,
36 roundness, and any other information needed for performing the wet tap
37 operation.
38
39 PART 2 — MATERIALS
40
41 2.01 GENERAL
42
43 A. Wet tap equipment shall be water tight, suitable for the low internal pressure of
44 the primary effluent pumping system, estimated to be about 5 psi at peak flow.
45
46 B. The wet tap sleeve and valve shall be installed on the primary effluent piping
47 and shall be rated for a minimum pressure of 30 psi.
WET TAP SYSTEM
13525 -2 04/23/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 C. All wet tap equipment including the tapping sleeve, the tapping valve, the cutter,
3 and all hardware shall be furnished and installed by the subcontractor
4 performing the wet tap work.
5
6 2.02 SHELL CUTTER
7
8 A. The shell cutter shall be cylindrical design, with an O.D. (outside diameter)
9 tolerance that will allow for the I.D. (inside diameter) of the valve. The cutting
10 tips will be constructed of carbide or high strength carbon steel to enable a
11 complete and smooth cut. The coupon section cut from the host pipe shall be
12 removed and submitted to the Owner.
13
14 2.03 PILOT BIT
15
16 A. The pilot bit shall be designed with a carbide or high strength carbon steel tip.
17 The pilot bit shall be constructed to ensure the retrieval of the coupon section of
18 pipe. The coupon section cut from the host pipe shall be removed and
19 submitted to the Owner.
20
21 2.04 TAPPING VALVE
22
23 A. The tapping valve shall be a non -rising stem RWGV conforming to all applicable
24 sections of AWWA C500 and C509 Standards and suitable for buried
25 applications. One end of the valve will be flanged with alignment device to
26 attach to the tapping sleeve flange. The other end will be mechanical joint with
27 a special adapter to allow attachment of the drilling machine.
28
29 2.05 TAPPING SLEEVE, GASKET, AND FLANGE
30
31 A. The wet tap sleeve shall be manufactured in two sections. The back section
32 shall be full encirclement design with an outside diameter range specific to the
33 pipe it is being installed on. The front half shall be of full encirclement design
34 matching the back half with a welded nozzle and flange outlet. Wet tap fittings
35 shall be the high strength type having a wide body, made of a minimum material
36 strength of ASTM 285 Grade C, ASTM A-36 Steel, or equal that conforms to
37 and reinforces the pipe. The sleeve shall have a gasket of Nitrile Butadiene
38 Rubber (NBR, Buna-N) per ASTM D2000 with corrosion resistant alloy bolts
39 (per ANSI 21.11/AWWA C-111) and nuts (per A563) or equal and sized
40 appropriately, and a 3/4" forged steel test outlet. The flanged outlet shall be
41 AWWA C207 Class D, ANSI 150 Ib. drilling.
42
43 B. Finish: Wet tap fittings and hardware that remain after the temporary equipment
44 is removed shall be epoxy coated.
45
46
47
WET TAP SYSTEM
13525 -3 04/23/2019
1 PART 3 — EXECUTION
2
3 3.01 GENERAL
4
5 A. Excavate and expose the existing piping to be wet tapped. Suitably protect the
6 existing pipe from all Toads associated with the sleeve, attributable to the wet
7 tap equipment mounted to the sleeve, and the weight of the pipe itself. Such
8 protection may include, but not be limited to, pouring concrete fill against
9 undisturbed earth to support the pipe and the equipment. Particular care should
10 be exercised in protecting the pipe at the point where it extends into the open
11 excavation.
12
13 B. Verify that the existing piping is furnished with thrust restraint. Provide a
14 concrete thrust collar around the pipe as necessary to prevent movement of
15 unrestrained pipe.
16
17 C. Clean piping as required to obtain proper sealing.
18
19 D. Tapping must be accomplished while the primary effluent piping system is in
20 operation and under pressure.
21
22 E. The Contractor shall provide written notification to the Owner two weeks in
23 advance of performing the wet tap procedure.
24
25 F. The wet tap system shall be installed per the wet tap installation Subcontractor's
26 instructions and recommendations and the various pieces of equipment
27 manufacturer's instructions and recommendations.
28
29
30
31
32 END OF SECTION
WET TAP SYSTEM
13525 -4 04/23/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13567
2
3 TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEM
4
5
6 PART 1 — GENERAL
7
8 1.01 SCOPE OF WORK
9
10 A. The Contractor shall design, furnish, install, startup, operate, maintain, and
11 coordinate a temporary raw sewage bypass pumping and preliminary treatment
12 system including temporary piping systems (temporary bypass system) as
13 shown, specified or required. The temporary bypass system shall be designed
14 for "firm" continuous duty 24 -hours per day operation. The temporary bypass
15 treatment system shall include facilities for flow measurement, screening and
16 grit removal. Collectively, the temporary bypass pumping, treatment and piping
17 system, when operated in conjunction with the new moving belt filters, shall
18 allow the entire existing preliminary treatment and primary treatment systems,
19 between the existing bar screens and the existing Diversion Chamber, to be
20 taken out of service to construct improvements associated with these facilities.
21 Refer to Sheet G1.05.
22
23 B. The temporary pumping system shall pump raw sewage from upstream of the
24 existing mechanical bar screens to a temporary screening facility and then
25 through a temporary grit removal facility. Effluent from the temporary grit
26 removal process shall overflow a weir and be conveyed by a temporary gravity
27 piping system that is to be connected to the existing 48 -inch pipe carrying flows
28 to secondary treatment, where shown on the drawings. The elevation of the
29 weir on the grit removal process shall be designed and selected to allow a
30 portion of the effluent to be routed from the temporary grit removal process to
31 each of the three (3) new Moving Belt Filters. Filtered water from the Moving
32 Belt Filters shall be conveyed in a separate temporary gravity piping system to
33 the existing 48 -inch pipe carrying flows to secondary treatment where shown on
34 the Drawings. Design flow rates for the temporary bypass pumping, treatment,
35 and piping systems are shown on Sheet G1.05.
36
37 C. All temporary systems shall be disassembled and removed after the permanent
38 systems are completed, tested, accepted and placed in service.
39
40 D. The Contractor shall employ the services of a subcontractor specializing in the
41 design, furnishing, installation and operation of similar temporary pumping,
42 treatment and piping systems. The Contractor shall provide five (5) references
43 for projects performed by the subcontractor of similar size and complexity as
44 the proposed system for review by the Engineer. The proposed systems shall
45 meet the requirements of all codes and regulatory agencies having jurisdiction.
46
TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEMS
13567-1 06/10/19
1 E. The Contractor shall be fully responsible for the hydraulic design, for the
2 equipment design and selection, and for the installation, operation and
3 maintenance of the entire temporary bypass pumping, treatment and piping
4 systems.
5
6 F. Operation and maintenance of the temporary bypass pumping and treatment
7 system requires personnel with appropriate skill sets but does not require a
8 State of Florida Licensed Wastewater Operator and does not require a person
9 to be on site 24 hours/day, or 7 days per week. The Contractor shall provide a
10 telecommunications system to provide remote monitoring of alarms for its staff,
11 with the ability for the Owner and Engineer to also monitor system alarms.
12
13 G. The Contractor may propose alternative treatment systems or processes for
14 approval by the Owner/Engineer. The alternative system shall have the same
15 performance and treatment levels as the existing system. The design TSS
16 removal requirement shall be 7,000 pounds/day at a flow rate of 13.5 MGD and
17 must be variable with the incoming flow.
18
19 1.02 SUBMITTALS
20
21 A. The Contractor shall prepare a written Temporary Bypass Pumping, Treatment
22 and Piping Plan (Plan) in accordance with Specification Section 01300 and
23 submit it to the Engineer for review prior to beginning any work at the site. The
24 Contractor shall attend a meeting with the Engineer and the Owner to review
25 the Plan, then update the plan to address the comments received from the
26 Owner and Engineer. The Plan shall be prepared, signed and sealed by a
27 Professional Engineer licensed in the State of Florida.
28
29 B. The Plan shall consist of detailed written descriptions of the proposed systems,
30 calculations supporting the sizing and elevation settings of all equipment and
31 piping, and general arrangement drawings of the proposed equipment and
32 piping systems layouts and routing. The Plan shall include process flow
33 diagrams and a process and instrumentation diagram.
34
35 C. The Plan shall include equipment schedules, time schedules, locations, pumps,
36 pump controls, piping and valves. Cut sheets for all equipment and materials
37 shall be submitted. All valves and pipe routing shall be enumerated and shown
38 on the diagrams.
39
40 D. Calculations shall be provided detailing the determination of the total dynamic
41 head and horsepower requirements for pumping from the screen chamber to
42 the temporary screening facility and from the temporary screening facility to the
43 temporary grit removal facility.
44
45 E. The Plan shall show at a minimum the following information:
46
TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEMS
13567-2 06/10/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. Number, size, material, and location of all pumps, flow meters, screens,
2 tanks, piping and valves.
3
4 2. Hydraulic calculations signed and sealed by a registered professional
5 engineer showing that weir elevations, water elevations, freeboard
6 elevations, headloss values, and velocities of the proposed Plan
7 temporary bypass facilities "fit" within the hydraulic profile of the existing
8 plant as shown on sheet 5 of 166 of the October 1988 drawings.
9
10 PART 2 — PRODUCTS
11
12 2.01 GENERAL REQUIREMENTS AND MATERIALS
13
14 A. All piping used shall be in accordance with the applicable specification.
15
16 B. Valves, suitable for throttling service and acceptable to the Engineer, shall be
17 installed as required. Existing valves shall not be used.
18
19 C. The Hazen -Williams C Value used for the design of temporary bypass piping
20 shall not exceed 140. Velocity in any pipe shall not exceed 8.5 feet per second.
21
22 D. Tank freeboard shall be not less than 12 -inches.
23
24 E. Suitable automatic air release valves shall be installed at each high point in the
25 temporary bypass piping system. Air release valves shall be in accordance with
26 Specification Section 15100.
27
28
29
30
31
32
33
F Actual plant flow rates for the 2 -year period ending in April 2016 are identified
in the table below and are provided for information only. Up to -date flow data is
available each month for the previous month and is reported to FDEP by the
City.
FLOW
NORTHEAST WRF
All Days
Average Day
6.6 MGD
Maximum Day (Volume)
12.1 MG
Peak Hour Flow (Rate)
15.8 MGD
Dry Season Average Day Flow (ADF)
6.4 MGD
Wet Season Average Day Flow (ADF)
7.0 MGD
Dry Season Average Diurnal Peaking Factor
1.21
Wet Season Average Diurnal Peaking Factor
1.19
TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEMS
13567-3 06/10/19
1
2 2.02 TEMPORARY BYPASS SYSTEM DESIGN AND PERFORMANCE CRITERIA
3
4 A. All temporary bypass system facilities and components shall be designed with
5 a hydraulic capacity of 27 MGD in accordance with Class I Reliability as defined
6 the EPA Document Design Criteria for Mechanical, Electric, and Fluid System
7 and Component Reliability — MCD -05. EPA -430/99-74-001.
8
9 B. Furnish and install a temporary bypass pumping system designed with a firm
10 pumping capacity of 27 MGD. The bypass pumping system shall be
11 automatically controlled to match the influent flow rate, i.e., constant level in the
12 chamber upstream of the existing screens. Each bypass pump shall have
13 variable speed drives.
14
15 C. Furnish and install on the discharge of the temporary bypass pump system a
16 temporary flowmeter suitable for raw sewage with an accuracy of 5% of range
17 over a 5-27 MGD. Furnish meter with a 4-20 mADC ouput signal and wire to
18 the existing plant SCADA system.
19
20 D. Furnish and install a manually or automatically cleaned temporary screening
21 facility with maximum 3h -inch clear openings. Removal, collection, dewatering,
22 and disposal of the screenings is the responsibility of the Contractor. A suitable
23 allowance shall be provided in the hydraulic design of the temporary screening
24 facility for partial clogging of the screen.
25
26 E. Furnish and install a temporary grit removal system consisting of a tank with a
27 detention time of not less than 3-5 minutes at a flow rate of 27 MGD with
28 dimensions meeting generally accepted design criteria for such tanks. Grit
29 removal may be automatic (continuous) or may be manually removed
30 periodically from the bottom of the tank by the Contractor using a Sand Dragon
31 or similar portable device. The existing grit and screenings collection container
32 volume is 10 yards and the container is typically emptied twice per week by the
33 City. The City will continue to haul the grit and screenings container throughout
34 the construction period unless the contents of the container do not pass the
35 paint filter test for free water, at which point disposal shall be by the Contractor
36 at no additional cost to the Owner.
37
38 F. Furnish and install temporary piping from the grit removal system to the new
39 Moving Belt Filters. The piping system shall be designed to convey up to 3500
40 gpm total to the Moving Belt Filters, and up to 1750 gpm to each Moving Belt
41 Filter.
42
43 G. Furnish and install temporary piping from the grit removal system to the existing
44 48 -inch primary effluent piping downstream of the Diversion Chamber where
45 shown on the drawings. The piping system shall be designed to convey up to
46 27 MGD.
47
TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEMS
13567-4 06/10/19
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 H. Furnish and install temporary piping from the Moving Belt Filters to the existing
2 48 -inch primary effluent piping downstream of the Diversion Chamber where
3 shown on the drawings. The piping system shall be designed to convey up to
4 3500 gpm.
5
6 I. Furnish a temporary steel slide gate in the Diversion Chamber to isolate the
7 Diversion chamber from the downstream 48 -inch effluent piping in order to take
8 the underground primary effluent channel that is upstream of the Diversion
9 Chamber out of service.
10
11 J. The temporary bypass systems may use the existing plant power supply and
12 distribution system, however the Contractor shall furnish and install an
13 independent automatic backup power generating system with on-site fuel
14 storage. A 4 -day supply of fuel at a pumping rate of 27 MGD shall be furnished
15 by the Contractor and stored on site for the temporary backup power system.
16
17
18
19
K. The temporary bypass system shall include alarm systems that will notify both
the Contractor's responsible personnel and the Owner's plant personnel via
telephone autodialer of the following conditions at a minimum:
20
21 a. Pump failure.
22 b. High water level at the existing screen chamber, the inlet of the
23 temporary screen facility, the grit removal facility, and the level
24 downstream of the grit removal system weir.
25
26 The temporary bypass pump system shall have visible and audible alarms for
27 pump failure and high water level. These visual and audible alarms shall be
28 made obvious to the plant operator while checking equipment in the area.
29
30 PART 3 — EXECUTION
31
32 3.01 STARTUP AND OPERATION
33
34 A. The Contractor shall install and demonstrate the mechanical and functional
35 integrity of the system to the Engineer and the Owner prior to beginning the
36 work on facilities for which the temporary bypass system is provided. The
37 system shall function to the Engineer's satisfaction for a period of not less than
38 72 consecutive hours prior to taking any of the existing equipment or piping out
39 of service.
40
41 B. The Contractor shall be responsible for operation and maintenance of the
42 system 24 hours per day and shall not depend on the Owner to perform any
43 operations or maintenance tasks.
44
TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEMS
13567-5 06/10/19
1 C. The Contractor shall be responsible for any wastewater or fuel spills attributable
2 to the system, and its operation, and shall pay for any and all fines, fees,
3 property damage, environmental damage, and cleanup costs that are
4 associated with the spills.
5
6 END OF SECTION
TEMPORARY BYPASS PUMPING, TREATMENT AND PIPING SYSTEMS
13567-6 06/10/19
1
1
1
1
1 SECTION 13600
2
3 INSTRUMENTATION GENERAL PROVISIONS
4
5 PART 1 — GENERAL REQUIREMENTS
6
7 1.01 DESCRIPTION
8
I9 A. General
10
11 1. This Section of the Specifications covers the general requirements for
112 the furnishing and installation of a Primary Instrumentation, Control, and
13 Monitoring System complete in every detail for the purposes specified
14 and shall form a part of any other technical specifications supplied unless
115 otherwise specified.
16
17 2. The intent of this specification is to require that the Supervisory Control
18 and Data Acquisition (SCADA) System, including all Sections of this
19 Specification, i.e., primary elements, panel mounted and miscellaneous
20 field instruments, etc., be furnished by a single Primary Instrumentation
1 21 and Control System Supplier (System Integrator, SI) to assure system
22 uniformity, subsystem compatibility and coordination of all secondary
23 system interfaces. Where specific manufacturers are designated,
124 substitutions will not be accepted. Deviations may be considered in
25 special circumstances but must be approved by the Engineer. The
26 Contractor shall include in his bid, the name of the System Integrator that
I27 will be used to furnish the system as described herein.
28
29 The Contractor shall provide, through the services of a single Systems
I30 Integrator (SI), all components, system installation services, systems
31 programming, as well as all required and specified ancillary services, in
32 connection with the Instrumentation and Control System (ICS).
I33
34 B. The Contractor shall provide all application software services. The City has
I35 preapproved for bidding four (4) Systems Integrators.
36
37 1. McKim and Creed
138 2. Curry Controls
39 3. Commerce Controls Inc.
40 4. Revere Controls
I41
42 C. The system shall include all materials, labor, tools, fees, and documentation
43 required to furnish, install, test, and place into operation, a complete and
44 operable ICS as shown and/or specified within this section, related ICS
45 specification sections, and subsections within equipment specifications.
46
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-1 12/18/20
1 D. The system shall include all measuring elements, signal converters,
2 transmitters, specialty cables, control panels, digital hardware and software,
3 remote telemetry units (RTU), signal and data transmission systems,
4 interconnecting wiring and such accessories as shown, specified, and/or
5 required to provide the functions indicated, whether specifically mentioned or
6 not.
7
8 E. The specifications provided within this section shall be applied to all of the
9 Instrumentation and Control specifications, as well as additional specifications
10 sections as referenced or where applicable. The ICS shall be provided as a
11 single and complete system as specified herein and as specified within the
12 following ICS specifications:
13
14 1. Section 13615 — Process Instrumentation & Equipment
15 2. Section 13630 — Local Control Panels and Control Systems
16 3. Section 13640 — Control Strategy
17
18 F. Where references are made to the SCADA System Programmer or the SSP, it
19 shall be understood that all application software services will be provided by the
20 SI. The Contractor shall provide, through the SI, all materials, labor,
21 documentation, etc., including coordination, programming, startup, and testing
22 services, as necessary to ensure the complete system is fully capable of
23 providing all specified functions.
24
25 G. The Contractor shall be ultimately responsible for installation of the ICS.
26 However, the SI will include installation within the scope of his subcontract to
27 provide for installation of the complete system as specified. The SI shall also
28 coordinate this work with the Contractor to ensure that the proper type, size,
29 and number of wires with their conduits are provided and installed. This
30 coordination will also ensure that proper electrical power circuits are provided
31 for all components and systems.
32
33 H. The Contractor's responsibilities, in addition to the SI's responsibilities, shall be
34 to provide all additional materials and work necessary to supplement the
35 materials and work provided by the SI; thereby satisfying all requirements that
36 are within ICS specification sections.
37
38 I. The Contractor shall coordinate structural work, penetrations, painting, etc., as
39 required for installation of a complete ICS. In-line or integrally mounted items
40 (such as flow elements, level sensors, etc.) shall be installed under the
41 supervision of the SI.
42
43 J. The Contractor shall be responsible for coordinating interfaces between ICS
44 equipment provided under the ICS specification sections and the equipment
45 provided under other sections of the specifications. The Contractor shall verify
46 and coordinate space requirements, process equipment power supply and
INSTRUMENTATION GENERAL PROVISIONS
13600-2 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
I4
35
I76
8
9
10
11
1 12
13
14
115
16
17
I18
19
20
1 21
22
23
I
24
25
26
I27
28
29
1 30
31
32
1 33
34
35
36
37
38
1 39
40
141
42
43
'44
45
46
1
1
voltage, process equipment control power supply and voltage, compatibility of
control signals, details of equipment installation and interconnection.
Coordination shall include distribution of approved shop drawings to all vendors,
subcontractors, etc., involved in the control interface. Likewise, the Contractor
shall ensure that instrumentation and control devices provided under other
sections of the specifications are compatible and of the same quality and
characteristics as similar devices specified under the ICS specification sections.
1.02 SCOPE OF WORK
A. Furnish and install all instrumentation and control systems hereinafter specified
to perform the intended function. Work shall include all labor, materials and
equipment, performance of all work necessary to complete the manufacture, to
make factory tests, to prepare and load for shipment, to deliver to the site, to
provide programming, configuration, related wire coordination, calibration,
installation supervision, system start-up, services and incidentals required to
completely furnish and install a programmable controller based control and data
acquisition system with instruments, modification to existing controls and control
devices for the automation of the Northeast WRF and including all work
necessary during the Warranty Period, as specified herein, under Section
01740: Warranties and Bonds, and shown on the Contract Drawings. The
installation of the system hardware shall be by the Contractor with supervision
by the System Integrator.
B. Furnish all tools, equipment, materials, and supplies and perform all labor
required to complete the furnishing, installation, validation, start-up and
operational testing of a complete SCADA System as specified herein.
C. Auxiliary and accessory devices necessary for system operation or
performance, such as transducers, shunt resistors or relays to interface with
existing equipment or equipment provided under other Sections of this
Specification, shall be included whether specified or not.
D. Equipment shall be fabricated, assembled, installed, and placed in proper
operating condition in full conformity with detail drawings, specifications,
engineering data, instructions and recommendations of the equipment
Manufacturer as approved by the Engineer.
E. The SI shall furnish all materials, labor, and services specified in the following
specifications sections as required to ensure that a single, coordination system
is supplied:
Section 13615 —
Section 13630 —
Section 13640
Section 13650
Process Instrumentation and Equipment
Local Control Panels and Control Systems
— Control Strategy
— Fiber Optic Cabling
INSTRUMENTATION GENERAL PROVISIONS
13600-3 12/18/20
1
2 F. Divisions required coordination shall include, but not be limited to, the following:
3
4 Division 1 — General Requirement
5 Division 11 — Equipment
6 Division 13 — Special Construction
7 Division 15 — Mechanical
8 Division 16 — Electrical
9
10 1.03 QUALITY ASSURANCE
11
12 A. The SCADA System as specified in this Specification shall be an integrated
13 system and therefore shall be provided by a competent, qualified
14 instrumentation and control SI who shall have total responsibility for the work of
15 this Specification and other related Specification. Entire system installation
16 including process parameter verification, calibration, validation, start-up, testing,
17 and training shall be performed by qualified personnel, possessing all the
18 necessary equipment and who have had a minimum of 5 years experience in
19 engineering, programming and installing of similar SCADA systems. The
20 system shall be integrated using the latest, most modern and proven design
21 and shall, as far as practical, be of one SI.
22
23 B. The SI shall be responsible for the correct selection of all instrumentation and
24 installation of all hardware and secondary control systems specified in this and
25 other related sections of this Specification.
26
27 C. Prior to the selection of any device coming in contact with the process, actual
28 on-site process conditions and the suitability of the device and materials of
29 construction for the stated application shall be verified with the original
30 equipment manufacturer by the SI. Unless notified in writing all devices and
31 component part numbers, when provided, shall be assumed to have been
32 verified as having been selected based on actual process parameters and
33 application. Ultimately, the Contractor shall be responsible for all cost
34 associated with replacements and delays due to improper equipment selection.
35
36 D. The SI shall be responsible that all components of the primary as well as
37 secondary control systems, including measuring, indicating, transmitting,
38 receiving, totaling, controlling, alarming devices and all appurtenances are
39 completely compatible, correctly sized for actual process conditions, and
40 properly interface to each other and shall function as outlined. The SI shall
41 furnish and install such additional equipment, accessories, etc. as are
42 necessary to meet these objectives at no additional cost to the Owner or
43 Engineer.
44
45 E. The SI shall be a recognized supplier of instrumentation, control panels, and
46 systems, etc., of the general type and complexity of the system specified herein
INSTRUMENTATION GENERAL PROVISIONS
13600-4 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 and shall have been regularly engaged in providing and engineering
2 instrumentation, control, and monitoring systems on a single system
I3 responsibility basis for a minimum of five (5) consecutive years. The personnel
4 employed for system engineering, supervision, start-up, operational testing and
5 training shall have been regularly employed and factory trained by the System
I6 Integrator for a minimum of two (2) years.
7
8 F The SI shall submit a detailed description of the experience of each engineer
I9 that will be assigned for the duration of the project for review and approval. The
10 SI lead engineer shall be an electrical or control systems Professional Engineer
11 registered in the state of Florida specializing in the selection and
112 implementation of instrumentation, control, and monitoring systems of the type
13 specified herein for the past five (5) consecutive years. References shall be
14 provided for all projects successfully completed by each engineer or software
115 programmer assigned to this project.
16
17 G. Actual installation may or may not be performed by the SI employees but the SI
118 shall be responsible for the technical supervision of the installation to ensure
19 that it is proper in all respects.
20
121 H. Secondary control systems shall include all instrumentation, switchgear,
22 variable frequency drives, and controls (including but not limited to gauges,
23 transmitters, panels, process and manual switches, indicators, controllers, etc.)
124 existing and/or furnished under other sections and are generally considered as
25 a "packaged" system supplied specifically for the equipment being specified
26 under that section.
127
28 I. Major constituents of each secondary system shall include, but not limited to, all
29 materials, equipment, field wiring and work required to implement a complete
130 and operating system of instrumentation and controls for its associated
31 equipment. The systems shall include primary elements for process variable
32 measurements, analog display and control elements, and discrete display and
I33 control elements as noted hereinafter and in the referenced Specification
34 sections.
35
136 J. Qualifications of the secondary System Supplier engineers shall be as specified
37 herein above unless otherwise noted. The Engineer reserves the right to reject
38 the use of any supplier not meeting the qualifications specified herein and under
39 the specific equipment specification.
40
141 K. Each bidder or his authorized representatives shall, before preparing a
42 proposal, visit all areas of the existing building(s) and/or proposed site where
43 work will take place and be performed to carefully inspect the present
I44 installation and conditions. The submission of the bid proposal shall be
45 considered evidence that the bidder has visited the project, fully reviewed the
46 Contract Documents, and noted the locations and conditions under which the
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-5 12/18/20
1 work will be performed, and that the bidder takes full responsibility for a
2 complete knowledge of all factors governing his work.
3
4 L. The SI shall coordinate all work related to the instrumentation and control
5 system with the Contractor, their sub -contractors and suppliers including as a
6 minimum the following services:
7
8 1. Attend all construction progress meetings.
9
10 2. Review all shop drawings related to the Primary Instrumentation and
11 Control System and provide responses to the Engineer and Contractor.
12
13 3. Coordinate with the Owner/Engineer for Ethernet IP list for configuration
14 of the electronic overload devices and power monitor device. The
15 Contractor to provide the electronics devices configuration and data table
16 to SSP for SCADA configuration.
17
18
19 1.04 RESPONSIBILITY
20
21 A. The Contractor shall be ultimately responsible and shall provide for the
22 verification of process conditions, supply, installation, certification, adjustment,
23 and start-up, of complete, coordinated systems, which shall reliably perform the
24 specified functions.
25
26 B. All interconnecting conduit and wiring, between elements of a single secondary
27 control system shall be furnished, installed and connected under the same
28 section as is the secondary control system unless the electrical drawings
29 specifically indicate otherwise.
30
31 C. All other electrical conduit and wiring are provided, installed and connected
32 under Division 16, Electrical. System Integrator is responsible for coordinating
33 all related control and wiring interfaces with control system supplied by other
34 sections of these specifications.
35
36 1.05 PRE -SUBMITTAL CONFERENCE
37
38 A. General
39
40 1. The Contractor/System Integrator shall arrange a pre -submittal
41 conference with the Owner or his representative within thirty (30) days
42 after award of the Contract for the purpose of informally discussing in
43 detail and verifying the correctness of the Contractor/System Integrator's
44 engineering methods, equipment, and to generally provide a framework
45 for communication and coordination. This meeting shall be attended by
46 the Contractor/System Integrator's Engineers, and duly authorized
INSTRUMENTATION GENERAL PROVISIONS
13600-6 12/18/20
1
1
1 representatives of the Owner.
2
I
32. The Contractor/System Integrator shall prepare a project schedule and
4 identify all major milestones in accordance with the project requirements.
5
I6 3. The Contractor/System Integrator shall prepare a draft copy of the
7 material that will be submitted for Owner's review. The draft shall include
8 the following, as a minimum:
9
10 a. Listing of major items proposed. Identify items by tag number,
11 description, function, manufacturer, model number, descriptive
I
12 literature and statement as to whether item is "as specified or
13 equivalent". Items identified, as "equivalent" shall be
14 accompanied by a comparative listing of the published
115 specifications for the item specified and for the item proposed.
16
17 b. Prior to making any submittals, the Contractor/System Integrator
118 shall submit to the Owner, a listing of all electrical components,
19 assemblies and panel(s) that are intended to be furnished that are
20 not UL approved or recognized or that does not comply with any
21 other Owner recognized third party approval agency. The System
22 Integrator shall utilize UL approved and recognized components,
23 panel(s), and assemblies when available.
1 24
25 c. Review and approval of all unlisted electrical devices, by the
26 Owner, is required prior to manufacturing. Any additional costs
127 associated with materials, installation of those materials, and
28 special on-site inspections necessary to meet the applicable NEC
29 and local electrical codes shall be arranged by and borne by the
130 System Integrator.
31
32 1.06 ENGINEERING SUBMITTALS
I33
34 A. Before proceeding with any manufacturing, submit the following for approval in
in 35 complete bound sets indexed by specification number. Describe and verify all
I36 component part numbers for the items being submitted. Submit only complete
37 systems, not pieces of equipment from various systems. Show dimensions,
38 physical configurations, methods of connecting instruments together, mounting
I39 details, and wiring schematics. Schematics shall be complete with all
40 components identified by a unique tag reference in accordance with ISA -5.1
r41 Instrumentation Symbols and Identification. Terminal number identification
42 associated with relays, lights, electrical devices, etc., shall be clearly identified
43 on all drawings. Submit fabrication drawings, nameplate legends, and control
I44 panel internal wiring and piping schematic drawings clearly showing all
45 equipment and tag numbers for all components. Submit panel graphic
46 drawings when applicable. Include material specifications listed where
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-7 12/18/20
1 applicable.
2
3 B. Include a draft of the theory of operation for all relay circuits including software
4 logic implemented via programmable controllers that will eventually be included
5 in the operation and maintenance instruction manuals required below.
6
7 C. Network riser diagram detailing all network components, interconnections
8 physical locations, and IP addressing. This diagram shall be designed such
9 that it shows the "schematic" layout of the network and how it functions and
10 shall encompass the entire project on one sheet.
11
12 D. Computer generated document detailing the license agreements for each
13 installation of software in the SCADA system including license numbers, license
14 details (product, number of tags, etc.), registered contact, key type (hard or
15 soft), expiration dates of support agreements and any other data that may be
16 helpful to personnel supporting the system in the future.
17
18 E. Computer generated document detailing all user names and passwords for
19 each PC in the system. This document shall be given directly to the Owner in a
20 sealed envelope to be kept in a safe location.
21
22 F Each submittal shall be bound in a white, standard three ring, clear view type,
23 hard cover binder which indicates the system name, submittal content, project
24 reference, revision date and purpose of the submittal on the spine as well as
25 the cover which shall also include the Engineers name, location, and supplier's
26 name. Binders shall not exceed three inches in thickness.
27
28 G. Provide copies of each of the following submittals per Section 01340 to the
29 Engineer for review and approval:
30
31 1. Hardware Submittal
32
33 a. Index and Comments
34
35 1) Provide a detailed index identifying each tabbed section
36 and its content.
37
38 2) If there are any deviations or clarifications to the
39 specifications, they shall be documented in writing in this
40 section. If there are no comments or concerns identified in
41 the submittal, it will be presumed that there are no
42 deviations from the Contract Documents for the system
43 being furnished.
44
45 b. Component Data Sheets
46
INSTRUMENTATION GENERAL PROVISIONS
13600-8 12/18/20
1
1
1
1
1 1 1) Component Data Sheets shall be specifically prepared for
2 all components being furnished under these Specifications.
I
3 The purpose of this material is to supplement the
4 generalized catalog information by providing the specifics
5 of each component (e.g., individual component tag ID
I6 reference, service, quantity supplied, part number,
7 breakdown and descriptions for all options, scales, ranges,
8 materials of construction, component location reference,
I9 and reference to associated drawings).
10
11 2) Include such other necessary data as would provide a
I 12 complete and adequate specification for re -ordering an
13 exact duplicate of the original item from the manufacturer at
14 some future date. More than one tag numbered item with
115 the same part number may be included on a sheet.
16
17 c. Catalog Cuts
118
19 1) Manufacturer's standard specification or data sheets shall
20 be clearly marked to delineate the options or styles to be
121 furnished. Standard manufacturer catalog information,
22 descriptive literature, wiring diagrams, and shop drawings
23 shall be provided for all devices, whether electrical or
I24 mechanical, furnished under these Specifications. This
25 includes, but is not limited to, pressure switches, gauges,
26 solenoid valves, controllers, indicators, power supplies,
I27 switches, lights, relays, timers, circuit breakers, fuses, etc.
28
29 d. Sizing Calculations
30
31 1) Complete certified sizing calculations shall be provided for
32 all control valves and flow elements. The calculations shall
I33 include the process data used, minimum and maximum
34 values, permanent head loss and all assumptions made.
35 Equations shall be submitted for all computing modules
I36 and function generating modules and shall include the
37 actual scaling factors and units used.
• 38
39 e. System Hardware Submittal Format
40
41 1) Tab 1. Component Index and Comments
I42
43 2) Tab"N" through "NN" (as required)
I44
45 3) Component "X" Data Sheet(s) - one tab shall be provided
46 per each component type and shall include the standard
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-9 12/18/20
1 manufacturer catalog information and sizing calculations
2 (when required).
3
4 2. System Control Panel(s) Drawing Submittal
5
6 a. All drawings shall be provided on "B" size paper and shall be laser
7 generated with a 300 DPI resolution, tabbed, and bound as
8 directed above. Drawing submittal may be combined with the
9 Hardware submittal providing the binder capacity is not exceeded.
10
11 1) Index and Comments
12
13
14 a) Provide a detailed index identifying each tabbed
15 section and its content.
16
17 b) If there are any deviations or clarifications to the
18 specifications, they shall be documented in writing in
19 this section. If there are no comments or concerns
20 identified in the submittal, it will be presumed that
21 there are no deviations from the contract documents
22 for the system being furnished.
23
24 2) Panel Layout Drawings
25
26 a) Provide detailed shop drawings for all panels and
27 enclosures. Drawings shall show the location of all
28 exterior and internal panel mounted devices to scale
29 and shall include a panel legend and bill of
30 materials. Layout drawings shall show all major
31 dimensions, front, back, side, and mounting details,
32 as well as all elevations, in inches from the base up,
33 of all rows of components.
34
35 b) The panel legend shall list and identify all front of
36 panel devices by the components unique tag
37 identifier, all nameplate inscriptions, service legends,
38 and annunciator inscriptions when applicable.
39 Service legends, and nameplate inscriptions shall
40 show size, engraving per line, character height and
41 color. Information may be included on the layout
42 drawing if spacing permits.
43
44 c) The bill of materials shall include all components
45 mounted within or on the panel that are not listed in
46 the panel legend, and shall include the component
INSTRUMENTATION GENERAL PROVISIONS
13600-10 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 identification tag, description, manufacturer, and
2 complete part number for re -ordering. Information
I
3 may be included on the layout drawing if spacing
4 permits.
5
I6 d) Fabrication drawings shall be submitted for review
7 and shall show all cut-out dimensions, support
8 details, brackets, materials of construction, finish,
I9 etc. to be used for fabrication of each panel.
10 Fabrication drawings may be submitted separately
11 after the layout drawings have been approved.
112 Construction of panels shall not be started until the
13 approval of the fabrication drawings is received.
14
I15 3. Detailed Panel Wiring Diagrams
16
17 a) Wiring diagrams shall be provided in the form of
1 18 ladder type schematics with line numbers for all
19 devices. All components shall be identified by a
20 unique identification tag, terminal block numbers,
I21 wire sizes and color codes clearly identified, and
22 external interconnections noted. Drawings shall be
23 drawn in "landscape" mode.
•24
25 b) Provide complete terminal identification of all internal
26 and external elements, panels, and junction boxes.
1 27
28 c) Polarity of all analog signals shall be shown at each
29 terminal as well as all shielded cable connections
I30 and grounding requirements.
31
32 d) All external panel wiring that must be provided and
I33 installed shall be clearly identified as a dashed line.
34 Use unique terminal symbols to denote MCC
35 locations.
136
37 e) All special cables that are provided with purchased
38 equipment external to panels shall be identified as
1 39 being supplied by the System Integrator.
40
I41 f) Wiring diagrams shall show all circuits individually;
42 no common diagrams will be allowed.
43
I44 g) Provide panel power wiring diagrams for all panels.
45 The diagrams shall include all grounding
46 requirements.
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-11 12/18/20
1
2 4. Control Panel Submittal Format
3
4 a) Tab 1. Index and Comments
5
6 b) Tab "N" through "NN" as required:
7
8 1) Heat Dissipation and Power Calculations
9 Summary.
10
11 2) Panel "A" Layout Drawing (one tab per
12 panel).
13 3) Panel "A" with Fabrication Drawing
14 Legend/Engravings/Bill of Materials.
15
16 4) Panel "A" Power Wiring.
17
18 5) Panel "A" Wiring Diagrams.
19
20 c) Tab "X". Loop Drawings (When Applicable)
21
22 d) Tab "Y". Installation Details (When Applicable)
23
24 3. Analog Loop Drawing Submittal
25
26 a. Provide an individual loop wiring diagram for each analog loop
27 showing all terminal numbers, the location of the DC power
28 source, the location of any dropping resistors, polarity, etc. The
29 loop diagrams shall meet the minimum requirements of ISA - S5.4
30 (latest edition), plus the following requirements:
31
32 1) Loop diagrams shall be on 11 -inch by 17 -inch paper. Only
33 one loop shall be shown on each drawing.
34
35 2) Reference to supplementary records and drawings, such
36 as installation details, P&IDs, location drawings, wiring
37 diagrams or drawings, and instrument specifications shall
38 be included. Drawings may be included in the Control
39 Panel Drawing Submittal when only a few drawings are
40 required.
41
42 4. Instrument Installation Details Submittal
43
44 a. The System Integrator shall develop and submit for review,
45 complete installation details for each field mounted device and
46 panel furnished prior to shipment and installation. Common
1
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-12 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 details may be referenced by an index showing the complete
2 instrument tag number, service, location, and device description.
I
3 Installation details shall be provided as required to adequately
4 define the installation of the components. Drawings may be
5 included in the Control Panel Submittal when only a few are
I6 required.
7
8 5. Power Requirement and Heat Dissipation Summary
9
• 10 a. Provide a summary of the power requirements and heat
11 dissipation for all control panels furnished. Power requirements
112 shall state required voltages, currents, and phase(s). Heat
13 dissipations shall be maximums and shall be given in BTU/Hr.
14 Summary shall be supplemented with calculations and show
I15 expected temperatures to be maintained for proper control
16 equipment operation.
17
1 18 6. PLC Subsystem Submittal
19
20 a. In addition to the detailed hardware submittal requirements noted
I21 herein, the following shall also be provided:
22
23 1) Theory of Operation and Logic Descriptions.
1 24 2) System block diagram and cabling requirements.
25 3) Annotated software program listing and I/O address
26 mapping.
I27 4) I/O arrangement and wiring drawings.
28
29 7 Operation and Maintenance Manuals Submittal
U30
31 a. Submit two (2) complete sets of Operation and Maintenance
32 Instruction Manuals and Part Lists to the Engineer for all
I33 equipment provided. Manuals shall be delivered no later than the
34 equipment shipment date. After installation is complete, update
I
35 the manuals to reflect any changes that occurred during
36 installation and deliver the balance of the six (6) -required manuals
37 to the Engineer.
I38
39 b. All manuals shall be original manufacturers literature provided as
40 noted herein above.
I41
42 c. Include in the manuals not less than the following applicable
43 information for each instrument, component, subsystem and/or
44 control loop.
45
46 1) Index and Comments
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-13 12/18/20
1
2 a) Provide a detailed index identifying each tabbed
3 section and its content.
4
5 b) If there are any deviations or clarifications to the
6 specifications, they shall be documented in writing in
7 this section. If there are not comments or concerns
8 identified in the submittal, it will be presumed that
9 there are no deviations from the contract documents
10 for the system being furnished.
11
12 2) Bill of Materials
13
14 a) A listing of all the panels, racks, instruments,
15 components, and devices furnished. All
16 components shall be grouped by component
17 type, i.e., pressure switches, pressure
18 gauges, indicators, etc. The list shall contain,
19 as a minimum:
20
21 i) Instrument, panel, rack or device tag
22 number
23 ii) Description
24 iii) Quantity supplied
25 iv) Reference to component data sheet
26 and/or catalog cut
27 v) Component type
28
29 3) Component Data Sheets
30
31 a) Refer to 1.05-7, A, (2) specified herein before.
32
33 4) Catalog Cuts
34
35 a) Refer to 1.05-7, A, (3) specified herein before.
36
37 5) Operation and Maintenance Manuals
38
39 a) Operation and Maintenance manuals shall be
40 submitted for all instruments and devices supplied.
41 The O&M manuals shall contain, as a minimum:
42
43 i) Operation procedures
44 ii) Installation procedures
45 iii) Maintenance procedures
46 iv) Troubleshooting procedures
INSTRUMENTATION GENERAL PROVISIONS
13600-14 12/18/20
1
1 1 v) Calibration procedures
2 vi) Internal device schematics and wiring
I3 diagrams
4 vii) Shut -down procedures
5 viii) Component parts list
I6 ix) Detailed circuit operational description
7 including programmable controller ladder
8 diagrams
9 x) Listing of Manufacturers with local telephone
10 numbers and contacts for all instrumentation
11 hardware furnished.
112
• 13 6) Spare Parts and Expendables List
14
I15 a) A spare parts and expendables list shall be
16 submitted to include not only those items being
17 supplied, but also any additional items
t18 recommended for successful long term operation.
19
20 7) Operation and Maintenance Manual Format
1 21
22 a) Volume I (or as required) - Hardware
23
1 24 i) Tab 1. Component Index and Comments
25
26 ii) Tab 2. Theory of Operation
27
28 iii) Tab "N" through "NN" as required:
29
I30 a) Component "X" Data Sheet(s) (one tab
31 per component type as required).
I32
33 b) Standard Manufacturer Catalog
34 Information, and Manufacturers O&M
35 Manual.
136
37 iv) Tab "X" Recommended Spare Parts and
38 Expendables Listing.
I39
40 v) Tab "Y" Y Current Manufacturers/Local
• 41 Representatives Telephone/address listing for
42 all major components.
43
I44 b) Volume II
45
46 i) Tab 1. Index and Comments
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-15 12/18/20
1
2 ii) Tab "N" through "NN" as required:
3
4 a) Panel "X" Layout Drawing
5 b) Panel "X" Fabrication Drawing
6 c) Panel "X" Legend/Engravings/Bill of
7 Materials
8 d) Panel "X" Power Wiring
9 e) Panel "X" Wiring Diagrams
10
11 iii) Tab "X" Loop Drawings (When
12 Applicable)
13
14 iv) Tab "Y" Installation Details (When
15 Applicable)
16
17 8. System Calibration and Test Documentation Submittal
18
19 a. The System Integrator shall submit an example of each type of
20 Instrument Calibration Report and Loop Functional Test Report
21 that will be used to verify that all preliminary calibration and testing
22 has been performed and the system is considered, by the
23 supplier, to be ready for the Engineer's acceptance testing.
24
25 b. After approval of the examples, the System Integrator shall
26 prepare Loop Functional Test Report(s) for each loop and an
27 Instrument Calibration Sheet for each active element (except
28 simple hand switches, lights, etc.). These sheets shall be
29 completed and submitted to the Engineer after completion of the
30 operational availability field tests.
31
32 1) Instrument Calibration Reports
33
34 a) An Instrument Calibration report shall be used to
35 certify that each instrument requiring calibration has
36 been calibrated to its published specified accuracy
37 shall be submitted to the Engineer. This report shall
38 include all applicable data as listed below plus an
39 area to identify any defects noted, corrective action
40 required, and corrections made.
41
42 b) Facility identification (Name, location, etc.)
43
44 c) Loop identification (Name or function)
45
46 d) Equipment tag and serial numbers
INSTRUMENTATION GENERAL PROVISIONS
13600-16 12/18/20
1
1
1
11
2 e) Scale ranges and units
I3
4 f) Test mode or type of test
5
I6 g) Input values or settings
7
8 h) Expected outputs and tolerances
9
10 i) Actual readings at 0, 10, 25, 50, 75, 90 and 100
11 percent of span
112
13 j) Percent of error for each reading
14
I15 k) Explanations or special notes as applicable
16
17 I) Date, time, and weather conditions
118
19 m) Tester's certification with name and signature
20
I21 2) Loop and Functional Test Reports
22
23 a) Loop Status Report - For each function that can be
24 demonstrated on a loop -by -loop basis:
25
26 i) Each form shall include:
1 27
28 a) Project name
29
I30 b) Loop number
31
32 c) Loop description
I33
34 d) Test procedure description, with a
35 space after each specific test to
I36 facilitate sign off on completion of each
37 test.
I38
39 e) For each component: tag number,
40 description, manufacturer, and data
I41 sheet number.
421
43 f) Space for sign off and date by the
I44 System Integrator
45
46 b) Functional Acceptance Test Report - For those
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-17 12/18/20
1 functions that cannot be demonstrated on a loop -by -
2 loop basis:
3
4 i) Each form shall include a listing of the specific
5 tests to be conducted. With each test
6 description the following information shall be
7 included:
8
9 a) Specification page and paragraph of
10 function to be demonstrated
11
12 b) Description of function
13
14 c) Test procedure description
15
16 d) Space after each specific test to
17 facilitate sign off on completion of each
18 test
19
20 3. System Integrator's Installation Certification Reports
21
22 a) Upon completion of all preliminary calibration and
23 functional testing, the SI, shall submit a certified
24 report for each control panel and its associated field
25 instruments certifying that the equipment (1) had
26 been properly installed under his or her supervision,
27 (2) is in accurate calibration, (3) was placed in
28 operation, (4) has been checked, inspected,
29 calibrated, and adjusted as necessary, (5) has been
30 operated under maximum power variation conditions
31 and operated satisfactorily, and (6) is fully covered
32 under the terms of the guarantee.
33
34 9. Functional Acceptance Test Procedures Submittal
35
36 a. Submit for approval not later than 30 days prior to the functional
37 acceptance test demonstration, a written plan for demonstrating
38 that each device and function of the equipment provided under
39 these specifications meets the specified operational requirements.
40
41 b. The plan shall detail procedures to be used in the functional
42 acceptance testing of all systems. The plan shall include a
43 description of test methods and materials that will be utilized for
44 testing each system.
45
46 c. Immediately correct defects and malfunctions with approved
INSTRUMENTATION GENERAL PROVISIONS
13600-18 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I1 methods and materials in each case and repeat the testing.
2
I3 1.07 SYSTEM TESTING AND ACCEPTANCE
4
5 A. Factory Tests
I6
7 1. Factory Testing
8
9 a. Each panel, computer and networking components shall have
• 10 been completely tested by the manufacturer personnel. Provide a
11 report certifying the control panel(s) are fully operable and meet
I
12 the Specifications. Factory testing may be witnessed by
13 Owner/Engineer at the Owner's option. Provide 2 -weeks' notice
14 prior to factory testing for all panels. If upon arrival, the panel(s)
115 are not ready for testing, the SI is liable for back charges for all
16 costs associated with the visit by the Owner/Engineer. The
17 Owner/Engineer shall have the right to check all test observations.
118 The SI shall demonstrate that the results of the Factory Tests are
19 accurate. As a minimum, tests shall verify the following:
20
I21 1. Accuracy of panel instruments for 4-20 mA inputs and
22 outputs
23
1 24 2. Location of interface wires on terminal blocks
25
26 3. Function of discrete panel components
27
28 4. Control logic
29
' 30 5. Network Hubs and Switches
31
32 6. Computers, Printers, etc.
I33
34 7. Media Converters, Network Devices
I35
36 8. HMI Graphics Operations
37
38 B. Installation Supervision
I39
40 1. Furnish the services of authorized factory personnel specially trained and
41 experienced in the installation of the equipment to: (1) supervise the
I42 installation in accordance with the approved Instruction Manuals; (2) be
43 present when the instruments and equipment are first delivered,
• 44 installed, and put into operation; (3) inspect, check, adjust as necessary,
45 and approve the installation; (4) calibrate the instruments, in accordance
46 with the Specifications herein, until all trouble or defects are corrected
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-19 12/18/20
1 and the installation and operation are acceptable.
2
3 C. Preliminary Calibration and Functional Testing
4
5 1. After approval of the Loop Status Report and Calibration Worksheets
6 described herein, the System Integrator shall prepare Loop Status
7 Report(s) for each loop and an Instrument Calibration Worksheet for
8 each active element (except simple hand switches, lights, etc.). These
9 sheets shall be completed, signed, and submitted to the Engineer after
10 the Preliminary Calibration and Functional Testing is completed.
11
12 2. Although the Preliminary Calibration and Functional Testing does not
13 require witnessing, the equipment System Integrator shall maintain the
14 reports and calibration worksheets at the job -site and make them
15 available for the Engineer's review at any time.
16
17 a. Preliminary Calibration
18
19 1) Provide the services of factory trained instrumentation
20 technician, tools and equipment to field calibrate each
21 instrument to its specified accuracy in accordance with the
22 manufacturer's specifications and instructions for
23 calibration.
24
25 b. Functional Testing
26
27 1) Provide Loop Status Report(s) for verifying all control
28 system functions as follows:
29
30 (a) Provide the services of factory trained and field
31 experienced instrumentation engineer(s) to validate
32 each system to verify that each system is
33 operational and performing its intended function
34 within system tolerance. System tolerance is
35 defined as the root -mean -square sum of the system
36 components specified accuracy from input to output.
37
38 (b) Validate calibration of each system by simulating
39 Inputs at the first element in the loop (i.e., sensor) of
40 zero, 10, 25, 50, 75, 90 and 100 percent of span, or
41 on/off and verify loop output devices (i.e., recorder,
42 indicator, alarm, etc. except controllers). During
43 system validation, make provisional settings on
44 levels, alarms, etc. Verify that all logic sequences
45 operate in accordance with the specifications.
46
INSTRUMENTATION GENERAL PROVISIONS
13600-20 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 (c) Cause malfunctions to sound alarms or switch to
2 standby to check system operation. Check all
I
3 systems thoroughly for correct operation.
4
5 (d) Immediately correct all defects and malfunctions
I6 disclosed by tests. Use new parts and materials as
7 required and approved and retest.
8
I 9 c. System Integrator's Certified Reports
• 10
11 1) Upon completion of the Preliminary Calibration and
112 Functional Testing, the System Integrator shall submit a
13 certified report for each control panel and associated field
14 instruments certifying that the equipment (1) had been
15 properly installed under his supervision, (2) is in accurate
16 calibration, (3) was placed in operation, (4) has been
17 checked, inspected, calibrated, and adjusted as necessary,
1 18 (5) has been operated under maximum power variation
19 conditions and operated satisfactory.
20
I21 D. Functional Demonstration Testing
22
23 1. Upon completion of the Preliminary Calibration and Functional Testing,
24 re -test all systems in the presence of the Engineer (or representative).
25 The intent of this test is to demonstrate and verify the operational
26 interrelationship of all instrumentation systems. This testing shall
I27 include, but not be limited to, all specified operational modes, taking
28 process variables to their limits (simulated or actual) to verify all alarms,
29 failure interlocks, and operational interlocks between systems and/or
I 30 mechanical equipment. Notify the Engineer in writing a minimum of 48
31 hours prior to the proposed date for commencing the test. Upon
I32 successful completion of this test the System Integrator shall begin the
33 Operational Acceptance Test Demonstration.
34
I35 E. Operational Acceptance Test Demonstration
36
37 1. Upon completion of the Functional Demonstration Testing, re -test all
I38 systems under actual process conditions in the presence of the Engineer
39 and the Engineer's Operators. The intent of this test is to demonstrate
40 and verify the operational interrelationship of all instrumentation systems
I41 to the Engineer's Operators. This testing shall include, but not be limited
42 to, all specified operational modes, taking process variables to their limits
43 (simulated or actual) to verify all alarms, failure interlocks, operational
144 interlocks between systems and/or mechanical equipment, and making
45 final adjustments. Notify the Engineer in writing a minimum of 48 hours
46 prior to the proposed date for commencing the test. Upon successful
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-21 12/18/20
1 completion of this test the System Integrator shall begin the 30 Day
2 Availability Test.
3
4 F. 30 Day Availability Test
5
6 1. After completion of the Operational Acceptance Test Demonstration, the
7 System Integrator shall be responsible for the operation of the supplied
8 system full time on-site for a period of 30 consecutive days, under
9 conditions of full process operation, without a single non -field repairable
10 malfunction.
11
12 2. During this test, plant operating and System Integrator personnel shall be
13 present as required. While the test is proceeding, the Engineer shall
14 have full use of the system.
15
16 3. If any failures should occur that cannot be corrected within 24 hours, or
17 more than two similar failures of any duration, the failure will be
18 considered as a non -field -repairable malfunction. The system shall be
19 repaired and the 30 day test period shall be re -started. Engineer
20 reserves the right to set the schedule.
21
22 4. Total availability of the system shall be greater than 99.5 percent during
23 this test period. Availability shall be defined as "Availability = (Total
24 Down Time) _ (Total Time)".
25
26 5. Down times due to power outages or other factors outside the normal
27 protection devices or back-up power supplies provided, shall not
28 contribute to the availability test times above.
29
30 6. Upon successful completion of the system availability testing, submit a
31 certified report, with substantiating data sheets, indicating that the
32 equipment furnished meets all the functional requirements specified
33 herein. The Engineers will countersign this report and it shall constitute
34 acceptance of the control system hardware.
35
36 1.08 FINAL DOCUMENTATION
37
38 A. Reproducible Drawings
39
40 1. The SI shall submit one (1) set of full size reproducible of complete
41 schematics, wiring diagrams and installation drawings to include all
42 installed field and panel instruments, mounting details, point-to-point
43 diagrams with cable, wire, and termination numbers. Drawings shall be
44 a record of work as actually constructed and shall be labeled "As -
45 Installed". One copy of applicable schematics and diagrams shall be
46 placed in each control panel in a protective envelope or binder.
INSTRUMENTATION GENERAL PROVISIONS
13600-22 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11
2 a. Loop Diagrams
3
4 (1) Refer to Section 1.05 specified herein before.
5
I6 b. Panel Construction Drawings and Wiring Diagrams
7
8 (1) Refer to Section 1.05 specified herein before.
9
10 c. Interconnecting Wiring Diagrams
11
112 (1) Refer to Section 1.05 specified herein before.
13
14 d. Instrument Installation Details
I15
16 (1) Refer to Section 1.05 specified herein before.
17
I18 B. Software
19
20 1. In addition to the reproducible hard copy of drawings and literature
I21 specifically generated for the project, one (1) CD-ROM shall be
22 submitted to the Engineer which shall include a copy of all files
23 specifically generated to create the drawings, data sheets, bill of
I24 materials, operating and test procedures, control logic, etc. Drawing
25 format shall be compatible with "AutoCAD", release version as directed
26 by the Engineer. Diskettes shall be clearly labeled with the following:
1 27
28 a. Project Name
29 b. Volume Number
I30 c. Software Program Name and Version used to generate the files
31 d. Label "As -Installed"
I32
33 2. Provide one copy of all programming software, application programs,
34 and source code utilized to generate, annotate, and debug all software
35 provided. Programming software, detailed programming instructions,
I36 software keys, cables, and licenses shall be provided for all
37 programmable devices, i.e., PLC, HMI, controllers, and smart
'38 39 transmitters. Special devices used in programming supplied hardware
shall be provided. It is the intent that the Engineer shall have the full
40 capability to re -program and modify any application on-site without the
I41 need to purchase additional software or hardware.
42
43 C. Operation and Maintenance Manuals
I44
45 1. Furnish the balance of the Operation and Maintenance Manuals for
46 equipment provided under these Specifications per Section 01730.
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-23 12/18/20
1 Content shall be as described above for the submittals.
2
3 1.09 TRAINING REQUIREMENTS
4
5 A. General
6
7 1. Provide the services of a factory trained and field experienced control
8 systems engineer to conduct group training of the Owner's designated
9 personnel in the operation of all Instrumentation, Control and Monitoring
10 equipment furnished. Include instruction covering basic system theory,
11 operating principles and adjustments, routine maintenance and repair,
12 and "hands-on" operation. The text for this training shall be the P&IDs,
13 panel wiring diagrams, layouts, ladder listings, and the operation and
14 maintenance manuals furnished under these Specifications.
15
16 B. Duration
17
18 1. Training specific to the system hardware shall be provided for a minimum
19 of three operating shifts with a time period necessary to cover complete
20 Operator and Maintenance Training.
21
22 C. Operator Training
23
24 1. Operator training shall include instruction in the use of all control system
25 hardware and software furnished. A detailed written description of the
26 system furnished and all equipment start-up, shut -down, troubleshooting,
27 and maintenance procedures shall be provided to each Operator
28 attending the training sessions. Training material shall be organized and
29 bound in appropriate binders. One digital and one hard copy of the
30 training manual shall be submitted to the Engineer prior to scheduling
31 any training sessions. As a minimum, the format for the training material
32 shall be as follows:
33
34 a. General system description and overview
35 b. Process and Instrumentation Diagrams
36 c. Sequence of Operation
37
38 1) Panel Layout Drawing
39 2) Legend
40 3) Alarm Handling
41 4) System Start -Up
42 5) System Shut -Down
43 6) Operator Adjustment & Setpoints
44
45 d. General Troubleshooting Techniques
46 e. Recommended Maintenance Procedures
INSTRUMENTATION GENERAL PROVISIONS
13600-24 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 f. Recommended Spare Parts
2
I
3 D. Maintenance Training
4
5 1. Maintenance training shall include instruction in the calibration,
I6 maintenance, programming, and repair for all systems furnished.
7
8 2. Maintenance training shall include instruction in the maintenance of all
I9 control system hardware and software furnished. A detailed written
10 description of the system furnished and all equipment start-up, shut -
11 down, troubleshooting, and maintenance procedures shall be provided to
112 each person attending the training sessions. Training material shall be
13 organized and bound in appropriate binders. One digital and one hard
14 copy of the training manual shall be submitted to the Engineer prior to
115 scheduling any training sessions. As a minimum, the format for the
16 training material shall be as follows:
17
I18 a. General system description and overview
19 b. Process and Instrumentation Diagrams
20 c. Sequence of Operation
121
22 1) Panel Layout Drawing
23 2) Legend
I24 3) Alarm Handling
25 4) System Start -Up
26 5) System Shut -Down
I27 6) Operator Adjustment & Setpoints
28
29 d. Detailed review of all schematic diagrams
I30 e. Detailed review of all software functions using actual software
31 listings
32 f. Detailed programming instruction of hardware furnished unless
I33 otherwise noted
34 g. Detailed calibration procedures for all furnished
35 h. Recommended Maintenance Procedures
I36 i. Recommended Spare Parts
37
38 E. Final Acceptance
I39
40 1. Final Engineer acceptance is defined as a point in time when (1) all
I41 training has been performed, (2) final "As Installed" documentation and
42 software (when applicable) have been received and approved, (3) the
43 system has successfully passed the availability test period, and (4) all
I44 punch list items have been resolved.
45
46 F. Guarantee and Warrantees
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-25 12/18/20
1
2 1 Guarantee all work of these Specifications for a period of one (1) year
3 from the date of final acceptance by the Engineer. With respect to
4 instruments and equipment, guarantee shall cover (a) faulty or
5 inadequate design; (b) improper assembly or erection; (c) defective
6 workmanship or materials; and (d) leakage, breakage, or other failure not
7 caused by Engineer misuse. For equipment bearing a manufacturer's
8 warranty in excess of one year, furnish a copy of the warranty to
9 Engineer with Owner named as beneficiary.
10
11 PART 2 - PRODUCTS
12
13 2.01 JOB CONDITIONS
14
15 A. Exercise care (1) to secure neat arrangement of all piping, valves, conduit, and
16 like items, and (2) to overcome structural interferences. Verify dimensions and
17 conditions at the place of work, and install materials and equipment in the
18 available spaces.
19
20 2.02 MATERIALS AND STANDARD SPECIFICATIONS
21
22 A. Provide instruments, equipment and materials suitable for service conditions
23 and meeting standard specifications such as Instrumentation, Systems and
24 Automation (ISA). The intent of this Specification is to secure instruments and
25 equipment of a uniform quality and manufacture throughout the facilities; i.e., all
26 instruments furnished by the System Integrator of the same type of function
27 shall be by the same manufacturer. This allows the stocking of the minimum
28 number of spare parts.
29
30 2.03 PRODUCT DELIVERY, STORAGE, AND HANDLING
31
32 A. Box, crate or otherwise enclose and protect instruments and equipment during
33 shipment, handling and storage. Keep all equipment dry and covered from
34 exposure to weather, moisture, corrosive liquids, and gases or any element
35 which could degrade the equipment. Protect painted surfaces against impact,
36 abrasion, discoloration, and other damage. Repair any damage as directed and
37 approved.
38
39 2.04 MOUNTING
40
41 A. Mount and install equipment as required. Mount field instruments according to
42 the best standard practice on pipe mounts, pedestal mounts, or other similar
43 means in accordance with manufacturer's recommendations.
44
45
46 B. Equipment specified for field mounting shall be suitable for direct pipe
INSTRUMENTATION GENERAL PROVISIONS
13600-26 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 mounting, pedestal mounting, or surface mounting. Non in-line indicators and
2 equipment with calibration adjustments or requiring periodic inspection shall be
I
3 mounted not lower than three (3) feet nor higher than five (5) feet above
4 walkways, platforms, catwalks, etc. All such equipment shall be weather and
5 splash proof, and electrical equipment shall be in NEMA 4X cases unless
I6 otherwise noted.
7
8 2.05 COMPONENT TAG NUMBERING SCHEME
9
10 A. All control equipment shall be identified by unique alphanumeric code or tag
11
I12
13
14
15
16
1
1
1
1
I17
18
19
I20
21
22
23
24
number based on the latest ISA standards S5.1.
Tag Numbering Scheme: a -b -c -d
Equipment tagging shall be based on the following scheme:
Example 1: HS -23-2-3
Tag number identifies a Hand Selector Switch. It is part of Loop 23 and the
second hand selector switch in the loop. This is the third identical process unit
(i.e., three identical pump control stations). It is also the only hand selector
switch in the loop.
25 Example 2: HS -23
126
27 Tag number identifies a Hand Selector Switch in Loop 23. It is also the only
28 hand selector switch in the loop.
129
30 2.06 INSTRUMENT IDENTIFICATION
31
132 A. All components provided, both field and panel mounted, shall be provided with
33 permanently mounted name tags bearing the entire tag number of the
34 component. Panel mounted tags shall be white with black lettering lamicoid
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-27 12/18/20
Description
TAG
Explanation
a.
ISA Functional
Identification
HS
Hand Switch
b.
Loop Number
23
Loop 23
c.
Component
Number
2
Second HS in Loop
d.
Unit
3 (When
Required)
Third Identical Process
Control System
Example 1: HS -23-2-3
Tag number identifies a Hand Selector Switch. It is part of Loop 23 and the
second hand selector switch in the loop. This is the third identical process unit
(i.e., three identical pump control stations). It is also the only hand selector
switch in the loop.
25 Example 2: HS -23
126
27 Tag number identifies a Hand Selector Switch in Loop 23. It is also the only
28 hand selector switch in the loop.
129
30 2.06 INSTRUMENT IDENTIFICATION
31
132 A. All components provided, both field and panel mounted, shall be provided with
33 permanently mounted name tags bearing the entire tag number of the
34 component. Panel mounted tags shall be white with black lettering lamicoid
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-27 12/18/20
1 plastic; field mounted tags shall be stamped stainless steel.
2
3 B. Nameplates for panels and panel mounted equipment shall be as indicated on
4 the Drawings.
5
6 C. Field mounted tags shall be 16 -gauge, 316 stainless steel with 3/16 inch high
7 characters.
8
9 D. Tags shall be attached to equipment with a commercial tag holder using a
10 stainless steel band with a worm screw clamping device or by a holder
11 fabricated with standard stainless steel hose clamps and meeting the same
12 description. In some cases where this would be impractical, use 20 -gauge
13 stainless steel wire.
14
15 E. For field panels or large equipment cases use stainless steel screws, however,
16 such permanent attachment shall not be on an ordinarily replaceable part. In all
17 cases, the tag shall be plainly visible to a standing observer and not obscure
18 adjustment ports or impair the function of the instrument. Field mounted control
19 stations, recorders or indicators shall have a nameplate indicating their function
20 and the variable controlled or displayed. Nameplate shall be attached by one of
21 the above methods.
22
23 2.07 STANDARD LIGHT COLORS AND INSCRIPTIONS
24
25 Unless otherwise noted, the following color code and inscriptions shall be followed:
26
Taq Function Inscription(s) Color
ON ON RED
OFF OFF GREEN
OPEN OPEN RED
CLOSED CLOSED GREEN
LOW LOW GREEN
FAIL FAIL RED
HIGH HIGH AMBER
AUTO AUTO WHITE
MANUAL MANUAL YELLOW
INSTRUMENTATION GENERAL PROVISIONS
13600-28 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 LOCAL LOCAL WHITE
REMOTE REMOTE AMBER
1
2 Lettering shall be black on white and amber lenses. Lettering shall be white on red
'3 and green lenses.
4
5 2.08 STANDARD PUSHBUTTON COLORS AND INSCRIPTIONS
I6
Tag Function Inscription(s) Color
1 00 ON RED
OC OFF GREEN
1 OC OPEN RED
CLOSED GREEN
IOCA OPEN RED
CLOSED GREEN
1 AUTO WHITE
OOA ON RED
1 AUTO WHITE
OC OFF GREEN
1 AUTO WHITE
MA MANUAL YELLOW
IAUTO WHITE
SS START RED
1 STOP GREEN
RESET RESET RED
I
7
8 All unused or non inscribed buttons shall be black. Lettering shall be black on white
9 and yellow buttons. Lettering shall be white on black, red, and green
I10
11 2.09 ELECTRONIC EQUIPMENT
I12
13 A. If the equipment is electronic in nature, provide industrial duty, solid state
14 equipment to the greatest extent practicable. Select components of
'15 construction for their suitability and reliability. Employ adequate component de-
16 rating to preclude failures because of transients and momentary overloads
17 reasonably expected in normal operation. Where conduit connection is
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-29 12/18/20
1 provided for mounting a surge/lightning suppressor directly to the instrument,
2 the arrestor shall be so mounted.
3
4 2.10 EQUIPMENT OPERATING CONDITIONS
5
6 A. All equipment shall be rated for normal operating performance with varying
7 operating conditions over the following ranges:
8
9 1. Power:
10
11 120 Vac ± 10%, 60 Hz ±1 Hz except where specifically stated otherwise
12 on the drawings or in the specifications.
13
14 2. Environmental Conditions:
15
16 a. Equipment rated NEMA 1 or NEMA 12 shall be suitable for the
17 following environmental conditions:
18
19 1) Temperature: 40 to 105 degrees F.
20 2) Relative Humidity: 10 to 80 percent.
21 3) Classification: Non -hazardous.
22
23 b. Equipment rated NEMA 4X shall be suitable for the following
24 environmental conditions:
25
26 1) Temperature: 20 to 105 degrees F.
27 2) Relative Humidity: 10 to 100 percent.
28 3) Classification: Non -hazardous.
29 4) Atmosphere: Corrosive.
30
31 2.11 SIGNAL ISOLATORS, CONVERTERS AND CONDITIONERS
32
33 A. Insure that input-output of all instruments and control devices (whether
34 furnished by the System Integrator or not) are compatible. Analog signals
35 between field and panels shall be 4 to 20 mA dc unless specifically approved
36 otherwise. Granting such approval does not relieve the System Integrator from
37 the compatibility requirement above. Provide signal isolators and converters as
38 necessary to obtain the required system performance. Mount the devices in
39 control panels or in the field at point of application, as required for accurate
40 signal acquisition.
41
42 2.12 AUXILIARY CONTACTS BY OTHERS
43
44 A. Provide instruments and equipment to connect to auxiliary contacts provided by
45 others for alarms, status of equipment, interlocking, and other functions as
46 indicated and as specified herein.
INSTRUMENTATION GENERAL PROVISIONS
13600-30 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11
2 2.13 ELECTRICAL
I
3
4 A. The construction work shall include all power supply wiring, instrumentation
5 wiring, interconnecting wiring and equipment grounding as indicated, specified,
I6 and required.
7
8 B. Wiring installations shall include cables, conductors, terminals, connectors, heat
111 9 shrunk wire markers on all terminations, conduits, conduit fittings, supports,
• 10 hardware, and all other required materials.
11
1 12 C. Provide the materials and complete all the required installations for equipment
13 grounding.
14
115 D. Incidental items not specifically included in the Contract Documents that can
16 legitimately and reasonably be inferred to belong in the instrumentation work
17 shall be provided and installed by the System Integrator at no additional cost to
118 the Owner.
19
20 E. Ring out all signal wiring prior to termination. Provide wire number tags marked
1 21 in indelible waterproof form of slip-on type and heat shrunk for each wire
22 termination point in the panel and field. Wire tagging shall identify the
23 destination point of the wire and when applicable, shall include the signal
1 24 polarity for analog signals. Each destination point shall be coded as follows:
25
26 1. Destination ID - Terminal Block ID - Terminal Number - (Polarity)
1 27
28 2.14 ELECTRICAL TRANSIENT PROTECTION
29
' 30 A. All instrument and control equipment mounted outside of protective structures
31 (field mounted equipment) shall be equipped with suitable surge -arresting
32 devices to protect the equipment from damage due to electrical transients
I33 induced in the interconnecting lines from lightning discharges or nearby
34 electrical devices. Both power and signal circuits shall be protected with surge
35 and transient protectors installed at the source and destination ends of the
136 circuits. Protective devices used on 120V ac inputs to field mounted equipment
37 shall be secondary valve surge protectors conforming to the requirements of
38 IEEE Standard 28-1972 (ANSI C62.1-1971).
I39
40 B. Surge and transient protectors shall be normally connected to the electrical
I41 system ground. When an electrical system ground is not available near the
42 device, the protectors shall be connected to a ground rod 10 ft. in length by 3/4
43 inch in diameter and located within 10 feet of the device.
144
45 C. Protectors for signal circuits at the field transmitter shall be Joslyn Model No.
46 1669-06, 1669-02, and 1800-20 in panels. Protectors for 120 -volt power
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-31 12/18/20
1 circuits shall be UL listed Joslyn Model No. 1250-32 secondary arrestor.
2
3 2.15 PROCESS CONNECTIONS
4
5 A. Provide instrument piping, tubing, and capillary tubing to meet the intended
6 process service and ambient environmental condition for corrosion resistance,
7 etc. All instrument pneumatic tubing shall be stainless steel with stainless steel
8 fittings. Slope lines according to service to promote self draining or venting
9 back to the process. Terminate connection to process lines or vessels in a
10 service rated block valve that will permit closing off the sense line or removal of
11 the element without requiring shut down of the process. Include drip legs and
12 blow -down valves for terminations of sense lines at the instruments when
13 mounted such that condensation can accumulate.
14
15 2.16 MISCELLANEOUS MECHANICAL
16
17 A. Three Valve Instrument Equalizing Manifold
18
19 1. Manifolds shall be of stainless steel construction for isolation and
20 equalization of differential pressure transducers. Units shall be
21 Rosemount or equal.
22
23 B. Welding of S.S. enclosures and instrument supports shall be TIG welded and
24 finished to provide corrosion free appearance.
25
26 2.17 PAINTING
27
28 A. Provide factory paint for all instruments and equipment. Provide paint as
29 required for non -stainless steel structural supports, brackets, etc.
30
31 2.18 CORROSION PROTECTION
32
33 A. All control panels, enclosures, and other equipment containing electrical or
34 instrumentation and control devices, including spare parts, shall be protected
35 from corrosion through the use of corrosion -inhibiting vapor capsules. Prior to
36 shipment, the capsules shall be provided within the shipping containers and
37 equipment as recommended by the capsule manufacturer's recommendations.
38 The Contractor, just prior to Engineer's final acceptance of the equipment, shall
39 replace all capsules. The corrosion -inhibiting vapor capsules shall be Northern
40 Instruments Model Zerust VC or Hoffman Model A -HCI. NEMA 4x panels shall
41 be provided with breather/drains, Crouse -Hinds Model ECD18; or approved
42 equal.
43
44
45 2.20 WORKMANSHIP
46
INSTRUMENTATION GENERAL PROVISIONS
13600-32 12/18/20
1
1 1 A. General
2
I 34 1. Install materials and equipment in a workmanlike manner utilizing
craftsman skilled in the particular trade. Provide work which has a neat
5 and finished appearance.
I6
7 2. Coordinate work with the Engineer, and work of other trades to avoid
8 conflicts, errors, delays, and unnecessary interference with operation of
I9 the facilities during construction.
10 B. Protection during Construction
11
112 1. Throughout this Contract, the Contractor shall provide protection for
13 materials and equipment against Toss or damage and the effects of
14 weather. Prior to installation, store items in indoor, dry locations.
1 15 Provide heating in storage areas for items subject to corrosion under
16 damp conditions. Specific storage requirements shall be in accordance
17 with the Engineer reviewed Contractor recommendations.
118
19 C. Material and Equipment Installation
20
I21 1. Follow manufacturers' installation instructions explicitly, unless otherwise
22 indicated. Wherever any conflict arises between manufacturers'
23 instructions, and these Contract Documents, follow the Engineers
124 decision, at no additional cost to the Engineer. Keep copy of
25 manufacturers' installation instructions on the jobsite available for review
26 at all times.
27
28 D. Removal or Relocation of Materials and Equipment
I29
30 1. Where existing materials and equipment are removed or relocated,
31 remove and deliver to the Engineer all materials no longer used unless
32 otherwise directed by the Engineer. Repair affected surfaces to conform
I 33 to the type, quality, and finish of the surrounding surface in a neat and
34 workmanlike manner. Follow any specific instructions by the Engineer.
I35
36 E. Cleaning and Touchup Painting
37
I38 1. Keep the premises free from accumulation of waste material or rubbish.
39 Upon completion of work, remove materials, scraps, and debris from
40 premises and from interior and exterior of all devices and equipment.
I41 Touch-up scratches, scrapes, or chips in interior and exterior surfaces of
42 panels and equipment with finishes matching as nearly as possible the
43 type, color, consistency, and type of surface of the original finish.
I44
45 F. Panels and Panel -Mounted Equipment
46
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-33 12/18/20
1
1 1. Panels and panel -mounted equipment shall be assembled as far as 1
2 possible at the factory. No work, other than correction of minor defects
3 or minor transit damage, shall be done on the panels at the jobsite.
4
5 G. Electrical
6
7 1. Arrange wiring neatly, cut to proper length, and remove surplus wire.
8 Provide abrasion protection for any wire bundles which pass through
9 holes or across edges of sheet metal.
10 2. Wiring shall not be spliced or taped except at the device terminals or
11 terminal blocks.
12
13 3. Use manufacturer's recommended tool with the proper sized anvil, for all
14 crimp terminations. No more than one wire may be terminated in a
15 single crimp lug and no more than two lugs may be installed on a single
16 screw terminal.
17
18 H. Inspections
19
20 1. All materials, equipment, and workmanship shall be subject to inspection
21 at any time by the Engineer. Correct any work, materials, or equipment '
22 not in accordance with these Contract Documents or found to be
23 deficient or defective in a manner satisfactory to the Engineer at no
24 additional cost to the Engineer. 1
25
26
27 END OF SECTION 1
28
29
1
1
1
1
1
1
INSTRUMENTATION GENERAL PROVISIONS
13600-34 12/18/20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13615
2
3 PROCESS INSTRUMENTATION AND EQUIPMENT
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. The Contractor shall furnish and install all instrumentation and controls
10 hereinafter specified to perform the intended function and achieve a fully
11 integrated and operational system. The equipment and services defined herein
12 shall be furnished by a single instrumentation system integrator who shall
13 coordinate the instrument and control system for proper operation with related
14 equipment and materials provided by other suppliers of the Owner.
15
16 B. Work shall include all labor, materials, plant facilities and equipment,
17 performance of all work necessary to complete the manufacture, to make
18 factory tests, to prepare and load for shipment, to deliver to the site, to provide
19 programming, calibration, installation supervision, training system start-up,
20 services and incidentals required to completely furnish and install an
21 instrumentation and control systems, including all work necessary during the
22 Warranty Period, as specified herein, in other specification sections as listed
23 below under related work, and as shown on the Contract Drawings.
24
25 C. The equipment and services to be provided include:
26
27 1. All general instrumentation requirements as specified herein.
28 2. All field and analytical equipment and services as specified herein.
29 3. All control panels and control panel mounted equipment and services as
30 specified herein and in Division 16
31 4. All coordination and interfacing with the control system equipment
32 specified under Section 13630.
33 5. All coordination and interfacing with each piece of equipment specified
34 under Division 11 (equipment), Division 15 (mechanical), and Division 16
35 (Electrical), where applicable.
36
37 D. Auxiliary and accessory devices necessary for system operation or
38 performance, such as transducers or relays to interface with existing equipment
39 or equipment provided by other suppliers under other Sections of these
40 Specifications, shall be furnished, coordinated and interfaced by the
41 instrumentation system integrator whether or not they are shown on the
42 drawings or specified herein.
43
44 E. Equipment shall be fabricated, assembled, installed, and placed in proper
45 operating condition in full conformity with detail Drawings and Specifications,
46 engineering data, instructions and recommendations of the equipment
47 manufacturer as approved by the Engineer.
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-1 02/24/2020
1
2 1.02 SUBMITTALS
3
4 A. The submittals shall be in accordance with Section 01300 and shall include.
5
6 1. Manufacturer's data.
7 2. Shop drawings.
8 3. Certificates of compliance.
9 4. Certified test reports.
10 5. Operation and maintenance manual.
11
12 1.03 QUALITY ASSURANCE
13
14 A. Instrumentation and control equipment furnished shall be manufactured by a
15 firm regularly and currently engaged in the design and manufacture of similar
16 equipment. Equipment furnished shall be new and of current design.
17
18 B. Equipment shall be designed for ease of maintenance and repair, and access
19 to critical parts shall not require a major disassembly. Internal field adjustments
20 where permitted or required herein shall be easily accessible upon removal of
21 a panel or cover.
22
23 C. Materials and Installation shall comply with the requirements of the referenced
24 electrical codes and standards, and the codes and standards referred to shall
25 be used for establishing the minimum quality of the materials and equipment
26 supplied and installed. Equipment of the same type shall be a product of the
27 same manufacturer. Capacities of equipment shall not be less than that
28 indicated on the drawings or specified.
29
30 D. All exposed pneumatic tubing shall be routed through a device designed to
31 protect the tubing from crushing through incidental contact. The pneumatic
32 tubing shall be attached to the protective track as required by manufacturer's
33 recommendations and shall be protected from crimping by those attachment
34 methods. The protective track devices shall be stainless steel and shall be
35 "Tube -Track" or approved equal.
36
37 E. All exterior mounted instruments shall be furnished with appropriately sized 304
38 stainless steel rain and sun shields.
39
40 F. Model numbers and names for equipment listed herein are for the purpose of
41 establishing a standard of quality or matching existing instrumentation. Like
42 equipment of a different manufacturer must be approved by the Engineer.
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-2 02/24/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1.04 PRODUCT HANDLING
2
3 A. Shipping Precautions
4
5 1. After completion of shop assembly, factory test and approval, all
6 equipment, cabinets and the panel insert shall be packed in protective
7 crates and enclosed in heavy duty polyethylene envelopes or secured
8 sheeting to provide complete protection from damage, dust and moisture.
9 Dehumidifiers shall be placed inside the polyethylene coverings. Boxed
10 weights shall be shown on shipping tags together with instructions for
11 unloading, transporting, storing and handling at job site.
12
13 2. Special instructions for proper field handling, storage and installation
14 required by manufacturer for proper protection shall be securely attached
15 to each piece of equipment prior to packaging and shipment.
16
17 3. None of the central control and monitoring equipment shall be shipped to
18 the site until the room(s) is/are environmentally suitable.
19
20 B. Identification
21
22 1. Each component shall be tagged to identify its location, tag number and
23 function in the system. Identification shall be prominently displayed on
24 the outside of the package.
25
26 2. A permanent stainless steel or other non -corrosive material tag firmly
27 attached and permanently and indelibly marked with the instrument tag
28 number, as given in the tabulation, shall be provided on each piece of
29 equipment supplied.
30
31 C. Storage
32
33 1. Equipment shall not be stored out-of-doors. Equipment shall be stored
34 in dry permanent shelters including in-line equipment, and shall be
35 adequately protected against mechanical injury. If any apparatus has
36 been damaged, such damage shall be repaired by the contractor at his
37 own expense. If any apparatus has been subject to possible injury by
38 water, it shall be thoroughly dried out and put through such tests as
39 directed by the engineer. This shall be at the cost and expense of the
40 contractor, or the apparatus shall be replaced by the contractor at his
41 own expense.
42
43 PART 2 — PRODUCTS
44
45 2.01 INSTRUMENTATION GENERAL
46
47 A. Type
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-3 02/24/2020
1
2 1 All instrumentation supplied shall be of the manufacturer's latest design
3 and shall produce or be activated by signals, which are established
4 standards for the water and wastewater industries.
5
6
7 2. Outputs of equipment that are not of the standard signals as outlined,
8 shall have the output immediately raised and/ or converted to compatible
9 standard signals for remote transmission. No zero based signals will be
10 allowed.
11
12 3. All instruments shall be provided with mounting hardware and floor
13 stands, wall brackets, or instrument racks as shown on the drawings or
14 as required.
15
16 4. Equipment installed in a hazardous area shall meet class, group and
17 division classification as shown on the electrical drawings, or comply with
18 the local or national electrical code, whichever requirement is most
19 stringent.
20
21 5. All indicators and recorder readouts shall be linear in process units.
22
23 6. All transmitters shall be provided with either integral indicators or conduit
24 mounted indicators in process units, accurate to two percent.
25
26 7. Electronic equipment shall be of the manufacturer's latest design,
27 utilizing printed circuitry and suitably coated to prevent contamination by
28 dust, moisture, and fungus. Solid-state components shall be
29 conservatively rated for their purpose, to assure optimum long term
30 performance and dependability over ambient atmosphere fluctuations
31 and 0 to 100 percent relative humidity. The field mounted equipment and
32 system components shall be designed for installation in dusty, humid,
33 and slightly corrosive service conditions.
34
35 8. All equipment, cabinets and devices furnished hereunder shall be heavy -
36 duty type, designed for continuous industrial service. The system shall
37 contain products of a single manufacturer, insofar as possible, and shall
38 consist of equipment models, which are currently in production. All
39 equipment provided shall be of modular construction and shall be
40 capable of field expansion.
41
42 B. Electrical
43
44 1. All equipment shall be designed to operate on a 60 hertz alternating
45 current power source at a normal 120 volts, plus or minus 10 percent,
46 except where specifically noted. All regulators and power supplies
47 required for compliance with the above shall be provided between power
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-4 02/24/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 supply and interconnected instrument loop. Where equipment requires
2 voltage regulation, constant voltage transformers shall be furnished and
3 installed.
4
5 2. All analog transmitter and controller outputs shall be 4 to 20 milliamps
6 into a minimum load range of 0-750 ohms, unless specifically noted
7 otherwise.
8
9 3. All switches shall have double -pole, double -throw contacts rated at a
10 minimum of 600 volts -amperes (VA), unless specifically noted otherwise.
11
12 4. Materials and equipment used shall be U.L. approved wherever such
13 approved equipment and materials are available.
14
15 5. All equipment shall be designed and constructed so that in the event of
16 a power interruption, the equipment specified hereunder shall resume
17 normal operation without manual resetting when power is restored.
18
19 2.02 LIGHTNING/SURGE SUPPRESSION
20
21 A. General - in addition to manufacturer's standard, internal protection,
22 supplementary lightning/surge protection shall be provided to protect all
23 systems from surges propagating along the signal and power supply lines. The
24 protection systems shall be such that the protective level shall not interfere with
25 normal operation, but shall be lower than the instrument surge withstand level,
26 and shall be maintenance -free and self -restoring. Instruments shall be housed
27 in a suitable metallic case, and properly grounded. Ground wires for all surge
28 protectors shall be connected to a good earth ground and, where practical, each
29 ground wire shall be run individually and insulated from each other. These
30 protectors and specified instrumentation/transmitters shall be mounted in a
31 separate NEMA 3R stainless steel vented enclosure. The units shall be
32 manufactured by DEHN. Substitutions will not be considered by the City.
33
34 B. Power supply - additional protection of all alternating current (ac) instrument
35 power supply lines shall be provided. Cabinet(s)/panel(s) and groups of field
36 instruments, as approved by the Engineer, shall be protected by isolation
37 transformers and surge suppressors. Individual field instruments shall be
38 protected by high discharge heavy-duty zinc oxide varistors/spark gap
39 combination. The ac suppressor shall have a response time of less than 25
40 nanoseconds, a surge current rating of 4kA, an input voltage of 120 VAC, 50/60
41 Hz, and have a 6kAms short-circuit withstand capability. Surge protection
42 device model 953 204 manufactured by DEHN. Substitutions will not be
43 considered by the City.
44
45 C. Signal line - protection of all field analog, discrete, digital and telemetered signal
46 lines shall be provided. Protection devices shall be installed at the both ends
47 as close to the instrument being protected as possible. Where signal lines enter
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-5 02/24/2020
1 control rooms through an interface cabinet, the protection devices shall be
2 mounted in the interface cabinet. Protection shall be with the use of silicone
3 avalanche diodes or approved equal. The suppressor shall be capable of
4 protecting a signal pair plus the cable shield with a DC clamping level of 33V,
5 be rated 20kA nominal discharge current and have at least a .75A current rating.
6 Surge protection device model 920 300 + 926 324 manufactured by DEHN.
7 Substitutions will not be considered by the City.
8
9 2.03 MAGNETIC FLOWMETERS
10
11 A. Primary Flow Head
12
13 1. Electromagnetic flowtube shall be Siemens Mag 5100W or Engineer -
14 approved equal.
15
16 2. Each meter will have an epoxy -coated steel metering tube welded at all
17 joints and a non-conductive liner, suitable for the liquid being metered.
18
19 3. Each connection will be steel flanged ANSI Class 150/300, for meter
20 sizes up to 24" and AWWA Class B, D or F for meters larger than 24".
21
22 4. There will be no electronic components on the primary flow head. An
23 integral or remote converter will supply coil drive power. Output signal
24 from the primary will be fed through cable supplied with the meter to the
25 signal converter.
26
27 5. Electrode material will be compatible with the process fluid. Liner
28 material shall be hard rubber (ebonite) and measurement and grounding
29 electrodes shall be Hastelloy-C for wastewater/sewage applications.
30
31 6. Meter shall have field replaceable electrodes with access ports or an
32 active electrode cleaning feature to remove grease deposits or build-up
33
34 7. When installed in Tined or non-metallic piping, the meter will be provided
35 with corrosion -resistant grounding rings or electrodes.
36
37 8. Meter calibration will be performed by a volumetric comparison method.
38 A calibration certificate will accompany each meter. The calibration
39 facility will be certified to 0.5% accuracy. The calibration facility must be
40 traceable to national standards.
41
42 9. The instrument will be manufactured in an ISO 9001 approved facility.
43
44 10. The meter shall communicate by HART protocol.
45
46 B. Converter
47
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-6 02/24/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. The Magnetic Flowmeter Converter shall be remote mounted. It will
2 provide precisely controlled and regulated primary field excitation. It shall
3 convert the primary flowmeter signal into a 4-20 mA DC and pulse output
4 directly proportional to the flow rate.
5
6 2. The full scale measuring range shall be a direct digital input in
7 engineering units and fully adjustable over a range from 1.0 to 33 ft/sec.
8
9 3. Each converter shall contain internal self -diagnostics, automatic data
10 integrity checking, and be completely interchangeable with other
11 converters of the same type without need for recalibration. No auxiliary
12 test meter or primary simulator shall be required for commissioning,
13 zeroing, or interchanging of flow meter/converter.
14
15 4. Each converter shall contain the following features as standard
16 equipment:
17 • Simultaneous analog output (500 -ohm load) and a scaled pulse
18 output.
19 • Status output.
20 • Low flow cutoff.
21 • Forward / reverse flow measurement capabilities.
22 • Integral rate of flow indicator and 7 -digit resettable LCD totalizer.
23 • Capability of testing analog and frequency outputs.
24 • Engineering units for display and programming; flow and total shall
25 be user programmable in any engineering unit of measure.
26
27 5. All adjustments and changes of programming shall be by local
28 pushbutton of direct digital input.
29
30 6. For ease of repair / replacement all converter configuration and totalizer
31 data shall be stored on a removable EPROM. When removed and placed
32 into a replacement / spare converter, no additional programming shall be
33 required.
34
35 7. For ease of wiring, power and output wiring terminals shall be a plug in
36 type, removable from the instrument without disconnecting wiring.
37
38 8. Repeatability shall be 0.10% of rate.
39
40 9. Accuracy of the system (Primary Flow Head and Converter) shall be:
41
42 • Meter sizes up to 40" +/- 0.4% of actual flow rate (for velocities >1
43 m/sec)
44
45 10. The enclosures shall be rated NEMA 4X minimum and in accordance
46 with the NFPA 820 classification in which it is located. The converter
47 shall incorporate EMI/RFI protection / suppression as well as overload
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-7 02/24/2020
1 protection for output circuits and meet the requirements of the EU -EMC
2 Directives and bear the CE Approval symbol.
3
4 11. The instrument shall be manufactured in an ISO 9001 approved facility.
5
6 2.04 LIQUID LEVEL FLOAT SWITCH
7
8 A. Type SO ball float switch shall be installed in the following locations and as
9 shown on the drawings:
10
11 B. Functional/performance:
12
13 1. Differential - less than one -inch.
14
15 2. Switch rating - 4.5 amps at 115V AC, 3.0 amps at 230V AC
16
17 C. Physical:
18
19 1. Float - molded high density polyethylene.
20
21 2. Switch - totally encapsulated mercury switch.
22
23 3. Cable - heavy duty, synthetic rubber jacketed, integral to float.
24
25 D. Options/accessories required:
26
27 1. Provide 316 stainless steel adjustable clamp tubes, pipe brackets, and
28 u -bolts;
29
30 2. The floats shall be mounted on a vertical one -inch stainless steel pipe
31 with all stainless steel hardware;
32
33 3. The lead wire shall be a waterproof cable of sufficient length so that no
34 splice is required prior to the junction box; and,
35
36 4. Provide a castle -aluminum NEMA 4X junction box with terminals for all
37 floats and tapped as required for conduit connections.
38
39 E. Manufacturers:
40
41 1. Consolidated Electric Co., Model LS.
42
43 2. Flygt ENH-10
44
45 3. Roto -float
46
47 4. Engineer approved equal
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-8 02/24/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 2.05 ULTRASONIC LEVEL TRANSMITTER
3
4 A. Ultrasonic level transmitter systems shall be furnished for fluid level
5 measurement. The ultrasonic level transmitter system shall include an
6 ultrasonic transducer and transmitter connected by a cable. The ultrasonic level
7 transducer shall be designed to operate on the principle of sound echoing to
8 provide level measurement without contact of fluid. The transducer shall
9 provide electronic signal output to the transmitter proportional to the fluid level.
10 The transmitter shall be furnished with all equipment as necessary to meet the
11 requirements as set forth herein shall be included and connected so as to
12 provide a complete and operational system.
13
14 B. The Contractor shall furnish cable with sufficient length for connection of the
15 transducer and the transmitter. Contractor shall size ultrasonic transducer to
16 measure entire depth of structure.
17
18 C. The transmitter shall operate on 120 volts, 60Hz, and shall have a minimum
19 NEMA 4X rated polycarbonate enclosure and shall be rated in accordance with
20 NFPA area classification requirements for the area in which it installed. The
21 transmitter output shall be 4-20 mA DC. Calibration parameters shall be
22 permanently stored even during power interruptions. Contractor shall be
23 responsible for calibration.
24
25 D. System shall operate off of a dynamic TVT curve with multiple algorithms
26 available to diagnose the true level.
27
28 E. Accuracy: +/- 1 mm plus 0.17 % of distance
29
30 F. Resolution: 0.1% of measurement or 2mm (.08") whichever is greater
31
32 G. The ultrasonic level transducers shall be Siemens Echomax XPS and
33 transmitters shall be Siemens LUT 400 or Engineer approved equal.
34
35 H. Ultrasonic level indicators shall be installed in the locations as shown on the
36 drawings using the manufacturers recommended mounting recommendations.
37
38 2.06 TRANSIENT PROTECTION/SURGE SUPPRESSION DEVICES
39
40 A. Surge and transient protection devices shall be two-stage units incorporating
41 gas discharge tube and diodes to earth. Surge protective device shall be rated
42 10kA nominal discharge current for surge events and 1 kA current for lightning
43 events. Surge protection shall be used on all 4-20 mA transmitters (e.g. LIT,
44 PIT, FIT). Surge protection devices for instrument loops of 4-20 mA shall be
45 Model 929 921 manufactured by DEHN. Substitutions will not be considered
46 by the City.
47
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-9 02/24/2020
1
2 2.07 SUBMERSIBLE TRANSDUCER AND PUMP CONTROLLER/DISPLAY
3
4 A. A submersible transducer type level transmitter system shall be furnished for
5 the sludge level measurement in the hoppers of each Salsnes Filter sludge
6 pump. Each system shall include a submersible level transducer connected to
7 a pump controller/display unit with 4 relays, cable, power supply, and a NEMA
8 4X stainless steel mounting enclosure.
9
10 B The submersible level transducer shall measure the height of liquid above its
11 mounting position referenced to atmospheric pressure. The transducer shall
12 provide an electronic signal output to the controller proportional to the sludge
13 level. The system shall be furnished with all equipment as necessary to meet
14 the requirements as set forth herein and connected so as to provide a complete
15 and operational system.
16
17 C. The Contractor shall furnish cable with sufficient length for connection of the
18 transducer and the controller. The system shall be sized to measure entire
19 depth of the progressive cavity pump hoppers.
20
21 D. The controller/display units shall be ProVu Dual Line 6 -Digit Process Meters
22 with 4 -relays by Precision Digital or approved equal. The transducers shall be
23 GES 870xxx Submersible Level Transducers by Gilson Engineering or
24 approved equal.
25
26 E. The Contractor shall make connections to I/O, modify existing and develop new
27 HMI graphic screens on the existing SCADA System and provide PLC ladder
28 logic programming to monitor all new I/O, register alarms, and provide control
29 and observation capabilities as appropriate for the new system.
30
31 F. The controller/display unit shall display the sludge level and provide a level
32 signal to the pump control PLC.
33
34 G. The submersible transducers and controllers/display units shall be installed in
35 the locations as shown on the drawings using the manufacturers mounting
36 recommendations.
37
38 PART 3 — EXECUTION
39
40 3.01 INSTALLATION
41
42 A. Field mounted elements shall be installed, calibrated, and started -up in strict
43 compliance with the manufacturer's requirements and recommendations.
44 Conflicts between the manufacturer's requirements and recommendations and
45 these Specifications or the Drawings shall be presented to the Engineer for
46 resolution before any affected work is started. Installed equipment shall be
47 certified as appropriate for the application and process by the Contractor.
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-10 02/24/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 B. Connections of instruments to process piping shall include, as close as practical
3 to the point of connection, a tight closing block valve suitable for the maximum
4 process pressure and temperature and for the material involved. If connections
5 are of threaded or welded pipe, there shall be a union or flanged connection
6 located to facilitate disassembly of the connection and removal of the instrument
7 without interrupting process operation.
8
9 C. All field -mounted instruments shall be protected and isolated from vibration,
10 temperature extremes, radiant heat, rain, sleet or falling water, and similar
11 adverse conditions.
12
13 D. Impulse lines of pressure instruments shall be as short as practical and shall be
14 installed with a minimum slope of 1 -inch per foot (1:12) downward toward the
15 instrument in liquid system and upward toward the instrument in gaseous
16 systems. If this preferred direction of slope cannot be maintained, the contractor
17 shall submit for approval an installation configuration utilizing traps, drains,
18 and/or vents at high and low points, which will ensure freedom from mixed
19 phase offset effects and provide ease of purging or draining. Pressure lines of
20 pressure instruments shall be insulated.
21
22 E. Field mounted elements shall be marked with data required for calibration such
23 as location of adjustments, span, offset, zero suppression, and test voltages. If
24 such data are not provided in permanent markings or on the manufacturer's
25 nameplate, a durable tag or label shall be affixed in a protected location that will
26 become readily visible in the normal course of servicing the instrument.
27
28 F. Provide DC power supplies for devices as required. Mount on a stanchion in
29 proximity of device in a NEMX 4X box. Provide conduit and wire to device.
30
31 3.02 EQUIPMENT TESTING AND CALIBRATION
32
33 A. Factory Tests and Calibration. All field -mounted elements shall be
34 factory -tested by the manufacturer to assure satisfactory performance prior to
35 shipment to the job site. Whenever possible, this shall include calibration to the
36 actual range and conditions of use. Calibration shall be traceable to the National
37 Bureau of Standards with an uncertainty not more than 1/2 of the specified or
38 claimed accuracy of the instruments.
39
40 B. Field Tests and Calibration. Field mounted elements which were not calibrated
41 to final working values of range, span, and zero suppression at the factory shall
42 be so calibrated prior to or at the time of installation. This calibration shall meet
43 the same requirements for accuracy and be traceable, as required for factory
44 testing above. The Engineer shall be given 48 hours' notice and the opportunity
45 to witness this calibration.
46
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-11 02/24/2020
1
1 C. The Contractor shall submit a certificate of proper installation and operation for 1
2 each field instrument. The certificates will be signed by the various equipment
3 factory representatives. I 4
5 END OF SECTION
6 I
8
9
10
11
1
PROCESS INSTRUMENTATION AND EQUIPMENT
13615-12 02/24/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13630
2
3 CONTROL PANELS AND CONTROL SYSTEM
4
5 PART 1 — GENERAL REQUIREMENTS
6
7 1.01 SCOPE OF WORK
8
9 A. Design, furnish and/or install local control panels in accordance with the
10 contract documents for the following new equipment:
11
12 • Grit Pumps (LCP-G1, LCP-G2, LCP-G3, LCP-G4)
13 • Grit Classifier (LCP-GC2)
14 • Moving Belt Filter Feed Pumps (LCP-SF1, LCP-SF2, LCP-SF3)
15 • Moving Belt Filter Sludge Pumps (LCP-SL1, LCP-SL2, LCP-SL3)
16 • Moving Belt Filters (LCP-S1, LCP-S2, LCP-S3)
17 • Scum Pump (LCP-SC1)
18 • Equalization Basin Feed Pumps (LCP-S1, LCP-S2)
19 • Equalization Basin Return Pumps (LCP-R1, LCP-R2)
20 • Equalization Basin Compressors (LCP-C1, LCP-C2)
21 • Equalization Basin Compressed Gas Mixing System Valve Panel (EMX-
22 VM -1)
23 • Macerator (LCP-MAC)
24 • In Plant Lift Station 2 (LCP-LS2)
25
26 B. Design, furnish and/or install control panels in accordance with the contract
27 documents for the following new equipment:
28 • Control Panel with PLC for Moving Belt Filter No. 1 (MCP-MBF1)
29 • Control Panel with PLC for Moving Belt Filter No. 2 (MCP-MBF2)
30 • Control Panel with PLC for Moving Belt Filter No. 3 (MCP-MBF3)
31 • Master Control Panel with PLC for Moving Belt Filter Feed Pumps, Moving
32 Belt Filter Sludge Pumps, Grit Pumps, and Grit Classifier (MCP -15)
33 • Master Control Panel with PLC for Equalization Basin Feed Pumps and
34 Equalization Basin Return Pumps (MCP -16)
35 • Master Control Panel with PLC for Equalization Basin Compressed Gas
36 Mixing System (MCP-CGM)
37
38 C. The Contractor shall furnish the services of a Systems Integrator (SI), as
39 specified in Section 13600 to perform the work of this section and related work
40 in Division 13 and Division 16 specifications, to install and coordinate
41 equipment start-up with the equipment manufacturers who are providing the
42 PLC programs, and to test a complete and operable system as indicated on
43 the Drawings and as specified herein. .
44
45 D. PLC ladder logic programming for the new Moving Belt Filter PLCs and
46 Compressed Gas Mixing System PLC shall be provided by the equipment
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-1
12/17/2020
1 manufacturer as specified in Division 11. PLC ladder logic programming for
2 the remaining Master Control Panels shall be provided by the SI. HMI
3 graphics, and alarms for the monitoring and control of equipment as specified
4 herein, shall be performed by the SI. The Contractor shall be responsible for
5 furnishing, installing and testing the complete control system. The Contractor
6 shall be responsible for all labor, materials, equipment, calibration,
7 coordination and incidentals required to furnish and install the control system
8 specified or required.
9
10 E. These Specifications are intended to give a general description of what is
11 required, but do not cover all details, which will vary in accordance with the
12 requirements of the equipment furnished. They are, however, intended to
13 cover the furnishing, the shop testing, the delivery and complete installation
14 and field testing, of all materials equipment and appurtenances for the
15 complete system herein specified, whether or not specifically mentioned in the
16 Specifications.
17
18 F For all systems, the Contractor shall furnish and install all necessary and
19 desirable accessory equipment and auxiliaries, whether or not specifically
20 mentioned in these Specifications. This work shall include field-testing of the
21 entire installation and instruction of the operating personnel in the care,
22 operation and maintenance of all equipment.
23
24 1.02 QUALIFICATIONS
25
26 A. The Contractor, thru the SI, shall assume full responsibility for the satisfactory
27 installation and operation of the control system.
28
29 B. All equipment furnished under these Specifications shall be new and unused
30 and shall be the standard cataloged product of a manufacturer having a
31 successful record of manufacturing and servicing the equipment and systems
32 specified herein.
33
34 1.03 SUBMITTALS
35
36 A. Copies of all materials required to establish compliance with the Specifications
37 shall be submitted in accordance with the General Conditions and the General
38 Requirements. Submittals shall include, but not be limited to, the following:
39
40 1. Shop drawings prepared by the manufacturer and submitted to the
41 Engineer for review prior to the manufacture of the equipment. The
42 shop drawings shall include outline dimensions and external connection
43 diagrams. A list of components, interface cables, specifications and a
44 copy of the manufacturer's warranty shall be included with the
45 submitted data.
46
47 2. Operating Instructions: The Contractor shall submit operation and
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-2 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 maintenance manuals for the entire control system.
2
3 a. General - equipment function, description and normal and
4 limiting operating characteristics.
5
6 b. Installation instructions - assembly procedures and alignment
7 and adjustment procedures.
8
9 c. Operation instructions - start-up procedures, normal operating
10 conditions, emergency and normal shutdown procedure.
11
12 d. Maintenance instructions.
13
14 e. Trouble -shooting guide.
15
16 f. Parts list and predicted life of parts subject to wear.
17
18 g. Drawings - cross sectional view, assembly and wiring diagrams.
19
20 3. Complete master wiring diagrams and control schematics shall be
21 furnished for approval before proceeding with manufacture or
22 modification of an existing panel.
23
24 4. Ethernet Network Drawings: furnish an Ethernet network drawing
25 showing cable types, all equipment (new and existing) connected to the
26 Ethernet network, and IP addresses.
27
28 5. Certifications: The Contractor shall furnish the Engineer with a written
29 certification signed by the manufacturer's representative that the
30 equipment has been properly installed, tested, calibrated, and operated
31 under typical operating conditions, and satisfactory operation has been
32 obtained.
33
34 6. The Contractor, through the SI, shall provide to the Owner and
35 Engineer a completed as -built drawing showing the actual control
36 components and devices (show existing and new devices) that are
37 mounted in the existing panels after modification. Drawing shall also
38 include identification of each wire in the existing panel to which terminal
39 strip it is connected, circuit breaker identification, Flex I/O modules and
40 corresponding I/O, etc. Two additional copies of the panel as -built shall
41 be placed in the pocket holder on the door of the new panel.
42
43 1.04 OPERATING INSTRUCTIONS
44
45 A. Operating and maintenance manuals shall be furnished in accordance with
46 Section 01730. The manuals shall be prepared specifically for this installation
47 and shall include all required cuts, drawings, equipment lists, descriptions,
48 programming logic, calibration requirements, etc., that are required to instruct
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-3 12/17/2020
1 operating and maintenance personnel unfamiliar with such equipment the
2 number and special requirements shall be as specified.
3
4 1.05 SPARE PARTS
5
6 A. The Contractor shall furnish the following spare parts:
7
8 1. One (1) spare of each type of PLC I/O module shall be provided.
9 2. One (1) spare DC power supply of each size and type shall be
10 provided.
11 3. Fuses: 20 percent of each size and type use, but no Tess than ten of
12 each size and type.
13 4. Relays: 20 percent of each type used, but no less than ten of each
14 type.
15 5. One copy of the PLC program, after debugging, recorded on CD-ROM
16 for each PLC.
17 6. One master copy of all PLC programs on a USB flash drive
18 7. One spare Operator Interface Terminal (OIT) for the Master Control
19 Panels.
20 8. Corrosion Inhibiting Vapor Capsules: Provide 100 of each type and
21 size used.
22
23 B. Spare parts shall be properly protected for long periods of storage and packed
24 in a box clearly identified with indelible markings as to the contents in
25 accordance with Division 1 General Requirements.
26
27 1.06 WARRANTY
28
29 A. The Contractor shall provide a warranty in accordance with Section 01740 and
30 shall guarantee that the equipment furnished is suitable for the purpose
31 intended and free from defects of design, material and workmanship. In the
32 event the equipment fails to perform as specified, the Contractor shall
33 promptly repair or replace the defective equipment without any cost to the
34 Owner (including handling, shipment and labor costs).
35
36 PART 2 — PRODUCTS
37
38 2.01 CONTROL PANELS
39
40 A. All new local control panels shall be at minimum NEMA 4X 316 S.S. and shall
41 comply with NFPA 820 area classifications. All panels shall be as
42 manufactured by Hoffman or approved equal.
43
44 B. The panels shall be the free standing or wall mounted and be complete with all
45 controls including switches, push buttons and speed adjustment
46 potentiometers as applicable and as specified herein.
47
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-4 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 C. Any control panels to be located in a non -air-conditioned space as shown on
2 the Drawings shall be designed to operate between 0 — 100 degrees F without
3 air conditioning including all components, wiring, and equipment. The three (3)
4 manufacturer -furnished Moving Belt Filter Master Control Panels(MCP-MBF1,
5 MCP-MBF2, MCP-MBF3), the two (2) Master Control Panels (MCP15,
6 MCP16), and the Compressed Gas Mixing System Master Control Panel
7 (MCP-CGM) shall be located in air-conditioned electrical enclosures and shall
8 be designed to operate between 0 — 80 degrees F.
9
10 D. Unless otherwise specified on applicable panel drawings, all panels shall be of
11 the fully enclosed type designed for use with high density instrumentation
12 mounting.
13
14 E. Conductors running from the field to the panels shall be continuous without
15 splices, except at approved junction boxes. The junction boxes shall have
16 terminal blocks with 20 percent spare terminals. Special care shall be
17 exercised to carry grounding lines through such junction boxes with the least
18 possible resistance. Cables entering panels shall be multi -conductor. Conduit
19 and multi -conductor cables entering panels shall be sealed to prevent the
20 intrusion of gas and moisture.
21
22 F. Multi -conductor cable shall be used between junction boxes and the panels.
23
24 G. Control panels shall be completely fabricated, with instruments installed and
25 wired, at the System Integrator's facility, except for the manufacturer -supplied
26 Moving Belt Filter Control Panels and the Compressed Gas Mixing System
27 Control Panel, which shall be completely fabricated, with instruments installed
28 and wired, at the manufacturer's facility.
29
30 H. All components shall be mounted in a manner that permits servicing,
31 adjustment, testing and removal without disconnecting, moving or removing
32 any other component. Components mounted on the inside of panels shall be
33 mounted on removable plates and not directly to the enclosure. Mounting
34 shall be rigid and stable unless shock mounting is otherwise required by the
35 manufacturer to protect equipment from vibration. Component mounting shall
36 be oriented in accordance with other internal components and shall be
37 identified with suitable plastic or metal engraved tags attached with drive pins
38 adjacent to (not on) each component, identifying the component in accordance
39 with the drawing, specifications, and System Integrator's data.
40
41 I. All exterior panel mounted equipment shall be installed with suitable gaskets,
42 faceplates, etc. required to maintain the NEMA rating of the panel.
43
44 J. All panels shall be supplied with suitable nameplates that identify the panel
45 and individual devices.
46
47 K. All panels and panel assemblies shall be assembled by a UL 508 approved
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-5 12/17/2020
1 panel shop. Each panel and panel assembly shall bear the mark of such.
2
3 L. Panels shall be constructed of stainless steel with angle or channel bracing.
4 Side filler panels, top filler panels, and sub panels shall be 12 gauge stainless
5 steel. Panels shall be suitable for the environments they are to be installed
6 within.
7
8 M. Panels shall be of continuous welded stainless steel construction. Provide
9 stainless steel angle stiffeners as required on the back of the panel face to
10 prevent panel deflection under instrument loading or operation. Internally the
11 panels shall be supplied with a structural stainless steel framework for
12 instrument support purposes and panel bracing. The internal framework shall
13 permit panel lifting without racking or distortion. Provide removable lifting rings
14 designed to facilitate simple, safe rigging, and lifting of the control panels
15 during installation. Plugs shall be provided and shall unobtrusively fill the
16 panel lifting ring holes when substituted for the lifting rings after installation is
17 complete. All exposed welds, seams, or edges shall be ground smooth.
18
19 N. Each panel shall be provided with full height, fully gasketed access doors.
20 Doors shall be provided with a three point latch and heavy duty locking handle.
21 Rear access doors shall be conveniently arranged and sized such that they
22 extend no further than 24 inches beyond the panel when opened to the 90
23 degree position. Panel access doors shall be provided with full length,
24 continuous, piano type, and stainless steel hinges with stainless steel pins.
25
26 O. The panels, including component parts, shall be constructed and assembled in
27 a thoroughly workmanlike manner and shall be free from sharp edges and
28 welding flaws. Wiring shall be free from kinks and sharp bends and shall be
29 routed for easy access to other components for maintenance and inspection
30 purposes.
31
32 P Provide overhead switched lighting and at least one (1) GFI convenience
33 duplex receptacle 110/120VAC in each Master Control Panel.
34
35 Q. The panel shall be suitable for top or bottom conduit entry as required. For top
36 mounted conduit entry the panel top shall be provided with nominal one foot
37 square removable access plates, which may be drilled to accommodate
38 conduit and cable penetrations. All conduit and cable penetrations shall be
39 provided with ground bushings, hubs, gasketed locknuts, or other accessories
40 as required to maintain the NEMA rating of the panel and electrical rating of
41 the conduit system.
42
43 R. Internal Electrical Wiring
44
45 1. Panel equipment shall be mounted and wired on or within the cabinet.
46 Wiring shall comply with the National Electrical Code. Wiring within the
47 panel shall be grouped together with harnesses or ducts and secured to
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-6 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 the structure. Wiring shall be numbered in compliance with the
2 numbering system used on the wiring/connection diagrams. Wiring and
3 connection diagrams shall comply with ISA 5.4 Instrument Loop
4 Diagrams and shall be submitted by the System Integrator as part of
5 the Shop Drawings for review by the Engineer.
6
7 2. Power and low voltage DC signal wiring shall be routed in separate wire
8 ways. Crossing of the two system wires shall be at right angles.
9
10 3. Control wire shall be 14 AWG Type THWN stranded and shall be insu-
11 lated for not Tess than 600 volts unless specified otherwise. Conductors
12 shall be of tinned copper construction. All interconnecting wiring,
13 except for electronic circuits, shall be rated for not less than 90 degrees
14 C.
15
16 4. Signal wire shall be 1 pair 16 AWG shielded. Conductors shall be of
17 tinned copper construction.
18
19 5. Wire color shall be: Line Power - Black; Neutral or Common - White;
20 AC Control - Red; DC Control - Blue; Equipment or Chassis
21 Ground - Green; specified externally powered circuits - Orange.
22
23 6. Wiring shall terminate at a master terminal board, rigid type and
24 numbered. The master terminal board shall have a minimum of 25
25 percent spares.
26
27 7. Terminal blocks shall be arranged in vertical rows and separated into
28 groups (Power, AC control, and DC signal).
29
30 8. Terminal blocks shall be barrier type with the appropriate voltage rating
31 (600 volts minimum). Terminal strips shall be provided for the purpose
32 of connecting all control and signal wiring. They shall be the raised
33 channel mounted type as manufactured by Allen Bradley or approved
34 equal.
35
36 9. Wiring trough for supporting internal wiring shall be plastic type with
37 snap on covers. The side walls shall be open top type to permit wire
38 changing without disconnecting. Trough shall be supported to the sub
39 panel by stainless steel screws. Trough shall not be bonded to the
40 panel with glue or adhesives.
41
42 10. Each wire shall be provided with numbered heat shrink tubing
43 identification markers at both ends and the numbering shall be in
44 accordance with the Control Panel Drawings. Identification markers
45 shall be pre -typed. Handwritten markers or paper markers are not
46 permitted.
47
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-7 12/17/2020
1 11. Direct interlock wiring between equipment is not allowed. Only one side
2 of a terminal block row shall be used for internal wiring. The field wiring
3 side of the terminal shall not be within 6 -inches of the side panel or
4 adjacent terminal.
5
6 12. Wiring troughs shall not be more than 60 percent visible fill. Wiring
7 trough covers shall be match marked to identify placement. If
8 component identification is shown on covers for visibility, the ID shall
9 also appear on the mounting sub -panel.
10
11 13. Each panel shall be provided with an isolated copper grounding bus for
12 all signal and shield ground connections. Shield grounding shall be in
13 accordance with the instrumentation manufacturer's recommendations.
14
15 14. Each panel shall be provided with a separate copper power grounding
16 bus (safety) in accordance with the requirements of the National
17 Electrical Code.
18
19 15. Each panel, where required, shall be provided with analog signal
20 isolation (1/I) where analog signals are sent from one panel or console
21 to another.
22
23 16. Each panel shall be provided with surge suppression protection
24 (electrical transients) for connections between AC power systems and
25 electrical and electronic equipment. Surge suppressor grounding shall
26 be in accordance with the manufacturer's recommendations.
27
28 17. All wiring to hand switches and the like that are live circuits independent
29 of the panel's normal circuit breaker protection shall be clearly identified
30 as such.
31
32 S. Relays not provided under Division 11, 15, or 16 and required for properly
33 completing the control function defined in this Section, shown on the
34 Drawings, or required for the proper operation of the equipment being
35 provided shall be provided under this Section. For example, discrete field
36 control and status circuitry shall be isolated from PLC I/O termination boards
37 using relays. Relays shall have red LED indicators that illuminate upon coil
38 energization.
39
40 T Relays shall be mounted in their respective panel and shall be clearly
41 identified as being live circuits independent of the panel's normal circuit
42 breaker protection.
43
44 U. Nameplates shall be provided for flush mounted equipment. The nameplates
45 shall be approximately 1 -in x 3 -in constructed of black and white laminated,
46 phenolic material having engraved Helvetica letters approximately 1/4 -in high,
47 extending through the black face into the white layer. Nameplates shall be
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-8 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 beveled and attached to panels by self -tapping stainless steel screws.
2 Adhesive bonded or glued -on name plates shall not be accepted.
3
4 V. Components shall be mounted in a manner that permits servicing, adjustment,
5 testing, and removal without disconnecting, moving or removing any other
6 component.
7
8 W. Components shall be mounted on plates on the inside of panels in such a
9 manner that allows for removal of the components without removal of the
10 plate. Components shall not be mounted directly to the enclosure.
11
12 X. Internal components shall be identified with suitable plastic engraved name
13 plates attached with stainless steel drive pins adjacent to (not on) each
14 component identifying the component in compliance with the Drawings,
15 Specifications, and System Supplier's data.
16
17 2.02 INSTRUMENT IDENTIFICATION
18
19 A. All components provided, both field and panel mounted, shall be provided with
20 permanently mounted name tags bearing the entire tag number of the
21 component. Panel mounted tags shall be white with black lettering Iamicoid
22 plastic; field mounted tags shall be stamped stainless steel.
23
24 B. Nameplates for panels and panel mounted equipment shall be as indicated on
25 the Drawings or as directed by the Engineer.
26
27 C. Field mounted tags shall be 16 -gauge 316 stainless steel, with 3/16 -inch high
28 characters.
29
30 D. Tags shall be attached to equipment with a commercial tag holder using a
31 stainless steel band with a worm screw clamping device or by a holder
32 fabricated with standard stainless steel hose clamps and meeting the same
33 description. In some cases where this would be impractical, use 20 -gauge
34 stainless steel wire.
35
36 E. For field panels or Targe equipment cases, use stainless steel screws,
37 however, such permanent attachment shall not be on an ordinarily replaceable
38 part. In all cases, the tag shall be plainly visible to a standing observer and
39 not obscure adjustment ports or impair the function of the instrument. Field
40 mounted control stations, recorders or indicators shall have a nameplate
41 indicating their function and the variable controlled or displayed. Nameplate
42 shall be attached by one of the above methods.
43
44 2.03 PANEL COMPONENTS
45
46 A. AH control panels shall accept a 110/120 VAC, 60 hertz, single phase power
47 input and be equipped with a fused disconnect switch. When the disconnect
48 switch is in the open position, all power shall be removed from the control
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-9 12/17/2020
1
1 system. Control panels shall also be equipped with a 120VAC transient
2 voltage surge suppressor (TVSS).
3
4 B. Industrial Relays and Time Delays
5
6 1. Type:
7
8 a. Industrial heavy duty relays.
9
10 2. Functional/Performance:
11
12 a. Contact arrangement/function shall be as required to meet the
13 specified control function.
14
15 b. Contacts shall be rated 10 amps continuous at 600 volts.
16
17 c. Relays shall be provided with convertible contact blocks.
18
19 d. Pneumatic time delay relays shall be used on time delays less
20 than 180 seconds and shall be adjustable.
21
22 e. Solid state time delay relays shall be used on time delays
23 between 180 seconds and one-hour.
24
25 3. Options/Accessories Required:
26
27 a. Provide all mounting rails, etc., as required.
28
29 4. Manufacturers:
30
31 a. Allen Bradley
32
33 b. Square D
34
35 C. General Purpose Relays and Time Delays
36
37 1. Relays shall be double pole, double throw, octal plug in type with a
38 transparent dust cover. The relay shall be equipped with an indicating
39 light to indicate when its coil is energized. The mechanical life of the
40 relay shall be 10,000,000 operations, minimum.
41
42 a. Type:
43
44 (1) Units shall be of the general purpose plug-in type.
45
46 b. Functional/Performance:
47
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-10 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 (1) Coil voltage shall match supply voltage.
2
3 (2) Contact arrangement/function shall be as required to meet
4 the specified control function.
5
6 c. Duty cycle shall be rated for continuous operation.
7
8 d. Solid state time delays shall be provided with polarity protection
9 (DC units) and transient protection.
10
11 e. Time delay units shall be adjustable and available in ranges from
12 0.1 second to 4.5 hours.
13
14 2. Physical:
15
16 a. For 120VAC service, provide contacts rated 10 amps at
17 120VAC; for 24VDC service provide contacts rated 5 amps at
18 28VDC, for electronic (milliamp/ millivolt) switching applicator
19 provide gold plated contacts rated for electronic service.
20
21 b. Relays shall be provided with dust and moisture resistant covers.
22
23 3. Options/Accessories Required:
24
25 a. Provide mounting sockets with pressure type terminal blocks
26 rated 300 volt and 10 amps.
27
28 b. Provide mounting rails/holders as required.
29
30 4. Manufacturers:
31
32 a. Allen Bradley
33
34 b. Potter & Brumfield
35
36 c. Eagle Signal Controls
37
38 D. Signal Isolators/Boosters/Converters
39
40 1. Type:
41
42 a. Externally powered solid state electronic type. Loop powered
43 devices are not acceptable.
44
45 2. Functional/Performance:
46
47 a. Accuracy - 0.15 percent.
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-11 12/17/2020
1
2 b. Inputs - Current, voltage, frequency, temperature, or resistance
3 as required.
4
5 c. Outputs - Current or voltage as required.
6
7 d. Isolation - There shall be complete isolation between input
8 circuitry, output circuitry, and the power supply.
9
10 e. Adjustments - Zero and span adjustment shall be provided.
11
12 f. Protection - Provide RFI protection.
13
14 3. Physical:
15
16 a. Mounting - Suitable for mounting in an enclosure or instrument
17 rack.
18
19 4. Options/Accessories Required:
20
21 a. Mounting rack or general purpose enclosure as required.
22
23 5. Manufacturers:
24
25 a. Phoenix Contact or approved equal
26
27
28 E. Signal Relay Switches (Current Trips)
29
30 1. Type:
31
32 a. Solid state electronic type.
33
34 2. Functional/Performance:
35
36 a. Input - 4-20 mA.
37
38 b. Output - Isolated contact output, double pole double throw, rated
39 5 amps at 120 VAC.
40
41 c. Accuracy - 0.1 percent.
42
43 d. Protection - Provide RFI protection.
44
45 e. Deadband - Adjustable between 0.1 to 5.0 percent of span.
46
47 f. Setpoint Adjustment - Provide graduated dial for each alarm
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-12 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 setpoint from 0 to full scale. Alarms shall be adjustable to trip on
2 rising or falling input signal.
3
4 g. Repeatability - Trip point repeatability shall be at least 0.1
5 percent of span.
6
7 3. Physical:
8
9 a. Mounting - Suitable for mounting in an enclosure or high density
10 instrument rack.
11
12 4. Options/Accessories Required:
13
14 a. Mounting rack or general purpose enclosure as required.
15
16 5. Manufacturers:
17
18 a. Rochester Instrument Systems
19
20 b. Acromag Inc.
21
22 c. Moore Industries
23
24 F Intrinsically Safe Relays
25
26 1. Type:
27
28 a. Relays shall be of the solid state electronic type in which the
29 energy level of the sensing or actuation circuit is low enough to
30 allow safe usage in hazardous areas.
31
32 2. Options/Accessories Required:
33
34 a. Relays shall match power supply provided.
35
36 b. Relays shall be located in non -hazardous areas.
37
38 3. Manufacturers:
39
40 a. Consolidated Electric
41
42 b. Gems Safe -Pak
43
44 c. Warrick Controls
45
46 d. R. Stahl, Inc.
47
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-13 12/17/2020
1 G. All other relays, switches, timers, lights, and ancillary control devices, ancillary
2 wiring, and hardware, whether specified herein or not, and required for a
3 complete and operational control system shall be furnished and installed.
4
5 2.04 PROGRAMMABLE LOGIC CONTROLLER (PLC) SYSTEM
6
7 A. New PLCs shall be furnished and installed in the respective master control
8 panels as applicable.
9
10 B. PLCs shall be an Allen-Bradley CompactLogix 5370 Model 1769-L33ER, with
11 Dual Ethernet, 2MB memory, and 2GB SD card.
12
13 C. PLCs shall be furnished with an Allen-Bradley series 1769 Power Supply to
14 provide power to the PLC and all I/O modules.
15
16 D. PLCs shall be furnished with sufficient I/O modules for all I/O plus 20%
17 installed spare. All I/O modules (Al, AO, DI, and DO) shall be series 1769 as
18 manufactured by Allen-Bradley.
19
20 E. All installed I/O shall be wired to terminal blocks for field termination.
21
22 F All input/output shall be color coded and titled with a distinctive label.
23
24 G. PLC Programming Software
25
26 1. The Moving Belt Filter Manufacturer and the Compressed Gas Mixing
27 System Manufacturer shall be responsible for developing the program
28 for controlling their respective equipment. The Systems Integrator shall
29 be responsible for developing all other programs. As such, the Moving
30 Belt Filter equipment manufacturer, the Compressed Gas Mixing
31 System Manufacturer, and the Systems Integrator shall possess a
32 complete licensed copy of the latest version of Rockwell Automation
33 RSLogix, RSLinx and RSNetworx programming software compatible
34 with the PLC specified herein.
35
36 2. The Moving Belt Filter manufacturer and the Compressed Gas Mixing
37 System Manufacturer shall supply all programming necessary to
38 provide a fully debugged and operating system. The SCADA Systems
39 Programmer shall supply all programming necessary to provide a fully
40 debugged and operating system for all other new equipment. The
41 software required shall consist of those programs necessary for the
42 equipment to efficiently perform the functions specified herein or other
43 parts of the Contract Documents. The Contractor shall provide any and
44 all additional controls required for smooth operation of the system,
45 whether or not specified herein, at no additional cost to the Owner. The
46 Owner and Engineer shall not be required to expend any programming
47 effort in order to achieve a fully operational system.
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-14 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 2.05 OPERATOR INTERFACE TERMINAL (OIT)
3
4 A. The Master Control Panels shall be furnished with color active -matrix TFT, 15-
5 inch touchscreen and keypad OIT.
6
7 B. The OIT shall communicate with the PLC via Ethernet.
8
9 C. Door mounted touchscreen and keypad OIT shall be Allen-Bradley Panelview
10 Plus 2711 P-B15C4A8.
11
12 D. The OIT shall be furnished with Rockwell Automation Factory Talk Studio
13 software to allow the Systems Integrator to develop graphic screens for the
14 OIT.
15
16 2.06 DC POWER SUPPLIES
17
18 A. 24VDC power supplies shall be provided in the control panels. 24VDC power
19 supplies shall be switching type, din rail mountable power supplies.
20
21 B. 24VDC power supplies shall be approved for use in UL -580 industrial control
22 cabinets.
23
24 C. Provide fuse or short-circuit protection. Provide a minimum of 1 set of dry
25 contacts configured to change state on failure for monitoring and signaling
26 purposes.
27
28 D. Operating temperature range: 0 degrees Celsius to 50 degrees Celsius.
29
30 E. Touch safe design: All connection terminals to be protected against accidental
31 touch.
32
33 F. Provide self -protecting power supplies with a means of limiting DC current in
34 case of short circuit.
35
36 G. 24VDC power supplies shall be Allen Bradley 1606 Series Power Supply.
37
38 2.07 UPS AND SURGE SUPPRESSION
39
40 A. An Uninterruptible Power Supply (UPS) shall be furnished in the LCP to
41 operate all critical components of the panel in the event of a power failure.
42
43 B. The UPS shall provide backup power for the entire PLC system including PLC
44 power supply, I/O modules, 24VDC power supplies and any other devices
45 inside the LCP.
46
47 C. The UPS shall be capable of sustaining the operation of the equipment for a
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-15
12/17/2020
1 minimum ten (10) minutes in the event of a power failure.
2
3 D. There shall be no measureable break in the output power of the UPS during
4 transfer from normal AC line supply to battery power or from battery power
5 back to normal AC line supply.
6
7 F. Exact sizing of the UPS shall be the responsibility of the Systems Integrator.
8 Submit LCP load calculation with UPS product data showing compliance with
9 specifications.
10
11 G. The UPS shall be capable of providing surge suppression for all equipment in
12 the event of a surge or spike on the incoming 120VAC power lines.
13
14 H. The UPS shall be by Allen-Bradley.
15
16 I. All UPS units shall be true online type.
17
18 2.08 MANAGED SWITCHES
19
20 A. Where shown on the drawings or required for proper communication, Ethernet
21 switches shall be furnished and installed in all control panels containing a
22 PLC.
23
24 B. All switches shall be capable of 10/100BT/X connection speeds and shall
25 auto -detect the appropriate speed for communication with the connected
26 device.
27
28 C. All switches shall have one port capable of being configured as an uplink port
29 to another switch for future expansion or shall provide an expansion slot for
30 this purpose.
31
32 D. All switches shall be capable of operating on 110-120VAC/60Hz or 24VDC
33 power.
34
35 E. All switches shall be capable of operation in a temperature range from 0 to 55
36 deg C with relative humidity of 90% non -condensing.
37
38 F. All switches shall provide diagnostic indicators for each channel indicating
39 connection speed, traffic and collision status.
40
41 G. All switches shall be capable of DIN rail mounting as designed or through the
42 use of a provided kit.
43
44 H. Managed switches shall be sized by the Systems Integrator with sufficient
45 quantities of Ethernet ports and Fiber Optic ports to connect all Ethernet/Fiber
46 devices as shown on the drawing plus two (2) spare Ethernet ports..
47
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-16 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 I. Managed switches shall be Allen-Bradley Stratix Switch 1783 series.
2
3 J. The Systems Integrator shall be responsible for configuring the Ethernet
4 switch (IP address, subnet, etc.) to be compatible with the existing Ethernet
5 network.
6
7 2.09 ETHERNET MEDIA AND SURGE SUPPRESSION
8
9 A. The network equipment shall be connected using pre -molded Cat -5e or Cat -6
10 patch cords with RJ -45 connectors. Lengths shall be as required.
11
12 B. If it is not possible to use pre -molded cables due to installation requirements,
13 plenum rated Cat -5e or Cat -6 cable shall be used. In addition, a qualified
14 installer must be employed to make the RJ -45 connections at each end of the
15 Ethernet run, as well as to test the cable. Testing shall include a computer
16 generated print-out of the test results, including pin connections and dB loss in
17 the cable. Furnish test results to the Engineer.
18
19 C. All non -fiber communications cables leaving a PLC panel or a network
20 enclosure shall be equipped with surge suppression devices capable of
21 protecting the communications cards in the event of a voltage spike on the
22 communications line.
23
24 D. Ethernet surge suppression rated for Cat 5/6 and POE applications shall be
25 fully shielded, provide protection for all pins, and shall be DEHN 929 121.
26 Substitutions will not be considered by the City.
27
28 2.10 LIGHTNING/SURGE SUPPRESSION
29
30 A. General - in addition to manufacturer's standard, internal protection,
31 supplementary lightning/surge protection shall be provided to protect all
32 systems from surges propagating along the signal and power supply lines.
33 The protection systems shall be such that the protective level shall not
34 interfere with normal operation, but shall be lower than the instrument surge
35 withstand level, and shall be maintenance -free and self -restoring. Instruments
36 shall be housed in a suitable metallic case, and properly grounded. Ground
37 wires for all surge protectors shall be connected to a good earth ground and,
38 where practical, each ground wire shall be run individually and insulated from
39 each other. These protectors and specified instrumentation/transmitters shall
40 be mounted in a separate NEMA 3R stainless steel vented enclosure. The
41 units shall be manufactured by DEHN. Substitutions will not be considered by
42 the City.
43
44 B. Power supply - additional protection of all alternating current (AC) instrument
45 power supply lines shall be provided. Cabinet(s)/panel(s) and groups of field
46 instruments, as approved by the Engineer, shall be protected by isolation
47 transformers and surge suppressors. Individual field instruments shall be
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-17 12/17/2020
1 protected by high discharge heavy-duty zinc oxide varistors/spark gap
2 combination. The ac suppressor shall have a response time of less than 25
3 nanoseconds, a surge current rating of 4kA, an input voltage of 120 VAC,
4 50/60 Hz, and have a 6kAms short-circuit withstand capability. Surge
5 protection device model 953 204 manufactured by DEHN. Substitutions will
6 not be considered by the City.
7
8 C. Signal line - protection of all field analog, discrete, digital and telemetered
9 signal lines shall be provided. Protection devices shall be installed at the both
10 ends as close to the instrument being protected as possible. Where signal
11 lines enter control rooms through an interface cabinet, the protection devices
12 shall be mounted in the interface cabinet. Protection shall be with the use of
13 silicone avalanche diodes or approved equal. The suppressor shall be
14 capable of protecting a signal pair plus the cable shield with a DC clamping
15 level of 33V, be rated 20kA nominal discharge current and have at least a
16 0.75A current rating. Surge protection device model 920 300 + 926 324
17 manufactured by DEHN. Substitutions will not be considered by the City.
18
19 2.11 IP ADDRESSING
20
21 A. The existing plant network has an IP address scheme defined for some
22 existing equipment. All new equipment requiring IP addresses shall be
23 assigned IP addresses matching the existing plant network IP address
24 scheme to allow the complete and operational control of all equipment as
25 specified herein.
26
27 B. The Contractor shall submit a list of proposed IP addresses for all new
28 equipment requiring IP addresses to be approved by the Owner.
29
30 2.12 FIBER OPTIC CONVERTERS
31
32 A. Media converters shall be industrially hardened and rated for use in the
33 environment specified or shown. Office grade media converters are not
34 acceptable.
35
36 B. The copper side of each media converter shall be a 10/100BT/X RJ -45
37 connector. The media converter shall support both 10Base-T and 100Base-
38 TX Ethernet.
39
40 C. The fiber side of each media converter shall be a standard ST or SC
41 connector.
42
43 D. The media converter shall provide an auxiliary RJ -45 port to maintain a local
44 programming connection for a laptop.
45
46 E. Sufficient quantities of Cat -5e or Cat -6 patch cable and fiber patch cables with
47 appropriate connectors shall be provided and installed where a fiber
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-18 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 connection is required. Patch cables shall conform to the specification
2 provided herein.
3
4 F Fiber Optic Converters shall be as manufactured by Phoenix Contact or
5 approved equal.
6
7 2.13 CORROSION CONTROL
8
9 A. Panels shall be protected from internal corrosion by the use of
10 corrosion -inhibiting vapor capsules as manufactured by Northern Instruments
11 Model Zerust VC, Hoffman Engineering Model A -HCI or approved equal.
12
13 2.14 OIT GRAPHIC SCREENS
14
15 A. The Contractor shall submit to the Engineer for review all OIT graphic screens
16 in color print on 8.5" x 11" sized paper. The Contractor shall provide the
17 following as a minimum for all OIT graphic screens:
18
19 1. All new OIT graphics for the filters shall generally match the existing
20 filter HMI graphics and include any new equipment installed as part of
21 the project.
22
23 2. All 4-20mA signals, such as level, pressure and flow signals, shall be
24 capable of being "trended" (depict historical data) on the OIT.
25
26 3. Each piece of equipment with a motor shall have a minimum one (1)
27 dedicated OIT graphic screen for control and monitoring.
28
29 2.15 EXISTING SCADA HMI GRAPHICS
30
31 A. The existing plant SCADA HMI System software is Citect SCADA.
32
33 B. The existing SCADA HMI graphics screens for all new equipment shall be
34 modified/updated to match those screens developed on the OIT.
35
36 C. The Systems Integrator shall be responsible for mapping the I/O in the SCADA
37 HMI System so that the monitoring and control functions that are on the
38 existing SCADA HMI System are available on the new HMI.
39
40 D. The Contractor shall submit to the Owner for approval all SCADA HMI graphic
41 screens that are new or being modified/updated in color print on 8.5" x 11"
42 sized paper.
43
44 PART 3 - EXECUTION
45
46 3.01 INSTALLATION
47
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-19 12/17/2020
1 A. The work included in this section consists of furnishing, installing and placing
2 in operation the instruments and appurtenances, including all conduit, wiring
3 and circuitry necessary to provide the Owner with a fully operable system
4 properly calibrated and installed.
5
6 B. Install and mount equipment in accordance with the Contract Documents,
7 manufacturer's instructions and installation detailed shop drawings. Mount
8 equipment so that it is rigidly supported, level and plumb, and in such a
9 manner as to provide accessibility; protection from damage; isolation from
10 heat, shock and vibration; and freedom from interference with other
11 equipment, piping and electrical.
12
13 C. Include the services of a factory trained, qualified service engineer of the
14 equipment manufacturer and the Systems Integrator to inspect the complete
15 equipment installation to assure that it is installed in accordance with the
16 manufacturer's recommendations, make all adjustments necessary to place
17 the system in trouble-free operation and instruct the operating personnel in the
18 proper care and operation of the equipment furnished.
19
20 D. All workmanship utilized in the manufacture and installation of this system
21 shall be of the highest quality and performed in a manner consistent with all
22 accepted practices for industrial controls.
23
24 3.02 START-UP SUPERVISION
25
26 A. The Systems Integrator shall provide a qualified service technician to inspect
27 all final connections and check the system prior to start-up. The service
28 technician shall coordinate with the Owner's representative and the equipment
29 manufacturer's representative for functional check-out of the complete system.
30
31 B. The Systems Integrator and SCADA Systems Programmer shall be on site
32 during start-up of the system to make adjustments and tune the system as
33 deemed necessary by the equipment manufacturer's representative and the
34 Engineer.
35
36 3.03 FIELD TESTS AND ACCEPTANCE
37
38 A. Field tests shall consist of the sequential installation check-out, Field
39 Acceptance Test and Final Inspection. Each phase of testing shall not be
40 commenced until the preceding phase is complete as determined by the
41 Engineer.
42
43 B. Field Test: When the operating setpoints have been established to the
44 satisfaction of the Engineer and the facility is complete and ready for
45 operation, the PLC and associated components shall be inspected and tested
46 for compliance with the Contract Documents. Testing of the equipment shall
47 be made by the Contractor in the presence of the Systems Integrator, the
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-20 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SCADA Systems Programmer, the Engineer, the Electrical subcontractor, the
2 equipment manufacturer's representative, and the Owner's representative.
3 The equipment field tests shall include, but not be limited to, the following:
4
5 1. Controls: Controls shall be tested to determine satisfactory
6 performance.
7
8 2. Electrical: Contractor shall record readings of voltage and amperage
9 on all electrical components at start and steady state operating
10 conditions. Such readings shall be recorded on a form provided by the
11 manufacturer and the results shall meet the manufacturer's prescribed
12 limits. If a tested item fails to meet its requirements, then it shall be
13 replaced. Results of the tests, including the serial number of the
14 accessories tested, shall be furnished to the Engineer.
15
16 3. Inspection: A thorough inspection of all mechanical and electrical
17 equipment and controls, fittings, brackets, mountings, seals, conduit,
18 painting, components, and features shall be made while the facility is
19 being tested to determine performance and compliance with design
20 requirements and specifications.
21
22 4. Repairs, Adjustments and Replacements: The Systems Integrator shall
23 make any and all necessary repairs, adjustments, and replacements
24 until performance has been demonstrated to the satisfaction of the
25 Engineer. The Contractor shall bear the cost of any repair, adjustment
26 and replacement.
27
28 5. Upon completion of the installation, the LCP equipment manufacturer's
29 field service technician shall furnish a certificate of compliance stating
30 that the local control panel and all components and materials have
31 been installed in strict accordance with the manufacturer's instructions.
32
33 3.04 TRAINING
34
35 A. Provide up to eight (8) hours of operator training by the Systems Integrator in
36 accordance with Section 01820 to train the Owner's personnel. Training shall
37 highlight procedures on navigating through screens, adjusting setpoints, and
38 turning on/off equipment through the OIT. Training shall also include the
39 operation and maintenance of all networking equipment and all new
40 equipment control panel PLCs.
41
42 3.05 AS -BUILT DRAWINGS
43
44 A. The Contractor, through the Systems Integrator, shall provide to the Owner
45 and Engineer complete as -built drawing(s) showing the actual control
46 components and devices Drawings shall also include identification of each
47 wire in the new panels, to which a terminal strip it is connected, circuit breaker
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-21 12/17/2020
1
1 identification, I/O modules, corresponding I/O, etc. Two additional copies of 1
2 the panel as -built drawings shall be placed in the pocket holder in the door of
3 the existing panel.4
I
5
6
7 END OF SECTION 111
LOCAL CONTROL PANELS AND CONTROL SYSTEM
13630-22 12/17/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13640
2
3 CONTROL STRATEGY
4
5 PART 1 - GENERAL
6
7 1.01 DESCRIPTION
8
9 Requirements specified in the conditions of the Contract and Division 1 form a part of
10 this section.
11
12 A. This section specifically describes the instrumentation, control and monitoring
13 system for the project. It is the intent of this Section to also supplement where
14 applicable, other Sections of Division 13.
15
16 B. The Contractor shall furnish the services of a Systems Integrator (SI) to
17 perform the work of this section and all related Division 13 and 16
18 specifications to install, program start-up, and test a complete and operable
19 instrumentation, control and monitoring system as indicated on the Drawings
20 and specified herein. The Contractor shall be responsible for coordinating with
21 all equipment manufacturers specified in Division 11, 13, and 16 to provide the
22 monitoring and controls specified herein.
23
24 C. It is the intent of this specification to briefly describe each main system so that
25 both the Contractor and the SI are aware of the magnitude of the total
26 instrumentation system and to ensure compatibility with systems already
27 existing. Certain systems described are to be furnished under other Divisions.
28 Interfacing and coordination with these systems is the responsibility of the SI
29 and is part of the Work of this Division. Manufacturer -supplied control panels
30 that are provided with equipment specified in Division 11 and 13 and
31 containing programmable logic controllers (PLCs) or other logic controllers
32 shall comply with this specification. All integration of manufactured supplied
33 control panels to the HMI SCADA System as specified herein shall be
34 provided by the SI.
35
36 1.02 SUBMITTALS
37
38 A. Copies of all materials required to establish compliance with the Specifications
39 shall be submitted in accordance with the General Conditions. Submittals
40 shall include, but not be limited to, the following:
41
42 1. Shop drawings prepared by the manufacturer and submitted to the
43 Engineer for review prior to the manufacture of the equipment. The
44 shop drawings shall include outline dimensions and external connection
45 diagrams. A list of components, interface cables, specifications and a
46 copy of the manufacturer's warranty shall be included with the
47 submitted data.
CONTROL STRATEGY
13640-1 12/18/2020
1
2 2. Operating Instructions: The Contractor shall submit operation and
3 maintenance manuals for the entire control system.
4
5 a. General - equipment function, description and normal and
6 limiting operating characteristics.
7
8 b. Installation instructions - assembly procedures and alignment
9 and adjustment procedures.
10
11 c. Operation instructions - start-up procedures, normal operating
12 conditions, emergency and normal shutdown procedure.
13
14 d. Maintenance instructions.
15
16 e. Trouble -shooting guide.
17
18 f. Parts list and predicted life of parts subject to wear.
19
20 g. Drawings - cross sectional view, assembly and wiring diagrams.
21
22 3. Complete master wiring diagrams and control schematics shall be
23 furnished for approval before proceeding with manufacture or
24 modification of an existing panel.
25
26 4. Ethernet Network Drawings: furnish an Ethernet network drawing
27 showing cable types, all equipment (new and existing) connected to the
28 Ethernet network, and IP addresses.
29
30 5. Certifications: The Contractor shall furnish the Engineer with a written
31 certification signed by the manufacturer's representative that the
32 equipment has been properly installed, tested, calibrated, and operated
33 under typical operating conditions, and satisfactory operation has been
34 obtained.
35
36 6. The Contractor through the Systems Integrator shall provide to the
37 Owner and Engineer a completed as -built drawing showing the actual
38 control components and devices (show existing and new devices) that
39 are mounted in the existing panels after modification. Drawing shall
40 also include identification of each wire in the existing panel to which
41 terminal strip it is connected, circuit breaker identification, Flex I/O
42 modules and corresponding I/O, etc. Two additional copies of the panel
43 as -built shall be placed in the pocket holder on the door of the new
44 panel.
45
46 1.03 GENERAL
47
48 A. Definitions
CONTROL STRATEGY
13640-2 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
2 1 HMI — Human Machine Interface, the existing software configured to
I
4
3 run on a computer located in the control room at the Clearwater
Northeast WRF.
5
I 6 2. CP — Control Panel. Control Panel with an OIT and a PLC located
7 remote from the piece of equipment and usually in the MCC enclosure.
8
19 3. LCP — Local Control Panel. Control Panel with a LOCAL -OFF -
10 REMOTE switch and an ON/OFF pushbutton switch mounted in the
11 field near the piece of equipment. Equipment that is driven at variable
I
12 speed shall have a manual potentiometer scaled 0-100% and readout
13 installed on the LCP.
14
I
15 4. OIT — Operator Interface Terminal, a terminal mounted on the CP that
16 allows the operator to control the equipment. All OITs shall include a
17 display that shows at a minimum the following parameters as
I18 applicable:
19
20 • Equipment Speed, 0-100%
I21 • Equipment Amps
22 • Water/Tank/Wet Well Level
23 • Flow (gpm)
24 • Temperature
25 • Pressure
I
26 • Elapsed Run Time
27 • Alarms
28 • Set Points
I29
30 B. All controls including delay timers, PLC ladder logic programming, HMI
31 graphics, ancillary programming and configuration as generally described
I32 herein shall be provided by the Contractor at no additional cost to the Owner.
33
34 C. All control commands made by the operator at the LCP shall override any
I
35 control commands from the HMI. The precedence for control shall be:
36
37 1. Any manual controls from the LCP located at the piece of equipment.
I
38 2. Any manual controls from the OIT on the CP.
39 3. Any automatic controls from the OIT on the CP.
40 4. Any manual controls from the HMI.
I
41 5. Any automatic controls from the HMI.
42
43 D. Each piece of equipment shall have a LCP with a LOCAL -OFF -REMOTE
1 44 switch and an ON/OFF pushbutton switch mounted in the field adjacent to the
45 piece of equipment. AH equipment shall operate as follows:
46
1 47 1. In LOCAL, the equipment shall start when the ON button is pushed and
CONTROL STRATEGY
13640-3 12/18/2020
1
1 shall run in manual mode. No automatic control, interlocks, or other
2 safety features shall be available in this mode of operation.
3 2. In OFF, the equipment shall turn off.
4 3. In REMOTE, the equipment shall be controlled remotely from the
5 respective PLC/OIT, or by the HMI.
6
7 E. All interlocks, such as low liquid level switches (LSL) described herein, shall
8 be hardwired to prevent pumps from operating under the interlock conditions
9 such as low water level.
10
11 F Where I/O is available all equipment run status shall be displayed on the HMI
12 and LCP whether specified herein or not.
13
14 G. The SI shall be responsible for programming, configuring and modifying the
15 existing HMI SCADA System graphic screens for all I/O shown in the Drawing
16 and specified herein.
17
18 H. Any additional HMI graphic screens required to provide controls and
19 monitoring as specified in Section 13630 shall be furnished by the Contractor
20 at no additional cost to the Owner. The Contractor shall furnish a minimum
21 additional 20% quantity of HMI graphics screens and PLC ladder logic
22 programming to provide controls and monitoring of any additional I/O at no
23 additional cost to the Owner.
24
25 I. All alarm conditions shall be indicated on an ALARM screen of the OIT and
26 HMI.
27
28 J. Any additional controls, including delay timers and ancillary programming
29 needed for the proper operation of the various systems, as directed by the
30 Engineer or required, shall be provided by the Contractor at no additional cost
31 to Owner or Engineer.
32
33 K. All panels shall have lightning and surge protection for all electrical power,
34 electrical controls, transmitters, and sensors.
35
36 L. At the completion of the project the Contractor shall furnish to the Owner on
37 CD ROM and on paper hardcopy, two (2) copies of all HMI/OIT program files,
38 PLC ladder logic and any changes made to the Owner's existing HMI
39 software.
40
41 1.04 CONTROL STRATEGY
42
43 A. Flow Meters (FM)
44
45 1. Flow meters shall measure, record, totalize and indicate rate of flow.
46
CONTROL STRATEGY
13640-4 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 2. The instantaneous flow rate, daily maximum flow rate, daily minimum
2 flow rate, a daily flow total, and yesterday's flow total shall be displayed
I
4
3 at the HMI SCADA System. The HMI Scada System shall store the
daily flow totals for each day for the most recent 6 months and make
5 that data available for recall.
I6
7 B. Level Indicating Transmitters (LIT)
8
I 9 1. The level transmitters shall measure, record, and indicate the water
10 level in the structure they are installed within.
11
I
12 2. The water level in the various structures shall be displayed at the
13 appropriate OIT/HMI.
14
I
15 3. Each level transmitter shall have an operator adjustable low level
16 setpoint and high level setpoint that shall be indicated and alarmed at
17 the OIT/HMI. The low and high level setpoints shall shutdown
18 applicable equipment that is in operation and prevent equipment from
19 starting until the alarm conditions are cleared.
20
I
21
22 C. Headworks Grit Pumps (GP)
23 1. Four (4) constant speed grit pumps are to be installed as shown on the
24 Drawings.
25
26 2. Each grit pump shall have a control panel with a LOCAL -OFF -REMOTE
1
27 switch and an ON/OFF pushbutton switch mounted near each pump. In
28 addition, the new grit pumps and seal water solenoids shall be capable
29 of being controlled by the PLC in MCP -15 located in the SF -MCC room.
30 The grit pumps shall operate as follows:
31
32 a. In LOCAL, the pump shall run when the ON button is pushed
I33 and shall run in manual mode. No automatic control, interlocks,
34 or other safety features are available in this mode of operation.
35
I36 b. In OFF, the pumps shall turn off.
37
38 c. In REMOTE the pump shall be controlled from MCP -15. The
I39 HMI shall be capable of monitoring and displaying the run status,
40 trip status, and elapsed run time of each pump. In the REMOTE
I
41
42 mode, each pump shall be automatically controlled from the HMI
using individual 24-hour ON/OFF timers.
43
I
44
45 d. The seal water solenoid valves shall open when the pump
receives a run signal and shall close when the pump is stopped.
46
I47 D. Headworks New Grit Classifier (GC)
CONTROL STRATEGY
13640-5 12/18/2020
1
1
2 1 One (1) constant speed grit classifier is to be installed as shown on the
3 Drawings.
4
5 2. The Grit Classifier shall have a control panel with a LOCAL -OFF -
6 REMOTE switch and an ON/OFF pushbutton switch mounted in the
7 headworks building near the classifier and shall operate as follows:
8
9 a. In LOCAL, the classifier shall run when the ON button is pushed
10 and shall run in manual mode. No automatic control, interlocks,
11 or other safety features are available in this mode of operation.
12
13 b. In OFF, the classifier shall turn off.
14
15 c. In REMOTE the classifier shall be controlled by the PLC in MCP -
16 15. The grit classifier shall start and run when either of the grit
17 pumps associated with it are started. The HMI shall be capable
18 of monitoring and displaying the run status, trip status, and
19 elapsed run time of the motor starter for the grit classifier. No
20 control functions shall be available from the HMI.
21
22 d. A zero speed switch, torque overload switch, and emergency
23 stop switch shall be provided by the manufacturer and installed
24 by the Contractor for the new grit classifier. The PLC shall
25 monitor and the HMI shall display the status of the zero speed
26 switch, the torque overload switch, and the emergency stop
27 switch and shall initiate an alarm when these devices detect a
28 problem.
29
30 E. Headworks Existing Grit Classifier
31
32 1. The existing headworks grit classifier is operated from a control panel
33 located in the MCC room on the lower level of the headworks building.
34 That control panel will remain in service and will be re -powered from
35 Panel L15 in the SF MCC. All existing monitoring and control
36 capabilities by the existing plant SCADA system shall be maintained.
37
38 F. Moving Belt Filters (Salsnes Filters - SAF)
39
40 1. Three (3) Moving Belt Filters (Salsnes Filters — SAF) are to be installed
41 with provisions for a future fourth unit as shown on the Drawings.
42
43 2. Each of the three filters shall have a dedicated main control panel with
44 a dedicated PLC furnished by the SAF manufacturer. That PLC
45 controls all functions specific to that SAF, except the associated feed
46 pump and sludge pump for that SAF. Each dedicated main control
47 panel shall include a PLC, equipment controllers, motor starters, drives,
CONTROL STRATEGY
13640-6 12/18/2020
1
I1 etc. and will be located in the climate controlled building on the SAF
2 platform. Each main control panel shall include the following:
3
4 a. Operator Interface Terminal (OIT) located on the front enclosure
5 door.
I
6
7 b. Programmable Logic Controller (PLC): Allen Bradley Compact
Logix L16, or equal.
8 c. Belt Filter Variable Frequency Drive (VFD): Yaskawa V1000, or
I
9 equal
10 d. Blower Motor Starter: Allen-Bradley SMC -3 or equal.
11 e. Unfused main disconnect operated from a flange mount
I
12 disconnect switch, or door mount disconnect switch.
13 f. All other equipment as required, for automatic operation and
14 SCADA functions of the Belt Filter.
I
15 g. Fiber optic Ethernet switch for communications with the plant
16 SCADA system.
17
II
18 3. A secondary control panel shall be located on or near each individual
19 SAF and have LOCAL -OFF -REMOTE switches, ON/OFF pushbutton
20 switches, and speed controls. The secondary control panels shall
I
21 operate as follows:
22
23 a. In LOCAL, the feed pump motor, sludge pump motor, blower
24 motor, and belt drive motor shall run. Speed control for the feed
25 pump, the sludge pump, and the belt drive to be adjusted
26 manually by speed potentiometers located on the secondary
I
27
28 control panel. The blower shall run at constant speed.
29 b. In OFF, the feed pump motor, sludge pump motor, blower motor,
I30 and belt drive motor shall turn off.
31
I32 c. In REMOTE, the belt drive motor and blower motor shall be
33 controlled by the SAF control panel PLC. The feed pump motor,
34 and sludge pump motor shall be controlled by the main control
I35 panel PLC (MCP -15) located in the SAF electrical enclosure.
36
37 4. The secondary control panels shall be provided with a sun shield to
I38 prevent direct sun exposure on the enclosure.
39
40 5. All control panels shall be shipped pre -assembled and pre -tested for
I
41
42 field wire connections.
43 6. The SAF system controls shall be completely self-contained and
I
44
45 capable of automatic operation. All SAF system control parameters
shall be adjustable at their respective control panel OIT's, and
46 displayed at the HMI.
1 47
1
CONTROL STRATEGY
13640-7 12/18/2020
1
1 7. In AUTO, the filter belt speed shall be paced by the level in the filter 1
2 inlet compartment, as measured by SAF LIT. Operator adjustable level
3 setpoints shall be made available at the SAF OIT and displayed at the I 4 HMI.
5
6 8. Hot water spray shall be controlled via operator adjustable frequency
I
7 and duration timers at the SAF OIT and displayed at the HMI.
8
9 9. Reclaimed water flush shall be controlled via operator adjustable
I
10 frequency and duration timers at the SAF OIT and displayed at the HMI.
11
12 10. A pressure transducer shall be mounted on the Air Knife bayonet
I
13 coupling. The SAF PLC shall monitor for absolute pressure, high and
14 low pressure alarms.
15 I
16 11. The HMI shall be capable of communicating with each SAF PLC and
17 MCP -15 and shall monitor and display the status of all outputs of all
18 four PLCs. However, no control functions shall be available from the
19 HMI for the Salsnes Filters.
20
21 G. Salsnes Filter Feed Pumps (SAF FP)
I
22
23 1. The SAF feed pumps shall be controlled by an independent master
24 control panel (MCP -15), not supplied by the SAF manufacturer.
1
25
26 2. Three (3) feed pumps, with provisions for a future feed pump, are to be
27 provided as shown on the drawings and specified herein. 1
28
29 3. Each feed pump will be equipped with a variable speed drive (VFD) and
30 each shall have a dedicated local control panel with a LOCAL -OFF -
1
31 REMOTE switch and an ON/OFF pushbutton switch mounted near the
32 pump. The VFDs shall be mounted in the SF -MCC building. The feed
I
33 pumps shall operate as follows:
34
35 a. In LOCAL, the pump shall run when the ON button is pushed I 36 and shall have manual speed control. The speed shall be
37 adjustable with a 0-100% potentiometer located on the
38 respective local pump control panel. No automatic control,
39 interlocks, or other safety features shall be available in this mode
40 of operation.
41 1 42 b. In OFF, the pump shall turn off.
43
44 c. In REMOTE, the pump shall be controlled by the PLC in MCP- I 45 15. The speed of the pump shall be automatically controlled
46 using a PID loop to maintain a preset adjustable SAF influent
47 flow set point selected by the operator. In REMOTE, a level
I
CONTROL STRATEGY
13640-8 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 indicating transmitter in the splitter box shall activate an alarm
2 and shall shut down all operating feed pumps on low level. The
3 Salsnes Filter feed pump flow rate in GPM shall be displayed on
4 the MCP -15 HMI. The flow setpoint in GPM shall be readily
5 changed from the MCP -15 HMI.
6
7 d. For each pump the OIT/HMI shall be capable of monitoring,
8 displaying, and archiving in digital or graphical format the
9 parameters listed below.
10 • The run status and trip status of the motor and VFD
11 • The speed of the motor on a 0-100% scale
12 • The instantaneous flow rate (gpm)
13 • The daily flow total (gallons) from each machine
14 • The sum of the daily total flows from all machines
15 (gallons)
16 • Daily flow totals shall be stored for a minimum of 6
17 months.
18 • Continuing elapsed run time
19
20 H. Salsnes Filter Sludge Pumps (SAF PP)
21
22 1. The SAF sludge pumps shall be controlled by an independent master
23 control panel (MCP -15) not supplied by the SAF manufacturer.
24
25 2. Three (3) SAF pumps, with provisions for a future fourth sludge pump
26 are to be provided as shown on the drawings and specified herein.
27
28 3. Each sludge pump will be equipped with a variable speed drive (VFD)
29 and each pump shall have a dedicated local control panel with a
30 LOCAL -OFF -REMOTE switch and an ON/OFF pushbutton switch
31 mounted near the pump. The VFDs shall be mounted in the SF MCC
32 building. The sludge pumps shall operate as follows:
33
34 a. In LOCAL, the pump shall run when the ON button is pushed
35 and shall have manual speed control. The speed shall be
36 adjustable with a 0-100% potentiometer located on the
37 respective local pump control panel. No automatic control,
38 interlocks, or other safety features shall be available in this mode
39 of operation.
40
41 b. In OFF, the pump shall turn off.
42
43 c. In REMOTE, the respective pump shall be controlled by the PLC
44 in MCP -15 to maintain sludge level in the dedicated SAF
45 discharge sludge hopper as measured by the level transmitter.
46 The sludge level shall be preset and adjustable by the plant
47 operator at the OIT/HMI. In REMOTE, the level indicating
CONTROL STRATEGY
13640-9 12/18/2020
1 transmitter in the sludge hopper shall activate an alarm and act
2 to shut down the sludge pump on low level, high discharge
3 pressure, or high stator temperature. The SAF sludge pump
4 speed RPM shall be displayed on the MCP -15 HMI. The sludge
5 hopper level and level setpoint shall be shown on the MCP -15
6 HMI.
7
8 d. For each pump, the HMI shall be capable of monitoring,
9 displaying, and archiving in digital or graphical format the
10 parameters listed below.
11 • The run status and trip status of the motor and VFD
12 • The speed of the motor on a 0-100% scale
13 • Continuing elapsed run time
14 • Pump discharge pressure and stator temperature
15
16 4. The pump manufacturer shall supply and the Contractor shall install a
17 pump discharge pressure monitor, a discharge pressure gauge, a
18 discharge pressure switch, a stator temperature monitor and a stator
19 temperature switch for each pump as previously described. The pump
20 discharge pressure gauge shall be visible from the local ON/OFF
21 Switch.
22
23 I. Flow Equalization Tank (FET)
24
25 1. One (1) flow equalization tank shall be constructed as shown on the
26 drawings and specified herein. Two (2) feed pumps and two (2) return
27 pumps shall be provided. Provisions for a third feed pump and a third
28 return pump shall be provided.
29
30 2. Each pump shall be driven at variable speeds and each shall have a
31 dedicated local control panel with a LOCAL -OFF -REMOTE switch, an
32 ON/OFF pushbutton switch, and a manual potentiometer with readout
33 mounted near the pump.
34
35 3. One (1) new Master Control Panel (MCP -16) shall be provided for
36 REMOTE control of the FET process, located in the new FET -MCC
37 electrical enclosure. MCP -16 shall be equipped with a PLC and an
38 OIT.
39
40 4. MCP -16 shall control all functions of the FET process except mixing. A
41 separate and independent control panel provided by the mixing process
42 equipment manufacture shall control the compressed air system (CAS).
43 The CAS control system shall include a PLC that shall communicate
44 with MCP -16.
45
46 5. The HMI shall be capable of communicating with the FET PLC and the
47 CAS PLC monitoring and displaying the status of all inputs and outputs
CONTROL STRATEGY
13640-10 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 of both PLCs. The only FET control function available from the HMI is
2 the plant flow rate set point. No other FET control functions shall be
3 available from the HMI.
4
5 J Flow Equalization Tank Supply Pumps (FET SP)
6
7 1. Two (2) FET feed pumps are being installed and provisions for a future
8 third pump shall be provided as shown on the drawings and specified
9 herein. Only two pumps shall be capable of operating simultaneously
10 with one pump designated as LEAD pump and the other pump
11 designated as LAG pump. Three pumps should never be operated
12 simultaneously. Should the third feed pump be installed, it will be
13 necessary to re -write the control strategy to accommodate the third
14 pump.
15
16 2. Each pump is variable speed and each shall have a dedicated local
17 control panel with a LOCAL -OFF -REMOTE switch and an ON/OFF
18 pushbutton switch mounted near the pump. The FET feed pumps shall
19 operate as follows:
20
21 a. In LOCAL, the pump shall run when the ON button is pushed
22 and shall have manual speed control. The speed shall be
23 adjustable with a 0-100% potentiometer located on the
24 respective local pump control panel. No automatic control,
25 interlocks, or other safety features shall be available in this mode
26 of operation.
27
28 b. In OFF, the pump shall turn off.
29
30 c. In REMOTE the pump shall be controlled remotely from the FET
31 PLC. The PLC shall have options for either manual or automatic
32 control.
33
34 d. When in REMOTE the status of each pump as a LEAD or LAG
35 pump must be determined. The FET PLC will make this
36 designation automatically and the LEAD pump will alternate each
37 on/off run cycle. The operator may override the lead pump
38 selection thru the OIT.
39
40 e. PLC logic and other equipment interlocks that must be satisfied
41 for feed pump operation in REMOTE include the following:
42 • The tank must not be at a high level condition
43 • The return pumps are disabled
44 • The desired plant flow rate set point has been entered by the
45 operator
46 • The actual plant influent flume flow rate is more than 10%
47 (adjustable) higher than the set point flow rate and has been
CONTROL STRATEGY
13640-11 12/18/2020
1 at that rate for a minimum of 30 minutes (adjustable).
2
3 3. When called for and when the conditions outlined previously are
4 satisfied, the LEAD pump shall start and run at an adjustable minimum
5 speed for an adjustable minimum length of time. The LEAD pump shall
6 operate at a variable speed throughout its range. After the LEAD pump
7 has reached an adjustable maximum speed for an adjustable length of
8 time, the FET PLC shall call the LAG pump to start and run at an
9 adjustable minimum speed for an adjustable minimum length of time.
10 When both pumps are running, both pumps shall operate in "load
11 sharing" mode such that both pump speeds are identical.
12
13 4. The PID loop logic consists of a flow meter signal from the existing
14 influent flume, a signal from new flow meters installed in the FET supply
15 pipe and return pipe, and an adjustable desired plant flow rate setpoint
16 input by the operator. The control signal to the feed pump VFDs is
17 generated by the PID loop which shall make the following equation true
18 at all times by increasing/decreasing the FET supply pipe flow or the
19 FET return pipe flow continuously:
20
21 • flume flow — FET supply pipe flow + FET return pipe flow = plant flow rate set point
22
23 5. A high level pump cutoff signal is provided by the FET level sensing
24 device and shall be adjustable with an initial setting equal to 1 -foot
25 below the overflow pipe invert. Upon reaching the high level cutoff
26 setpoint, a high level alarm shall be registered by the PLC, displayed at
27 the OIT/HMI and all feed pumps shall stop. The status of the feed
28 pumps shall remain unchanged until the high level alarm condition is
29 cleared.
30
31 6. The HMI shall be capable of monitoring, displaying, and archiving in
32 digital or graphical format at minimum the parameters listed below for
33 the feed pump system.
34 • The run status and trip status of the motor VFDs
35 • Motor amps
36 • The speed of the motor on a 0-100% scale
37 • The instantaneous flow rate (gpm)
38 • The daily flow total (gallons)
39 • Daily flow totals shall be stored for a minimum of 6 months.
40 • Continuing elapsed run time for each pump
41 • All alarms and high level cutoffs
42 • The tank level
43
44 K. Flow Equalization Tank Return Pumps (FET RP)
45
46 1. Two (2) FET return pumps are being installed and provisions for a
47 future third pump shall be provided as shown on the drawings and
CONTROL STRATEGY
13640-12 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 specified herein. Only two pumps shall be capable of operating
2 simultaneously with one pump designated as LEAD pump and the other
3 pump designated as LAG pump. Three pumps should never be
4 operated simultaneously. Should the third feed pump be installed, it will
5 be necessary to re -write the control strategy to accommodate the third
6 pumps.
7
8 2. Each pump is variable speed and each shall have a dedicated local
9 control panel with a LOCAL -OFF -REMOTE switch and an ON/OFF
10 pushbutton switch mounted near the pump.
11
12 a. In LOCAL, the pump shall run when the ON button is pushed
13 and shall have manual speed control. The speed shall be
14 adjustable with a 0-100% potentiometer located on the
15 respective local pump control panel. No automatic control,
16 interlocks, or other safety features are available in this mode of
17 operation.
18
19 b. In OFF, the pump shall turn off
20
21 c. In REMOTE the pump shall be controlled remotely from the FET
22 PLC.
23
24 d. When in REMOTE the status of each pump as a LEAD or LAG
25 pump must be determined. The FET PLC will make this
26 designation automatically and the LEAD pump will alternate each
27 on/off run cycle. The operator may override the lead pump
28 selection thru the OIT.
29
30 e. PLC logic and other equipment interlocks that must be satisfied
31 for feed pump operation in REMOTE include the following:
32 • The tank must not be at a low level condition
33 • The feed pumps are disabled
34 • The desired plant flow rate set point has been entered by
35 the operator
36 • The actual plant influent flume flow rate is more than 10%
37 (adjustable) lower than the set point flow rate and has
38 been at that rate for a minimum of 30 minutes
39 (adjustable).
40
41 3. When called for and when the conditions outlined previously are
42 satisfied, the LEAD pump shall start and run at an adjustable minimum
43 speed for an adjustable minimum length of time. The LEAD pump shall
44 operate at a variable speed throughout its range. After the LEAD pump
45 has reached an adjustable maximum speed for an adjustable length of
46 time, the PLC shall call the LAG pump to start and run at an adjustable
47 minimum speed for an adjustable minimum length of time. When both
CONTROL STRATEGY
13640-13 12/18/2020
1 pumps are running, both pumps shall run at the same speed.
2
3 4. The PID loop logic consists of a flow meter signal from the existing
4 influent flume, a signal from new flow meters installed in the FET supply
5 pipe and return pipe, and an adjustable desired plant flow rate setpoint
6 input by the operator. The control signal to the supply pump VFDs is
7 generated by the PID loop which shall make the following equation true
8 all the times:
9
10 • flume flow — FET supply pipe flow + FET return pipe flow = plant flow rate set point
11
12 5. A low level pump cutoff signal is provided by the FET level sensing
13 device and shall be adjustable with an initial setting of 4 feet of water
14 above the bottom. Upon reaching the low level cutoff setpoint, a low
15 level alarm shall be registered by the PLC, displayed at the OIT/HMI
16 and all return pumps shall stop, and all return pump MOVs shall close.
17 The status of the return pumps shall remain unchanged until the low
18 level alarm condition is cleared.
19
20 6. The HMI shall be capable of monitoring, displaying, and archiving in
21 digital or graphical format at minimum the parameters listed below for
22 the feed pump system.
23 • The run status and trip status of the motor VFDs
24 • Motor amps
25 • The speed of the motor on a 0-100% scale
26 • The instantaneous flow rate (gpm)
27 • The daily flow total (gallons)
28 • Daily flow totals shall be stored for a minimum of 6 months.
29 • Continuing elapsed run time for each pump
30 • All alarms and low level cutoffs
31 • The tank level
32
33 L. Compressed Air Mixing System (FET CAS)
34
35 1. The CAS is a stand-alone system with a master control panel, a valve
36 control panel and 2 air -compressors. These components shall be
37 supplied by the mixing system manufacturer. Control of the CAS is
38 described in the Compressed Gas Mixing System Specification and is
39 also provided by the CAS manufacturer.
40
41 2. The HMI shall be capable of monitoring, displaying, and archiving in
42 digital or graphical format at minimum the parameters listed below for
43 the CAS system.
44 • The run status and trip status of the compressor motors
45 • Compressor motor amps
46 • Compressor temperature status
CONTROL STRATEGY
13640-14 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 • Intake filter differential pressure
2 • System pressure in PSI
3 • Elapsed run time for each compressor
4 • All alarms and equipment cutoffs
5
6 M. Scum Pumps (SCP)
7
8 1. One constant speed progressive cavity scum pump and control panel
9 shall be provided as shown on the drawings and specified herein.
10
11 2. The scum pump shall have a dedicated local control panel with a
12 manual ON/OFF switch mounted such that the level in the scum well is
13 visible from the control panel. The starter for the scum pump shall be
14 mounted inside the scum pump control panel.
15
16 3. Control of this pump will be manual by the plant operator.
17
18 4. The pump manufacturer shall supply and the Contractor shall install a
19 pump discharge pressure monitor, a discharge pressure gauge, a
20 discharge pressure switch, a stator temperature monitor and a stator
21 temperature switch for the scum pump.
22
23 5. The pressure and temperature monitors and switches shall activate an
24 alarm in the control panel and act to shut down the scum pump on high
25 discharge pressure or high stator temperature.
26
27 6. The scum pump control panel shall be equipped with an analog hour
28 meter to track elapsed run time for the pump.
29
30 N. Existing Mechanical Screens
31
32 1. The Contractor shall furnish the services of the manufacturer of the
33 existing screenings equipment as necessary to reset the level controls
34 (elevations initiating automatic raking mechanism) for proper operation
35 of the screen at the higher downstream depths resulting from the
36 improvements to the grit system.
37
38 O. Macerator
39
40 1. One (1) constant speed sludge Macerator shall be installed as shown
41 on the Drawings.
42
43 2. A control panel shall be furnished for the Macerator with a LOCAL -OFF -
44 REMOTE switch and an ON/OFF pushbutton switch mounted adjacent
45 to the Macerator and shall operate as follows:
46
47 a. In LOCAL, the Macerator shall run when the ON button is
CONTROL STRATEGY
13640-15
12/18/2020
1 pushed and shall run in manual mode. No automatic control,
2 interlocks, or other safety features are available in this mode of
3 operation.
4
5 b. In OFF, the Macerator shall turn off.
6
7 c. In REMOTE the classifier shall be controlled by the PLC in MCP -
8 15. The grit classifier shall start and run when any of the sludge
9 pumps associated with the Moving Belt Filters are operated. The
10 HMI shall be capable of monitoring and displaying the run status,
11 trip status, and elapsed run time of the motor starter for the
12 Macerator. No control functions shall be available from the HMI.
13
14 P. Lift Station #2
15
16 1. One (1) constant speed duplex lift station shall be rehabilitated
17 as shown on the Drawings.
18
19 2. One new Nema 4X control panel shall be furnished for the lift
20 station with typical duplex pump controls including a pump
21 alternator, audible and visual alarms, phase detection and
22 protection, ultrasonic water level detection with backup floats,
23 provisions for connection to a remoter generator, elapsed time
24 meters for both pumps, moisture detectors for the pump seal
25 systems, lightning and surge protection systems.
26
27 3. The lift station control panel shall be provided by the pump
28 supplier.
29
30 1.05 TAG NAMES
31
32 A. Tag names shall be furnished for all equipment. The tag names listed below
33 do not necessarily represent all equipment included in the project. Any
34 equipment not listed below that is shown elsewhere in the Drawings or
35 specifications shall be furnished and installed and identified using the following
36 tag naming scheme.
37
38
Tag Name Description
Grit Removal System
GP 1-4 Grit Pumps 1-4
GP LCP 1-4 Grit Pump Local Control Panels
GS CP Grit System Control Panel
GC Grit Classifier
GC ZSW Grit Classifier Zero Speed Switch
Salsnes Filters
CONTROL STRATEGY
13640-16 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SAF 1-3
SAF CP 1-3
SAF FP 1-3
SAF FP LCP 1-3
SAF FP FM 1-3
SAF FP LIT
SAS LIT 1-3
SAS BL 1-3
SAS BL PIT 1-3
SAF SP 1-3
SAF SP LCP 1-3
SAF CP CP
SAF SP LIT 1-3
SAF SV 1-9
SAF MAC 1
Salsnes Filters 1-3
Salsnes Filters Control Panels 1-3
Salsnes Filters Feed Pumps 1-3
Salsnes Filters Feed Pump Local Control Panels 1-3
Salsnes Filter Feed Pump Flow Meter 1-3
Salsnes Filter Feed Pump Level Detector
Salsnes Filter Level 1-3
Salsnes Filter Blower 1-3
Salsnes Filter Blower Pressure Transmitter 1-3
Salsnes Filters Sludge Pumps 1-3
Salsnes Filters Sludge Pump Local Control Panels 1-3
Salsnes Filter Common Pump Control Panel
Salsnes Filter Sludge Pump Level Detectors 1-3
Salsnes Filter Solenoid Valve 1-9
Salsnes Filter Sludge Macerator
Flow Equalization Tank
FET MCP Flow Equalization Tank Master Control Panel
FET LIT Flow Equalization Tank Level Detector
FET SP 1-2 Flow Equalization Tank Supply Pumps 1-2
FET SP LCP 1-2 Flow Equalization Tank Supply Pumps Local Control Panels 1-2
FET SFM Flow Equalization Tank Supply Flow Meter
FET RP 1-2 Flow Equalization Tank Return Pumps 1-2
FET RP LCP 1-2 Flow Equalization Tank Return Pumps Local Control Panels 1-2
FET RFM Flow Equalization Tank Return Flow Meter
FET COM 1-2 Flow Equalization Tank Compressor 1-2
FET CAS MCP Flow Equalization Tank Compressed Air Mixing System Master
Control Panel
FET AC LCP 1-2 Flow Equalization Tank Air Compressors Local Control Panels
1-2
FET SV 1-13 Flow Equalization Tank Solenoid Valves 1-13
1
2 PART 2 — PRODUCTS (NOT USED)
3
4 PART 3 — EXECUTION
5
6 3.01 INSTRUMENTATION LEGEND
7
8 A. The following table is the legend for the instrumentation drawings included in
9 the Contract Documents.
10
CONTROL STRATEGY
13640-17 12/18/2020
1
23
4
5
6
END OF SECTION
CONTROL STRATEGY
13640-18 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
First Letters
Succeeding Letters
Measuredllnitiating
Variable
Variable
Modifier
Readout/Passive
Function
Output/Active
Function
Function
Modifier
A
Analysis
Alarm
B
Burner, Combustion
User's Choice
User's Choice
User's Chace
C
Users Choice
Control
Close
D
User's Choice
Difference. Differential
Deviation
E
Voltage
Sensor, Primary
Element
F
Flow, Flow Rate
Ratio
G
Users Choice
Glass, Gauge, Viewing
Device
H
Hand
High
1
Current
Indicate
J
Power
Scan
K
Time. Schedule
Time Rate of Change
Control Station
L
Level
Light
Low
M
User's Choice
Middle, Intermediate
N
Users Choice
User's Choice
User's Choice
User's Choice
O
User's Choice
Orifice, Restriction
Open
p
Pressure
Point (Test Connection)
Q
Quantity
Integrate, Totalize
Integrate. Totalize
Run
R
Radiation
Record
S
Speed, Frequency
Safety
Switch
Stop
T
Temperature
Transmit
U
Multivariahle
Multifunction
Multifunction
V
Vibration, Mechanical
Analysis
Valve, Damper. Louver
W
Weight, Force
Well, Probe
X
Unclassified
X-axis
Accessory Devices,
Unclassified
Unclassified
Unclassified
Y
Event, State, Presence
Y-axis
-
Auxiliary Devices,
Z
Position, Dimension
Z-axis, Safety
Instrumented System
Driver. Actuator, Unclassified
final control element
END OF SECTION
CONTROL STRATEGY
13640-18 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 13650
2
3 FIBER OPTIC CABLE
4
5 PART 1 - GENERAL
6
7 1.01 DESCRIPTION
8
9 A. Contractor shall provide all labor, materials, equipment and incidentals as
10 shown, specified and required to furnish and install fiber optic cabling, including
11 fiber testing, accessories and splicing requirements.
12
13 B. The entire fiber optic system is considered to be one component and provided
14 by a single source, hereafter referred to as the Supplier.
15
16 C. The Contractor shall furnish and install fiber optic (FO) data lines and connection
17 equipment for the following:
18
19 1. Fiber optic cable for connection of all SCADA system equipment as
20 shown on the Drawings.
21
22 1.02 REFERENCES
23
24 A. Standards referenced in this Section are listed below:
25
26 1. ASTM D 1248, Specification for Polyethylene Plastics Molding and
27 Extrusion Materials.
28
29 2. ASTM D 1603, Test Method for Carbon Black in Olefin Plastics.
30
31 3. ASTM D 1765, Classification System for Carbon Blacks used in Rubber
32 Products.
33
34 4. ASTM D 3349, Test Method for Absorption Coefficient of Ethylene
35 Polymer Material Pigmented with Carbon Black.
36
37 1.03 SUBMITTALS
38
39 A. Shop Drawings: Submit the following:
40
41 1. Cut sheets and catalog literature for proposed fiber optic cable, and fiber
42 optic cable accessories (terminations).
43
44 2. Manufacturer specifications and data clearly and unambiguously
45 showing that the fiber optic cable meets all the requirements specified
46 herein.
47
FIBER OPTIC CABLE
13650-1 03/20/2020
1 3. Samples of the proposed cable.
2
3 4. Physical dimensional drawings of all fiber optic accessories.
4
5 5. Proposed fiber identification sequence and labeling.
6
7 6. Provide a Recommended Spare Parts List (RSPL).
8
9 1.04 MAINTENANCE AND SPARE PARTS
10
11 A. Provide off-line maintenance aids and on-line diagnostics to check the
12 performance of the communication links and interfaces of devices on the data
13 highway.
14
15 B. Provide a list of recommended special tools for fiber installation, testing or
16 maintenance.
17
18
19
20
21 D. Furnish to the Owner one hand-held optical power meter with ATT -compliant
22 adapters (SC or ST), Corning, or equal.
23
24 PART 2 - PRODUCTS
25
26 2.01 FIBER OPTIC CABLE SUMMARY SPECIFICATIONS
27
28 A. The Contractor shall use multimode fiber where distances between connecting
29 equipment are within the fiber optic cable manufacturer's recommended
30 maximum distance. The Contractor shall submit to the Engineer, for approval,
31 the type of fiber optic cable that shall be used if distances between connecting
32 equipment exceed the multimode fiber optic cable manufacturer's
33 recommendation. The fiber optic cable shall meet the following summary
34 specifications:
35
C. Furnish to the Owner one (1) hand-held optical light source with ATT -compliant
adapters (SC or ST), Corning, or equal.
36
37
38
39
40
41
42
43
44
45
46
47
1. Fiber Type: Multimode.
2. Core Diameter: 62.5 microns.
3. Cladding Diameter: 125 microns.
4. Cable Outside Diameter: 13.30 -mm (0.52 -in).
5. Cable Weight: 191 kg/km (128 lbs/1000 ft).
6. Maximum Attenuation: 3.5 dB/km at 850 nm, 1.0 dB/km at 1300 nm.
7. Bandwidth: 160/500 (MHZ X km)2.
8. Buffer Type: Loose tube, gel filled.
9. Number of Fibers: Twenty-four (24)
10. Cable Central Strength Member: Dielectric.
11. Cable Fill: Waterbocked, gel -free
12. Outer Jacket: MDPE.
FIBER OPTIC CABLE
13650-2 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 13. Maximum Pulling Load: 600 Ibf (2700 N).
2 14. Operating Temperature Range: -40°C to +70°C.
3 15. Parallel Plate Crush Resistance: 400 Ibf.
4 16. Quantity: As shown.
5 17. Packaging: Spools/reels, protected from shipment.
6
7 B. Fibers within the cable shall be color -coded so that each fiber may be
8 individually identified. The color sequence suggested is as follows: blue,
9 orange, green, brown, slate, white, red, black, yellow and violet. Dashed
10 versions of the same colors may be used to continue the sequence, depending
11 on the cable structure and fiber count.
12
13 C. The outer jackets of the cable shall be continuous, free from holes, splits,
14 blisters or inclusions. The same requirement holds for any inner jackets within
15 a given cable structure as well as for fiber coatings.
16
17 D. Materials used for fiber optic cable shall present no environmental or
18 toxicological hazards as defined by current industry standards and shall comply
19 with OSHA and EPA standards or applicable federal or state laws or regulations.
20
21 E. The color of the polyethylene outer jacket material shall be black in accordance
22 with ASTM D 1248, and contain a suitable antioxidant substance. The carbon
23 black used shall be furnace -type conforming to designation N 110 in accordance
24 with the requirements of ASTM D 1765. The carbon black content in the jacket
25 material when measured in accordance with the requirements of ASTM D 1603
26 shall be 2.6 percent ±0.25 percent by weight. The Tight absorption coefficient of
27 the jacket material shall be at least 400 when measured at a wavelength of 375
28 nm in accordance with the requirements of ASTM D 3349.
29
30 1. Outer polyethylene jacket materials shall meet tensile strength and
31 elongation minimum requirements for unaged and aged samples as
32 follows:
33
34 a. Tensile Strength at Break: 2800 psi (Unaged), 2100 psi (Aged).
35 b. Elongation at Rupture: 400 percent (Unaged), 375 percent
36 (Aged).
37
38 F. The cable jacket shrinkage test measures the shrinkage or expansion of a cable
39 jacket exposed to temperature aging for a specified period of time. Maximum
40 shrinkage shall be Tess than five percent for each specimen tested. The test
41 procedure is described in EIA -RS -455, FOTP-86.
42
43 2.02 CABLE PACKAGING
44
45 A. The cable shall be permanently marked to identify the manufacturer, date of
46 manufacture, length markings, a product identification code, and UL messages,
47 where appropriate. The markings shall be printed at regular intervals of not
FIBER OPTIC CABLE
13650-3
03/20/2020
1
1 more than two feet apart. 1
2
3 B. The cable shall be packaged on a reel with inner hub diameter greater than the
4 recommended minimum bending diameter of the cable. The anchor holes on I
5 the reels shall admit a 2 -1/2 -inch diameter spindle without binding. The package
6
7 shall be sturdy enough to endure reasonable handling in the process of shipping I
and storage. The package shall bear the name of the manufacturer, the product
8 identification code and the total amount of product on the reel.
9
10C. The following information shall be securely attached to the reel as a tag or
11 clearly and permanently stenciled or labeled on each reel:
12 I 13 1. Customer Order Number.
14 2. Customer Job Number.
15 3. Customer Reel Number. I 16 4. Termination.
17 5. Ship Date.
18 6. Manufacturer's Name.
1
19 7. Factory Reel Number.
20 8. Manufacturer's Cable Code (Type and Fiber count).
21
22 9. Length of Cable.
I
10. Weight of Cable and Reel.
23 11. Defect Tag.
24
1
25 D. The ends of all cable shall be sealed to prevent the escape of filling compound
26 and to prevent the entry of moisture during shipping, handling, storage and
27 installation. 1
28
29 2.03 ADDITIONAL FIBER
30 1 31 A. The fiber count of the cable shall be as specified above. Each fiber will be tested
32 at the completion of cable installation to verify that there are, indeed, the total
33 quantity of fibers, which conforms to these Specifications.
I
34
35 B. Contractor may, at their option, furnish a cable with more than the specified
36 numbers of fibers to allow for accidental fibers damaged during installation. 1
37
38 2.04 FIBER OPTIC CABLE MANUFACTURER
39
I
40 A. Manufacturers: Provide products of one of the following:
41
42 1. Corning Inc.
I
43 2. Lucent.
44 3. Or equal.
45
46 2.05 MANUFACTURER TEST DOCUMENTATION
47
FIBER OPTIC CABLE
13650-4 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Test documentation from the fiber optic cable manufacturer shall be delivered
2 to the Engineer upon delivery of the cable to the Site, as a prerequisite for cable
3 installation.
4
5 B. The documentation shall include Optical Time Domain Reflectometer (OTDR)
6 traces for each fiber of each reel at 850 nm and 1300 nm. Optical attenuation
7 test data shall be furnished for each fiber of each reel, as measured at 850 nm
8 and 1300 nm.
9
10 2.06 PRE -INSTALLATION TESTING
11
12 A. Contractor shall test the fiber optic cable prior to its installation. This testing
13 shall be witnessed by the Engineer.
14
15 B. Testing shall consist of making an OTDR trace of each fiber of each reel, at both
16 850 nm and 1300 nm. The test shall incorporate a one km long backscatter
17 suppression cable inserted between the OTDR and the fiber end. Each trace
18 shall include the optical length and average attenuation.
19
20 C. The results of the testing shall be submitted to the Engineer prior to installation.
21 Any cable that shows "out -of -spec" performance shall be replaced, at no
22 additional cost to the Owner.
23
24 2.07 CABLE TERMINATION ENCLOSURE AND HARDWARE
25
26 A. Cable termination enclosures shall be furnished and installed at each site
27 accessed by fiber optic cable. The enclosures shall be used to terminate each
28 fiber of the cable.
29
30 B. The enclosures/cabinets shall be suitable to be mounted within a control panel
31 and having provisions for terminating multiple fiber optic cables. Splice trays,
32 strain relief cable attachment points, fiber organizers and bend radius hardware
33 shall be furnished within each termination cabinet. The cabinets shall be
34 furnished with an integral lock to prevent unauthorized entry. All locks shall be
35 keyed identically, and two keys shall be furnished for each cabinet installed.
36
37 C. The enclosure cabinets shall house a patch panel internally. The patch panel
38 shall swing out for ease of use. Panel size shall be suited to the number of
39 fibers in the cable, for both directions. Bayonet/flanged couplings shall be
40 furnished and mounted for each fiber to be terminated.
41
42 D. The termination enclosure shall have a swing -down front door that provides
43 access to all splice trays and patch panels. They shall be sized to accept two,
44 12 fiber cables and provide space for unstripped, coiled cable, each being up to
45 25 feet long.
46
47 E. The cable termination enclosures and hardware shall be manufactured by
FIBER OPTIC CABLE
13650-5 03/20/2020
1 Blackbox, or equal.
2
3 2.08 PIGTAIL CABLES AND CONNECTORS
4
5 A. Each of the fibers shall be terminated by splicing pigtails in the termination
6 enclosures.
7
8 B. Pigtails shall be nine feet long. They shall be multimode for operation at 850
9 nm and 1300 nm, loose -buffered and manufactured from fiber meeting these
10 Specifications described for the main cable.
11
12 C. All connectors shall be identical. They shall be stainless steel AT&T and be
13 compatible with the equipment to which the fiber optic cable is connected.
14
15 2.09 SPLICING
16
17 A. Contractor shall field splice each fiber to a pigtail cable at the termination
18 enclosures. All splices shall be made by the fusion process and shall have a
19 splice loss no greater than 0.35 dB. Loss measurement shall be performed at
20 the time of splicing and documentation shall be furnished for each splice. Splice
21 testing shall be witnessed by the Engineer.
22
23 B. Prior to stripping the cable, Contractor shall record the cable length from the
24 cable jacket. This length shall be documented and included in the test
25 documentation, specified elsewhere.
26
27 2.10 COMMUNICATIONS PULL BOXES
28
29 A. Pull boxes shall be manufactured of fiber reinforced polymer concrete. Minimum
30 dimensions shall be 24" wide x 36" long x 30" deep.
31
32 B. Pull boxes shall be equipped with cable racking on both long walls, suitable to
33 support fiber optic cable of all sizes.
34
35 C. All pull boxes shall be provided with 20K traffic -rated lids. Lids shall have the
36 identification marking of "FIBER OPTIC" permanently indented in the cover.
37
38 2.11 FINK PLATED MARKER POSTS
39
40 A. All fiber optic cables shall be furnished with fiber optic and electrical buried Fink
41 Plated marker warning posts that meet the following requirements:
42
43 1. Material: Composite reinforced thermoplastic, or High Density Polymer.
44 2. Length: 6 ft.
45 3. Top: Domed Cap
46 4. Color: White Post and Cap (orange cap at pull box)
47 5. Text: Caution Buried Communication Cable Call (front and back).
FIBER OPTIC CABLE
13650-6
03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 6. Text Color: Black on Orange Background.
2 7. Width: 3 -inch minimum (diameter).
3 8. Phone number to call if line is hit
4
5 B. Fink Plated marker warning posts, (Model 303 or current Model) shall be
6 provided by Pro -Mark or approved equal.
7
8 C. Marker post shall be installed at 100 feet spacing and shall be buried a minimum
9 18 -inch and encased in 12 -inch deep concrete footing.
10
11 2.12 DETECTION WIRE AND WARNING TAPE
12
13 A. Fiber optic warning tape shall be bright orange color, minimum 3 -inches wide.
14 Warning tape shall be installed for the full length of the cable or conduit run.
15
16 B. Warning tape shall be marked "WARNING FIBER OPTIC CABLE."
17
18 C. Warning tape shall be buried 12 -inches below existing grade.
19
20 D. The tape shall be a dielectric, polyolefin film tape. The tape shall be
21 constructed using material and ink colors, which will not change when
22 exposed to acids and other destructive substances commonly found in the
23 soil.
24
25 E. Detection wire of #12 gauge (minimum) shall be woven into the tape.
26
27 2.13 CONDUIT
28
29 A. All fiber optic cable shall be installed in conduit specified herein. Conduit shall
30 be manufactured from virgin high-density polyethylene. Conduit shall be
31 extruded from colored material for uniform full-thickness coloring. Where
32 striping is required, a minimum of three colored longitudinal stripes of HDPE
33 material shall be co -extruded on the conduit outer wall. The three stripes shall
34 be equally spaced around the circumference and continuous for the entire
35 length of conduit. Printed or embossed striping is not permitted.
36
37 B. All conduit shall be labeled with durable identification giving the name of the
38 manufacturer, conduit size (inner diameter trade size and wall thickness/rating),
39 manufacture/date codes, and sequential foot marking. Labeling shall occur a
40 maximum of every 2 feet. Conduits to be used in bends and sweeps shall have
41 a minimum burn through time of 30 minutes when tested in accordance with
42 Generic Requirement GR -356 -CORE, Issue 1, October 1995.
43
44 C. Conduits shall be 2 in. diameter and shall conform to ASTM D-3035 meeting
45 the following requirements:
46
47 1. Smoothwall SDR 11
FIBER OPTIC CABLE
13650-7 03/20/2020
1 2. Nominal outer diameter: 2 in
2 3. Minimum inner diameter: 2 in.
3 4. Minimum wall thickness: 0.151 in.
4
5 D. Conduits shall be factory treated with an atomized silicone or manufactured in
6 a manner to reduce friction during pulling of fiber optic cable.
7
8 PART 3 - EXECUTION
9
10 3.01 CABLE INSTALLATION
11
12 A. AH fiber optic cable shall be installed, terminated, and tested by the fiber
13 subcontractor specified above.
14
15 B. In pulling the cable, strain -release, or other tension limiting devices shall be
16 used to limit the pull tension to less than 600 pounds. The Engineer shall
17 witness the cable being pulled.
18
19 C. Minimum bend radius restrictions shall be satisfied both during and after cable
20 installation.
21
22 D. All conduit and cabinet entrances shall be sealed with RTV or other re -enterable
23 sealant material to prevent ingress of water, dust or other foreign materials.
24
25 E. Splices in the fiber optic cable shall only be made at termination points where
26 connectorized pigtails are applied. Non -terminating field splices shall not be
27 made, unless authorized by the Engineer, in writing. If a field splice is required,
28 it shall be fusion spliced and placed in a buried pull box. Closures shall be AT&T
29 UCB1 with Type 2000 outer case, Siecor SC5, or equal. Encapsulant shall be
30 placed between inner and outer closures. Such splices shall meet the loss
31 parameters/testing requirements specified elsewhere.
32
33 3.02 CABLE DAMAGE DURING INSTALLATION
34
35 A. If the cable is damaged during installation, Contractor shall stop operations and
36 notify the Engineer, in writing, immediately. The Owner and Engineer will decide
37 whether to replace the entire reel of cable or to install a splice at the damaged
38 section.
39
40 B. If the Owner decides to replace the entire reel of cable, Contractor shall begin
41 the installation at the last designated splice point. The damaged cable between
42 these points shall be removed, coiled, tagged, and given to the Owner.
43 Installation of new cable to replace damaged cable shall not be a basis of extra
44 payment.
45
46 C. If the Owner decides to install a splice at the damaged point, and the cable is
47 damaged a second time, the entire reel of damaged cable (and all subsequent
FIBER OPTIC CABLE
13650-8 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 damaged reels) shall be replaced with new reels at the Contractor's expense.
2
3 3.03 CABLE ACCEPTANCE TESTING
4
5 A. Acceptance testing of the data highway (fiber and electronic equipment) shall
6 be conducted as a part of integrated system field-testing, as specified
7 elsewhere. Prior to such tests, however, the fiber optic cable shall be tested as
8 specified herein.
9
10 B. The Contractor shall conduct fiber optic cable testing as specified below. All
11 testing shall be witnessed by the Engineer and the Owner. A test plan shall be
12 submitted at least one week prior to the proposed test date(s). The test plan
13 and procedures shall be mutually agreed upon prior to conducting the tests.
14
15 C. Each optical fiber in every span shall be tested after installation and termination.
16 For each fiber, an OTDR trace hardcopy shall be provided. This end-to-end
17 trace shall be performed from BOTH ends of the fiber. The traces shall be made
18 at 850 nm and 1300 nm. Also for each fiber, and end-to-end power attenuation
19 (insertion loss) test shall be performed from BOTH ends of the fiber. The
20 attenuation test shall use a stabilized optical source and an optical power meter
21 calibrated to the appropriate operating wavelength (850 nm and 1300 nm).
22
23 D. For each installed fiber, the power attenuation shall not exceed the following,
24 tested from connector to connector at the respective patch panels, at 850 nm
25 and 1300 nm. For the 1300 nm test, substitute 0.0020 for 0.0035 in the first
26 term of the equation.
27
28 (0.0035)L + (0.35)N + 3.0 dB
29
30 where L = the length of the fiber in meters, and
31 N = the number of fusion splices in the fiber.
32
33 E. Any fiber optic cables containing one or more fibers not meeting this
34 performance criteria will not be accepted by the Owner, and shall be repaired
35 or replaced at no additional cost to the Owner.
36
37 F. All fiber optic testing shall be documented on approved test forms. Three copies
38 of all documents (including OTDR traces) shall be submitted to the Engineer
39 upon successful completion of the testing.
40
41 G. Work at the termination cabinets shall be performed such that the fiber optic
42 cables, and the fibers, are not subjected to undesirable bending both during the
43 Work and when permanently fixed in place. The cables, fibers, pigtails, etc.
44 shall be organized in a neat and orderly fashion within the enclosure. Inspection
45 of the Work shall be performed by the Engineer. Unsatisfactory Work shall be
46 reworked.
47
FIBER OPTIC CABLE
13650-9 03/20/2020
1
2
3
4
5
6
7
END OF SECTION
THIS PAGE INTENTIONALLY LEFT BLANK
FIBER OPTIC CABLE
13650-10 03/20/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15010
2
3 BASIC MECHANICAL REQUIREMENTS
4
5 PART 1 — GENERAL
6
7 1.01 RELATED DOCUMENTS
8
9 Drawings and general provisions of the Contract, including all specification sections
10 apply to the work.
11
12 1.02 SUMMARY
13
14 This Section specifies the basic requirements for mechanical installations and includes
15 requirements common to more than one section of these specifications.
16
17 1.03 ACCESSIBILITY
18
19 Equipment and materials shall be installed allowing for adequate access for service.
20 Coordinate the final location of concealed equipment with the final location of access
21 panels and doors. Allow ample space to remove all parts that may be replaced or
22 require service. Extend all grease fittings to an accessible location.
23
24 1.04 MECHANICAL INSTALLATIONS
25
26 A. Coordinate mechanical equipment and materials installation with other building
27 components. Verify all dimensions by field measurements. Verify final locations
28 for rough -ins with field measurements and with the requirements of the actual
29 equipment to be connected. Arrange for chases, slots, and openings in other
30 building components to allow for mechanical installations.
31
32 B. Coordinate the installation of supporting devices and sleeves to be set in poured
33 in place concrete and other structural components, as they are constructed.
34 Sequence, coordinate, and integrate installations of mechanical materials and
35 equipment for efficient flow of the work. Give particular attention to Targe
36 equipment requiring positioning.
37
38 C. Where mounting heights are not detailed or dimensioned, install mechanical
39 services and overhead equipment to provide the maximum headroom possible.
40 Coordinate the installation of mechanical materials and equipment above
41 ceilings with suspension system, Tight fixtures, and other installations.
42
43 D. Coordinate connection of mechanical systems with exterior underground and
44 overhead utilities and services. Comply with requirements of governing
45 regulations, franchised service companies, and controlling agencies. Provide
46 required connection for each service.
BASIC MECHANICAL REQUIREMENTS
15010-1 03/22/2019
1
2
3 1.05 NAMEPLATE DATA
4
5 Provide permanent operational data nameplate on each item of power operated
6 mechanical equipment, indicating manufacturer, product name, model number, serial
7 number, capacity, operating and power characteristics, labels of tested compliances,
8 and similar essential data. Locate nameplates in an accessible location.
9
10 1.06 THIRD PARTY CERTIFICATION
11
12 All packaged equipment shall be Independently Third Party labeled as a system for its
13 intended us by a Nationally Recognized Testing Laboratory (NRTL) in accordance with
14 OSHA Federal Regulation 29CFR1910.399 and NFPA 70, "National Electrical Code"
15 (NEC), Article 90-7.
16
17 PART 2 — PRODUCTS (NOT USED)
18
19 PART 3 — EXECUTION (NOT USED)
20
21
22 END OF SECTION
BASIC MECHANICAL REQUIREMENTS
15010-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15062
2
3 DUCTILE IRON PIPE AND FITTINGS
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. The Contractor shall furnish all the materials, tools, labor, supervision and
10 appliances for and properly install, connect, adjust, test and place in continuous
11 satisfactory service all ductile iron pipe and fittings at the locations and to the
12 elevations indicated, specified or required for the proper completion of all work.
13
14 B. Wherever Construction activities disturb existing conditions or work already
15 completed, Contractor shall restore the same to its original condition in every
16 detail. All such replacement and repair shall be a no additional expense to the
17 Owner.
18
19 C. Ductile iron pipe and fittings are not necessarily completely indicated or detailed
20 on the Construction Drawings. The Drawings are schematic only, and indicate
21 pipe and fittings in a general way. It is the Contractor's responsibility to furnish
22 all materials, pipe and fittings required.
23
24 D. It is the intent of these Contract Documents to require an installation, complete
25 in every detail, whether or not indicated on the Construction Drawings, or
26 specified herein. Consequently, the Contractor shall be responsible for all
27 details, devices, accessories, and special construction necessary to properly
28 furnish, install, adjust, test, place into continuous satisfactory service, and
29 complete the Work in an acceptable manner.
30
31 E. Full responsibility for designing, fabricating, and installing the ductile iron pipe
32 and fittings, for selecting materials of construction, and for demonstrating
33 compliance with specified performance requirements shall rest with the
34 Contractor, and through the Contractor, the Manufacturer and the Material
35 Supplier. The Engineer's review of 1) the manufacture and installation of the
36 ductile iron pipe and fittings 2) the use of materials included in this Specification,
37 and 3) alternative materials offered by the Contractor, shall not relieve the
38 Contractor and Supplier of full responsibility for meeting all performance
39 requirements and guarantees.
40
41 F The requirements of this specification 15062 supersede relevant articles in
42 Section IV.
43
44 1.02 DESCRIPTION OF SYSTEM
45
46 A. Piping shall be installed in the locations as shown on the Drawings and as
DUCTILE IRON PIPE AND FITTINGS
15062-1 03/22/2019
1 specified herein.
2
3 B. All pipe, fittings, specials and appurtenances used for potable water piping shall
4 be NSF -61 certified for continuous contact with potable water.
5
6 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
7
8 All Work specified herein shall be in accordance with the standards of the below listed
9 organizations, except as otherwise shown or specified. Where reference is made to a
10 standard of one of these, or other organizations the version of the standard in effect at
11 the time of bid opening shall apply.
12
13 American National Standards Institute (ANSI)
14 BI.1 - Standard Specification for Unified Inch Screw Threads.
15 B16.5 - Standard Specification for Pipe Flanges and Flanged Fittings and other
16 special Alloys.
17 American Society for Testing Materials (ASTM)
18 A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi
19 Tensile Strength.
20 C33 - Standard Specification for Concrete Aggregates.
21 C128 - Standard Specification for Specific Gravity and Absorption of Fine
22 Aggregate.
23 C144 - Standard Specification for Masonry Mortar.
24 C150 - Portland Cement.
25 D75- Standard Practice for Sampling Aggregates.
26 E8 - Methods of Tension Testing of Metallic Materials.
27 E23 - Methods for Notched Bar Impact Testing of Metallic Materials.
28 G95 - Cathodic Disbondment Test.
29
30 American Water Works Association (AWWA)
31 C104 - Standard for Cement - Mortar Lining for Ductile Iron Pipe and Fittings for
32 Water.
33 C105 - Standard for Polyethylene Encasement for Ductile -Iron Piping for Water
34 and Other Liquids.
35 C111 - Standard for Rubber - Gasket Joints for Ductile Iron Pressure Pipe and
36 Fittings.
37 C115 - American National Standard for Flanged Ductile -Iron Pipe with Threaded
38 Flanges.
39 C150 - Standard for the Thickness Design of Ductile Iron Pipe.
40 C151 - Standard for Ductile - Iron Pipe. Centrifugally Cast for Water or Other
41 Liquids.
42 C153 - Standard for Ductile Iron Compact Fittings. 3 -inch through 16 -inch for
43 Water and Other Liquids.
44 C600 - Standard for Installation of Ductile Iron Water Mains and Their
45 Appurtenances.
46 C651 - Standard for Disinfecting Water Mains.
DUCTILE IRON PIPE AND FITTINGS
15062-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 NSF International, The Public Health and Safety Company
3
4 No. 60 - Drinking Water Treatment Chemicals - Health Effects.
5 No. 61 -Drinking Water System Components - Health Effects.
6
7 1.04 SUBMITTALS
8
9 A. The Contractor shall submit Shop Drawings to the Engineer of pipe, fittings and
10 all appurtenances in accordance with these Contract Documents and Sections
11 01300 and 01340. The requirements of AWWA C110, C150, C151 and the
12 following supplemental requirements are applicable:
13
14 1. Certified dimensional drawings of all pipe, specials and fittings.
15
16 2. Joint and pipe/fitting wall construction details, which indicate the type and
17 thickness of the wall; manufacturing tolerances; performance history; and
18 all other pertinent information required for the manufacture of the
19 product.
20
21 3. Details of fittings and specials such as elbows, wyes, tees, outlets,
22 connections, test bulkheads, bosses and nozzles or other specials where
23 shown on the Construction Drawings, which indicate amount and position
24 of reinforcement. All fittings and specials shall be properly reinforced to
25 withstand the internal pressure both circumferential and longitudinal, and
26 the external loading conditions as indicated in the Contract Documents.
27 Shop Drawings shall clearly detail special castings indicating all pertinent
28 dimensions.
29
30 B. The Contractor shall furnish a certified affidavit of compliance for all pipe and
31 other products or materials furnished under this Section of the Specifications,
32 as specified in ANSI/AWWA C105, C110, C150, and C151; respectively, and
33 certified copies of the following supplemental data for all pipe, fittings, and
34 specials:
35
36 1. The Supplier shall provide, through the Contractor, a sworn statement
37 that the inspection and all specified tests have been made and all results
38 thereof comply with the requirements of these Specifications.
39
40 C. All expenses incurred in making samples for certification of tests and in the
41 preparation of any design reports shall be borne by the Contractor.
42
43 D. Review of the Shop Drawings shall not relieve the Contractor of the
44 responsibility to ensure that the pipe is designed and installed in strict
45 accordance with the Contract Documents.
46
DUCTILE IRON PIPE AND FITTINGS
15062-3 03/22/2019
1 1.05 QUALITY ASSURANCE
2
3 A. The Contractor shall furnish materials under this Section that are new, unused
4 and as specified, or if not particularized herein, which are the best of their
5 respective kind, free of defects and imperfections, and suitable for the service
6 intended, subject to review by the Engineer.
7
8 B. The Contractor shall provide workmanship that is first class in every respect,
9 and have the installation performed by workmen thoroughly experienced in such
10 work. A neat and workmanlike appearance in the finished Work shall be
11 required.
12
13 C. The Contractor shall perform Work in accordance with all applicable laws and
14 regulations and in accordance with all applicable permits and easements.
15
16 D. The ductile iron pipe furnished under this Specification shall comply with AWWA
17 C151 except as it may be modified herein.
18
19 E. Welders and welding methods shall be certified to a nationally recognized
20 welding specification for the type of ductile iron used to manufacture the pipe
21 and fittings.
22
23 F. All test equipment used in activities affecting quality control shall be calibrated
24 and certified at no longer than annual intervals, unless otherwise specified or
25 required.
26
27 G. All pipe shall be clean, sound, and without defects. No manner of repair will be
28 accepted, unless otherwise specified by the Engineer.
29
30 H. The Contractor, at no additional cost to the Owner, shall perform all the testing
31 and recording that is required in these Specifications unless otherwise specified.
32
33 I The Engineer shall have the right to determine the amount of pipe to be rejected
34 as defined in AWWA C151 Section 5.7.1 "Determining Rejection."
35
36 1.06 SUPPLIER'S QUALIFICATIONS
37
38 All pipe shall be manufactured, fabricated, coated, cement mortar -lined or epoxy -lined
39 by a single qualified Manufacturer. Fittings may be fabricated and the lining for force
40 main pipe and fittings may be applied at a site other than where the pipe is
41 manufactured. The Manufacturer shall have at least 5 years of experience in work
42 similar in specification to that which is to be furnished on this project. The Manufacturer
43 shall be required to show experience in supplying pipe in environments similar to those
44 expected to exist on this project and that the pipe supplied in those environments has
45 functioned satisfactorily.
46
DUCTILE IRON PIPE AND FITTINGS
15062-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1.07 SHOP TESTS
2
3 All pipes shall be tested by the Manufacturer in accordance with AWWA C104, C110,
4 C150, and C151, the Manufacturer's standard procedures, and this Specification.
5 Shop Tests shall be subject to witness by the Engineer and/or Owner, and/or the
6 Owner's Representative and certified test reports shall be submitted to the Engineer
7 by the Contractor. No lot of pipe shall be shipped to the site of the Work until
8 acceptable shop tests are completed and have been reviewed by the Engineer.
9
10 1.08 INSPECTION
11
12 A. All Work under this Specification, including but not limited to proof of design
13 testing, shop testing and the production of the pipe, fittings and specials, shall
14 be subject to inspection by the Owner's representatives and/or the Engineer in
15 the Supplier's plant. All travel, lodging and meal costs associated with this plant
16 inspection shall be incurred by the Owner and/or the Engineer.
17
18 B The Engineer shall have the right to order any pipe that, in the Engineer's
19 opinion, does not meet the Specifications to be rejected and not shipped to the
20 Project site.
21
22 PART 2 — PRODUCTS
23
24 2.01 GENERAL
25
26 A. All ductile iron pipes, including flanged, mechanical joint, push -on joint,
27 restrained joint, and plain end pipe, shall be manufactured in accordance with
28 ANSI/AWWA Specification C 151/A 21.51.
29
30 B. Where ductile iron pipe is supplied for the Project or shown on the Drawings,
31 above ground pipe shall be flanged and buried (underground) pipe shall be
32 mechanical joint, restrained joint or push -on joint, as required.
33
34 C. All ductile iron fittings shall be marked in accordance with ANSI/AWWA C 110/A
35 21.10 Section 10-9, "Markings on Fittings." All ductile iron pipe shall be marked
36 in accordance with Section 51-10, "Marking Pipe" of ANSI/AWWA Specification
37 C 151/A 21.51.
38
39 D. Maximum pipe laying lengths shall be 20 feet with shorter lengths provided as
40 required by the Construction Drawings or to complete the Work and as allowed
41 by AWWA C151.
42
43 E. Shop cement -mortar lined pipe shall have smooth dense interior surfaces and
44 shall be free from fracture, excessive interior surface crazing and roughness.
45
46 F Pipe joints shall not be bonded for electrical conductivity in accordance with
DUCTILE IRON PIPE AND FITTINGS
15062-5 03/22/2019
1 these Specifications and the details as shown on the Construction Drawings
2 and the following schedule:
3
4 1. All blow -offs, air valve assemblies, and lateral connections to or from the
5 pipe shall not be fitted with dielectric gaskets and/or couplings.
6
7 G. All materials that may be in contact with the water being conveyed (linings,
8 gaskets, lubricants, grout, disinfecting agents, etc.) shall be in accordance with
9 and approved by the appropriate NSF Standard 60 or 61.
10
11 2.02 DESIGN CRITERIA
12
13 A. The pipe furnished under this section shall be ductile iron pipe, cement mortar
14 or epoxy lined and asphalt coated, with EPDM gasket joints. The pipe shall
15 consist of a cast ductile iron wall, shop lined with Portland cement mortar
16 (potable water and reclaimed water) or epoxy (sanitary force main) and an
17 exterior coating of asphalt.
18
19 B. The pipe shall be designed, manufactured, tested, inspected, and marked
20 according to applicable requirements stated herein and except as modified,
21 shall conform to ANSI/AWWA C104, C150, C151.
22
23 C. Pipe supplied for this project shall be suitable for use with neutral pH
24 (approximately 7.0) meeting FDEP Part IV water quality standards (reclaimed
25 water), domestic raw sewage (force mains) or chloraminated drinking water
26 (potable water).
27
28 2.03 PIPE DESIGN
29
30 A. All ductile iron pipe shall have a minimum wall thickness corresponding to Class
31 150, as calculated according to AWWA C150.
32
33 B. Where threaded flanges are used on ductile iron pipe, the minimum thickness
34 of the pipe wall at the last critical thread after threading shall not be less than
35 the minimum calculated thickness of the pipe including net thickness, casting
36 tolerance and service allowance.
37
38 C. The Contractor shall provide design data on the pipe including calculations
39 showing the separate and combined stresses in the wall of the pipe due to the
40 design loads.
41
42 2.04 MATERIALS
43
44 A. All ductile -iron pipes shall meet the requirements of ANSI/AWWA C 151/A21.51.
45 The interior of the pipe shall be finished so that the Hazen -Williams friction factor
46 will not be less than 130. Each length of pipe shall be hydrostatically tested to
DUCTILE IRON PIPE AND FITTINGS
15062-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 at least 500 psi by the manufacturer in accordance with ANSI/AWWA C
2 151/A21.51. Additionally, 30 -inch and larger pipe shall be hydrostatically tested
3 to 75% of the yield strength of the metal, based on the nominal thickness of the
4 pipe.
5
6 B. Castings and connecting pieces, such as bell and bell, bell and spigot, bell and
7 flange, flange and flange, flange and spigot, and flange and flare, shall meet the
8 requirements of ANSI/AWWA C110/A21.10. Connecting pieces may be
9 fabricated.
10
11 C. The exterior of exposed ductile iron pipe, fittings, glands and bolts shall be field
12 coated with one prime coat of Tnemec 66, 3.0 to 5.0 mils minimum dry film
13 thickness, a second coat of compatible Tnemec Enamel, 4.0 to 6.0 mils per coat
14 minimum dry film thickness and a final coat of Tnemec 73, 2.5 to 4.5 mils per
15 coat minimum dry film thickness. Field coatings shall be applied in strict
16 conformance with the coating manufacturer's recommendations and Section
17 09900.
18
19 D. Pipe that is to be buried shall have the standard asphaltic outside coating
20 specified in ANSI/AWWA C151/A21.51.
21
22 E. The weight and class designation shall be painted conspicuously in a
23 contrasting color on the outside of each pipe, fitting, and special casting after
24 the shop coat has cured.
25
26 F Epoxy lining for force mains shall be an amine cured epoxy containing at least
27 20% ceramic quartz pigment by volume. The standard of quality is Proteco 401
28 Ceramic Epoxy.
29
30 2.05 JOINTS
31
32 A. Flanges and flanged joints for ductile iron piping shall conform to the dimensions
33 and requirements of ANSI Specification B 16.1. Where threaded flanges are
34 used, they shall be ductile iron and conform to the requirements of ANSI/AWWA
35 Specification C 115/A 21.15. All flanged ductile iron pipe and fittings shall be
36 rated for 250 pound working pressure and shall be faced and drilled to match
37 ANSI B16.1 Class 125 flanges unless special drilling is called for or required.
38 Where tap or stud bolts are required, flanges shall be drilled and tapped
39 accordingly.
40
41 B. All pipe flanges shall be coated with a rust preventive coating, as specified in
42 ANSI/AWWA Specification C 115/A 21.15, immediately after they have been
43 faced and drilled.
44
45 C. Flanged bolt holes on each end of flanged pipe and fittings shall accurately
46 straddle the same horizontal and vertical centerlines unless special drilling is
DUCTILE IRON PIPE AND FITTINGS
15062-7 03/22/2019
1 called for, or required.
2
3 D. The Contractor shall be responsible for assuring that the flanges of the pipe are
4 compatible with the flanges of the various components and/or appurtenances.
5
6 E. Flanged pipe, approximately twelve (12) inches or less in length, shall have
7 flanges cast solidly to pipe barrel. Flanges on pipe longer than twelve (12)
8 inches in length may be of the threaded type. Pipe threads shall be of such
9 length that, with flanges screwed home, the end of the pipe shall project beyond
10 the face line of the flange. Flange and pipe shall then be faced to give a flush
11 finish to the flange and the flange surface shall be normal to the axis of the pipe.
12 Flanges shall be of such design that the flanged neck completely covers the
13 threaded portion of the pipe to protect it against damage and corrosion.
14
15 F. Push -on joints for ductile iron piping shall conform to the dimensions and
16 requirements of ANSI/AWWA Specification C111/A 21.11 as they apply to
17 push -on joints.
18
19 G. Mechanical joints for ductile iron piping shall conform to the dimensions and
20 requirements of ANSI/AWWA Specification C 111/A 21.11. Where stud bolts
21 are required, bells shall be drilled and tapped accordingly. The Contractor shall
22 tighten joint bolts with appropriate wrenches, to a tension recommended by the
23 pipe Supplier.
24
25 H. Where joints are in contact with liquids, or buried underground, the Contractor
26 shall paint all bolts and nuts with two (2) heavy coats of coal tar pitch and where
27 joints are buried, the joints, including glands and bolts, shall be wrapped with
28 two laps of 8 mil polyethylene film and sealed to the pipe with polyethylene
29 adhesive tape.
30
31 I. Restrained Joints:
32
33 1. All buried pipe shall be restrained as shown on the Drawings and as
34 specified herein. Pipes subject to pressure or being fed by a pumping
35 system shall be restrained based on the pressures shown on the
36 drawings or specified elsewhere herein. Pipes subject to gravity flow
37 shall be restrained based on 30 psi of working pressure. Restrained joint
38 length indicated in the Tables included on the Drawings represents the
39 length on all sides of fittings and valves within which all joints must be
40 restrained. As a minimum, the joints at all fittings and valves shall be
41 restrained.
42
43 2. Restrained joints shall be capable of holding against withdrawal for line
44 pressures 50 percent above the normal working pressure, but not less
45 than 200 psi. The pipe and fittings shall be restrained push -on joints or
46 restrained mechanical joints.
DUCTILE IRON PIPE AND FITTINGS
15062-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 3. The pipe Supplier's standard restrained joints shall be of the type utilizing
3 cast lugs, shop welded retainer lugs or retainer rings bearing against pipe
4 shoulders. Field installed joint restraint systems, such as Megalugs, as
5 manufactured by EBAA Iron, or equal, are required for restraining
6 mechanical joint fittings. Field welding or grooving of the restrained joint
7 or components shall not be acceptable. Restrained joints shall be
8 capable of withstanding full bulkhead thrust that can be developed within
9 the pipeline due to the sum of the working and surge pressures.
10
11 4. Thrust blocks shall not be permitted unless specifically identified on the
12 Drawings.
13
14 5. Joints in tunnels and casings shall be restrained joints as defined
15 previously.
16
17 2.06 FITTINGS
18
19 A. All restrained joint, flanged, mechanical joint, and push -on joint shall be ductile
20 iron and shall be manufactured in accordance with, and shall meet the
21 requirements of ANSI/AWWA Specification C 110/A 21.10 or C153.
22
23 B. Dimensions of flanged fittings not included under ANSI/AWWA Specification
24 C110/A 21.10 shall conform to the requirements of ANSI Specification B 16.1,
25 Class 125. Fittings shall be short radius (compact) type were possible.
26
27 C. All fittings shall meet the requirements, as to dimensions and weights, as shown
28 in the current Edition of the "Handbook of Ductile Iron Pipe" of the Ductile Iron
29 Pipe Research Association.
30
31 D. All fittings furnished under ANSI/AWWA Specification C110/A 21.10 or C153
32 shall be ductile iron and shall have the same minimum pressure rating as the
33 pipe to which it is connected.
34
35 E. Special fittings, where required, shall have the same diameters and thickness
36 as standard fittings, unless otherwise required, but their laying lengths and other
37 functional dimensions shall be determined by their positions in the pipelines and
38 by the particular piping materials to which they connect.
39
40 2.07 INTERIOR LINING
41
42 A. Potable Water and Reclaimed Water Piping:
43
44 1. All ductile iron pipe and fittings shall be lined with standard single
45 thickness cement mortar lining and bituminous seal coated inside, at the
46 point of manufacture, in accordance with ANSI/AWWA Specification C
DUCTILE IRON PIPE AND FITTINGS
15062-9 03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
104/A 21.4. Portland cement for cement mortar lining shall be in
accordance with the requirements of ASTM C150, Type II cement. Shop
cement -mortar lined pipe shall have smooth dense interior surfaces and
shall be free from fractures, excessive interior surface crazing,
disbondment, and roughness.
2. The Contractor shall take precautions to prevent damage to the interior
lining and shall repair all damaged linings to the satisfaction of the
Engineer.
1
1
1
1
1
3. Test records shall be submitted to the Engineer for review.
4. The use and type of any admixtures must be reviewed by the Engineer
prior to their use. All material batching shall be by weight.
5. The method of placing and curing of the mortar lining shall be one with
which the manufacturer has experience and can demonstrate a
successful history. The lining shall be cured in a manner acceptable to
the Engineer so that it will provide a hard and durable lining with a
minimum of cracks, surface crazing and disbonded areas.
B. Epoxy Lining for Wastewater Service
1. All pipe and fittings for sewer force mains shall be Coated with Protecto
401 as specified.
1
1
1
1
2. Prior to abrasive blasting, the entire area to receive the protective
1
compound shall be inspected for oil, grease, etc. Any areas with oil,
grease, or any substance that can be removed by solvent, shall be
solvent cleaned to remove those substances. After the surface has been
made free of grease, oil or other substances, all areas to receive the
protective compounds shall be abrasive blasted using sand or grit
abrasive media. The entire surface to be lined shall be struck with the
blast media so that all rust, loose oxides, etc., are removed from the
surface. Only slight stains and tightly adhering oxide may be left on the
surface. Any area where rust reappears before lining must be re -blasted. 1
3. After the surface preparation and within 8 hours of surface preparation,
the interior of the pipe shall receive 40 mils nominal dry film thickness of
Protecto 401. No lining shall take place when the substrate or ambient
temperature is below 40 degrees Fahrenheit. The surface also must be
dry and dust free. If flange pipe or fittings are included in the project, the
lining shall not be used on the face of the flange.
Due to the tolerances involved, the gasket area and spigot end up to 6
inches back from the end of the spigot end must be coated with 6 mils
DUCTILE IRON PIPE AND FITTINGS
15062-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 nominal, 10 mils maximum using Protecto Joint Compound. The Joint
2 Compound shall be applied by brush to ensure coverage. Care should
3 be taken that the Joint Compound is smooth without excess buildup in
4 the gasket seat or on the spigot ends. Coating of the gasket seat and
5 spigot ends shall be done after the application of the lining.
6
7 5. The number of coats of lining applied shall be as recommended by the
8 lining manufacturer. However, in no case shall this material be applied
9 above the dry thickness per coat recommended by the lining
10 manufacturer in printed literature. The maximum or minimum time
11 between coats shall be that time recommended by the lining material
12 manufacturer. To prevent delamination between coats, no material shall
13 be used for lining which is not indefinitely recoatable with itself without
14 roughening of the surface.
15
16 6. Protecto Joint Compound shall be used for touch-up or repair in
17 accordance with manufacturer's recommendations.
18
19 2.08 EXTERIOR COATINGS
20
21 A. The exterior of all pipe and fittings to be submerged in water and for
22 underground installation shall be given a bituminous coating at the point of
23 manufacture, in accordance with ANSI/AWWA Specification C 151/A 21.51.
24
25 2.09 PIPE APPURTENANCES
26
27 A. Threaded flanges shall be ductile iron and shall meet the requirements of
28 ANSI/AWWA C115/A21.15. Flanges with long hubs for flanged pipe shall be
29 screwed on the threaded end of the pipe in the shop. The face of the flange
30 and the end of the pipe shall be refaced together. There shall be no leakage
31 through the pipe threads, and the flanges shall be designed to prevent corrosion
32 of the threads from outside. Flanges shall meet the requirements of ANSI
33 B16.1, and shall be faced and drilled to that standard, unless special drilling is
34 called for or required. The Contractor shall be responsible for assuring that the
35 flanges of the pipe are compatible with the flanges of the various components
36 and/or appurtenances. They shall be faced accurately at right angles to the
37 pipe axis, drilled smooth and true, and the machined faces covered with zinc
38 dust and tallow or equivalent material. The back of the flanges and bolt holes
39 shall be coated with asphaltic coating meeting the requirements of ANSI/AWWA
40 C151 /A21.51, Section 51-8.1. Coating material shall be applied immediately
41 after facing and drilling. Where tap or stud bolts are required, flanges shall be
42 tapped. All flanged joints shall be thoroughly bolted through, stud or tap bolts
43 of required size. All flanged joints buried underground shall also be protected
44 as specified under Section 2.08. Only flanges made in USA shall be supplied to
45 the Project.
46
DUCTILE IRON PIPE AND FITTINGS
15062-11 03/22/2019
1 B. All bolts, studs, and threaded rods used in the finished work for flanges shall be
2 of carbon steel and shall conform to the ASTM A 307 Grade B. All bolts and
3 nuts intended for underground service shall be corrosion resistant Cor -Ten
4 ASTM A242.The ends of all bolts shall be finished to the standard radius in an
5 acceptable manner. All screw threads shall be "American Standard, Coarse
6 Thread (N.C.). Stud bolts shall be hexagonal, cold pressed semi -finished and
7 made of medium open-hearth steel. All dimensions shall be in accordance with
8 "American Standard, Heavy." Nuts used shall be "Grade A Heavy Hex" in
9 conformance with ASTM A563 and be compatible with the bolts. Bolts and nuts
10 shall be cadmium or zinc plated at the point of manufacture with a plating
11 thickness of 0.0003 to 0.0005 inches. All bolts and nuts furnished shall be
12 delivered to the field free from grease, rust, and dirt.
13
14 C. All nuts and bolts that come into contact with water or that are to be buried shall
15 be painted with two (2) heavy coats of an coat tar pitch, in accordance with
16 Section 09900.
17
18 D. Gaskets for flanged joints shall be full-faced type EPDM gaskets one-eighth
19 (1/8) inch thick. All gaskets for flanged joints shall be EPDM having a Durometer
20 of 75 to 85 or neoprene having a Durometer of 55 to 65. As an alternate, the
21 Contractor may supply the pipe Supplier's (manufacturer's) gasket such as
22 American Cast Iron Pipe Company's "Toruseal" gasket or U.S. Pipe's "Flange
23 Tyte" gasket. Gaskets for bell and spigot joints shall be fabricated and tested
24 in accordance with AWWA C111.
25
26 E. Subject to the Engineer's review, welded outlets shall be allowed; however, the
27 welded -on outlet diameter shall not be greater than one quarter the diameter of
28 the main line.
29
30 2.10 COMPRESSION SLEEVE COUPLINGS
31
32 A. The Contractor shall furnish and install where required or where shown on the
33 Drawings, manufactured compression couplings equal to Style 38 or Style 39
34 where isolating dielectric couplings are required, as manufactured by the
35 Dresser Manufacturing Division of Dresser Industries or equal. The
36 compression couplings shall consist of two (2) steel follower flanges, one (1)
37 steel middle ring with pipe stops removed, and sufficient rolled thread,
38 track -head bolts to properly compress the gaskets. After fabrication, the middle
39 and follower rings shall be cold expanded to size and dimension. Thickness of
40 the middle ring shall be suitable for the pressures specified, and the application,
41 and in no case be less than one-half (1/2) inch thick. All parts of the
42 compression coupling shall be galvanized or heavily cadmium plated at the
43 point of manufacture and shall be epoxy coated in accordance with AWWA
44 C210 or AWWA C203.
45
46 B. The entire compression sleeve coupling unit shall be rated for working pressure
DUCTILE IRON PIPE AND FITTINGS
15062-12 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 plus surge pressure as a minimum.
2
3 C. The Contractor shall provide field coating for buried couplings in accordance
4 with AWWA C203 and these Contract Documents.
5
6 D. Small deflections in the pipe alignment shall be allowed at compression type
7 coupling joints, but such deflections shall not exceed three (3) degrees between
8 any two (2) adjacent pipe sections. Where changes in line and/or grade in
9 excess of three (3) degrees are required the deflections shall be made by
10 deflecting multiple joints.
11
12 PART 3 — EXECUTION
13
14 3.01 HANDLING PIPE AND FITTINGS
15
16 A. The Contractor shall transport, deliver and distribute along the line of the work,
17 the pipe, specials and appurtenances. All Work shall be in strict accordance
18 with the provisions of applicable permits and easements.
19
20 B. Pipe shall be loaded for shipment upon suitable cars or trucks that shall be
21 provided with padded bunks with nylon belt tie -down straps or padded banding.
22 In loading and unloading the pipe, more than ordinary care shall be taken to
23 prevent any injury to the pipe, ends, coatings and connections. Such work shall
24 be done slowly with the pipe at all times under control, and under no condition
25 shall the pipe be dropped. Field repair of damaged pipe shall not be allowed,
26 except for linings and coatings. The pipe shall be protected during shipping by
27 covering or some other means acceptable to the Engineer to prevent
28 contamination of the pipe and to protect the lining from drying during transport.
29
30 C. All pipe, fittings, etc., shall be carefully handled and protected against damage
31 to the lining and coating/interior and exterior surfaces, impact shocks, and free
32 fall. All pipe handling equipment shall be acceptable to the Engineer. Pipe
33 handling equipment shall consist of wide belt slings, padded cradles, or other
34 devices designed and constructed to prevent damage to the pipe or coatings.
35 The use of forks, chains, hooks, or other equipment that may damage the pipe
36 or its lining or coating shall not be allowed.
37
38 D. In distributing the pipe in the field, each pipe shall be placed as nearly as
39 possible to the point where it is to be laid, and facing in the proper direction.
40 Pipe shall not be placed directly on rough ground but shall be supported in a
41 manner that will protect the pipe against injury whenever stored at the trench
42 site or elsewhere. Coated pipe shall be stored on padded skids, sand or dirt
43 berm, sand bags, or other suitable means so that coating will not be damaged.
44 Coated pipe shall be handled with wide belt slings. Pipe fittings and specials
45 which are placed in storage, streets or drives must be so arranged as not to
46 cause undue inconvenience to traffic and must be protected sufficiently to
DUCTILE IRON PIPE AND FITTINGS
15062-13 03/22/2019
1 prevent any damage including but not limited to the interior lining and exterior
2 coatings. Chains, cables or other equipment likely to cause damage to the pipe,
3 fitting or special coating or lining shall not be used. Pipe which has been
4 improperly distributed and which must be moved longitudinally along the trench
5 shall be reloaded on a suitable car or truck or lifted and swung by a derrick or
6 moved by such means as may be satisfactory to the Engineer.
7
8 E. If in the process of manufacture, transportation, or handling, any ductile iron
9 pipe, fitting or special receives any deformation to the pipe wall, ends or
10 connections, such pipe, fitting or special shall be rejected and replaced at the
11 Contractor's expense.
12
13 F In the presence of the Engineer, the Contractor shall inspect upon delivery all
14 pipe, fittings, and specials and mark as "rejected" all pipe lengths and fittings or
15 specials exhibiting signs of damage to the exterior coating, interior cement
16 mortar linings, joint ends, or pipe wall and the Contractor shall at the
17 Contractor's expense immediately remove the same from the job site, or repair
18 to the Engineer's satisfaction. Any pipe, fittings or specials deemed not suitable
19 for installation shall be replaced in kind by the Contractor at the Contractor's
20 own expense.
21
22 G. The Contractor shall inspect each pipe and fitting to insure that there are no
23 damaged portions of the pipe. If any defective pipe is discovered after having
24 been laid, it shall be removed and replaced with a sound pipe or fitting in a
25 satisfactory manner, by the Contractor at the Contractor's own expense.
26
27 H. The Contractor shall thoroughly clean each pipe or fitting of any foreign
28 substance that may have collected on or in it prior to the pipe or fitting being
29 placed in the trench. The openings of all pipes and fittings in the trench shall
30 be closed during any interruption of the Work. As pipe laying progresses, the
31 Contractor shall keep the pipe interior free of all debris. The Contractor shall
32 completely clean the interior of the pipe of all sand, dirt, mortar splatter, and any
33 other debris following completion of pipe laying, pointing of joints and any
34 necessary interior repairs prior to testing and disinfecting the completed
35 pipeline.
36
37 3.02 INSTALLATION OF PIPE
38
39 A. Ductile iron piping shall be installed in strict accordance with the manufacturer's
40 instructions. Pipe shall be laid only after the trench has been excavated as
41 described Division 2 of the Specifications. Pipe laid in trench shall be laid to a
42 firm and even bearing for its full length. Precautions shall be taken against
43 flotation. The pipe shall be backfilled with selected fine excavated material as
44 shown on the Drawings and thoroughly compacted to one foot above the top of
45 the pipe and thereafter backfilled as specified in Section 02221.
46
DUCTILE IRON PIPE AND FITTINGS
15062-14 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. Precautions shall be taken against flotation. Pipe shall be laid directly on the
2 bedding material. Pipe shall be laid in the trench where the bedding forms a
3 continuous and uniform support for the full length of the pipe except that the
4 grade may be disturbed for the removal of lifting tackle. Bell holes shall be
5 formed at the ends of the pipe to prevent point loading at the bells or couplings.
6 Excavation shall be made as needed outside the normal trench section at field
7 joints to permit adequate access to the joints for field connection operations.
8
9 C. Each section of pipe shall be laid in the order and position shown on the laying
10 schedule. In laying pipe, it shall be laid to the set line and grade, within plus or
11 minus one inch.
12
13 D. The maximum obtainable separation between raw water, potable water,
14 reclaimed water and sewage lines shall be practiced. A minimum horizontal
15 separation of 3 feet, outside to outside, shall be maintained between raw water
16 lines, potable water mains and reclaimed water mains or a minimum of 6 feet
17 separation between sewage lines and either water or potable water lines. In
18 instances where water lines cross a potable water main or a sewage collection
19 line, a minimum vertical separation of 12 inches shall be maintained between
20 the invert of the upper pipe and the crown of the lower pipe. In instances where
21 a vertical separation of 12 inches between a raw water line and a potable water
22 main or a sewage collection line cannot be achieved, then the raw water line
23 shall be placed in a cast iron sleeve or encased in concrete centered at the point
24 of crossing.
25
26 E. Where necessary to raise or lower the pipe due to unforeseen obstructions or
27 other causes, the Engineer may change the alignment and/or the grades. Such
28 change shall be made by the deflection of joints, or by the use of additional
29 fittings.
30
31 F Except for short runs that may be permitted by the Engineer, pipe shall not be
32 laid uphill on grades exceeding 10 percent. Pipe that is laid on a downhill grade
33 shall be blocked and held in place until sufficient support is furnished by the
34 following pipe to prevent movement.
35
36 G. Contractor shall coordinate yard piping installation such that a minimum of 36
37 inches of cover is maintained over piping at all times, unless otherwise indicated
38 on the plans. At crossings, a minimum of 6 inches of vertical separation
39 between pipes shall be maintained while also maintaining 36 -inch minimum
40 cover, unless otherwise indicated on the Drawings.
41
42 H. Bedding and backfilling shall be in accordance with Section 02221 of these
43 Specifications and the details shown on the Construction Drawings.
44
45 I. Bedding shall be carefully worked into the area between the trench bottom and
46 the pipe wall to keep it round. Bedding shall not be deposited on top of the pipe,
DUCTILE IRON PIPE AND FITTINGS
15062-15 03/22/2019
1
1 but alongside it, and in such a way that it rises evenly on both sides. 1
2
3 J. All joints shall be assembled in accordance with the Manufacturer's I 4 recommended procedures. In general the procedure shall be as described
5 herein. Immediately before jointing pipe, the bell of the pipe shall be thoroughly
6 cleaned, and a clean gasket shall be placed in the bell groove. The spigot shall
7 be carefully cleaned and the bell containing the gasket and the spigot lubricated
8 with a vegetable-based lubricant. The spigot of the pipe section shall then be
9 aligned with the bell end and inserted into the bell of the previously laid joint and
10 telescoped into its proper position. Tilting of the pipe to insert the spigot into the
11 bell will not be permitted.
12
I
13 K. Restrained joints shall be assembled in a similar manner as described above
14 except that the restraining device shall be installed in accordance with the
15 Manufacturer's recommended procedures. I 16
17 L. Bolt holes of flanges shall straddle the field horizontal and field vertical
18 centerlines of the pipe. The Contractor shall clean flanges by wire brushing
I
19 before installing flanged fittings. The Contractor shall clean flange bolts and
20 nuts by wire brushing.
21
I
22 M. The Contractor shall insert the nuts and bolts (or studs), finger tighten, and
23 progressively tighten diametrically opposite bolts uniformly around the flange to
24 the proper tension. The Contractor shall execute care when tightening joints to
I
25 prevent any strain upon valves, pumps and other equipment. After tightening
26 all bolts any stulls shall be removed from the interior of the pipe if it is not to be
27 buried.
1
28
29 N. If flanges leak under pressure testing, loosen or remove the nuts and bolts, reset
30 or replace the gasket, reinstall or retighten the bolts and nuts, and retest the
31 joints. Flanged joints shall be watertight.
32
33 O. Pipe stulls, if recommended by the Supplier, shall be left in place until bedding
I
34 and backfilling operations have been completed. After the backfill has been
35 placed, the stulls shall be removed and shall remain the property of the
36 Contractor.
1
37
38 P After stulls are removed, the Contractor shall check the inside diameter of the
39 pipe to verify that deflection has not exceeded the allowable 3 percent. The I
40 frequency of checking shall be as directed by the Engineer but in no case shall
41 be less than the frequency of soil density testing.
42
I
43 Q. All pipes shall be laid with a 2 -inch metallic tape, appropriately color coded and
44 imprinted with the type of service, 12 inches below final grade and directly above
45 the utility, for identification and ease of location. The appropriate tape color I
46 codes are as follows:
DUCTILE IRON PIPE AND FITTINGS
15062-16 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 Sanitary Force Main: Green
3 Potable Water: Blue
4 Reclaimed Water: Purple
5
6 R. Care shall be taken in bolting flanged joints so that there is no restraint on the
7 opposite end of one piece which would induce stresses in the pipe or fitting or
8 prevent pressure from being evenly and uniformly applied upon the gasket. The
9 pipe or fitting shall be free to move in any direction while bolting. Bolts shall be
10 gradually tightened, each in turn, at a uniform rate of gasket compression
11 around the entire flange.
12
13 S. No pipe shall be installed upon a foundation into which frost has penetrated or
14 at any time that there is a danger of the formation of ice or penetration of frost
15 at the bottom of the excavation. No pipe shall be laid unless it can be
16 established that the trench will be backfilled before the formation of ice and frost
17 occurs.
18
19 T Pipes underneath structures and slabs shall be ductile iron and shall have a 6-
20 inch minimum concrete encasement for pipes 24 inches and smaller (except
21 pipes 3 inches and smaller, which shall be SCH 80 PVC). 8 -inch minimum
22 concrete encasement for pipes larger than 24 inches up to and including 36
23 inches and 9 inches minimum concrete encasement for pipes larger than 36
24 inches. Concrete encasement shall extend a minimum of 12 inches past edge
25 of structure or slab.
26
27 U. All pipe and fitting joints occurring within restrained joint limits as required on
28 the Construction Drawings, or as ordered, shall be properly secured to prevent
29 thrust forces from pulling the pipeline joints apart. All tied joints shall be
30 harnessed by using the pipe Manufacturer's standard restrained joint
31 arrangements conforming to these Specifications. Certain joints may be
32 restrained by the use of rods and clamps as directed by the Engineer. The rods
33 and clamp harnessing arrangements shall be installed utilizing lugged fittings
34 and pipe with saddle clamps placed to bear against the pipe bells. Saddle
35 clamps around the barrel of the pipe that depend on friction or set screws to
36 prevent sliding of the clamp are not acceptable. The pipe clamps, tie rods and
37 their assembly shall meet the requirements of the National Fire Protection
38 Association Bulletin No. 24. After each tied joint is connected up, all pipe
39 clamps, bolts, heads, tie rods and nuts shall be coated as recommended by the
40 Supplier.
41
42 V. Careful inspection shall be made of every joint to insure a smooth continuous
43 interior surface. The Contractor shall thoroughly clean the interior of the pipe
44 and remove any obstructions that may reduce the pipe's carrying capacity.
45 Following completion of pipeline progressively or in sections, including
46 completion of inside inspections, insofar as might be possible or practicable, the
DUCTILE IRON PIPE AND FITTINGS
15062-17 03/22/2019
1 line shall be kept partially filled with water.
2
3 W. The Contractor shall patch the cement mortar lining of any pipe that has a crack
4 exceeding the allowable crack as determined by the Engineer. Lining failures
5 that exceed 100 square inches and that have dimension greater than 12 -inches
6 shall be cause for the pipe to be rejected. There shall not be more than one
7 patch on the lining of any one joint of pipe, fitting or special.
8
9 X. Wherever necessary and directed by the Engineer, patches shall be made by
10 the Contractor with a mortar of one part Portland cement and two parts clean,
11 sharp sand; all measurements to be by weight. No pipe requiring the lining to
12 be patched shall be installed until the patch is placed. Pipe thus patched shall
13 not be installed until the patch has been properly and adequately cured and
14 observed by the Engineer.
15
16 Y All buried process piping (excluding drainage and stormwater piping) shall be
17 restrained in accordance with the restrained joint table provided in the Drawings.
18 Pipes subject to pressure or being fed by a pumping system shall be restrained
19 based on a 150 psi working pressure. Pipes subject to gravity flow shall be
20 restrained based on a 30 psi working pressure. Restrained joint length indicated
21 in the Tables represents the length on all sides of fittings and valves within which
22 all joints must be restrained. As a minimum, the joints at all fittings and valves
23 shall be restrained. Restrained joints shall be capable of holding against
24 withdrawal for line pressures 50 percent above the normal working pressure but
25 not less than 150 psi on pipe subject to pressure and 30 psi on pipe subject to
26 gravity flow. The pipe and fittings shall be restrained mechanical joints.
27
28 3.03 CUTTING PIPE
29
30 Whenever pipes require cutting to fit into the lines, the work shall be done in a
31 satisfactory manner so as to leave a smooth end, at right angles to the axis of the pipe.
32 Pipe cutting shall only be done by saws specifically designed for that purpose. After
33 cutting, the end of the pipe shall be beveled to the dimensions of the Manufacturer's
34 specifications.
35
36 3.04. COMPRESSION SLEEVE COUPLINGS
37
38 A. The Contractor shall thoroughly clean with a wire brush all surfaces that will be
39 in contact with the gaskets.
40
41 B. The follower rings shall be placed over the pipe ends, then the Contractor shall
42 slip the lubricated gaskets (vegetable based lubricant) over the pipe ends. The
43 Contractor shall place the middle ring over the previously laid pipe then insert
44 the end of the joining pipe into the middle ring, and position both gaskets evenly
45 in the middle ring gasket grooves. The Contractor shall insert bolts in bolt holes
46 of follower rings and tighten nuts in the sequence and with the torque
DUCTILE IRON PIPE AND FITTINGS
15062-18 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 requirements of the coupling manufacturer. After tightening all bolts the stulls
2 shall be removed from the interior of the pipe if it is not to be buried.
3
4 3.05 DRILLING AND TAPPING
5
6 A. Where shown on the Construction Drawings or where required, ductile iron pipe,
7 fittings or specials shall be drilled and tapped to receive drainage outlets, air
8 relief outlets, or other pipe or plugs for pressure testing and/or chlorination.
9 Holes shall be drilled accurately and at right angles to the axis of the pipe or
10 fitting.
11
12 B. Where size of the outlet pipe to be connected is such as to require bosses or
13 reinforcement saddles for making the connection, the Contractor shall furnish
14 such outlet connections with bosses or reinforcement saddles drilled and tapped
15 as indicated on the Construction Drawings or as directed by the Engineer.
16
17 3.06 SURFACE PREPARATION AND PAINTING
18
19 A. The Contractor shall remove all debris, dirt, grease, mortar and other foreign
20 material by the use of soap and water or other solvent as may be required.
21
22 B. After each joint has been made the Contractor shall give all steel bolts and nuts
23 a chemical wash of the phosphate type followed by one (1) coat of primer
24 especially prepared for the finish of the bolt and nut installed. After this
25 pretreatment, the Contractor shall coat all bolts and nuts as follows:
26
27 C. Give all bolts and nuts that will be exposed one (1) coat of primer.
28
29 D. Paint all bolts and nuts that will be underground in accordance with these
30 Contract Documents.
31
32 E. All piping and fittings shall have its surface prepared and painted as specified
33 in Sections 09865 and 09900.
34
35 3.07 SUPPLIER'S FIELD SERVICE
36
37 Contractor shall, at no additional cost to Owner, arrange for pipe Manufacturer's field
38 representative to be on-site and provide instruction to each crew working during the
39 installation of a minimum of four push -on joints and four restrained joints The
40 Manufacturer's field representative shall certify that the installations observed were
41 satisfactorily completed and all pipe installation crews were familiar with the proper
42 methods and procedures for the pipeline installations.
43
44 3.08 FLUSHING AND TESTING
45
46 A. The Contractor shall remove all sand and foreign matter from the pipeline as
DUCTILE IRON PIPE AND FITTINGS
15062-19 03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
work progresses. The ends of all pipes shall be suitably closed at each break
or pause in pipe laying, and at the end of each work day, so as to minimize the
amount of materials that can enter the pipe.
B. Prior to pressure testing, all 24 -inch and smaller mains shall be flushed to
remove all sand and other foreign matter. The velocity of the flushing water
shall not be Tess than 2 feet per second. Flushing shall be terminated at the
direction of the Engineer. The Contractor shall dispose of the flushing water
without causing property damage or violation of environmental regulations or
permits.
C. Prior to pressure testing, all 30 -inch and larger mains shall be televised. All dirt
and foreign matter shall be removed and the pipe shall be cleaned. After
cleaning, the mains shall be re -televised. Pre -and post -cleaning videotapes
shall be furnished to the Owner.
D. Testing of lines shall be as specified in Section 01625.
END OF SECTION
DUCTILE IRON PIPE AND FITTINGS
15062-20 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15064
2
3 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required and install in
10 the locations as shown on the Drawings, the PVC piping, fittings and
11 appurtenances as specified herein.
12
13 B. The requirements of this specification 15064 supersede relevant articles in
14 Section IV.
15
16 1.02 DESCRIPTION OF SYSTEM
17
18 A. Piping shall be installed in the locations as shown on the Drawings.
19
20 B. All pipe, fittings, valves, solvents and glue used for potable water piping shall
21 be NSF -61 certified for continuous contact with potable water.
22
23 1.03 QUALIFICATIONS
24
25 A. All PVC pipe, fittings and appurtenances shall be furnished by a single
26 manufacturer who is fully experienced, reputable and qualified in the
27 manufacture of the items to be furnished. The equipment shall be designed,
28 constructed, and installed in accordance with the best practices and methods
29 and shall comply with these Specifications.
30
31 1.04 SUBMITTALS
32
33 A. Shop drawings shall be submitted to the Engineer for review in accordance
34 with the General Conditions and shall include dimensioning and technical
35 specification for all piping to be furnished.
36
37 B. Submit to the Engineer, for review, samples of all materials specified herein.
38
39 1.05 TOOLS
40
41 A. Special tools, solvents, lubricants, and caulking compounds required for
42 normal installation shall be furnished with the pipe.
43
44 PART 2 - PRODUCTS
45
46 2.01 MATERIALS
47
PVC PIPE AND FITTINGS
15064-1 03/22/2019
1 A. Polyvinyl Chloride (PVC) Pipe:
2
3 1. Class -rated PVC pipe and accessories four to twelve inches (4"-12") in
4 diameter, where shown or as specified on the Drawings, shall meet the
5 requirements of AWWA Specification C900 "Polyvinyl Chloride (PVC)
6 Pressure Pipe." Pipe shall be Class 235, meeting requirements of
7 Dimension Ratio (DR) 18 with cast iron outside diameters. Each length
8 of pipe shall be hydrotested to four (4) times its class pressure by the
9 manufacturer in accordance with AWWA C900. W3 RCW piping shall
10 be pipe Class 200 meeting requirements of Dimension Ratio (DR) 14.
11
12 2. Class -rated fourteen inch (14") or larger PVC pipe and accessories for
13 force main use only shall meet the requirements of AWWA Speci-
14 fication C905, "Polyvinyl Chloride Water Transmission Pipe". Pipe shall
15 be Class 235, meeting the requirements of DR 18 with cast iron outside
16 diameters. Each length of pipe shall be hydrotested by the
17 manufacturer to two (2) times its class pressure in accordance with
18 AWWA C905.
19
20 3. Pressure rated PVC pipe smaller than 4" shall be 200 psi SDR -21
21 conforming to the requirements of ASTM D2241. Potable water main
22 pipe shall have EPDM gasket push -on joints conforming to ASTM F
23 477. Force main pipe shall have SBR gasket push -on joints conforming
24 to ASTM F-477.
25
26 4. PVC pipe less than 4" in diameter that is exposed to view shall be
27 ASTM D-1785 Schedule 80 pipe with UV inhibitors.
28
29 5. All PVC pipe shall be new, unused and manufactured for this project.
30 Polyvinyl chloride sewer pipe shall conform to ASTM D-3034 and D-
31 1784 (PVC compound). Profile pipe shall conform to ASTM F-794.
32 The PVC pipe shall be manufactured by Johns -Manville Corporation,
33 Certain -Teed Corporation, or equal. All PVC sewer pipe shall be green
34 and conspicuously labeled with the manufacturer's name, nominal pipe
35 size, applicable material code or PVC cell classification, standard
36 dimension ratio number, product type, standard specification
37 designation, and production record code.
38
39 6. Pipe shall be listed by Underwriters Laboratories. Provisions shall be
40 made for expansion and contraction at each joint with an elastomeric
41 ring, and shall have an integral thickened bell as part of each joint.
42 PVC Class pipe shall be installed in accordance with the Uni-Bell
43 Plastic Pipe Association Guide Specification UNI -B-3-76, and as
44 recommended by the manufacturer.
45
46 7. Pipe shall be furnished in nominal lengths of approximately 20 feet,
47 unless otherwise directed by the Engineer. Pipe for potable water
PVC PIPE AND FITTINGS
15064-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 supply and accessories shall bear the NSF mark indicating pipe size,
2 manufacturer's name, and AWWA and/or ASTM Specification number,
3 working pressure and production code. Pipe and couplings shall be
4 made from Class 12454-A or Class 12454-B virgin compound, as
5 designed in ASTM D1784.
6
7 8. PVC pipe shall be color coded as follows: sanitary mains - green;
8 potable water mains - blue; reclaimed water mains — lavender, process
9 piping — brown. Specific colors shall match county standard colors as
10 applicable.
11
12 B. Joints:
13
14 1. Joints for PVC sewer shall be of the bell and spigot type conforming to
15 ASTM D-3212 using factory installed flexible elastomeric seals
16 (gaskets). These gaskets shall be SBR and shall conform to ASTM F-
17 477. Joints for PVC water pipe shall be of the bell and spigot type
18 using factory installed, flexible elastomeric seals (gaskets). These
19 gaskets shall be EPDM and shall conform to ASTM F-477.
20
21 2. The PVC joints for buried pipe shall be of the push -on type unless
22 otherwise directed by the Engineer so that the pipe and fittings may be
23 connected on the job without the use of solvent cement or any special
24 equipment. The push -on joint shall be a single rubber gasket joint
25 designed to be assembled by the positioning of a continuous, molded
26 rubber ring gasket in annular recess in the pipe or fitting socket and the
27 forcing of the plain end of the entering pipe into the socket, thereby
28 compressing the gasket radially to the pipe to form a positive seal. The
29 gasket and annular recess shall be designed and shaped so that the
30 gasket is locked in place against displacement as the joint is
31 assembled. The rubber ring joint shall be designed for thermal
32 expansion or contraction with a total temperature change of at least 75
33 degrees F in each joint per length of pipe. The bell shall consist of an
34 integral wall section with a solid cross-section elastomeric ring which
35 shall meet requirements of ASTM D1869. The thickened bell section
36 shall be designed to be at least as strong as the pipe wall. Lubricant
37 furnished for lubricating joints shall be nontoxic, shall not support the
38 growth of bacteria, shall have no deteriorating effects on the gasket or
39 pipe material, and shall not impart color, taste, or odor to the water.
40
41 3. PVC joints for exposed pipe shall be threaded or solvent welded joints
42 where called for on the Drawings, unless otherwise directed by the
43 Engineer. Teflon thread tape or liquid Teflon thread lubricant shall be
44 used on all threaded joints to serve as both a sealer and lubricant.
45 Threaded joints should be made hand tight (hard). When the joint is
46 hand tight a strap wrench should be used to make up one to two (1-2)
PVC PIPE AND FITTINGS
15064-3 03/22/2019
1 additional full turns past the hand tight point. Do not use pipe wrenches
2 or pump pliers on plastic pipe or fittings.
3
4 C. Fittings:
5
6 1. Fittings for pressure rated PVC pipe smaller than 4" in diameter shall be
7 solvent weld or threaded Schedule 80 PVC and shall conform to ASTM
8 Specification D 2467 or D D2464 as appropriate.
9
10 2. The manufacturer of the pipe shall supply all polyvinyl chloride
11 accessories as well as any adaptors and/or specials required to perform
12 the work as shown on the Drawings and specified herein. Standard
13 double bell couplings will not be accepted where the pipe will slip
14 completely through the coupling.
15
16 2.02 RESTRAINED JOINTS
17
18 A. All buried piping shall be restrained in accordance with the restrained joint
19 table provided in the Drawings. Pipes subject to pressure or being fed by a
20 pumping system shall be restrained based on a 150 psi working pressure.
21 Pipes subject to gravity flow shall be restrained based on a 30 psi working
22 pressure. Restrained joint length indicated in the Tables represents the length
23 on all sides of fittings and valves within which all joints must be restrained. As
24 a minimum, the joints at all fittings and valves shall be restrained.
25
26 B. Restrained joints shall be capable of holding against withdrawal for line
27 pressures 50 percent above the normal working pressure but not less than
28 150 psi. The pipe and fittings shall be restrained push -on joints or restrained
29 mechanical joints.
30
31 C. PVC push -on pipe bell and spigot joints shall be restrained with the Uni-Flange
32 Corp. Series 1390 Restrainer or equal. The restraining device shall be
33 manufactured of high strength ductile iron meeting ASTM A-536, Grade 65-45-
34 12. Connecting rods and clamping bolts and nuts shall be manufactured of
35 corrosion resistance high strength, low alloy COR -TEN steel meeting the
36 requirements of ASTM A-242 or AWWA C111.
37
38 D. Ductile iron mechanical joint fittings used with PVC pipe shall be restrained
39 with the Uni-Flange Corp. Series 1300 Restrainer, EBAA Iron, Inc., Series
40 2000PV Mechanical Joint Restraint Gland, or equal. The restraining device
41 shall be manufactured of high strength ductile iron meeting ASTM A-536,
42 Grade 65-45-12. T -bolts and clamping bolts and nuts shall be manufactured
43 of corrosion resistance high strength, low alloy COR -TEN steel meeting the
44 requirements of ASTM A-242 or AWWA C111.
45
46 E. Thrust blocks shall not be permitted unless specifically shown on the
47 Drawings.
PVC PIPE AND FITTINGS
15064-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 PART 3 — EXECUTION
3
4 3.01 HANDLING PIPE AND FITTINGS
5
6 A. Care shall be taken in loading, transporting, and unloading to prevent injury to
7 the pipe. Pipe or fittings shall not be dropped. Any damaged pipe or fittings
8 shall be replaced.
9
10 B. All pipe and fittings shall be subjected to a careful inspection just prior to being
11 laid or installed, and no piece shall be installed which is found to be defective.
12
13 C. If any defective pipe is discovered after it has been laid or installed, it shall be
14 removed and replaced with a sound pipe in a satisfactory manner at no
15 additional expense to the Owner. All pipe and fittings shall be thoroughly
16 cleaned before laying, shall be kept clean until they are used in the work, and
17 when installed or laid, shall conform to the lines and grades required.
18
19 3.02 INSTALLING EXPOSED PVC PIPE AND FITTINGS
20
21 A. All piping and fittings shall be installed true to alignment and rigidly supported
22 thrust anchors shall be provided where required. Each length of pipe shall be
23 cleaned out before erection.
24
25 B. Sleeves shall be installed of proper size for all pipes passing through floors or
26 walls as shown on the Drawings. Where indicated on the Drawings or
27 required for liquid or gas -tightness the pipe be sealed with a mechanical seal
28 equal to Link -Seal as manufactured by Thunderline Corp., Wayne, Michigan.
29
30 C. Concrete inserts for hangers and supports shall be furnished and installed in
31 the concrete as it is placed. The inserts shall in accordance with the
32 requirements of the piping layout and jointing method and their locations shall
33 be verified from piping layout drawings and the structural drawings. Pipe
34 hangers and supports are specified in Section 15094 of these specifications.
35
36 D. All valves, fittings, equipment, and appurtenances needed upon the pipelines
37 shall be set and jointed as indicated on the Drawings or as required. Valves
38 and appurtenances are included in Section 15100 of these specifications. All
39 pipe and appurtenances connected to equipment shall be supported in such a
40 manner as to prevent any strain being imposed on the equipment. When
41 manufacturers have indicated requirements that piping loads shall not be
42 transmitted to their equipment, a certification shall be submitted stating that
43 such requirements have been complied with.
44
45 3.03 FLUSHING AND TESTING
46
PVC PIPE AND FITTINGS
15064-5 03/22/2019
1 A. Prior to pressure testing, all mains shall be flushed to remove all sand and
2 other foreign matter. The velocity of the flushing water shall not be Tess than 2
3 feet per second. Flushing shall be terminated at the direction of the Engineer.
4 The Contractor shall dispose of the flushing water without causing a nuisance
5 or property damage.
6
7 B. Complete PVC piping systems shall be field pressure tested after installation
8 and including all components to 150 psi for 2 hours. Any leaks discovered
9 during testing shall be repaired. The repaired component or portion must be
10 retested until the entire system passes the pressure testing. Perform pressure
11 testing in accordance with Section 01625.
12
13 3.04 SURFACE PREPARATION AND PAINTING
14
15 A. All piping and fittings exposed to view shall have its surface prepared and be
16 painted as specified in Sections 09865 and 09900 of these specifications.
17 Surface preparation and shop priming is a part of the work of this Section.
18 Pipe marking is included in Section 09900, but it shall be part of the work of
19 this Section to assist as required by the Engineering in identifying pipe
20 contents, direction of flow and all else required for proper marking of pipe.
21
22
23 END OF SECTION
PVC PIPE AND FITTINGS
15064-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15065
2
3 STAINLESS STEEL PIPE AND FITTINGS
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE
8
9 A. This specification covers the preparation of detailed shop drawings and the
10 fabrication, furnishing, installation, inspection and testing of stainless steel
11 process piping systems as shown on the drawings and described herein.
12
13 B. All work shall be done in accordance with applicable standards as listed herein
14 unless otherwise stated in the purchase order and/or attached addenda to this
15 specification. Sound engineering practices shall be followed in the absence of
16 specified standards or specifications.
17
18 C. Fabrication of piping subject to the requirements of the ASME boiler and
19 Pressure Vessel Code, Section I, "Power Boilers," is not covered in this
20 specification.
21
22 1.02 APPLICABLE STANDARDS
23
24 A. ANSI and/or ASME Standards
25
26 B1.1 Unified Inch Screw Threads
27 B1.20.1 Pipe Threads (Except Dryseal)
28 B16.5 Pipe Flanges and Flanged Fittings
29 B16.9 Factory -made Wrought Steel Buttwelding Fittings
30 B16.11 Forged Steel Fittings, Socket Welding and Threaded
31 B16.25 Buttwelding Ends
32 B18.2.2 Square and Hex Nuts
33 B31.3 ASME Code for Pressure Piping - Process Piping
34 B36.10 Welded and Seamless Wrought Steel Pipe
35 B36.19 Stainless Steel Pipe.
36
37 B. MSS Standards
38
39 SP -43 Wrought Stainless Steel Butt Welding Fittings
40
41 C. PFI Standards
42
43 ES -3 Fabricating Tolerances
44
45 D. Standards
46
STAINLESS STEEL PIPE AND FITTINGS
15065-1 03/22/2019
1 1. ASTM A 999 — Standard Specification for General Requirements for
2 Alloy and Stainless Steel Pipe.
3 2. ASTM B 804 - Standard Specification for UNS N08367 and UNS
4 N08926 Welded Pipe.
5 3. ASTM A 403 - Standard Specification for Wrought Austenitic Stainless
6 Steel Piping Fittings.
7 4. ASTM A 276 - Standard Specification for Stainless Steel Steel Bars and
8 Shapes.
9 5. ASTM A 312 -. Standard Specification for Seamless and Welded
10 Austenitic Stainless Steel Pipes.
11 6. ASTM A 403 — Standard Specification for Wrought Austenitic Stainless
12 Steel Piping Fittings.
13 7. ASTM A 774 - Standard Specification for As -Welded Wrought
14 Austenitic Stainless Steel Fittings for General Corrosive Service at Low
15 and Moderate Temperatures.
16 8. ASTM A 778 - Standard Specification for Welded Unannelaed Austenic
17 Stainless Steel Tubular Products.
18 9. AWWA C220 - Stainless Steel Pipe
19 10. AWWA C226 - Stainless Steel Fittings for Waterworks Service
20 11. AWWA C228 Stainless Steel Pipe Flange Joints for Water Service
21
22 E. Documents referenced in each of the above are hereby incorporated by
23 reference.
24
25 F. The latest revision of all documents shall apply unless otherwise noted herein.
26
27 1.03 SUBMITTALS
28
29 A. The fabricator shall prepare the necessary detail fabrication drawings from the
30 isometric piping drawings. Pipe size and dimensions of the existing piping
31 system shall be verified and measured in the field before the drawings are
32 submitted.
33
34 B. All piping shown on the isometric drawings is shown in normal assembly and
35 operating position. When specifically required, thermal expansion
36 requirements and cold springing will be shown on the drawings.
37
38 C. Pipe detail pieces shall be fabricated in accordance with the piece marks
39 shown on the drawings, unless otherwise required for handling and/or
40 shipping. Changes from the piece mark arrangement shown on the drawings
41 shall require approval of the Engineer.
42
43 D. If any conflicts exist between the Isometric Drawings and the Piping Material
44 Specification, such conflict shall be immediately brought to the attention of the
45 Engineer.
46
STAINLESS STEEL PIPE AND FITTINGS
15065-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 E. In addition to the above, the following shall be submitted:
2
3 1. The weight of each length of completed piping.
4 2. A complete total bill of materials.
5 3. Applicable Material Data Sheets from the supplying mill.
6 4. Original copies of mill certifications for each heat of material to be
7 utilized.
8 5. Original copies of certified design calculations.
9 6. Original written certification from the supplying mill stating that the
10 fabricator has been pre -qualified for all required fabrication processes.
11 7. Original copies of certified test reports including a statement that the
12 pipe, flanges and appurtenances have been fabricated in accordance
13 with all applicable standards.
14 8. Recommended solvents and cleaning procedures for removal of
15 protective coatings applied prior to shipment.
16 9. Proposed welding repair methods.
17 10. A complete fabrication schedule.
18
19 1.04 APPROVAL OF PROCEDURES
20
21 A. The fabricator shall submit a minimum of five (5) copies of his welding
22 procedures and procedure qualification records to the Engineer for review.
23
24 B. An approval of welding procedures is required from the supplying mill, in
25 writing, before welding is performed.
26
27 PART 2 — PRODUCTS
28
29 2.01 PROCESS PLANT INFLUENT PIPE AND FITTINGS
30
31 A. The Contractor shall furnish and install the pipes, fittings, supports, hangers,
32 hardware, as shown on the drawings.
33
34 B. All stainless steel piping shall be provided with flanged or welded connections
35 as shown.
36
37 2.02 FABRICATION DIMENSIONAL TOLERANCES
38
39 A. Flanged branches with raised face or lap joint flanges:
40
41 center of header to face of flange or lap ±1/8" (3.2 mm)
42 maximum lateral offset ±1/16" (1.6 mm)
43
44 B. Flanged branches with RTJ or tongue and groove flanges:
45
46 center of header to face of flange ±3/32" (2.4 mm)
STAINLESS STEEL PIPE AND FITTINGS
15065-3 03/22/2019
1 maximum lateral offset ±1/16" (1.6 mm)
2
3 C. Beveled end branches:
4
5 center of header to end of bevel ±1/8" (3.2 mm)
6 maximum lateral offset ±1/16" (1.6 mm)
7
8 D. In fitting reinforcing pads to the curvature of the pipe the maximum allowable
9 gap shall be 1/8" (3.2 mm).
10
11 E. Flange faces must be square with the pipe. The tolerance measured across
12 the outside diameter of the gasket surface with a level and thickness gage
13 shall be with the following:
14
15 Up to 4" ±1/32" (0.8 mm)
16 6" to 8" ±1/16" (1.6 mm)
17 10" ±3/32" (2.4 mm)
18 12" and Up ±1/8" (3.2 mm)
19
20 F Bolt holes shall straddle the vertical centerlines of horizontal piping and in
21 vertical piping the centerline of the detail (spool) unless otherwise specified,
22 and shall be within 1/16" (1.6 mm) of exact alignment
23
24 2.03 MATERIALS
25
26 A. All stainless steel pipe shall be a minimum wall thickness of Schedule 40, and
27 rated for a minimum of 150 psi.
28
29 B. All stainless steel pipe and fittings shall be fabricated from Type 316L extra
30 low carbon grade austenitic stainless steel.
31
32 1. Pipe shall conform to ASTM A-312 or ASTM A 778.
33
34 2. Fittings shall conform to ASTM A-403 or ASTM A-774.
35
36 3. Ends of pipe shall be true and perpendicular to the longitudinal axis with
37 the edges deburred.
38
39 4. Longitudinal seams on pipe and fittings shall be shop welded by either
40 tungsten gas or the metallic -gas method. Welding rod or wire shall be
41 of same composition or superior to the pipe and fittings material.
42
43 5. The weld deposit at the seam shall have a slight crown on both sides of
44 the weld and no cracks or crevices shall be allowed. Excessive weld
45 deposits, slag, weld spatter, and projections into interior of pipe shall be
46 removed by grinding. The interior welds shall be smooth, even, and
STAINLESS STEEL PIPE AND FITTINGS
15065-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 shall not have an internal bead higher than 1/16 inch.
2
3 6. All pieces shall be marked with gauge and type of stainless steel.
4
5 7 Pipe and fittings shall be immersed in pickling solution in
6 Manufacturer's plant and scrubbed and washed until all discoloration
7 and possible iron, picked up from manufacturing process, is removed.
8
9 D. Fittings:
10
11 1. All fittings for buried or submerged pipe shall be shop fabricated, butt -
12 welded and flanged conforming to ASTM A403, class WP, using the
13 same material and wall thickness as the pipe, conforming to ANSI
14 B16.9. Elbows shall be long radius.
15
16 2. Flanges shall be Class 150 per ANSI B16.5. Flanges shall be welded
17 on both sides.
18
19 3. Pipe ends shall be prepared for flanges and couplings as required.
20
21 4. Blind flanges shall be constructed entirely of the same material (or
22 better) as the pipe (minimum thickness 3/8 -inch).
23
24 E. Any material which is not in accordance with the classification shall be noted
25 on the Fabricator's Drawings as "out of spec." material. Material substitutions
26 must be approved in writing.
27
28 1. The fabricator shall provide Mill Test Reports for pipe and Certificates of
29 Compliance for fittings and flanges.
30
31 F All materials shall be heat treated, welded, pickled, passivated and tested in
32 accordance with the supplying mill's requirements for the intended service
33 conditions. Any conflict between the supplying mill's requirements and these
34 specifications shall be immediately brought to the Engineer's attention.
35
36 2.04 SOCKET WELD FITTINGS
37
38 A. To avoid possible cracking of fillet welds when the pipe is seated against the
39 bottom of the socket prior to welding, it is required that the pipe be withdrawn
40 approximately 1/16" (1.6 mm) away from contact with the bottom of the socket
41 before starting welding.
42
43 2.05 FABRICATION
44
45 A. Fabrication shall be in accordance with American National Standard, ASME
46 B31.3, "Process Piping" Ian:est edition. Any allowable exceptions are noted on
STAINLESS STEEL PIPE AND FITTINGS
15065-5 03/22/2019
1 the Piping Drawings or Piping Material Specifications.
2
3 B. Shop Welding
4
5 1. All welding procedures shall be in accordance with the requirements of
6 the mill supplying the pipe and fittings. Any conflicts between the mill
7 requirements and those specified herein shall be brought to the
8 Engineer's attention prior to initiating welding.
9
10 2. Welding procedures and operators shall be qualified for welding
11 materials specified in accordance with ASME Boiler and Pressure
12 Vessel Code, Section IX, "Welding and Brazing Qualifications," latest
13 issue. Welding Procedures and Welder's Qualification Test records
14 shall be available for examination by the Owner.
15
16
17
18
19
20 4. All welding, brazing and cutting shall be performed in accordance with
21 Occupational Safety and Health Standards (OSHA).
22
23 5. The fabricator's welding techniques shall be GTAW, GMAW, SAW and
24 SMAW, used either individually or in combination with one another.
25
26 6. The design of weld joint, welding bevel, and reinforcement shall be in
27 accordance with ASME B31.3.
28
29 7 Prior to welding, the welding groove and adjacent base metal shall be
30 cleaned inside and outside of all scale, rust, oxides, paints, oils, or other
31 materials that may affect the welding.
32
33 8. The edges or surfaces of parts to be joined by welding shall be
34 prepared in the manner specified in the fabricator's qualified welding
35 procedure.
36
37 9. The ends of piping components to be joined by welding shall be aligned
38 as accurately as is practicable within the tolerances of diameter, wall
39 thickness, etc. Where the misalignment exceeds 1/16" (1.6 mm), the
40 inside diameter of the pipe extending internally shall be trimmed with
41 the angle of the bevel not to exceed 30 degrees. However, this
42 trimming shall not result in a piping component wall thickness less than
43 the design thickness plus corrosion allowance.
44
45 10. Alignment shall be preserved during welding by tack welds, spaced as
46 required, but with at least one tack weld in each quadrant. Tack welds
STAINLESS STEEL PIPE AND FITTINGS
15065-6 03/22/2019
3. All welding shall be performed by welders or welding operators qualified
in accordance with ASME Boiler and Pressure Vessel Code, Section IX,
"Welding and Brazing Qualifications" welder performance qualification.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 shall be of the same quality and material as the completed weld and
2 shall be thoroughly 'fused with the weld beads. Otherwise they shall be
3 removed during the welding operation.
4
5 11. The use of backing rings or strips is not permitted in the welding of girth
6 or longitudinal joints.
7
8 12. The total joint penetration shall not be less than the thinner of the two
9 components being joined, except that incomplete root penetration is
10 permissible if it does not exceed 1/32" (0.8 mm) or 20 percent of the
11 nominal wall thickness of the thinner component, whichever is smaller.
12 The total length of such incomplete root penetration shall not exceed 1-
13 1/2" (38 mm) in any 6" (150 mm) of weld length. Welds on which 100
14 percent radiography is specified shall have complete joint penetration.
15
16 13. The undercut and weld reinforcement of a butt weld shall be in
17 accordance with Table 341.3.2 of ASME B31.3.For double welded
18 joints this limitation on reinforcement shall apply to each surface of the
19 weld separately.
20
21 14. On Targe diameter lines, where practicable, weld metal shall be
22 deposited from both sides (double welded).
23
24 15. Prior to depositing each weld layer, the previous weld shall be
25 thoroughly cleaned to remove all oxide, scale, slag, flux, or defects.
26 Grinding or chipping may be required to correct the defects. Peening
27 shall not be used to close cavities in the weld metal.
28
29 16. Longitudinal seams shall be located to clear openings and attachments
30 where practicable, and shall be staggered a minimum of 5t or 2" (50
31 mm) whichever is less in adjoining courses. Where necessary to add
32 outside structural attachment to pipe across longitudinal seam weld,
33 omit attachment weld where crossing seam weld and notch out
34 attachment.
35
36 17. The fabricator shall bevel, or otherwise prepare joint ends that are to be
37 field welded.
38
39 18. Alloy welding electrodes (filler metal) should be of the same
40 approximate analysis as piping material being welded.
41
42 2.06 ACCESSORIES
43
44 A. Bolts and Nuts for Flanged Fittings:
45
46 1. Bolts and nuts for flanged connections shall be Type 316 stainless steel
STAINLESS STEEL PIPE AND FITTINGS
15065-7 03/22/2019
1 conforming to ASTM A913, Grade B8M, for bolts and ASTM A194,
2 Grade 8M, for nuts.
3
4 2. Provide washer for each nut. Washers shall be the same material as
5 the nuts.
6
7 B. Gaskets for flanged connections shall be full-faced gaskets for flat -faced
8 flanges and ring gaskets for raised face flanges. Gaskets shall be EPDM or
9 FKM suitable for the service of the pipe.
10
11 2.07 TESTING
12
13 A. Testing of the pipe and pipe materials shall be as outlined in Section 3.07 of
14 this specification.
15
16 2.08 EXAMINATION AND INSPECTION
17
18 A. Examination
19
20 1. The fabricator shall examine all welds in accordance with the
21 requirements set forth by ASME B31.3.
22
23 2. The acceptance criteria for welds shall be per Table 341.3.2 of ASME
24 B31.3. If weld examination reveals a defect it shall be repaired per
25 paragraph 328.6 of ASME B31.3. Further, for any weld defect revealed
26 with random or spot examination, additional items per paragraph
27 341.3.4 of ASME B31.3 shall be examined.
28
29 3. The Engineer and/or Owner's Inspector may specify further
30 examination in any category where he feels it is necessary.
31
32 4. The intent of these examinations is to provide the examiner and the
33 inspector with reasonable assurance that the requirements of ASME
34 B31.3 and the engineering design have been met. The fabricator shall
35 provide the inspector a certification that all the quality control
36 requirements of the Code have been met.
37
38 B. The Owner's Inspector shall perform such inspection as deemed necessary.
39
40 PART 3 — EXECUTION
41
42 3.01 PREPARATION FOR SHIPMENT
43
44 A. All pipe shall be delivered clean. Cleaning shall consist of removing all non -
45 adhering material such as loose scale, sand, weld spatter particles, rust,
46 cutting chips, oil or mineral spirits, etc., from the inside of the piping assembly
STAINLESS STEEL PIPE AND FITTINGS
15065-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 by any suitable means. Pipe shall not be coated with any protective or oil
2 based coatings.
3
4 B. Open ends, whether plain, beveled, or flanged shall be protected from damage
5 or entrance of foreign materials with suitable protectors securely fastened.
6
7 C. Small pieces shall be boxed or wired together to avoid Toss in transit.
8
9 D. Loading and handling shall be done with reasonable care and details braced
10 where required to prevent damage during transit.
11
12 E. Marking
13
14 1. Each fabricated pipe detail shall be marked as follows, using waterproof
15 paint, or paint protected with a clear waterproof varnish.
16
17 2. On stainless steel and alloy material, the marker shall be lead, zinc and
18 sulfur free, and less than 200 PPM chlorides.
19
20 3. The Pipe Detail Number shall be marked on each end of the detail on
21 opposite sides. The detail number consists of area number, piece
22 designation, and line number.
23
24 Example: 111-A-25, 111-B-25, etc.
25
26 4. The welders identification symbol shall be marked adjacent to each
27 weld. Metal stamping shall not be used on austenitic stainless and
28 other high alloy type materials. Additionally, stamping on carbon and
29 alloy steel materials shall be prohibited when the design temperature
30 specified is below -20°F (-29°C). In these cases, the welders symbol
31 shall be applied in waterproof paint.
32
33 3.02 FIELD WELDING
34
35 A. Field welding shall only be allowed when approved by the Engineer. Welding
36 procedures and operators shall be qualified for welding materials specified in
37 accordance with ASME Boiler and Pressure Vessel Code, Section IX,
38 "Welding and Brazing Qualifications," latest issue. Welding Procedures and
39 Welder's Qualification Test records shall be submitted in accordance with
40 Section 01300.
41
42 B. Gas tungsten arc, gas metal arc, shielded metal arc or submerged arc welding
43 (GTAW, GMAW, SMAW & SAW) may be used. An inert gas purge shall be
44 used for the root and second passes in all welding processes except the
45 shielded metal arc.
46
STAINLESS STEEL PIPE AND FITTINGS
15065-9 03/22/2019
1 C. Preheat is not required unless the metal temperature is below 50°F (10°C).
2 When such a condition exists, the metal shall be heated until it is warm to the
3 hand before any welding is performed.
4
5 D. Post weld heat treatment (stress relieving) is not required
6
7 3.03 ERECTION
8
9 A. The piping systems shall be erected to conform to the piping drawings and
10 specifications. Qualified craftsmen shall perform all work in a neat and
11 workmanlike manner.
12
13 B. Piping shall be installed in a manner such that the resultant forces on the
14 equipment will be kept to a minimum. Particular care shall be taken at
15 mechanical equipment where piping forces can cause misalignment. Flange
16 misalignment beyond the acceptable tolerance shall be corrected by cutting
17 and re -welding, and not by the use of force on the bolting. Bending of pipe
18 and fittings is not allowed.
19
20 C. Pipe supports, anchors and guides shall be installed and adjusted in
21 accordance with the pipe support drawings and specifications to properly
22 support the piping and to control movements due to expansion of piping and
23 equipment. Sufficient ties shall be installed to prevent excessive sway and/or
24 vibration of the piping and lines having outstanding unsupported corners.
25
26 D. Where necessary to provide piping anchor points that are not shown on the
27 job pipe support drawings, consideration shall be given to expansion and
28 contraction movements of the piping and equipment, with minimum forces and
29 stress being transmitted to the equipment.
30
31 E. When permanent pipe supports cannot be installed during erection, adequate
32 temporary supports shall be provided, so that piping is not strained or
33 deformed during the erection process.
34
35 F All precautions shall be taken to assure internal cleanliness of installed piping.
36 Flange protectors, or other end closures shall not be removed until time of
37 installation. Pipe sections shall be inspected just prior to installation, to assure
38 that all debris has been removed. Wherever practicable, hydrostatic test water
39 shall be drained quickly to promote flushing for further cleaning.
40
41 3.04 EXAMINATION AND INSPECTION
42
43 A. Examination
44
45 1. The acceptance criteria for welds shall be per Table 341.3.2 of ASME
46 B31.3. If weld examination reveals a defect it shall be repaired per
STAINLESS STEEL PIPE AND FITTINGS
15065-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 paragraph 328.6 of ASME B31.3. Further, for any weld defect revealed
2 with random or spot examination, additional items per paragraph
3 341.3.4 of ASME B31.3 shall be examined.
4
5 2. The Welding Inspector may specify further examination in any category
6 where he feels it is necessary.
7
8 B. Inspector shall inspect all piping systems including pipe supports to assure
9 that the installation has been made in a good workmanlike manner and
10 conforms to the drawings and specifications. In addition, the work may be
11 subject to inspection by the client's authorized agency such as an insurance
12 company or government agency.
13
14 3.05 TESTING
15
16 A. A general hydrostatic test of all completed shop fabricated details is not
17 required.
18
19 B. Testing shall be conducted after the completion of all erection by deadheading
20 the pumps at the valve vault and running them for 1 minute. Testing medium
21 shall be water.
22
23 C. All visible leaks shall be corrected. Any defective material or components and
24 all lines that fail to meet the test shall be repaired and retested as necessary,
25 until all test requirements are met. All repairs and retests shall be performed
26 at the Contractor's own expense with no additional cost to the Owner.
27
28
29 END SECTION
30
STAINLESS STEEL PIPE AND FITTINGS
15065-11
03/22/2019
1 THIS PAGE INTENTIONALLY LEFT BLANK
STAINLESS STEEL PIPE AND FITTINGS
15065-12 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15080
2
3 SMALL DIAMETER METAL PIPE AND FITTINGS
4
5
6 PART 1 - GENERAL
7
8 1.01 WORK INCLUDED
9
10 The Contractor shall furnish all the materials, tools, labor, supervision and appliances
11 for and shall properly install, connect, adjust, test and place at the locations shown
12 on the Drawings, or as directed, all copper pipe and fittings and small diameter
13 miscellaneous pipe and fittings at the locations and to the elevations indicated,
14 specified or required, as necessary for the proper completion of the Work.
15
16 Attention is called to the fact that miscellaneous pipe and fittings are not necessarily
17 shown complete on the Drawings, which are more or less schematic, but the
18 Contractor shall do all piping work indicated or required for the proper operation of
19 all equipment and services requiring such piping, and all such work shall be done by
20 competent workmen in a thorough workmanlike manner, according to best custom
21 and practice, and in compliance with all laws and regulations, with proper provisions
22 for dismantling, draining, expansion and contraction.
23
24 Wherever the Work disturbs existing conditions or Work already completed, the same
25 shall be restored to its original condition in every detail. All such replacement and
26 repair shall meet with the approval of the Engineer.
27
28 It is the intent of these Contract Documents to require an installation under this
29 Section complete in every detail, whether or not indicated on the Drawings, or
30 specified herein. Consequently, the Contractor shall be responsible for all details,
31 devices, accessories and special construction necessary to properly furnish, install,
32 adjust, test and place in continuous and satisfactory service a complete installation of
33 miscellaneous pipe and fittings.
34
35 Full responsibility for fabricating, and installing the miscellaneous pipe and fittings, for
36 selecting materials of construction, and for demonstrating strict compliance with
37 specified performance requirements shall rest with the Contractor and, through the
38 Contractor, the Supplier. The Engineer's approval of the 1) Shop Drawings, 2)
39 construction of the miscellaneous pipe and fittings, 3) the use of materials included in
40 this Specification, shall not relieve the Contractor and Suppliers of full responsibility
41 for meeting all performance requirements and guarantees specified in the Contract
42 Documents.
43
44 1.02 REFERENCE TO OTHER SECTIONS
45
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-1 03/22/2019
1 Requirements contained herein under the Specification for Ductile Iron Pipe 42
2 Inches and Less, Section 02060, shall be considered as and are hereby made a part
3 of the Specifications for Small Diameter Pipe and Fittings, Section 15080, insofar as
4 they may apply.
5
6 1.03 WORKMANSHIP AND MATERIALS
7
8 The Contractor shall furnish materials under this Specification which are new, unused
9 and as specified, or if not particularized herein, which are the best of their respective
10 kind, free of defects and imperfections, and suitable for the service intended, subject
11 to the approval of the Engineer.
12
13 The Contractor shall provide workmanship which is first class in every respect and
14 have the installation performed by workers thoroughly experienced in such work. A
15 neat and workmanlike appearance in the finished work shall be required.
16
17 The Contractor shall perform the Work in accordance with all Laws and Regulations.
18
19 1.04 SUBMITTALS
20
21 The Contractor shall submit detailed, dimensioned Shop Drawings and data
22 conforming to the requirements of Section 01300 of the General Requirements to the
23 Engineer for approval before fabrication, shipment or Work specified under this
24 Section begins.
25
26 The Contractor shall make detail drawings for pipe and fittings to a scale of not less
27 than 1/4 inch equals one (1) foot, indicating piping layout in plan and elevation as
28 may be required to clearly indicate all pipe and fittings. Completely dimension the
29 drawings and indicate connections to equipment and reference to approved shop
30 drawings of such equipment.
31
32 The Contractor shall include a complete schedule of pipe, fittings and specials with
33 mark numbers on the schedules and on drawings corresponding to the mark
34 numbers which will be on the pipe, fittings and specials when delivered to the job site,
35 as called for hereinafter.
36
37 The Contractor shall indicate location and type of pipe supports, hangers and
38 anchors on the Shop Drawings.
39
40 PART 2 - MATERIALS
41
42 2.01 STEEL PIPE AND FITTINGS
43
44 Steel pipe, when specifically called for, shall meet the "Standard Specification for
45 Pipe, Steel, Black and Hot -Dipped Zinc -Coated (Galvanized) Welded and Seamless,
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 for Ordinary Uses," - A.S.T.M. Designation: A 53. Schedule 40 pipe shall be
2 "Standard Weight" pipe and used except as modified herein. Fittings used on black
3 steel pipe lines two and one-half (2-1/2) inches or less in diameter, unless otherwise
4 specifically called for, shall be standard weight, one hundred fifty (150) pound,
5 beaded, malleable iron conforming to ASTM A338 for "Malleable Iron Flanges, Pipe
6 Fittings and Valve Parts for Railroad, Marine and other Heavy Duty Service" at
7 temperatures up to 650°F (345°C), Class 150. Fittings used on black steel pipe lines
8 three (3) inches and larger shall be of the welded American National Standards
9 Institute (A.N.S.I.) type, long radius design of standard weights, A.N.S.I. B 16.9-1971,
10 "Factory- Made Wrought Steel Buttwelding Fittings."
11
12 Flanges shall be of the forged steel slip-on type, faced and drilled, of the one
13 hundred fifty (150) pound series, meeting A.N.S.I. Specification B 16.5-1977 "Steel
14 Pipe Flanges and Flanged Fittings" , and "Standard Specification for Forging, Carbon
15 Steel for General Purpose Piping," A.S.T.M. Designation:
16 A 181-83.
17
18 All gaskets for flanged pipe joints except for air or steam service shall be full face
19 type with a minimum thickness of one-eighth (1/8) inch and shall be red rubber or
20 neoprene. Air and steam service gaskets shall be compressed non -asbestos material
21 Style No. 3000 Garlock Blue Gard, similar products by Cranite or equal.
22
23 The Contractor shall provide unions in each run of pipe and at equipment for easy
24 removal. Furnish unions of the ground joint type with brass seats. No gasketed
25 unions shall be permitted.
26
27 The Contractor shall provide fittings as required and expansion couplings in each run
28 of straight pipe and at structural expansion joints. Groove pipe for expansion
29 couplings where noted or specified.
30
31 The Contractor shall provide each length of pipe with a coupling, if applicable.
32
33 Malleable iron screwed fittings shall meet the standards of A. N.S.I. B 16.3-1977,
34 "Malleable Iron Threaded Fittings". Hot -dipped galvanized malleable iron fittings
35 shall be used on all galvanized steel pipe lines. Malleable iron grooved end fittings
36 shall meet the requirements of "Standard Specification for Malleable Iron Castings",
37 A.S.T.M. A 47-77 and be hot -dipped galvanized. Furnish pipe and fittings with sound,
38 well -fitting threads. Pieces having defective threads shall be rejected.
39
40 2.02 STAINLESS STEEL PIPE AND FITTINGS
41
42 All stainless steel pipe and fittings shall be made of Type 304 stainless steel, unless
43 shown or specified otherwise. Stainless steel pipe shall be seamless or welded and
44 furnished in strict accordance with "Standard Specification for Seamless and Welded
45 Austenitic Stainless Steel Pipe" , A.S. T.M. Designation A 312-83 and fittings in
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-3 03/22/2019
1 accordance with "Standard Specification for Wrought Austenitic Stainless Steel
2 Piping Fittings", A.S.T.M. Designation A 403-83a. Butt welded fittings shall meet
3 the standards of ANSI B 16.9-1971. All pipe and fittings shall be annealed and
4 pickled, and shall have a surface finish equivalent to a No. 1 MiII Finish in accordance
5 with "Standard Specification for General Requirements for Flat -Rolled Stainless and
6 Heat- Resisting Steel Plate, Sheet and Strip", A.S.T.M. Designation A 480/ A 480M-
7 83a. Schedule 40 pipe shall be "Standard Weight." Fittings shall have the same
8 schedule wall thickness as the pipe.
9
10 Where stainless steel pipe is connected by grooved -end couplings or flange
11 adaptors, the pipe shall be of the roll grooved (no metal removed) end type.
12
13 All welding shall be done by a fully automatic, shielded arc, inert gas method. Welds
14 shall be fully penetrated and gas shielded on both sides. All welds shall be smooth,
15 uniform bead and thickness, and brushed with stainless steel wire brush, with
16 deposits and discoloration removed.
17
18 2.03 COPPER PIPE AND FITTINGS
19
20 All copper pipe shall be of standard size, as indicated on the Drawings, specified or
21 required and shall conform in all respects to the "Standard Specification for Seamless
22 Copper Water Tube," A.S.T.M. Designation: B 88-83. The Contractor shall provide
23 copper tubing manufactured by Anaconda American Brass Company, Revere Copper
24 and Brass, Inc., or equal. Copper water pipe, when used underground, shall be Type
25 K, soft temper, coil or straight lengths as directed and when used elsewhere shall be
26 Type L, hard temper, drawn copper tubing, unless otherwise specifically called for.
27 All fittings on these lines shall be cast bronze fittings, as manufactured by Mueller
28 Company; Stanely G. Flagg Co.; or equal. For soft temper tubing the Contractor shall
29 provide cast bronze flared tube type fittings. For hard drawn copper tube fittings the
30 Contractor shall provide the cast bronze sweat type. Unions shall be of the solder
31 type, with brass -to -brass seats. Gasketed unions shall not be acceptable. A liberal
32 amount of unions shall be installed to allow removal of valves and equipment.
33
34 Where copper piping is connected to steel pipe, the Contractor shall furnish and
35 install an insulating union, by EPCO Sales, Incorporated, or Capital Manufacturing
36 Co., or equal.
37
38 Where copper pipe is connected to ductile iron pipe, the Contractor shall furnish and
39 install a tapped cap, Clow F-1042, or ACIPCO Type A-338 or equal, and a brass
40 corporation stops, Type HI5025 by Mueller Co., or equal.
41
42 2.04 BRASS PIPE AND FITTINGS
43
44 Brass pipe shall meet the "Standard Specification for Seamless Brass Tube,"
45 A.S.T.M. Designation: B 135-82, drawn temper. Fittings shall be brass.
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3 2.05 PIPING SCHEDULE
4
5 Unless otherwise called for by the Drawings or elsewhere in these Specifications, the
6 following schedule shall be a guide of minimum requirements for piping for the Work.
7
8 I. Pipe for Underground Service
9
10 A. Potable Water and Sealing Water
11
12 1. 3" and smaller - Type K (heavy wall) soft temper copper tube
13 with soldered fittings.
14
15 B. Compressed Air
16
17 1. 2" and smaller - Type K (heavy wall) soft temper copper tube
18 with soldered fittings.
19
20 2. 2-1/2" to 4" - Schedule 40 galvanized steel pipe with
21 screwed joints, slip-on flanges or compression couplings.
22
23 All ungalvanized (black) steel pipe for underground service shall be
24 coated with a polyethylene sheath. The coating system shall meet
25 Federal Specification L -C -530B. All joints shall be wrapped after
26 laying, so that the finished job shall be completely protected.
27
28 II. Pipe for Nonburied Service, Carrying:
29
30 A. Potable Water and Sealing Water
31
32 1. 3" and smaller - Type L (medium wall) hard temper copper pipe
33 with soldered fittings. Red brass pipe around equipment, and in other
34 locations where vibration is expected.
35
36 B. Compressed Air
37
38 1. 2" and smaller - Type L (medium wall), hard temper copper pipe
39 with soldered fittings. Red brass pipe around equipment, and in other
40 locations where vibration is expected.
41
42 2. 2-1/4" to 6" - Schedule 40 galvanized steel pipe, with screwed
43 joints, slip-on flanges or compression couplings.
44
45 C. Vent Gases
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-5 03/22/2019
1
2 1. 3-1/2" and smaller - Schedule 40 galvanized steel, with
3 screwed joints, slip-on flanges or compression couplings, unless
4 otherwise shown on the drawings.
5
6 D. Hydraulic Piping
7
8 1. 1/2" and less Schedule 40 stainless steel pipe with
9 hydraulic connectors.
10
11 2. 3/4" and larger - Schedule 40 stainless steel pipe with
12 screwed joints or welded joints.
13
14 All ungalvanized (black) steel piping for interior use, that is not covered
15 by insulation, shall be primed and painted as specified under the
16 painting schedule of Section 09900.
17
18 Where more rigidity is required in erecting and supporting copper pipe,
19 the Contractor shall, with the approval of the Engineer or when so
20 directed by the Engineer, substitute brass pipe.
21
22 2.06 HANGERS AND SUPPORTS
23
24 The Contractor shall provide all necessary hangers and supports for piping installed
25 in the Work.
26
27 Hangers and supports for all steel or other piping shall meet the following
28 requirements. No perforated strap hangers and no wire supports shall be permitted.
29
30 Hangers supporting insulated piping 2-1/2" and larger shall be sized to fit the pipe
31 plus the insulation. The insulation at support points shall be provided with metal
32 shields to prevent damage to the insulation.
33
34 Pipe hangers used to support uninsulated copper piping shall be copper or copper
35 plated.
36
37 Guides shall be located not more than twenty (20) feet away from each expansion
38 loop or joint.
39
40 Horizontal runs of pipe shall have supports spaced so that the sag of the
41 unsupported length shall not create any pockets in the piping.
42
43 All vertical piping shall be supported at the base with fittings made for this purpose or
44 supported from the nearest horizontal member or floor with a riser extension pipe
45 clamp. The Contractor shall provide riser extension clamps at each floor.
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 All anchors that are installed in existing concrete shall be Grinnell Figure 117, Modem
3 Figure 740, or equal expansion case inserts. The Contractor shall drill clean holes for
4 insertion of case and patch concrete around drill hole as required.
5
6 The Contractor shall furnish and install concrete inserts that shall be cast in the
7 concrete walls and slabs as required for the proper hanging and supporting of the
8 piping and equipment that is to be furnished and installed in the Work.
9
10 If approved by the Engineer, continuous slotted concrete inserts shall be Crawford
11 Figure 148, Fee & Mason 9000, or equal. The Contractor shall provide secondary
12 angle supports between main inserts to hang the various pipes where the loads are
13 such that they can be properly supported by this arrangement.
14
15 All inserts and support bolts shall be galvanized.
16
17 2.07 SLEEVES AND FLOOR PLATES
18
19 Wherever pipes pass through floors, walls or ceilings, the Contractor shall provide
20 Standard Wall steel pipe sleeves of the proper size. The Contractor shall properly
21 cement or build sleeves into the masonry in a rigid position. The Contractor shall set
22 ends of the sleeves flush at wall and ceiling surfaces and to extend one inch above
23 floor surfaces.
24
25 For sleeves in walls below grade, the Contractor shall provide water stops and tightly
26 caulk with oakum and lead after the pipe is installed. Such sleeves shall be
27 completed tight and tested for leaks.
28
29 PART 3 - EXECUTION
30
31 3.01 INSTALLATION
32
33 All pipe shall be carefully placed by the Contractor to proper lines and grades and
34 shall be connected up, unless otherwise shown or indicated, with screw fittings.
35 Screw joints shall be made tight, with an approved jointing compound, and screwed
36 home. If welding of pipe is called for, it shall be installed in accord with the
37 requirements of the Engineer.
38
39 All piping shall be installed in such manner and at such times as will require a
40 minimum of cutting and repairing of the building structures. In case any such cutting
41 and repairing is necessary, it shall be done only with the permission of the Engineer.
42 All cutting and repairing shall be performed by mechanics of the trade which originally
43 executed the work, with all repairs matching the original condition.
44
45 The following general piping practices, when applicable, shall be followed in installing
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-7 03/22/2019
1 all steel, copper and brass piping:
2
3 1. Full lengths of pipe shall be used wherever possible; short lengths of pipe with
4 couplings shall not be permitted.
5
6 2. All pipe shall be cut to exact measurement and shall be installed without
7 forcing or springing.
8
9 3. Tool marks and unnecessary pipe threads shall not be allowed. Burrs formed
10 when cutting pipe shall be removed by reaming. Before installing any pipe,
11 care shall be taken that the inside is thoroughly clean and free of cuttings and
12 foreign matter.
13
14 4. In general, all changes in direction shall be made by using pipe fittings. Field
15 bends of pipe shall not be permitted. Wherever there is a galvanized steel
16 pipeline longer than 30 feet, the Contractor shall provide a plugged tee in the
17 line.
18
19 5. A liberal number of unions shall be used on pipe two and one-half (2-1/2)
20 inches or smaller in diameter, and companion flanges on pipe three (3)
21 inches and larger, to permit the ready removal of any section. Unions shall
22 be installed in all piping connections to equipment, to regulating valves, and
23 wherever necessary to facilitate the removal of valves, strainers, accessories
24 and other items requiring maintenance. Flanges on equipment may be
25 considered as unions when connecting pipe is provided with companion
26 flanges. All unions shall be of the ground joint type, with brass -to -metal seats.
27 No gasketed unions will be permitted. Where wrought iron or steel pipe is to
28 be connected to copper pipe, a dielectric union, such as those
29 manufactured by EPCO Sales, Inc., Capital Manufacturing Company, or
30 equal, shall be used.
31
32 6. Exposed piping shall be neatly arranged, straight, run parallel and at right
33 angles to walls, unless otherwise directed or shown, and shall be so graded
34 that the entire system can be drained. Drain valves or stop and waste valves
35 shall be installed at all low points of piping.
36
37 7. Installed piping shall not interfere with the operation or accessibility of doors or
38 windows, shall not encroach on aisles, passageways, and equipment, and
39 shall not interfere with the servicing or maintenance of any equipment.
40
41 8. The Contractor shall cut annealed, Type K, copper tube square, ream ends
42 and flare using suitable tools. The Contractor shall use bending tools for
43 making bend on annealed copper pipe only and shall assemble hard drawn,
44 Type L, copper tubing, using solder alloy and flux as recommended by the
45 manufacturer of the tubing. The Contractor shall cut tubing square, ream ends,
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 and polish both fitting and tube with steel wool before fluxing; properly heat,
2 taking care not to overheat and after running solder, wipe the joint clean. The
3 Contractor shall install copper tubing only in accordance with the Supplier's
4 instructions.
5
6 9. Where copper tubing is connected to ferrous piping or equipment with ferrous
7 fittings, the Contractor shall provide approved insulating bushings.
8
9 10. Where copper lines pass through exterior walls, the Contractor shall carry
10 Type K through a pipe sleeve provided for this purpose and connect Type L
11 inside the building by use of adapter fittings.
12
13 11. All welding of steel pipe shall be carried out in strict accordance with A.W.S.
14 procedures, and all Laws and Regulations. Welding of black steel pipe shall be
15 accomplished by means of the manual, shielded metal -arc process. Welding
16 of stainless steel pipe shall be by the shielded arc, inert gas method.
17
18 All welding shall be performed by men who are thoroughly qualified for this
19 type of work.
20
21 12. When cast iron companion flanges are required to connect steel piping to cast
22 iron piping, or in steel pipe two and one-half (2-1/2) inches or larger in lieu of
23 unions, such flanges shall be furnished drilled and tapped, as necessary, and
24 included with the pipe.
25
26 13. After welding slip-on flanges to galvanized steel pipe, the disturbed galvanized
27 interior and exterior areas the Contractor shall clean and restore, by hot -dip
28 galvanizing or painting with a zinc -rich cold galvanizing paint.
29
30 14. After testing, exposed pipe threads on joints laid in the ground the Contractor
31 shall paint with one (1) coat of Bitumastic No. 50, Tnemecol or equal coal -tar
32 pitch paint.
33
34 15. In general, the Contractor shall furnish and install pipe expansion joints on all
35 piping where such piping crosses structure expansion joints, whether or not
36 shown on the Drawings. The Contractor shall assemble expansion couplings
37 with bolts drawn sufficiently tight to prevent leakage but not to prevent
38 expansion and contraction.
39
40 16. Where pipes pass through concrete or masonry walls or floors, the Contractor
41 shall provide galvanized pipe sleeves. For pipe two (2) inches and smaller in
42 diameter, provide sleeves two (2) sizes larger than the pipe itself. For pipe 2-
43 1/2 inches and larger in diameter, provide sleeves one (1) pipe size larger than
44 the pipe itself. The Contractor shall extend sleeves through the floor two (2)
45 inches above the finished slab, except in finished areas where the Contractor
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-9 03/22/2019
1
2
3
4
5
shall finish the sleeve just above the finished slab, unless it is noted to be
flush. The Contractor shall make ends of sleeves flush with wall and ceiling
surface, shall render sleeves gas tight and caulk sleeves passing through
exterior walls watertight using lead wool.
6 17. Provide chromium plated floor, wall and ceiling plates to cover exposed piping
7 passing through surfaces; furnish Grinnell Fig. 10, American Standard, or
8 equal.
9
10 18. Underground piping shall be cradled and backfilled as specified under
11 Sections 02221, as applicable. The use of slag for cradle or backfill material
12 under, around or over steel, copper and brass pipe will be prohibited.
13
14 3.02 TESTING
15
16 After all piping has been connected up in place and before application of
17 insulation or covering, the Contractor shall test to the satisfaction of the Engineer
18 all piping in accordance with the requirements of Section 01 6 2 5 of these
19 Specifications, as applicable. Any leaks which develop shall be made tight before
20 final acceptance of the work, by rewelding, tightening, renewing packing, or
21 replacing materials, as required or as ordered. Caulking will not be permitted. All
22 labor, material and equipment for tests shall be furnished by the Contractor. After
23 all lines have been tested and approved, they shall be blow n dry with
24 compressed air and carefully cleaned by the Contractor.
25
26 3.03 DISINFECTION
27
28 All steel or copper or brass piping carrying potable water shall be disinfected after
29 testing, in accordance with the procedures specified in Section 01625, as applicable.
30
31
32 END OF SECTION
33
34
SMALL DIAMETER METAL PIPE AND FITTINGS
15080-10 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15094
2
3 PIPE HANGERS AND SUPPORTS
4
5 PART 1 — GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. It is the intent of the project to remove existing pipe supports, hangers, and
10 straps and furnish and install new pipe supports, hangers, and straps as
11 shown on the Drawings.
12
13 B. Furnish all labor, materials, equipment and incidentals and install hangers,
14 supports, concrete inserts, and anchor bolts, including metallic hanging and
15 supporting devices for supporting exposed piping.
16
17 C. All new pipe supports, hangers, straps hardware, clips, unistrut, and anchors
18 shall be 304 stainless steel and shall match the number, type, location, and
19 capacity of the existing supports.
20
21 1.02 QUALIFICATIONS
22
23 A. Hangers and supports shall be of standard design and shall be adequate to
24 maintain the supported load in proper position under all operating conditions.
25 The minimum working factor for pipe supports shall be five (5) times the
26 ultimate tensile of the material, assuming 10 feet of water filled pipe being
27 supported.
28
29 B. All pipe and appurtenances connected to equipment shall be supported in
30 such a manner as to prevent any strain being imposed on the equipment.
31 When manufacturers have indicated requirements that piping loads shall not
32 be transmitted to their equipment, the Contractor shall submit a certification
33 stating that such requirements have been complied with.
34
35 1.03 SUBMITTALS
36
37 A. Submit to the Engineer for review, as provided in the General Conditions, shop
38 drawings of all items to be furnished under this section.
39
40 B. Submit to the Engineer, for review, samples of all materials specified herein.
41
42 PART 2 — PRODUCTS
43
44 2.01 GENERAL
45
46 A. All pipe and tubing shall be supported as required to prevent significant
47 stresses in the pipe or tubing material, valves and fittings, and to support and
PIPE HANGERS AND SUPPORTS
15094-1 03/22/2019
1 secure the pipe in the intended position and alignment. All supports shall be
2 designed to adequately secure the pipe against excessive dislocation due to
3 thermal expansion and contraction, internal flow forces, and all probable
4 external forces such as equipment, pipe and personnel contact. All pipe
5 supports shall be reviewed by the Engineer prior to installation.
6
7 B. All materials used in manufacturing hangers and supports shall be capable of
8 meeting, the respective ASTM Standard Specifications with regard to tests
9 and physical and chemical properties, and be in accordance with MSS SP -58.
10
11 C. Hangers and supports shall be spaced in accordance with ANSI B31.1.0 that
12 the maximum unsupported span shall not exceed 10 feet otherwise specified
13 herein.
14
15 D. Unless otherwise specified herein, pipe hangers and supports shall be
16 manufactured by Piping Technology & Products, Inc. or equal. Any reference
17 to a specific figure or number is for the purpose of establishing a type and
18 quality of and shall not be considered as proprietary.
19
20 2.02 PIPE HANGERS AND SUPPORTS FOR METAL PIPE
21
22 A. Suspended single pipes shall be supported by 304 SS hangers suspended by
23 steel from 304 SS concrete inserts, beam clamps or ceiling mounting as
24 follows:
25
26 1. Hangers:
27
28 Pipe Size, Inches Piping Technology & Products Fig. No.
29 1/2" to 3" 50
30 3" to 30" 83
31 Above 30" See SPECIAL SUPPORTS,
32 Paragraph 2.04
33
34 2. Hanger rods shall be rolled 304 stainless steel machine threaded with
35 Toad ratings conforming to ASTM Specifications and the strength of the
36 rod shall be based on root diameter. Hanger rods shall have the
37 following minimum diameters:
38
39 Pipe Size, Inches Min Rod Diameter, In.
40 Less than 2-1/2 3/8
41 2-1/2 though 4 1/2
42 4 5/8
43 6 3/4
44 8-12 7/8
45 14-16 1
46 20-30 1-1/2
47 Above 30 See SPECIAL SUPPORTS,
PIPE HANGERS AND SUPPORTS
15094-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 Paragraph 2.04
2
3 3. Where applicable, structural attachments shall be beam clamps. Beam
4 clamps, for rod sizes 1/2 -inch through 3/4 -inch shall be equal to Grinnell
5 Fig. No. 229, and for rod sizes 7/8 -inch through 1-1/4 inches shall be
6 equal to Grinnell Fig. No. 228 or equal.
7
8 4. Concrete inserts for pipe hangers shall be designed to be used in
9 ceilings, walls or floors, spot inserts for individual pipe hangers or
10 ceiling mounting bolts for individual pipe hangers, and shall be as
11 manufactured by Ramset/Red Head, or equal, and shall be as follows:
12
13 a. 304 SS Multi Set II drop in style anchors shall be used where
14 applicable and shall be used for hanger rods up to and including
15 7/8 -inch diameter.
16
17 b. Ceiling mounting plates shall be used, where applicable, and be
18 for hanger rod sizes 1 -inch through and including 1-1/4 inches,
19 shall be Fig. 47, Fig. 49 or Fig, 52 as manufactured by Grinnell
20 or equal. All pipe hangers shall be capable of vertical
21 adjustment under load and after erection. Turnbuckles, as
22 required and where applied, shall 304 SS be equal to Grinnell
23 Fig. No. 230. Wall or column supported pipes shall be
24 supported by welded steel brackets equal to Grinnell Fig. 194,
25 195, and 199, as required, for pipe sizes up to and including
26 20 -inch diameter. Additional wall bearing plates shall be
27 provided where required.
28
29 5. Where the pipe is located above the bracket, the pipe shall be set on a
30 0.5 -inch neoprene pad and U -bolt assembly supported by the bracket
31 for pipes 4 -inches and larger or by a U -bolt for pipes smaller than
32 4 -inches. U -bolts shall be equal to Grinnell Fig. 120 and 137.
33
34 6. Where the pipe is located below the bracket, the pipes shall be
35 supported by pipe hangers suspended by steel rods from the bracket.
36 Hangers and steel rods shall be as specified above.
37
38 7. Wall or column supported pipes 8 -inches and smaller may be supported
39 by hangers equal to Grinnell Figures 103, as required.
40
41 B. Floor supported pipes 3 -inches and larger in diameter shall be supported by
42 either cast -in-place concrete supports or adjust -able pipe saddle supports as
43 directed by the Engineer. In general, concrete supports shall be used when
44 lateral displacement of the pipes is probable (unless lateral support is
45 provided), and adjustable pipe saddle type supports shall be used where
46 lateral displacement of the pipes is not probable.
47
PIPE HANGERS AND SUPPORTS
15094-3 03/22/2019
1 1 Each concrete support shall conform to the details shown on the
2 Drawings. Concrete shall be poured after the pipe is in place with
3 temporary supports. Top edges and vertical corners of each concrete
4 support shall have 1 -inch bevels. Each pipe shall be secured on each
5 concrete support by a wrought iron or steel anchor strap anchored to
6 the concrete with cast -in-place bolts or with expansion bolts. Where
7 directed by the Engineer, vertical reinforcement bars shall be grouted
8 into drilled holes in the concrete floor to prevent overturning or lateral
9 displacement of the concrete support. Unless otherwise directed by the
10 Engineer, maximum height shall be five (5) feet.
11
12 2. Concrete piers used to support base elbows and tees shall be similar to
13 that specified above. Piers may be square or rectangular.
14
15 3. Adjustable pipe saddle support shall be screwed or welded to the
16 corresponding size 150 Ib. companion flanges or slip-on welding
17 flanges respectively. Supporting pipe shall be of Schedule 40 steel
18 pipe construction of the size recommended by the pipe support
19 manufacturer. Each flange shall be secured to the concrete floor by a
20 minimum of two (2) expansion bolts per flange. Adjustable saddle
21 supports shall be equal to Grinnell Fig. No. 259. Where used under
22 base fittings, a suitable flange shall be substituted for the saddle. Floor
23 supported pipes less than 3 -inches shall be supported by fabricated
24 steel supports.
25
26 C. Vertical piping shall be supported as follows:
27
28 1. Where pipes change from horizontal to vertical, the pipes shall be
29 supported on the horizontal runs within 2 feet of the change in direction
30 by pipe supports as previously specified herein.
31
32 2. For vertical runs exceeding 15 feet pipes and greater than eight -inches
33 in diameter shall be supported by the fabricated pipe support as shown
34 in the drawings.
35
36 3. Where vertical piping passes through a steel floor sleeve, the pipe shall
37 be supported by a friction type pipe clamp which is supported by the
38 pipe sleeve. Pipe clamps shall be equal to Grinnell Fig. 262. Anchor
39 bolts shall be equal to Kwik -Bolt as manufactured by the McCullock
40 Industries, Minneapolis, Minnesota or Wej-it manufactured by Wej-it
41 Expansion Products, Inc., Bloomfield, Colorado.
42
43 D. All rods, hangers, inserts, brackets, and components shall be 304 Stainless
44 Steel
45
46 2.03 PIPE HANGERS AND SUPPORTS FOR PLASTIC PIPE
47
PIPE HANGERS AND SUPPORTS
15094-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Single plastic pipes shall be supported by pipe supports as previously
2 specified herein.
3
4 B. Multiple, suspended, horizontal plastic pipe runs, where possible, and rubber
5 hose shall be supported by ladder type cable trays such as the Electray
6 Ladder by Husky-Burndy, the Globetray by the Metal Products Division of
7 United States Gypsum, or equal. Ladder shall be of mild steel construction.
8 Rung spacing shall be approximately 18 inches for plastic pipe and 12 inches
9 for rubber nose. Tray width shall be approximately 6 inches for single runs of
10 rubber hose and 12 inches for double runs of rubber hose. Ladder type cable
11 trays shall be furnished complete with all hanger rods, rod couplings, concrete
12 inserts, hanger clips, etc., required for a complete support system. Individual
13 plastic pipes shall be secured to the rungs of the cable tray by strap clamps
14 fasteners equal to Globe Model M -CAC, Husky-Burndy Model SCR or equal.
15 Spacing between clamps shall not exceed 9 feet. The cable shall provide
16 continuous support along the length of the pipe.
17
18 C. Individual clamps, hangers, and supports in contact plastic pipe shall provide
19 firm support, but not so firm as to prevent longitudinal due to thermal
20 expansion and contraction.
21
22 2.04 SPECIAL SUPPORTS
23
24 A. Pipes, requiring special supports as defined in this specification or shown on
25 the drawing, shall be supported by means of a supporting framework anchored
26 into the floor or curbing. The vertical piping shall be suitably secured to
27 horizontal support members connected at each end vertical support members
28 and spaced as required to provide a rigid installation.
29
30 1. The complete supporting system shall be as manufactured by the
31 Unistrut Corporation, Globe -Strut as manufactured by the Metal
32 Products Division of U.S. Gypsum, or equal. Vertical and horizontal
33 supporting members shall be U-shaped channels similar to Unistrut
34 Series P1000.
35
36 2. Vertical piping shall be secured to the horizontal members by pipe
37 clamps or pipe straps equal to Unistrut Series P1100M and Series
38 P2558. All components shall be of 304 stainless steel.
39
40 3. The assemblies shall be furnished complete with all nuts, bolts, and
41 fittings required for a complete assembly.
42
43 4. The design of each individual framing system shall be the responsibility
44 of the Contractor. Shop drawings shall be submitted and shall show all
45 details of the installation including dimensions and types of supports.
46
PIPE HANGERS AND SUPPORTS
15094-5 03/22/2019
1 B. Any required pipe supports for which the supports specified in this Section are
2 not applicable, including pipe supports for above 30 -inch diameter pipe; high
3 temperature and high pressure (greater than 150 psi) shall be fabricated or
4 constructed from standard aluminum shapes in accordance with
5 Specifications, concrete and anchor hardware similar to items previously
6 specified herein and shall meet the minimum requirements listed below and be
7 subject to review by the Engineer.
8
9 1. Pipe support systems shall meet all requirements of this Section and all
10 related Sections of this Specification.
11
12 2.
13 Complete design details of the entire pipe support systems shall be I
provided, for review by the Engineer.
14
15 3. The pipe support system shall not impose loads on the supporting
16 structures, in excess of the loads for which the supporting structure is
17 designed.
18
19 Hanger rods for above 30 -inch pipe shall be a minimum of 1 -1/2 -inch diameter
20 and shall not exceed the Manufacturer's standard maximum recommended
21 safe load.
22
23 2.05 PIPE HANGER AND SUPPORT SPACING
1
1
24
25
26
27
28
29
30
31
32 PART 3 — EXECUTION
33
34 3.01 INSTALLATION
35
Pipe hanger and support spacing shall be in accordance with ANSI B31.1.1.0 and
MSS SP -69. In no case shall the spacing of hangers or supports exceed the
following:
Maximum Unsupported Pipe Span (feet
Nominal Pipe Size -
Inches
Ductile Iron
Steel
PVC -1 and PVC -2
(Sch. 80)
1/2
N/A
5
3.5
3/4
N/A
6
3.5
1
N/A
7
3.8
1-1/4
N/A
7
4.0
1-1/2 - 3
N/A
9
4.0
4
7
10
5.5
5-10
10
10
10
12-48
10
per manufacturer
or as shown on
drawings
10
PIPE HANGERS AND SUPPORTS
15094-6
03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. All pipes, horizontal and vertical, shall be rigidly supported from the building
2 structure with supports. Supports shall be provided at changes in direction
3 and elsewhere as shown in the Drawings or specified herein. No piping shall
4 be supported from other piping or from metal stairs, ladders and walkways,
5 unless it is so indicated on the Drawings, or specifically directed or authorized
6 by the Engineer.
7
8 B. All pipe supports shall be designed with liberal strength and stiffness to
9 support the respective pipes under the maximum combination of peak loading
10 conditions to include pipe weight, liquid weight, liquid movement, and pressure
11 forces, thermal expansion and contraction, vibrations and all probable
12 externally applied forces. Prior to installation, all pipe supports shall be
13 reviewed by the Engineer.
14
15 C. Pipe supports shall be provided to minimize lateral forces through valves, both
16 sides of split type couplings, and sleeve type couplings and to minimize all
17 pipe forces on pump housings. Pump housings shall not be utilized to support
18 connecting pipes.
19
20 D. Pipe supports shall be provided as follows:
21
22 1. Cast iron and ductile iron shall be supported at a maximum support
23 spacing of 10 feet -0 -inches with a minimum of one support per pipe
24 section at the joints.
25
26 2. Supports for multiple PVC pipes shall be continuous wherever possible.
27 Individually supported PVC pipes shall be supported as recommended
28 by the manufacturer except that support spacing shall not exceed five
29 (5) feet.
30
31 3. Support spacing for galvanized steel pipe and copper tubing shall not
32 exceed five (5) feet.
33
34 4. All vertical pipes shall be supported at each floor or at intervals of at
35 least 15 feet by pipe collars, clamps, brackets or wall rests, and at all
36 points necessary to insure rigid construction.
37
38 E. Pipe supports shall not result in point loadings, but shall distribute pipe loads
39 evenly along the pipe circumference.
40
41 F. Effects of thermal expansion and contraction of the pipe shall be accounted for
42 in pipe support selection and installation.
43
44 G. Inserts for pipe hangers and supports shall be installed on forms before
45 concrete is poured. Before setting these items, all Drawings and figures shall
46 be checked which have a direct bearing on the pipe location. Responsibility
47 for the proper location of pipe supports is included under this Section.
PIPE HANGERS AND SUPPORTS
15094-7 03/22/2019
1
2 H. Continuous metal inserts shall be embedded flush with the concrete surface.
3
4 3.02 PRIME COATING
5
6 A. Prior to prime coating, all pipe hangers and supports shall be thoroughly clean,
7 dry, and free from all mill -scale, rust, grease, dirt, paint and other foreign
8 substances to the satisfaction of the Engineer.
9
10 B. All submerged pipe supports shall be prime coated with Koppers 654 Epoxy
11 Primer or equal. All other pipe supports shall be prime coated with Rust -
12 Inhibitive Primer No. 621 as manufactured by Koppers Company, Inc.,
13 Pittsburgh, Pa. or equal.
14
15 C. Finish coating shall be compatible with the prime coating used and shall be
16 applied, as specified in Section 09900.
17
18 3.03 PROTECTION AGAINST ELECTROLYSIS
19
20 A. Where dissimilar metals are used in conjunction with each other, suitable
21 insulation shall be provided between adjoining surfaces to eliminate direct
22 contact and any resulting electrolysis. The insulation shall be bituminous
23 impregnated felt, heavy bituminous coatings, nonmetallic separators or
24 washers.
25
26
27 END OF SECTION
PIPE HANGERS AND SUPPORTS
15094-8 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15100
2
3 VALVES AND APPURTENANCES
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish all labor, materials, equipment and incidentals required for complete
10 and ready operation of all valves and appurtenances shown on the Construction
11 Drawings and as specified herein.
12
13 B. All valves and appurtenances shall be of the size shown on the Construction
14 Drawings. All equipment of the same type shall be from one manufacturer.
15
16 C. All valves and appurtenances shall have the name of the maker and the
17 pressure for which they are designed cast in raised letters some appropriate
18 part of the body.
19
20 D. The equipment shall include, but not be limited to, the following:
21
22 1. Resilient seated and resilient wedge gate valves
23 2. Ball valves
24 3. Butterfly valves for water service
25 4. Eccentric plug valves
26 5. Valve Actuators
27 6. Air release valves
28 7. Air and vacuum valves
29 8. Valve boxes
30 9. Corporation stops and ballcorps
31 10. Flexible Type Expansion joints
32 11. Flange adapter coupling
33 12. Compression Type Flexible couplings
34 13. Unions
35 14. Hose bibbs
36 15. Pressure and vacuum gauges
37 16. Quick connect couplings
38 17. Hydrants
39 18. Tapping saddles, sleeves and valves
40 19. Hydraulic control valves
41 20. Cushioned Swing Check Valve with Bottom Mounted Oil Buffer
42 21. Slanting Disk Check Valve
43 22. Mud Valves
44 23. Telescoping Valves
45 24. Butterfly valves for air service
46
47
VALVES AND APPURTENANCES
15100-1 12/18/2020
1
1 1.02 DESCRIPTION OF SYSTEMS 1
2
3 A. All of the equipment and materials specified herein are intended to be standard I 4 for use in controlling the flow of potable water, wastewater, reclaimed water,
5 chemicals, etc., depending on the applications.
6
I
7 B. Unless otherwise specified herein or on the drawings all resilient seats, seals,
8 and other sealing components of valves and flexible fittings shall be EPDM.
9 I 10 C. All valves are to be provided with an operator mounted such that the valve can
11 be operated from the nearest normal working surface.
12 I 13 1.03 QUALIFICATIONS
14
15
16 A. All of the types of valves and appurtenances shall be products of well- I
established reputable firms, who are fully experienced and qualified in the
17 manufacture of the particular equipment to be furnished. The equipment shall
18
19 be designed, constructed and installed in accordance with the best practices 1
and methods and shall comply with these Specifications, as applicable.
20
21
22 B. For warranty and service purposes all products shall be supplied by I
Manufacturer's authorized municipal sales representative unless otherwise
23 stated herein.
24
I
25 1.04 SUBMITTALS
26
27
28 A. Complete shop drawings of all valves and appurtenances shall be submitted to
I
the Engineer for review, in accordance with the requirements of Section 01340,
29 01300 and the General Conditions.
30 1
31 B. Electric actuated valves shall have information on closing times submitted to the
32 Engineer for review.
33 1
34 1.05 TOOLS
35
36 A. Special tools, if required for normal operation and maintenance, shall be
I
37 supplied with the equipment.
38
39 B. Three (3) sets of spare valve seals or packing materials shall be provided for I
40 each valve. The seals/packing materials shall be in individual containers clearly
41 marked showing the contents and the intended application.
42
1
43 C. Four (4) tee -handled gate wrenches of various lengths shall be furnished to
44 operate all valves with valve boxes.
45
I
46 1.06 VALVE INDICES
47
VALVES AND APPURTENANCES
15100-2 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. The Contractor shall be responsible for furnishing tags for all valves required on
2 the work and installing the tags required for his own work. Tags on above
3 ground valves shall be noncorrosive metal or plastic, 2 inches in diameter, 19
4 gauge thick. Tags for buried valves shall be secured to a concrete base as
5 shown on the Construction Drawings. Submit to the Engineer for approval, two
6 (2) samples of each type of tag proposed and manufacturer's standard color
7 chart and letter styles. Tags shall have stamped on them the information shown
8 on the Construction Drawings and/or the data described herein. The Contractor
9 shall submit to the Engineer, for approval no less than 120 days before start-up,
10 a valve schedule containing all valves required for the work. The schedule shall
11 contain for each valve, the location, type, a number, words to identify the valve's
12 function, and the normal operating position. The information contained in the
13 valve schedules shall be coded on the tags in a system approved by the Owner.
14 Above ground valve tags shall be furnished with noncorrosive metal wire for
15 attachment thereof.
16
17 PART 2 - PRODUCTS
18
19 2.01 RESILIENT SEATED AND RESILIENT WEDGE GATE VALVES
20
21 A. All gate valves 4 inches to 24 inches in diameter shall be resilient seated or
22 resilient wedge, manufactured to meet or exceed the requirements of AWWA
23 C515 of latest revision and in accordance with the following Specifications.
24 Valves shall have an unobstructed waterway equal to or greater than the full
25 nominal diameter of the valve.
26
27 B. The valves are to be non -rising stem with the stem made of cast, forged or rolled
28 bronze shown in AWWA C515. Two stem seals shall be provided and shall be
29 EPDM of the 0 -ring type, one above and one below the thrust collar.
30
31 C. The sealing mechanism shall consist of a cast iron gate having an EPDM
32 coating. The resilient sealing mechanism shall provide zero leakage at the valve
33 design pressure when installed with the line flow in either direction.
34
35 D. The valve body, bonnet, and bonnet cover shall be cast iron ASTM A126, Class
36 B. All ferrous surfaces inside and outside shall have a minimum 10 mil
37 fusion -bonded epoxy coating. A handwheel or wrench nut shall be provided for
38 operating the valve. All Valves are to be tested in strict accordance with AWWA
39 C515.
40
41 E. Handwheels or chain wheels shall be turned left or counterclockwise to open
42 the valves. Handwheels shall be of ample size and shall have an arrow and the
43 word OPEN cast thereon to indicate the direction of opening.
44
45 F. Valves shall have a factory -applied, internal and external, fusion bonded epoxy
46 resin coating with a minimum thickness of 8 mils, conforming to all applicable
47 requirements of the American Water Works Association Standard C550-90
VALVES AND APPURTENANCES
15100-3 12/18/2020
1 entitled "Protective Interior Coatings for Valves and Hydrants".
2
3 G. Valves shall be equal to those as manufactured by American, M&H, Mueller,
4 Kennedy, Clow, or equal.
5
6 2.02 BALL VALVES
7
8 A. PVC ball valves shall be of Type 1, Grade 1 PVC with union, socket, threaded
9 or flanged ends as required. Ball valves shall be full port, full flow, all plastic
10 construction, 150 psi rated with Teflon seat seals and T -handles. PVC ball
11 valves shall be as manufactured by Spears, Plastiline, or equal.
12
13 B. Vented PVC ball valves shall be manufactured to ASTM F 1970 and constructed
14 from PVC Type I, ASTM D 1784 Cell Classification 1245. All 0 -rings shall be
15 Latharge Viton. All valves shall have stem with double 0 -ring seals. All valve
16 handles shall be polypropylene with built-in lockout mechanism. All valve union
17 nuts shall have Buttress threads. All seal carriers shall be Safe -T -Blocked. All
18 valve components shall be replaceable. All valves shall be certified by NSF
19 International for use in potable water service. All 1/2 -inch through 2 -inch valves
20 shall be pressure rated to 235 psi, all 2 -1/2 -inch through 6 -inch, 8 -inch Venturied
21 and all flanged valves shall be pressure rated to 150 psi for water at 73° F.
22 Valve shall have a 1/8 -inch vent hole in the ball to equalize internal fluid
23 pressures. Install valve with ball vent on the pressure (upstream) side when in
24 closed position. Vented ball valves shall be True Union 2000 Industrial Ball
25 Valves as manufactured by Spears or approved equal.
26
27 C. Bronze, brass or stainless steel ball valves shall be of 2 -piece (1 -inch and
28 smaller) or 3 -piece (1 -1/2 -inch and larger) construction. Valves shall be rated
29 for 150 psi saturated steam pressure and 400 psi WOG pressure. Valves shall
30 have stainless steel, bronze or brass body, stainless steel or chrome plated
31 brass ball, replaceable Teflon or TFE seats and seals, blowout proof stem and
32 vinyl covered steel handle. All end connections shall be threaded.
33
34 D. All valves shall be mounted in such a position that valve position indicators are
35 plainly visible when standing on the floor.
36
37 2.03 BUTTERFLY VALVES
38
39 A. Butterfly valves shall conform to the AWWA Standard Specifications for Rubber
40 Seated Butterfly Valves, Designation C504, except as hereinafter specified.
41 Valves, except as specified hereinafter, shall be Class 150A or B, and equal to
42 those manufactured by Henry Pratt Company, DeZurik, American, Kennedy,
43 Mueller or equal. The valve discs shall be constructed of cast iron conforming
44 to ASTM A-48, Class 40, ASTM A-126, Class B or ductile iron conforming ASTM
45 A536, Grade 65-45-12 for Class 150 or less. Ductile iron conforming to ASTM
46 A536, Grade 65-45-12 shall be provided for all Class 250 valves.
47
VALVES AND APPURTENANCES
15100-4 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. The face-to-face dimensions of flanged end valves shall be in accordance with
2 Table 2 of above-mentioned AWWA Specification for short -body valve.
3 Adequate two-way thrust bearings shall be provided. Flange drilling shall be in
4 accordance with ANSI B16.1.
5
6 C. Valve seats shall be EPDM synthetic rubber compound. Valve seats 24 inches
7 and larger shall be field adjustable and replaceable without dismounting
8 operator disc or shaft and without removing the valve from the line. All retaining
9 segments and adjusting devices shall be of corrosion resistant material with
10 stainless Nylock screws and be capable of a 1/8 -inch adjustment. Valves 20
11 inches and smaller shall have bonded or mechanically restrained seats as
12 outlined in AWWA C504. Where elastomer seat is mounted on the valve body,
13 the mating edge of the valve disc shall be 18-8 stainless steel or Nickel -Chrome,
14 80-20%. Where elastomer seat is mounted on the valve disc, the valve body
15 shall be fitted with an 18-8 stainless steel seat offset from the shaft,
16 mechanically restrained and covering 360 degrees of the peripheral opening or
17 seating surface.
18
19 D. The valve body shall be constructed of ductile iron or close grain cast iron per
20 ASTM A-126, Class B with integrally cast hubs for shaft bearing housings of the
21 through boss -type. Butterfly valves for water service of the "wafer" or "spool"
22 type will not be accepted.
23
24 E. The valve shaft shall be turned, ground, and polished constructed of 18-8,
25 ASTM A-276, Type 304 stainless steel and designed for both torsional and
26 shearing stresses when the valve is operated under its greatest dynamic or
27 seating torque. Shaft shall be of either a one-piece unit extending full size
28 through the valve disc and valve bearing or it may be of a stub shaft design.
29 Shaft bearings shall be Teflon or nylon, self -lubricated type.
30
31 F. All valves shall be subject to hydrostatic and leakage tests at the point of
32 manufacture. The valves shall be tested in conformance with AWWA C-504.
33
34 G. Gearing for the operators shall be totally enclosed in a gear case in accordance
35 with Paragraph 3.8 of the above-mentioned AWWA Standard Specification.
36
37 H. The manufacturer shall certify that the required tests on the various materials
38 and on the completed valves have been satisfactory and that the valves conform
39 with all requirements of the Specification and the AWWA standard.
40
41 I. Where indicated on the Construction Drawings extension stems, floor stands,
42 couplings, stem guides and floor boxes, as required, shall be furnished and
43 installed.
44
45 J. Valves shall have a factory -applied, internal and external, fusion bonded epoxy
46 resin coating with a minimum thickness of 8 mils, conforming to all applicable
47 requirements of the American Water Works Association Standard C550-90
VALVES AND APPURTENANCES
15100-5 12/18/2020
1 entitled "Protective Interior Coatings for Valves and Hydrants".
2
3 2.04 ECCENTRIC PLUG VALVES
4
5 A. All plug valves shall be manufactured and installed in accordance with standard
6 ANSI/AWWA C517 Table 1, Resilient -Seated Cast -Iron Eccentric Plug Valves,
7 of the latest revision unless otherwise specified. Manufacturer shall provide
8 affidavit of compliance with AWWA Standard. Valves shall be as manufactured
9 by DeZurik, Val -Matic, Homestead or approved equal.
10
11 B. Plug valves shall be tested in accordance with AWWA C517, latest edition.
12 Each valve shall be performance tested in accordance with Paragraph 5.2 of
13 the above reference and shall be given a leakage test and hydrostatic test as
14 described in Paragraphs 5.2.2 and 5.2.3 of the above reference. The leakage
15 test shall be applied to the face of the plug tending to unseat the valve. The
16 manufacturer shall furnish certified copies of reports covering proof of design
17 testing as described in Section 5.2.4 of the above reference.
18
19 C. Valves shall be of the non -lubricated eccentric type with resilient faced plugs
20 and shall be furnished with end connections as shown on the plans. Flanged
21 valves shall be faced and drilled to the ANSI B16.1 125/150 Ib. standard.
22 Mechanical joint ends shall be in full compliance with ANSI/ AWWA
23 C111/A21.11. Screwed ends shall be to the NPT standard.
24
25 D. Valve bodies shall be of ASTM A126 Class B or ASTM A48, Class 40 cast iron.
26
27 E. Port areas for valves 20 inches and smaller shall be a minimum of 80 percent
28 of full pipe area. Valves 24 -inch and larger shall have a minimum port area of
29 100 percent of full nominal pipe area.
30
31 F All exposed nuts, bolts, springs, washers, etc., shall be zinc or cadmium plated.
32 Valve plugs shall be constructed of ASTM A-48, Class 40 cast iron or ASTM A-
33 536 ductile iron. Resilient plug facings shall be of Neoprene.
34
35 G. Valves shall be furnished with permanently lubricated stainless steel,
36 oil -impregnated bronze or non-metallic upper and lower plug stem bearings.
37
38 H. Valve seats shall be either nickel or stainless steel. Epoxy seats are not
39 acceptable.
40
41 I. Plug valves greater than 6 inches in diameter shall be supplied with manual
42 gear actuators unless otherwise shown on the Drawings.
43
44 J. Shaft seals shall be of the multiple V -ring type with a packing gland follower.
45 Shaft seals shall be externally adjustable and repackable without removing the
46 actuator or bonnet from the valve.
47
48 K. Valves shall have a factory -applied, internal and external, fusion bonded epoxy
VALVES AND APPURTENANCES
15100-6 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 resin coating with a minimum thickness of 8 mils, conforming to all applicable
2 requirements of the American Water Works Association Standard C550-90
3 entitled "Protective Interior Coatings for Valves and Hydrants".
4
5 2.05 VALVE ACTUATORS
6
7 A. General
8
9 1. All gate and plug valve actuators shall conform to AWWA C541 for
10 Hydraulic and Pneumatic Actuators and to AWWA C542 for Electric
11 Actuators.
12
13 2. Butterfly valve actuators shall conform to AWWA C504.
14
15 3. All actuators shall be capable of seating and unseating the disc or plug
16 against the full design pressure and velocity, as specified for each class,
17 into a dry system downstream, and shall transmit a minimum torque to
18 the valve. Actuators shall be rigidly attached to the valve body.
19
20 4. The valve or gate manufacturer is responsible for installation and setup
21 of the actuator that is properly sized for the rated valve pressure.
22
23 5. The Contractor is responsible for handling and installing the valve and
24 actuator in strict accordance with manufacturer's instructions. The
25 Contractor shall replace any actuator damaged, including voiding of
26 warranty, without cost to the Owner.
27
28 B. Manual Actuators
29
30 1. Manual actuators shall have permanently lubricated, totally enclosed
31 gearing with hand wheel and gear ratio sized on the basis of rated valve
32 pressures and actual velocities. Actuators shall be equipped with hand
33 wheel, position indicator, and mechanical stop -limiting locking devices to
34 prevent over travel of the disc in the open and closed positions. They
35 shall turn counter -clockwise to open valves and have an arrow and the
36 word OPEN cast thereon to indicate the direction of opening.
37
38 2. Manual actuators for eccentric plug valves shall be a worm gear type with
39 self-locking features designed to hold the valve in any intermediate
40 position between fully open and fully closed without creeping or fluttering.
41
42 3. Actuators shall be fully enclosed and designed to produce the specified
43 torque with a maximum pull of 80 pounds on the hand wheel or chain
44 wheel. Actuator components shall withstand an input of 450 -foot pounds
45 for 30 -inch and smaller and 300 -foot pounds for larger than 30 -inch size
46 valves at extreme actuator positions without damage.
47
VALVES AND APPURTENANCES
15100-7 12/18/2020
1 4. Valves located above grade shall have hand wheel or chain wheel and
2 position indicators.
3
4 5. Valves located below grade shall be equipped with an extension to raise
5 the 2 -inch square AWWA operating nut to ground level and with a cast
6 iron extension type valve box.
7
8 6. Manually operated valves located six (6) feet or more above the floor
9 level shall be equipped with a chain wheel actuator that allows operation
10 of the valve from the floor without the use of a ladder or steps.
11
12 C. Electric Motor -Operated Actuators
13
14 1. Motor -Operated actuators shall be provided as indicated and in
15 accordance with AWWA C542. Each actuator shall include the electric
16 motor, reduction gearing, valve stem drive nut/bushing, position sensor,
17 overload torque sensor, ductile iron gear case, automatic de-clutchable
18 handwheel, local control & mechanical position indication, and remote
19 control & position indication.
20
21 2. All actuators that are installed greater than five (5) feet above the finished
22 floor surface shall be provided with a remote control unit, such that the
23 vale can be operated while standing at floor grade. The remote control
24 unit shall be hardwired to the actuator and be equipped with all the
25 controls/functionality as on the face of the actuator. Remote controllers
26 shall be mounted between 3 feet and 5 feet from the nearest operator
27 accessible floor surface.
28
29 3. Motors shall be totally enclosed, non -ventilated 480 volt, 3 phase and
30 specifically designed for high torque, non -continuous, low inertia duty.
31 Motors for actuators shall also be specifically designed and rated for 15-
32 minute duty operation at 104°F (40°C). Output capacity shall be
33 sufficient to open or close the valve against the maximum differential
34 pressure when the voltage is 10% above or below normal at the specified
35 service conditions. Motors shall have Class F insulation. Motors must
36 be protected by 3 thermal contacts, which are embedded in the motor
37 windings. The actuator shall be suitable for up to 60 starts per hour for
38 open/close service and 1200 starts per hour for modulating service.
39
40 4. The actuators shall be suitable for use on nominal 3 phase power supply
41 and must include motor, integral reversing starters, local controls and
42 terminals for remote control and indication housed within a self -
43 contained, sealed enclosure. The actuator gearing shall be totally
44 enclosed in a lubricant filled cast iron gearcase suitable for operation in
45 any orientation. Non-metallic gearing is not acceptable. For rising stem
46 valves the output shaft shall be hollow to accept a rising stem, and
47 incorporate thrust bearings of the roller type at the base of the actuator.
VALVES AND APPURTENANCES
15100-8
12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 All gearing and bearings shall be oil or grease lubricated and suitable for
2 year-round service based on prevailing ambient temperature conditions.
3
4 5. The actuator shall be furnished with a handwheel with a maximum rim
5 pull requirement of 60 pounds for valve travel loads. An external manual
6 declutch lever shall be included to place actuator in the manual mode.
7 The lever shall not require more than 10 pounds of force to engage even
8 when the valve has been tightly seated. The lever is to be padlockable
9 in either handwheel or motor mode.
10
11 6. Operation by motor shall not cause the handwheel to rotate, or operation
12 of the handwheel shall not cause the motor to rotate. Handwheel shall
13 operate in the clockwise direction to close.
14
15 7 Manual operation shall be by handwheel. Manual operation will be via
16 power gearing to minimize required rimpull and facilitate easy
17 changeover from motor to manual operation when the actuator is under
18 load. A seized or inoperable motor shall not prevent manual operation.
19
20 8. Two nameplates, made of stainless steel, shall be attached to each
21 actuator; one on the motor housing, showing all relevant motor data, one
22 on the actuator housing showing all relevant actuator data. Special
23 information, such as the valve tag no., shall be shown if required. The
24 nameplates shall be securely fixed to the actuator and motor, so that they
25 cannot be removed or scratched off during shipment, installation,
26 operation or maintenance.
27
28 9. The rated output torque of the motor actuator shall be at least 1.5 times
29 the maximum torque required to open or close the valve at any position
30 including seating and unseating conditions when subjected to the most
31 severe operating condition including any mechanical friction and/or other
32 restrictive conditions that are inherent in the valve assembly. Do not
33 include hammer -blow effect in sizing the actuator to comply with this
34 torque requirement.
35
36 10. The valve manufacturer is responsible to assure that the motor actuator
37 stall torque output does not exceed the torque limits of the valve
38 operating stem or shaft. Maximum torque shall include seating or
39 unseating torque, bearing torque, dynamic torque, and hydrostatic
40 torque. Assume that the differential pressure across the valve is equal
41 to the pressure or head rating of the valve.
42
43 11. Actuator housings, supports, and connections to the valve shall have a
44 minimum safety factor of five based on the ultimate strength or three
45 based on the yield strength of the material used. Actuators shall be 0-
46 ring sealed, watertight to NEMA 4/6 (6 feet for 30 minutes). All external
47 fasteners shall be of stainless steel. Gear case shall be cast iron.
VALVES AND APPURTENANCES
15100-9 12/18/2020
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
12. Torque switch bypass to be provided for the torque sensing system to
inhibit torque switch trip during unseating or during starting in mid travel
against high inertia loads.
13. Test each actuator prior to shipment in accordance with AWWA C542.
The application torque shall be the maximum torque required to open or
close the valve at any position including seating and unseating
conditions.
14. The operator face plate shall include as a minimum:
a. Buttons for OPEN - STOP — CLOSE — RESET.
b. Backlit LCD display showing the actuator status in plain English
text.
c. Lockable selector switch with LOCAL - OFF - REMOTE function.
d. Indication lights for CLOSED, OPEN, RUNNING, and FAULT.
15. The terminal compartment shall provide sufficient space to
accommodate the possible maximum number of incoming wires. A
minimum of three cable entries must be provided. Each cable entry shall
be properly sealed by cable glands during site installation. The cable
glands size shall be chosen by the Contractor, responsible for wiring
during the commissioning phase.
16. Liquid Crystal Display (LCD) — back -lit for setting menu showing status
indication and diagnostic information. The actuator shall include a digital
position indicator with a display from fully open to fully closed in 1%
increments. For all actuators that utilize a battery, the actuator
manufacturer shall furnish one (1) spare battery for each actuator
furnished.
17. Setting of all actuator parameters including the torque levels, position
limits, configuration of the indication contacts, and positioner functionality
shall be accomplished without removing covers from the actuator control
assemblies or housing.
18. Actuators shall be suitable for indoor and outdoor use. The actuator shall
be capable of functioning in an ambient temperature ranging from -20 °F
to +140°F, up to 100% relative humidity. In order to prevent
condensation, a space heater shall be installed inside the actuator,
suitable for continuous operation. The actuator shall be stored according
to the Manufacturer's instructions. If the Contractor voids the actuator
warrantee in any way, he shall replace the actuator at no cost to the
Owner.
19. Actuators are to receive remote input commands for OPEN, CLOSE, and
VALVES AND APPURTENANCES
15100-10 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 POSITION (as required). Actuators are to provide remote indication as
2 listed above.
3
4
5 20. Contractor is to provide startup, inspection, and instruction services from
6 the Manufacturer's authorized technical representative. Startup and
7 inspection shall not be less than one (1) day for each actuator and one
8 (1) additional day to provide training for plant personnel in the proper
9 operation and maintenance of all electric actuators.
10
11 21. The Contractor shall provide digital interface hardware compatible with
12 an Allen Bradley SLC 5/05 PLC for the actuators. Digital control protocol
13 shall be non-proprietary Modbus. Contractor shall submit the Modbus
14 digital protocol with information supporting compatibility with an AB SLC
15 5/05 and details for programming and interfacing. The actuator
16 manufacturer shall provide all hardware, communication modules for the
17 actuator and software required for commissioning, operation, and
18 maintenance of the actuators and digital control system. The Contractor
19 shall furnish and install sufficient quantities of a Modbus communication
20 module as manufactured by ProSoft Technology or equal, in the AB SLC
21 5/05 to which the valves are connected. The Contractor shall be
22 responsible for furnishing and installing transient surge protection on all
23 Modbus communication wiring both ends of termination.
24
25 22. The Contractor shall furnish all programming of the PLC and the SCADA
26 HMI and HMI graphics (specified in Division 13) so as to display all
27 available signals/I/O from the actuator through Modbus (such as all
28 torque information, valve position, etc.) whether shown on Table 13640-
29 1 or not.
30
31 23. All electric actuators for this project shall be provided by one
32 Manufacturer. Contractor shall coordinate installation on valves and
33 gates with valve and gate manufacturers. Electric actuators shall be as
34 manufactured by EIM Tec 2000, Auma Matic, Rotork IQ, Limitorque or
35 approved equal.
36
37 24. Each actuator shall be warranted for a minimum of 24 months from the
38 date of system acceptance by the Owner.
39
40 2.06 AIR RELEASE VALVES
41
42 A. The air release valves shall be installed as shown on the Drawings or as
43 required elsewhere in these specifications. The valves shall have a cast iron or
44 ductile iron body cover and baffle, stainless steel float, EPDM seat and stainless
45 steel trim. The fittings shall be threaded. Air release valves shall be equipped
46 with a vacuum ball or check feature in order to prevent air from entering the
47 valve during vacuum conditions. The valves for wastewater and sludge
VALVES AND APPURTENANCES
15100-11 12/18/2020
1
2
3
4
5
applications shall be Model D-025 as manufactured by A.R.I., Model ASR
Series 400 as manufactured by DeZurik, or equal. Air release valves for
reclaimed and potable water service shall be A.R.I. Model D -040 -C -VAC or
equal.
6 B. Sewage Air Release Valves shall have an elongated body and be designed to
7 operate automatically (open) while pressurized allowing accumulated air in the
8 pipeline, sewage pump or wastewater system to escape through the air release
9 orifice without spillage.
10
11 C. After accumulated air escapes through the air release orifice, the valve orifice
12 shall be closed by a needle mounted on a compound lever mechanism. The
13 lever mechanism is energized by a concave float. The air release orifice will
14 then remain closed until more air accumulates and the opening cycle repeats
15 automatically.
16
17 D. Valve internal linkage shall be fitted with a stem having a stainless steel concave
18 float threaded onto the opposite end. The internal compound lever mechanism
19 shall be stainless steel to prevent corrosion.
20
21 E. Valve concave float shall hang inside the valve body, slightly above the inlet and
22 maintain an air gap between the lever mechanism and the waste media.
23
24 F. If specified, optional Backflushing attachments shall include Blowoff valves, with
25 quick disconnect couplings, and minimum 5' (1.5m) hose for flushing.
26
27 G. Two Year Warranty shall be provided for all valves.
28
29 H. A stainless steel or brass ball valve shall be provided on the inlet of all air release
30 valves. Stainless steel or brass piping shall be provided for air release valves
31 on pumps.
32
33 2.07 AIR AND VACUUM VALVES
34
35 A. The air and vacuum valves for the transfer pump discharge lines shall be
36 installed as shown on the Construction Drawings. The valves shall have a cast
37 iron body cover and baffle, stainless steel float, and an EPDM seat. The valves
38 shall be 2 -inch threaded connection. Air and vacuum valves shall be equipped
39 with a baffle to protect the float from direct contact with the rushing air and water
40 and to prevent the float from closing prematurely in the valve. The valves shall
41 be Model D -040-C as manufactured by A.R.I. or equal.
42
43 B. A stainless steel ball valve shall be provided on the inlet of all air and vacuum
44 valves.
45
46 2.08 TELESCOPING VALVES
47
VALVES AND APPURTENANCES
15100-12 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Furnish and install new 6 -inch telescopic valve assembly at the location shown
2 on the Drawings. .
3
4 B. Each valve assembly shall be of the rising stem type and shall be complete and
5 include but not be limited to the following components:
6
7 ■ Cast iron or ductile iron floor mounting pedestal
8 ■ Manual, rack and pinion style lifting mechanism with a cast hand wheel
9 ■ A clear acrylic rack cover with a calibrated Mylar strip position indictor
10 shall be provided.
11 ■ Stem Guide (brass, bronze or UHMW polyethylene)
12 ■ Bail (304L ASTM A240 stainless steel)
13 ■ Slip Tube with v -notch (304L ASTM A240 Stainless Steel)
14 ■ Gasket Retainer and Flange (stainless steel)
15
16 C. The slip tube shall be of 304 stainless steel and manufactured from seamless
17 pipe minimum 1/8 -inch wall thickness. The finish O.D. of the tube shall be within
18 + 0.04 inches runout, cylindrical within 0.100 TIR and have a smooth 125 micro -
19 inch or better surface. The slip tube shall have two opposing v -notch weirs at
20 the top and penetrate the existing riser pipe a minimum of 3 -inches in the up
21 position and have a 12 -inch minimum travel as shown on the drawings.
22
23 D. The bail shall be of the same material as the slip tube and shall be rigidly welded
24 to the slip tube and shall be connected to the rack stem with a flanged type
25 connection and multiple fasteners. A connection with the stem penetrating a
26 single hole in the bail with jamb nuts on either side of the bail is not acceptable.
27
28 E. A stainless steel companion flange and Buna-N wiper gasket shall be installed
29 and attached to the top of the riser pipe. The gasket shall be of split design,
30 sandwiched between the riser pipe flange and the companion flange, and
31 replaceable without removing the slip tube from the riser pipe or any of the lifting
32 mechanism components.
33
34 F. Lifts shall be rack and pinion type with a hand wheel and a worm type gearbox
35 mechanism with bronze bushings. The valve assembly shall be mounted to a
36 floor stand pedestal. The lifting mechanism shall be self-locking and able to
37 secure the rack in any infinite position throughout the travel range. All moving
38 components of the worm type gearbox shall be replaceable without removing
39 the rack assembly from the valve body.
40
41 G. The valve manufacturer shall select the proper size handwheel to ensure that
42 the valve can be operated with no more than a 40 Ib effort and shall be a
43 minimum of 16 -inches in diameter of cast aluminum, cast iron, or stainless steel.
44 An arrow with the word "OPEN" shall be permanently attached or cast onto the
45 wheel to indicate the direction or rotation to open the valve. The handwheel
46 shall be removable.
47
VALVES AND APPURTENANCES
15100-13 12/18/2020
1 H. Stainless steel anchor bolts shall be used to mount the floor stand assembly to
2 the support. Cleaning, shop prime coating, and finish painting of the floor stand
3 assembly shall be as specified in Section 09865 and Section 09900.
4
5 I. The telescoping valve shall be machined, assembled, and tested in the USA for
6 quality assurance.
7
8 J. Manufacturer shall show proof of ISO 9001:2008 certification.
9
10 K. The telescoping valve assemblies shall be manufactured by Troy Valve or
11 approved equal.
12
13 2.09 VALVE BOXES
14
15 A. All new buried valves shall have cast-iron three-piece valve boxes. Valve boxes
16 disturbed by construction shall be replaced with new valve boxes. Valve boxes
17 shall be provided with suitable heavy bonnets and to extend to such elevation
18 at or slightly above the finished grade surface, as shown on the details of the
19 drawings. The barrel shall be two-piece, sliding type, having 5 -1/4 -inch shaft.
20 The upper section shall have a flange at the bottom having sufficient bearing
21 area to prevent settling and shall be complete with cast iron covers.
22
23 B. All valves shall have actuating nuts extended within 12 inches of the top of the
24 valve boxes. Valve boxes shall be provided with concrete base and valve
25 nameplate engraved with lettering 1/8 -inch deep as shown on the Construction
26 Drawings.
27
28 2.10 CORPORATION STOPS AND BALLCORPS
29
30 A. Corporation stops for connections to ductile iron piping or service saddles shall
31 be all brass or bronze suitable for 150 psi operating pressure and shall be of
32 sizes required and/or noted on the Construction Drawings.
33
34 B. Corporation stops shall be manufactured to conform to AWWA Standard C800
35 and shall be Ford Ballcorp Corporation Stop or equal.
36
37 2.11 FLEXIBLE TYPE EXPANSION JOINTS
38
39 A. Expansion joints shall be manufactured of molded EPDM rubber with filled
40 arches and wire reinforcement. Joints shall be reinforced with baked enamel
41 ductile iron or split galvanized steel retaining rings placed directly against the
42 inside of the flange to prevent damage to the rubber surface when the bolts are
43 tightened. Flanges shall be drilled to ANSI 150#. Rated working pressure shall
44 be 150 psi. Retaining rings, control rods, bolts, nuts, and washers shall be
45 coated according to Section 09900 or shall be 304 or 316 stainless steel.
46
47 B. Joints shall be rated for a minimum operating temperature of 180°F.
VALVES AND APPURTENANCES
15100-14 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
2 C. Tapered expansion joints shall be eccentric, single arch, and shall be capable
I
3
4 of a 1/2 -inch maximum lateral deflection. Double arch expansion joints shall be
required where called out on the drawings.
5
I
6
7 D. Joints shall be provided and installed with the manufacturer's standard control
rods. Total joint deflection shall not exceed the manufacturer's recommended
8 maximum. Joints shall be installed in neutral position. Manufacturer shall
9 recommend pressure and spring rates for pipe expansion joints.
10
11 E. Expansion joints shall be Flexicraft, Mercer Series FER, Proco, Red Valve
I
12 Redflex, or equal.
13
14 2.12 FLANGE ADAPTER COUPLINGS
I15
16 A. Flange adapter couplings shall be of the sizes shown on the Construction
17 Drawings.
I18
19 B. Flange adapter couplings shall have a 150 psi minimum pressure rating.
20
I
21 C. All couplings shall be restrained and shall have a sufficient number of anchor
22 studs to meet or exceed the test pressure rating for this project, 150 psi
23 minimum.
I
24
25 D. Couplings shall be JCM Model 301R, Ebba Iron Series 2100 Megaflange, or
26 equal.
I27
28 2.13 COMPRESSION TYPE FLEXIBLE COUPLINGS
29
I
30 A. Flexible couplings shall be either the split type or the sleeve type as shown on
31 the Construction Drawings.
32
I
33 B. Split type coupling shall be used with all interior piping and with exterior piping
34 as noted on the Construction Drawings. The couplings shall be mechanical type
I35 for radius groove piping. The couplings shall mechanically engage and lock
36 grooved pipe ends in a positive couple and allow for angular deflection and
37 contraction and expansion.
'38
39 C. Couplings shall consist of malleable iron, ASTM Specification A47, Grade
40 32510 housing clamps in two or more parts, a single chlorinated butyl
I41 composition sealing gasket with a "C" shaped cross-section and internal sealing
42 lips projecting diagonally inward, and two or more oval track head type bolts
43 with hexagonal heavy nuts conforming to ASTM Specification A183 and A194
I44 to assemble the housing clamps. Bolts and nuts shall be hot -dipped galvanized
45 after fabrication.
46
I47 D. Victaulic type couplings and fittings may be used in lieu of flanged joints. Pipes
VALVES AND APPURTENANCES
1
15100-15 12/18/2020
1 shall be radius grooved as specified for use with the Victaulic couplings.
2 Flanged adapter connections at fittings, valves, and equipment shall be Victaulic
3 Vic Flange Style 741, equal by Gustin-Bacon Group, Division of Certain -Teed
4 Products, Kansas City, Kansas or equal.
5
6 E. Sleeve type couplings shall be of ductile iron and shall be Dresser Style 38 or
7 40, ROMAC 501 RC, as shown on the Construction Drawings, or equal. The
8 coupling shall be provided with 316 SS hardware unless indicated otherwise.
9
10 F All couplings shall be furnished with the pipe stop removed.
11
12 G. Couplings shall be provided with gaskets of a composition suitable for exposure
13 to the liquid within the pipe.
14
15 H. If the Contractor decides to use victaulic couplings in lieu of flanged joints, he
16 shall be responsible for supplying supports for the joints.
17
18 2.14 UNIONS
19
20 A. Unions on ferrous pipe 2 inches in diameter and smaller shall be 150 pounds
21 malleable iron, zinc -coated. Unions on water piping 2-1/2 inches in diameter
22 and larger shall be flange pattern, 125 -pound class, zinc -coated. Gaskets for
23 flanged unions shall be of the best quality EPDM. Unions shall not be concealed
24 in walls, ceilings, or partitions.
25
26 2.15 HOSE BIBBS
27
28 A. Hose bibbs shall be brass, polished chromium plated, as manufactured by
29 Chicago Faucet Company or equal. Contractor shall install a nonpotable water
30 sign over every hose bibb connected to a nonpotable water line. Such signs
31 shall be as shown in the Construction Drawings and shall read:
32
33 BIOHAZARD
34 NONPOTABLE WATER
35 DO NOT DRINK / NO BEBER
36
37 2.16 PRESSURE AND VACUUM GAUGES
38
39 A. All pumps furnished under this contract shall have pressure/vacuum gauges
40 installed on their respective suction lines and pressure gauges installed on their
41 discharge lines. All pressure and vacuum gauges furnished under this Contract
42 shall be mounted per manufacturer requirements using tapping saddles and
43 sleeves specified in Section 15100, 2.19.
44
45 B. Each gauge shall be silicone filled direct mounted, 316 stainless steel case with
46 a 4 -1/2 -inch diameter dial and furnished with a clear glass crystal window, and
47 1/2 -inch shut-off valve. Provide stainless steel diaphragm seals between
VALVES AND APPURTENANCES
15100-16 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 shut-off valve and pressure gauge on all lines with nonclear matter in
2 suspension of solution. All gauges shall be weatherproofed.
3
4 C. Pressure gauge shall be bourdon tube type with 270 degrees pointer travel.
5 Dials shall be white finished aluminum with black graduations and figures, and
6 size shall be 4-1/2 inches diameter. The face dial shall read in units of both
7 pounds per square inch and feet of head.
8
9 D. A piston or porous type snubber to suppress and dampen pressure pulses and
10 spikes shall be installed immediately upstream of all gauges. The snubbers
11 shall be 316 stainless steel or brass as recommended by the gauge
12 manufacturer. All internal components of the snubber shall be compatible with
13 the media being measured.
14
15 C. Suction gauges shall read from 10 inches of mercury vacuum to 50 feet of head.
16 Discharge gauges shall read from zero feet of head to 130 percent of maximum
17 range pressure without damage to gauge or sensing element.
18
19 D. Pressure gauges shall be as manufactured by Ashcroft, Wika, Ametek, U.S.
20 Gauge or approved equal.
21
22 2.17 QUICK CONNECT COUPLINGS
23
24 A. Quick connect couplings shall be Model 633-E hose shank adapter and Model
25 633-C hose shank coupler as manufactured by Dover Corporation OPW
26 Division, Cincinnati, Ohio, Ever-tite Coupling Co., Inc., New York, New York, or
27 equal.
28
29 2.18 HYDRANTS
30
31 A. Fire hydrants shall be for 6 -inch pipe connections with 5-1/4 inch valve opening
32 and two 2-1/2 inch and one 4-1/2 inch steamer connections. Hydrants shall be
33 designed for 150 pounds working pressure and shall conform to the
34 requirements of AWWA Specification C502, "Standards for Dry Barrel Hydrants"
35 (latest revision) for post type used in public water supply systems.
36
37 B. All working parts shall be of cast iron and high-grade bronze. All hose threads
38 shall be National Standard threads. The 2-1/2 inch nozzles shall have 60'
39 V -threads, 7-1/2 threads per inch and 3-1/16 inch outside diameter of the male
40 thread. The 4-1/2 inch steamer nozzle shall have four threads per inch and 5-
41 3/4 inch outside diameter of the male threads.
42
43 C. Hydrant shoes shall be provided with lugs for strapping and hydrants shall be
44 held in place with bolted rods designed to absorb all thrust.
45
46 D. All fire hydrants shall be provided with an auxiliary gate valve so that the water
47 to the hydrant may be shut off without the necessity of closing any other valve
VALVES AND APPURTENANCES
15100-17 12/18/2020
1 in the distribution system.
2
3 E. Hydrants shall be painted one coat of red primer paint at the factory and two
4 finish coats of an approved paint after installation, color as directed, all in
5 accordance with Division 09 Specifications.
6
7 2.19 TAPPING SADDLES, SLEEVES AND VALVES
8
9 A. Tapping saddles shall be fabricated of epoxy -coated ductile iron and suitable for
10 either wet or dry installation. The sealing gasket shall be the "O" -Ring type
11 suitable for the applicable service. Tie straps and bolts shall be 304L stainless
12 steel. Saddles shall be as manufactured by Mueller, or equal.
13
14 B. Tapping sleeves shall be constructed of epoxy -coated ductile iron or 304 stainless
15 steel and shall provide a full circumferential seal. All tapping sleeves shall be
16 suitable for tapping ductile iron pipe, C-900 PVC pipe, asbestos cement pipe and
17 all pipe manufactured in accordance with ANSI A21 Standard. Tapping sleeves
18 shall be Mueller Model H-304, Ford FTSC, JCM 432, or equal.
19
20 C. All tapping sleeves shall be split sleeve design with one half containing the outlet
21 half of the sleeve, the hub, and the other half completing the encompassing effect
22 of the sleeve, the back. A 3/4 -inch NPT test plug shall be provided on the outlet
23 throat of the sleeve for pressure testing the sealed sleeve at 150 psi prior to
24 tapping the pipe. All tapping sleeves shall allow a full size cutting head to pass
25 through the outlet of the hub. All bolts joining the two halves of the sleeve shall
26 be high strength, low alloy steel in accordance with Section 11-6.5 of AV VVA C-
27 111, latest edition.
28
29 D. All tapping sleeve connection flanges shall be a 150 Ib flange joint with a counter
30 bore per MSS SP -60 dimensions.
31
32 E. Mechanical joint tapping sleeves shall, after bolting the halves together, form a
33 mechanical joint at each end of the sleeve. The sleeve shall then be sealed to
34 the pipe by assembling the mechanical joint using split gaskets and follower
35 glands.
36
37 F Service saddles shall be double strap, ductile iron, or brass full circle type
38 saddles, as applicable. Sealing gaskets shall be suitable for the applicable
39 service and straps shall be 304L stainless steel. Service saddles shall be as
40 manufactured by Mueller or approved equal.
41
42 G. Tapping valves shall be gate valves satisfying the requirements for gate valves
43 specified herein. Tapping valves shall be comparative with the connecting sleeve
44 or saddle and shall be specially designed for wet tapping installation operations.
45
46 2.20 HYDRAULIC CONTROL VALVES (HCV)
47
VALVES AND APPURTENANCES
15100-18 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. HCVs shall be full port with throttling plugs, single -seated, diaphragm -actuated
2 globe pattern valves. V -port throttling plugs, anti -cavitation cages or orifice
3 plates shall be provided to reduce the potential for cavitation damage. The
4 diaphragm assembly shall be the only moving part and shall form a sealed
5 chamber in the upper portion of the valve, separating operating pressure from
6 line pressure. HCVs shall be either of the double chamber design, or single
7 chamber design with a separating partition between the lower surface of the
8 diaphragm and the main valve, or be capable of being modified to a double
9 chamber design. Double chamber valves shall be furnished with a removable
10 plug between the upper and lower chambers.
11
12 B. HCV body and cover shall be of a ductile iron ASTM Grade A-536, rated for a
13 250 psi working pressure, and shall have a factory -applied, internal and
14 external, fusion bonded epoxy resin coating with a minimum thickness of 8 mils,
15 conforming to all applicable requirements of the American Water Works
16 Association Standard C550-90 entitled "Protective Interior Coatings for Valves
17 and Hydrants". HCV ends shall be Class 150 Ib flanges per ANSI Standard
18 B16.42.
19
20 C. The diaphragm assembly shall include a stainless steel shaft of sufficient
21 diameter for the service intended, and fully guided by a bearing in the separating
22 partition or by a bearing in the valve cover and an integral bearing in the valve
23 seat. The seat shall be a solid, one-piece design. Valve trim and seat shall be
24 type 304 or 316 stainless steel.
25
26 D. HCV seat, shaft and the bearing in the valve cover shall be removable. If used,
27 the lower bearing of the valve shaft shall be contained concentrically within the
28 seat and shall be exposed to the flow on all sides to avoid deposits. The valve
29 body and cover shall be machined with a locating lip to insure proper alignment
30 of the valve stem. "Pinned" covers shall be permitted. HCVs shall be furnished
31 with stainless steel position indicators.
32
33 E. HCVs shall contain a resilient seat disc forming a tight seal against a single
34 removable seat. The disc guide shall be contoured and shall hold the seat disc
35 firmly in place. The diaphragm shall not be used as the seating surface. The
36 disc retainer shall be of a one-piece design. The diaphragm shall consist of
37 nylon fabric bonded with EPDM rubber. The diaphragm shall be fully supported
38 in the valve body and cover by machined surfaces.
39
40 F All necessary repairs and/or modifications other than replacement of the main
41 valve body shall be possible without removing the valve from the pipeline.
42 Packing glands and/or stuffing boxes shall not be permitted.
43
44 G. Pilot Systems
45
46 1. The pilot system shall be fully assembled and installed on the main valve
47 by the manufacturer prior to shipping and shall consist of a solenoid
VALVES AND APPURTENANCES
15100-19 12/18/2020
1 control, a backpressure sustaining control, a modulating level (float)
2 control (to be provided as a separate device for installation in the tank),
3 rate of flow control, orifice plates, pilot isolation valves, opening and
4 closing speed controls, and all necessary tubing and fittings. Tubing shall
5 be copper, fittings shall be brass. All rubber components in the pilot shall
6 be EPDM.
7
8 2. The solenoid control shall be as manufactured by the ASCO Corporation.
9 The solenoid control shall be 120 volt AC, 60 Hertz and shall have a
10 NEMA 4 weatherproof enclosure. All rubber components in the solenoid
11 shall be EPDM.
12
13 3. The backpressure sustaining controls shall be a direct -acting, adjustable,
14 spring-loaded, diaphragm valve designed to permit flow when controlling
15 pressure exceeds or falls below the adjustable spring setting. Sustaining
16 Pilot control sensing shall be upstream of the pilot system strainer so
17 accurate control may be maintained if the strainer is partially blocked. A
18 full range of spring settings shall be available in ranges from 0-175 psi.
19
20 4. The pressure reducing controls shall be direct acting, adjustable, spring -
21 loaded, diaphragm valve designed to regulate control valve toward the
22 closed position when downstream pressure exceeds the setpoint of the
23 pilot. Reducing Pilot control sensing shall be downstream of the control
24 valve. A full range spring setting shall be used to offer pressure reduction
25 from 175 psi to7 psi.
26
27 5. The float pilot shall be of the modulating type. The valve shall open when
28 the float is at a low liquid level. The valve shall close drip tight when the
29 float is at a high level. Float controls shall be constructed of brass with
30 304 stainless steel trim, and EPDM synthetic materials. Float rod length
31 shall be as required for the application, but not Tess than 24 -inch for 6-
32 inch valves or 48 -inch for 8 -inch and larger valves. Float rod and linkage
33 materials shall be of PVC or stainless steel, with a polypropylene float
34 ball.
35
36 6. The rate of flow control pilot shall close when controlling differential
37 exceeds the adjustable spring setting. The differential pressure control
38 shall react to changes in the pressure differential sensed across the
39 upstream orifice plate assembly and shall cause the main valve to
40 modulate so as to maintain a constant flow rate, selectable over a 3:1
41 range.
42
43 7 Orifice plate assemblies, with appropriately sized orifice bore, shall be
44 furnished by the valve manufacturer and shall be mounted by the
45 Contractor on the inlet and outlet flanges of the main hydraulic control
46 valve. Where recommended by the valve manufacturer for proper flow
47 measurement and/or operation, the orifice plates shall be installed
VALVES AND APPURTENANCES
15100-20 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 between pipe flanges at locations and in a manner approved by the
2 Engineer, at no additional cost to the Owner. The orifice plate assembly
3 upstream of the HCV shall have a high pressure sensing port on the inlet
4 side and a low pressure sensing port on the outlet side, and shall be
5 furnished with copper sensing tubes with brass fittings, for connection to
6 the differential pressure flow transmitters valve manifolds specified
7 elsewhere in these specifications, as detailed on the drawings. The
8 downstream orifice plate shall be sized to prevent cavitation of the HCV.
9 The valve manufacturer shall be responsible for sizing, selecting and
10 furnishing orifice plates, based on the specified pressures and with 7 feet
11 per second flow rate in the piping in which the HCV is to be installed, over
12 a 4:1 range. Orifice plates shall be of the flange type for mounting
13 between pipe flanges, and be constructed of type 304 stainless steel.
14 The valve manufacturer shall furnish the differential pressure -to -flow
15 calibration data to the supplier of the differential pressure instrument
16 furnished under Section 13610, and shall be responsible for assuring
17 compatibility between the orifice plate and differential pressure
18 transmitter, as applicable.
19
20 8. The surge anticipator high and low-pressure relief pilots shall be direct
21 acting, adjustable, spring-loaded diaphragm actuated valves. The high -
22 pressure pilot shall have a built-in needle valve to adjust the main valve
23 closing speed. The body and cover of the pilot valves shall be of brass
24 or bronze construction with stainless steel trim and resilient seal. The
25 main valve shall be equipped with a mechanical or hydraulic flow-limiting
26 device. Liquid to the pilots must be filtered by a large control canister
27 style filter and cock valves must be provided to isolate the control loop
28 and main valve cover.
29
30 H. Those valves noted on the drawings shall include a hydraulic check feature to
31 close drip tight and prevent reverse flow. This feature shall also include a
32 closing speed control to prevent water hammer.
33
34 1 The valve shall be as manufactured by Bermad, OCV, Ames, or approved equal.
35
Location
Size
Functions
Orifice Plate Bore
Diameter (Inlet/Outlet)
36 ROF = Rate of flow
37 BPS = Back pressure sustaining
38 PRV = Pressure reducing valve
VALVES AND APPURTENANCES
15100-21
12/18/2020
1 SOV = Solenoid operated valve
2 LC = Hydraulic level control
3 CV = Equipped with hydraulic check feature
4 *Existing control valve to be modified and retrofitted with the functions shown in above table.
5
6 J. The valve manufacturer shall warrant all hydraulic control valves supplied
7 against defects in workmanship and materials for a period of five (5) years under
8 normal use, operation and service. If any part of the valve should fail during the
9 warranty period, it shall be replaced in the unit(s) and restored to service at no
10 expense to the Owner.
11
12 K. All hydraulic valve control piping shall be insulated to the satisfactory of the
13 engineer.
14
15 2.21 CUSHIONED SWING CHECK VALVE WITH OIL BOTTOM MOUNTED BUFFER
16
17 A. The body and cover of the swing check valves shall be constructed of cast iron
18 meeting ASTM A126 Grade B, with a bronze or stainless steel seat ring, and a
19 noncorrosive shaft for attachment of weight and lever. Flanges shall be drilled
20 for ANSI Standard B.16.1, 125 Ib. Class. Check valves shall absolutely prevent
21 the return of water or wastewater back through the valve when the inlet pressure
22 decreases below the delivery pressure.
23
24 B. The valves must be tight seating and must operate without hammer or shock.
25 The seat ring must be renewable and shall be securely held in place by stainless
26 steel locking screws.
27
28 C. The disc shall be ductile Iron, utilizing a double crevice hinge to prevent disc
29 tipping, and be connected to a ductile Iron disc arm. The disc seat shall be
30 Buna-N (replaceable) to provide water tight shutoff. The disc arm assembly
31 shall be suspended from the stainless steel shaft.
32
33 D. The valve shall have a bottom hydraulic buffer to permit free open, but positive
34 non -slam control closure of the disc. The hydraulic buffer shall make contact
35 with the disc during the last 10% of closure to control the valve disc until shut -
36 off in a manner to prevent slam and water hammer. The last 10% of closure
37 shall be externally adjustable to suit operating conditions. The hydraulic buffer
38 and oil system shall be removable without need to remove the entire valve and
39 the oil system and shall be totally independent from the main line to prevent
40 corrosion or contamination to the main line media. The buffer rod shall be
41 stainless steel meeting ASTM A582 T303.
42
43 E. The valves shall be as manufactured by APCO Series 6000B with bottom
44 mounted oil buffer or approved equal, and shall be suitable for horizontal
45 installation.
46
47 2.22 SLANTING DISK CHECK VALVE WITH BOTTOM MOUNTED BUFFER
48
VALVES AND APPURTENANCES
15100-22 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Valve body shall be heavy two-piece ASTM A126 Grade B cast iron. The two
2 (2) body halves and body seat shall be 0 -ring sealed and bolted together in a
3 manner to sandwich the body seat on a 55° angle. Each body half shall have a
4 covered access hole for internal inspection and each body half and disc shall
5 be fully machined to accept the attachment of a bottom buffer oil dashpot.
6
7 B. The seat ring and disc ring shall permit replaceability in the field without need
8 for special tools or machining. Disc and seat ring shall be bronze. The area
9 throughout the valve body must be equal to full pipe area.
10
11 C. The pivot pins in the body and the bushings in the disc lugs shall be stainless
12 steel of different hardnesses to prevent galling. The bushings shall be pressfit
13 to prevent wear.
14
15 D. An indicator shall be provided to show position of the disc.
16
17 E. Valve shall be Apco slanting disc check valve or approved equal.
18
19 2.23 MUD VALVES
20
21 A. Mud valves shall be of the heavy-duty flanged type designed to provide a
22 positive seal under both seating and unseating head conditions. The valves
23 shall be rising stem style as detailed on the schedule or plans. Frame, plug and
24 yoke shall be cast iron (ASTM126B) or 316 SS as shown on the plans. Valve
25 operating stem and lift nut shall be bronze (B421) or 316 SS. The seat ring shall
26 be bronze (B62) or 316 SS with a tapered, accurately machined seating face.
27 The plug seat shall be seamless molded EPDM tapered to accurately mate with
28 the seat ring for a positive seal.
29
30 B. Where required, extension stems, floor stands, and stem guides shall be
31 furnished by the valve manufacturer to make a complete and operable unit.
32 Paint will as shown under Division 09 painting specifications.
33
34 C. Valves and accessories shall be manufactured by Troy Valve, M&H Valve, or
35 approved equal.
36
37
38 2.24 BUTTERFLY VALVES FOR AIR SERVICE
39
40 A. Butterfly valves shall be Class 150A or B, and equal to those manufactured by
41 Henry Pratt Company, DeZurik, American, Kennedy, Mueller, Homestead, or
42 equal. The valve discs shall be constructed of cast iron conforming to ASTM
43 A-48, Class 40, ASTM A-126, Class B or ductile iron conforming ASTM A536,
44 Grade 65-45-12 for Class 150 or Tess
45
46 B. The face-to-face dimensions of flanged end valves shall be in accordance with
47 Table 2 of AWWA Specification for short -body valve. Adequate two-way thrust
48 bearings shall be provided. Flange drilling shall be in accordance with ANSI
VALVES AND APPURTENANCES
15100-23 12/18/2020
1 B16.1. All air service valves shall be wafer style.
2
3 C. Valve seats and sealing rings shall be EPDM synthetic rubber compound
4 adequate for constant service at 250 degrees F. Valve seats 24 inches and
5 larger shall be field adjustable and replaceable without dismounting operator
6 disc or shaft and without removing the valve from the line. All retaining
7 segments and adjusting devices shall be of corrosion resistant material with
8 stainless Nylock screws and be capable of a 1/8 -inch adjustment. Valves 20
9 inches and smaller shall have bonded or mechanically restrained seats. Where
10 elastomer seat is mounted on the valve body, the mating edge of the valve disc
11 shall be 18-8 stainless steel. Where elastomer seat is mounted on the valve
12 disc, the valve body shall be fitted with an 18-8 stainless steel seat offset from
13 the shaft, mechanically restrained and covering 360 degrees of the peripheral
14 opening or seating surface.
15
16 D. The valve body shall be constructed of ductile iron or close grain cast iron per
17 ASTM A-126, Class B with integrally cast hubs for shaft bearing housings of the
18 through boss -type.
19
20 E. The valve shaft shall be turned, ground, and polished constructed of 18-8,
21 ASTM A-276, Type 304 stainless steel and designed for both torsional and
22 shearing stresses when the valve is operated under its greatest dynamic or
23 seating torque. Shaft shall be of either a one-piece unit extending full size
24 through the valve disc and valve bearing or it may be of a stub shaft design.
25 Shaft bearings shall be Teflon or nylon, self -lubricated type adequate for
26 constant service at 250 degrees
27
28 F Gearing for the operators shall be totally enclosed in a gear case in accordance
29 with Paragraph 3.8 of the AWWA C-504 Standard Specification.
30
31 G. Where indicated on the Construction Drawings extension stems, operators with
32 extended handles, floor stands, couplings, stem guides and floor boxes, as
33 required, shall be furnished and installed.
34
35 H. Valves shall have a factory -applied, internal and external, fusion bonded epoxy
36 resin coating with a minimum thickness of 8 mils, conforming to all applicable
37 requirements of the American Water Works Association Standard C550-90
38 entitled "Protective Interior Coatings for Valves and Hydrants".
39
40 2.25 SWING CHECK VALVES — LEVER AND WEIGHT
41
42 A. Swing check valves shall be constructed with heavy cast iron or ASTM A536
43 Grade 65-45-12 ductile iron. The valve shall meet the minimum requirements
44 of AWWA C-508. Flanges shall be drilled for ANSI Standard B.16.1, 125 Ib.
45 Class. Check valves shall absolutely prevent the turn of water back through the
46 valve when the inlet pressure decreases below the delivery pressure.
47
VALVES AND APPURTENANCES
15100-24 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. The valves must be tight seating and must operate without hammer or shock.
2 The seat ring shall be replaceable bronze or stainless steel and shall be
3 securely held in place by a threaded joint or other mechanical fastener. The
4 shaft shall be non -corrosive steel. The shaft seals shall be a stuffing box and
5 packing.
6
7 C. Check valves shall be the lever and weight type with an adjustable position
8 weight and lever arm attached to a cast or ductile iron disc assembly to allow
9 adjustment of the closure force and include a side -mounted, corrosion -resistant,
10 spring assist to control closing speed over the final 10% of stroke.
11
12 D. The valves shall be APCO Series 6000 CLW, Kennedy, Val -Matic Swing -Flex,
13 or approved equal, and shall be suitable for horizontal and vertical installation.
14
15 PART 3 - EXECUTION
16
17 3.01 INSTALLATION
18
19 A. All valves and appurtenances shall be installed in the locations shown, true to
20 alignment and rigidly supported. Any damage to the above items shall be
21 repaired to the satisfaction of the Engineer before they are installed.
22
23 B. After installation, all valves and appurtenances shall be tested at least 2 hours
24 at the working pressure corresponding to the class of pipe, unless a different
25 test pressure is specified. If any joint proves to be defective, it shall be repaired
26 to the satisfaction of the Engineer.
27
28 C. Install all floor boxes, brackets, extension rods, guides, the various types of
29 operators and appurtenances as shown on the Construction Drawings that are
30 in masonry floors or walls, and install concrete inserts for hangers and supports
31 as soon as forms are erected and before concrete is poured. Before setting
32 these items, the Contractor shall check all plans and figures which have a direct
33 bearing on their location and he shall be responsible for the proper location of
34 these valves and appurtenances during the construction of the structures.
35
36 D. Pipe for use with flexible couplings shall have plain ends as specified in the
37 respective pipe sections in Division 15.
38
39 E. Flanged joints shall be made with high strength, low alloy Corten bolts, nuts and
40 washers. Mechanical joints shall be made with mild corrosion resistant alloy
41 steel bolts and nuts. All exposed bolts shall be painted the same color as the
42 pipe. All buried bolts and nuts shall be heavily coated with two (2) coats (14-20
43 mils DFT) of bituminous paint comparable to Carboline Bitumastic 300M,
44 Tnemec Series 46H-413 Tneme-Tar, or approved equal.
45
46 F Prior to assembly of split couplings, the grooves, as well as other parts, shall be
47 thoroughly cleaned. The ends of the pipes and outside of the gaskets shall be
VALVES AND APPURTENANCES
15100-25 12/18/2020
1 moderately coated with petroleum jelly, cup grease, soft soap or graphite paste,
2 and the gasket shall be slipped over one pipe end. After the other pipe has
3 been brought to the correct position, the gasket shall be centered properly over
4 the pipe ends with the lips against the pipes. The housing sections then shall
5 be placed. After the bolts have been inserted, the nuts shall be tightened until
6 the housing sections are firmly in contact, metal -to -metal, without excessive bolt
7 tension.
8
9 G. Prior to the installation of sleeve -type couplings, the pipe ends shall be cleaned
10 thoroughly for a distance of 8 inches. Soapy water may be used as a gasket
11 lubricant. A follower and gasket, in that order, shall be slipped over each pipe
12 to a distance of about 6 inches from the end, and the middle ring shall be placed
13 on the substantial completion date unless otherwise requested by the Owner.
14
15 H. Valve boxes with concrete bases shall be installed as shown on the
16 Construction Drawings. Mechanical joints shall be made in the standard
17 manner. Valve stems shall be vertical in all cases. Place cast iron box over
18 each stem with base bearing on compacted fill and top flush with final grade.
19 Boxes shall have sufficient bracing to maintain alignment during backfilling.
20 Knobs on cover shall be parallel to pipe. Remove any sand or undesirable fill
21 from valve box.
22
23 3.02 SHOP PAINTING
24
25 A. Ferrous surfaces of above ground valves and appurtenances to be painted shall
26 receive a coating of rust -inhibitive primer compatible to paint system specified
27 in Section 09900. All pipe connection openings shall be capped to prevent the
28 entry of foreign matter prior to installation.
29
30 3.03 FIELD PAINTING
31
32 A. All metal valves and appurtenances specified herein and exposed to view,
33 except ball valves, shall be painted as part of the work in Section 09900.
34
35 3.04 INSPECTION AND TESTING
36
37 A. Completed pipe shall be subjected to a hydrostatic pressure and leakage in
38 accordance with Section 01625. All leaks shall be repaired and lines retested.
39 Prior to testing, the pipelines shall be supported in an approved manner to
40 prevent movement during tests.
41
42
43 END OF SECTION
VALVES AND APPURTENANCES
15100-26 12/18/2020
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 15480
2
3 ELECTRIC WATER HEATER
4
5 PART 1 - GENERAL
6
7 1.01 SCOPE OF WORK
8
9 A. Furnish and install all labor, equipment, materials, tools and incidentals
10 required for a complete and operable installation of a hot water system as
11 necessary to provide a complete and operational system as shown on the
12 drawings and specified herein. The equipment shall be of the latest design
13 and shall be fabricated of materials and in a fashion that will fully perform
14 the functions described below. An approved Manufacturer shall supply the
15 equipment and the Contractor shall install the equipment.
16
17 B. The hot water equipment shall consist of but not be limited to the following:
18
19 1. ASME Rated Insulated Stainless Steel Water Storage Tank
20 2. Heating Element(s)
21 3. Power and Controls Panel
22
23 C. The equipment shall be installed as shown on the plans, as recommended
24 by the manufacturer, and in compliance with all OSHA, local, state, and
25 federal codes and regulations.
26
27 D. The hot water equipment shall be fully automatic. All components shall be
28 furnished by one manufacturer who shall be responsible for the design,
29 coordination and proper operation of the entire system.
30
31 E. These Specifications are intended to give a general description of the
32 system required, but do not cover all details; which will vary in accordance
33 with the requirements of the equipment as offered. They are, however,
34 intended to cover the furnishing, shop testing, delivery and complete
35 installation and field testing of all materials, equipment and appurtenances
36 for the complete unit as herein specified, whether specifically mentioned in
37 these Specifications or not. The scope of work includes providing a
38 manufacturer's authorized representative to perform startup of the
39 equipment, and to instruct the Owner's personnel in the care, operation and
40 maintenance of all equipment provided under this section
41
42 F This equipment will be used on a potable water system and all materials of
43 the heater that come in contact with the potable water, whether specified or
44 not, shall be NSF -61 certified.
45
46
47
ELECTRICAL WATER HEATER
15480-1 03/22/2019
1 1.02 QUALIFICATIONS
2
3 A. The equipment shall be as supplied from a manufacturer specializing in the
4 design, fabrication and supply of commercial hot water storage and heating
5 systems.
6
7 B. Strict adherence to the standards of design, fabrication, erection, product
8 quality, and long term performance established in this Specification will be
9 required by the Owner and Engineer.
10
11 C. To assure unity of responsibility, all equipment specified in this Section shall
12 be furnished and coordinated by the hot water tank manufacture. The
13 Contractor and supplier shall assume full responsibility for the satisfactory
14 installation and operation of the system. The equipment shall be designed,
15 constructed and installed in accordance with the best practices and
16 methods.
17
18 D. The hot water system shall be as manufactured by AO Smith, Rheem,
19 Bradford White or approved equal.
20
21 1.03 REFERENCE STANDARDS
22
23 A. The design, products, and installation shall comply with at least, but not
24 limited to, the following industry standards, wherever applicable:
25
26 Institute of Electrical and Electronics Engineers (IEEE) Standards
27 National Electrical Manufacturers Association (NEMA)
28 National Electric Code (NEC)
29 Underwriters Laboratories, Inc. (UL)
30 National Fire Protection Association (NFPA)
31 American National Standards Institute (ANSI)
32 Occupational Health and Safety Administration (OSHA)
33 American Society for Testing and Materials (ASTM)
34 National Electrical Contractors Association (NECA)
35 National Electrical Testing Association (NETA)
36 International Building Code (IBC)
37 International Code Council (ICC)
38 International Association of Plumbing and Mechanical Officials (IAPMO)
39 IAPMO Backflow Prevention Reference Manual Second Edition
40 Amercan Society of Mechanical Engineers (ASME)
41
42 1.04 SUBMITTALS
43
44 A. Provide shop drawings and product data as specified in Division 1 for the
45 equipment being furnished. The submittal information shall at minimum
46 include the following:
47
ELECTRICAL WATER HEATER
15480-2 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. Certified shop drawings showing all details of construction,
2 dimensions and anchor bolt requirements.
3 2. Descriptive product literature and catalog cuts
4 3. Complete parts and bill of materials lists for the equipment.
5 4. Recommended spare parts list
6 5. Manufacturer's installation drawings and instructions.
7 6. Wiring and schematic diagrams.
8 7. Operation and Maintenance Data as specified in Division 1.
9 8. Manufacturer's Certificate of Compliance certifying compliance with
10 the referenced Specification and standards
11 9. Certified copies of reports of factory tests specified in this Section
12 and required by the referenced standards.
13 10. Equipment weights and lifting points.
14 11. Recommendations for unloading, handling, short and long term
15 storage.
16 12. A copy of the manufacturer's warranty
17
18 1.05 STORAGE AND PROTECTION
19
20 A. Store products in accordance with the manufacturer's instructions, with
21 seals and labels intact and legible.
22
23 B. Arrange storage in a manner to provide easy access for inspection. Make
24 periodic inspections of stored products to assure that products are
25 maintained under specified conditions, and free from damage or
26 deterioration.
27
28 1.06 SPECIAL TOOLS
29
30 A. Manufacturers of equipment and machinery shall furnish any special tools
31 required for normal adjustment, operations and maintenance, together with
32 instructions for their use. The Contractor shall preserve and deliver to the
33 Owner these tools and instructions in good order no later than upon
34 completion of the Contract.
35
36 1.07 WARRANTY
37
38 A. The manufacturer shall warranty all components against defects in
39 workmanship and material for a period of one (1) year from date of start-up,
40 and the pressure vessel for a full five (5) years Non Pro -Rated from date of
41 start-up.
42
43 1.08 SPARE PARTS
44
45 A. Spare parts to be included with the shipment of the electric water heater
46 include the following:
47
ELECTRICAL WATER HEATER
15480-3 03/22/2019
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
1. One (1) of each type and size of heating elements
2. All consumables used for changing the elements
3. 10 spares of each size fuse used in the control panel
PART 2 — PRODUCTS
2.01 PRODUCT DESCRIPTION:
A. Electric hot water heater, constructed in accordance with Section IV of the
ASME Code for 150 psi working pressure.
The hot water system design criteria is as listed:
Nominal Storage Capacity
Minimum Heating Capacity
Power
Temperature Rise:
B Configuration:
160 gallons
27,800 BTU/hour
480V 3 phase
70 - 195 degrees F
1. The entire water heating package shall be prewired to solderless
terminal lugs, factory tested, complete with a CSA Certified and
ASME Rated T&P relief valve and bear the Underwriters'
Laboratories label.
2. The entire unit is to be complete with all operating controls and
require only plumbing and electrical service connections.
3. The heater shall configured for vertical or horizontal installation as
shown on the drawings and with lifting lugs and a stainless steel
base.
4. Fasteners and hardware throughout system shall be stainless steel
or material of equivalent corrosion resistance
5. Unprotected steel shall not to be used in any components
C. Tank Body:
1. The tank shall be all welded construction designed for 150 psi
working pressure and contain at least 160 gallons of storage.
2. The tank is to be fabricated from 316L stainless steel, and shall not
require any type of anodic protection.
ELECTRICAL WATER HEATER
15480-4 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 D. Insulation: Entire tank is to be insulated with fiberglass insulation or a
2 minimum of two (2) inches of thick polyurethane foam insulation and exceed
3 the latest ASHRAE standard for stand-by heat Toss.
4
5 E. Connections
6
7 1. The cold water inlet shall be 1" Female NPT and include a non -
8 corrosive strata -flow diffuser which prevents incoming cold water
9 from mixing too rapidly with hot water in the tank.
10
11 2. A 3/4" hose connection drain shall be fitted at the bottom of the unit.
12
13 3. The hot water outlet shall be 1" Male NPT and shall include a factory
14 installed built-in heat trap to prevent water from radiating through the
15 piping during stand-by periods.
16
17 4. A separate 1" Female NPT tap is to be provided for relief valve
18 installation. An ASME rated automatic reseating combination
19 temperature and pressure safety relief valve set at 150 psi and 210°F
20 shall be factory supplied
21
22 F. Heating Elements
23
24 1. The heating elements shall be a high quality incoloy sheath electric
25 immersion type, and be completely replaceable.
26
27 2. Heating elements shall be 4 -bolt flange mounted with prewired
28 terminal leads.
29
30 3. A minimum of two (2) heating elements shall be installed
31
32 4. These elements will be switched by magnetic contactors which are
33 operated by a fused control circuit protected by a manual reset high
34 current limit trip device. The control circuit is activated by a master
35 thermostat switch and electronic low water cutoff.
36
37 i. This control shall prevent the entire electrical Toad from being
38 switched on instantaneously. The control shall have even load
39 progressive sequencing which utilizes the "first on, first off'
40 principle thereby equalizing the operating time of heating
41 elements and contactors.
42
43 ii. Each magnetic contactor and heating element circuit will be
44 protected by cartridge type fuses with a minimum of 100,000
45 amp interrupting capacity
46
47
ELECTRICAL WATER HEATER
15480-5 03/22/2019
1 G. Electrical
2
3 1. The heater shall be designed to operate at 480 volts 3 phase 60 Hz
4 (balanced) with all necessary operating controls factory mounted,
5 wired and tested.
6
7 2. Each circuit is to be independently operated through a definite
8 purpose magnetic contactor having a resistive Toad rating exceeding
9 the ampere rating of that particular circuit.
10
11 3. Water temperature shall be controlled through an adjustable snap
12 action surface thermostat. An over -temperature manual reset Hi -
13 Limit shall be factory installed to disconnect all conductors to the
14 heating element(s) in the event of an over -temperature condition in
15 the pressure vessel.
16
17 4. The enclosure shall be NEMA 4x rated of stainless steel construction
18 and have a hinged locking door over electric controls.
19
20 5. Provide electrical equipment and wiring in accordance with Division
21 16.
22
23 H. The mounting base for all equipment shall be fabricated 304 stainless steel.
24
25 PART 3 — INSTALLATION
26
27 3.01 GENERAL
28
29 A. Install equipment in accordance with the approved shop drawings and the
30 manufacturer's installation instructions.
31
32 B. Prior to initial start-up, the manufacturer's representative shall provide
33 written certification to the Owner that the equipment has been installed,
34 tested in accordance with the Manufacturer's approved method, and testing
35 requirements specified herein and shall certify that the equipment is ready
36 for permanent operation.
37
38 3.02 TESTING AND COMMISSIONING
39
40 A. Following completion of construction, the Contractor shall provide startup
41 and acceptance testing as specified in Division 1.
42
43
44 END SECTION
45
ELECTRICAL WATER HEATER
15480-6 03/22/2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16010
2
3 BASIC ELECTRICAL REQUIREMENTS
4
5 PART I - GENERAL
6
7 1.01 RELATED DOCUMENTS: Drawings and general provisions of Contract,
8 including General and Supplementary Conditions and Division 1 Specification
9 sections, apply to work of this Section.
10
11 1.02 CODES:
12
13 A. The work shall be in conformance with the latest adopted version of the
14 following:
15
16 NFPA 70 National Electric Code
17 FBC Florida Building Code
18 NFPA National Fire Protection Association Codes
19
20 B. The installation shall also comply with all applicable rules and regulations
21 of local and state laws and ordinances. Include in the work, without extra
22 cost, any labor, materials, services, apparatus and drawings required to
23 comply with all applicable laws, ordinances, rules and regulations. Inform
24 the engineer of any work or materials which conflict with any of the
25 applicable codes, standards, laws, and regulations before submitting their
26 bid.
27
28 1.03 ROUGH -IN:
29
30 A. Verify final locations for rough -ins with field measurements and with the
31 requirements of the actual equipment to be connected.
32
33 B. Refer to equipment specifications in Divisions 2 through 15 for rough -in
34 requirements.
35
36 1.04 ELECTRICAL INSTALLATIONS:
37
38 A. Existing services shall not be interrupted without prior consent of the
39 owner's authorized representative and may be interrupted only at, and for,
40 the specific time designated by the owner's authorized representative.
41
42 B. Make a thorough examination of the site and the contract documents. No
43 claim for extra compensation will be recognized if difficulties are
44 encountered which an examination of site conditions and contract
45 documents prior to executing contract would have revealed.
46
BASIC ELECTRICAL REQUIREMENTS BID DOCUMENTS
16010 - 1 1/08/2021
1 C. Coordinate electrical equipment and materials installation with other
2 building components.
3
4 D. Verify all dimensions by field measurements.
5
6 E. Arrange for chases, slots, and openings in other building components to
7 allow for electrical installations.
8
9 F Coordinate the installation of required supporting devices and sleeves to
10 be set in poured -in-place concrete and other structural components, as
11 they are constructed. Sequence, coordinate, and integrate installations of
12 electrical materials and equipment for efficient flow of the work. Give
13 particular attention to large equipment requiring positioning prior to
14 closing -in the building.
15
16 G. Coordinate the cutting and patching of building components to
17 accommodate the installation of electrical equipment and materials.
18
19 H. Install electrical equipment to facilitate maintenance and repair or
20 replacement of equipment components. As much as practical, connect
21 equipment for ease of disconnecting, with minimum of interference with
22 other installations.
23
24 I. Coordinate the installation of electrical materials and equipment above
25 ceilings with suspension system, mechanical equipment and systems, and
26 structural components.
27
28 J. Temporary electrical service and construction lighting shall be provided
29 under this section. Provide all Temporary electrical equipment as shown
30 on the drawings for the duration of the project. All Temporary electrical
31 equipment and its installation shall not interfere with the operation of the
32 facility and shall not interfere with access to the existing facility's
33 equipment. Provide for all electrical service for construction period,
34 making all connections and removal of same at job conclusion. Furnish
35 and install temporary lighting for construction period. At job completion,
36 all temporary lamps shall be removed and replaced with new lamps; and
37 all temporary electrical equipment shall be disconnected and removed
38 from the project site.
39
40 K. All existing and new conduit/raceways within the project area shall be
41 properly (maximum of 6 feet between supports) supported. Add support
42 to existing conduit as required to comply with the NEC.
43
44 L. All enclosures for new electrical equipment shall be NEMA 4X stainless
45 (316) steel. All enclosures shall have internal mounting plates for
46 components and an interior safety door.
BASIC ELECTRICAL REQUIREMENTS BID DOCUMENTS
16010 - 2 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 M. There shall be no penetrations of existing clarifier tank or process basin
3 walls. All conduits shall be run surface mounted or on top of walls.
4 Conduit supports or associated hardware shall NOT penetrate existing
5 clarifier tank walls or process basin walls.
6
7
8 1.05 CUTTING AND PATCHING:
9
10 A. Refer to the Division 1 Section: CUTTING AND PATCHING for general
11 requirements for cutting and patching.
12
13 B. Do not endanger or damage installed work through procedures and
14 processes of cutting and patching.
15
16 C. Arrange for repairs required to restore other work because of damage
17 caused as a result of electrical installations.
18
19 D. No additional compensation will be authorized for cutting and patching
20 work that is necessitated by ill-timed, defective, or non -conforming
21 installations.
22
23 E. Perform cutting, fitting, and patching of electrical equipment and materials
24 required to:
25
26 1. Uncover work to provide for installation of ill-timed work.
27
28 2. Remove and replace defective work.
29
30 3. Remove and replace work not conforming to requirements of the
31 contract documents.
32
33 4. Remove samples of installed work as specified for testing.
34
35 5. Install equipment and materials in existing structures.
36
37 6. Upon written instructions from the engineer, uncover and restore
38 work to provide for engineer observation of concealed work.
39
40 F. Cut, remove and legally dispose of, selected electrical equipment,
41 components, and materials as indicated; including, but not limited to,
42 removal of electrical items indicated to be removed and items made
43 obsolete by the new work.
44
45 G. Protect the structure, furnishings, finishes, and adjacent materials not
46 indicated or scheduled to be removed.
BASIC ELECTRICAL REQUIREMENTS BID DOCUMENTS
16010 - 3 1/08/2021
1
2 H. Provide and maintain temporary partitions or dust barriers adequate to
3 prevent the spread of dust and dirt to adjacent areas.
4
5 I. Locate, identify, and protect electrical services passing through
6 remodeling or demolition area and serving other areas required to be
7 maintained operational. When transit services must be interrupted,
8 provide temporary services for the affected areas and notify the owner
9 prior to changeover.
10
11 1.06 ELECTRICAL SUBMITTALS:
12
13 A. Refer to the Conditions of the Contract (General and Supplementary) and
14 Division 1 Section: SHOP DRAWINGS, PRODUCT DATA, AND
15 SAMPLES for submittal definitions, requirements, and procedures.
16
17 B. Submittal of shop drawings, product data, and samples will be accepted
18 only when submitted by the contractor. Data submitted from
19 subcontractors and material suppliers directly to the engineer will not be
20 processed.
21
22 C. Submit Operation and Maintenance Manuals with part lists as specified in
23 Division 1 Project Closeout; for the following electrical equipment: Panel
24 boards, Control Panels, Variable Frequency Drives, Soft Starters. Motor
25 Starters, Motors, Transformers, and Programmable Logic Controllers.
26
27 1.07 PRODUCT OPTIONS AND SUBSTITUTIONS: Refer to the Instructions to
28 Bidders and the Division 1 Section: PRODUCTS AND SUBSTITUTION for
29 requirements in selecting products and requesting substitutions.
30
31 1.08 PRODUCT LISTING:
32
33 A. Prepare listing of major electrical equipment and materials for the project.
34
35 B. Submit this listing as a part of the submittal requirement specified in the
36 Division 1 Section: PRODUCTS AND SUBSTITUTIONS.
37
38 C. When two or more items of the same material or equipment are required,
39 they shall be of the same manufacturer. Product manufacturer uniformity
40 does not apply to raw materials, bulk materials, wire, conduit, fittings,
41 sheet metal, steel bar stock, welding rods, solder, fasteners, motors for
42 dissimilar equipment units, and similar items used in work, except as
43 otherwise indicated.
44
45 D. Provide products which are compatible within systems and other
46 connected items.
BASIC ELECTRICAL REQUIREMENTS BID DOCUMENTS
16010 - 4 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 E. No substitution will be considered unless written request has been
3 submitted to the engineer at least ten (10) days prior to the date for
4 receipt of bids.
5
6 F If the engineer approves any proposed substitutions, such approval will be
7 set forth in an addendum.
8
9 1.09 DELIVERY, STORAGE, AND HANDLING:
10
11 A. Deliver products to project properly identified with names, model numbers,
12 types, grades, compliance labels, and similar information needed for
13 distinct identifications; adequately packaged and protected to prevent
14 damage during shipment, storage, and handling.
15
16 B. Store equipment and materials at the site, unless off-site storage is
17 authorized in writing. Protect stored equipment and materials from
18 damage.
19
20 C. Coordinate deliveries of electrical materials and equipment to minimize
21 construction site congestion. Limit each shipment of materials and
22 equipment to the items and quantities needed for the smooth and efficient
23 flow of installation.
24
25 1.10 RECORD DOCUMENTS:
26
27 A. Refer to the Division 1 Section: PROJECT CLOSEOUT or PROJECT
28 RECORD DOCUMENTS for requirements. The following paragraphs
29 supplement the requirements of Division 1.
30
31 B. Mark drawings to indicate revisions to conduit size and location, both
32 exterior and interior; actual equipment locations, dimensioned from
33 column lines; concealed equipment, dimensioned to column lines;
34 distribution and branch electrical circuitry; fuse and circuit breaker size
35 and arrangements; support and hanger details; change orders; concealed
36 control system devices.
37
38 C. Mark Specifications to indicate approved substitutions; change orders;
39 actual equipment and materials used.
40
41 D. Contractor shall provide engineer with record drawings (AutoCAD
42 compatible file format) and one set of blueprints.
43
44 1.11 WARRANTIES:
45
46 A. Refer to the Division 1 Section: SPECIFIC WARRANTIES for procedures
BASIC ELECTRICAL REQUIREMENTS BID DOCUMENTS
16010 - 5 1/08/2021
1 and submittal requirements for warranties. Refer to individual equipment
2 specifications for warranty requirements.
3
4 B. Compile and assemble the warranties specified in Division 16 into a
5 separated set of vinyl- covered, three-ring binders, tabulated and indexed
6 for easy reference.
7
8 C. Provide complete warranty information for each item to include product or
9 equipment; date of beginning of warranty or bond; duration of warranty or
10 bond; and names, addresses, and telephone numbers and procedures for
11 filing a claim and obtaining warranty services.
12
13 1.12 CLEANING:
14
15 A. Refer to the Division 1 Section: PROJECT CLOSEOUT or FINAL
16 CLEANING for general requirements for final cleaning.
17
18
19
20 END OF SECTION 16010
21
22
23
24
25
26
BASIC ELECTRICAL REQUIREMENTS BID DOCUMENTS
16010 - 6 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16050
2
3 ELECTRICAL EQUIPMENT ENCLOSURE
4
5 PART I - GENERAL
6
7 1.01 SECTION INCLUDES
8
9 A. Pre -fabricated, operation ready electrical equipment enclosure.
10
11 1.02 RELATED SECTIONS:
12
13 A. Section 15050 — Basic Mechanical Methods and Materials.
14
15 B. Section 16050 — Basic Electrical Methods and Materials.
16
17 1.03 REFERENCES:
18
19 A. ANSI C80.1 — Standard for Electrical Rigid Steel Conduit (ERSC).
20
21 B. ANSI/SDI 100 — Recommended Specifications for Standard Steel Doors and
22 Frames.
23
24 C. ASTM A 36 — Standard Specification for Carbon Structural Steel
25
26 D. ASTM A 572 — Standard Specification for High -Strength Low -Alloy
27 Columbium -Vanadium Structural Steel
28
29 E. ASTM C 177 — Standard Test Method for Steady -State Heat Flux
30 Measurements and Thermal Transmission Properties by Mans of the
31 Guarded Hot -Plate Apparatus.
32
33 F ASTM C 518 — Standard Test Method for Steady -State Thermal
34 Transmission Properties by Means of the Heat Flow Meter Apparatus.
35
36 G. ASTM D 2247 — Standard Practice for Testing Water Resistance of Coatings
37 in 100% Relative Humidty.
38
39 H. Federal Specifications (Fed. Spec.) — TT -C -520B — Coating Compounds,
40 Bituminous, Solvent Type, Underbody.
41
42 I. IEEE — C37.2.2 — Guide for Protective Relay Applications to Power System
43 Buses.
44
45
46 J. National Electrical Manufacturers Association (NEMA) 250 — Enclosure for
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 1 1/08/2021
1 Electrical Equipment (1000 V Maximum).
2
3 L. NEC — National Electric Code
4
5 M. Steel Structure Painting Council (SSPC) SP3 — Surface Preparation
6 Standards and Specifications (Power Tool Cleaning).
7
8 N. Steel Structure Painting Council (SSPC) SP 1 — Surface Preparation
9 Standards and Specifications (Solvent Cleaning).
10
11 O. Underwriters Laboratories Inc. (UL) 50 — Enclosure for Electrical Equipment,
12 Non -Environmental Considerations.
13
14 P. Underwriters Laboratories Inc. (UL) 508 — Industrial Control Equipment.
15
16 1.04 SYSTEM DESCRIPTION:
17
18 A. General:
19
20 1. The enclosure is a completely self-contained pre-engineered package
21 custom designed to specific power requirements and environmental
22 conditions. The enclosure is designed to house specified electrical
23 equipment and any associated relay and control panels. The minimum
24 aisle space and clearance around the equipment are designed per
25 Section 110 (working clearances) of the latest National Electric Code.
26
27 2. Provide a NEMA 3R enclosure structure with exterior walls and roof
28 fabricated from interlocking panels to house and protect the internal
29 equipment from the elements.
30
31 a. Type 3R Enclosures are intended for outdoor use primarily to
32 provide a degree of protection against falling rain, sleet and
33 snow; undamaged by the formation of ice on the enclosure
34 (NEMA 250).
35
36 3. Structural grid base and floor system shall be designed for applicable
37 floor loading allowing the enclosure to be lifted and transported with
38 the interior equipment installed.
39
40 B. Design and construction shall conform to the applicable sections of the latest
41 standards as issued by the following agencies, as a minimum:
42
43 1. International Building Code (IBC): Default Structural loading criteria
44 shall be per the IBC.
45
46 2. American National Standards Institute (ANSI).
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 2 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 3. American Society of Civil Engineers (ASCE).
3
4 4. American Institute of Steel Construction (AISC).
5
6 5. American Iron and Steel Institute (AISI) — Specification for the Design
7 of Cold Formed Steel Structural Members.
8
9 6. Metal Building Manufacturers Association (MBMA).
10
11 7. American Society for Testing and Material (ASTM).
12
13 8. American Society for Heating, Refrigeration, and Air Conditioning
14 Engineers (ASHRAE).
15
16 9. National Electric Manufacturers Association (NEMA).
17
18 10. National Electric Code (NEC).
19
20 11. National Fire Protection Association (NFPA).
21
22 12. Steel Door Institute.
23
24 C. Structural Performance
25
26 1. The enclosure shall be designed and constructed to withstand
27 external loading conditions as prescribed by the International Building
28 Code for the specified final location.
29 2. Building components shall be designed to withstand external loading
30 as prescribed by the applicable codes as a minimum, with co -lateral
31 considerations as follows:
32
33 a. Base and floor system shall be designed to withstand all dead
34 and live loads as applicable or a minimum of 250 Ib/sf (1220
35 kg/sm) over the entire floor area, while supported at indicated
36 minimum locations only.
37 b. Maximum deflection of all base members shall not exceed
38 L/240 with all applicable dead and live loads applied.
39 c. Roof loading: Per International Building Code [30 lb/sf (146
40 kg/sm) minimum].
41 d. Wind loading: Per International Building Code3 — Exposure C
42 minimum.
43 e. Seismic: Per International Building Code.
44
45 f. Interior Walls: Interior walls shall be capable of mounting and
46 supporting 400 Ib/If (595 kg/m) and 200 ft -lbs (28 kg -meters) of
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 3 1/08/2021
1 moment / torque at any place along the perimeter wall space,
2 with attachment to the interlocking ribs, or metal studs, located
3 on 16 inches (406 mm) centers behind interior walls.
4 g. Each shipping piece shall be designed for lifting by lugs located
5 along the base perimeter members at 15 feet (4.5 m)
6 approximate intervals.
7 h. All lifting lugs shall be removable.
8 i. The ceiling shall be capable of withstanding a single
9 continuous load of 1000 Ib/If (149 kg/meter) located at mid
10 span of the ceiling panels, and running the entire building
11 length. The ceiling panels shall act alone, structurally and not
12 depend on the roof or the interior equipment for support.
13 j. All shipping splits and other penetrations shall have adequate
14 structural reinforcement via rigid frames or other means to
15 minimize distortion during handling and transportation.
16
17 D. HVAC Performance:
18
19 1. Redunacy: NONE. One or multiple units as required to meet
20 atmospheric and internal heating and cooling requirements.
21
22 2. Redundancy: N+1. Multiple units as required to meet atmospheric and
23 internal heating and cooling requirements plus one additional unit for
24 redundancy purposes.
25
26 3. Redundancy: 100%. Two independent systems consisting of multiple
27 units as required meeting atmospheric and internal heating and
28 cooling requirements.
29
30 4. Exterior Design Temperatures:
31
32 a. Summer: (Per ASHRAE 2.5% design temperature).
33 b. Winter: (Per ASHRAE 97.5% design temperature).
34
35 5. Interior Design Temperatures:
36
37 a. Summer: 80 degree F (27 degrees C).
38 b. Winter: 60 degree F (16 degrees C)
39 c. Occupancy: Number of Persons -
40 d. Ventilation Air (cfm): (L/minute).
41
42
43
44
45 E. Certifications:
46
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 4
1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. The enclosure shall be Third Party certified by UL as NEC (National
2 Electric Code) and / or CEC (Canadian Electric Code) and /or UL 3R
3 RAIN TEST and / or IEEE C37.2.2 — 199 RAIN TEST compliant, and
4 shall bear a UL Label.
5 2. The enclosure design shall be accomplished under the auspices of a
6 Professional Engineer and drawings and supporting calculations will
7 bear the Professional Engineer's seal.
8
9 Part 2 - PRODUCTS
10
11 2.01 ACCEPTABLE MANUFACTURERS:
12
13 A. Acceptable manufacturers: Subject to compliance with requirements,
14 manufacturers offering electrical equipment enclosures which may be
15 incorporated in the work are limited to the following:
16
17 Schneider/Square D
18 ABB
19 Cutler Hammer/Eaton
20
21 B. Set of certified structural design calculations performed by a Professional
22 Engineer registered in the state of Florida. Includes State Certification. It will
23 include wind load calculations in accordance with the State of Florida codes
24 for this location. Note: The "APPROVAL" drawing package will reflect
25 preliminary calculations. Calculations sealed by a professional engineer will
26 be furnished only after customer's final approval and release for manufacture
27 of the Equipment Center. Extra cost will result for any changes to the
28 Equipment Center affecting the layout and/or design after the performance of
29 these calculations.
30
31 2.02 FABRICATION:
32
33 A. All facets of construction through coating and weatherproofing shall be
34 performed indoors, protected from outdoor weather conditions. Construction
35 prior to this stage out-of-doors is not acceptable.
36
37
38
39
40 B. At shipping splits (when required due to transportation restrictions), each
41 open area shall be sealed with 2 inches (52 mm) thick wooden framing and a
42 complete OSB wood cover for temporary protection during transportation and
43 setting. Seams in OSB wood shall be liberally caulked at the exterior.
44
45 C. All permanent coatings and finishes shall be applied inside a dedicated paint
46 booth with ventilation and filtration provisions in compliance with the coating
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 5 1/08/2021
1 manufacturer's requirements. Coatings applied in outside, ambient air
2 conditions shall not be acceptable.
3
4 2.03 MATERIALS AND CONSTRUCTION
5
6 A. Base members shall be ASTM A572 wide flange, ASTM A36 channel,
7 angle and tube shapes forming a self-supporting grid. All members shall
8 be continuously welded to adjoining members.
9
10 B. Floor shall be 1/4 inch (6 mm) minimum thickness flat ASTM A36 steel
11 plate, welded to all longitudinal and transverse base members.
12
13 1. Floor plate seams shall be continuously welded at all joints, and
14 ground smooth to minimize visibility of seams. Welding of floor
15 plate shall be staggered to produce a flat and ripple free surface.
16
17 C. Exterior walls shall be 18ga (1.214 mm) (minimum) aluminum sheet
18 interlocking panels formed by computer numerical controlled equipment to
19 create a tightly interlocking panel design, nominally 3 inches (152 mm)
20 deep. Interlocking panel ribs shall repeat at a typical maximum nominal
21 dimension of 16 inches (406 mm).
22
23 D. Following assembly (and coating) of all interlocking wall panels, each
24 exterior seam shall be neatly caulked using a high -modulus, silicone base
25 product.
26
27 E. Roof material shall be 18ga (1.214 mm) (minimum) aluminum sheet
28 interlocking panels formed by computer numerical controlled equipment to
29 create a tightly interlocking panel design with vertical standing ribs
30
31
32 F. Interior walls shall be 18ga (1.214 mm) (minimum) aluminum sheet firmly
33 attached to interlocking ribs of exterior wall panels utilizing ASTM shear
34 and pull out rated self tapping screws on 24 inches (610 mm) maximum
35 centers. Each interior wall panel shall be formed to receive adjacent
36 panels at overlaps.
37
38 G. Ceiling panels shall be 18ga (1.214 mm) (minimum) aluminum sheet
39 interlocking panels formed by computer numerical controlled equipment to
40 create a tightly interlocking panel design with vertical standing ribs.
41
42 H. Wall insulation shall be secured to exterior wall panels by glue pins, straps
43 or other means prior to assembly of interior wall (liner) panels. Ceiling
44 insulation shall be laid between interlocking ceiling panels. Floor
45 insulation shall be sprayed urethane foam.
46
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 6 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 I. Insulation levels:
2
3 1. Ceiling: Fiberglass batt (R15).
4
5 2. Walls: Fiberglass batt (R15).
6
7 3. Floor: 1 inch (25mm) Spray Applied Polyurethane insulation (R6).
8 4. Equipment Access Doors: 1 inch (25 mm) urethane board (R 7.2)
9 with welded metal cover.
10 5. Personnel Doors: (R2.4).
11
12 J. The entire roof perimeter shall be trimmed with a fascia that aesthetically
13 hides the standing rib roof edges, prevents high velocity rainwater run-off,
14 and prevents built-up ice from sliding off the roof in large sheets.
15
16 K. All permanent components shall consist of materials that do not freely
17 support combustion. Use of wood or any other materials that freely
18 support combustion shall not be allowed as permanent components.
19
20 2.04 PERSONNEL AND EQUIPMENT ACCESS DOORS
21
22 A. Personnel Doors: #4080 Single leaf, double wall, honeycomb reinforced
23 personnel door, aluminum, #18ga (1.214 mm), 1-3/4 inches (44 mm) thick.
24 Required as shown with hardware as indicated.
25
26 1. Panic Hardware: Thumb latch with keyed cylinder lock. Button
27 type aluminum (Magnokrom #N1550-5X0T53-US28). ANSI/SDI
28 100 compliant.
29
30 2. Closer with stopping arm (Yale series #50).
31
32 3. Wind safety chain.
33
34 4. Drip shield.
35
36 5. Threshold: Aluminum.
37
38 6. Factory frame.
39
40 7. Caps in top.
41
42 8. Weather stripping.
43
44 9. Stainless steel hinges.
45
46 10. R2.4 thermal resistance rating.
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 7 1/08/2021
1
2 11. Fire resistance rating and label (1.5 hour minimum rating).
3
4 12. "Danger High Voltage / Keep Out" signs.
5
6
7 B. Equipment Rear -Access Doors in Exterior Walls: 12ga (1.214 mm)
8 Aluminum.:
9
10 1. Posts (mullions) shall be easily removable (allowing total door and
11 post removal) providing full open access, of (at least) any four
12 continuous doors without temporary structural reinforcement, for
13 potential equipment replacement or the addition of future
14 equipment.
15
16 2. NEMA 3R rating.
17
18 3. Stainless steel continuous piano type hinge.
19
20 4. Stainless steel pad lockable vault handle.
21
22 5. Three point latching system.
23
24 6. Full gasketing and drip shield.
25
26 7. Signage as appropriate for internal equipment.
27
28 8. Hold open device.
29
30 9. Metal inner skin over insulation welded to door.
31
32 10. "Danger High Voltage / Keep Out" signs.
33
34
35
36
37
38 2.05 FINISH
39
40 A. All coatings shall be applied using an electrostatic application process as
41 indicated. Unless specified differently the enclosure standard colors are
42 as follows:
43
44 1. Interior and Exterior — ANSI 61
45
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 8 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. All exterior and interior surfaces shall be thoroughly cleaned prior to
2 coating application per the coating manufacturer's recommended practice.
3
4 C. Exterior surfaces:
5
6 1. Cleaning:
7
8 a. Clean exterior base surface to SSPC-SP3 (Standard of the
9 Society for Protective Coatings for Power Tool Cleaning).
10 b. Clean all other surfaces to SSPC-SP1 (Solvent Cleaning).
11
12 2. Primer:
13
14 a. Base: Apply epoxy mastic primer 2.0 Mils (0.05 mm) dry film
15 thickness (DFT).
16 b. Walls, Roof and Fascia: Apply epoxy primer 1.5 Mils (0.04
17 mm) DFT.
18
19 3. Finish: Apply DuPont lmron 3.5 HG high solids polyurethane
20 enamel 1.8 Mils (0.045 mm) DFT.
21
22 4. Field Touch-up Paint: One quart (ships inside structure).
23
24 D. Interior surfaces:
25
26 1. Cleaning: Clean all surfaces to SSPC-SP1 (Solvent Cleaning).
27
28 2. Primer: Apply epoxy primer 1.5 Mils (0.04 mm) DFT**.
29
30 3. Finish: Apply DuPont Imron 3.5 HG high solids polyurethane
31 enamel 1.8 Mils (0.045 mm) DFT**.
32
33 4. Field Touch-up Paint: One quart (ships inside structure).
34
35 E. Floor (Top Side):
36
37 1. Cleaning: Clean all surfaces to SSPC-SP1 (Solvent Cleaning).
38
39 2. Primer: Apply epoxy mastic primer 1.5 Mils (0.04 mm) DFT*.
40
41 3. Finish: Apply DuPont lmron 3.5 HG high solids polyurethane
42 enamel 1.8 Mils (0.045 mm) DFT* with non-skid additive.
43
44 4. Field Touch-up Paint: One quart (ships inside structure).
45
46 F Base and Floor (Underside):
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 9 1/08/2021
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1 Cleaning:
a. Clean all surfaces to SSPC-SP3 (Power Tool Cleaning).
b. Clean to remove oil, dirt, water, and loose rust.
2. Undercoat: Apply Transcoat #101 10 Mils (0.025 mm) DFT.
a. VOC: 0.0 g/I.
b. Federal Specification TT -C -520B.
c. Asbestos Free.
d. Flame Spread Rating: 0.
G. All wall mounted HVAC units shall be aluminum exterior and painted the
same color as the enclosure's exterior walls.
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 10 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 2.06 ELECTRICAL UTILITIES
3
4 A. Conduit:
5
6 1. Interior Conduit: Exposed EMT Conduit (set screw fittings) as required
7 by NEC. 3/4 inch (19 mm) diameter minimum ANSI C80.3.
8
9 2. Exterior Conduit: Exposed Rigid Aluminum Conduit as required by
10 NEC. 3/4 inch (19 mm) diameter minimum ANSI C80.1
11
12 B. All utilities shall be UL listed and recognized devices.
13
14 C. All utilities shall be functionally tested prior to completion.
15
16 D. Interior Lights: 48 inches LED as required meeting lighting requirements of
17 30 foot candles at 3 foot above floor.
18
19 1. LED Wrap Around Acrylic Lens, Surface Mount.
20
21 E. Emergency Light(s): LED Combination Emergency Light / Exit Sign (Red).
22
23 1. Power Rating: 15W, AC Input Voltage 120/277 Volts DC Output
24 Voltage 6 Volts, Lead Calcium Battery, Lamp LED / Color Red.
25
26 F. Exterior Lights: LED lighting where indicated or required.
27
28 1. UL 1598 for Wet Locations.
29
30 2. Internal photocell.
31
32 3. Lamp (included w/fixture).
33
34 4. HOA switch specification grade, as indicated.
35
36 G. Light Switch: 3 -way, specification grade 20A 125V, where indicated.
37
38 H. Duplex Receptacles: Specification grade 20A 125V GFCI duplex receptacle,
39 where indicated or required.
40
41 I. Wire Type "XHHW"
42
43 1. Power Wiring: #12 AWG minimum (sized as required for load).
44
45 2. HVAC Control Wiring: #18 AWG thermostat cable.
46
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 11 1/08/2021
1 J. AC Distribution Panel: 480V Primary — 208Y/120V secondary 45kVA rated
2 176 degree F (80 degree C) rise.
3
4 L. AC Distribution Panel: 208Y/120VV, 3 phase, 4 wire, 42 circuit bolt in
5 breakers, surface mount, 10kAIC rated with 225A main breaker.
6
7 M. Wiring Circuits:
8
9 1. 480V AC panel to customer equipment.
10
11 2. Transformer to 480V panel.
12
13 3. AC Distribution panel to Transformer.
14
15 4. AC distribution panel to interior lighting.
16
17 5. AC distribution panel to exterior lighting.
18
19 6. AC distribution panel to emergency lighting.
20
21 7. AC distribution panel to receptacles.
22
23 8. 480 or 208V AC distribution panel to HVAC units.
24
25 N. Grounding:
26
27 1. Ground pads: 4 -hole Stainless Steel Welded to base.
28
29 2. 2 -Hole Copper Ground Lug #410.
30
31
32
33 2.07 CONTROL SYSTEM EQUIPMENT:
34
35 A. Equipment listed shall be supplied and installed, unless noted otherwise.
36
37 2.08 CUSTOMER FURNISHED ELECTRICAL EQUIPMENT:
38
39 A. Equipment listed shall be supplied by Customer and installed, unless
40 noted otherwise.
41
42
43 2.09 HVAC SYSTEM
44
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 12 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. HVAC system shall maintain the maximum interior temperature required
2 with consideration to ambient conditions and the specified internal
3 equipment total heat load.
4
5 B. HVAC Unit(s): Size and quantity as required to maintain interior design
6 temperatures and redundancy requirements. Industrial quality, vertical,
7 self-contained, wall mounted unit(s) with aluminum fin, riffle tube copper
8 coild:
9
10 1. Cooling capacity: tons capacity as required to meet design
11 temperatures as specified in section 1.4 D.
12 2. Heating capacity: Kw as required to meet design
13 temperatures as specified in section 1.4 D.
14 3. Thermostat, Auto Change Over, Digital, F or C Display:
15
16 a. Smart recovery (heating mode).
17 b. Droopless control, 4 cycles/hr.
18 c. Backlit display.
19 d. Settings never lost during power failure.
20 e. 5 minute compressor protection.
21 f. Separate set points for heating and cooling.
22 g. Battery -less operation.
23 h. Electro -Mechanical relay design.
24
25 4. Low Pressure Switch.
26 5. High Pressure Switch.
27 6. Low Ambient Control.
28 7. Compressor anti -cycle relay.
29 8. Alarm Relay.
30 9. Barometric Damper.
31 10. Supply and Return Grills.
32 11. Pleated Filter 2 inches (51 mm) MERV 8.
33 12. R410A Refrigerant.
34
35 2.10 ACCESSORIES
36
37 A. Removable Lift Lugs: Spaced along base length at approximate 15 feet
38 (4.6 m) centers per shipping piece.
39
40 B. Floor Cutouts: Under equipment for cable entry and exit from below floor
41 with gasketed 12ga (1.214 mm) galvanized top cover plates attached to
42 the floor by screws.
43
44 C. Wall penetrations as required.
45
46 D. Option accessories:
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 13 1/08/2021
1
2 1 Removable End Wall: Provide demountable end wall across the
3 entire width to allow for future expansion and aisle. Main structural
4 reinforcing post located in the removable wall may remain following
5 expansion; however, it shall be located not to interfere with the
6 equipment Zine -up extension.
7 2. Stairs and Platforms.
8 3. Computer or sub floors.
9 4. Bulk heads (wall cutouts) for top entry/exit of power cables.
10 5. Gutters and downspouts.
11 6. Many more, please consult for available options.
12
13 2.11 FACTORY TESTING
14
15 A. Finish: The following minimum finish system test results shall be certified
16 (from in process, manufacturer's samples) by independent laboratory tests
17 performed under ASTM criteria. Copies of the test results and certification
18 shall be submitted for review:
19
20 1. Substrate: Prepared Aluminum sheet: Corrosion Resistance (Salt spray):
21 Passes 2500 hours per ASTM B117.
22
23
24 B. Control systems: As recommended by the manufacturer.
25
26 PART 3 - EXECUTION
27
28 3.01 EXAMINATION
29
30 A. Do not begin installation until supporting foundation or building pad has
31 been properly prepared.
32
33 3.02 PREPARATION
34
35 A. Locate and verify utility services and structural foundation prior to
36 installation.
37
38 B. Prepare foundation using the methods recommended by the
39 manufacturer.
40
41 3.03 INSTALLATION
42
43 A. enclosure can be installed by manufacturer installation services team.
44
45 3.04 PROTECTION
46
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 14 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Protect delivered units, accessories and installed products until completion
2 of project.
3
4 B. Touch-up, repair or replace damaged products before Substantial
5 Completion.
6
7
8
9
10
11 END OF SECTION 16050
12
13
14
15
16
17
ELECTRICAL EQUIPMENT ENCLOSURE BID DOCUMENTS
16050 - 15 1/08/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16110
2
3 RACEWAYS
4
5 PART 1 — GENERAL
6
7 1.01 RELATED DOCUMENTS
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section and is part of each Division 16 section making reference to
15 electrical raceways specified herein.
16
17 1.02 DESCRIPTION OF WORK
18
19 A. Extent of raceway work is indicated by drawings and schedules.
20
21 B. Types of raceways specified in this section include the following:
22
23 Heavy Wall Aluminum
24 PVC Schedule 80
25 Liquid -tight flexible PVC coated metal conduit
26
27 1.03 QUALITY ASSURANCE
28
29 A. Manufacturers: Firms regularly engaged in manufacture of raceway
30 systems of types and sizes require, whose products have been in
31 satisfactory use in similar service for not less than five (5) years.
32
33 B. Installer's Qualifications: Firms with at least three (3) years of successful
34 installation experience on projects with electrical raceway work similar to
35 that required for this project.
36
37 C. Codes and Standards:
38
39 1. UL Compliance Labeling: Comply with applicable requirements of
40 UL safety standards pertaining to electrical raceway systems.
41 Provide raceway products and components which have been UL
42 listed and labeled.
43
44
45
RACEWAYS
16110 - 1
BID DOCUMENTS
1/8/2021
1 PART 2 — PRODUCTS
2
3 2.01 METAL CONDUIT AND TUBING
4
5 A. General: Provide aluminum conduit, tubing and fittings of types, grades,
6 sizes and weights (wall thickness) for each service indicated.
7
8 B. Where types and grades are not indicated, provide proper selection
9 determined by installer to fulfill wiring requirements and comply with
10 applicable portions of NEC for raceways.
11
12 C. Rigid aluminum Conduit: Provide rigid aluminum, heavy wall, threaded
13 type.
14
15 D. Liquid -Tight Flexible Non-metallic Conduit: Provide liquid -tight flexible
16 non-metallic conduit for all motor connections.
17
18 E. Conduit Fittings: Couplings and connectors for conduit sizes 2" and
19 smaller shall be aluminum hex -nut, expansion -gland type. Aluminum set
20 screw type fittings may be used for conduit sizes 21/2" and larger.
21
22 2.02 NONMETALLIC CONDUIT AND DUCTS
23
24 A. General: Provide nonmetallic conduit, ducts and fittings of types, sizes
25 and weights for each service indicated. Where types and grades are not
26 indicated, provide proper selection determined by installer to fulfill wiring
27 requirements which comply with provisions for NEC for raceways.
28
29 B. Electrical Plastic Conduit:
30
31 1. Heavy Wall Conduit: Schedule 80, 90°C, UL -rated, constructed of
32 Schedule 80, 90 polyvinyl chloride. For direct burial, UL listed and in
33 conformity with NEC Article 347.
34 2. Standard Wall Conduit: PVC UL rated, constructed of Schedule 40
35 polyvinyl chloride. For exterior above grade exposure, direct exposure
36 to sunlight, UL listed for direct sunlight and in conformity with NEC
37 Article 352.
38
39 C. Conduit and Tubing Accessories: Provide conduit, tubing and duct
40 accessories of types, sizes and materials, complying with manufacturer's
41 published product information, which mate and match conduit and tubing.
42
43 D. Conduit Bodies: Provide galvanized cast -metal conduit bodies of types,
44 shapes and sizes as required to fulfill job requirements and NEC
45 requirements. Construct conduit bodies with threaded conduit -entrance
RACEWAYS
16110 - 2
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 ends, removable covers, either cast or galvanized steel and corrosion -
2 resistant screws.
3 PART 3 — EXECUTION
4
5 3.01 OBSERVATION
6
7 A. Examine areas and conditions under which raceways are to be installed
8 and substrate which will support raceways. Notify contractor in wiring of
9 conditions detrimental to proper completion of the work. Do not proceed
10 with work until unsatisfactory conditions have been corrected in manner
11 acceptable to installer.
12
13 3.02 INSTALLATION OF RACEWAYS
14
15 A. General: Raceways run below grade, under floors on grade or in concrete
16 shall be PVC heavy wall type (Schedule 80) conduit, provided rigid
17 aluminum conduit is used on elbows and risers to boxes, cabinets, etc.
18
19 B. Sizes of raceways shall be not less than NEC requirements and shall not
20 in any case be less than indicated on drawings. Larger size raceways
21 and/or pull boxes shall be installed if there is excessive length unbroken
22 run or excessive number of bends. Combining of circuits other than those
23 indicated on the drawings will not be permitted.
24
25 C. Coordinate with other work, including wires/cables, boxes and panel work
26 as necessary to interface installation of electrical raceways and
27 components with other work.
28
29 1. Avoid use of similar metals throughout system to eliminate
30 possibility of electrolysis. Where dissimilar metals are in contact,
31 coast surfaces with corrosion inhibiting compound before
32 assembling.
33
34 2. Use roughing -in dimensions of electrically operated unit furnished
35 by supplier. Set conduit and boxes for connection to units only
36 after receiving review of dimensions and after checking location
37 with other trades.
38
39 3. Provide nylon pullcord in empty conduits where indicated. Test all
40 empty conduits with ball mandrel. Clear any conduit which rejects
41 ball mandrel. Pay costs involved for restoration of conduit and
42 surrounding surfaces to original condition.
43
44 4. Use liquid -tight flexible conduit where subjected to one or more of
45 the following conditions:
46
RACEWAYS
16110 - 3
BID DOCUMENTS
1/8/2021
1
1 a. Exterior location. 1
2 b. Moist or humid atmosphere where condensate can be
3 expected to accumulate. '
4 c. Corrosive atmosphere.
5 d. Subjected to water spray or dripping oil, water or grease.
6
I
7 D. Cut conduits straight, ream properly and cut threads for heavy wall conduit
8 deep and clean.
9
I
10 E. Field -bend conduit with benders designed for purpose so as not to distort
11 nor vary internal diameter.
12
I
13 F Fasten conduit terminations in sheet metal enclosures by two (2) locknuts
14 and terminate with bushing. Install lock nuts inside and outside enclosure.
15
16 G. Conduits are not to cross pipe shafts or ventilating duct openings.
17
18 H. Keep conduits a minimum distance of 6" from parallel runs of flues, hot
19 water pipes or other sources of heat. Do not install horizontal raceway
20 runs below water and steam piping.
21
II
22 I. Support riser conduit at each floor level with clamp hangers.
23
24 J. Use of running threads at conduit joints and terminations is prohibited.
1
25 Where required, use 3 -piece union or split couplings.
26
27 K. Complete installation of electrical raceways before starting installation of
I
28 cables/wires within raceways.
29
30 L. Concealed Conduits:
1
31
32 1. Metallic raceways installed underground or in floors below grade, or
33 outside are to have conduit threads painted with corrosion -inhibiting
I
34 compound before couplings are assembled. Draw up coupling and
35 conduit sufficiently tight to ensure water tightness.
36
I
37 2. For floors -on -grade, install conduits under concrete slab.
38
39 3. Install underground conduits a minimum of 24" below finished 1
40 grade.
41
42 4. All conduits installed below grade or under concrete slab to be 1
43 minimum of 3/4 inch.
44
45 M. Conduits in Concrete Slab:
I
46
RACEWAYS
16110-4
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. Place conduits between bottom reinforcing steel and top reinforcing
2 steel. Place conduits either parallel or at 90° to main reinforcing
3 steel.
4
5 2. Separate conduits by not less than diameter of largest conduit to
6 ensure proper concrete bond.
7
8 3. Conduits crossing in slab must be reviewed for proper cover by
9 engineer.
10
11 4. Embedded conduit diameter is not to exceed one-third (1/3) of slab
12 thickness.
13
14 N. Install conduits as not to damage or run through structural members.
15 Avoid horizontal or cross runs in building partitions or side walls.
16
17 0. Exposed Conduits:
18
19 1. Install exposed conduits and extensions from concealed conduit
20 systems neatly, parallel with or at right angles to walls of building.
21
22 2. Install exposed conduit work as not to interfere with ceiling inserts,
23 lights or ventilation ducts or outlets.
24
25
26
27
28
29 4. Run conduits for outlets on waterproof walls exposed. Set anchors
30 for supporting conduit on waterproof wall in waterproof cement.
31
32
33 installed in space above hung ceilings and in crawl spaces.
34
35 P. Non -Metallic Conduits:
36
37 1. Make solvent cemented joints in accordance with recommendations
38 of manufacturer.
39
40 2. Install PVC conduits in accordance with NEC and in compliance
3. Support exposed conduits by use of hangers, clamps or clips.
Support conduits minimum of 18" on each side of bends and outlet
boxes and on spacing not to exceed 6'-0".
5. Above requirements for exposed conduits also apply to conduits
41 with local utility practices.
42
43 Q. Conduit Fittings:
44
RACEWAYS
16110 - 5
BID DOCUMENTS
1/8/2021
1
1 1. Construct locknuts for securing conduit to metal enclosure with 1
2 sharp edge for digging into metal and ridged outside circumference
3 for proper fastening. I 4
5 2. Bushings for terminating conduits smaller than 1" and are to have
6 flared bottom and ribbed sides, with smooth upper edges to prevent I 7 injury to cable insulation.
8
9 3. Install insulated type bushings for terminating conduits 1" and
10 larger. Bushings are to have flared bottom and ribbed sides.
11 Upper edge to have phenolic insulating ring molded into bushing.
12
Il
13 4. Bushing of standard or insulated type to have screw type grounding
14 terminal.
15
I
16 5. Miscellaneous fittings such as reducers, chase nipples, 3 -piece
17 unions, split couplings and plugs to be specifically designed for
18 their particular application.
19
20 3.03 FIELD QUALITY CONTROL
21
I
22 A. General: Mechanically assemble metal enclosures and raceways for
23 conductors to form continuous electrical conductor and connect to
24 electrical boxes, fittings and cabinets as to provide effective electrical
I
25 continuity and rigid mechanical assembly.
26
27 B. Avoid use of dissimilar metals throughout system to eliminate possibility of
I
28 electrolysis. Where dissimilar metals are in contact, coat all surfaces with
29 corrosion -inhibiting compound before assembling.
30
31 C. Install expansion fittings in all raceways wherever structural expansion
32 joints are crossed.
33
III
34 D. Make changes in direction of raceway run with proper fittings supplied by
35 raceway manufacturer. No field bends of raceway sections will be
36 permitted.
37
38 E. Properly support and anchor raceways for their entire length by structural
39 materials. Raceways are not to span any space unsupported.
40
41 F Use boxes as supplied by raceway manufacturer wherever junction, pull,
42 or device boxes are required. Standard electrical "handy" boxes, etc. shall
I
43 not be permitted for use with surface raceway installations.
44
45 G. Raceway penetrations of fire -rated walls and/or floors shall be sealed to
46 maintain integrity of construction. All products, materials and methods of
47 installation shall be UL approved and meet NFPA requirements.
RACEWAYS
16110 - 6
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 H. Unless otherwise noted on drawings, notified by engineer and/or
3 authorities having jurisdiction, the following materials may be used:
4
5 1. Rock Wool: Minimum four pound cubit foot density; flame spread
6 15, smoke developed 0, fuel contribution 0 by ASTM 384; minimum
7 melting point 2000°F.
8
9 2. Concrete and masonry are also approved fire stop materials by
10 NFPA 90A.
11
12 3. UL approved products such as Nelson Type CLK Silicon Sealant.
13 Manufacturer's recommendations shall be strictly followed.
14
15 I. Submit complete data on fire -stopping materials and construction methods
16 for review by engineer before proceeding with work.
17
18 END OF SECTION 16110
RACEWAYS
16110 - 7
BID DOCUMENTS
1/8/2021
THIS PAGE INTENTIONALLY LEFT BLANK
RACEWAYS BID DOCUMENTS
16110 - 8 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16120
2
3 WIRES AND CABLES
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is part of each Division 16 section making reference to wires
15 and cables specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of electrical wire and cable work is indicated by drawings and
20 schedules.
21
22 B. Types of electrical wire, cable, and connectors specified in this Section
23 include the following:
24
25 Copper conductors
26 Split -bolt connectors
27 Wirenut connectors
28
29 C. Applications of electrical wire, cable, and connectors required for project
30 are as follows:
31
32 1. For power distribution circuits
33 2. For lighting circuits
34 3. For motor -branch circuits
35 4. For control circuits
36
37 1.03 QUALITY ASSURANCE:
38
39 A. Manufacturers: Firms regularly engaged in manufacture of electrical wire
40 and cable products of types, sizes, and ratings required, whose products
41 have been in satisfactory use in similar service for not Tess than five years.
42
43 B. Installer's Qualifications: Firm with at least three years of successful
44 installation experience with projects utilizing electrical wiring and cabling
45 work similar to that required for this project.
46
WIRES AND CABLES BID DOCUMENTS
16120 - 1 1/8/2021
1 C. NEC Compliance: Comply with NEC requirements as applicable to
2 construction, installation, and color -coding of electrical wires and cables.
3
4 D. IEEE Compliance: Comply with applicable requirements of IEEE Stds. 82,
5 "Test Procedures for Impulse Voltage Tests on Insulated Conductors",
6 and Std. 241, "IEEE Recommended Practice for Electric Power Systems
7 in Commercial Buildings" pertaining to wiring systems.
8
9 E. ASTM Compliance: Comply with applicable requirements of ASTM B1, 2,
10 3, 8 and D-753. Provide copper conductors with conductivity of not less
11 than 98% at 20°C (68°F).
12
13 F. The following systems of color -coding shall be strictly adhered to:
14 Grounded Leads Green
15 Grounded Neutral Leads White
16 277/480 Volt, Ungrounded Phase Wires Brown, Orange and Yellow
17 120/208 Volt, Ungrounded Phase Wires Red, Blue, Black
18
19 G. The color code assigned to each phase wire shall be consistently followed
20 throughout.
21
22 H. Where existing base building color -coding differs from color -coding
23 assigned herein. Contractor shall use existing color coding as required to
24 maintain consistency. Advise engineer in writing of color -coding to be
25 used.
26
27 1.04 DELIVERY, STORAGE, AND HANDLING:
28
29 A. Deliver wire and cable properly packaged in factory -fabricated type
30 containers, or wound on NEMA specified type wire and cable reels.
31
32 B. Store wire and cable in clean dry space in original containers. Protect
33 products from weather, damaging fumes, construction debris and traffic.
34
35 C. Handle wire and cable carefully to avoid abrading, puncturing and tearing
36 wire and cable insulation and sheathing. Ensure that dielectric resistance
37 integrity of wires/cables is maintained.
38
39 PART 2 - PRODUCTS
40
41 2.01 Building Wires:
42
43 A. Provide factory -fabricated wires of sizes, ampacity ratings, and materials
44 for applications and services indicated.
45
WIRES AND CABLES BID DOCUMENTS
16120 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. Conductor insulation shall be dual type THHN/THWN 75°C (167°F) for
2 dry, damp, and wet locations. Conductor insulation with single type
3 marking THHN 90°C (194°F) may be used for dry locations only.
4
5 PART 3 — EXECUTION
6
7 3.01 INSTALLATION OF WIRES AND CABLES:
8
9 A. General: Install electrical cables, wires and wiring connectors as
10 indicated, in compliance with applicable requirements of NEC, NEMA, UL,
11 and NECA's "Standard of Installation" and in accordance with recognized
12 industry practices.
13
14 B. Unless otherwise noted, all branch circuit conductors shall be No. 12
15 AWG. Branch circuits over 75 feet in length shall be No. 10 AWG unless
16 noted otherwise.
17
18 C. Install UL Type THWN or THHN wiring in conduit, for feeders and branch
19 circuits.
20
21 D. Pull conductors simultaneously where more than one is being installed in
22 same raceway.
23
24 E. Use pulling compound or lubricant, where necessary. Compound used
25 must not deteriorate conductor or insulation.
26
27 F. Use pulling means including, fish tape, cable, rope, and basket weave
28 wire/cable grips which will not damage cables or raceway.
29
30 G. Keep conductor splices to minimum.
31
32 H. Install splices and tapes which possess equivalent -or -better mechanical
33 strength and insulation ratings than conductors being spliced. Use splices
34 and tap connectors which are compatible with conductor material.
35
36 3.02 FIELD QUALITY CONTROL:
37
38 A. Prior to energization of circuitry, check installed feeder wires and cables
39 with megohm meter to determine insulation resistance levels to ensure
40 requirements are fulfilled. A list of feeders tested shall be submitted to the
41 engineer indicating the insulation resistance level for each cable.
42
43 B. Prior to energization, test wires and cables for electrical continuity and for
44 short-circuits.
45
46
WIRES AND CABLES BID DOCUMENTS
16120 - 3 1/8/2021
1 C. Subsequent to wire and cable hook-ups, energize circuitry and
2 demonstrate functioning in accordance with requirements. Where
3 necessary, correct malfunctioning units, and then retest to demonstrate
4 compliance.
5
6 END OF SECTION 16120
WIRES AND CABLES BID DOCUMENTS
16120 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16135
2
3 ELECTRICAL BOXES & FITTINGS
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is a part of each Division 16 section making reference to
15 electrical wiring boxes and fittings specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of electrical box and associated fitting work is indicated by
20 drawings and schedules.
21
22 B. Types of electrical boxes and fittings specified in this Section include the
23 following:
24 Control Panels
25 Outlet boxes.
26 Junction boxes.
27 Pull boxes.
28
29 1.03 QUALITY ASSURANCE:
30
31 A. Manufacturers: Firms regularly engaged in the manufacture of electrical
32 boxes and fittings of types, sizes, and capacities required, whose products
33 have been in satisfactory use in similar service for not Tess than three (3)
34 years.
35
36 B. Installer's Qualifications: Firms with at least three (3) years of successful
37 installation experience on projects utilizing electrical boxes and fittings
38 similar to those required for this project.
39
40 C. NEC Compliance: Comply with NEC as applicable to construction and
41 installation of electrical wiring boxes and fittings.
42
43 D. UL Compliance: Comply with applicable requirements of UL 50, UL 514-
44 Series, and UL 886 pertaining to electrical boxes and fittings. Provide
45 electrical boxes and fittings which are UL listed and labeled.
ELECTRICAL BOXES, FITTINGS, AND RACEWAYS BID DOCUMENTS
16135 - 1 1/8/2021
1
2 PART 2 - PRODUCTS
3
4 2.01 FABRICATED MATERIALS:
5
6 A. Outlet Boxes: Provide aluminum outlet wiring boxes, of shapes, cubic inch
7 capacities, and sizes (including box depths as indicated), suitable for
8 installation at respective locations. Construct outlet boxes with mounting
9 holes and with cable and conduit -size knockout openings in bottom and
10 sides.
11
12 1. Outlet Box Accessories: Provide outlet box accessories as required
13 for each installation; including box supports, mounting ears and
14 brackets, wallboard hangers, box extension rings, fixture studs,
15 cable clamps and metal straps for supporting outlet boxes, which
16 are compatible with outlet boxes being used to fulfill installation
17 requirements for individual wiring situations.
18
19 B. Device Boxes: Provide aluminum, non-gangable device boxes, of shapes,
20 cubic inch capacities, and sizes (including box depths as indicated),
21 suitable for installation at respective locations. Construct device boxes for
22 flush mounting with mounting holes, and with cable -size knockout
23 openings in bottom and ends and with threaded screw holes in end plates
24 for fastening devices. Provide cable clamps and corrosion -resistant
25 screws for fastening cable clamps and for equipment type grounding.
26
27 1. Device Box Accessories: Provide device box accessories as
28 required for each installation; including mounting brackets, device
29 box extensions, switch box supports, plaster ears, and plaster
30 board expandable grip fasteners, which are compatible with device
31 boxes being utilized to fulfill installation requirements for individual
32 wiring situations.
33
34 2. Flush mounted wall outlets shall be 4" square boxes or gang
35 boxes, not less than 1W deep. Boxes shall be provided with
36 extension rings and/or covers with sufficient depth to bring the
37 covers flush with the finished wall.
38
39 3. Boxes for flush mounting in concrete block work with one or two
40 devices shall have covers with square corners on the raised portion
41 of the cover. The covers shall have a sufficient amount of depth to
42 be flush with the face of the block. The bottom side of the covers
43 or boxes shall be installed at the masonry course nearest to the
44 dimension specified or noted.
45
46
ELECTRICAL BOXES, FITTINGS, AND RACEWAYS BID DOCUMENTS
16135 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 4. Outlet boxes for exposed wall mounting and outdoor installation
2 shall be cast aluminum boxes with suitable cast aluminum covers.
3 Weatherproof receptacle covers shall have spring hinged lids.
4
5 C. Rain -Tight Outlet Boxes: Provide corrosion -resistant, cast -aluminum, rain -
6 tight outlet wiring boxes; of types, shapes and sizes (including depth of
7 boxes), with threaded conduit holes for fastening electrical conduit, cast -
8 aluminum face plates with spring -hinged watertight caps suitably
9 configured for each application, including face plate gaskets and
10 corrosion- resistant plugs and fasteners.
11
12 D. Junction and Pull Boxes: Provide aluminum junction and pull boxes, with
13 screw -on covers; of types, shapes and sizes, to suit each respective
14 location and installation; with welded seams and equipped with stainless
15 steel nuts, bolts, screws and washers. All junction boxes shall be
16 designated with permanent marker circuit numbers and panelboard
17 numbers of circuits contained within.
18
19 E. Control Panels/Enclosures:
20
21 1. The control panel/enclosures shall contain, as a minimum, devices
22 and equipment indicated on the drawings or other sections of these
23 specifications. All control panel/enclosures shall contain interior
24 mounting plate.
25
26 2. The control panel enclosure shall be NEMA 4X stainless steel,
27 Underwriters Laboratories (UL) 50 type 4 listed.
28
29 3. The control panel enclosure shall be NEMA 9 (Explosion Proof) for
30 Class 1, Div. 1 & 2 environment.
31
32 4. There shall be permanently affixed to the interior side of the
33 exterior enclosure door both a nameplate and a 10" x 12" pocket
34 for drawing storage. The nameplate shall contain the following
35 information: voltage, phase, date manufactured and intended use
36 - equipment service or function.
37
38 5. Inner safety door (dead front) shall be aluminum.
39 6. Provide surge arrestor per county requirements.
40
41 7. Contractor shall furnish shop drawings for control panel. Include
42 dimension, mounting and material requirements of control panel.
43 Furnish wiring diagrams of all internal components and devices.
44 Schematic diagram of system and PLC connection diagrams and
45 data sheet and programming functions. Furnish operating and
46 maintenance and programming manuals.
ELECTRICAL BOXES, FITTINGS, AND RACEWAYS BID DOCUMENTS
16135 - 3 1/8/2021
1 PART 3 - EXECUTION
2
3 3.01 INSTALLATION OF ELECTRICAL BOXES AND FITTINGS:
4
5 A. General: Install electrical boxes and fittings as indicated, in accordance
6 with manufacturer's written instructions, applicable requirements of NEC,
7 and in accordance with recognized industry practices to fulfill project
8 requirements.
9
10 B. Coordinate installation of electrical boxes and fittings with wire/cable,
11 wiring devices, and raceway installation work.
12
13
14 C. Provide weather -tight outlets for interior and exterior locations exposed to
15 weather or moisture.
16
17 D. Provide knockout closures to cap unused knockout holes where blanks
18 have been removed.
19
20 E. Install electrical boxes in those locations which ensure ready accessibility
21 to enclosed electrical wiring. All existing and new junction boxes within
22 the project area shall be made accessible. Relocate existing junction
23 boxes as required to comply with the NEC.
24
25 F Metallic and approved nonmetallic electrical outlet boxes may be installed
26 in vertical fire resistive assemblies classified as 2 -hour or less without
27 affecting the fire classification, provided such openings occur on one side
28 only in each framing space and that openings do not exceed 16 square
29 inches. Boxes located opposite sides of walls or partitions shall be
30 separated by a horizontal distance of 24".
31
32 G. In openings larger than 16 square inches, the wall shall be built around
33 openings so as not to interfere with the integrity of the wall rating.
34
35 H. All clearances between such boxes and the gypsum board shall be
36 completely filled with joint compound or other approved material.
37
38 I. Position recessed outlet boxes accurately to allow for surface finish
39 thickness.
40
41 J. Set floor boxes level and flush with finish flooring material.
42
43 K. Fasten electrical boxes firmly and rigidly to substrates, or structural
44 surfaces to which attached, or solidly embed electrical boxes in concrete
45 or masonry.
ELECTRICAL BOXES, FITTINGS, AND RACEWAYS BID DOCUMENTS
16135 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3 L. Subsequent to installation of boxes, protect boxes from construction
4 debris and damage.
5
6 END OF SECTION 16135
7
8
9
10
ELECTRICAL BOXES, FITTINGS, AND RACEWAYS BID DOCUMENTS
16135 - 5 1/8/2021
THIS PAGE INTENTIONALLY LEFT BLANK.
ELECTRICAL BOXES, FITTINGS, AND RACEWAYS BID DOCUMENTS
16135 - 6 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16142
2
3 ELECTRICAL CONNECTIONS FOR EQUIPMENT
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is part of each Division 16 section making reference to
15 electrical connections for equipment specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of electrical connections for equipment is indicated by drawings
20 and schedules. Electrical connections are hereby defined to include
21 connections used for providing electrical power to equipment.
22
23 B. Electrical connections for equipment, not furnished as integral part of
24 equipment, are specified in other Division 16 sections, and are work of
25 this Section.
26
27 C. Motor starters and controllers not furnished as integral part of equipment
28 are specified in applicable Division 16 sections and are work of this
29 Section.
30
31 D. Junction boxes and disconnect switches required for connecting motors
32 and other electrical units of equipment are specified in applicable Division
33 16 sections, and are work of this Section.
34
35 E. Electrical identification for wire/cable conductors is specified in Division 16
36 section, "Electrical Identification", and is work of this Section.
37
38 F. Raceways and wires/cables required for connecting motors and other
39 electrical units of equipment are specified in applicable Division 16
40 sections, and are work of this Section.
41
42 1.03 QUALITY ASSURANCE:
43
44 A. Manufacturers: Firms regularly engaged in manufacture of electrical
4-5 connectors and terminals, of types and ratings required, and ancillary
46 connection materials, including electrical insulating tape, soldering fluxes,
ELECTRICAL CONNECTIONS FOR EQUIPMENT BID DOCUMENTS
16142 - 1 1/8/2021
1
1 and cable ties; whose products have been in satisfactory use in similar
2 service for not Tess than five (5) years.
3
4 B. Installer's Qualifications: Firms with at least two (2) years of successful
5 installation experience with projects utilizing electrical connections for
6 equipment similar to that required for this project.
7
8 C. NEC Compliance: Comply with applicable requirements of NEC as to
9 type products used and installation of electrical power connections
10 (terminals and splices) for junction boxes, motor starters, and disconnect
11 switches.
12
13 D. UL Compliance: Comply with UL Std 486A, "Wire Connectors and
14 Soldering Lugs for Use With Copper Conductors" including, but not limited
15 to, tightening of electrical connectors to torque values indicated. Provide
16 electrical connection products and materials which are UL listed and
17 labeled.
18
19 PART 2 - PRODUCTS
20
21 2.01 MATERIALS AND COMPONENTS:
22
23 A. General: For each electrical connection indicated, provide complete
24 assembly of materials; including, but not necessarily limited to, pressure
25 connectors, terminals (lugs), electrical insulating tape, cable ties,
26 solderless wirenuts, and other items and accessories as needed to
27 complete splices and terminations of types indicated. Metal shall not be
28 used for outdoor applications. The contractor shall use aluminum for
29 outdoor installations.
30
31 B. Metal Conduit, Tubing and Fittings, General: Provide metal conduit,
32 tubing and fittings of types, grades, sizes and weights (wall thicknesses)
33 indicated for each type service. Where types and grades are not
34 indicated, provide proper selection as determined by installer to fulfill
35 wiring requirements and comply with NEC requirements for raceways.
36 Provide products complying with Division 16 Basic Electrical and in
37 accordance with the following listing of metal conduit, tubing and fittings:
38
39 Rigid aluminum conduit.
40 Rigid metal conduit fittings.
41 Electrical metallic tubing.
42 EMT fittings.
43 Flexible metal conduit.
44 Flexible metal conduit fittings.
45 Liquid -tight flexible metal conduit.
46 Liquid -tight flexible metal conduit fittings.
ELECTRICAL CONNECTIONS FOR EQUIPMENT BID DOCUMENTS
16142 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3 C. Wires, Cables, and Connectors:
4
5 1. General: Provide wires, cables, and connectors complying with
6 Division 16 Basic Electrical Materials And Methods section "Wires
7 and Cables".
8
9 2. Wires/Cables: Unless otherwise indicated, provide wires/cables
10 (conductors) for electrical connections which match (including sizes
11 and ratings) wires/cables which are supplying electrical power.
12 Provide copper conductors with conductivity of not Tess than 98% at
13 20°C (68°F).
14
15 D. Connectors and Terminals: Provide electrical connectors and terminals
16 which mate and match (including sizes and ratings) with equipment
17 terminals, and are recommended by equipment manufacturer for intended
18 applications.
19
20 PART 3 - EXECUTION
21
22 3.01 OBSERVATION:
23
24 A. Observe area and conditions under which electrical connections for
25 equipment are to be installed and notify contractor in writing of conditions
26 detrimental to proper completion of the work. Do not proceed with the
27 work until unsatisfactory conditions have been corrected in a manner
28 acceptable to installer.
29
30 3.02 INSTALLATION OF ELECTRICAL CONNECTIONS:
31
32 A. Install electrical connections as indicated; in accordance with equipment
33 manufacturer's written instructions, with recognized industry practices, and
34 complying with applicable requirements of UL and NEC to ensure that
35 products fulfill requirements.
36
37 B. Coordinate with other work, including wires/cables, raceway, and
38 equipment installation as necessary to properly interface installation of
39 electrical connections for equipment with other work.
40
4-1 C. Connect electrical power supply conductors to equipment conductors in
42 accordance with equipment manufacturer's written instructions and wiring
43 diagrams. Mate and match conductors of electrical connections for proper
44 interface between electrical power supplies and installed equipment.
45
ELECTRICAL CONNECTIONS FOR EQUIPMENT BID DOCUMENTS
16142 - 3 1/8/2021
1 D. Maintain existing electrical service and feeders to occupied areas and
2 operational facilities unless otherwise indicated, or when authorized
3 otherwise in writing by owner or engineer. Provide temporary service
4 during interruptions to existing facilities. When necessary, schedule
5 momentary outages for replacing existing wiring systems with new wiring
6 systems. When that "cutting -over" has been successfully accomplished,
7 remove, relocate, or abandon existing wiring as indicated.
8
9 E. Cover splices with electrical insulating material equivalent to, or of greater
10 insulation resistivity rating, than electrical insulation rating of those
11 conductors being spliced.
12
13 F Prepare cables and wires by cutting and stripping covering armor, jacket,
14 and insulation properly to ensure uniform and neat appearance where
15 cables and wires are terminated. Exercise care to avoid cutting through
16 tapes which will remain on conductors. Also avoid "ringing" copper
17 conductors while skinning wire.
18
19 G. Trim cables and wires as short as practicable and arrange routing to
20 facilitate inspection, testing, and maintenance.
21
22 H. Provide flexible conduit for motor connections and other electrical
23 equipment connections where subject to movement and vibration.
24
25 I Provide liquid -tight flexible conduit for connection of motors and other
26 electrical equipment where subject to movement and vibration; and also
27 where connections are subjected to one or more of the following
28 conditions:
29
30 1. Exterior location.
31 2. Moist or humid atmosphere where condensate can be expected to
32 accumulate.
33 3. Corrosive atmosphere.
34 4. Water spray.
35 5. Dripping oil, grease, or water.
36
37 3.03 FIELD QUALITY CONTROL:
38
39 A. Upon completion of installation of electrical connections, and after circuitry
40 has been energized with rated power source, test connections to
41 demonstrate capability and compliance with requirements. Ensure that
42 direction of rotation of each motor fulfills requirement. Correct
43 malfunctioning units at site, then retest to demonstrate compliance.
44
45 END OF SECTION 16142
ELECTRICAL CONNECTIONS FOR EQUIPMENT BID DOCUMENTS
16142 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16143
2
3 WIRING DEVICES
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is part of each Division 16 section making reference to wiring
15 devices specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. The extent of wiring device work is indicated by drawings and schedules.
20 Wiring devices are defined as single discrete units of electrical distribution
21 systems which are intended to carry but not utilize electric energy.
22
23 B. Types of electrical wiring devices in this section include the following:
24
25 Receptacles.
26 Ground -fault circuit interrupters.
27 Switches.
28 Wallplates.
29
30 1.03 QUALITY ASSURANCE:
31
32 A. Manufacturers: Firms regularly engaged in manufacture of electrical
33 wiring devices, of types, sizes, and ratings required, whose products have
34 been in satisfactory use in similar service for not less than three (3) years.
35
36 B. Installer's Qualifications: Firm with at least two (2) years of successful
37 installation experience on projects utilizing wiring devices similar to those
38 required for this project.
39
40 C. NEC Compliance: Comply with NEC as applicable to installation and
41 wiring of electrical wiring devices.
42
43 D. UL Compliance: Provide wiring devices which are UL listed and labeled.
44
45 1.04 SUBMITTALS:
46
WIRING DEVICES
16143 - 1
BID DOCUMENTS
1/8/2021
1 A. Product Data: Submit manufacturer's data on electrical wiring devices.
2
3 PART 2 - PRODUCTS
4
5 2.01 ACCEPTABLE MANUFACTURERS:
6
7 A. Manufacturers: Subject to compliance with requirements, manufacturers
8 providing wiring devices which may be incorporated in the work include;
9 but are not limited to, the following (for each type and rating of wiring
10 device):
11
12 Arrow -Hart, Cooper Industries
13 Eagle Electric Manufacturing Co., Inc.
14 Harvey Hubbell Inc.
15 Pass and Seymour Inc.
16
17
18 2.02 FABRICATED WIRING DEVICES:
19
20 A. General: Provide factory -fabricated wiring devices, in types, colors, and
21 electrical ratings for applications indicated and which comply with NEMA
22 Standards. Pub/No. WD1. Provide ivory color devices except as otherwise
23 indicated.
24
25 B. Receptacles:
26
27 1. All receptacles shall be the grounding type with ground connection
28 made through an extra pole that shall be permanently connected to
29 the green grounding conductor.
30
31 2. Duplex receptacles for 20 ampere, 120 volt service shall be two -
32 pole, three -wire receptacles, rated 20 amperes at 125 volts.
33 Receptacles shall be Harvey Hubbell, Inc., Catalog No. 5362-1.
34
35 3. Single receptacles for 20 amps, 120 volts service shall be two -pole,
36 three -wire rated 20 amperes at 125 volts. Receptacles shall be
37 Harvey Hubbell Inc., Catalog No. 5361-1.
38
39 C. Switches:
40
41 1. Snap: Provide toggle switches, rated 20 amperes at 120/277 volts,
42 quiet type, and shall be UL approved without derating for tungsten
43 lamp loads or inductive loads. All switches shall have a grounding
44 terminal which shall be connected to the green grounding
45 conductor. The following catalog numbers are Harvey Hubbell, Inc.
46
WIRING DEVICES BID DOCUMENTS
16143 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3 Type Catalog No.
4
5 Single Pole HBL 1221-1
6
7 2.03 WIRING DEVICE ACCESSORIES:
8
9 A. 'In Use' covers for exterior receptacles.
10
11 B. Weatherproof caps for switches.
12
13 PART 3 - EXECUTION
14
15 3.01 INSTALLATION OF WIRING DEVICES:
16
17 A. Install wiring devices as indicated, in accordance with manufacturer's
18 written instructions, applicable requirements of NEC, NECA's "Standard of
19 Installation", and in accordance with recognized industry practices to fulfill
20 project requirements.
21
22 B. Install wiring devices only in electrical boxes which are clean; free from
23 excess building materials, dirt, and debris.
24
25 C. Install wiring devices after wiring work is completed.
26
27 D. Install wallplates after painting work is completed.
28
29 3.02 PROTECTION OF WALLPLATES AND RECEPTACLES:
30
31 A. Upon installation of wallplates and receptacles, advise contractor
32 regarding proper and cautious use of convenience outlets. At time of
33 substantial completion, replace those items which have been damaged,
34 including those burned and scored by faulty plugs.
35
36 3.03 GROUNDING:
37
38 A. Provide equipment grounding connections for all wiring devices, unless
39 otherwise indicated.
40
41 3.04 TESTING:
42
43 A. Prior to energizing circuitry, test wiring for electrical continuity and for
44 short-circuits. Ensure proper polarity of connections is maintained.
45 Subsequent to energization, test wiring devices to demonstrate
46 compliance with requirements.
WIRING DEVICES BID DOCUMENTS
16143 - 3 1/8/2021
1
2
3
END OF SECTION 16143
WIRING DEVICES
16143 - 4
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16170
2
3 CIRCUIT AND MOTOR DISCONNECTS
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is part of each Division 16 section making reference to circuit
15 and motor disconnects specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of circuit and motor disconnect switch work is indicated on
20 drawings and schedules.
21
22 B. Types of circuit and motor disconnect switches in this Section include the
23 following:
24
25 Equipment disconnects.
26 Appliance disconnects.
27 Motor -circuit disconnects.
28
29 C. Wires/cables, raceways, and electrical boxes and fittings required in
30 connection with circuit and motor disconnect work are specified in other
31 Division 16 Basic Electrical Materials and Methods sections.
32
33 1.03 QUALITY ASSURANCE:
34
35 A. Manufacturers: Firms regularly engaged in manufacture of circuit and
36 motor disconnect switches of types and capacities required, whose
37 products have been in satisfactory use in similar service for not less than
38 three (3) years.
39
40 B. Installer's Qualifications: Firm with at least three (3) years of successful
41 installation experience with projects utilizing circuit and motor disconnect
42 work similar to that required for this project.
43
44 C. NEC Compliance: Comply with NEC requirements pertaining to
45 construction and installation of electrical circuit and motor disconnect
46 devices.
CIRCUIT AND MOTOR DISCONNECTS BID DOCUMENTS
16170 - 1 1/8/2021
1 D. UL Compliance: Comply with requirements of UL 98, "Enclosed and
2 Dead -Front Switches." Provide circuit and motor disconnect switches
3 which have been UL listed and labeled.
4
5 E. NEMA Compliance: Comply with applicable requirements of NEMA Stds.
6 Pub No. KS 1, "Enclosed Switches" and 250, "Enclosures for Electrical
7 Equipment (1000 Volts Maximum)."
8
9 1.04 SUBMITTALS:
10
11 A. Product Data: Submit manufacturer's data on circuit and motor
12 disconnect switches.
13
14 B. Submit shop drawings in booklet form with separate sheet for each circuit
15 and motor disconnect with proposed switch and accessories clearly
16 identified on each sheet. Identify each device with corresponding names,
17 abbreviations (numbers and lettering) to match terminology of contract
18 documents.
19
20 PART 2 - PRODUCTS
21
22 2.01 ACCEPTABLE MANUFACTURERS:
23
24 A. Available Manufacturers: Subject to compliance with requirements,
25 manufacturers offering circuit and motor disconnects which may be
26 incorporated in the work are limited to the following:
27
28 Schneider/Square D
29 ABB
30 Cutler Hammer/Eaton
31
32 2.02 FABRICATED SWITCHES:
33
34 A. Heavy -Duty Safety Switches: Provide surface -mounted, heavy-duty type,
35 NEMA 4X stainless steel enclosed safety switches, of types, sizes and
36 electrical characteristics indicated; incorporating quick -make, quick -break
37 type switches. Construct so that switch blades are visible in OFF position
38 with door open. Equip with operating handle which is integral part of
39 enclosure base and whose operating position is easily recognizable, and
40 is padlockable in OFF position. Construct current carrying parts of high -
41 conductivity copper, with silver -tungsten type switch contacts and positive
42 pressure type reinforced fuse clips.
43
44 1. All fuses for safety switches shall be dual element, cartridge type.
45 Fuses shall be Bussman "Fusetron" or Chase-Shawmut "Trionic."
46 The contractor shall furnish and install proper size fuses where
CIRCUIT AND MOTOR DISCONNECTS BID DOCUMENTS
16170 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 required for all fusible equipment and shall furnish to the owner one
2 spare fuse for each fuse installed.
3
4 PART 3 - EXECUTION
5
6 3.01 INSTALLATION OF CIRCUIT AND MOTOR DISCONNECT SWITCHES:
7
8 A. Install circuit and motor disconnect switches as indicated, complying with
9 manufacturer's written instructions, applicable requirements of NEC,
10 NEMA, NECA's "Standard of Installation", and in accordance with
11 recognized industry practices.
12
13 B. Install disconnect switches for use with motor -driven appliances and
14 motors and controllers within sight of controller position unless otherwise
15 indicated.
16
17 C. Unless otherwise indicated, protective devices shall be mounted with top
18 of cabinet or enclosure 6'-6" above finished floor; shall be properly
19 aligned; and shall be adequately supported independently of the
20 connecting raceways and other equipment. All steel shapes, etc.,
21 necessary for the support of the equipment shall be furnished and
22 installed where the building structure is not suitable for mounting the
23 equipment directly thereon. Unless otherwise indicated, all branch circuit
24 protective devices enclosures shall be NEMA type I, general purpose
25 type. Branch circuit protective devices installed outdoors or exposed to
26 the weather shall have weatherproof enclosures, NEMA Type 4X.
27
28 3.02 GROUNDING:
29
30 A. Provide equipment grounding connections sufficiently tight to assure a
31 permanent and effective ground for electrical disconnect switches where
32 indicated.
33
34 3.03 FIELD QUALITY CONTROL:
35
36 A. Subsequent to completion of installation of electrical disconnect switches,
37 energize circuitry and demonstrate capability and compliance with
38 requirements. Where possible, correct malfunctioning units at project site,
39 then retest to demonstrate compliance. Otherwise remove and replace
40 with new units and retest.
41
42
43
44 END OF SECTION 16170
45
CIRCUIT AND MOTOR DISCONNECTS BID DOCUMENTS
16170 - 3 1/8/2021
THIS PAGE INTENTIONALLY LEFT BLANK
CIRCUIT AND MOTOR DISCONNECTS
16170 - 4
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16190
2
3 SUPPORTING DEVICES
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is a part of each Division 16 section making reference to
15 electrical supporting devices specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of supports, anchors, sleeves, and seals is indicated by drawings
20 and schedules and/or specified in other Division 16 sections.
21
22 B. Types of supports, anchors, sleeves, and seals specified in this Section
23 include the following:
24
25 Clevis hangers.
26 One -hole conduit straps.
27 Two -hole conduit straps.
28 Round steel rods.
29 Expansion anchors.
30 Toggle bolts.
31 Wall and floor seals.
32 Corn Clamps.
33
34 C. Supports, anchors, sleeves, and seals furnished as part of factory
35 fabricated equipment are specified as part of that equipment assembly in
36 other Division 16 sections.
37
38 1.03 QUALITY ASSURANCE:
39
40 A. Manufacturers: Firms regularly engaged in manufacture of supporting
41 devices, of types, sizes, and ratings required, whose products have been
42 in satisfactory use in similar service for not less than three (3) years.
43
44 B. Installer's Qualifications: Firm with at least three (3) years of successful
45 installation experience with projects utilizing electrical supporting device
46 work similar to that required for this project.
SUPPORTING DEVICES BID DOCUMENTS
16190 - 1 1/8/2021
1 C. NECA Compliance: Comply with National Electrical Contractors
2 Association's "Standard of Installation", pertaining to anchors, fasteners,
3 hangers, supports, and equipment mounting.
4
5 D. UL Compliance: Provide electrical components which are UL listed and
6 labeled.
7
8 1.04 SUBMITTALS:
9
10 A. Product Data: Submit manufacturer's data on supporting devices,
11 including catalog cuts, specifications, and installation instructions for each
12 type of support, anchor, sleeve, and seal.
13
14 PART 2 - PRODUCTS
15
16 2.01 MANUFACTURED SUPPORTING DEVICES:
17
18 A. General: Provide supporting devices which comply with manufacturer's
19 standard materials, design and construction, in accordance with published
20 product information and as required for complete installation and as
21 herein specified. Where more than one type of supporting device meets
22 indicated requirements, selection is installer's option.
23
24 B. Supports: Provide supporting devices of types, sizes, and materials
25 indicated and having the following construction features:
26
27 1. Clevis Hangers: For supporting conduit; aluminum with '/2"
28 diameter hole for round steel rod, approximately 54 pounds per 100
29 units.
30
31 2. Reducing Couplings: Aluminum rod reducing coupling, 1/2" by 5/8",
32 approximately 16 pounds per hundred 100 units.
33
34 3. One -Hole Conduit Straps: For supporting conduit; aluminum.
35
36 4. Two -Hole Conduit Straps: For supporting conduit; aluminum.
37
38 5. Hexagon Nuts: For 1/2" rod size, aluminum.
39
40 6. Round Aluminum Rod: '/2" diameter.
41
42 7. Offset Conduit Clamps: For supporting 2" rigid metal conduit;
43 aluminum.
44
45 C. Anchors: Provide anchors of types, sizes, and materials indicated with
46 the following construction features: (all aluminum).
SUPPORTING DEVICES BID DOCUMENTS
16190 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. Expansion Anchors: '/2'.
2
3 2. Toggle Bolts: Springhead, 3/16" by 4".
4
5 D. Sleeves and Seals: Provide sleeves and seals, of types, sizes and
6 materials indicated, with the following construction features:
7
8 1. Wall and Floor Seals: Provide factory -assembled watertight wall
9 and floor seals, of types and sizes indicated, suitable for sealing
10 around conduit, pipe, or tubing passing through concrete floors and
11 walls. Construct seals with steel sleeves, malleable iron body,
12 neoprene sealing grommets and rings, metal pressure rings,
13 pressure clamps, and cap screws. Seals shall be fire -rated where
14 required.
15
16 E. U -Channel Strut Systems: Provide U -channel strut system for supporting
17 electrical equipment; aluminum of types and sizes indicated. Construct
18 with 3/16" diameter holes, 8" O.C. on top surface, and with the following
19 fittings which mate and match with U -channel:
20
21 Fixture hangers.
22 Channel hangers.
23 End caps.
24 Beam clamps.
25 Wiring studs.
26 Thinwall conduit clamps.
27 Rigid conduit clamps.
28 Conduit hangers.
29
30 2.02 FABRICATED SUPPORTING DEVICES:
31
32 A. Pipe Sleeves: Provide pipe sleeves of Aluminum Pipe: Fabricate from
33 schedule 40 galvanized aluminum pipe. Remove burrs.
34
35 B. Sleeve Seals: Provide sleeves for piping which penetrate foundation walls
36 below grade or exterior walls. Caulk between sleeve and pipe with
37 nontoxic, UL classified caulking material to ensure watertight seal. Seals
38 shall be fire -rated where required.
39
40 PART 3 - EXECUTION
41
42 3.01 INSTALLATION OF SUPPORTING DEVICES:
43
44 A. Install hangers, anchors, sleeves, and seals as indicated, in accordance
45 with manufacturer's written instructions and with recognized industry
46 practices to insure supporting devices comply with requirements. Comply
47 with requirements of NECA and NEC for installation of supporting devices.
SUPPORTING DEVICES BID DOCUMENTS
16190 - 3 1/8/2021
1
2 B. Coordinate with other electrical work, including raceway and wiring work,
3 as necessary to interface installation of supporting devices with other
4 work.
5
6 C. Install hangers, supports and attachments to support piping properly from
7 building structure. Arrange for grouping of parallel runs of horizontal
8 conduits to be supported together on trapeze type hangers where
9 possible. Install supports with spacings indicated and in compliance with
10 NEC requirements.
11
12 END OF SECTION 16190
SUPPORTING DEVICES BID DOCUMENTS
16190 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16195
2
3 ELECTRICAL IDENTIFICATION
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is part of each Division 16 section making reference to
is electrical identification specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of electrical identification work is indicated by drawings and
20 schedules.
21
22 B. Types of electrical identification work specified in this Section include the
23 following:
24
25 Equipment/system identification signs.
26
27 PART 2 - PRODUCTS
28
29 2.01 ELECTRICAL IDENTIFICATION MATERIALS:
30
31 A. Engraved Plastic -Laminate Signs:
32
33 1. General: Provide engraving stock melamine plastic laminate in
34 sizes and thicknesses indicated, engraved with engraver's standard
35 letter style of sizes and wording indicated; black face and white
36 core plies (letter color) except as otherwise indicated, punched for
37 mechanical fastening except where adhesive mounting is
38 necessary because of substrate.
39
40 2. Signs shall be black face with white core plies (letter color).
41
42 a. Thickness: 1/16", except as otherwise indicated.
43 b. Fasteners: Self -tapping stainless steel screws, except
44 contact -type permanent adhesive where screws cannot, or
45 should not, penetrate substrate.
46 c. Nameplates for essential electrical systems shall be red with
47 white letters.
ELECTRICAL IDENTIFICATION BID DOCUMENTS
16195 - 1 1/8/2021
1
2 2.02 LETTERING AND GRAPHICS:
3
4 A. General: Coordinate names, abbreviations, and other designations used
5 in electrical identification work with corresponding designations shown,
6 specified, or scheduled. Provide numbers, lettering and wording as
7 indicated or, if not otherwise indicated, as recommended by manufacturer
8 or as required for proper identification and operation/maintenance of
9 electrical systems and equipment.
10
11 PART 3 - EXECUTION
12
13 3.01 APPLICATION AND INSTALLATION:
14
15 A. General Installation Requirements:
16
17 1. Install electrical identification products as indicated, in accordance
18 with manufacturer's written instructions and requirements of NEC.
19
20 2. Coordination: Where identification is to be applied to surfaces
21 which require finish, install identification after completion of
22 painting.
23
24 3. Regulations: Comply with governing regulations and requests of
25 governing authorities for identification of electrical work.
26
27 B. Equipment/System Identification:
28
29 1. General: Install engraved plastic -laminate sign on each major unit
30 of electrical equipment in building; including central or master unit
31 of each electrical system including communication/ control/signal
32 systems, unless unit is specified with its own self-explanatory
33 identification or signal system. Provide text matching terminology
34 and numbering of the contract documents and shop drawings.
35 Provide signs for each unit of the following categories of electrical
36 work:
37
38 a. Panelboards, electrical cabinets and enclosures.
39 b. Access panels/doors to electrical facilities.
40 c. Transformers.
41 d. Fire alarm equipment cabinets.
42 e. Disconnect switches, motor starters, contactors, including
43 current origination.
44
45 2. Install signs at locations indicated or, where not otherwise
46 indicated, at location for best convenience of viewing without
ELECTRICAL IDENTIFICATION BID DOCUMENTS
16195 - 2 1/8/2021
1 interference with operation and maintenance of equipment. Secure
2 to substrate with fasteners, except use adhesive where fasteners
3 should not, or cannot, penetrate substrate.
4
5 END OF SECTION 16195
ELECTRICAL IDENTIFICATION BID DOCUMENTS
16195 - 3 1/8/2021
THIS PAGE INTENTIONALLY LEFT BLANK
ELECTRICAL IDENTIFICATION BID DOCUMENTS
16195 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16452
2
3 GROUNDING
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Materials and Methods section, and is
14 part of each Division 16 Section making reference to grounding specified
15 herein.
16
17 1.02 SUMMARY:
18
19 A. The extent of electrical grounding and bonding work is indicated by
20 drawings and schedules, and as specified herein. Grounding and bonding
21 work is defined to encompass systems, circuits, and equipment. All new
22 grounding electrodes (rods) and new ground conductors shall be bonded
23 to the existing grounding grid at four locations, minimum. All new control
24 panels, VFDs and electrical panels and cabinets shall be grounded with
25 new ground rods and shall also be bonded to the existing grounding grid.
26 All new connections to the existing grounding grid shall be made by
27 exothermic weld process. Contractor shall obtain approval the grounding
28 connections from owner before installation. Contractor shall furnish and
29 install one grounding test station at each Polymer control Panel and at
30 each VFD sample pump Panel. Test station shall include in grade box
31 with removable lid to exposed top of ground rod and grounding conductor;
32 all connections in test station shall be mechanical type — not exothermic
33 weld.
34
35 B. The type of electrical grounding and bonding work specified in this Section
36 includes the following:
37
38 Solidly grounded
39
40 C. Applications of electrical grounding and bonding work in this Section
41 includes the following:
42
43 Electrical power systems
44 Grounding electrodes
45 Separately derived systems
46 Raceways
GROUNDING
16452 - 1
BID DOCUMENTS
1/8/2021
1 Service equipment
2 Enclosures/Control Panels
3 Equipment
4
5 D. Refer to other Division 16 sections for wires/cables, electrical raceways,
6 boxes and fittings, and wiring devices which are required in conjunction
7 with electrical grounding and bonding work; not work of this section.
8
9 1.03 SUBMITTALS:
10
11 A. Product Data: Submit manufacturer's data on grounding and bonding
12 products and associated accessories.
13
14
15 1.04 QUALITY ASSURANCE:
16
17 A. Manufacturer's Qualifications: Firms regularly engaged in the
18 manufacture of grounding and bonding products, of types and ratings
19 required, and ancillary grounding materials; including stranded cable,
20 copper braid and bus, grounding electrodes and plate electrodes, and
21 bonding jumpers; whose products have been in satisfactory use in similar
22 service for not less than five (5) years.
23
24 B. Installer's Qualifications: Firm with at least three (3) years of successful
25 installation experience on projects with electrical grounding work similar to
26 that required for project.
27
28 C. Codes and Standards:
29
30 1. Electrical Code Compliance: Comply with applicable local electrical
31 code requirements of the authority having jurisdiction and NEC as
32 applicable to electrical grounding and bonding, pertaining to
33 systems, circuits, and equipment.
34
35 2. UL Compliance: Comply with applicable requirements of UL
36 Standards No.'s 467, "Electrical Grounding and Bonding
37 Equipment", and 869, "Electrical Service Equipment", pertaining to
38 grounding and bonding of systems, circuits, and equipment. In
39 addition, comply with UL Std. 486A, "Wire Connectors and
40 Soldering Lugs for Use with Copper Conductors." Provide
41 grounding and bonding products that are UL listed and labeled for
42 their intended usage.
43
44 PART 2 - PRODUCTS
45
46 2.01 GROUNDING AND BONDING:
47
GROUNDING
16452 - 2
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Materials and Components, General: Except as otherwise indicated,
2 provide electrical grounding and bonding systems indicated; with
3 assembly of materials, including, but not limited to, cables/wires,
4 connectors, solderless lug terminals, grounding electrodes and plate
5 electrodes, bonding jumper braid, surge arresters, and additional
6 accessories needed for a complete installation. Where more than one
7 type component product meets indicated requirements, selection is
8 installer's option. Where materials or components are not indicated,
9 provide products that comply with NEC and UL, requirements, and with
10 established industry standards for those applications indicated.
11
12 B. Conductors: Unless otherwise indicated, provide electrical grounding
13 conductors for grounding system connections that match power supply
14 wiring materials and are sized according to NEC.
15
16 C. Bonding Plates, Connectors, Terminals and Clamps: Provide electrical
17 bonding plates, connectors, terminals, lugs, and clamps as recommended
18 by bonding plate, connector, terminal, and clamp manufacturers for
19 indicated applications.
20
21 D. Ground Electrodes: Solid copper, 5 Ohms, three-quarter inch (3/")
22 diameter by twenty feet (20').
23
24 PART 3 - EXECUTION
25
26 3.01 EXAMINATION:
27
28 A. Examine areas and conditions under which electrical grounding and
29 bonding connections are to be made, and notify contractor in writing of
30 conditions detrimental to proper completion of work. Do not proceed with
31 work until unsatisfactory conditions have been corrected in a manner
32 acceptable to installer.
33
34 3.02 INSTALLATION OF ELECTRICAL GROUNDING AND BONDING SYSTEMS:
35
36 A. General: Install electrical grounding and bonding systems as indicated, in
37 accordance with manufacturer's instructions; applicable portions of NEC,
38 NECA's "Standard of Installation", and in accordance with recognized
39 industry practices, to ensure that products comply with requirements.
40
41 B. Coordinate with other electrical work as necessary to interface installation
42 of electrical grounding and bonding system work with other work.
43
44 C. Ground electrical service system neutral at service entrance to the
45 building cold water line and to three (3) three-fourths inch (3/4") diameter,
46 twenty feet (20') long ground rods spaced ten feet (10') apart.
47
GROUNDING
16452 - 3
BID DOCUMENTS
1/8/2021
1 D. Ground each separately -derived system neutral to separate grounding
2 electrode.
3
4 E. Connect together system neutral, service equipment enclosures, exposed
5 noncurrent carrying metal parts of electrical equipment, metal raceway
6 systems, grounding conductor in raceways and cables, receptacle ground
7 connectors, and plumbing systems.
8
9 F. All raceways with No. 10 or 12 AWG phase conductors for receptacles,
10 lighting fixtures, and similar circuits shall be provided with a parity -sized
11 green equipment ground conductor. Ground conductor shall be installed
12 in entire raceway system, including wall switches and flexible conduit to
13 Tight fixtures. Equipment ground conductor sizes for circuits with phase
14 conductors larger than No. 12 AWG are indicated on drawings. Ground
15 conductors shall be connected to ground buss in panelboards. All power,
16 lighting, control circuits shall have a fully sized insulated copper conductor
17 run the entire length of the circuit. The raceway/conduit system shall not
18 be used as a means of the grounding system.
19
20 G. Terminate feeder and branch circuit insulated equipment -grounding
21 conductors with grounding lug, bus, or bushing. Conductors looped under
22 screw or bolt heads will not be permitted.
23
24 H. Connect grounding electrode conductors to one inch (1") diameter or
25 greater metallic cold water pipe, using a suitably sized ground clamp.
26 Provide connections to flanged piping at street side of flange.
27
28 I Install clamp -on connectors on clean metal contact surfaces to ensure
29 electrical conductivity and circuit integrity.
30
31 J. Provide a grounding bushing and a continuous copper bonding jumper
32 from the bushing to the equipment ground bus in all feeders. The bonding
33 jumper shall be the same size as the equipment ground conductor.
34
35 3.03 FIELD QUALITY CONTROL
36
37 A. Upon completion of installation of electrical grounding and bonding
38 systems, test ground resistance with ground resistance tester. Where tests
39 show resistance -to -ground is over twenty-five (25) ohms, take appropriate
40 action to reduce resistance to twenty-five (25) ohms or less by driving
41 additional ground rods then retest to demonstrate compliance.
42
43 B. Submit test results (3 copies) to engineer of record. Test results shall
44 include grounding test method used, equipment used (manufacturer and
45 model number) with certification of calibration and data results.
46
47 END OF SECTION 16452
GROUNDING
16452 - 4
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1 SECTION 16460
2
I
3
4 TRANSFORMERS
5 PART 1 - GENERAL
I6
7 1.01 RELATED DOCUMENTS:
8
I
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
I12
13 B. This is a Division 16 Basic Electrical Materials and Methods section, and
14 is part of each Division 16 Section making reference to transformers
I
15 specified herein.
16
17 1.02 DESCRIPTION OF WORK:
I18
19 A. Extent of transformer work is indicated by drawings and schedules.
20
I
21
22 B. Types of transformers specified in this Section include the following:
23 Dry -Type Transformers
I
24
25 C. Electrical wiring connections for transformers are specified in applicable
26 Division 16 sections.
I27
28 1.03 QUALITY ASSURANCE:
29
1 30 A. Manufacturers: Firms regularly engaged in the manufacture of
31 power/distribution transformers of types and ratings required; whose
32 products have been in satisfactory use in similar service for not Tess than
33 five (5) years.
34
35 B. Installer's Qualifications: Firm with at least five (5) years of successful
I 36 installation experience on projects utilizing electrical power and
37 distribution transformers similar to those required for this project.
I38
39 C. NEC Compliance: Comply with NEC as applicable to installation and
40 construction of electrical power/distribution transformers.
I41
42 D. ANSI Compliance: Comply with applicable requirements of ANSI
43 Standards C57 -Series pertaining to power/distribution transformers.
44
45 E. NEMA Compliance: Comply with requirements of NEMA Std Pub/No.'s
46 ST 20; "Dry -Type Transformers for General Applications", TR 1, and TR
1
1
TRANSFORMERS BID DOCUMENTS
16460 - 1 1/8/2021
1 27.
2
3 F UL Compliance: Comply with applicable requirements of ANSI/UL 506;
4 "Safety Standard for Specialty Transformers".
5
6 G. NESC Compliance: Comply with applicable requirements of National
7 Electrical Safety Code (ANSI Std C2) pertaining to indoor and outdoor
8 installation of transformers.
9
10 1.04 SUBMITTALS:
11
12 A. Product Data: Submit manufacturer's technical product data; including
13 rated kVA, frequency, primary and secondary voltages, and percent taps.
14
15 PART 2 - PRODUCTS
16
17 2.01 ACCEPTABLE MANUFACTURERS:
18
19 A. Available Manufacturers: Subject to compliance with requirements,
20 manufacturers offering products which may be incorporated in the work
21 are limited to the following:
22
23 Schneider/Square D
24 ABB
25 Cutler Hammer/Eaton
26
27 2.02 POWER/DISTRIBUTION TRANSFORMERS:
28
29 A. General: Except as otherwise indicated, provide manufacturer's standard
30 materials and components as indicated by published product information,
31 designed and constructed as recommended by manufacturer, and as
32 required for complete installation.
33
34 B. Dry -Type Distribution Transformers:
35
36 1. Transformers sized 15 kVA and below shall have two (2) — 2 1/2
37 percent taps above and below rated primary voltage.
38
39 2. Transformers 15 kVA and below shall be 115°C temperature rise
40 above 40°C ambient, unless noted otherwise.
41
42 3. Limit transformer surface temperature rise to maximum of 50°C rise
43 above a 40°C ambient. Provide wiring connectors suitable for
44 copper or aluminum wiring. Cushion -mount transformers with
45 external vibration isolation supports; sound -level ratings not to
46 exceed 45 dB for transformers 15 to 45 kVA and 50 dB for 50 to
TRANSFORMERS BID DOCUMENTS
16460 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 150 kVA as determined in accordance with ANSI/NEMA standards.
2 Electrically ground core and coils to transformer enclosure by
3 means of flexible metal grounding strap. Provide transformers with
4 fully -enclosed sheet -steel enclosures. Provide transformers
5 suitable for wall mounting.
6
7 C. Equipment/System Identification: Provide equipment/system identification
8 nameplates complying with Division 16 Basic Electrical Materials and
9 Methods section "Electrical Identification" in accordance with the following
10 listing: Equipment/System Identification.
11
12 D. Finishes: Coat interior and exterior surfaces of transformer, including
13 bolted joints, with manufacturer's standard color baked -on enamel.
14
15 PART 3 - EXECUTION
16
17 3.01 INSPECTION: Installer must examine areas and conditions under which
18 power/distribution transformers and ancillary equipment are to be installed, and
19 notify contractor in writing of conditions detrimental to proper completion of the
20 work. Do not proceed with the work until satisfactory conditions have been
21 corrected in a manner acceptable to installer.
22
23 3.02 INSTALLATION OF TRANSFORMERS: Install transformers as indicated,
24 complying with manufacturer's written instructions, applicable requirements of
25 NEC, NESC, NEMA, ANSI, and IEEE standards, and in accordance with
26 recognized industry practices to ensure that products fulfill requirements.
27
28 3.03 GROUNDING: Provide equipment grounding connections for power/distribution
29 transformers as indicated.
30
31 3.04 TESTING:
32
33 A. Prior to energization of transformers, check all accessible connections for
34 compliance with manufacturer's torque tightening specifications.
35
36 B. Prior to energization, check circuitry for electrical continuity and for short -
37 circuits
38 C. Upon completion of installation of transformers, energize primary circuitry
39 at rated voltage and frequency from normal power source, and test
40 transformers; including (but not limited to) audible sound levels, to
41 demonstrate capability and compliance with requirements.
42
43 D. Where possible, correct malfunctioning units at site, then retest to
44 demonstrate compliance; otherwise, remove and replace with new units or
45 components, and proceed with retesting.
46
TRANSFORMERS BID DOCUMENTS
16460 - 3 1/8/2021
1 END OF SECTION 16460
2
TRANSFORMERS
16460 - 4
BID DOCUMENTS
1/8/2021
1
1 1 SECTION 16470
2
I
3
4 PANELBOARDS
5 PART 1 - GENERAL
I6
7 1.01 RELATED DOCUMENTS:
8
I
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification Sections, apply to
11 work of this Section.
I12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is a part of each Division 16 section making reference to
I15 panelboards specified herein.
16
17 1.02 SUMMARY:
I18
19 A. Extent of panelboard and enclosure work, including cabinets and cutout
20 boxes, is indicated by drawings and schedules and as specified herein.
I21
22 B. Types of panelboards and enclosures required for the project include the
23 following:
I
24
25 Power Distribution Panelboards
26 Lighting and Appliance Panelboards
I
27
28 C. Refer to other Division 16 Sections for wires/cables, electrical boxes and
29 fittings and raceway work required in conjunction with installation of
I30 panelboards and enclosures.
31
32 1.03 SUBMITTALS:
I33
34 A. Product Data: Submit manufacturer's data on panelboards and
I
35 enclosures. Shop drawings shall indicate arrangement of busses, branch
36 circuits, enclosures, dimensions, etc.
37
I38 1.04 QUALITY ASSURANCE:
39
40 A. Manufacturer's Qualifications: Firms regularly engaged in the
I
41
42 manufacture of panelboards and enclosures, of types, sizes, and ratings
required; whose products have been in satisfactory use in similar service
43 for not less than five (5) years.
I44
45 B. Installer's Qualifications: A firm with at least three (3) years of successful
46 installation experience on projects utilizing panelboards similar to those
1
1
PANELBOARDS BID DOCUMENTS
16470 - 1 1/8/2021
1 required for this project.
2
3 C. Codes and Standards:
4
5 1. Electrical Code Compliance: Comply with applicable local code
6 requirements of the authority having jurisdiction and NEC Article
7 384 as applicable to the installation and construction of electrical
8 panelboards and enclosures.
9 2. UL Compliance: Comply with applicable requirements of UL 67,
10 "Electric Panelboards", and UL codes 50, 869, and 1053 pertaining
11 to panelboards, accessories and enclosures. Provide panelboard
12 units that are UL listed and labeled.
13
14 PART 2 - PRODUCTS
15
16 2.01 MANUFACTURERS:
17
18 A. Available Manufacturers: Subject to compliance with requirements,
19 manufacturers offering electrical panelboard products that may be
20 incorporated in the work are limited to the following:
21
22 Schneider/Square D
23 ABB
24 Cutler Hammer/Eaton
25
26 2.02 PANELBOARDS:
27
28 A. General: Except as otherwise indicated, provide panelboards,
29 enclosures, and ancillary components, of types, sizes, and ratings
30 indicated, which comply with manufacturer's standard materials; with the
31 design and construction in accordance with published product information.
32 Equip with proper number of unit panelboard devices as required for
33 complete installation. Where types, sizes, or ratings are not indicated,
34 comply with NEC, UL, and established industry standards for those
35 applications indicated.
36
37 B. Power Distribution Panelboards: Provide dead -front, safety -type power
38 distribution panelboards as indicated; with panelboard switching and
39 protective devices in quantities, ratings, types, and with arrangement
40 shown; with anti -turn, solderless pressure type main lug connectors
41 approved for use with copper conductors. Select unit with feeders
42 connecting at top of panel. Equip with copper bus bars with not less than
43 98 percent conductivity, and with full-sized neutral bus. Provide suitable
44 lugs on neutral bus for outgoing feeders requiring neutral connections.
45 Provide bolt -on, molded -case circuit breaker types for each circuit, with
46 toggle handles that indicate when tripped. Provide panelboards with bare
PANELBOARDS BID DOCUMENTS
16470 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 uninsulated grounding bars suitable for bolting to enclosures. Select
2 enclosures fabricated by same manufacturer as panelboards which mate
3 and match properly with panelboards.
4
5 1. Power panelboards shall be General Electric type 'Spectra', Square
6 D type 'I Line', or Cutler -Hammer type 'PRL3a'. Voltage shall be as
7 indicated.
8
9 C. Lighting and Appliance Panelboards: Provide dead -front safety type
10 lighting and appliance panelboards as indicated; with switching and
11 protective devices in quantities, ratings, types and arrangements shown;
12 with anti -burn solderless pressure type lug connectors approved for use
13 with copper conductors. Construct unit for connecting feeders at top of
14 panel. Equip with copper bus bars, full-sized neutral bar, with bolt -in type
15 heavy-duty, quick -make, quick -break, circuit breakers, with toggle handles
16 that indicate when tripped. Provide suitable lugs on neutral bus for each
17 outgoing feeder required, and provide bare uninsulated grounding bars
18 suitable for bolting to enclosures. Select enclosures fabricated by same
19 manufacturer as panelboards that mate and match properly with
20 panelboards.
21
22 1. Panelboards shall be General Electric A -Series, Square D type
23 "NQ", or Cutler -Hammer type PRL2. Panelboard boxes shall be
24 five and three-fourths inches (5 3/") deep. Voltage shall be as
25 indicated.
26
27 D. Panelboard Enclosures: Provide galvanized sheet steel cabinet -type
28 enclosures, in sizes and NEMA types as indicated; code -gauge, minimum
29 16 -gauge thickness. Cabinets shall be furnished without knockouts and
30 all holes for raceways shall be drilled and punched on the job.
31 Panelboard enclosures shall be five and three-fourths inches (5 3/4') deep.
32 Provide fronts with adjustable trim clamps and doors with flush locks and
33 keys; all panelboard enclosures keyed alike, with concealed piano door
34 hinges and door swings as indicated. Provide baked gray enamel finish
35 over a rust inhibitor coating. Design enclosures for recessed mounting.
36 Provide enclosures that are fabricated by same manufacturer as
37 panelboards that mate and match properly with panelboards to be
38 enclosed.
39
40 E. All panelboards shall be connected distributed phase with circuit
41 numbering as indicated on the drawings. Panelboards shall be numbered
42 with odd numbers on the left side of the panel and even numbers on the
43 right side of the panel. Panelboards shall have a circuit directory card
44 mounted in a frame with plastic cover, mounted on the inside of the door,
45 and directory cards shall be completed with a typewriter to indicated areas
46 and/or devices served by each circuit. All new and existing panelboards
PANELBOARDS BID DOCUMENTS
16470 - 3 1/8/2021
1 being used for this project shall have new typed directories.
2
3 F. Molded -Case Circuit Breakers: Provide factory -assembled, bolt -on,
4 molded -case circuit breakers of frame sizes, characteristics, and ratings,
5 including RMS symmetrical interrupting ratings indicated. Select breakers
6 with permanent thermal and instantaneous magnetic trip, and with fault -
7 current limiting protection; ampere ratings as indicated. Multi -pole
8 breakers shall have a common trip bar so that the tripping of one pole will
9 automatically trip all poles of the breaker. Construct with over -center, trip -
10 free, toggle -type operating mechanisms with quick -make, quick -break
11 action, and positive handle trip indication. Construct breakers for
12 mounting and operating in any physical position and operating in an
13 ambient temperature of 40°C. Provide breakers with mechanical screw
14 type removable connector lugs; AL/CU rated.
15
16 1. Individual Enclosed Circuit Breakers: Circuit breakers shall be
17 molded case type. Breakers shall have thermal -magnetic trip units
18 and magnetic trip shall be adjustable. Breakers shall have a
19 common trip bar so that the tripping of one pole will automatically
20 trip all poles of the breaker. Breakers shall be trip free and trip
21 indicating and shall have quick -make, quick- break contacts.
22 Enclosure shall have insulated, groundable neutral.
23
24 G. Panelboards shall be installed complete with connectors and associated
25 hardware for all circuit breakers and circuit breaker spaces listed in the
26 panelboard schedule.
27
28 H. When connecting equipment to existing panelboards, the new and
29 existing circuit breakers shall be identified. A new circuit directory card
30 shall be provided.
31
32 PART 3 - EXECUTION
33
34 3.01 EXAMINATION:
35
36 Examine areas and conditions under which panelboards and enclosures are to
37 be installed and notify contractor in writing of conditions detrimental to proper
38 completion of work. Do not proceed with work until unsatisfactory conditions
39 have been corrected in a manner acceptable to installer.
40
41 3.02 INSTALLATION OF PANELBOARDS:
42
43 A. Install panelboards and enclosures as indicated, in accordance with
44 manufacturer's written instruction, applicable requirements of NEC
45 standards, NECA's "Standards of Installation", and in compliance with
46 recognized industry practices to ensure that products fulfill requirements.
PANELBOARDS BID DOCUMENTS
16470 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 B. Tighten connectors and terminals, including screws and bolts, in
3 accordance with equipment manufacturer's published torque -tightening
4 values for equipment connectors.
5
6 C. Fasten enclosures firmly to walls and structural surfaces, ensuring that
7 they are permanently and mechanically anchored.
8
9 3.03 GROUNDING:
10
11 A. Provide equipment grounding connections for panelboard enclosures as
12 indicated.
13
14 B. Prior to energization, check panelboards for electrical continuity of circuits
15 and for short-circuits.
16
17 3.04 ADJUSTING AND CLEANING:
18
19 A. Adjust operating mechanisms for free mechanical movement.
20
21 B. Touch-up scratched or marred surfaces to match original finishes.
22
23 END OF SECTION 16470
PANELBOARDS BID DOCUMENTS
16470 - 5 1/8/2021
1
1 1
2
3
4
5 1
6 THIS PAGE INTENTIONALLY LEFT BLANK7 1
8
PANELBOARDS
16470 - 6
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16480
2
3 MOTORS
4
5 PART 1 — GENERAL
6
7 1.01 DESCRIPTION
8
9 Furnish and install the motors as hereinafter specified and as called for in other
10 sections of these Specifications.
11
12 1.02 QUALIFICATIONS
13
14 Motor shall be sufficient size for the duty to be performed and shall not exceed
15 their full -rated load when the driven equipment is operating at specified capacity.
16
17 1.03 SUBMITTALS
18
19 A. The motor manufacturer shall submit to the Engineer certified dimension
20 prints showing nameplate data and outline dimensions within three weeks
21 of the date they receive the order.
22
23 B. Submit Operation and Maintenance Manual and parts lists as specified in
24 Division 1 PROJECT CLOSEOUT.
25
26 C. Guarantee: All equipment furnished and installed under this Section shall
27 be guaranteed against defects of workmanship, materials and improper
28 installation for a period of eighteen month from date of acceptance. All
29 such equipment or parts proven defective, due to the above noted causes,
30 shall be replaced in the machines by the CONTRACTOR at no expense to
31 the Owner.
32
33 D. Provide equipment warranty in accordance with Division 1 SPECIFIC
34 WARRANTIES.
35
36 PART 2 - PRODUCTS
37
38 2.01 RATING
39
40 A. Unless otherwise noted, all motors shall be of the low voltage type. All
41 motors 2 through 100 horsepower shall be rated 230/460 volt, 3 phase, 60
42 Hertz A.C.; motors 125 horsepower through 300 horsepower shall be
43 rated 460 volt, 3-phase, 60 Hertz, and motors below 2 horsepower shall
44 be rated 115/230 volt, 1 phase, 60 Hertz A.C.
MOTORS
16480-1
BID DOCUMENTS
1/8/2021
1
2 2.02 THREE PHASE INDUCTION MOTORS
3
4 A. Motors 25 HP and larger shall have a 120 -volt space heater for moisture
5 control.
6
7
8
9
10
11
12
13
14 C. Motors operating with variable frequency drives shall indicate on the
15 nameplate that they are suitable for their intended applications (Inverter
16 duty Rated) and they shall be provided with an integral temperature switch
17 that opens on high temperature. Motors operating with Variable
18 Frequency Drives (VFD's) shall meet the requirements of NEMA MG1
19 Part 31.
20
21 2.03 CONSTRUCTION
22
23 A. General:
24
25 1. All dripproof and weather protected Type I motors shall have epoxy
26 encapsulated windings. Totally enclosed motors shall not be
27 encapsulated. Motors not readily available with encapsulated
28 windings may be standard type. Motors exposed to the outside
29 atmosphere shall be totally enclosed fan cooled (TEFC) unless
30 otherwise specified.
31
32 2. Squirrel -cage rotors shall be made from high-grade steel
33 laminations adequately fastened together and to the shaft, or shall
34 be cast aluminum or bar -type construction with brazed end rings.
35
B. Unless specifically noted in other sections of these Specifications, all
motors shall have an efficiency as indicated in the table below. Motors
shall be "premium efficiency" type.
TABLE 1
Motor
HP
Min.
Eff.
Max.
dba
Motor
HP
Min.
Eff.
Max.
dba
1-2
84.0%
74
25-30
92.0%
92
3-5
86.5%
79
40-50
93.0%
97
7.5-10
90.2%
84
60-75
94.0%
100
15-20
91.0%
89
100
94.1%
102
MOTORS
16480-2
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. Low Voltage, Three Phase Motors:
2
3 1. Motors shall be of the squirrel -cage induction type, NEMA design
4 B. Horizontal, vertical solid shaft, vertical hollow shaft, normal
5 thrust and high thrust types shall be furnished as specified herein.
6 All motors shall be built in accordance with current NEMA, IEEE,
7 ANSI and AFBMA standards where applicable. Motors shall be of
8 the type and quality described by these Specifications, fully
9 capable of performing in accordance with manufacturer's
10 nameplate rating, and free from defective material and
11 workmanship.
12
13 2. Motors shall have normal or high starting torque (as required), low
14 starting current (not to exceed 600 percent full load current), and
15 low slip.
16
17 3. Outdoor motors shall be totally enclosed fan -cooled construction
18 with 1.15 service factor unless otherwise noted. Indoor motors
19 shall be ODP unless otherwise noted.
20
21 4. Outdoor motors shall be mill and chemical duty suitable for
22 operation in moist air with hydrogen sulphide gas present.
23
24 5. The output shaft shall be suitable for direct connection or belt drive
25 as required.
26
27 6. Motors shall have a Class B nonhygroscopic insulation system.
28 Class F insulation may be used but shall be limited to Class B
29 temperature rise.
30
31 7. All motors shall have a final coating of chemical resistant corrosion
32 and fungus protective epoxy fortified enamel finish sprayed over
33 red primer over all interior and exterior surfaces. Stator bore and
34 rotor of all motors shall be epoxy coated.
35
36 8. All fittings, bolts, nuts, and screws shall be 316 stainless steel.
37 Bolts and nuts shall have hex heads.
38
39 9. All machine surfaces shall be coated with rust inhibitor for easy
40 disassembly.
41
42 10. Conduit boxes shall be gasketed. Lead wires between motor frame
43 and conduit box shall be gasketed.
44
45 11. Totally enclosed motors shall be provided with condensate drain
46 hole and epoxy coated motor windings to protect against moisture.
MOTORS
16480-3
BID DOCUMENTS
1/8/2021
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
12. Nameplates shall be stainless steel. Lifting lugs or "0" type bolts
shall be supplied on all frames 254T and larger. Enclosures will
have stainless steel screen and motors shall be protected for
corrosion, fungus and insects.
13. Low voltage, three phase motors shall be manufactured by General
Electric, U.S. Motors, Westinghouse or approved equal.
14. Fractional Horsepower:
a. Fractional horsepower motors shall be rigid, welded -steel,
designed to maintain accurate alignment of motor
components and provide adequate protection. End shields
shall be reinforced, lightweight die-cast aluminum. Windings
shall be of varnish -insulated wire with slot insulation of
polyester film, baked -on bonding treatment to make the
stator winding strongly resistant to heat, aging, moisture,
electrical stresses and other hazards.
b. Motor shaft shall be made from high-grade, cold -rolled shaft
steel with drive -shaft extensions carefully machined to
standard NEMA dimensions for the particular drive
connection.
c. All motors shall be equipped with vacuum -degassed
(sealed) antifriction bearings made to AFBMA Standards,
and be of ample capacity for the motor rating. The bearing
housing shall be large enough to hold sufficient lubricant to
minimize the need for frequent lubrication, but facilities shall
be provided for adding new lubricant and draining out old
lubricant without motor disassembly. The bearing housing
shall have long, tight, running fits or rotating seals to protect
against the entrance of foreign matter into the bearings, or
leakage of lubricant out of the bearing cavity.
15. Integral Horsepower:
a. Motor frames and end shields shall be cast iron or heavy
fabricated steel of such design and proportions as to hold all
motor components rigidly in proper position and provide
adequate protection for the type of enclosure employed.
b. Windings shall be adequately insulated and securely braced
to resist failure due to electrical stresses and vibrations.
c. The shaft shall be made of high-grade machine steel or steel
forging of size and design adequate to withstand the load
stresses normally encountered in motors of the particular
rating. Bearing journals shall be gound and polished.
MOTORS
16480-4
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 d. Rotors shall be made from high-grade steel laminations
2 adequately fastened together, and to the shaft. Rotor
3 squirrel -cage windings may be copper or bar -type
4 construction with brazed end rings.
5 e. All motors shall be equipped with vacuum -degassed
6 (sealed) antifriction bearings made to AFBMA Standards,
7 and be of ample capacity for the motor rating. The bearing
8 housing shall be large enough to hold sufficient lubricant to
9 minimize the need for frequent lubrication, but facilities shall
10 be provided for adding new lubricant and draining out old
11 lubricant without motor disassembly. The bearing housing
12 shall have long, tight, running fits or rotating seals to protect
13 against the entrance of foreign matter into the bearings, or
14 leakage of lubricant out of the bearing cavity.
15 f Bearings of high thrust motors will be locked for momentary
16 up thrust of 30% down thrust. All bearings shall have a
17 minimum B10 life rating of 100,000 hours in accordance with
18 AFBMA life and thrust values.
19 g. Vertical hollow -shaft motors will have nonreverse ratchets to
20 prevent backspin.
21
22 C. Low Voltage, Single Phase Motors:
23
24 1. Single phase motors shall be split -phase and capacitor -start
25 induction types rated for continuous horsepower at the rpm called
26 for on the Drawings. Motors shall be rated 115/230 volts, 60 Hertz,
27 single phase, open drip proof, or totally enclosed fan cooled as
28 called for on the Drawings, with temperature rise in accordance
29 with NEMA Standards for Class B insulation.
30
31 2. Totally enclosed fan cooled motors shall be designed for
32 severe -duty.
33
34 3. Motors shall have corrosion and fungus protective finish on internal
35 and external surfaces. All fittings shall have a corrosion protective
36 plating.
37
38 4. Mechanical characteristics shall be the same as specified for
39 polyphase fractional horsepower motors.
40
41 PART 3 - EXECUTION
42
43 3.01 INSTALLATION
44
45 A. Motor Connections: All motors shall be connected to the conduit system
46 by means of a short section of flexible conduit, 18 inch minimum and 60
MOTORS
16480-5
BID DOCUMENTS
1/8/2021
1 inches maximum, unless otherwise indicated. For all motor connections,
2 the CONTRACTOR shall install a grounding conductor in the conduit and
3 terminate at the motor control center with an approved grounding clamp.
4
5 B. Connection to motor leads shall be compression type with 3M brand heat
6 shrink boot.
7
8 3.02 TESTS AND CHECKS
9
10 A. The following tests shall be performed on all motors after installation but
11 before putting motors into service.
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
1
1
1
1
1
1. The CONTRACTOR shall megger each motor winding before
energizing the motor, and, if insulation resistance is found to be
low, shall notify the Engineer and shall not energize the motor. The
CONTRACTOR shall check direction of rotation of all motors and
reverse connections if necessary. The following table gives
minimum acceptable insulation resistance in megohms at various
temperatures and for various voltages with readings being taken
after one minute of megger test run.
TABLE 2
Degree
Winding
Temperature
Voltage
°F
°C
115V
230V
460V
37
3.9
60
108
210
50
10
32
60
120
68
20
13
26
50
86
30
5.6
11
21
104
45
2.4
4.5
8.8
122
50
1
2
3.7
140
60
.5
.85
1.6
2. The CONTRACTOR shall check each motor for correct clearances
and alignment and for correct lubrication, and shall lubricate if
required in accordance with manufacturer's instructions.
END OF SECTION 16481
MOTORS
16480-6
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16481
2
3 MOTOR CONTROL CENTER
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9
10
11
A. Drawings and general provisions of Contract, including General and
Supplementary Conditions and Division 1 Specification sections, apply to
work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is a part of each Division 16 section making reference to
15 motor control centers specified herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of alternating -current motor control center (MCC) work is indicated
20 by drawings and schedules. The motor control center shall contain all
21 equipment shown on the drawings to provide complete control and
22 protection for the motors and feeders indicated.
23
24 1.03 QUALITY ASSURANCE:
25
26 A. Manufacturers: Firms regularly engaged in the manufacture of motor
27 control centers of types, sizes, and ratings required; whose products have
28 been in satisfactory use in similar service for not less than five years.
29
30 B. Installer's Qualifications: Firms with at least three years of successful
31 installation experience on projects with motor control center installation
32 work similar to that required for project.
33
34 C. Codes and Standards:
35
36 1. NEMA Compliance: Comply with NEMA Stds. Pub/No. ICS -2,
37 pertaining to construction, testing, and installation of motor control
38 centers and with applicable NEMA standards for circuit breakers
39 and fuses.
40
41 2. UL Compliance: Comply with applicable requirements of UL Std.
42 486A, "Wire Connectors and Soldering Lugs for Use with Copper
43 Conductors", and UL Std. 845, "Electric Motor Control Centers".
44 Provide MCC's and ancillary equipment which are UL listed and
45 labeled.
MOTOR CONTROL CENTER BID DOCUMENTS
16481 - 1 1/8/2021
1 3. NEC Compliance: Comply with requirements of NEC as applicable
2 to motor control center equipment and components.
3
4 1.04 SUBMITTALS:
5
6 A. Shop Drawings: Submit layout drawings of motor control centers showing
7 accurately scaled basic equipment sections; including but not limited to,
8 motor starters, controllers, device panels, and circuit breakers. Show
9 spatial relationships of MCC components to proximate electrical
10 equipment. Clearly differentiate on wiring diagrams those conductors
11 which are factory -installed and those which are field -installed.
12
13 B. Maintenance Data: Submit maintenance data and parts list for each
14 motor control center, including "trouble -shooting" maintenance guide.
15 Include that data, product data, and shop drawings in a maintenance
16 manual in accordance with requirements of Division 1.
17
18 1.05 DELIVERY, STORAGE, AND HANDLING:
19
20 A. Handle motor control centers carefully to prevent damage, breaking, and
21 scoring. Do not install damaged sections or components; replace with
22 new.
23
24 B. Store motor control center equipment in clean dry place. Protect from
25 weather, dirt, fumes, water, construction debris, and physical damage.
26
27 PART 2 - PRODUCTS
28
29 2.01 ACCEPTABLE MANUFACTURERS:
30
31 A. Acceptable Manufacturers: Subject to compliance with requirements,
32 manufacturers offering motor control centers which may be incorporated
33 in the work include are limited to the following:
34
35 Schneider/Square D
36 ABB
37 Cutler Hammer/Eaton
38
39 2.02 MOTOR CONTROL CENTERS AND COMPONENTS:
40
4-1 A. General: Provide motor control centers and ancillary components of
42 sizes, ratings, classes, types, and characteristics indicated; which comply
43 with manufacturer's standard design, materials, components, and
44- construction in accordance with published product information, as
45 required for complete installation, and as specified herein.
46
MOTOR CONTROL CENTER BID DOCUMENTS
16481 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 B. Motor Control Centers: The motor control center shall be for operation on
2 480 volts, three phase, four wire, 60 cycle service and shall be furnished
3 in accordance with NEMA Class I, Type B construction. All busses shall
4 be braced for 42,000 amperes RMS symmetrical.
5
6 C. The Motor Control Center shall be housed in a NEMA 1. Construct each
7 section 90 inches high with 9 inch horizontal wireways at top and bottom,
8 24 or 20 inches wide, and with 20 inch section depth for front -of -board
9 unit arrangement. The entire Motor Control Center shall be provided as
10 part of a completely pre -assembled Equipment & Control Enclosure as
11 described in specification 16650.
12
13 D. Each vertical section shall have a separate continuous vertical wireway.
14 All equipment in the control center shall be easily accessible for
15 maintenance. The doors for access to starters, compartments, etc., shall
16 be formed of steel sheet sections mounted on concealed hinges with
17 thumb screws of similar type latches. Doors of compartments containing
18 circuit breakers shall be mechanically interlocked to prevent opening of
19 the door unless breaker is in the "OFF" position. All steel work after
20 fabrication shall be cleaned and given a rust resisting prime coat of paint.
21 The entire structure, inside and out, shall be finished with the
22 manufacturer's standard color of synthetic enamel.
23
24 E. Combination Circuit Breaker Magnetic Starters:
25
26 1. Combination circuit breaker magnetic starter shall be 480 -volt, 3-
27 phase, 60 hertz across -the -line units. The starters shall be for full
28 voltage, non -reversing operation (FVNR), or as indicated in the
29 drawings.
30
31 2. Circuit breakers for combination starter shall be of the molded
32 case, designed for 480 -volt, 60 hertz service. Breakers shall be 3-
33 pole units with magnetic adjustable trip units actuating a common
34 tripping bar to open all poles when short circuit occurs. The
35 breakers shall not have thermal elements. Each entire breaker/
36 starter combination shall be rated for fault interruption of 42,000
37 RMS amperes symmetrical. Equipment shall be General Electric
38 Company "Mag -Break" motor circuit protectors with limiter,
39 Westinghouse Type MCP with limiter, or equal.
40
41 3. Provide necessary interface for PLC Control System. Coordinate
4-2 with PCL system's contractor. Provide Tesys T overload protective
43 and metering relay with Ethernet UP communications on all
44 Starters. Provide Front Door Display and Programming Port.
45 Include Two Hand Held Programming Terminals.
46
MOTOR CONTROL CENTER BID DOCUMENTS
16481 - 3 1/8/2021
1 4. Specific Requirements for the Intelligent Motor Protection Relay
2 (IMPR)
3 a. Metering: The IMPR shall include as a minimum the
4 following features:
5 b. Measurements including line currents, ground fault current,
6 average line current, current phase imbalance, thermal
7 capacity level, motor temperature sensor and, as an option,
8 frequency, line to line voltage, line voltage imbalance,
9 average voltage, power factor, active power, reactive power,
10 active power consumption and reactive power consumption.
11 For line current measurements, the IMPR shall have
12 integrated Current Transformers rated up to 100 A. For
13 motors larger than 100 A, the connection of external current
14 transformers shall be possible. For ground current, it shall be
15 possible either to calculate from line currents or, without
16 need of any additional component, to connect on the IMPR
17 an external ground Current Transformer. The motor
18 temperature measurement must be possible through several
19 types of sensors including PTC binary, PTC analog, NTC
20 analog and PT100. Without any additional component, the
21 IMPR shall allow the connection of the temperature sensor.
22 Voltage measurement shall allow for line voltage up to 690V.
23 c. Statistics including protection fault counts, protection
24 warning counts, diagnostic fault counts, motor control
25 function counts and fault history.
26 d. Diagnostics including internal watchdog results, controller
27 internal temperature, temperature sensor connections,
28 current connections, control commands (start, stop, run
29 check back and stop check back), control configuration
30 checksum, communication loss and, as an option, voltage
31 connections.
32 e. Motor control states (motor starter/L01 starts/ LO2 starts,
33 operating time, motor starts per hour, last start max current,
34 last start time, time to trip and time to reset).
35 f. Motor Protection Functions: As a minimum, the IMPR shall
36 allow the selection of the following protection functions :
37 thermal overload, current phase imbalance, current phase
38 loss, current phase reversal, long start, jam, undercurrent,
39 overcurrent, ground current, motor temperature sensor,
40 rapid cycle lockout and, as an option, voltage phase
41 imbalance, voltage phase Toss, voltage phase reversal,
42 undervoltage, overvoltage, voltage dip management
43 (autorestart and load shedding), power limits and power
44 factor limits.
45 i. The thermal overload trip curve shall be selectable
46 between inverse (12t) and definite time (Ixt) curves.
MOTOR CONTROL CENTER BID DOCUMENTS
16481 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 ii. The Auxiliary Fan Cooling application shall be also
2 selectable.
3
4 F. Feeder Circuit Breaker:
5
6 1. Circuit breakers shall be molded plastic case, bolt -on or draw -out,
7 molded case circuit breaker type. Breakers shall have the thermal -
8 magnetic trip units, and minimum of 65kaic rating as for
9 combination starters.
10
11 G. Equipment/System Identification: Provide equipment/system identification
12 nameplates complying with Division 16 Basic Materials and Methods
13 section "Electrical Identification" in accordance with Motor Control
14 Schedule on drawings. All MCC control wiring to be labeled with
15 permanent wire labels at each end. Wire labels to be plastic sleeve type.
16
17 H. Variable Frequency Drives — All drives in MCC's must Yaskawa model
18 iQ1000 by ICON technologies as referenced in VFD Specification.
19
20 PART 3 - EXECUTION
21
22 3.01 INSPECTION:
23
24 A. Examine areas and conditions under which motor control centers are to
25 be installed, and substrate which will support motor control centers. Do
26 not proceed with work until unsatisfactory conditions have been corrected
27 in manner acceptable to installer.
28
29 3.02 INSTALLATION OF MOTOR CONTROL CENTERS:
30
31 A. Motor control centers shall be installed in pre -assembled electrical and
32 Control enclosure as indicated, in accordance with equipment
33 manufacturer's written instructions, with recognized industry practices; and
34 complying with applicable requirements of NEC, NEMA's Std. Pub/No.
35 ICS -2, and NECA's "Standard of Installation."
36
37 B. Tighten connectors and terminals, including screws and bolts, in
38 accordance with equipment manufacturer's published torque tightening
39 values for equipment connectors.
40
41
42
43
44 3.03 ADJUSTING AND CLEANING:
45
46
A. Adjust operating mechanisms for free mechanical movement.
MOTOR CONTROL CENTER BID DOCUMENTS
16481 - 5 1/8/2021
1
2 B. Touch-up scratched or marred surfaces to match original finishes.
3
4 3.04 GROUNDING:
5
6 A. Provide equipment grounding connections for motor control centers as
7 indicated.
8
9 3.05 FIELD QUALITY CONTROL:
10
11 A. Prior to energization of motor control centers, check with insulation
12 resistance tester for proper values of phase -to -phase and phase -to -
13 ground insulation resistances. Log that data, and submit to engineer.
14
15 B. Prior to energization of circuitry, check control center electrical circuits for
16 continuity and for short-circuits.
17
18 C. Subsequent to wire/cable and raceway hook-ups, energize motor control
19 center circuitry, check each motor for proper phase rotation, and
20 demonstrate capability and compliance with requirements. Where
21 possible, correct malfunctioning units at site, then retest to demonstrate
22 compliance. Otherwise, remove and replace with new units and proceed
23 with retesting
24
25 END OF SECTION 16481
26
27
28
29
30
31
32
33
34
35
36
37
38
39
MOTOR CONTROL CENTER BID DOCUMENTS
16481 - 6 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16482
2
3 MOTOR STARTERS
4
s PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This is a Division 16 Basic Electrical Materials and Methods section, and
14 is part of each Division 16 Section making reference to motor starters
15 herein.
16
17 1.02 DESCRIPTION OF WORK:
18
19 A. Extent of motor starter work is indicated by drawings and schedules.
20
21 1.03 QUALITY ASSURANCE:
22
23 A. Manufacturers: Firms regularly engaged in the manufacture of motor
24 starters of types, ratings, and characteristics required; whose products
25 have been in satisfactory use in similar service for not less than five (5)
26 years.
27
28 B. Installer's Qualifications: Firm with at least three (3) years of successful
29 installation experience on projects utilizing motor starters similar to that
30 required for this project.
31
32 C. NEC Compliance: Comply with NEC as applicable to wiring methods,
33 construction, and installation of motor starters.
34
35 D. UL Compliance: Provide motor starters and components which are UL
36 listed and labeled.
37
38 1.04 SUBMITTALS:
39
40 A. Product Data: Submit manufacturer's data on motor starters.
41
42 PART 2 - PRODUCTS
43
44 2.01 ACCEPTABLE MANUFACTURERS:
45
MOTOR STARTERS BID DOCUMENTS
16482 - 1 1/8/2021
1 A. Available Manufacturers: Subject to compliance with requirements,
2 manufacturers offering motor starters which may be incorporated in the
3 work are limited to the following:
4
5 Schneider/Square D
6 ABB
7 Cutler Hammer/Eaton
8
9 2.02 MOTOR STARTERS:
10
11 A. General: Except as otherwise indicated, provide motor starters and
12 ancillary components which comply with manufacturer's standard
13 materials, design, and construction in accordance with published product
14 information, and as required for complete installation.
15
16 B. Manual motor starters for 115 volts, single phase motors one horsepower
17 and smaller shall be single pole, horsepower rated switches with thermal
18 overload units and heaters. Starters shall be Square D Class 2510, with
19 stainless steel cover plates.
20
21 C. Magnetic full voltage starters for three phase motors shall be three pole,
22 horsepower- rated, magnetically operated, with three thermal overload
23 units and four extra auxiliary contacts. Control voltage shall be 120 volts
24 supplied from a control power transformer. A Hand -Off -Automatic, HOA
25 switch shall be mounted in front cover. Starters shall be Square D Class
26 8536.
27
28 D. Combination magnetic, full voltage starters for three phase motors shall
29 be three pole horsepower -rated, magnetically operated switches, with
30 three thermal overload units and four extra auxiliary contacts. Control
31 voltage shall be 120 volts supplied from a control power transformer. A
32 three pole horsepower -rated, non -fusible disconnect switch shall also be
33 included in the enclosure. An HOA switch shall be mounted in front cover.
34- Starters shall be Square D Class 8538.
35
36 E. Phase Toss protection shall be provided on all starters serving motors 15
37 horsepower or larger.
38
39 F. Provide 0-15 minute on -delay auto restart function on each starter.
40
41 G. Provide PLC contact. Coordinate with PLC controls contractor.
42
43 PART 3 - EXECUTION
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
44
I
45 3.01 INSTALLATION OF MOTOR STARTERS:
46
MOTOR STARTERS BID DOCUMENTS
16482 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Install motor starters as indicated, in accordance with equipment
2 manufacturer's written instructions and with recognized industry practices;
3 complying with applicable requirements of NEC, UL and NEMA standards
4 to insure that products fulfill requirements.
5
6 B. Motor starters or any other electrical equipment located in smoke or fire
7 rated walls shall be mounted on Unistrut channels. Channels shall be
8 supported from floor and structure above ceiling. There shall be no
9 penetrations of the fire rated assembly pursuant to the equipment
10 installation.
11
12 C. Unless otherwise indicated, motor starters shown on the drawing shall be
13 furnished and installed under this Section. The full Toad current and
14 starting characteristics of each motor shall be verified for proper selection
1 s of motor over load devices.
16
17 D. Furnish and install all steel shapes, etc., necessary for a support of all
18 motor starters.
19
20 E. Tighten connectors and terminals, including screws and bolts, in
21 accordance with equipment manufacturer's published torque tightening
22 values for equipment connectors.
23
24 3.02 ADJUSTING AND CLEANING:
25
26 A. Inspect electrical starter's operating mechanisms for malfunctioning and,
27 where necessary, adjust units for free mechanical movement.
28
29 B. Touch-up scratched or marred surfaces to match original finish.
30
31 3.03 FIELD QUALITY CONTROL:
32
33 A. Subsequent to connecting wires/cables, energize motor starter circuitry
34 and demonstrate functioning of equipment in accordance with
35 requirements. Where necessary correct malfunctioning units, and then
36 retest to demonstrate compliance. Ensure that direction of rotation of
37 each motor fulfills requirements.
38
39 END OF SECTION 16482
40
41
42
43
MOTOR STARTERS BID DOCUMENTS
16482 - 3 1/8/2021
1 SECTION 16620
2
3 SURGE SUPPRESSION
4
5 SECTION 16620 - SURGE SUPPRESSION
6
7 PART I - GENERAL
8
9 1.01 RELATED DOCUMENTS
10
11 A. Drawings and general provisions of Contract, including General and
12 Supplementary Conditions and Division 1 Specification sections, apply to
13 work of this Section.
14
15 B. This Section is a Division 16 Basic Electrical Materials and Methods
16 section, and is a part of each Division 16 section making reference to
17 electrical surge suppression specified herein.
18
19 1.02 DESCRIPTION OF WORK
20
21 A. The work required under this division shall include all materials, labor, and
22 auxiliaries required to furnish and install complete surge suppression for
23 the protection of building electrical and electronics systems from the
24 effects of line -induced transient voltage surge and lightning discharge, as
25 indicated on drawings or specified in this section.
26
27 B. Types of surge suppression specified in this section include the following:
28 Service entrance type.
29 Distribution and branch circuit panels.
30 Point of use type (receptacle and plug-in units).
31
32 1.03 QUALITY ASSURANCE
33
34 A. All surge suppression devices shall be manufactured by a company
35 normally engaged in the design, development, and manufacture of such
36 devices for electrical and electronics systems equipment.
37
38 B. The surge suppressor manufacturer shall offer technical assistance
39 through support by a factory representative and local stocking distributor.
40
41 C. Obtain suppression devices and accessories through one source, from a
42 single manufacturer.
43
44 1.04 WARRANTY
45
46 A. Manufacturer shall provide a product warranty for a period of not less than
SURGE SUPPRESSION BID DOCUMENTS
16620 - 1 1/8/2021
1 five (5) years from date of installation. Warranty shall cover unlimited
2 replacement of suppressor's modules during the warranty period. Those
3 firms responding to this specification shall provide proof that they have
4 regularly engaged in the design, manufacturing and testing of suppressors
5 for not less than twenty five (25) years.
6
7 1.05 CODES AND STANDARDS
8
9 A. The following standards and publications are referenced in various parts
10 of this specification and shall apply:
11
12 UL 1449-2009 (Third Edition):
13 Standard for Safety, Transient Voltage Surge Suppressors.
14
15 UL 1283- (listed as an electromagnetic interference filter that provides
16 noise attenuation)
17
18 IEEE C62.41-2002 (IEEE 587):
19 Guide for Surge Voltages in Low -Voltage AC Power Circuits.
20
21 IEEE C62.33-2002:
22 Standard Test Specifications for Varistor Surge Protection Devices.
23
24 IEEE C62.45-2002:
25 IEEE Guide for Surge Testing for Equipment Connected to Low -
26 Voltage AC Power Circuits.
27
28 NEC 285, 250.56 — 2008
29
30 NFPA 780 and CSA — (National Fire Protection Association and Canadian
31 Standards Associations)
32
33 ISO 9001:2000 — Quality standard / Military Standards (MIL -STD 220A)
34
35 UL 96A — Lightning Protection Master Label
36
37 B. The fusing element must be capable of allowing the suppressor's rated
38 single impulse current to pass through the suppressor at least one time
39 without failure. The system shall be tested to 1,000 sequential per
40 C62.45-2002 section B.38 referencing C62.41.1 and C62.41.2 Category
41 C3 combination wave transients. The Category C3 combination wave is
42 defined as a 1.2 x 50ps wave at 20,000 volt open circuit voltage waveform
43 and 8 x 20ps wave at 10,000 amperes short circuit current waveform. In
44 addition, the system components shall be tested repetitively 1,000 times
45 testing based on IEEE C62.33 (MOV test) and C62.35 (SAD test) without
46 failure or degradation exceeding ±10%.
SURGE SUPPRESSION BID DOCUMENTS
16620 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 C. All manufacturers must comply with above listed standards and any
3 additions current revisions of industry standards. All products that do not
4 comply with current industry standards will not be accepted.
5
6 1.06 SUBMITTALS
7
8 A. Must have ten day prior approval to bid on project. Request for submittal
9 must be in writing and attached with independent documentation of the
10 following items.
11
12 B. Drawings: Electrical and mechanical drawings shall be provided by the
13 manufacturer which show unit dimensions, weights, mounting provisions,
14 connection notes, wire size and wiring diagram.
15
16 C. Equipment manual: The manufacturer shall furnish an installation manual
17 with installation notes, start-up and operating instructions for the specified
18 system. Installation instructions shall clearly state whether the system
19 requires an external overcurrent device to maintain the system's UL 1449
20 listing.
21
22 D. Independent Testing:
23
24 1. High exposure with the 10 x 1,000ps tests per IEEE C62.41.2
25 Section 7.2
26
27 2. Life Cycle/Repetitive Testing per C62.45-2002 section B.38
28 minimum of 1,000 to 2,000 times.
29
30 E. UL 1449 stipulation for fused TVSS — The manufacturer's authorized
31 representative is required to submit the following:
32
33 1. Certify that the TVSS system is UL 1449 listed (UL Card) with UL
34 Card.
35
36 2. Indicate the type of internal or external fusing that is incorporated in
37 the TVSS system and what impact the fusing has on the
38 performance of the device with respect to surge capacity and
39 clamping levels.
40
41 1.07 REQUIRED SUPPRESSORS
42
43 A. Provide surge suppression for the equipment described herein:
44
45 1. On main electrical service entrance panels as shown in the project
46 drawings.
SURGE SUPPRESSION BID DOCUMENTS
16620 - 3 1/8/2021
1
2 2. On distribution and branch circuit panels as shown in the project
3 drawings.
4
5 3. On all equipment identified in the project drawings.
6
7 PART 2 - PRODUCTS
8
9 2.01 SERVICE ENTRANCE SUPPRESSORS
10
11 A. ACCEPTABLE MANUFACTURERS
12
13 LEA International — PV200
14 Current Technology — TG100-L2
15 Liebert — SI-025-ANCE
16
17 B. The surge suppressor manufacturer shall offer a complete line of surge
18 suppression products to support the required suppressors listed in Part 1.
19
20 C. The surge suppressor's minimum surge current capacity shall be 200kA
21 per phase (L -N plus L -G) and 100kA per mode (L -N, L -G, L -L and N -G).
22
23 D. The system protection modules shall contain a technology that utilizes a
24 symmetrical array of balanced metal oxide varistors (MOV). Each MOV
25 will be individually coordinated to pass UL 1449.
26
27 E. The service entrance surge suppressors shall be designed with
28 replaceable modules for purposes of in-service replacement. The unit
29 suppressor shall be designed with redundant back-up surge protection in
30 the event of a module failure.
31
32 F Module status indicators shall be provided to indicate individual module
33 status. When a module has failed, the module LED status indicator shall
34 indicate said failure.
35
36 G. Each protection module shall have a capacitive filtering system connected
37 in each Line to Neutral (L-N)(Wye) mode or Line to Line (L-L)(Delta) mode
38 to provide EMI/RFI noise attenuation (UL 1283)
39
40 H. Service entrance suppressors shall utilize normal and common modes of
41 protection - each phase line to neutral, each phase line to ground and
42 neutral to ground.
43
44 I. Surge suppressor shall provide the following monitoring features: dry
45 contacts, digital surge counter, and audible alarm with alarm disable
46 switch. Suppressor shall utilize a NEMA 4 or NEMA 12 enclosure.
SURGE SUPPRESSION BID DOCUMENTS
16620 - 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 J. Service entrance and panel type suppressors shall be installed with a
3 means of disconnecting the suppressor. If no dedicated circuit breaker is
4 included in panel, manufacturer shall provide an integral fused disconnect.
5
6
7 K. Suppressors shall be of a hybrid design and include circuitry with tight,
8 wave -tracking clamping characteristics.
9
10 L. Suppressors shall be designed to withstand a maximum continuous
11 operating voltage of not less than 115% of nominal RMS line voltage.
12
13 M. Each suppressor shall have an internal disconnect switch when not
14 connected to a separate circuit breaker or fused disconnect switch which
15 is dedicated specifically for the suppressor.
16
17 N. Suppressors shall be failsafe, shall allow no follow-through current, shall
18 have repeated surge capability, shall be solid state, shall be self -restoring,
19 and shall be fully automatic.
20
21 O. Suppressors shall have an operating temperature range of -40 EC to
22 +85C.
23
24 2.02 DISTRIBUTION BRANCH PANEL SUPPRESSORS
25
26 A. ACCEPTABLE MANUFACTURERS
27
28 LEA International — SP200
29 Current Technology — CG100
30 Liebert — Al I-111-RKE
31
32 B. Suppressors shall meet all specification requirements in section 2.1
33 except as follows:
34
35 1. The suppressor's minimum surge current capacity shall be 200kA
36 per phase (L -N plus L -G) and 100kA per mode (L -N, L -G, L -L and
37 N -G).
38
39 2. The suppressor protection modules shall contain a technology that
40 utilizes a symmetrical array of balanced metal oxide varistors
41 (MOV). Each MOV will be individually coordinated to pass UL
42 1449. The suppressor is non -modular.
43
44 3. The suppressor shall provide the following monitoring features: dry
45 contacts, audible alarm and utilize a NEMA 4X enclosure.
46
SURGE SUPPRESSION BID DOCUMENTS
16620 - 5 1/8/2021
1 2.03 BRANCH PANEL SUPPRESSORS
2
3 A. ACCEPTABLE MANUFACTURERS
4
5 LEA International — SP100
6 Current Technology — CG060
7 Liebert —ACV-111-RKE
8
9 B. Suppressors shall meet all specification requirements in section 2.1
10 except as follows:
11
12 1. The suppressor's minimum surge current capacity shall be 100kA
13 per phase (L -N plus L -G) and 50kA per mode (L -N, L -G, L -L and N-
14 G).
15
16 2. The suppressor protection modules shall contain a technology that
17 utilizes a symmetrical array of balanced metal oxide varistors
18 (MOV). Each MOV will be individually coordinated to pass UL
19 1449. The suppressor is non -modular.
20
21 3. The suppressor shall provide the following monitoring features: dry
22 contacts, audible alarm and utilize a NEMA 4X enclosure.
23
24 PART 3 - EXECUTION
25
26 3.01 INSTALLATION OF SUPPRESSORS
27
28 A. Suppressors shall be installed as close as practical to the electric panel or
29 electronic equipment to be protected, consistent with available space.
30 Suppressors shall be close nippled to the device being protected in a
31 position near the point of connections, which will minimize lead length
32 between suppressor and the buses or control breaker to which the
33 suppressor connects. Must have a grounding of 25 Ohms (NEC 250.56)
34 or less and avoid any unnecessary or sharp bends.
35
36 B. For service entrance suppressors the lead length shall not exceed 36"
37 from power it is protecting and use a 3 pole 60 amp breaker for
38 disconnection means. For distribution and sub panels, the lead length
39 shall not exceed 18" from the power it is protecting and use a 3 pole 30
40 amp breaker for disconnection means.
41
42 END OF SECTION 16620
SURGE SUPPRESSION BID DOCUMENTS
16620 - 6 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16670
2
3 LIGHTNING PROTECTION SYSTEMS
4
5 PART 1 - GENERAL
6
7 1.01 RELATED DOCUMENTS:
8
9 A. Drawings and general provisions of Contract, including General and
10 Supplementary Conditions and Division 1 Specification sections, apply to
11 work of this Section.
12
13 B. This Section is a Division 16 Basic Electrical Materials and Methods
14 section, and is part of each Division 16 Section making reference to
15 lightning protection systems specified herein.
16
17 1.02 DESCRIPTION OF WORK: Extent of lightning protection system work is
18 indicated on the project drawings.
19
20 1.03 QUALITY ASSURANCE:
21
22 A. Manufacturers: Firms regularly engaged in the manufacture of early
23 streamer emission lightning protection system components of types, sizes,
24 and ratings required; whose products have been in satisfactory use in
25 similar service for not less than three (3) years, and who are certified with
26 ETL and listed with UL.
27
28 B. NEC Compliance: Comply with NEC requirements pertaining to lightning
29 (surge) arresters, grounding, grounding electrodes, and down conductor
30 clearances.
31
32 C. The lightning protection manufacturer shall provide a $10,000,000.00, 100
33 year guarantee to the original building owner to provide lightning
34 protection for the protected area as shown and installed per the
35 manufacturer's shop drawings.
36
37 1.04 SUBMITTALS:
38
39 A. Product Data: Submit manufacturer's data on lightning protection systems
40 and associated components.
41
42 B. Shop Drawings: Submit layout drawings of lightning protection system
43 equipment and components including, but not limited to, air terminals,
44 mounting details, conductor routing, connections, and grounding.
45
46
LIGHTNING PROTECTION SYSTEMS BID DOCUMENTS
16670 - 1 1/8/2021
1 PART 2 - PRODUCTS
2
3 2.01 ACCEPTABLE MANUFACTURERS: Subject to compliance with requirements,
4 the manufacturer of lightning protection components shall be Lightning Preventor
5 of America.
6
7 2.03 LIGHTNING PROTECTION SYSTEM COMPONENTS:
8
9 A. General: Provide material and components, of types, sizes, ratings, for
10 early streamer emission (ESE) lightning protection of buildings and
11 property, which comply with manufacturer's standard materials, design,
12 and construction in accordance with published product information, and as
13 required for complete installation. Where type components or materials
14 are not otherwise indicated, comply with proposed NFPA 781 standards.
15 Unless noted otherwise, all air terminals, conductors, connectors, and
16 ground rods shall be copper.
17
18 B. ESE Air Terminal: The complete assembly shall consist of a stainless
19 steel air terminal, 5/8" diameter minimum, stainless steel housing, with the
20 ESE initiator, sensing mechanism, triggering mechanism, to be completely
21 sealed. Provide threaded base for connection to mast and nameplate.
22
23 C. Copper conductors shall be 28 strands of 14 gauge wire rope lay, with a
24 net weight of 375 pounds per 1,000 feet, minimum, or copper strip of
25 equivalent capacity.
26
27 D. Aluminum mast height to be determined by the area of protection, with
28 threaded connections for the ESE air terminal and bonding plate for cable
29 connection. Wind and safety factors shall be engineered to comply with
30 geographic location, to determine the size and structure of mast. All
31 masts are to be ETL listed.
32
33 E. Ground rods shall be copper -clad 3/4" x 20' minimum. One set of tripod
34 (DELTA) grounds shall be installed for each down conductor, two (2)
35 minimum per system with allowed exceptions.
36
37 F Provide all connectors, fittings, fasteners, hardware, clamps, lugs, crimps,
38 etc. as required to connect and install all parts of the system. All material
39 to be ESE system certified by ETL and listed.
40
41 G. All equipment shall be fabricated from copper and/or bronze, stainless
42 steel, and be ESE system certified by ETL for the type of installation.
43
44 H. All connections between dissimilar metals shall have connectors that are
45 ESE system certified by ETL for the type of installation.
46
LIGHTNING PROTECTION SYSTEMS BID DOCUMENTS
16670 - 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 PART 3 - EXECUTION
2
3 3.01 INSTALLATION OF LIGHTNING PROTECTION SYSTEMS:
4
5 A. Installation of equipment shall be done under the direct supervision of a
6 manufacturer's certified installer and in accordance with equipment
7 manufacturer's written instructions.
8
9 B. All work shall be installed in accessible locations and properly guarded
10 and protected.
11
12 C. All material shall be installed in a manner to prevent electrolytic action
13 under presence of moisture.
14
15 D. All wall or other building penetrations shall be made in a manner to
16 prevent the ingress of water or moisture.
17
18 E. PVC sleeves shall be provided where conductors pass through all floors.
19
20 F. All conductors shall be secured every 3'0" maximum. Fasteners and clips
21 utilized shall be of equal corrosion resistance as the material being
22 secured to.
23
24 G. Bonding of all conductive material within six (6) feet of the conductor shall
25 be accomplished via secondary conductors no smaller than #6 copper.
26
27 H. Bare copper material shall not be installed on dissimilar metals. Corrosion
28 resistant copper or bronze equipment shall be utilized where these
29 conditions exist. Corrosion resistant copper conductors and fittings shall
30 be utilized where corrosive atmospheres are present.
31
32 I. Conductors shall be installed so that a conductor shall always have a
33 horizontal or downward path, free of "U" or "V" pockets, with the exception
34 that an eight (8) inch maximum rise or a rise of three (3) inches maximum
35 from every twelve (12) inches of conductor length shall be permitted in a
36 main conductor run.
37
38 J. Each ESE terminal shall have two (2) paths to ground from the base plate
39 of the mast.
40
41 K. The electrical contractor shall furnish and install all necessary PVC
42 conduit (1") for concealed down conductors.
43
44 L. No bend of a conductor shall be less than ninety (90) degrees and shall
45 not have a radius of bend of less than eight (8) inches. Exceptions are
46 through roof and wall assemblies and "T" connections.
LIGHTNING PROTECTION SYSTEMS BID DOCUMENTS
16670 - 3 1/8/2021
1
2 M. Notify architect/engineer prior to installation if lightning protection
3 equipment and/or installation will conflict with other building materials.
4
5 N. Coordinate with other work, including electrical wiring and roofing work, as
6 necessary to interface installation of lightning protection system with other
7 work.
8
9 O. The complete lightning protection system shall be fully tested in the
10 presence of the engineer, and a certified ground test is to be performed
11 and witnessed by the engineer with all documents to be completed and
12 forwarded to the ESE manufacturer and engineer for evaluation,
13 certification, archiving, and documentation.
14
15 P. The completed system shall be videotaped and documented during
16 installation. Documentation and videotape is to be returned to
17 manufacturer for certification and issuance of manufacturer's guarantees
18 and warranties, and for archiving and system documentation.
19
20 3.02 GROUNDING AND BONDING:
21
22 A. Provide equipment grounding and bonding connections, sufficiently tight to
23 assure permanent and effective grounds and bonds, for lightning
24 protection connection devices as indicated.
25
26 B. Ground rods, ground plates and ground loop conductors shall be installed
27 a minimum of two (2) feet below grade and a minimum of two (2) feet
28 away from the foundation.
29
30 C. A minimum of one (1) inspection and test well, rated for the traffic of the
31 installation area, shall be installed for each down conductor or two (2)
32 minimum per ground loop.
33
34 D. Bonding of grounded systems shall be via main size conductors. The
35 bonding shall be accomplished to achieve equal potential of all grounds.
36 All grounding connections shall be via Burndy high compression crimps, or
37 Cadweld, or via a pre -approved connection suitable for direct burial.
38
39 E. All ground grids are to have a ground resistance of ten (10) ohms or less.
40 Testing method shall be of the "Fall of Potential Method" as described by
41 IEEE. Delta grids shall be tested without the service ground connection,
42 and documented as such, then connection to the service ground can be
43 made, and retested and documented for future testing and trends.
44
LIGHTNING PROTECTION SYSTEMS BID DOCUMENTS
16670 - 4 1/8/2021
1
1 F The ground resistance of the completed system shall be tested in the
2 presence of the engineer and shall be so noted on a Certified Ground Test
3 document.
4
5 END OF SECTION 16670
6
LIGHTNING PROTECTION SYSTEMS BID DOCUMENTS
16670 - 5 1/8/2021
THIS PAGE INTENTIONALLY LEFT BLANK
LIGHTNING PROTECTION SYSTEMS
16670 - 6
BID DOCUMENTS
1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 SECTION 16775
2
3 VARIABLE FREQUENCY MOTOR CONTROLLERS
4
5 PART 1 - GENERAL
6
7 1.01 SUMMARY
8
9 A. Scope: Provide labor, material, equipment, related services, and
10 supervision required, including, but not limited to, manufacturing,
11 fabrication, erection, and installation for adjustable or variable frequency
12 motor controllers (identified as VFDs or Variable Frequency Drives) as
13 required for the complete performance of the work, and as shown on the
14 Drawings and as herein specified.
15
16 B. Section Includes: The work specified in this Section includes, but shall not
17 be limited to, Variable Frequency Drives (VFDs) rated 600 V and less for
18 the speed control of three-phase squirrel -cage induction motors, and
19 synchronous motors as specified herein and where shown on the
20 associated schedules and the Drawings.
21
22 C. Related Sections: Related sections include, but shall not be limited to, the
23 following:
24
25 1. Drawings and general provisions of the Contract, including General
26 and Supplementary Conditions and Division 01 Specification
27 Sections, apply to this Section.
28
29 2. Applicable general requirements for electrical Work specified within
30 Division 26 Specification Sections, apply to this Section.
31
32 3. Refer to the specifications sections for the VFD driven equipment
33 for additional requirements.
34
35 4. [Section 26 24 19 — Motor Control Centers, for VFDs installed in
36 motor -control centers.]
37
38 D. [The system supplier of the motor driven equipment shall be responsible
39 for furnishing the Variable Frequency Drive.]
40
41 1.02 REFERENCES
42
43 A. General, Publications: The publications listed below form a part of this
44 Specification to the extent referenced. The publications are referred to in
45 the text by the basic designation only. The edition/revision of the
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 1 1/8/2021
1 referenced publications shall be the latest date as of the date of the
2 Contract Documents, unless otherwise specified.
3
4 1. ANSI®/NFPA® 70 — National Electrical Code® (NEC®)
5
6 2. CSA® C22.2 No. 14-M91 — Industrial Control Equipment
7
8 3. IEC 61000 — Electromagnetic Compatibility
9
10 4.
11 a. NEMA 250 — Enclosures for Electrical Equipment
12 b. NEMA ICS7 — Industrial Control and Systems Adjustable
13 Speed Drives
14 c. NEMA ICS 7.1 — Safety Standards for Construction and
15 Guide for Selection Installation and Operation of Adjustable
16 Speed Drives
17 5.
18 a. UL® 50 — Enclosures for Electrical Equipment
19 b. UL 98 — Disconnect Switches
20 c. UL 507 — Electric Fans
21 d. UL 508 — Industrial Control Equipment
22 e. UL 508C or UL 61800-5-1 — Power Conversion Equipment
23 f. UL 991 — Safety Tests for Safety Related Controls
24 Employing Solid State Devices
25
26 6. OSHA® 1910.95 — AC Drive Controller Acoustical Noise
27
28 7. IBC® — International Building Code®
29
30 8. ASCE/SEI 7® — Seismic Performance Requirements
31
32 9. ICC ES AC156 — Shake -Table Test Acceptance Criteria
33
34 10. IEEE519 — "IEEE Recommended Practices and Requirements for
35 Harmonic Control in Electrical Power Systems"
36
37 B. General, Definitions: Unless specifically defined within the Contract
38 Documents, the words or acronyms contained within this specification
39 shall be as defined by the references listed within this specification, the
40 Contract Documents, or, if not listed by either, by common industry
41 practice.
42
43 1.03 SUBMITTALS
44
45 A. General: Submit sufficient information to determine compliance with the
46 Contract Documents. Identify submittal data with the specific equipment
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 2 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 tags and/or service descriptions to which they pertain. Submittal data shall
2 be clearly marked to identify the specific model numbers, options, and
3 features of equipment and Work proposed.
4
5 1. Refer to [Section 01 33 00 - Submittal Procedures] [Section 01300
6 - Submittals].
7 2. All deviations from the Contract Documents shall be indicated
8 within a submittal. Each deviation shall reference the
9 corresponding drawing or specification number, show the contract
10 document requirement text and/or illustration, and shall be
11 accompanied by a detailed written justification for the deviation.
12
13 B. Product Data: Submit product data specific to each type and rating of VFD
14 proposed to include the following:
15
16 1. Manufacturer, supplier, and proposal specific contact information.
17
18 2. Manufacturer's catalog data indicating model numbers, equipment
19 specifications and construction features including all furnished
20 options, and accessories.
21
22 3. VFD assembly rated input KVA and output KVA, percent efficiency,
23 operating characteristics, and electrical characteristics.
24
25 4. Maximum [Btu] [kJ] heat release data and ambient cooling
26 requirements.
27
28 5. Enclosure type, [NEMA][IEC] rating, material and finishes.
29
30 6. Certification of UL conformity
31
32 7. Electronic 2D dimensional drawing and 3D model CAD files for
33 standard units shall be provided upon request if not available from
34 the manufacturer's website.
35
36 C. Shop Drawings: Submit shop drawings for each product and accessory
37 required. Include information not fully detailed in manufacturer's standard
38 product data. Shop drawings shall include, but not be limited to the
39 following:
40
41 1. Equipment assembly. Indicate dimensions, shipping section
42 dimensions, weights, foundation requirements, required
43 clearances, location and size of each field connection, and
44 mounting and installation instructions.
45
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 3 1/8/2021
1 2. Include elementary and interconnection diagrams for power, signal,
2 control, and communications wiring. Diagrams shall provide the
3 minimum detail as shown for drawings in the appendix of NFPA 79.
4 All field terminals shall be identified and updated later within the
5 O&M data to include actual field connection information. Drawings
6 shall not be typical, but be provided for each VFD furnished.
7
8 D. Coordination Drawings: Floor plans, drawn to scale, showing dimensioned
9 layout on which the following items are shown and coordinated with each
10 other, using input from installers of the items involved:
11
12 1. Required working clearances and required area above and around
13 VFDs.
14
15 2. Show VFD layout and relationships between electrical components
16 and adjacent structural and mechanical elements.
17
18 3. Show support locations, type of support, and weight on each
19 support.
20
21 4. Indicate field measurements.
22
23 E. Harmonic Analysis Report: Provide project -specific calculations and
24 manufacturer's statement of compliance with IEEE 519, latest revision.
25 Owner shall supply detailed electrical power system characteristics to
26 support harmonic calculations.
27
28 F Operation & Maintenance (O&M) Manuals: Submit installation, operation
29 and maintenance data to be included within operation and maintenance
30 manuals. In addition to items specified in Section [01 78 23] "Operation
31 and Maintenance Data", O&M data shall include but not be limited to the
32 following:
33
34 1. O&M manuals shall be submitted prior to arrival of equipment on
35 site.
36
37 2. Manufacturer, supplier, support, and repair center specific contact
38 information.
39
40 3. Manufacturer's standard operation and maintenance data
41 assembled for each size and type of equipment furnished.
42
43 4. [All construction, installation, schematic, and wiring diagrams
44 updated to an as -installed and commissioned state.] [All submittal
45 information updated to an as -installed and commissioned state.]
46
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 4 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 5. All configured settings/parameters for adjustable components
2 updated to an as -installed and commissioned stated if different
3 from the factory default. Electronic copies of configuration files
4 shall be provided, on media acceptable to the Owner (e.g. CD,
5 USB stick, etc.), where these configurations can be saved as an
6 electronic file for future upload into replaced or repaired
7 components.
8
9 6. List of furnished and recommended spare parts.
10
11 7. Statement of standard Warranty. [Statement of extended warranty
12 options and costs.]
13
14 1.04 QUALITY ASSURANCE
15
16 A. Manufacturer Qualifications: Manufacturer shall be a firm engaged in the
17 manufacture of VFDs of types and sizes required, and whose products
18 have been in satisfactory use in similar service for a minimum of five
19 years.
20
21 1. The VFD manufacturer shall have a valid ISO 9001 certification
22 and an applicable quality assurance system.
23
24 2. The VFD manufacturer shall have the Environment Certification
25 ISO 14001 for EcoDesign.
26
27 B. Commissioning and Training: VFDs shall be inspected and commissioned
28 by a factory trained representative of the VFD manufacturer. VFD
29 operation and maintenance training shall be conducted by a factory -by a
30 factory -trained representative of the VFD manufacturer trained in the
31 installation, operation, and maintenance of the VFD.
32
33 C. Regulatory Requirements: Comply with applicable requirements of the
34 laws, codes, ordinances, and regulations of Federal, State, and local
35 authorities having jurisdiction. Obtain necessary approvals from such
36 authorities.
37
38 1. Without limiting the generality of other requirements of this Section,
39 all work specified herein shall conform to or exceed the applicable
40 requirements of the following standards; provided, that wherever
41 the provisions of said publications are in conflict with the
42 requirements specified herein, the more stringent requirements
43 shall apply:
44
45 a. ANSI/NFPA 70: National Electrical Code
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 5 1/8/2021
1 b. EN61800-5: Electronic equipment for use in power
2 installation
3 c. CSA C22.2 No. 14-M91: Industrial Control Equipment
4 d. IEC 68 Part 2-3: Basis Environmental Testing Procedures
5 Part 2: Tests — Test Ca: Damp Heat
6 e. IEC 146.1:Semiconductor Converters — General
7 Requirements and Line Commutated Converters Part 1-1: -
8 Specifications of Basic Requirements
9 f. IEC 664: Insulation Co-ordination for Equipment within Low -
10 Voltage Systems
11 g. IEC 447: Man -Machine Interface Actuating Principles
12 h. IEC 439 Part 1: Low Voltage Switch gear and Control gear
13 Components
14 i. IEC 364: Electrical Installation of Buildings
15 j. IEC 204/NFPA 79: Electrical Equipment of Industrial
16 Machines/Industrial Machinery
17 k. IEC 106: Guide for Specifying Environmental Conditions for
18 Equipment Performance Rating
19 I. IEC 529: Degrees of protection provided by enclosure
20 m. IEC 1000: Electromagnetic Compatibility
21 n. IEC 1800: Adjustable speed Electrical power drive systems
22 o. IEC 721: Classification of Environmental Conditions
23 p. IEC 255-8: Overload Relays
24 q. IEC 801-2,-3,-4,-5: Immunity Tests
25 r. NEMA ICS Part 4: Overload Relays
26 s. NEMA ICS7: Industrial Control and Systems Variable Speed
27 Drives
28 t. UL 508C, UL 61800-5-1: UL Standard for Safety Power
29 Conversion Equipment
30
31 D. Single Source Responsibility: Obtain VFDs and required accessories from
32 a single source with resources to produce products of consistent quality in
33 appearance and physical properties without delaying the work. Any
34 materials which are not produced by the manufacturer shall be acceptable
35 to and approved by the manufacturer.
36
37 E. All VFDs shall be functionally tested by the manufacturer
38
39 1.05 SPECIAL TOOLS AND SPARE PARTS
40
41 A. A replacement VFD shall be provided for 1-125 HP 460V, and 1-60 HP
42 230V, in lieu of replacement components.
43
44 B. Spare parts shall be provided for each type and size of VFD furnished
45 greater than 125 HP 460V, and 60 HP 230V. [Provide the minimum spare
46 parts recommended by the manufacturer.][Provide at least one complete
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 6 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 set of all plug-in replaceable components of each size and type used.] At
2 a minimum the following shall be provided:
3
4 1. Power and control fuses
5
6 2. Non -LED type indicating lights
7
8 3. Rectifier power semiconductors
9
10 4. Inverter power semiconductors
11
12 5. One of each type of printed circuit board and gate firing board
13
14 6. Other field replaceable components]
15
16 C. Any manufacturer specific special tool, not normally found in an
17 electrician's toolbox, required to remove and install recommended or
18 furnished spare parts shall be furnished. At a minimum the following shall
19 be provided:
20
21 1. PC-based configuration software tool.
22
23 2. Electronic configuration files, in a media format acceptable by the
24 Owner (e.g. CD, USB stick, etc.), updated to an as -installed and
25 commissioned state.
26
27 1.06 DELIVERY, STORAGE, AND HANDLING
28
29 A. Prior to delivery to the Project site, ensure that suitable storage space is
30 available to store materials in a well ventilated area protected from
31 weather, moisture, soiling, extreme temperatures, humidity, and corrosive
32 atmospheres. Materials shall be protected during delivery and storage and
33 shall not exceed the manufacturer stated storage requirements.
34
35 B. Deliver materials to the Project site in supplier's or manufacturer's original
36 wrappings and containers, labeled with supplier's or manufacturer's name,
37 material or product brand name, and lot number, if any.
38
39 C. Inspect and report any concealed damage or violation of delivery storage,
40 and handling requirements to the [Engineer/Contract Manager].
41
42 1.07 WARRANTY
43
44 A. Warranty on drives shall be at a minimum 18 months from commissioning
45 or as specified in the
46
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 7 1/8/2021
1 B. Additional Owner Rights: The warranty shall not deprive the Owner of
2 other rights the Owner may have under other provisions of the Contract
3 Documents and shall be in addition to and run concurrent with other
4 warranties made by the Contractor under requirements of the Contract
5 Documents.
6
7 PART 2 - PRODUCTS
8
9 2.01 MANUFACTURERS
10
11 A. Yaskawa Model IQ1000 by ICON Technologies, no equal.
12
13 B. Acceptable Products: VFDs specified herein shall be the product of a
14 single manufacturer. All VFD's provided In MCC must meet UL 845. Note:
15 UL 508 will be accepted. Provide Yaskawa Model iQ1000, no equal.
16
17 C. The VFD manufacturer shall provide for repair and service of the drive
18 components with worldwide support. The VFD manufacturer shall provide
19 remote diagnostic services in conjunction with the VFD's user interface to
20 provide QR code, or equivalent, linked access to worldwide web based
21 enhanced diagnostics, documentation, and customer service.
22
23 2.02 SYSTEM REQUIREMENTS
24
25 A. Variable Frequency Drives (VFDs) shall provide for the starting and speed
26 control of standard IEC or NEMA A design AC inverter duty asynchronous
27 motors and synchronous motors with permanent magnets by the
28 adjustment of output voltage and frequency.
29
30 B. The VFD manufacturer shall design the device with more than 70% of
31 recyclability rate.
32
33 C. The VFD Manufacturer shall design the device according to the IEC
34 62635 guidelines to reduce the carbon footprint. The materials used in the
35 VFD shall be recyclable, non-toxic and flame retardant. The VFD
36 manufacturer shall provide the carbon foot print of the devices.
37
38 D. The VFDs shall be built to comply with the UL standard and shall be
39 marked in accordance with to UL 508 or UL 61800-5-1.
40
41 E. The VFD shall be compliant with the "Green" Premium label (REACH,
42 RoHS-2, EOL, and PEP).
43
44 2.03 Variable Frequency Drives
45
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 8 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. The VFD shall be a digitally controlled drive, using Pulse Width
2 Modulation (PWM). All VFDs above 75HP shall be 12 -pulse low harmonic
3 type. 6 -pulse technology shall be provided for all VFDs 75HP and below.
4
5 B. Environment and Construction
6
7 1. The VFD shall be rated to withstand the following environmental
8 conditions while able to give a 100% output current continuously.
9 Where derating is necessary to meet on site environmental
10 conditions, the manufacturer shall submit the VFDs derated
11 performance. The derating factor shall be specified so that neither
12 the lifetime of the VFD nor the unit's performance, overload
13 capability included, nor the reliability of the VFD shall suffer.
14
15 a. Storage Temperature: -40°C to 70°C,
16
17 b. Operating Temperature for UL Type 1 VFDs: -15°C to 50°C
18 without derating, up to 60°C with derating of power stage
19 (UL Type 1)
20
21 c. Operating Temperature for enclosed VFDs: 0°C to 40°C
22 without derating, down to -10°C with enclosure heater, up to
23 55°C with derating of power stage
24
25 d. Relative Humidity: <_95% relative humidity without
26 condensation per IEC 60068-2-3
27 e.
28 f. Operating Altitude: <_1000m without derating, up to 4800m
29 with derating.
30
31 g. Corrosion Protection Level: Class 3C3 according to IEC
32 60721-3-3 for cooling air and chemical gases
33
34 h. Biological Protection Level: Class 3B1 according IEC
35 60721-3-3
36
37 i. Dust Protection Level: Class 3S3 according to IEC 60721-3-
38 3
39
40 j. Vibration and Shock Protection Level: Class 3M3 according
41 to IEC 60721-3-3
42
43
44 2. The VFDs shall have an integral enclosure that shall protect from
45 ingress of dirt and water in accordance with UL Type 1 or as shown
46 on drawings. The user interface terminal shall be rated UL Type 12,
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 9 1/8/2021
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
mounted on front face of enclosure, and accessible for
programming and controls with the main door closed.
3. VFD enclosures shall be front cabinet accessible and constructed
in conformance with IEC 60439-1. Conduit entry shall be bottom
entry as standard to allow for top mounted cooling components.
The VFD enclosure shall have a forced air and heat sink cooling
system that does not require liquid or air condition cooling
components for ambient temperatures within the drives stated
ambient temperature operating range.
C. Application Requirements
1. The VFD shall be able to control motors using the following motor
control types in accordance with the applications needs and energy
savings: Volts per hertz VC Standard,
2. The VFD shall provide a Real Time Clock management with battery
backup.
3. The VFD shall be capable of automatic tuning of motor parameters
through measurement of the motor without rotation, and without the
need to disconnect the load from the motor.
4. The VFD shall provide functionality adjustable within the drive
parameters to reduce voltage surges on motor cables.
5. The Contractor shall provide AC chokes and filters to fit installation
and motor requirements per the following guidelines:
a. Voltage reflection suppression for motors compliant to
IEC60034-25 or NEMA MG1 Part 31
i. Unshielded motor cable length up to 500 feet (150
meters) shall be managed with the VFD functionality
ii. Unshielded motor cable length up to 1000 feet (300
meters) an AC choke shall be required
iii. Unshielded motor cable length up to 1640 feet (500
meters) a dV/dt filter shall be required
iv. Unshielded motor cable length up to 3280 feet (1000
meters) a Sinus filter shall be required
b. Voltage reflection suppression with motors not compliant to
IEC60034-25 or NEMA MG1 Part 31
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 10 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 i. Unshielded motor cable length up to 50 meters a
2 dV/dt filter shall be required
3 ii. Unshielded motor cable length up to 1000 meters a
4 Sinus filter shall be required
5
6 D. Performance Requirements
7
8 1. The VFD shall be rated for the nominal input voltage specified or
9 shown on the drawings. The VFD shall have an input voltage
10 tolerance within the following range of the corresponding nominal
11 input voltage:
12
13 a. Standard product, three phases power supply:
14
15 i. 200V -15% 240V +10%, three-phase up to 100 HP /
16 75 KW
17 ii. 380V -15% 480V +10%, three-phase up to 250 HP /
18 160 KW
19 iii. 500 to 690V -15% / +10%, three-phase up to 250 HP
20 / 160 KW
21
22 b. Enclosed Drive System, three phases power supply:
23
24 i. 200V -15% 240V +10%, three-phase up to 60 HP / 45
25 KW
26 ii. 380V -15% 480V +10%, three-phase up to 1,100 HP /
27 800 KW
28 iii. 500 to 600V -15% / +10%, three-phase up to 1,500
29 HP / 1,500 KW
30
31 2. The VFD shall meet the following minimum operating requirements:
32 a. Rated Frequency: 50 Hz -5% to 60 Hz + 5%, [The VFD shall
33 operate from 40 to 72 Hz when powered by standby or
34 emergency generators]
35
36 b. Displacement Power Factor: >_0.97
37
38 c. Efficiency:
39
40 i. >98 % at nominal load for VFD (IP 21 / UL Type 1)
41 ii. >97.5 % at nominal Toad for enclosed VFD systems.
42 iii. >96 % at nominal Toad for low harmonic VFD (IP 21 /
43 UL Type 1)
44 iv. >95.5 % at nominal load for low harmonic enclosed
45 VFD systems.
46
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 11 1/8/2021
1
1 d. Overload Capability: [Normal duty at 110%] [Heavy Duty at 1
2 150%] nominal current for 1 min
3
4 e. Harmonics Mitigation: [<48% THDi according to IEC/EN
5 61000-3-12][<5% at VFD input terminals] at 80-100% load
6
7 f Surge immunity according to IEC/EN 61000-4-5 Level
8 3
9
I
10 g. [The VFD shall be compliant with SEMI F47: degraded
11 running operation under voltage conditions.]
12
I
13 3. The VFD shall provide a speed range in the motor quadrant 1:100
14 in sensor less vector control and in the generator quadrant 1:50 in
15 sensor less vector control.
I
16
17 4. The VFD shall provide an over torque capability better than [110%
18 of the rated motor torque for normal duty applications] [150% of the
I
19 rated motor torque for heavy duty applications] during 60s, every
20 10 minutes.
21
I
22 5. The VFD shall provide a speed accuracy ±10% of the nominal slip
23 of the motor in sensor less vector control
24
1
25 6. The VFD shall provide a torque control accuracy ±15% in sensor
26 less vector control for AC motors
27
1
28 E. Protection
29
30 1. The VFD shall have coordinated short circuit rating designed to UL
1
31 508C or UL 61800-5-1 and NEMA ICS 7.1 Short Circuit Rating: 65
32 kAIC
33
1
34 2. Micro -short voltage sag immunity per SEMI F47.
35
36 3. Upon power -up the VFD shall automatically test for valid operation I
37 of memory, option module, loss of analogue reference input, loss of
38 communication, DC to DC power supply, control power and the
39 pre -charge circuit.
I
40
41 4. The VFD shall be protected against short circuits, between output
42 phases and ground and the logic and analogue outputs. I
43
44 5. The VFD shall have a selectable ride through function that will
45 allow the logic to maintain control for a minimum of one second I
46 without tripping.
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 12 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2 6. The deceleration mode of the VFD shall be programmable for
3 normal and trip conditions. The stop modes shall include freewheel
4 stop, fast stop.
5
6 7 Upon loss of the analog process follower reference signal, the VFD
7 shall trip and/or operate at a user -defined speed set by a software
8 programmed speed settings or last speed.
9
10 8. The VFD shall integrate a protection against IGBT and heat sink
11 over temperature.
12
13 9. The VFD shall have solid state thermal protection that is UL Listed
14 and meets UL 508C as a Class 10 overload protection and meets
15 IEC 947.
16
17 10. The VFD shall have a motor thermal memory retention function per
18 UL requirements.
19
20 11. The VFD shall be able to protect the motor when temperature
21 probes are connected.
22
23 12. The VFD shall be able to limit the motor surge ( I dv/dt ) at twice
24 the DC bus voltage
25
26 13. The VFD shall provide IGBT protection
27
28 a. IGBT overcurrent protection
29 b. IGBT check up sequence
30 c. IGBT check up sequence before PWM enable sequence
31 d. IGBT over -heat protection
32
33 14. The VFD shall provide VFD Current protection
34
35 a. Phase short circuit protection
36 b. Ground protection
37 c. Over -current protection
38
39 15. The VFD shall provide VFD Voltage error protection
40
41 a. Mains over -voltage protection
42 b. Mains under -voltage protection
43 c. DC Bus over -voltage protection
44 d. DC Bus pre -charge protection
45
46 16. The VFD shall provide VFD Thermal protection
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 13 1/8/2021
1
2 a. VFD over -temperature protection
3 b. FAN management
4 c. Switching Frequency management
5
6 17. The VFD shall provide internal error detection.
7
8 18. The VFD shall provide Motor protection functions
9
10 a. Motor output phase detection
11 b. Motor surge voltage
12 c. Motor over Toad detection
13 d. Motor stall protection
14
15 19. The VFD shall provide Application protection functions
16
17 a. Catch on fly function
18 b. Mains input phase lost protection
19 c. Motor over -speed input protection
20 d. Current limitation
21 e. Power limitation
22 f. Reverse inhibition
23 g. Under -load protection
24 h. Over -load protection
25 i. External error management
26 j. Loss of follower signal
27 k. Thermal Sensor management
28 I. PID Feedback
29 m. Customer defined input
30
31 F. Indicators
32
33 1. The VFD shall display a signal by LED near the connection point of
34 the device when a hazardous voltage is present.
35
36 2. The VFD shall have 3 LEDs for local diagnostics.
37
38 3. The VFD shall have 3 dual color LEDs for embedded
39 communication status.
40
41 4. The VFD shall have 4 dual color LEDs for optional communication
42 status
43
44 G. User Interface
45
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 14 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. A detachable UL Type 12/IP65 rated bi-color backlit graphical user
2 interface terminal with keypad and capacitive wheel shall be
3 provided for monitoring, annunciation, and configuration. The
4 graphical display shall change to a red backlit color when an alarm
5 occurs. The door mounting for the user interface shall be done
6 with a 22 mm hole.
7
8 2. A "Simply Start "menu for fast and easy commissioning shall be
9 provided and parameter setting shall be easily accessible and user
10 friendly with plain text messaging and actual setting range.
11
12 3. The keypad shall be capable of providing password protection.
13
14 4. The user interface shall be capable of saving and downloading
15 configurations of the VFDs, as well as porting them to other VFDs.
16
17 5. The user interface shall offer a Mini -USB port for mass storage or
18 PC device connection.
19
20 6. The mechanical mounting for the user interface on the cabinet shall
21 be done with a 22 mm hole.
22
23 7 The VFD shall have self-diagnostic capabilities to display alarms,
24 errors, and warnings as they occur and be able to store at least 15
25 last messages into the memory. These shall be accessible by PC
26 maintenance tools or web server with flash record for data logging
27 expertise
28
29 8. The user interface shall be identical throughout the power range to
30 avoid confusion amongst the users and need for training in several
31 different units.
32 9. The displayed messages shall be in plain text English, [French],
33 [Spanish].
34
35 H. Control Interface:
36
37 1. VFD shall interface with automation systems to monitor, control,
38 display, and record data for use in processing reports. VFD settings
39 shall be retained within VFD's nonvolatile memory.
40
41 2. The speed command and reference may come from different
42 control sources:
43
44 a. I/O terminals
45 b. Communication network
46 c. Web server
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 15 1/8/2021
1 d. Remote graphic display terminal
2
3 3. A minimum of the following standard inputs / outputs shall be
4 provided to interface with control systems and instrumentation:
5
6 a. Analog Inputs: [3][5] programmable 0(4)-20 mA or 0-10 vdc
7
8 i. 2 analog inputs shall also be programmable for
9 temperature sensors (PTC, PT100, PT1000, KTY84)
10
11 b. Analog Outputs: 2 programmable 0(4)-20 mA or 0-10 vdc
12
13 c. Discrete Inputs: [6][12] programmable isolated logic inputs
14 as either sink or source
15
16 i. 2 discrete inputs shall also be programmable as 0-30
17 kHz pulse inputs
18
19 ii. 2 discrete inputs shall be dedicated Safe Torque Off
20 safety function in accordance with IEC/EN 61508-1
21 SIL3
22
23 d. Discrete Outputs: [3][6] programmable relay contacts [and 1
24 open collector output]
25
26 i. 1 discrete output shall be dedicated to product
27 watchdog logic
28
29 4. Programmable analog inputs shall be able to be assigned the
30 following parameters:
31
32 a. Speed reference
33 b. Summing reference
34 c. Subtracting reference
35 d. Multiplying reference
36 e. Torque reference
37 f. Torque limitation
38 g. PID feedback
39 h. Manual PID reference
40 i. PID speed reference
41 j. Forced local reference
42
43 5. Programmable analog outputs shall be able to be assigned the
44 following parameters:
45
46 a. Motor current
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 16 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 b. Motor frequency
2 c. Motor torque (signed or unsigned)
3 d. Motor power
4 e. Motor voltage
5 f. Output frequency (signed or unsigned)
6 g. PID error
7 h. PID feedback
8 i. PID output
9 j. PID reference
10 k. Ramp output
11 I. Signed ramp
12 m. Drive thermal state
13 n. Motor thermal state
14 o. Pressure sensor
15 p. Flow sensor
16
17 6. Programmable discrete inputs shall be able to be assigned the
18 following parameters:
19
20 a. Run
21 b. Forward
22 c. Reverse
23 d. Jog
24 e. Preset speeds
25 f. Reference switching
26 g. Ramp switching
27 h. Error reset
28 i. Error inhibition
29 j. Product reset
30 k. PID regulation mode (auto)
31 I. PID speed regulation mode (manual)
32 m. PID integral reset
33 n. Preset PID reference
34 o. Sleep/wake-up
35 P. Activate sleep mode by flow detection
36 q. Analogue torque limitation activation
37 r. Torque reference sign
38 s. Command switching
39 t. Parameter sets selection
40 u. Fast stop
41 v. DC injection
42 w. Freewheel stop
43 x. + speed
44 y. - speed
45 z. External error
46 aa. Pre Fluxing
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 17 1/8/2021
1 bb. Forced local control
2 cc. Current limitation activation
3 dd. Output contactor feedback
4 ee. Reference memorization
5 ff. Auto -tuning
6 gg. Forced operation
7 hh. Under load detection
8 ii. Overload detection
9 jj. Limiting low speed operating time
10 kk. Switching frequency, noise reduction
11 II. Drive lock assignment
12 mm. Outlet pressure switch select
13 nn. Pipe fill
14 00. External anti jam trigger
15 pp. Dry running no flow switch select
16 qq. Pump low flow no flow switch select
17
18 7 Programmable discrete outputs shall be able to be assigned the
19 following parameters:
20
21 a. Ready
22 b. Drive running
23 c. Frequency reference attained
24 d. Current attained
25 e. High speed attained
26 f. Drive error
27 g. Frequency threshold attained
28 h. Torque sign
29 i. Motor thermal state attained
30 j. Drive thermal state attained
31 k. Torque or current limitation attained
32 I. Output contactor command
33 m. Input contactor command
34 n. Current present
35 0. Power removed
36 P. Alarm Groups
37 q. Alarms: load slipping, 4-20mA loss, brake control, external
38 error, PTC, PID error, PID feedback, IGBT temperature,
39 under voltage, torque control, drive temperature, braking
40 resistor, fan counter, fan feedback, customer warning, power
41 threshold, electrical power drift
42 r. Active configuration
43 s. Active parameter set
44 t. Active channel
45 u. DC bus charged
46 v. DC bus charging
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 18 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 w. Water Command: jockey pump, priming pump
2 x. Water running: anti -jam, pipe fill, priming pump, jockey pump
3 y. Water warning: dry running, flow, inlet pressure, outlet
4 pressure, pump cycling, anti -jam, outlet pressure switch,
5
6 8. Safety Inputs
7
8 a. The VFD shall provide 2 inputs dedicated to Safe Torque Off
9 (STO) safety function, which prohibits unintended equipment
10 operation, in accordance with IEC/EN 61508-1 SIL3.
11 b. The VFD shall be compliant with EN13849 (PL e).
12 c. The VFD shall be compliant with safety of machinery EN
13 954-1
14 d. The VFD manufacturer shall provide the certified schematics
15 and the list of devices in order to comply with IEC/EN 60204-
16 1 stopping category 0 and 1.
17 e. The VFD shall integrate the safety contacts in compliance
18 with EN -81 13.2.2.3
19
20 I. Communications
21
22 1. The VFD shall provide at a minimum 1 Modbus and 1 Ethernet
23 Modbus TCP communications ports. [In addition, the following
24 communications options shall be provided as necessary for
25 communications. Refer to communication requirements specified
26 elsewhere within the Contract Documents.]
27
28 f. [Ethernet IP or Modbus TCP, RJ45 dual port for daisy chain]
29 g. [Profibus DP V2, SUB -D9 connection, compliant with Drive
30 Profile networking]
31 h. [Profinet, RJ45 dual port for daisy chain]
32 i. [DeviceNet, 5 terminal points]
33 j. [CanOpen daisy Chain, RJ45 dual port for daisy chain]
34 k. [CanOpen SUB -D9 connection]
35 I. [CanOpen Open terminals, 5 terminal points]
36
37 2. VFD Ethernet ports shall be IPv6 compliant, allow for web server
38 access and provide network management via SNMP and clock
39 synchronization.
40
41 3. The VFD shall provide an embedded web server for enhanced
42 diagnostic, configuration, parameter access, and energy
43 management. There shall be the capability to create a user -defined
44 custom dashboard for viewing drive and process status through
45 tables, charts, and graphical views. It shall be possible to export
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 19 1/8/2021
1
2
3
4
5
6
7
8
9
10
11
12
13
data in standard table format using the webserver, for information
around energy consumption as well as error and warning history.
4. The VFD shall be compliant with the Cyber Security Management
ISA Secure /Achilles.
5. The VFD shall be capable of providing Wi-Fi connectivity via option
for wireless diagnostic, configuration, and parameter access.
6. VFD communications modules shall be [capable of being] remotely
powered by a separate external 24 VDC to allow for continued
communications when the drive power supply is off.
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 20 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 7. The VFD shall provide integration connectivity via
2
3 a. DHCP protocol for Fast Device Replacement
4 b. DTM library in compliance with standard FDT technology
5
6 J. Configuration
7
8 1. The VFD shall be capable of accepting independent command and
9 speed reference signals from:
10
11 a. Terminals
12 b. Modbus port
13 c. Ethernet port
14 d. Communication option card
15 e. Keypad display.
16
17 2. The VFD shall provide a Speed set -point function capable of:
18
19 a. Maximum output frequency function
20 b. Low and High speed scaling and limitation function
21 c. Jump frequency
22 d. Speed summing references function
23 e. Preset -speed references function
24 f. Jog function
25 g. Up -Down speed references
26
27 3. The VFD shall provide a Stop function capable of:
28
29 a. Deceleration ramp on power Toss
30 b. Freewheel stop
31 c. Stop by DC injection at motor stop detection
32 d. Stop by DC injection by Logic Input
33 e. Stop on deceleration ramp adaptation
34
35 4. The VFD shall have an acceleration/deceleration, time adjustable
36 ramp function capable of:
37
38 a. Ramp type: linear ramp, S shape ramp, with U or
39 customized profile.
40 b. Ramp Deceleration adaptation
41 c. Ramp switching
42
43 5. Application programming dedicated to pumps
44
45 a. The VFD shall provide Pump Control & Monitoring Functions
46 i. Centrifugal pump characteristics and configurations.
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 21 1/8/2021
1 ii. Pump monitoring function in order to define data
2 relevant for pump (acceleration, low speed, high
3 speed, etc.)
4 iii. Application Units function in order to define units used
5 in applications
6 iv. Pump Cyclic Start Protection in order to protect the
7 pump against too many restarts in a dedicated time
8 period.
9 v. Multi -pump functions.
10
11 b. The VFD shall provide Pump Protection Functions
12 i. Anti -Jam function in order to remove automatically
13 clogging substances from the pump impellers.
14 ii. Pipe Cleaning function in order to start pump regularly to
15 avoid sedimentation in pump impeller
16 iii. Cavitation Pump Protection
17 iv. Inlet protection in order to avoid system dry running.
18
19 c. The VFD shall provide Application control functions
20 i. Stop and Go function in order to reduce consumption
21 of VFD in case of pump doesn't work
22 ii. Pulse input in order to connect a flow meter.
23 iii. Process control (PID) function in order to maintain a
24 process at a given pressure or flow reference.
25 iv. Flow limitation function in order to allow limiting the
26 consumption of water.
27 v. Friction loss compensation function in order to
28 compensate pressure losses in pipes due to friction.
29 vi. Pipe Fill function in order to manage a smooth control
30 during pipe filling and to lessen the affects of water
31 hammer.
32 vii. Sleep wake-up function in order to manage periods of
33 the application when process demand is low and
34 when it is not needed.
35 viii. Low demand function in order to define periods of the
36 application when process demand is low in order to
37 save energy.
38 ix. Jockey pump control function in order to start a jockey
39 pump, during sleep period, to maintain emergency
40 service pressure or demand such as low water.
41 x. Sensor management in order to define how will be
42 used drive inputs to manage Pressure sensor or flow
43 sensor
44
45 d. The VFD shall provide Application protection functions
46
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 22 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1. High flow protection function in order to detect pipe
2 burst or detect running outside normal working area
3 ii. Outlet pressure protection function in order to fix
4 minimum and maximum pressure.
5
6 e. The VFD shall provide Pump curve input to help optimize
7 pump performance.
8
9 i. Input and storage of the pump characteristics
10 including 5 points of the pump curve.
11 ii. A best efficiency point (BEP) function in order to run
12 in optimum conditions and detect deviation from this
13 point.
14
15 K. Diagnostics and Configuration
16
17 1. The VFD Supplier shall have Windows based PC software for
18 configuring and diagnosing the VFD. It shall be possible to set and
19 modify parameters, control the drive, read actual values and make
20 trend analysis using the software. The PC -tools may be connected
21 to the VFD by wired or wireless connection.
22
23 ii.The VFD shall display all faults in plain text and help screens shall be
24 available to guide the user in the troubleshooting. Codes are not
25 acceptable.
26
27 iii.The VFD shall provide a Real Time Clock management for time stamping
28 of detected errors.
29
30 iv.The VFD shall display detected errors with QR codes to guide the user in
31 the troubleshooting.
32
33 v.The VFDs must provide LED lights to indicate the status of the VFD.
34
35 vi.The VFD must have the ability to dynamically display I/O status.
36
37 L. Energy Management
38
39 1. The VFD shall provide a data logging function in order to keep files
40 ready for maintenance or user.
41
42 2. The VFD shall provide information related to Energy management
43 through different ways such as: web server, keypad, facet for
44 SCADA, communication networks.
45
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775-23 1/8/2021
1 3. The user interface shall be able to display a chart relative to energy
2 efficiency and energy management.
3
4 a. Report in KW
5 b. Display energy history for instant, weekly, monthly, and
6 yearly.
7 c. Trend base on variation /time
8 d. All power measurement precision must be less than 5 % of
- 9 deviation.
10
11 4. The user interface shall be able to display the "efficient" set point
12 for pump based on pump characteristics.
13
14 5. The user interface shall be able to display the "efficiency board"
15 including CO2 savings, Savings viewer, and Return of Investment.
16
17
18 PART 3 - EXECUTION
19
20 3.01 EXAMINATION
21
22 A. Examine VFD exterior and interior prior to installation. Report any damage
23 and do not install any VFDs that are structurally, moisture, or mildew
24 damaged.
25
26 B. Prior to locating the VFD at the planned installation site, ensure that the
27 location is prepared for the installation and that the storage or operating
28 condition requirements can be maintained. Verify installation space
29 requirements are satisfied. Report any conditions that are detrimental to
30 performance of the work. Proceed with installation only after detrimental
31 conditions have been corrected.
32
33 C. Before, during, and after installation ensure that the VFD is protected from
34 area construction activities and site contaminants.
35
36 3.02 INSTALLATION
37
38 A. In addition to the requirements specified herein the installation shall be in
39 accordance with Specification Section 16010 and Drawings.
40
41 B. Installation shall comply with manufacturer's instructions, drawings, and
42 recommendations.
43
44 3.03 FIELD QUALITY CONTROL
45
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 24 1/8/2021
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 A. Configuration and Startup: Provide the services of a qualified factory -
2 trained manufacturer's representative to assist the installing contractor
3 with the installation, configuration and startup of each VFD. The
4 manufacturer's representative shall inspect the installation of each VFD
5 prior to energizing and configure each VFD for operation under the
6 specified conditions. The manufacturer's representative shall conduct the
7 initial startup and operation of each VFD. The manufacturer's
8 representative shall revisit the project site as often as necessary to ensure
9 that all issues are corrected and that the installation and operation are the
10 VFD are satisfactory.
11
12 B. Certification: The Contractor shall submit a written report certifying that
13 each VFD has been installed, configured, and tested under load in
14 accordance with the manufacturer's recommendations. This report shall
15 be signed by a factory -trained manufacturer's representative and shall
16 include a listing of all modifications and adjustments made onsite to
17 include any settings / parameters not are not identified as factory defaults
18 within the equipment's O&M documentation.
19
20 C. Specified products shall be tested as a system for conformance to
21 specification requirements prior to scheduling the acceptance tests.
22 Contractor shall conduct performance verification tests in the presence of
23 Government representative, observing and documenting complete
24 compliance of the system to the specifications. Contractor shall submit a
25 signed copy of the test results, certifying proper system operation before
26 scheduling tests.
27
28 3.04 TRAINING
29
30 A. The services of a factor -trained instructor shall be provided for the
31 purpose of training the Owner's staff in the proper operation and
32 maintenance of the VFDs. Training shall consist of not less than [1][2
33 repeated] session(s) with [6][4][2] hours of onsite classroom and hands-on
34 instruction for a minimum of [4] attendees per session. The instructor shall
35 provide sufficient time and detail in each session to cover the following as
36 a minimum:
37
38 1. Theory of operation
39
40 2. Operation of VFDs furnished
41
42 3. Maintenance and configuration
43
44 4. Configurations of VFDs furnished
45
46 5. Troubleshooting and repair
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 25 1/8/2021
1
2 6. Replacement of component level parts
3
4 3.05 TESTING AND COMMISSIONING
5
6 A. General: VFDs and related equipment shall be tested and commissioned
7 in accordance with Specification Section [26 08 00][16080].
8
9 B. Field Harmonic Testing: When 75HP and above VFDs are supplied, the
10 Contractor shall record and provide in a report the harmonic line distortion
11 for ac voltage and current to include individual harmonic values up to the
12 50th harmonic as well as the total harmonic distortion (THD) and total
13 demand distortion (TDD) for all drives furnished above [90] KW. Testing
14 shall be in accordance with IEEE 519.
15
16 END OF SECTION 16775
VARIABLE FREQUENCY DRIVES BID DOCUMENTS
16775- 26 1/8/2021